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Chrysler 1998 Voyager, Service Manual, Page: 85 / 1938

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Chrysler 1998 Voyager Service Manual Download Page 85

BASE BRAKE SYSTEM

INDEX

page

page

DESCRIPTION AND OPERATION

CHASSIS TUBES AND HOSES . . . . . . . . . . . . . . 7
FRONT DISC BRAKE SYSTEM . . . . . . . . . . . . . . 4
HUB/BEARING REAR WHEEL . . . . . . . . . . . . . . . 9
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 7
PARKING BRAKE SYSTEM OPERATION . . . . . . . 5
POWER BRAKE VACUUM BOOSTER

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PROPORTIONING VALVES . . . . . . . . . . . . . . . . . 5
REAR DISC BRAKES . . . . . . . . . . . . . . . . . . . . . . 5
REAR DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . 5
RED BRAKE WARNING LAMP OPERATION . . . . . 8
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . 9

DIAGNOSIS AND TESTING

ADJUSTER REAR DRUM BRAKE

(AUTOMATIC) . . . . . . . . . . . . . . . . . . . . . . . . . 14

BRAKE FLUID CONTAMINATION . . . . . . . . . . . . 19
BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE SYSTEM BASIC DIAGNOSIS GUIDE . . . . 9
BRAKE SYSTEM DIAGNOSIS CHARTS . . . . . . . 10
PROPORTIONING VALVES . . . . . . . . . . . . . . . . 16
RED BRAKE WARNING LAMP TEST . . . . . . . . . 19
STOP LAMP SWITCH TEST PROCEDURE . . . . . 19
TRACTION CONTROL LAMP TEST . . . . . . . . . . 19

SERVICE PROCEDURES

BLEEDING BASE BRAKE

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 20

BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . 24
BRAKE TUBE REPAIR PROCEDURE . . . . . . . . . 24
MASTER CYLINDER BLEEDING

PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 22

MASTER CYLINDER FLUID LEVEL CHECK . . . . 20
PARK BRAKE AUTO ADJUSTER

MECHANISM RELEASE . . . . . . . . . . . . . . . . . 26

ROTOR MACHINING (FRONT/REAR) . . . . . . . . . 22

REMOVAL AND INSTALLATION

BRAKE SUPPORT PLATE (REAR DRUM

BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

FRONT DISC BRAKE CALIPER . . . . . . . . . . . . . 27
FRONT DISC BRAKE PADS . . . . . . . . . . . . . . . . 30
FRONT PARK BRAKE CABLE . . . . . . . . . . . . . . 65
HUB/BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . 40
HYDRAULIC BRAKE TUBES AND HOSES . . . . . 58
INTERMEDIATE PARK BRAKE CABLE

. . . . . . . 66

JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . . 55
LEFT REAR PARK BRAKE CABLE . . . . . . . . . . . 67
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 44
PARK BRAKE PEDAL MECHANISM . . . . . . . . . . 58

PARK BRAKE SHOES (WITH REAR DISC

BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

PROPORTIONING VALVE (W/ABS BRAKES) . . . 56
PROPORTIONING VALVE

(W/O ABS BRAKES) . . . . . . . . . . . . . . . . . . . . 57

REAR BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . 33
REAR BRAKE WHEEL CYLINDER . . . . . . . . . . . 39
REAR DISC BRAKE CALIPER . . . . . . . . . . . . . . 28
REAR DISC BRAKE SHOES . . . . . . . . . . . . . . . . 31
REAR DRUM BRAKE SHOES . . . . . . . . . . . . . . . 34
RIGHT REAR PARK BRAKE CABLE

. . . . . . . . . 66

STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 69
VACUUM BOOSTER 2.4 LITER ENGINE . . . . . . 47
VACUUM BOOSTER 3.0 LITER ENGINE . . . . . . 49
VACUUM BOOSTER 3.3/3.8 LITER ENGINE . . . . 52
WHEEL AND TIRE INSTALLATION . . . . . . . . . . . 27

DISASSEMBLY AND ASSEMBLY

FRONT DISC BRAKE CALIPER . . . . . . . . . . . . . 71
MASTER CYLINDER BRAKE FLUID LEVEL

SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

MASTER CYLINDER FLUID RESERVOIR

FILL TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

MASTER CYLINDER FLUID RESERVOIR . . . . . . 70
MASTER CYLINDER TO POWER BRAKE

BOOSTER VACUUM SEAL . . . . . . . . . . . . . . . 69

WHEEL CYLINDER REAR DRUM BRAKE . . . . . . 76

CLEANING AND INSPECTION

BRAKE HOSE AND BRAKE LINES

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 78

FRONT DISC BRAKE PAD LINING

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 76

REAR DISC BRAKES . . . . . . . . . . . . . . . . . . . . . 76
REAR DRUM BRAKE SHOE LINING

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 77

REAR DRUM BRAKE WHEEL CYLINDER . . . . . . 78
REAR WHEEL HUB AND BEARING

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

ADJUSTMENTS

PARK BRAKE CABLE ADJUSTMENT . . . . . . . . . 81
PARK BRAKE SHOES (WITH REAR DISC

BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

PROPORTIONING VALVE

(HEIGHT SENSING) . . . . . . . . . . . . . . . . . . . . 81

REAR DRUM BRAKE SHOE ADJUSTMENT . . . . 79
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 78

SPECIFICATIONS

BRAKE ACTUATION SYSTEM . . . . . . . . . . . . . . 83
BRAKE FASTENER TORQUE

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 83

NS

BRAKES

5 - 3

Summary of Contents for 1998 Voyager

Page 1: ...C MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER INTERNATIONAL Chrysler International reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obli gations upon itself to install them on its products previously manufactured Litho in U S A Copyright 1976 Chrysler Corporation ...

Page 2: ... after the group title is aligned to a solid tab on the first page of each group The first page of the group has a contents section that lists major topics within the group If you are not sure which Group contains the infor mation you need look up the Component System in the alphabetical index located in the rear of this manual Tightening torques are provided as a specific value throughout this ma...

Page 3: ...anel and Systems 8H Vehicle Speed Control System 8K Wiper and Washer Systems 8L Lamps 8Q Vehicle Theft Security Systems 8U Chime Warning Reminder System 8W Wiring Diagrams 9 Engine 13 Frame and Bumpers 14 Fuel System 2 5L Diesel Engine 2 0L Gas Engine 19 Steering 21 A 598 Manual Transaxle 23 Body 24 Heating and Air Conditioning 25 Emission Control System ...

Page 4: ...pper left cor ner of the instrument panel near the left windshield pillar Fig 2 The VIN consists of 17 characters in a combination of letters and numbers that provide spe cific information about the vehicle Refer to VIN Code Breakdown Chart for decoding information VIN CHECK DIGIT To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the nin...

Page 5: ...aravan P Plymouth Voyager Grand Voyager T AWD Chrysler Town Country T AWD Dodge Grand Caravan T AWD Plymouth Grand Voyager 6 Series 2 FWD Caravan Grand Caravan Voyager Grand Voyager 4 Caravan SE Grand Caravan SE Voyager SE Grand Voyager SE 5 Caravan LE or ES Grand Caravan LE or ES Voyager LE Grand Voyager LE Town Country LX 6 Town Country LXI 7 Body Style 4 Long Wheel Base 5 Short Wheel Base 8 Eng...

Page 6: ...GITS 1 2 AND 3 Transaxle Codes DGB 31TH 3 Speed Automatic Transaxle DGL 41TE 4 speed Electronic Automatic Tran saxle DGM 31TH 3 Speed Automatic Transaxle DIGIT 4 Open Space DIGIT 5 Market Code C Canada B International M Mexico U United States DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number Refer to Vehicle Identification Number VIN paragraph for proper breakdown of VIN code IF...

Page 7: ...des range from grade 2 to grade 8 The higher the grade number the greater the bolt strength Identification is determined by the line marks on the top of each bolt head The actual bolt strength grade corresponds to the number of line marks plus 2 The most commonly used metric bolt strength classes are 9 8 and 12 9 The metric strength class identification number is imprinted on the head of the bolt ...

Page 8: ...FASTENER IDENTIFICATION NS INTRODUCTION 5 GENERAL INFORMATION Continued ...

Page 9: ...FASTENER STRENGTH 6 INTRODUCTION NS GENERAL INFORMATION Continued ...

Page 10: ...sed on quantities of one ten one hundred one thousand and one million Fig 6 The following chart will assist in converting metric units to equivalent English and SAE units or vise versa Refer to the Conversion Chart to convert torque values listed in metric Newton meters N m Also use the chart to convert between millimeters mm and inches in TORQUE REFERENCES Individual Torque Charts appear at the e...

Page 11: ...METRIC CONVERSION 8 INTRODUCTION NS GENERAL INFORMATION Continued ...

Page 12: ...TORQUE SPECIFICATIONS NS INTRODUCTION 9 GENERAL INFORMATION Continued ...

Page 13: ...e VIN Decoding Information Table to interpret VIN code VIN CHECK DIGIT To protect the consumer from theft and possible fraud the manufacturer is required to include a check Digit at the ninth position of the VIN The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation The formula to use the check digit is not released ...

Page 14: ...2721 kg 5001 6000 lbs 5 Car Line C Voyager Grand Voyager AWD Y Voyager Grand Voyager FWD 6 Series 4 Voyager Grand Voyager SE FWD 5 Voyager Grand Voyager LE FWD AWD 6 Voyager LX FWD AWD N 5 Speed Manual Transmission B 4 Speed Automatic Transmission 7 Body Style 2 Short Wheelbase 4 Door 3 Short Wheelbase 3 Door 4 Long Wheelbase Premium 4 Door 5 Long Wheelbase Highline 4 door 7 Short Wheelbase Commer...

Page 15: ...fication Number VIN Refer to Vehicle Identification Number VIN para graph for proper breakdown of VIN code IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate will be fol lowed by END When two plates are required the last code space on the first plate will indicate contin ued CTD When a second plate is required the first four spaces of each line will not be used due to overlap...

Page 16: ......

Page 17: ...ns portation Schedule B lists maintenance intervals for vehi cles that are operated under the conditions listed at the beginning of the Maintenance Schedule section Use the schedule that best describes your driving conditions Where time and mileage are listed follow the interval that occurs first PARTS AND LUBRICANT RECOMMENDATIONS When service is required Chrysler Corporation recommends that only...

Page 18: ...icants In addition API classification defines the lubricants usage LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI All approved products have the NLGI symbol Fig 3 on the label At the bottom NLGI symbol is the usage and quality identification letters Wheel bearing lubricant is identified by the letter G Chassis lubricant is identified by the latter L The letter...

Page 19: ...hten terminals as required Check fluid levels of coolant reservoir brake master cylinder power steering and transaxle and add as needed Check all lights and all other electrical items for correct operation Check rubber seals on each side of the radiator for proper fit At Each Oil Change Inspect exhaust system Inspect brake hoses Inspect the CV joints and front suspension com ponents Rotate the tir...

Page 20: ...rk plugs on 3 3L and 3 8L engines Replace ignition cables on 3 3L and 3 8L engines 105 000 Miles 168 000 km or at 84 months Change engine oil Replace engine oil filter Inspect serpentine drive belt replace if neces sary This maintenance is not required if belt was previously replaced Flush and replace engine coolant if it has been 30 000 miles 48 000 km or 24 months since last change 112 500 Miles...

Page 21: ...r cleaner element Replace as necessary Drain and refill automatic transmission fluid and replace filter Adjust bands if so equipped See note Inspect brake linings Change AWD power transfer unit fluid 48 000 Miles 77 000 km Change engine oil Replace engine oil filter 51 000 Miles 82 000 km Change engine oil Flush and replace engine coolant 54 000 Miles 86 000 km Change engine oil Replace engine oil...

Page 22: ...e if neces sary This maintenance is not required if belt was previously replaced Drain and refill automatic transmission fluid and filter Adjust bands if so equipped See note Change AWD power transfer unit fluid Change AWD overrunning clutch and rear car rier fluid 108 000 Miles 173 000 km Change engine oil Replace engine oil filter Inspect brake linings 111 000 Miles 178 000 km Change engine oil ...

Page 23: ...ion Fuel fumes or leakage correct if necessary CAUTION If the cause of starting problem on dis abled vehicle is severe damage to booster vehicle charging system can result 2 When using another vehicle as a booster source park the booster vehicle within cable reach Turn off all accessories set the parking brake place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn ...

Page 24: ...rance If minimum ground clearance cannot be reached use a towing dolly If a flat bed device is used the approach angle should not exceed 15 degrees GROUND CLEARANCE CAUTION If vehicle is towed with wheels removed install lug nuts to retain brake drums or rotors A towed vehicle should be raised until the lifted wheels are a minimum 100 mm 4 in from the ground Be sure there is at least 100 mm 4 in c...

Page 25: ...es can be flat towed at speeds not to exceed 40 km h 25 mph for not more than 25 km 15 miles The steering column must be unlocked and gear selector in neutral 4 speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km h 44 mph for not more than 160 km 100 miles The steering column must be unlocked and gear selector in neutral HOISTING RECOMMENDATIONS Refer to O...

Page 26: ......

Page 27: ...tion shown on the container should be used ENGINE OIL DIESEL ENGINES Use only Diesel Engine Oil meeting standard MIL 2104C or API Classification SG CD or CCMC PD2 SAE VISCOSITY GRADE CAUTION Low viscosity oils must have the proper API quality or the CCMC G5 designation To assure of properly formulated engine oils it is recom mended that SAE Grade 15W 40 engine oils that meet Chrysler material stan...

Page 28: ...ice or delivery service Trailer towing UNSCHEDULED INSPECTION At Each Stop for Fuel Check engine oil level add as required Check windshield washer solvent and add if required Once a Month Check tire pressure and look for unusual wear or damage Inspect battery and clean and tighten terminals as required Check fluid levels of coolant reservoir brake master cylinder power steering and transaxle and a...

Page 29: ...t should be replaced once a year if the vehicle is driven less than 40 000 km annually or if power loss from fuel star vation is detected EVERY 10 000 KM AFTER 100 000 KM Change engine oil Change engine oil filter EVERY 20 000 KM AFTER 100 000 KM Change engine oil Change engine oil filter Replace air filter element Check drive belt tension Check glow plug operation SCHEDULE B DIESEL 500 KM Check c...

Page 30: ...glow plug operation Change MTX fluid 75 000 KM Change engine oil Change engine oil filter 80 000 KM Change engine oil Change engine oil filter Replace air filter element Check glow plug operation Replace drive belt Check engine smoke Replace engine coolant 85 000 KM Change engine oil Change engine oil filter 90 000 KM Change engine oil Change engine oil filter Replace air filter element Check driv...

Page 31: ...l lift Fig 1 is recommended When using a wheel lift towing device be sure the disabled vehicle has at least 100 mm 4 in ground clearance If minimum ground clearance cannot be reached use a towing dolly If a flat bed device is used the approach angle should not exceed 15 degrees GROUND CLEARANCE CAUTION If vehicle is towed with wheels removed install lug nuts to retain brake drums or rotors A towed...

Page 32: ...s must be free to rotate Use towing dollies at unlifted end of vehicle Unlock steering column and secure steering wheel in straight ahead position with a clamp device designed for towing 4 speed electronic automatic transaxle vehicles can be flat towed at speeds not to exceed 72 km h 44 mph for not more than 160 km 100 miles The steering column must be unlocked and gear selector in neutral TOWING ...

Page 33: ...the vehicle The method of checking front and rear wheel align ment will vary depending on the type of equipment being used The instructions furnished by the manu facturer of the equipment should always be followed With the exception that the wheel alignment specifi cations recommended by Chrysler Corporation should always be used The Chrysler Corporation recom mended alignment specifications are l...

Page 34: ...owing sequence 1 Camber 2 Toe Camber is the number of degrees the top of the wheel and tire assembly is tilted inboard or outboard from a true vertical line Inboard tilt is negative cam ber Outboard tilt is positive camber Fig 1 Excessive camber is a tire wear factor negative camber causes wear on the inside of the tires tread surface while positive camber causes wear to the outside of the tires t...

Page 35: ...Loose strut mount to body attachment 7 Tighten strut attachment to specified torque 8 Loose crossmember bolts 8 Tighten crossmember bolts to specified torque Front End Whine With Vehicle Going Straight At A Constant Speed 1 Defective wheel bearing 1 Replace wheel bearing 2 Incorrect wheel alignment 2 Check and reset wheel alignment 3 Worn tires 3 Replace tires 4 Worn or defective transaxle gears o...

Page 36: ...eservoir to correct level 4 Loose power steering pump drive belt 4 Correctly adjust power steering pump drive belt 5 Lack of lubricant in ball joints 5 Lubricate or replace ball joints 6 Steering gear malfunction 6 Replace steering gear 7 Lack of lubricant in steering coupler 7 Replace steering coupler PRE WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignme...

Page 37: ...ications proceed to step Step 3 for the Toe in adjustment procedure if required If Camber readings are not within specifications refer to step Step 1 in the front camber adjustment cam bolt adjustment proce dure CAMBER ADJUSTMENT CAM BOLT PACKAGE INSTALLATION PROCEDURE 1 If the front camber readings obtained are not within the vehicle s specifications use the following procedure and the Mopar Clev...

Page 38: ... the original attach ing bolts onto the replacement bolts from the service kit Tighten the bolts just enough to hold the steering knuckle in position when adjusting camber while still allowing the steering knuckle to move in clevis bracket 9 Lower vehicle until the full weight of the vehi cle is supported by the vehicles suspension Then correctly jounce the front and rear of vehicle an equal amoun...

Page 39: ...r boots during front wheel Toe adjustment 3 Loosen front inner to outer tie rod end jam nuts Fig 7 Grasp inner tie rods at serrations and rotate inner tie rods of steering gear Fig 7 to set front Toe to the preferred Toe specification See Alignment Specifications in this group of the service manual for preferred specification 4 Tighten tie rod jam nuts Fig 7 to 75 N m 55 ft lbs torque 5 Adjust ste...

Page 40: ... Difference Not To Exceed 0 00 0 50 MAX 0 00 0 50 MAX 0 00 0 50 MAX FRONT INDIVIDUAL CASTER IN DEGREES 1 40 or 1 00 1 40 or 1 00 1 40 or 1 00 Front Side To Side Caster Difference Not To Exceed 0 00 1 00 MAX 0 00 1 00 MAX 0 00 1 00 MAX FRONT INDIVIDUAL TOE RIGHT LEFT 0 05 or 0 10 0 05 or 0 10 0 05 or 0 10 FRONT TOTAL TOE Specified In Degrees 0 10 or 0 20 0 10 or 0 20 0 10 or 0 20 FRONT SIDE TO SIDE...

Page 41: ... at the time the vehicle is designed Lower control arms are attached inboard to the cast aluminum front suspension cradle and outboard to the bottom of the steering knuckle Attachment of the lower control arm to the steering knuckle is done through a ball joint in the lower control arm During steering maneuvers the strut and the steering knuckle through the ball joint and a pivot bearing in the st...

Page 42: ...lamp bolt clearance The stud is clamped and locked into the steering knuckle leg with a clamp bolt The ball joint is lubricated for the life of the vehi cle and does not require any periodic lubrication STABILIZER BAR The stabilizer bar interconnects both Mc Pherson strut assemblies of the vehicle and is attached through rubber isolator bushings to the front suspen sion cradle Jounce and rebound m...

Page 43: ...y the studs CAN NOT be hammered out of the hub flange If a stud is removed by hammering it out of the bearing flange damage to the hub and bearing assembly will occur leading to premature bearing failure Use the procedure and special tools shown in the service procedures section for the wheel mounting studs when replacing the wheel attaching studs The hub and bearing assembly does not require remo...

Page 44: ... off sway bar HUB AND BEARING ASSEMBLY The condition of the front hub and bearing assem bly is diagnosed using the inspection and testing pro cedure detailed below The bearing contained in the Unit III front hub bearing assembly will produce noise and vibration when worn or damaged The noise will generally change when the bearings are loaded A road test of the vehicle is normally required to deter...

Page 45: ...ont of vehicle requiring strut removal 3 If both strut assemblies are to be removed mark the strut assemblies right or left according to which side of the vehicle they were removed from 4 Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets Fig 6 NOTE When removing nut from stud of stabilizer bar attaching link do not allow stud ...

Page 46: ...rom rotating by inserting a Torx Plus 40IP bit in the end of the stud as shown in Fig 10 4 Tighten the stabilizer bar link to strut attach ing nut using a Torx Plus 40IP bit and crowfoot as shown in Fig 10 to a torque of 88 N m 65 ft lbs 5 Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly brackets Fig 6 Tighten the routing bracket attaching bolts to a torqu...

Page 47: ... Caliper is removed by first rotating top of caliper away from steering knuckle and then removing bottom of caliper out from under machined abutment on steering knuckle Fig 14 8 Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly Fig 15 Do not allow the brake caliper assem bly to hang by the brake flex hose Fig 11 Hub Bearing To Stub Axle Retaining Nu...

Page 48: ... Fig 18 12 Remove the front wheel speed sensor Fig 19 from the steering knuckle 13 If equipped remove the wheel stop Fig 20 from the steering knuckle When installing the pinch bolt when assembling the steering knuckle to the ball joint the pinch bolt must be installed from the rear facing the front on the vehicle Fig 16 Remove Install Brake Rotor Fig 17 Removing Tie Rod End Attaching Nut Fig 18 Ti...

Page 49: ...e turned during removal Remove nuts while holding bolts stationary in the steering knuckles 17 Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts Fig 24 18 Remove the steering knuckle from the strut INSTALL 1 Transfer or install if necessary a new hub bearing assembly into the steering knuckle Refer to Hub And Bearing Assembly Service in this section of the service manual...

Page 50: ... caliper against top abutment Fig 14 8 Install disc brake caliper assembly to steering knuckle attaching bolts Fig 13 Tighten the disc brake caliper assembly attaching bolts to a torque of 35 N m 30 ft lbs 9 Clean all foreign matter from the threads of the outer C V joint stub axle Install the washer and stub axle to hub bearing assembly nut on stub axle and securely tighten nut 10 Install wheel s...

Page 51: ...e cradle plate are of two different thread sizes Nine of the bolts are a M 14 thread and one of the bolts is a M 12 thread Refer to Fig 30 for the cradle plate attaching bolt locations 5 Remove the 10 bolts Fig 30 attaching the cra dle plate to the front suspension cradle Then remove the cradle plate from the cradle CAUTION Pulling steering knuckle out from vehi cle after releasing from ball joint...

Page 52: ...vot bolt to clear the tran saxle 10 Lower the left front corner of the suspension cradle until pivot bolt will clear end of transaxle Fig 35 Remove the pivot bolt and the lower control arm from the cradle INSTALL NOTE If the left lower control arm is being installed on the vehicle the front suspension cradle needs to be lowered for the pivot bolt to clear the transaxle 1 Position lower control arm...

Page 53: ...le attaching bolts Fig 30 Tighten the 9 M 14 attach ing bolts Fig 30 to a torque of 165 N m 123 ft lbs Tighten the 1 M 12 attaching bolt Fig 30 to a torque of 108 N m 80 ft lbs CAUTION When locating jack stands under lower control arm do not place the jack stands under the ball joints Fig 38 7 Position jack stands under the lower control arms as close to the ball joints as possible Fig 38 Lower th...

Page 54: ... joint is not cocked in the bore of the control arm this will cause the ball joint to bind when being pressed into control arm 2 Position control arm with installed ball joint in an arbor press with Receiving Cup Special Tool 6758 supporting the lower control arm Fig 42 Then cen ter Installer Special Tool 6908 4 on the bottom of the ball joint Fig 42 3 Carefully align all pieces Then press the bal...

Page 55: ...l balloon and dam age seal boot Do not over grease the ball joint this will prevent the seal boot from pushing down on the stud of the ball joint CAUTION After the ball joint is properly greased clip the end of the grease fitting off below the hex The ball joint seal boot is non purgeable and further greasing is not required and can result in damage to the seal boot STABILIZER BAR REMOVE 1 Raise v...

Page 56: ...ward the ground when the stabilizer bar is installed on the vehi cle Fig 49 2 Position stabilizer bar into front suspension cradle so stabilizer bar bushings are aligned with depressions in cradle Install stabilizer bar bushing retainers onto crossmember aligning raised bead on retainer with cutouts in bushings Fig 50 Do not tighten Stabilizer bar bushing retainers at this time 3 Check position of...

Page 57: ... NOTE Replacement of the Unit III front hub bearing assembly can be normally done without having to remove the steering knuckle from the vehicle In the event that the hub bearing is frozen in the steering knuckle and cannot be removed by hand it will have to be pressed out of the steering knuckle The steering knuckle will require removal from the vehi cle to allow the hub bearing assembly to be pr...

Page 58: ...kle attaching bolts Fig 54 7 Remove disc brake caliper assembly from steer ing knuckle Caliper is removed by first rotating top of caliper away from steering knuckle and then removing bottom of caliper out from under machined abutment Fig 55 8 Support disc brake caliper assembly using a wire hook Fig 56 do not hang caliper assembly by hydraulic hose 9 Remove the braking disc from the front hub bea...

Page 59: ... of 65 N m 45 ft lbs 3 Install the hub bearing assembly to stub shaft washer and retaining nut Fig 61 Tighten but do not torque the hub nut at this time 4 Install the braking disk on the hub and bearing assembly 5 Install front brake caliper back over braking disc and align with caliper mounting holes on steer ing knuckle Fig 55 Caliper is installed by first installing bottom of caliper under mach...

Page 60: ...rocedure to be used for this vehicle 2 Remove the front wheel and tire assembly from the vehicle 3 Remove the front caliper assembly from the front steering knuckle assembly Fig 62 Refer to Front Disc Brake Service in the Brake Section of this service manual for caliper removal procedure 4 Remove front rotor from hub by pulling it straight off wheel mounting studs Fig 63 5 Install a lug nut on the...

Page 61: ... of the wheel attaching studs 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 the rear wheel and tire assembly 3 Remove the rear brake drum 4 Install a lug nut on the wheel stud to be removed from the hub and bearing assembly Fig 66...

Page 62: ...RUT ASSEMBLY COIL SPRING IS COM PRESSED REMOVING SPRING TENSION FROM UPPER SPRING SEAT AND BEARING ASSEMBLY WARNING WHEN COMPRESSING COIL SPRING FOR REMOVAL FROM STRUT ASSEMBLY THE UPPER SPRING SEAT AND SECOND COIL OF THE COIL SPRING MUST BE CAPTURED BY THE JAWS OF THE COIL SPRING COMPRESSOR Fig 69 3 Compress strut coil spring using Pentastar Service Equipment Spring Compressor 7522A Fig 69 Be sur...

Page 63: ...ect strut damper for any condition of shaft binding over full stroke of the shaft 12 Inspect the strut mount and the upper spring seat assembly for the following Mount for cracks and distortion and retaining studs for any sign of damage Severe deterioration of rubber isolator Binding strut assembly pivot bearing If pivot bearing is replaced it is to be installed with the larger diameter end of bea...

Page 64: ... to be installed with the end of the bottom coil aligned with the clevis bracket on the strut assembly Fig 77 6 Install the upper spring seat on the coil spring Fig 77 Spring seat must be installed with the notch in the spring seat Fig 77 aligned with the clevis bracket on the strut WARNING WHEN COMPRESSING THE COIL SPRING THE COIL SPRING UPPER SEAT AND THE BOTTOM COIL OF THE SPRING MUST BE CAP TU...

Page 65: ...l the sealing boot on the ball joint Damage to the seal ing boot will occur if excessive pressure is applied to the sealing boot when it is being installed 2 Place Installer Special Tool 6758 over seal boot and squarely align it with bottom edge of seal boot Fig 81 Apply hand pressure to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm CAUTION A replac...

Page 66: ...2 Fig 82 INSTALL 1 Securely mount the lower control arm in a vise NOTE The lower control arm front bushing is a directional bushing It must be installed in the lower control arm positioned as shown in Fig 83 2 Position the front bushing in the lower control arm so that the 2 rubber blocks on the bushing are positioned horizontally as shown in Fig 83 3 Assemble for installation of the front bushing...

Page 67: ...lubricant specified below to the control arm bushing 1 Apply Mopar Silicone Spray Lube or an equiv alent to the hole in lower control arm rear bushing This will aid in the installation of the bushing on the lower control arm 2 With the lower control arm held securely in a vise install bushing on lower control arm Install bushing by pushing and rocking the bushing until it is fully installed on low...

Page 68: ...taching Bolts 183 N m 135 ft lbs Tie Rod End Adjusting Sleeve Nut 75 N m 55 ft lbs Tie Rod End To Steering Knuckle Nut 61 N m 45 ft lbs FRONT SUSPENSION CRADLE To Body Attaching Bolts 163 N m 120 ft lbs Lower Control Arm Pivot Bolt 185 N m 137 ft lbs Lower Control Arm Rear Bushing Retainer Bolt 68 N m 50 ft lbs Reinforcement Plate Attaching Bolts M 12 108 N m 80 ft lbs Reinforcement Plate Attachin...

Page 69: ...SPECIAL TOOLS FRONT SUSPENSION Installer Ball Joint 6758 Wrench Strut Rod Nut 6864 Remover Ball Joint 6919 Remover Installer Control Arm Bushing 6908 Remover Tie Rod End MB 991113 NS SUSPENSION 2 37 ...

Page 70: ...N The rear suspension design on this vehicle uses leaf springs and a tube and casting axle Fig 1 and Fig 2 It is designed to handle the various load requirements of the vehicle The leaf springs used on the rear suspension of this vehicle are of either a mono leaf or multi leaf design The rear axle used on front wheel drive applica tions of this vehicle is mounted to the rear leaf springs using iso...

Page 71: ...bearings are permanently sealed and require no maintenance The bearing and hub are serviced as an assembly For service procedures refer to Group 5 Brakes DESCRIPTION AND OPERATION REAR WHEEL ALIGNMENT Alignment adjustment is not required The rear axle alignment settings are preset at the factory and therefore no alignment is necessary REAR TRACK BAR On front wheel drive applications of this vehicl...

Page 72: ...which is just the extension and compression of the shock absorber On the outside it looks like a larger than normal shock absorber Internally it consists of a hydraulic pump and gas spring cushion for leveling as well as the normal shock absorbing mechanism All the height leveling sensors pump etc are contained inside the shocks The shocks are mounted at an angle parallel to the springs and forwar...

Page 73: ...r axle Fig 6 6 Remove the axle plate from the rear axle and the leaf spring Fig 7 7 Using the jack stands slowly lower the rear axle permitting the rear springs to hang free 8 Loosen and remove the 4 bolts Fig 8 from the front mount of the leaf spring 9 Loosen and remove the nuts from the spring hanger Fig 9 for the rear leaf spring Then remove the hanger plate from the hanger and remove the sprin...

Page 74: ...tallation of spring 2 Raise front of spring and install four hanger bolts tighten to 61 N m 45 ft lbs torque 3 Install rear of spring onto rear spring shackle Install shackle plate Do not tighten 4 Verify lower leaf spring isolator is in position 5 Raise axle into correct position on leaf spring with axle centered under spring locator post Fig 12 6 Verify that the leaf spring isolator is correctly...

Page 75: ...5 Using 2 jack stands positioned under the outer ends of the axle raise the axle enough to remove the weight of the axle from the rear springs 6 Loosen and remove the axle plate bolts from the rear axle Fig 14 7 Using the jack stands slowly lower the rear axle permitting the rear springs to hang free 8 Loosen and remove the 4 bolts Fig 15 at the front mount of the rear leaf spring 9 Loosen and rem...

Page 76: ...r hanger Install the inner half of the rear hanger Install the nut and bolts on the rear hanger but do not tighten at this time 4 Raise axle assembly into correct position with axle centered under spring locator post 5 Install axle plate bolts Tighten bolts to 108 N m 80 ft lbs torque 6 Install shock absorber bolts Do not tighten 7 Lower vehicle to floor and with full weight of vehicle on wheels T...

Page 77: ...ir specified torques REAR TRACK BAR REMOVE 1 Remove the nut and bolt mounting the track bar to the rear axle Fig 19 2 Remove the nut and bolt attaching the track bar to the track bar mount on the body of the vehicle Remove the track bar from the track bar mount INSTALL 1 Install the track bar first into the body mount for the track bar Fig 20 Install the track bar bolt with the head of the bolt fa...

Page 78: ...lizer bar bushings on the stabilizer bar with the slit in the bushings facing up 3 Lift the stabilizer bar onto the rear axle and install the retainers and the four mounting bolts DO NOT TIGHTEN 4 Install the two lower link arm bolts on the sta bilizer bar DO NOT TIGHTEN 5 Lower the vehicle so that the full weight of the vehicle is on all four tires With the vehicle at its curb height tighten all ...

Page 79: ...t the weight of the axle and leaf spring 3 Remove the lower mounting bolt from the shock absorber 4 Remove the bolts attaching the leaf spring front mount Fig 26 to the body of the vehicle 5 Lower the leaf spring and remove the front mount from the spring INSTALLATION 1 For installation reverse removal procedure Do not tighten front through bolt fully until vehicle is lowered and the full vehicle ...

Page 80: ...ls Tighten rear spring mount bolts to 61 N m 45 ft lbs Tighten shackle nuts to 61 N m 45 ft lbs SPECIFICATIONS REAR SUSPENSION FASTENER TORQUES DESCRIPTION TORQUE SHOCK ABSORBER MOUNTING BOLTS Standard Shock Absorber 101 N m 75 ft lbs Self Load Leveling Shock Absorber 101 N m 75 ft lbs JOUNCE BUMPER To Frame Rail 33 N m 290 in lbs TRACK BAR To Axle And Mounting Bracket Pivot Bolt 95 N m 70 ft lbs ...

Page 81: ...r proper ride heights and damaged worn out suspension components and replace as necessary Toe In is positive Toe Camber and thrust angle are not adjustable If found to be out of specification check for proper ride heights and damaged worn out suspension components and replace as necessary When Measuring ride heights 1 Ensure that the tire pressures are correct 2 Jounce the vehicle at the bumper se...

Page 82: ...MAX REAR INDIVIDUAL CAMBER IN DEGREES 0 00 or 0 25 0 00 or 0 25 0 10 or 0 25 REAR INDIVIDUAL TOE RIGHT LEFT 0 00 or 0 40 0 00 or 0 40 0 00 or 0 40 REAR TOTAL TOE Specified In Degrees TOE OUT When Backed On Alignment Rack Is TOE In When Driving 0 00 or 0 40 0 00 or 0 40 0 00 or 0 40 REAR THRUST ANGLE 0 00 or 0 30 0 00 or 0 30 0 00 or 0 30 STEERING WHEEL ANGLE 0 00 or 2 50 0 00 or 2 50 0 00 or 2 50 ...

Page 83: ...r hoisting positions for this vehicle are to be used whenever it is necessary to lift a vehicle Failure to raise a vehicle from the recommended locations could result in lifting a vehicle by the hydraulic control unit mounting bracket Lifting a vehicle by the hydraulic control unit mounting bracket will result in damage to the mount ing bracket and the hydraulic control unit BASE BRAKE SYSTEM COMP...

Page 84: ...2 Non Antilock Brakes Hydraulic Brake Tube Routing And Fitting Locations Fig 3 Antilock Brakes Traction Control Hydraulic Brake Tube Routing And Fitting Locations 5 2 BRAKES NS GENERAL INFORMATION Continued ...

Page 85: ...E CABLE 66 JUNCTION BLOCK 55 LEFT REAR PARK BRAKE CABLE 67 MASTER CYLINDER 44 PARK BRAKE PEDAL MECHANISM 58 PARK BRAKE SHOES WITH REAR DISC BRAKES 60 PROPORTIONING VALVE W ABS BRAKES 56 PROPORTIONING VALVE W O ABS BRAKES 57 REAR BRAKE DRUM 33 REAR BRAKE WHEEL CYLINDER 39 REAR DISC BRAKE CALIPER 28 REAR DISC BRAKE SHOES 31 REAR DRUM BRAKE SHOES 34 RIGHT REAR PARK BRAKE CABLE 66 STOP LAMP SWITCH 69 ...

Page 86: ...ts which thread directly into the steering knuckle Fig 3 The two machined abutments on the steering knuckle position and align the caliper fore and aft The guide pin bolts sleeves and bushings control the side to side movement of the caliper The piston seal is designed to assist in maintaining the proper brake shoe to rotor clearance All the front brake forces generated during braking of the vehic...

Page 87: ...le is equipped with a caliper having a 42 mm 1 65 in piston and uses a 15 inch solid non vented rotor The disc brake caliper floats on rubber bushings using threaded guide pin bolts which are attached to the back side of the adapter The adapter and rotor shield are mounted to the rear axle The adapter is used to mount the brake shoes and actuating cables for the parking brake sys tem The adapter i...

Page 88: ...s on this vehicle are prohibited Using air shock absorbers or helper springs on this vehicle will cause the height sens ing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes This inap propriate reduction in hydraulic pressure potentially could result in increased stopping distance of the vehicle On vehicles not equipped with ABS brakes the brake systems hydrau...

Page 89: ...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 the external surfaces and the flex hoses are made of reinforced rubber The rubber flex hoses allow for the movement of the vehi cles suspension MASTER CYLINDER The master cylinder Fig 9 ...

Page 90: ...master cylinder move forward this creates the hydraulic pressure in the brake system The different engine combinations used on this vehicle require that different vacuum hose routings to the power brake vacuum booster be used All vacuum hoses must be routed from the engine to the power brake vacuum booster without kinks excessively tight bends or potential for damage to the vacuum hose The power b...

Page 91: ...s The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the stop lamps HUB BEARING REAR WHEEL The rear hub and bearing assembly used on this vehicle is serviceable only as a complete assembly No attempt should be made to disassemble a rear hub and bearing assembly in an effort to repair it The rear hub and bearing assembly is attached to the rear axle us...

Page 92: ...BRAKE SYSTEM DIAGNOSIS CHARTS MISCELLANEOUS BRAKE SYSTEM CONDITIONS 5 10 BRAKES NS DIAGNOSIS AND TESTING Continued ...

Page 93: ...RED BRAKE WARNING LAMP FUNCTION NS BRAKES 5 11 DIAGNOSIS AND TESTING Continued ...

Page 94: ...POWER BRAKE SYSTEM DIAGNOSTICS 5 12 BRAKES NS DIAGNOSIS AND TESTING Continued ...

Page 95: ...VEHICLE ROAD TEST BRAKE NOISE NS BRAKES 5 13 DIAGNOSIS AND TESTING Continued ...

Page 96: ...king surface of the rotor Flatness If a vehicle has not been driven for a period of time the rotors will rust in the area not covered by the brake lining and cause noise and chatter when the brakes are applied Excessive wear and scoring of the rotor can cause temporary improper lining contact if ridges are not removed from braking surface of rotor before instal lation of new brake shoe assemblies ...

Page 97: ...ication install rotor on hub with chalk marks two wheel studs apart Fig 16 Tighten nuts in the properse quence and torque to specification Finally check lat eral runout of rotor to see if lateral runout is now within specification If lateral runout is not within specification install a new rotor or reface rotor being careful to remove as little rotor material as possible from each side of rotor Re...

Page 98: ... a vehicle being tested are either original equipment manufac turers OEM or original replacement brake shoe assemblies meeting the OEM lining mate rial specification The vehicles brake system is not balanced for after market brake shoe assembly lining material If brake shoe assembly lining material is of satis factory condition and of the correct material specifi cation check for proper proportion...

Page 99: ...nlet pressure is obtained replace the proportioning valve 9 Repeat steps 2 through 7 for the other propor tioning valve of the assembly CAUTION When mounting the original or a replacement proportion valve on the frame rail of the vehicle install the mounting bolts in only the two forward holes of the mounting bracket Fig 19 HEIGHT SENSING PROPORTIONING VALVE CAUTION The use of after market load le...

Page 100: ...g 23 3 Install the required fittings from Pressure Test Fittings Special Tool 6833 Fig 24 into the inlet port of the proportioning valve assembly from which the chassis brake line was removed Install the removed chassis brake line into the Pressure Test Fitting Fig 24 Install the required fitting from Pressure Test Fittings Special Tool 6833 into the required outlet port of the proportioning valve...

Page 101: ...ly flush system Replace master cylinder propor tioning valve caliper seals wheel cylinder seals Antilock Brakes hydraulic unit and all hydraulic fluid hoses RED BRAKE WARNING LAMP TEST For diagnosis of specific problems with the red brake warning lamp system refer to Brake System Diagnostics Chart 2 located in the Diagnosis And Testing section in this group of the service manual TRACTION CONTROL L...

Page 102: ...ore removing the master cylinder cover throughly clean the cover and master cylin der fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir CAUTION Use bleeder tank Special Tool C 3496 B with adapter Special Tool 6921 to pressurize the hydraulic system for bleeding CAUTION When pressure bleeding the brakes hydraulic system the fluid reservo...

Page 103: ...the brakes hydraulic system will require the aid of a helper NOTE To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted Prior to the manual bleeding of the brake hydraulic system correctly adjust the rear brakes NOTE The following wheel sequence should be used when bleeding the brake hydraulic system The use of this wheel sequence will ensure...

Page 104: ...nstall fill cap on reservoir 6 Remove master cylinder from vise 7 Install the filler cap from the master cylinder filler neck on the master cylinder fluid reservoir 8 Install the master cylinder assembly on the power brake vacuum booster NOTE Note It is not necessary to bleed the ABS hydraulic control unit HCU after replacing the master cylinder But the base brake hydraulic sys tem must be bled to...

Page 105: ...ides of the rotor at the same time is highly recommended RESURFACNG BRAKE ROTOR This operation can be used when rotor surface is rusty has lining deposits or excessive lateral runout or thickness variation is evident A sanding rotor attachment Fig 33 will remove surface contamination without removing much rotor material It will generally follow variations in thickness that are in the rotor Fig 32 ...

Page 106: ...in steel tubing with Al rich ZW AC alloy coating and the correct tube nuts are to be used for replacement of a hydraulic brake tube NOTE On vehicles equipped with traction control the primary and secondary hydraulic tubes between the master cylinder and the hydraulic control unit are 6 mm 15 64 in These tubes are also coated with the Al rich ZW AC alloy and must be replaced with tubes having the s...

Page 107: ...d of the tubing Remove gauge and con tinue to screw down until tool is firmly seated in tub ing Remove tubing from flaring tool and inspect seat Refer to tube routing diagrams for proper brake tube routing and clip locations Replace any damaged tube routing clips ISO TUBING FLARES CAUTION All ISO style tubing flares Fig 39 and Fig 40 are of metric dimensions When performing any service procedures ...

Page 108: ...k brake pedal mechanism used in this vehi cle is designed so that the auto adjuster is not required to be locked out when servicing the park brake pedal and or the park brake cables This park brake pedal mechanism is designed so that the adjuster mechanism will rotate only half a turn when the tension is released from the park brake cable This eliminates the requirement to lock out the automatic a...

Page 109: ...29 N m 95 ft lbs Never use oil or grease on studs or nuts FRONT DISC BRAKE CALIPER SERVICE PRECAUTIONS WARNING ALTHOUGH FACTORY INSTALLED BRAKE LININGS ARE MADE FROM ASBESTOS FREE MATERIALS SOME AFTER MARKET BRAKE LINING MAY CONTAIN ASBESTOS THIS SHOULD BE TAKEN INTO ACCOUNT WHEN SERVICING A VEHICLE S BRAKE SYSTEM WHEN AFTERMARKET BRAKE LININGS MAY HAVE BEEN INSTALLED ON THE VEHICLE ALWAYS WEAR A ...

Page 110: ...r of the steering knuckle bosses 3 Install the caliper guide pin bolts Fig 44 and tighten to a torque of 41 N m 40 ft lbs Extreme caution should be taken not to cross thread the caliper guide pin bolts 4 Install the wheel and tire assembly 5 Using a torque wrench tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification Then repeat the tightening sequ...

Page 111: ...the rear rotor on the hub making sure it is squarely seated on the face of the hub CAUTION Use care when installing the caliper assembly onto the adapter so the caliper guide pin bushings do not get damaged by the mounting bosses 4 Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse proce dure for removal Fig 48 CAUTION When installing guide pin bolts extreme ...

Page 112: ... FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBES TOS CAUTION During service procedures grease or any other foreign material must be kept off brake shoe assemblies and braking surfaces of brake drum and external surfaces of hub bearing assem bly 1 Remove outboard brake pad by prying the pad retaining clip over raised area on caliper Fig 50 Then slide the pad down and off the caliper 2 Pull i...

Page 113: ...rease or any other for eign material must be kept off brake shoe assem blies and braking surfaces of brake drum and external surfaces of hub bearing assembly Handling of the braking disc and caliper is to be done in such a way as to avoid deformation of the disc and scratching or nicking of brake linings If inspection reveals that the square sectioned cal iper piston seal is worn or damaged it MUS...

Page 114: ...dust boot and caliper pin bush ings to determine if they are in good condition Replace if they are damaged dry or found to be brit tle Refer to Cleaning And Inspection Of Brake Cali per INSTALL NOTE Step 1 below is only required when install ing a caliper after new brake shoes have been installed 1 Completely retract caliper piston back into pis ton bore of caliper assembly 2 Lubricate both adapte...

Page 115: ... park brake cable for the wheel of the vehicle that is being worked on from the park brake cable equalizer Fig 60 This is required to gain access to the star wheel If the cable is not removed from the equalizer the cable and spring inside of the brake drum is in the way of the star wheel 2 Remove the rear brake shoe adjusting hole cover plug 3 Insert a thin screwdriver into brake adjusting hole an...

Page 116: ...VI RONMENTAL PROTECTION AGENCY EPA FOR HANDLING AND DISPOSAL OF PRODUCTS CON TAINING ASBESTOS 1 Raise vehicle on jackstands or centered on a hoist See Hoisting in the Lubrication and Mainte nance section of this manual 2 Remove the rear wheel and tire assemblies from the vehicle 3 Remove rear brake drum to hub retaining nuts if equipped Then remove rear brake drums from hub and bearing assemblies ...

Page 117: ...ver and park brake actuating strut Fig 69 Remove the automatic adjuster assembly from the leading brake shoe 12 Remove the leading brake shoe assembly to brake support plate hold down spring and pin Fig 70 from the brake shoe Remove the leading brake shoe from the brake support plate 13 Remove the park brake actuator Fig 71 from the leading brake shoe and transfer to the replacement brake shoe Fig...

Page 118: ...tic adjuster screw on the leading brake shoe Then install the trailing brake shoe on the park brake actuating lever and park brake actuating strut Fig 69 Position trailing brake shoe on brake support plate 5 Install the brake shoe hold down pin and spring on the trailing brake shoe Fig 68 6 Install the brake shoe to brake shoe upper return spring Fig 67 Fig 69 Trailing Brake Shoe Removal Installat...

Page 119: ... mounting stud nuts in proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 130 N m 95 ft lbs 19 Road test vehicle The automatic adjuster will continue the brake adjustment during the road test of the vehicle BRAKE SUPPORT PLATE REAR DRUM BRAKES REMOVE 1 Raise vehicle on jackstands or centered on a frame contact type h...

Page 120: ...the hole until tool fits properly d Align bolt in Special Tool 8214 2 with pilot hole in Special Tool 8214 1 Tighten bolt against Special Tool 8214 1 e Press hub bearing out of axle by continuing to tighten bolt in Special Tool 8214 2 against Spe cial Tool 8214 1 9 Remove the hub bearing from the rear axle and brake support plate Fig 77 10 Using a suitable tool such as a 14 mm box wrench Fig 78 or...

Page 121: ... 8 Install the rear wheel speed sensor on the rear hub bearing flange Fig 74 Install the speed sensor attaching bolt and tighten to a torque of 12 N m 105 in lbs 9 Install the rear park brake cable into its mounting hole in the rear brake support plate 10 Install the park brake cable on the park brake actuation lever 11 Install the rear brake shoes on the brake sup port plate Refer to Brake Shoe S...

Page 122: ...not be removed unless the speed sensor is removed first CAUTION When working in the area of the rear hub bearing and when removing it from the rear axle care must be used so the teeth on the tone wheel are not damaged Damage to the teeth on the tone wheel will result in false ABS cycling and cor rosion of the tone wheel 5 Remove the 4 bolts Fig 83 attaching the hub bearing to the rear axle CAUTION...

Page 123: ...equence to a torque of 129 N m 95 ft lbs 9 Adjust the rear brakes See Adjusting Service Brakes in Service Adjustments section in this group of the service manual ALL WHEEL DRIVE REMOVE 1 Set the parking brake The parking brake is set to keep the hub bearing and axle shaft from rotating when loosening the hub nut 2 Raise vehicle Vehicle is to be raised and sup ported on jackstands or on a frame con...

Page 124: ...aliper to prevent the weight of the caliper from damaging the flexible brake hose Fig 93 13 Remove the rotor from the hub bearing Fig 87 Spring Washer Fig 88 Hub Nut And Washer Fig 89 Driveshaft Attachment To Driveline Module Fig 90 Wheel Speed Sensor Fig 91 Caliper Guide Pin Bolts Fig 92 Removing Installing Caliper 5 42 BRAKES NS REMOVAL AND INSTALLATION Continued ...

Page 125: ...he disc brake caliper adapter and hub bearing from the axle The hub bearing will then need to be removed from the caliper adapter 16 Remove the hub bearing from the axle Fig 95 17 If the disc brake caliper adapter and hub bearing were removed as an assembly from the axle and the hub bearing cannot be removed from the adapter by hand use the following procedure to remove it from the adapter With a ...

Page 126: ...al times to insure the vehicle has a firm brake pedal to adequately stop vehicle 19 Road test vehicle to ensure proper operation of the brake system MASTER CYLINDER CAUTION Different types of master cylinders are used on this vehicle Vehicles equipped with trac tion control use a center port master cylinder Vehi cles not equipped with traction control use a compensating port master cylinder Be sur...

Page 127: ...linder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster 9 Remove the vacuum seal located on the mount ing flange of the master cylinder The vacuum seal is removed from the master cylinder by carefully pull ing it away from the master cylinder Do not attempt to pry the seal off the master cylinder by inserting a sharp tool between seal and mas ter cylinde...

Page 128: ... expelled from master cylinder 5 Remove bleeding tubes from master cylinder outlet ports and then plug outlet ports and install fill cap on reservoir 6 Remove master cylinder from vise NOTE Note It is not necessary to bleed the ABS hydraulic control unit HCU after replacing the master cylinder But the base brake hydraulic sys tem must be bled to ensure no air is entered the hydraulic system when t...

Page 129: ...th the vehicle s engine not running until a firm feeling brake pedal is achieved 1 With engine not running pump brake pedal until a firm pedal is achieved 4 5 strokes 2 Remove both battery cables from battery 3 Remove the battery thermal guard and the bat tery from the battery tray 4 Remove the air inlet resonator and hoses as an assembly from the throttle body and air cleaner housing Fig 104 5 If...

Page 130: ...r up and toward the center of vehicle to remove CAUTION Do not attempt to disassemble the vac uum booster it is to be serviced ONLY as a com plete assembly INSTALL CAUTION When installing the vacuum booster in the vehicle be sure the heater hoses do not become trapped between the booster and the dash panel of the vehicle 1 Position vacuum booster onto dash panel using the reverse procedure for its...

Page 131: ...Install the battery cables on the battery 18 Check the operation of the stop lamp switch and adjust if necessary VACUUM BOOSTER 3 0 LITER ENGINE REMOVE CAUTION Stored vacuum in the vacuum booster must be pumped down removed before removing master cylinder from power brake booster This is necessary to prevent the power brake booster from sucking in any contamination as the master cylin der is remov...

Page 132: ... to brake pedal attachment under instrument panel Position a small screwdriver between the cen ter tang on the power brake booster input rod to brake pedal pin retaining clip Fig 115 14 Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin Then pull retaining clip off brake pedal pin Discard retaining clip It is not to be reused Replace only with a new r...

Page 133: ...ON The master cylinder is used to create the seal for holding vacuum in the power brake vac uum booster The vacuum seal on the master cylin der MUST be replaced with a NEW seal whenever the master cylinder is removed from the power brake vacuum booster CAUTION When removing the vacuum seal from the master cylinder do not use a sharp tool 6 Using a soft tool such as a trim stick remove the vacuum s...

Page 134: ...the vehicle s engine not running until a firm feeling brake pedal is achieved 1 With engine not running pump the brake pedal until a firm pedal is achieved 4 5 strokes 2 Remove both battery cables from battery 3 Remove the battery thermal guard and the bat tery from the battery tray 4 Remove the air inlet resonator and hoses as an assembly from the throttle body and air cleaner housing Fig 118 5 I...

Page 135: ...cylinder when removing the master cylinder from the vacuum booster 14 Remove master cylinder and brake tubes as an assembly from the vacuum booster When master cylinder is removed lay it out of the way on top of the left motor mount Fig 120 Electrical Connector At EGR Transducer Fig 121 Electrical And Vacuum Connections To Throttle Body Fig 122 Throttle Body Attachment To Intake Manifold Fig 123 F...

Page 136: ...attempt to disassemble the power brake vacuum booster it is to be serviced ONLY as a complete assembly INSTALL CAUTION When installing the power brake vacuum booster in the vehicle be sure the heater hoses do not become trapped between the booster and the dash panel of the vehicle 1 Position vacuum booster on dash panel using the reverse procedure of its removal 2 Install the 4 nuts mounting the v...

Page 137: ...the 2 bolts and the nut to a torque of 14 N m 125 in lbs 17 If vehicle is equipped with speed control install the speed control servo and bracket on the battery tray Install and securely tighten bolt attach ing bracket to battery tray 18 If vehicle is equipped with speed control install the wiring harness connector on the speed control servo Then connect the vacuum lines onto the speed control ser...

Page 138: ...avel This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve 2 Raise vehicle on jackstands or centered on a hoist See Hoisting in the Lubrication And Mainte nance Group of this service manual CAUTION Before removing the brake tubes from the proportioning valve the proportioning valve and the brake tubes must be thoroughly...

Page 139: ...not function ing properly the proportioning valve must be replaced as an assembly REMOVE 1 Using a brake pedal depressor move and lock the brake pedal to a position past its first 1 inch of travel This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve 2 Raise vehicle on jackstands or centered on a hoist See Hoisting in t...

Page 140: ... wall 4 75mm 3 16 in steel tubing with Al rich ZW AC alloy coating and the correct tube nuts are to be used for replacement of a hydraulic brake tube NOTE On vehicles equipped with traction control the primary and secondary hydraulic tubes between the master cylinder and the hydraulic control unit are 6 mm 15 64 in These tubes are also coated with the Al rich ZW AC alloy and must be replaced with ...

Page 141: ...hen install retainer into pedal bracket 4 Install cable strand button into the clevis on the park brake pedal mechanism 5 Install wiring harness connector on red brake warning lamp ground switch 6 Install the park brake release cable on the release mechanism of the park brake pedal 7 Position the park brake pedal mechanism into its installed position on the body of the vehicle 8 Remove the lock ou...

Page 142: ...140 from the stub shaft of the outer C V joint 6 Remove the hub nut and washer Fig 141 from the stub shaft of the outer C V joint 7 Release the parking brake 8 Create slack in the rear park brake cables by locking the out the automatic adjuster as described Grasp the exposed section of front park brake cable and pull downward on it Then install a pair of lock ing pliers on the front park brake cab...

Page 143: ...tainer 16 Remove the attaching bolt from the wheel speed sensor Fig 148 Then remove wheel speed sensor from hub bearing and adapter 17 Remove the hub bearing to axle mounting bolts Fig 149 18 Remove the hub bearing from the axle and the stub shaft of the outer C V joint Fig 150 19 Remove the adapter from the rear axle 20 Mount the adapter in a vise using the anchor boss for the park brake cable Fi...

Page 144: ...d pin Fig 153 from the leading park brake shoe Fig 148 Speed Sensor Attaching Bolt Fig 149 Hub Bearing Mounting Bolts Fig 150 Hub Bearing Removal And Installation Fig 151 Adapter Mounted In Vise Fig 152 Lower Return Spring Fig 153 Leading Brake Shoe Hold Down Pin And Spring 5 62 BRAKES NS REMOVAL AND INSTALLATION Continued ...

Page 145: ... INSTALL 1 Install the trailing brake shoe on the adapter NOTE When the hold down pin is installed the long part of the hold down pin is to be positioned strait up and down This will ensure that the hold down pin is correctly engaged with the adapter 2 Install the hold down spring and pin Fig 157 on the trailing park brake shoe 3 Install the upper return springs Fig 156 on the trailing park brake ...

Page 146: ...n the park brake cable retainer Fig 146 The horseshoe clip is installed between the retainer for the park brake cable and the adapter Horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of the curved end facing toward the rear of the vehicle Fig 146 16 Remove the locking pliers Fig 142 from the front park brake cable 17 Adjust the park brake drum in h...

Page 147: ...of the floor pan of vehicle 9 Pull park brake cable strand end forward and disconnect button from clevis Tap cable housing end fitting out of pedal assembly bracket 10 Remove cable retainer from the park brake pedal assembly bracket 11 Pull park brake cable assembly out of vehicle through hole in floor pan INSTALL 1 Pass park brake cable assembly through hole in floor pan from the inside of the ve...

Page 148: ...rake cable This will activate the automatic adjuster and correctly adjust the park brake cables 5 Install and position the foam collar on the park brake cable to prevent it from rattling against floor 6 Lower vehicle and apply the park brake pedal 1 time this will seat the park brake cables RIGHT REAR PARK BRAKE CABLE REMOVE 1 Raise vehicle on jackstands or centered on a hoist See Hoisting in the ...

Page 149: ...et making certain that cable housing retainer fingers lock the housing firmly into place 5 Connect the right rear park brake cable to the connector on the intermediate park brake cable Fig 165 6 Install the brake drum and the wheel and tire assembly 7 Remove the locking pliers from the front park brake cable This will automatically adjust the park brake cables 8 Apply and release park brake pedal ...

Page 150: ...tion Section of this service manual for the required procedure 8 Disconnect park brake cable from park brake actuator lever 9 Remove the park brake cable housing retainer from the brake support plate using a 14mm wrench to compress the retaining fingers Fig 171 INSTALL 1 Install the park brake cable in the brake sup port plate Insert cable housing retainer into brake support plate making certain t...

Page 151: ...n switch is fully installed in bracket rotate switch clockwise approximately 30 to lock switch into bracket CAUTION Do not use excessive force when pulling back on brake pedal to adjust the stop lamp switch If to much force is used damage to the stop lamp switch or striker Fig 172 can result 4 Gently pull back on brake pedal until the pedal stops moving This will cause the switch plunger to ratche...

Page 152: ...g to brake fluid reservoir seal grommets Fig 176 7 Install new master cylinder housing to brake fluid reservoir sealing grommets Fig 176 in master cylinder housing 8 Lubricate reservoir mounting area with fresh clean brake fluid Place reservoir in position over sealing grommets Seat reservoir into sealing grom mets using a rocking motion while firmly pressing down on fluid reservoir 9 Be sure flui...

Page 153: ...nder or brake fluid reservoir does not have to be removed from the vehicle for replace ment of the brake fluid level sensor 1 Remove wiring harness connector from brake fluid reservoir level sensor Fig 178 2 Using fingers compress the retaining tabs on the end of brake fluid level switch Fig 179 3 With retaining tabs compressed Fig 179 grasp opposite end of brake fluid level switch and pull it out...

Page 154: ...section of the bushing Fig 182 2 Insert the folded bushing into the caliper hous ing Fig 183 Do not use a sharp object to per form this step due to possible damage to the bushing 3 Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing Flanges should be seated evenly on both sides of the bushing hole Fig 184 4 Lubricate the inside surface...

Page 155: ...TION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE 1 Remove caliper from brake rotor See Brake Shoe Removal Hang assembly on a wire hook away Fig 183 Installing Caliper Guide Pin Bushing Fig 184 Bushing Correctly Installed In Caliper Fig 185 Installing Sleeve In Bushing Fig 186 Correctly Installed Caliper Sleeve And Bushin...

Page 156: ... seal groove 9 Clean all parts using alcohol or a suitable sol vent and wipe dry using only a lint free cloth No lint residue can remain in caliper bore Clean out all drilled passages and bores Whenever a caliper has been disassembled a new boot and seal must be installed at assembly 10 Inspect the piston bore for scoring or pitting Bores that show light scratches or corrosion can usu ally be clea...

Page 157: ...aliper bore pushing it past the piston seal until it bottoms in the caliper bore Fig 191 6 Position dust boot into the counterbore of the caliper assembly piston bore 7 Using a hammer and Installer Piston Caliper Boot Special Tool C 4689 and Handle Special Tool C 4171 drive boot into counterbore of the caliper Fig 192 8 Install guide pin sleeves and bushings See Install Guide Pin Bushings section ...

Page 158: ...anders in cylinder Install cups in each end of cylinder with open end of cups facing each other Fig 193 4 Install piston in each end of cylinder having the flat face of each piston contacting the flat face of each cup already installed Fig 193 5 Install a boot over each end of cylinder Fig 193 Be careful not to damage boot during installation CLEANING AND INSPECTION FRONT DISC BRAKE PAD LINING INS...

Page 159: ...sible disassemble cal iper assembly and install a new seal and boot and piston if scored Refer to Rear Disc Brake Caliper in the Disassembly And Assembly Section in this group of the service manual Check the guide pin dust boots to determine if they are in good condition Replace if they are damaged dry or found to be brittle Refer to Rear Disc Brake Caliper in the Disassembly And Assembly Section ...

Page 160: ...cle and should require no mainte nance The following procedure may be used for eval uation of bearing condition With wheel and brake drum removed rotate flanged outer ring of hub Excessive roughness lat eral play or resistance to rotation may indicate dirt intrusion or bearing failure If the rear wheel bear ings exhibit these conditions during inspection the hub and bearing assembly should be repl...

Page 161: ... upward until a slight drag is felt when road wheel is rotated 5 Insert a thin screwdriver or piece of welding rod into brake adjusting hole Push adjusting lever out of engagement with star wheel Care should be taken so as not to bend adjusting lever or dis tort lever spring While holding adjusting lever out of engagement back off star wheel to ensure a free wheel with no brake shoe drag 6 Repeat ...

Page 162: ...al Tool C 3919 or equivalent over the park brake shoes Fig 202 The special tool must be located straight across at the center widest point of the park brake shoes Fig 202 9 Using the star wheel adjuster adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool 10 Install rotor on hub bearing 11 Rotate rotor to verify that the park brake shoes ar...

Page 163: ... checked OK during inspection the height sens ing proportioning valve required replacement or there is a complaint of excessive pedal effort and the vacuum booster and brake pedal checked OK Make sure the proportioning valve and the mounting bracket are firmly attached to the vehicle Then pro ceed with the following procedure to perform the adjustment of the actuator 1 Raise vehicle Vehicle is to ...

Page 164: ...r type of brake fluid is recommended or approved for usage in the vehicle brake system Use only Mopar brake fluid or an equivalent from a tightly sealed container CAUTION Never use reclaimed brake fluid or fluid from an container which has been left open An open container will absorb moisture from the air and contaminate the fluid CAUTION Never use any type of a petroleum based fluid in the brake ...

Page 165: ...DESCRIPTION TORQUE BRAKE TUBES Tube Nuts To Fittings And Components 17 N m 145 in lbs BRAKE HOSE To Caliper Banjo Bolt 48 N m 35 ft lbs Intermediate Bracket 12 N m 105 in lbs MASTER CYLINDER To Vacuum Booster Mounting Nut 25 N m 225 in lbs FIXED PROPORTIONING VALVE To Frame Rail Attaching Bolts 14 N m 125 in lbs HEIGHT SENSING PROPORTIONING VALVE To Mounting Bracket Attaching Bolts 23 N m 200 in l...

Page 166: ...oportioning Valve Testing 6833 Tubes Master Cylinder Bleeding 6920 Adapter Master Cylinder Pressure Bleed Cap 6921 Dial Indicator C 3339 Gauge Brake Safe Set Gauge Set C 4007 A Fig 204 Handle Universal C 4171 Fig 205 Installer Dust Boot C 4689 5 84 BRAKES NS ...

Page 167: ...EL SPEED SENSOR FRONT 105 WHEEL SPEED SENSOR REAR AWD 108 WHEEL SPEED SENSOR REAR FWD 106 SPECIFICATIONS BRAKE FASTENER TORQUE SPECIFICATIONS 112 SPEED SENSOR TONE WHEEL RUNOUT 112 WHEEL SPEED SENSOR TO TONE WHEEL CLEARANCE 112 DESCRIPTION AND OPERATION ANTILOCK BRAKES OPERATION DESCRIPTION The purpose of an Antilock Brake System ABS is to prevent wheel lock up under braking conditions on virtu al...

Page 168: ...virtually uncontrollable In addition extreme steering maneuvers at high speed or high speed cor nering beyond the limits of tire adhesion to the road surface may cause vehicle skidding independent of vehicle braking For this reason the ABS system is termed Antilock instead of Anti Skid NOISE AND BRAKE PEDAL FEEL During ABS braking some brake pedal movement may be felt In addition ABS braking will ...

Page 169: ...of a master cylinder and power brake booster Fig 1 as a vehicle not equipped with antilock brakes A vehicle equipped with Teves Mark 20 ABS with Traction control uses a unique center port master cylinder If the master cylinder is replaced on a vehicle equipped with traction control be sure the right type of master cylin der is installed A vehicle equipped with four wheel disc brakes AWD applicatio...

Page 170: ...rvicing the ICU should a 12 volt power source be applied to any electrical connector of the HCU or the CAB INLET VALVES AND SOLENOIDS There are four inlet solenoids one for each wheel In the released position they provide a fluid path from the master cylinder to the wheel brakes of the vehicle When the ABS cycle has been completed the inlet solenoids will return to their released open position OUT...

Page 171: ...strument panel message center is located in the junction block On vehicles equipped with traction control the fuse for the traction control switch is also located in the junction block The junction block is located on the left hand front cowl panel on the vehicle ABS RELAYS On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are located in the CAB If either of...

Page 172: ... the front tone wheel on all vehicles and the rear tone wheel on all wheel drive vehicles are serviced as part of the front or rear driveshaft out board constant velocity joint Fig 7 and Fig 9 Correct ABS system operation is dependent on accurate wheel speed signals The vehicle s wheels and tires must all be the same size and type to gen erate accurate signals Variations in wheel and tire size can...

Page 173: ...program memory There are multiple fault messages which may be stored in the CAB and displayed through the DRB Scan Tool These fault messages will remain in the CAB memory even after the ignition has been turned off The fault messages can be read and or cleared from the CAB memory by a technician using the DRB Scan Tool The fault occurrence and the fault code will also be automati cally cleared fro...

Page 174: ...SOLENOID VALVE FUNCTION This hydraulic circuit diagram Fig 12 shows the vehicle in the ABS braking mode This hydraulic cir cuit Fig 12 shows a situation where one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than the surface the vehicle s tires are on will allow The normally open and nor mally closed valves modulate the brake hydraulic pressure as require...

Page 175: ...with every brake pedal application so pressure is not created at the inlet to the pump TEVES MARK 20 ABS WITH TRACTION CONTROL ABS BRAKING HYDRAULIC CIRCUIT SOLENOID AND SHUTTLE VALVE FUNCTION This hydraulic circuit diagram Fig 15 shows a vehicle equipped with ABS and traction control in the ABS braking mode This hydraulic circuit Fig 15 shows a situation where one wheel is slipping because the dr...

Page 176: ...Fig 13 ABS Mode Secondary Hydraulic Circuit Fig 14 ABS With Traction Control Normal Braking Hydraulic Circuit 5 94 BRAKES NS DESCRIPTION AND OPERATION Continued ...

Page 177: ...brake conditions which are obvi ously mechanical in nature should be directed to Group 5 Brakes in this service manual This includes brake noise brake pulsation lack of power assist parking brake Red BRAKE Warning Lamp lighting or vehicle vibration during normal braking Many conditions that generate customer com plaints may be normal operating conditions but are judged to be a problem due to not b...

Page 178: ...d the DRB operators manual for its proper operational information ABS BRAKE DIAGNOSTIC TOOL CONNECTOR On this vehicle the diagnostic connector used for the diagnosis of the ITT Teves Mark 20 ABS system is located under the lower steering column cover to the left side of the steering column just below the hood release lever Fig 17 The ITT Teves Mark 20 ABS system uses the ISO 9141 K connector which...

Page 179: ...ult to accurately diagnose Most intermittent electrical problems are caused by faulty electrical connections or wiring When an intermittent fault is encountered check suspect cir cuits for A visual inspection for loose disconnected or mis routed wires should be done before attempting to diagnose or service the ITT Teves Mark 20 antilock brake system A visual inspection will eliminate unnecessary t...

Page 180: ...aft assembly or rear hub bearing assembly if tonewheel runout exceeds the specification Inspect tonewheels for looseness on their mounting surfaces Tonewheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface Check the wheel speed sensor head alignment to the tone wheel Also check the gap between the speed sensor head and the tone wheel to ensur...

Page 181: ...connectors always turn the ignition to the OFF position CAUTION Use only factory wiring harnesses Do not cut or splice wiring to the brake circuits The addition of after market electrical equipment car phone radar detector citizen band radio trailer lighting trailer brakes ect on a vehicle equipped with antilock brakes may affect the function of the antilock brake system SERVICE PROCEDURES BRAKE F...

Page 182: ...ng an ABS equipped vehicle CAUTION Only the recommended jacking or hoist ing positions for this vehicle are to be used when ever it is necessary to lift a vehicle Failure to raise a vehicle from the recommended locations could result in lifting a vehicle by the hydraulic control unit mounting bracket Lifting a vehicle by the hydraulic control unit mounting bracket will result in damage to the moun...

Page 183: ...ubes 6 Thoroughly clean all surfaces of the HCU and all brake tube nuts located on the HCU Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU 7 Remove the brake tubes 6 from the inlet and outlet ports on the HCU Fig 21 8 Remove the 3 bolts Fig 22 attaching the HCU mounting bracket to the front suspension cross member 9 Remove HCU and the mounting bracket as a un...

Page 184: ...cated cor rectly in the valve block to ensure proper ABS oper ation Refer to Fig 21 for the correct chassis brake tube locations NOTE The chassis brake tube attachment loca tions to the HCU are marked on the bottom of the HCU mounting bracket 4 Install the 6 chassis brake tubes into their cor rect port locations on the HCU valve block as shown in Fig 21 Tighten the tube nuts to a torque of 17 N m ...

Page 185: ...m the CAB using the following procedure Grasp the lock on the 25 way connector Fig 25 and pull it as far out as possible Fig 26 This will unlock and raise the 25 way con nector from the socket on the CAB CAUTION Before removing the brake tubes from the HCU the HCU must be thoroughly cleaned This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake tubes 5...

Page 186: ...mounting bracket Fig 29 Install the 3 bolts Fig 29 attaching the HCU to the mounting bracket Tighten the 3 mounting bolts to a torque of 11 N m 97 in lbs CAUTION The HCU mounting bracket to front sus pension cradle mounting bolts have a unique corro sion protection coating and a special aluminum washer For this reason only the original or origi nal equipment Mopar replacement bolts can be used to ...

Page 187: ...Install the routing clips Fig 33 on the brake tubes 9 Lower vehicle 10 Connect negative cable back on negative post of the battery 11 Bleed the base brakes and the ABS brakes hydraulic system Refer to the Bleeding ABS System in this section of the manual for the proper bleeding procedure 12 Road test vehicle to ensure proper operation of the base and ABS brake systems WHEEL SPEED SENSOR FRONT REMO...

Page 188: ...n the 2 attaching bolts to a torque of 11 N m 95 in lbs 4 Insert speed sensor cable grommets into inter mediate bracket on strut Fig 37 Route cable from strut to steering knuckle on the rearward side of the stabilizer bar link 5 Install the wheel speed sensor to steering knuckle attaching bolt Fig 36 Tighten the speed sensor attaching bolt to a torque of 12 N m 105 in lbs 6 Check the air gap betwe...

Page 189: ...ube clip and the routing clip from the track bar bracket on the axle Fig 40 6 Remove the 2 rear wheel speed sensor cable brake tube routing clips Fig 41 Then un clip the speed sensor cable from the routing clips on rear brake tube Fig 41 CAUTION If the speed sensor has seized due to corrosion do not use pliers on speed sensor head in a attempt to remove it Use a hammer and a punch and tap edge of ...

Page 190: ...n the axle brake flex hose bracket Fig 40 CAUTION The wheel speed sensor cable connec tors for the left and right rear wheel speed sensors are keyed differently Therefore when connecting a wheel speed sensor cable to the vehicle wiring har ness do not force the connectors together If the connectors are forced together damage to the con nectors will occur 7 Plug speed sensor cable connector into ve...

Page 191: ...ssembly 8 Remove the speed sensor assembly from the vehicle INSTALL CAUTION Proper installation of wheel speed sen sor cables is critical to continued system operation Be sure that cables are installed in retainers Fail ure to install cables in retainers as shown in this section may result in contact with moving parts and or over extension of cables resulting in an open circuit 1 Install wheel spe...

Page 192: ...ectors are forced together damage to the con nectors will occur 6 Plug speed sensor cable connector into vehicle wiring harness Fig 43 Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector 7 Install the speed sensor cable grommet into the body being sure the grommet is fully seated into the body hole 8 Install the tire and wheel assembly on vehicle 9...

Page 193: ...ring mounting bolts Fig 48 to a torque of 129 N m 95 ft lbs 7 Install the rear wheel speed sensor on the rear hub bearing flange Fig 47 Install the speed sensor attaching bolt and tighten to a torque of 12 N m 105 in lbs 8 Check the air gap between the face of the wheel speed sensor and the top surface of the tone wheel Air gap must be less then the maximum allowable tolerance of 1 2 mm 047 in 9 I...

Page 194: ...N m 200 in lbs Actuator Assembly Adjustment Nut 5 N m 45 in lbs Mounting Bracket To Frame Rail Bolts 17 N m 150 in lbs JUNCTION BLOCK NON ABS BRAKES To Suspension Cradle Mounting Bolt 28 N m 250 in lbs VACUUM BOOSTER To Dash Panel Mounting Nuts 28 N m 250 in lbs DESCRIPTION TORQUE REAR WHEEL CYLINDER To Support Plate Mounting Bolts 8 N m 75 in lbs Bleeder Screw 10 N m 80 in lbs BRAKE SUPPORT PLATE...

Page 195: ...INDER The master cylinder used on this vehicle functions the same as master cylinders used in other brake systems Refer to the Master Cylinder in the Descrip tion and Operation section of group 5 for more infor mation DIAGNOSIS AND TESTING REAR DRUM BRAKE ADJUSTMENT The rear drum brakes on front wheel drive vehicles automatically adjust when required during the nor mal operation of the vehicle eve...

Page 196: ...Y RHD LHD VEHICLES REMOVE 1 Raise vehicle on jackstands or centered on a hoist See Hoisting in the Lubrication and Mainte nance group of this service manual 2 Remove the intermediate and left rear park brake cable from the park brake cable equalizer Fig 2 3 Remove the front park cable housing retainer from body outrigger bracket Fig 3 Cable is remov able by sliding a 14 mm box wrench over cable re...

Page 197: ...ake grommet on the floor pan of the passenger compartment 5 Compress the parking brake cable retainer by sliding a 14 mm box wrench over the cable retainer and compress the three 3 retaining fingers 6 Hook the loop on the end of the parking brake to the equalizer bar on the parking brake gearshift lever bracket 7 Attach the parking brake assembly and place assembly on the parking brake gearshift l...

Page 198: ...ke Booster retaining nuts from inside the passenger compart ment Do not remove nuts from stud Fig 6 6 The pedal arm link and pedal bracket can be disconnected from the torque shaft to make it easier to remove 7 Remove torque shaft from vehicle INSTALL 1 Install torque shaft Reconnect pedal arm link and pedal bracket assembly to torque shaft as neces sary 2 Tighten the retaining nut 1 for the Brake...

Page 199: ...CLUTCH TIGHTENING REFERENCE 16 GENERAL INFORMATION CLUTCH COMPONENTS The clutch used in the 2 0 liter and 2 4 liter gaso line engine is a single dry disc modular clutch assembly The modular clutch assembly combines the pressure plate cover pressure plate disc and fly wheel into one unit The unit rides on the input shaft of the transmission and is bolted to the drive plate mounted on the rear of th...

Page 200: ...m free of air contamination and leaks There is no rou tine maintenance required The hydraulic clutch link age is serviced as an assembly and the individual components cannot be overhauled or serviced sepa rately The hydraulic linkage consists of a clutch master cylinder with integral reservoir a clutch slave cylinder and an interconnecting fluid line with quick disconnect coupling Fig 5 The clutch...

Page 201: ...s a 240 mm 9 5 in standard clutch and pressure plate arrangement Although the clutches are the same size they do not interchange CLUTCH REPLACEMENT The transaxle must be removed to service the clutch assembly fork or bearing Fig 5 Hydraulic Clutch Linkage System RHD Fig 6 Clutch Master Cylinder Mounting RHD NS GS CLUTCH 6 3 GENERAL INFORMATION Continued ...

Page 202: ...o the release lever which moves the bear ing into contact with the clutch cover diaphragm spring Slave cylinder force causes the release lever to move the release bearing into contact with the dia phragm spring As additional force is applied the bearing presses the diaphragm spring fingers inward on the fulcrums This action moves the pressure plate rearward relieving clamp force on the disc The cl...

Page 203: ...ee if the switch is mak ing contact when the pedal is between 25 mm 1 0 in and 6 mm 0 25 in from the floor If this condi tion is met then the problem is either the clutch or the clutch actuation system See Clutch Will Not Disengage Properly If this condition is not met then the switch mounting tab on the brake bracket is bent and the brake bracket must be replaced If vehicle will not crank even wi...

Page 204: ...distorted Replace clutch assembly Clutch misalignment Check alignment and runout of flywheel disc or cover Check clutch housing to engine dowels and dowel holes for damage Correct as necessary SERVICE DIAGNOSIS CLUTCH SLIPS CONDITION POSSIBLE CAUSES CORRECTION DISC FACING WORN OUT Normal wear Replace clutch assembly Driver frequently rides slips clutch results in rapid wear overheating Replace clu...

Page 205: ...cable slack Pull on cable conduit at transaxle as if disconnecting cable to check adjuster operation Clutch pedal travel restricted Verify clutch pedal can travel all the way to the downstop on the bracket SERVICE DIAGNOSIS CLUTCH PEDAL NOISE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH PEDAL MAKES REPEATED 9POP9 NOISE IN THE FIRST INCH OF TRAVEL Self adjusting mechanism in cable defective LHD Appl...

Page 206: ...ary CLASH INTO REVERSE COMPLAINTS 1 Depress clutch pedal to floor and hold After three seconds shift to reverse If clash is present clutch has excessive spin time NOTE Verify that nothing is obstructing pedal travel Floormats or other articles located under neath the clutch pedal could prevent the clutch from disengaging fully 2 Remove transaxle See Group 21 Manual Tran saxle for procedure 3 Check...

Page 207: ...e caution if lifting the clutch pedal once the clutch pedal upstop spacer has been removed The clutch pedal assist spring provides enough pedal force to cause an injury Also on 2 5L Turbo Diesel vehicles lifting the clutch pedal with the upstop spacer removed may bend the cruise control cutout switch bracket located near the top of the clutch pedal This will result in non opera tional cruise contr...

Page 208: ...is properly seated on the bracket 2 If the adjust mechanism functions properly route cable to the transaxle Install battery and cable guide 3 Snap cable into cable guide located at the left shock tower 4 Insert cable into transaxle and through clutch release lever Ensure the cable is routed through the smaller hole in the transaxle deck Fig 10 5 Pull down on cable and insert cable retaining clip o...

Page 209: ...ing to facili tate the removal of the master cylinder assembly and slave cylinder assembly separately Fig 14 Refer to the removal and installation procedure in this section for detailed instructions on disconnecting and con necting the quick connect coupling 2 Remove the master cylinder assembly Fig 15 Refer to the master cylinder removal and installation procedure in this section for detailed ins...

Page 210: ...cyl inder pass through in the dash panel Fig 16 5 Remove the master cylinder assembly from the engine compartment by rotating it clockwise from the 12 o clock lock position to the 2 o clock unlock posi tion and pulling the master cylinder out tilted 20 degrees down NOTE A Twist and Lock type mechanism is used to secure the master cylin der to the clutch pedal bracket which is attached to the dash ...

Page 211: ...ng oil seal and transaxle input shaft seal If leakage is noted it should be corrected at this time The friction faces of the flywheel and pressure plate should not have Excessive discoloration Burned areas Small cracks Deep grooves Ridges Replace parts as required CAUTION Do not polish flywheel to a mirror like surface Clean the flywheel face with medium sand paper 80 160 grade then wipe the surfa...

Page 212: ...pattern until all bolts are seated Tighten pressure plate bolts to 27 N m 20 ft lbs 4 Remove the universal clutch alignment tool 5 Install the transaxle refer to Group 21 Tran saxle 6 Fill transaxle to the proper level with the spec ified lubricant 7 While the vehicle is elevated slightly run the transaxle through all the forward gears Apply brakes and shift into reverse Run the transaxle through ...

Page 213: ...will cause faulty opera tion During inspection note if any components are con taminated Look for evidence of oil grease or water road splash on clutch components OIL CONTAMINATION Oil contamination indicates a leak at the rear main seal and or transaxle input shaft Oil leaks produce a residue of oil on the transaxle housing interior clutch cover and flywheel Heat buildup caused by slippage can bak...

Page 214: ...ute cable to the transaxle 3 Insert cable into transaxle and through clutch release lever Ensure the cable is routed through the smaller hole in the transaxle deck Fig 10 4 Pull down on cable and insert cable retaining clip onto clutch cable end 5 Check clutch pedal position switch operation CLUTCH PEDAL POSITION SWITCH The clutch pedal position switch is mounted to a bracket located behind the cl...

Page 215: ...GINE BLOCK HEATER 23 FAN MODULE 22 RADIATOR DRAINCOCK 21 RADIATOR 21 THERMOSTAT 2 4L ENGINE 19 THERMOSTAT 3 0L ENGINE 20 THERMOSTAT 3 3 3 8L ENGINES 20 WATER PUMP INLET TUBE 2 4L ENGINE 17 WATER PUMP 3 3 3 8L ENGINES 19 WATER PUMP 2 4L ENGINE 17 WATER PUMP 3 0L ENGINE 18 CLEANING AND INSPECTION ACCESSORY DRIVE BELT 25 CHEMICAL CLEANING 25 COOLING SYSTEM CLEANING 25 RADIATOR PRESSURE CAP 25 REVERSE...

Page 216: ...rpose is to maintain engine temper ature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions It also provides hot water cool ant for heater performance and cooling for automatic transmission oil It does this by transferring heat from engine metal to coolant moving this heated coolant to the radiator and then transferring this heat ...

Page 217: ...rature of the coolant rises in hot weather to around 104 C 220 F Above this temperature the coolant temperature is controlled by the fan the radiator and the ambient temperature not the ther mostat WATER PUMPS A quick test to tell whether the pump is working is to see if the heater warms properly A defective pump can not circulate heated coolant through the long heater hose The water pump on all m...

Page 218: ...reased radia tor cooling capacity There is also a vent valve in the center of the cap This valve also opens when coolant is cooling and contracting allowing coolant to return to radiator from coolant reserve system tank by vacuum through connecting hose If valve is stuck shut or the coolant recovery hose is pinched the radiator hoses will be collapsed on cool down Clean the vent valve Fig 9 and in...

Page 219: ...ent 110 Volt A C through a power cord located behind the radiator grille This provides easier engine starting and faster warm up when vehicle is operated in areas having extremely low temperatures The heater is mounted in a core hole in place of a core hole plug in the engine block with the heating element immersed in coolant Fig 7 Cooling Module 3 0L Front A C Only Fig 8 Cooling Module 3 0 3 3 3 ...

Page 220: ...mixtures cannot be measured with field equipment This can lead to problems associated with 100 percent glycol RADIATOR HOSES AND CLAMPS WARNING IF VEHICLE HAS BEEN RUN RECENTLY WAIT 15 MINUTES BEFORE WORKING ON VEHICLE RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP ALLOW FLUIDS AND STEAM TO ESCAPE THROUGH THE OVERFLOW TUB...

Page 221: ... WHEN ACCELERATING ENGINE 1 Belts too loose 1 Adjust belt tension 4 cyl engine Replace belt 6 cyl engine 2 Belt glazed 2 Replace belts BELT SQUEAK AT IDLE 1 Belts too loose 1 Adjust belt tension 4 cyl engine Replace belt 6 cyl engine 2 Dirt or paint imbedded in belt 2 Replace belt 3 Non uniform belt 3 Replace belt 4 Misaligned pulleys 4 Align accessories 5 Non uniform groove or eccentric pulley 5 ...

Page 222: ...COOLING SYSTEM DIAGNOSIS 7 8 COOLING SYSTEM NS DIAGNOSIS AND TESTING Continued ...

Page 223: ...NS COOLING SYSTEM 7 9 DIAGNOSIS AND TESTING Continued ...

Page 224: ...7 10 COOLING SYSTEM NS DIAGNOSIS AND TESTING Continued ...

Page 225: ...NS COOLING SYSTEM 7 11 DIAGNOSIS AND TESTING Continued ...

Page 226: ...7 12 COOLING SYSTEM NS DIAGNOSIS AND TESTING Continued ...

Page 227: ...or Fan Control this section 4 Heat exchanger air side plugged 4 Clean as required 5 Engine missing or running rich 5 Repair as required Poor Driveability Suspect Failed Open Thermostat 1 Check diagnostics is code 17 set Engine too cold for too long 1 If yes change thermostat Poor Heater Performance Suspect Failed Open Thermostat 1 Does gauge read low 1 See 3 2 Check coolant level 2 See 3 3 Check d...

Page 228: ... to prevent the following Intermittent engine overheating Relay thermal shutdown or relay damage ELECTRIC FAN MOTOR TEST Refer to Powertrain Diagnostic Manual for proce dure TESTING COOLING SYSTEM FOR LEAKS With engine not running wipe the radiator filler neck sealing seat clean The radiator should be full Attach the Radiator Pressure Tool to the radiator as shown in Fig 12 and apply 104 kPa 15 ps...

Page 229: ...olant 3 Conducting service procedures 4 Checking for vacuum leaks WARNING IF VEHICLE HAS BEEN RUN RECENTLY WAIT 15 MINUTES BEFORE REMOVING CAP THEN PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE COUN TERCLOCKWISE TO THE FIRST STOP ALLOW FLU IDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOL ANT AND STEAM INTO THE CRS TANK AND PRES SURE DROPS PUSH DOWN A...

Page 230: ...g system is closed and designed to main tain coolant level to the top of the radiator When servicing requires a coolant level check in the radiator the engine must be off and not under pressure Drain several ounces of coolant from the radiator draincock while observing the Coolant Recovery System CRS Tank Coolant level in the CRS tank should drop slightly Then remove the radi ator cap The radiator...

Page 231: ... ring and cause a coolant leak 2 Assemble pump body to block and tighten screws to 12 N m 105 in lbs Fig 16 Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O ring for leaks 3 Rotate pump by hand to check for freedom of movement 4 Install rear timing belt cover 5 Install camshaft sprockets and torque bolts to 101 N m 75 ft lbs 6 Install timing belt idler...

Page 232: ... Fig 20 and Fig 21 and remove INSPECTION Replace the water pump if it has any of the follow ing defects 1 Damage or cracks on the pump body 2 Coolant leaks if the shaft seal is leaking evi dent by traces of coolant leaks from vent hole A in Fig 21 3 Impeller rubs the inside of pump 4 Loose or rough turning bearing Fig 18 Water Pump Inlet Tube Hose Connections Fig 19 Water Pump Inlet Tube Service F...

Page 233: ...Fig 23 Remove water pump 6 Remove and discard O ring seal 7 Clean O ring groove and O ring surfaces on pump and chain case cover Take care not to scratch or gouge sealing surface INSTALLATION 1 Install new O ring into groove Fig 24 2 Install pump to chain case cover Torque screws to 12 N m 105 in lbs 3 Rotate pump by hand to check for freedom of movement 4 Position pulley on pump Install screws an...

Page 234: ...both gasket sealing surfaces INSTALLATION 3 0L ENGINE 1 Center thermostat in water box pocket Check that the flange is seated correctly in the countersunk portion of the intake manifold water box Fig 26 and Fig 27 2 Install new gasket on water box 3 Install housing over gasket and thermostat and tighten bolts to 12 N m 105 in lbs 4 Refill the cooling system to the proper level Refer to Cooling Sys...

Page 235: ...e condenser is supported in position 13 Remove A C filter dryer mounting bracket 2 bolts to the fan module and 2 nuts to the filter dryer 14 Radiator can now be lifted free from engine compartment Care should be taken not to dam age radiator cooling fins or water tubes during removal INSTALLATION 1 Be sure the air seals are in position before radiator is installed Slide radiator down into posi tio...

Page 236: ...ission line from the radiator fitting on the lower left side 13 Raise vehicle on the hoist and remove the fil ter drier fan module and radiator mounting bolts located on the lower right of the module 14 Lower the vehicle on hoist and remove the upper fan module to radiator retaining clips 15 Remove the fan module from the vehicle INSTALLATION 1 Install fan module assembly into attaching clips on t...

Page 237: ...TION ADJUST GENERATOR AND AIR CONDITIONING 1 Loosen lower generator pivot bolt and upper locking nut then loosen adjusting bolt Fig 32 to remove belt tension CAUTION Belt damage may occur if the following procedure is not performed 2 Tighten lock nut to 21 N m 180 in lbs and torque generator pivot bolt to 54 N m 40 ft lbs To assure proper alignment of generator assembly Adjust belt tension by tigh...

Page 238: ...ATOR POWER STEERING PUMP AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT The Poly V Drive belt is provided with a dynamic tensioner Fig 36 to maintain proper belt tension To remove or install this belt 1 Raise vehicle on hoist 2 Remove right front splash shield 3 Release tension by rotating the tensioner clockwise Fig 36 4 Reverse above procedure to install CLEANING AND INSPECTION WATER PUMP...

Page 239: ...r hose is hot Stop engine and drain water from system If water is dirty fill run and drain system again until water runs clear REVERSE FLUSHING THE RADIATOR Drain cooling system and remove radiator hoses from engine Install suitable flushing gun in radiator lower hose Fill radiator with clean water and turn on air in short blasts CAUTION Internal radiator pressure must not exceed 138 kPa 20 psi as...

Page 240: ... 8L 12 N m 250 in lbs Bolts 3 0L 27 N m 240 in lbs Water Pump Inlet Tube Bolts 2 4L 12 N m 250 in lbs Bolts 3 0L 11 N m 94 in lbs Water Pump Pulley Bolts 3 3 3 8L 28 N m 250 in lbs Transaxle Oil Cooler Hose Clamps All Engines 2 N m 18 in lbs Radiator Mounting Upper Bracket Nut All Engines 12 N m 105 in lbs SPECIAL TOOLS COOLING ACCESSORY DRIVE BELT GAUGE 2 4L ENGINE A C COMPRESSOR GENERATOR NEW 19...

Page 241: ... is closed the cooling system has no flow through the radiator The coolant flows through the engine heater system and bypass When the Engine is warm Thermostat is open the cooling system has flow through radiator engine heater system and bypass COOLING SYSTEM 2 5L VM DIESEL The cooling system has a radiator coolant electric fan motors shroud pressure cap thermostat coolant pressure bottle hoses a ...

Page 242: ...es that provide greater strength along with sufficient heat transfer capabili Fig 1 Cooling System Operation 2 5L VM Diesel Fig 2 Coolant Pressure Bottle 2 5L VM Diesel Fig 3 Low Coolant Warning Sensor Connector 2 5L VM Diesel 7 2 COOLING SYSTEM NS GS GENERAL INFORMATION Continued ...

Page 243: ...iven by the timing belt Refer to Group 9 Engine section for component removal to access the water pump NOTE The water pump on all models can be replaced without discharging the air conditioning system 2 5L VM DIESEL The Diesel engine water pump has an aluminum body and housing with a stamped steel impeller The pump uses an O ring gasket between body and hous ing The water pump is driven by the acc...

Page 244: ... 13 17 psi for gasoline engines and 110 124 kPa 16 18 psi for diesel engines The actual pressure relief point in pounds is labeled on top of the cap Fig 11 The cooling system will operate at pressures slightly above atmospheric pressure This results in a higher coolant boiling point allowing increased radi ator cooling capacity The cap Fig 11 contains a spring loaded pressure relief valve This val...

Page 245: ...s overall effec tive temperature range is smaller than that of ethyl ene glycol The freeze point of 50 50 propylene glycol and water is 32 deg C 26 deg F 5 deg C higher than ethylene glycol s freeze point The boiling point protection against summer boil over of propylene glycol is 125 deg C 257 deg F at 96 5 kPa 14 psi compared to 128 deg C 263 deg F for ethylene gly col Use of propylene glycol ca...

Page 246: ...esult WARNING BECAUSE OF HIGH SPRING PRES SURE DO NOT ATTEMPT TO DISASSEMBLE THE AUTOMATIC BELT TENSIONER UNIT IS SERVICED AS AN ASSEMBLY THERMOSTAT DIAGNOSIS Diesel engines due to their inherent efficiency are slower to warm up than gasoline powered engines and will operate at lower temperatures when the vehicle is unloaded Because of this lower tempera ture gauge readings for diesel versus gasol...

Page 247: ...off engine 2 Remove radiator pressure cap 3 Open draincock and allow coolant to drain REFILLING COOLING SYSTEM 2 0L GASOLINE Refer to the gasoline engine cooling system infor mation in this manual Cooling system capacity is 6 0 liters 6 34 qts which includes the heater and cool ant recovery tank 2 5L VM DIESEL First clean system to remove old glycol see Cooling System Cleaning 1 Disconnect upper r...

Page 248: ...ck water pump shaft seal and O ring for leaks 3 Rotate pump by hand to check for freedom of movement 4 Install inner timing belt cover 5 Install timing belt 6 Fill cooling system See Filling Cooling Sys tem 7 Install power steering pump and accessory drive belts WATER PUMP 2 5L VM DIESEL REMOVAL 1 Drain cooling system Refer to Draining Cool ing System in this Group 2 Remove the right inner splash ...

Page 249: ...rmo stat level Refer to Draining Cooling System in this section 2 Remove radiator hose at thermostat cover 3 Remove thermostat cover bolts Fig 20 4 Remove Thermostat INSTALLATION 1 Remove old gasket material from thermostat housing and cover 2 Install new thermostat gasket 3 Install thermostat and tighten cover bolts to 10 8 N m 96 in lbs 4 Install radiator hose 5 Refill cooling system Refer to Re...

Page 250: ...n adjusting bolt and remove belt INSTALLATION 1 Install water pump belt 2 Turn adjusting bolt clockwise to tighten belt 3 Tighten lock nut 4 Tighten belt tensioner bracket bolts 5 Lower vehicle 6 Install generator power steering belt Refer to procedure in this section GENERATOR POWER STEERING BELT 2 5L VM DIESEL REMOVAL 1 Loosen generator pivot bolt Fig 24 2 Loosen adjusting bracket bolt 3 Loosen ...

Page 251: ... GAUGE METHOD Use belt tensioning Special Tool Kit C 4162 for CAUTION The Burroughs gauge for the Poly V belt is not to be used on the V belt These gauges are not interchangeable For conventional V belts affix the Burroughs gauge Special Tool C 4162 to the belt Adjust the belt tension for New or Used belt as prescribed in the Belt Tension Chart For a Poly V belt affix the Poly V Burroughs gauge to...

Page 252: ... Pump Mounting Bolts 12 N m 105 in lbs 22 6 N m 204 in lbs Water Pump Pulley Bolts N A 27 5 N m 240 in lbs Upper Radiator Mounting Bracket Bolts 12 N m 105 in lbs 12 N m 105 in lbs Turbocharger Oil Supply Line N A 24 5 N m 215 in lbs Turbocharger Oil Return Line N A 10 8 N m 96 in lbs Water Pump Housing Nuts N A 9 5 N m 84 in lbs Water Manifold Bolts N A 11 2 N m 96 in lbs Coolant Bottle Bolts 2 0...

Page 253: ... the battery cover The specific gravity indicates the battery s state of charge The OE bat tery is sealed and water cannot be added The battery is vented to release gases that are cre ated when the battery is being charged and dis charged The battery top posts and terminals should be cleaned when other under hood maintenance is performed When the electrolyte level is below the top of the plates Cl...

Page 254: ... electrolyte will rise bringing the green ball Fig 1 into view at approximately 75 percent state of charge DIAGNOSIS AND TESTING BATTERY BUILT IN TEST INDICATOR USING TEST INDICATOR The Test Indicator Fig 1 Fig 2 and Fig 3 measures the specific gravity of the electrolyte Spe cific Gravity SG of the electrolyte will show state of charge voltage The test indicator WILL NOT show cranking capacity of ...

Page 255: ...fective battery BATTERY IGNITION OFF DRAW IOD High current draw on the battery with the ignition OFF will discharge a battery After a dead battery is serviced the vehicle Ignition Off Draw IOD should be checked Determine if a high current draw condi tion exists first check the vehicle with a test lamp 1 Verify that all electrical accessories are OFF Remove key from ignition switch Turn off all lig...

Page 256: ... to battery and clean battery 1 Loose battery post Cracked battery cover or case Leaks or Any other physical 2 Battery OK 1 Replace Battery 2 Check state of charge Refer to Test Indicator TEST INDICATOR Check Charge Eye Color 1 GREEN 2 BLACK 3 CLEAR 1 Battery is charged Perform Battery 0pen Circuit Voltage Test 2 Perform Battery Charging procedure 3 Replace Battery BATTERY OPEN CIRCUIT VOLTAGE TES...

Page 257: ... Group 5 Voltage drop will vary according to battery temperature at the time of the load test Battery temperature can be estimated by the temperature of exposure over the preceding several hours If the bat tery has been charged or boosted a few minutes prior to the test the battery would be slightly warmer Refer to Battery Load Test Temperature Table 6 If battery passes load test it is in good con...

Page 258: ... TACT WITH SKIN EYES OR CLOTHING IN THE EVENT OF CONTACT FLUSH WITH WATER AND CALL PHYSICIAN IMMEDIATELY KEEP OUT OF REACH OF CHILDREN CAUTION Disconnect the battery NEGATIVE cable first Fig 4 before charging battery to avoid dam age to electrical systems Do not exceed 16 0 volts while charging battery Refer to the instructions supplied with charging equipment NOTE The battery cannot be refilled w...

Page 259: ...ovide For the time required for the battery to accept measurable charger current at various voltages refer to Battery Charging Rate table If charge current is still not measurable after charging times the battery should be replaced If charge current is measurable during charging time the battery may be good and charging should be completed in the normal manner VISUAL INSPECTION CAUTION Do not allo...

Page 260: ...minals from the battery posts negative first Fig 14 3 Remove battery heat shield Fig 15 4 Remove battery hold down Fig 16 5 Remove battery from vehicle Fig 17 INSTALLATION Inspect and clean battery and attaching compo nents before installation 1 Install battery in vehicle making sure that bat tery is properly positioned on battery tray 2 Install battery hold down Fig 12 Cleaning Battery Post Fig 1...

Page 261: ...ghten terminal nuts to 8 5 N m 75 in lbs BATTERY TRAY REMOVAL 1 Remove battery refer to the above procedures 2 Remove nut and two bolts from battery tray Fig 18 3 Remove battery tray from vehicle 4 Remove speed control servo attaching bolt from battery tray if equipped Use care when disconnect ing vacuum lines from reservoir Fig 19 INSTALLATION For installation reverse the above procedures Fig 16 ...

Page 262: ...gth of time a battery can deliver 25 amps and maintain a minimum terminal voltage of 10 5 volts at 27 C 80 F TORQUE DESCRIPTION TORQUE Battery Hold Down Bolt Clamp Bolt 14 N m 125 in lbs Fig 19 Speed Control Servo Removal Load Test Amps Cold Cranking Rating 0 F Reserve Capacity 250 Amp 500 Amp 110 Minutes 300 Amp 600 Amp 120 Minutes 340 Amp 685 Amp 125 Minutes 8A 10 BATTERY NS REMOVAL AND INSTALLA...

Page 263: ... cell of the battery As the battery discharges the plates react with the acid from the electrolyte When the charging system charges the battery the water is converted to sulfuric acid in the battery The concentration of acid in the electrolyte is measured as specific gravity using a hydrometer The specific gravity indicates the battery s state of charge The battery is vented to release gases that ...

Page 264: ...amp rate will rise Also the specific gravity of the electrolyte will rise The electrolyte should be tested with a Hydrometer to check the specific gravity USING HYDROMETER Before performing a hydrometer test remove the battery caps and check the electrolyte level Add dis tilled water as required NOTE Periodically disassemble the hydrometer and wash components with soap and water Inspect the float ...

Page 265: ...compart ments and engine compartment lights OFF The con tinuous draw is due to various electronic features or accessories that require electrical current with the ignition OFF to function properly When a vehicle is not used over an extended period of approximately 20 days the IOD fuse should be disconnected The fuse is located in the power distribution center Disconnec tion of this fuse will reduc...

Page 266: ... Loose terminal s 3 Loose battery post Cracked battery cover or case Leaks or Any other physical 4 Battery OK 1 Clean post s or terminal s 2 Clean and tighten 3 Replace Battery 4 Check state of charge Refer to Hydrometer Test PERFORM BATTERY HYDROMETER TEST 1 1 285 2 1 235 3 1 175 or a variation between cells of 0 050 or greater 1 Battery is charged Perform Battery 0pen Circuit Voltage Test 2 Perf...

Page 267: ... Test battery with a hydrometer If battery charge is low the charge battery Refer to Battery Charging Procedures 2 Connect a Volt Ammeter Load tester to the bat tery posts Fig 6 Rotate the load control knob of the Carbon pile rheostat to apply a 300 amp load Apply this load for 15 seconds to remove the surface charge from the battery and return the control knob to off Fig 7 3 Allow the battery to ...

Page 268: ...m the battery and return the control knob to off Fig 7 3 Allow the battery to stabilize for 2 minutes and then verify the open circuit voltage Fig 9 4 This voltage reading will approximate the state of charge of the battery It will not reveal battery cranking capacity Fig 10 SERVICE PROCEDURES BATTERY CHARGING WARNING DO NOT CHARGE A BATTERY THAT HAS EXCESSIVELY LOW ELECTROLYTE LEVEL BATTERY MAY S...

Page 269: ...ETELY DISCHARGED BATTERY The following procedure should be used to recharge a completely discharged battery Unless procedure is properly followed a good battery may be needlessly replaced Fig 11 1 Measure the voltage at battery posts with a voltmeter accurate to 1 10 volt Fig 12 If below 10 volts charge current will be low and it could take some time before it accepts a current in excess of a few ...

Page 270: ...erify that the ignition switch and all accesso ries are OFF 2 Disconnect battery cable terminals from the battery posts negative first Fig 16 3 3 Remove battery hold down Fig 17 4 Remove battery from vehicle Fig 18 INSTALLATION Inspect and clean battery and attaching compo nents before installation 1 Install battery in vehicle making sure that bat tery is properly positioned on battery tray 2 Inst...

Page 271: ...pped Use care when disconnect ing vacuum lines from reservoir Fig 20 INSTALLATION For installation reverse the above procedures SPECIFICATIONS BATTERY SPECIFICATIONS CRANKING RATING The current battery can deliver for 30 seconds and maintain a terminal voltage of 7 2 volts or greater at specified temperature Fig 16 Battery Cable Disconnected Fig 17 Battery Hold Down Fig 18 Remove Battery Fig 19 Ba...

Page 272: ...Bolt 14 N m 125 in lbs Fig 20 Speed Control Servo Removal Reserve Cold Cranking Reserve Amps Rating 17 8C 0 0F Capacity DIN BCI 200 Amp 500 Amp 110 Minutes 250 Amp 600 Amp 120 Minutes 315 Amp 685 Amp 125 Minutes 8A 10 BATTERY NS GS SPECIFICATIONS Continued ...

Page 273: ...only Wiring harness Battery Starter motor with an integral solenoid Positive Temperature Coefficient PTC is the circuit protection for the ignition feed to the starter relay coil The PTC is located in the Junction Block These components form two separate circuits A high amperage circuit that feeds the starter motor up to 300 amps and a control circuit that operates on less than 20 amps DESCRIPTION...

Page 274: ...N IS IN THE PARK POSITION NEUTRAL WITH THE PARKING BRAKE APPLIED RELAY TEST The starter relay is located in the Power Distribu tion Center PDC in the engine compartment Refer to the PDC label for relay identification and location Remove the starter relay from the PDC as described in this group to perform the following tests 1 A relay in the de energized position should have continuity between term...

Page 275: ...h refer to Group 21 Transaxle IGNITION SWITCH After testing starter solenoid and relay test igni tion switch and wiring Refer to Group 8D Ignition Systems or Group 8W Wiring Diagrams Check all wiring for opens or shorts and all connectors for being loose or corroded BATTERY Refer to Group 8A Battery for proper procedures ALL RELATED WIRING AND CONNECTORS Refer to Group 8W Wiring Diagrams FEED CIRC...

Page 276: ...r lead to the battery positive terminal and negative lead to bat tery cable terminal on starter solenoid Fig 5 Rotate and hold the ignition switch in the START position If voltage reads above 0 2 volt correct poor contact at battery cable to solenoid connec tion If reading is still above 0 2 volt after correct ing poor contacts replace battery positive cable b If resistance tests do not detect fee...

Page 277: ...ps or the Diesel engine above 450 amps check for engine seizing or faulty starter If voltage reads 12 4 volts or greater and amper age reads 0 to 10 amps check for corroded cables and or bad connections Voltage below 9 6 volts and amperage draw above 300 amps or Diesel engine above 500 amps the problem is the starter Replace the starter refer to starter removal 5 After the starting system problems...

Page 278: ...d starter to transaxle bell housing 3 Place solenoid and B wires in position on starter terminals 4 Install nut to hold B wire to terminal 5 Install nut to hold solenoid wire to terminal 6 Lower vehicle 7 Connect battery negative cable 8 Verify starter operation STARTER 3 3 3 8L ENGINE REMOVAL 1 Release hood latch and open hood 2 Disconnect battery negative cable Fig 8 3 Hoist and support vehicle ...

Page 279: ...ESCRIPTION TORQUE Starter Mounting Bolts 54 N m 40 ft lbs Starter Solenoid Battery Nut 10 N m 90 in lbs Fig 13 Starter Bolts Fig 14 Starter 3 3 3 8L Engine MANUFACTURER NIPPONDENSO Engine Application 2 4L 3 0L 3 3 3 8L Power rating 1 2 Kw Voltage 12 VOLTS No of Fields 4 No of Poles 4 Brushes 4 Drive Conventional Gear Train Free running Test Voltage 11 Amperage Draw 73 Amp Minimum Speed 3401 RPM So...

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Page 281: ...emove bolts holding starter to transaxle bell housing Fig 2 7 Remove starter INSTALLATION 1 Place starter in position on vehicle 2 Install starter attaching bolts to transaxle bell housing and tighten to the proper torque 3 Place solenoid and B wires in position on starter terminals 4 Install nut to hold B wire to terminal 5 Connect solenoid wire connector onto terminal 6 Lower vehicle 7 Connect b...

Page 282: ...ll housing and tighten to the proper torque 3 Place solenoid and B wires in position on starter terminals 4 Install nut to hold B wire to terminal 5 Connect solenoid wire connector onto terminal 6 Lower vehicle 7 Connect battery negative cable 8 Verify starter operation 2 4L ENGINE With Automatic Transaxle REMOVAL 1 Release hood latch and open hood 2 Disconnect battery negative cable Fig 1 3 Hoist...

Page 283: ...enoid wire connector onto terminal 6 Lower vehicle 7 Connect battery negative cable 8 Verify starter operation 3 0L ENGINE REMOVAL 1 Release hood latch and open hood 2 Disconnect battery negative cable Fig 1 3 Hoist and support vehicle on safety stands 4 Remove nut holding solenoid wire to terminal Fig 5 5 Remove nut holding B wire to terminal Fig 6 6 Disconnect solenoid and B wires from starter t...

Page 284: ...on safety stands 4 Remove nut holding B terminal to starter solenoid Fig 7 5 Disconnect solenoid connector from starter 6 Remove bolts holding starter to transaxle bell housing 7 Remove starter from bellhousing Fig 8 8 Separate starter spacer from transaxle bell housing INSTALLATION 1 Place starter spacer in position on transaxle bellhousing flange toward flywheel 2 Place starter in position on be...

Page 285: ... Remove nut holding B wire to terminal 6 Disconnect solenoid and B wires from starter terminal 7 Remove three bolts holding starter to transaxle bellhousing Fig 9 8 Remove starter INSTALLATION For installation reverse the above procedures and verify the operation of the starter Fig 8 Starter 3 3 3 8L Engine Fig 9 Starter 2 5L Diesel Engine NS GS STARTING SYSTEM 8B 5 REMOVAL AND INSTALLATION Contin...

Page 286: ......

Page 287: ...and 12 volt test lamp may be required All OBD sensed systems are monitored by the PCM Each monitored circuit is assigned a Diagnos tic Trouble Code DTC The PCM will store a DTC in electronic memory for any failure it detects See the On Board Diagnostics Test in Group 8C Charging System for more information DESCRIPTION AND OPERATION CHARGING SYSTEM OPERATION The charging system consists of Generato...

Page 288: ... refer to Battery Temperature Sen sor for more information It then compensates and regulates generator current output accordingly Also refer to Charging System Operation for additional information DIAGNOSIS AND TESTING CHARGING SYSTEM When the ignition switch is turned to the ON posi tion battery potential will register on the voltmeter During engine cranking a lower voltage will appear on the met...

Page 289: ...CHARGING SYSTEM SCHEMATIC TYPICAL NS CHARGING SYSTEM 8C 3 DIAGNOSIS AND TESTING Continued ...

Page 290: ...is point A volt age drop test may be performed at each connection in this circuit to locate the excessive resistance This test can also be performed between the gener ator case and the engine If test voltage is higher than 0 3 volts check for corrosion at generator mounting points or loose generator mounting CURRENT OUTPUT TEST The current output test will determine if the charging system can deli...

Page 291: ...CHARGING SYSTEM TEST NS CHARGING SYSTEM 8C 5 DIAGNOSIS AND TESTING Continued ...

Page 292: ...OVERCHARGE TEST 8C 6 CHARGING SYSTEM NS DIAGNOSIS AND TESTING Continued ...

Page 293: ...ould not be met refer to the appropriate Powertrain Diagnostic Procedures manual for testing ON BOARD DIAGNOSTIC SYSTEM TEST GENERAL INFORMATION The Powertrain Control Module PCM monitors critical input and output circuits of the charging sys tem making sure they are operational A Diagnostic Trouble Code DTC is assigned to each input and output circuit monitored by the OBD system Some circuits are...

Page 294: ...VOLTAGE DROP TEST 8C 8 CHARGING SYSTEM NS ...

Page 295: ...nector onto back of generator 7 Install accessory drive belt refer to Group 7 Cooling System for proper procedures 8 Connect battery negative cable 9 Verify generator charge rate GENERATOR 3 0L ENGINE REMOVAL 1 Release hood latch and open hood 2 Disconnect battery negative cable Fig 3 3 Remove windshield wiper housing refer to Group 8K Windshield Wipers and Washers for proper procedures 4 Remove a...

Page 296: ...m for proper procedures 5 Remove bolt holding top of generator mount bracket to engine air intake plenum Fig 7 6 Remove bolts holding outside of generator mount bracket to generator mount plate 7 Remove bolt holding top of generator to mount bracket 8 Remove generator mount bracket from vehicle 9 Rotate generator toward rear dash panel 10 Disconnect the push in field wire connector from back of ge...

Page 297: ...r intake plenum 11 Install accessory drive belt refer to Group 7 Cooling System for proper procedures 12 Install windshield wiper housing refer to Group 8K Windshield Wipers and Washers for proper procedures 13 Connect battery negative cable 14 Verify generator charge rate SPECIFICATIONS GENERATOR Part number is located on the side of the generator TORQUE DESCRIPTION TORQUE Battery Hold Down Bolt ...

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Page 299: ... 3 3 3 8L ENGINES 8 TESTING FOR SPARK AT COIL 3 0L 8 THROTTLE POSITION SENSOR 13 SERVICE PROCEDURES IGNITION TIMING PROCEDURE 15 POWERTRAIN CONTROL MODULE 13 SPARK PLUG GAP ADJUSTMENT 13 GENERAL INFORMATION INTRODUCTION This group describes the ignition systems for the 2 4 3 0 and 3 3 3 8L engines On Board Diagnostics is described in Group 25 Emission Control Systems Group 0 Lubrication and Mainte...

Page 300: ...e the spark plugs and examine them for burned electrodes and fouled cracked or broken por celain insulators Keep plugs arranged in the order in which they were removed from the engine An iso lated plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder Replace spark plugs at the intervals recommended in Group O Lubrication and Maintenance Spark plugs tha...

Page 301: ... spark plug electrodes or ceramic insulator Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark plugs without reading the 3 3 3 8L Spark Plug Gap Mea surement procedures in this section Always tighten spark plugs to the specified torque Over tightening can cause distortion resulting in a change in the spark plug gap Overtightening can also damage the cylinde...

Page 302: ...pen dent coils molded together Fig 4 The coil assembly is mounted on the intake manifold Spark plug cables route to each cylinder from the coil The coil fires two spark plugs every power stroke One plug is the cyl inder under compression the other cylinder fires on the exhaust stroke The Powertrain Control Module PCM determines which of the coils to charge and fire at the correct time Coil 1 fires...

Page 303: ...de of the transmission housing above the differen tial housing Fig 8 The bottom of the sensor is posi tioned next to the drive plate CAMSHAFT POSITION SENSOR The camshaft position sensor provides cylinder identification to the Powertrain Control Module PCM Fig 9 The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it Fig 10 The PCM keeps track of crankshaft rot...

Page 304: ...e Powertrain Control Module PCM As engine load changes manifold pressure varies The changes in engine load cause the MAP sensors resistance to change The change in MAP sensor resistance results in a different input voltage to the PCM The input voltage level supplies the PCM with information relating to ambient barometric pressure during engine start up cranking and engine load while its operating ...

Page 305: ...uel injector pulse width and ignition timing based on these inputs LOCK KEY CYLINDER The lock cylinder is inserted in the end of the housing opposite the ignition switch The ignition key rotates the cylinder to 5 different detents Fig 14 Accessory Off lock Unlock On Run Start KNOCK SENSOR The knock sensor threads into the side of the cyl inder block in front of the starter motor When the knock sen...

Page 306: ...n the coil tower after testing to avoid damage to the coil and catalytic converter 5 Repeat the above test for the remaining coils If there is no spark during all cylinder tests proceed to the Failure To Start Test 6 If one or more tests indicate irregular weak or no spark proceed to Check Coil Test TESTING FOR SPARK AT COIL 3 0L WARNING APPLY PARKING BRAKE AND OR BLOCK THE WHEELS BEFORE PERFORMIN...

Page 307: ...thin tolerance 4 Remove ignition cables from the secondary tow ers of the coil Measure the secondary resistance of the coil between the towers of each individual coil Fig 18 Secondary resistance should be 7 000 to 15 800 ohms Replace the coil if resistance is not within tolerance CHECK COIL TEST 3 3 3 8L Coil 1 fires cylinders 1 and 4 coil 2 fires cyl inders 2 and 5 and coil 3 fires cylinders 3 an...

Page 308: ...th an orange tracer Do not spread the terminal with the test light probe 4 Turn the ignition key to the ON position The test light should flash On and then Off Do not turn the Key to off position leave it in the On posi tion a If the test light flashes momentarily the PCM grounded the Auto Shutdown ASD relay Proceed to step 5 b If the test light did not flash the ASD relay did not energize The cau...

Page 309: ...for cleaning platinum spark plugs This would damage the platinum pads which would shorten spark plug life Some fuel refiners in several areas of the United States have introduced a manganese additive MMT for unleaded fuel During combustion fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit The rust color deposits can be misdi agnosed as being caused by coolant in t...

Page 310: ...ge the chemical nature of deposits and decrease spark plug misfire tendencies Notice that accumula tion on the ground electrode and shell area may be heavy but the deposits are easily removed Spark plugs with scavenger deposits can be consid ered normal in condition cleaned and reused CHIPPED ELECTRODE INSULATOR A chipped electrode insulator usually results from bending the center electrode while ...

Page 311: ... Open Throttle WOT At idle TPS output volt age should be approximately 0 38 volts to 1 2 volts At wide open throttle TPS output voltage should be approximately 3 1 volts to 4 4 volts The output volt age should gradually increase as the throttle plate moves slowly from idle to WOT Check for spread terminals at the sensor and PCM connections before replacing the TPS SERVICE PROCEDURES SPARK PLUG GAP...

Page 312: ...ors 9 Remove 3 screws holding PCM to fender Fig 36 10 Remove PCM from vehicle INSTALLATION 1 Connect 2 40 Way electrical connectors to PCM Fig 35 2 Install PCM Tighten mounting screws 3 Install PDC bracket 4 Install battery Fig 30 Setting Spark Plug Electrode Gap Typical Fig 31 Power Distribution Center Retaining Screws Fig 32 Battery Heat Shield Fig 33 Battery Clamp 8D 14 IGNITION SYSTEM NS SERVI...

Page 313: ... a fixed igni tion system Basic ignition timing is not adjustable The Powertrain Control Module PCM regulates ignition timing Fig 34 PDC Rear Bracket Fig 35 PCM 40 Way Connectors Fig 36 PCM Removal Installation NS IGNITION SYSTEM 8D 15 SERVICE PROCEDURES Continued ...

Page 314: ...four timing reference notches and a 60 degree signature notch Fig 1 From the crankshaft position sensor input the PCM determines engine speed and crankshaft angle position The notches generate pulses from high to low in the crankshaft position sensor output voltage When a metal portion of the counterweight aligns with the crankshaft position sensor the sensor output voltage goes low less than 0 3 ...

Page 315: ...AMSHAFT POSITION SENSOR The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor From the two inputs the PCM determines crankshaft position The camshaft position sensor attaches to the rear of the cylinder head Fig 2 A target magnet attaches to the rear of the camshaft and indexes to the correc...

Page 316: ...lugs REMOVAL Always remove cables by grasping at the boot rotating the boot 1 2 turn and pulling straight back in a steady motion 1 Prior to removing the spark plug spray com pressed air around the spark plug hole and the area around the spark plug 2 Remove the spark plug using a quality socket with a foam insert 3 Inspect the spark plug condition Refer to Spark Plug Condition in this section INST...

Page 317: ...n this posi tion and install and tighten the retaining bolt to 11 9 N m 105 in lbs torque CAMSHAFT POSITION SENSOR The camshaft position sensor is mounted to the rear of the cylinder head Fig 9 REMOVAL 1 Disconnect the filtered air tube from the throt tle body and air cleaner housing Disconnect the air tube from the oil separator hose Remove filtered air tube 2 Remove the air cleaner inlet tube 3 ...

Page 318: ... intake manifold INSTALLATION 1 Reverse the above procedure for installation THROTTLE POSITION SENSOR Refer to Group 14 Fuel Injection Section for Removal Installation ENGINE COOLANT TEMPERATURE SENSOR 2 4L The coolant sensor threads into the top of the ther mostat housing Fig 13 New sensors have sealant applied to the threads WARNING HOT PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING COOLING SY...

Page 319: ...or from knock sen sor 2 Use a crow foot socket to remove the knock sensors INSTALLATION 1 Install knock sensor Tighten knock sensor to 10 N m 7 ft lbs torque Over or under tighten ing effects knock sensor performance possibly causing improper spark control 2 Attach electrical connector to knock sensor INTAKE AIR TEMPERATURE SENSOR 2 4L The intake air temperature sensor threads into the intake mani...

Page 320: ...ark Plugs 28 N m 60 in lbs SPARK PLUG CABLE RESISTANCE 2 4L Coil Manufacture Primary Resistance at 21 C 27 C 70 F 80 F Secondary Resistance at 21 C 27 C 70 F 80 F Weastec Steel Towers 0 45 to 0 65 Ohms 7 000 to 15 800 Ohms Coil Polarity Engine Spark Plug Gap Thread Size 2 4L RC12YC5 0 048 TO 0 053 14mm 3 4 in reach CABLE Maximum Resistance 1 4 4 2K ohms 2 3 3 2K ohms 8D 22 IGNITION SYSTEM NS ...

Page 321: ... synchronization and cylinder identification from inputs provided by the camshaft position sensor and crankshaft position sensor From the two inputs the PCM determines crankshaft position The 3 0L engine is equipped with a camshaft driven mechanical distributor containing a shaft driven distributor rotor The distributor is also equipped with an internal camshaft position fuel sync sensor Fig 1 Thi...

Page 322: ...ion Refer to Spark Plug Condition in this section INSTALLATION 1 To avoid cross threading start the spark plug into the cylinder head by hand 2 Tighten spark plugs to 28 N m 20 ft lbs torque 3 Install spark plug cables over spark plugs A click will be heard and felt when the cable properly attaches to the spark plug IGNITION COIL 3 OL The ignition coil is located at the back of the intake manifold...

Page 323: ...harness connector Fig 4 3 Remove crankshaft position sensor retaining bolt 4 Pull crankshaft position sensor straight up out of the transaxle housing INSTALLATION NOTE If the removed sensor is to be reinstalled clean off the old spacer on the sensor face A NEW SPACER must be attached to the sensor face before installation If the sensor is being replaced confirm that the paper spacer is attached to...

Page 324: ...blish proper relationship between the dis tributor shaft and Number 1 piston position as follows a Rotate the crankshaft until number one pis ton is at top of compression stroke b Rotate rotor to number one rotor terminal Fig 8 c Lower the distributor into the opening engaging distributor drive with drive on camshaft With distributor fully seated on engine rotor should be under the number 1 termin...

Page 325: ... mild detergent Scrub the cap with a soft brush Thoroughly rinse the cap and dry it with a clean soft cloth DISTRIBUTOR ROTOR 3 0L Replace the rotor if it is cracked the tip is exces sively burned or heavily scaled Fig 10 SPECIFICATIONS SPARK PLUG TORQUE DESCRIPTION TORQUE Distributor Hold Down 14 N m 124 in lbs Ignition Coil Bracket 10 N m 96 in lbs Ignition Switch 2 N m 17 in lbs Spark Plugs 28 ...

Page 326: ...TION SPARK PLUG CABLE SERVICE 3 3 3 8L ENGINES WARNING The ignition cables should not be removed while the engine is hot This could cause sever injury burns and can cause damage to the ignition cables The spark plug boot heat shield needs to be installed correctly on the boot before being installed on the engine Fig 1 If it is not installed correctly engine misfire would occur Do not use pliers to...

Page 327: ...ling the spark plug cables make sure the coil and spark plug insulator and terminals are fully seated A click sound should be heard or terminal engagement is felt when the terminals are properly attached 2 Rotate Generator back into place 3 Install upper Generator bracket with the four bolts 4 Install the accessory drive belt refer to Group 7 Cooling SPARK PLUG SERVICE 3 3 3 8L ENGINES WARNING The...

Page 328: ...elt refer to Group 7 Cooling IGNITION COIL REMOVAL 1 Remove spark plug cables from coil Fig 2 Always twist the spark plug boots to break the seal with the plug and pull straight back on the boot 2 Remove ignition coil electrical connector 3 Remove ignition coil mounting screws 4 Remove ignition coil INSTALLATION 1 Reverse the above procedure for installation Tighten mounting screws to 12 N m 105 i...

Page 329: ... If the removed sensor is reinstalled clean off the old spacer on the sensor face A NEW SPACER must be attached to the face before installation Inspect O ring for damage replace if necessary If the sensor is being replaced confirm that the paper spacer is attached to the face and O ring is positioned in groove of the new sensor Fig 8 1 Apply a couple drops of clean engine oil to the O ring prior t...

Page 330: ...sensor 5 Disconnect electrical connector from engine coolant temperature sensor 6 Remove sensor from engine INSTALLATION 1 Tighten the sensor to 7 N m 60 in lbs torque 2 Connect electrical connector to sensor 3 Fill cooling system Refer to Group 7 Cooling System 4 Install coil Tighten coil mounting screws to 12 N m 105 in lbs torque 5 Connect electrical connector to coil THROTTLE POSITION SENSOR R...

Page 331: ...possibly causing improper spark control 2 Attach electrical connector to knock sensor SPECIFICATIONS IGNITION COIL Fig 12 Knock Sensor Coil Manufacture Primary Resistance at 21 C 27 C 70 F 80 F Secondary Resistance at 21 C 27 C 70 F 80 F Weastec Aluminum Towers 0 45 TO 0 65 Ohms 7 000 to 15 800 Ohms Diamond Electric Brass Towers 0 45 TO 0 65 Ohms 7 000 to 15 800 Ohms Coil Polarity Coil Polarity NS...

Page 332: ...3 8L Ignition Coil 12 N m 105 in lbs Ignition Switch 2 N m 17 in lbs Spark Plugs 28 N m 20 ft lbs SPARK PLUG CABLE RESISTANCE 3 3 3 8L Engine Spark Plug Gap Thread Size 3 3L RN14PMP5 0 048 TO 0 053 14mm 3 4 in reach 3 8L RN14PMP5 0 048 TO 0 053 14mm 3 4 in reach CABLE Maximum Resistance 1 18 5K ohms 2 15 5K ohms 3 20 4K ohms 4 21 2K ohms 5 27 7K ohms 6 26 7K ohms 8D 34 IGNITION SYSTEM NS SPECIFICA...

Page 333: ...lock position unless the shifter is in the park position On vehicles equipped with floor shift refer to Group 21 Transaxle for Automatic Transmission Shifter Igni tion Interlock LOCK KEY CYLINDER The lock cylinder is inserted in the end of the housing opposite the ignition switch The ignition key rotates the cylinder to 5 different detents Fig 1 Accessory Off lock Unlock On Run Start REMOVAL AND I...

Page 334: ...er retaining tab and remove key cylinder Fig 6 6 Remove ignition switch mounting screw Fig 7 with a 10 Torxt tamper proof bit 7 Depress retaining tab Fig 3 or Fig 8 and gently pry ignition switch from steering column Fig 9 8 Disconnect electrical connectors from ignition switch and remove switch Fig 10 Fig 3 Steering Column Cover Fig 4 Parking Brake Release Cable Fig 5 Steering Column Shroud Screw...

Page 335: ... mounting screw Fig 7 4 Install upper and lower shrouds 5 Install key cylinder cylinder retaining tab will depress only in the RUN position 6 Connect negative cable to battery 7 Check for proper operation of ignition switch and key in warning switch Fig 7 Ignition Switch Mounting Screw Fig 8 Ignition Switch Retaining Tab Fig 9 Removing Ignition Switch Fig 10 Ignition Switch Connectors Fig 11 Ignit...

Page 336: ...the housing To align the socket with the lock cylinder ensure the socket is in the Run position Fig 12 3 Align the lock cylinder with the grooves in the housing Slide the lock cylinder into the housing until the tab sticks through the opening in the hous ing 4 Turn the key to the Off position Remove the key 5 Install lower steering column shroud 6 Install steering column cover 7 Connect negative c...

Page 337: ...UVERS 27 INSTRUMENT PANEL RIGHT END COVER 29 INSTRUMENT PANEL TOP COVER 29 INSTRUMENT PANEL 25 JUNCTION BLOCK 30 KNEE BLOCKER REINFORCEMENT 30 LOWER CONSOLE 30 LOWER INSTRUMENT PANEL 31 LOWER STEERING COLUMN COVER 31 MECHANICAL TRANSMISSION RANGE INDICATOR 32 MESSAGE CENTER LAMP 32 MESSAGE CENTER 32 OUTLET 12 VOLT BASE 32 OVER STEERING COLUMN BEZEL 32 POWER MIRROR SWITCH LAMP 34 POWER MIRROR SWITC...

Page 338: ... resistance value in ohms or diode test Use the values in the third column to determine meter setting If Headlamp Switch is not within spec ifications replace as necessary The Chrysler Town and Country is available with optional Automatic Headlamps For diagnosis refer to the proper Body Diagnostic Procedures Manual SELF DIAGNOSTIC TEST To activate self diagnostic program 1 With the ignition switch...

Page 339: ...mally a problem exists in the display board CONDITIONS Refer to the following tables Instrument Cluster Speedometer Tachometer Fuel Gauge Temperature Gauge Odometer Electronic Transmission Range Indicator PRND3L Mechanical Transmission Range Indicator PRND21 for possible problems causes and corrections INSTRUMENT CLUSTER DTC TABLE DTC DESCRIPTION 110 Memory Fault in cluster 111 Calibration fault i...

Page 340: ...rm Self Diagnostic Test If OK complete installation If not OK go to Step e e Replace subdial assembly and use a scan tool to calibrate cluster If not OK look at another possible cause for the speedometer failure f Use a scan tool to calibrate speedometer and perform Self Diagnostic Test If OK stop If not OK go to Step b 2 No speed CCD Bus Message or Zero mph CCD Speed Bus Message 2 a Check the Bod...

Page 341: ...m cluster self diagnostic test and check for fault codes If the pointer moves during test but still appears erratic and fault codes 110 or 111 don t appear in the odometer display then go to Step b If fault code 110 is displayed in the odometer go to Step e If fault code 111 appears in the odometer display go to Step d If fault codes 905 920 or 940 are displayed in the odometer display refer to th...

Page 342: ... is being used with tires on vehicle Refer to transmission section of manual for test and repair procedure If the incorrect pinion is in transmission then replace with correct pinion If the correct pinion is in the transmission calibrate speedometer using a scan tool to correct for the inaccuracy c use a scan tool to check the TCM to see if the correct tire size has been programmed into the TCM If...

Page 343: ...uster pc board Go to Step c c Connect cluster into instrument panel wiring harness Place it back into the proper position in the instrument panel Put in the top two mounting screws to hold the cluster in place DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS CALIBRATED AND TESTED Go to Step d d use a scan tool to calibrate cluster and perform Self Diagnostic Test If OK continue ...

Page 344: ... fault code chart to identify which module is causing the fault and repair module b Replace cluster subdial assembly Go to Step c c Connect cluster into instrument panel wiring harness Place it back into the proper position in the instrument panel Put in the top two mounting screws to hold the cluster in place DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS CALIBRATED AND TESTE...

Page 345: ...ce it back into the proper position in the instrument panel Put in the top two mounting screws to hold the cluster in place DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS CALIBRATED AND TESTED Go to Step d d Use a scan tool to calibrate cluster and perform Self Diagnostic Test If OK continue installation If not OK go to Step e e Replace subdial assembly and use a scan tool to ...

Page 346: ... the fault and repair module b Replace cluster subdial assembly Go to Step c c Connect cluster into instrument panel wiring harness Place it back into the proper position in the instrument panel Put in the top two mounting screws to hold the cluster in place DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS CALIBRATED AND TESTED Go to Step d d Use a scan tool to calibrate cluster...

Page 347: ...luster in place DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS CALIBRATED AND TESTED Go to Step d d use a scan tool to calibrate cluster and perform Self Diagnostic Test If OK continue installation If not OK go to Step e e Replace subdial assembly and use a scan tool to calibrate cluster If not OK look at another possible cause for the temperature gauge failure f Use a scan to...

Page 348: ... 940 is displayed refer to the fault code chart to identify which mode is causing the fault and repair module b Replace cluster subdial assembly Go to Step c c Connect cluster into instrument panel wiring harness Place it back into the proper position in the instrument panel DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT IS CALIBRATED AND TESTED Go to Step d d Use a scan tool to ...

Page 349: ...o to Step b If fault code 920 or 921 is displayed use a scan tool to check BCM b Remove cluster from instrument panel and verify that odometer assembly is properly connected to main pc board If OK go to Step c If not OK reconnect odometer assembly to main pc board c Replace odometer assembly Go to Step d d Connect cluster into instrument panel wiring harness Place it back into the proper position ...

Page 350: ...ace it back into the proper position in the instrument panel DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL UNIT TESTED Go to Step e e Perform Self diagnostic Test If OK continue installation If not OK go to Step f f Replace main cluster pc board and use a scan tool to calibrate cluster If not OK look at another possible cause for the odometer failure 2 Bad CCD Bus Message from Body C...

Page 351: ...electronic TCM b Remove cluster from instrument panel and verify that PRND3L assembly is properly connected to main pc board If OK go to Step c If not OK reconnect PRND3L assembly to main pc board c Replace PRND3L assembly Go to Step d d Connect cluster into instrument panel wiring harness Place it back into the proper position in the instrument panel DO NOT COMPLETELY INSTALL CLUSTER TO INSTRUMEN...

Page 352: ...agnostic Test If OK continue installation If not OK go to Step f f Replace main cluster pc board and use a scan tool to calibrate cluster If not OK look at another possible cause for the PRND3L failure 2 Bad CCD Bus Message from the Electronic Transmission Control Module TCM 2 Use a scan tool to check the electronic TCM Refer to the electronic TCM section of the manual to properly diagnose and rep...

Page 353: ...g and attachment of PRNDL cable and guide tube c Re adjust PRNDL indicator in Neutral using adjuster wheel below steering column INDICATOR DOES NOT FOLLOW GEAR SHIFT LEVER Not attached 1 a Verify indicator cable connected to shift lever pin in the groove b Verify indicator clip secure and attached to steering column transmission shift cable bracket and clip not broken If broken replace clip on ind...

Page 354: ...er to Convenience Bin Cup Holder Removal and Installation procedure in this section 2 Remove the screw access cover from the bottom of the radio bezel Fig 5 3 Remove the center bezel 4 Remove the convenience bin track attaching screws and pull the convenience bin track rearward to disengage the rear guide studs from instrument panel Fig 7 5 Disengage the clip holding convenience bin lamp to track ...

Page 355: ... opening 3 Install the cluster lens and screws to the rear shell around perimeter of lens 4 Install the instrument cluster INSTRUMENT CLUSTER ELECTRONIC ODOMETER AND TRANSMISSION RANGE INDICATOR REMOVAL 1 Remove instrument cluster 2 Remove cluster lens 3 Disconnect wire connector from odometer and transmission range indicator 4 Remove screws holding odometer and transmis sion range indicator to cl...

Page 356: ... above procedures HEADLAMP SWITCH REMOVAL 1 Remove instrument cluster bezel Fig 13 2 Remove screws holding the headlamp switch bezel to cluster bezel 3 Disconnect the wire connectors from the head lamp switch and wire connector from the power mir ror switch 4 Remove headlamp switch bezel from cluster bezel INSTALLATION For installation reverse the above procedures Fig 9 Glove Box Fig 10 Glove Box ...

Page 357: ...Pull bulb socket from HVAC INSTALLATION For installation reverse the above procedures INSTRUMENT CLUSTER BACK PANEL REMOVAL 1 Remove instrument cluster 2 Remove screws holding back panel to instru ment cluster Fig 16 3 Remove back panel INSTALLATION For installation reverse the above procedures INSTRUMENT CLUSTER BEZEL REMOVAL 1 Remove steering column cover 2 Remove over steering column bezel Fig ...

Page 358: ...el to instru ment panel on each side of steering column 5 Install screw at left end of cluster bezel and headlamp switch 6 Install left end cover 7 Install over steering column bezel 8 Install lower steering column cover INSTRUMENT CLUSTER LAMPS REMOVAL 1 Remove the instrument cluster Refer to Instru ment Cluster Removal procedure 2 Locate the lamp Fig 18 3 Remove the lamps from cluster with a 1 4...

Page 359: ... the cluster Fig 21 4 Remove the subdial from the cluster INSTALLATION For installation reverse the above procedures INSTRUMENT CLUSTER SUBDIAL MECHANICAL TRANSMISSION RANGE INDICATOR REMOVAL 1 Remove instrument cluster 2 Remove screws holding cluster lens to the rear shell from around perimeter of lens 3 Remove lens from cluster guide shift indicator cable through cluster shell 4 Remove gauge sub...

Page 360: ... P to 1 by gently pulling on the cable and relaxing the cable DO NOT SNAP THE CABLE ONCE IT IS PULLED 2 Position the instrument cluster in instrument panel and route the indicator cable and guide tube through the opening in the instrument panel Posi tion the cluster by leading the bottom in first con nect the wire connector and rotate upward 3 Install the screws to hold the instrument clus ter to ...

Page 361: ...23 Body REMOVAL 1 Disconnect the battery negative cable first 2 Remove the lower console 3 Remove the screw holding the lower heat duct to the instrument panel support Fig 26 4 Disconnect the heat duct from the vehicle 5 Remove the bolts holding the lower supports to the instrument panel frame Fig 27 6 Remove the bolts holding the lower supports to the floor pan 7 Remove the right and left end cov...

Page 362: ...e to the instrument panel 25 Remove the bolt holding the hood release han dle to the instrument panel 26 Position the hood release handle out of the way 27 Remove the instrument panel top cover 28 Disconnect the wire connector from the HVAC wire harness behind the glove box area 29 Remove the bolts holding the instrument panel frame to the brackets on cowl side panels Fig 30 and Fig 31 30 Loosen b...

Page 363: ...ght side Fig 33 3 Using a flat bladed tool release the louver housing locks tabs Fig 34 4 Release the upper left lock tab first then the two lower louver tabs 5 Applying pressure on the housing release the upper right lock tab and the lower right 6 Push out the louver housing from the cluster bezel INSTALLATION 1 Verify the function of the vanes 2 Set louver housing into the cluster bezel 3 Using ...

Page 364: ...elease the pivot pin from the louver and pull outward till released from pin 3 Place tool on the other side of louver and release the other pivot pin and pull housing free from the instrument panel Use the same procedure for either inner or outer louver INSTALLATION The inner and outer louvers have different size pivot pins on the housing The outer housing has a larger pin on the right side then t...

Page 365: ...r rearward to disengage hooks holding front of top cover to instrument panel 5 Remove top cover INSTALLATION 1 Place instrument panel top cover in position on vehicle 2 Push top cover forward to engage hooks to hold front of top cover to instrument panel 3 Connect wire harness to message center 4 Engage clips to hold rear edge of top cover to instrument panel 5 Pull top cover rearward 6 Install A ...

Page 366: ...dy Control Module downward to dis connect guide studs on Junction Block from BCM ting bracket 9 Separate Junction Block from Body Control Module INSTALLATION For installation reverse the above procedures KNEE BLOCKER REINFORCEMENT REMOVAL 1 Remove lower steering column cover Fig 42 2 Remove screws holding knee blocker reinforce ment to instrument panel 3 Remove reinforcement INSTALLATION 1 Place r...

Page 367: ...es sary to gain access to the lower instrument panel screws 14 Remove the screw holding instrument panel to the upper panel below the instrument cluster 15 Remove the screws holding rear of storage pocket to the panel support frame 16 Remove the screws holding the lower instru ment panel to the upper instrument panel from below radio 17 Remove the screws holding lower instrument panel to the suppo...

Page 368: ...instrument panel top cover 5 Install A pillar trim MESSAGE CENTER LAMP REMOVAL 1 Remove instrument panel top cover Refer to Instrument Panel Top Cover Removal procedures 2 Locate the lamp in question Fig 48 3 Remove lamp and check lamp If lamp is good test the power supply to the lamp INSTALLATION For installation reverse the above procedures OUTLET 12 VOLT BASE REMOVAL 1 Look inside and note posi...

Page 369: ...rol switch discon nect the wire pigtail connector from the traction con trol switch 6 Remove the over steering column bezel INSTALLATION 1 Place the over steering column bezel in position and engage clips to the cluster bezel If equipped Fig 48 Message Center Lamp Location Fig 49 Outlet Base Removal Fig 50 Tool For Outlet Removal Fig 51 Over Steering Column Bezel NS INSTRUMENT PANEL AND SYSTEMS 8E...

Page 370: ...ience bin cup holder Refer to Convenience Bin Cup Holder Removal and Installa tion procedure in this section 2 Insert the trim stick special tool C 4755 between access cover and radio bezel above conve nience bin cup holder 3 Carefully pry the access cover from the instru ment panel Fig 54 4 Separate the access cover from the vehicle 5 Remove convenience bin cup holder track Refer to Convenience B...

Page 371: ...of switch to radio bezel HVAC Control 4 Remove switch from radio bezel HVAC Control INSTALLATION For instrument reverse the above procedures REAR HEATER A C SWITCH LAMP REMOVAL 1 Remove radio bezel HVAC Control 2 Rotate bulb socket counterclockwise one quar ter Fig 57 3 Pull bulb socket from switch INSTALLATION For installation reverse the above procedures TRACTION CONTROL SWITCH REMOVAL 1 Remove ...

Page 372: ......

Page 373: ...T PANEL TOP COVER 24 JUNCTION BLOCK 25 KNEE BLOCKER REINFORCEMENT 25 LOWER CONSOLE 26 LOWER INSTRUMENT PANEL 26 LOWER STEERING COLUMN COVER 27 MESSAGE CENTER 27 OVER STEERING COLUMN BEZEL 28 POWER MIRROR SWITCH 28 POWER MIRROR SWITCH LAMP 28 RADIO BEZEL AND HVAC CONTROL 29 REAR HEATER A C SWITCH 29 REAR HEATER A C SWITCH LAMP 29 GENERAL INFORMATION INTRODUCTION The instrumentation gauges on GS veh...

Page 374: ...ic system monitors the CCD bus messages If an electronic problem occurs a Diagnostic Trouble Code DTC will be displayed in the odometer window of the cluster The following CCD bus messages are continuously monitored by the diagnostic system Body Control Module Powertrain Control Module HEADLAMP SWITCH Using a Digital Multimeter equipped with a diode test to perform the Headlamp Switch Test below F...

Page 375: ...t VF displays will dim down If the VF display brightness does not change a problem exists in the cluster CLUSTER CALIBRATION TABLE Speedometer Calibration Point 1 0 Km h 0 mph 2 40 Km h 20 mph 3 80 Km h 55 mph 4 120 Km h 75 mph Tachometer Calibration Point 1 0 rpm 2 1000 rpm 3 3000 rpm 4 4000 rpm Fuel Gauge Calibration Point 1 Empty E 2 1 8 Filled 3 1 4 Filled 4 Full F Temp Gauge Calibration Point...

Page 376: ...brated using a scan tool DRB III Refer to the proper Body Diag nostic Procedure Manual for calibration procedures ODOMETER SEGMENT TEST When CHEC 2 is displayed in the odometer win dow each digit of the odometer will illuminate sequentially If a segment in the odometer does not illuminate normally a problem exists in the display CONDITIONS Refer to the following charts for possible problems causes...

Page 377: ...NS GS INSTRUMENT PANEL AND SYSTEMS 8E 5 DIAGNOSIS AND TESTING Continued ...

Page 378: ...8E 6 INSTRUMENT PANEL AND SYSTEMS NS GS DIAGNOSIS AND TESTING Continued ...

Page 379: ...NS GS INSTRUMENT PANEL AND SYSTEMS 8E 7 DIAGNOSIS AND TESTING Continued ...

Page 380: ...8E 8 INSTRUMENT PANEL AND SYSTEMS NS GS DIAGNOSIS AND TESTING Continued ...

Page 381: ...NS GS INSTRUMENT PANEL AND SYSTEMS 8E 9 DIAGNOSIS AND TESTING Continued ...

Page 382: ...8E 10 INSTRUMENT PANEL AND SYSTEMS NS GS DIAGNOSIS AND TESTING Continued ...

Page 383: ...NS GS INSTRUMENT PANEL AND SYSTEMS 8E 11 DIAGNOSIS AND TESTING Continued ...

Page 384: ...8E 12 INSTRUMENT PANEL AND SYSTEMS NS GS DIAGNOSIS AND TESTING Continued ...

Page 385: ...NS GS INSTRUMENT PANEL AND SYSTEMS 8E 13 DIAGNOSIS AND TESTING Continued ...

Page 386: ...8E 14 INSTRUMENT PANEL AND SYSTEMS NS GS DIAGNOSIS AND TESTING Continued ...

Page 387: ...Remove screw from ash receiver lamp module 6 Carefully pull lamp module and wiring rear ward from instrument panel Fig 6 7 Disconnect lamp module from the wiring con nector INSTALLATION For installation reverse the above procedures CONVENIENCE BIN REMOVAL 1 Remove the ash receiver cup holder from the instrument panel 2 Remove the screw access cover from the bottom of the radio bezel Fig 5 3 Remove...

Page 388: ... Junction Block INSTALLATION For installation reverse the above procedures CIGAR LIGHTER BASE REMOVAL 1 Look inside and note position of the retaining bosses Fig 9 2 Using external snap ring pliers with 90 degree tips Insert pliers with tips against bosses and squeeze forcing bosses out of base 3 Pull out base through mounting ring gently rocking pliers 4 Disconnect the base wires 5 Set base aside...

Page 389: ...lightly pry glove box lamp switch from instrument panel 3 Disengage wire connector from glove box lamp and switch 4 Remove glove box lamp and switch 5 Remove lamp Fig 12 INSTALLATION For installation reverse the above procedures GLOVE BOX LOCK STRIKER REMOVAL 1 Open glove box door Fig 13 2 Disengage clip holding checkstraps to glove box door 3 Remove screws holding lock striker to instru ment pane...

Page 390: ...reverse the above procedures HVAC CONTROL LAMP REMOVAL 1 Remove radio bezel and HVAC Control Fig 16 2 Remove rear cover from HVAC control 3 Rotate bulb socket counterclockwise one quar ter turn 4 Pull bulb socket from HVAC INSTALLATION For installation reverse the above procedures INSTRUMENT CLUSTER BACK PANEL REMOVAL 1 Remove instrument cluster 2 Remove screws holding back panel to instru ment cl...

Page 391: ...nd of cluster bezel and headlamp switch 6 Install left end cover 7 Install over steering column bezel 8 Install lower steering column cover INSTRUMENT CLUSTER LENS REMOVAL 1 Remove instrument cluster 2 Remove screws holding lens to instrument clus ter Fig 19 3 Remove lens from cluster INSTALLATION For installation reverse the above procedures INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD REMOVAL 1 Remo...

Page 392: ...trument cluster bezel Fig 22 2 Remove screws holding instrument cluster to instrument panel 3 Rotate top of cluster outward 4 Remove instrument cluster from instrument panel 5 Disconnect wire connector from back of instru ment cluster 6 Remove instrument cluster INSTALLATION For installation reverse the above procedures INSTRUMENT PANEL The instrument panel is removed as a unit The steering column...

Page 393: ... 20 Remove the nuts holding the instrument panel frame to the die cast brake pedal support on each side of the steering column 21 With mechanical transmission range indica tor a Remove the indicator cable loop b Remove the clip holding gear shift cable end to the gear selector adapter c Pull the cable end from gear selector d Disconnect the clip for the indicator cable and guide tube from the shif...

Page 394: ...ps holding end cover to instru ment panel 5 Remove instrument panel end cover and foam pad covering the A C inlet projection of the end cover if equipped INSTALLATION For installation reverse the above procedures INSTRUMENT PANEL LOUVERS CENTER LOUVER HOUSING REMOVAL 1 Remove the instrument cluster bezel Refer to Instrument Cluster Bezel removal and installation procedures 2 Place cluster bezel on...

Page 395: ...e lower lock tabs 6 Push out the louver housing from the cluster bezel INSTALLATION 1 Verify the function of the vanes 2 Set louver housing into the cluster bezel and align the slot of the housing with the T location pins 3 Using care do not push on the vanes apply pressure on outer edge of the housing and push lou ver housing into place 4 After in place check function of the vanes PASSENGER SIDE ...

Page 396: ... and the pad panel vinyl covering Fig 34 2 Lightly pry housing inward and by hand pull the housing free from panel Fig 35 INSTALLATION 1 Place the slotted pin on the right side of the opening 2 Set housing in to position and push into place The housing may need to be rocked to get the best fit within the opening INSTRUMENT PANEL TOP COVER REMOVAL 1 Remove A pillar trim 2 Using a trim stick disenga...

Page 397: ... lower steering column cover and knee blocker reinforcement 3 Disconnect four forty way connectors from Junction Block Fig 38 4 Disconnect two wire connectors from bottom of Body Control Module 5 Remove bolts holding Junction Block to dash panel mounting 6 Remove Junction Block from mounting bracket 7 Remove screws holding Body Control Module to Junction Block 8 Slide Body Control Module downward ...

Page 398: ...d instrument panel supports 3 Install screws to hold lower console to floor bracket and instrument panel LOWER INSTRUMENT PANEL REMOVAL 1 Remove right end cover 2 Remove steering column bezel 3 Remove radio bezel and HVAC control 4 Remove lower console 5 Remove ash receiver cup holder and track 6 Remove glove box 7 Remove glove box latch striker 8 Remove glove box lamp 9 Disconnect wire connector ...

Page 399: ...rse the above procedures LOWER STEERING COLUMN COVER REMOVAL 1 Remove screws holding parking brake release handle to instrument panel Fig 42 2 Remove screws holding bottom of lower steer ing column cover to instrument panel Fig 43 3 Remove screw holding right side of lower steer ing column cover to instrument panel 4 Disengage park brake release cable case from groove on end of release handle Fig ...

Page 400: ...l in position and engage clips to the cluster bezel If equipped with traction control switch connect the wire pigtail before engaging clips 2 Install the screws to hold the over steering col umn bezel to the cluster bezel 3 Install the lower column cover POWER MIRROR SWITCH REMOVAL 1 Remove instrument cluster bezel Fig 46 2 Disconnect wire connector from back of power mirror switch 3 Disengage loc...

Page 401: ... the instru ment panel 4 Install screws to hold the top of radio bezel to instrument panel 5 Install screws to the hold bottom of the radio bezel to the instrument panel 6 Install the access cover REAR HEATER A C SWITCH REMOVAL 1 Remove radio bezel and HVAC Control Fig 49 2 Remove screw holding rear heater A C switch to radio bezel HVAC Control 3 Disengage hook holding bottom of switch to radio be...

Page 402: ......

Page 403: ...nect located near the right end of the instrument panel This additional disconnect allows the instru ment panel assembly to be removed and installed without removing the radio The factory installed Electronically Tuned Radios ETRs automatically compensate for radio antenna trim Therefore no antenna trimmer adjustment is required or possible when replacing the receiver or the antenna INTERFERENCE E...

Page 404: ...r to the proper Diagnostic Procedures manual for more information on DRB testing of the audio systems The radio can only be serviced by an authorized radio repair station Refer to the latest Warranty Pol icies and Procedures manual for a current listing of authorized radio repair stations For more information on radio features setting procedures and control functions refer to the owner s manual in...

Page 405: ...IS AND TESTING ANTENNA WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY The following four tests are used to diagnose the antenna with an ohmme...

Page 406: ... 1 ohm 3 If the resistance is more then 1 ohm clean and or tighten the antenna base to fender mounting hardware AUDIO SYSTEM WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMEN...

Page 407: ... IGNITION OFF DRAW FUSE REPLACE FUSE IF REQUIRED 2 CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR REPAIR IF REQUIRED 3 CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR REPAIR WIRING IF REQUIRED 4 CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND A KNOWN GOOD GROUND THERE SHOULD BE CONTINUITY REPAIR GROUND IF REQUIRED 5 EXCHANGE OR REPLACE RADIO IF REQUIRED POOR RADIO RECEPTION 1 ANTENNA FAULTY 2 GROUND FAUL...

Page 408: ...PONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable Wait two minutes for the airbag system capac itor to discharge before further service 2 Remove the remote radio switch es from the steering wheel 3 Use an ohmmeter to check the switch resis tance as shown ...

Page 409: ...o Group 23 Body for proper procedures 9 Slide the plastic sleeve up on antenna mast for access to mast Remove antenna mast from antenna base Fig 10 10 Remove plastic cap from the cap nut Using cap nut tool remove cap nut holding antenna base to front fender Fig 11 11 Remove antenna base from under front fender INSTALLATION For installation reverse the above procedure ANTENNA EXTENSION CABLE REMOVA...

Page 410: ...s from back of radio 7 Remove radio from vehicle INSTALLATION For installation reverse the above procedure INSTRUMENT PANEL SPEAKER INSTALLATION 1 Remove instrument panel top cover 2 Remove screws holding speaker to instrument panel and remove speaker Fig 14 or Fig 15 3 Remove anti rocking finger screw 4 Disconnect wire connector from speaker 5 Remove speaker INSTALLATION For installation reverse ...

Page 411: ...ring wheel far enough to access the wire harness connec tors on the back of the airbag module 4 Unplug the airbag module and horn switch wire harness connectors from the back of the airbag module 5 Remove the driver side airbag module from the vehicle 6 Remove the steering wheel from the steering column Refer to Group 19 Steering for service pro cedure 7 Unplug the wire harness connector from the ...

Page 412: ... procedure D PILLAR SPEAKER REMOVAL 1 Remove D pillar trim panel as necessary to gain access to door speaker Refer to Group 23 Body for proper procedures 2 Disconnect wire connector from speaker 3 Remove by sliding speaker out of bracket by pushing on magnet The capacitor is wrapped with foam tape Fig 18 4 Remove speaker INSTALLATION For installation reverse the above procedure Fig 17 Quarter Pane...

Page 413: ... and the other lead to the positive wire ter minal Fig 3 3 Depress the horn switch battery voltage should be present 4 If no voltage refer to Horn Will Not Sound If voltage is OK go to step Step 5 5 Using ohmmeter test ground wire for continu ity to ground 6 If no ground repair as necessary 7 If wires test OK and horn does not sound replace horn HORN RELAY 1 Remove horn relay 2 Using ohmmeter test...

Page 414: ...uity tester with the horns dis connected test continuity of the X2 cavity of the horn relay to ground Refer to Group 8W Wiring Diagrams for circuit information If continuity is detected the circuit is grounded between the Junction Block and the horns Locate and repair pinched harness FUSE OK 1 Remove the horn relay from the Junction Block 2 Using a continuity tester Depress horn switch and test co...

Page 415: ...ly Unplug the horn relay from Power Distribution Center Refer to Horn Relay Test Refer to Group 8W Wiring Diagrams for circuit and wiring information HORN SYSTEM TEST CONDITION POSSIBLE CAUSE CORRECTION Horn sounds continuously NOTE Immediately unplug horn relay in the Power Distribution Center PDC 1 Faulty horn relay 2 Horn control circuit to relay shorted to ground 3 Pinched horn switch wire und...

Page 416: ...Group 8W Wire Diagrams REMOVAL AND INSTALLATION HORN SWITCH The horn switch is molded into the airbag cover The horn switch cannot be serviced separately Refer to Group 8M Restraint System for Driver Airbag Module Removal and Installation procedures HORNS REMOVAL 1 Hoist and support the front of the vehicle on safety stands 2 From behind the front fascia and forward of the left front wheel disconn...

Page 417: ...f the ON OFF SET RESUME ACCEL CANCEL and DECEL buttons Fig 1 DESCRIPTION AND OPERATION SPEED CONTROL SERVO The servo unit consists of a solenoid valve body and a vacuum chamber The PCM controls the sole noid valve body The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo The servo unit cannot be repaired and is serviced only as a complete asse...

Page 418: ...s closed the TCM causes the transaxle to downshift to THIRD gear After downshifting the automatic speed control resumes normal operation To ensure that an upshift is appropriate after the set speed is reached the TCM waits until the speed con trol system opens the throttle at least 8 degrees before upshifting to OVERDRIVE again If the driver applies the brakes canceling auto matic speed control op...

Page 419: ...Corrosion should be removed from electrical terminals and a light coating of Mopar Multipurpose Grease or equivalent applied Leaking vacuum reservoir Loose or leaking vacuum hoses or connections Defective one way vacuum check valve Secure attachment at both ends of the speed control servo cable Smooth operation of throttle linkage and throttle body air valve Conduct electrical test at PCM Failed s...

Page 420: ...als If these components are damaged intermittent or complete system failure may occur When electrical connections are removed corrosion should be removed from electrical terminals and a light coating of Mopar Multi Purpose Grease or equivalent applied Inspect connectors for damage terminals A poor connection can cause a complete or inter mittent malfunction and is also the only connection in the c...

Page 421: ...Fig 2 Speed Control Circuit NS VEHICLE SPEED CONTROL SYSTEM 8H 5 DIAGNOSIS AND TESTING Continued ...

Page 422: ...CONTROL SWITCH TEST Refer to the appropriate Powertrain Diagnostic Manual for switch test valves STOP LAMP SWITCH TEST 1 Remove the stop lamp switch refer to Stop Switch Removal Installation in this section Discon nect connector from stop lamp switch Fig 4 Using an ohmmeter switch continuity may be checked as follows 2 With switch plunger released there should be continuity between Pin 5 and Pin 6...

Page 423: ...to ground If continuity repair as necessary l If continuity is OK check continuity from cavity 2 of servo connector to cavity 80 of PCM connector If no continuity repair open circuit m Using an ohmmeter check continuity from cavity 2 of servo connector to ground If continuity repair as necessary n Using an ohmmeter check continuity from cavity 1 of servo connector to cavity 2 of servo con nector I...

Page 424: ... vehicles with 3 3 3 8 L engine remove air cleaner resonator Refer to Group 14 Fuel System for proper procedure 3 Disconnect the throttle and speed control cable ends from throttle body Fig 8 4 Depress lock tabs holding speed control cable casing to cable mount bracket Fig 9 5 Disconnect vacuum line from nipple on air intake plenum 6 Remove tie wrap holding vacuum line throttle cable and speed con...

Page 425: ...that mates with the bracket slot at the top of the square hole Align key and push switch into square hole in bracket while depressing the brake pedal Once the switch is seated in the hole rotate clockwise approximately 30 degrees to lock into place The switch will automatically adjust when the pedal is released Pull back on the pedal to assure correct adjustment SPEED CONTROL CABLE REMOVAL 1 Relea...

Page 426: ...t vacuum hoses from vacuum reser voir INSTALLATION 1 Connect vacuum hoses to vacuum reservoir 2 Install battery tray 3 Install battery Refer to Group 8B for Battery Removal Installation 4 Connect negative cable to battery VEHICLE SPEED SENSOR For Removal Installation refer to Vehicle Speed Sensor in Group 14 Fuel Injections Fig 12 Speed Control Cable 8H 10 VEHICLE SPEED CONTROL SYSTEM NS REMOVAL A...

Page 427: ... control system operation is restricted to speeds between 56 km h 35 MPH to 145 km h 90 MPH Inputs to the MSA that allow speed control oper ation are from the vehicle speed sensor and the Speed Control Switch Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver s airbag module Switch features are a Within the two switch modules five m...

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Page 429: ...k is released the stalk will spring back into the neutral position turning OFF the turn signal With the ignition switch ON and the turn signal switch stalk actuated left or right current flows through the Combination flasher Multi function switch Turn indicator lamp Front and rear turn signal bulbs A chime will sound after the vehicle has traveled a distance of approximately 0 5 mile with the turn...

Page 430: ...the steering column of the vehicle To gain access to the device remove the lower steering column cover and knee blocker refer to Group 8E Instrument Panel and Gauges The combination flasher DRL may be operated in its hazard warning mode either with or without the ignition circuit being active However in order to operate in the turn signal mode or the DRL mode the ignition circuit must be completed...

Page 431: ...e junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side The circuit designation out of the fuse is A22D This circuit feeds the combo flasher and the following systems with Ignition voltage if the vehicle is so equipped Back Up Lamps Electrochromic Inside Rear view Mirror A C Control Head Mini Trip Computer ABS Module Front Blower Relay Coil Rear Blower Relay Coil AWD Soleno...

Page 432: ...UT TO LAMP 3 L60 18 TN RIGHT FRONT T S OUTPUT TO LAMP 4 L63 18 DG RD LEFT REAR T S OUTPUT TO LAMP 5 L62 18 BR RD RIGHT REAR T S OUTPUT TO LAMP 6 A22D 20 BK OR IGNITION INPUT SENSE ONLY 7 L305 22 LB WT LEFT T S SWITCH INPUT SENSE ONLY 8 L302 22 LB YL RIGHT T S SWITCH INPUT SENSE ONLY 9 L91 22 DB PK HAZARD SWITCH INPUT SENSE ONLY 8J 4 TURN SIGNAL AND FLASHERS NS DIAGNOSIS AND TESTING Continued ...

Page 433: ...TO LAMP 5 L62 18 BR RD RIGHT REAR T S OUTPUT TO LAMP 6 A22D 20 BK OR IGNITION INPUT SENSE ONLY 7 L305 22 LB WT LEFT T S SWITCH INPUT SENSE ONLY 8 L302 22 LB YL RIGHT T S SWITCH INPUT SENSE ONLY 9 L91 22 DB PK HAZARD SWITCH INPUT SENSE ONLY 10 G09 22 GY BK PARK BRAKE SWITCH INPUT SENSE ONLY 11 Z01 14 BK GROUND MAIN GRD 12 L93 22 RD YL HEADLAMP RELAY SWITCH INPUT SENSE ONLY NS TURN SIGNAL AND FLASHE...

Page 434: ...FUNCTION SWITCH 4 REPLACE JUNCTION BLOCK SYSTEM WILL FLASH HAZARD WARNING LAMPS AND RIGHT TURN SIGNAL LAMPS BUT WILL NOT FLASH LEFT TURN SIGNAL LAMPS 1 FAULTY LEFT TURN SIGNAL WIRING CONNECTION BETWEEN JUNCTION BLOCK AND MULTI FUNCTION SWITCH 2 FAULTY COMBINATION FLASHER 3 FAULTY MULTI FUNCTION SWITCH CONTACTS 4 FAULTY TERMINALS IN JUNCTION BLOCK 1 REPAIR OR REPLACE FAULTY WIRING CONNECTION BETWEE...

Page 435: ...CONNECTION TO RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP 4 REPLACE FAULTY MULTI FUNCTION SWITCH 5 REPLACE JUNCTION BLOCK BOTH TURN SIGNAL INDICATORS IN MESSAGE CENTER DO NOT FLASH IN CONJUNCTION WITH OUTSIDE TURN SIGNAL LAMPS 1 FAULTY GROUND WIRING CONNECTION FROM COWL GROUND SPLICE 1 REPAIR OR REPLACE WIRING CONNECTION FROM COWL GROUND SPLICE LEFT OR RIGHT TURN SIGNAL INDICATOR IN MESSAGE CENTER ...

Page 436: ...1 FAULTY 10 AMP FUSE IN THE JUNCTION BLOCK 2 FAULTY COMBINATION FLASHER DRL MODULE 3 FAULTY MULTI FUNCTION SWITCH CONTACTS 4 FAULTY TERMINALS IN JUNCTION BLOCK 1 REPLACE FAULTY FUSE IN JUNCTION BLOCK 2 REPLACE COMBINATION FLASHER DRL MODULE 3 REPLACE FAULTY MULTI FUNCTION SWITCH 4 REPLACE JUNCTION BLOCK RIGHT TURN SIGNAL OPERATES PROPERLY BUT LEFT TURN SIGNAL FLASHES FAST Hazard mode can be used f...

Page 437: ...FAULTY GROUND WIRING CONNECTION TO RIGHT FRONT OR RIGHT REAR TURN SIGNAL LAMP 4 REPLACE FAULTY MULTI FUNCTION SWITCH 5 REPLACE JUNCTION BLOCK BOTH TURN SIGNAL INDICATORS IN MESSAGE CENTER DO NOT FLASH IN CONJUNCTION WITH OUTSIDE TURN SIGNAL LAMPS 1 FAULTY GROUND WIRING CONNECTION FROM COWL GROUND SPLICE 1 REPAIR OR REPLACE WIRING CONNECTION FROM COWL GROUND SPLICE LEFT OR RIGHT TURN SIGNAL INDICAT...

Page 438: ...EEN THE PARK BRAKE SWITCH AND THE JUNCTION BLOCK 3 3 OR BETWEEN THE BRAKE PRESSURE SWITCH AND THE JUNCTION BLOCK 3 4 OR BETWEEN THE IGNITION SWITCH AND THE JUNCTION BLOCK 3 5 OR A SHORTED IGNITION SWITCH CONTACT SHOULD ONLY BE MADE WHEN IN START POSITION 4 0 L93 CIRCUIT FALSELY GROUNDED BETWEEN JUNCTION BLOCK AND MULTI FUNCTION SWITCH 4 1 L307 CIRCUIT FALSELY GROUNDED BETWEEN HEADLAMP SWITCH AND B...

Page 439: ...ion switch Fig 6 5 Remove screws holding turn signal switch to steering column adapter collar 6 Remove turn signal switch INSTALLATION For installation reverse the above procedures Ver ify switch operation by placing the control stalk in either the right or left position and turning the steer ing wheel to ensure the automatic cancellation of the switch COMBINATION FLASHER WITH WITHOUT DRL MODULE R...

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Page 441: ...windshield washer cir cuit is protected by a 6 amp fuse 9 located in the Junction Block The wiper motor has permanent magnetic fields The speeds are determined by cur rent flow to the appropriate set of brushes inside the motor The current flow is controlled by the multi function switch stalk mounted wiper switch high speed low speed relays located in the PDC The speed sensitive intermittent wiper...

Page 442: ...tch and circuit can be tested using the Wiper System Diagnosis table WIPER SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION WIPER BLADES DO NOT PARK PROPERLY 1 WIPER ARMS IMPROPERLY PARKED 2 WIPER ARMS ARE LOOSE ON PIVOT SHAFT 3 MOTOR CRANK LOOSE AT OUTPUT SHAFT 1 REMOVE WIPER ARMS AND REPARK REFER TO WIPER ARM REMOVAL AND INSTALLATION 2 REMOVE WIPER ARM AND REPARK REFER TO WIPER ARM REMOVAL ...

Page 443: ...IN MOTOR 1 REPLACE WORN LINK REFER TO WIPER LINKAGE REMOVAL AND INSTALLATION 2 REPLACE WIPER MOTOR REFER TO WIPER MOTOR REMOVAL AND INSTALLATION WIPER MOTOR WILL NOT RUN 1 BLOWN FUSE 2 NEW FUSE BLOWS 3 NEW FUSE BLOWS 4 NO VOLTAGE AT MOTOR 5 POOR GROUND 1 REPLACE FUSE AND RUN SYSTEM 2 CHECK FOR SHORT IN WIRING OR SWITCH 3 REPLACE FUSE REMOVE MOTOR CONNECTOR TURN SWITCH ON FUSE DOES NOT BLOW REPLACE...

Page 444: ...ve screws holding turn signal switch to steering column adapter collar 6 Remove turn signal switch INSTALLATION For installation reverse the above procedures Ver ify switch operation by placing the control stalk in either the right or left position and turning the steer ing wheel to ensure the automatic cancellation of the switch WINDSHIELD WASHER BOTTLE REMOVAL 1 Hoist and support vehicle on safe...

Page 445: ...ATION For installation reverse the above procedure WINDSHIELD WIPER BLADE REMOVAL 1 Lift the wiper arm away from windshield 2 Disengage the release tab holding the wiper blade to the wiper arm and remove the wiper blade from the wiper arm Fig 6 3 Remove the wiper blade from the wiper arm INSTALLATION For installation reverse the above procedure Fig 5 Rear Washer Hose Routing Fig 4 Front Washer Hos...

Page 446: ...sconnect wire connectors from back of wiper motor Fig 16 4 Remove wiper linkage from motor crank Do NOT remove crank from motor 5 Remove bolts holding wiper motor to mount plate and remove motor Fig 9 and Fig 10 INSTALLATION 1 Place wiper unit on a suitable work surface 2 Place wiper motor in position on mount plate 3 Install bolts to hold wiper motor to mount plate 4 Install wiper linkage and mot...

Page 447: ...iper arms 2 Remove the cowl cover Refer to Group 23 Body for proper procedure 3 Release the hood latch and open hood 4 Disconnect the positive lock on the wiper unit wire connector Fig 13 5 Disconnect the wiper unit wire connector from the engine compartment wire harness 6 Disconnect the windshield washer hose from coupling inside unit 7 Disconnect the drain tubes from nipples on bot tom of the wi...

Page 448: ...n will cause the blade to skip or chatter across the wind shield If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper s the wiper blade is not roll ing over center If this condition exists refer to the Wiper Arm Alignment paragraph of this group ADJUSTMENTS WIPER ARM ALIGNMENT 1 Verify wiper blade element condition and wiper arm spring...

Page 449: ... REAR WINDOW WIPER WASHER SWITCHES The rear window wiper washer switches are incor porated into the HVAC switch panel Refer to Group 8E Instrument Panel for proper service procedures DIAGNOSIS AND TESTING DIAGNOSTIC PROCEDURES The rear window wiper system operates in several modes Continuous wipe Intermittent wipe Wash Wipe after wash The windshield wiper circuits are continuously monitored and co...

Page 450: ...lding wiper arm to wiper pivot upward 3 Allow wiper arm to rest against lock 4 Pull wiper from pivot Fig 4 INSTALLATION For installation reverse the above procedure REAR WIPER BLADE REMOVAL 1 Lift wiper blade away from rear window 2 Release latch holding blade to wiper arm Fig 5 3 Remove blade from wiper arm INSTALLATION For installation reverse the above procedure REAR WIPER BLADE ELEMENT Refer t...

Page 451: ...nozzles that are mounted in the front fascia of the vehicle These nozzles spray the headlamps when the system is activated REMOVAL AND INSTALLATION WINDSHIELD HEADLAMP WASHER RESERVOIR Removal 1 Remove the right headlamp assembly Refer to Group 8L Lamps 2 Partially remove the inner fender well as needed to gain access to the reservoir 3 Disconnect the windshield washer pump rear washer pump and he...

Page 452: ...nnect the headlamp washer pump electri cal connector 3 Disconnect the headlamp washer pump hose 4 Remove the headlamp washer pump from the reservoir Installation 1 For installation reverse the above procedures Fig 1 Reservoir Removal Fig 2 HeadLamp Washer Nozzle Fig 3 Headlamp Washer Pump 8K 2 WIPER AND WASHER SYSTEMS NS GS REMOVAL AND INSTALLATION Continued ...

Page 453: ...should not be sprung open or disengaged from the insulator Bent and sprung terminals can be repaired using needle nose pliers and pick tool Corroded terminals appear chalky or green Corroded terminals should be replaced to avoid recurrence of the problem symp toms Begin electrical system failure diagnosis by testing related fuses in the fuse block and power distribution center Verify that bulbs ar...

Page 454: ...urn signal mode or the DRL mode the ignition circuit must be completed to the module While the combination flasher portion is idle there is no current drawn through the module The device does not become active in the turn signal or hazard warning modes until a signal ground circuit is sup plied to either of the turn signal inputs or the hazard warning input With the ignition OFF there is no curren...

Page 455: ... 1 Test and repair charging system Refer to Group 8A 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations Refer to Group 8W 3 High resistance in headlamp circuit 3 Test amperage draw of headlamp circuit 4 Low beam headlamp fog lamp fuse blown 4 Locate cause of blown fuse and repair HEADLAMPS FLASH RANDOMLY 1 Poor lighting circuit Z1 ground 1 Test for voltage drop ac...

Page 456: ...WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system Refer to Group 8A 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations Refer to Group 8W 3 High resistance in fog lamp circuit 3 Test amperage draw of fog lamp circuit FOG LAMPS FLASH RANDOMLY 1 Poor lighting circuit Z1 ground 1 Test for voltage drop across Z1 ground lo...

Page 457: ...erify proper tire inflation 4 Clean headlamp lenses 5 Verify that luggage area is loaded as the vehi cle is routinely used 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 ADJUSTMENTS HEADLAMP FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN ALIGNMENT SCREEN PREPARATION 1 Position vehicle on a level surface perpendicu lar to a flat wal...

Page 458: ... are aligned properly To adjust headlamp alignment rotate adjusting screws to achieve the specified low beam hot spot location Fig 3 HEADLAMP ADJUSTMENT TOWN AND COUNTRY A properly aimed low beam headlamp will project the center of the low beam hot spot on the alignment screen 152 mm 6 in 6 50 mm 2 in below the headlamp center line The center of the hot spot should be 254 mm 10 in 6 50 mm 2 in rig...

Page 459: ...mp module and radiator closure panel 3 Through slotted hole in magnifying window insert small screw driver into bubble level calibration screw 4 Rotate calibration screw in proper direction until bubble is centered on the O 5 Install magnifying window making sure O ring seal is in place 6 If necessary calibrate magnifying window MAGNIFYING WINDOW CALIBRATION HORIZONTAL AIM After the headlamp align...

Page 460: ...nt screen 100 mm 4 in below the fog lamp center line and straight ahead Fig 6 To improve visual interpretation of the fog lamp pattern on the alignment screen disable the headlamps by disengaging the wire connectors from the headlamp bulbs The Town and Country fog lamp adjustment screw is located through the lens Fig 7 Fig 6 Fog Lamp Alignment Fig 5 Magnifying Window and Bubble Level Calibration F...

Page 461: ...el insert headlamp bulb into back of headlamp 2 Engage retaining ring onto headlamp Fig 1 3 Rotate headlamp bulb retaining ring clockwise 4 Connect wire connector into headlamp bulb base 5 Verify headlamp alignment HEADLAMP BULB TOWN COUNTRY HEADLAMP HIGH BEAM REMOVAL 1 Release hood latch and open hood 2 From behind radiator closure panel disconnect wire connector from back of high headlamp bulb b...

Page 462: ...headlamp bulb operation 4 Install the headlamp module 5 Verify headlamp alignment FOG LAMP BULB REMOVAL 1 Remove fog lamp from vehicle 2 Remove rear cover from fog lamp 3 Disengage wire clip holding bulb in fog lamp Fig 5 4 Hinge wire retainer clip out of bulb removal path 5 Pull bulb from lamp 6 Disconnect wire connector from fog lamp wire harness INSTALLATION CAUTION Do not touch the glass of ha...

Page 463: ...ONT SIDE MARKER LAMP BULB TOWN and COUNTRY REMOVAL 1 Remove screw attaching side marker lamp to fascia 2 Remove housing by pulling rearward and away from fascia Fig 7 3 Rotate lamp socket counterclockwise one quar ter turn 4 Pull bulb socket from the rear of lamp Fig 8 5 Pull bulb from socket INSTALLATION 1 Insert bulb into socket 2 Insert bulb socket into rear of housing 3 Rotate park and turn si...

Page 464: ... SIGNAL AND BACK UP LAMP BULB REMOVAL 1 Release liftgate latch and open liftgate 2 Remove screws holding tail stop turn signal and back up lamp to rear door opening trough 3 Remove inner end of lamp from quarter panel 4 Disengage hook holding outer end of lamp to quarter panel opening 5 Remove lamp from quarter panel 6 Rotate lamp socket counterclockwise one quar ter turn Fig 12 7 Pull socket from...

Page 465: ...HIGH MOUNTED STOP LAMP CHMSL BULB REMOVAL 1 Release liftgate latch and open liftgate 2 Disengage clips holding CHMSL access trim cover to liftgate 3 Remove trim cover from liftgate 4 Rotate bulb socket counterclockwise one quar ter turn 5 Pull socket from lamp Fig 15 6 Pull bulb from socket INSTALLATION 1 Insert bulb into socket 2 Insert socket into lamp 3 Rotate bulb socket clockwise one quarter ...

Page 466: ...n turn signal switch Proper proce dures can be found in Group 8J Turn Signal and Flashers More information can be found in Group 8W Wiring Diagrams REMOVAL AND INSTALLATION HEADLAMP MODULE REMOVAL 1 Release hood latch and open hood 2 From inside engine compartment remove nuts holding headlamp module to radiator closure panel 3 Remove screw holding top of module to closure panel 4 Remove headlamp m...

Page 467: ...fog lamp to fascia FRONT SIDE MARKER LAMP TOWN and COUNTRY REMOVAL 1 Remove screw attaching side marker lamp 2 Remove housing by pulling rearward and away from fascia Fig 7 3 Rotate lamp socket counterclockwise one quar ter turn 4 Pull bulb socket from the rear of lamp Fig 4 5 Remove side marker housing from vehicle INSTALLATION 1 Insert bulb socket into rear of housing 2 Rotate park and turn sign...

Page 468: ...nect wire connector from tail lamp cir cuit board 9 Remove tail lamp from vehicle INSTALLATION 1 Place tail lamp in position on vehicle 2 Connect wire connector into tail lamp circuit board 3 Connect positive lock on wire connector 4 Place lamp in position in position on quarter panel 5 Engage hook to hold outer end of lamp to quar ter panel opening 6 Position inner end of lamp into quarter panel ...

Page 469: ...e 2 Disengage clips holding CHMSL access cover to liftgate 3 Remove cover from liftgate 4 Rotate bulb sockets counterclockwise one quar ter turn 5 Pull sockets from lamp 6 Remove screws holding CHMSL to liftgate 7 Remove CHMSL from vehicle Fig 9 INSTALLATION 1 Place CHMSL in position on vehicle 2 Install screws to hold CHMSL to liftgate 3 Insert bulb into socket 4 Insert sockets into lamp 5 Rotate...

Page 470: ...rn counterclockwise 3 Pull socket out of lamp Fig 1 4 Pull bulb from socket INSTALLATION 1 Push bulb into socket 2 Push socket into lamp 3 Rotate reading lamp bulb socket one quarter turn clockwise 4 Insert tab on lamp lens between lamp switch and overhead console 5 Snap lens onto lamp lens pivots HEADER READING COURTESY LAMP REMOVAL 1 Grasp outer edges of header reading courtesy lamp at headlinin...

Page 471: ...ab to lamp switch 7 Press lens pivots to tabs on lamp housing until both pivots are seated GLOVE BOX LAMP AND SWITCH REMOVAL 1 Open glove box door 2 Using a trim stick lightly pry glove box lamp switch from instrument panel 3 Disconnect wire connector from glove box lamp Fig 5 4 Remove glove box lamp from vehicle INSTALLATION 1 Position glove box lamp in vehicle 2 Connect wire connector from glove...

Page 472: ...4 Remove the access cover from the vehicle 5 Using needle nose pliers carefully squeeze the vertical metal legs of the lamp hood 6 Lift the lamp hood upward from the cup holder tray 7 Carefully pull the lamp and wiring rearward from the instrument panel Fig 10 8 Pull the lamp hood from the lamp socket 9 Pull bulb from socket INSTALLATION For installation reverse the above procedures INSTRUMENT PAN...

Page 473: ...amp is fully engaged to headlining 5 Push upward on dome lamp until dome lamp is tight to headlining 6 Pivot dome lamp lens upward Verify that lamp lens hook is above the headlining 7 Install left side of dome lamp lens to lamp body DOME LAMP BULB REMOVAL 1 Insert a small flat bladed pry tool between dome lamp lens and dome lamp body on left side of dome lamp 2 Disengage left side of dome lamp len...

Page 474: ...r edge of housing into trim panel FRONT DOOR COURTESY LAMP BULB REMOVAL 1 Using a small flat bladed pry tool pry rear edge of courtesy lamp lens from courtesy lamp Fig 15 2 Remove lens from lamp 3 Squeeze brass lamp bulb contacts together gen tly 4 Disengage bulb from lamp contacts Fig 16 5 Remove bulb from lamp Fig 14 Door Courtesy Lamp Housing Fig 15 Door Courtesy Lamp Lens Fig 16 Door Courtesy ...

Page 475: ...tacts in rail lamp mod ule 2 Insert tab on lamp lens between rail lamp mod ule and rail lamp switch 3 Snap lens onto lens pivots on module LIFTGATE COURTESY LAMP REMOVAL 1 Insert trim stick between courtesy lamp and liftgate trim panel at upper inboard corner of cour tesy lamp Fig 19 2 Disengage tabs holding courtesy lamp to lift gate trim panel Fig 20 3 Disconnect wire connector from courtesy lam...

Page 476: ... lens to courtesy lamp body Fig 21 4 Remove lamp lens from lamp body 5 Carefully press lamp bulb contact toward oppo site contact 6 Remove bulb from lamp body INSTALLATION 1 Carefully press lamp bulb contact toward oppo site contact 2 Position bulb to lamp bulb contacts 3 Position long side of lamp lens to tabs on lamp body 4 Press on center of lens to engage tabs on oppo site side of lamp body 5 ...

Page 477: ... H3 Fog Lamp T C 9040 Headlamp 9007 Headlamp high beam T C 9005 Headlamp low beam T C 9005 SLL License Plate 168 Parking Turn Signal Front Side Marker 3157NA Parking Turn Signal T C 4157NAK Tail Stop Turn Signal and Side Marker 3057 Front Side Marker 194NA INTERIOR LAMP BULBS LAMP BULB ABS PC194 Air Bag PC194 Alarm Set Security PC194 Brake Warning PC194 Center Rear Reading Lamps 578 Center Rear Do...

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Page 479: ...m the insulator Female terminals should not be sprung open or disengaged from the insulator Bent and sprung terminals can be repaired using needle nose pliers and pick tool Corroded terminals appear chalky or green Corroded terminals should be replaced to avoid recurrence of the problem symp toms Begin electrical system failure diagnosis by testing related fuses in the fuse block and power distrib...

Page 480: ...ground locations Refer to Group 8W HEADLAMP BULBS BURN OUT FREQUENTLY 1 Charging system output too high 1 Test and repair charging system Refer to Group 8A 2 Loose or corroded terminals or splices in circuit 2 Inspect and repair all connectors and splices Refer to Group 8W HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system Refer to G...

Page 481: ...WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system Refer to Group 8A 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations Refer to Group 8W 3 High resistance in fog lamp circuit 3 Test amperage draw of fog lamp circuit FOG LAMPS FLASH RANDOMLY 1 Poor lighting circuit Z1 ground 1 Test for voltage drop across Z1 ground lo...

Page 482: ...up 8W Wiring 3 Defective motor 3 Replace motor BOTH MOTORS DO NOT OPERATE 1 No voltage at headlamp leveling switch 1 Repair circuit or replace fuse Refer to Group 8W Wiring 2 No voltage at both motors 2 Repair circuit or replace fuse Refer to Group 8W Wiring 3 Poor connection at motors 3 Secure connectors on motors 4 Both motors defective 4 Replace motors 8L 4 LAMPS NS GS DIAGNOSIS AND TESTING Con...

Page 483: ...utinely used 7 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 ADJUSTMENTS HEADLAMP FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN ALIGNMENT SCREEN PREPARATION 1 Position vehicle on a level surface perpendicu lar to a flat wall 10 meters 32 8 ft away from front of headlamp lens Fig 1 2 Place 75 kg in the driver s seat to simulate the ...

Page 484: ... side of vehicle centerline Use these lines for left right adjustment reference HEADLAMP ADJUSTMENT A properly aimed low beam headlamp will project a high intensity light pattern on the screen with the horizontal cut off line aligned with the tape line 130 mm 5 12 in below the headlamp centerline Fig 1 The intersection of the horizontal and 15 degree cut off lines in the projected pattern should a...

Page 485: ...s section A properly aligned fog lamp will project a pattern on the alignment screen 200 mm 8 in below the fog lamp centerline and straight ahead Fig 3 To improve visual interpretation of the fog lamp pattern on the alignment screen disable the headlamps by disengaging the wire connectors from the headlamp bulbs Fig 3 Fog Lamp Alignment Fig 2 Headlamp Adjusters Left Side Shown NS GS LAMPS 8L 7 ADJ...

Page 486: ...g 2 5 Pivot spring clip from headlamp bulb removal path 6 Pull headlamp bulb from back of headlamp Fig 3 INSTALLATION CAUTION Do not touch the glass of halogen bulbs with fingers of other possibly oily surface Reduced bulb life will result 1 Insert headlamp bulb to headlamp 2 Pivot spring clip over headlamp bulb 3 Engage retaining spring clip to headlamp 4 Install rubber seal boot 5 Engage wire co...

Page 487: ...ubber bushing in headlamp housing Fig 5 3 Pull bulb from socket Fig 6 INSTALLATION 1 Position citylight lamp bulb to lamp socket 2 Push bulb into socket 3 Push citylight lamp into bushing in headlamp housing 4 Install headlamp module to vehicle FOG LAMP BULB REMOVAL 1 Remove fog lamp from vehicle 2 Remove rear cover from fog lamp 3 Disengage wire clip holding bulb in fog lamp Fig 7 4 Hinge wire re...

Page 488: ...ush side repeater lamp to one side and release retaining tab Fig 8 2 Pull side repeater lamp out and disengage bulb socket from lamp Fig 9 3 Rotate and pull bulb from socket INSTALLATION 1 Push and twist bulb into socket 2 Push side repeater lamp socket into side repeater lamp 3 Position side repeater lamp to hole in fender 4 Push side repeater lamp to one side and seat retaining tab into fender 5...

Page 489: ... 9 Pull bulb from bulb holder socket Fig 12 INSTALLATION 1 Align key on bulb base to groove in bulb holder socket and insert bulb into socket Fig 12 2 Position bulb holder to lamp housing 3 Verify that the rubber washers are properly positioned between the bulb holder and lamp housing at the screw locations 4 Install screws to hold bulb holder to lamp hous ing 5 Position lamp to quarter panel 6 En...

Page 490: ...g CHMSL cover to lift gate trim panel Fig 14 3 Separate CHMSL cover from liftgate trim panel 4 Depress plastic tab holding bulb holder to lamp housing Fig 15 5 Separate bulb holder from lamp housing 6 Pull bulb or if equipped bulbs from lamp socket Fig 16 INSTALLATION 1 Align bulb to bulb holder socket 2 Push bulb into bulb holder socket 3 Position bulb holder to CHMSL housing 4 Snap bulb holder i...

Page 491: ...se hood latch and open hood 2 Remove bolt holding headlamp module to radi ator closure panel Fig 1 3 From behind the radiator closure panel remove the nuts holding the headlamp module to the radia tor closure panel 4 Separate headlamp module from radiator clo sure panel 5 Disengage wire connector from headlamp bulb 6 Disengage wire connector from headlamp level ing motor 7 Disengage wire connector...

Page 492: ...e 6 Install headlamp module to vehicle FOG LAMP REMOVAL 1 Remove screws holding fog lamp to front bumper fascia Fig 4 2 Separate fog lamp from fascia 3 Disengage wire connector from body wire har ness 4 Separate fog lamp from vehicle INSTALLATION 1 Position fog lamp on vehicle 2 Engage wire connector to body wire harness 3 Insert fog lamp into bumper fascia 4 Install screws to hold fog lamp to fro...

Page 493: ...le 2 Engage wire connector into bulb holder 3 Engage positive lock on wire connector 4 Place lamp in position in position on quarter panel 5 Engage hook to hold outer end of lamp to quar ter panel opening 6 Position inner end of lamp into quarter panel 7 Install screws to hold tail lamp to rear door opening trough 8 Verify tail lamp operation LICENSE PLATE LAMP REMOVAL 1 Release liftgate latch and...

Page 494: ...MSL REMOVAL 1 Release liftgate latch and open liftgate 2 Disengage clip holding CHMSL access cover to liftgate 3 Separate cover from liftgate 4 Depress plastic tab holding bulb holder to lamp housing Fig 10 5 Separate bulb holder from lamp housing 6 Remove screws holding CHMSL to liftgate 7 Separate CHMSL from vehicle INSTALLATION 1 Place CHMSL in position on vehicle 2 Install screws to hold CHMSL...

Page 495: ...oth To remove road dirt wash with a mild soap solution followed by rinsing with water Do not use abrasive cleaning components solvents steel wool or other aggressive material to clean the lenses SPECIFICATIONS EXTERIOR LAMP BULBS LAMP BULB Back up P21W CHMSL Non Solar Tint P21W CHMSL Solar Tint R10W LAMP BULB Fog Lamp H3 Headlamp H4 License Plate C5W Front Turn Signal PY21W Citylight T4W Front Sid...

Page 496: ......

Page 497: ...TEM COMPONENTS WITH MOPART REPLACEMENT PARTS SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE BUT INTERNAL DIFFERENCES MAY RESULT IN INFE RIOR OCCUPANT PROTECTION WEAR SAFETY GLASSES RUBBER GLOVES AND LONG SLEEVED CLOTHING WHEN CLEANING POWDER RESIDUE FROM VEHICLE AFTER AIRBAG DEPLOYMENT SODIUM HYDROXIDE POWDER RESIDUE EMITTED FROM A DEPLOYED AIRBAG CAN CAUSE SKIN IRRITATION FLUSH AFFECTED AREA WITH CO...

Page 498: ...and bag components Refer to Group 8G Horns for proper service procedure for horn switch The Passenger Airbag Module is serviced as an assembly WARNING WHEN THE AIRBAG SYSTEM IS DEPLOYED BECAUSE OF A COLLISION THE FOL LOWING MUST BE REPLACED COMPLETE STEERING COLUMN ASSEMBLY LOWER STEERING COUPLER STEERING WHEEL STEERING COLUMN CLOCKSPRING DRIVER AIRBAG COVER HORN SWITCH DRIVER AIRBAG MODULE PASSEN...

Page 499: ... airbag deployment Sodium hydroxide powder can irritate the skin eyes nose and throat Wear safety glasses rubber gloves and long sleeved clothing when cleaning any of the powder residue from the vehicle If you find that the cleanup is irritating your skin run cool water over the affected area Also if you experience nasal or throat irritation exit the vehicle for fresh air until the irritation ceas...

Page 500: ... 6 10 Remove the ACM from vehicle INSTALLATION WARNING DO NOT REMOVE THE BOLTS HOLD ING THE ACM TO THE ACM BRACKET THESE BOLTS ARE SAFETY TORQUED AT THE MANUFAC TURING FACILITY AND SHOULD NOT BE REMOVED FOR ANY REASON THE NEW ACM WILL COME WITH A NEW BRACKET INSTALLED CAUTION USE CORRECT SCREWS WHEN INSTALLING THE ACM For installation reverse the above procedures Attach the ACM bracket assembly to...

Page 501: ...heel Fig 8 7 Remove steering column shrouds Fig 9 8 Disconnect 2 way and 4 way connectors between the clockspring and the instrument panel wiring harness 9 Remove clockspring from housing assembly by depressing the two tabs on the clockspring Fig 10 INSTALLATION For installation reverse the above procedures Do not connect battery negative cable Refer to Diagno sis and Testing for Airbag System Tes...

Page 502: ...ag horn switch to steering wheel Fig 7 3 Remove Driver Airbag Module from steering wheel 4 Disconnect wire connectors from airbag mod ule horn switch and speed control switches if equipped 5 Remove screws holding vehicle speed control switches to airbag cover and remove INSTALLATION For installation reverse the above procedures and do not connect battery negative cable Do not connect battery negat...

Page 503: ...ting tape wire coil in the clockspring is not positioned properly with the steering wheel and the front wheels the clockspring may fail The fol lowing procedure MUST BE USED to center the clockspring if it is not known to be properly posi tioned or if the front wheels were moved from the straight ahead position WARNING DISCONNECT AND ISOLATE THE BAT TERY NEGATIVE CABLE BEFORE BEGINNING AIR BAG SYS...

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Page 505: ...d shield wiper de icer circuit is protected by fuse 21 25 amp in the Junction Block The Heated Windshield Wiper Deicer is also acti vated when the DEFROST mode is selected on the HVAC In the DEFROST mode the rear defogger relay timer is bypassed the heated windshield wiper de icer will stay ON until the another mode is selected For circuit information and component loca tion refer to Group 8W Wiri...

Page 506: ...tch Rear window defogger relay in the relay bank Check for loose connector or a wire pushed out of connector Rear window or the windshield grid lines all grid lines would have to be broken or one of the feed pigtails not connected to the bus bar for no ammeter deflection 8 If turning the switch ON produces severe volt meter deflection the circuit should be closely checked for a shorting condition ...

Page 507: ...ront windshield or the rear win dow grids are the same The repair of grid lines and replacement of the ter minal is possible using the Mopart Repair Package or equivalent 1 Clean area surrounding grid line or terminal by gently rubbing area with steel wool 2 Wipe area with clean cloth soaked in alcohol or similar solvent It is necessary that all contaminants be removed from repair area 3 Remove pa...

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Page 509: ... automatic door lock feature can be dis abled if desired All doors and liftgate can be locked or unlocked using mechanical button or key cylinder methods DESCRIPTION AND OPERATION AUTOMATIC DOOR LOCK FEATURE The vehicle comes with two options for power door locks Rolling automatic lock ENABLE doors auto matically lock at approximately at 25 7 Km h 16 mph No rolling automatic lock DISABLE doors do ...

Page 510: ... motor is faulty check each individual door for electrical lock and unlock or dis connect the motor connectors one at a time while operating the door lock switch In the event that none of the motors work the problem may be caused by a shorted motor a relay or a bad switch Discon necting the defective motor will allow the others to work To test an individual door lock motor disconnect the electrica...

Page 511: ...ION FRONT DOOR LOCK MOTOR LATCH Refer to Group 23 Body for proper service proce dures LIFTGATE LOCK MOTOR REMOVAL 1 Remove liftgate trim panel 2 Remove bolts holding liftgate lock motor to lift gate Fig 5 3 Disconnect the wire connector from power lock motor 4 Disconnect the liftgate lock motor from outside handle lock link 5 Remove the liftgate lock motor from vehicle INSTALLATION For installatio...

Page 512: ...o gain access to push in fasteners holding sliding door lock plunger wiring harness to inner door panel 3 Make note of wiring harness routing to aid installation Fig 8 4 Remove push in fasteners holding lock plunger wiring harness to inner door panel 5 Disconnect plunger wiring harness from sliding door lock motor 6 Remove screw holding lock plunger to door frame Fig 8 7 Remove lock plunger from s...

Page 513: ... memory even after vehicle power has been interrupted The RKE system activates the optional memory seat and mirror system if equipped Two primary key fob transmitters can be programmed to actuate memory seat and mirror setting 1 or 2 Two addi tional key fob transmitters can be added but they will not be able to operate the memory seat and mir ror system Refer to Group 8R Power Seats and Group 8T P...

Page 514: ...tton A single chime will sound to verify that the RKE module is set to receive the new Vehicle Access Code s 6 Within 30 seconds of the chime press any but ton on each new key fob transmitter After 30 sec onds or when ignition switch is turned OFF the RKE module will end the programming mode A single chime will sound to verify that the RKE module will no longer receive additional Vehicle Access Co...

Page 515: ...tic connector above the accel erator pedal ENABLING To initialize the VTSS feature the operator must with the engine compartment hood open cycle the key in the liftgate key cylinder to the unlock position giving the BCM a disarm signal At this time the visual alarm outputs the headlamps and marker lamps will function However the audio alarm output the horn and engine disable portion of the VTSS wi...

Page 516: ...le BCM Fig 1 4 Remove the bolts holding the Junction Block to the dash panel mounting bracket 5 Remove the Junction Block from the mounting bracket 6 Remove the screws holding BCM to Junction Block 7 Slide the BCM downward to disengage guide studs on Junction Block from the channels on the BCM mounting bracket 8 Remove the BCM from Junction Block INSTALLATION For installation reverse the above pro...

Page 517: ...ector from the liftgate ajar switch 3 Remove the screw holding the ajar switch to the liftgate latch and remove the switch Fig 5 INSTALLATION For installation Reverse the above procedure LIFTGATE LOCK CYLINDER SWITCH REMOVAL 1 Remove the inner trim panel from the liftgate Refer to Group 23 Body for proper procedure 2 Disconnect the door lock cylinder switch wire connector from the liftgate harness...

Page 518: ...e sliding door on outside of the vehicle pry door ajar switch from quarter panel opening Fig 7 3 Disconnect the wire connector from the back of the ajar switch 4 Remove the sliding door ajar switch INSTALLATION For installation reverse the above procedure Fig 7 Sliding Door Ajar Switch 8Q 4 VEHICLE THEFT SECURITY SYSTEM NS REMOVAL AND INSTALLATION Continued ...

Page 519: ...rt unless the key tran sponder is also programmed to the vehicle The SKIS will recognize no more than eight valid Smart Key transponders at any one time The SKIS performs a self test each time the igni tion switch is turned to the On position and will store Diagnostic Trouble Codes DTCs if a system malfunction is detected The SKIS can be diagnosed and any stored DTC can be retrieved using a DRB sc...

Page 520: ...etects an invalid key when the igni tion switch is turned to the On position it sends messages to the instrument cluster to flash the SKIS indicator lamp The SKIM can also send messages to the instrument cluster to flash the lamp and to gen erate a single audible chime tone For diagnosis or initialization of the SKIM and the PCM a DRB scan tool and the proper Diagnostic Procedures manual are requi...

Page 521: ...p comes on and stays on after the bulb test func tion diagnosis of the SKIS should be performed with a DRB scan tool and the proper Diagnostic Proce dures manual DIAGNOSIS AND TESTING SMART KEY IMMOBILIZER SYSTEM WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERV...

Page 522: ...NEW EMS The SKIM module will send the secret key data to the PCM 7 Program ignition keys to the SKIM module PROGRAMMING IGNITION KEYS WITH THE DRBIII 1 Turn ignition on Transmission must be in park or neutral Alarm set lamp will flash 2 Use the DRBIII and select SKIM under the MISCELLANEOUS menu 3 Select LEARN NEW KEY Alarm Set lamp will begin flashing NOTE The PIN must be re entered each time an ...

Page 523: ...al procedures to install Tighten the non tilt steering column mounting nuts to 22 N m 200 in lbs and the steering column shroud mounting screws to 2 N m 18 in lbs 12 If the SKIM is replaced with a new unit a DRB scan tool and the proper Diagnostic Procedures manual MUST be used to initialize the new SKIM and to program at least two Smart Key transponders Fig 3 Smart Key Immobilizer Module Remove I...

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Page 525: ...n the opposite direction Refer to Group 8W Wiring Diagrams for circuit infor mation and component locations DIAGNOSIS AND TESTING POWER VENT WINDOW MOTOR TEST If the power vent window motor is receiving proper current and ground and does not operate proceed with motor test Refer to Group 8W Wiring Diagrams for circuit information and component locations 1 Remove D pillar trim panel necessary to ga...

Page 526: ... Diagrams for circuit information and component locations 1 Remove front door trim panel and water shield as necessary to gain access to power window motor wire connector refer to Group 23 Body for proper procedures 2 Disconnect power window motor wire connector from door harness 3 Using two jumper wires connect one to a bat tery source and the other to a good ground 4 Connect the Negative jumper ...

Page 527: ...wer vent motor 7 Pull the crank system from the motor INSTALLATION Before installing crank cycle replacement motor to the open position Install crank hinge in extended position to the motor and for installation reverse the above procedures POWER WINDOW SWITCH To remove power window switches refer to Group 23 Body for proper procedures POWER WINDOW MOTOR WARNING DO NOT HAVE ANY HANDS OR FIN GERS IN...

Page 528: ...d a small amount approximately 1 to 2 inches The drum will rotate when the glass is low ered Lowering the glass will require assistance of a second person 2 install the replacement cover plate onto the replacement motor Crimp toy tabs 3 Connect the wiring harness to the window motor connector 4 Remove the tape holding the window in place and test window operation Fig 5 Power Window Motor Removal 8...

Page 529: ...The circuit breaker also protects the passenger side power seat track circuit Check both sides of the cir cuit breaker connector for voltage on the wire side If not OK replace circuit breaker If battery voltage is detected on both sides of the circuit breaker Refer to Seat Motor in the Diagnostic and Testing in this section If seat motors test OK refer to the Seat Switch in the Diagnostic and Test...

Page 530: ...Fig 1 Seat Motor Test Fig 2 Power Seat Switch Test 8R 2 POWER SEATS NS DIAGNOSIS AND TESTING Continued ...

Page 531: ... the power mirror switch The Memory Seat Mirror Module monitors the mem ory switches and has the capability to store desired positions in non volatile memory in response to a valid input sequence Refer to Memory Selector Switches 1 2 and S and Remote Keyless Entry RKE Data Link The memory seat mirror module also can activate the previously described motors in response to a recall request from an i...

Page 532: ...ETERS A potentiometer is mounted to each seat track and recliner motor end bell to provide a sense voltage to the Memory Seat Mirror Module that will indicate to the module where the seat track or recliner is posi tioned This sense voltage is derived from a 5 volt source provided by the module to the potentiometer The sense voltage is input into the module and stored by the Memory Seat Mirror Modu...

Page 533: ...rors use the same functions The rheostat for position sensing utilizes the wire from the module to the mirror as both feed and sense line on the same wires D and F The ground return wire E stands alone Refer to Fig 2 and the Mirror Mechanization Table The mirror motors for each side use a common con nection B which becomes automatically connected to the proper polarity power connection during eith...

Page 534: ...old the S and 2 buttons for 5 seconds to enter diagnostic mode 2 This mode is exited after 5 seconds of switch inactivity or upon grounding the RKE input by moving the transmis sion out of the PARK position Mode 2 will Place the seat and mirror motors at their mid point When a single axis of seat or mirror motion is requested by pressing a switch the corresponding motor is energized This tests swi...

Page 535: ...ay connector If the power door locks rear blower and front fog lamps if so equipped are functional and the seats are both nonfunctional repair replace the open wir ing and or circuit breaker in the driver s seat harness to correct the condition Ensure that the 12 ga ground wire Z1 BK from the electrical distribution wiring ground splice into the 4 way connector is providing ground The Z1 BK is dou...

Page 536: ...on when actuated pro ceed with the following analysis Verify power ON F35 and ground Z1 into the system as indicated above Verify all connectors are mated with the memory seat mirror module Place the vehicle gear shift lever in any position except PARK causes the Memory Seat Mirror Mod ule to wake up and provide a position sense voltage to the seat motor potentiometers and the mirror rheostat s Th...

Page 537: ...volt meter must be used as follows Connect the negative probe to the P28 circuit cavity 10 of the 21 way connector Connect the positive probe to the P29 circuit cavity 20 of the 21 way connector and verify a volt age reading between 3 5 and 5 volts when a seat or recliner switch is activated An internal timer in the Memory Seat Mirror Module MSM Module regulates the length of time this voltage sta...

Page 538: ...s initiated by either of the validly pro grammed transmitters NOTE The module will abort a recall if the trans mission is moved out of the PARK position or if any seat recliner or memory switch is pressed REMOVAL AND INSTALLATION MEMORY SWITCHES REMOVAL 1 Insert a proper tool through the access slot located at the front forward edge of the switch bezel 2 Pry the switch out from the door trim panel...

Page 539: ...mper wires Connect one to a 12 volt source Connect the other to a good body ground Refer to the Mirror Test Chart for wire hookups at the switch connector Fig 1 4 If results shown in chart are not obtained check for broken or shorted circuit or replace mirror assembly as necessary MIRROR SWITCH TEST 1 Remove power mirror switch from mounting position 2 Disconnect wiring harness at switch connector...

Page 540: ...Fig 1 Power Mirror Test Fig 2 Mirror Switch Test 8T 2 POWER MIRRORS NS DIAGNOSIS AND TESTING Continued ...

Page 541: ...screws 3 Disconnect wire connector s 4 Remove mirror from vehicle INSTALLATION For installation reverse the above procedures POWER MIRROR SWITCH Refer to Group 8E Instrument Panel and Systems for service procedure Fig 4 Fig 3 Power Side View Mirror Fig 4 Power Mirror Window Switch NS POWER MIRRORS 8T 3 ...

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Page 543: ...in 9 of the internal 32 way connector of the BCM for battery feed b Pin 8 of the internal 32 way connector of the BCM for ignition feed c If voltage OK go to step Step 3 d If NO voltage repair as necessary Refer to Group 8W Wiring Diagrams for component loca tions and circuit information 3 Check driver s seat belt buckle switch input for a closed circuit when not buckled If input not seen look for...

Page 544: ...The key in ignition chime will act as a warning to the driver that the ignition key has been left in the ignition switch With the ignition switch is in OFF position ONLY Driver s door is open ajar door ajar switch is closed to ground Key is in the ignition switch key in ignition switch is closed to ground The chime will sound until one of the above condi tions is removed Chime rate 168 to 192 chim...

Page 545: ...vehicle has exceeded 24 km h 15 mph for 6 4 km 4 0 miles When the above two conditions are met the chime will sound The chime will stop when no fur ther voltage change is detected If hazard warning signals are pulsing no chime will sound If speed drops below 24 km h 15 mph before the warning is issued the warning will not be issued and the distance counter will be reset If turn signal lamps are no...

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Page 547: ...dule PCM will enable or disable this fea ture for the appropriate vehicles Right hand drive gas vehicles only The Body Control Module BCM will monitor the CCD bus for status and signal a cat alyst overheat condition with continuous warning chime when the following conditions are met Ignition switch in the ON position Engine running at 420 to 480 rpm for 10 sec onds CCD status and with a chime rate...

Page 548: ...engine 116 C 241 F The chime will turn OFF after four minutes or when the temperature reaches 117 C 242 F or diesel engine 108 C 226 F which ever occurs first EXTERIOR LAMPS ON CHIME The exterior lamp on chime will warn the driver that the exterior lights have been left on With the ignition switch OFF Driver s door is open door ajar switch is closed to ground Parking lamps or headlamps ON parking ...

Page 549: ... the accumulated distance traveled will be reset The turn signal chime is not activated when the emergency flashers are turned on This feature can also be disabled in EEPROM Chime rate 38 to 62 chimes per minute For the turn signal warning system to operate Must have input from either the right or left turn signal lamps Creates a voltage change between 0 and battery voltage The vehicle speed senso...

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Page 551: ...of the internal check the CMTC will display PASS FAIL CCd If any segment of the CMTC fails to light replace the module If FAIL is displayed replace the module If CCd is displayed check the CCD and Body Con trol Module BCM for proper operation refer to the appropriate diagnostic test procedures manual If the CCD and the BCM are OK replace the CMTC mod ule For additional diagnostic information on th...

Page 552: ...s section This procedure may be per formed anytime that the compass appears to be inac curate If the calibration data stored in the body control module is not received the compass will read only NE North East The CMTC is self calibrating and requires no adjusting The word CAL is displayed to show that the compass is in calibration mode CAL will turn off after the vehicle has gone through three com...

Page 553: ...y information for any of the screens for which it did not receive the bus messages The label corresponding to the missing information will be lit If no traveler data is displayed check the CCD com munications and the BCM If the brightness level is improper check the CCD bus One general method for checking the CCD bus communications between CMTC and the BCM is refer to the following proce dure 1 ST...

Page 554: ...ters a fast calibration mode where is tries to compensate for the large magnetic shifts If the compass is inaccurate appears to be inaccu rate and the CAL is not illuminated the fast calibra tion mode may be manually entered by using the following procedure 1 Set the CMTC to Compass Temperature mode and press the reset button for 10 continuous seconds Manual activation of the fast calibration is g...

Page 555: ... windshield with the demagnetizing tool plugged in 10 Contact the roof panel with the tip of the tool Using slow sweeping motions of 1 2 inch between sweeps Move the tool approximately four inches either side of the center line and at least 11 inches back from the windshield 11 With the demagnetizing tool still energized slowly back away from the roof panel until the tip is at least two feet from ...

Page 556: ...contact tab on the lens between the lamp switch plunger and the lamp bezel Then snap lens onto the two lens pivots on the bezel OVERHEAD CONSOLE REMOVAL 1 Open the transmitter bin door Fig 9 2 Remove screw holding the overhead console to the headliner With the screw removed the console is retained by one engagement tab located inside the eyeglass storage bin 3 Open the eyeglass bin door 4 Press th...

Page 557: ...olding the reading lamp to the overhead console Fig 12 4 Remove the lamp from the overhead console 5 Disconnect the wire connectors from the back of the reading lamp Fig 13 6 Disconnect the reading lamp switch from the keyhole slot in the reading lamp 7 Remove the reading lamp from the overhead console Installation For installation reverse the above procedures UNIVERSAL TRANSMITTER REMOVAL The Uni...

Page 558: ...om Universal Transmitter and remove bin door from vehicle INSTALLATION For installation reverse the above procedures The Universal Transmitter will need to be retrained Refer to SERVICE PROCEDURES in this section Fig 9 Overhead Console Fig 10 Reading Courtesy lamp lens Fig 11 Socket and Lamp Fig 12 Reading Courtesy Lamp Fig 13 Connector and Switch 8V 8 OVERHEAD CONSOLE NS REMOVAL AND INSTALLATION ...

Page 559: ...SPECIAL TOOLS SPECIAL TOOL Degausser 6029 NS OVERHEAD CONSOLE 8V 9 ...

Page 560: ......

Page 561: ...N CIGAR LIGHTER POWER OUTLET 8W 41 1 INSTRUMENT CLUSTER 8W 40 1 INTERIOR LIGHTING 8W 44 1 JUNCTION BLOCK 8W 12 1 MESSAGE CENTER 8W 46 1 OVERHEAD CONSOLE 8W 49 1 POWER DISTRIBUTION 8W 10 1 POWER DOOR LOCKS 8W 61 1 POWER MIRRORS 8W 62 1 POWER SEAT 8W 63 1 POWER WINDOWS 8W 60 1 REAR LIGHTING 8W 51 1 SPLICE INFORMATION 8W 70 1 SPLICE LOCATIONS 8W 95 1 STARTING SYSTEM 8W 21 1 TRAILER TOW 8W 54 1 TRANSM...

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Page 563: ...effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle it is impor tant to understand all of their features and charac teristics Diagrams are arranged such that the power B side of the circuit is placed near the top of the page and the ground B side of the circuit is placed near the bottom of the page All switches components and modules are shown in the at rest position...

Page 564: ...8W 01 2 8W 01 GENERAL INFORMATION NS GS DESCRIPTION AND OPERATION Continued ...

Page 565: ...NS GS 8W 01 GENERAL INFORMATION 8W 01 3 DESCRIPTION AND OPERATION Continued ...

Page 566: ...T BR BROWN WT DB DARK BLUE WT DG DARK GREEN WT GY GRAY BK LB LIGHT BLUE BK LG LIGHT GREEN BK OR ORANGE BK PK PINK BK or WT RD RED WT TN TAN WT VT VIOLET WT WT WHITE BK YL YELLOW BK WITH TRACER CIRCUIT FUNCTION A BATTERY FEED B BRAKE CONTROLS C CLIMATE CONTROLS D DIAGNOSTIC CIRCUITS E DIMMING ILLUMINATION CIRCUITS F FUSED CIRCUITS G MONITORING CIRCUITS GAUGES H OPEN I NOT USED J OPEN K POWERTRAIN C...

Page 567: ...throughout the wir ing diagrams These symbols are consistent with those being used around the world GROUP TOPIC 8W 01 thru 8W 09 General Information and Diagram Overview 8W 10 thru 8W 19 Main Sources of Power and Vehicle Grounding 8W 20 thru 8W 29 Starting and Charging 8W 30 thru 8W 39 Powertrain Drivetrain Systems 8W 40 thru 8W 49 Body Electrical items and A C 8W 50 thru 8W 59 Exterior Lighting W...

Page 568: ...Wiring Diagram Symbols 8W 01 6 8W 01 GENERAL INFORMATION NS GS DESCRIPTION AND OPERATION Continued ...

Page 569: ... ground location illustrations The illustrations contain the connector name or number ground number and component identification Connector ground location charts in Section 8W 90 reference the illustration number for components and connectors Section 8W 80 shows each connector and the cir cuits involved with that connector The connectors are identified using the name number on the Dia gram pages S...

Page 570: ...s touch a known good ground before han dling the part This should be repeated while han dling the part and more frequently after sliding across a seat sitting down from a standing position or walking a distance 2 Avoid touching electrical terminals of the part unless instructed to do so by a written procedure 3 When using a voltmeter be sure to connect the ground lead first 4 Do not remove the par...

Page 571: ...fully seated Spread terminals or terminal push out Terminals in the wiring assembly are fully seated into the connector component and locked in position Dirt or corrosion on the terminals Any amount of corrosion or dirt could cause an intermittent prob lem Damaged connector component casing exposing the item to dirt and moisture Wire insulation that has rubbed through causing a short to ground Som...

Page 572: ...s added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify these add on items are not the cause of the problem 1 Verify the problem 2 Verify any related symptoms Do this by per forming operational checks on components that are in the same circuit Refer to the wiring diagrams 3 Analyze the symptoms Use the wiring dia grams to determine wh...

Page 573: ...attery 2 Disconnect the connector from its mating half component 3 Insert the terminal releasing special tool 6742 into the terminal end of the connector Fig 11 4 Using special tool 6742 release the locking fin gers on the terminal Fig 12 5 Pull on the wire to remove it from the connec tor 6 Repair or replace the connector or terminal as necessary CONNECTOR REPLACEMENT 1 Disconnect battery 2 Disco...

Page 574: ...h is the same as the original Fig 16 7 Remove 1 inch of insulation from each wire 8 Place a piece of heat shrink tubing over one side of the wire Be sure the tubing will be long enough to cover and seal the entire repair area 9 Spread the strands of the wire apart on each part of the exposed wires 10 Push the two ends of wire together until the strands of wire are close to the insulation 11 Twist ...

Page 575: ...ing the proper pick from special tool kit 6680 Pull on the wire to remove the terminal from the connector Fig 20 Fig 21 5 Cut the wire 6 inches from the back of the con nector 6 Remove 1 inch of insulation from the wire on the harness side 7 Select a wire from the terminal repair assem bly that best matches the color wire being repaired 8 Cut the repair wire to the proper length and remove 1 inch ...

Page 576: ...nector and 2 inches past the repair 18 Connect battery and test all affected systems DIODE REPLACEMENT 1 Disconnect the battery 2 Locate the diode in the harness and remove the protective covering 3 Remove the diode from the harness pay atten tion to the current flow direction Fig 22 4 Remove the insulation from the wires in the harness Only remove enough insulation to solder in the new diode 5 In...

Page 577: ...0 Dome Lamp Switch 8W 50 Door Ajar Indicator Lamp 8W 40 Door Ajar Switches 8W 39 40 44 Door Lock Relay 8W 61 Speakers 8W 47 Component Page Door Unlock Relay 8W 61 Oxygen Sensors 8W 30 Door Ajar Switches 8W 39 40 44 45 Door Arm Disarm Switches 8W 39 61 Door Courtesy Lamps 8W 44 Door Lock Motors 8W 61 Door Lock Switches 8W 61 Door Unlock Relays 8W 61 Heated Seat Backs 8W 63 Heated Seat Cushions 8W 6...

Page 578: ...Component Page Manifold Absolute Pressure Sensor 8W 30 Memory Power Seat Switch 8W 63 Seat Sensors 8W 63 Memory Seat Mirror Module 8W 62 63 Memory Set Switch 8W 62 63 Message Center 8W 46 Mid Reading Lamps 8W 44 Mode Door Actuator 8W 42 Name Brand Speaker Relay 8W 47 Needle Movement Sensor 8W 30 Odometer 8W 40 Output Shaft Speed Sensor 8W 31 Overdrive Pressure Switch 8W 31 Overdrive Solenoid 8W 31...

Page 579: ...1 Transmission Control Relay 8W 10 31 Transmission Control Solenoids 8W 31 Transmission Range Sensor 8W 31 Trip Odometer 8W 40 Component Page Turbine Speed Sensor 8W 31 Turbo Boost Pressure Sensor 8W 30 Turn Indicators 8W 46 52 Turn Signal Hazard Switch 8W 46 52 Underdrive Solenoid 8W 31 Universal Garage Door Opener 8W 49 Vacuum Solenoid 8W 33 Vehicle Speed Control Servo 8W 33 Vehicle Speed Sensor...

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Page 581: ...8 16 Fuse 24 PDC 8W 10 8 15 Fuse 25 PDC 8W 10 8 15 Fuse 26 PDC 8W 10 8 13 Fuse 27 PDC 8W 10 8 12 Fuse 28 PDC 8W 10 9 11 Fusible Link A11 8W 10 8 Fusible Link A54 8W 10 8 G100 8W 10 27 28 G103 8W 10 27 28 G200 8W 10 14 32 G300 8W 10 14 18 19 31 Generator 8W 10 8 23 25 Glove Box Lamp 8W 10 20 Glow Plug Relay 8W 10 8 25 Headlamp Dimmer Switch 8W 10 32 Headlamp Switch 8W 10 21 34 High Beam Relay 8W 10...

Page 582: ... 21 22 23 24 25 26 SPARE SPARE HORN RELAY RELAY CLUTCH COMPRESSOR A C FRONT BLOWER MOTOR RELAY ENGINE STARTER MOTOR RELAY PARK LAMP RELAY CIGAR ACC RELAY LOW HIGH WIPER RELAY RELAY ON WIPER HIGH BEAM RELAY RELAY BEAM LOW RELAY CONTROL TRANSMISSION FUEL PUMP RELAY AUTOMATIC SHUT DOWN RELAY IOD GAS GAS DIESEL RELAY HEATER FUEL GAS RELAY POWER DIESEL 87A 87A 87A 87A 87A 87A 87A 87A 87A 87A 87A 87A 87...

Page 583: ...A 19 40A 21 40A 22 40A 23 40A 24 40A 25 40A 26 40A 27 40A 28 10A 20A A22 12BK OR A0 6RD INTERNAL A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD L9 18BK WT A1 12RD A16 12GY A10 12RD DG A2 12PK BK A4 12BK RD M1 20PK L43 18VT 7 15A A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD INTERNAL L34 20RD OR 20 INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL IN...

Page 584: ...A C COMPRESSOR CLUTCH RELAY OUTPUT C3 18DB BK FUSED IGNITION ST RUN F87 18WT BK A C COMPRESSOR CLUTCH RELAY CONTROL C13 18DB OR INTERNAL FUSED B 87A 86 85 30 A C COMPRESSOR CLUTCH RELAY FUNCTION CAVITY CIRCUIT 87 85 86 C13 20DB OR A142 18DG OR 87 CIRCUIT CAVITY FUNCTION DIESEL POWER RELAY 30 85 86 87A 87 FUSED B INTERNAL K51 20DB YL DIESEL POWER RELAY CONTROL A0 6RD B A142 18DG OR DIESEL POWER REL...

Page 585: ...2DB FRONT BLOWER MOTOR RELAY OUTPUT ENGINE STARTER MOTOR RELAY OUTPUT T40 12BR FUSED IGNITION ST F45 18YL RD ENGINE STARTER MOTOR RELAY CONTROL K90 18TN INTERNAL FUSED B 87A 86 85 30 ENGINE STARTER MOTOR RELAY FUNCTION CAVITY CIRCUIT 86 T141 20YL RD 87 EATX MTX FUEL HEATER RELAY OUTPUT A141 16DG WT FUSED IGNITION ST RUN INTERNAL GROUND Z1 20BK INTERNAL FUSED B 87A 86 85 30 FUEL HEATER RELAY DIESEL...

Page 586: ...EAM RELAY FUNCTION CAVITY CIRCUIT 85 L193 20OR WT LOW BEAM RELAY CONTROL CHRYSLER HIGH BEAM RELAY OUTPUT INTERNAL B A0 6RD HIGH BEAM RELAY CONTROL L324 20WT LG A0 6RD B 87A 86 85 30 HIGH BEAM RELAY FUNCTION CAVITY CIRCUIT CIRCUIT CAVITY FUNCTION HORN RELAY 30 85 86 87A FUSED B INTERNAL X4 20GY OR HORN RELAY CONTROL A0 6RD B X2 18DG RD HORN RELAY OUTPUT 87 87 87A INTERNAL INTERNAL 87 8W 10 6 8W 10 ...

Page 587: ...GH V4 12RD YL WIPER ON RELAY OUTPUT V16 20WT WIPER HIGH LOW RELAY CONTROL WIPER ON RELAY OUTPUT 87 86 85 30 WIPER HIGH LOW RELAY FUNCTION CAVITY CIRCUIT CIRCUIT CAVITY FUNCTION TRANSMISSION CONTROL RELAY GAS 30 85 86 87A FUSED B INTERNAL Z16 18BK GROUND T15 18LG 12 V SUPPLY T16 18RD TRANSMISSION CONTROL RELAY OUTPUT 87 INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL NS GS 8W 10 POWER DISTRIBUTION 8W ...

Page 588: ...30A 86 WIPER ON RELAY 40A FUSE 27 6 C1 A4 12 BK RD BLOCK JUNCTION TO GENERATOR A11 6 BK GY ES09 A11 LINK FUSIBLE 10 DG A 8W 10 9 MOTOR TO FUSE 28 PDC 4 C7 A17 12 RD BK FAN RELAY RADIATOR TO NO 3 FAN RELAY RADIATOR TO NO 2 DIESEL GAS RD 2 A0 DIESEL GAS ES11 DIESEL GAS RELAY PLUG GLOW DIESEL 1 RD 10 FUSIBLE LINK A54 ES26 ES28 A54 10 RD DIESEL 8W 20 2 8W 20 3 8W 21 2 8W 21 3 8W 10 13 8W 10 15 8W 10 1...

Page 589: ... 20 PK PK 20 M1 TO MEMORY SEAT MIRROR MODULE TO FUSE 13 PDC FROM FUSE 19 PDC GAS 30 20A FUSE 16 9 C6 RELAY HEATER FUEL A14 18 RD WT MODULE TO POWERTRAIN CONTROL DIESEL 30 20A FUSE 16 RELAY PUMP FUEL GAS 30 25A FUSE 17 RELAY POWER DIESEL DIESEL GAS 86 86 A 8W 10 8 B 8W 10 10 8W 10 28 8W 31 2 8W 30 2 8W 10 20 8W 10 11 8W 30 29 8W 10 26 8W 30 6 8W 30 20 8W 10 26 8W 10 25 8W 30 28 8W 10 23 NS GS 8W 10...

Page 590: ...CH COMPRESSOR A C RELAY EXCEPT BUILT UP EXPORT BUILT UP EXPORT EXPORT BUILT UP EXCEPT BUILT UP EXPORT CHRYSLER PLYMOUTH DODGE PLYMOUTH DODGE CHRYSLER OTHER CHRYSLER OTHER CHRYSLER VT RD 20 L44 VT RD 20 L44 VT RD 20 L44 VT 18 L43 VT 18 L43 L34 20 RD OR L34 20 RD OR L33 20 RD HEADLAMP RIGHT TO TO HEADLAMP LOW RIGHT BS15 TO FOG LAMP RELAY IN JB TO TO LEFT HEADLAMP RIGHT HIGH HEADLAMP TO TO LEFT HIGH ...

Page 591: ...0 M1 C3 2 C3 1 3 0 2 1 4 SWITCH IGNITION M1 20 PK A81 20 DG RD INSTRUMENT CLUSTER 2 M1 20 PK C1 RADIO 7 M1 20 PK M1 20 PK 16 DATA LINK CONNECTOR BLOCK JUNCTION 10A FUSE 2 C4 15 D1 D3 8 7 P50 NOT USED RHD M1 22 PK 4 ACC 3 LOCK 0 OFF 2 RUN 1 START 8W 10 8 8W 10 9 8W 12 2 8W 62 3 8W 63 4 8W 45 2 8W 61 5 8W 46 2 8W 10 14 8W 40 2 8W 47 2 8W 30 3 8W 12 2 8W 12 9 NS GS 8W 10 POWER DISTRIBUTION 8W 10 11 G...

Page 592: ... RELAY 10A FUSE 7 C4 20 4 DRIVER POWER MIRROR MIRROR POWER PASSENGER 4 DEFOGGER WINDOW REAR C15 12 BK WT 12 B17 LJ01 C15 12 BK WT L16 J03A 1 C15 12 BK WT 6 C1 C1 C1 C16 20 LB YL C16 20 LB YL 8W 10 8 8W 10 8 8W 12 2 8W 48 2 8W 12 10 8W 48 2 8W 48 2 8W 48 2 8W 10 12 8W 10 POWER DISTRIBUTION NS GS J988W 1 GS001012 ...

Page 593: ...D B09 3 A2 12 PK BK OTHER HEATED SEATS BATT A0 9A 3 PTC 40A FUSE 26 CENTER DISTRIBUTION POWER 5 C4 4 C1 A2 12 PK BK 85 85 85 87A 87A 87A 30A BREAKER CIRCUIT SEAT POWER P WASHER MODULE BUILT UP EXPORT 8W 12 2 8W 61 3 8W 61 4 8W 61 7 8W 61 8 8W 61 3 8W 61 4 8W 61 7 8W 61 8 8W 61 7 8W 61 8 8W 10 8 8W 12 14 8W 12 15 8W 10 8 8W 63 2 8W 63 3 8W 63 4 8W 53 5 NS GS 8W 10 POWER DISTRIBUTION 8W 10 13 GS0010...

Page 594: ...ATT M1 C1 10 C1 7 3 0 2 1 4 SWITCH IGNITION C1 9 3 0 2 1 4 8 C1 C3 2 C3 1 3 0 2 1 4 2 C1 G9 20 GY BK 9 MESSAGE CENTER BLOCK JUNCTION 8 C3 G9 20 GY BK C 8W 10 13 FROM BLOCK JUNCTION CENTER DISTRIBUTION POWER 10A FUSE 1 2 C3 11 FUSE 20A BLOCK JUNCTION C4 1 12 FUSE 10A 31 C2 A22 12 BK OR 1 START 2 RUN 0 OFF 3 LOCK 4 ACC 11 RHD 8W 40 4 8W 45 5 8W 12 19 8W 15 6 8W 15 4 8W 10 16 8W 10 16 8W 10 16 8W 46 ...

Page 595: ...UTION POWER 6 C4 25 CONTROLLER ANTI LOCK BRAKE 24 FUSE 40A C7 6 GY 12 A16 RELAY FAN RADIATOR 4 GAS DIESEL 8 A16 12 GY NO 2 RELAY FAN RADIATOR A16 12 GY 8W 10 8 8W 10 8 8W 35 2 8W 42 8 8W 42 10 NS GS 8W 10 POWER DISTRIBUTION 8W 10 15 GS001015 J988W 1 ...

Page 596: ... 1 2 0 3 9 C1 IGNITION SWITCH 4 1 2 0 3 7 C1 10 C1 8 FUSE 10A C4 7 BLOCK JUNCTION F45 18 YL RD A1 12 RD TRANSMISSION CONTROL MODULE D1 D3 BODY CONTROL MODULE 14 1 START 2 RUN 0 OFF 3 LOCK 4 ACC 31 15A FUSE 9 ST F45 ST T141 MTX EATX F45 20 YL RD T141 20 YL RD 3 MODULE CONTROL POWERTRAIN 6 E95 B107 DIESEL GAS K90 18 TN K90 18 TN K90 20 TN 8W 10 8 8W 10 8 8W 21 2 8W 21 3 8W 30 6 8W 30 20 8W 12 20 8W ...

Page 597: ... LAMP PARK C1 4 BLOCK JUNCTION C2 9 2 C1 16 3 FUSE 15A L7 12 BK YL BODY CONTROL MODULE L97 18 PK DB 15A FUSE 5 1 10A FUSE 1 FUSE 4 BUILT UP 15A EXPORT 8W 10 8 8W 10 8 8W 12 2 8W 12 8 8W 45 3 8W 12 8 8W 12 8 8W 12 8 NS GS 8W 10 POWER DISTRIBUTION 8W 10 17 GS001017 J988W 3 ...

Page 598: ...C4 DB 12 C71 1 FRONT BLOWER MOTOR B35 P18 B23 35 C71 12 DB 85 87 30 86 C1 3 G300 10 Z1 18 BK 5 C2 JUNCTION BLOCK 10A FUSE 12 7 C2 RUN A22 F20 20 WT RELAY 8W 10 8 8W 10 8 8W 42 2 8W 15 7 8W 12 2 8W 12 12 8W 10 14 8W 10 18 8W 10 POWER DISTRIBUTION NS GS J988W 3 GS001018 ...

Page 599: ...RD VT C1 73 MODULE CONTROL BODY 5 V16 20 WT G300 10 Z1 18 BK B1 P18 B23 1 V16 20 WT SWITCH FUNCTION MULTI PART OF SWITCH WIPER FRONT WIPER ON RELAY WIPER HIGH LOW RELAY DIESEL C7 4 8 RD BK 12 A17 NO 3 RELAY FAN RADIATOR 8W 10 8 8W 10 8 8W 53 2 8W 45 4 8W 15 7 8W 53 2 8W 53 3 8W 53 2 8W 53 3 8W 53 2 8W 42 10 NS GS 8W 10 POWER DISTRIBUTION 8W 10 19 GS001019 J988W 3 ...

Page 600: ... RIGHT VISOR MIRROR VANITY B 3 LAMPS SWITCH READING FRONT F41 20 PK VT F41 20 PK VT PK VT 20 F41 PK VT 20 F41 F41 20 PK VT PK VT 20 F41 PK VT 20 F41 CS02 OVERHEAD CONSOLE OTHERS C20 B75 2 PK VT 20 F41 FRONT READING SWITCH LAMPS 4 4 OPENER DOOR GARAGE UNIVERSAL F41 20 PK VT 1 MODULE IMMOBILIZER KEY SENTRY F41 20 PK VT LAMPS READING FRONT PART OF SWITCH BUILT UP EXPORT 8W 10 8 8W 10 9 8W 12 2 8W 62 ...

Page 601: ...K 20 M113 LB PK 20 M113 LEFT 1 MID LAMP READING READING LAMP MID RIGHT 1 C2 22 LB PK 20 M113 M112 22 BR LG 10 C3 3 C1 17 M113 20 LB PK 28 C3 C1 C1 11 C3 34 85 BLOCK JUNCTION FROM D 8W 10 20 JUNCTION BLOCK COURTESY LAMP RELAY 87 30 86 SWITCH BR WT 22 M111 9 HEADLAMP CONTROL BODY MODULE D4 C20 B75 4 2 CENTER DOME LAMP LAMP DOME REAR 2 CS1 M113 20 LB PK M113 20 LB PK F 8W 10 22 POWER TO MIRROR UNFOLD...

Page 602: ...ER PASSENGER 6 6 DRIVER POWER 5 MIRROR 11 C3 C4 11 F 8W 10 21 86 87 30 85 FOLD MIRROR POWER RELAY RELAY 85 POWER MIRROR UNFOLD 30 87 86 JUNCTION BLOCK C2 C2 C2 C2 87A 87A M 8W 62 8 8W 62 8 8W 62 8 8W 62 8 8W 12 2 8W 10 22 8W 10 POWER DISTRIBUTION BUILT UP EXPORT NS GS J988W 3 GS001022 ...

Page 603: ...GNITION 2 DG OR A142 E 8W 10 24 TO E78 A142 DG OR A142 18 DG OR NO 1 INJECTOR FUEL 2 2 4L 3 3L 3 8L 18 18 18 18 2 FUEL INJECTOR NO 2 DG OR 18 A142 2 FUEL INJECTOR NO 3 DG OR 18 A142 2 FUEL INJECTOR NO 4 DG OR 18 A142 A142 18 DG OR B70 E43 2 F09 E69 10 2 DG OR 18 A142 2 3 DG OR 18 A142 2 0L ES99 TO G 8W 10 24 2 4L 3 3L 3 8L 2 0L 2 4L 8W 10 8 8W 10 9 8W 30 2 8W 30 7 8W 30 21 8W 30 7 8W 30 21 8W 20 2...

Page 604: ...OR NO 6 DG OR 18 A142 DG OR 18 A142 E 8W 10 23 ES12 FROM F02 E78 1 2 0L A142 18 DG OR NO 4 INJECTOR FUEL 2 A142 18 DG OR NO 3 INJECTOR FUEL 2 A142 18 DG OR NO 2 INJECTOR FUEL 2 2 FUEL INJECTOR NO 1 DG OR 18 A142 ES99 FROM ES12 G 8W 10 23 A142 18 DG OR 3 3L 3 8L 8W 30 23 8W 30 23 8W 30 23 8W 30 23 8W 30 23 8W 30 23 8W 30 9 8W 30 9 8W 30 9 8W 30 9 8W 10 24 8W 10 POWER DISTRIBUTION GAS NS GS J988W 3 ...

Page 605: ...DULE DG OR 18 A142 DG OR 18 A142 1 B108 E96 7 BS33 ES29 BATT A0 20A FUSE 17 CENTER DISTRIBUTION POWER C6 5 DG OR 18 A142 MODULE CONTROL POWERTRAIN 85 87 30 86 8 C6 42 DB YL 20 K51 ES06 GENERATOR A142 18 DG OR DIESEL POWER RELAY SOLENOID EGR FUEL PUMP MODULE 86 A C COMPRESSOR CLUTCH RELAY POWER DISTRIBUTION CENTER 1 C6 85 8W 42 10 8W 42 10 8W 42 10 8W 30 32 8W 30 28 8W 10 8 8W 10 9 8W 30 28 8W 20 3...

Page 606: ...L C2 7 DG WT 16 A141 MODULE 46 CONTROL POWERTRAIN C2 85 87 30 86 3 C6 BLOCK JUNCTION 30 C1 9A 1 PTC ST RUN A21 6 C2 F87 18 WT BK C2 74 BR 18 K31 4 B13 AW4 8W 10 8 8W 10 9 8W 30 6 8W 30 20 8W 30 2 8W 30 6 8W 30 20 8W 12 2 8W 12 13 8W 10 16 8W 10 26 8W 10 POWER DISTRIBUTION GAS NS GS J988W 3 GS001026 ...

Page 607: ... DG WT 16 A141 85 87 30 86 3 C6 BLOCK JUNCTION 30 C1 9A 1 PTC ST RUN A21 6 C2 F87 18 WT BK DIESEL 38 CONTROL POWERTRAIN MODULE C6 6 SENSOR VEHICLE SPEED 1 F87 18 WT BK 1 ES40 A141 18 DG WT A141 18 DG WT CRANK CASE HEATER 8W 30 29 8W 20 3 8W 15 3 8W 10 8 8W 10 9 8W 12 2 8W 12 13 8W 10 16 8W 30 36 8W 30 36 8W 30 29 NS GS 8W 10 POWER DISTRIBUTION DIESEL 8W 10 27 GS001027 J988W 3 ...

Page 608: ...6 18 RD MODULE CONTROL TRANSMISSION RD DB 18 A5 56 17 C8 2 10 C8 RELAY CONTROL TRANSMISSION 20A FUSE 15 TRANSMISSION CONTROL 4 SOLENOIDS BATTERY ES11 G100 G103 Z0 6 BK Z0 8 BK Z0 10 BK Z16 18 BK 8W 10 8 8W 10 9 8W 31 2 8W 31 6 8W 31 7 8W 20 2 8W 15 2 8W 10 28 8W 10 POWER DISTRIBUTION GAS NS GS J988W 3 GS001028 ...

Page 609: ...NTROL POWERTRAIN 6 C6 C6 1 ES07 F87 18 WT BK F87 18 BK WT C13 20 DB OR POWERTRAIN CONTROL MODULE 28 9 E97 B106 C13 18 DB OR DIESEL GAS 38 MODULE CONTROL POWERTRAIN DIESEL F87 18 WT BK DIESEL GAS VEHICLE SPEED SENSOR 1 30 87 DIESEL POWER RELAY 20A FUSE 17 BATT A0 CENTER DISTRIBUTION POWER 5 C6 DIESEL GAS ES06 ES29 A142 18DG OR 8W 10 8 8W 10 10 8W 33 5 8W 51 7 8W 35 2 8W 42 7 8W 42 9 8W 12 2 8W 50 1...

Page 610: ...8 C2 C2 4 X2 18 DG RD HORN NOTE HIGH A BS19 X2 18 DG RD X2 18 DG RD GY OR 20 X4 JUNCTION BLOCK 4 C2 CONTROL RELAY HORN 18 MODULE BODY CONTROL 20 C2 RELAY CONTROL 1 C2 HORN X3 20 BK RD HORN SWITCH 8W 10 8 8W 10 10 8W 41 2 8W 41 2 8W 41 2 8W 12 2 8W 45 3 8W 10 30 8W 10 POWER DISTRIBUTION NS GS J988W 3 GS001030 ...

Page 611: ...23 P34 1 OUTLET POWER LIGHTER CIGAR REAR 1 C4 2 Z1 18 BK F30 16 RD F30 16 RD G300 10 JUNCTION BLOCK 9A 7 PTC 16 C2 9 C2 RUN ACC A31 F1 20 DB FRONT CIGAR LIGHTER POWER OUTLET 8W 10 8 8W 10 10 8W 41 3 8W 41 3 8W 15 7 8W 12 2 8W 12 16 8W 10 16 8W 41 3 NS GS 8W 10 POWER DISTRIBUTION 8W 10 31 GS001031 J988W 3 ...

Page 612: ...ADLAMP DIMMER G200 13 12 33 C3 15 BLOCK JUNCTION COMBINATION FLASHER DRL MODULE MODULE CONTROL BODY CONTROL RELAY BEAM HIGH LOW L93 22 PK 86 30 HEADLAMP SENSE SWITCH PART OF MULTI FUNCTION SWITCH CHRYSLER DODGE PYLMOUTH L193 20 OR WT Z1 18 BK 76 C1 8W 10 10 8W 10 8 8W 10 33 8W 10 34 8W 10 33 8W 10 34 8W 10 33 8W 10 34 8W 10 33 8W 10 34 8W 15 4 8W 12 2 8W 45 5 8W 50 2 8W 10 32 8W 10 POWER DISTRIBUT...

Page 613: ...MP HIGH LEFT RIGHT LOW HEADLAMP TO TO HEADLAMP RIGHT 1 CENTER MESSAGE RIGHT HEADLAMP TO TO HEADLAMP HIGH RIGHT 18 B23 P18 B18 L34 20 RD OR L34 20 RD OR L33 20 RD L33 20 RD L44 20 VT RD L44 20 VT RD L43 18 VT L43 18 VT L34 20 RD OR L34 20 RD OR LOW BEAM RELAY RELAY BEAM HIGH FOG LAMP RELAY IN JB TO 8W 10 10 8W 10 8 8W 50 6 8W 50 6 8W 50 5 8W 50 4 8W 50 6 8W 50 8 8W 46 4 8W 50 6 8W 50 8 8W 50 4 8W 5...

Page 614: ...OR L34 20 RD OR LOW BEAM RELAY RELAY BEAM HIGH RHD 6 2 1 HEADLAMP LEFT RIGHT HEADLAMP 1 2 2 HEADLAMP SWITCH B3 B23 3 MOTOR LEVELING HEADLAMP LEFT RIGHT HEADLAMP LEVELING MOTOR 3 BS16 P18 3 L44 20 VT RD L44 20 VT RD L44 20 VT RD L44 20 VT RD L44 20 VT RD C1 8W 10 10 8W 10 8 8W 46 4 8W 50 2 8W 50 2 8W 50 6 8W 50 8 8W 50 10 8W 50 8 8W 50 8 8W 10 34 8W 10 POWER DISTRIBUTION BUILT UP EXPORT NS GS J988W...

Page 615: ...C2 6 1 C4 B24 24 B23 P18 F23 18 DB YL 31 C2 9A 1 PTC C1 30 RUN A22 F87 18 WT BK A22 12 BK OR EXPORT F14 18 LG YL F14 20 LG YL BUILT UP UP EXPORT EXCEPT BUILT EXCEPT BUILT UP EXPORT EXPORT BUILT UP DB YL 20 F23 DB YL 18 F23 8W 10 16 8W 10 8 8W 43 2 8W 12 2 8W 12 13 8W 10 14 8W 10 14 NS GS 8W 10 POWER DISTRIBUTION 8W 10 35 GS001035 J988W 3 ...

Page 616: ......

Page 617: ...W 12 2 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Key In Halo Lamp 8W 12 19 22 26 Left Combination Relay 8W 12 18 Left Fog Lamp 8W 12 8 25 Left Front Park Turn Signal Lamp 8W 12 8 18 Left Liftgate Flood Lamp 8W 12 22 Left Low Headlamp 8W 12 25 Left Rear Lamp Assembly 8W 12 8 18 Left Rear Sliding Door Contact 8W 12 14 15 Left Repeater Lamp 8W 12 18 Left Stop Turn Signal Relay 8W 12 18 L...

Page 618: ...D 1 8 15 19 23 30 2 3 4 5 6 7 14 13 12 11 10 9 16 20 21 22 18 17 29 36 35 34 33 32 31 24 25 26 27 28 28 27 26 25 24 31 32 33 34 35 36 29 17 18 22 21 20 16 9 10 11 12 13 14 7 6 5 4 3 2 30 23 19 15 8 1 28 27 26 25 24 31 32 33 34 35 36 29 17 18 22 21 20 16 9 10 11 12 13 14 7 6 5 4 3 2 30 23 19 15 8 1 28 27 26 25 24 31 32 33 34 35 36 29 17 18 22 21 20 16 9 10 11 12 13 14 7 6 5 4 3 2 30 23 19 15 8 1 C1...

Page 619: ...R 10A 15A 15A 15A 20A 10A 10A 10A 20A 10A INTERNAL L7 12BK YL INTERNAL V20 18RD 15A A21 12DB A22 12BK OR 9A 9A 9A 9A 9 10 8 7 6 5 4 3 2 INTERNAL 9A 1 FEED CIRCUIT FUSED CIRCUIT AMPS PTC NO POSITIVE TEMPERATURE COEFFICIENT PTC S F21 12TN FOG LAMPS F39 18PK LG INTERNAL A21 12DB INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL L78 20DG YL L78 20DG YL F39 18PK LG C16 20LB YL NS ...

Page 620: ...LAY OUTPUT INTERNAL COMBINATION FLASHER DRL MODULE RIGHT REAR TURN SIGNAL 5 FUSED IGNITION RUN 6 LEFT TURN SIGNAL SENSE L305 22LB WT 7 RIGHT TURN SIGNAL SENSE L302 22LB YL 8 COMBINATION FLASHER SWITCHED GROUND L91 20DB PK 9 COURTESY LAMP RELAY CONTROL CIRCUIT CAVITY FUNCTION COURTESY LAMP RELAY 30 85 86 87 INTERNAL M111 22BR WT FUSED B FUSED B COURTESY LAMP RELAY OUTPUT INTERNAL INTERNAL INTERNAL ...

Page 621: ... UNLOCK RELAY OUTPUT F131 20BK PK DOOR UNLOCK RELAY CONTROL FUSED B FUSED B GROUND 87A CIRCUIT CAVITY FUNCTION DOOR UNLOCK RELAY 30 85 86 87 DOOR UNLOCK RELAY OUTPUT INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL CHRYSLER FUSED LOW BEAM RELAY OUTPUT 87A FOG LAMP RELAYCONTROL CIRCUIT CAVITY FUNCTION FOG LAMP RELAY 30 85 86 87 INTERNAL L94 20OR WT ...

Page 622: ...7 86 85 30 BUILT UP EXPORT FUNCTION CAVITY CIRCUIT P159 20DG FUSED B INTERNAL 87A INTERNAL GROUND POWER MIRROR UNFOLD OUTPUT POWER MIRROR UNFOLD OUTPUT POWER MIRROR FOLD OUTPUT POWER MIRROR FOLD OUTPUT GROUND INTERNAL 87A INTERNAL FUSED B P160 20LB CIRCUIT CAVITY FUNCTION BUILT UP EXPORT 30 85 86 87 P160 20LB P171 20VT WT INTERNAL FUSED B POWER MIRROR FOLD RELAY POWER MIRROR UNFOLD RELAY 8W 12 6 8...

Page 623: ... ANODE 2 1 D1 ORIENTATION CAVITY CIRCUIT CATHODE D2 WASHER MODULE CONTROL FUSED PARK LAMP RELAY OUTPUT CIRCUIT CAVITY FUNCTION BUILT UP EXPORT 30 31 56 P V53 18RD YL INTERNAL INTERNAL INTERNAL WASHER MODULE OUTPUT FUSED B WASHER MODULE S INTERNAL FUSED IGNITION RUN ACC INTERNAL INTERNAL INTERNAL INTERNAL INTERNAL NS GS 8W 12 JUNCTION BLOCK 8W 12 7 GS001207 J988W 3 ...

Page 624: ... 5 L15 J02A 6 T05 B99 4 T08 B98 4 L78 20 DG YL TRAILER TOW OTHERS 2 TRAILER TOW CONNECTOR L78 18 BR L77 20 BR LB L77 20 BR LB OTHERS TOW TRAILER SIGNAL SIGNAL LAMP WASHER MODULE BUILT UP EXPORT C2 5 EXPORT BUILT UP SWITCH HEADLAMP 28 B23 P18 B28 L77 18 BR YL 1 3 1 3 4 FUSE 15A C1 3 1 1 EXPORT BUILT UP LAMP FOG LEFT RIGHT FOG LAMP BUILT UP EXPORT F39 18 PK LG F39 18 PK LG BUILT UP EXPORT 56 8W 10 8...

Page 625: ...18 BR PK 10 CONTROL A C C1 V23 18 BR PK V23 18 BR PK V23 18 BR PK REAR WIPER 2 MOTOR L16 J03A 3 LJ01 B17 8 HEATER 1 AUTOMATIC DAY NIGHT MIRROR C1 14 11 B75 C20 1 C19 EC1 V23 18 BR PK V23 18 BR PK 13 CS04 COMPASS MINI TRIP COMPUTER CONSOLE OVERHEAD 4 V23 18 BR PK F11 20 RD WT 4 P50 NOT USED V23 18 BR PK 8W 10 16 8W 40 2 8W 12 2 8W 10 16 8W 45 2 8W 31 5 8W 46 2 8W 42 4 8W 53 4 8W 44 6 8W 49 2 NS GS ...

Page 626: ...7 C4 20 DEFOGGER WINDOW REAR C15 12 BK WT 12 B17 LJ01 C15 12 BK WT L16 J03A 1 C15 12 BK WT C16 20 LB YL C16 20 LB YL 4 PASSENGER POWER MIRROR MIRROR POWER DRIVER 4 C1 C1 8W 10 12 8W 12 2 8W 48 2 8W 48 2 8W 48 2 8W 48 2 8W 12 10 8W 12 JUNCTION BLOCK NS GS J988W 3 GS001210 ...

Page 627: ...3 BK 14 Z1 C3 24 C1 6 RADIO 1 C2 X12 18 RD WT X60 20 RD DG 20A FUSE 11 RUN A22 C2 12 C40 12 BR WT UNIT A C REAR 3 HEATER 9 FUSE 15A 15 C3 ELECTRIC WIPER DE ICER V20 18 RD X12 20 RD WT 6 P50 NOT USED 1 C1 8W 10 16 8W 12 2 8W 47 4 8W 15 6 8W 47 2 8W 47 4 8W 10 14 8W 42 6 8W 48 3 8W 12 19 NS GS 8W 12 JUNCTION BLOCK 8W 12 11 GS001211 J988W 3 ...

Page 628: ...20 18 WT F20 20 WT E36 B33 5 F20 20 WT 4 B09 HS5D 6 HEATER HS2 F20 20 WT F20 20 WT 23 BRAKE ANTI LOCK CONTROLLER F20 18 WT HS4 F20 20 WT F20 20 WT HS5P B56 4 D B SWITCH SEAT HEATED DRIVER PASSENGER HEATED SEAT SWITCH B D EATX MTX GAS DIESEL B33 5 E36 5 E120 B33 F20 20 WT F20 18 WT 1 SWITCH BACK UP F20 20 WT F20 20 WT 85 8W 12 2 8W 10 14 8W 51 3 8W 48 2 8W 42 4 8W 31 3 8W 42 2 8W 10 8 8W 35 2 8W 63...

Page 629: ...87 18 WT BK 19 C4 3 EXPORT BUILT UP MODULE IMMOBILIZER KEY SENTRY F87 20 WT BK EGR SOLENOID EXCEPT BUILT UP EXPORT 2 C5 EXPORT BUILT UP UP EXPORT EXCEPT BUILT F14 18 LG YL F14 20 LG YL 1 AIRBAG CONTROL MODULE F14 18 LG YL B23 B23 P18 23 FUEL HEATER RELAY DIESEL 85 86 85 85 GAS DIESEL 1 C6 TO ES29 C2 A142 18 DG OR GAS 8W 12 2 8W 10 16 8W 10 9 8W 10 10 8W 10 35 8W 30 6 8W 30 20 8W 42 7 8W 42 9 8W 30...

Page 630: ... PK F131 20 BK PK F136 20 VT YL F136 20 VT YL B03 D01P 9 F136 20 VT YL F136 20 VT WT F136 20 VT WT F136 20 VT WT F136 20 VT WT 10 B17 LJ01 5 J02A L15 2 2 9A PTC 3 RKE OTHER LIFTGATE LOCK MOTOR 85 85 5 BODY CONTROL MODULE 6 87A 87A 8W 10 13 8W 12 2 8W 61 3 8W 61 4 8W 61 7 8W 61 8 8W 61 7 8W 61 8 8W 61 3 8W 61 7 8W 61 3 8W 61 7 8W 61 4 8W 61 8 8W 61 4 8W 61 8 8W 61 3 8W 61 7 8W 45 7 8W 10 13 8W 12 1...

Page 631: ...BR RD F133 20 BR RD F133 20 BR RD F133 20 BR YL F133 20 BR YL D01D B02 12 D01P B03 10 9 B17 LJ01J01A 4 J02A L15 1 1 9A PTC 3 LIFTGATE LOCK MOTOR MODULE WASHER 15 B75 C20 F133 20 BR YL 87A P 8 BODY CONTROL MODULE 85 UP EXPORT BUILT 8W 12 2 8W 61 3 8W 61 4 8W 61 7 8W 61 8 8W 10 13 8W 61 3 8W 61 7 8W 61 3 8W 61 7 8W 61 4 8W 61 8 8W 61 4 8W 61 8 8W 61 3 8W 61 7 8W 53 5 8W 45 7 8W 10 13 NS GS 8W 12 JUN...

Page 632: ...W D01P B03 12 C2 13 F55 12 TN DG ST A41 C2 10 86 MOTOR STARTER ENGINE C2 3 RELAY 7 C8 TRANSMISSION CONTROL MODULE 8 F45 18 YL RD 7 C3 5 F1 20 DB SWITCH FUNCTION MULTI PART OF SWITCH WIPER FRONT MODULE WASHER EATX MTX 2 1 T141 20 YL RD F45 20 YL RD F45 20 YL RD JUMPER SWITCH INTERLOCK CLUTCH 2 1 SWITCH INTERLOCK CLUTCH F45 20 YL RD T141 20 YL RD S 85 85 UP EXPORT BUILT 8W 12 2 8W 10 16 8W 10 8 8W 4...

Page 633: ... TO BRAKE PARK IGNITION SWITCH TO TO CENTER MESSAGE MODULE BODY CONTROL 18 C2 4 C2 4 POWER DISTRIBUTION CENTER X4 20 GY OR 85 RELAY HORN HORN RELAY CONTROL 5 P50 L91 20 DB PK NOT USED C2 8 EATX MTX TURN SIGNAL HAZARD SWITCH PART OF MULTI FUNCTION SWITCH TO 86 8W 10 29 8W 12 2 8W 46 3 8W 52 2 8W 46 3 8W 10 14 8W 46 3 8W 45 3 8W 10 10 8W 41 2 8W 52 2 8W 46 3 NS GS 8W 12 JUNCTION BLOCK 8W 12 17 GS001...

Page 634: ...EFT TO RELAY COMBINATION LEFT LEFT STOP TURN RELAY TO RIGHT COMBINATION RELAY TO TO RELAY TURN STOP RIGHT L63 18 DG RD L63 18 DG RD L62 18 BR RD L62 18 BR RD L63 18 DG RD L63 18 DG RD L63 18 DG RD L62 18 BR RD L62 18 BR RD 1 B99 T05 T08 B98 1 TRAILER TOW OTHERS 21 19 15 SIGNAL SIGNAL RIGHT REPEATER LAMP BUILT UP EXPORT TO L62 18 BR RD TO EXPORT BUILT UP LAMP REPEATER LEFT L63 18 DG RD 8W 12 2 8W 5...

Page 635: ...ODULE CONTROL BODY 3 RELAY UNLOCK 87A DOOR DRIVER DOOR UNLOCK RELAY 87A 87A RELAY LOCK DOOR JUNCTION BLOCK 8 RKE Z1 18 BK Z1 20 BK Z2 20 BK LG Z2 20 BK LG 3 4 FROM SWITCH LAMP STOP Z1 20 BK 2 EXPORT BUILT UP SWITCH MIRROR FOLDING POWER Z1 20 BK RHD RHD GAS 30 30 30 86 G300 4 87 87 87 8W 50 9 8W 50 10 8W 50 13 8W 44 3 8W 62 2 8W 62 4 8W 62 5 8W 35 2 8W 10 14 8W 40 4 8W 44 7 8W 46 4 8W 47 4 8W 45 2 ...

Page 636: ...M1 20 PK A81 20 DG RD INSTRUMENT CLUSTER 2 M1 20 PK C1 RADIO 7 M1 20 PK M1 20 PK 16 DATA LINK CONNECTOR BLOCK JUNCTION 10A FUSE 2 C4 15 D1 D3 1 START 2 RUN 3 LOCK 0 OFF 4 ACC 8 RHD 7 P50 NOT USED M1 22 PK 8W 10 11 8W 12 2 8W 45 2 8W 61 5 8W 46 2 8W 40 2 8W 47 2 8W 30 3 8W 12 2 8W 12 9 8W 10 14 8W 10 16 8W 12 20 8W 12 JUNCTION BLOCK NS GS J988W 3 GS001220 8W 30 30 ...

Page 637: ... F41 OVERHEAD CONSOLE OTHERS C20 B75 2 F41 20 PK VT PK VT 20 F41 TO CS02 FRONT READING LAMPS SWITCH TO A 8W 12 22 TO COURTESY LAMP RELAY 1 EXPORT BUILT UP MODULE IMMOBILIZER KEY SENTRY F41 20 PK VT 8W 10 20 8W 12 2 8W 62 2 8W 62 4 8W 44 2 8W 10 20 8W 44 2 8W 39 5 NS GS 8W 12 JUNCTION BLOCK 8W 12 21 GS001221 J988W 3 ...

Page 638: ... LB 20 M11 3 B17 LJ01 M11 20 PK LB L15 J02A 3 PK LB 20 M11 1 FLOOD LAMP LIFTGATE LEFT M11 20 PK LB RIGHT LIFTGATE LAMP FLOOD 1 1 COURTESY LAMP DOOR PASSENGER DRIVER DOOR LAMP COURTESY 1 M11 20 PK LB M11 20 PK LB D02 B01 3 6 B03 D01P PK LB 20 M11 M11 20 PK LB A 8W 12 21 FROM JUNCTION BLOCK CS01 TO DOME LAMP OTHER 8W 50 9 8W 50 10 8W 44 4 8W 45 4 8W 12 2 8W 44 3 8W 44 4 8W 44 4 8W 44 3 8W 44 3 8W 44...

Page 639: ...CK DOOR PASSENGER PASSENGER POWER WINDOW SWITCH TO TO SWITCH WINDOW POWER DRIVER E2 20 OR E2 20 OR E2 20 OR 4 D01D B02 11 D01P B03 OR 20 E2 A C UNIVERSAL GARAGE DOOR OPENER TO E2 20 OR TO FRONT BLOWER REAR CONTROL SWITCH E2 20 OR PANEL LAMPS DRIVER READING HEADER FRONT PART OF LAMPS SWITCH FUNCTION MULTI PART OF 31 WASHER MODULE BUILT UP EXPORT 17 B75 C20 GAS E2 20 OR FRONT CIGAR LIGHTER POWER OUT...

Page 640: ...CONTROL MODULE 18 C3 21 C2 34 C1 11 V10 20 BR BR 20 V10 MOTOR WASHER FRONT B B V53 18 RD YL WASHER HEADLAMP WASHER MODULE SWITCH FUNCTION MULTI PART OF SWITCH WIPER FRONT S 56 P 31 30 8W 12 2 8W 10 17 8W 10 8 8W 10 8 8W 50 11 8W 10 16 8W 10 12 8W 12 16 8W 12 15 8W 12 8 8W 45 4 8W 53 3 8W 53 5 8W 53 3 8W 12 24 8W 12 JUNCTION BLOCK BUILT UP EXPORT NS GS J988W 3 GS001224 ...

Page 641: ... 20 L94 20 OR WT SWITCH FUNCTION MULTI PART OF SWITCH DIMMER HEADLAMP C1 31 L39 18 LB LEFT FOG LAMP LAMP FOG RIGHT L39 18 LB 1 1 C1 25 L39 18 LB B3 B23 P18 3 L39 18 LB C2 5 SWITCH HEADLAMP FOG LAMP RELAY 8W 10 33 8W 10 8 8W 10 10 8W 50 2 8W 12 2 8W 50 5 8W 50 5 8W 50 5 8W 50 5 8W 50 9 8W 50 5 NS GS 8W 12 JUNCTION BLOCK EXCEPT BUILT UP EXPORT CHRYSLER 8W 12 25 GS001225 J988W 3 ...

Page 642: ...MIRROR POWER PASSENGER C2 5 C2 6 P159 20 DG P159 20 DG P160 20 LB P160 20 LB 11 C3 C4 11 POWER FOLDING MIRROR SWITCH 2 1 P136 20 YL SWITCH MIRROR FOLDING 39 C2 SIGNAL 36 C4 BK 20 Z1 HALO KEY IN FROM LAMP Z1 20 BK POWER POWER 1 2 M M 1 UNFOLD 2 FOLD RELAY FOLD MIRROR POWER RELAY UNFOLD MIRROR POWER POWER 8W 10 8 8W 15 6 8W 12 2 8W 10 20 8W 10 9 8W 45 10 8W 44 3 8W 62 8 8W 62 8 8W 62 8 8W 62 8 8W 62...

Page 643: ... Rear Door Ajar Switch 8W 15 13 Left Rear Lamp Assembly 8W 15 13 Left Rear Speaker 8W 15 5 Left Repeater Lamp 8W 15 5 Left Speed Control Switch 8W 15 4 Left Stop Turn Signal Relay 8W 15 13 License Lamp 8W 15 14 Liftgate Ajar Switch 8W 15 14 Liftgate Arm Disarm Switch 8W 15 14 Low Coolant Level Switch 8W 15 3 Low Note Horn 8W 15 10 Low Washer Fluid Switch 8W 15 11 12 Memory Power Seat Switch 8W 15 ...

Page 644: ...AN RADIATOR 2 2 RADIATOR FAN NO 1 Z1 12 BK Z1 12 BK Z1 12 BK E40 RF3 2 Z1 12 BK RELAY FAN RADIATOR 1 Z1 18 BK BK 14 Z1 2 A C COMPRESSOR CLUTCH CONTROL SPEED VEHICLE 4 Z1 18 BK BK 18 Z1 Z1 10 BK G101 SERVO ES18 SENSOR UPSTREAM HEATED OXYGEN A24 1 85 TRANSMISSION CONTROL RELAY CENTER DISTRIBUTION POWER 4 C8 Z16 18 BK 86 8W 20 2 8W 31 2 8W 30 2 8W 30 3 8W 42 8 8W 42 8 8W 42 8 8W 42 7 8W 33 3 8W 30 7 ...

Page 645: ...EEDLE BK 18 Z122 ES31 2 E97 B106 Z122 18 BK Z1 18 BK BS41 Z1 18 BK ENGINE SPEED SENSOR Z122 18 BK ES30 BK 18 Z1 BK 18 Z122 7 Z12 18 BK BS40 BK 18 Z1 Z12 14 BK TN A 8W 15 5 TO G300 B 8W 15 12 TO G301 RELAY RADIATOR 2 NO 1 FAN FAN 1 RADIATOR DISCONNECT Z1 12 BK BK 12 Z1 ES12 Z1 12 BK G102 SHIELD SHIELD Z1 18 BK 2 A C COMPRESSOR CLUTCH CRANK CASE HEATER 86 8W 20 3 8W 30 28 8W 30 29 8W 45 9 8W 10 9 8W...

Page 646: ...4 7 6 13 10 2 5 1 Z2 20 BK Z2 22 BK SWITCH CONTROL SPEED LEFT RIGHT SPEED CONTROL SWITCH SWITCH C1 5 MIRROR POWER DRIVER HEATER A C HEATER MULTI FUNCTION SWITCH PART OF C1 OUTLET POWER LIGHTER CIGAR FRONT 8 Z1 18 BK 8 P50 NOT USED 11 Z2 20 BK LG 2 EXPORT BUILT UP MODULE IMMOBILIZER KEY SENTRY 1 BK 20 Z1 9 EXPORT BUILT UP SWITCH HEADLAMP 3 C2 C2 11 AIRBAG CONTROL MODULE G204 Z2 18 BK LG C1 8W 35 2 ...

Page 647: ...POWER SEAT SWITCH 1 Z1 20 BK C19 EC1 2 12 C20 B75 Z1 20 BK Z1 20 BK 12 7 3 2 BK 14 Z1 BK 12 Z1 1 S02 B56 Z12 20 BK TN B09 S02 1 Z1 12 BK PREMIUM PREMIUM 11 1 SWITCH SEAT POWER DRIVER BK DG 16 X15 Z1 14 BK AUTOMATIC DAY NIGHT MIRROR 2 EXPORT BUILT UP LAMP REPEATER LEFT Z1 18 BK A 8W 15 3 BS31 DIESEL FROM Z12 14 BK TN MEMORY OTHER Z1 14 BK Z1 14 BK Z1 20 BK 8W 47 2 8W 53 2 8W 63 3 8W 30 7 8W 30 21 8...

Page 648: ... MODULE CONTROL BODY 3 RELAY UNLOCK 87A DOOR DRIVER DOOR UNLOCK RELAY 87A 87A RELAY LOCK DOOR JUNCTION BLOCK 8 G300 RKE Z1 18 BK Z1 20 BK Z2 20 BK LG Z2 20 BK LG 3 4 FROM SWITCH LAMP STOP Z1 20 BK 2 EXPORT BUILT UP SWITCH MIRROR FOLDING POWER Z1 20 BK RHD RHD GAS 30 30 30 86 87 87 87 4 8W 50 9 8W 50 10 8W 50 13 8W 44 3 8W 62 2 8W 62 4 8W 62 5 8W 35 2 8W 10 14 8W 40 4 8W 44 7 8W 46 4 8W 47 4 8W 45 ...

Page 649: ... 2 SWITCH MEMORY SET 3 2 LAMP COURTESY DOOR PASSENGER PASSENGER POWER WINDOW SWITCH 7 SIGNAL LAMP LEFT FRONT PARK TURN 3 RELAY ACCESSORY CIGAR 85 2 C4 CENTER DISTRIBUTION POWER Z1 18 BK 87A FROM SWITCH LAMP STOP 2 BUILT UP EXPORT 86 86 30 87 LHD 8W 53 2 8W 53 3 8W 42 2 8W 60 2 8W 60 3 8W 44 3 8W 62 3 8W 63 4 8W 44 3 8W 60 3 8W 50 11 8W 50 12 8W 41 3 8W 10 8 8W 33 3 NS GS 8W 15 GROUND DISTRIBUTION ...

Page 650: ...20 BK Z1 20 BK Z1 20 BK Z1 20 BK UP EXPORT EXCEPT BUILT BUILT UP EXPORT 9 B BRAKE PRESSURE SWITCH Z1 20 BK Z1 20 BK Z1 20 BK Z1 20 BK 3 LEFT HEADLAMP OTHER CHRYSLER B LEFT LOW HEADLAMP HEADLAMP LEFT 2 Z1 20 BK Z1 20 BK DIESEL 8W 50 5 8W 40 4 8W 30 39 8W 50 8 8W 46 3 8W 50 6 8W 50 5 8W 50 6 8W 15 8 8W 15 GROUND DISTRIBUTION NS GS J988W 3 GS001508 ...

Page 651: ...BACK SEAT HEATED PASSENGER PASSENGER HEATED SEAT CUSHION D E SWITCH SEAT HEATED PASSENGER PASSENGER HEATED SEAT MODULE F BK 18 Z1 BK 18 Z1 BK 18 Z1 BK 18 Z1 HS3 7 MODULE MIRROR SEAT MEMORY MEMORY POWER SEAT SWITCH 1 1 HS6D S02 Z1 20 BK Z1 14 BK Z1 14BK C2 8W 63 7 8W 63 7 8W 63 7 8W 63 7 8W 63 8 8W 63 8 8W 63 8 8W 63 8 8W 62 3 8W 63 4 8W 63 5 8W 63 5 NS GS 8W 15 GROUND DISTRIBUTION HEATED SEATS 8W ...

Page 652: ...T UP EXPORT EXPORT BUILT UP BUILT UP EXPORT BUILT UP EXCEPT EXPORT BUILT RIGHT HEADLAMP DODGE PLYMOUTH 2 B Z1 20 BK BK 20 Z1 B BK 20 Z1 3 HEADLAMP RIGHT Z1 20 BK CHRYSLER HEADLAMP LOW RIGHT RIGHT HIGH HEADLAMP CHRYSLER 3 2 UP EXPORT LAMP SIGNAL TURN PARK FRONT RIGHT RIGHT FRONT PARK TURN SIGNAL LAMP Z1 20 BK Z1 18 BK RKE OTHER Z2 20 BK LG Z2 20 BK LG 8W 41 2 8W 61 2 8W 61 6 8W 39 3 8W 44 5 8W 51 3...

Page 653: ...WASHER 14 GROUND Z2 18 BK LG B75 C20 9 B HIGH BK LG 18 Z2 Z1 18 BK 5 1 OVERHEAD CONSOLE 3 G301 CS06 GARAGE UNIVERSAL OPENER 3 DOOR READING LAMPS PART OF FRONT SWITCH Z2 18 BK LG COMPASS MINI TRIP COMPUTER RKE OTHER Z2 20 BK LG Z2 20 BK LG 8W 39 3 8W 41 2 8W 61 2 8W 61 6 8W 53 3 8W 49 2 8W 49 3 NS GS 8W 15 GROUND DISTRIBUTION GAS 8W 15 11 GS001511 J988W 3 ...

Page 654: ... SWITCH A FLUID Z1 20 BK 3 BK LG 20 Z2 B02 D01D 3 Z2 20 BK LG DOOR 3 SWITCH DRIVER LOCK DISARM DOOR DRIVER 1 ARM Z2 20 BK LG NOTE HORN SWITCH DOOR GARAGE 3 UNIVERSAL 3 CS06 OPENER PART OF FRONT READING LAMPS SWITCH CONSOLE OVERHEAD Z2 18 BK LG Z2 18 BK LG RKE OTHER Z2 20 BK LG Z2 20 BK LG 8W 30 30 8W 63 3 8W 53 3 8W 61 2 8W 61 6 8W 41 2 8W 39 3 8W 49 3 8W 49 2 8W 15 12 8W 15 GROUND DISTRIBUTION DI...

Page 655: ...REAR ASSEMBLY B99 T05 6 Z1 20 BK BK 18 Z1 TURN LEFT STOP 2 SIGNAL RELAY COMBINATION RIGHT RELAY 2 TURN RIGHT STOP SIGNAL RELAY RELAY LEFT COMBINATION 2 Z1 18 BK Z1 18 BK Z1 18 BK TRAILER TOW 2 AWS1 1 AW4 B13 B13 AW4 1 Z1 16 BK Z1 16 BK 3 8L SOLENOID DRIVE WHEEL ALL 3 8L Z1 14 BK Z1 14 BK 1 C1 1 C2 Z1 16 BK 3 8L OTHERS BUILT UP EXPORT C 8W 15 14 1 1 1 1 Z1 18 BK Z1 18 BK Z1 20 BK 8W 44 5 8W 44 5 8W...

Page 656: ...FLOOD 2 Z1 20 BK AJAR LIFTGATE SWITCH 1 BK 20 Z1 STOP HIGH CENTER LAMP 1 MOUNTED BK 20 Z1 1 LAMP LICENSE BK LG 20 Z2 1 DISARM LIFTGATE ARM SWITCH 6 8 L15 J02A 1 LJ01 B17 11 BK 12 Z1 BK 12 Z1 1 G400 9 7 2 3 11 5 C 8W 15 13 8W 48 2 8W 53 4 8W 44 4 8W 44 4 8W 44 5 8W 51 7 8W 51 2 8W 39 3 8W 15 14 8W 15 GROUND DISTRIBUTION NS GS J988W 3 GS001514 ...

Page 657: ... ES01 8W 20 3 ES06 8W 20 3 ES09 8W 20 2 ES11 8W 20 2 3 ES12 8W 20 2 ES26 8W 20 3 Component Page ES28 8W 20 3 Fuse 17 PDC 8W 20 2 3 Fusible Link 8W 20 2 3 G100 8W 20 2 3 G103 8W 20 2 3 Generator 8W 20 2 3 Glow Plug Relay 8W 20 3 Power Distribution Center 8W 20 2 3 Powertrain Control Module 8W 20 2 3 Voltage Regulator 8W 20 3 NS GS 8W 20 CHARGING SYSTEM 8W 20 1 ...

Page 658: ... A142 GENERATOR 1 2 C1 6 MODULE CONTROL POWERTRAIN AUTOMATIC SHUT DOWN RELAY 5 C6 ES12 A142 18 DG OR DG OR 18 A142 ES09 DG 10 A11 FUSIBLE LINK RD 6 A0 ENGINE STARTER MOTOR Z0 10 BK FROM ES11 OUTPUT RELAY DOWN SHUT AUTOMATIC FUSED B 8W 10 23 8W 10 9 8W 30 2 8W 30 2 8W 10 23 8W 21 2 8W 15 2 8W 20 2 8W 20 CHARGING SYSTEM GAS NS GS J988W 3 GS002002 ...

Page 659: ...0 BK FROM ES01 OUTPUT RELAY VOLTAGE REGULATOR 1 RELAY PLUG GLOW A0 10 RD FUSIBLE LINK A54 16 DB A54 10 RD ES26 ES28 A0 2 RD BS33 A142 16 DG OR 1 7 E96 B108 A142 18 DG OR A142 18 DG OR DG OR 18 A142 DG OR 18 A142 DIESEL RELAY OUTPUT A142 16 DG OR 68 RELAY OUTPUT D DF DIESEL POWER RELAY POWER POWER DIESEL POWER DIESEL 8W 10 25 8W 10 9 8W 30 28 8W 10 25 8W 21 3 8W 15 3 8W 30 32 8W 30 28 NS GS 8W 20 C...

Page 660: ......

Page 661: ...r 8W 21 2 3 Engine Starter Motor Relay 8W 21 2 3 ES01 8W 21 3 ES26 8W 21 3 ES28 8W 21 3 Fuse 10 JB 8W 21 2 3 Component Page Fuse 23 PDC 8W 21 2 3 Fusible Link 8W 21 3 G100 8W 21 3 G103 8W 21 3 Glow Plug Relay 8W 21 3 Junction Block 8W 21 2 3 Power Distribution Center 8W 21 2 3 Powertrain Control Module 8W 21 2 3 NS GS 8W 21 STARTING SYSTEM 8W 21 1 ...

Page 662: ...3 C7 BR 12 T40 85 87 30 86 A0 6 RD 4 C6 3 C2 JUNCTION BLOCK C2 10 FUSE 10 10A ST A41 2 1 CLUTCH INTERLOCK SWITCH INTERLOCK CLUTCH MTX EATX F45 20 YL RD 1 2 BATTERY M 1 PULL IN 2 HOLD IN JUMPER SWITCH F45 20 YL RD T141 20 YL RD K90 18 TN T141 20 YL RD 8W 30 6 8W 10 16 8W 10 8 8W 12 2 8W 12 16 8W 10 16 8W 20 2 8W 21 2 8W 21 STARTING SYSTEM GAS NS GS J988W 3 GS002102 ...

Page 663: ...BR 12 T40 85 87 30 86 A0 2 RD 4 C6 3 C2 JUNCTION BLOCK C2 10 FUSE 10 10A ST A41 YL RD 20 F45 1 2 M 1 PULL IN 2 HOLD IN T141 20 YL RD 6 E95 B107 3 MODULE CONTROL POWERTRAIN K90 20 TN TO ES01 Z0 10 BK ENGINE STARTER MOTOR RELAY CONTROL FUSED B SWITCH INTERLOCK CLUTCH BATTERY 8W 30 32 8W 10 16 8W 10 8 8W 12 2 8W 12 16 8W 10 16 8W 30 28 8W 15 3 8W 20 3 NS GS 8W 21 STARTING SYSTEM DIESEL 8W 21 3 GS0021...

Page 664: ......

Page 665: ... Solenoid 8W 30 33 Fuel Tank Module 8W 30 6 20 Fuel Temperature Sensor 8W 30 33 Fuel Timing Solenoid 8W 30 33 Fuse 6 JB 8W 30 32 Fuse 13 PDC 8W 30 39 Fuse 16 PDC 8W 30 2 6 20 29 Fuse 17 PDC 8W 30 2 7 8 9 14 15 21 22 23 28 29 32 33 Fuse 28 PDC 8W 30 3 30 Fusible Link A0 8W 30 32 G100 8W 30 2 3 29 G101 8W 30 7 21 G103 8W 30 2 3 29 G200 8W 30 3 5 30 G300 8W 30 7 13 19 21 27 28 35 39 G301 8W 30 30 35 ...

Page 666: ...T RUN A21 ES12 ES11 BK 10 Z0 BATTERY JUNCTION BLOCK 30 C1 F87 18 WT BK 17 FUSE 20A POWER DISTRIBUTION CENTER BATT A0 8 C6 5 C6 A142 18 DG OR C6 9 20A FUSE 16 6 C2 6 C6 ES07 F87 18 WT BK AUTOMATIC SHUT DOWN RELAY Z0 6 BK G103 G100 BK 8 Z0 OUTPUT ST RUN 2 GENERATOR GENERATOR FIELD DRIVER C1 8 K20 18 DG 8W 12 13 8W 10 16 8W 10 23 8W 15 2 8W 20 2 8W 12 2 8W 10 23 8W 10 9 8W 10 8 8W 10 26 8W 12 13 8W 2...

Page 667: ...K 20 D21 B23 P18 E36 B33 4 SCI C2 65 7 D21 20 PK D21 18 PK 7 PK 18 D21 D21 18 PK TRANSMIT SCI TRANSMIT TRANSMISSION CONTROL MODULE ES24 B70 E43 P34 B23 BK WT 20 Z11 9 5 4 Z2 20 BK LG G200 1 Z11 20 BK WT Z11 18 BK WT ES11 CONNECTOR LINK DATA M1 20 PK MODULE 17 B17 16 B16 24 A24 Z0 6 BK G103 G100 BK 8 Z0 EATX MTX 8W 20 2 8W 10 11 8W 10 9 8W 10 8 8W 12 2 8W 47 2 8W 63 4 8W 31 8 8W 15 4 8W 15 2 8W 12 ...

Page 668: ...1 18 VT BR D2 18 WT BK VT BR 18 D1 WT BK 20 D2 D1 20 VT BR BS05 BS06 MODULE CONTROL TRANSMISSION 5 6 B75 C20 D2 18 WT BK VT BR 18 D1 CONSOLE OVERHEAD PK LB 18 D6 WT BK 18 D2 D1 18 VT BR POWERTRAIN CONTROL MODULE 7 B33 E36 2 6 D6 20 PK LB D2 18 WT BK VT BR 18 D1 14 D6 20 PK LB B14 B13 B12 PAIR TWISTED PAIR TWISTED PAIR TWISTED LINK DATA CONNECTOR PAIR TWISTED PAIR TWISTED PAIR TWISTED EATX MTX MTX ...

Page 669: ...3 B70 1 DG LB 20 C103 C103 18 DG LB 3 4 CLOCKSPRING 18 8 B70 E43 P34 B23 RD LG 20 V37 SPEED CONTROL SWITCH 41 C2 SIGNAL V37 20 RD LG V37 RD LG Z2 20 BK LG G200 3 36 B36 21 A21 A C HEATER CONTROL V37 20 WT Z2 20 BK V37 22 WT BK 22 Z2 1 RESUME ACCEL 3 COAST 2 CANCEL 3 SWITCH CONTROL SPEED RIGHT 2 1 1 2 2 ON OFF LEFT SPEED CONTROL SWITCH 1 SET WT 20 V37 C2 C2 CONTROL RELAY FAN RADIATOR 8W 10 26 8W 10...

Page 670: ...85 ENGINE STARTER MOTOR RELAY ST T141 FUEL PUMP RELAY 1 AW4 B13 Z1 14 BK Z1 16 BK MODULE CONTROL BODY 3 B13 AW4 G4 18 DB B13 AW4 2 BACK UP LAMP FEED L1 20 VT BK 2 B13 AW4 L1 20 VT BK BS02 EATX VT BK 18 L1 B33 E36 10 6 TRANSMISSION RANGE SENSOR 10 E36 B33 2 SWITCH BACK UP L1 18 VT BK 4 BACK UP LAMP FEED BACK UP LAMP FEED MTX L1 20 VT BK L1 20 VT BK ST F45 C2 3 T141 20 YL BK F45 20 YL BK MTX EATX 8W...

Page 671: ...OR 18 A142 ES12 B70 E43 2 ES21 K4 18 BK LB ES18 G101 G300 3 51 C2 SIGNAL SENSOR OXYGEN HEATED DOWNSTREAM 10 B70 E43 K141 18 TN WT TN WT 20 K141 K4 20 BK LB BK TN 20 Z12 UPSTREAM HEATED OXYGEN SENSOR SIGNAL C1 30 BK DG 18 K41 Z1 18 BK BK 10 Z1 BK LB 18 K4 1 B33 E36 K4 18 BK LB DG OR A142 18 8W 10 23 8W 10 8 8W 30 2 8W 10 9 8W 10 23 8W 70 4 8W 70 5 8W 15 2 8W 15 2 8W 15 5 NS GS 8W 30 FUEL IGNITION S...

Page 672: ...ON CAMSHAFT POSITION SENSOR SIGNAL 33 C1 TN YL 18 K44 SENSOR POSITION CAMSHAFT ES17 K7 18 OR K7 18 OR K4 BK LB SUPPLY 8V 8V SUPPLY 87 30 DG OR 18 A142 ES12 17 FUSE 20A BATT A0 5 C6 A142 18 DG OR AUTOMATIC SHUT DOWN RELAY 3 1 DRIVER NO 2 COIL IGNITION K19 18 GY RD C1 11 CENTER DISTRIBUTION POWER PACK 44 18 18 18 K4 BK LB CRANCKSHAFT CAMSHAFT DRIVER NO 1 COIL IGNITION 8W 70 4 8W 70 4 8W 70 9 8W 10 2...

Page 673: ... A142 DG OR YL WT 18 K13 FUEL INJECTOR NO 3 7 INJECTOR NO 3 DRIVER 2 1 A142 DG OR LB BR 18 K14 FUEL INJECTOR NO 4 16 INJECTOR NO 4 DRIVER 2 1 C1 C1 C1 87 30 ES12 17 FUSE 20A BATT A0 5 C6 A142 18 DG OR AUTOMATIC SHUT DOWN RELAY CENTER DISTRIBUTION POWER 18 18 18 A142 18 DG OR 8W 10 23 8W 10 23 8W 10 8 8W 30 2 8W 10 9 NS GS 8W 30 FUEL IGNITION SYSTEM 2 0L 8W 30 9 GS003009 J988W 3 ...

Page 674: ...SURE A C ES02 18 K4 BK LB BK LB K4 18 K2 18 TN BK 26 C1 2 1 SENSOR TEMPERATURE COOLANT ENGINE ES03 BK LB K4 18 K6 18 VT WT K6 18 VT WT SIGNAL SENSOR PRESSURE ABSOLUTE MANIFOLD SIGNAL SENSOR TEMPERATURE COOLANT ENGINE INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18 BK RD 37 C1 B GROUND SENSOR 5V SUPPLY TEMPERATURE SENSOR SIGNAL SIGNAL SENSOR MAP PRESSURE SENSOR INTAKE AIR TEMPERATURE MANIFOLD ABSOLUTE ...

Page 675: ... K4 18 BK LB WT OR 18 G7 2 3 SENSOR GROUND SENSOR SIGNAL C2 66 BK LB K4 18 K6 18 VT WT OR DB 18 K22 SENSOR SPEED VEHICLE 8V SUPPLY 44 C2 SUPPLY 8V 1 K7 18 OR ES17 K7 18 OR ES03 SIGNAL SENSOR POSITION THROTTLE VEHICLE SPEED SENSOR SIGNAL SPEED VEHICLE 8W 70 4 8W 70 4 8W 70 9 8W 70 7 NS GS 8W 30 FUEL IGNITION SYSTEM 2 0L 8W 30 11 GS003011 J988W 3 ...

Page 676: ...BR WT K59 18 VT BK C2 70 K70 18 VT RD CONTROL AIR IDLE IDLE AIR CONTROL DRIVER NO 2 MOTOR IDLE AIR CONTROL DRIVER NO 3 MOTOR IDLE AIR CONTROL DRIVER NO 4 MOTOR MOTOR NO 4 DRIVER CONTROL AIR IDLE MOTOR NO 3 DRIVER CONTROL AIR IDLE MOTOR NO 2 DRIVER CONTROL AIR IDLE IDLE AIR DRIVER NO 1 MOTOR CONTROL MODULATED PURGE CURRENT SENSE WIDTH PULSE 8W 30 12 8W 30 FUEL IGNITION SYSTEM 2 0L NS GS J988W 3 GS0...

Page 677: ... 20 K29 V32 20 YL RD STOP LAMP SWITCH SENSE SPEED CONTROL ON OFF SWITCH SENSE 2 6 G300 BK 20 Z1 DB RD 20 V30 K20 18 DG 8 C1 2 GENERATOR 7 ST RUN V23 CENTER MESSAGE SERVICE ENGINE SOON LAMP C1 22 5 B70 E43 P34 B23 2 A2 G3 20 BK PK BK PK 20 G3 BK PK 18 G3 LAMP DRIVER SOON INDICATOR ENGINE SEVICE DRIVER FIELD GENERATOR 13 RHD RHD LHD JUNCTION BLOCK TO Z1 20 BK GENERATOR FIELD DRIVER 8W 33 3 8W 33 3 8...

Page 678: ... POSITION SENSOR SIGNAL 33 C1 TN YL 18 K44 SENSOR POSITION CAMSHAFT ES17 K7 18 OR K7 18 OR K4 BK LB SUPPLY 8V 8V SUPPLY 87 30 DG OR 18 A142 ES12 17 FUSE 20A BATT A0 5 C6 A142 18 DG OR AUTOMATIC SHUT DOWN RELAY 3 1 DRIVER NO 2 COIL IGNITION K19 18 GY RD C1 11 CENTER DISTRIBUTION POWER PACK 44 18 18 ES05 GY BK 18 K24 EATX MTX IGNITION COIL NO 1 DRIVER CRANKSHAFT CAMSHAFT 8W 70 5 8W 70 5 8W 70 9 8W 1...

Page 679: ...R NO 3 7 INJECTOR NO 3 DRIVER 2 1 A142 DG OR LB BR 18 K14 FUEL INJECTOR NO 4 16 INJECTOR NO 4 DRIVER 2 1 DG OR 18 A142 1 2 3 4 E69 F09 C1 C1 C1 K14 18 LB BR K13 18 YL WT K12 18 TN WT WT DB 18 K11 87 30 ES12 17 FUSE 20A BATT A0 5 C6 A142 18 DG OR AUTOMATIC SHUT DOWN RELAY CENTER DISTRIBUTION POWER E69 F09 18 18 18 8W 10 23 8W 10 23 8W 10 8 8W 30 2 8W 10 9 NS GS 8W 30 FUEL IGNITION SYSTEM 2 4L 8W 30...

Page 680: ...ER K4 18 BK LB DB 18 C18 1 2 3 SENSOR GROUND A C PRESSURE SWITCH SIGNAL SUPPLY 5V E69 F09 9 C18 18 DB C2 42 SIGNAL SWITCH PRESSURE A C FS01 18 K4 BK LB BK LB K4 18 K2 18 TN BK 26 C1 2 1 SENSOR TEMPERATURE COOLANT ENGINE 12 TN BK 18 K2 FS02 VT WT 18 K6 BK LB K4 18 5 K6 18 VT WT K6 18 VT WT K6 18 VT WT SIGNAL SENSOR PRESSURE ABSOLUTE MANIFOLD SIGNAL SENSOR TEMPERATURE COOLANT ENGINE 8W 70 5 8W 70 5 ...

Page 681: ...SENSOR TEMPERATURE AIR INTAKE BK LB K4 18 K6 18 VT WT OR DB 18 K22 ES08 SENSOR SPEED VEHICLE 8V SUPPLY 44 C2 SUPPLY 8V 1 K7 18 OR ES17 K7 18 OR G7 18 WT OR EATX MTX WT OR 18 G7 SIGNAL SENSOR 58 MODULE CONTROL TRANSMISSION ES03 SIGNAL SENSOR POSITION THROTTLE INTAKE AIR TEMPERATURE SENSOR SIGNAL VEHICLE SPEED SENSOR SIGNAL EATX SPEED VEHICLE 8W 70 5 8W 70 5 8W 70 9 8W 31 4 8W 70 7 8W 70 8 NS GS 8W ...

Page 682: ...9 C2 48 C2 58 3 4 MOTOR CONTROL AIR IDLE MOTOR NO 1 DRIVER 2 1 K39 18 GY RD K60 18 YL BK K40 18 BR WT K59 18 VT BK 70 C2 6 K70 18 VT RD K70 18 VT RD MTX SOLENOID EGR EVAP PURGE SOLENOID CONTROL PURGE MODULATED WIDTH PULSE CONTROL AIR IDLE DRIVER NO 2 MOTOR CONTROL AIR IDLE DRIVER NO 3 MOTOR CONTROL AIR IDLE DRIVER NO 4 MOTOR CONTROL AIR IDLE IDLE AIR CONTROL MOTOR NO 4 DRIVER IDLE AIR CONTROL MOTO...

Page 683: ...L VACUUM SOLENOID CONTROL CONTROL SOLENOID VENT CONTROL SPEED WT PK 20 K29 V32 20 YL RD STOP LAMP SWITCH SENSE SPEED CONTROL ON OFF SWITCH SENSE 2 6 G300 BK 20 Z1 DB RD 20 V30 GENERATOR FIELD DRIVER K20 18 DG 8 C1 2 GENERATOR TRANSMISSION RANGE SWITCH T41 SENSE 10 YL DG 18 T10 SENSE REQUEST MANAGEMENT TORQUE TORQUE MANAGEMENT REQUIREMENT SENSE 63 C2 7 ST RUN V23 CENTER MESSAGE SERVICE ENGINE SOON ...

Page 684: ...AY MOTOR STARTER ENGINE 86 85 ENGINE STARTER MOTOR RELAY ST F45 4 AW4 B13 3 B13 AW4 1 1 SOLENOID DRIVE WHEEL ALL 1 C2 C1 BODY CONTROL MODULE EGR SOLENOID 3 8L 3 3L Z1 16 BK Z1 16 BK Z1 16 BK Z1 18 BK Z1 18 BK AWS1 GROUND GROUND Z1 14BK 2 BACK UP SWITCH SENSE AWS2 2 B13 AW4 BS02 L1 20 VT BK VT BK 20 L1 VT BK 20 L1 MTX FEED LAMP UP BACK FEED LAMP UP BACK VT BK 18 L1 BACK UP SWITCH 2 B33 E36 10 SENSO...

Page 685: ...8 DG OR DG OR 18 A142 ES12 B70 E43 2 ES02 K4 18 BK LB ES18 G101 G300 3 51 C2 SIGNAL SENSOR OXYGEN HEATED 10 B70 E43 K141 18 TN WT TN WT 20 K141 K4 20 BK LB BK TN 20 Z12 HEATED OXYGEN SENSOR SIGNAL C1 30 BK DG 18 K41 Z1 18 BK BK 10 Z1 BK LB 18 K4 1 B33 E36 BK LB 18 K4 4 18 DG OR A142 8W 10 23 8W 10 8 8W 30 2 8W 10 9 8W 10 23 8W 70 6 8W 15 2 8W 15 2 8W 15 5 NS GS 8W 30 FUEL IGNITION SYSTEM 3 3L 3 8L...

Page 686: ...IC SHUT DOWN RELAY CENTER DISTRIBUTION POWER 1 2 3 4 PACK COIL IGNITION C1 3 2 C1 IGNITION COIL NO 1 DRIVER DRIVER NO 2 COIL IGNITION IGNITION COIL NO 3 DRIVER K18 18 RD YL DB TN 18 K17 K19 18 GY RD 18 K4 BK LB 44 ES05 K24 18 GY BK 3 3L SENSOR FUEL FLEXIBLE ETHANOL SUPPLY 8V 1 SENSOR GROUND 2 3 SIGNAL SENSOR 54 C2 K4 18 BK LB K50 18 YL WT K7 18 OR F02 E78 7 8 F02 E78 FS02 14 F02 E78 K4 18 BK LB K4...

Page 687: ...CTOR NO 4 DRIVER DG OR 18 A142 3 4 5 6 C1 C1 C1 87 30 ES12 17 FUSE 20A BATT A0 5 C6 A142 18 DG OR AUTOMATIC SHUT DOWN RELAY CENTER DISTRIBUTION POWER E78 F02 18 18 18 18 C1 F02 E78 13 2 1 DRIVER NO 6 INJECTOR 14 NO 6 INJECTOR FUEL K58 18 BR DB DG OR A142 NO 5 INJECTOR FUEL A142 DG OR 18 12 C1 DRIVER NO 5 INJECTOR 15 K38 18 GY 2 1 2 1 2 1 2 1 2 1 DG OR A142 18 FS01 8W 10 23 8W 10 23 8W 10 8 8W 30 2...

Page 688: ... A C PRESSURE SIGNAL SUPPLY 5V C18 18 DB C2 42 PRESSURE A C 18 K4 BK LB BK LB K4 18 K2 18 TN BK 26 C1 2 1 SENSOR TEMPERATURE COOLANT ENGINE ES03 14 K6 18 VT WT K6 18 VT WT FS02 E78 F02 11 TN BK 18 K2 SENSOR TEMPERATURE COOLANT ENGINE SIGNAL SENSOR PRESSURE ABSOLUTE MANIFOLD E78 F02 2 E78 F02 ES21 18 K4 BK LB 3 8L SENSOR KNOCK 2 CAMSHAFT POSITION SENSOR K4 18 BK LB SENSOR GROUND SIGNAL SIGNAL 8W 70...

Page 689: ...ISSION ES03 VT WT 18 K6 SIGNAL SENSOR SPEED VEHICLE VEHICLE SPEED SENSOR SIGNAL SIGNAL SENSOR POSITION CRANKSHAFT CRANKSHAFT POSITION SENSOR SIGNAL 6 32 C1 K24 18 GY BK ES05 12 THROTTLE POSITION SENSOR SIGNAL K24 18 GY BK OR DB 18 K22 ES08 C1 35 SIGNAL SENSOR POSITION THROTTLE K22 18 OR DB 8W 70 6 8W 70 7 8W 31 4 8W 70 8 NS GS 8W 30 FUEL IGNITION SYSTEM 3 3L 3 8L 8W 30 25 GS003025 J988W 3 ...

Page 690: ...K60 18 YL BK K40 18 BR WT K59 18 VT BK SENSE SWITCH PUMP DETECTION LEAK LEAK DETECTION PUMP SOLENOID CONTROL PULSE WIDTH MODULATED PURGE 70 C2 BUILT UP EXPORT EXCEPT K70 18 VT RD CONTROL CONTROL AIR IDLE IDLE AIR CONTROL NO 2 MOTOR MOTOR NO 4 CONTROL AIR IDLE IDLE AIR CONTROL NO 3 MOTOR PUMP DETECTION LEAK PUMP DETECTION LEAK MOTOR NO 3 CONTROL AIR IDLE IDLE AIR CONTROL NO 4 MOTOR MOTOR NO 2 CONTR...

Page 691: ...TROL ON OFF SWITCH SENSE 2 6 G300 BK 20 Z1 DB RD 20 V30 TRANSMISSION RANGE SENSOR 2 8 C1 K20 18 DG DRIVER FIELD GENERATOR GENERATOR 7 ST RUN V23 CENTER MESSAGE SERVICE ENGINE SOON LAMP C1 22 INDICATOR LAMP DRIVER SERVICE ENGINE SOON 5 B70 E43 P34 B23 2 A2 G3 20 BK PK BK PK 20 G3 BK PK 18 G3 13 RHD LHD JUNCTION BLOCK TO RHD GENERATOR FIELD DRIVER 10 TRANSMISSION CONTROL MODULE C2 63 T10 18 YL DG TO...

Page 692: ...EL POWER RELAY TO CENTER DISTRIBUTION POWER A142 16 DG OR 45 RELAY POWER DIESEL OUTPUT A142 16 DG OR 68 RELAY POWER DIESEL OUTPUT 7 E96 B108 1 DG OR 18 A142 DG OR 18 A142 A142 18 DG OR ES06 WT BK 18 F87 24 GROUND Z12 16 BK TN BK TN 16 Z12 Z12 16 BK TN BS31 G300 7 86 85 IN PDC RELAY MOTOR STARTER ENGINE 6 B107 E95 STARTER RELAY CONTROL 3 K90 18 TN K90 20 TN 8W 12 13 8W 10 16 8W 12 2 8W 10 25 8W 10 ...

Page 693: ...16 BK BK 18 Z1 POWERTRAIN CONTROL MODULE K35 20 GY YL 25 C6 5 20A FUSE 17 A142 18 DG OR 30 87 JUNCTION BLOCK ES06 CONTROL SOLENOID EGR 2 E96 B108 Z1 18 BK 2 1 HEATER CASE CRANK A141 18 DG WT A141 18 DG WT ES40 1 2 A142 18 DG OR K35 20 GY YL EGR SOLENOID A141 18 DG WT F87 18 WT BK DIESEL POWER RELAY 8W 12 13 8W 10 16 8W 10 26 8W 10 9 8W 10 8 8W 30 36 8W 20 3 8W 15 3 8W 15 3 8W 10 25 8W 12 2 8W 30 2...

Page 694: ...DIO PK 20 D21 B23 P18 61 7 D21 20 PK P34 B23 BK WT 20 Z11 5 4 Z2 20 BK LG G200 1 Z11 20 BK WT CONNECTOR LINK DATA MODULE 17 B17 24 A24 TRANSMIT SCI 1 G301 FUSED B 16 C1 MODULE MIRROR SEAT MEMORY M1 20PK 8W 10 11 8W 10 9 8W 10 8 8W 12 2 8W 47 2 8W 15 4 8W 15 12 8W 63 4 8W 12 20 8W 30 30 8W 30 FUEL IGNITION SYSTEM DIESEL NS GS J988W 3 GS003030 ...

Page 695: ...BR D1 18 WT BK 18 D2 P18 B23 13 B13 CCD BUS BUS CCD WT BK 18 D2 D1 18 VT BR BUS CCD BUS CCD 19 BS05 20 CONTROLLER ANTI LOCK BRAKE BODY CONTROL MODULE C2 34 3 C2 BS06 TWISTED PAIR 6 VT BR 18 D1 6 CCD BUS OVERHEAD CONSOLE BUS CCD 1 COMPASS MINI TRIP COMPUTER D2 18 WT BK 5 C20 B75 3 11 CONNECTOR LINK DATA PAIR TWISTED TWISTED PAIR PAIR TWISTED TWISTED PAIR 8W 43 3 8W 40 2 8W 35 3 8W 45 3 8W 49 2 8W 4...

Page 696: ...LUG GLOW K154 12 BK BK 12 K154 GLOW PLUG NO 1 BK 12 K154 GLOW PLUG NO 3 BK 12 K154 GLOW PLUG NO 4 ES37 20 G85 OR BK 26 LAMP PLUG GLOW LAMP FAULT P34 B23 17 A17 OR BK G85 20 7 10 CENTER MESSAGE PLUG GLOW 6 FUSE 20A JUNCTION BLOCK BR PK 18 V23 C4 14 ST RUN A21 LAMP DIESEL POWER RELAY C1 10 A C HEATER CONTROL V23 18 BR PK 8W 10 9 8W 10 8 8W 20 3 8W 10 25 8W 10 25 8W 10 25 8W 46 3 8W 12 9 8W 12 2 8W 1...

Page 697: ...E96 9 GY 20 K156 63 FUEL TEMPERATURE SENSOR K4 20 BK LB BK LB 20 K4 BS34 ES05 K4 20 BK LB 8 E96 B108 TN WT 18 K140 K140 TN WT 5 4 TN WT 18 K140 49 TN WT K140 BS32 TWISTED PAIR FUEL QUANTITY ACTUATOR 18 18 18 TN WT K140 K126 18 LG B106 E97 1 LG 20 K126 51 CONTROL SOLENOID TIMING SIGNAL OR DG 18 K153 E95 B107 4 53 FUEL SHUTDOWN SOLENOID CONTROL K153 18 OR DG MODULE K4 18 BK LB SIGNAL 8W 10 9 8W 10 8...

Page 698: ...ENSOR POSITION SLEEVE CONTROL SLEEVE POSITION SENSOR SUPPLY 5V SENSOR GROUND SENSOR TEMPERATURE AIR INTAKE BK LB K4 20 K9 LB 41 64 BK RD K21 20 3 2 1 20 B106 E97 6 33 BOOST PRESSURE SIGNAL 40 DG RD 20 K1 4 K4 18 BK LB K9 18 LB ES05 K4 20 BK LB K4 18 BK LB 8 6 7 E120 B33 SENSOR PRESSURE BOOST TURBO K21 18 BK RD K1 18 DG RD SIGNAL PRESSURE BOOST INTAKE AIR TEMPERATURE SENSOR GROUND SENSOR 5V SUPPLY ...

Page 699: ... BS31 Z12 14 BK TN Z1 18 BK BK 18 Z1 7 Z122 18 BK BK 18 Z1 ES30 ENGINE SPEED SENSOR Z122 18 BK K3 20 BK VT K24 18 GY BK BS40 6 G301 SHIELD SHIELD SENSOR RETURN ENGINE SPEED SENSOR SENSOR MOVEMENT NEEDLE Z12 18 BK NEEDLE MOVEMENT SENSOR 9 E120 B33 SENSOR MOVEMENT NEEDLE NEEDLE MOVEMENT SENSOR SIGNAL SPEED ENGINE ENGINE SPEED SENSOR RETURN 8W 15 5 8W 15 3 8W 15 12 NS GS 8W 30 FUEL IGNITION SYSTEM DI...

Page 700: ...3 G58 20 BK YL BODY CONTROL MODULE 72 C1 75 C1 BS30 G7 18 WT OR WT OR 18 G7 SENSOR SPEED VEHICLE SENSOR GROUND GROUND SENSOR K4 20 BK LB COOLANT TEMPERATURE SENSOR TEMPERATURE COOLANT ENGINE COOLANT TEMPERATURE SENSOR SIGNAL SENSOR TEMPERATURE ST RUN IGNITION FUSED SENSOR SPEED VEHICLE SIGNAL SENSOR SPEED ENGINE ENGINE DISABLE SIGNAL DISABLE SIGNAL SENSOR SIGNAL ENGINE SPEED F87 18 WT BK ENGINE K4...

Page 701: ...9 E97 B106 DB OR 20 C13 1 E95 B107 NO 1 NO 3 RELAY FAN RADIATOR 6 ES09 C137 20 YL YL 20 C137 C137 20 YL 10 LOW SPEED RADIATOR FAN RELAY NO 2 CONTROL 6 C24 20 DB PK NO 2 RELAY FAN RADIATOR 6 DB PK 20 C24 C103 LOW SPEED RADIATOR FAN RELAY CONTROL CONTROL RELAY FAN RADIATOR SPEED HIGH CONTROL RELAY RADIATOR FAN SPEED HIGH CONTROL NO 1 3 FAN RELAY RADIATOR HIGH SPEED 8W 10 29 8W 10 10 8W 42 9 8W 42 3 ...

Page 702: ...9 3 BS34 20 K151 WT 65 5 A D PRESSURE A C BK LB K4 20 SENSOR GROUND LOW IDLE POSITION SWITCH SIGNAL SENSOR PEDAL ACCELERATOR GROUND SENSOR PEDAL ACCELERATOR SUPPLY 5V SWITCH POSITION IDLE LOW ACCELERATOR PEDAL SENSOR SIGNAL SUPPLY 5V GROUND SENSOR PEDAL ACCELERATOR 20 K4 BK LB 20 K4 BK LB SENSOR POSITION 8W 70 11 8W 30 38 8W 30 FUEL IGNITION SYSTEM DIESEL NS GS J988W 3 GS003038 ...

Page 703: ...WITCH RIGHT 20 WT PK 20 K29 BK 18 Z1 6 5 44 STOP LAMP SWITCH SIGNAL SENSE SWITCH BRAKE BS01 CLUTCH SWITCH SIGNAL L50 18 WT TN WT TN 18 L50 LB RD 20 V38 27 C1 56 P34 B23 A21 21 36 V37 20 RD LG SPEED CONTROL SWITCH SIGNAL RD LG 20 V37 BODY CONTROL MODULE SWITCH CONTROL SPEED DRIVER LAMP CONTROL SPEED 4 3 4 C2 SPEED CONTROL LAMP DRIVER 8W 10 29 8W 10 10 8W 10 8 8W 50 11 8W 15 7 8W 15 8 8W 50 8 8W 70 ...

Page 704: ......

Page 705: ...5 Component Page Fuse 12 JB 8W 31 3 Fuse 15 PDC 8W 31 2 6 7 G100 8W 31 2 G103 8W 31 2 G302 8W 31 3 Junction Block 8W 31 3 5 Low Reverse Pressure Switch 8W 31 6 Low Reverse Solenoid 8W 31 7 Output Shaft Speed Sensor 8W 31 3 Overdrive Pressure Switch 8W 31 6 Overdrive Solenoid 8W 31 7 Power Distribution Center 8W 31 2 5 6 7 Powertrain Control Module 8W 31 4 5 6 PS01 8W 31 8 PS02 8W 31 8 Throttle Pos...

Page 706: ...10 C8 56 B FUSED OUTPUT RELAY TRANSMISSION TRANSMISSION RELAY OUTPUT BATTERY Z0 10 BK ES11 CENTER DISTRIBUTION POWER BATT A0 C8 3 C8 4 C8 2 TRANSMISSION CONTROL RELAY T16 18 RD RD 18 T16 Z0 8 BK BK 6 Z0 G100 G103 Z16 18 BK Z16 18 BK EATX EATX 8W 10 28 8W 10 28 8W 20 2 8W 15 2 8W 10 9 8W 10 8 8W 31 2 8W 31 TRANSMISSION CONTROL SYSTEM NS GS J988W 3 GS003102 ...

Page 707: ... T52 18 RD BK 52 SIGNAL SENSOR SPEED SHAFT OUTPUT GROUND SENSOR SPEED SIGNAL SENSOR SPEED INPUT DB BK B33 E36 10 BS02 VT BK 18 L1 RUN A22 2 B13 AW4 1 AWS2 3 8L SOLENOID DRIVE WHEEL ALL 1 2 L1 20 VT BK Z1 16 BK 23 CONTROLLER ANTI LOCK BRAKE F20 18 WT C2 C1 C1 C2 2 1 F20 18 WT L1 20 VT BK Z1 18 BK BK 18 Z1 AWS1 FUSED IGNITION RUN 8W 12 12 8W 12 2 8W 15 13 8W 70 8 8W 70 2 8W 10 14 8W 35 2 8W 15 13 NS...

Page 708: ... 18 OR DB ES08 ES05 POWERTRAIN CONTROL MODULE GROUND SENSOR SENSOR GROUND BK LB 18 K4 K4 18 BK LB ES21 SIGNAL SENSOR SPEED VEHICLE VEHICLE SPEED SENSOR SIGNAL WT OR 18 G7 43 C2 51 58 66 C2 OR DB 18 K22 ES02 ES21 ES02 3 3L 3 8L 2 4L BK LB 18 K4 K4 18 BK LB CRANKSHAFT POSITION SENSOR SIGNAL THROTTLE POSITION SENSOR SIGNAL 8W 30 14 8W 30 22 8W 30 17 8W 30 25 8W 30 14 8W 30 17 8W 30 22 8W 30 25 8W 70 ...

Page 709: ...ION RANGE SWITCH T42 SENSE TRANSMISSION RANGE SWITCH T41 SENSE 76 POWERTRAIN CONTROL MODULE C2 SENSE T41 SWITCH RANGE TRANS F45 20 YL RD 10 C2 10A FUSE 10 BLOCK JUNCTION 8 YL RD 18 F45 ST A41 POWER DISTRIBUTION CENTER 7 C8 3 C2 TRANSMISSION ST IGNITION FUSED FUSED IGNITION ST RUN OFF 10A FUSE 2 ST RUN OFF A81 C1 20 RD WT 20 F11 E36 B33 8 F11 18 RD WT 11 2 1 T141 20 YL RD F45 20 YL RD JUMPER SWITCH...

Page 710: ... BK 2 4 PRESSURE SWITCH SENSE SENSE SWITCH PRESSURE OVERDRIVE SENSE SWITCH PRESSURE REVERSE LOW LOW REVERSE PRESSURE SWITCH SWITCH PRESSURE 2 4 SWITCH PRESSURE OVERDRIVE 18 ES01 RD 18 T16 20A FUSE 15 BATT A0 TRANSMISSION CONTROL RELAY 2 C8 8W 10 9 8W 10 28 8W 10 28 8W 10 8 8W 31 2 8W 31 6 8W 31 TRANSMISSION CONTROL SYSTEM NS GS J988W 3 GS003106 ...

Page 711: ... CONTROL T19 18 WT T60 18 BR T59 18 PK LOW REVERSE SOLENOID SOLENOID 2 4 UNDERDRIVE SOLENOID OVERDRIVE SOLENOID SOLENOIDS CONTROL TRANSMISSION 87 30 CENTER DISTRIBUTION POWER T16 18 RD ES01 RD 18 T16 20A FUSE 15 BATT A0 TRANSMISSION CONTROL RELAY 2 C8 8W 10 9 8W 10 28 8W 10 28 8W 10 8 8W 31 2 NS GS 8W 31 TRANSMISSION CONTROL SYSTEM 8W 31 7 GS003107 J988W 3 ...

Page 712: ... SENSE D6 20 PK LB D21 18 PK 7 14 DATA LINK CONNECTOR ES24 PK 18 D21 D1 20 VT BR D2 20 WT BK 3 11 PS01 PS02 P18 B23 E36 B33 6 D6 20 PK LB P18 B23 E36 B33 4 WT BK 20 D2 VT BR 20 D1 7 2 ES14 ES13 BS06 BS05 D21 20 PK B17 17 13 B13 12 B12 14 B14 D1 18 VT BR D2 18 WT BK PAIR TWISTED PAIR TWISTED 8W 30 3 8W 30 19 8W 30 27 8W 30 3 8W 30 4 8W 30 3 8W 30 4 8W 30 4 8W 30 4 8W 30 4 8W 30 4 8W 30 4 8W 31 8 8W...

Page 713: ...01 8W 33 3 G200 8W 33 2 4 Component Page G300 8W 33 3 5 Junction Block 8W 33 3 Left Headlamp Leveling Motor 8W 33 5 Left Speed Control Switch 8W 33 2 4 Power Distribution Center 8W 33 5 Powertrain Control Module 8W 33 2 3 4 5 Right Speed Control Switch 8W 33 2 4 Stop Lamp Switch 8W 33 3 5 Transmission Control Module 8W 33 2 Vacuum Solenoid 8W 33 3 Vehicle Speed Control Servo 8W 33 3 Vehicle Speed ...

Page 714: ... B23 P34 A21 RD LG 20 V37 Z2 20 BK SIGNAL SENSOR SPEED VEHICLE WT OR 18 G7 C2 66 EATX MTX G7 18 WT OR WT OR 18 G7 58 3 VEHICLE SPEED SENSOR TRANSMISSION CONTROL MODULE V37 22 WT Z2 22 BK 2 CANCEL 1 RESUME ACCEL 3 COAST 1 SET 2 ON OFF 21 C2 C2 SIGNAL SENSOR SPEED VEHICLE VEHICLE SPEED SENSOR SIGNAL 8W 30 11 8W 30 17 8W 30 25 8W 15 4 8W 30 11 8W 31 4 8W 33 2 8W 33 VEHICLE SPEED CONTROL GAS NS GS J98...

Page 715: ...ROL ON OFF SWITCH POWERTRAIN CONTROL MODULE C1 5 DB RD 20 V30 3 VACUUM SOLENOID SOLENOID DUMP SOLENOID VENT 3 62 C2 SENSE SWITCH LAMP STOP YL RD 18 V32 YL RD 20 V32 E43 B70 3 6 B70 E43 V30 18 DB RD 7 K29 18 WT PK 1 Z1 20 BK 2 WT PK 20 K29 G300 6 RHD LHD JUNCTION BLOCK TO 5 6 SENSE 8W 15 2 8W 15 2 8W 30 13 8W 30 19 8W 30 27 8W 15 7 8W 12 19 NS GS 8W 33 VEHICLE SPEED CONTROL GAS 8W 33 3 GS003303 J98...

Page 716: ...V38 27 56 BODY CONTROL MODULE A21 V37 20 RD LG WT 22 V37 C1 SPEED CONTROL LAMP 43 VEHICLE SPEED SENSOR SENSOR SPEED VEHICLE C1 42 SIGNAL G7 WT OR 18 BS30 G7 18 WT OR G7 18 WT OR 4 B108 E96 G7 18 WT OR 3 VEHICLE SPEED SENSOR SIGNAL VEHICLE SPEED SENSOR DRIVER SPEED 1 RESUME ACCEL 2 CANCEL 3 COAST 1 SET 2 ON OFF B23 P34 C2 C2 SIGNAL 8W 30 36 8W 30 39 8W 15 4 8W 45 9 8W 30 36 8W 33 4 8W 33 VEHICLE SP...

Page 717: ... WT PK 20 CENTER DISTRIBUTION POWER PK DB 18 F32 BATT A0 13 FUSE 20A 8 C3 SENSE SWITCH BRAKE 20 44 STOP LAMP SWITCH SIGNAL 6 STOP LAMP SWITCH 2 1 5 K167 BR YL 20 20 OR DB K22 K6 VT WT 20 ACCELERATOR PEDAL POSITION SENSOR MODULE CONTROL POWERTRAIN PAIR TWISTED TWISTED PAIR FUEL PUMP MODULE 3 4 ACCELERATOR PEDAL SENSOR SIGNAL 5V SUPPLY ACCELERATOR PEDAL SENSOR GROUND GROUND FUEL QUANTITY ACCUATOR SI...

Page 718: ......

Page 719: ...e 13 PDC 8W 35 3 Fuse 25 PDC 8W 35 2 G104 8W 35 2 Component Page G300 8W 35 2 Junction Block 8W 35 2 3 Left Front Wheel Speed Sensor 8W 35 4 Left Rear Wheel Speed Sensor 8W 35 4 Message Center 8W 35 3 Power Distribution Center 8W 35 2 3 Power Mirror Switch 8W 35 2 PS01 8W 35 3 PS02 8W 35 3 Right Front Wheel Speed Sensor 8W 35 4 Right Rear Wheel Speed Sensor 8W 35 4 Stop Lamp Switch 8W 35 3 Tractio...

Page 720: ...K GROUND 22 TRACTION CONTROL SWITCH P34 B23 B27 18 RD YL 1 2 3 SWITCH CONTROL TRACTION 35 G300 8 2 C2 C4 JUNCTION BLOCK Z1 14 BK Z1 20 BK RD YL 20 B27 30 C4 E2 20 OR 2 PANEL LAMPS DRIVER 11 POWER MIRROR SWITCH BK 20 Z1 BODY CONTROL MODULE A1 1 GAS GROUND SENSE 8W 10 29 8W 10 8 8W 10 10 8W 10 8 8W 10 15 8W 10 14 8W 12 12 8W 12 2 8W 15 6 8W 12 2 8W 62 2 8W 62 4 8W 62 5 8W 45 5 8W 12 23 8W 12 19 8W 3...

Page 721: ...MODULE ABS WARNING LAMP DRIVER LG OR 20 G19 D2 18 WT BK CCD BUS 19 D1 18 VT BR 20 PS02 PS01 BUS CCD 11 3 VT BR 20 D1 WT BK 20 D2 3 A3 DATA LINK CONNECTOR PAIR TWISTED TWISTED PAIR DRIVER LAMP WARNING ABS 2 RHD BS06 BS05 B13 P18 13 12 B12 B23 D2 20 WT BK D1 20 VT BR D1 18 VT BR D2 18 WT BK 8W 10 29 8W 10 10 8W 10 8 8W 33 5 8W 51 7 8W 70 2 8W 12 9 8W 12 2 8W 10 16 8W 46 2 8W 30 4 8W 30 31 8W 30 4 8W...

Page 722: ...EED WHEEL FRONT RIGHT 3 SENSOR SPEED WHEEL FRONT RIGHT B9 18 RD RD DB 18 B8 WT DB 18 B6 WT 18 B7 18 18 11 B4 LG B3 LG DB LEFT REAR WHEEL SPEED SENSOR SENSOR SPEED WHEEL REAR LEFT LEFT REAR WHEEL SPEED SENSOR RIGHT REAR WHEEL SPEED SENSOR 1 2 RIGHT REAR WHEEL SPEED SENSOR SENSOR SPEED WHEEL REAR RIGHT YL DB B1 YL B2 18 18 17 1 8W 35 4 8W 35 ANTI LOCK BRAKES NS GS J988W 3 GS003504 ...

Page 723: ...orn Switch 8W 39 2 Junction Block 8W 39 2 5 Component Page Left Rear Door Ajar Switch 8W 39 4 Liftgate Ajar Switch 8W 39 4 Liftgate Arm Disarm Switch 8W 39 3 Low Note Horn 8W 39 2 Memory Seat Mirror Module 8W 39 2 Message Center 8W 39 2 Passenger Door Ajar Switch 8W 39 2 Passenger Door Arm Disarm Switch 8W 39 3 Passenger Door Lock Switch 8W 39 3 Power Distribution Center 8W 39 2 5 PS01 8W 39 5 PS0...

Page 724: ...ENGER AJAR SWITCH SENSE DRIVER DOOR AJAR SWITCH SWITCH AJAR DOOR PASSENGER G75 18 TN G74 18 TN RD HORN NOTE LOW HIGH NOTE HORN X2 18 DG RD X2 18 DG RD X2 18 DG RD BS19 A A B B Z1 18 BK Z1 18 BK G301 FUSED B 1 13 HORN SWITCH CLOCKSPRING X3 20 BK RD 20 C2 1 X3 20 BK RD CONTROL RELAY HORN 7 8 RHD C2 3 MODULE ENTRY KEYLESS REMOTE 7 P50 NOT USED M1 20 PK M1 22 PK 8W 10 30 8W 10 8 8W 10 9 8W 10 10 8W 46...

Page 725: ...97 3 DRIVER DOOR LOCK SWITCH 2 WT DG 20 P97 D01D B02 11 WT DG 18 P97 DRIVER BODY CONTROL MODULE C1 45 DOOR SWITCH MUX SWITCH DISARM ARM LIFTGATE 1 2 2 1 1 2 2 1 PASSENGER DOOR ARM DISARM SWITCH SWITCH DISARM ARM DOOR DRIVER 1 2 2 1 2 3 1 UNLOCK 2 LOCK 2 LOCK 1 UNLOCK 2 LOCK 1 UNLOCK PASSANGER DOOR SWITCH MUX MUX SWITCH DOOR DRIVER PASSANGER DOOR SWITCH MUX GROUND 8W 15 14 8W 61 6 8W 15 10 8W 15 11...

Page 726: ...59 C1 TN BK 18 G78 G302 BK 18 Z1 BK 18 Z1 REAR RIGHT C1 77 DOOR AJAR SWITCH SENSE G76 18 TN YL TN OR 18 G77 2 SWITCH AJAR HOOD 1 2 RIGHT REAR DOOR AJAR SWITCH 1 1 SWITCH AJAR DOOR REAR LEFT 2 SENSE SWITCH AJAR DOOR 47 C1 MODULE CONTROL BODY LEFT REAR 8 14 12 11 8W 15 14 8W 15 10 8W 15 13 8W 45 7 8W 45 8 8W 39 4 8W 39 VEHICLE THEFT SECURITY SYSTEM NS GS J988W 3 GS003904 ...

Page 727: ...LE IMMOBILIZER KEY SENTRY 1 F41 20 PK VT 3 F87 20 WT BK FUSED B FUSED IGNITION ST RUN CCD BUS BUS CCD GROUND Z2 20 BK G200 2 5 6 D1 20 VT BR D2 20 WT BK TO PS01 TO PS02 8W 10 20 8W 10 8 8W 10 9 8W 12 13 8W 10 16 8W 12 2 8W 15 4 8W 30 4 8W 30 4 NS GS 8W 39 VEHICLE THEFT SECURITY SYSTEM BUILT UP EXPORT 8W 39 5 GS003905 J988W 3 ...

Page 728: ......

Page 729: ...nt Page Ignition Switch 8W 40 2 4 Instrument Cluster 8W 40 2 3 4 5 6 7 8 9 10 11 Junction Block 8W 40 2 3 4 5 6 8 10 Left Rear Door Ajar Switch 8W 40 3 Left Speed Control Switch 8W 40 10 11 Liftgate Ajar Indicator Lamp 8W 40 3 Liftgate Ajar Switch 8W 40 3 Low Fuel Warning Indicator Lamp 8W 40 2 Low Washer Fluid Level Indicator Lamp 8W 40 10 11 Low Washer Fluid Switch 8W 40 10 11 Memory Seat Mirror...

Page 730: ... INDICATOR LAMP JUNCTION BLOCK C1 16 FUSED B M1 20 PK LEVEL FUEL 46 C1 BODY CONTROL MODULE SENSOR SIGNAL LOW CCD BUS BUS CCD 9 10 3 FUEL TANK MODULE FUEL LEVEL SENSOR SIGNAL B13 AW4 3 G4 18 DB G4 18 DB WT BK 20 D2 D1 20 VT BR C2 3 CCD BUS C2 34 CCD BUS PS01 PS02 M1 20 PK PAIR TWISTED D1 4 P50 NOT USED F11 20 RD WT 8W 12 2 8W 10 11 8W 10 8 8W 10 9 8W 10 16 8W 12 9 8W 62 3 8W 63 4 8W 10 14 8W 15 4 8...

Page 731: ... SWITCH G74 18 TN RD TN 18 G75 C1 79 SENSE SWITCH AJAR DOOR DRIVER CONTROL LAMP AJAR LIFTGATE AJAR INDICATOR CONTROL LAMP INDICATOR LAMP AJAR DOOR DOOR AJAR INDICATOR PS02 PS01 CCD BUS BUS CCD BUS CCD 34 C2 BUS CCD 3 C2 VT BR 20 D1 D2 20 WT BK 10 9 MODULE CONTROL BODY RD WT 20 F11 FUSED IGNITION ST RUN OFF 11 C4 10 INSTRUMENT CLUSTER 2 FUSE 10A ST RUN OFF A81 BLOCK JUNCTION LIFTGATE INDICATOR LAMP...

Page 732: ... BUS PS01 JUNCTION BLOCK ST RUN OFF A81 10A FUSE 2 CLUSTER INSTRUMENT 10 C4 11 ST RUN OFF IGNITION FUSED F11 20 RD WT 9 10 CCD BUS BUS CCD LAMP LAMP CONTROL INDICATOR BELT BELT INDICATOR BODY CONTROL MODULE GROUND 2 Z1 20 BK FROM CONTROL A C E2 20 OR C2 SEAT SEAT HEATER PAIR TWISTED D1 8W 10 14 8W 15 6 8W 15 8 8W 12 2 8W 30 4 8W 30 31 8W 30 4 8W 30 31 8W 12 2 8W 10 16 8W 12 9 8W 45 3 8W 45 5 8W 45...

Page 733: ...CCD 59 C2 BUS CCD 60 C2 D2 18 WT BK MODULE CONTROL POWERTRAIN BODY CONTROL MODULE CONTROL ODOMETER TRIP VT BR 20 D1 WT BK 20 D2 WT BK 20 D2 C2 34 CCD BUS PS02 D1 20 VT BR C2 3 CCD BUS PS01 9 10 CCD BUS BUS CCD ST RUN OFF IGNITION CLUSTER INSTRUMENT FUSED EATX ES14 EATX B13 B12 PAIR TWISTED TWISTED PAIR 43 4 BUS CCD BUS CCD TWISTED PAIR D1 8W 12 2 8W 10 16 8W 12 9 8W 31 8 8W 30 4 8W 30 31 8W 30 4 8...

Page 734: ...T BK 20 D2 VT BR 20 D1 BODY CONTROL MODULE 9 10 WT BK 20 D2 D1 20 VT BR C2 3 CCD BUS C2 34 CCD BUS PS01 PS02 CCD BUS BUS CCD TACHOMETER CONTROL TACHOMETER CONTROL SPEEDOMETER SPEEDOMETER JUNCTION BLOCK ST RUN OFF A81 10A FUSE 2 CLUSTER INSTRUMENT 10 C4 11 ST RUN OFF IGNITION FUSED F11 20 RD WT EATX EATX B12 B13 PAIR TWISTED TWISTED PAIR D1 D1 20 VT BR D2 20 WT BK 8W 31 4 8W 30 11 8W 30 17 8W 30 4 ...

Page 735: ...D SENSOR WT OR 18 G7 VEHICLE SPEED SENSOR SIGNAL BS30 B108 E96 4 G7 18 WT OR G7 18 WT OR G7 18 WT OR SENSOR SPEED ENGINE 3 GY BK 18 K24 5 E97 B106 K24 20 GY BK SPEED ENGINE 8 SENSOR 2 SIGNAL ENGINE SPEED SENSOR SIGNAL SIGNAL SENSOR ENGINE SPEED C1 75 VT RD 20 K159 Z122 18 BK ES30 7 G301 6 Z12 18 BK Z1 18 BK BS40 FROM TWISTED PAIR SHIELD Z122 18 BK SIGNAL SENSOR SPEED ENGINE SENSOR SIGNAL 8W 30 35 ...

Page 736: ...BUS C2 60 CCD BUS 12 13 P18 B23 BS05 BS06 B33 2 7 E36 ES13 ES14 D2 18 WT BK D1 18 VT BR CCD BUS BUS CCD BUS CCD 34 C2 BUS CCD 3 C2 VT BR 20 D1 D2 20 WT BK 10 9 MODULE CONTROL BODY D1 20 VT BR D2 20 WT BK RD WT 20 F11 FUSED IGNITON ST RUN OFF 11 C4 10 INSTRUMENT CLUSTER 2 FUSE 10A ST RUN OFF A81 BLOCK JUNCTION B12 B13 EATX EATX PAIR TWISTED TWISTED PAIR D2 20 WT BK D1 20 VT BR D1 8W 30 10 8W 30 16 ...

Page 737: ...MODULE CONTROL BODY D1 20 VT BR D2 20 WT BK FUSED IGNITION ST RUN OFF INSTRUMENT CLUSTER ST RUN OFF F11 3 G58 20 BK YL BATT M1 B FUSED PAIR TWISTED BK YL 20 G58 PK 20 D21 61 POWERTRAIN CONTROL MODULE SCI TRANSMIT 7 3 11 D1 20 VT BR D2 20 WT BK 17 B23 P18 B17 D21 20 PK TWISTED PAIR TWISTED PAIR DATA LINK CONNECTOR TEMPERATURE ENGINE COOLANT SENSOR SIGNAL 8W 30 36 8W 30 31 8W 30 31 8W 45 3 8W 45 9 8...

Page 738: ...S CCD BUS BUS CCD VT BR 18 D1 WT BK 18 D2 E36 7 2 B33 BS06 BS05 B23 P18 13 12 BUS CCD 60 C2 BUS CCD 59 C2 D1 18 VT BR D2 18 WT BK PS01 PS02 POWERTRAIN CONTROL MODULE V37 18 RD LG SWITCH C2 41 SPEED CONTROL SIGNAL LAMP INDICATOR CRUISE CRUISE INDICATOR CONTROL LAMP INDICATOR CONTROL LEVEL FLUID LOW WASHER FLUID EATX ES14 ES13 EATX B12 B13 A21 PAIR TWISTED PAIR TWISTED C2 V37 20 RD LG D1 20 VT BR D2...

Page 739: ... CCD BUS BUS CCD POWERTRAIN CONTROL MODULE SWITCH 36 SPEED CONTROL SIGNAL LAMP INDICATOR CRUISE CRUISE INDICATOR CONTROL LAMP INDICATOR CONTROL LEVEL FLUID LOW WASHER FLUID A21 V37 20 RD LG ST RUN OFF F11 FUSED IGNITION ST RUN OFF PS02 PS01 PAIR TWISTED V37 22 WT DRIVER CONTROL SPEED LAMP LB RD 20 V38 LAMP C1 56 SPEED CONTROL DRIVER LB RD 20 V38 27 TWISTED PAIR C2 WASHER FLUID SWITCH SENSE 8W 53 3...

Page 740: ......

Page 741: ...ighter Power Outlet 8W 41 3 Fuse 8 PDC 8W 41 3 Fuse 9 PDC 8W 41 2 G200 8W 41 3 G300 8W 41 3 G301 8W 41 2 Component Page G302 8W 41 3 High Note Horn 8W 41 2 Horn Relay 8W 41 2 Horn Switch 8W 41 2 Junction Block 8W 41 2 3 Low Note Horn 8W 41 2 Power Distribution Center 8W 41 2 3 PTC 7 JB 8W 41 3 Rear Cigar Lighter Power Outlet 8W 41 3 NS GS 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 ...

Page 742: ...8 CONTROL C2 4 GY OR 20 X4 HORN NOTE LOW HIGH NOTE HORN X2 18 DG RD X2 18 DG RD X2 18 DG RD BS19 A A B B Z1 18 BK Z1 18 BK G301 CLOCKSPRING HORN SWITCH 13 1 RELAY CONTROL 20 C2 1 C2 X3 20 BK RD HORN 8W 10 30 8W 10 8 8W 10 10 8W 12 2 8W 45 3 8W 15 10 8W 15 11 8W 41 2 8W 41 HORN CIGAR LIGHTER POWER OUTLET NS GS J988W 3 GS004102 ...

Page 743: ...D 16 F30 RD 16 F30 REAR CIGAR LIGHTER POWER OUTLET 1 3 RD 16 F30 C2 10 P34 B23 A22 3 1 G200 10 G302 11 10 G300 FRONT CIGAR LIGHTER 22 2 C1 11 E2 20 OR A C HEATER CONTROL BUILT UP EXPORT OUTLET POWER PANEL LAMPS FEED 8W 10 10 8W 10 8 8W 10 31 8W 12 16 8W 10 16 8W 12 2 8W 15 4 8W 15 13 8W 15 7 8W 42 3 NS GS 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 3 GS004103 J988W 3 ...

Page 744: ......

Page 745: ... Page G200 8W 42 3 4 G201 8W 42 2 3 6 G300 8W 42 2 G302 8W 42 6 HVAC Control 8W 42 2 3 4 5 Illumination Lamp 8W 42 3 Instrument Cluster 8W 42 3 JS01b 8W 42 5 JS02b 8W 42 5 JS03 8W 42 5 Junction Block 8W 42 2 3 4 6 7 Message Center 8W 42 4 Mode Door Actuator 8W 42 5 Passenger s Side Radiator Fan 8W 42 10 Power Distribution Center 8W 42 2 7 8 9 10 Powertrain Control Module 8W 42 3 7 8 9 10 PTC 1 JB ...

Page 746: ...3 5 6 FRONT BLOWER MOTOR RESISTOR BLOCK B31 B23 P18 B30 B33 B34 B32 C4 16 TN C5 16 LG C6 14 LB C104 12 RD WT C107 12 TN BK TN BK 12 C107 RD WT 12 C104 LB 14 C6 LG 16 C5 TN 16 C4 HVAC CONTROL FRONT BLOWER OFF GROUND G300 BK 12 Z1 C2 6 G201 7 10 SWITCH CONTROL FRONT BLOWER REAR Z1 12 BK 4 M3 2 M1 3 M2 1 LOW 0 OFF 5 HIGH 35 32 34 33 30 31 GROUND M 8W 10 8 8W 10 18 8W 12 2 8W 12 12 8W 10 8 8W 10 14 8W...

Page 747: ... 8 BLOCK JUNCTION 6 CLUSTER INSTRUMENT E2 20 OR E2 20 OR WASH WIPE REAR C1 2 38 C2 SWITCH WIPEER REAR V26 22 YL WT 37 SIGNAL SWITCH A C POWERTRAIN CONTROL MODULE SIGNAL SWITCH A C ON OFF C1 3 C103 20 DG LB P18 B23 B36 SENSE DRIVER WIPER DE ICE ELECTRIC ELECTRIC WIPER DE ICER C1 7 C66 18 BK WT MODULE CONTROL POWERTRAIN A C SWITCH SIGNAL 38 C1 1 DG LB 18 C103 E43 B70 GAS DIESEL C103 20 DG LB 36 1 PA...

Page 748: ...200 5 BLOCK JUNCTION INDICATOR MODE RECIRCULATE REAR WINDOW DEFOGGER RELAY CONTROL 10 C1 C1 1 RUN IGNITION FUSED 14 C4 BR PK 18 V23 20A FUSE 6 ST RUN A21 C14 22 WT RD C4 32 DRIVER INDICATOR MODE RECIRCULATE SWITCH SENSE DEFOGGER WINDOW REAR 10 CENTER MESSAGE V23 18 BR PK REAR WINDOW DEFOGGER RELAY 85 86 RECIRCULATE 8W 15 4 8W 12 2 8W 12 9 8W 10 16 8W 46 2 8W 48 2 8W 42 4 8W 42 AIR CONDITIONING HEA...

Page 749: ...AP C1 20 SENSOR GROUND JS01B 6 C1 SIGNAL FEEDBACK MODE DOOR 9 C1 SUPPLY 5V JS02B C1 5 BLEND DOOR FEEDBACK SIGNAL C1 20 SENSOR GROUND SUPPLY 5V C1 9 C57 20 DB GY C57 20 DB GY C57 20 DB GY C57 22 DB GY 2 1 C26 22 PK DB C26 20 PK DB C26 20 PK DB C26 20 PK DB 7 C36 22 RD WT C36 20 RD WT 12 P30 J01D 2 8 1 6 5 3 C32 22 GY DB C32 20 GY DB C34 20 DB WT C34 20 DB WT C34 20 DB WT C34 22 DB WT C26 22 PK DB C...

Page 750: ... P34 B23 A34 C61 20 DB C34 20 DB WT Z1 18 BK 33 P34 B23 Z1 12 BK 31 C50 12 BK LG C50 12 BK LG C60 16 BK LB C60 16 BK LB C60 16 BK LB C65 14 BK OR C70 12 DG C70 12 DG C70 12 DG A35 B23 P34 34 36 A31 A33 35 M M 0 OFF 1 LOW 2 MEDIUM 3 HIGH 3 HIGH 2 LOW 1 REAR 0 OFF A 8W 42 5 B 8W 42 5 A C HEATER CONTROL FROM CONTROL A C HEATER FROM C34 20 DB WT C61 20 DB 8W 45 5 8W 12 2 8W 12 11 8W 10 14 8W 70 3 8W 1...

Page 751: ...A C 2 1 3 TRANSDUCER PRESSURE A C SIGNAL SWITCH PRESSURE A C 42 C2 SENSOR GROUND C2 43 C13 18 DB OR ES03 K6 18 VT WT K6 18 VT WT C18 18 DB 6 C6 1 C6 ES07 F87 18 WT BK F87 18 BK WT 3 3L 3 8L 2 0L K4 18 BK LB ES02 ES21 ES21 FS01 BK LB 18 K4 K4 18 BK LB ES21 ES02 2 4L 5 E69 F09 ES02 8W 10 10 8W 10 29 8W 10 8 8W 12 13 8W 12 2 8W 10 16 8W 30 5 8W 15 2 8W 15 2 8W 70 7 8W 12 13 8W 70 4 8W 70 4 8W 70 5 8W...

Page 752: ...0A BATT A0 C7 6 G102 RFS2 FUSED B FAN RELAY CONTROL RELAY 2 RFS1 1 E40 RF3 C23 12 DG C23 12 DG C23 12 DG C23 12 DG 1 GROUND ES23 Z1 14 BK Z1 12 BK Z1 12 BK Z1 12 BK E40 RF3 2 Z1 12 BK Z1 12 BK A16 12 GY M M LG DB 14 K173 RADIATOR OUTPUT RADIATOR FAN 8W 10 8 8W 30 5 8W 10 15 8W 10 8 8W 15 2 8W 15 2 8W 42 8 8W 42 AIR CONDITIONING HEATER GAS NS GS J988W 3 GS004208 ...

Page 753: ...RESSURE A C 13 SENSOR GROUND 33 C13 20 DB OR K7 20 OR C18 20 DB K4 20 BK LB 2 Z2 18 BK Z1 16 BK Z0 10 BK ES01 ES02 Z0 6 BK G100 Z0 2 BK G103 BATTERY 30 87 DIESEL POWER RELAY 20A FUSE 17 BATT A0 C6 5 ES29 ES06 A142 18 DG OR A142 18 DG OR A142 18 DG OR 9 E97 B106 C13 20 DB OR BS34 1 8W 10 9 8W 10 29 8W 10 8 8W 30 38 8W 20 3 8W 15 3 8W 15 3 8W 30 28 8W 10 25 8W 10 8 8W 10 25 8W 10 25 8W 70 11 NS GS 8...

Page 754: ... SPEED HIGH 48 ES09 1 E95 B107 10 B106 E97 ES29 C24 20 DB PK C137 20 YL C137 20 YL C137 20 YL A142 18 DG OR A142 18 DG OR A142 18 DG OR C27 12 DB PK C27 12 DB PK C27 12 DB PK BATT A17 ES12 G102 Z1 12 BK Z1 12 BK Z1 12 BK C116 12 LG WT DRIVER S SIDE RADIATOR FAN FAN RADIATOR SIDE PASSENGER S M M DISCONNECT FAN RADIATOR 4 8 2 5 8 A17 12 RD BK 8W 10 8 8W 30 37 8W 10 15 8W 10 8 8W 10 25 8W 15 3 8W 15 ...

Page 755: ...3 2 Data Link Connector 8W 43 3 Driver Airbag Squib 8W 43 2 Fuse 1 PDC 8W 43 2 Fuse 2 PDC 8W 43 2 Fuse 6 JB 8W 43 3 Component Page G204 8W 43 2 Junction Block 8W 43 3 Message Center 8W 43 3 Passenger Airbag Squib 8W 43 3 Power Distribution Center 8W 43 2 PS01 8W 43 3 PS02 8W 43 3 NS GS 8W 43 AIRBAG SYSTEM 8W 43 1 ...

Page 756: ... ST RUN F87 11 C2 GROUND Z2 18 BK LG 1 2 SQUIB POWER DISTRIBUTION CENTER 24 B23 P18 F23 18 DB YL 23 G204 B23 B24 PAIR TWISTED CLOCKSPRING DG LB 18 R45 BK LB 18 R43 LINE 1 LINE 2 EXPORT F14 18 LG YL BUILT UP EXCEPT BUILT UP EXPORT F14 20 LG YL DB YL 20 F23 DB YL 18 F23 UP EXPORT EXCEPT BUILT BUILT UP EXPORT 1 C1 2 C1 8W 10 35 8W 10 35 8W 10 14 8W 10 26 8W 10 8 8W 15 4 8W 43 2 8W 43 AIRBAG SYSTEM NS...

Page 757: ...K 6 FUSE 20A C4 14 ST RUN A21 V23 18 BR PK AIRBAG CONTROL MODULE SQUIB AIRBAG PASSENGER LINE 2 AIRBAG PASSENGER 2 1 2 C1 PASSENGER AIRBAG LINE 1 C1 1 R44 18 DG YL R42 18 BK YL PAIR TWISTED TWISTED PAIR NO 1 9 RHD LINE AIRBAG PASSENGER PASSENGER AIRBAG LINE NO 2 WARNING 8W 30 4 8W 30 31 8W 30 4 8W 30 31 8W 30 4 8W 30 31 8W 46 2 8W 12 2 8W 12 9 8W 10 16 NS GS 8W 43 AIRBAG SYSTEM 8W 43 3 GS004303 J98...

Page 758: ......

Page 759: ...W 44 2 3 4 Headlamp Switch 8W 44 2 7 Hood Ajar Switch 8W 44 5 Ignition Switch 8W 44 8 Instrument Cluster 8W 44 8 Interior Lamps On Switch 8W 44 2 Junction Block 8W 44 2 3 4 6 7 8 9 Key In Halo Lamp 8W 44 3 Left Liftgate Flood Lamp 8W 44 4 Left Mid Reading Lamp 8W 44 4 Left Rear Door Ajar Switch 8W 44 5 Left Rear Reading Lamp 8W 44 4 Left Visor Vanity Mirror Lamps 8W 44 3 Liftgate Ajar Switch 8W 44...

Page 760: ...2 OTHERS CONSOLE OVERHEAD FRONT READING LAMPS SWITCH 1 4 2 B75 C20 PK VT 20 F41 28 C3 34 C3 RELAY LAMP COURTESY 86 30 87 85 C2 19 PK VT 20 F41 C2 15 JUNCTION BLOCK CENTER DISTRIBUTION POWER 18 FUSE 15A 2 C2 BATT A0 READING FRONT B22 3 6 2 OVERHEAD CONSOLE OTHERS B5 BODY CONTROL MODULE C3 BLOCK JUNCTION PK VT F41 20 M20 20 BR M20 20 BR M20 20BR D4 8W 70 3 8W 50 9 8W 50 10 8W 10 20 8W 12 2 8W 10 9 8...

Page 761: ...4 BK Z1 20 BK BLOCK JUNCTION DRIVER DOOR COURTESY 2 1 LAMP LAMP 1 2 COURTESY DOOR PASSENGER M11 20 PK LB 3 B01 D02 M11 20 PK LB D01P B03 6 M11 20 PK LB 5 11 Z1 20 BK DS01 Z1 12 BK B02 D01D 10 Z1 20 BK Z1 18 BK 5 D01P B03 PASSENGER POWER WINDOW SWITCH TO BK 12 Z1 OVERHEAD CONSOLE M1 20 PK LB B75 5 B23 P18 GLOVE BOX LAMP 2 M20 20BR COURTESY LAMP RELAY LAMP COURTESY GROUND 8W 12 2 8W 10 9 8W 10 20 8W...

Page 762: ...OD LIFTGATE RIGHT C20 B75 2 F41 20 PK VT C2 19 RELAY LAMP COURTESY 86 30 87 85 PK VT 20 F41 C2 15 JUNCTION BLOCK CENTER DISTRIBUTION POWER 18 FUSE 15A 2 C2 BATT A0 C2 22 OVERHEAD CONSOLE M11 20 PK LB 3 2 LAMP DOME CENTER REAR DOME LAMP 2 3 1 C20 B75 M20 20 BR M20 20 BR M2 20BR 80 CS1 CS03 M2 20 BR M2 20 BR MODULE CONTROL BODY GLOVE BOX LAMP F41 20 PK VT D4 GROUND LAMP COURTESY 8W 10 20 8W 15 14 8W...

Page 763: ...R AJAR SWITCH SENSE 2 LEFT REAR DOOR AJAR SWITCH 1 1 SWITCH AJAR DOOR REAR RIGHT 2 G77 18 TN OR TN YL 18 G76 SENSE SWITCH AJAR DOOR 77 C1 RIGHT REAR Z1 18 BK Z1 18 BK G302 G78 18 TN BK C1 59 LIFTGATE AJAR SWITCH SENSE LJ01 B17 4 G78 18 TN BK 4 J03A L16 1 3 LIFTGATE AJAR SWITCH G400 Z1 20 BK G78 18 TN BK Z1 18 BK G301 12 2 1 SWITCH AJAR HOOD 8W 45 7 8W 45 8 8W 15 13 8W 15 14 8W 15 10 NS GS 8W 44 IN...

Page 764: ...MIRROR 4 C2 5 4 POWER MIRROR B B MIRROR POWER 5 4 20 C20 B75 19 20 P34 B23 18 A18 A20 P112 20 YL WT P112 20 YL WT P114 20 YL BK P114 20 YL BK 51 C1 18 7 L24 20 WT LG L24 20 WT LG L24 20 WT LG 12 FUSE 10A RUN A22 BODY CONTROL MODULE AUTOMATIC HEADLAMP SIGNAL 6 1 C19 EC1 AUTOMATIC SIGNAL HEADLAMP L1 20 VT BK GAS DIESEL 10 10 B33 E120 E36 B33 BACK UP SWITCH 5 B33 E36 F20 20 WT GAS DIESEL B33 5 5 E120...

Page 765: ...TCH SIGNAL SENSE SENSE 21 C4 JUNCTION BLOCK BK 14 Z1 BK 18 Z1 C4 22 29 C4 GROUND GROUND 10 C2 C2 14 Z2 20 BK LG Z2 20 BK LG MESSAGE CENTER FROM C2 2 2 C1 L7 12 BK YL PK DB 18 L97 C2 9 C1 4 RELAY LAMP PARK 86 30 87 85 CENTER DISTRIBUTION POWER 22 FUSE 40A 10 C3 BATT A0 1 10A FUSE 1 3 FUSE 15A OUTPUT RELAY LAMP PARK FUSED OTHER OVERHEAD Z1 18 BK Z1 20 BK 1 3 RHD 8W 12 2 8W 15 6 8W 45 4 8W 45 5 8W 50...

Page 766: ...WITCH 4 8 HEATER A C 11 C1 6 C2 1 C4 C4 8 DRIVER LAMPS PANEL 1 C1 2 BODY CONTROL MODULE BLOCK JUNCTION 3 30 C4 E2 20 OR GROUND CONTROL 3 2 BK 16 Z1 G200 10 OUTLET POWER LIGHTER CIGAR FRONT E2 20 OR 5 G301 Z2 18 BK LG 2 3 LAMPS READING FRONT PART OF OPENER DOOR GARAGE UNIVERSAL SWITCH CS06 9 C20 B75 Z2 18 BK LG Z1 20BK E2 20OR DRIVER 8W 47 2 8W 35 2 8W 62 2 8W 62 4 8W 15 13 8W 10 14 8W 40 4 8W 12 2...

Page 767: ... 4 11 E2 20 OR E2 20 OR SWITCH WINDOW POWER DRIVER PASSENGER POWER WINDOW SWITCH E2 20 OR E2 20 OR E2 20 OR E2 20 OR B03 D01P 14 13 6 7 5 G300 11 Z1 12 BK DS01 B02 D01D 10 Z1 20 BK Z1 18 BK 5 2 Z1 20 BK LAMP COURTESY DOOR PASSENGER GROUND 8W 45 5 8W 12 2 8W 15 10 8W 15 11 8W 60 2 8W 60 3 8W 61 2 8W 61 6 8W 61 2 8W 61 6 8W 15 7 8W 15 7 8W 44 3 NS GS 8W 44 INTERIOR LIGHTING 8W 44 9 GS004409 J988W 3 ...

Page 768: ......

Page 769: ... 2 5 Instrument Cluster 8W 45 5 Junction Block 8W 45 2 3 4 5 6 7 10 Key In Halo Lamp 8W 45 10 Component Page Left Mid Reading Lamp 8W 45 8 Left Rear Door Ajar Switch 8W 45 8 Left Rear Reading Lamp 8W 45 8 Left Visor Vanity Mirror Lamps 8W 45 8 Liftgate Ajar Switch 8W 45 7 Liftgate Arm Disarm Switch 8W 45 6 LJ01 B17 8W 45 4 6 Low Beam Relay 8W 45 5 Low Coolant Level Switch 8W 45 9 Low Washer Fluid ...

Page 770: ...T A1 15 C4 31 C4 BK WT 12 A31 8 3 0 2 1 4 31 C3 14 RUN ACC IGN FUSED C3 C1 C1 D1 C1 16 MODULE MIRROR SEAT MEMORY FUSED B PK 20 M1 C2 C4 21 C4 C1 6 C2 2 GROUND C2 2 Z1 14 BK G300 8 Z2 20 BK LG SWITCH HEADLAMP GROUND 4 1 START 2 RUN 3 LOCK 0 OFF 4 ACC Z2 20 BK LG Z1 20 BK Z1 18 BK 13 GROUND 8W 12 2 8W 12 9 8W 12 9 8W 10 8 8W 10 11 8W 10 9 8W 10 11 8W 10 14 8W 10 16 8W 62 3 8W 63 4 8W 15 6 8W 50 9 8W...

Page 771: ...ENSE C2 8 SWITCH HEADLAMP 12 E92 22 OR BK C1 DIMMER SWITCH SIGNAL BUS CCD 3 C2 VT BR 20 D1 PS01 D1 20 VT BR PS02 D2 20 WT BK C2 34 CCD BUS WT BK 20 D2 3 11 DATA LINK CONNECTOR 4 C2 C2 9 1 FUSE 10A PAIR TWISTED TWISTED PAIR 2 C1 DIMMER SWITCH SIGNAL WIPER PARK SWITCH SENSE SENSE SWITCH FLUID WASHER 1 C2 C1 41 CLOCKSPRING X3 20 BK RD RELAY HORN CONTROL CONTROL HORN RELAY 8W 53 3 8W 50 11 8W 50 12 8W...

Page 772: ...C2 C2 C2 40 LG WT 20 L308 8 SWITCH HEADLAMP 4 M32 22 BK LB 2 C2 C1 3 M112 22 BR LG 17 C1 5 E17 20 YL BK 11 C2 C1 COURTESY LAMP SWITCH SENSE 10 C3 DRIVER LAMP RELAY COURTESY STEP DIMMER SWITCH C1 4 RADIO YL BK 20 E17 18 C3 HEADLAMP SWITCH SENSE PARK LAMP SWITCH SENSE SENSE HEADLAMP AUTO C2 C2 12 BK YL 22 L110 7 C2 2 C1 6 GROUND C4 21 4 Z1 20 BK Z1 18 BK SWITCH FUNCTION MULTI PART OF SWITCH WIPER FR...

Page 773: ... 1 SWITCH HEADLAMP E2 20 OR C4 1 OR 20 E2 C1 5 RADIO 5 POWER MIRROR SWITCH 3 TRACTION CONTROL SWITCH A C HEATER CONTROL 85 IN PDC RELAY BEAM LOW 76 C1 L193 20 OR WT CONTROL LOW BEAM RELAY SWITCH FUNCTION MULTI PART OF SWITCH DIMMER HEADLAMP E2 20 OR 7 1 RHD 86 FRONT CIGAR LIGHTER POWER OUTLET TO E2 20 OR FEED LAMPS PANEL FEED LAMPS PANEL FEED LAMPS PANEL FEED LAMPS PANEL FEED LAMPS PANEL FEED LAMP...

Page 774: ...E G19 20 LG OR 3 P34 B23 A3 LG OR 18 G19 5 LG OR 20 G19 CENTER MESSAGE ABS WARNING LAMP ABS WARNING LAMP DRIVER INTERFACE RKE SIGNAL CENTER MESSAGE SIGNAL A23 C1 44 UNLOCK LOCK LIFTGATE 2 SWITCH DISARM ARM LIFTGATE B17 LJ01 6 J03A L16 6 P98 20 WT RD WT RD 20 P98 WT RD 20 P98 CONTROL HVAC A C HEATER CONTROL 2 RHD 12 1 C1 POWER WINDOW SWITCH UNIVERSAL GARAGE DOOR OPENER PART OF FRONT READING LAMPS S...

Page 775: ...K 4 J03A L16 TN BK 18 G78 LIFTGATE AJAR SWITCH 1 43 G70 18 BR TN C1 HOOD AJAR SWITCH SENSE HOOD AJAR SWITCH 86 85 DOOR LOCK RELAY RELAY UNLOCK DOOR 85 86 6 85 86 5 RELAY UNLOCK DOOR DRIVER CONTROL RELAY DOOR LOCK DOOR UNLOCK RELAY CONTROL CONTROL RELAY UNLOCK DRIVER BATT A2 SEAT 3 PTC 9A GAS ENGINE ENGINE OIL PRESSURE SWITCH SENSE SEAT BELT SWITCH SENSE FUEL LEVEL SENSOR SIGNAL LIFTGATE AJAR SWITC...

Page 776: ...TN OR SWITCH AJAR DOOR REAR LEFT RIGHT REAR DOOR AJAR SWITCH TN YL 18 G76 2 C1 77 C1 LEFT REAR DOOR AJAR SWITCH SENSE SENSE SWITCH DOOR AJAR REAR RIGHT 7 AUTOMATIC DAY NIGHT MIRROR AUTOMATIC HEADLAMP SIGNAL 51 C1 C20 B75 18 6 C19 EC1 L24 20 WT LG MODULE CONTROL BODY OTHER RKE RKE OTHER P96 20 WT LG DOOR SWITCH MUX LEFT REAR DOOR AJAR SWITCH SENSE RIGHT REAR SWITCH DOOR AJAR SENSE AUTOMATIC HEADLAM...

Page 777: ...L POWERTRAIN 3 60 G58 20 BK YL C1 SIGNAL SENSOR TEMPERATURE COOLANT 3 COOLANT TEMPERATURE SENSOR DIESEL DRIVER LAMP CONTROL SPEED 75 K159 20 VT RD C1 SIGNAL SENSOR SPEED ENGINE 2 59 ENGINE DISABLE SIGNAL C1 OR BK 20 G55 72 ENGINE SPEED SENSOR SIGNAL BODY CONTROL MODULE SIGNAL SENSOR SPEED VEHICLE 43 VEHICLE SPEED SENSOR SIGNAL C1 WT OR 18 G7 42 G7 18 WT OR BS30 G4 18 DB ENGINE 2 B13 AW4 3 B13 AW4 ...

Page 778: ... 6 P159 20 DG P159 20 DG P160 20 LB P160 20 LB 11 C3 C4 11 POWER FOLDING MIRROR SWITCH 2 1 P136 20 YL SWITCH MIRROR FOLDING 39 C2 SIGNAL 36 C4 BK 20 Z1 HALO KEY IN FROM LAMP Z1 20 BK POWER POWER 1 2 M M 1 UNFOLD 2 FOLD RELAY FOLD MIRROR POWER RELAY UNFOLD MIRROR POWER POWER BATT F41 8W 15 6 8W 12 2 8W 44 3 8W 62 8 8W 62 8 8W 62 8 8W 62 8 8W 62 8 8W 10 20 8W 12 19 8W 45 10 8W 45 BODY CONTROL MODULE...

Page 779: ... 46 3 Headlamp Dimmer Switch 8W 46 4 High Beam Indicator 8W 46 4 Component Page High Beam Relay 8W 46 4 Ignition Switch 8W 46 3 Junction Block 8W 46 2 3 4 5 Left Rear Lamp Assembly 8W 46 5 Left Repeater Lamp 8W 46 5 Left Turn Indicator 8W 46 5 Low Beam Relay 8W 46 4 Low Oil Pressure Lamp 8W 46 2 Memory Seat Mirror Module 8W 46 2 Message Center 8W 46 2 3 4 5 Park Brake Switch 8W 46 3 Power Distribu...

Page 780: ...W SENSE C2 PRESSURE OIL ENGINE 33 SWITCH G6 22 GY OIL PRESSURE SWITCH SENSE 52 C1 1 E36 B33 1 G6 16 GY SWITCH PRESSURE OIL ENGINE POWER DISTRIBUTION CENTER C3 5 28 FUSE 10A MEMORY SEAT MODULE MIRROR VTSS LAMP ST RUN IGNITION FUSED A C CONTROL 12 BATT A0 13 16 VTSS DRIVER C2 LAMP BK OR 22 G69 16 C1 FUSED B C4 6 13 C1 M1 20 PK M1 20 PK M1 20 PK 3 HEATER B FUSED 3 ENTRY MODULE KEYLESS REMOTE M1 20PK ...

Page 781: ... ENGINE SERVICE 7 CENTER MESSAGE 10 ST RUN A21 20A FUSE 6 BLOCK JUNCTION 14 C4 BR PK 18 V23 C1 10 A C CONTROL V23 18 BR PK A2 HEATER GLOW PLUG LAMP 7 G85 20 OR BK POWERTRAIN CONTROL MODULE 26 GLOW PLUG LAMP DRIVER GAS DIESEL A17 17 P34 B23 OR BK 20 G85 10 MODULE DRL FLASHER COMBINATION BRAKE LAMP SENSE MTX 1 START 2 RUN 3 LOCK 0 OFF 4 ACC 13 11 G3 18 BK PK EATX 8 C2 RHD INDICATOR 8W 15 4 8W 15 8 8...

Page 782: ...WT LG 20 L324 SWITCH DIMMER HEADLAMP 12 8 INDICATOR BEAM HIGH P18 B23 18 1 POWER DISTRIBUTION CENTER MESSAGE CENTER MODULE CONTROL BODY C3 2 C5 6 5 FUSE 10A BATT A0 86 30 87 85 B21 B18 10 PART OF MULTI FUNCTION SWITCH HIGH BEAM RELAY FROM RELAY BEAM LOW L94 20 OR WT 6 4 RHD 8W 12 2 8W 15 6 8W 50 2 8W 15 4 8W 10 10 8W 45 5 8W 10 33 8W 10 34 8W 10 8 8W 50 2 8W 50 2 8W 12 19 8W 46 4 8W 46 MESSAGE CEN...

Page 783: ...SIGNAL DRL FLASHER COMBINATION MODULE L63 18 DG RD L62 18 BR RD REAR REAR 4 2 C3 14 21 C3 BLOCK JUNCTION 19 21 5 4 8 7 9 MULTI FUNCTION SWITCH PART OF 3 RIGHT 2 LEFT 1 HAZARD 1 1 L62 18 BR RD ASSEMBLY LAMP REAR RIGHT 5 36 C2 EXPORT BUILT UP LAMP REPEATER RIGHT L62 18 BR RD L63 18 DG RD 1 1 LEFT REPEATER LAMP BUILT UP EXPORT 5 3 4 RHD EXCEPT BUILT UP EXPORT 5 P50 NOT USED L91 20 DB PK LEFT REAR TUR...

Page 784: ......

Page 785: ...7 6 7 Left Front Speaker 8W 47 3 Left Rear Pillar Speaker 8W 47 5 Component Page Left Rear Speaker 8W 47 3 4 5 Memory Seat Mirror Module 8W 47 2 Name Brand Speaker Relay 8W 47 4 Power Distribution Center 8W 47 2 Power Mirror Switch 8W 47 2 PS01 8W 47 2 PS02 8W 47 2 Radio 8W 47 2 3 4 5 6 7 Radio Choke 8W 47 4 5 6 7 Right Door Speaker 8W 47 4 6 7 Right Front Panel Speaker 8W 47 6 7 Right Front Speak...

Page 786: ...TCH DIMMER STEP SWITCH HEADLAMP E17 20 YL BK E17 20 YL BK X12 18 RD WT 5 POWER MIRROR SWITCH E2 20 OR E2 20 OR GROUND G202 CCD BUS C3 1 BUS CCD 2 C3 D1 20 VT BR D2 20 WT BK M1 20 PK M1 20 PK 16 DATA LINK CONNECTOR MODULE MIRROR SEAT MEMORY TO PS01 PS02 TO 6 P50 NOT USED X12 20 RD WT X15 16BK DG PANEL LAMP FEED FEED 8W 10 9 8W 10 11 8W 10 8 8W 12 2 8W 12 11 8W 45 2 8W 45 4 8W 45 5 8W 10 16 8W 50 9 ...

Page 787: ... REAR SPEAKER 6 3 3 2 SPEAKER FRONT RIGHT 3 6 SPEAKER REAR RIGHT P34 B23 8 10 7 9 X55 20 BR RD X53 20 DG X51 20 BR YL X51 20 BR YL X57 20 BR LB X57 20 BR LB X52 20 DB WT X52 20 DB WT X58 20 DB OR X58 20 DB OR X54 20 VT X56 20 DB RD A9 A7 A10 A8 SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER SPEAKER NS GS 8W 47 AUDIO SYSTEM BASE 8W 47 3 GS004703 J988W 3 ...

Page 788: ...R SPEAKER REAR RIGHT 5 BS03 X13 16 RD DG X13 16 RD DG 5 RIGHT DOOR SPEAKER SPEAKER DOOR LEFT 5 RD DG 16 X13 X13 16 RD DG 14 B03 D01P RD DG 16 X13 RD DG 16 X13 2 B01 D02 RADIO CHOKE OUTPUT RADIO CHOKE OUTPUT RADIO CHOKE OUTPUT RADIO CHOKE OUTPUT 8W 12 2 8W 10 16 8W 15 6 8W 12 11 8W 47 3 8W 47 5 8W 47 3 8W 47 5 8W 47 6 8W 47 7 8W 47 6 8W 47 7 8W 12 19 8W 47 4 8W 47 AUDIO SYSTEM PREMIUM NS GS J988W 3...

Page 789: ...B X157 20 BR LB X51 20 BR YL X51 20 BR YL X151 20 BR YL X52 20 DB WT X52 20 DB WT X152 20 DB WT X58 20 DB OR X58 20 DB OR X158 20 DB OR G202 P34 B23 11 A11 X15 16 BK DG BS08 BK DG 16 X15 X15 16 BK DG X15 16 BK DG 2 CHOKE RADIO 5 4 1 5 4 1 X13 16 RD DG X13 16 RD DG X13 16 RD DG BS03 SPEAKER SPEAKER SPEAKER SPEAKER RADIO CHOKE OUTPUT 8W 15 5 8W 15 5 8W 47 4 8W 47 4 NS GS 8W 47 AUDIO SYSTEM PREMIUM 8...

Page 790: ...4 20 VT X156 20 VT WT X56 20 DB RD X56 20 DB RD X154 20 WT VT G202 P34 B23 11 A11 X15 16 BK DG BS08 BK DG 16 X15 X15 16 BK DG X15 16 BK DG D02 B01 2 D01P B03 14 RD DG 16 X13 RD DG 16 X13 1 1 D02 B01 D01P B03 BS03 2 CHOKE RADIO B26 P18 B23 B6 D02 B120 7 3 1 4 4 1 5 10 B01 D02 B2 B23 P18 B25 X153 20 WT BR X155 20 BR WT 25 2 6 26 X154 20 WT VT X156 20 VT WT X13 16 RD DG 8 9 7 8 SPEAKER SPEAKER SPEAKE...

Page 791: ...3 20 DG X155 20 BR WT X55 20 BR RD X55 20 BR RD X153 20 WT BR G202 P34 B23 11 A11 X15 16 BK DG BS08 BK DG 16 X15 X15 16 BK DG X15 16 BK DG D01P B03 14 D02 B01 2 RD DG 16 X13 RD DG 16 X13 1 1 D02 B01 D01P B03 BS03 2 CHOKE RADIO B25 P18 B23 B2 D02 B120 7 3 1 4 4 1 5 10 B01 D02 B6 B23 P18 B26 X154 20 WT VT X156 20 VT WT 26 6 2 25 X153 20 WT BR X155 20 BR WT X13 16 RD DG 8 9 7 8 SPEAKER SPEAKER SPEAKE...

Page 792: ......

Page 793: ...e 9 JB 8W 48 3 Fuse 12 JB 8W 48 2 Fuse 27 PDC 8W 48 2 G200 8W 48 2 Component Page G400 8W 48 2 HVAC Control 8W 48 2 3 Junction Block 8W 48 2 3 Message Center 8W 48 2 Passenger Power Mirror 8W 48 2 Power Distribution Center 8W 48 2 Rear Window Defogger 8W 48 2 Rear Window Defogger Relay 8W 48 2 Rear Window Defogger Switch 8W 48 2 NS GS 8W 48 WINDOW DEFOGGERS 8W 48 1 ...

Page 794: ... REAR G400 5 4 5 REAR WINDOW DEFOGGER SWITCH SENSE 7 6 C16 20 LB YL C16 20 LB YL L16 J03A 1 12 B17 LJ01 C15 12 BK WT Z1 12 BK Z1 20 BK Z1 20 BK POWER DISTRIBUTION CENTER 10 CONTROL CENTER MESSAGE V23 18 BR PK V23 18 BR PK BATT A0 HVAC CONTROL C1 C1 C1 C1 DRIVER POWER MIRROR MIRROR POWER PASSENGER FUSED IGNITION ST RUN 8W 12 12 8W 10 11 8W 10 14 8W 10 8 8W 12 10 8W 15 4 8W 10 16 8W 12 2 8W 12 9 8W ...

Page 795: ...ROL HEATER A C ELECTRIC WIPER DE ICER DRIVER C66 18 BK WT HVAC CONTROL 9 FUSE 15A RUN ACC A31 BLOCK JUNCTION 15 C3 V20 18 RD 1 C2 1 C1 8W 42 3 8W 42 3 8W 12 11 8W 12 2 8W 10 16 NS GS 8W 48 REAR WINDOW DEFOGGER 8W 48 3 GS004803 J988W 3 ...

Page 796: ......

Page 797: ...2 BS06 8W 49 2 Compass Mini Trip Computer 8W 49 2 CS02 8W 49 3 CS04 8W 49 2 CS06 8W 49 2 3 Component Page Fuse 6 JB 8W 49 2 Fuse 18 PDC 8W 49 3 G301 8W 49 2 3 Junction Block 8W 49 2 3 Overhead Console 8W 49 2 3 Power Distribution Center 8W 49 3 Universal Garage Door Opener 8W 49 3 NS GS 8W 49 OVERHEAD CONSOLE 8W 49 1 ...

Page 798: ...TURE AIR AMBIENT 2 G32 20 BK LB 10 8 B75 C20 5 G31 20 VT LG G31 20 VT LG G32 20 BK LB SENSOR TEMPERATURE AMBIENT SENSOR GROUND SIGNAL D1 18 VT BR 6 D1 18 VT BR PAIR TWISTED 9 B75 C20 CS06 Z2 18 BK LG TO BS05 BS06 TO WT BK 18 D2 B75 C20 5 WT BK 18 D2 1 CCD BUS 3 DIESEL 8W 12 9 8W 12 2 8W 10 16 8W 12 9 8W 15 11 8W 49 3 8W 30 4 8W 30 31 8W 30 4 8W 30 31 8W 49 2 8W 49 OVERHEAD CONSOLE NS GS J988W 3 GS...

Page 799: ... FRONT READING UNIVERSAL GARAGE DOOR OPENER PART OF SWITCH 4 2 FUSED B PANEL LAMPS FEED GROUND 3 F41 20 PK VT F41 20 PK VT F41 20 PK VT Z2 18 BK LG CS06 Z2 18 BK LG Z2 18 BK LG Z2 18 BK LG E2 20 OR E2 18 OR 9 B75 C20 G301 5 2 BODY CONTROL MODULE 3 DIESEL 8W 10 20 8W 10 8 8W 10 9 8W 12 2 8W 12 2 8W 10 20 8W 15 11 8W 15 12 8W 45 6 NS GS 8W 49 OVERHEAD CONSOLE 8W 49 3 GS004903 J988W 3 ...

Page 800: ......

Page 801: ...ch 8W 50 2 5 13 Headlamp Switch 8W 50 7 8 9 10 Component Page High Beam Relay 8W 50 2 3 4 5 6 Ignition Switch 8W 50 13 Illumination Lamp 8W 50 9 10 Junction Block 8W 50 2 5 7 9 10 11 12 13 Left Fog Lamp 8W 50 5 6 7 Left Front Park Turn Signal Lamp 8W 50 11 12 Left Headlamp 8W 50 3 6 Left Headlamp Leveling Motor 8W 50 8 Left High Headlamp 8W 50 3 5 Left Low Headlamp 8W 50 5 Low Beam Relay 8W 50 2 3...

Page 802: ...R G200 13 12 33 C3 15 BLOCK JUNCTION COMBINATION FLASHER DRL MODULE MODULE CONTROL BODY CONTROL RELAY BEAM LOW L93 22 PK 86 30 LOW BEAM SENSE SWITCH PART OF MULTI FUNCTION SWITCH CHRYSLER DODGE PYLMOUTH C1 76 L193 20 OR WT Z1 18 BK CONTROL RELAY BEAM LOW C5 8 C3 1 C5 1 C5 6 8W 10 10 8W 10 8 8W 10 33 8W 10 34 8W 10 33 8W 10 34 8W 10 33 8W 10 34 8W 10 33 8W 10 34 8W 15 4 8W 12 2 8W 45 5 8W 50 2 8W 5...

Page 803: ... HEADLAMP TO TO HEADLAMP RIGHT 1 CENTER MESSAGE RIGHT HEADLAMP TO TO HEADLAMP HIGH RIGHT 18 B23 P18 B18 L34 20 RD OR L34 20 RD OR L33 20 RD L33 20 RD L44 20 VT RD L44 20 VT RD L43 18 VT L43 18 VT L34 20 RD OR L34 20 RD OR LOW BEAM RELAY RELAY BEAM HIGH FOG LAMP RELAY IN JB TO FUSED HIGH BEAM RELAY OUTPUT 8W 10 10 8W 10 8 8W 10 33 8W 10 33 8W 10 33 8W 10 33 8W 50 6 8W 50 6 8W 50 5 8W 50 4 8W 50 6 8...

Page 804: ...RD OR Z1 20 BK Z1 20 BK BATT A0 30 87 15A FUSE 7 LOW BEAM RELAY 1 C3 C5 6 RELAY BEAM HIGH 5 FUSE 10A 87 30 POWER DISTRIBUTION CENTER 8W 15 10 8W 10 8 8W 10 33 8W 50 2 8W 50 2 8W 10 33 8W 10 10 8W 50 4 8W 50 FRONT LIGHTING EXCEPT BUILT UP EXPORT CHRYSLER NS GS J988W 3 GS005004 ...

Page 805: ...TI PART OF SWITCH DIMMER HEADLAMP 20 B20 L94 20 OR WT L94 20 OR WT LEFT LOW HEADLAMP A B G300 9 B A HEADLAMP HIGH LEFT 1 Z1 20 BK Z1 20 BK L43 18 VT L33 20 RD CENTER DISTRIBUTION POWER 30 87 10A FUSE 4 HIGH BEAM RELAY 1 C5 C5 8 RELAY BEAM LOW 6 FUSE 20A 87 30 BATT A0 L43 18 VT LOW BEAM RELAY CONTROL 8W 12 2 8W 50 2 8W 15 8 8W 10 10 8W 10 33 8W 50 2 8W 50 2 8W 10 33 8W 10 8 8W 50 9 8W 50 9 NS GS 8W...

Page 806: ...AM RELAY 8 C5 C5 1 RELAY BEAM HIGH 4 FUSE 10A 87 30 POWER DISTRIBUTION CENTER 10A FUSE 5 7 FUSE 15A C5 6 C3 1 UP EXPORT EXCEPT BUILT EXPORT BUILT UP L43 18 VT L43 18 VT C 8W 50 8 TO BS16 L44 20 VT RD L44 20 VT RD EXCEPT BUILT UP EXPORT BUILT UP EXPORT 2 1 3 D 8W 50 8 EXPORT UP BUILT EXCEPT BUILT UP EXPORT RIGHT HEADLAMP TO L34 20 RD OR L34 20 RD OR BUILT UP EXPORT 8W 15 8 8W 15 10 8W 10 8 8W 10 33...

Page 807: ...UNCTION 15A FUSE 4 2 C1 F39 18 PK LG F39 18 PK LG C1 4 POWER DISTRIBUTION CENTER PARK LAMP RELAY BATT A0 L7 12 BK YL 40A FUSE 22 30 87 F 8W 50 10 HEADLAMP SWITCH TO Z39 18BK GROUND 8W 50 10 8W 12 2 8W 12 8 8W 10 8 8W 50 11 8W 50 12 8W 10 8 8W 10 17 NS GS 8W 50 FRONT LIGHTING BUILT UP EXPORT 8W 50 7 GS005007 J988W 3 ...

Page 808: ...D P18 B23 B3 3 2 2 1 3 1 L44 20 VT RD L44 20 VT RD A16 P34 B23 16 L13 20 BR YL L13 20 BR YL L13 18 BR YL Z1 20 BK Z1 20 BK G200 9 Z1 20 BK M M C 8W 50 6 JUNCTION BLOCK FROM SWITCH HEADLAMP 2 C1 8 C1 1 C1 9 D 8W 50 6 FROM CENTER DISTRIBUTION POWER L34 20 RD OR 8W 15 8 8W 15 10 8W 15 4 8W 50 10 8W 50 8 8W 50 FRONT LIGHTING BUILT UP EXPORT NS GS J988W 3 GS005008 ...

Page 809: ... 20 LG OR L308 20 LG WT M13 20 BK YL M13 20 BK YL Z1 18 BK Z1 20 BK Z2 20 BK LG Z2 20 BK LG Z1 14 BK LAMP ILLUM INDIC LAMP FOG 2 HEAD 3 AUTO 1 PARK 0 OFF A 8W 50 5 B 8W 50 5 FROM P18 P18 FROM 5 C2 C2 6 Z39 18 BK L39 18 LB 3 2 1 0 0 1 2 3 4 ON 7 C2 C2 12 SWITCH HEADLAMP AUTO L110 22 BK YL COURTESY LAMP RELAY DOME LAMP SWITCH 4 C1 5 C1 C2 2 MODULE CONTROL BODY 11 C2 M32 22 BK LB E17 20 YL BK M13 20 ...

Page 810: ...20 LG WT M13 20 BK YL M13 20 BK YL Z1 18 BK Z1 20 BK Z1 14 BK COURTESY LAMP RELAY LAMP ILLUM INDIC LAMP FOG 3 2 1 0 0 1 2 3 0 1 2 3 REAR FOG LAMP INDIC DOME LAMP SWITCH C2 2 4 C1 5 C1 11 C2 STEP SWITCH DIMMER C1 4 RADIO STEP DIMMER SWITCH SIGNAL 14 C2 C2 10 GROUND GROUND M32 22 BK LB E17 20 YL BK 0 OFF 1 PARK 3 REAR 2 HEAD 4 ON SWITCH LAMP DOME 5 C2 6 C2 7 C2 Z2 20BK LG Z2 20BK LG D4 F 8W 50 7 FRO...

Page 811: ...SE 5 3 FUSE 15A 5 C1 5 C2 11 C2 Z1 18 BK Z1 18 BK L77 20 BR YL L61 18 LG L78 20 DG YL L60 18 TN SIGNAL TURN FRONT RIGHT LEFT FRONT TURN SIGNAL 4 ASSEMBLY LAMP REAR RIGHT L78 20 DG YL COMBINATION FLASHER DRL MODULE PARK LAMP RELAY 2 3 1 3 2 3 2 3 1 EXPORT BUILT UP EXCEPT BUILT UP EXPORT BK 20 Z1 BUILT UP EXPORT E 8W 50 10 HEADLAMP SWITCH TO L77 18 BR YL B28 B23 P18 28 L77 18 BR YL FUSED B 8W 45 3 8...

Page 812: ...97 18 PK DB L7 12 BK YL L9 18 BK WT PARK LAMP RELAY CONTROL 22 FUSE 40A BATT A0 1 FUSE 10A 15A FUSE 5 3 FUSE 15A 5 C1 5 C2 11 C2 Z1 20 BK Z1 18 BK L77 20 BR YL L61 18 LG L78 20 DG YL L60 18 TN SIGNAL TURN FRONT RIGHT LEFT FRONT TURN SIGNAL COMBINATION FLASHER DRL MODULE LAMP RELAY PARK B FUSED 3 2 8W 45 3 8W 10 8 8W 10 10 8W 12 2 8W 10 29 8W 15 7 8W 15 10 8W 10 17 8W 10 8 8W 12 8 8W 12 8 8W 12 8 8...

Page 813: ...KE 1 COMBINATION FLASHER DRL MODULE 11 10A FUSE 12 2 BODY CONTROL MODULE 33 C3 9 SWITCH FUNCTION MULTI PART OF SWITCH DIMMER HEADLAMP L93 22 PK RUN A22 6 12 HIGH LOW BEAM RELAY CONTROL FUSED IGNITION RUN GROUND 2 C2 Z1 14 BK G9 20 GY BK BLOCK JUNCTION 8W 15 7 8W 46 3 8W 15 4 8W 10 14 8W 12 12 8W 45 3 8W 50 2 8W 10 14 8W 12 2 8W 12 17 NS GS 8W 50 FRONT LIGHTING DRL 8W 50 13 GS005013 J988W 3 ...

Page 814: ......

Page 815: ...G301 8W 51 3 G302 8W 51 4 5 G400 8W 51 2 7 Component Page Headlamp Switch 8W 51 2 6 Junction Block 8W 51 2 3 4 5 6 Left Rear Lamp Assembly 8W 51 4 5 6 Left Repeater Lamp 8W 51 3 License Lamp 8W 51 2 Park Lamp Relay 8W 51 2 6 Power Distribution Center 8W 51 2 3 4 5 6 7 Rear Fog Lamp 8W 51 6 Rear Fog Lamp Indicator 8W 51 6 Right Front Park Turn Signal Lamp 8W 51 2 Right Rear Lamp Assembly 8W 51 4 5 ...

Page 816: ...LAMP RELAY CONTROL FUSED B L308 20 LG WT C2 2 21 C4 2 C2 Z1 18 BK Z1 14 BK TO ASSEMBLY LAMP REAR LEFT TO ASSEMBLY LAMP REAR RIGHT L77 20 BR LB L77 20 BR LB L78 20 DG YL L78 20 DG YL TURN PARK FRONT RIGHT 7 G400 Z1 20 BK LAMP SIGNAL 0 OFF 2 PARK 1 HEAD 2 1 B 8W 51 4 A 8W 51 4 L77 20 BR LB BUILT UP EXPORT FUSED B 8W 45 3 8W 45 4 8W 10 8 8W 12 2 8W 15 6 8W 10 17 8W 10 8 8W 12 8 8W 12 8 8W 12 8 8W 15 ...

Page 817: ...G RD 2 1 BUILT UP LAMP REPEATER LEFT EXPORT Z1 18 BK 14 G300 L63 18 DG RD C 8W 51 4 LEFT REAR LAMP ASSEMBLY TO TO ASSEMBLY LAMP REAR RIGHT BR RD 18 L62 G301 10 BK 18 Z1 EXPORT RIGHT REPEATER LAMP BUILT UP 1 2 BR RD 18 L62 D 8W 51 4 4 5 COMBINATION FLASHER DRL MODULE 8W 10 29 8W 10 8 8W 10 10 8W 12 2 8W 10 14 8W 12 12 8W 15 5 8W 15 10 8W 51 5 8W 51 5 NS GS 8W 51 REAR LIGHTING 8W 51 3 GS005103 J988W...

Page 818: ...T A0 F32 18 PK DB 6 1 20A FUSE 13 12 FUSE 10A 18 C2 BLOCK JUNCTION BS01 BS02 R L50 18 WT TN L50 18 WT TN L50 18 WT TN L63 18 DG RD L77 20 BR LB L78 20 DG YL L62 18 BR RD L1 20 VT BK L1 20 VT BK L1 20 VT BK RUN A22 F20 20 WT F20 18 WT E36 B33 5 6 6 9 G302 3 Z1 20 BK Z1 20 BK E36 B33 10 VT BK L1 18 TRANSMISSION RANGE SENSOR STOP LAMP SWITCH 5 3 6 4 1 4 1 5 3 6 BUILT UP EXPORT 8W 10 10 8W 10 8 8W 10 ...

Page 819: ...13 12 FUSE 10A 18 C2 BLOCK JUNCTION BS01 BS02 L50 18 WT TN L50 18 WT TN L50 18 WT TN L63 18 DG RD L77 20 BR LB L78 20 DG YL L62 18 BR RD L1 20 VT BK L1 20 VT BK L1 20 VT BK RUN A22 F20 20 WT 6 6 9 G302 3 Z1 20 BK Z1 20 BK STOP LAMP SWITCH 5 3 6 4 1 4 1 5 3 6 BUILT UP EXPORT BACK UP SWITCH 18 L1 VT BK 10 B33 E120 2 1 WT 20 F20 5 B33 E120 DIESEL BACK UP SWITCH GAS 18 L1 VT BK 10 B33 E36 5 B33 E36 WT...

Page 820: ...K JUNCTION C4 21 Z1 18 BK 3 4 BODY CONTROL MODULE GROUND GROUND B27 B23 P18 27 L36 20 LG 3 2 REAR FOG LAMP ASSEMBLY LAMP REAR LEFT L36 20 LG RIGHT REAR LAMP ASSEMBLY LAMP FOG REAR 2 3 L77 20 BR LB FROM 3 JB FUSE L78 20 DG YL L36 20 LG C1 6 DIMMER SWITCH Z1 20BK L77 18 BR YL C1 C1 18 8W 50 11 8W 50 12 8W 10 8 8W 10 8 8W 10 17 8W 12 8 8W 12 2 8W 50 9 8W 12 2 8W 45 4 8W 12 8 8W 51 6 8W 51 REAR LIGHTI...

Page 821: ... LAMP STOP F32 18 PK DB G400 2 CENTER HIGH MOUNTED STOP LAMP Z1 20 BK 20A FUSE 13 BS01 L50 18 WT TN L15 J02A 2 J01A B17 2 L50 20 WT TN L50 18 WT TN L50 20 WT TN 8W 10 10 8W 10 8 8W 15 14 8W 10 29 8W 70 2 NS GS 8W 51 REAR LIGHTING 8W 51 7 GS005107 J988W 3 ...

Page 822: ......

Page 823: ...ft Front Park Turn Signal Lamp 8W 52 2 Left Rear Lamp Assembly 8W 52 2 Component Page Left Repeater Lamp 8W 52 2 Left Turn Indicator 8W 52 2 Message Center 8W 52 2 3 Power Distribution Center 8W 52 2 3 Right Front Park Turn Signal Lamp 8W 52 3 Right Rear Lamp Assembly 8W 52 3 Right Repeater Lamp 8W 52 3 Right Turn Indicator 8W 52 3 Tail Turn Signal Lamp 8W 52 2 3 Turn Signal Hazard Switch 8W 52 2 ...

Page 824: ...MP SIGNAL TURN PARK FRONT LEFT 10 Z1 18 BK FUSED IGN RUN BATT A0 POWER DISTRIBUTION CENTER 20A FUSE 10 9 C5 C2 27 B FUSED 1 4 9 7 2 6 L9 18 BK WT 12 FUSE 10A RUN A22 PART OF MULTI FUNCTION SWITCH 1 HAZARD 2 LEFT 3 RIGHT 3 2 3 4 LEFT REAR LAMP 6 1 ASSEMBLY LAMP SIGNAL TURN TAIL 2 1 LEFT REPEATER LAMP BUILT UP EXPORT 14 Z1 18 BK RHD BUILT UP EXPORT L63 18 DG RD 5 1 CENTER MESSAGE 8 1 2 3 1 4 20 DB P...

Page 825: ...UTION CENTER 20A FUSE 10 9 C5 C2 27 B FUSED 1 5 8 9 3 6 L9 18 BK WT 12 FUSE 10A RUN A22 3 2 5 4 RIGHT REAR LAMP 6 1 ASSEMBLY LAMP SIGNAL TURN TAIL 2 1 RIGHT REPEATER LAMP BUILT UP EXPORT Z1 18 BK RHD BUILT UP EXPORT L62 18 BR RD G301 8 8 G300 G301 10 1 5 CENTER MESSAGE FUNCTION SWITCH 1 HAZARD 2 LEFT 3 RIGHT DB PK 22 L91 L302 22 LB YL C3 26 C3 22 TURN SIGNAL HAZARD SWITCH PART OF MULTI 8 1 2 3 1 3...

Page 826: ......

Page 827: ... 8W 53 4 Junction Block 8W 53 2 3 4 5 Low Washer Fluid Switch 8W 53 3 Component Page Park Lamp Relay 8W 53 5 Power Distribution Center 8W 53 2 3 5 PTC 3 JB 8W 53 5 PTC 7 JB 8W 53 2 3 4 5 Rear Washer Motor 8W 53 3 4 Rear Washer Switch 8W 53 4 Rear Wiper Delay On Indicator 8W 53 4 Rear Wiper Delay Switch 8W 53 4 Rear Wiper Motor 8W 53 4 Rear Wiper On Indicator 8W 53 4 Rear Wiper On Switch 8W 53 4 Wa...

Page 828: ...ER SWITCH 6 5 3 WT 20 V16 P18 B23 B1 V16 20 WT 41 C1 7 C2 C1 73 V52 20 DG YL V14 18 RD VT WIPER ON OFF RELAY CONTROL FRONT WIPER SWITCH WIPER PARK SWITCH SENSE MODULE CONTROL BODY 10 1 0 2 1 0 OFF 1 HIGH 3 WASH 2 LOW 7 7 PTC 9A RUN ACC A31 BLOCK JUNCTION 5 C3 F1 20 DB SWITCH FUNCTION MULTI PART OF 11 8 MUX M 8W 10 19 8W 10 8 8W 10 8 8W 15 5 8W 15 7 8W 45 3 8W 45 4 8W 12 16 8W 12 2 8W 10 16 8W 53 2...

Page 829: ...NT WIPER SWITCH 5 3 WT 20 V16 P18 B23 1 V16 20 WT C1 73 V14 18 RD VT WIPER ON OFF RELAY CONTROL JUNCTION BLOCK BODY CONTROL MODULE 8 11 20 18 C3 C2 21 V10 20 BR CONTROL MOTOR WASHER FRONT JUNCTION BLOCK RUN ACC A31 PTC 7 9A 3 C2 30 B1 0 OFF 1 HIGH 2 LOW 3 WASH SWITCH FUNCTION MULTI PART OF 7 6 WASHER MODULE BUILT UP EXPORT 87 87A 31 FUSED IGNITION RUN ACC M 8W 15 11 8W 53 4 8W 15 4 8W 10 8 8W 53 2...

Page 830: ... 2 7 8 B17 LJ01 BR LG 18 V13 BR PK 18 V23 2 REAR WIPER MOTOR M 1 3 49 C1 REAR WIPER MOTOR DRIVER BK WT 20 V20 C2 38 REAR MUX WASH WIPE CONTROL MOTOR WASHER REAR C1 50 7 C1 ST RUN IGN FUSED 12 11 6 FUSE 20A ST RUN A21 MODULE CONTROL BODY C2 3 9A 7 PTC RUN ACC A31 BLOCK JUNCTION A B F1 20 DB MOTOR WASHER REAR FRONT WASHER MOTOR A F1 20 DB CONTROL HEATER A C 13 FUSED IGNITION RUN ACC PUMP M 8W 15 4 8...

Page 831: ...10 20 BR BR 20 V10 MOTOR WASHER FRONT B V53 18 RD YL WASHER HEADLAMP WASHER MODULE B A 11 Z1 18 BK SWITCH FUNCTION MULTI PART OF SWITCH WIPER FRONT G301 31 30 S 56 P FRONT WASHER MOTOR CONTROL WASHER PUMP CONTROL SWITCH OUTPUT M 8W 12 2 8W 10 17 8W 10 8 8W 10 8 8W 50 11 8W 10 16 8W 10 13 8W 12 16 8W 12 15 8W 12 8 8W 45 4 8W 53 3 8W 53 3 8W 15 10 NS GS 8W 53 WIPERS BUILT UP EXPORT 8W 53 5 GS005305 ...

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Page 833: ...ombination Relay 8W 54 2 3 Left Rear Lamp Assembly 8W 54 2 3 Component Page Left Stop Turn Signal Relay 8W 54 2 3 License Lamp 8W 54 2 Park Lamp Relay 8W 54 2 Power Distribution Center 8W 54 2 Right Combination Relay 8W 54 2 3 Right Front Park Turn Signal Lamp 8W 54 2 Right Rear Lamp Assembly 8W 54 2 3 Right Stop Turn Signal Relay 8W 54 2 3 Stop Lamp Switch 8W 54 3 Trailer Tow Connector 8W 54 2 3 ...

Page 834: ...REAR RIGHT 1 1 4 1 RELAY SIGNAL TURN STOP LEFT LEFT COMBINATION RELAY RELAY COMBINATION RIGHT 1 RIGHT STOP TURN SIGNAL RELAY 4 2 TRAILER TOW CONNECTOR L63 18 DG RD L63 18 DG RD L62 18 BR RD L62 18 BR RD L78 18 BR L77 20 BR LB B99 T05 4 T08 B98 4 1 LAMP SIGNAL TURN PARK FRONT RIGHT LAMP LICENSE FUSED PARK LAMP RELAY OUTPUT 1 5 3 5 3 BUILT UP EXPORT 4 5 LEFT REAR TURN SIGNAL FUSED LEFT INBOARD TAIL ...

Page 835: ...G L73 18 YL L74 18 LG 2 2 2 2 9 Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK LEFT REAR LAMP ASSEMBLY 6 6 T05 B99 Z1 20 BK Z1 20 BK STOP LAMP SWITCH 5 WT TN 18 L50 L50 18 WT TN 5 T05 B99 5 L50 18 WT TN WT TN 18 L50 WT TN 18 L50 BS01 4 4 1 1 6 1 1 BUILT UP EXPORT L50 18 WT TN 5 B98 T08 5 6 L50 18 WT TN STOP LAMP SWITCH OUTPUT STOP LAMP SWITCH OUTPUT GROUND OUTPUT SWITCH LAMP STOP GROUND 8W 15 13 8W 51 4 8W 5...

Page 836: ......

Page 837: ...01 8W 60 2 3 Express Down Module 8W 60 2 G300 8W 60 2 3 Junction Block 8W 60 2 3 Component Page Left Rear Vent Motor 8W 60 2 Passenger Door Courtesy Lamp 8W 60 3 Passenger Door Lock Switch 8W 60 3 Passenger Power Window Switch 8W 60 3 Passenger Window Motor 8W 60 3 PTC 8 JB 8W 60 2 3 PTC 9 JB 8W 60 2 Right Rear Vent Motor 8W 60 2 NS GS 8W 60 POWER WINDOWS 8W 60 1 ...

Page 838: ... LOCK DOOR DRIVER E2 20 OR E2 20 OR G300 5 Z1 12 BK DS01 B02 D01D 10 Z1 12 BK 1 2 M MOTOR WINDOW DRIVER Q21 16 WT Q11 16 LG DB 18 Q13 RD WT 18 Q23 LEFT REAR VENT MOTOR 3 2 1 2 MOTOR VENT REAR RIGHT Q14 18 GY Q24 18 DG 13 2 8 1 M M 1 DOWN 2 UP 4 CLOSE 3 OPEN LHD LHD RHD MOTOR VENT REAR RIGHT RHD LEFT REAR VENT MOTOR 3 1 RHD PANEL LAMPS FEED 8W 12 2 8W 12 16 8W 12 16 8W 10 16 8W 45 6 8W 61 2 8W 15 7...

Page 839: ...CC A31 D01P B03 13 C2 C2 17 BLOCK JUNCTION 9A 8 PTC TN DG 14 F55 7 TN DG 12 F55 2 BODY CONTROL MODULE 8 C1 PANEL LAMPS FEED E2 20 OR 11 B02 D01D 1 SWITCH LOCK DOOR PASSENGER E2 20 OR G300 5 Z1 12 BK DS01 B02 D01D 10 Z1 12 BK 2 4 13 2 1 2 1 4 3 4 SWITCH WINDOW POWER DRIVER 3 EXPRESS DOWN MODULE 9 1 DOWN 2 UP 3 OPEN 4 CLOSE 2 UP 1 DOWN Z1 20BK PANEL FEED LAMPS GROUND 8W 44 3 8W 10 16 8W 12 2 8W 12 1...

Page 840: ......

Page 841: ...ock 8W 61 2 3 4 5 6 7 8 Component Page Left Rear Sliding Door Contact 8W 61 3 4 7 8 Left Rear Sliding Door Lock Motor 8W 61 4 8 Liftgate Arm Disarm Switch 8W 61 6 Liftgate Lock Motor 8W 61 3 4 7 8 Memory Seat Mirror Module 8W 61 5 Passenger Door Arm Disarm Switch 8W 61 6 Passenger Door Lock Motor 8W 61 3 4 7 8 Passenger Door Lock Switch 8W 61 2 6 Passenger Power Window Switch 8W 61 2 6 Power Distr...

Page 842: ...2 Z2 20 BK LG Z2 20 BK LG P97 20 WT DG 11 P97 20 WT DG WT LG 20 P96 D01P B03 4 WT LG 20 P96 D01D B02 4 11 E2 20 OR E2 20 OR SWITCH WINDOW POWER DRIVER PASSENGER POWER WINDOW SWITCH E2 20 OR E2 20 OR 6 14 E2 20 OR E2 20 OR SWITCH LOCK DOOR PASSENGER PANEL LAMP FEED PANEL LAMP FEED 8W 45 8 8W 12 2 8W 15 10 8W 15 11 8W 15 12 8W 60 2 8W 60 3 8W 12 23 8W 61 2 8W 61 POWER DOOR LOCKS STANDARD NS GS J988W...

Page 843: ... D01P B03 10 BR 20 F133 BR 20 F133 Z1 14 BK 8 G300 2 1 11 C1 C1 15 C1 19 C1 9 C1 32 DRIVER DOOR LOCK MOTOR 1 2 DOOR UNLOCK RELAY CONTROL CONTROL RELAY LOCK DOOR 6 MODULE CONTROL BODY 8 C2 2 87A 86 87 85 30 DOOR LOCK RELAY RELAY UNLOCK DOOR JUNCTION BLOCK 30 85 87 86 87A M M M MOTOR LOCK LIFTGATE BATT A2 9A PTC 3 F136 20 VT WT MOTOR LOCK DOOR PASSENGER 8W 61 4 8W 61 4 8W 15 6 8W 45 7 8W 12 2 8W 10 ...

Page 844: ...LIFTGATE F133 20 BR YL DOOR SLIDING REAR RIGHT LOCK MOTOR BATT A2 2 C2 G300 8 BK 14 Z1 C1 26 15 C1 85 30 BLOCK JUNCTION DOOR UNLOCK RELAY RELAY LOCK DOOR 30 85 8 BODY CONTROL MODULE 6 DOOR LOCK RELAY CONTROL CONTROL RELAY UNLOCK DOOR M M 2 2 1 1 86 87 87A 86 87 87A 9A PTC 3 VT WT 20 F136 VT YL 20 F136 15 C20 B75 8W 61 3 8W 61 3 8W 10 13 8W 15 6 8W 12 2 8W 45 7 8W 12 14 8W 12 15 8W 10 13 8W 61 4 8W...

Page 845: ...2 PK 20 M1 PK 20 M1 B FUSED REMOTE KEYLESS ENTRY MODULE 4 3 MEMORY SEAT MIRROR MODULE 16 C1 C4 6 PK 20 M1 C1 13 MODULE CONTROL BODY 9 FUSED B JUNCTION BLOCK CENTER DISTRIBUTION POWER BATT A0 28 FUSE 10A 5 C3 A23 M1 22 PK 7 P50 USED NOT RKE MODULE PROGRAM ENABLE 8W 15 4 8W 62 3 8W 45 6 8W 12 2 8W 10 9 8W 10 8 8W 10 11 8W 12 20 NS GS 8W 61 POWER DOOR LOCKS RKE 8W 61 5 GS006105 J988W 3 ...

Page 846: ...1P B03 BK LG 20 Z2 Z2 20 BK LG Z2 20 BK LG P97 20 WT DG 11 P97 20 WT DG WT LG 20 P96 D01P B03 4 WT LG 20 P96 D01D B02 4 11 E2 20 OR E2 20 OR 14 SWITCH WINDOW POWER DRIVER PASSENGER POWER WINDOW SWITCH E2 20 OR E2 20 OR E2 20 OR PASSENGER DOOR ARM DISARM SWITCH 1 2 VTSS P96 20 WT LG Z2 20 BK LG VTSS 2 1 SWITCH DISARM ARM DOOR DRIVER Z2 20 BK LG P97 20 WT DG SWITCH LOCK DOOR PASSENGER PANEL FEED LAM...

Page 847: ...K 8 G300 2 1 11 C1 C1 15 C1 19 C1 9 C1 32 DRIVER DOOR LOCK MOTOR 1 2 DOOR UNLOCK RELAY CONTROL CONTROL UNLOCK FRONT LEFT 6 MODULE CONTROL BODY 5 C2 2 87A 86 87 85 30 DOOR LOCK RELAY RELAY UNLOCK DOOR JUNCTION BLOCK BATT A2 30 85 87 86 87A DRIVER DOOR UNLOCK RELAY 8 DOOR LOCK RELAY CONTROL 87A 87 86 30 85 M M M 3 PTC 9A MOTOR LOCK LIFTGATE F136 20 VT WT MOTOR LOCK DOOR PASSENGER 16 C20 B75 8W 61 8 ...

Page 848: ...R SLIDING REAR LEFT LOCK MOTOR VT YL 20 F136 TO LOCK DOOR PASSENGER MOTOR C1 19 F133 20 BR YL LEFT REAR SLIDING DOOR CONTACT CONTACT DOOR SLIDING REAR RIGHT RIGHT REAR SLIDING DOOR CONTACT CONTACT DOOR SLIDING REAR LEFT M M 2 2 1 1 86 87 87A 87A 87A 87 87 86 86 5 J02A L15 LJ01 B17 10 F136 20 VT WT C20 B75 16 F136 20 VT YL 9 B03 D01P F136 20 VT YL 15 B75 C20 F133 20 BR YL 9A PTC 3 8W 45 7 8W 12 2 8...

Page 849: ... Power Seat Switch 8W 62 3 Memory Seat Mirror Module 8W 62 3 4 5 6 7 Memory Set Switch 8W 62 3 Component Page Passenger Power Mirror 8W 62 2 5 8 Passenger Power Seat Switch 8W 62 3 Power Distribution Center 8W 62 2 3 4 8 Power Folding Mirror Switch 8W 62 8 Power Mirror Fold Relay 8W 62 8 Power Mirror Switch 8W 62 2 4 5 Power Mirror Unfold Relay 8W 62 8 Power Seat Circuit Breaker 8W 62 3 Remote Key...

Page 850: ... G300 8 35 C4 2 C2 BLOCK JUNCTION Z1 14 BK JUNCTION BLOCK 2 BODY CONTROL MODULE PANEL LAMPS FEED 2 18 FUSE 15A POWER DISTRIBUTION CENTER C2 16 C3 15 C2 F41 20 PK VT F41 20 PK VT M M C1 C1 C1 C1 C1 C1 6 RIGHT MIRROR 1 LEFT 2 RIGHT 4 DOWN 3 UP 5 LEFT MIRROR 1 C4 C1 4 C1 5 5 C1 C1 4 8W 10 8 8W 15 6 8W 12 2 8W 12 2 8W 45 5 8W 10 20 8W 10 9 8W 12 23 8W 12 21 8W 12 19 8W 62 2 8W 62 POWER MIRRORS STANDAR...

Page 851: ...23 6 PK RD 20 P23 P24 20 PK WT 7 B01 D02D P24 20 PK WT GROUND C2 7 5 G300 2 Z1 14 BK B09 S02 1 Z1 12 BK 1 Z1 20 BK SWITCH SEAT POWER MEMORY Z1 20 BK DS01 Z1 12 BK B02 D01D 10 INTERFACE RKE 19 C1 6 1 C2 MODULE ENTRY KEYLESS REMOTE BODY CONTROL MODULE G96 20 LG RD 23 B23 P34 G96 20 LG RD G96 20 LG RD RKE INTER FACE FACE INTER RKE A23 1 SET 2 MEM 1 3 MEM 2 FUSED B B FUSED GROUND POWER SEAT CIRCUIT BR...

Page 852: ... PK VT 20 F41 C2 CENTER DISTRIBUTION POWER 15A FUSE 18 2 FEED LAMPS PANEL 2 BK 14 Z1 JUNCTION BLOCK C2 2 C4 35 8 G300 9 POWER MIRROR SWITCH Z1 20 BK 11 2 1 3 1 2 2 1 2 1 6 5 4 3 4 3 3 4 6 12 7 P73 20 YL PK 5 E2 20 OR BATT A0 JUNCTION BLOCK BODY CONTROL MODULE 16 C3 15 C2 A26 A28 A27 B8 B15 B10 M M 6 RIGHT MIRROR 1 LEFT 2 RIGHT 4 DOWN 3 UP 5 LEFT MIRROR C4 1 P73 20 YL PK DRIVER POWER MIRROR P71 20 ...

Page 853: ...S FEED C1 C1 C1 C2 1 2 C2 3 C2 C1 14 C1 23 MODULE MIRROR SEAT MEMORY 13 C1 15 C1 P67 20 YL RD 30 B23 P34 25 WT BK 20 P66 29 DG RD 20 P68 RIGHT MIRROR VERTICAL POSITION GROUND POSITION MIRROR RIGHT HORIZONTAL MIRROR RIGHT RIGHT MIRROR COMMON P70 20 WT 7 JUNCTION BLOCK BODY CONTROL MODULE E2 20 OR B7 B9 B11 A30 A25 A29 1 LEFT 2 RIGHT 3 UP 4 DOWN 5 LEFT MIRROR 6 RIGHT MIRROR 1 C4 6 7 12 POSITION C1 4...

Page 854: ...R LEFT LEFT MIRROR COMMON LEFT MIRROR VERTICAL HORIZONTAL MIRROR LEFT C1 11 12 C1 8 B23 P18 15 P71 20 YL P75 20 DB WT 6 C1 C2 4 AUTOMATIC DAY NIGHT MIRROR 4 5 20 18 P34 B23 C20 B75 20 19 4 5 C19 EC1 A20 A18 P112 20 YL WT P112 20 YL WT P114 20 YL BK P114 20 YL BK P75 20 DB WT P71 20 YL P64 20 YL OR P69 20 WT RD P65 20 DB YL POWER MIRROR B B MIRROR POWER POWER MIRROR B B MIRROR POWER 8W 44 6 8W 62 6...

Page 855: ... RD 20 P69 26 DB YL 20 P65 LEFT MIRROR POSITION GROUND POSITION MIRROR LEFT POSITION HORIZONTAL MIRROR LEFT LEFT MIRROR COMMON LEFT MIRROR VERTICAL HORIZONTAL MIRROR LEFT C1 11 12 C1 8 B23 P18 15 P71 20 YL P75 20 DB WT P75 20 DB WT P71 20 YL P64 20 YL OR P69 20 WT RD P65 20 DB YL VERTICAL NS GS 8W 62 POWER MIRRORS MEMORY BUILT UP EXPORT 8W 62 7 GS006207 J988W 3 ...

Page 856: ... WT FOLD MIRROR POWER 71 C1 6 C2 5 C2 DRIVER POWER MIRROR MIRROR POWER PASSENGER C2 5 C2 6 P159 20 DG P159 20 DG P160 20 LB P160 20 LB 11 C3 C4 11 POWER FOLDING MIRROR SWITCH 2 1 P136 20 YL SWITCH MIRROR FOLDING 39 C2 SIGNAL 36 C4 BK 20 Z1 POWER POWER 1 2 M M 1 UNFOLD 2 FOLD RELAY RELAY POWER MIRROR UNFOLD POWER 8W 10 8 8W 15 6 8W 12 2 8W 10 20 8W 10 9 8W 45 10 8W 12 19 8W 62 8 8W 62 POWER MIRRORS...

Page 857: ...ont Vertical Position Sensor 8W 63 6 Component Page Memory Seat Horizontal Motor 8W 63 5 Memory Seat Horizontal Position Sensor 8W 63 6 Memory Seat Rear Vertical Motor 8W 63 5 Memory Seat Rear Vertical Position Sensor 8W 63 6 Memory Seat Recline Position Sensor 8W 63 6 Memory Seat Recliner Motor 8W 63 5 Memory Seat Mirror Module 8W 63 2 3 4 5 6 7 Memory Set Switch 8W 63 4 Passenger Heated Seat Bac...

Page 858: ...VERTICAL MOTOR 2 1 S02 B09 BK 12 Z1 G300 2 4 3 1 2 2 1 4 3 M DRIVER SEAT SEAT DRIVER SEAT DRIVER SEAT DRIVER 4 REARWARD 2 DOWN 1 UP 3 FORWARD HEATED SEAT OTHER C2 8 MODULE MIRROR SEAT MEMORY 2 HS5D B09 HS6D S02 3 LINK FUSIBLE 10A A 8W 63 7 DRIVER HEATED SEAT MODULE TO F35 14 RD F35 14 RD F35 14 RD F35 14 RD F35 14 RD 3 B09 S02 POWER SEAT CIRCUIT BREAKER 30A FUSED B 8W 10 13 8W 15 5 8W 15 9 8W 62 3...

Page 859: ...OTOR MOTOR RECLINER REAR VERTICAL MOTOR 2 1 S02 B56 BK 12 Z1 G300 7 4 3 1 2 1 2 3 4 M SEAT PASSENGER SEAT PASSENGER SEAT PASSENGER SEAT PASSENGER 4 REARWARD 2 DOWN 1 UP 3 FORWARD 2 HS5P B56 3 S02 HS6P HEATED SEATS OTHER F35 14 RD LINK FUSIBLE 10A B 8W 63 8 PASSENGER HEATED SEAT MODULE TO F35 14 RD F35 14 RD S02 B56 3 POWER SEAT CIRCUIT BREAKER 30A MODULE MIRROR SEAT MEMORY 8W 10 13 8W 15 5 8W 62 3...

Page 860: ...K RD 6 P23 20 PK RD PK BK 20 P22 4 PK BK 20 P22 MEMORY NO 2 MEMORY NO 1 SET MEMORY C1 21 C1 20 8 C1 SWITCH SET MEMORY 3 2 1 3 4 6 5 RD 14 F35 8 C2 FUSED B BATT A2 2 PK 20 M1 B FUSED C1 16 MEMORY SEAT MIRROR MODULE PK 20 M1 BLOCK JUNCTION C1 13 BATT A0 5 28 FUSE 10A POWER DISTRIBUTION CENTER C3 A23 1 SET 2 MEM 1 3 MEM 2 POWER SEAT CIRCUIT BREAKER 30A FUSED B GROUND 8W 45 6 8W 61 5 8W 15 7 8W 63 5 8...

Page 861: ...R HORIZONTAL FRONT VERTICAL MOTOR REAR VERTICAL MOTOR RD 20 P9 P17 22 RD LB P15 22 YL LB RD WT 22 P13 YL WT 22 P11 P48 22 GY WT P40 22 GY LB RD LG 22 P21 YL LG 22 P19 SEAT RECLINE RWD 4 C3 SEAT RECLINE FWD 15 C3 SEAT FRONT DOWN 1 C3 SEAT FRONT UP 12 C3 C3 13 UP REAR SEAT C3 2 DOWN REAR SEAT SEAT FWD 14 C3 SEAT RWD 3 C3 C3 11 B FUSED 5 POWER SEAT SWITCH 3 6 1 9 8 2 4 10 7 MEMORY MODULE MIRROR SEAT ...

Page 862: ...ORY SEAT HORIZONTAL POSITION SENSOR SENSOR MEMORY SEAT FRONT VERTICAL POSITION POSITION VERTICAL REAR SEAT MEMORY SENSOR A B C C B A A B C C3 17 C3 18 C3 10 C3 7 C3 8 20 C3 A B C SENSE POSITION RECLINER HORIZONTAL POSITION SENSE FRONT SENSE POSITION SEAT VERTICAL 6V SUPPLY MEMORY SEAT MIRROR MODULE VERTICAL SEAT POSITION SENSE REAR SEAT COMMON SENSE POSITION SEAT SEAT 8W 63 6 8W 63 POWER SEATS MEM...

Page 863: ... 18 RD WT Z1 18 BK B09 HS5D 1 Z1 12 BK Z1 18 BK HEATED SEAT BACK DRIVER SEAT HEATED GROUND FUSED IGNITION RUN RUN IGNITION FUSED HS2 4 B09 HS5D F20 20 WT 10A FUSE 12 RUN A22 JUNCTION BLOCK 14 C2 1 S02 HS6D Z1 14 BK MODULE MIRROR SEAT MEMORY Z1 14 BK 7 BK 20 Z1 1 MEMORY POWER SEAT SWITCH HEATED SEAT DRIVER C2 HEATED SEAT TEMPERATURE SENSOR SWITCH SEAT HEATED DRIVER DRIVER HEATED SEAT SWITCH SENSOR ...

Page 864: ...18 BK Z1 18 BK Z1 14 BK P87 18 RD WT P89 20 BK RD P88 18 RD WT Z1 18 BK B56 HS5P 1 Z1 12 BK Z1 18 BK HEATED SEAT BACK DRIVER SEAT HEATED GROUND FUSED IGNITION RUN RUN IGNITION FUSED HS4 4 B56 HS5P F20 20 WT 10A FUSE 12 RUN A22 JUNCTION BLOCK 7 C2 HEATED SEAT DRIVER HEATED SEAT TEMPERATURE SENSOR SWITCH SEAT HEATED PASSENGER PASSENGER HEATED SEAT SWITCH SENSOR TEMPERATURE SEAT HEATED BACK SEAT HEAT...

Page 865: ...07 GAS 8W 12 13 ES08 8W 30 25 ES08 8W 70 8 ES09 DIESEL 8W 42 10 ES09 GAS 8W 20 2 Component Page ES10 8W 70 8 ES11 8W 15 2 ES12 DIESEL 8W 15 3 ES12 GAS 8W 10 23 ES13 8W 30 4 ES13 8W 40 5 ES14 8W 30 4 ES17 2 0L 2 4L 8W 70 9 ES17 3 3L 3 8L 8W 30 22 ES18 8W 15 2 ES21 8W 70 4 5 6 ES23 8W 15 2 ES24 8W 30 3 ES26 8W 20 3 ES28 8W 20 3 ES29 8W 10 25 ES30 8W 15 3 ES31 8W 15 3 ES37 8W 30 32 ES40 8W 10 27 ES99...

Page 866: ...EEL ALL 6 2 TRANSMISSION RANGE SENSOR 3 LEFT REAR LAMP ASSEMBLY ASSEMBLY LAMP REAR RIGHT 3 L1 18 VT BK B33 E36 10 VT BK 18 L1 L1 20 VT BK L1 20 VT BK BS02 B13 AW4 2 L1 20 VT BK L1 20 VT BK 3 EC1 C19 B75 C20 13 EATX MTX SIGNAL SIGNAL COMBINATION RELAY RIGHT L50 18 WT TN L1 18 VT BK 2 C2 2 C1 AWS2 AUTOMATIC DAY NIGHT MIRROR 6 6 WT TN 18 L50 44 DIESEL MODULE CONTROL POWERTRAIN SWITCH BACK UP GAS DIES...

Page 867: ...M20 A MIRROR VANITY VISOR RIGHT LAMPS LAMPS LEFT VISOR VANITY MIRROR A M20 20 BR BR 20 M20 1 B75 C20 B5 5 P18 B23 BR 20 M20 OTHERS CONSOLE OVERHEAD 2 SWITCH LAMPS READING FRONT FRONT READING LAMPS SWITCH 6 C1 BODY CONTROL MODULE 80 LAMP BOX GLOVE 2 HEATER M20 20 BR M20 20 BR 3 CENTER DOME LAMP LAMP DOME REAR 3 M20 20 BR M20 20 BR 8W 42 6 8W 42 6 8W 42 6 8W 44 4 8W 44 4 8W 44 4 8W 44 4 8W 44 3 8W 4...

Page 868: ... K4 18 BK LB ES02 2 0L BK LB 18 K4 BK LB 18 K4 2 0L ES21 SENSOR OXYGEN HEATED DOWNSTREAM UPSTREAM HEATED OXYGEN SENSOR K4 20 BK LB 1 E36 B33 K4 18 BK LB 2 SENSOR KNOCK 1 K4 18 BK LB BK LB 18 K4 43 C2 2 K4 18 BK LB SENSOR PRESSURE ABSOLUTE MANIFOLD TEMPERATURE AIR INTAKE BK LB 18 K4 3 3 8W 30 10 8W 30 8 8W 30 11 8W 30 8 8W 30 8 8W 30 11 8W 30 10 8W 30 7 8W 30 7 8W 30 10 8W 30 10 8W 70 4 8W 70 SPLIC...

Page 869: ... 18 K4 BK LB 18 K4 BK LB 18 K4 BK LB 18 K4 KNOCK SENSOR 2 1 SENSOR TEMPERATURE COOLANT ENGINE MANIFOLD ABSOLUTE PRESSURE SENSOR SENSOR POSITION CAMSHAFT 2 1 THROTTLE POSITION SENSOR SENSOR POSITION CRANKSHAFT 2 EATX 51 TRANSMISSION CONTROL MODULE MODULE CONTROL POWERTRAIN 2 VEHICLE SPEED SENSOR SENSOR TEMPERATURE INTAKE A 1 8W 30 7 8W 30 7 8W 30 16 8W 30 16 8W 30 16 8W 30 16 8W 30 14 8W 30 17 8W 3...

Page 870: ...K4 18 BK LB K4 18 BK LB K4 18 BK LB ES02 A C PRESSURE TRANSDUCER FS02 14 E78 F02 K4 18 BK LB K4 18 BK LB K4 18 BK LB K4 18 BK LB BK LB 18 K4 BK LB 18 K4 BK LB 18 K4 ES21 1 SENSOR OXYGEN HEATED DOWNSTREAM 51 KNOCK SENSOR 3 8L FLEXIBLE FUEL SENSOR 3 3L ETHANOL 2 K4 18 BK LB 2 SENSOR POSITION CAMSHAFT K4 18 BK LB 8W 30 21 8W 30 21 8W 31 4 8W 30 22 8W 30 25 8W 30 24 8W 30 24 8W 30 24 8W 30 21 8W 30 24...

Page 871: ...NSOR THROTTLE POSITION SENSOR TRANSDUCER PRESSURE A C K6 18 VT WT 61 C2 VT WT 18 K6 3 2 0L 2 4L ES03 2 4L FS02 K6 18 VT WT B 2 E69 F09 8 K6 18 VT WT K6 18 VT WT K6 18 VT WT 3 VT WT 18 K6 C 2 0L SENSOR PRESSURE ABSOLUTE MANIFOLD TEMPERATURE AIR INTAKE K6 18 VT WT K6 18 VT WT 2 0L 2 4L 8W 30 24 8W 30 25 8W 30 24 8W 30 24 8W 30 11 8W 30 17 8W 30 11 8W 30 17 8W 30 10 8W 30 16 8W 30 16 8W 30 10 NS GS 8...

Page 872: ... TRANSMISSION 12 2 SENSOR POSITION THROTTLE ES08 K22 18 OR DB OR DB 18 K22 K22 18 OR DB GY BK 18 K24 K24 18 GY BK GY BK 18 K24 ES05 CRANKSHAFT POSITION SENSOR 3 6 TRANSMISSION CONTROL MODULE MODULE CONTROL POWERTRAIN 32 C1 SHAFT 8W 31 3 8W 31 5 8W 31 3 8W 31 5 8W 30 17 8W 30 25 8W 31 4 8W 30 17 8W 30 25 8W 30 14 8W 30 22 8W 31 4 8W 30 14 8W 30 22 8W 70 8 8W 70 SPLICE INFORMATION EATX NS GS J988W 3...

Page 873: ...R 1 K7 18 OR 1 OR 18 K7 OR 18 K7 C2 MODULE CONTROL POWERTRAIN 44 SENSOR POSITION CAMSHAFT ES17 K7 18 OR CRANKSHAFT POSITION SENSOR 1 VEHICLE SPEED SENSOR 1 HEATER 1 3 3L ETHANOL SENSOR FUEL FLEXIBLE K7 18 OR 8W 42 5 8W 42 5 8W 42 5 8W 42 5 8W 42 5 8W 30 8 8W 30 14 8W 30 8 8W 30 14 8W 30 8 8W 30 14 8W 30 11 8W 30 22 NS GS 8W 70 SPLICE INFORMATION 8W 70 9 GS007009 J988W 3 2 0L 2 4L ...

Page 874: ...R DOOR BLEND MODE DOOR ACTUATOR 2 2 4 C57 20 DB GY 2 P30 J01D DB GY 22 C57 C1 9 C1 20 C26 22 PK DB P30 J01D 1 PK DB 20 C26 C26 20 PK DB PK DB 20 C26 PK DB 20 C26 JS02B CONTROL HEATER A C A C ACTUATOR DOOR ZONE A C DUAL ZONE A C DUAL ZONE A C 8W 42 5 8W 42 5 8W 42 5 8W 42 5 8W 42 5 8W 42 5 8W 42 5 8W 42 5 8W 70 10 8W 70 SPLICE INFORMATION NS GS J988W 3 GS007010 ...

Page 875: ...SURE TRANSDUCER 1 DIESEL BS34 6 E97 B106 2 SENSOR SPEED VEHICLE ENGINE COOLANT TEMPERATURE SENSOR 2 K4 20 BK LB TURBO BOOST PRESSURE SENSOR BK LB 18 K4 1 FUEL PUMP MODULE 4 BK LB 20 K4 K4 20 BK LB DIESEL ES05 8W 30 38 8W 30 38 8W 30 38 8W 30 36 8W 30 36 8W 30 34 8W 30 33 NS GS 8W 70 SPLICE INFORMATION DIESEL 8W 70 11 GS007011 J988W 3 ...

Page 876: ......

Page 877: ...gen Sensor 8W 80 22 Driver Door Arm Disarm Switch 8W 80 22 Driver Door Courtesy Lamp 8W 80 22 Driver Door Lock Motor 8W 80 23 Driver Door Lock Switch 8W 80 23 Driver Heated Seat Back 8W 80 23 Driver Heated Seat Cushion 8W 80 23 Driver Heated Seat Module 8W 80 23 Driver Heated Seat Switch 8W 80 24 Driver Power Mirror C1 8W 80 24 Driver Power Mirror C2 8W 80 24 Driver Power Seat Switch 8W 80 25 Driv...

Page 878: ...Headlamp Except Built Up Export 8W 80 50 Left Headlamp Leveling Motor Built Up Export 8W 80 50 Left High Headlamp Chrysler Except Built Up Export 8W 80 50 Left Liftgate Flood Lamp 8W 80 51 Left Low Headlamp Chrysler Except Built Up Export 8W 80 51 Left Mid Reading Lamp 8W 80 51 Left Rear Door Ajar Switch 8W 80 51 Left Rear Lamp Assembly Built Up Export 8W 80 51 Left Rear Lamp Assembly Except Built...

Page 879: ... 8W 80 74 Radiator Fan Relay No 2 Diesel 8W 80 74 Radiator Fan Relay No 3 Diesel 8W 80 74 Radio C1 8W 80 74 Radio C2 8W 80 75 Component Page Radio C3 8W 80 75 Radio Choke 8W 80 75 Rear A C Heater Unit 8W 80 75 Rear Blower Front Control Switch 8W 80 76 Rear Blower Rear Control Switch 8W 80 76 Rear Cigar Lighter Power Outlet 8W 80 76 Rear Dome Lamp 8W 80 77 Rear Washer Motor 8W 80 77 Rear Wiper Moto...

Page 880: ...80 84 Trailer Tow Connector 8W 80 84 Transmission Control Module 8W 80 85 Component Page Transmission Control Solenoids 8W 80 86 Transmission Range Sensor 8W 80 86 Turbine Speed Sensor 8W 80 87 Turbo Boost Pressure Sensor 8W 80 87 Upstream Heated Oxygen Sensor 8W 80 87 Vehicle Speed Control Servo 8W 80 87 Vehicle Speed Sensor 8W 80 88 Wiper Module Built Up Export 8W 80 88 Wiper Module Except Built...

Page 881: ...LG C57 22DB GY C32 22GY DB C35 22DG YL C33 22DB RD D2 20WT BK C62 22DB PK D1 20VT BR C61 20DB C34 22DB WT E2 20OR V23 18BR PK C26 22PK DB C21 22DB OR C66 18BK WT C37 22YL C36 22RD WT C102 22LG C103 20DG LB V26 22YL WT C14 22WT RD 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV GROUND SENSOR GROUND RECIRCULATION DOOR DRIVER MODE DOOR DRIVER BLEND DOOR DRIVER CCD DUAL ZONE A C ACTUATOR CCD...

Page 882: ...UIT PASSENGER AIRBAG LINE NO 1 PASSENGER AIRBAG LINE NO 2 DRIVER AIRBAG LINE NO 1 DRIVER AIRBAG LINE NO 2 CAV 1 2 3 4 R42 18BK YL R44 18DG YL R43 18BK LB R45 18DG LB 1 3 2 4 GRAY 1 4 YELLOW A C PRESSURE TRANSDUCER GAS A C ZONE DOOR ACTUATOR AIRBAG CONTROL MODULE C1 DIESEL TRANSDUCER PRESSURE A C 10 5 6 1 DIESEL SENSOR CIRCUIT FUNCTION CAV 1 2 3 K4 20BK LB SENSOR GROUND 6 K151 20WT LOW IDLE POSITIO...

Page 883: ...AMBIENT TEMPERATURE SENSOR SIGNAL SENSOR GROUND CAV 1 2 G31 20VT LG G32 20BK LB GRAY 2 1 FUNCTION CIRCUIT GROUND BACK UP LAMP FEED CAV 1 2 Z1 18BK L1 18VT BK GRAY 2 1 13 1 6 2 1 GROUND BACK UP LAMP FEED CIRCUIT Z1 18BK L1 18VT BK CAV 2 1 FUNCTION GRAY AIRBAG CONTROL MODULE C2 ALL WHEEL DRIVE SOLENOID C1 3 8L ONLY AMBIENT AIR TEMPERATURE SENSOR 3 8L ONLY SOLENOID C2 DRIVE ALL WHEEL NS GS 8W 80 CONN...

Page 884: ...8OR P112 20YL WT 4 P114 20YL BK 5 6 L24 20WT LG 7 BLACK FUSED IGNITION ST RUN POWER MIRROR B POWER MIRROR B AUTOMATIC HEADLAMP SIGNAL ASH RECEIVER LAMP LHD AUTOMATIC DAY NIGHT MIRROR RHD LAMP RECEIVER ASH EXCEPT BUILT UP EXPORT E2 18OR 2 1 CAV PANEL LAMPS FEED CIRCUIT FUNCTION 3 1 3 Z1 18BK GROUND RED 8W 80 8 8W 80 CONNECTOR PIN OUTS NS GS J988W 3 NSGS8008 ...

Page 885: ... 11 12 L50 20WT TN M11 20PK LB G78 18TN BK L77 20BR LB P98 20WT RD V13 18BR LG V23 18BR PK F133 20BR RD F136 20VT WT Z1 12BK C15 12BK WT BLACK 7 14 1 8 BLACK 7 14 1 8 B17 LJ01 CIRCUIT CAV 1 2 3 4 Z1 14BK L1 20VT BK G4 18DB A141 16DG WT CIRCUIT CAV 1 2 3 4 Z1 16BK L1 20VT BK G4 18DB A141 16DG WT LT GRAY 1 4 LT GRAY 1 4 B13 AW4 HS5D B09 3 4 2 1 BLACK 4 2 3 1 BLACK F20 20WT F35 14RD Z1 14BK Z1 14BK 4...

Page 886: ... 20VT RD A1 12RD M20 20BR P70 20WT P70 20WT P71 20YL P71 20YL P72 20YL BK P72 20YL BK P73 20YL PK P73 20YL PK P74 20DB P74 20DB D1 20VT BR D2 20WT BK D6 20PK LB P75 20DB WT P75 20DB WT D20 20LG D21 20PK L34 20RD OR Z39 18BK L94 20OR WT L324 22WT LG M13 20BK YL F14 18LG YL F23 18DB YL C104 12RD WT C107 12TN BK C4 16TN C6 14LB C5 16LG C71 12DB C103 20DG LB 7 8 9 10 11 15 GRAY 1 8 15 19 23 30 7 14 18...

Page 887: ... YL X52 20DB WT X15 16BK DG X53 20DG X54 20VT X55 20BR RD X56 20DB RD V37 20RD LG F30 16RD Z11 20BK WT P66 20WT BK P65 20DB YL P64 20YL OR P69 20WT RD P68 20DG RD P67 20YL RD C50 12BK LG C60 16BK LB C60 16BK LB C34 20DB WT C70 12DG C61 20DB A12 GRAY 1 8 15 19 23 30 7 14 18 22 29 36 A7 A36 A1 A30 BLACK B1 B36 B7 B30 A22 A23 F30 16RD P34 B23 L13 20BR YL L13 18BR YL L13 20BR YL K29 20WT PK K29 20WT P...

Page 888: ...RD K21 18BK RD A141 18DG WT G58 20BK YL G18 20BK PK G6 16GY 10 9 8 7 6 4 3 2 1 CAV CIRCUIT CAV 2 3 4 5 1 CIRCUIT G6 20GY G18 20PK BK G58 20BK YL A141 16DG WT F20 20WT 7 6 8 10 9 K21 20BK RD K1 20DG RD K9 20LB K3 20BK VT L1 20VT BK BLACK 1 6 5 10 S02 B56 CIRCUIT CAV 1 2 3 4 Z1 12BK A2 12PK BK F20 20WT CIRCUIT CAV 1 2 3 4 Z1 14BK A2 12PK BK BLACK 1 3 2 4 BLACK 1 2 4 3 F35 14RD Z1 20BK F35 14RD F20 2...

Page 889: ...VT YL E2 18OR L24 20WT LG P112 20YL WT P114 20YL BK 12 14 15 16 17 13 19 20 18 12 14 15 16 17 13 19 20 18 Z1 20BK L1 20VT BK G74 18TN RD F133 20BR YL F136 20VT YL E2 20OR P114 20YL BK P112 20YL WT L24 20WT LG 7 9 10 11 8 G32 20BK LB 7 9 10 11 8 G32 20BK LB Z2 18BK LG G31 20VT LG V23 18BR PK 1 11 10 20 11 10 20 1 D1 18VT BR D2 18WT BK M113 20LB PK M13 20BK YL F41 20PK VT M20 20BR 6 5 4 3 2 1 CAV CI...

Page 890: ...D L62 18BR RD 5 3 2 CAV CIRCUIT 6 4 1 L50 18WT TN L1 20VT BK 5 3 2 CAV CIRCUIT B99 TRAILER TOW TRAILER TOW B98 T08 T05 DOOR ACTUATOR BLEND 2 1 BACK UP SWITCH BACK UP LAMP FEED L1 18VT BK 2 F20 20WT FUSED IGNITION SWITCH OUTPUT FUSED IGNITION SWITCH OUTPUT F20 18WT 1 1 CAV FUNCTION CIRCUIT DIESEL FUNCTION CIRCUIT BLEND AIR DOOR DRIVER 5 VOLT SUPPLY BLEND DOOR FEEDBACK SIGNAL SENSOR GROUND BLEND AIR...

Page 891: ...ASHER MOTOR CONTROL REAR WIPER MOTOR CONTROL PASSENGER DOOR AJAR SWITCH SENSE LEFT REAR DOOR AJAR SWITCH SENSE FUEL LEVEL SENSOR SIGNAL DRIVER DOOR SWITCH MUX LIFTGATE LOCK UNLOCK MUX HOOD AJAR SWITCH SENSE WIPER PARK SWITCH SENSE CIRCUIT FUNCTION G7 18WT OR V38 20LB RD G18 20PK BK G58 20BK YL ENGINE COOLANT TEMPERATURE SENSOR SIGNAL G55 20OR BK ENGINE DISABLE SIGNAL POWER MIRROR FOLD RELAY P171 2...

Page 892: ...24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV PARK LAMP SWITCH SENSE REAR WIPER SWITCH MUX RKE MODULE PROGRAM ENABLE CCD BUS ENGINE OIL PRESSURE SWITCH SENSE ABS WARNING LAMP DRIVER VTSS LAMP DRIVER GROUND HEADLAMP SWITCH SENSE STEP DIMMER SWITCH SENSE GROUND GROUND DIMMER SWITCH SIGNAL FRONT WIPER SWITCH MUX ENGINE TEMPERATURE WARNING LAMP DRIVER KEY IN IGNITION SWITCH SENSE ...

Page 893: ...UNCTION CENTER DOME LAMP GROUND CENTER DOME LAMP FEED CIRCUIT CAV 1 2 M113 20LB PK M20 20BR 3 3 1 3 1 RED 3 1 BLACK L50 20WT TN Z1 20BK 3 2 1 CAV STOP LAMP SWITCH OUTPUT GROUND FUNCTION CIRCUIT K44 18TN YL K4 18BK LB K7 18OR 3 2 1 CAV CAMSHAFT POSITION SENSOR SIGNAL SENSOR GROUND 8 VOLT SUPPLY CIRCUIT FUNCTION CENTER DOME LAMP CENTER HIGH MOUNTED STOP LAMP SENSOR POSITION CAMSHAFT NS GS 8W 80 CONN...

Page 894: ... RD 4 3 2 1 CAV SPEED CONTROL SWITCH SIGNAL GROUND HORN RELAY DRIVER CIRCUIT FUNCTION 1 2 YELLOW R45 18DG LB R43 18BK LB 2 1 CAV DRIVER AIRBAG LINE NO 2 DRIVER AIRBAG LINE NO 1 CIRCUIT FUNCTION CLOCKSPRING C2 CLOCKSPRING C1 2 1 BLACK CIRCUIT FUNCTION CAV 1 2 T141 20YL RD IGNITION SWITCH OUTPUT START CLUTCH INTERLOCK SWITCH MTX CLUTCH INTERLOCK SWITCH JUMPER EATX T141 20YL RD IGNITION SWITCH OUTPUT...

Page 895: ...D B GROUND FUSED IGNITION RUN TRACTION CONTROL SWITCH SENSE CCD BUS CCD BUS RIGHT FRONT WHEEL SPEED SENSOR RIGHT REAR WHEEL SPEED SENSOR ABS WARNING LAMP DRIVER STOP LAMP SWITCH SENSE LEFT FRONT WHEEL SPEED SENSOR LEFT REAR WHEEL SPEED SENSOR FUSED B GROUND LEFT FRONT WHEEL SPEED SENSOR RIGHT FRONT WHEEL SPEED SENSOR LEFT REAR WHEEL SPEED SENSOR RIGHT REAR WHEEL SPEED SENSOR FUNCTION CIRCUIT 1 2 C...

Page 896: ...CUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Q13 18DB Q14 18GY Z2 20BK LG E2 20OR F131 20BK PK Q26 14VT RD F55 14TN DG Q23 18RD WT Q16 14BR WT Z1 12BK P97 20WT DG F133 20BR Q24 18DG F21 16TN BLACK 7 14 1 8 8 9 9 10 10 9 9 8 5 5 6 7 8 10 8 1 14 7 BLACK X13 16RD DG Q16 12BR WT F55 12TN DG E2 20OR F133 20BR F136 20VT YL X54 20VT X56 20DB RD M11 20PK LB Z1 18BK P96 20WT LG Z2 20BK LG Q26 12VT RD X15 16BK...

Page 897: ...2 1 CAV CIRCUIT 6 1 10 5 BLACK X156 20VT WT X154 20WT VT 10 9 8 7 6 5 4 3 2 1 CAV CIRCUIT D02 B120 LHD RHD B120 D02 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 X153 20WT BR X155 20BR WT BLACK 5 10 1 6 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 BLACK 5 10 1 6 NS GS 8W 80 CONNECTOR PIN OUTS 8W 80 21 NSGS8021 J988W 3 ...

Page 898: ...UND AUTOMATIC SHUT DOWN RELAY OUTPUT SENSOR GROUND HEATED OXYGEN SENSOR 1 2 SIGNAL CAV 1 2 3 4 Z12 20BK TN A142 18DG OR K4 20BK LB K141 20TN WT 1 2 3 4 BLACK OXYGEN SENSOR DOWNSTREAM HEATED COURTESY LAMP DRIVER DOOR SWITCH ARM DISARM DRIVER DOOR 2 1 BLACK 2 1 BLACK Z1 20BK M11 20PK LB 2 1 CAV GROUND COURTESY LAMP RELAY OUTPUT FUNCTION CIRCUIT P97 20WT DG Z2 20BK LG 2 1 CAV DRIVER DOOR SWITCH MUX G...

Page 899: ...EAT DRIVER GROUND CAV A B P88 18RD WT Z1 18BK SEAT BACK DRIVER HEATED FUNCTION CIRCUIT HEATED SEAT DRIVER HEATED SEAT DRIVER CAV P87 18RD WT P88 18RD WT P89 20BK RD Z1 18BK A B C DRIVER HEATED SEAT CUSHION D HEATED SEAT BACK GROUND FUSED B DRIVER HEATED SEAT SWITCH D SEAT MODULE DRIVER HEATED C B A F35 18RD P7 20WT BK P86 20VT P87 18RD WT CAV HEATED SEAT TEMPERATURE SENSOR DRIVER HEATED SEAT SWITC...

Page 900: ...OWN CIRCUIT FUNCTION Z1 20BK C16 20LB YL P73 20YL PK P71 20YL P75 20DB WT 6 5 4 3 2 1 CAV GROUND REAR DEFOGGER LAMP DRIVER DRIVER POWER MIRROR RIGHT DOWN DRIVER POWER MIRROR LEFT DRIVER POWER MIRROR UP CIRCUIT FUNCTION EXCEPT BUILT UP EXPORT POWER MIRROR B P112 20YL WT FUSED IGNITION RUN D SEAT SWITCH DRIVER HEATED C B A F20 20WT F20 20WT P86 20VT CAV FUSED IGNITION RUN HEATED SEAT TEMPERATURE SEN...

Page 901: ... DOWN CAV 1 2 3 4 5 6 7 8 9 10 Z1 14BK P43 14GY LB P17 14RD LB P41 14GY WT F35 14RD P15 14YL LB P19 14YL LG P11 14YL WT P13 14RD WT P21 14RD LG GREEN 1 5 6 10 HORIZONTAL MOTOR DRIVER SEAT FUNCTION CIRCUIT DRIVER POWER SEAT HORIZONTAL FORWARD DRIVER POWER SEAT HORIZONTAL REARWARD CAV A B P15 14YL LB P17 14RD LB B A BLACK MOTOR FRONT VERTICAL DRIVER SEAT FUNCTION CIRCUIT DRIVER POWER SEAT FRONT DOWN...

Page 902: ...1 16WT Q11 16LG 2 1 CAV DRIVER WINDOW DOWN DRIVER WINDOW UP CIRCUIT FUNCTION E40 RF3 CIRCUIT CAV 1 2 C23 12DG Z1 12BK CIRCUIT CAV 1 2 C23 12DG Z1 12BK 1 2 BLACK 1 2 BLACK RECLINER MOTOR DRIVER SEAT A B BLACK DRIVER SEAT RECLINER SWITCH UP DRIVER SEAT RECLINER SWITCH DOWN P41 14GY WT P43 14GY LB CIRCUIT CAV A B FUNCTION 8W 80 26 8W 80 CONNECTOR PIN OUTS NS GS J988W 3 NSGS8026 ...

Page 903: ... 7 1 8 14 BLACK K2 18TN BK K1 18DG RD A142 18DG OR C18 18DB K6 18VT WT K52 18PK BK K70 18VT RD K4 18BK LB K14 18LB BR K13 18YL WT K12 18TN WT K11 18WT DB 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV CIRCUIT K2 18TN BK K1 18DG RD A142 18DG OR C18 18DB K6 18VT WT K52 18PK BK K70 18VT RD K4 18BK LB K14 18LB BR K13 18YL WT K12 18TN WT K11 18WT DB 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV CIRCUIT BLACK 1 3 4 6 1 4 ...

Page 904: ... CAV 1 2 3 4 6 5 B106 DIESEL E97 DIESEL 10 9 8 7 C13 20DB OR K2 20TN BK Z122 18BK 7 8 9 10 5 6 K68 18LG YL 4 K67 18BR BK Z122 18BK 3 2 1 K126 18LG CAV CIRCUIT K24 20GY BK K4 20BK LB BLACK 1 6 5 10 5 10 1 6 6 1 10 5 LT GRAY K135 18WT BK K134 18LB BK CIRCUIT CAV A142 18DG OR 1 2 3 K35 20GY YL K51 20DB YL 4 G7 18WT OR 6 5 10 9 8 7 A142 18DG OR K140 18TN WT K156 18GY K156 20GY K140 18TN WT A142 18DG O...

Page 905: ...NE COOLANT TEMPERATURE SENSOR SIGNAL ENGINE COOLANT TEMPERATURE SENSOR SIGNAL G58 20BK YL 3 ENGINE COOLANT TEMPERATURE SENSOR DIESEL 1 2 3 BLACK GAS TEMPERATURE SENSOR ENGINE COOLANT 1 2 BLACK K2 18TN BK K4 18BK LB 2 1 CAV ENGINE COOLANT TEMPERATURE SENSOR SIGNAL SENSOR GROUND CIRCUIT FUNCTION PRESSURE SWITCH ENGINE OIL BLACK 2 0L 1 GREEN 2 G6 16GY 2 1 CAV ENGINE OIL PRESSURE SWITCH SENSE CIRCUIT ...

Page 906: ...RAY 1 4 4 K50 18YL WT 3 FUNCTION 1 CAV K7 18OR CIRCUIT 2 K4 18BK LB EXCEPT BUILT UP EXPORT DETECTION PUMP EVAP LEAK LEAK DETECTION PUMP SWITCH SENSE K107 18YL BK 4 F87 18WT BK K106 18WT DG K107 18DB WT 4 3 2 1 CAV FUSED IGNITION SWITCH OUTPUT LEAK DETECTION PUMP SOLENOID CONTROL LEAK DETECTION PUMP SWITCH SENSE FUNCTION CIRCUIT GRAY LIGHT 1 1 3 ENGINE SPEED SENSOR DIESEL ENGINE SPEED SENSOR SIGNAL...

Page 907: ...1 C4 16TN C107 12TN BK C104 12RD WT C6 14LB C5 16LG 10 9 8 7 6 5 4 3 2 1 CAV LOW SPEED BLOWER MOTOR HIGH SPEED BLOWER MOTOR M3 SPEED BLOWER MOTOR M2 SPEED BLOWER MOTOR M1 SPEED BLOWER MOTOR CIRCUIT FUNCTION MOTOR FRONT BLOWER 1 2 BLACK C7 12BK TN C71 12DB 2 1 CAV HIGH SPEED BLOWER MOTOR BLOWER MOTOR DRIVER CIRCUIT FUNCTION RED BLUE 3 NS GS 8W 80 CONNECTOR PIN OUTS 8W 80 31 NSGS8031 J988W 3 ...

Page 908: ...CUIT CIRCUIT FUNCTION FRONT READING LAMP FEED COURTESY LAMP GROUND FUSED B CAV 1 2 3 M13 20BK YL M20 20BR F41 20PK VT BLACK 3 1 FRONT READING LAMPS SWITCH FRONT READING LAMPS SWITCH OVERHEAD CONSOLE BLUE PANEL LAMPS FEED FRONT READING LAMP FEED GROUND FUSED B Z2 18BK LG F41 20PK VT 5 4 3 CIRCUIT M13 20BK YL E2 18OR CAV 2 1 FUNCTION COURTESY LAMP GROUND M20 20BR 6 1 3 6 4 8W 80 32 8W 80 CONNECTOR P...

Page 909: ...ION INJECTOR NO 2 DRIVER CIRCUIT FUNCTION CAV K12 18TN WT 1 2 A142 18DG OR AUTO SHUTDOWN RELAY OUTPUT 2 0L 2 4L NO 2 FUEL INJECTOR 1 2 BLACK 3 3L 3 8L NO 2 FUEL INJECTOR 1 2 BLACK K12 18TN WT A142 18DG OR 2 1 CAV INJECTOR NO 2 DRIVER AUTOMATIC SHUTDOWN RELAY OUTPUT CIRCUIT FUNCTION INJECTOR NO 3 DRIVER CIRCUIT FUNCTION CAV K13 18YL WT 1 2 A142 18DG OR AUTO SHUTDOWN RELAY OUTPUT 2 0L 2 4L NO 3 FUEL...

Page 910: ...CTION 3 3L 3 8L NO 5 FUEL INJECTOR 1 BLACK 2 K38 18GY A142 18DG OR 2 1 CAV INJECTOR NO 5 DRIVER AUTOMATIC SHUTDOWN RELAY OUTPUT CIRCUIT FUNCTION 3 3L 3 8L NO 4 FUEL INJECTOR 1 BLACK 2 K14 18LB BR A142 18DG OR 2 1 CAV INJECTOR NO 4 DRIVER AUTOMATIC SHUTDOWN RELAY OUTPUT CIRCUIT FUNCTION INJECTOR NO 4 DRIVER CIRCUIT FUNCTION CAV K14 18LB BR 1 2 A142 18DG OR AUTO SHUTDOWN RELAY OUTPUT 2 0L 2 4L NO 4 ...

Page 911: ...UEL PUMP RELAY OUTPUT FUEL LEVEL SENSOR SIGNAL GROUND FUNCTION CIRCUIT SHUT OFF FEED K153 18OR DG SLEEVE POSITION SENSOR CIRCUIT FUNCTION CAV K134 18LB BK 1 2 K57 18LG OR 3 K135 18WT BK SLEEVE POSTION SENSOR 6 K126 18LG SOLENOID CONTROL SENSOR GROUND K4 20BK LB 5 4 FUEL TEMPERATURE SENSOR SIGNAL K156 18GY 7 8 K140 18TN WT 9 A142 18DG OR A142 18DG OR 10 CONTROL SLEEVE POSTION SENSOR FUEL QUANTITY A...

Page 912: ... 14 13 12 10 8 7 5 4 3 2 1 CAV CIRCUIT Z1 18BK 11 9 6 Z1 20BK Z1 14BK Z1 18BK Z1 20BK Z1 20BK Z1 14BK Z1 12BK Z1 18BK Z1 20BK Z1 12BK Z1 12BK Z1 20BK 14 13 12 10 8 5 4 3 2 1 CAV CIRCUIT Z12 20BK TN EXCEPT BUILT UP EXPORT BUILT UP EXPORT 8W 80 36 8W 80 CONNECTOR PIN OUTS NS GS J988W 3 NSGS8036 ...

Page 913: ...BK LG Z1 18BK Z1 20BK Z1 18BK Z1 20BK 1 3 GAS G301 BLACK 8 1 14 7 BLACK 8 1 14 7 Z1 BUS BAR 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV CIRCUIT Z1 20BK Z1 18BK Z1 18BK Z1 20BK Z1 20BK Z2 18BK LG Z2 20BK LG Z2 20BK LG Z1 18BK 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV CIRCUIT Z1 20BK Z1 18BK Z1 18BK BUILT UP EXPORT EXCEPT BUILT UP EXPORT PLYMOUTH DODGE EXCEPT BUILT UP EXPORT CHRYSLER Z1 20BK 7 Z1 20BK 7 NS GS 8...

Page 914: ...CIRCUIT REAR A C HEATER BLACK 8 1 14 7 BLACK 8 1 14 7 Z1 BUS BAR 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV CIRCUIT Z1 18BK Z1 18BK Z1 16BK Z1 12BK Z1 20BK Z1 18BK Z1 14BK Z1 20BK 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV CIRCUIT G302 G400 GENERATOR 2 3 1 BLACK K20 18DG A142 18DG OR 3 2 1 CAV GENERATOR FIELD DRIVER ASD RELAY OUTPUT FUNCTION CIRCUIT GAS 8W 80 38 8W 80 CONNECTOR PIN OUTS NS GS J988W 3 NSGS8038...

Page 915: ...111 22BR WT Z1 20BK E17 20YL BK E17 20YL BK M32 22BK LB M112 22BR LG 13 12 11 10 9 8 7 6 4 3 2 1 CAV DIMMER SWITCH SIGNAL READING LAMP FEED COURTESY LAMP RELAY OUTPUT COURTESY LAMP RELAY CONTROL GROUND STEP DIMMER SWITCH SENSE STEP DIMMER SWITCH SENSE COURTESY LAMP SWITCH SENSE COURTESY LAMP RELAY CONTROL FUNCTION CIRCUIT 3 4 2 1 BLACK 4 2 3 1 BLACK A2 12PK BK Z1 14BK 4 3 2 1 CAV CIRCUIT A2 12PK B...

Page 916: ...LAMP SWITCH SENSE GROUND PANEL LAMPS FEED FUNCTION CIRCUIT A B WASHER RELAY OUTPUT V53 18RD YL B A Z1 18BK CAV FUNCTION CIRCUIT GROUND BUILT UP EXPORT WASHER HEADLAMP HIGH NOTE HORN B BLACK A Z1 18BK X2 18DG RD B A CAV GROUND HORN RELAY OUTPUT CIRCUIT FUNCTION 5 L39 18LB FOG LAMP SWITCH OUTPUT 7 L110 22BK YL SENSOR SIGNAL EXCEPT BUILT UP EXPORT 8W 80 40 8W 80 CONNECTOR PIN OUTS NS GS J988W 3 NSGS8...

Page 917: ...R IDLE AIR CONTROL MOTOR NO 1 DRIVER CAV 1 2 3 4 K59 18VT BK K40 18BR WT K60 18YL BK K39 18GY RD BLACK 4 1 IDLE AIR CONTROL MOTOR 2 0L 2 4L IGNITION COIL PACK 3 1 BLACK K19 18GY RD A142 18DG OR K17 18DB TN 3 2 1 CAV IGNITION COIL NO 1 DRIVER ASD RELAY OUTPUT IGNITION COIL NO 2 DRIVER CIRCUIT FUNCTION 3 3L 3 8L IGNITION COIL PACK BLACK 3 4 2 1 K17 18DB TN A142 18DG OR K19 18GY RD K18 18RD YL 4 3 2 ...

Page 918: ...CTION IGNITION SWITCH C2 2 1 GREEN Z1 20BK G26 20LB 2 1 CAV GROUND KEY IN IGNITION SWITCH SENSE CIRCUIT FUNCTION IGNITION SWITCH C3 1 2 BLACK A81 20DG RD M1 20PK 2 1 CAV IGNITION SWITCH OUTPUT OFF RUN START FUSED B CIRCUIT FUNCTION INSTRUMENT CLUSTER RED 7 1 13 6 11 Z1 20BK F11 20RD WT D1 20VT BR D2 20WT BK Z2 20BK LG E2 20OR M1 20PK 13 12 10 9 8 7 6 5 4 3 2 1 CAV GROUND FUSED IGNITION ST RUN OFF ...

Page 919: ...TURE SIGNAL SENSOR GROUND CIRCUIT FUNCTION 6 1 L16 J03A 6 1 BLACK P98 20WT RD G78 18TN BK V23 18BR PK V13 18BR LG C15 12BK WT 6 5 4 3 2 1 CAV CIRCUIT P98 20WT RD G78 18TN BK V23 18BR PK V13 18BR LG C15 12BK WT 6 5 4 3 2 1 CAV CIRCUIT L15 J02A 1 6 6 1 BLACK L77 20BR LB F136 20VT WT F133 20BR RD M11 20PK LB L50 20WT TN Z1 12BK 6 5 4 3 2 1 CAV CIRCUIT L77 20BR LB F136 20VT WT F133 20BR RD M11 20PK LB...

Page 920: ...PK BK REAR DEFOGGER RELAY OUTPUT FUSED B E2 20OR L7 12BK YL F11 20RD WT X1 16DG RD PANEL LAMPS FEED PARK LAMP RELAY OUTPUT FUSED IGNITION SWITCH OUTPUT ST RUN OFF NAME BRAND SPEAKER RELAY OUTPUT F131 20BK PK M1 20PK M1 20PK F136 20VT WT F136 20VT WT F136 20VT YL F136 20VT YL DRIVER UNLOCK RELAY OUTPUT FUSED B FUSED B UNLOCK RELAY OUTPUT UNLOCK RELAY OUTPUT UNLOCK RELAY OUTPUT UNLOCK RELAY OUTPUT 3...

Page 921: ...PK LB L63 18DG RD F21 16TN L97 18PK DB V10 20BR C40 12BR WT F45 20YL RD F55 12TN DG F1 20DB F41 20PK VT F41 20PK VT F20 20WT F1 20DB M11 20PK LB X4 20GY OR G9 20GY BK 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV RIGHT TURN SIGNAL IGNITION SWITCH OUTPUT RUN FUSED IGNITION SWITCH OUTPUT PARK LAMP RELAY CONTROL WASHER PUMP CONTROL SWITCH OUTPUT 5...

Page 922: ... OUTPUT RED BRAKE WARNING LAMP DRIVER RED BRAKE WARNING LAMP DRIVER FUSED B FUSED B L93 22PK L91 22DB PK M113 20LB PK A31 12BK WT M111 22BR WT HIGH BEAM RELAY CONTROL READING LAMP FEED IGNITION SWITCH OUTPUT RUN ACC SWITCHED COURTESY LAMP RELAY CONTROL 36 23 22 15 14 1 30 29 19 18 8 7 GRAY F1 20DB A22 12BK OR 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 ...

Page 923: ...1 30 32 27 34 36 33 36 29 22 18 14 7 30 23 19 15 8 1 GRAY Z1 18BK Z1 20BK A21 12DB C14 22WT RD C16 20LB YL C16 20LB YL Z1 20BK Z1 20BK Z1 20BK E2 20OR M1 20PK M1 20PK M1 20PK E2 20OR E2 20OR F11 20RD WT E2 20OR E2 20OR A2 12PK BK A81 20DG RD V23 18BR PK V23 18BR PK GROUND GROUND IGNITION SWITCH OUTPUT ST RUN REAR DEFOGGER RELAY CONTROL REAR DEFOGGER LAMP DRIVER REAR DEFOGGER LAMP DRIVER GROUND GRO...

Page 924: ...COMBINATION 4 2 3 5 1 BLACK GROUND 3 2 L615 18OR L50 18WT TN L50 18WT TN Z1 18BK Z1 18BK L63 18DG RD 5 4 1 CAV LEFT COMBINATION RELAY OUTPUT STOP LAMP SWITCH OUTPUT STOP LAMP SWITCH OUTPUT LEFT TURN SIGNAL CIRCUIT FUNCTION 2 0L 2 4L 3 8L KNOCK SENSOR 2 1 GRAY K4 18BK LB K42 18DB LG 2 1 CAV SENSOR GROUND KNOCK SENSOR SIGNAL CIRCUIT FUNCTION SWITCH KEY IN 1 2 GREEN Z1 20BK G26 20LB 2 1 CAV GROUND KE...

Page 925: ...T INBOARD TAIL LAMP BUILT UP EXPORT TURN SIGNAL LAMP LEFT FRONT PARK 1 4 BLACK FUNCTION CIRCUIT LEFT FRONT SPEAKER CAV 1 2 X55 20BR RD LEFT FRONT SPEAKER X53 20DG 4 3 EXCEPT BUILT UP EXPORT FOG LAMP LEFT GRAY 1 PURPLE 2 2 1 CAV CIRCUIT FUNCTION BLACK 2 1 CAV FUNCTION CIRCUIT LEFT FOG LAMP BUILT UP EXPORT 1 2 Z39 20BK FOG LAMP SWITCHED GROUND L39 18LB FOG LAMP RELAY OUTPUT L39 18VT RD FOG LAMP RELA...

Page 926: ...ED RIGHT LOW BEAM OUTPUT 3 LEFT HEADLAMP BUILT UP EXPORT FUSED LEFT HIGH BEAM OUTPUT CIRCUIT FUNCTION CAV L33 20RD 1 2 L43 18VT FUSED LEFT LOW BEAM OUTPUT 2 1 BLACK 3 Z1 20BK GROUND SPEED SENSOR LEFT FRONT WHEEL B9 18RD B8 18RD DB 2 1 CAV LEFT FRONT WHEEL SPEED SENSOR LEFT FRONT WHEEL SPEED SENSOR CIRCUIT FUNCTION EXCEPT BUILT UP EXPORT HEADLAMP CHRYSLER LEFT HIGH FUNCTION B A CAV Z1 20BK L33 20RD...

Page 927: ...AMP BACK UP SWITCH OUTPUT LEFT TURN SIGNAL CIRCUIT FUNCTION FUNCTION CIRCUIT LEFT TURN SIGNAL BACK UP SWITCH OUTPUT FUSED LEFT INBOARD TAIL LAMP STOP LAMP SWITCH OUTPUT GROUND CAV 1 2 3 4 5 6 L63 18DG RD L1 20VT BK L77 20BR LB L50 18WT TN Z1 20BK BLACK 4 1 6 3 LEFT REAR LAMP ASSEMBLY BUILT UP EXPORT L36 20LG REAR FOG LAMP SWITCH OUTPUT SWITCH DOOR AJAR LEFT REAR 2 1 NATURAL G77 18TN OR Z1 18BK 3 2...

Page 928: ...51 20BR YL X15 16BK DG X151 20BR YL 4 1 CAV LEFT REAR SPEAKER RADIO CHOKE OUTPUT LEFT REAR SPEAKER LEFT REAR SPEAKER AMPLIFIER SPEAKER GROUND LEFT REAR SPEAKER CIRCUIT FUNCTION CONTACTS SLIDING DOOR LEFT REAR 3 1 BLACK F136 20VT WT F133 20BR YL 3 2 1 CAV FUSED DOOR UNLOCK RELAY OUTPUT FUSED DOOR LOCK RELAY OUTPUT CIRCUIT FUNCTION READING LAMP LEFT REAR 3 1 GRAY F41 20PK VT M20 20BR M113 20LB PK 3 ...

Page 929: ... TURN SIGNAL GROUND STOP LAMP SWITCH OUTPUT CIRCUIT FUNCTION GRAY GROUND Z1 18BK 2 1 L63 18DG RD CAV FUNCTION CIRCUIT LEFT REPEATER LAMP SIGNAL 1 2 SENSOR WHEEL SPEED LEFT REAR GRAY 2 1 B4 18LG B3 18LG DB 2 1 CAV LEFT REAR WHEEL SPEED SENSOR LEFT REAR WHEEL SPEED SENSOR FUNCTION CIRCUIT LEFT REAR VENT MOTOR OPEN Q24 18DG 3 3 1 NATURAL LEFT REAR VENT MOTOR RHD LEFT REAR VENT MOTOR CLOSE Q14 18GY 2 ...

Page 930: ...TOR LIFTGATE 1 3 BLACK F136 20VT WT F133 20BR RD 3 2 1 CAV LOCK RELAY OUTPUT UNLOCK RELAY OUTPUT CIRCUIT FUNCTION DISARM SWITCH LIFTGATE ARM 2 1 GRAY P98 20WT RD Z2 20BK LG 2 1 CAV LIFTGATE LOCK UNLOCK MUX GROUND CIRCUIT FUNCTION AJAR SWITCH LIFTGATE 3 1 BLACK G78 18TN BK Z1 20BK 3 2 1 CAV LIFTGATE AJAR SWITCH SENSE GROUND CIRCUIT FUNCTION COOLANT LEVEL SWITCH SENSE CIRCUIT FUNCTION CAV G18 20BK P...

Page 931: ...ER REARWARD SEAT HORIZONTAL REARWARD SEAT BACK UP RECLINER SWITCH TO MEMORY MODULE GROUND CIRCUIT FUNCTION MEMORY POWER SEAT SWITCH HORIZONTAL MOTOR MEMORY SEAT A B BLACK P117 14RD LB P115 14YL LB B A CAV SEAT HORIZONTAL REARWARD SEAT HORIZONTAL FORWARD CIRCUIT FUNCTION POSITION SENSOR FRONT VERTICAL MEMORY SEAT A C BLACK P28 20BR RD P26 22BR P29 20BR WT C B A CAV SEAT POSITION SENSE COMMON SEAT F...

Page 932: ...MEMORY SEAT C A BLACK P29 20BR WT P27 22LB RD P28 20BR RD C B A CAV 5 VOLT SUPPLY SEAT REAR VERTICAL POSITION SENSE SEAT POSITION SENSE COMMON CIRCUIT FUNCTION VERTICAL MOTOR MEMORY SEAT REAR B A BLACK P113 14RD WT P111 14YL WT B A CAV SEAT REAR VERTICAL DOWN SEAT REAR VERTICAL UP CIRCUIT FUNCTION HORIZONTAL POSITION SENSOR MEMORY SEAT A C BLACK P29 20BR WT P25 22VT RD P28 20BR RD C B A CAV 5 VOLT...

Page 933: ... 20WT P24 20PK WT P23 20PK RD G96 20LG RD M1 20PK P68 20DG RD P67 20YL RD P66 20WT BK P75 20DB WT P71 20YL P73 20YL PK P22 20PK BK P65 20DB YL P64 20YL OR P69 20WT RD 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV RIGHT MIRROR HORIZONTAL RIGHT MIRROR VERTICAL RIGHT MIRROR COMMON MEMORY NO 2 MEMORY NO 1 RKE INTERFACE FUSED B RIGHT MIRROR POSITION HORIZONTAL RIGHT MIRROR POSIT...

Page 934: ...3 P23 20PK RD P22 20PK BK P24 20PK WT Z1 20BK 6 5 4 3 2 1 CAV MEMORY NO 2 MEMORY SET MEMORY NO 1 GROUND CIRCUIT FUNCTION MODULE C3 MEMORY SEAT MIRROR 21 10 11 NATURAL 1 P29 20BR WT P25 22VT RD P47 22LB P40 22GY LB P15 22YL LB P11 22YL WT P19 22YL LG P9 20RD P28 20BR RD P26 22BR P27 22LB RD P48 22GY WT P17 22RD LB P13 22RD WT P21 22RD LG 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV 6 V...

Page 935: ...0DB WT 5 4 3 2 1 CAV MODE DOOR DRIVER SENSOR GROUND MODE DOOR FEEDBACK SIGNAL 5 VOLT SUPPLY DOOR COMMON CIRCUIT FUNCTION FUSED RIGHT HIGH BEAM OUTPUT L34 20RD OR 7 13 1 6 ENGINE TEMPERATURE WARNING LAMP DRIVER CIRCUIT FUNCTION CAV G2 22VT 1 2 G19 20LG OR 3 L63 18DG RD LEFT TURN SIGNAL 6 L62 18BR RD RIGHT TURN SIGNALS GROUND Z1 20BK 5 4 G69 22BK OR 7 8 M1 20PK 9 R41 18BK OR V23 18BR PK 10 13 G3 20B...

Page 936: ...C102 22LG C62 22DB PK C61 22DB C37 22YL C36 22RD WT C35 22DG YL C34 22DB WT C33 22DB RD C32 22GY DB C57 22DB GY C26 22PK DB 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV CIRCUIT CONSOLE OVERHEAD RED 5 6 4 1 2 3 D1 18VT BR G31 20VT LG V23 18BR PK Z2 18BK LG G32 20BK LB D2 18WT BK 6 5 4 3 2 1 CAV CCD BUS AMBIENT TEMPERATURE SENSOR SIGNAL FUSED IGN ST RUN GROUND SENSOR GROUND CCD BUS FUNCTION CIRCUIT SPEED SE...

Page 937: ... 18VT 3 2 1 CAV FUSED IGNITION ST RUN OFF PARK NEUTRAL POSITION SWITCH SENSE PARK NEUTRAL POSITION SWITCH OUTPUT CIRCUIT FUNCTION EATX POSITION SWITCH PARK NEUTRAL 1 3 BLACK F20 18WT T41 18BK WT L1 18VT BK 3 2 1 CAV FUSED IGNITION RUN PARK NEUTRAL POSITION SWITCH SENSE BACK UP LAMP RELAY OUTPUT CIRCUIT FUNCTION RHD 8 7 8 Z1 18BK M1 22PK 7 L91 20DB PK X12 20RD WT 8 3 4 1 P50 5 6 4 3 2 1 CAV CIRCUIT...

Page 938: ...SWITCH MUX PANEL LAMPS FEED CIRCUIT FUNCTION FUNCTION CIRCUIT HEATED SEAT DRIVER GROUND CAV A B P88 18RD WT Z1 18BK SEAT BACK PASSENGER HEATED FUNCTION CIRCUIT HEATED SEAT DRIVER HEATED SEAT DRIVER CAV P87 18RD WT P88 18RD WT P89 20BK RD Z1 18BK A B C PASSENGER HEATED SEAT CUSHION D HEATED SEAT BACK GROUND FUSED B PASSENGER HEATED SEAT SWITCH D SEAT MODULE PASSENGER HEATED C B A F35 18RD P8 20WT B...

Page 939: ... 5 4 3 2 1 CAV GROUND FUSED B MIRROR SWITCH COMMON MIRROR SWITCH OUTPUT VERTICAL MIRROR SWITCH OUTPUT HORIZONTAL CIRCUIT FUNCTION 4 5 P159 20DG PASSENGER MIRROR UNFOLD SIGNAL 6 P160 20LB PASSENGER MIRROR FOLD SIGNAL BUILT UP EXPORT FUSED IGNITION RUN D SEAT SWITCH PASSENGER HEATED C B A F20 20WT F20 20WT P86 20VT CAV FUSED IGNITION RUN HEATED SEAT TEMPERATURE SENSOR CIRCUIT FUNCTION Z1 18BK E GROU...

Page 940: ...T FRONT WINDOW UP GROUND PANEL LAMPS FEED RIGHT FRONT WINDOW DOWN RIGHT FRONT WINDOW UP RIGHT FRONT WINDOW DOWN FUSED IGNITION SWITCH OUTPUT RUN ACC CIRCUIT FUNCTION SWITCH POWER SEAT PASSENGER 10 5 6 1 GREEN P18 14YL LG P10 14YL WT P12 14RD WT P20 14RD LG P14 14YL LB F35 14RD P42 14GY WT P16 14RD LB P44 14GY LB Z1 14BK 10 9 8 7 6 5 4 3 2 1 CAV SEAT FRONT VERTICAL UP SEAT REAR VERTICAL UP SEAT REA...

Page 941: ...ER SEAT B BLACK A P44 14GY LB P42 14GY WT B A CAV SEAT RECLINER FORWARD SEAT RECLINER REARWARD CIRCUIT FUNCTION REAR VERTICAL MOTOR PASSENGER SEAT B BLACK A P10 14YL WT P12 14RD WT B A CAV SEAT REAR VERTICAL UP SEAT REAR VERTICAL DOWN CIRCUIT FUNCTION WINDOW MOTOR PASSENGER RED 2 1 Q21 16WT Q11 16LG 2 1 CAV DRIVER WINDOW DOWN DRIVER WINDOW UP CIRCUIT FUNCTION NS GS 8W 80 CONNECTOR PIN OUTS 8W 80 6...

Page 942: ... DODGE PLYMOUTH OR BUILT UP EXPORT CHRYSLER PREMIUM CENTER C2 DISTRIBUTION POWER 6 1 10 5 ORANGE F30 16RD F1 20DB X2 18DG RD A141 16DG WT F87 18WT BK F20 20WT X4 20GY OR F45 20YL RD F41 20PK VT 10 9 8 7 6 5 4 3 2 1 CAV CIGAR AND ACCESSORY RELAY OUTPUT WIPE FEED HORN RELAY OUTPUT FUEL PUMP RELAY OUTPUT FUSED IGN ST RUN IGNITION FEED FOR EVIC HORN RELAY CONTROL FUSED IGNITION SWITCH OUTPUT START FUS...

Page 943: ...NTER C5 DISTRIBUTION POWER FUSED IGNITION SWITCH OUTPUT ST RUN 2 F14 18LG YL HIGH BEAM RELAY OUTPUT L34 20RD OR 10 6 1 5 LT GRAY F23 20DB YL L9 18BK WT L43 18VT V14 18RD VT L34 20RD OR V16 20WT V4 12RD YL V3 12BR WT F14 20LG YL L33 20RD 10 9 8 7 6 5 4 3 1 CAV FUSED IGNITION SWITCH OUTPUT RUN FUSED HAZARD FLASHER FEED DEDICATED LOW BEAM RELAY OUTPUT WIPER ON RELAY DRIVER HIGH BEAM RELAY OUTPUT WIPE...

Page 944: ...RANSMISSION CONTROL RELAY OUTPUT FUNCTION CIRCUIT BUILT UP EXPORT 2 1 GROUND Z1 20BK POWER FOLDING MIRROR INPUT P136 20YL CIRCUIT FUNCTION CAV 1 2 POWER FOLDING MIRROR SWITCH BLACK POWER MIRROR SWITCH BLACK 7 1 13 6 P72 20YL BK P71 20YL Z1 20BK F41 20PK VT P74 20DB P75 20DB WT P73 20YL PK E2 20OR P70 20WT 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV RIGHT VERTICAL LEFT VERTICAL GROUND FUSED B RIGHT HORIZONTA...

Page 945: ...NGINE SPEED SENSOR SIGNAL K159 20VT RD FUNCTION CIRCUIT ENGINE STARTER MOTOR RELAY CONTROL LOW SPEED RADIATOR FAN RELAY NO 2 CONTROL CONTROL SLEEVE POSITION SENSOR ENGINE SPEED SENSOR FEED NEEDLE MOVEMENT SENSOR RETURN A C PRESSURE SWITCH SIGNAL CLUTCH SWITCH SIGNAL GLOW PLUG LAMP DRIVER SENSOR GROUND A C SWITCH SIGNAL BOOST PRESSURE SENSOR SIGNAL CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1...

Page 946: ...RELAY OUTPUT GROUND Z12 16BK TN 47 VEHICLE SPEED SENSOR SIGNAL G7 18WT OR 43 K51 20DB YL DIESEL POWER RELAY 42 41 K9 20LB CAV FUNCTION CIRCUIT 5 VOLT SUPPLY 56 59 G55 20OR BK 60 58 K6 20VT WT 5 VOLT SUPPLY 57 61 D21 20PK 66 62 63 K156 20GY FUEL TEMPERATURE SENSOR SIGNAL LOW IDLE POSITION SWITCH SIGNAL K151 20WT 65 K21 20BK RD INTAKE AIR TEMPERATURE SENSOR SIGNAL 64 SCI TRANSMIT ENGINE DISABLE SIGN...

Page 947: ...ONTROL MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL THROTTLE POSITION SENSOR SIGNAL CAMSHAFT POSITION SENSOR SIGNAL CRANKSHAFT POSITION SENSOR SIGNAL HEATED OXYGEN SENSOR SIGNAL ENGINE COOLANT TEMPERATURE SENSOR SIGNAL SERVICE ENGINE SOON INDICATOR LAMP DRIVER FUSED IGNITION SWITCH OUTPUT ST RUN INJECTOR NO 2 DRIVER INJECTOR NO 4 DRIVER INJECTOR NO 5 DRIVER 3 3L 3 8L INJECTOR NO 6 DRIVER 3 3L 3 8L INJ...

Page 948: ...NSE SCI RECEIVE FUEL PUMP RELAY CONTROL RADIATOR FAN RELAY CONTROL EVAP LEAK DETECTION PUMP STROKE SENSE EVAP PURGE SOLENOID CONTROL AUTOMATIC SHUT DOWN RELAY CONTROL VEHICLE SPEED SENSOR SIGNAL SCI TRANSMIT A C COMPRESSOR CLUTCH RELAY CONTROL TORQUE MANAGEMENT REQUEST SENSE STOP LAMP SWITCH SENSE 5 VOLT SUPPLY CCD BUS CCD BUS IDLE AIR CONTROL MOTOR NO 4 DRIVER IDLE AIR CONTROL MOTOR NO 1 DRIVER S...

Page 949: ... 1 RADIATOR FAN 2 1 BLACK Z1 12BK C23 12DG 2 1 CAV GROUND LOW SPEED RADIATOR FAN RELAY OUTPUT CIRCUIT FUNCTION BLACK RADIATOR FAN RELAY OUTPUT HIGH SPEED RELAY OUTPUT C116 12LG WT C25 12YL 4 3 4 1 RADIATOR FAN RELAY CONTROL C27 12DB PK 2 1 Z1 12BK CAV FUNCTION CIRCUIT GROUND DIESEL DISCONNECT RADIATOR FAN PRNDL SWITCH 3 NATURAL 1 T1 18LG BK T42 18VT WT Z13 18BK RD 3 2 1 CAV PRNDL SWITCH SENSE PRND...

Page 950: ...ITCH SENSE RIGHT DOOR SPEAKER RIGHT DOOR SPEAKER LEFT DOOR SPEAKER LEFT DOOR SPEAKER CIRCUIT FUNCTION 1 3 6 4 7 9 2 5 8 FAN RELAY NO 3 DIESEL RADIATOR RADIATOR FAN RELAY CONTROL CIRCUIT FUNCTION CAV C27 12DB PK 2 4 A142 18DG OR AUTO SHUTDOWN RELAY OUTPUT 8 6 C137 20YL A17 12RD BK FUSED B HIGH SPEED RADIATOR FAN RELAY CONTROL NATURAL 1 3 6 4 7 9 2 5 8 FAN RELAY NO 2 DIESEL RADIATOR RADIATOR FAN REL...

Page 951: ...K D2 20WT BK D1 20VT BR 2 1 CAV CCD BUS CCD BUS CIRCUIT FUNCTION RADIO C2 RADIO CHOKE 1 2 LT GRAY X13 16RD DG X1 16DG RD 2 1 CAV RADIO CHOKE OUTPUT NAME BRAND SPEAKER RELAY OUTPUT CIRCUIT FUNCTION DUAL ZONE A C ACTUATOR REAR A C HEATER UNIT CIRCUIT FUNCTION A C MODE DOOR DRIVER A REAR BLOWER RELAY OUTPUT REAR BLOWER MEDIUM SPEED REAR BLOWER MEDIUM SPEED REAR BLOWER HIGH SPEED CAV 1 2 3 4 5 6 7 8 9...

Page 952: ... 1 CAV PANEL LAMPS FEED REAR BLOWER LOW SPEED GROUND REAR BLOWER HIGH SPEED REAR BLOWER MEDIUM SPEED REAR BLOWER MEDIUM SPEED FUNCTION CIRCUIT CONTROL SWITCH REAR BLOWER FRONT 1 8 BLACK E2 20OR Z1 12BK C50 12BK LG C60 16BK LB C70 12DG 8 7 6 5 4 3 2 1 CAV PANEL LAMPS FEED GROUND REAR BLOWER LOW SPEED REAR BLOWER MEDIUM SPEED REAR BLOWER HIGH SPEED FUNCTION CIRCUIT 8W 80 76 8W 80 CONNECTOR PIN OUTS ...

Page 953: ...MP REAR DOME BLACK COURTESY LAMP GROUND READING LAMP FEED CIRCUIT CAV 1 2 M113 20LB PK M20 20BR 3 3 1 ENTRY MODULE REMOTE KEYLESS RED 5 6 4 1 2 3 G96 20LG RD D9 22GY BK Z2 20BK LG M1 20PK 6 5 4 3 2 1 CAV RKE INTERFACE RKE MODULE PROGRAM ENABLE GROUND FUSED B CIRCUIT FUNCTION DOOR ACTUATOR RECIRCULATION 1 5 NATURAL C32 20GY DB C34 20DB WT 5 4 3 2 1 CAV RECIRCULATION DOOR DRIVER COMMON DOOR DRIVER C...

Page 954: ...UILT UP EXPORT 1 2 PREMIUM SPEAKER RIGHT DOOR X56 20DB RD RIGHT FRONT SPEAKER RADIO CHOKE OUTPUT X13 16RD DG 6 5 3 6 4 1 BLACK X155 20BR WT X54 20VT X15 16BK DG X153 20WT BR 4 3 2 1 CAV RIGHT FRONT I P SPEAKER RIGHT FRONT SPEAKER AMPLIFIED SPEAKER GROUND RIGHT I P SPEAKER FUNCTION CIRCUIT PANEL SPEAKER RIGHT FRONT 3 4 X153 20WT BR RIGHT FRONT I P SPEAKER BLACK 4 1 X155 20BR WT 2 1 CAV RIGHT FRONT ...

Page 955: ...ON RIGHT FRONT SPEAKER BASE 1 4 BLACK FUNCTION CIRCUIT RIGHT FRONT SPEAKER CAV 1 2 X56 20DB RD RIGHT FRONT SPEAKER X54 20VT 4 3 3 2 1 FUSED RIGHT HIGH BEAM RELAY OUTPUT CIRCUIT FUNCTION CAV L34 20RD OR 1 2 L44 20VT RD 3 Z1 20BK GROUND RIGHT HEADLAMP BUILT UP EXPORT FUSED RIGHT LOW BEAM OUTPUT BLACK WHEEL SPEED SENSOR RIGHT FRONT 1 2 BLACK B7 18WT B6 18WT DB 2 1 CAV RIGHT FRONT WHEEL SPEED SENSOR R...

Page 956: ...1 20BK M11 20PK LB 2 1 CAV GROUND COURTESY LAMP RELAY OUTPUT CIRCUIT FUNCTION EXCEPT BUILT UP EXPORT HEADLAMP CHRYSLER RIGHT HIGH FUNCTION B A CAV Z1 20BK L34 20RD OR CIRCUIT GROUND FUSED RIGHT HIGH BEAM OUTPUT B A 1 3 BUILT UP EXPORT GROUND CIRCUIT FUNCTION CAV Z1 20BK 1 2 L13 18BR YL 3 L44 20VT RD FUSED RIGHT LOW BEAM OUTPUT RIGHT HEADLAMP LEVELING MOTOR HEADLAMP ADJUST SIGNAL BLACK RIGHT LOW HE...

Page 957: ...IGHT REAR PILLAR SPEAKER RIGHT REAR PILLAR SPEAKER CIRCUIT FUNCTION BUILT UP EXPORT LAMP ASSEMBLY RIGHT REAR 3 6 1 4 BLACK L50 18WT TN L62 18BR RD L1 20VT BK L78 20DG YL Z1 20BK 6 5 4 3 2 1 CAV STOP LAMP SWITCH OUTPUT RIGHT TURN SIGNAL BACK UP LAMP FEED FUSED B GROUND L36 20LG CIRCUIT REAR FOG LAMP FUNCTION SWITCH DOOR AJAR RIGHT REAR 2 3 1 NATURAL G76 18TN YL Z1 18BK 3 2 1 CAV RIGHT REAR DOOR AJA...

Page 958: ...UIT LHD VENT MOTOR RIGHT REAR 1 3 NATURAL Q14 18GY Q24 18DG 3 2 1 CAV RIGHT REAR VENT MOTOR CLOSE RIGHT REAR VENT MOTOR OPEN FUNCTION CIRCUIT 2 1 RIGHT TURN SIGNAL CIRCUIT FUNCTION CAV L62 18BR RD 1 2 Z1 18BK GROUND GRAY SENSOR WHEEL SPEED RIGHT REAR GRAY 2 B2 18YL B1 18YL DB 2 1 CAV RIGHT REAR WHEEL SPEED SENSOR RIGHT REAR WHEEL SPEED SENSOR FUNCTION CIRCUIT 1 CONTACTS SLIDING DOOR RIGHT REAR 3 1...

Page 959: ...IZER SENTRY KEY CAV CIRCUIT FUNCTION 1 F41 20PK VT FUSED B 2 Z2 20BK GROUND 3 F87 20WT BK FUSED IGNITION ST RUN 4 5 D2 20WT BK CCD BUS 6 D1 20VT BR CCD BUS SWITCH SEAT BELT 2 1 BLACK Z1 20BK G10 18LG RD 2 1 CAV GROUND SEAT BELT SWITCH SENSE FUNCTION CIRCUIT VANITY MIRROR LAMPS RIGHT VISOR A B BLACK F41 20PK VT M20 20BR B A CAV FUSED B COURTESY LAMP GROUND FUNCTION CIRCUIT SIGNAL RELAY STOP TURN RI...

Page 960: ...ONTROL SWITCH SENSE GROUND CIRCUIT FUNCTION 3 1 BLACK EXCEPT 2 0L POSITION SENSOR THROTTLE K4 18BK LB SENSOR GROUND 1 3 CAV CIRCUIT FUNCTION 1 K22 18OR DB THROTTLE POSITION SENSOR SIGNAL 2 K6 18VT WT 5 VOLT SUPPLY 3 CIRCUIT FUNCTION CAV 1 2 K4 18BK LB CRANK POSITION SENSOR THROTTLE POSITION SENSOR SIGNAL K22 18OR DB 3 K6 18VT WT 5V SUPPLY 2 0L SENSOR THROTTLE POSITION WHITE 3 1 WHITE 8W 80 84 8W 8...

Page 961: ... 11 10 9 8 7 6 5 4 3 2 1 CAV LOW REVERSE SOLENOID CONTROL 2 4 SOLENOID CONTROL TRANSMISSION CONTROL RELAY OUTPUT TRANSMISSION CONTROL RELAY OUTPUT 12 VOLT SUPPLY OUTPUT SHAFT SPEED SENSOR SIGNAL SPEED SENSOR GROUND THROTTLE POSITION SENSOR SIGNAL FUSED IGNITION ST RUN OFF TORQUE MANAGEMENT REQUEST SENSE OVERDRIVE PRESSURE SWITCH SENSE FUSED IGNITION ST SCI TRANSMIT CRANKSHAFT POSITION SENSOR SIGNA...

Page 962: ...18BK WT T54 18VT LG T13 18DB BK F20 18WT 10 9 8 7 6 5 4 3 2 1 CAV TRANSMISSION RANGE SENSOR T41 SENSE TRANSMISSION RANGE SENSOR T42 SENSE TRANSMISSION RANGE SENSOR T3 SENSE TRANSMISSION RANGE SENSOR T1 SENSE BACK UP LAMP FEED TRANSMISSION RANGE SENSOR T41 SENSE TRANSMISSION TEMPERATURE SENSOR SIGNAL SPEED SENSOR GROUND FUSED IGNITION SWITCH OUTPUT CIRCUIT FUNCTION 5 6 3 4 8 7 2 1 BLACK T19 18WT T2...

Page 963: ...1 18BK 4 3 2 1 CAV UPSTREAM HEATED OXYGEN SENSOR SIGNAL SENSOR GROUND ASD RELAY OUTPUT GROUND CIRCUIT FUNCTION GRAY 1 BOOST PRESSURE SIGNAL K1 18DG RD 4 4 1 TURBO BOOST PRESSURE SENSOR DIESEL K9 18LB 3 K21 18BK RD INTAKE AIR TEMPERATURE SIGNAL SENSOR GROUND K4 18BK LB 2 1 CAV FUNCTION CIRCUIT FUNCTION CIRCUIT SPEED SENSOR GROUND INPUT SPEED SENSOR SIGNAL CAV 1 2 T13 18DB BK T52 18RD BK GRAY 1 2 TU...

Page 964: ...XPORT MODULE WIPER CAV CIRCUIT FUNCTION 1 V3 12BR WT WIPER HIGH LOW RELAY LOW SPEED OUTPUT 2 V7 20DG WT WIPER PARK SWITCH SENSE 3 V4 12RD YL WIPER HIGH LOW RELAY HIGH SPEED OUTPUT 4 EXCEPT 3 3L 3 8L SENSOR VEHICLE SPEED 3 2 8 VOLT SUPPLY K7 18OR G7 18WT OR VEHICLE SPEED SENSOR SIGNAL K4 20BK LB SENSOR GROUND FUSED IGNITION ST RUN CAV CIRCUIT FUNCTION 1 F87 18WT BK 1 K4 18BK LB SENSOR GROUND 2 DIES...

Page 965: ...ator NAT LT Side of HVAC 15 Airbag Control Module C1 YL Rear of I P Center Stack 12 Airbag Contol Module C2 BK Rear of I P Center Stack 12 All Wheel Drive Solenoid BK Near Fuel Tank 20 Ambient Temperature Sensor BK On Radiator Closure Panel 4 Ash Receiver Lamp RD At Lamp 10 Automatic Day Night Mirror BK At Mirror 15 B01 BK LT Kick Panel 18 B02 BK LT Kick Panel 18 B03 BK RT Kick Panel 18 Component ...

Page 966: ...r C2 BK At Right Base of Windshield 11 Component Ground Color Location Fig Engine Coolant Temp Sensor 2 4L BK On Cylinder Block N S Engine Coolant Temp Sensor 2 5 BK On Cylinder Head 8 Engine Coolant Temp Sensor 3 3L 3 8L BK On Cylinder Block N S Engine Oil Pressure Switch GN On Cylinder Block 5 6 7 8 9 Engine Starter Motor Rear of Starter 5 6 7 8 9 EVAP Purge Solenoid BK RT Motor Mount 3 Evaporat...

Page 967: ...Location Fig Horn Switch Rear of Driver Airbag 11 Idle Air Control Motor BK On Throttle Body 5 6 7 8 9 Ignition Coil Pack 2 0L BK Top of Valve Cover 5 Ignition Coil Pack 2 4L BK Top of Valve Cover 6 7 Ignition Coil Pack 3 3L 3 8L BK RT Side of Engine 9 Ignition Switch C1 GY Rear of Switch 11 Ignition Switch C2 GN Rear of Switch 11 Ignition Switch C3 BK Rear of Switch 11 Instrument Cluster RD Rear ...

Page 968: ...Reading Lamp BK At Lamp 15 Left Rear Sliding Door Contacts BK LT B Pillar 14 Component Ground Color Location Fig Left Rear Sliding Door Lock Motor BK At Motor N S Left Rear Speaker BK At Speaker 21 Left Rear Vent Motor NAT At Motor 21 Left Rear Wheel Speed Sensor BK Center Rear of Floor Pan 16 Left Repeater Lamp GY At Lamp N S Left Speed Control Switch Left Side of Steering Wheel Pad 11 Left Stop ...

Page 969: ...Folding Mirror Switch BK At Switch N S Component Ground Color Location Fig Power Mirror Switch BK Rear of Switch 11 Power Steering Pressure Switch BK RT Side of Engine Compartment N S Powertrain Control Module C1 BK LT Fender Side Shield 3 Powertrain Control Module C2 BK LT Fender Side Shield 3 Radiator Fan No 1 BK At Motor N S Radiator Fan No 2 BK At Motor N S Radiator Fan Solid State Relay BK LT...

Page 970: ...or Ajar Switch BK RT C Pillar 22 Component Ground Color Location Fig Right Rear Pillar Speaker BK At Speaker 22 Right Rear Reading Lamp GY At Lamp 17 Right Rear Sliding Door Contact BK RT B Pillar 14 Right Rear Sliding Door Lock Motor BK At Motor N S Right Rear Speaker BK At Speaker 22 Right Rear Vent Motor NAT At Motor 22 Right Rear Wheel Speed Sensor BK Center Rear of Floor Pan 16 Right Repeater...

Page 971: ...itch 11 Upstream Heated Oxygen Sensor GY Rear of Engine 5 6 7 8 9 Component Ground Color Location Fig Vehicle Speed Control Servo BK LT Rear of Engine Compartment 5 6 7 8 9 Vehicle Speed Sensor BK Rear of Transmission 5 6 8 Windshield Wiper Switch BK Part of Multifunction Switch 11 Wiper Module BK LT Side of Engine 2 NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 7 DESCRIPTION AND OPERATION Continue...

Page 972: ...Fig 1 Ground Locations LHD 8W 90 8 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 973: ...Fig 2 Engine Compartment Connetions LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 9 DESCRIPTION AND OPERATION Continued ...

Page 974: ...Fig 3 Engine Compartment Connections LHD 8W 90 10 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 975: ...Fig 4 Engine Compartment Connections LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued ...

Page 976: ...Fig 5 Engine Connections 2 0L LHD 8W 90 12 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 977: ...Fig 6 Engine Connections 2 4L M T LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 13 DESCRIPTION AND OPERATION Continued ...

Page 978: ...Fig 7 Engine Connections 2 4L A T LHD 8W 90 14 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 979: ...Fig 8 Engine Connections 2 5L LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued ...

Page 980: ...Fig 9 Engine Connections 3 3L 3 8L LHD 8W 90 16 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 981: ...Fig 10 Instrument Panel Connections LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 17 DESCRIPTION AND OPERATION Continued ...

Page 982: ...Fig 11 Instrument Panel Connections LHD 8W 90 18 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 983: ...Fig 12 Instrument Panel Connections LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 19 DESCRIPTION AND OPERATION Continued ...

Page 984: ...Fig 13 Cowl Panel Connections LHD 8W 90 20 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 985: ...Fig 14 Body Connections LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 21 DESCRIPTION AND OPERATION Continued ...

Page 986: ...Fig 15 HVAC Connections LHD 8W 90 22 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 987: ...Fig 16 Body Connections LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 23 DESCRIPTION AND OPERATION Continued ...

Page 988: ...Fig 17 Roof Panel Connections LHD 8W 90 24 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 989: ...Fig 18 Body to Door Connections LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 25 DESCRIPTION AND OPERATION Continued ...

Page 990: ...Fig 19 Door Connections LHD 8W 90 26 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 991: ...Fig 20 Underbody Connections LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 27 DESCRIPTION AND OPERATION Continued ...

Page 992: ...Fig 21 Left Rear Quarter Connections LHD 8W 90 28 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 993: ...Fig 22 Right Rear Quarter Connections LHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 29 DESCRIPTION AND OPERATION Continued ...

Page 994: ...Fig 23 Liftgate Connections LHD 8W 90 30 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 995: ...LT GY LT Frame Rail 2 B75 BL Bottom of RT B Pillar 14 B98 BK Rear of RT Tail Lamp N S Component Ground Color Location Fig B99 BK Rear of LT Tail Lamp N S B120 BK LT Kick Panel N S Backup Lamp Switch M T BK On Transmission 5 6 8 Blend Door Actuator NAT LT Side of HVAC 15 Body Control Module C1 NAT On Junction Block 12 Body Control Module C2 NAT On Junction Block 12 Brake Pressure Switch BK On Maste...

Page 996: ...lock BK LT Side of Engine 2 Front Cigar Lighter BK Rear of Lighter 11 Component Ground Color Location Fig Front Reading Lamps Switch BL At Lamp 17 Front Washer Motor BK Bottom of Reservior 4 Fuel Injector 1 BK At Injector N S Fuel Injector 2 BK At Injector N S Fuel Injector 3 BK At Injector N S Fuel Injector 4 BK At Injector N S Fuel Injector 5 BK At Injector N S Fuel Injector 6 BK At Injector N S...

Page 997: ... of Cylinder Block 6 7 Knock Sensor 3 3L 3 8L GY Front of Cylinder Block N S L15 BK Top of Liftgate 23 Component Ground Color Location Fig L16 BK Top of Liftgate 23 Left Combination Relay BK LT Rear Quarter Panel N S Left Door Ajar Switch BK LT B PIllar 12 Left Door Arm Disarm Switch BK At Switch 19 Left Door Courtesy Lamp BK At Lamp 19 Left Door Speaker BK At Speaker 19 Left Fog Lamp GY At Lamp 4...

Page 998: ... Memory Set Switch BL At Switch 19 Component Ground Color Location Fig Message Center BL Rear of Message Center 11 Mode Door Actuator BK LT Side of HVAC 15 Multi Function Switch BK Rear of Switch 11 Name Brand Speaker Relay LT GY LT of Steering Column N S Output Shaft Speed Sensor GY Front of Transmission 7 9 Overhead Console RD Front of Console 17 P18 GY RT of Steering Column 12 P30 BK RT Side of...

Page 999: ...anel N S Right Door Arm Disarm Switch BK At Switch 19 Right Door Courtesy Lamp BK At Lamp 19 Component Ground Color Location Fig Right Door Speaker BK At Speaker 19 RF3 BK At Radiator Fan Module N S Right Fog Lamp GY At Lamp 4 Right Front Door Ajar Switch BK RT B Pillar 12 Right Front Door Lock Motor BK At Motor 19 Right Front Panel Speaker BK At Speaker 11 Right Front Park Turn Signal Lamp BK At ...

Page 1000: ...05 BK LT Quarter Panel N S T08 BK RT Quarter Panel N S Component Ground Color Location Fig Throttle Position Sensor NAT On Throttle Body 5 6 7 8 9 Trailer Tow Connector BK LT Quarter Panel N S Transmission Control Module BK RT Fender Side Shield 3 Transmission Range Sensor BK Top of Transmission 7 9 Transmission Control Solenoids BK Front of Transmission 7 9 Turbine Speed Sensor GY Front of Transm...

Page 1001: ...Fig 1 Ground Locations RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 37 DESCRIPTION AND OPERATION Continued ...

Page 1002: ...Fig 2 Engine Compartment Connetions RHD 8W 90 38 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1003: ...Fig 3 Engine Compartment Connections RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 39 DESCRIPTION AND OPERATION Continued ...

Page 1004: ...Fig 4 Engine Compartment Connections RHD 8W 90 40 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1005: ...Fig 5 Engine Connections 2 0L RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 41 DESCRIPTION AND OPERATION Continued ...

Page 1006: ...Fig 6 Engine Connections 2 4L M T RHD 8W 90 42 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1007: ...Fig 7 Engine Connections 2 4L A T RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 43 DESCRIPTION AND OPERATION Continued ...

Page 1008: ...Fig 8 Engine Connections 2 5L RHD 8W 90 44 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1009: ...Fig 9 Engine Connections 3 3L 3 8L RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 45 DESCRIPTION AND OPERATION Continued ...

Page 1010: ...Fig 10 Instrument Panel Connections RHD 8W 90 46 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1011: ...Fig 11 Instrument Panel Connections RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 47 DESCRIPTION AND OPERATION Continued ...

Page 1012: ...Fig 12 Instrument Panel Connections RHD 8W 90 48 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1013: ...Fig 13 Cowl Panel Connections RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 49 DESCRIPTION AND OPERATION Continued ...

Page 1014: ...Fig 14 Body Connections RHD 8W 90 50 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1015: ...Fig 15 HVAC Connections RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 51 DESCRIPTION AND OPERATION Continued ...

Page 1016: ...Fig 16 Body Connections RHD 8W 90 52 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1017: ...Fig 17 Roof Panel Connections RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 53 DESCRIPTION AND OPERATION Continued ...

Page 1018: ...Fig 18 Body to Door Connections RHD 8W 90 54 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1019: ...Fig 19 Door Connections RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 55 DESCRIPTION AND OPERATION Continued ...

Page 1020: ...Fig 20 Underbody Connections RHD 8W 90 56 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1021: ...Fig 21 Left Rear Quarter Connections RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 57 DESCRIPTION AND OPERATION Continued ...

Page 1022: ...Fig 22 Right Rear Quarter Connections RHD 8W 90 58 8W 90 CONNECTOR GROUND LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1023: ...Fig 23 Liftgate Connections RHD NS GS 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 59 DESCRIPTION AND OPERATION Continued ...

Page 1024: ......

Page 1025: ... S BS33 2 5L In BCM T O N S BS34 2 5L In BCM T O N S BS40 2 5L In Engine Harness T O 5 BS41 2 5L In Engine Harness T O N S CS01 Above Right Rear Door 11 CS02 Above Right Rear Door 11 CS03 Right B Pillar 11 CS04 Right B Pillar 11 DS01 Near LT Power WDO T O 10 ES01 In TCM T O 7 ES01 2 5L Near Battery Positive Terminal T O N S Splice Number Location Fig ES02 2 0L Near Camshaft Position Sensor T O 3 E...

Page 1026: ...Engine Ground T O 4 ES18 3 3L 3 8L Near Engine Ground T O 7 Splice Number Location Fig ES21 2 0L Near Body Ground T O N S ES21 2 4L Near Engine Ground T O 4 ES21 3 3L 3 8L Near A C Clutch T O 6 ES23 2 0L Near Radiator Fan T O N S ES23 2 4L Near Radiator Fan T O 4 ES23 3 3L 3 8L Near Engine ground T O 7 ES24 2 4L Near Transmission T O 4 ES24 3 3L 3 8L Near Transmission T O 7 ES26 2 5L In Battery Po...

Page 1027: ...Fig 1 Front End Splices LHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 3 DESCRIPTION AND OPERATION Continued ...

Page 1028: ...Fig 2 Engine Splices 2 0L LHD 8W 95 4 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1029: ...Fig 3 Engine Splices 2 0L LHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 5 DESCRIPTION AND OPERATION Continued ...

Page 1030: ...Fig 4 Engine Splices 2 4L LHD 8W 95 6 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1031: ...Fig 5 Engine Splices 2 5L LHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 7 DESCRIPTION AND OPERATION Continued ...

Page 1032: ...Fig 6 Engine Splices 3 3L 3 8L LHD 8W 95 8 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1033: ...Fig 7 Engine Compartment Splices 3 3L 3 8L LHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 9 DESCRIPTION AND OPERATION Continued ...

Page 1034: ...Fig 8 Instrument Panel Splices LHD 8W 95 10 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1035: ...Fig 9 Cowl Panel Splices LHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 11 DESCRIPTION AND OPERATION Continued ...

Page 1036: ...Fig 10 Left Door Splice LHD 8W 95 12 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1037: ...Fig 11 Dome Harness Splices LHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 13 DESCRIPTION AND OPERATION Continued ...

Page 1038: ...Fig 12 Floor Pan and Underbody Splices LHD 8W 95 14 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1039: ...2 0L Near Battery Positive Terminal N S Splice Number Location Fig ES11 2 4L Near Battery Negative Terminal T O 4 ES11 3 3L 3 8L Near Battery Negative Terminal 5 6 ES12 2 0L Near Engine Ground T O 2 ES12 2 4L Near Throttle Body T O 4 ES12 3 3L 3 8L Near Battery Positive Terminal T O 6 ES13 2 4L Near Generator T O 4 ES13 3 3L 3 8L Near Battery Negative Terminal 4 ES14 2 4L Near Generator Field T O ...

Page 1040: ...Fig 1 Front End Splices RHD 8W 95 16 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1041: ...Fig 2 Engine Splices 2 0L RHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 17 DESCRIPTION AND OPERATION Continued ...

Page 1042: ...Fig 3 Engine Splices 2 0L RHD 8W 95 18 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1043: ...Fig 4 Engine Splices 2 4L RHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 19 DESCRIPTION AND OPERATION Continued ...

Page 1044: ...Fig 5 Engine Splices 3 3L 3 8L RHD 8W 95 20 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1045: ...Fig 6 Engine Compartment Splices 3 3L 3 8L RHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 21 DESCRIPTION AND OPERATION Continued ...

Page 1046: ...Fig 7 Instrument Panel Splices RHD 8W 95 22 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1047: ...Fig 8 Cowl Panel Splices RHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 23 DESCRIPTION AND OPERATION Continued ...

Page 1048: ...Fig 9 Left Door Splice RHD 8W 95 24 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1049: ...Fig 10 Dome Harness Splices RHD NS GS 8W 95 SPLICE LOCATIONS 8W 95 25 DESCRIPTION AND OPERATION Continued ...

Page 1050: ...Fig 11 Floor Pan and Underbody Splices RHD 8W 95 26 8W 95 SPLICE LOCATIONS NS GS DESCRIPTION AND OPERATION Continued ...

Page 1051: ... used interchangeably CAUTION Silicone sealer and anaerobic sealers each will inhibit the cure of the other and care should be taken to keep usages separated as much as possible MOPART SILICONE RUBBER ADHESIVE SEALANT Mopart Silicone Rubber Adhesive Sealant or equivalent normally black in color is available in three ounce tubes Moisture in the air causes the Mopart Silicone Rubber Adhesive Sealant...

Page 1052: ... material off loca tion CRANKSHAFT SPROCKET BOLT ACCESS PLUG An Access plug is located in the right inner fender shield Remove the plug and insert the proper size socket extension and ratchet when crankshaft rota tion is necessary ENGINE CORE PLUGS REMOVAL Using a blunt tool such as a drift or a screwdriver and a hammer strike the bottom edge of the cup plug Fig 1 With the cup plug rotated grasp f...

Page 1053: ...s Fig 2 4 A controlled hone motor speed between 200 300 RPM is necessary to obtain the proper cross hatch angle The number of up and down strokes per minute can be regulated to get the desired 50 60 degree angle Faster up and down strokes increase the cross hatch angle 5 After honing it is necessary that the block be cleaned again to remove all traces of abrasive CAUTION Ensure all abrasives are r...

Page 1054: ...tions you are checking CONNECTING ROD BEARING CLEARANCE Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent The following is the recommended procedure for the use of Plastigage 1 Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke 2 Remove oil film from surface to be checked Plastigage is soluble in oil 3 Place a pie...

Page 1055: ...onnect negative battery cable 12 Start engine and check for any leaks ENGINE OIL Checking Oil Level To assure proper engine lubrication the engine oil must be maintained at the correct level Check the oil level at regular intervals such as every fuel stop The best time to check the oil level is about 5 min utes after a fully warmed up engine is shut off or before starting the vehicle after it has ...

Page 1056: ...ns are located on the label of engine oil plastic bottles and the top of engine oil cans Fig 6 ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule TO CHANGE ENGINE OIL Run engine until achieving normal operating tem perature 1 Position the vehicle on a level surface and turn engine off 2 Hoist and support vehicle on safety stands Refer to Hoistin...

Page 1057: ... been found 4 Repair as required CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc tions Ensure the battery is completely charged and the engine starter motor is in good operating condition Otherwise the indicated compression pressures may not be valid for diagnosis purposes 1 Check engine oil level and add oil...

Page 1058: ...o the tester manufacturer s instructions While testing listen for pressurized air escaping through the throttle body tailpipe and oil filler cap opening Check for bubbles in the radiator coolant All gauge pressure indications should be equal with no more than 25 leakage FOR EXAMPLE At 552 kPa 80 psi input pres sure a minimum of 414 kPa 60 psi should be main tained in the cylinder LASH ADJUSTER TAP...

Page 1059: ...pproximately 24 km 15 miles Inspect the engine for signs of an oil leak by using a black light INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine a more involved inspection is necessary The following steps should be followed to help pinpoint the source of the leak If the leakage occurs at the crankshaft rea...

Page 1060: ...roup 14 Fuel System 2 Incorrect fuel mixture 2 Refer to Group 14 Fuel System 3 Intake manifold leakage 3 Inspect intake manifold manifold gasket and vacuum hoses Refer to Group 11 Exhaust System and Intake Manifold 4 Incorrect ignition wiring 4 Install correct wiring 5 Faulty coil s 5 Test and replace as necessary Refer to Group 8D Ignition System ENGINE LOSS OF POWER 1 Dirty or incorrectly gapped...

Page 1061: ...es 4 Faulty coil s 4 Test and replace as necessary Refer to Group 8D Ignition System ENGINE MISSES AT HIGH SPEED 1 Dirty or incorrect spark plug gap 1 Clean spark plugs and set gap Refer to Group 8D Ignition System 2 Faulty coil s 2 Test and replace as necessary Refer to Group 8D Ignition System 3 Dirty fuel injector s Test and replace as necessary Refer to Group 14 Fuel System 4 Contamination in ...

Page 1062: ...nd surface 6 Misaligned connecting rods 6 Replace bent connecting rods MAIN BEARING NOISE 1 Insufficient oil supply 1 Check engine oil level 2 Low oil pressure 2 Check engine oil level Inspect oil pump relief valve and spring 3 Thin or diluted oil 3 Change oil to correct viscosity 4 Excessive bearing clearance 4 Measure bearings for correct clearance Repair as necessary 5 Excessive end play 5 Chec...

Page 1063: ...unction 1 Check system and repair as necessary Refer to Group 25 Emission Control Systems 2 Worn scuffed or broken rings 2 Hone cyinder bores Install new rings 3 Carbon in oil ring slots 3 Install new rings 4 Rings fitted too tightly in grooves 4 Remove rings and check grooves If groove is not proper width replace piston 5 Worn valve guides 5 Ream guides and replace valves with oversize valves and...

Page 1064: ...4 SPECIFICATIONS 2 4L ENGINE 55 TORQUE CHART 2 4L 57 SPECIAL TOOLS 2 4L ENGINE 58 DESCRIPTION AND OPERATION ENGINE IDENTIFICATION The engine identification number is located on the rear of the cylinder block Fig 1 ENGINE LUBRICATION SYSTEM OIL PAN A structural die cast aluminum oil pan provides lower engine protection as well as serving as the engine oil reservoir Oil pan is attached to block and ...

Page 1065: ...s is 4 5 mm The bed plate incorporates main bearing caps Rear seal retainer is integral with the block CRANKSHAFT A nodular cast iron crankshaft is used The engine has 5 main bearings with number 3 flanged to control thrust The 60 mm diameter main and 50 mm diameter crank pin journals all have undercut fillets that are deep rolled for added strength To evenly distribute bearing loads and min imize...

Page 1066: ...front engine cover and driven by the crankshaft Pressurized oil is then routed through the main oil gallery running the length of the cylin der block supplying main and rod bearings with fur ther routing Pistons are lubricated from rod bearing throw off and lubricating slots on the connecting rod assemblies Camshaft and valve mechanisms are lubricated from a full length cylinder head oil gallery s...

Page 1067: ...Piston Size Location Fig 3 Piston Measurement Fig 4 Piston Ring Gap PISTON RING SPECIFICATION CHART Ring Position Ring Gap Wear Limit Upper Ring 0 025 to 0 51 mm 0 0098 to 0 020 in 0 8 mm 0 031 in Intermediate Ring 0 23 to 0 48 mm 0 009 to 0 018 in 0 8 mm 0 031 in Oil Control Ring 0 25 to 0 64 mm 0 0098 to 0 025 in 1 0 mm 0 039 in Ring Position Groove Clearance Max Clearance Upper Ring 0 030 to 0 ...

Page 1068: ...or the use of Plastigage 1 Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke 2 Remove oil film from surface to be checked Plastigage is soluble in oil 3 Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approx imately 6 35 mm 1 4 in off center and away from the oil hole Fig 9 In addition suspect areas can be checke...

Page 1069: ...before installation Bearing shells are available in standard and the following undersized 0 025 mm 0 001 in and 0 250 mm 0 010 in Never install an undersize bearing that will reduce clearance below specifications MAIN BEARING INSTALLATION 1 Install the main bearing shells with the lubri cation groove in the cylinder block Fig 11 2 Make certain oil holes in block line up with oil holes in bearings ...

Page 1070: ... in it s furthest forward position Step 5 Install and tighten bolts 1 10 in sequence shown in Fig 13 to 41 N m 30 ft lbs Step 6 Remove wedge tool used to hold crank shaft 9 Tighten bolts 1 10 again to 41 N m 30 ft lbs 1 4 turn in sequence shown in Fig 13 10 Install main bearing bedplate to engine block bolts 11 through 20 and torque each bolt to 28 N m 20 ft lbs in sequence shown in Fig 13 11 Afte...

Page 1071: ... valves have been removed for inspec tion reconditioning or replacement valve springs should be tested As an example the compression length of the spring to be tested is 33 34 mm 1 5 16 inches Turn tool table until surface is in line with the 33 34 mm 1 5 16 in mark on the threaded stud and the zero mark on the front Place spring over stud on the table and lift compressing lever to set tone device...

Page 1072: ...one Intake valve seat diameter is 34 37 34 63 mm 1 158 1 363 inch Exhaust valve seat diameter is 29 37 29 63 mm 1 156 1 166 inch 6 Valve seats which are worn or burned can be reworked provided that correct angle and seat width are maintained Otherwise the cylinder head must be replaced 7 When seat is properly positioned the width of intake and exhaust seats should be 0 9 to 1 3 mm 0 35 to 0 051 in...

Page 1073: ...stall a 762 mm 0 030 inch spacer under the valve spring seat to bring spring height back within specification 5 Install rocker arm shafts as previously described in this section 6 Checking dry lash Dry lash is the amount of clearance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed Specified dry lash is 1...

Page 1074: ...should only be serviced as an assembly to prevent noise vibration and harshness concerns 1 Remove the purge duty solenoid and wiring harness from engine mount bracket 2 Remove the two right engine mount insulator vertical fasteners from frame rail and loosen the one horizontal fastener Do not remove the large nut located at the end of the core Fig 24 3 Remove the load on the engine mounts by caref...

Page 1075: ... oil pan collar and or bending strut 1 Perform the following steps for installing struc tural collar and bending strut Refer to Fig 26 Step 1 Place collar into position between tran saxle and oil pan Hand start only collar to transaxle bolt 1 Step 2 Install bolt 4 collar to oil pan hand tight only Step 3 Position bending strut in place and hand start bolt 3 into the upper transaxle hole Step 4 Ins...

Page 1076: ...g engine and transmission 27 Lower vehicle so the weight of ONLY THE ENGINE AND TRANSMISSION are on the cradle 28 Remove engine and transmission mount bolts 29 Raise vehicle slowly It may be necessary to move the engine transmission assembly on the cradle to allow for removal around the body INSTALLATION 1 Position engine and transmission assembly under vehicle and slowly lower the vehicle over th...

Page 1077: ...Fig 27 Positioning Engine Cradle Support Post Mounts Typical NS 2 4L ENGINE 9 27 REMOVAL AND INSTALLATION Continued ...

Page 1078: ...rs to 4 5 N m 40 in lbs b Tighten all fasteners to 9 0 N m 80 in lbs c Tighten all fasteners to 12 N m 105 in lbs 5 Install ignition coil pack and plug wires Tighten fasteners to 12 N m 105 in lbs 6 Install ground strap 7 Install front and rear intake manifold support brackets and attaching nuts but do not tighten at this time 8 Install upper intake manifold Refer to Group 11 Exhaust System and In...

Page 1079: ...hafts 1 Remove camshaft retaining caps and lubricate bearing journals Install cam followers and camshafts with clean oil Install right and left camshaft bearing caps 2 thru 5 and right 6 Tighten M6 fasteners to 12 N m 105 in lbs in sequence shown in Fig 34 2 Apply Mopart Gasket Maker to No 1 and No 6 bearing caps Fig 35 Install bearing caps and tighten M8 fasteners to 28 N m 250 in lbs 3 Bearing e...

Page 1080: ...efer to procedure pre viously outlined in this section 3 Install timing belt sprockets and covers using procedure outlined in this section 4 Install cylinder head cover using procedure out lined in this section BALANCE SHAFTS CARRIER ASSEMBLY BALANCE SHAFTS REMOVAL Refer to Timing Belt Cover and Timing Belt removal procedure in this section To repair balance shafts carrier assembly 1 Remove chain ...

Page 1081: ...op 3 Remove carrier to crankcase attaching bolts to remove carrier BALANCE SHAFT INSTALLATION Balance shaft and carrier assembly installation is the reverse of the removal procedure During instal lation crankshaft to balance shaft timing must be established Refer to Timing procedure out lined in this section BALANCE SHAFT TIMING 1 With balance shafts installed in carrier Fig 42 position carrier on...

Page 1082: ...e chain is over the number 1 cylinder timing mark on the crankshaft sprocket Fig 45 7 Place balance shaft sprocket into the timing chain Fig 45 so that the timing mark on the sprocket yellow dot mates with the lower nickel plated link on the chain 8 With balance shaft keyways pointing up 12 o clock slide the balance shaft sprocket onto the nose of the balance shaft The balance shaft may have to be...

Page 1083: ...c lash adjusters for reassembly in their original position Lash adjusters are serviced as an assembly INSTALLATION 1 Install hydraulic lash adjuster assembly mak ing sure adjusters are at least partially full of oil This is indicated by little or no plunger travel when the lash adjuster is depressed 2 Install cam follower assembly as previously outlined in this section 3 Install camshaft as previo...

Page 1084: ...mshafts and cam followers Refer to procedures outlined in this section for procedures 15 Remove cylinder head bolts and remove cyl inder head from engine block 16 Inspect and clean cylinder head Refer to Cleaning and Inspection outlined in this section for procedures INSTALLATION NOTE The Cylinder head bolts should be exam ined BEFORE reuse If the threads are necked down the bolts should be replac...

Page 1085: ...insure installation in original location 4 Inspect and clean the valves Refer to Cleaning and Inspection outlined in this section for procedure INSTALLATION 1 Coat valve stems with clean engine oil and insert in cylinder head 2 Install new valve stem seals on all valves using a valve stem seal tool Fig 51 The valve stem seals should be pushed firmly and squarely over valve guide CAUTION When overs...

Page 1086: ...using M12 1 75 x 150 mm bolt washer thrust bearing and nut from Special Tool 6792 Install crankshaft vibration damper bolt and tighten to 142 N m 105 ft lbs Fig 54 Fig 52 Checking Spring Installed Height and Valve Tip Height Dimensions Fig 53 Crankshaft Vibration Damper Removal Fig 54 Crankshaft Vibration Damper Installation 9 36 2 4L ENGINE NS REMOVAL AND INSTALLATION Continued ...

Page 1087: ...teners Fig 56 2 Install camshaft sprockets While holding sprocket with Special Tools C 4687 and C 4687 1 tighten center bolt to 101 N m 75 ft lbs 3 Install timing belt idler pulley and tighten mounting bolt to 61 N m 45 ft lbs 4 Install Timing Belt Refer to procedure outlined in this section 5 Install engine mount bracket and tighten bolts to 61 N m 45 ft lbs 6 Install front covers TIMING BELT REM...

Page 1088: ...t sprocket trail ing edge of sprocket tooth Fig 58 NOTE The crankshaft sprocket mark is located on the trailing edge of the sprocket tooth Failure to align trailing edge of sprocket tooth to mark on oil pump housing will cause the camshaft marks to be misaligned Fig 58 9 Install 6 mm Allen wrench into belt tensioner Before rotating the tensioner insert the long end of a 1 8 or 3 mm Allen wrench in...

Page 1089: ... to align marks and take up belt slack NOTE A new tensioner is held in the wound posi tion by a pull pin 5 Remove the pull pin or Allen wrench from the belt tensioner 6 Once timing belt has been installed and ten sioner released rotate crankshaft two 2 complete revolutions Verify that the TDC marks on crank shaft and timing marks on the camshafts are aligned as shown in Fig 60 7 Install right engi...

Page 1090: ... properly align tensioner assembly in stall one of the engine bracket mounting bolts M10 5 to 7 turns into the tensioner s upper mounting loca tion Fig 65 2 Torque the tensioner s lower mounting bolt to 61 N m 45 ft lbs Remove the upper bolt used for tensioner alignment 3 Install rear timing belt cover and fasteners 4 Install timing belt idler pulley and tighten mounting bolt to 61 N m 45 ft lbs 5...

Page 1091: ...urface must be free of varnish dirt or nicks Polish with 400 grit paper if necessary 2 Install camshaft seal into cylinder head using Special Tool MD 998306 until flush with head Fig 68 3 Install camshaft sprocket While holding sprocket with Special Tools C 4687 and 4687 1 tighten center bolt to 101 N m 75 ft lbs Fig 66 Fig 65 Timing Belt Tensioner Assembly Removal Installation Fig 66 Camshaft Spr...

Page 1092: ... using Tool 6780 Fig 72 2 Place seal into opening with seal spring towards the inside of engine Install seal until flush with cover 3 Install crankshaft sprocket Fig 73 Using Special Tool 6792 4 Install timing belt and timing belt covers Refer to Timing System Section for timing belt covers and belt 5 Install crankshaft damper Fig 74 Use thrust bearing washer and 12M 1 75 x 150 mm bolt from Specia...

Page 1093: ...st lip against metal case of the seal Pry out seal CAUTION Do not permit the screwdriver blade to contact crankshaft seal surface Contact of the screwdriver blade against crankshaft edge cham fer is permitted Fig 73 Crankshaft Sprocket Installation Fig 74 Crankshaft Damper Installation Fig 75 Rear Crankshaft Oil Seal Removal NS 2 4L ENGINE 9 43 REMOVAL AND INSTALLATION Continued ...

Page 1094: ...SIDE OUT on seal Fig 76 Pilot tool should remain on crankshaft during instal lation of seal Ensure that the lip of the seal is facing towards the crankcase during installation CAUTION If the seal is driven into the block past flush this may cause an oil leak 3 Drive the seal into the block using Special Tool 6926 2 and handle C 4171 Fig 77 until the tool bot toms out against the block Fig 78 Fig 7...

Page 1095: ...nding strut Refer to Fig 79 Step 1 Place collar into position between tran saxle and oil pan Hand start only collar to transaxle bolt 1 Step 2 Install bolt 4 collar to oil pan hand tight only Step 3 Position bending strut in place and hand start bolt 3 into the upper transaxle hole Step 4 Install bolt 2 through strut and collar Hand starting only Step 5 Install bolt 6 strut to cylinder block hand ...

Page 1096: ...ft INSTALLATION 1 Install the main bearing shells with the lubri cation groove in the cylinder block Fig 82 2 Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots CAUTION Do not get oil on the bedplate mating surface It will may effect the sealer ability to seal the bedplate to cylinder block 3 Oil the bearings and journals Install crank sh...

Page 1097: ... 20 ft lbs in sequence shown in Fig 84 11 After the main bearing bedplate is installed check the crankshaft turning torque The turning torque should not exceed 5 6 Nzm 50 in lbs OIL FILTER CAUTION When servicing the oil filter avoid deforming the filter can by installing the remove in stall tool band strap against the can to base lock seam The lock seam joining the can to the base is reinforced by...

Page 1098: ...pump to align or damage may result 5 Install new front crankshaft seal using Special Tool 6780 Fig 88 6 Install crankshaft sprocket using Special Tool 6792 Fig 89 7 Install oil pump pick up tube CAUTION Installation and torque procedure for the collar must be followed or damage could occur to oil pan or collar 8 Install oil pan and collar Refer to procedure outlined in this section 9 Install Timin...

Page 1099: ...moved from top of cylinder block Rotate crankshaft so that each connecting rod is centered in cylinder bore 5 Remove Balance Shaft Assembly Refer to Bal ance Shaft Removal in this section 6 Remove connecting rod cap bolts Push each piston and rod assembly out of cylinder bore NOTE Be careful not to nick crankshaft journals 7 After removal install bearing cap on the mat ing rod 8 Piston and Rods ar...

Page 1100: ...n connecting rod journal NOTE The rod bearing bolts should not be reused 7 Before installing the NEW bolts the threads should be coated with clean engine oil 8 Install each bolt finger tight than alternately torque each bolt to assemble the cap properly CAUTION Do not use a torque wrench for second part of last step 9 Tighten the bolts to 27 N m PLUS 1 4 turn 20 ft lbs PLUS 1 4 turn 10 Using a fee...

Page 1101: ...ct camshaft bearing journals for scoring VALVE GUIDES 1 Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner 2 Using a small hole gauge and a micrometer measure valve guides in 3 places top middle and bot tom Fig 97 Refer to Valve Guide Specification Chart Replace guides if they are not within specifi cation 3 Check valve guide height Fig 98 VALVE AND VALVE ...

Page 1102: ...rtant that the final paper or cloth pol ish after any journal regrind be in the same direc tion as normal rotation in the engine OIL PUMP 1 Clean all parts thoroughly Mating surface of the oil pump should be smooth Fig 100 Replace pump cover if scratched or grooved 2 Lay a straightedge across the pump cover sur face Fig 101 If a 0 025 mm 0 001 in feeler gauge can be inserted between cover and stra...

Page 1103: ...t should test between 18 and 19 pounds when compressed to 40 5 mm 1 60 inches Replace spring that fails to meet specifications 10 If oil pressure is low and pump is within specifications inspect for worn engine bearings or other reasons for oil pressure loss Fig 102 Measuring Outer Rotor Thickness Fig 103 Measuring Inner Rotor Thickness Fig 104 Measuring Outer Rotor Clearance in Housing Fig 105 Me...

Page 1104: ...ansmission assembly with a floor jack 2 Loosen the right engine mount insulator verti cal fastener and the fore and aft fasteners and the front engine mount bracket to front crossmember screws 3 Pry the engine right or left as required to achieve the proper drive shaft assembly length Refer to Group 2 Suspension and Driveshafts for drive shaft identification and related assembly length mea suring ...

Page 1105: ...n Piston Ring Side Clearance Top and Second Compression Rings 0 030 0 080 mm 0 0011 0 0031 in Oil Ring Pack 0 012 0 178 mm 0 0004 0 0070 in Piston Ring Width Compression Rings 1 47 1 50 mm 0 057 0 059 in Oil Ring Pack 2 72 2 88 mm 0 107 0 1133 in Connecting Rod Bearing Clearance 0 025 0 071 mm 0 0009 0 0027 in Piston Pin Bore Diameter 20 96 20 98 mm 0 8252 0 8260 in Large End Bore Diameter 53 007 ...

Page 1106: ...r Intake 5 934 5 952 mm 0 234 0 234 in Stem Diameter Exhaust 5 906 5 924 mm 0 233 0 233 in Stem to Guide Clearance Intake 0 048 0 066 mm 0 0018 0 0025 in Stem to Guide Clearance Exhaust 0 0736 0 094 mm 0 0029 0 0037 in Max Allowable Stem to Guide Clearance Intake and Exhaust 0 025 mm 0 010 in Valve Springs Free Length Approx 48 4 mm 1 905 in Spring Tension Valve Closed 338 N 620 N 38 0 mm 75 98 lb...

Page 1107: ...nder Head Cover Bolts 12 N m 105 in lbs DESCRIPTION TORQUE Engine Mount Bracket Bolts 61 N m 45 ft lbs Engine Mount Front and Rear Through Bolt 61 N m 45 ft lbs Exhaust Manifold to Cylinder Head Bolts 23 N m 200 in lbs Exhaust Manifold Heat Shield Bolts 12 N m 105 in lbs Front Torque Bracket 2 0 2 4L Engine Bolts 33 N m 24 ft lbs Front Torque Bracket Strut 2 0 2 4L Engine Long Bolts 110 N m 80 ft ...

Page 1108: ...GINE Puller 1026 Crankshaft Damper Removal Insert 6827 A Dolly 6135 Cradle 6710 Post Kit Engine Cradle 6848 Camshaft Sprocket Remover Installer C 4687 Camshaft Sprocket Remover Installer Adapter C 4687 1 9 58 2 4L ENGINE NS ...

Page 1109: ...998306 Crankshaft Damper Installer 6792 Valve Spring Compressor MD 998772 A Valve Spring Compressor Adapter 6779 Cylinder Bore Gage C 119 Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Remover Insert C 4685 C2 NS 2 4L ENGINE 9 59 SPECIAL TOOLS Continued ...

Page 1110: ...e Gage C 3292 Rear Crankshaft Seal Guide and Installer 6926 1 and 6926 2 Balance Shaft Sprocket Installer 6052 Post Kit Engine Cradle 6848 Post Adapter 8130 Front Crankshaft Oil Seal Installer 6780 9 60 2 4L ENGINE NS SPECIAL TOOLS Continued ...

Page 1111: ...ne identification number is located on the rear of the cylinder block just below the cylinder head Fig 1 ENGINE LUBRICATION System is a full flow filtration pressure feed type The oil pump is mounted behind the timing belt cover The pump inner rotor is driven by the crank shaft The engine oil pan contains a baffle plate to control oil level fluctuation during engine operation ENGINE COMPONENTS BLO...

Page 1112: ...operating against the cam shaft The valve actuating end of the rocker arms are machined to retain hydraulic lash adjusters elimi nating valve lash adjustment VALVES Are made of heat resistant steel valve springs are especially designed to be short The valve spring wire cross section is oval shaped and provides the same spring tension as longer springs Valve spring retainers locks and seals are con...

Page 1113: ...cessary CRANKSHAFT OIL CLEARANCE MECHANICAL MEASUREMENT Measure the journal outside diameter and the main bearing inside diameter Fig 6 Fig 7 If the clearance exceeds the specifications limit replace the main bearing s and if necessary replace the crankshaft Refer to Crankshaft Clearance Specifica tion Chart PLASTIGAGE MEASUREMENT 1 Remove oil from journal and bearing shell 2 Install crankshaft 3 ...

Page 1114: ...case of a bearing supplied as a service part its iden tification color is painted at the position show in Fig 10 NOTE Service replacement parts have identifica tion marks but factory assembled parts have no identification marks Service crankshaft identifica tion may have marks or paint at counterweights Refer to Crankshaft Size Classification Chart Fig 6 Measure Crankshaft Journal O D Fig 7 Measur...

Page 1115: ...4 60 000 mm 2 3620 2 3622 in 0 YELLOW ENAMEL CONNECTING ROD JOURNAL 49 980 49 985 mm 1 9677 1 9679 in III WHITE ENAMEL 49 985 49 995 mm 1 9679 1 9683 in II NONE 49 995 50 000 mm 1 9683 1 9685 in I YELLOW ENAMEL Fig 10 Bearing Identification Fig 11 Checking Crankshaft End Play CRANKSHAFT SPECIFICATION CHART Crankshaft End Play New Part 0 05 0 25 mm 0 002 0 001 in Wear Limit 0 30 mm 0 012 in Main Be...

Page 1116: ... at Point B 3 Check for even contact at face center with valve seat Point C 4 Check margin Fig 14 Replace valve if mar gin is out of specification Refer to Valve Specification Chart 5 Check valve guide height Fig 15 6 Measure valve stem to guide clearance Refer to Valve Specification Chart 7 Measure Valve spring free length and square ness Fig 16 Refer to Valve Specification Chart Fig 12 Remove Va...

Page 1117: ...embly compressing the valve spring more than necessary to install valve spring retainer locks can cause the retainer to be forced against the stem seal and damaging it VALVE SPECIFICATION CHART Valve Dimensions INTAKE VALVE MINIMUM Stem Diameter 7 960 mm 0 313 in Face Angle 45 Valve Margin 0 700 mm 0 028 in Length 103 0 mm 4 055 in EXHAUST VALVE MINIMUM Stem Diameter 7 930 mm 0 312 Face Angle 45 V...

Page 1118: ... mount adjustment Refer to Engine Mount Insulator Adjustment FRONT MOUNT REMOVAL 1 Support the engine and transmission assembly with a floor jack so it will not rotate 2 Remove the front engine mount through bolt from the insulator and front crossmember mounting bracket Fig 21 3 Remove six screws from air dam to allow access to the front mount screws 4 Remove the front engine mount screws and remo...

Page 1119: ...move battery cover battery and battery tray with integral vacuum reservoir from vehicle 5 Block off heater hoses to rear heater assembly if equipped 6 Drain cooling system Refer to Group 7 Cooling System for procedure 7 Disconnect heater hoses 8 Remove fan module and radiator Refer to Group 7 Cooling System for procedure 9 Disconnect transmission shift linkage 10 Disconnect throttle body linkage a...

Page 1120: ...Install power steering pump and bracket and accessory drive belt Refer to Group 7 Accessory Drive Belts Section for installation procedure 9 Raise vehicle and install axle shafts Refer to Group 2 Driveshafts for procedure 10 Install transmission and engine mount and bracket assemblies Refer to Engine Mounts in this section for procedure 11 Connect exhaust system to manifold Refer to Group 11 Exhau...

Page 1121: ... caps do not remove the bolts from the bearing caps Remove the rocker arm rocker shafts and bearing cap as an assembly CAMSHAFT INSPECTION 1 Inspect camshaft bearing journals for damage and binding Fig 28 If journals are binding also check the cylinder head for damage Also check cyl inder head oil holes for clogging 2 Front cylinder head camshaft check the tooth surface of the distributor drive ge...

Page 1122: ...and rear assemblies are opposite to each other 3 Tighten bearing cap bolts in the following order to 10 N m 85 in lbs First 3 then 2 1 and 4 4 Repeat step 3 increasing the torque to 20 N m 180 in lbs 5 Install distributor drive adaptor assembly Fig 30 CAMSHAFT SEAL CAMSHAFT END SEAL PLUG IN VEHICLE SERVICE 1 Remove air cleaner assembly from engine 2 Use a small punch and a hammer carefully remove ...

Page 1123: ...ead 6 Replace air cleaner assembly CAMSHAFT OIL SEAL PLUG OUT OF VEHICLE SERVICE 1 Apply light coat of engine oil to the camshaft oil seal lip 2 Install the oil seal using camshaft oil seal installer tool MD 998713 Fig 31 CAMSHAFT END SEAL PLUG SERVICE OUT OF VEHICLE SERVICE Install end seal plug with Special Tool MD 998306 Fig 32 Fig 29 Rocker Arm Shaft Direction Fig 30 Distributor Drive Fig 31 C...

Page 1124: ...et over locating dowels 2 Install head on locating dowels 3 Install 10 mm Allen hex head bolts with wash ers CAUTION Attach the cylinder head bolt washer in the direction shown in Fig 34 4 Tighten bolts in the order shown in Fig 35 When tightening the cylinder head bolts tighten gradually working in two or three steps and finally tighten to specified torque of 108 N m 80 ft lbs 5 Install rocker ar...

Page 1125: ...on for installation Fig 38 2 Loosen timing belt tensioner bolt Fig 40 and remove timing belt 3 Remove crankshaft sprocket flange shield Fig 36 Fig 36 Timing Belt System Fig 37 Timing Belt Covers NS 3 0L ENGINE 9 75 REMOVAL AND INSTALLATION Continued ...

Page 1126: ...n timing belt tensioner counterclockwise full travel in adjustment slot and tighten bolt to tem porarily hold this position Fig 41 INSTALLATION TIMING BELT 1 Install timing belt on crankshaft sprocket and keep belt tight on tension side Fig 38 Install belt on the front radiator side camshaft sprocket Install belt on the water pump pulley rear camshaft sprocket and finally on the timing belt tensio...

Page 1127: ...cessory drive belts in reverse order OIL PAN Oil pan to crankcase sealing is provided with Mopart Silicone Rubber Adhesive Sealant or equiva lent gasket material See Form In Place Gaskets in Standard Service Procedures 1 Apply sealant as shown in Fig 42 2 Install pan and tighten screws to 6 N m 50 in lbs in sequence shown in Fig 43 Fig 41 Positioning Belt Tensioner Fig 42 Oil Pan Sealing Fig 43 Oi...

Page 1128: ... front of engine are to be installed in cylinders 2 4 6 3 Mark connecting rod and cap with cylinder number Fig 46 4 Remove piston rings Fig 47 FITTING PISTONS Measure approximately 2 mm 0 080 in above the bottom of the piston skirt and across the thrust face Fig 48 See Boring Cylinder in Cylinder Block Fig 44 Pistons and Connecting Rods Fig 45 Mark Pistons Fig 46 Mark Matching Parts Fig 47 Remove ...

Page 1129: ...the top of the pis ton Fig 51 CAUTION Install piston rings in the following order a Oil ring expander b Upper oil ring side rail PISTON RING SPECIFICATION CHART Ring Position Ring Gap Ring Gap Wear Limit Groove Clearance Maximum Groove Clearance Upper Ring 0 30 0 45 mm 0 012 0 018 in 0 8 mm 0 031 in 0 05 0 09 mm 0 002 0 0035 in 0 10 mm 0 004 in Intermediate Ring 0 25 0 40 mm 0 010 0 016 in 0 8 mm ...

Page 1130: ...ide rail gaps but not on the piston pin center or on the thrust direction 7 Connecting rod front mark 72 must always face forward toward timing belt end Fig 55 8 Install the piston and connecting rod assembly into there respective bore from the cylinder block top CAUTION Piston assemblies are not to be inter changed from bank to bank 9 Check alignment marks made during disassem bly and that bearin...

Page 1131: ...ono block main bearing cap bolts evenly Remove lower bearing shells and identify for reassembly 4 Lift out crankshaft and remove upper thrust washers from each side of number three main bear ing in the crankcase Fig 57 Fig 57 Crankshaft and Cylinder Block Fig 58 Oil Pump Assembly Fig 59 Rear Seal Assembly NS 3 0L ENGINE 9 81 REMOVAL AND INSTALLATION Continued ...

Page 1132: ...nto the main bearing cap Fig 60 3 Apply a thin film of grease to plain side of thrust washers and position them on each side of number three main bearing Grooved surface towards crankshaft 4 Oil the bearings and journals and install crankshaft 5 Install lower main bearing shells without oil grooves in mono block cap 6 Install one pair of thrust washers in cap Refer to Thrust Bearings Fig 60 7 Care...

Page 1133: ...ntire circumference of oil seal lip 4 Install seal assembly on cylinder block and tighten bolts to 12 N m 104 in lbs FRONT CRANKSHAFT OIL SEAL 1 Install oil pump gasket and oil pump case Fig 65 and Fig 64 CAUTION Install bolts depending on length in locations shown in Fig 64 2 Using front crankshaft oil seal installer Special Tool MD 998717 install oil seal in oil pump Fig 65 Fig 62 Rear Crankshaf...

Page 1134: ...free of debris or old pieces of rubber Fig 68 2 Check adaptor for cracks and oil leaks CAUTION When servicing the oil filter avoid deforming the filter Install the remove install tool band strap against the can to base lock seam The lock seam joining the can to base is reinforced by the base plate 3 Using Tool C 4065 turn filter counterclockwise to remove from base Properly discard filter 4 Wipe b...

Page 1135: ...ng with small wire clean as required Fig 70 REASSEMBLE 1 Align the camshaft bearing caps with arrows depending on cylinder bank directed as shown in Fig 71 and in numerical order Identify number one bearing cap number one and number four caps are similar Fig 72 2 Install rocker shafts so that bearing cap num ber one with end notches positioned as shown in Fig 72 that the machined portion of the ro...

Page 1136: ...t Missing teeth The sides are normal if they are sharp as if cut by a knife Fig 74 NOTE If none of the above conditions are seen on the belt the belt cover can be installed CYLINDER HEAD CLEANING AND INSPECTION 1 Before cleaning check for leaks damage and cracks 2 Clean cylinder head and oil passages 3 Check cylinder head for flatness Fig 76 4 Cylinder head must be flat within Standard dimension l...

Page 1137: ...mum out of round or taper 0 02 mm 0 0008 in OIL PUMP 1 Check oil pump case for damage Remove rear oil pump cover 2 Remove pump rotors and inspect case for exces sive wear 3 Measure clearance between case and inner rotor Fig 78 4 Insert the rotor into the oil pump case and measure clearance between outer rotor and case with a feeler gauge Fig 79 Replace if out of specifica tions Fig 74 Timing Belt ...

Page 1138: ...er and the fore and aft fasteners and the front engine mount bracket to front crossmember screws 3 Pry the engine right or left as required to achieve the proper drive shaft assembly length Refer to Group 2 Suspension and Driveshafts for drive shaft identification and related assembly length mea suring 4 Tighten engine mounts and fasteners in the following order a Right engine mount insulator vert...

Page 1139: ...mm 0 0007 0 0014 in Side Clearance 0 10 0 25 mm 0 004 0 010 in Wear Limit 0 4 mm 0 015 in Length Center to Center 140 9 141 0 mm 5 547 5 551 in Parallelism Twist 0 05 mm 0 0019 in Torsion 0 1 mm 0 0039 in Crankshaft Main Journal Diameter 59 980 60 0 mm 2 361 2 362 in Connecting Rod Journal Diameter 49 980 50 000 mm 1 968 1 969 in Out of Round Max 0 03 mm 0 001 in Taper Max 0 005 mm 0 0002 in Main ...

Page 1140: ...er to Head Oil Pump Bolts 12 N m 105 in lbs Camshaft Sprocket Bolt 95 N m 70 ft lbs Connecting Rod Cap Bolts 27 N m 20 ft lbs Plus 1 4 Turn Crankshaft Main Bearing Cap Bedplate M8 Bedplate Bolts 34 N m 250 in lbs M11 Main Cap Bolts 41 N m 30 ft lbs Plus 1 4 Turn Crankshaft Vibration Damper Bolt 135 N m 100 ft lbs DESCRIPTION TORQUE Cylinder Head Bolts Refer To Cylinder Head Installation Cylinder H...

Page 1141: ...IAL TOOLS 3 0L ENGINE Dolly 6135 Cradle 6710 Adaptor 6909 Adaptor 6910 Camshaft End Plug Installer MD 998306 Valve Stem Seal Installer MD 998729 Rear Crankshaft Seal Installer MD 998718 NS 3 0L ENGINE 9 91 ...

Page 1142: ...Front Crankshaft Seal Installer MD 998717 Oil Filter Wrench C 4065 Spanner Camshaft Sprocket MB 990775 9 92 3 0L ENGINE NS SPECIAL TOOLS Continued ...

Page 1143: ...ow the cylinder head Fig 1 ENGINE LUBRICATION SYSTEM The lubrication system is a full flow filtration pres sure feed type Oil from the oil pan is pumped by a internal gear type oil pump directly coupled to the crankshaft The pressure is regulated by a relief valve located in the chain case cover The oil is pumped through an oil filter and feeds a main oil galley This oil gallery feeds oil under pr...

Page 1144: ...ower output The intake manifold is also cored with upper level EGR passages for balanced cylinder to cylinder EGR distribution VALVE TRAIN Valve train design incorporates the use of hydraulic roller tappets Rocker arms are installed on a rocker arm shaft attached to the cylin der head with four bolts and retainers Viton valve stem seals provide valve sealing Conventional type pushrods retainers an...

Page 1145: ...ng and create foam Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to become soft and allow valves to seat noisily OIL LEVEL TOO LOW Low oil level may allow pump to take in air which when fed to the tappets causes them to become soft and allows valves to seat noisily Any leaks on intake side of pump through which air can be drawn will create the same tappet actio...

Page 1146: ...aptor install a dial indicator into 2 spark plug hole Using the indicator find TDC on the compression stroke 5 Position the degree wheel to zero 6 Remove dial indicator from spark plug hole 7 Place a 5 08 mm 0 200 in spacer between the valve stem tip of 2 intake valve and rocker arm pad Allow tappet to bleed down to give a solid tappet effect 8 Install a dial indicator so plunger contacts the 2 in...

Page 1147: ...e bank until complete The bearing caps are not interchangeable and should be marked at removal to insure correct assembly The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps Install cap with the tangs on the same side as the rod Limits of taper or out of round on any crankshaft journals should be held to 0 025 mm 0 001 in Bearings are availab...

Page 1148: ... m PLUS 1 4 turn 40 ft lbs PLUS 1 4 turn 5 Using a feeler gauge check connecting rod side clearance Fig 12 Refer to Connecting Rod Specifi cation Chart FITTING MAIN BEARINGS CRANKSHAFT OIL CLEARANCE Measure the journal outside diameter as shown in Fig 14 Refer to Crankshaft Specification Chart PISTON RING SPECIFICATION CHART Ring Position Ring Gap Wear Limit Groove Clearance Maximum Clearance Uppe...

Page 1149: ...the Plasti gage may be smeared CRANKSHAFT END PLAY DIAL INDICATOR METHOD 1 Mount a dial indicator to front of engine locat ing probe on nose of crankshaft Fig 16 Fig 12 Checking Connecting Rod Side Clearance CONNECTING ROD SPECIFICATION CHART Connecting Rod Bearing Clearance New Part 0 019 0 073 mm 0 0008 0 0029 in Wear Limit 0 074 mm 0 003 in Connecting Rod Side Clearance New Part 0 13 0 32 mm 0 ...

Page 1150: ...ide clearance as follows a Install valve into cylinder head so it is 14 mm 0 551 in off the valve seat A small piece of hose may be used to hold valve in place b Attach dial indicator Tool C 3339 to cylinder head and set it at right angle of valve stem being measured Fig 17 5 Move valve to and from the indicator Refer to Valve Guide Specification Chart 6 Ream the guides for valves with oversized s...

Page 1151: ...2 in total indicator reading 3 Inspect the valve seat using Prussian blue to determine where the valve contacts the seat To do this coat valve seat LIGHTLY with Prussian blue then set valve in place Rotate the valve with light pressure If the blue is transferred to the center of valve face contact is satisfactory If the blue is trans ferred to top edge of valve face lower valve seat with a 15 degr...

Page 1152: ...nt Multiply this reading by two This will give the spring load at test length Fractional measure ments are indicated on the table for finer adjust ments Refer to specifications to obtain specified height and allowable tensions Discard the springs that do not meet specifications REMOVAL AND INSTALLATION WIPER UNIT When performing work on the upper engine Refer to Section 8K Windshield Wipers and Wa...

Page 1153: ...r a Tighten bolts 2 3 and 4 to 108 N m 80 ft lbs b Tighten bolts 1 and 5 to 54 N m 40 ft lbs 2 Engine mount adjustment Refer to Engine Mount Insulator Adjustment of this section 3 Install six screws to air dam and tighten to 12 N m 105 in lbs LEFT SIDE MOUNT REMOVAL 1 Raise vehicle on hoist and remove left front wheel 2 Support the transmission with a transmission jack 3 Remove the insulator throu...

Page 1154: ...m for procedure 7 Disconnect heater hoses 8 Remove fan module and radiator Refer to Group 7 Cooling System for procedure 9 Disconnect transmission shift linkage 10 Disconnect throttle body linkage and vacuum hoses from throttle body 11 Remove accessory drive belts Refer to Group 7 Accessory Drive Belts located in Cooling System for procedure 12 Remove air conditioning compressor from engine and se...

Page 1155: ...owly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135 6710 6848 and 6909 4 Remove Special tools 6912 and install bending braces 5 Lower vehicle Install generator and wiring harness 6 Connect wiring harness on the front of the engine 7 Install Air Conditioning Compressor 8 Install power steering pump and bracket and accessory drive belt Refer to Accessory drive Section ...

Page 1156: ...or rocker arm for positioning on the shaft INSTALLATION 1 Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions tighten to 28 N m 250 in lbs Fig 31 CAUTION THE ROCKER ARM SHAFT SHOULD BE TORQUED DOWN SLOWLY STARTING WITH THE CENTER BOLTS ALLOW 20 MINUTES TAPPET BLEED DOWN TIME AFTER INSTALLATION OF THE ROCKER SHAFTS BEFORE ENGINE OPERATION 2 Clean cylinder ...

Page 1157: ...cal connector to igni tion coils 16 Install Intake Manifold Refer to Group 11 Exhaust System and Intake Manifold for procedure 17 Connect negative cable to battery CYLINDER HEAD COVER REMOVAL NOTE The cylinder head cover can be either an isolated type Fig 32 or a non isolated type FRONT CYLINDER HEAD COVER 1 Disconnect ignition cables from spark plugs 2 Disconnect crankcase vent hose from cylinder...

Page 1158: ...ach cylinder head and remove cylinder heads Fig 33 INSTALLATION 1 Clean all sealing surfaces of cylinder block and cylinder heads 2 Install new gaskets on cylinder block Fig 34 3 The cylinder head bolts are torqued using the torque yield method they should be exam ined BEFORE reuse If the threads are necked down the bolts should be replaced Fig 35 4 Necking can be checked by holding a scale or str...

Page 1159: ...t Fig 38 Torque end seal retainer screws to 12 N m 105 in lbs 4 Install intake manifold and 8 bolts and torque to 1 N m 10 in lbs Then tighten bolts to 22 N m 200 in lbs in sequence shown in Fig 39 Then tighten again to 22 N m 200 in lbs After intake manifold is in place inspect to make sure seals are in place Refer to Group 11 Exhaust System and Intake Manifold to complete intake manifold install...

Page 1160: ... counterbore to bring spring height back to normal 1 17 32 to 1 19 32 inch 39 1 to 40 6 mm TAPPET REMOVAL 1 Refer to Cylinder Head Removal in this section Cylinder Head must be removed to gain access to tappets for service 2 Remove yoke retainer and aligning yokes 3 Use Tool C 4129 to remove tappets from their bores If all tappets are to be removed identify tap pets to insure installation in origi...

Page 1161: ...9 Remove A C compressor mounting bracket 10 Remove crankshaft damper Fig 44 11 Remove idler pulley from engine bracket 12 Remove engine bracket Fig 45 13 Remove cam sensor from chain case cover Fig 46 14 Remove chain case cover Fig 46 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 insure cor rect oi...

Page 1162: ...ount 18 Fill crankcase with oil to proper level 19 Fill cooling system Refer to Group 7 Cooling System for procedure 20 Connect negative cable to battery TIMING CHAIN REMOVAL 1 Disconnect negative cable from battery 2 Remove timing chain cover Refer to procedure outlined in this section 3 Remove camshaft sprocket attaching bolt and timing chain with camshaft sprocket 4 Using a suitable puller remo...

Page 1163: ...ove camshaft being careful not to damage cam bearings with the cam lobes INSTALLATION 1 Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 2 inches of its final position in cylinder block 2 Install camshaft thrust plate with two screws as shown in Fig 51 Tighten to 12 N m 105 in lbs torque 3 Rotate crankshaft so the timing arrow is at the 12 o clock position 4...

Page 1164: ...g must index with the oil passage to the right cylinder head If the camshaft bearing shell oil holes are not in exact alignment remove and rein stall them correctly Install a new core hole plug at the rear of camshaft Be sure this plug does not leak OIL PAN REMOVAL 1 Disconnect negative cable from battery and remove engine oil dipstick 2 Raise vehicle on hoist and drain engine oil 3 Remove bending...

Page 1165: ...rnals 6 After removal install bearing cap on the mat ing rod INSTALLING PISTON AND CONNECTING ROD ASSEMBLY 1 Before installing pistons and connecting rod assemblies into the bore be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap Fig 58 2 Before installing the ring compressor make sure the oil ring expander ends are butted and the rail gaps located a...

Page 1166: ...d 0 305 mm 0 012 in under the standard journal diameter Do NOT grind thrust faces of Number 2 main bearing Do NOT nick crank pin or bearing fillets After grinding remove rough edges from crankshaft oil holes and clean out all passages CAUTION With the nodular cast iron crankshafts used it is important that the final paper or cloth pol ish after any journal regrind be in the same direc tion as norm...

Page 1167: ...l between the rear of the cylinder block and rear crankshaft counter weight This will hold the crankshaft in it s most for ward position d Tighten the 2 Thrust Bearing cap bolts to 41 N m 1 4 Turn 30 ft lbs 1 4 Turn Remove the holding tool 7 Install oil pan 8 Fill engine crankcase with proper oil to correct level CRANKSHAFT OIL SEAL FRONT REMOVAL 1 Disconnect negative cable from battery 2 Raise ve...

Page 1168: ...on the crankshaft edge chamfer cleanup with 400 grit sand paper to prevent seal damage during installa tion of new seal 1 Place Special Tool 6926 1 magnetic pilot tool on crankshaft Fig 70 2 Lightly coat seal O D with Mopart Stud N Bearing Mount Adhesive or equivalent 3 Place seal over Special Tool 6926 1 Pilot Using Special Tool 6926 2 Installer with C 4171 Handle drive seal into the retainer hou...

Page 1169: ...ol and remove plug Fig 72 CAUTION Do not drive cup plug into the casting as restricted cooling can result and cause serious engine problems INSTALLATION Thoroughly clean inside of cup plug hole in cylin der block or head Be sure to remove old sealer Lightly coat inside of cup plug hole with Loctite Stud N Bearing Mount or equivalent Make certain the new plug is cleaned of all oil or grease Using p...

Page 1170: ...ring Check valve could be flat or ball ASSEMBLY 1 Clean all tappet parts in a solvent that will remove all varnish and carbon 2 Replace tappets that are unfit for further ser vice with new assemblies 3 If plunger shows signs of scoring or wear valve is pitted or valve seat on end of plunger indicates any condition that would prevent valve from seating install a new tappet assembly 4 Assemble tappe...

Page 1171: ...sure clearance between rotor and chain case cover Fig 80 If measurement is 0 39 mm 0 015 in or more replace CCC only if outer rotor is in specification 6 Install inner rotor into chain case cover If clearance between inner and outer rotors Fig 81 is 0 203 mm 0 008 in or more replace both rotors 7 Place a straightedge across the face of the chain case cover between bolt holes If a feeler gauge of 0...

Page 1172: ...ced Measure the cylinder bore at three levels in direc tions A and B Fig 83 Top measurement should be 12 mm 0 50 in down and bottom measurement should be 12 mm 0 50 in up from bottom of bore Refer to Cylinder Bore and Piston Specification Chart Fig 79 Measuring Inner Rotor Thickness Fig 80 Measuring Outer Rotor Clearance in Housing Fig 81 Measuring Clearance Between Rotors Fig 82 Measuring Clearan...

Page 1173: ...PM Torque 3 3L 203 lb ft 3600 RPM Torque 3 8L 240 lb ft 3600 RPM Firing Order 1 2 3 4 5 6 Compression Pressure Refer to Engine Performance in Standard Service Procedures Cylinder Number Front to Rear Front Bank 2 4 6 Rear Bank 1 3 6 Cylinder Block Cylinder Bore Standard 3 3L 93 0 mm 3 66 in Cylinder Bore Standard 3 8L 96 0 mm 3 779 in Out of Round Max 0 076 mm 0 003 in Taper Max 0 051 mm 0 002 in ...

Page 1174: ...5195 in Out of Round Max 0 025 mm 0 001 in Taper Max 0 025 mm 0 001 in Connecting Rod Journals Diameter 58 005 57 979 mm 2 2837 2 2827 in Out of Round Max 0 025 mm 0 001 in Taper Max 0 025 mm 0 001 in Camshaft Drive Chain Bearings Steel Backed Babbitt Number 4 Diametrical Clearance 0 025 0 101 mm 0 001 0 004 in Max Allowable 0 127 mm 0 005 in Thrust Taken By Thrust Plate End Play 0 127 0 304 mm 0 ...

Page 1175: ... 40 in Valve Tip Height From Cylinder Head Surface 49 541 51 271 mm 1 950 2 018 in Stem Diameter Standar 7 906 7 924 mm 0 3112 0 3119 in Stem to Guide Clearance 0 051 0 175 mm 0 002 0 006 in Max Allowable Rocking Method 0 414 mm 0 016 in Valves for Service Oversize Stem Diameters Std 0 015 mm 0 005 in 0 40 mm 0 015 in 0 80 mm 0 030 in Valve Springs Free Length Approx 48 5 mm 1 909 in Wire Diameter...

Page 1176: ...Pivot Nut 41 N m 30 ft lbs Intake Manifold Bolts 23 N m 200 in lbs Intake Manifold Gasket Retaining Screws 12 N m 105 in lbs Intake Manifold Plenum Bolts 28 N m 250 in lbs Main Bearing Cap Bolts 41 N m 30 ft lbs 1 4 Turn Oil Filter Attaching Nipple 41 N m 30 ft lbs DESCRIPTION TORQUE Oil Pan Bolts 12 N m 105 in lbs Drain Plug 27 N m 20 ft lbs Level Sensor Plug 41 N m 30 ft lbs Oil Pressure Gauge S...

Page 1177: ...SPECIAL TOOLS 3 3 3 8L ENGINE Adaptor 6909 Dolly 6135 Cradle 6710 Adaptor 6912 Puller 1023 Indicator Cylinder Bore C 119 NS 3 3 3 8L ENGINE 9 127 ...

Page 1178: ...shaft Pulley Remover L 4524 1 Front Crankshaft Seal Installer C 4992 Camshaft Bearing Remover and Installer C 3132 A Crankshaft Main Bearing Remover and Installer C 3059 Rear Crankshaft Seal Guide and Installer 6926 1 and 6926 2 Oil Filter Wrench C 4065 9 128 3 3 3 8L ENGINE NS SPECIAL TOOLS Continued ...

Page 1179: ... 10 FRONT CRANKSHAFT OIL SEAL 18 OIL FILTER 24 OIL FILTER ADAPTER 24 OIL PAN 17 OIL PUMP 25 PISTON AND CONNECTING ROD 25 ROCKER ARM HYDRAULIC LASH ADJUSTER 8 SPARK PLUG TUBE 7 TIMING BELT COVER 11 TIMING BELT SYSTEM 13 VALVE SEALS AND SPRINGS IN VEHICLE 10 VIBRATION DAMPER 28 DISASSEMBLY AND ASSEMBLY OIL PUMP 29 VALVE SERVICE WITH THE CYLINDER HEAD REMOVED 29 CLEANING AND INSPECTION CYLINDER BLOCK...

Page 1180: ...ting Rod bearing oil throw off lubricates the pistons from directed slots on the side of the connecting rod assemblies Camshaft and valve mechanisms are lubricated from a full length cylinder head oil gallery supplied from the crankcase main oil gallery PRESSURE LUBRICATION Oil drawn up through the pickup tube is pressur ized by the pump and routed through the full flow fil ter to the main oil gal...

Page 1181: ...ckage consist of 2 steel rails and a expander spacer CYLINDER HEAD SOHC It features a Single Over Head Camshaft four valves per cylinder cross flow design The valves are arranged in two inline banks with the two intake per cylinder facing toward the radiator The exhaust valves facing toward the dash panel Rocker arm shafts mount directly to the cylinder head It incorporates powder metal valve guid...

Page 1182: ... from the bot tom of the skirt as shown in Fig 4 Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in Fig 3 Refer to Cylinder Bore and Speci fications Table Correct piston to bore clearance must be established in order to assure quiet and economi cal operation Chrysler engines use pistons designed specifically for each engine...

Page 1183: ... 1 4 turn 20 ft lbs PLUS 1 4 turn Do not use a torque wrench for last step 5 Using a feeler gauge check connecting rod side clearance Fig 8 Refer to Connecting Rod Specifica tion Chart for specifications Fig 5 Piston Ring Gap Fig 6 Piston Ring Side Clearance PISTON RING SPECIFICATION CHART Ring Position Ring Gap Ring Gap Wear Limit Groove Clearance Maximum Groove Clearance Upper Ring 0 23 0 52 mm ...

Page 1184: ...head and cover mating surfaces Make certain the cylinder head cover mating surface is flat 1 Install new valve cover gasket CAUTION Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping 2 Install cover assembly to head and tighten fas teners to 12 N m 105 in lbs 3 Install ignition coil pack Tighten fasteners to 23 N m 200 in lbs CONNECT...

Page 1185: ...EMOVAL 1 Perform fuel system pressure release procedure before attempting any repairs Refer to Group 14 Fuel System 2 Remove the cylinder head cover Refer to proce dure outlined in this section 3 Mark rocker arm shaft assemblies so that they are installed in their original positions 4 Remove rocker arm shaft bolts Refer to proce dure outlined in this section 5 Remove timing belt timing belt tensio...

Page 1186: ...shaft sprocket and tighten to 115 N m 85 ft lbs 8 Install inner timing belt cover 9 Install timing belt tensioner and timing belt Refer to procedures outlined in this section 10 Install rocker arm assemblies in correct order as removed Tighten the rocker arm assemblies in sequence shown in Fig 14 to 28 N m 250 in lbs 11 Install cylinder head cover and tighten fasten ers to 12 N m 105 in lbs 12 Ins...

Page 1187: ... plunger travel Place the rocker arm assembly into clean engine oil and pump the plunger until the lash adjuster travel is taken up If travel is not reduced replace the assembly Hydraulic lash adjuster and rocker arm are serviced as an assembly 2 Install rocker arm and shaft assemblies with NOTCH in the rocker arm shafts pointing up and toward the timing belt side of the engine Fig 17 Install the ...

Page 1188: ... avoid nicking valve stems air pressure required piston at TDC 3 Install rocker arm shaft assemblies as previ ously outlined in this section 4 Install valve cover as previously outlined in this section CYLINDER HEAD REMOVAL 1 Perform fuel system pressure release procedure before attempting any repairs Refer to Group 14 Fuel System 2 Disconnect negative battery cable Drain cool ing system Refer to ...

Page 1189: ...own in Fig 23 Using the 4 step torque method tighten according to the following values First All to 34 N m 25 ft lbs Second All to 68 N m 50 ft lbs Third All to 68 N m 50 ft lbs Fourth Turn an additional 1 4 Turn Do not use a torque wrench for this step For the rest of installation reverse removal proce dure TIMING BELT COVER REMOVAL 1 Remove accessory drive belts Refer to Group 7 Cooling System f...

Page 1190: ... procedure is outlined in this section Remove cam shaft sprocket bolt with the Modified Special Tool C 4687 1 as shown in Fig 25 2 Hold camshaft sprocket with modified tool while removing bolt Remove sprocket from camshaft 3 Remove camshaft seal using Special Tool C 4679 A Fig 26 CAUTION Do not nick shaft seal surface or seal bore 4 Shaft seal lip surface must be free of varnish dirt or nicks Poli...

Page 1191: ...C on the compression stroke Remove the access plug from the outer timing belt cover Fig 28 Check the timing mark on the camshaft sprocket it should align with the arrow on the rear belt cover Fig 29 REMOVAL TIMING BELT 1 Remove accessory drive belts Refer to Group 7 Cooling System for procedure outlined in that sec tion 2 Remove crankshaft damper bolt Remove damper using the large side of Special ...

Page 1192: ...ith soft jaws and slowly compress the plunger Fig 34 CAUTION Index the tensioner in the vise the same way it is installed on the engine This is to ensure proper pin orientation when tensioner is installed on the engine 3 When plunger is compressed into the tensioner body install a 1 9 mm 5 64 allen wrench or pin through the body and plunger to retain plunger in place until tensioner is installed 4...

Page 1193: ... N m 250 in lbs of torque Fig 38 10 With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 N m 275 in lbs Fig 38 11 Pull tensioner plunger pin Pretension is cor rect when pin can be removed and installed 12 Rotate crankshaft 2 revolutions and check the alignment of the timing marks Fig 38 13 Install front half of tim...

Page 1194: ... wrench while pushing in lightly on the 1 8 in or 3 mm Allen wrench until it slides into the locking hole 9 Remove timing belt CAUTION Do not rotate the camshafts once the timing belt has been removed or damage to valve components may occur CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND BELT INSTALLATION SOHC ENGINE 1 Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil ...

Page 1195: ...2 Remove transmission inspection cover 3 If equipped with air conditioning remove oil fil ter and adaptor Refer to Oil Filter Adapter Removal and Installation in this section 4 Remove oil pan 5 Clean oil pan and all gasket surfaces Fig 40 Timing Belt System Fig 41 Camshaft Timing Marks Fig 42 Right Inner Splash Shield NS GS ENGINE 9 17 REMOVAL AND INSTALLATION Continued ...

Page 1196: ...r 3 8 Liters 4 0 Qts FRONT CRANKSHAFT OIL SEAL REMOVAL 1 Using Special Tool 1026 and Insert 6827 A remove crankshaft damper Fig 53 2 Remove outer timing belt cover and timing belt Refer to Timing Belt System outlined in this section 3 Remove crankshaft sprocket using Special Tool 6793 and insert C 4685 C2 Fig 54 CAUTION Do not nick shaft seal surface or seal bore Fig 43 Crankshaft Damper Removal F...

Page 1197: ...ing Special Tool 6792 NOTE Make sure the word front on the sprocket is facing you 4 Install timing belt and covers Refer to Timing Belt System in this section for installation 5 Install crankshaft damper Fig 58 Use thrust bearing washer and 12M 1 75 x 150 mm bolt from Fig 47 Crankshaft Sprocket Timing Fig 48 Camshaft Timing Mark Fig 49 Adjusting Crankshaft Sprocket for Timing Belt Installation Fig...

Page 1198: ...the screwdriver blade to contact crankshaft seal surface Contact of the screwdriver blade against crankshaft edge cham fer is permitted INSTALLATION CAUTION If burr or scratch is present on the crankshaft edge chamfer cleanup with 400 grit sand paper to prevent seal damage during installa tion of new seal Fig 52 Oil Pan Sealing Fig 53 Crankshaft Damper Removal Fig 54 Crankshaft Sprocket Removal Fi...

Page 1199: ...lock using Special Tool 6926 2 and handle C 4171 Fig 61 until the tool bot toms out against the block Fig 62 CRANKSHAFT REMOVAL 1 Remove oil filter and adapter from bedplate 2 Remove collar from oil pan to transmission housing 3 Remove oil pan 4 Remove crankshaft sprocket and oil pump both procedures outlined in this section 5 Remove all main bearing cap and bedplate bolts from the engine block Fi...

Page 1200: ...O NOT nick crank pin or bearing fillets After grinding remove rough edges from crankshaft oil holes and clean out all passages CAUTION With the nodular cast iron crankshafts used it is important that the final paper or cloth pol ish after any journal regrind be in the same direc tion as normal rotation in the engine Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust...

Page 1201: ...n bearing cap bedplate Make certain the bearing tabs are seated into the bedplate slots Install the main bear ing bedplate into engine block 6 Before installing the bolts oil threads with clean engine oil wipe off any excess oil 7 Install main bearing bedplate to engine block bolts 11 17 and 20 finger tight Tighten this bolts down together until the bedplate contacts the cylin der block Torque bol...

Page 1202: ...located in the passenger compartment at the lower edge of instrument panel near the steering column Turn the ignition switch on and access the mis cellaneous screen Select re learn cam crank option and follow directions on DRB screen OIL FILTER ADAPTER REMOVE AND INSTALL Ensure O ring is in the groove on adapter Align roll pin into engine block and tighten assembly to 80 N m 60 ft lbs Fig 68 OIL F...

Page 1203: ...r bores with a reli able ridge reamer before removing pistons from cyl inder block Be sure to keep tops of pistons covered during this operation Mark piston with matching cylinder number Fig 75 2 Remove oil pan Scribe the cylinder number on the side of the rod and cap Fig 76 for identification 3 Pistons will have a stamping in the approxi mate location shown in Fig 75 These stamps will be either a...

Page 1204: ...deposits PISTON RINGS INSTALLATION 1 Install rings with manufacturers I D mark fac ing up to the top of the piston Fig 78 CAUTION Install piston rings in the following order a Oil ring expander b Upper oil ring side rail c Lower oil ring side rail d No 2 Intermediate piston ring Fig 71 Oil Pump and Tube Fig 72 Oil Pump Sealing Fig 73 Front Crankshaft Seal Installation 9 26 ENGINE NS GS REMOVAL AND...

Page 1205: ...lower side rail 3 Install No 2 piston ring and then No 1 piston ring Fig 78 4 Position piston ring end gaps as shown in Fig 80 5 Position oil ring expander gap at least 45 from the side rail gaps but not on the piston pin center or Fig 74 Crankshaft Sprocket Installation Fig 75 Piston Markings Fig 76 Identify Connecting Rod to Cylinder Fig 77 Piston Rings Removing and Installing Fig 78 Piston Ring...

Page 1206: ...r DOHC engine Fig 75 5 Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore Insert rod and piston assembly into cylinder bore and guide rod over the crankshaft journal 6 Tap the piston down in cylinder bore using a hammer handle At the same time guide connecting rod into position on connecting rod journal 7 Install rod caps Install New bolts and tighten to 27 ...

Page 1207: ...ve retaining locks valve spring retainers valve stem seals and valve springs 3 Before removing valves remove any burrs from valve stem lock grooves to prevent dam age to the valve guides Identify valves to insure installation in original location VALVE INSPECTION 1 Clean valves thoroughly and discard burned warped and cracked valves 2 Measure valve stems for wear Measure stem about 60 mm beneath t...

Page 1208: ...1 16 inch out of square install a new spring REFACING VALVES AND VALVE SEATS 1 The intake and exhaust valve seats and valve face have a 45 degree angle 2 Inspect the remaining margin after the valves are refaced Fig 90 Intake valves with less than 0 95 mm 1 32 inch margin and Exhaust valves with less than 1 05 mm 3 64 inch margin should be discarded 3 When refacing valve seats it is important that...

Page 1209: ...1 81 in for intake valve over spring seat when installed in the head Fig 92 The valve tip chamfer may need to be reground to prevent seal damage when the valve is installed CLEANING Clean all valve guides valves and valve spring assemblies thoroughly with suitable cleaning solution before reassembling VALVE INSTALLATION 1 Coat valve stems with clean engine oil and insert in cylinder head 2 Install...

Page 1210: ...nder head camshaft bearings for wear Check camshaft journals for scratches and worn areas If light scratches are present they may be removed with 400 grit sand paper If deep scratches are present replace the camshaft and check the cyl inder head for damage Replace the cylinder head if worn or damaged Check the lobes for pitting and wear If the lobes show signs of wear check the cor responding rock...

Page 1211: ...nspect oil pressure relief valve plunger for scoring and free operation in its bore Small marks may be removed with 400 grit wet or dry sandpaper 9 The relief valve spring has a free length of approximately 60 7 mm 2 39 inches it should test between 18 and 19 pounds when compressed to 40 5 mm 1 60 inches Replace spring that fails to meet specifications 10 If oil pressure is low and pump is within ...

Page 1212: ... Bore Diameter 87 4924 87 5076 mm 3 4446 3 4452 in Out of Round Max 0 051 mm 0 002 in Taper Max 0 051 mm 0 002 in Pistons Federal Emission Clearance 17 5 mm 11 16 in from bottom of skirt 0 012 0 044 mm 0 0004 0 0017 in Weight 325 335 grams 11 47 11 82 oz Land Clearance Diametrical 0 734 0 797 mm 0 029 0 031 in Piston Length 64 mm 2 520 in Piston Ring Groove Depth No 1 3 989 4 188 mm 0 157 0 165 in...

Page 1213: ...and 4 40 45 mm 1 59 in Rocker Arm Hydraulic Lash Adjuster Rocker Arm Inside Diameter 20 00 20 02 mm 0 787 0 788 in Rocker Arm Shaft Clearance 0 016 0 054 mm 0 0006 0 0021 in Body Diameter 22 949 22 962 mm 0 9035 0 9040 in Plunger Travel Minimum Dry 2 2 mm 0 087 in Rocker Arm Ratio 1 4 to 1 Cylinder Head Camshaft Bearing Diameter No 1 41 20 41 221 mm 1 622 1 6228 in No 2 41 6 41 621 mm 1 637 1 638 ...

Page 1214: ...t lbs Step 3 Collar to Oil Pan Bolts 54 N m 40 ft lbs Crankshaft Main Bearing Cap Bedplate M8 Bedplate Bolts 30 N m 22 ft lbs M11 Main Cap Bolts 81 N m 60 ft lbs Crankshaft Damper Bolt 142 N m 105 ft lbs Cylinder Head Bolts Refer To Cylinder Head Installation Cylinder Head Cover Bolts 12 N m 105 in lbs Engine Mount Bracket Right Bolts 61 N m 45 ft lbs DESCRIPTION TORQUE Engine Mounting Bolts Refer...

Page 1215: ...aller C 4687 Camshaft Sprocket Remover Installer Adapter C 4687 1 Camshaft Seal Remover C 4679 A Camshaft Seal Installer MD 998306 Crankshaft Damper Installer 6792 Valve Spring Compressor MD 998772 A Spring Compressor Adapter 6779 NS GS ENGINE 9 37 SPECIAL TOOLS Continued ...

Page 1216: ...kshaft Seal Remover 6771 Front Crankshaft Seal Installer 6780 Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Remover Insert C 4685 C2 Crankshaft Sprocket Installer 6792 Rear Crankshaft Seal Guide and Installer 6926 1 and 6926 2 9 38 ENGINE NS GS SPECIAL TOOLS Continued ...

Page 1217: ...Pressure Gage C 3292 Dial Indicator C 3339 Indicator Bore Size C 119 Valve Spring Tester C 647 NS GS ENGINE 9 39 SPECIAL TOOLS Continued ...

Page 1218: ...CYLINDER HEAD NOT REMOVED 55 VALVES AND VALVE SPRINGS HEAD OFF 60 VIBRATION DAMPER 61 DISASSEMBLY AND ASSEMBLY HYDRAULIC TAPPETS 73 CLEANING AND INSPECTION CRANKSHAFT 77 CRANKSHAFT MAIN BEARING 77 CYLINDER HEAD 75 CYLINDER HEAD COVERS 74 CYLINDER LINER 78 HYDRAULIC TAPPETS 76 OIL PAN 78 OIL PUMP 76 PISTON AND CONNECTING ROD 76 ROCKER ARMS AND PUSH RODS 74 TIMING GEAR COVER 75 VALVES AND VALVE SPRI...

Page 1219: ... through a pressure relief valve 2 to the filter 7 and through galleries in the crankcase to the crankshaft bearings 8 cam shaft bearings 11 and turbocharger 10 The piston pins connecting rod small ends and insides of the pistons are lubricated and cooled by oil sprayed out from jets 9 in the crankshaft mounting blocks The lubricating oil is sent to the rockers 12 through an external pipe Fig 3 A ...

Page 1220: ...Fig 3 Lubrication Lines 9 42 ENGINE NS GS DESCRIPTION AND OPERATION Continued ...

Page 1221: ... 6 Excessive fuel inlet restriction 6 Check for restriction Correct cause 7 Injection pump not getting fuel or fuel is aerated 7 Check fuel flow bleed fuel system 8 One or more injectors worn or not operating properly 8 Check replace bad or improperly operating injectors 9 Camshaft out of time 9 Check correct timing chain sprocket alignment ENGINE HARD TO START OR WILL NOT START SMOKE FROM EXHAUST...

Page 1222: ...ipping plugs 7 Worn oil pump 7 Check replace oil pump 8 Suction tube loose or seal leaking 8 Check and replace seal 9 Worn bearing or wrong bearing installed 9 Inspect and replace connecting rod or main bearings check and replace piston cooling oil jet 10 Oil jets under piston loose or bad fit 10 Check oil jets position LUBRICATING OIL LOSS 1 External oil leaks 1 Visually inspect for oil leaks Rep...

Page 1223: ...tion system defective 5a Instrumented injection 5b Timing solenoid of the fuel pump 5c Pre and post heat time of the glow plugs Check the fault codes in the ECU EXCESSIVE ENGINE NOISES 1 Drive belt squeal insufficient tension or abnormally high loading 1 Inspect the drive belts Make sure water pump pulley generator and power steering all turn freely 2 Intake air and exhaust leak 2 Refer to excessi...

Page 1224: ...ENGINE DIAGNOSIS MECHANICAL CONT 9 46 ENGINE NS GS DIAGNOSIS AND TESTING Continued ...

Page 1225: ... the affected spring and or rocker arm to vibrate or feel rough in operation NOTE Worn valve guides or cocked springs are sometimes mistaken for noisy tappets If such is the case noise may be dampened by applying side thrust on the valve spring If noise is not apprecia bly reduced it can be assumed the noise is in the tappet Inspect the rocker arm push rod sockets and push rod ends for wear 3 Valv...

Page 1226: ... oil fill cap 9 Start engine and inspect for leaks 10 Stop engine and inspect oil level ENGINE OIL ENGINE OIL QUALITY Use only oils conforming to API American Petro leum Institute quality SG CD or CCMC G4 Use only Diesel engine oil meeting standard MIL 2104C or API service classification SG CD or CCMM PD1 OIL VISCOSITY Grade 15W 40 is recommended for temperatures between 35 C to 10 C 95 F to 14 F ...

Page 1227: ... any marked gears or gear driven component s VALVE AND SEAT REFACING VALVE REFACING 1 Use a valve refacing machine to reface the intake and exhaust valves to the specified angle 2 After refacing a margin of at least 4 52 4 49 mm 178 177 inch must remain Fig 8 If the mar gin is less than 4 49 mm 177 inch the valve must be replaced VALVE SEAT REFACING 1 Install a pilot of the correct size in the val...

Page 1228: ...m in valve guide is 060 to 095 mm 0023 to 0037 in 4 If valve stem clearance in valve guide exceeds tolerances new valve guides must be installed FITTING PISTON RING 1 Wipe cylinder bore clean Insert ring and push down with piston to ensure it is square in bore The ring gap measurement must be made with the ring positioning at least 12 mm 0 50 in from bottom of cylinder bore Fig 11 Check gap with f...

Page 1229: ...mount assembly Remove insulator 5 If replaceing or removing right engine mount bracket the torque on the mounting bolts is 40 N m 30 ft lbs 6 Reverse removal procedure for installation 7 Torque engine mount top bolt Vertical to 101 N m 75 ft lbs 8 Torque engine mount thru bolt Horizontal to 145 N m 107 ft lbs 9 Torque engine mount to frame bolts to 68 N m 50 ft lbs MOUNT LEFT SIDE 1 Raise vehicle ...

Page 1230: ... both shifter cables at transmission Remove the retainers holding the cables to the mount Fig 18 6 Remove the mount assembly 7 Reverse removal procedure for installation 8 Install mount assembly Torque bolts at engine and transmission to 101 N m 75 ft lbs 9 Align insulator at crossmember and install thru bolt Torque to 68 N m 50 ft lbs Fig 15 Right Engine Mount VM Diesel Fig 16 Left Side Mount VM ...

Page 1231: ...onnectors 15 Disconnect electrical connector at number 1 fuel injector 16 Raise vehicle on hoist 17 Remove right side splash shield Fig 20 WARNING THE COOLANT IN A RECENTLY OPER ATED ENGINE IS HOT AND PRESSURIZED USE CARE TO PREVENT SCALDING BY HOT COOLANT CAREFULLY RELEASE THE PRESSURE BEFORE REMOVING THE RADIATOR DRAIN COCK AND CAP 18 Drain the cooling system refer to Group 7 Cooling 19 Lower ve...

Page 1232: ...he engine support brackets 45 Lower vehicle so weight of only the engine and transmission is on the dolly and cradle assem bly 46 Remove left side splash shield to gain access to thru bolt for left side mount 47 Remove right engine mount and left side mount Refer to procedure outlined in this section 48 Raise vehicle slowly It may be necessary to move the engine transmission assembly on the dolly ...

Page 1233: ...An Arkansas smooth stone should be used to remove nicks and high spots INSTALLATION 1 Install valve spring and retainer 2 Compress the valve spring with Valve Spring Compressor Tool and insert the valve locks Release the spring tension and remove the tool Tap the spring from side to side to ensure that the spring is seated properly on the engine cylinder head 3 Disconnect the air hose Remove the a...

Page 1234: ... exhaust manifold 16 Remove the support strut from block to turbo charger exhaust elbow 17 Remove Exhaust manifold Refer to Group 11 Exhaust System and Intake Manifold 18 Remove oil line at pressure switch 19 Remove oil feed line for rocker arm assemblies Fig 26 20 Remove Crankcase breather hose from valve cover 21 Remove the engine cylinder head cover Fig 23 Intercooler Assembly Fig 24 Turbocharg...

Page 1235: ...emove the engine cylinder heads and gasket NOTE A single steel head gasket is used for 4 cyl inder heads Fig 32 31 Stuff clean lint free shop towels into the cyl inder bores CYLINDER HEAD GASKET NOTE If cylinder wall liners have not been removed the same thickness head gasket removed may be used CAUTION Piston protrusion must be measured to determine cylinder head gasket thickness if one or more c...

Page 1236: ...icated Use the cylinder head align ment studs tool number VM 1009 Position the heads on the block and secure with the ten large center bolts and spacers clamps finger tight only b Ensure that the various clamps are installed correctly and the head gasket remain in their proper position completely covered Then lubricate and install the eight small bolts also finger tight 6 Loosen assembly oil feed ...

Page 1237: ...assem blies and oil pressure switch to 13 N m 112 in lbs 18 Install push rods and rocker arm assemblies tighten nut to 29 4 N m 264 in lbs 19 Install fuel injectors use tool VM 1012 refer to Group 14 Fuel System 20 Install valve cover tighten nuts to 14 7 N m 132 in lbs 21 Connect crankcase breather hose 22 Connect the injector sensor wire connector and the glow plug connectors 23 Install oil feed...

Page 1238: ...ad cover Refer to cylinder head cover removal in this section 3 Remove rocker assembly and push rods Iden tify push rods to ensure installation in original loca tion Fig 34 4 Remove cylinder head intake manifold and exhaust manifold Refer to cylinder head removal in this section 5 Remove yoke retainer and aligning yokes Fig 35 6 Slide Hydraulic Tappet Remover Installer Tool through opening in bloc...

Page 1239: ...shaft INSTALLATION NOTE Before installing damper be sure the O ring inside the center of the damper is in its grove 1 Install vibration damper CAUTION Correct torque on the vibration damper nut is important or engine damage can occur 2 Install vibration damper nut and tighten to 441 N m 325 ft lbs 3 Remove flywheel locking tool and install engine starter 4 Install both accessary drive belts Refer ...

Page 1240: ...he timing cover NOTE Before installing damper be sure O ring on inside center of damper is in place 5 Install vibration damper CAUTION Correct torque on the vibration damper nut is important or engine damage can occur 6 Tighten vibration damper nut to 441 N m 325 ft lbs 7 Install accessary drive belts Refer to Group 7 cooling for procedure 8 Install splash shield 9 Lower vehicle 10 Connect battery...

Page 1241: ...er proper adapter 2 Position rear bearing in the tool Install horse shoe lock and by reversing removal procedure care fully drive bearing shell into place 3 Install remaining bearings in the same man ner Bearings must be carefully aligned to bring oil holes into full register with oil passages from the main bearing If the camshaft bearing shell oil holes are not in exact alignment remove and insta...

Page 1242: ... N m 31 ft lbs Fig 44 3 Slide special tool VM 1002 over the crank shaft gear and insert the crankshaft and carrier assembly into the crankcase in the same manner used for removal 4 Align the holes in the lower carriers with the center of the crankcase webs Fig 45 5 Secure each carrier assembly to the crankcase with the main bearing oil feed and carrier locators and tighten them to 54 N m 40 ft lbs...

Page 1243: ...nal c Loosen the next 2 bolts 180 apart and follow the same procedure d Loosen the last 2 bolts 180 apart and follow the same procedure 23 Install Transmission Refer to procedure in Group 21 Transmission 24 Install pistons and connecting rod assemblies refer to piston and connecting rods in this section 25 Install oil pick up tube and tighten bolts to 25 N m 18 ft lbs 26 Install oil pan refer to o...

Page 1244: ... 31 Install front cover Refer to procedure in this section 32 Install vibration damper Refer to procedure in this section 33 Install cylinder heads Refer to procedure in this section 34 Install rocker arms and push rods Refer to procedure in this section 35 Install cylinder head cover Refer to procedure in this section 36 Install accessary drive system 37 Install engine in vehicle Refer to procedu...

Page 1245: ...etaining screws to 27 5 N m 240 in lbs 3 Install front cover Refer to Timing Gear Cover Installation in this section 4 Install pump shaft support bracket assembly CAUTION Correct torque on the vibration damper nut is important or engine damage can occur 5 Install vibration damper Torque nut to 441 N m 325 ft lbs 6 Install both accessory drive belts Refer to Group 7 Cooling 7 Install right splash s...

Page 1246: ...l the vacuum pump align the outer part of the gear with the inner part using a screw driver or similar tool align with timing marks on gear set and install 2 Install bolts and tighten to 20 N m 15 ft lbs 3 Install front cover PISTONS AND CONNECTING ROD REMOVAL 1 Disconnect the battery cable 2 Remove cylinder heads refer to cylinder head removal in this section 3 Raise vehicle on host 4 Remove oil ...

Page 1247: ...emoval DO NOT rotate piston and connecting rod or damage to the oil jets extending out into the cylinder bore will occur Fig 56 NOTE Be careful not to nick crankshaft journals 8 After removal install bearing cap on the mat ing rod PISTON PIN REMOVAL 1 Secure connecting rod in a soft jawed vice 2 Remove 2 clips securing piston pin Fig 57 3 Push piston pin out of piston and connecting rod Fig 53 Vac...

Page 1248: ...iston sets 3 Check piston ring to groove clearance Fig 60 Top compression ring gap 08 to 130 mm 0031 to 0051 in Second compression ring gap 070 to 102 mm 0027 to 0040 in Oil control ring gap 040 to 072 mm 0015 to 0028 in PISTON RINGS INSTALLATION 1 Install rings on the pistons using a suitable ring expander Fig 58 2 Top compression ring is tapered and chromium plated The second ring is of the scra...

Page 1249: ... same side 4 Install piston pin 5 Install clips in piston to retain piston pin 6 Remove connecting rod from vice PISTON INSTALLATION 1 Before installing pistons and connecting rod assemblies into the bore be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap Fig 62 2 Before installing the ring compressor make sure the oil ring expander ends are butted a...

Page 1250: ...ning 2 Measure the liner recess relative to block deck with a dial indicator mounted on a special tool VM 1010 A All the measurements must be taken on camshaft side Zero dial gauge on block deck 3 Move dial gauge to cylinder liner record read ing on dial gauge 4 Remove liner and special tool 5 Then select the correct shim thickness to give proper protrusion 0 01 0 06 mm 6 Fit the shim and the O ri...

Page 1251: ...rque the 2 bolts to 20 N m 180 in lbs Then using a torque angle gauge rotate the 2 bolts 65 additional c Loosen the next 2 bolts 180 apart and follow the same procedure d Loosen the last 2 bolts 180 apart and follow the same procedure 3 Install Transmission Refer to procedure in Group 21 Transmission DISASSEMBLY AND ASSEMBLY HYDRAULIC TAPPETS DISASSEMBLE AND ASSEMBLE 1 Pry out plunger retainer spr...

Page 1252: ...cuffed pitted cracked or excessively worn Inspect the valve stem tip contact surface of each rocker arm and replace any rocker arm that is deeply pitted Inspect each push rod end for excessive wear and replace as required If any push rod is excessively worn because of lack of oil replace it and inspect the corresponding hydraulic tappet for excessive wear Inspect the push rods for straightness by ...

Page 1253: ...s height requirement 2 Measurement A Fig 71 13 50 14 00 mm VALVE STEM TO GUIDE CLEARANCE MEASUREMENT 1 Measure and record internal diameter of valve guides Valve guide internal diameter is 8 0 to 8 015 mm 3149 to 3155 in 2 Measure valve stems and record diameters Intake valve stem diameter 7 94 to 7 96 mm 3125 to 3133 in Exhaust valve stem diameter 7 92 to 7 94 mm 3118 to 31215 in 3 Subtract diame...

Page 1254: ...ve all varnish and carbon 2 Replace tappets that are unfit for further ser vice with new assemblies 3 If plunger shows signs of scoring or wear install a new tappet assembly If valve is pitted or valve seat on end of plunger is prevented from seat ing install a new tappet assembly OIL PUMP CLEANING Wash all parts in a suitable solvent and inspect carefully for damage or wear Fig 74 INSPECTION 1 Be...

Page 1255: ... digit number on both the rod and the cap These numbers must both face the camshaft as well as the recess on the piston crown Fig 76 Lightly heat the piston in oven Insert piston pin in position and secure it with provided snap rings The Four digit numbers marked on con rod big end and rod cap must be on the same side as the camshaft Fig 76 After having coated threads with Molyguard tighten con ro...

Page 1256: ... installed and honed and new pistons and rings fitted Measure the cylinder bore at three levels in direc tions A and B Fig 79 Top measurement should be 10 mm 3 8 inch down and bottom measurement should be 10 mm 3 8 inch up from bottom of bore SPECIFICATIONS 2 5L VM DIESEL DESCRIPTION SPECIFICATIONS Type 425CLIEE 36B Number of Cylinder 4 Bore 92 mm Stroke 94 mm Capacity 2499 5 cm3 Injection Order 1...

Page 1257: ...ckness 1 42 6 0 1 mm 0 Holes Gasket thickness 1 62 6 0 1 mm 1 Holes DESCRIPTION SPECIFICATIONS Gasket thickness 1 52 6 0 1 mm 2 Holes End Plates Height 89 02 90 00 mm Connecting Rods Weight Without the crank bearing 1129 1195 grams Small End Bearing Internal Diameter Minimum 30 035 mm Maximum 30 050 mm Crankshaft Bearings Standard Internal Diameter 53 997 54 016 mm Pistons Skirt Diameter 91 935 91...

Page 1258: ...e 26 N m 19 ft lbs DESCRIPTION TORQUE EGR Tube to EGR Valve Bolts 26 N m 19 ft lbs Engine Mount Front Support Bracket Engine Bolts 68 N m 50 ft lbs Support Bracket Transmission Bolts 101 N m 75 ft lbs Support Cushion Crossmember Bolts 54 N m 40 ft lbs Support Cushion Thru Bolt 65 N m 48 ft lbs Engine Mount Rear Support Bracket Transmission Bolts 101 N m 75 ft lbs Support Bracket to Engine Bracket ...

Page 1259: ... 54 N m 40 ft lbs Power Steering Pressure Hose Fastener 28 N m 240 in lbs Power Steering Pulley Nut 170 N m 125 ft lbs Rear Crankshaft Bearing Carrier Bolts 10 8 N m 95 in lbs Rocker Arm Cover Bolts 14 7 N m 132 in lbs Rocker Arm Mounting Nuts 29 4 N m 264 in lbs Power Steering Pump Mounting Nuts 24 5 N m 216 in lbs Turbocharger Mounting Nuts 32 N m 288 in lbs Turbocharger Oil Delivery Bolt 27 5 N...

Page 1260: ...eeve VM 1004 Torque Angle Gauge VM 1005 Cylinder Head Bolt Wrench VM 1006A Cylinder Head Guide Studs VM 1009 Cylinder Liner Protrusion Tool VM 1010 Injector Socket Remover Installer VM 1012A 9 82 ENGINE NS GS SPECIAL TOOLS Continued ...

Page 1261: ...al Indicator Gauge VM 1013 Flywheel Locking Tool VM 1014 Timing Cover Oil Seal Installer VM 1015 Cylinder Retainers VM 1016 Cylinder Head Bolt Wrench M12 VM 1018 NS GS ENGINE 9 83 SPECIAL TOOLS Continued ...

Page 1262: ...Adapter Cylinder Leakage Tester VM 1021 Cylinder Head Bolt Wrench M14 VM 1019 Support Brackets Engine Removal Installation VM 1026 9 84 ENGINE NS GS SPECIAL TOOLS Continued ...

Page 1263: ...urations depending on engine and vehicle Fig 1 AWD vehicles have a catalytic converter mounted heat shield The tailpipes mufflers and resonators are tuned to each vehicle powertrain combination CATALYTIC CONVERTERS There is no regularly scheduled maintenance on any Chrysler catalytic converter If damaged the con verter must be replaced CAUTION Due to exterior physical similarities of some catalyti...

Page 1264: ...O CEDURES ON THE EXHAUST GAS RECIRCULA TION SYSTEM AND COMPONENTS HEAT SHIELDS Heat shields Fig 2 are needed to protect both the vehicle and the floor pan from the high temperatures developed near the catalytic converter and muffler Avoid application of rust prevention com pounds or undercoating materials to exhaust system floor pan heat shields on cars so equipped Light over spray near the edges ...

Page 1265: ...ntributes to the engine s broad flat torque curve which was desired for excel lent engine tractability response and usable power output The intake manifold is also cored with upper level EGR passages for balanced cylinder to cylinder EGR distribution The exhaust manifolds are log type with a cross over and are attached directly to the cylinder heads They are made from nodular cast iron DIAGNOSIS A...

Page 1266: ...t be used To insure proper alignment with other parts in the system Provide acceptable exhaust noise levels and does not change exhaust system back pressure that could effect emissions and performance INSTALLATION 1 Assemble pipes muffler support and clamp loosely to permit alignment of all parts 2 Beginning at front of system align and clamp each component to maintain position and proper clearanc...

Page 1267: ...om intake manifold to front support bracket Fig 11 12 Remove dipstick 13 Remove dipstick tube CAUTION Moving the dipstick tube will cause dam age to the sealer causing an oil leak Dipstick tube must be sealed at cylinder block 14 Remove upper intake manifold bolts Remove upper intake manifold CAUTION Cover intake manifold to prevent foreign material from entering engine Fig 6 Throttle Body Electri...

Page 1268: ...ical connectors for MAP sensor throttle position sensor and idle air control motor 12 Install air intake tube and resonator box to throttle body 13 Connect negative cable to battery INTAKE MANIFOLD LOWER 2 4L ENGINE WARNING RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES NEVER SMOKE WHILE SERVICING THE VEHICL...

Page 1269: ... fasteners Fig 16 Remove the manifold from engine 13 Inspect and clean manifold Refer to Cleaning and Inspection outlined in this section for proce dures INSTALLATION If the following items were removed install and torque to Fuel Rail Bolts 22 N m 200 in lbs Engine Outlet Connector Bolts 28 N m 250 in lbs Coolant Temperature Sensor 7 N m 60 in lbs Intake Air Temperature Sensor 28 N m 250 in lbs 1 ...

Page 1270: ...ifold Fig 17 4 Inspect and clean manifold Refer to Cleaning and Inspection outlined in this section for proce dures INSTALLATION 1 Install exhaust manifold with a new gasket and tighten attaching nuts in the order shown in Fig 17 to 20 N m 175 in lbs 2 Attach exhaust pipe to exhaust manifold and tighten bolt to 28 N m 250 in lbs 3 Connect heated oxygen sensor lead Fig 17 INTAKE MANIFOLD 3 0L ENGIN...

Page 1271: ...ss from engine wiring harness Fig 19 Electrical and Vacuum Connections to Throttle Body Fig 20 Ignition Coil Removal Fig 21 Coolant Temperature Sensor Electrical Connections Fig 22 Air Intake Plenum to Intake Manifold Attaching Bolts Fig 23 Removing Air Intake Plenum Fig 24 Vacuum Connections for Fuel Rail and Fuel Pressure Regulator NS EXHAUST SYSTEM AND INTAKE MANIFOLD 11 9 REMOVAL AND INSTALLAT...

Page 1272: ... 4 Lube injector O ring with a drop of clean engine oil to ease installation 5 Put the tip of each injector into their ports Push the assembly into place until the injectors are seated in the ports 6 Install the fuel rail attaching bolts and torque to 13 N m 115 in lbs 7 Install fuel supply and the vacuum crossover tube hold down bolt and torque to 10 N m 95 in lbs 8 Remove covering from lower int...

Page 1273: ...s turned to the OFF position or Stop All Test is selected EXHAUST MANIFOLD 3 0L ENGINE REMOVAL 1 Raise vehicle and disconnect exhaust pipe from rear cowl side exhaust manifold at the flex joint 2 Disconnect Oxygen Sensor lead wire at the rear exhaust manifold Fig 28 3 Remove bolts attaching cross over pipe to manifold Fig 30 4 Remove rear heat shield Fig 29 5 Remove nuts attaching rear manifold to...

Page 1274: ...e attempting any repairs Refer to Group 14 Fuel System for procedure 3 Drain cooling system See Cooling System Group 7 for procedure 4 Remove air inlet resonator to throttle body hose assembly 5 Remove throttle cable Refer to Group 14 Fuel Systems for procedure Remove wiring harness from throttle cable bracket 6 Remove automatic idle speed AIS motor and throttle position sensor TPS wiring connecto...

Page 1275: ...ounting bolt and move bracket up so intake manifold can clear mounting studs Fig 38 18 Remove intake manifold bolts and remove the manifold Fig 38 19 Cover intake manifold with suitable cover when servicing Fig 39 20 Remove fuel tube retainer bracket screw and fuel rail attaching bolts Fig 39 Spread the retainer bracket to allow fuel tube removal clearance 21 Disconnect cam sensor and coolant temp...

Page 1276: ...Adhesive Sealant or equivalent onto each of the four manifold to cylinder head gasket corners Fig 44 3 Carefully install the new intake manifold gas ket Fig 43 Torque end seal retainer screws to 12 N m 105 in lbs 4 Install intake manifold and bolts and torque to 1 N m 10 in lbs Then torque bolts to 22 N m 200 in lbs in sequence shown in Fig 42 Then torque again to 22 N m 200 in lbs After intake ma...

Page 1277: ... 17 Connect ground strap and MAP sensor electri cal connectors 18 Connect vacuum harness to intake plenum Fig 34 19 Using a new gasket connect the EGR tube flange to the intake manifold and torque to 22 N m 200 in lbs 20 Clip wiring harness into the hole in the throt tle cable bracket 21 Connect the wiring connectors to the throttle position sensor TPS and Automatic Idle Speed AIS motor Fig 33 22 ...

Page 1278: ...r vehicle and remove screws attaching front heat shield to front manifold Fig 46 14 Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to cylinder head Remove assemblies Fig 47 15 Inspect and clean manifold Refer to Cleaning and Inspection outlined in this section for proce dures INSTALLATION 1 Install rear exhaust manifold and tighten attaching bolts to 23...

Page 1279: ...ed Check for cylinder head mounting surface distor tion using a straightedge and thickness gauge Refer to specifications for warpage specification CLEANING Remove the gasket material from the manifold sur faces Be careful not to gouge or scratch the sealing sur face EXHAUST MANIFOLD INSPECTION Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface...

Page 1280: ...m 250 in lbs Heat Shield Muffler Fastener 2 N m 23 in lbs Heat Shield Toe Board Fastener 2 N m 23 in lbs Insulator Mounting Bracket on Muffler to Body Bolts 28 N m 250 in lbs Insulator Mounting Bracket on Resonator to Body Bolts 28 N m 250 in lbs Intake Manifold Gasket Retainer Fastener 12 N m 105 in lbs Intake Air Plenum 3 0L Bolts 15 N m 130 in lbs Intake Cross Manifold 3 0L Bolts 20 N m 174 in ...

Page 1281: ...olts holding bottom of fascia air dam to radiator closure panel 8 Disconnect fog lamp parking and turn signal lamp wire connector if necessary 9 Remove bumper fascia from vehicle INSTALLATION 1 Position front bumper fascia on vehicle 2 Lower vehicle 3 Install bolts to hold fascia to headlamp mount ing panel at each side of grille 4 Raise vehicle 5 Install bolts to hold fascia to bottom of front fe...

Page 1282: ...r the liftgate Ensure acceptable and consistent gap between liftgate and fascia 4 Install plastic rivets to hold bottom of rear fas cia to bumper reinforcement 5 Install screws holding rear fascia to rear fascia brackets 6 Lower vehicle REAR BUMPER REINFORCEMENT REMOVAL 1 Remove rear bumper fascia 2 Support rear bumper reinforcement on a suit able lifting device 3 Mark position of nuts on frame ra...

Page 1283: ...aft Fig 1 6 Remove steering column coupling from tele scoping steering gear shaft 7 Hoist and support vehicle on safety stands 8 Position a drain pan under power steering pump and oil return hose coupling 9 Using a hose pinch off pliers C 4390 pinch power steering oil return hose off between the cross member coupling and the pump 10 Loosen hose clamp at the crossmember cou pling 11 Disconnect retu...

Page 1284: ...ing device Fig 4 2 Position crossmember to vehicle 3 Loosely install bolts to hold crossmember to front frame rails 4 Align crossmember to previously made marks on frame rails 5 Tighten bolts holding crossmember to frame rails 6 Install bolt holding rear engine mount to cross member Fig 4 Crossmember Fig 2 Rear Engine Mount Fig 3 Crossmember Mount 13 4 FRAME AND BUMPERS NS REMOVAL AND INSTALLATION...

Page 1285: ...STALLATION 1 Apply rubber lube or soap to replacement bush ing 2 Insert lower half of bushing into square hole in crossmember 3 Place upper half of bushing on top of cross member aligned to receive square tube protruding upward from lower bushing half 4 Squeeze bushing halves together to ensure they are properly mated 5 Lift crossmember upward to close gap between the bushing and frame 6 Verify th...

Page 1286: ...Fig 5 Front Crossmember Dimensions 13 6 FRAME AND BUMPERS NS SPECIFICATIONS Continued ...

Page 1287: ...Fig 6 Engine Compartment Top View NS FRAME AND BUMPERS 13 7 SPECIFICATIONS Continued ...

Page 1288: ...Fig 7 Engine Compartment and Frame Rail Side View 13 8 FRAME AND BUMPERS NS SPECIFICATIONS Continued ...

Page 1289: ...Fig 8 Full Vehicle Bottom View NS FRAME AND BUMPERS 13 9 SPECIFICATIONS Continued ...

Page 1290: ...Fig 9 Windshield Opening Fig 10 Liftgate Opening 13 10 FRAME AND BUMPERS NS SPECIFICATIONS Continued ...

Page 1291: ...Fig 11 Body Side Openings NS FRAME AND BUMPERS 13 11 SPECIFICATIONS Continued ...

Page 1292: ......

Page 1293: ...olding front tow hook bracket to lower radiator crossmember 6 Separate front tow hook bracket from vehicle INSTALLATION 1 Position front tow hook bracket to vehicle 2 Install bolts to hold front tow hook bracket to lower radiator crossmember 3 Remove support stand from under engine and transaxle assembly 4 Install front tow hook eyelet to front tow hook bracket 5 Install screws to hold the bottom ...

Page 1294: ...m vehicle INSTALLATION 1 Position rear tow hook bracket on vehicle 2 Install bolts to hold rear tow hook bracket to rear frame rail 3 Lower vehicle Fig 2 Rear Tow Hook Bracket 13 2 FRAME AND BUMPERS NS GS REMOVAL AND INSTALLATION Continued ...

Page 1295: ...I NAL IDENTIFICATION NUMBER VIN AND THE VEHICLES ORIGINAL MILEAGE IF THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE DTC MAY BE SET FUEL REQUIREMENTS Your vehicle was designed to meet all emission reg ulations and provide excellent fuel economy when using high quality unleaded gasoline Use unleaded gasolines having a minimum posted octane of 87 If your vehicle develops occasional light spark knock...

Page 1296: ...ate use of fuel system cleaning agents should be avoided Many of these materials intended for gum and varnish removal may contain active sol vents of similar ingredients that can be harmful to fuel system gasket and diaphragm materials E 85 GENERAL INFORMATION The information in this section is for Flexible Fuel Vehicles FFV only These vehicles can be identified by the unique Fuel Filler Door Labe...

Page 1297: ...ompared to gasoline operation REPLACEMENT PARTS Many components in your Flexible Fuel Vehicle FFV are designed to be compatible with ethanol Always be sure that your vehicle is serviced with cor rect ethanol compatible parts CAUTION Replacing fuel system components with non ethanol compatible components can damage your vehicle and may void the warranty NS FUEL SYSTEM 14 3 GENERAL INFORMATION Conti...

Page 1298: ... pump module contains the fuel pump and pressure regulator The pump is serviced as part of the fuel pump module Refer to Fuel Pump Module The fuel filter is a replaceable in line filter The fil ter attaches to a bracket mounted on top of the fuel tank Refer to the Maintenance Schedules in the Introduction section of this manual for recommended fuel filter replacement intervals A returnless fuel sy...

Page 1299: ...he return port The pressure regulator is a mechanical device that is NOT controlled by the PCM or engine vacuum FUEL INJECTORS The fuel injectors are 12 ohm electrical solenoids Fig 2 The injector contains a pintle that closes off an orifice at the nozzle end When electric current is supplied to the injector the armature and needle move a short distance against a spring allowing fuel to flow out t...

Page 1300: ...ormation CAUTION The interior components o rings spac ers of quick connect fitting are not serviced sepa rately Do not attempt to repair damaged fittings or fuel lines tubes If repair is necessary replace the complete fuel tube assembly Fuel tubes connect fuel system components with plastic quick connect fuel fittings The fitting con tains non serviceable O ring seals Fig 4 CAUTION Quick connect f...

Page 1301: ...system If the gauge reading equals 338 kPa 49 psi 3 3L uses approximately 379 kPa 55 psi further testing is not required If pressure is not correct record the pressure If pressure is above specifications check for a kinked or restricted fuel return tube from filter to pump module If the fuel return tube is not pinched or restricted replace the fuel pressure regulator If fuel pressure is below spec...

Page 1302: ...FUEL PRESSURE BELOW SPECIFICATIONS 14 8 FUEL SYSTEM NS DIAGNOSIS AND TESTING Continued ...

Page 1303: ... sensor connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector Fig 8 Move the float lever to the positions shown in the resistance chart Fig 8 Record the resistance at each point Replace the level sensor if the resis tance is not within specifications FUEL INJECTORS For fuel injector diagnosis refer to the Fuel Injec tor Diagnosis charts For poor...

Page 1304: ...FUEL INJECTOR DIAGNOSIS 14 10 FUEL SYSTEM NS DIAGNOSIS AND TESTING Continued ...

Page 1305: ...the Power Distribution Center PDC For location of the relay refer to the label on the underside of the PDC cover 2 Start and run engine it stalls 3 Attemp restarting engine until it will no longer run 4 Turn ignition key to OFF position CAUTION Steps 1 2 3 and 4 must be performed to relieve high pressure fuel from within the fuel rail Do not attempt to use the following steps to relieve this press...

Page 1306: ...ECT FIT TINGS REFER TO THE FUEL PRESSURE RELEASE PROCEDURE 1 Disconnect negative cable from battery 2 Perform Fuel Pressure Release Procedure Refer to the Fuel Pressure Release Procedure in this section 3 Squeeze retainer tabs together and pull fuel tube quick connect fitting assembly off of fuel tube nipple The retainer will remain on fuel tube INSTALLATION CAUTION Never install a quick connect f...

Page 1307: ...ND AVOID IGNITION SOURCES NEVER SMOKE WHILE SERVICING THE VEHICLE WARNING THE FUEL RESERVOIR OF THE FUEL PUMP MODULE DOES NOT EMPTY OUT WHEN THE TANK IS DRAINED THE FUEL IN THE RESERVOIR WILL SPILL OUT WHEN THE MODULE IS REMOVED REMOVAL 1 Remove fuel filler cap and perform Fuel Sys tem Pressure Release procedure 2 Disconnect negative cable from battery 3 Insert fuel siphon hose into fuel filler ne...

Page 1308: ...ller cap FUEL PRESSURE REGULATOR The fuel pressure regulator is part of the fuel pump module Fig 18 Remove the fuel pump mod ule from the fuel tank to access the fuel pressure reg ulator WARNING FUEL SYSTEM PRESSURE MUST BE RELEASED BEFORE SERVICING ANY FUEL SYS TEM COMPONENT PERFORM THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE REMOVAL 1 Spread tangs on pressure regulator retainer Fig 18 2 Pry fuel ...

Page 1309: ...voir body Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer 4 Install fuel pump module Refer to Fuel Pump Module Installation in this section FUEL LEVEL SENSOR REMOVAL Remove fuel pump module Refer to Fuel Pump Module in this section 1 Depress retaining tab and remove the fuel pump level sensor connector from the BOTTOM of the fuel pump module electrical ...

Page 1310: ... into guide grooves slide level sensor up into channel until it snaps into place Fig 28 Ensure tab at bottom of sensor locks in place 4 Install level sensor wires in connector Push the wires up through the connector and then pull them down until they lock in place Ensure signal and ground wires are installed in the correct posi tion 5 Install locking wedge on connector 6 Push connector up into bot...

Page 1311: ...vent rub ber hoses at the fuel tank 7 Disconnect fuel supply lines from the steel sup ply line The fuel pump module electrical connector has a retainer that locks it in place 8 Slide fuel pump module electrical connector lock to unlock Fig 29 9 Push down on connector retainer Fig 30 and pull connector off module 10 Use a transmission jack to support fuel tank Remove bolts from fuel tank straps 11 ...

Page 1312: ...energized for 7 minutes or until the test is stopped or until the ignition switch is turned to the Off position 10 Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system Check for leaks FUEL INJECTOR RAIL 2 4L REMOVAL 1 Perform fuel system pressure release procedure before servicing or starting repairs Refer to Fuel System Pressure Release Procedure in this sec tion 2 Disconnect ...

Page 1313: ...orque 8 Install fuel hose quick connector fitting to chas sis tubes Refer to Fuel Hoses Clamps and Quick Connect Fittings in this Section Push the fitting onto the chassis tube until it clicks into place Pull on the fitting to ensure complete insertion 9 Reverse removal procedures Step 2 thru Step 12 for installation CAUTION When using the ASD Fuel System Test the ASD relay and fuel pump relay rem...

Page 1314: ...g 39 9 Remove the fuel hose quick connect fitting from the chassis tube Fig 40 Refer to Fuel Hoses Clamps and Quick Connect Fittings in this Sec tion Place a shop towel under the connections to absorb any fuel spilled from the fitting WARNING WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE Fig 36 Air Inlet Resonator Fig 37 Throttle Cable Attachment Fig 38 Electrical and Vacuum Connec...

Page 1315: ...nd tighten to 13 N m 115 in lbs torque 10 Connect fuel line to fuel rail 11 Connect vacuum harness to air intake ple num 12 Connect coolant temperature sensor electrical connector to sensor 13 Connect PCV and brake booster supply hose to intake plenum 14 Connect idle air control motor and Throttle Position Sensor TPS electrical connectors 15 Connect vacuum vapor harness to throttle body 16 Install...

Page 1316: ...ectrical connector from the MAP sensor Fig 47 11 Remove engine mounted ground strap 12 Remove the fuel hose quick connect fitting from the chassis tube Fig 48 Refer to Fuel Hoses Clamps and Quick Connect Fittings in this Section WARNING WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE Fig 43 Throttle Cable Attachment Fig 44 Electrical and Vacuum Connection to Throttle Body Fig 45 Vacu...

Page 1317: ... position sensor Fig 52 and engine coolant temperature sensor 19 Remove fuel rail Be careful not to damage the injector O rings upon removal from their ports Fig 53 INSTALLATION 1 Ensure injector holes are clean Replace O rings if damaged 2 Lubricate injector O rings with a drop of clean engine oil to ease installation 3 Put the tip of each injector into their ports Push the assembly into place un...

Page 1318: ...fasteners to 12 N m 105 in lbs torque 19 Install fuel hose quick connector fitting to chassis tubes Refer to Fuel Hoses Clamps and Quick Connect Fittings in this Section Push the fitting onto the chassis tube until it clicks into place Pull on the fitting to ensure complete insertion 20 Install throttle cable and speed control cable if equipped 21 Install air inlet resonator 22 Connect negative ca...

Page 1319: ...tor straight out of fuel rail receiver cup Fig 55 8 Check injector O ring for damage If O ring is damaged it must be replaced If injector is to be reused a protective cap must be installed on the injector tip to prevent damage 9 Repeat procedure for remaining injectors INSTALLATION 1 Before installing an injector the rubber O ring must be lubricated with a drop of clean engine oil to aid in instal...

Page 1320: ... rail receiver cap Be careful not to damage O ring during installa tion Fig 56 4 Repeat steps for remaining injectors 5 Connect fuel injector wiring ACCELERATOR PEDAL CAUTION When servicing the accelerator pedal throttle cable or speed control cable do not dam age or kink the core wire inside the cable sheath ing REMOVAL 1 Working from the engine compartment remove the throttle control shield 2 Ho...

Page 1321: ...t pull the throttle cable out of the dash panel grommet The grommet should remain in the dash panel 6 Remove the throttle cable from throttle bracket by carefully compressing both retaining ears simulta neously Then gently pull the throttle cable from throttle bracket INSTALLATION 1 From the engine compartment push the hous ing end fitting into the dash panel grommet 2 Install the cable housing th...

Page 1322: ...3 0L 22 N m 200 in lbs Fuel Tube Holddown Screw 4 N m 35 in lbs Intake Manifold Bolts 2 4L 22 N m 200 in lbs Intake Manifold Bolts 3 0L 13 N m 115 in lbs Intake Manifold Bolts 3 3 3 8L 28 N m 250 in lbs Accelerator Pedal to Dash Nuts 12 N m 105 in lbs FUEL TANK CAPACITY Vehicle Liters U S Gallons NS 75 O 20 Nominal refill capacities are shown A variation may be observed from vehicle to vehicle due...

Page 1323: ...RGE SOLENOID 43 SOLID STATE FAN RELAY PCM OUTPUT 46 SPEED CONTROL SOLENOIDS PCM OUTPUT 46 SPEED CONTROL PCM INPUT 39 STARTER RELAY PCM OUTPUT 42 SYSTEM DIAGNOSIS 32 TACHOMETER PCM OUTPUT 47 THROTTLE BODY 47 THROTTLE POSITION SENSOR TPS PCM INPUT 40 TORQUE CONVERTER CLUTCH SOLENOID PCM OUTPUT 46 TRANSAXLE PARK NEUTRAL SWITCH PCM INPUT 40 VEHICLE SPEED AND DISTANCE PCM INPUT 41 DIAGNOSIS AND TESTING...

Page 1324: ...OP During OPEN LOOP modes the PCM receives input signals and responds according to preset PCM programming Input from the oxygen O2S sensor is not monitored during OPEN LOOP modes During CLOSED LOOP modes the PCM does mon itor the O2S sensor input This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air fuel ratio of 14 7 parts air to 1 part fuel B...

Page 1325: ...d engine output and vehicle acceleration The PCM increases injector pulse width in response to increased fuel demand When the engine is at operating temperature this is a CLOSED LOOP mode During cruising speed the following inputs are received by the PCM Engine coolant temperature Manifold absolute pressure Engine speed crankshaft position sensor Throttle position Exhaust gas oxygen content A C co...

Page 1326: ...ntake Air Temperature Sensor 2 4L only Knock Sensor execpt 3 0L Manifold Absolute Pressure MAP Sensor SCI Receive Speed Control System Controls Throttle Position Sensor Transaxle Park Neutral Position Switch auto matic transaxle Transmission Control Module Vehicle Speed Sensor PCM Outputs Air Conditioning Clutch Relay Automatic Shutdown ASD Relay Data Link Connector Proportional Purge Solenoid Ele...

Page 1327: ...ne load AUTOMATIC SHUTDOWN ASD SENSE PCM INPUT The ASD sense circuit informs the PCM when the ASD relay energizes A 12 volt signal at this input indicates to the PCM that the ASD has been acti vated This input is used only to sense that the ASD relay is energized When energized the ASD relay supplies battery voltage to the fuel injectors ignition coils and the heating element in each oxygen sensor...

Page 1328: ...ed above the camshaft sprocket The distance between the bottom of sensor and the camshaft sprocket is critical to the opera tion of the system When servicing the camshaft position sensor refer to the 3 3L and 3 8L Multi Port Fuel Injection Service Procedures sec tion in this Group 2 4L The camshaft position sensor attaches to the rear of the cylinder head Fig 5 A target magnet attaches to the rear...

Page 1329: ...on which piston will next be at TDC from the camshaft posi tion sensor input It may take the PCM one engine revolution to determine crankshaft position The PCM uses the crankshaft position sensor sig nal to determine injector sequence ignition timing and presence of misfire Once crankshaft position has been determined the PCM begins energizing the injectors in sequence Fig 5 Camshaft Position Sens...

Page 1330: ...ope By counting the pulses and referencing the pulse from the 60 degree signature notch the PCM calcu lates crankshaft angle position In each group of timing reference notches the first notch represents 69 degrees before top dead center BTDC The sec ond notch represents 49 degrees BTDC The third notch represents 29 degrees The last notch in each set represents 9 degrees before top dead center TDC ...

Page 1331: ...s produces a low voltage When there is a lesser amount present rich air fuel mixture it pro duces a higher voltage By monitoring the oxygen content and converting it to electrical voltage the sensors act as a rich lean switch The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes Maintaining correct sensor temperatur...

Page 1332: ...stream heated oxygen sensor input is used to detect catalytic convertor deteriora tion As the convertor deteriorates the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By com paring the downstream heated oxygen sensor input to the input from the upstream sensor the PCM cal culates catalytic convertor efficiency When the catalytic converter...

Page 1333: ...voltage and inputs from other sensors the PCM adjusts spark advance and the air fuel mixture The MAP sensor Fig 22 or Fig 23 or Fig 24 mounts to the intake manifold near the throttle body inlet to the manifold The sensor connects electrically to the PCM SPEED CONTROL PCM INPUT The speed control system provides five separate voltages inputs to the Powertrain Control Module PCM The voltages correspo...

Page 1334: ...axle is in Park or Neutral This input is used to determine idle speed varying with gear selection and ignition tim ing advance The park neutral switch is sometimes referred to as the neutral safety switch THROTTLE POSITION SENSOR TPS PCM INPUT The TPS is mounted on the throttle body and con nected to the throttle blade shaft Fig 26 or Fig 27 or Fig 28 The TPS is a variable resistor that provides t...

Page 1335: ...mperature of the intake air as it enters the engine The sensor supplies one of the inputs the PCM uses to determine injector pulse width and spark advance The IAT sensor threads into the intake manifold Fig 29 AIR CONDITIONING A C CLUTCH RELAY PCM OUTPUT The PCM operates the air conditioning clutch relay ground circuit The radiator fan control module sup plies battery power to the solenoid side of...

Page 1336: ...for the solenoid side of the relay on and off The PCM turns the ground path off when the ignition switch is in the Off position When the ignition switch is in the On position the PCM ener gizes the fuel pump If the crankshaft position sensor does not detect engine rotation the PCM de ener gizes the relay after approximately one second The fuel pump relay is located in the PDC Fig 30 A label affixe...

Page 1337: ...arm up period and the hot start time delay the PCM does not energize the sole noid When de energized no vapors are purged The proportional purge solenoid operates at a fre quency of 200 hz and is controlled by an engine con troller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow The proportional purge ...

Page 1338: ...g the fuel and ignition strategy FUEL INJECTORS PCM OUTPUT The fuel injectors are 12 ohm electrical solenoids Fig 37 The injector contains a pintle that closes off an orifice at the nozzle end When electric current is supplied to the injector the armature and needle move a short distance against a spring allowing fuel to flow out the orifice Because the fuel is under high pressure a fine spray is ...

Page 1339: ...mbly consists of independent coils molded together Fig 39 or Fig 40 or Fig 41 The coil assembly is mounted on the intake manifold High tension leads route to each cylinder from the coil The coil fires two spark plugs every power stroke One plug is the cylinder under compression the other cylinder fires on the exhaust stroke The PCM determines which of the coils to charge and fire at the correct ti...

Page 1340: ...ature and A C system pressure The radiator fan circuit contains a Solid State Fan Relay SSFR Refer to the Group 8W for a circuit schematic A 5 volt signal is supplied to the SSFR The PCM provides a pulsed ground for the SSFR Depending upon the amount of pulse on time the SSFR puts out a proportional voltage to the fan motor at the lower speed For instance if the on time is 30 percent then the volt...

Page 1341: ...perated throttle blade located in the base of the throttle body Fig 43 or Fig 44 or Fig 45 DIAGNOSIS AND TESTING VISUAL INSPECTION 2 4L ENGINE A visual inspection for loose disconnected or mis routed wires and hoses should be made before attempting to diagnose or service the fuel injection system A visual check helps save unnecessary test and diagnostic time A thorough visual inspection will inclu...

Page 1342: ...m aged Fig 48 5 Verify the quick connect fuel fitting is fully inserted on the fuel supply tube 6 Check the oil pressure sending unit electrical connection 7 Verify the electrical connector at the knock sen sor is fully seated and not damaged Fig 49 Fig 45 Throttle Body 3 3 3 8L Fig 46 Ignition Coil Pack Electrical Connection Fig 47 Camshaft Position Sensor 14 48 FUEL SYSTEM NS DIAGNOSIS AND TESTI...

Page 1343: ...nsure the harness connectors for the fuel injectors are attached to the correct injector and not damaged 12 Verify the fuel injector harness and engine wiring harness connectors are fully inserted into the main wiring harness 13 Check the vacuum connections at the throttle body and intake plenum Fig 48 Engine Coolant Temperature Sensor Fig 49 Knock Sensor Fig 50 Proportional Purge Solenoid Fig 51 ...

Page 1344: ...Fig 55 18 Verify the Manifold Absolute Pressure MAP sensor electrical connector is attached to the sensor and not damaged Fig 56 19 Check the heated oxygen sensor electrical con nectors for damage Fig 57 and Fig 58 20 Verify the engine ground strap is attached at the engine and dash panel Inspect the strap for cor rosion or damage 21 Inspect the generator wiring connections for damage Fig 52 Throt...

Page 1345: ...Fig 60 A label affixed to the underside of the PDC cover identifies the relays and fuses in the PDC 25 Inspect battery cable connections for corro sion 26 Check the power brake booster hose connec tion without anti lock brake systems Fig 61 27 Inspect the speed control vacuum connection 28 Inspect hose and wiring connections at fuel pump module Check that wiring connector is making contact with te...

Page 1346: ...outing Ensure that the cables are completely connected to the spark plugs and distributor 2 Check ignition coil electrical connections Fig 62 3 Verify that the electrical connector is attached to the Proportional Purge Solenoid Fig 63 4 Verify that vacuum connection at the duty cycle Proportional Purge Solenoid valve is secure and not leaking Fig 60 Power Distribution Center PDC Fig 61 Power Brake...

Page 1347: ...harness connector 10 Verify the distributor connector is connected to the harness connector Fig 67 11 Verify the coolant temperature sensor connec tor is connected to the harness connector Fig 68 12 Check vacuum hose connection at fuel pres sure regulator and intake plenum connector Fig 68 Fig 64 Map Sensor Electrical and Vacuum Connections Fig 65 Evaporative Canister Fig 66 Engine Ground Strap Fi...

Page 1348: ...20 Check power brake booster vacuum connec tions 21 Check engine harness to main harness electri cal connections 22 Check all electronic automatic transaxle elec trical connections Fig 73 23 Inspect the Powertrain Control Module PCM 40 way electrical connectors for damage or spread Fig 69 Oil Pressure Sending Unit Electrical Connection Fig 70 Throttle Body Electrical and Vacuum Hose Connections Fi...

Page 1349: ...s save unnecessary test and diagnostic time A thorough visual inspection will include the following checks 1 Check ignition cable routing from the coil pack to the spark plugs Verify the cable are routed in the correct order and are fully seated to the coil and spark plug 2 Check direct ignition system DIS coil electri cal connection for damage and a complete connection to the coil pack Fig 75 3 V...

Page 1350: ...hoses are securely attached to the EVAP canister Fig 80 11 Ensure the harness connectors for the fuel injectors are attached to the correct injector and not damaged 12 Verify the fuel injector harness and engine wiring harness connectors are fully inserted into the main wiring harness Fig 77 Engine Coolant Temperature Sensor Fig 78 Knock Sensor and Oil Pressure Sending Unit Electrical Connection F...

Page 1351: ... are not damaged Fig 83 16 Inspect the PCV system connections for dam age Fig 84 17 Inspect the crankshaft position sensor electri cal connector for damage Fig 85 18 Verify the Manifold Absolute Pressure MAP sensor electrical connector is attached to the sensor and not damaged Fig 86 Fig 81 Throttle Body Vacuum Connections Fig 82 Throttle Body Electrical Connections Fig 83 Automatic Transaxle Elec...

Page 1352: ...nectors at the Powertrain Control Module PCM Fig 89 for dam age or spread terminals Verify that the connectors are fully inserted into the PCM sockets Ensure the wires are not stretched or pulled out of the connector 24 Inspect fuses in the Power Distribution Cen ter PDC Verify all fuses and relays are fully Fig 85 Crankshaft Position Sensor Fig 86 MAP Sensor Fig 87 Upstream Heated Oxygen Sensor F...

Page 1353: ...tor is making contact with terminals on pump ASD AND FUEL PUMP RELAYS The following description of operation and tests apply only to the Automatic Shutdown ASD and fuel pump relays The terminals on the bottom of each relay are numbered Fig 93 or Fig 94 OPERATION Terminal number 30 is connected to battery volt age For both the ASD and fuel pump relays termi nal 30 is connected to battery voltage at...

Page 1354: ...er wire to relay terminal 86 This activates the relay The ohm meter should now show continuity between relay ter minals 87 and 30 The ohmmeter should not show continuity between relay terminals 87A and 30 8 Disconnect jumper wires 9 Replace the relay if it did not pass the continu ity and resistance tests If the relay passed the tests it operates properly Check the remainder of the ASD and fuel pu...

Page 1355: ...000 rpm If the output falls outside of this range a DTC will be set CAMSHAFT AND CRANKSHAFT POSITION SENSOR Refer to Group 8D Ignition for Diagnosis and Test ing of Camshaft and Crankshaft Sensors ENGINE COOLANT TEMPERATURE SENSOR 1 With the key off disconnect wire harness con nector from coolant temperature sensor Fig 96 or Fig 97 or Fig 98 2 Connect a high input impedance digital volt ohmmeter t...

Page 1356: ... cycled on and off at least once 2 Ensure that all accessories are off 3 Shut off engine 4 3 0L Engine a Hook up the timing check device and tachom eter b Disconnect the engine coolant temperature sensor and set basic timing to 12 BTDC 6 2 c Shut off engine Reconnect coolant tempera ture sensor wire 5 Disconnect the PCV valve hose from the intake manifold nipple Fig 101 Fig 102 or Fig 103 6 Cap th...

Page 1357: ...r Parts Cleaner to clean the throttle body c Using a soft scuff pad clean the top and bot tom of throttle body bore and the edges and mani fold side of the throttle blade The edges of the throttle blade and portions of the throttle bore that are closest to the throttle blade when closed must be free of deposits d Use compressed air to dry the throttle body e Inspect throttle body for foreign mater...

Page 1358: ...d attaching nuts 8 Remove throttle body and gasket INSTALLATION 1 Reverse procedure for installation Tighten throttle body mounting nuts to 25 N m 225 in lbs torque FUEL PUMP RELAY The fuel pump relay is located in the PDC The inside top of the PDC cover has a label showing relay and fuse location AUTOMATIC SHUTDOWN ASD RELAY The Automatic Shutdown relay ASD relay is located in the PCD The inside ...

Page 1359: ...emble components with new O rings and seals where applicable Never use lubricants on O rings or seals damage may result If assembly of component is difficult use water to aid assembly Use care when removing hoses to prevent damage to hose or hose nipple REMOVAL 1 Disconnect negative cable from battery 2 Remove electrical connector from idle air con trol motor 3 Remove idle air control motor mounti...

Page 1360: ...13 2 Remove two screws holding sensor to the intake manifold INSTALLATION 1 Reverse the above procedure for installation MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 3 0L REMOVAL 1 Remove vacuum hose and mounting screws from manifold absolute pressure MAP sensor Fig 114 2 Disconnect electrical connector from sensor Remove sensor INSTALLATION 1 Reverse the above procedure for installation PROPORTIONAL PUR...

Page 1361: ...cle 6 Rotate PDC toward center of vehicle to remove from rear bracket Fig 119 7 Pull PDC rearward to remove from front bracket Lay PDC aside to allow access to Powertrain Control Module PCM 8 Squeeze tabs on 40 way connector Pull connec tor rearward to remove from PCM Fig 120 Remove both way connectors Fig 115 Proportional Purge Solenoid Valve Fig 116 Power Distribution Center Retaining Screws Fig...

Page 1362: ...es UPSTREAM OXYGEN SENSOR The oxygen sensor is installed in the exhaust man ifold Fig 122 or Fig 123 or Fig 124 CAUTION Do not pull on the oxygen sensor wire when unplugging the electrical connector WARNING THE EXHAUST MANIFOLD AND CATA LYTIC CONVERTER MAY BE EXTREMELY HOT USE CARE WHEN SERVICING THE OXYGEN SENSOR REMOVAL 1 Raise and support vehicle 2 Unplug oxygen sensor electrical connector 3 Us...

Page 1363: ...EAM OXYGEN SENSOR REMOVAL 1 Raise and support vehicle WARNING THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT USE CARE WHEN SERVICING THE OXYGEN SENSOR 2 Remove grommet cover to expose connector Fig 125 3 Push locking tab back and unplug oxygen sen sor electrical connector Fig 126 4 Use a socket such as Snap On YA8875 or equivalent to remove sensor Fig 127 Fig 123 Upstream Heated Oxygen Sensor 3 0L Fig ...

Page 1364: ... 2 Loosen 3 clamps holding air cleaner housing halves together 3 Remove left side of air cleaner housing Fig 129 4 Remove element from air cleaner housing Fig 130 INSTALLATION 1 Install a new element in housing 2 Position left side of housing 3 Snap clamps into place 4 Install hoses and air inlet resonator ENGINE COOLANT TEMPERATURE SENSOR 2 4L The coolant sensor threads into the top of the ther m...

Page 1365: ...connector 3 Remove coolant sensor INSTALLATION 1 Install coolant sensor Tighten sensor to 7 N m 60 in lbs torque 2 Attach electrical connector to sensor 3 Fill cooling system Refer to Group 7 Cooling System ENGINE COOLANT TEMPERATURE SENSOR 3 3 3 8L The sensor is installed next to the thermostat housing Fig 132 WARNING HOT PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING COOLING SYSTEM MUST BE PAR...

Page 1366: ...r 3 3 3 8L 7 N m 62 in lbs Cly Head to Intake Manifold Strut Bolts 3 3 3 8L 54 N m 40 ft lbs EGR Tube to Intake Manifold Screws 22 N m 200 in lbs Idle Air Control Motor 2 N m 18 in lbs Ignition Coil Fasteners 12 N m 105 in lbs Intake Air Temperature Sensor 28 N m 20 ft lbs MAP Sensor 2 4L 4 N m 35 in lbs MAP Sensor 3 0L 4 N m 35 in lbs MAP Sensor 3 3 3 8L 4 N m 35 in lbs Upstream O2S 27 N m 20 ft ...

Page 1367: ...Metering Orifice Fuel Line Tool Fuel Line Adapter Fuel Line Adapter 1 4 O2S Oxygen Sensor Remover Installer C 4907 NS FUEL SYSTEM 14 73 SPECIAL TOOLS Continued ...

Page 1368: ......

Page 1369: ...cket located inside the vehicle under the dashpanel to the left of the steering column Fig 1 The PCM is mounted at the base of the center console in front of the Air Bag Module Fig 2 The Fuel System consists of the fuel tank fuel injection pump engine mounted fuel filter water separator fuel tank module electrical fuel gauge sending unit glow plugs glow plug relay PCM and all the electrical compon...

Page 1370: ...and provide excellent fuel economy when using high quality unleaded gasoline Use high quality unleaded gasoline with a mini mum research octane rating of 91 The vehicle will operate on fuels ranging from unleaded fuel having a minimum research octane of 91 to super unleaded fuel with a minimum research octane of 98 GASOLINE OXYGENATE BLENDS Refer to Gasoline Oxygenate blends for the 2 4 3 0 3 3 3 ...

Page 1371: ...N AND OPERATION INTRODUCTION This Fuel Delivery section will cover components not controlled by the PCM For components con trolled by the PCM refer to the Fuel Injection Sys tem 2 5L Diesel Engine section of this group The fuel heater relay fuel heater and fuel gauge are not operated by the PCM These components are controlled by the ignition key switch All other fuel system electrical components n...

Page 1372: ...o read full As the fuel level decreases the float and arm move down This increases the sending unit resis tance causing the fuel gauge on the instrument panel to read empty FUEL FILTER WATER SEPARATOR The fuel filter water separator assembly is located in the engine compartment near the strut tower Fig 3 The combination fuel filter water separator pro tects the fuel injection pump by helping to re...

Page 1373: ...fuel is injected is controlled by the vehicle s PCM instead of by a mechanical governor assembly A solenoid controlled by the PCM is used in place of the mechanical gov ernor assembly and it moves a control sleeve inside the pump that regulates the amount of fuel being injected There is no mechanical connection between the accelerator pedal and the electronically controlled injection pump Instead ...

Page 1374: ...r 1 or needle movement sensor It is used to tell the PCM when the 1 injector s internal spring loaded valve seat has been forced open by pressurized fuel being delivered to the cylin der which is at the end of its compression stroke When the instrumented injector s valve seat is force open it sends a small voltage spike pulse to the PCM This tells the PCM that the engine is at TDC on the number on...

Page 1375: ...essary replace the complete fuel tube assembly HIGH PRESSURE FUEL LINES CAUTION The high pressure fuel lines must be held securely in place in their holders The lines cannot contact each other or other components Do not attempt to weld high pressure fuel lines or to repair lines that are damaged Only use the recom mended lines when replacement of high pressure fuel line is necessary High pressure ...

Page 1376: ...w through the heater element stops Voltage to operate the fuel heater is supplied from the ignition key switch and through the fuel heater relay Refer to the following Fuel Heater Relay for additional information The fuel heater and fuel heater relay are not controlled by the Power train Control Module PCM Current draw for the heater element is 150 watts at 14 volts DC FUEL HEATER RELAY Voltage to...

Page 1377: ...me A thorough visual inspection of the fuel injection system includes the following checks 1 Be sure that the battery connections are tight and not corroded 2 Be sure that the 68 way connector is fully engaged with the PCM Fig 12 3 Verify that the electrical connections for the Diesel PCM relay are clean and free of corrosion This relay is located in the PDC For the location of the relay within th...

Page 1378: ...Fig 17 12 Inspect for exhaust system restrictions such as pinched exhaust pipes or a collapsed or plugged muffler 13 Verify that the harness connector is firmly connected to the vehicle speed sensor Fig 18 14 Verify turbocharger wastegate operation Refer to Group 11 Exhaust System and Intake Man ifold Group for information 15 Verify that the harness connector is firmly connected to the engine cool...

Page 1379: ...ter water separator fuel filter bowl injection pump high pressure lines or injectors are removed or disconnected Air will also enter the fuel system whenever the fuel tank has been run empty Air trapped in the fuel system can result in hard starting a rough running engine engine misfire low power excessive smoke and fuel knock After service is performed air must be bled from the system before star...

Page 1380: ...n the high pressure fuel line nut at the injector Fig 21 Listen for a change in engine speed If engine speed drops the injector was operating normally If engine speed remains the same the injector may be malfunctioning After test ing tighten the line nut to 30 N m 22 ft lbs torque Test all injectors in the same manner one at a time Once an injector has been found to be malfunction ing remove it fr...

Page 1381: ...e fuel lines with the correct replacement line CAUTION The high pressure fuel lines must be clamped securely in place in the holders The lines cannot contact each other or other components Do not attempt to weld high pressure fuel lines or to repair lines that are damaged Only use the recom mended lines when replacement of high pressure fuel line is necessary FUEL SHUTDOWN SOLENOID TEST Since dies...

Page 1382: ...gh pressure fuel lines and check for fuel spray onto the cardboard Fig 24 If a high pressure line con nection is leaking bleed the system and tighten the connection Refer to the Air Bleed Procedure in this group for procedures Replace damaged restricted or leaking high pressure fuel lines with the correct replacement line CAUTION The high pressure fuel lines must be clamped securely in place in th...

Page 1383: ...low valve HIGH PRESSURE FUEL LINE BLEEDING WARNING THE INJECTION PUMP SUPPLIES HIGH PRESSURE FUEL OF APPROXIMATELY 59 000 KPA 8 557 PSI TO EACH INDIVIDUAL INJECTOR THROUGH THE HIGH PRESSURE LINES FUEL UNDER THIS AMOUNT OF PRESSURE CAN PENE TRATE THE SKIN AND CAUSE PERSONAL INJURY WEAR SAFETY GOGGLES AND ADEQUATE PRO TECTIVE CLOTHING AND AVOID CONTACT WITH FUEL SPRAY WHEN BLEEDING HIGH PRESSURE FUE...

Page 1384: ...LATION 1 Install a new element in housing 2 Position left side of housing 3 Snap clamps into place 4 Install hoses and clamps FUEL DRAIN TUBES The fuel drain tubes Fig 28 are low pressure type Pull each tube from the injector for removal Push on for installation Clamps are not required for these tubes FUEL FILTER WATER SEPARATOR The fuel filter water separator is located in the engine compartment ...

Page 1385: ...TALLATION 1 Clean bottom of fuel filter base 2 Apply clean diesel fuel to new fuel filter gasket 3 Install and tighten filter to filter base The bev eled part of the rubber gasket should be facing up towards the filter base 4 Clean the inside of bowl with a soap and water mixture before installation Carefully clean any resi due between the two metal probes at the top of the water in fuel sensor Do...

Page 1386: ...ut of connec tor Fig 33 4 Push level sensor signal and ground terminals out of the connector Fig 34 5 Insert a screwdriver between the fuel module and the top of the level sensor housing Fig 35 Push level sensor down slightly 6 Slide level sensor wires through opening fuel module Fig 36 7 Slide level sensor out of installation channel in module Fig 31 Fuel Module Level Sensor Electrical Connector ...

Page 1387: ...OVAL 1 Disconnect negative battery cable at battery 2 Thoroughly clean the area around the injection pump and fuel lines of all dirt grease and other con taminants Due to the close internal tolerances of the injection pump this step must be per formed before removing pump 3 Remove the engine accessory drive belt Refer to Group 7 Cooling System for procedures 4 Remove the generator assembly 5 Remov...

Page 1388: ...ndicator to the top of the valve stem g Rotate engine back and forth to find the TDC position with the indicator on the valve stem Mark the damper and timing cover for TDC NOTE On later model 1997 engines a hole in the bottom of the clutch housing can be lined up with a hole in the flywheel allowing the engine to be held at TDC with a special alignment tool part VM1035 12 Remove injection pump dri...

Page 1389: ...ing nuts This is not the final tightening sequence 6 Remove the special gear puller and adapter tools from timing gear cover 7 Install the injection pump drive gear nut and washer Tighten nut to 88 N m 65 ft lbs torque 8 Remove access plug and plug washer at rear of pump Fig 45 Thread special dial indicator adapter tool VM 1011 Fig 46 into this opening Hand tighten only 9 Attach special dial indic...

Page 1390: ... ness to the engine wiring harness 26 Connect the overflow valve banjo fitting fuel return line assembly Replace copper gaskets before installing 27 Connect the rubber fuel return and supply hoses to metal lines at pump Tighten hose clamps to 2 N m 20 in lbs torque 28 Install generator assembly 29 Install engine accessory drive belt Refer to Group 7 Cooling System for procedures 30 Install negativ...

Page 1391: ... Disconnect the fuel return line and banjo fit ting above the solenoid by removing un threading the overflow valve Fig 50 Place a towel below the valve before removal Discard old sealing washers after removal 3 Disconnect the electrical connector nut Fig 50 4 Remove wiring at solenoid 5 Remove solenoid from injection pump INSTALLATION 1 Install solenoid into injection pump 2 Install wiring and nut...

Page 1392: ...n fuel tank on transmission jack Con nect fuel filler tube vent hose and replace clamp 2 Raise tank into position and carefully work filler tube into tank A light coating of clean engine oil on the tube end may be used to aid assembly 3 Feed filler vent line thru frame rail Careful not to cross lines 4 Tighten strap bolts to 54 N m 40 ft lbs torque Remove transmission jack CAUTION Ensure straps ar...

Page 1393: ...rom fuel module by depressing quick connect retainers with thumb and fore finger Fig 54 8 Slide module electrical connector lock to unlock 9 Push down on connector retainer Fig 55 and pull connector off module 10 Using Special Tool 6856 remove plastic lock nut counterclockwise to release pump module Fig 56 11 Carefully remove module and O ring from tank Fig 57 12 Discard old O ring INSTALLATION 1 ...

Page 1394: ...on pump delivery valve 5 Very carefully remove each line from the engine Note the position firing order of each line while removing Do not bend the line while removing CAUTION Be sure that the high pressure fuel lines are installed in the same order that they were removed Prevent the injection pump delivery valve holders Fig 58 from turning when removing or installing high pressure lines from inje...

Page 1395: ... variation may be observed from vehicle to vehicle due to man ufacturing tolerances ambient temperatures and refill procedures IDLE SPEED 900 rpm 625 rpm with engine at normal operat ing temperature FUEL INJECTOR FIRING SEQUENCE 1 3 4 2 FUEL SYSTEM PRESSURE Peak Injection Pressure Fuel Injection Pump Operating Pressure 40 000 45 000 kPa 5801 6526 psi Opening Pressure of Fuel Injector 15 000 15 800...

Page 1396: ...ines in the Fuel Delivery System Section of group 14 for more information FUEL LEVEL SENSOR Refer to the Fuel Level Sensor for the 2 4 3 0 3 3 3 8L engines in the Fuel Delivery System section of group 14 for more information FUEL PRESSURE REGULATOR Refer to the Fuel Pressure Regulator for the 2 4 3 0 3 3 3 8L engines in the Fuel Delivery System sec tion of group 14 for more information FUEL INJECT...

Page 1397: ...TALLATION FUEL FILTER 2 0L ENGINE Refer to the Fuel Filter for the 2 4 3 0 3 3 3 8L engines under Removal and Installation in the Fuel Delivery System section of group 14 for more infor mation FUEL PUMP MODULE 2 0L ENGINE Refer to the Fuel Pump Module for the 2 4 3 0 3 3 3 8L engines under Removal and Installation in the Fuel Delivery System section of group 14 for more information FUEL PRESSURE R...

Page 1398: ...c tors Fig 4 5 Remove fuel rail mounting screws 6 Lift rail off of intake manifold Cover the fuel injector openings in the intake manifold 7 Remove fuel injector retainer Fig 5 8 Pull injector out of fuel rail Replace fuel injec tor O rings Fig 6 INSTALLATION 1 Apply a light coating of clean engine oil to the upper O ring 2 Install injector in cup on fuel rail 3 Install retaining clip 4 Apply a li...

Page 1399: ... of group 14 for more informa tion TORQUE SPECIFICATION DESCRIPTION TORQUE Accelerator Pedal to Dash Nuts 12 N m 105 in lbs Fuel Pump Module Locknut 58 N m 43 ft lbs Fuel Tank Strap Bolts 54 N m 40 ft lbs Fuel Rail Bolts 23 N m 195 in lbs Ignition Coil Mounting Bolts 11 N m 95 in lbs Intake Manifold Bolts 11 N m 95 in lbs Throttle Control Shield 5 6 N m 50 in lbs NS GS FUEL SYSTEM 2 5L DIESEL ENGI...

Page 1400: ...AMP PCM OUTPUT 2 0L ENGINE 36 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR PCM INPUT 2 0L ENGINE 34 POWERTRAIN CONTROL MODULE 2 0L ENGINE 33 RADIATOR FAN CONTROL MODULE PCM OUTPUT 2 0L ENGINE 36 SPEED CONTROL SOLENOIDS PCM OUTPUT 2 0L ENGINE 36 SPEED CONTROL PCM INPUT 2 0L ENGINE 34 STARTER RELAY PCM OUTPUT 2 0L ENGINE 35 SYSTEM DIAGNOSIS 2 0L ENGINE 33 TACHOMETER PCM OUTPUT 2 0L ENGINE 36 THROTTLE BODY ...

Page 1401: ...0L ENGINE Refer to the Battery Voltage for 2 4 3 0 3 3 3 8L engines under Description and Operation in the Fuel Injection System section of group 14 for more infor mation CAMSHAFT POSITION SENSOR PCM INPUT 2 0L ENGINE Refer to the Camshaft Position Sensor for 2 4L engine under Description and Operation in the Fuel Injection System section of group 14 for more infor mation CRANKSHAFT POSITION SENSO...

Page 1402: ...eration in the Fuel Injection System section of group 14 for more infor mation SPEED CONTROL PCM INPUT 2 0L ENGINE Refer to the Speed Control for 2 4 3 0 3 3 3 8L engines under Description and Operation in the Fuel Injection System section of group 14 for more infor mation Fig 3 Engine Coolant Temperature Sensor 2 0L engine Fig 4 Upstream Heated Oxygen Sensor 2 0L Engine Fig 5 Downstream Heated Ox...

Page 1403: ... mation STARTER RELAY PCM OUTPUT 2 0L ENGINE Refer to the Starter Relay for 2 4 3 0 3 3 3 8L engines under Description and Operation in the Fuel Injection System section of group 14 for more infor mation IDLE AIR CONTROL MOTOR PCM OUTPUT 2 0L ENGINE Refer to the Idle Air Control Motor for 2 4 3 0 3 3 3 8L engines under Description and Operation in the Fuel Injection System section of group 14 for ...

Page 1404: ...stem perform a visual inspection for loose discon nected or misrouted wires and hoses A thorough visual inspection that includes the following checks saves unnecessary test and diagnostic time 1 Inspect the battery connections Clean corroded terminals 2 Check the 2 PCM 40 way connector for stretched wires on pushed out terminals 3 Open the Power Distribution Center PDC Check for blown fuses Ensure...

Page 1405: ...6 Inspect the electrical connections at the gen erator Fig 21 Check the generator belt for glazing or damage 17 Inspect the electrical connector at the crank shaft position sensor Fig 22 18 Check the electrical connection at the vehicle speed sensor Fig 23 Fig 12 Idle Air Control Motor and Throttle Position Sensor Typical Fig 13 PCV Valve Fig 14 MAP Intake Air Temperature Sensor Fig 15 Fuel Inject...

Page 1406: ... Fig 24 Fig 17 Starter Motor and Ground Strap Fig 18 Knock Sensor Fig 19 Camshaft Position Sensor and Engine Coolant Temperature Sensor Fig 20 Electronic EGR Transducer Fig 21 Generator Fig 22 Crankshaft Position Sensor 14 38 FUEL SYSTEM 2 5L DIESEL ENGINE 2 0L GAS ENGINE NS GS DIAGNOSIS AND TESTING Continued ...

Page 1407: ...the ASD and Fuel Pump Relays for 2 4 3 0 3 3 3 8L engines under Diagnosis and Testing in the Fuel Injection System section of group 14 for more information MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 2 0L ENGINE To perform a complete test of the MAP sensor and its circuitry refer to the DRB scan tool and appropri ate Powertrain Diagnostics Procedures manual To test the MAP sensor only refer to the follo...

Page 1408: ... knock sensor output voltage to the PCM can be read with the DRB III scan tool Sensor output should be between 80 mV and 4 volts with the engine running between 576 and 2208 rpm If the output falls outside of this range a DTC will be set CAMSHAFT AND CRANKSHAFT POSITION SENSOR Refer to Group 8D Ignition for Diagnosis and Test ing of Camshaft and Crankshaft Sensors ENGINE COOLANT TEMPERATURE SENSOR...

Page 1409: ...a link connector inside the passenger compartment 7 Run engine in Park or Neutral until the cooling fan has cycled on and off at least once 180 F 8 Using the DRB scan tool access Minimum Air flow Idle Speed 9 The following will then occur Idle air control motor will fully close Idle spark advance will become fixed PCM will go open loop enriched DRB scan tool displays engine RPM 10 If idle RPM is w...

Page 1410: ...b lem is not caused by the throttle body 12 Shut off engine 13 Remove Air Metering Orifice 6457 Install purge hose 14 Remove cap from PCV valve Connect hose to PCV valve 15 Remove DRB scan tool SPECIFICATIONS TORQUE DESCRIPTION TORQUE Air Cleaner Wingnut 1 5 N m 15 in lbs Air Cleaner Mount Stud To Thrott Body 10 N m 90 in lbs Crankshaft Position Sensor Mounting Bolts 8 N m 70 in lbs Engine Coolant...

Page 1411: ...A C CLUTCH RELAY 53 DIESEL PCM RELAY 53 ENGINE COOLANT TEMPERATURE SENSOR 54 ENGINE SPEED SENSOR 53 GLOW PLUG RELAY 55 GLOW PLUGS 54 POWERTRAIN CONTROL MODULE PCM 55 VEHICLE SPEED SENSOR 55 SPECIFICATIONS GLOW PLUG CURRENT DRAW 56 TORQUE CHART 2 5L DIESEL 57 GENERAL INFORMATION INTRODUCTION This section will cover components either regulated or controlled by the Powertrain Control Module PCM The f...

Page 1412: ...s to the PCM are con sidered PCM Inputs PCM Inputs are Air Conditioning Selection Theft Alarm Clutch Switch Diesel PCM Relay ISO Protocol Control Sleeve Fuel Temperature Boost Pressure Sensor Accelerator Pedal Sensor EGR A C Pressure Engine Coolant Temperature Sensor Low Idle Position Switch 5 Volt Supply Vehicle Speed Sensor Sensor Return Glow Plug Engine Speed Sensor rpm Fuel Injector 1 Sensor S...

Page 1413: ...he Glow Plug Lamp will start to blink and the vehicle will not start The PCM cannot be flashed to remove the VTA BATTERY VOLTAGE PCM INPUT The battery voltage input provides power to the PCM It also informs the PCM what voltage level is being supplied by the generator once the vehicle is running The battery input also provides the voltage that is needed to keep the PCM memory alive The memory stor...

Page 1414: ...es its own output signal If this signal is not received the engine will not start by the PCM The engine speed sensor input is used in conjunc tion with the first injector sensor to establish fuel injection pump timing The flywheel has four notches at its outer edge Fig 6 Each notch is spaced equally every 90 The notches cause a pulse to be generated when they pass under the speed sensor Fig 6 Thes...

Page 1415: ...ke light switch is activated the PCM receives an input indicating that the brakes are being applied After receiving this input the PCM is used to control the speed control system There is a Primary and a Secondary brake switch The Second ary brake switch is closed until the brake pedal is pressed DATA LINK CONNECTOR PCM INPUT AND OUTPUT The 16 way data link connector diagnostic scan tool connector...

Page 1416: ...PCM OUTPUT This circuit supplies approximately 5 volts to power the Accelerator Pedal Postion Sensor Mass Air Flow Sensor and A C Pressure Sensor ENGINE COOLANT GAUGE PCM OUTPUT Refer to the Instrument Panel and Gauges group for additional information ENGINE OIL PRESSURE GAUGE PCM OUTPUT Refer to the Instrument Panel and Gauges group for additional information GLOW PLUG LAMP PCM OUTPUT The Glow Pl...

Page 1417: ...is tied to this circuit Lamp operation is also controlled by the PCM With a cold engine the glow plug relay and glow plugs may be activated for a maximum time of 200 seconds Refer to the following Glow Plug Control chart for a temperature time comparison of glow plug relay operation In this chart Pre Heat and Post Heat times are mentioned Pre heat is the amount of time the glow plug relay circuit ...

Page 1418: ... SPEED SENSOR TEST To perform a test of the engine speed sensor and its related circuitry refer to the DRB scan tool Diagnostic Trouble Codes Refer to On Board Diagnostics in Group 25 Emission Control System for a list of Diagnostic Trouble Codes DTC s for cer tain fuel system components ENGINE COOLANT TEMPERATURE SENSOR TEST The sensor is located on the side of cylinder head near the rear of fuel...

Page 1419: ...w plug tip should start to glow an orange color after 5 seconds If the tip did not glow after 5 seconds replace the glow plug Before discarding the glow plug check the position of the circuit breaker on the bottom of the plug tester It may have to be reset Reset if necessary b Continue to hold the tester button while observing the amp gauge and the 4 timer lamps When all 4 lamps are illuminated in...

Page 1420: ... to the relay the fault is either with the relay or the relay input from the PCM To test the relay only refer to Relays Operation Test ing in this section of the group If the relay test is good refer to the DRB scan tool Diagnostic Trouble Codes Refer to On Board Diagnostics in Group 25 Emission Control System for a list of Diagnostic Trouble Codes DTC s for cer tain fuel system components RELAYS ...

Page 1421: ...ainder of the Die sel PCM and other relay circuits Refer to group 8W Wiring Diagrams BOOST PRESSURE SENSOR If the boost pressure sensor fails the PCM records a DTC into memory and continues to operate the engine in one of the three limp in modes When the PCM is operating in this mode a loss of power will be present as if the turbocharger was not operating The best method for diagnosing faults with...

Page 1422: ...sconnect electrical connector from sensor 3 Remove sensor from cylinder head INSTALLATION 1 Install a new copper gasket to sensor 2 Install sensor to cylinder head 3 Tighten sensor to 18 N m 13 ft lbs torque 4 Connect electrical connector to sensor 5 Replace any lost engine coolant Refer to Group 7 Cooling System GLOW PLUGS The glow plugs are located above each fuel injector Fig 20 Four individual...

Page 1423: ... air bag module Fig 23 REMOVAL 1 Disconnect the negative battery cable at the battery 2 Loosen the 68 Way connector Fig 23 The electrical connector has a sliding bar which moves inward to lock or outward to unlock 3 Remove the electrical connector by pulling straight out 4 Remove PCM INSTALLATION 1 After the PCM electrical connector has been separated from the PCM inspect the pins for corro sion b...

Page 1424: ...ighten sensor mounting bolt To prevent dam age to sensor or speedometer adapter be sure the sensor is mounted flush to the adapter before tight ening 3 Connect electrical connector to sensor SPECIFICATIONS GLOW PLUG CURRENT DRAW Initial Current Draw Approximately 22 25 amps per plug After 20 seconds of operation Approximately 9 12 amps per plug Fig 25 Sensor Removal Installation Typical Fig 24 Veh...

Page 1425: ...TORQUE CHART 2 5L DIESEL NS GS FUEL SYSTEM 2 5L DIESEL ENGINE 2 0L GAS ENGINE 14 57 SPECIFICATIONS Continued ...

Page 1426: ......

Page 1427: ...ded by an open center rotary type control valve It is used to direct oil from the pump to either side of the integral steering rack piston Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle As required steering effort increases as in a turn the torsion bar twists causing relative rotary motion between the rotary valve body and the valve spool This move ment...

Page 1428: ...nting bolts Tighten to specified torque if found to be loose 2 Front suspension crossmember to frame bolts or studs loose 2 Tighten the front suspension crossmember attaching bolts or studs to the specified torque 3 Tie rod is loose outer or inner 3 Check tie rod pivot points for wear Replace worn loose parts as required 4 Loose lower control arm to front suspension crossmember bolts 4 Tighten con...

Page 1429: ...age diagnosis 4 Air leak between power steering fluid reservoir and power steering pump 4 Inspect and or replace power steering fluid reservoir or supply hose as required SQUEAK OR RUBBING SOUND 1 Sound coming from steering column 1 Check for squeak in steering column Inspect for contact between shroud intermediate shaft column and steering wheel Realign if necessary Note Check steering column for...

Page 1430: ...inding 9 Realign the steering column to eliminate the binding condition 10 Binding lower ball joint 10 Replace the lower ball joint 11 Excessive friction in steering gear 11 Replace steering gear assembly CONDITION POSSIBLE CAUSES CORRECTION VIBRATION OF THE STEERING WHEEL AND OR DASH DURING DRY PARK OR LOW SPEED STEERING MANEUVERS 1 Air in the fluid of the power steering system 1 Steering shudder...

Page 1431: ...NOT RETURN TO CENTER POSITION 1 Tires not inflated to specified pressure 1 Inflate tires to specified pressure 2 Improper front wheel alignment 2 Check and adjust as necessary 3 Steering column U joints misaligned 3 Realign steering column U joints 4 Mispositioned dash cover 4 Reposition dash cover To evaluate items 6 and 7 disconnect the intermediate shaft Turn the steering wheel and feel or list...

Page 1432: ...ng wheel installed and steering column shaft disconnected from intermediate coupler Verify that steering wheel attaching nut is tightened to the specified torque Verify that the 4 mounting nuts for the steering column are tightened to the specified torque 5 Loose lower control arm ball joint 5 Check and or replace the ball joint or control arm as required 6 Loose steering knuckle to lower ball joi...

Page 1433: ...oose steering column to instrument panel mounting nuts 3 Verify that the 4 mounting nuts for the steering column are tightened to the specified torque 4 Binding intermediate steering shaft coupler 4 Disconnect intermediate steering coupler and see if looseness no longer exists If yes replace intermendiate steering coupler CONDITION POSSIBLE CAUSES CORRECTION LOW FLUID LEVEL WITH NO VISIBLE SIGNS O...

Page 1434: ... the power steering fluid is low Add power steering fluid as required to bring level up to specification 3 Cracked power steering pump housing 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 Water contamination 4 Drain the power steering fluid from the system if there is evidence ...

Page 1435: ... the power steering gear is provided by a belt driven power steering pump Fig 1 The power steering pump is a constant flow rate and displacement vane type pump The power steering pump used on all applications is the Vane Submerged remote reservoir style power steering pump The remote reservoir type pump Fig 1 has the pump housing and internal components combined with the fluid housing But it has a...

Page 1436: ...positions until against the stops recording the highest indicated pressure at each position Compare pressure gauge readings to power steering pump specifications If highest output pressures are not the same against either stop the steering gear is leaking internally and must be replaced SERVICE PROCEDURES POWER STEERING SYSTEM FLUID LEVEL CHECK WARNING FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF...

Page 1437: ...or the required lifting procedure 7 Disconnect the oxygen sensor wiring harness from the vehicle wiring harness Access to connection at vehicle wiring harness is through the oxygen sen sor wiring harness grommet in the floor pan of the vehicle NOTE The exhaust system needs to be removed from the engine to allow for an area to remove the power steering pump from the vehicle 8 Remove the catalytic c...

Page 1438: ...luid from tube 15 Remove the nut attaching rear of power steer ing pump to the cast mounting bracket Fig 9 16 Loosen the 3 bolts Fig 10 attaching the power steering pump to its front mounting bracket Then remove the nut and the bolt Fig 10 attaching the power steering pump front to the cast bracket 17 Remove the power steering pump and the front bracket from the cast bracket as an assembly Fig 6 A...

Page 1439: ... tube connection Be sure hose clamps are properly reinstalled Tighten the screw clamp to a torque of 2 N m 18 in lbs CAUTION The protective heat shield sleeves must cover the entire rubber hose and hose to tube con nection portion of both the power steering fluid pressure and return hoses Fig 5 This is required to prevent the overheating of the power steering hoses 12 When used properly position t...

Page 1440: ...possible Fig 12 9 Raise the heat sleeve on the power steering return hose to expose the return hose to steel tube connection Remove the hose from the power steering fluid return line on the front suspension cradle Fig 13 Allow the remaining power steering fluid to drain from the power steering pump and reservoir through the removed hose 10 Remove the accessory drive splash shield Fig 14 11 Remove ...

Page 1441: ...ing Fig 15 Be sure hose clamps are prop erly reinstalled and return hose is clear of all accessory drive belts 6 Install the power steering fluid supply hose from the power steering fluid reservoir on the power steering pump fluid fitting Fig 15 Be sure all hose clamps are properly reinstalled 7 Install the serpentine drive belt Fig 11 See Cooling Group 7 for detailed installation procedure 8 Inst...

Page 1442: ...nce section of this service man ual for the required lifting procedure 5 Disconnect the oxygen sensor wiring harness from the vehicle wiring harness Access to connection at vehicle wiring harness is through the oxygen sen sor wiring harness grommet in the floor pan of the vehicle NOTE The exhaust system needs to be removed from the engine to allow for an area to remove the power steering pump from...

Page 1443: ...er mounting bracket Fig 23 16 Remove the power steering pump from its mounting bracket 17 The power steering pump is removed from the vehicle by pulling it out through the exhaust tunnel area in the floor pan of the vehicle INSTALL 1 Install power steering pump back in vehicle using the reverse order of its removal through the exhaust tunnel are of the vehicle 2 Install the power steering pump on ...

Page 1444: ...rly position the protective heat sleeves on the power steering hoses Fig 18 Then tie strap the heat sleeves to the power steering hoses to keep them in their proper position 11 Install the exhaust pipe on the exhaust man ifold Install all exhaust system hangers isolators on the exhaust system brackets 12 Connect the oxygen sensor wiring harness to the vehicle wiring harness Install wiring harness ...

Page 1445: ...oper level and let the fluid settle for at least two 2 min utes 9 Start the engine and let run for a few seconds Then turn the engine off 10 Add fluid if necessary Repeat the above pro cedure until the fluid level remains constant after running the engine 11 Raise the front wheels off the ground 12 Start the engine Slowly turn the steering wheel right and left lightly contacting the wheel stops 13...

Page 1446: ...ring pump and steering gear Route hose avoiding tight bends or kinking Do not bend tube ends of the power steering hoses when installing 4 Install the power steering fluid hoses to sus pension cradle routing bracket Fig 28 Power steer ing fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces of the vehicle CAUTION When tightening and torquin...

Page 1447: ...ible from the power steering fluid reservoir 3 Raise vehicle See Hoisting Group 0 Put oil drain pan under vehicle to catch power steering fluid 4 Raise the insulating heat sleeve on the power steering hoses to expose the hose to steel tube con nection Remove hose clamp where rubber portion of power steering fluid return hose attaches to steel tube on suspension cradle Fig 30 Remove rubber hose fro...

Page 1448: ...trut tower Fig 32 3 Install the fluid supply hose onto the power steering fluid reservoir fitting Fig 31 Install the hose clamp on the fluid supply hose at the fluid res ervoir Be sure hose clamp in installed past bead on fluid reservoir fitting 4 Raise vehicle on jack stands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this service man ual ...

Page 1449: ...ONTROL VALVE SEAL DISASSEMBLE WARNING POWER STEERING OIL ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING DO NOT START ENGINE WITH ANY LOOSE OR DIS CONNECTED HOSES DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST 1 Remove cap from power steering fluid reser voir 2 Using a siphon pump remove as much power steering fluid as possible from the power steer...

Page 1450: ...ield sleeves must cover the entire rubber hose and hose to tube con nection portion of both the power steering fluid pressure and return hoses Fig 36 This is required to keep the power steering hoses from becoming overheated 6 When used properly position the protective heat sleeves Fig 36 on the power steering hoses Then tie strap the heat sleeves to the power steering hoses to keep them in their ...

Page 1451: ...SPECIAL TOOLS POWER STEERING PUMP Installer C 4063B Puller C 4333 P S System Analyzer 6815 NS STEERING 19 25 ...

Page 1452: ...n in this manual for proper procedure The power steering system consists of these four major components Power Steering Gear Power Steering Pump Pressure Hose and Return Line Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack teeth Power assist steering is provided by an open center rotary type control valve which directs oil ...

Page 1453: ...ing should be in the range of 345 552 kPa 50 80 psi The flow meter should read between 1 3 and 1 9 GPM CAUTION The following test procedure involves testing power steering pump maximum pressure output and flow control valve operation Do not leave valve closed for more than 5 seconds as the pump could be damaged 8 Close valve fully three times and record high est pressure indicated each time All th...

Page 1454: ... sleeve Fig 4 on the power steering return hose to expose the return hose to steel tube connection Remove the return hose from the metal tube of the power steering fluid return line Fig 4 Then allow the remaining power steering fluid to drain from the system through the hose and metal tube 8 Remove nut attaching outer tie rod end to steering knuckle Fig 5 Nut is to be removed from tie rod end usin...

Page 1455: ...ove the bracket Fig 9 attaching the power steering fluid tubes to the front suspension cradle 13 Using a 18mm crowfoot Fig 10 remove the power steering fluid pressure and return lines Fig 10 from the power steering gear 14 Remove the 3 bolts and nuts Fig 11 mount ing the steering gear to the front suspension cradle Fig 7 HCU Bracket Attaching Bolts Fig 8 Front Suspension Cradle Plate And Attaching...

Page 1456: ...ecial Tool 6831A through the center of the roll pin securing it with the knurled nut Fig 13 Hold threaded rod station ary while turning nut this will pull the roll pin into the intermediate coupler 4 Install steering gear assembly on the front sus pension cradle Install the 3 steering gear to front suspension cradle mounting bolts and nuts Fig 11 CAUTION Proper torque on the steering gear to suspe...

Page 1457: ... interme diate coupler Install steering column coupler to intermediate shaft retaining pinch bolt Fig 3 Tighten the pinch bolt nut to a torque of 28 N m 250 in lbs CAUTION Do not use automatic transmission fluid in the power steering system Only use Mopar Power Steering Fluid or an exact equivalent prod uct 16 Fill power steering pump fluid reservoir to the proper level 17 Start the engine and let...

Page 1458: ...p inner tie rod boot to steering gear clamp using Crimper Special Tool C4975A Fig 20 When installing clamp Special Tool C4975A must have bot tom bolt tightened until their is no gap between the 2 bars of the tool Fig 20 5 Lubricate inner tie rod boot groove with sili cone type lubricant then install outer boot seal to inner tie rod clamp Fig 18 Clamp will have to be loosened for toe adjustment 6 I...

Page 1459: ...ure boot is not twisted OUTER TIE ROD END DISASSEMBLE 1 Loosen inner tie rod to outer tie rod jam nut Fig 22 2 Remove nut attaching outer tie rod end to steering knuckle Fig 23 Nut is to be removed from tie rod end using the following procedure hold tie rod end stud with a 11 32 socket while loosening and removing nut with wrench 3 Remove the tie rod end stud from steering knuckle arm using Remove...

Page 1460: ...n Front Suspen sion Service Procedures in this group of the service manual Refer to the Specifications Section at the end of this group for the desired front Toe specifica tion 5 Tighten tie rod jam nut Fig 22 to 55 N m 75 ft lbs torque 6 Adjust the steering gear to inner tie rod boots at inner tie rod if they became twisted during Toe adjustment SPECIFICATIONS STEERING GEAR FASTENER TORQUE SPECIF...

Page 1461: ...SPECIAL TOOLS POWER STEERING GEAR Remover Tie Rod End MB 991113 Remover Installer Steering Shaft Roll Pin 6831A P S System Analyzer 6815 Installer Boot Clamp C 4975A NS STEERING 19 35 ...

Page 1462: ...ESCRIPTION The steering column Fig 1 has been designed to be serviced only as a complete assembly if a compo nent of the steering column is defective The only replaceable components of the steering column assembly are the key cylinder ignition switch multi function switch clockspring halo lamp speed control switches driver airbag trim shrouds and steering wheel These replaceable components of the ...

Page 1463: ...Steering Column And Steering System Components NS STEERING 19 37 DESCRIPTION AND OPERATION Continued ...

Page 1464: ...AND SAFE SER VICE PROCEDURES NOTE Safety goggles should be worn at all times when working on steering columns CAUTION Disconnect negative ground cable from the battery before servicing any column com ponent CAUTION Do not attempt to remove the pivot pins to disassemble the tilting mechanism Damage will occur REMOVAL AND INSTALLATION STEERING COLUMN ASSEMBLY To service the steering wheel and its co...

Page 1465: ...the steering wheel retaining nut Fig 7 from the steering column shaft 10 Remove the steering wheel damper Fig 7 from the steering wheel CAUTION Do not bump or hammer on steering column or steering column shaft when removing steering wheel from steering column shaft Fig 3 Park Brake Release Cable Attachment To Release Lever Fig 4 Lower Steering Column Cover Attachment Fig 5 Steering Wheel In Locked...

Page 1466: ... 13 Remove the vehicle wiring harness connectors Fig 10 from the clock spring assembly CAUTION Do not rotate the clock spring after it is removed from the multifunction switch 14 Remove the clock spring from the multi func tion switch 15 Remove the vehicle wiring harness connector from the top of the multi function switch Fig 11 16 Remove the screw Fig 12 attaching the multi function switch housin...

Page 1467: ...ing it off with a screw driver Fig 16 23 Remove the gear selector cable and its mount ing bracket as an assembly from the upper mounting bracket for the steering column Fig 17 24 Remove the instrument cluster trim bezel Fig 18 from the instrument panel The trim bezel is mounted to the instrument panel using 2 attaching screws and retaining clips 25 Remove the steering column fixed shroud from the ...

Page 1468: ...lies attaching the steering column lower mounting bracket Fig 21 Then remove the 2 nut washer assemblies attaching the steering column upper mounting bracket Fig 21 Fig 17 Gear Selector Cable Mounting Bracket Fig 18 Instrument Cluster Trim Bezel Fig 19 Steering Column Fixed Shroud Fig 20 Steering Column Shaft To Intermediate Coupler Attachment Fig 21 Steering Column Upper And Lower Mounting Bracke...

Page 1469: ...NDL actuating cable on the steer ing column shift cable bracket Cable guide tube will bow toward passenger side of vehicle Verify that actuating cable is operating correctly then slip the loop on the end of the cable over end of pin on shift lever and install in groove Fig 15 8 Install the steering column fixed shroud on the steering column assembly Fig 19 Shroud is mounted to steering column usin...

Page 1470: ...l retaining nut 18 Align master splines on steering wheel and steering shaft and flats on steering wheel with for mations on clock spring Install the steering wheel on the steering column shaft Fig 26 All wiring leads from the clock spring must be routed as shown in Fig 26 NOTE Before installing the damper on the steering wheel inspect the damper to ensure the rubber iso lator on the damper is not...

Page 1471: ...rake release lever in the lower steering col umn cover Fig 3 26 Install the lower steering column trim panel on the lower instrument panel Install and securely the screws attaching the lower steering column cover to the instrument panel Fig 2 27 Connect negative ground cable on the bat tery terminal SPECIFICATIONS STEERING COLUMN FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE STEERING WHEEL Ret...

Page 1472: ......

Page 1473: ...viced or adjusted If a malfunction or oil leak occurs the complete steering gear should be replaced Refer to the Power Steering Gear in group 19 for more information POWER STEERING GEAR SERVICE PROCEDURES POWER STEERING PUMP INITIAL OPERATION WARNING THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS CAUTION Use MOPAR Power Steering Fluid or equivalent Do no...

Page 1474: ...x wrench to secure the power steering shaft while removing the pulley bolt with a box wrench Fig 2 CAUTION Do not use an impact wrench to remove the pump pulley this can cause rear pump seal damage Do not secure power steering shaft with a wrench on the coupling to the A C compressor this can cause rear pump seal damage 3 Remove coupling bolts 2 from A C compressor side of coupling 4 Loosen A C co...

Page 1475: ...TUBES 18 OIL PUMP VOLUME CHECK 19 REMOVAL AND INSTALLATION FRONT PUMP OIL SEAL 21 PARK NEUTRAL STARTING AND BACK UP LAMP SWITCH 19 TRANSAXLE AND TORQUE CONVERTER REMOVAL 20 VEHICLE SPEED SENSOR PINION GEAR 19 DISASSEMBLY AND ASSEMBLY ACCUMULATOR RECONDITION 36 DIFFERENTIAL REPAIR 46 FRONT CLUTCH RECONDITION 32 FRONT PLANETARY ANNULUS GEAR RECONDITION 35 KICKDOWN SERVO CONTROLLED LOAD RECONDITION 3...

Page 1476: ...nnected to the front clutch by a driving shell The drive shell is splined to the sun gear and front clutch retainer The hydraulic system consists of an oil pump and a single valve body which con tains all of the valves except the governor valves The transaxle sump and differential sump are both vented through the dipstick Output torque from the main center line is delivered through helical gears t...

Page 1477: ... and downshift The throttle valve transmits regulated pressure to the transaxle dependent on throttle position to con trol upshift and downshift FLOW CONTROL VALVES The manual valve provides the different transaxle drive ranges as selected by the vehicle operator The 1 2 shift valve automatically shifts the tran saxle from first to second or from second to first depending on the vehicle operation ...

Page 1478: ...e transaxle should be oper ated in each position to check for slipping and any variation in shifting If vehicle operates at high speeds but has poor acceleration the converter s overrunning clutch may be slipping If acceleration is normal but high throt tle opening is needed for high speeds the stator clutch may have seized Observe closely for slipping or engine speed flare up Slipping or flare up...

Page 1479: ...Diagnosis Guide NS TRANSAXLE AND POWER TRANSFER UNIT 21 5 DIAGNOSIS AND TESTING Continued ...

Page 1480: ...Diagnosis Guide 21 6 TRANSAXLE AND POWER TRANSFER UNIT NS DIAGNOSIS AND TESTING Continued ...

Page 1481: ...Diagnosis Guide NS TRANSAXLE AND POWER TRANSFER UNIT 21 7 DIAGNOSIS AND TESTING Continued ...

Page 1482: ...Diagnosis Guide 21 8 TRANSAXLE AND POWER TRANSFER UNIT NS DIAGNOSIS AND TESTING Continued ...

Page 1483: ...Diagnosis Guide NS TRANSAXLE AND POWER TRANSFER UNIT 21 9 DIAGNOSIS AND TESTING Continued ...

Page 1484: ...Diagnosis Guide 21 10 TRANSAXLE AND POWER TRANSFER UNIT NS DIAGNOSIS AND TESTING Continued ...

Page 1485: ...Diagnosis Guide NS TRANSAXLE AND POWER TRANSFER UNIT 21 11 DIAGNOSIS AND TESTING Continued ...

Page 1486: ...Diagnosis Guide 21 12 TRANSAXLE AND POWER TRANSFER UNIT NS DIAGNOSIS AND TESTING Continued ...

Page 1487: ...s moved counterclockwise to 80 to 88 psi 6 Low reverse pressure should read the same as line pressure within 3 psi 7 This tests pump output pressure regulation and condition of rear clutch and rear servo hydraulic circuits TEST TWO SELECTOR IN 2 1 Attach one gauge to line pressure port and tee another gauge into lower cooler line fitting This will allow lubrication pressure readings to be taken 2 ...

Page 1488: ...crease as lever is moved counterclock wise to 260 to 300 psi 5 This tests pump output pressure regulation and condition of front clutch and rear servo hydraulic circuits 6 Move selector lever on transaxle to D position to check that low reverse pressure drops to zero 7 This tests for leakage into rear servo due to case porosity which can cause reverse band burn out TEST RESULT INDICATIONS 1 If pro...

Page 1489: ...tch is operating Hold air pressure on for a few seconds and inspect system for excessive oil leaks REAR CLUTCH Apply air pressure to rear clutch apply passage and listen for a dull thud which indicates that rear clutch is operating Also inspect for excessive oil leaks If a dull thud cannot be heard in the clutches place finger tips on clutch housing and again apply air pressure Movement of piston ...

Page 1490: ...duces additives into the transaxle TRANSAXLE FLUID EXCHANGER METHOD 1 To perform the transaxle fluid exchange the transaxle must be at operating temperature Drive the vehicle till it reaches full operating temperature 2 Verify that the fill tank on the transaxle fluid exchanger ATF 2000 or equivalent is clean and dry 3 Fill the tank to the recommended fill capacity with Mopar ATF Plus 3 Type 7176 ...

Page 1491: ...on the dip stick 9 Recheck the fluid level after the transaxle is at normal operating temperature The level should be in the HOT range Drive the vehicle a minimum of 10 miles 10 Raise the vehicle on the hoist 11 Check for leaks around the transaxle oil pan sealing surfaces 12 Recheck the fluid level The level should be in the HOT range SEVERE USAGE SERVICE If the vehicle exhibits any of the follow...

Page 1492: ...vel should be in the HOT region ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum transaxle case and valve body can be repaired by the use of Heli Coils or equivalent This repair consists of drilling out the worn out damaged threads Then tapping the hole with a Heli Coil tap or equivalent and installing a Heli Coil insert or equivalent into the hole This brings the hole back to its or...

Page 1493: ...acceptable limits replace the cooler Then fill transmission to the proper level using Mopart ATF PLUS 3 Type 7176 automatic transmission fluid 6 If fluid flow is still found to be inadequate check the line pressure using the Transaxle Hydrau lic Pressure Test procedure REMOVAL AND INSTALLATION VEHICLE SPEED SENSOR PINION GEAR When the sensor is removed for any reason a NEW O ring must be installed...

Page 1494: ...d Disconnect exhaust pipe from manifold 11 Remove torque converter dust cover Mark torque converter and drive plate with chalk for reas sembly Rotate engine clockwise and remove torque converter mounting bolts 12 Remove engine mount bracket from front crossmember 13 Remove front mount insulator through bolt and bellhousing bolts 14 Position transaxle jack Fig 6 15 Remove rear engine mount shield 1...

Page 1495: ...gs and clean the unit preferably with steam When disassembling each part should be washed in a suitable solvent then dried with compressed air Do not wipe parts with shop towels All mating sur faces in the transaxles are accurately machined therefore careful handling of all parts must be exer cised to avoid nicks or burrs DISASSEMBLY Remove all old sealant before applying new seal ant Use only Mop...

Page 1496: ...t washer change is required The thrust washer is located between input and output shafts Fig 11 Oil Filter Screws Fig 12 Oil Filter Fig 13 Remove Parking Rod E Clip Fig 14 Parking Rod Fig 15 Valve Body Attaching Bolts Fig 16 Valve Body and Governor Tubes 21 22 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1497: ...h Record indicator reading for reference when reas sembling the transaxle Remove Number 6 thrust washer from sun gear driving shell Fig 17 Measure Input Shaft End Play Fig 18 Loosen Lock Nut and Tighten Kickdown Band Adjusting Screw Fig 19 Pump Attaching Bolts Fig 20 Install Tool C 3752 with Adapters L 4437 Fig 21 Oil Pump with No 1 Thrust Washer NS TRANSAXLE AND POWER TRANSFER UNIT 21 23 DISASSEM...

Page 1498: ...n Kickdown Band Adjusting Screw Fig 24 Kickdown Band and Strut Fig 25 Front Clutch Assembly Fig 26 No 2 Thrust Washer and Rear Clutch Fig 27 No 3 Thrust Washer 21 24 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1499: ...29 Front Planetary Gear Assembly Fig 30 Sun Gear Driving Shell Fig 31 Sun Gear Driving Shell Components Fig 32 No 9 Thrust Washer Fig 33 Rear Planetary Gear Assembly NS TRANSAXLE AND POWER TRANSFER UNIT 21 25 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1500: ...g Clutch Cam Assembly Fig 36 Overrunning Clutch Rollers and Spring Fig 37 Loosen or Adjust Low Reverse Band Fig 38 Low Reverse Band and Strut Fig 39 No 11 Thrust Washer 21 26 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1501: ...ssive leakage or both When removing or installing valves or plugs slide them in or out carefully Do not use force NOTE TAG ALL SPRINGS AS THEY ARE REMOVED FOR REASSEMBLY IDENTIFICATION Fig 40 Install Overrunning Clutch Rollers and Springs Fig 41 Detent Spring Attaching Screw and Spring Fig 42 Using Tool L 4553 on Valve Body Screw Fig 43 Remove or Install Valve Body Screws Fig 44 Transfer Plate and...

Page 1502: ... Install Throttle Shaft E Clip Fig 47 Throttle Shaft E Clip Washer and Seal Fig 48 Manual Valve Lever Assembly Fig 49 Throttle Valve Lever Assembly Fig 50 Manual Valve 21 28 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1503: ...Fig 52 Pressure Regulators and Manual Controls Fig 51 Pressure Regulator and Adjusting Screw Bracket NS TRANSAXLE AND POWER TRANSFER UNIT 21 29 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1504: ...Fig 53 Governor Plugs Fig 54 Pressure Regulator Valve Plugs 21 30 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1505: ...learance with a straight edge and a feeler gauge See Specifica tions Fig 55 Shift Valves and Shuttle Valve Fig 56 Reaction Shaft Support Bolts Fig 57 Reaction Shaft Support NS TRANSAXLE AND POWER TRANSFER UNIT 21 31 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1506: ...uld be protected from damage during disassembly and han dling Note ball check in clutch retainer make sure ball moves freely Inspect piston seal surfaces in clutch retainer for nicks or deep scratches light scratches will not interfere with sealing of seals Inspect clutch retainer inner bore surface for wear from reaction shaft support seal rings Inspect clutch retainer bushing for wear or scores ...

Page 1507: ...ball check in piston make sure ball moves freely Inspect seal rings surfaces in clutch retainer for nicks or deep scratches light scratches will not interfere with sealing of the seals Inspect neoprene seal rings for deterioration wear and hard ness Inspect piston spring and waved snap ring for distortion or breakage Inspect teflon and or cast iron seal rings on input shaft for wear Do not remove ...

Page 1508: ...tch 4 Disc Shown Fig 68 Piston Spring Waved Snap Ring Fig 69 Rear Clutch Piston and Piston Spring Fig 70 Remove or Install Input Shaft Snap Ring Fig 71 Input Shaft Snap Ring 21 34 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1509: ...nt Planetary Gear Snap Ring and No 4 Thrust Washer Always Install a New Snap Ring Fig 74 Front Planetary Gear Fig 75 Annulus Gear Support Front Snap Ring Fig 76 Front Annulus Gear Support and Snap Ring Fig 77 Front Annulus Gear Support Snap Ring NS TRANSAXLE AND POWER TRANSFER UNIT 21 35 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1510: ...OR RECONDITION DISASSEMBLY Fig 78 Low Reverse Lever Fig 79 Low Reverse Servo Snap Ring Fig 80 Remove Retainer Spring and Servo Fig 81 Low Reverse Servo Assembly Fig 82 Accumulator Snap Ring Fig 83 Accumulator Plate and Snap Ring 21 36 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1511: ... assemble reverse the above procedure Fig 84 Accumulator Spring and Piston Fig 85 Kickdown Servo Snap Ring Fig 86 Kickdown Servo Rod Guide and Snap Ring Fig 87 Kickdown Piston Return Spring and Piston Fig 88 Controlled Load Kickdown Servo NS TRANSAXLE AND POWER TRANSFER UNIT 21 37 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1512: ...lling cover NOTE Remove or install both governor valves and governor body Fig 89 Rear Cover Bolts Fig 90 Remove or Install Rear Cover Fig 91 Remove Transfer Shaft Gear Retaining Nut Fig 92 Transfer Shaft Gear Nut and Washer Fig 93 Remove Transfer Shaft Gear 21 38 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1513: ...e Transfer Shaft Gear Bearing Cone Fig 96 Install Transfer Shaft Gear Bearing Cone Fig 97 Governor Support Retainer Fig 98 Remove Governor Support Retainer Bearing Cup Fig 99 Install Governor Support Retainer Bearing Cup NS TRANSAXLE AND POWER TRANSFER UNIT 21 39 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1514: ...earing Snap Ring Fig 103 Remove Transfer Shaft and Bearing Retainer Assembly Fig 104 Remove or Install Transfer Shaft and Bearing Retainer Assembly Using Tool L 4512 Fig 105 Transfer Shaft and Bearing Retainer 21 40 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1515: ...Shaft Bearing Cone Fig 107 Install Transfer Shaft Bearing Cone Fig 108 Remove Transfer Shaft Bearing Cup Fig 109 Install Transfer Shaft Bearing Cup NS TRANSAXLE AND POWER TRANSFER UNIT 21 41 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1516: ...Procedure in rear of this section to determine proper shim thickness ASSEMBLY To install transfer shaft reverse the above proce dure PARKING PAWL DISASSEMBLY ASSEMBLY To install reverse the above procedure Fig 110 Tighten Transfer Shaft Gear Retaining Nut to 271 N m 200 ft lbs Fig 111 Checking Transfer Shaft End Play Fig 112 Parking Sprag Rod Support Fig 113 Support and Bolts Fig 114 Parking Pawl ...

Page 1517: ...ing torque Fig 115 Remove Output Shaft Retaining Nut and Washer Fig 116 Remove Output Shaft Gear Fig 117 Output Shaft Gear and Select Shim Fig 118 Remove Output Shaft Gear Bearing Cone Fig 119 Install Output Shaft Gear Bearing Cone Fig 120 Remove Output Shaft and Rear Annulus Gear Assembly NS TRANSAXLE AND POWER TRANSFER UNIT 21 43 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1518: ...23 Install Rear Planetary Annulus Gear Bearing Cone Fig 124 Install Output Shaft into Rear Planetary Annulus Gear Fig 125 Remove Output Shaft Gear Bearing Cup Fig 126 Remove Rear Planetary Annulus Gear Bearing Cup 21 44 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1519: ...termine proper shim thickness Check output shaft bearings turning torque using an inch pound torque wrench If turning torque is 3 to 8 inch pounds the proper shim has been installed Fig 127 Install Output Shaft Gear Bearing Cup Fig 128 Install Rear Planetary Annulus Gear Bearing Cup Fig 129 Install Output Shaft Assembly Fig 130 Output Shaft and Select Shims in Position Fig 131 Start Output Shaft G...

Page 1520: ...Fig 133 Tighten Output Shaft Retaining Nut to 271 N m 200 ft lbs Fig 134 Checking Output Shaft End Play Fig 135 Checking Bearings Turning Torque Fig 136 Remove Extension Seal Fig 137 Install New Seal into Extension Fig 138 Differential Cover Bolts 21 46 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1521: ...rential Cover Fig 140 Remove Bearing Retainer Axle Seal Fig 141 Install Bearing Retainer Axle Seal Fig 142 Differential Bearing Retainer Bolts Fig 143 Remove or Install Bearing Retainer Fig 144 Differential Bearing Retainer Typical NS TRANSAXLE AND POWER TRANSFER UNIT 21 47 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1522: ...Adhesive Sealant or equivalent when installing extension housing Fig 145 Extension Bolts Fig 146 Remove or Install Extension Housing Fig 147 Differential and Extension Fig 148 Remove Differential Bearing Cone Extension Housing Side Fig 149 Position Bearing Cone Onto Differential Fig 150 Install Differential Bearing Cone 21 48 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1523: ...e differential you must replace the differential assembly along with the transfer shaft CAUTION Side gear end play must be BETWEEN 0 001 to 0 013 inch Fig 151 Position Button and Collets Onto Differential and Bearing Ring Gear Side Fig 152 Position Tool 5048 Over Button and Collets at Differential Bearing Fig 153 Remove Differential Bearing Cone Fig 154 Checking Side Gear End Play Fig 155 Checking...

Page 1524: ...with compressed air Make sure all passages are clean and free from obstructions Inspect manual and throttle valve operating levers and shafts for being bent worn or loose If a lever is loose on its shaft it should be replaced Do not attempt to straighten bent levers Inspect all mating surfaces for burrs nicks and scratches Minor blemishes may be removed with cro cus cloth using only a very light p...

Page 1525: ...sure it is in park lock Reset the park brake 6 Tighten the cable adjustment screw to 8 N m 70 in lbs Gearshift cable should now be properly adjusted 7 Verify PRNDL indicator still displays the corre sponding gear completely If not readjustment of PRNDL may be required 8 Check adjustment by using the preceding pro cedure THROTTLE PRESSURE LINKAGE ADJUSTMENT The throttle pressure rod adjustment is v...

Page 1526: ...p or cone Burrs or nicks on the bearing seat will give a false end play reading while gauging for proper shims Improperly seated bearing cup and cones are subject to low mile age failure 2 Bearing cups and cones should be replaced if they show signs of pitting or heat distress 3 If distress is seen on either the cup or bearing rollers both cup and cone must be replaced NOTE Bearing end play and dr...

Page 1527: ...nion mate shaft 3 Rotate the differential at least one full revolu tion to ensure the tapered roller bearings are fully seated 4 Using Tool L 4436A and an inch pound torque wrench check the turning torque of the differential The turning torque should be between 5 and 18 inch pounds 5 If the turning torque is within specifications remove tools Setup is complete 6 If turning torque is not within spe...

Page 1528: ...71 N m 200 ft lbs 4 To measure bearing end play 5 Attach Tool L 4432 to the transfer gear 6 Mount a steel ball with grease into the end of the transfer shaft 7 Push and pull the gear while rotating back and forth to insure seating of the bearing rollers 8 Using a dial indicator measure transfer shaft end play 9 Refer to the Transfer Bearing Shim Chart for the required shim combination to obtain th...

Page 1529: ... thinner shim combination If end play is too low install a 05 mm 002 inch thicker shim com bination Repeat until 05 to 25 mm 002 to 010 inch end play is obtained TRANSFER BEARING SHIM CHART NS TRANSAXLE AND POWER TRANSFER UNIT 21 55 ADJUSTMENTS Continued ...

Page 1530: ...SCHEMATICS AND DIAGRAMS 31TH TRANSAXLE HYDRAULIC SCHEMATIC 31TH TRANSAXLE HYDRAULIC SCHEMATIC 21 56 TRANSAXLE AND POWER TRANSFER UNIT NS ...

Page 1531: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 57 SCHEMATICS AND DIAGRAMS Continued ...

Page 1532: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC 21 58 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued ...

Page 1533: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 59 SCHEMATICS AND DIAGRAMS Continued ...

Page 1534: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC 21 60 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued ...

Page 1535: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 61 SCHEMATICS AND DIAGRAMS Continued ...

Page 1536: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC 21 62 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued ...

Page 1537: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 63 SCHEMATICS AND DIAGRAMS Continued ...

Page 1538: ...es Outer Gear To Pocket 0 045 0 141mm 0 0018 0 0056 in Outer Gear Side Clearance 0 020 0 046mm 0 0008 0 0018 in Inner Gear Side Clearance 0 020 0 046mm 0 0008 0 0018 in Tapered Roller Bearing Settings Differential Assembly 6 to 12 in lbs Drag Torque Output Hub 0 to 3 in lbs Drag Torque Transfer Shaft 0 002 to 0 010 in End Play Overall Drag At Output Hub 3 to 16 in lbs Drag Torque Clutch Pack Clear...

Page 1539: ...Screw 95 N m 70 ft lbs Front Motor Mount Bolt 54 N m 40 ft lbs Speedo To Ext Hous Screw 7 N m 60 in lbs Governor Counterweight Screw 28 N m 250 in lbs Sprag Ret To Transfer Case Bolt 28 N m 250 in lbs Governor To Support Bolt 7 N m 60 in lbs Starter To Trans Bell Bolts 54 N m 40 ft lbs Kickdown Band Adj Lock Nut 47 N m 35 ft lbs Throttle Cable To Trans Case Bolt 12 N m 105 in lbs Left Motor Mount ...

Page 1540: ...C TRANSAXLE Adapter Blocks C 293 45 Adapter Blocks C 293 52 Puller Press C 293 PA Pressure Gauge Low C 3292 Pressure Gauge High C 3293SP Dial Indicator C 3339 Spring Compressor C 3575 A 21 66 TRANSAXLE AND POWER TRANSFER UNIT NS ...

Page 1541: ...er Oil Pump Puller C 3752 Throttle Setting Gauge Seal Puller C 3981B Universal Handle C 4171 Seal Installer C 4193A Bearing Installer C 4637 Adapter C 4658 NS TRANSAXLE AND POWER TRANSFER UNIT 21 67 SPECIAL TOOLS Continued ...

Page 1542: ...995 Adapter C 4996 Remover Kit L 4406 Bearing Remover Cup L 4406 1 Bearing Remover Jaws L 4406 2 Adapter L 4406 3 Gear Puller L 4407A Puller L 4407 6 21 68 TRANSAXLE AND POWER TRANSFER UNIT NS SPECIAL TOOLS Continued ...

Page 1543: ...nstaller L 4410 Bearing Installer L 4411 Installer Adapter L 4429 3 Gear Checking Plate L 4432 Gear Removing Plate L 4434 Bearing Puller L 4435 Differential Tool L 4436A NS TRANSAXLE AND POWER TRANSFER UNIT 21 69 SPECIAL TOOLS Continued ...

Page 1544: ...er Nut L 4439 Transfer Shaft Remover Installer L 4512 Bearing Cup Remover L 4517 Special Jaw Set L 4518 Installer L 4520 Bearing Splitter P 334 Cooling System Tester 7700 21 70 TRANSAXLE AND POWER TRANSFER UNIT NS SPECIAL TOOLS Continued ...

Page 1545: ...ER 84 OIL PUMP SEAL 92 SOLENOID ASSEMBLY REPLACE 85 SPEED SENSOR INPUT 86 SPEED SENSOR OUTPUT 86 TRANSAXLE 89 TRANSMISSION CONTROL MODULE 87 TRANSMISSION RANGE SENSOR 85 VALVE BODY 88 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL REPAIR 139 INPUT CLUTCHES RECONDITION 110 TRANSAXLE ASSEMBLE 122 TRANSAXLE DISASSEMBLE 95 VALVE BODY RECONDITION 92 CLEANING AND INSPECTION CLEANING VALVE BODY 144 ADJUSTMENTS GE...

Page 1546: ...air bubbles make the fluid spongy therefore pressures will be low and build up slowly Improper filling can also raise the fluid level too high When the transaxle has too much fluid the gears churn up foam and cause the same conditions which occur with a low fluid level In either case the air bubbles can cause overheat ing fluid oxidation and varnishing This can inter fere with normal valve clutch ...

Page 1547: ...served Some of these signals are read directly from the engine con trol sensors others are read from a multiplex circuit with the powertrain control module ELECTRONICS The 41TE Transmission Control Module TCM is located underhood in a potted die cast aluminum housing The module used is a new controller called EATX III The TCM has a sealed 60 way connector ADAPTIVE CONTROLS These controls function ...

Page 1548: ...c Pinion Factor Procedure The Transmission Control Module is located on the right inner fender panel in the engine compartment It is held in place by four mounting screws NOTE If the Transmission Control Module has been replaced the following procedures must be performed Quick Learn Procedure This procedure will allow the transmission control module to learn the characteristics of the vehicle Elec...

Page 1549: ...f acceleration is normal but high throttle opening is needed for high speeds the clutch may have seized Both of these stator defects require replacement of the torque converter The clutch that is slipping can be determined by noting the transaxle operation in all selector posi tions Then comparing which internal units are applied in those positions The Elements in Use Chart provides a basis for ro...

Page 1550: ...gauge to the overdrive clutch tap 2 Move selector lever to the Circle D position 3 Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 20 mph 4 Overdrive clutch pressure should read 74 to 95 psi 5 Move selector lever to the 3 position and increase indicated vehicle speed to 30 mph 6 The vehicle should be in second gear and over drive clutch pressure ...

Page 1551: ...an 5 psi in Step 4 of Test 2A a defective solenoid assembly or TCM is the cause CLUTCH AIR PRESSURE TESTS Inoperative clutches can be located using a series of tests by substituting air pressure for fluid pressure Fig 3 Fig 4 The clutches may be tested by apply ing air pressure to their respective passages The valve body must be removed and Tool 6056 installed To make air pressure tests proceed as...

Page 1552: ...OUSING AREA 1 Check for source of leakage 2 Fluid leakage at or around the torque converter area may originate from an engine oil leak The area should be examined closely Factory fill fluid is red and therefore can be distinguished from engine oil 3 Prior to removing the transaxle perform the following checks 4 When leakage is determined to originate from the transaxle check fluid level prior to r...

Page 1553: ... the vehicle till it reaches full operating temperature 2 Verify that the fill tank on the transaxle fluid exchanger ATF 2000 or equivalent is clean and dry 3 Fill the tank to the recommended fill capacity with Mopar ATF Plus 3 Type 7176 4 Hookup the vehicle to the machine following the manufacturers instructions Perform the exchange procedure following the instructions pro vided with the machine ...

Page 1554: ...tions ending in neutral or park 8 Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm 1 8 in below the ADD mark on the dip stick 9 Recheck the fluid level after the transaxle is at normal operating temperature The level should be in the HOT range Drive the vehicle a minimum of 10 miles 10 Raise the vehicle on the hoist 11 Check for leaks around t...

Page 1555: ...lean the oil pan and magnet Reinstall pan using new MOPARt RTV sealant Tighten oil pan bolts to 19 N m 165 in lbs 5 Pour four quarts of MOPARt ATF PLUS 3 Automatic Transmission Fluid Type 7176 through the fill tube 6 Start engine and allow to idle for at least one minute Then with parking and service brakes applied move selector lever momentarily to each position ending in the park or neutral posi...

Page 1556: ...ransmission fluid 12 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 13 Disconnect alligator clips from battery Recon nect flusher lines to cover plate and remove flushing adapters from cooler lines OIL PUMP VOLUME CHECK After the new or repaired transmission ...

Page 1557: ...ted under the instrument panel 2 Select the Transmission menu 3 Select the Miscellaneous menu 4 Select Pinion Factor Then follow the instruc tions on the DRBIII scan tool screen REMOVAL AND INSTALLATION GEARSHIFT CABLE REMOVAL 1 Remove cable eyelet attachment from transaxle operating lever pin Fig 6 2 Using pliers squeeze ears of cable conduit attachment at mounting bracket Fig 7 and push through ...

Page 1558: ...ke 2 Place the gearshift lever in park P gate posi tion and remove key 3 Loosen the cable adjustment screw at the tran saxle operating lever Fig 10 4 Pull the transaxle operating lever fully forward to the park detent position 5 Release the park brake then rock the vehicle to assure it is in park lock Reset the park brake 6 Tighten the cable adjustment screw to 8 N m 70 in lbs Gearshift cable shou...

Page 1559: ... lever 5 Disconnect transmission range sensor connec tor 6 Hoist vehicle 7 Carefully remove transaxle oil pan and drain fluid 8 Remove transaxle oil filter Let transaxle oil drain fully 9 Remove valve body retaining bolts 10 Extract park rod from guide bracket and remove valve body from transaxle 11 Place valve body on workbench Fig 18 12 Remove TRS retaining screw Fig 19 Fig 12 Manual Valve Lever...

Page 1560: ...remain in old sensor The input speed sensor is located to the left of the manual shift lever Fig 22 SPEED SENSOR OUTPUT CAUTION When disconnecting speed sensor con nector be sure that the weather seal does not fall off or remain in old sensor The output speed sensor is located to the right of the manual shift lever Fig 23 Fig 17 Gearshift Cable And Manual Valve Lever Fig 18 Valve Body W TRS Fig 19...

Page 1561: ...e This procedure will allow the transmission control module to learn the characteristics of the vehicle Electronic Pinion Factor Procedure This proce dure will reprogram the TCM to compensate for dif ferent tire sizes and final drive ratios REMOVAL 1 Loosen 60 way retaining screw located in the center of the 60 way connector Fig 24 Then discon nect the 60 way connector on Transmission Control Modu...

Page 1562: ...ully clockwise Fig 26 Transaxle Control Module Fig 27 Remove Oil Pan Bolts Fig 28 Remove Oil Pan Fig 29 Remove Oil Filter Fig 30 Remove Valve Body Attaching Bolts Fig 31 Push Park Rod Rollers from Guide Bracket 21 88 TRANSAXLE AND POWER TRANSFER UNIT NS REMOVAL AND INSTALLATION Continued ...

Page 1563: ...bushing or oil seal may be damaged The drive plate will not support a load therefore none of the weight of the transaxle should be allowed to rest on the drive plate during removal REMOVAL 1 Disconnect negative battery cable 2 Remove air cleaner duct Disconnect transaxle shift linkage at manual valve lever Fig 34 3 Squeeze grommet clips and remove cable at transaxle bracket Fig 35 Fig 36 4 Remove ...

Page 1564: ...h drive shafts CAUTION The exhaust flex joint must be discon nected from the exhaust manifold anytime the engine is lowered If the engine is lowered while the flex pipe is attached damage will occur 16 Remove bolts securing exhaust flex joint to exhaust manifold Disconnect exhaust pipe from manifold 17 Remove torque converter dust shield to gain access to torque converter bolts Fig 40 Fig 36 Remov...

Page 1565: ...saxle to access the crankshaft posi tion sensor remove crankshaft position sensor from bell housing For installation procedure refer to sec tion 8D of this service manual CAUTION Remove the crankshaft position sensor from the bell housing before transmission removal or installation 27 Remove lower bellhousing bolts 28 Carefully lower the transaxle assembly from vehicle INSTALLATION 1 For installat...

Page 1566: ...BODY RECONDITION Fig 45 Remove Oil Pump Seal Fig 46 Install Oil Pump Seal Fig 47 Transmission Range Sensor Screw Fig 48 Transmission Range Sensor Removed Fig 49 Manual Shaft and Rooster Comb 21 92 TRANSAXLE AND POWER TRANSFER UNIT NS REMOVAL AND INSTALLATION Continued ...

Page 1567: ...te Fig 51 TRS Manual Shaft and 2 4 Accumulator Fig 52 Valve Body Screws Fig 53 Valve Body and Transfer Plate Fig 54 Transfer Plate and Separator Plate NS TRANSAXLE AND POWER TRANSFER UNIT 21 93 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1568: ...Fig 55 Ball Check Location Fig 56 Remove Dual Retainer Plate Fig 57 Springs and Valves Location 21 94 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1569: ... plates as the unit might then fail 1 Remove input and output speed sensors 2 Remove transaxle solenoid pack Fig 59 Fig 58 Low Reverse Switch Valve And T C Limit Valve Fig 59 Remove Solenoid Pack Fig 60 Remove Oil Pan Bolts Fig 61 Remove Oil Pan Fig 62 Remove Oil Filter NS TRANSAXLE AND POWER TRANSFER UNIT 21 95 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1570: ...the valve body from the manual valve Damage could result Fig 63 Remove Valve Body Attaching Bolts Fig 64 Push Park Rod Rollers from Guide Bracket Fig 65 Remove Valve Body Fig 66 Valve Body Removed Fig 67 Remove Accumulators 21 96 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1571: ...isassembling mark accu mulator spring location to ease assembly Fig 68 Accumulator Underdrive Fig 69 Accumulator Overdrive Fig 70 Remove Low Reverse Accumulator Snap Ring Fig 71 Remove Low Reverse Accumulator Plug Cover Fig 72 Remove Low Reverse Accumulator Piston Fig 73 Remove Low Reverse Accumulator NS TRANSAXLE AND POWER TRANSFER UNIT 21 97 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1572: ...put shaft in and out to obtain end play reading End play specifications are 13 to 64 mm 005 to 025 inch Record indicator reading for reference when reas sembling the transaxle CAUTION Be sure input speed sensor is removed before removing oil pump OIL PUMP INSPECTION When disassembling the transaxle it is necessary to inspect the oil pump for wear and damage 1 Remove the reaction shaft support bolt...

Page 1573: ...e clearance between the outer gear and the pump crescent Clearance should be 0 020 0 046mm 0 0008 0 0018 in Fig 82 7 Measure the clearance between the inner gear and the pump crescent Clearance should be 0 020 0 046mm 0 0008 0 0018 in Fig 83 Fig 79 Remove Oil Pump Gasket Fig 80 Reaction Shaft Support Fig 81 Measure Outer Gear to Pocket Fig 82 Measure Outer Gear To Crescent Fig 83 Measure Inner Gea...

Page 1574: ...an old valve When installing bypass valve insert with O ring end towards rear of case Fig 84 Remove Bypass Valve Fig 85 Remove Caged Needle Bearing Fig 86 Remove Input Clutches Assembly Fig 87 No 4 Thrust Plate Fig 88 Remove Front Sun Gear Assembly 21 100 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1575: ...ool Fig 89 Remove Front Carrier and Rear Annulus Assembly Fig 90 Remove Rear Sun Gear Fig 91 Remove 2 4 Clutch Retainer Snap Ring Fig 92 Remove 2 4 Clutch Retainer Fig 93 2 4 Clutch Retainer Fig 94 Remove 2 4 Clutch Return Spring NS TRANSAXLE AND POWER TRANSFER UNIT 21 101 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1576: ...Clutch Pack Fig 96 Remove Tapered Snap Ring Fig 97 Remove Low Reverse Reaction Plate Fig 98 Remove One Disc Fig 99 Remove Low Reverse Reaction Plate Snap Ring Fig 100 Remove Low Reverse Clutch Pack 21 102 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1577: ...er Bolts Fig 102 Remove Rear Cover Fig 103 Remove Transfer Shaft Gear Nut Fig 104 Transfer Shaft Gear Nut and Coned Washer Fig 105 Remove Transfer Shaft Gear Fig 106 Remove Transfer Shaft Gear and Select Shim NS TRANSAXLE AND POWER TRANSFER UNIT 21 103 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1578: ...ing Cup Retainer Fig 108 Remove Transfer Gear Bearing Cone Fig 109 Remove Transfer Shaft Bearing Cup Fig 110 Remove Transfer Shaft Bearing Snap Ring Fig 111 Remove Transfer Shaft Fig 112 Bearing Cup Removed 21 104 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1579: ...strap is used to hold the stirrup to the output gear and prevent the stirrup retaining bolts from backing out CAUTION When installing be sure guide bracket and split sleeve touch the rear of the transaxle case Fig 113 Remove Transfer Shaft Bearing Cone Fig 114 Loosen Stirrup Strap Bolts Fig 115 Remove Strap Bolts Fig 116 Remove Stirrup Strap Fig 117 Remove Stirrup NS TRANSAXLE AND POWER TRANSFER U...

Page 1580: ...119 Output Gear Bolt and Washer Fig 120 Remove Output Gear Fig 121 Output Gear and Select Shim Fig 122 Remove Bearing Cone Fig 123 Remove Rear Carrier Assembly 21 106 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1581: ... 125 Low Reverse Spring Compressor Tool Fig 126 Compressor Tool in Use Fig 127 Remove Snap Ring Fig 128 Low Reverse Piston Return Spring Fig 129 Drive Out Anchor Shaft NS TRANSAXLE AND POWER TRANSFER UNIT 21 107 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1582: ...Remove Guide Bracket Pivot Shaft Fig 132 Pivot Shaft and Guide Bracket Fig 133 Guide Bracket Fig 134 Guide Bracket Disassembled Fig 135 Remove Low Reverse Clutch Piston 21 108 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1583: ...t clutch assembly refer to Input Clutches Recondition Fig 136 Remove Piston Retainer Attaching Screws Fig 137 Remove Piston Retainer Fig 138 Remove Piston Retainer Gasket Fig 139 Remove Output Bearing Inner Cup Fig 140 Remove Output Bearing Outer Cup NS TRANSAXLE AND POWER TRANSFER UNIT 21 109 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1584: ...on Fig 141 Tapping Reaction Plate Fig 142 Reverse Clutch Snap Ring Fig 143 Pry Reverse Clutch Reaction Plate Fig 144 Reverse Clutch Reaction Plate Fig 145 Reverse Clutch Pack Fig 146 OD Reverse Pressure Plate Snap Ring 21 110 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1585: ...Fig 147 OD Reverse Pressure Plate Fig 148 Waved Snap Ring Fig 149 Remove OD Clutch Pack Fig 150 Overdrive Clutch Pack Fig 151 Overdrive Shaft Assembly Fig 152 Underdrive Shaft Assembly NS TRANSAXLE AND POWER TRANSFER UNIT 21 111 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1586: ...tches reaction plate has a step on both sides Install the OD UD clutches reac tion plate tapered step side up NOTE Tag underdrive clutch pack for reassembly identification Fig 153 No 2 Needle Bearing Fig 154 OD UD Reaction Plate Tapered Snap Ring Fig 155 OD UD Reaction Plate Fig 156 Remove One UD Clutch Disc Fig 157 UD Clutch Flat Snap Ring 21 112 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY A...

Page 1587: ...ig 158 Underdrive Clutch Pack Fig 159 UD Spring Retainer Snap Ring Fig 160 UD Return Spring and Retainer Fig 161 Underdrive Clutch Piston Fig 162 Input Hub Tapered Snap Ring Fig 163 Tap on Input Hub NS TRANSAXLE AND POWER TRANSFER UNIT 21 113 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1588: ...65 Pull Retainer from Piston Fig 166 Remove Snap Ring Fig 167 Snap Ring and Return Spring Fig 168 Remove Input Shaft Snap Ring Fig 169 Remove Input Shaft 21 114 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1589: ... of components Fig 170 Install Input Shaft Fig 171 Install Input Shaft Snap Ring Fig 172 Return Spring and Snap Ring Fig 173 Install Snap Ring Fig 174 Install OD Reverse Piston NS TRANSAXLE AND POWER TRANSFER UNIT 21 115 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1590: ...ngs are thicker and the position of the ring lands have changed Fig 175 Install Input Shaft Hub Assembly Fig 176 Install Input Hub Tapered Snap Ring Fig 177 Underdrive Clutch Piston Fig 178 Seal Compressor Special Tool 5067 Fig 179 UD Return Spring and Retainer 21 116 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1591: ...ll the OD UD clutches reaction plate tapered step side up Fig 180 Install UD Spring Retainer and Snap Ring Fig 181 Underdrive Clutch Pack Fig 182 UD Clutch Flat Snap Ring Fig 183 Install Last UD Clutch Disc Fig 184 OD UD Reaction Plate Fig 185 Tapered Snap Ring NS TRANSAXLE AND POWER TRANSFER UNIT 21 117 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1592: ...e clutch pack clearance must be 0 91 to 1 47 mm 036 to 058 inch Select the proper reaction plate to achieve specifications Fig 186 Seating Tapered Snap Ring Fig 187 Set Up Dial Indicator for Clutch Clearance Fig 188 Use Hook Tool to Raise One Clutch Disc UNDERDRIVE REACTION PLATE CHART Fig 189 Install OD Clutch Pack 21 118 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1593: ...nap Ring Fig 191 OD Reverse Pressure Plate Fig 192 Pressure Plate Installed Fig 193 Install Flat Snap Ring Fig 194 Check OD Clutch Pack Clearance NS TRANSAXLE AND POWER TRANSFER UNIT 21 119 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1594: ...ere is no adjustment for the OD clutch clearance Fig 195 Install Reverse Clutch Pack Fig 196 Install Reaction Plate Fig 197 Install Reverse Clutch Snap Ring Fig 198 Seating Snap Ring to Determine Reverse Clutch Clearance Fig 199 Check Reverse Clutch Pack Clearance 21 120 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1595: ...t clutch retainer the reverse clutch and the overdrive clutch must be removed from the retainer CAUTION Do not intermix clutch parts Keep in exact same order Now proceed with the next phase of the assembly REVERSE CLUTCH SNAP RING CHART Fig 200 Install No 2 Needle Bearing Fig 201 Install Underdrive Shaft Assembly Fig 202 Install No 3 Thrust Washer Fig 203 Install No 3 Thrust Plate NS TRANSAXLE AND...

Page 1596: ...RANSAXLE ASSEMBLE To assemble the transaxle centerline refer to the following procedures Fig 204 Install Overdrive Shaft Assembly Fig 205 Input Clutch Assembly Fig 206 Install Both Output Bearing Cups Fig 207 Install Piston Retainer Gasket Fig 208 Install Piston Retainer 21 122 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1597: ... Install Low Reverse Clutch Piston Fig 211 Guide Bracket Disassembled Fig 212 Guide Bracket Fig 213 Pivot Shaft and Guide Bracket Fig 214 Install Guide Bracket Pivot Shaft NS TRANSAXLE AND POWER TRANSFER UNIT 21 123 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1598: ... 215 Install Anchor Shaft and Plug Fig 216 Install Low Reverse Piston Return Spring Fig 217 Low Reverse Spring Compressor Tool Fig 218 Compressor Tool in Use Fig 219 Install Snap Ring Fig 220 Install Rear Carrier Bearing Cone 21 124 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1599: ... lbs To measure bearing end play 3 Attach Tool L 4432 to the gear 4 Push and pull the gear while rotating back and forth to insure seating of the bearing rollers 5 Using a dial indicator mounted to the tran saxle case measure output gear end play Fig 223 Fig 221 Install Rear Carrier Assembly Fig 222 Install Output Gear Bearing Cone Fig 223 Checking Output Gear Bearings End Play NS TRANSAXLE AND PO...

Page 1600: ... 66mm 026 in 3 82mm 150 in 4412815 20mm 008 in 4 26mm 168 in 4412826 69mm 027 in 3 78mm 149 in 4412814 23mm 009 in 4 22mm 166 in 4412825 71mm 028 in 3 74mm 147 in 4412813 25mm 010 in 4 22mm 166 in 4412825 74mm 029 in 3 74mm 147 in 4412813 28mm 011 in 4 18mm 165 in 4412824 76mm 030 in 3 70mm 146 in 4412812 30mm 012 in 4 14mm 163 in 4412823 79mm 031 in 3 66mm 144 in 4412811 33mm 013 in 4 14mm 163 in...

Page 1601: ...Install output gear stirrup and strap bolts All transaxles utilize a stirrup and retaining strap that is attached to the output gear The stirrup pre vents the output gear retaining bolt from turning and backing out of the rear carrier The strap is used to hold the stirrup to the output gear and prevent the stirrup retaining bolts from backing out Fig 226 Install Output Gear Bolt and Washer Fig 227...

Page 1602: ...ar Retaining Bolt Fig 233 Tighten Stirrup Strap Bolts To 23 N m 200 in lbs Fig 234 Bend Tabs On Strap Up Against Flats Of Bolts Fig 235 Install Transfer Shaft Bearing Cone Fig 236 Install Bearing Cup To Shaft 21 128 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1603: ...ck and forth to insure seating of the bearing rollers Using a dial indicator measure transfer shaft end play 3 Refer to the Transfer Bearing Shim Chart for the required shim combination to obtain the proper bearing setting 4 Use Tool 6259 to remove the retaining nut and washer Remove the transfer shaft gear using Tool L 4407 Fig 237 Install Transfer Shaft Fig 238 Install Transfer Shaft Bearing Sna...

Page 1604: ...mm 042 in 3 62mm 143 in 4412810 38mm 015 in 4 30mm 169 in 4412827 1 08mm 043 in 3 62mm 143 in 4412810 41mm 016 in 4 30mm 169 in 4412827 1 12mm 044 in 3 58mm 141 in 4412809 43mm 017 in 4 26mm 168 in 4412826 1 14mm 045 in 3 54mm 139 in 4412808 46mm 018 in 4 22mm 166 in 4412825 1 17mm 046 in 3 54mm 139 in 4412808 48mm 019 in 4 22mm 166 in 4412825 1 19mm 047 in 3 50mm 138 in 4412807 50mm 020 in 4 18mm...

Page 1605: ... play as outlined in End play should be between 05 mm and 10 mm 002 to 004 inch NOTE If end play is too high install a 04 mm 0016 inch thinner shim If end play is too low install a 04 mm 0016 inch thicker shim combina tion Repeat until 05 to 10 mm 002 to 004 inch end play is obtained NOTE Install the low reverse reaction plate stepped side up Fig 242 Transfer Shaft Gear and Select Shim Fig 243 Ins...

Page 1606: ...tch Pack Fig 248 Install Low Reverse Reaction Plate Snap Ring Fig 249 Install One Disc Fig 250 Tapered Snap Ring Instructions Fig 251 Snap Ring Installed 21 132 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1607: ...ot align refer to Fig 254 Fig 252 Check Low Reverse Clutch Clearance LOW REVERSE REACTION PLATE CHART PART NUMBER THICKNESS 4567893 6 92mm 273 in 4567899 6 66mm 262 in 4567898 6 40mm 252 in 4567897 6 14mm 242 in 4567896 5 88mm 232 in 4567895 5 62mm 221 in 4567894 5 36mm 211 in Fig 253 Install 2 4 Clutch Pack Fig 254 Stagger 2 4 Clutch Plate Pads Fig 255 Install 2 4 Clutch Return Spring Fig 256 Pro...

Page 1608: ...late Using petrolatum Fig 263 to hold thrust plate in position install input clutch assembly Be sure the input clutch assembly is completely seated Fig 264 CAUTION If view through input speed sensor hole is not as shown above the input clutches assembly is not seated properly Remove the oil pump O ring Fig 265 You will be able to install and remove the oil pump and gasket very easily to select the...

Page 1609: ... Input shaft end play must be 005 to 025 inch For example if end play reading is 055 inch select No 4 Thrust Plate which is 071 to 074 thick This should provide an input shaft end play reading of 020 inch which is within specifications Fig 262 Install Front Sun Gear Assembly Fig 263 Select Thinnest No 4 Thrust Plate Fig 264 View Through Input Speed Sensor Hole Fig 265 Remove Oil Pump O Ring Fig 26...

Page 1610: ...2 91mm 036 in 4431663 1 14mm 045 in 4431664 1 37mm 054 in 4431665 1 60mm 063 in 3836237 1 73mm 068 in 4431666 1 80mm 071 in 3836238 1 96mm 077 in 4431667 2 03mm 080 in 3836239 2 16mm 085 in 4431668 2 24mm 088 in 3836240 2 39mm 094 in 4431669 2 46mm 097 in 3836241 2 62mm 103 in 4446670 2 67mm 105 in 4446671 2 90mm 114 in 4446672 3 15mm 124 in 4446601 3 38mm 133 in Fig 267 Install Input Clutches Ass...

Page 1611: ...stallation of the valve body turn the manual valve fully clockwise Fig 271 Install Oil Pump Fig 272 Install Pump Attaching Bolts Fig 273 Install Low Reverse Accumulator Fig 274 Install Low Reverse Accumulator Plug Cover Fig 275 Install Low Reverse Accumulator Snap Ring Fig 276 Accumulator Underdrive NS TRANSAXLE AND POWER TRANSFER UNIT 21 137 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1612: ...uld result Fig 277 Accumulator Overdrive Fig 278 Install Accumulators Fig 279 Install Valve Body Fig 280 Install Valve Body Attaching Bolts Fig 281 Install Oil Filter Fig 282 Install Oil Pan 21 138 TRANSAXLE AND POWER TRANSFER UNIT NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1613: ...y along with the transfer shaft DISASSEMBLE The transfer shaft should be removed for differen tial repair and bearing turning torque checking 1 Remove the differential cover and bolts Fig 285 Fig 286 2 Remove the differential bearing retainer and bolts Fig 287 Fig 288 3 Using a plastic hammer remove extension housing adapter plate on the right side of the tran saxle Fig 283 Install Pan Bolts Fig 2...

Page 1614: ...ler Special Tool L 4518 remove the differential bearing race from the extension housing 7 Using Miller Special Tool 6062A remove the differential bearing race from the bearing retainer Fig 292 Fig 293 Fig 288 Remove Bearing Retainer Fig 289 Position Button and Collets Onto Differential and Bearing Ring Gear Side Fig 290 Position Tool 5048 Over Button and Collets at Differential Bearing Ring Gear S...

Page 1615: ...IAL SERVICE TOOLS COMPONENT REMOVER INSTALLER Diff Bear On Retainer Side 5048 5048 4 Collets L 4539 2 Button 5052 C 4171 Diff Bear On Ext Hous Side 5048 5048 3 Collets L 4539 2 Button L 4410 C 4171 Diff Race On Retainer Side 6062 A 6061 C 4171 Diff Race On Ext Hous Side L 4518 L 4520 C 4171 Extension Housing Seal 7794 A C 637 Slide Hammer L 4520 C 4171 Bearing Retainer Seal 794 A C 637 Slide Hamme...

Page 1616: ...ing torque is within specifications remove tools Setup is complete 6 If turning torque is not within specifications proceed with the following steps a Remove differential bearing retainer from the transaxle case b Remove the bearing cup from the differential bearing retainer using Tool 6062A c Remove the existing shim from under the cup d Measure the existing shim NOTE If the turning torque was to...

Page 1617: ...er bearings are fully seated 7 Attach a dial indicator to the case and zero the dial Place the tip on the end of Special Tool L 4436 A 8 Place a large screwdriver to each side of the ring gear and lift Check the dial indicator for the amount of end play CAUTION Do not damage the transaxle case and or differential retainer sealing surface 9 Using the end play measurement that was determined add 18m...

Page 1618: ...d to avoid nicks or burrs NOTE Tag all springs as they are removed for reassembly identification ADJUSTMENTS GEARSHIFT CABLE ADJUSTMENT Lift and rotate the gearshift hand lever into the park P gate position and remove the ignition key This confirms the shift lever is in the gated park P position After confirming the park gate position turn the ignition switch If the starter will operate the park g...

Page 1619: ...SCHEMATICS AND DIAGRAMS 41TE TRANSAXLE HYDRAULIC SCHEMATICS 41TE TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 145 ...

Page 1620: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 146 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued ...

Page 1621: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 147 SCHEMATICS AND DIAGRAMS Continued ...

Page 1622: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 148 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued ...

Page 1623: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 149 SCHEMATICS AND DIAGRAMS Continued ...

Page 1624: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 150 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued ...

Page 1625: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 151 SCHEMATICS AND DIAGRAMS Continued ...

Page 1626: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 152 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued ...

Page 1627: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 153 SCHEMATICS AND DIAGRAMS Continued ...

Page 1628: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 154 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued ...

Page 1629: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 155 SCHEMATICS AND DIAGRAMS Continued ...

Page 1630: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC 21 156 TRANSAXLE AND POWER TRANSFER UNIT NS SCHEMATICS AND DIAGRAMS Continued ...

Page 1631: ...41TE TRANSAXLE HYDRAULIC SCHEMATIC NS TRANSAXLE AND POWER TRANSFER UNIT 21 157 SCHEMATICS AND DIAGRAMS Continued ...

Page 1632: ...4 in Reverse Clutch Select Snap Ring 0 76 1 24mm 0 030 0 049 in Overdrive Clutch No Selection 0 96 2 26mm 0 038 0 089 in Underdrive Clutch Select Pressure Plate 0 91 1 47mm 0 036 0 058 in Transmission End Play 0 12 0 63mm 0 005 0 025 in 41TE TORQUE SPECIFICATIONS DESCRIPTION TORQUE Cooler Line Fittings 12 N m 105 in lbs Differential Cover 19 N m 165 in lbs Differential Ring Gear 95 N m 70 ft lbs D...

Page 1633: ...RANSAXLE Puller C 637 Pressure Gauge Low C 3292 Pressure Gauge High C 3293SP Dial Indicator C 3339 Oil Pump Puller C 3752 Seal Puller C 3981B Universal Handle C 4171 Seal Installer C 4193A NS TRANSAXLE AND POWER TRANSFER UNIT 21 159 ...

Page 1634: ...r Kit L 4406 Gear Puller L 4407A Bearing Installer L 4410 Gear Checking Plate L 4432 Bearing Puller L 4435 Differential Tool L 4436A Special Jaw Set L 4518 21 160 TRANSAXLE AND POWER TRANSFER UNIT NS SPECIAL TOOLS Continued ...

Page 1635: ... L 4520 Thrust Button L 4539 2 Bearing Splitter P 334 Puller Set 5048 Remover Installer 5049 A Installer 5050A Installer 5052 Compressor 5058A NS TRANSAXLE AND POWER TRANSFER UNIT 21 161 SPECIAL TOOLS Continued ...

Page 1636: ...Compressor 5059 A Installer 5067 Pliers 6051 Installer 6052 Installer 6053 Button 6055 Plate 6056 Disk 6057 21 162 TRANSAXLE AND POWER TRANSFER UNIT NS SPECIAL TOOLS Continued ...

Page 1637: ...Installer 6061 Remover 6062 A Holder 6259 Bolt 6260 Installer 6261 Tip 6268 Remover Installer 6301 Remover Installer 6302 NS TRANSAXLE AND POWER TRANSFER UNIT 21 163 SPECIAL TOOLS Continued ...

Page 1638: ...Installer 6536 A Cooler Flusher 6906A Puller 7794 A 21 164 TRANSAXLE AND POWER TRANSFER UNIT NS SPECIAL TOOLS Continued ...

Page 1639: ...housing would normally be located The Transfer Unit provides the power to the rear wheels through a hypoid ring gear and pinion set The Power Transfer Unit is sealed from the tran saxle and has its own oil sump The Unit uses SAE 85W 90 gear lubricant and holds 1 15 liters 1 22 quarts The Power Transfer Unit fill plug is located on the end cover Fig 1 Do not mistake the black plas tic inspection pl...

Page 1640: ...Power Transfer Unit Components 21 166 TRANSAXLE AND POWER TRANSFER UNIT NS DIAGNOSIS AND TESTING Continued ...

Page 1641: ... of these seals refer to Power Transfer Unit Service Procedures If fluid is leaking from weep hole B Fig 6 the type of fluid leaking will determine which seal is leaking If the fluid leaking is red in color transmis sion fluid this indicates that the input shaft end seal should be replaced If the fluid leaking is light brown gear lube this indicates that the half shaft inner seal and P T U input s...

Page 1642: ...amage to the shaft will occur 5 Suspend propeller shaft from underbody of vehicle 6 Remove cradle plate Fig 8 7 Remove the Power Transfer Unit mounting bracket bolts at the rear of the unit Fig 9 8 Remove the right outboard support bracket and bolts near the right axle shaft 9 Remove the four mounting bolts for the P T U Fig 10 and Fig 11 10 Remove P T U assembly from vehicle Fig 7 Driveshaft Flan...

Page 1643: ... N m 250 in lbs in the sequence shown in Fig 14 Retighten first bolt after all others are tight CAUTION When end cover is installed be careful not to damage the P T U Input Shaft Cover Seal 6 Reinstall P T U into vehicle 7 Check and fill fluids as required INPUT SHAFT SEAL The Power Transfer Unit must be removed from the vehicle to service this seal Refer to Power Trans fer Unit Removal in this se...

Page 1644: ...surfaces of end cover and reinstall Tighten bolts to 28 N m 250 in lbs CAUTION When end cover is installed be careful not to damage the P T U Input Shaft Cover Seal 6 Reinstall P T U assembly into vehicle 7 Check and fill fluids as required DIFFERENTIAL CARRIER SEAL The Power Transfer Unit must be removed from the vehicle to replace this seal REMOVAL 1 Remove P T U from vehicle Fig 15 P T U End Co...

Page 1645: ... vehicle on hoist 2 Remove rear cover retaining bolts Fig 22 3 Index rear cover to the case for later reassem bly Fig 23 4 Pull rear cover out of the P T U case Fig 24 5 Remove rear cover O Ring Fig 25 INSTALLATION 1 To install reverse removal procedure POWER TRANSFER UNIT OUTPUT SEAL The power transfer unit must be removed from the vehicle to replace this seal Fig 19 Seal Removal Fig 20 Seal Inst...

Page 1646: ...cover to the case for later reassem bly Fig 27 5 Pull rear cover out of the P T U case Fig 28 Fig 23 Mark Rear Cover Fig 24 Rear Cover Removal Fig 25 O Ring Removal Fig 26 Rear Cover Bolts Fig 27 Mark Rear Cover Fig 28 Rear Cover Removal 21 172 TRANSAXLE AND POWER TRANSFER UNIT NS REMOVAL AND INSTALLATION Continued ...

Page 1647: ...s section to determine correct shim requirements INSTALLATION 1 Install new seal with Seal Installer 5049 Fig 32 2 If the original flange is used align index marks and press flange onto pinion If a new flange is used disregard the alignment marks on the pinion and press flange onto the pinion 3 Install flange nut and tighten to 244 N m 180 ft lbs Fig 29 Output Flange Nut Fig 30 Mark Flange and Sha...

Page 1648: ...over Fig 35 The race must be removed to gain access to the seal 4 Use special tool No 7794 A to remove seal Fig 36 INSTALLATION 1 Clean and inspect seal area 2 Use special tool No MD998803 and install seal Fig 37 When installing seal the spring side of the seal must face toward the special tool 3 Reinstall the original bearing race and shim using special tool No 6522 Fig 38 and Fig 39 CAUTION The ...

Page 1649: ...wo seals located on the inside of the end cover REMOVAL 1 Remove power transfer unit from the vehicle 2 Remove end cover bolts Fig 41 3 Tap on end cover ears to separate cover from case Fig 42 4 Drive seal out with a hammer and small chisel Fig 43 Fig 36 Seal Removal Fig 37 Seal Installation Fig 38 Bearing Shim and Race Fig 39 Installing Bearing Race Fig 40 Bolt Tightening Sequence NS TRANSAXLE AN...

Page 1650: ...oulder in the cover 3 Clean sealing surfaces of the end cover and P T U case Apply a bead of Mopart Gasket Maker Loctite Gasket Eliminator No 518 or equivalent 4 Place end cover onto P T U case and install bolts Tighten bolts to 28 N m 250 in lbs in the Fig 41 End Cover Bolts Fig 42 End Cover Removal Fig 43 Seal Removal Fig 44 Seal Installation 21 176 TRANSAXLE AND POWER TRANSFER UNIT NS REMOVAL A...

Page 1651: ...ip after installing seal into input shaft 4 Clean sealing surfaces of the end cover and P T U case Apply a bead of Mopart Gasket Maker Loctite Gasket Eliminator No 518 or equivalent 5 Place end cover onto P T U case and install bolts Tighten bolts to 28 N m 250 in lbs in the sequence shown in Fig 49 Retighten first bolt after all others are tight CAUTION When end cover is installed be careful not ...

Page 1652: ...nstalled without removing the Power Transfer Unit from the vehicle When replacing the bearing the out put seal must be removed to gain access to the bear ing REMOVAL 1 Raise vehicle on hoist 2 Remove right front half shaft from vehicle 3 Remove output seal with a hammer and chisel Fig 52 4 Remove bearing retaining snap ring Fig 53 5 Use bearing puller MD998346 to remove bear ing Fig 54 Fig 48 Seal...

Page 1653: ...nap ring does not cover bearing oil passage 3 Install new outer half shaft seal using MD998334 seal installer Fig 56 Do not reuse the old seal 4 Reinstall right front half shaft 5 Check and fill fluids as required Fig 52 Output Seal Removal Fig 53 Bearing Snap Ring Fig 54 Bearing Removal Fig 55 Bearing Installation Fig 56 Installing New Seal NS TRANSAXLE AND POWER TRANSFER UNIT 21 179 REMOVAL AND ...

Page 1654: ...ents are not equal use a new shim that protrudes from new output flange Make sure it protrudes the same amount 7 For Example The original shim protrudes 0 075 inch from the original output flange Place the original shim into the new output flange The pro trusion of the shim in the new flange is 0 085 inch This indicates that a 0 010 inch thinner shim is required to maintain the original protrusion...

Page 1655: ...TRANSFER UNIT 5049 a Seal Puller 5065 Bearing Installer 6514 Bearing Remover 6522 Bearing Remover 7794 a Bearing Remover C 4171 Handle C 4171 2 Handle Extension C 4657 Seal Installer NS TRANSAXLE AND POWER TRANSFER UNIT 21 181 ...

Page 1656: ......

Page 1657: ...16 AXLE SEALS 11 BACK UP LAMP SWITCH 9 CRANKSHAFT POSITION SENSOR 2 5L VM DIESEL 10 CROSSOVER LEVER 11 GEARSHIFT BOOT 5 GEARSHIFT BOOT 5 GEARSHIFT CABLES 5 GEARSHIFT CABLES RHD VEHICLES 7 GEARSHIFT KNOB 5 GEARSHIFT MECHANISM REPLACEMENT 7 GEARSHIFT MECHANISM REPLACEMENT RHD VEHICLES 8 INPUT SHAFT FRONT BEARING RETAINER 15 INPUT SHAFT SEAL 16 SELECTOR LEVER 11 SHIFT SHAFT SEALS 12 TRANSAXLE 12 VEHI...

Page 1658: ...axle Fig 2 NOTE Certain transaxle assemblies utilize high strength steel in various gears It is imperative that the correct transaxle assembly number is utilized when ordering service parts Do not remove this tag so the information is available for future ser vice The last eight digits of the Vehicle Identification Number V I N are stamped on a raised boss on top of the clutch housing area SELECTI...

Page 1659: ... Final drive ratio of 4 08 was selected for maximum performance All forward gears are synchronized GEARSHIFT PATTERN The A 598 transaxle shift pattern is a H pattern Fig 3 Overdrive fifth and reverse gears are in line and to the right of the first through fourth gear posi tions GEARSHIFT PATTERN RHD VEHICLES The A 558 transaxle shift pattern is a H pattern Fig 4 Overdrive fifth and reverse gears a...

Page 1660: ...ualifications as the fac tory fill lubricant SAE GL5 10W 40 engine oil is a suitable service fill alternative CLUTCH PROBLEMS Worn damaged or misaligned clutch components can cause difficult shifting gear clash and noise A worn or damaged clutch disc pressure plate or release bearing can cause hard shifting and gear clash SERVICE PROCEDURES FLUID DRAIN AND FILL TRANSAXLE FLUID DRAIN 1 Hoist vehicl...

Page 1661: ...step 2 GEARSHIFT BOOT REMOVAL 1 Remove shifter knob Refer to gearshift knob removal 2 Pull up on boot until retention clips disengage from the console and remove Fig 7 INSTALLATION 1 For installation reverse removal procedure taking care to fully engage the retention clips GEARSHIFT BOOT REMOVAL 1 Remove shifter knob Refer to gearshift knob removal 2 Pull up on boot until retention clips disengage...

Page 1662: ... reinstallation Clips must be installed to span the slotted holes 9 Disconnect shift cables from shifter Pry with equal force on both sides of shifter cable isolator bushings to avoid damaging bushings 10 Lift vehicle on hoist Cut gearshift cable tie strap at floor pan with diagonal cutters 11 Remove shift cables from vehicle by grasping cables and grommets one at a time and tugging down through f...

Page 1663: ...fter Fig 20 Fig 21 CAUTION It is recommended that new cable retain ing clips be used for reinstallation Clips must be installed to span the slotted holes 9 Disconnect shift cables from shifter Pry with equal force on both sides of shifter cable isolator bushings to avoid damaging bushings 10 Lift vehicle on hoist Cut gearshift cable tie strap at floor pan with diagonal cutters 11 Remove shift cabl...

Page 1664: ...ocedure GEARSHIFT MECHANISM REPLACEMENT RHD VEHICLES REMOVAL 1 Remove shifter knob and boot Refer to Shifter Knob And Boot Removal procedure in this section 2 Remove console assembly Refer to Console Removal procedure in Group 23 in this manual Fig 15 Gearshift Cables Fig 16 Crossover Lever Shift Cable Fig 17 Selector Lever Shift Cable 21 8 A 598 MANUAL TRANSAXLE NS GS REMOVAL AND INSTALLATION Con...

Page 1665: ...Carefully remove vehicle speed sensor so that sensor drive gear does not fall into tran saxle Should sensor drive gear fall into the tran saxle during sensor removal drive gear must be reattached to sensor 5 Remove speed sensor drive gear from speed sensor INSTALLATION 1 To install reverse removal procedure 2 Confirm vehicle speedometer is functioning properly following installation BACK UP LAMP S...

Page 1666: ...ing installation CRANKSHAFT POSITION SENSOR 2 5L VM DIESEL The crankshaft position sensor is located on the transaxle bellhousing The sensor measures the posi tion of the crankshaft and relays that information to the Powertrain Control Module Fig 22 Gearshift Cables Fig 23 Vehicle Speed Sensor Fig 24 Back Up Lamp Switch Location 21 10 A 598 MANUAL TRANSAXLE NS GS REMOVAL AND INSTALLATION Continued...

Page 1667: ...ver 3 Remove the selector lever from the transaxle selector shaft INSTALLATION 1 For installation reverse removal procedure Replace the roll pin with a new one AXLE SEALS The axle shaft seals are identical for both sides of the differential and will interchange EXTENSION HOUSING AXLE SEAL REMOVAL 1 Remove axle shaft Refer to Group 2 Suspen sion and Driveshafts for service procedures 2 Insert a fla...

Page 1668: ...ll socket TRANSAXLE The following items can be serviced without remov ing the transaxle from the vehicle Gearshift housing 5th speed synchronizer 5th speed gear Roller detents and springs Speedometer pinion Vehicle speed sensor Bearing retainer plate All external covers Shift shaft seals Axle shaft seals To service any other component of the A 598 tran saxle you must remove it from the vehicle REM...

Page 1669: ...id Fig 37 20 Remove right and left axle shaft assemblies 21 Remove vehicle speed sensor wiring connector Fig 38 22 Remove clutch cable retaining clip Fig 39 Remove clutch cable from transaxle housing 23 Remove adapter plate and front engine mount bolts Fig 40 Fig 41 24 Remove two remaining rear engine mount bolts CAUTION Always use a safety chain when remov ing or installing transaxle assembly Fig...

Page 1670: ...lled with the bolt heads to the rear of the ball joints 2 Fill transaxle to the proper level with the spec ified lubricant 3 While the vehicle is elevated slightly run the transaxle through all the forward gears Apply brakes and shift into reverse Run the transaxle through reverse gear Fig 35 Lower Control Arm Pinch Bolt Fig 36 Unseat Control Arm Fig 37 Transaxle Drain Plug Fig 38 Vehicle Speed Se...

Page 1671: ...ove the clutch release bearing from the input bearing retainer sleeve Fig 45 5 Remove the three bolts retaining the input shaft bearing retainer sleeve Fig 46 6 Remove the input bearing retainer sleeve from the front of the bellhousing INSTALLATION 1 For installation reverse removal procedure Use Mopart Gasket Maker to seal input bearing retainer sleeve to bellhousing Fig 40 Front Engine Mount Lef...

Page 1672: ...tion in this group A 558 TRANSAXLE ASSEMBLY RHD VEHICLES REMOVAL 1 Disconnect battery negative cable 2 Remove air intake hose 3 Remove connector for back up lamp Fig 48 4 Remove wiring harness bracket at transaxle Fig 49 5 Unbolt slave cylinder and actuator rod at the transaxle Fig 50 6 Install engine support fixture and chain onto engine Fig 51 and Fig 52 7 Remove cover from accelerator cables at...

Page 1673: ...Fig 49 Wiring Harness Bracket Fig 50 Hydraulic Clutch Linkage Fig 51 Engine Bridge Fixture NS GS A 598 MANUAL TRANSAXLE 21 17 REMOVAL AND INSTALLATION Continued ...

Page 1674: ...ring knuckle Fig 57 18 Remove drain plug and drain transaxle fluid Fig 58 19 Remove right and left axle shaft assemblies 20 Remove vehicle speed sensor wiring connector Fig 59 21 Remove structural brace from engine and transaxle Fig 52 Engine Support Chain Typical Fig 53 Throttle Control Shield Fig 54 Throttle Control Support Bracket Fig 55 Shift Cables Fig 56 Lower Control Arm Pinch Bolt 21 18 A ...

Page 1675: ...nbolt rear engine mount through bolt and two 2 mount bolts 29 Remove the left front fender splash shield 30 Unbolt left engine mount through bolt and unbolt mount from the transaxle 31 Remove front engine mount Fig 60 and Fig 61 32 Lower the transaxle and modular clutch To service the drive plate refer to Group 9 Engine INSTALLATION 1 Position the modular clutch assembly onto the input shaft of th...

Page 1676: ...SAXLE The A 598 transaxle Fig 63 is similar to the A 523 A 568 transaxle with the following exceptions The major differences are that the input shaft is sup ported by ball and roller bearings and the intermedi ate shaft is supported by tapered roller bearings Also the front intermediate bearing will not clear the final drive gear for disassembly or reassembly In vehicle service is limited to Shift...

Page 1677: ...cover Remove shift cover carefully 6 Remove shift cover Fig 70 Fig 72 Fig 64 Engine Mount Bracket Fig 65 Differential Bearing Retainer Fig 66 Extension Housing Fig 67 Differential Cover Fig 68 Differential Fig 69 Differential Components NS GS A 598 MANUAL TRANSAXLE 21 21 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1678: ...used on the forward gear detents while the reverse detent spring is a different tension and color 9 Remove reverse pivot lever actuator arm Fig 76 10 Remove 1 2 roll pin at 1 2 shift fork Fig 77 11 Rotate 1 2 shift lug out of the way 12 Remove 3 4 roll pin at 3 4 shift lug Fig 78 13 Remove 5th gear synchro end cover Fig 79 Fig 80 Fig 70 Gearshift Cover Fig 71 Gearshift Cover Shouldered Bolts Fig 7...

Page 1679: ...chro Fig 83 Fig 84 17 Use Special Tool 6252 to hold 5th gear and remove 5th gear nut Fig 85 at input shaft Fig 75 Shift Detent Rollers Fig 76 Reverse Pivot Lever Actuator Arm Fig 77 1 2 Shift Fork Roll Pin Fig 78 3 4 Shift Lug Roll Pin Fig 79 End Cover Fig 80 End Cover Removed NS GS A 598 MANUAL TRANSAXLE 21 23 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1680: ...load shim at intermediate shaft Fig 90 Fig 81 5th Gear Shift Fork Roll Pin Fig 82 5th Gear Synchronizer Snap Ring Fig 83 5th Gear Shift Fork Rail and Synchronizer Fig 84 5th Gear Shift Fork Rail and Synchronizer Removed Fig 85 5th Gear Retaining Nut Fig 86 5th Gear 21 24 A 598 MANUAL TRANSAXLE NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1681: ... NOTE The shift rails are positioned as shown Fig 95 Fig 87 Bearing Retainer Plate Bolts Fig 88 Bearing Retainer Plate Fig 89 Retainer Plate Removed Fig 90 Bearing Preload Shim Fig 91 Input Shaft Bearing Snap Ring Fig 92 Snap Ring Removed NS GS A 598 MANUAL TRANSAXLE 21 25 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1682: ...gear shift rail has a small inter lock pin that is contained within the shift lug and rail Use caution when removing shift rail Fig 93 Interlock Plate Fig 94 Shuttles Fig 95 Shift Rail Identification Fig 96 Bearing Support Plate Fig 97 Support Plate Removed Fig 98 Reverse Idler Gear 21 26 A 598 MANUAL TRANSAXLE NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1683: ...4 shift rail lugs out of the way Fig 106 30 Remove geartrain set Fig 107 Fig 99 Reverse Idler Removed Fig 100 Shift Rail C clip Fig 101 5th Gear Shift Rail Fig 102 5th Gear Shift Rail Removed Fig 103 5th Gear Shift Rail Interlock and Pin Fig 104 Reverse Shift Rail NS GS A 598 MANUAL TRANSAXLE 21 27 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1684: ...te shaft preload refer to Intermediate Shaft Preload Adjustment 1 Install geartrain set CAUTION The 5th gear shift rail has a small inter lock pin that is contained within the shift lug and rail Use caution when installing shift rail 2 Carefully install 5th gear shift rail Fig 109 Fig 110 3 Install 5th gear shift rail C clip 4 Install reverse shift rail 5 Install reverse idler gear Fig 111 Fig 105...

Page 1685: ...ghten bearing retainer plate to 17 N m 250 in lbs NOTE If the transaxle housing intermediate shaft bearing retainer plate or bearings are replaced you must perform the intermediate shaft bearing pre load procedure Refer to Intermediate Shaft Bearing Preload Adjustment procedure in the ADJUST MENTS section 11 Install 5th gear 12 Use Special Tool 6252 to hold 5th gear and install 5th gear nut at inp...

Page 1686: ...th gear synchro Fig 119 16 Install 5th gear shift fork roll pin Fig 120 Fig 115 Input Shaft Bearing Snap Ring Fig 116 Bearing Preload Shim Fig 117 Staking 5th Gear Retaining Nut Fig 118 5th Gear Shift Fork Rail and Synchronizer Fig 119 5th Gear Synchronizer Snap Ring Fig 120 5th Gear Shift Fork Roll Pin 21 30 A 598 MANUAL TRANSAXLE NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1687: ...ansaxle same direction as the shift rails NOTE On some A 598 transaxles all four detent springs are of the same color and spring tension On other A 598 transaxles three identical springs are used on the forward gear detents while the reverse detent spring is a different tension and color 21 Install shift detents springs and rollers Fig 124 Fig 125 22 Install shift cover splash shield Fig 126 Fig 1...

Page 1688: ... lbs 27 Apply a bead of RTV silicone to the extension housing Install extension housing Tighten extension housing bolts to 28 N m 250 in lbs 28 Install engine mount bracket INPUT SHAFT The input shaft is serviced as an assembly The only serviceable component of the input shaft is the rear bearing DISASSEMBLY 1 Install the bearing splitter 1130 under the rear bearing 2 Position the input shaft into...

Page 1689: ...ress procedures 5 Using Special Tool 6792 1 as a driver press off and remove 4th speed gear Fig 134 6 Remove intermediate shaft from shop press 7 Install Special Tool 6938 onto front intermedi ate bearing for protection 8 Remove 3 4 synchro snap ring Fig 135 Fig 136 NOTE The 3 4 synchro has a master spline Fig 137 Fig 130 Position Bearing Fig 131 Press Input Bearing Onto Shaft Fig 132 Bearing Spli...

Page 1690: ...Remove the two split washers 12 Remove the anti spin pin Fig 140 13 Remove 2nd speed gear Fig 141 14 Remove 1 2 synchro snap ring precision ground Fig 142 Fig 143 Fig 136 Snap Ring Removed Fig 135 3 4 Synchro Snap Ring Fig 137 Master Spline 21 34 A 598 MANUAL TRANSAXLE NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1691: ...Fig 139 Thrust Washer Outer Retainer Fig 138 3 4 Synchro and 3rd Speed Gear Fig 140 Anti Spin Pin Fig 141 2nd Speed Gear NS GS A 598 MANUAL TRANSAXLE 21 35 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1692: ...rmediate shaft front bearing 17 Position shaft into shop press 18 Position Special Tool MD998802 01 over the intermediate shaft 19 Remove the intermediate shaft front bearing Fig 145 Fig 143 Snap Ring Removed Fig 142 1 2 Synchro Snap Ring Fig 144 1 2 Dual Cone Synchro 21 36 A 598 MANUAL TRANSAXLE NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1693: ...speed gear 4 Install 1 2 synchro snap ring precision ground Fig 147 5 Install 2nd speed gear Fig 148 6 Install the anti spin pin Fig 149 7 Install the two split washers 8 Install thrust washer outer retainer Fig 150 NOTE The 3 4 synchro has a master spline Fig 151 9 Install 3 4 synchro assembly and 3rd speed gear 10 Install 3 4 synchro snap ring Fig 152 11 Install 4th speed gear over the 3 4 synch...

Page 1694: ...Fig 148 2nd Speed Gear Fig 151 Master Spline Fig 149 Anti Spin Pin Fig 150 Thrust Washer Outer Retainer 21 38 A 598 MANUAL TRANSAXLE NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1695: ...fferential you should replace the differential assembly Shim thickness need be determined only if any of the following parts are replaced Transaxle gear case Differential case Differential bearings Differential cover Refer to Bearing Adjustment Procedure in the Adjustments section at the end of this section to determine proper shim thickness This will provide correct bearing preload and proper bea...

Page 1696: ...Fig 155 Install Differential Bearing Cone Fig 156 Remove Differential Bearing Cone Fig 157 Install Differential Bearing Cone Fig 158 Remove Differential Bearing Retainer Cup 21 40 A 598 MANUAL TRANSAXLE NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1697: ... Install Oil Baffle Fig 161 Insert Select Shim and Differential Bearing Retainer Cup Fig 162 Remove Extension Bearing Cup Fig 163 Extension Fig 164 Install Extension Oil Baffle NS GS A 598 MANUAL TRANSAXLE 21 41 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1698: ...2 Remove pinion shaft Fig 169 3 Rotate side gears to opening in differential Fig 170 4 Remove differential gears Fig 171 Fig 165 Install Extension Bearing Cup Fig 166 Remove or Install Ring Gear Bolts and Ring Gear Fig 167 Remove Pinion Shaft Retaining Pin Fig 168 Retaining Pin Removed Fig 169 Pinion Shaft Removal 21 42 A 598 MANUAL TRANSAXLE NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1699: ...allest end play recorded shim that side gear to within 02540 mm to 3302 mm 0 001 to 0 013 inch The other side gear should be checked using the same procedure CAUTION Side gear end play must be within 02540 mm to 3302 mm 0 001 to 0 013 inch Five select thrust washers are available 0 027 0 032 0 037 0 042 and 0 047 inch SYNCHRONIZER The 1 2 synchronizer is a dual cone synchronizer Fig 176 The disass...

Page 1700: ...ove the synchronizer springs on both sides of the hub 6 Carefully remove the synchro hub from the synchro sleeve 7 Remove the three struts from the hub ASSEMBLY 1 Insert the three struts into the synchro hub 2 Place the hub into the synchro sleeve NOTE Stagger both synchronizer springs install tang in different winged struts Fig 173 Staking Retaining Pin Fig 174 Checking Side Gear End Play Typical...

Page 1701: ...assembled and worn parts can be replaced individually Fig 178 DISASSEMBLY 1 Remove gearshift housing roll pin at shift lever Fig 179 2 Remove shift selector shaft dust boot Fig 180 3 Remove selector shaft oil seal Fig 181 4 Remove shifter housing vent cap at crossover lever Fig 182 5 Remove roll pin and crossover lever at cross over shaft Fig 183 6 Remove the 5th reverse gear blocker Fig 184 7 Rem...

Page 1702: ...move selector shaft outer C clip Fig 187 Fig 180 Dust Boot Fig 181 Oil Seal Fig 182 Vent Cap Fig 183 Crossover Lever and Roll Pin Fig 184 5th Reverse Blocker Fig 185 Crossover Shaft 21 46 A 598 MANUAL TRANSAXLE NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1703: ...stall selector shaft roll pin flush with selec tor 3 Install outer selector shaft C clip 4 Install inner selector shaft C clip 5 Install crossover shaft NOTE Proper torque of the 5 R blocker bolts is very important 6 Install the 5th reverse gear blocker bolts Fig 191 7 Install roll pin and crossover lever at crossover shaft 8 Install vent cap Fig 186 Inner C clip Fig 187 Outer C clip Fig 188 Cente...

Page 1704: ...he intermediate shaft front bearing cup Fig 193 2 Tighten the special tool so that the tool fingers spread out and seat underneath the bearing cup 3 Install Special Tool 3752 Slide Hammer onto the Special Tool 6787 4 Remove the intermediate shaft front bearing cup Fig 194 5 Remove the bearing oil feeder if necessary INSTALLATION 1 Insert the bearing oil feeder if necessary into the transaxle case ...

Page 1705: ...aring from the input bearing retainer sleeve Fig 199 4 Remove the three bolts retaining the input shaft bearing retainer sleeve Fig 200 5 Remove the input bearing retainer sleeve from the front of the bellhousing Fig 201 6 Position transaxle case in a shop press bell housing side down 7 Install Special Tool 5066 into input bearing 8 Install Special Tool C 4171 into Special Tool 5066 9 Press out th...

Page 1706: ...l 6933 into input bearing Fig 204 4 Install Special Tool C 4171 into Special Tool 6933 5 Press input bearing into transaxle case Fig 205 Fig 199 Clutch Release Fork Fig 200 Input Bearing Retainer Fig 201 Remove Input Bearing Retainer Fig 202 Press Out Input Bearing Fig 203 Input Bearing 21 50 A 598 MANUAL TRANSAXLE NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1707: ...pecial Tool 6786 into rail bushing that is to be removed Fig 207 2 Tighten tool until the tool is thoroughly imbed ded into the bushing 3 Install Special Tool 3752 Slide Hammer into Special Tool 6786 Fig 208 4 Tap out shift rail bushing Fig 209 INSTALLATION 1 Lubricate outer shell of the shift rail bushing 2 Position shift rail bushing into the shift rail bore 3 Tap bushing into the bore flush wit...

Page 1708: ...locking rings in sol vent The friction material will become contaminated Place synchronizer components in a suitable holder and clean with solvent Air dry INSPECT Proper inspection of components involve Teeth for wear scuffed nicked burred or bro ken teeth Struts for wear or distortion Springs for distortion cracks or wear If any of these conditions exist in these compo nents replace as necessary ...

Page 1709: ...hift console screws and remove the console Fig 215 8 Loosen crossover cable adjustment screw 9 Verify gearshift mechanism is in the neutral position CAUTION Be sure crossover bellcrank does NOT move when tightening adjusting screw Fig 210 Gearshift Mechanism Fig 211 Auxiliary Vent Removal Fig 212 Lock Pin Installation NS GS A 598 MANUAL TRANSAXLE 21 53 ADJUSTMENTS Continued ...

Page 1710: ...ary vent to 8 N m 70 in lbs 12 Check for shift into first and reverse 13 Gearshift mechanism and cables are now functioning properly 14 Install gearshift console 15 Install gearshift boot 16 Install gearshift knob 17 Stow gearshift lock pin in glove packet Fig 213 Gearshift Knob Fig 214 Gearshift Boot Fig 215 Gearshift Console Fig 216 Crossover Cable Adjustment Fig 217 Auxiliary Vent Installation ...

Page 1711: ...s been included in the new vehicle packet located in the glove box 3 Place transaxle gearshift in the neutral posi tion 4 Insert lock pin so long end is down into same threaded hole Fig 220 A hole in the selector shaft will align with the lock pin allowing the lock pin to be screwed into the housing This operation locks the selector shaft in the 3 4 neutral position 5 Remove gearshift knob Fig 221...

Page 1712: ... 15 Install gearshift boot 16 Install gearshift knob 17 Stow gearshift lock pin in glove packet BEARING ADJUSTMENT PROCEDURE The A 598 T 750 transaxle has two bearing adjustment procedures that must be performed if the transaxle case or related components have been replaced If the intermediate shaft and or bearing cups and cones have been replaced you must per form the intermediate shaft preload s...

Page 1713: ...th differential bear ings 5 Bearing cones must not be reused if removed 6 Turning torque readings should be obtained while smoothly rotating in either direction INTERMEDIATE SHAFT BEARING PRELOAD The intermediate shaft preload must be checked if the housing intermediate shaft bearing plate bear ings or transaxle case are replaced The intermediate shaft bearing preload procedure must be done with t...

Page 1714: ... two bolts retaining the bearing support plate Remove the bearing support plate Fig 227 5th Gear Shift Fork Roll Pin Fig 228 5th Gear Retaining Nut Fig 229 5th Gear Synchronizer Snap Ring Fig 230 5th Gear Fig 231 Bearing Retainer Plate Fig 232 Bearing Preload Shim 21 58 A 598 MANUAL TRANSAXLE NS GS ADJUSTMENTS Continued ...

Page 1715: ... 40 ft lbs Diff Bearing Retainer 61 N m 45 ft lbs Diff Ring Gear Bolts 94 N m 70 ft lbs End Cover Bolts 28 N m 21 ft lbs Extension Housing 28 N m 250 in lbs Gearshift Housing 28 N m 250 in lbs Input Gear Nut 176 N m 130 ft lbs Input Retainer 28 N m 250 in lbs Reverse Blocker 12 N m 105 in lbs Transaxle Case Bolts 29 N m 21 ft lbs Vehicle Speed Sensor 7 N m 60 in lbs Vent 6 N m 60 in lbs NOTE The 5...

Page 1716: ...must be level when checking Fill transaxle to proper level with SAE 5W 30 engine oil meeting SG and or SG CD qualifications G5 SAE 10W 40 engine oil is a suitable service fill alternative TRANSAXLE METRIC MEA SURE U S MEASURE A 558 1 9 2 2 Liters 2 0 2 3 Quarts Bearing Splitter 1130 Slide Hammer 3752 Bearing Remover 5066 Gear Holder 6252 Bearing Remover 6786 Bearing Remover 6787 21 60 A 598 MANUAL...

Page 1717: ...ol 6930 Bearing Installer 6933 Bearing Installer 6938 Bearing Installer 6939 Bearing Installer 6950 Puller Press C 293 PA Adapters C 293 45 Handle C 4171 NS GS A 598 MANUAL TRANSAXLE 21 61 SPECIAL TOOLS Continued ...

Page 1718: ...aller L 4410 Bearing Remover L 4518 Bearing Installer L 4520 Bearing Installer MD998323 Bearing Remover MD998802 01 Fig 235 Handle C 4171 Fig 236 Bearing Installer L 4520 21 62 A 598 MANUAL TRANSAXLE NS GS SPECIAL TOOLS Continued ...

Page 1719: ...its which will shorten the life of any tire are Rapid acceleration Severe application of brakes High speed driving Taking turns at excessive speeds Striking curbs and other obstacles Radial ply tires are more prone to irregular tread wear It is important to follow the tire rotation inter val shown in the section on Tire Rotation This will help to achieve a greater tread life potential TIRE IDENTIF...

Page 1720: ...es from different manu factures NOT be mixed The proper tire pressure should be maintained on all four tires For proper tire pressure refer to the Tire Inflation Pressure Placard located in the glove box SPARE TIRE TEMPORARY The temporary spare tire is designed for emer gency use only The original tire should be repaired and reinstalled at the first opportunity or replaced with a new Do not exceed...

Page 1721: ...pacity should not be driven at speeds above 75 mph 120 km h For emergency vehicles that are driven at speeds over 90 mph 144 km h special high speed tires must be used Consult tire manufacturer for correct inflation pressure recommendations REPLACEMENT TIRES The original equipment tires provide a proper bal ance of many characteristics such as Ride Noise Handling Durability Tread life Traction Rol...

Page 1722: ...ply tires are sensitive to force impulses caused by improper mounting vibration wheel defects or possibly tire imbalance To find out if tires are causing the noise or vibra tion drive the vehicle over a smooth road at varying speeds Note the noise level during acceleration and deceleration The engine differential and exhaust noises will change as speed varies while the tire noise will usually rema...

Page 1723: ...LEAD CORRECTION CHART NS TIRES AND WHEELS 22 5 DIAGNOSIS AND TESTING Continued ...

Page 1724: ...heel Use lubrication such as a mild soap solution when dismounting or mounting tire Use tools free of burrs or sharp edges which could dam age the tire or wheel rim Before mounting tire on wheel make sure all rust is removed from the rim bead and repaint if neces sary Install wheel on vehicle and progressively tighten all 5 wheel nuts to a torque of 135 N m 100 ft lbs TIRE AND WHEEL MATCH MOUNTING...

Page 1725: ... in that direction Fig 10 This procedure will normally reduce the runout to an acceptable amount CLEANING AND INSPECTION CLEANING TIRES Remove protective coating on tires before delivery of vehicle This coating may cause deterioration of tires To remove the protective coating applying warm water and let it soak for a few minutes Then scrub the coating away with a soft bristle brush Steam cleaning ...

Page 1726: ...SPECIFICATIONS TIRE SPECIFICATIONS 22 8 TIRES AND WHEELS NS ...

Page 1727: ...t part All aluminum wheels have wheel stud nuts with an enlarged nose This enlarged nose is necessary to ensure proper retention of the wheels Vehicles that are equipped with bolt on wheel cov ers use large nose wheel nuts The wheel nuts used on a vehicle equipped with bolt on wheel covers are externally threaded so that the wheel covers can be attached to the wheel nuts Before installing a wheel ...

Page 1728: ...rom a parked position Verify all wheel nuts are properly torqued Fig 2 Use run out gauge D 128 TR to determine run out Fig 3 Relocate the wheel on the mounting studs two studs over from the original position Retighten wheel nuts until all are properly torqued This will prevent brake distortion Check radial run out If still excessive mark tire sidewall wheel and stud at point of maximum run out Fig...

Page 1729: ...cing should be used only when a two plane balancer is not available Off vehicle tire and wheel balancing is recom mended to be used on this vehicle NOTE If on vehicle equipment is being used to bal ance the tire wheel assemblies remove the oppo site tire wheel from the vehicle For static balancing find the location of heavy spot on tire wheel causing the imbalance Counter balance wheel directly op...

Page 1730: ...el Mounting Stud Size M12 x 1 5mm Mounting Stud Lug Nut Hex Size 19mm Mounting Lug Nut Tightening Torque 135 N m 100 ft lbs Fig 8 Static Unbalance Balance Fig 9 Dynamic Unbalance Balance 22 12 TIRES AND WHEELS NS SERVICE PROCEDURES Continued ...

Page 1731: ...ystem can result Do not use abrasive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning sol vents on painted or upholstered surfaces Damage to finish or color can result Do not hammer or pound on plastic trim panel when servicing interior trim Plastic panels can break Chrysler Corporation uses many different types of push in fasteners to...

Page 1732: ...ear coat for durability PAINTED SURFACE TOUCH UP When a painted metal surface has been scratched or chipped it should be touched up as soon as possi ble to avoid corrosion For best results use Mopart Scratch Filler Primer Touch Up Paints and Clear Top Coat Refer to Introduction group of this manual for Body Code Plate information TOUCH UP PROCEDURE 1 Scrape loose paint and corrosion from inside sc...

Page 1733: ...AW Flame Red Clear Coat PR4 4679 21836 B9326 46916 CHA93 PR4 Golden White Pearl Tri Coat GW7 83554 83642 26095 B9623 B9624 51074 51075 CHA96 SWP Island Teal Satin Glow SPJ 47425 26085 B9610 51065 CHA95 SPJ Light Iris Pearl Coat PC5 4788 24078 B9455 48782 CHA94 PC5 Light Silverfern Pearl Coat RJM 47383 25043 B9525 50269 CHA95 RJM Taupe Frost Pearl Coat TTK 5244 27040 B9750 52567 CHA97 TTK Herberts ...

Page 1734: ...nted 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 windshield It is difficult to salvage a windshield during the removal operation The windshield is part of the structural support for the roof The urethane bonding used to secure the windshield to the fence is difficult to cut or clean...

Page 1735: ... or pieces of masking tape and ink pen to use as a reference for installation Fig 3 4 Remove replacement windshield from wind shield opening 5 Position the windshield inside up on a suitable work surface with two padded wood 10 cm by 10 cm by 50 cm 4 in by 4 in by 20 in blocks placed par allel 75 cm 2 5 ft apart Fig 4 WARNING DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYI...

Page 1736: ...es REMOVAL 1 Remove interior trim as necessary to gain access attaching locations on back of glass 2 Remove nuts holding stationary glass to fence 3 Using razor knife cut butyl sealer holding glass to fence from between the mounting studs Fig 6 4 Push glass from opening INSTALLATION The stationary glass fence should be cleaned of all old butyl sealer 1 Apply a 6 mm 0 25 in butyl tape around perime...

Page 1737: ... to use To avoid stressing the replacement rear window the urethane bonding material on the rear window fence should be smooth and consistent to the shape of the replacement glass 1 Place replacement glass into rear window open ing 2 Verify the glass lays evenly against the pinch weld fence at the sides top and bottom of the replacement rear window If not the fence must be formed to the shape of t...

Page 1738: ...urface Fig 8 15 Clean excess urethane from exterior with Mopart Super Kleen or equivalent 16 Apply 150 mm 6 in lengths of 50 mm 2 in masking tape spaced 250 mm 10 in apart to hold molding in place until urethane cures 17 Install rear window side moldings and wiper arm Fig 7 18 Install interior trim 19 After urethane has cured remove tape strips and water test rear window to verify repair Fig 8 Low...

Page 1739: ...M REST REMOVAL 1 Using a screw driver pry cap from side of arm rest Fig 1 2 Remove bolt holding arm rest to seat back 3 Remove arm rest from seat INSTALLATION 1 Place arm rest in position on seat 2 Install bolt to hold arm rest to seat back 3 Install cap into side of arm rest Fig 1 BENCH SEAT BACK COVER REMOVAL 1 Remove plastic grocery bag retainer attaching screws and remove retainer 2 Using a fo...

Page 1740: ... for proper procedures Fig 4 2 Using a awl pry synchronizing cable end from clip on left seat back hinge 3 Pull cable out of housing until cable is tight 4 Push retaining clip on hinge latch release arm rearward to take up play in hinge mechanism 5 Engage cable end into retaining clip on hinge BENCH SEAT BACK HINGE COVERS REMOVAL 1 If necessary remove seat from vehicle Refer to Owner s Manual for ...

Page 1741: ...n position on seat 2 Install bolts to hold riser to seat cushion frame Fig 7 3 Install seat track BENCH SEAT TRACK SECOND REAR REMOVAL 1 Remove second rear seat from vehicle Refer to Owner s Manual for proper procedure 2 Place seat on clean covered work surface bot tom side up 3 Disengage seat track adjuster link wire from track being removed 4 Remove nuts holding track to seat riser Fig 8 5 Remov...

Page 1742: ...rap to seat back 3 Remove assist strap from vehicle INSTALLATION 1 Place assist strap in position on vehicle 2 Install screws to hold assist strap to seat back 3 Insert screw plugs into ends of assist strap Fig 10 BUCKET SEAT CUSHION PAN REMOVAL 1 Remove bucket seat from vehicle 2 Remove seat cushion side covers 3 If equipped remove power seat track front and rear cover 4 If equipped remove stowag...

Page 1743: ... Fig 12 INSTALLATION 1 Place side cover in position on seat cushion 2 If equipped connect wire connector into power seat switch 3 Install screw to hold rear of side cover to seat cushion frame 4 Install screws to hold seat cushion side cover to bucket seat Fig 11 BUCKET SEAT RECLINER MANUAL REMOVAL 1 Remove bucket seat cushion pan 2 Remove E clip holding pin in seat track 3 Remove pin holding manu...

Page 1744: ...at track Fig 15 3 If equipped install storage bin into riser 4 Install seat into vehicle BUCKET SEAT TRACK MANUAL REMOVAL 1 Remove seat from vehicle 2 Remove seat cushion pan 3 Remove riser 4 On inboard track remove nut holding recliner to seat back frame 5 Remove bolt holding seat back frame to seat track Fig 16 6 Remove seat track from seat adjuster handle Fig 17 7 Remove seat track from seat IN...

Page 1745: ...1 Place front cover in position on seat 2 Install screws to hold front cover to seat track Fig 18 BUCKET SEAT TRACK REAR COVER POWER REMOVAL 1 Disengage arrowhead retainer from loop strip holding rear cover to power seat track crossbar Fig 19 2 Disengage fasteners holding rear cover to slots on power seat track 3 Remove rear cover from seat INSTALLATION 1 Place rear cover in position on seat 2 Eng...

Page 1746: ... 3 Install screws to hold child restraint seat mod ule hinges to seat back frame lower rail Fig 20 4 Install screws to hold top of module to seat back frame upper rail Fig 22 5 Install push in fasteners to hold upper bolster to child restraint seat module Fig 21 6 Return seat back to folded position 7 Install seat back cover 8 Verify child restraint seat operation HEAD RESTRAINT BENCH SEAT REMOVAL...

Page 1747: ...RAINT BUCKET SEAT REMOVAL 1 Lift head restraint to top of travel 2 Depress lock button on side of sleeve at top of seat back Fig 28 3 Pull head restraint from top of seat back Fig 23 Child Restraint Seat Module Fig 24 Interlock Lever Fig 25 Head Restraint Sleeve Escutcheon Fig 26 Release Retainer Fig 27 Install Retainer and Escutcheon NS BODY 23 17 REMOVAL AND INSTALLATION Continued ...

Page 1748: ...r 4 Install head restraint HEATED SEAT HEATING ELEMENT Diagnostic information for heated seat heating ele ment is located in Group 8R Power Seats The heating elements are sewn into the covers To replace a heating element the cushion or back trim covers need to be replaced HEATED SEAT MODULE Diagnostic information for heated seat module is located in Group 8R Power Seats REMOVAL 1 Remove four bolts...

Page 1749: ...ICAL LUMBAR HANDLE ASSEMBLY REMOVAL 1 Remove screw attaching lumbar handle to seat back Fig 33 2 Remove seat back assembly from cushion 3 Detrim the seat back assembly 4 Remove frame and replace INSTALLATION 1 Trim the seat back frame 2 Install seat back assembly to cushion 3 Install attaching screw to lumbar handle The handle is to be installed between two and three O clock position 4 Test lumbar...

Page 1750: ...ide cover RECLINER HANDLE MANUAL REMOVAL 1 Remove screw holding recliner handle to recliner spline shaft Fig 37 2 Remove recliner handle from spline shaft INSTALLATION 1 Place recliner handle in position on spline shaft 2 Install screw to hold recliner handle to recliner spline shaft Fig 37 UNDER SEAT STORAGE BIN REMOVAL 1 Release under seat storage bin latch and open bin 2 Depress lock tabs at th...

Page 1751: ...under seat storage bin UNDER SEAT STORAGE BIN LOCK LATCH REMOVAL 1 Open under seat storage bin 2 Remove screws holding under seat storage bin lock latch to storage bin Fig 40 3 Remove lock latch from bin INSTALLATION 1 Place lock latch in position on storage bin 2 Install screws to hold lock latch to storage bin Fig 40 3 Verify under seat storage bin latch operation Fig 38 Storage Bin Fig 39 Under...

Page 1752: ...TRIM PANEL 44 LIFTGATE CHMSL ACCESS PANEL 47 LIFTGATE HINGE 47 LIFTGATE LATCH STRIKER 47 LIFTGATE LATCH 47 LIFTGATE LOCK CYLINDER 48 LIFTGATE OUTSIDE HANDLE 48 LIFTGATE PROP ASSEMBLY 49 LIFTGATE SILL PLATE 49 LIFTGATE STABILIZER WEDGE STRIKER 49 LIFTGATE STABILIZER WEDGE 49 LIFTGATE TRIM PANEL 50 LIFTGATE UPPER FRAME MOLDING 50 LIFTGATE UPPER FRAME SIDE MOLDINGS 51 LIFTGATE 46 LOWER B PILLAR TRIM ...

Page 1753: ...o stop a water leak that occurs under severe conditions can cause premature seal wear and excessive closing or latching effort After completing a repair water test vehicle to verify leak has stopped before returning vehicle to use VISUAL INSPECTION BEFORE WATER LEAK TESTS Verify that floor and body plugs are in place body drains are clear and body components are properly aligned and sealed If comp...

Page 1754: ...g conditions Moving sealing surfaces will not always seal airtight under all conditions At times side glass or door seals will allow wind noise to be noticed in the passenger compartment during high crosswinds Over compensating on door or glass adjustments to stop wind noise that occurs under severe conditions can cause premature seal wear and excessive closing or latching effort After a repair pr...

Page 1755: ...on A pillar trim in vehicle 3 Align locator pins 4 Engage hidden clips COWL COVER WARNING No fingers or tools should be put under the cowl cover while the wiper motor is operating REMOVAL 1 Remove wiper arms Refer to Group 8K Wind shield Wipers and Washers for proper procedures 2 Remove screws holding lower area of cowl cover to wiper module Fig 3 3 Disengage quarter turn fasteners holding outer e...

Page 1756: ...nels 11 Remove floor escutcheons Fig 6 12 Remove push in fasteners holding carpet to floor in front seat area 13 Roll carpet from under instrument panel to center of sliding door 14 Roll carpet forward away from rear door open ing 15 Extract carpet through sliding door opening Fig 7 INSTALLATION 1 Insert carpet through sliding door opening 2 Roll carpet rearward toward rear door opening 3 Roll car...

Page 1757: ...ositive lock slide on the side of the wire connectors Fig 8 5 Depress lock tab holding wire connector halves together 6 Disconnect door harness from body wiring har ness 7 Remove bolts holding door check strap to A pil lar Fig 9 8 Support door on suitable lifting device 9 Remove bolts holding lower hinge to door end frame Fig 10 10 Steady door on lifting device and remove bolts holding upper hinge...

Page 1758: ...e Fig 11 INSTALLATION 1 Position applique on vehicle 2 Hook rear edge of applique over rear edge of door frame and seat applique bottom edge on sheet metal 3 Engage clips to hold front edge of applique to door frame 4 Install outer door belt molding FRONT DOOR CHECK STRAP REMOVAL 1 Remove front door trim panel 2 Remove door speaker if equipped 3 Remove bolts attaching door check strap to A pillar ...

Page 1759: ... trim panel and water shield 2 Remove inner belt molding 3 Remove outer belt molding 4 Remove radio speaker if equipped 5 Position glass to gain access to front and rear regulator lift plates through front and rear access holes in door panel 6 Remove clips holding door glass to regulator lift plates Fig 14 7 Remove glass from regulator lift plates 8 Disengage glass from glass run weather strip 9 I...

Page 1760: ...orner of glass run weather strip to inner door panel 8 Remove screw holding glass run weather strip to inner door panel 9 Remove inner belt weather strip 10 Pull weather strip from front glass run chan nel 11 Remove glass run weather strip from vehicle INSTALLATION 1 Position glass run weather strip on vehicle 2 Push weather strip into front glass run chan nel 3 Install screw to hold glass run wea...

Page 1761: ...eration Adjust as necessary FRONT DOOR INNER BELT MOLDING REMOVAL 1 Remove door trim panel 2 Peel upper corner seals away form inner belt molding to clear removal path 3 Pull inner belt molding upward to disengage retaining channel in bottom of molding from door panel flange Fig 17 4 Remove inner belt molding from vehicle INSTALLATION 1 Place inner belt molding in position on door 2 Push inner bel...

Page 1762: ...TION 1 Position latch striker and any shims retrieved on vehicle 2 Loosely install screws to hold latch striker to B pillar 3 Align latch striker to outline on B pillar made previously 4 Tighten all fasteners 5 Verify door fit and operation Adjust latch striker as necessary FRONT DOOR LOCK CYLINDER REMOVAL 1 Remove front door trim panel and water shield as necessary to gain access to the outside d...

Page 1763: ...LLATION 1 Place belt molding in position on door 2 Engage interlocking lip at the base of the inward edge of the belt molding on door panel 3 Install door trim panel FRONT DOOR OUTSIDE HANDLE REMOVAL 1 Remove front door trim panel and water shield as necessary to gain access to the outside door han dle 2 Roll door glass up 3 Through access hole at rear of inner door panel disconnect vehicle theft ...

Page 1764: ...oor sill 2 Remove sill plate from vehicle Fig 25 INSTALLATION 1 Place sill plate in position on vehicle 2 Align locating pins on backside of trim plate to mating holes in door sill 3 Engage hidden clips to hold door sill plate to door sill FRONT DOOR TRIM PANEL REMOVAL 1 Using a trim stick C 4755 pry courtesy lamp from door trim 2 Disconnect wire connector from courtesy lamp 3 If equipped remove s...

Page 1765: ...lips to attach door trim to door frame around perimeter of panel 7 If equipped install screw to attach door trim to door panel behind inside latch release handle 8 If equipped connect power switch into wire connector 9 Place power accessary switch in position on door trim 10 Connect wire connector into memory seat mir ror switch and install switch into trim panel 11 Install screws to attach access...

Page 1766: ...TALLATION 1 Position window crank to regulator shaft 2 Push window crank onto regulator shaft to engage retaining clip FRONT DOOR WINDOW REGULATOR REMOVAL 1 Remove door trim panel and water shield 2 Remove door glass retaining clips and allow glass to rest on bottom of door 3 Disconnect wire connector from power window motor if equipped Refer to Group 8S Power Win dows for proper procedures 4 Loos...

Page 1767: ... procedures FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove front wheel Refer to Group 22 Wheels and Tires for proper procedures 3 Remove push in fasteners holding splash shield to frame rail forward of suspension 4 Remove push in fasteners holding splash shield to frame rail rearward of suspension 5 Remove screws holding wheelhouse splash shield to fro...

Page 1768: ...tch striker to sliding door rear end frame Fig 37 4 Remove fuel fill door blocker latch striker from vehicle INSTALLATION 1 Position fuel fill door blocker latch striker on vehicle 2 Install screws to hold fuel fill door blocker latch striker to sliding door rear end frame 3 Install sliding door water shield 4 Install sliding door trim panel FUEL FILL DOOR BLOCKER LOCKOUT LINK REMOVAL 1 Remove lef...

Page 1769: ...nk into clip on fuel fill door 4 Engage clip to hold link to fuel fill door 5 Insert lockout link through grommet in panel between inner and outer quarter panel 6 Close fuel fill door 7 Install fuel filler housing to outer quarter panel 8 Verify that all clips on fuel filler housing are fully engaged to outer quarter panel 9 Place fuel fill neck in position 10 Install screws to hold fuel fill neck...

Page 1770: ...ped install coat hooks 9 Install dome lamp 10 If equipped install reading lamp 11 If equipped install overhead console 12 Install rear door opening header trim 13 Install D pillar upper trim covers 14 Install C pillar upper trim covers 15 Install B pillar upper trim covers 16 Install A pillar trim covers HOOD REMOVAL 1 Raise hood to full up position 2 Mark all bolt and hinge attachment locations w...

Page 1771: ...nder flange 4 Install wiper unit Refer to Group 8K Wind shield Wipers and Washers for proper procedures 5 Install hood 6 Align all marks and secure bolts The hood should be aligned to 4 mm 0 160 in gap to the front fenders and flush across the top surfaces along fend ers Shims can be added or removed under hood hinge to achieve proper hood height HOOD LATCH REMOVAL 1 Release hood latch and open ho...

Page 1772: ...sconnect cable from mechanic s wire 12 Remove hood release cable from vehicle INSTALLATION 1 Place hood release cable in position under instrument panel 2 Attach latch end of hood release cable to mechanic s wire protruding through dash panel 3 Route cable forward through engine compart ment toward latch by pulling on mechanic s wire Fig 48 4 Disconnect mechanic s wire from cable 5 Engage rubber g...

Page 1773: ... on quar ter trim panel 3 Close quarter trim panel bin storage cover LEFT D PILLAR TRIM PANEL REMOVAL 1 Remove rear header trim cover 2 Remove liftgate sill plate 3 Remove second rear seat belt turning loop on long wheel base vehicle 4 Remove bolt holding second rear seat belt lower anchor to quarter on short wheel base vehicle 5 Remove jack storage cover 6 Remove screws holding trim panel to D pi...

Page 1774: ...or sill plate on four door vehicle 5 Remove left quarter trim bolster 6 Remove upper left B pillar trim on three door vehicle 7 Remove C pillar trim panel 8 Remove left D pillar trim panel 9 Remove first rear seat belt anchor 10 Remove second rear seat belt anchor on long wheel base vehicle 11 Remove left front seat belt opening bezel from quarter trim on three door vehicle 12 Remove screws holdin...

Page 1775: ... metal between B pillar and C pillar on three door vehicle 9 Install screws to hold rear edge of quarter trim to attaching bracket or inner quarter panel 10 Install screws to hold quarter trim to inner quarter panel in bolster area 11 Install screws to hold quarter trim to inner quarter panel in B pillar area on three door vehicle 12 Install left front seat belt opening bezel into quarter trim on ...

Page 1776: ...ge to roof header Fig 55 9 With assistance remove liftgate from vehicle INSTALLATION 1 With assistance place liftgate in position on vehicle 2 Install bolts to hold liftgate hinge to roof header 3 Install screws to hold support cylinders to lift gate 4 Remove lifting device from under liftgate 5 Connect liftgate wire harness into body wire harness 6 Install screws to holding wire connector to rear...

Page 1777: ... Align hinge to marks on liftgate 4 Install bolts to hold hinge to liftgate Fig 56 5 Align hinge to marks on roof header 6 Install bolts to hold liftgate hinge to roof header 7 Remove duct tape from roof and liftgate 8 Support liftgate on a suitable lifting device 9 Verify liftgate alignment Refer to Liftgate Remove and Installation for proper gap measure ments LIFTGATE LATCH REMOVAL 1 Remove lift...

Page 1778: ...LIFTGATE OUTSIDE HANDLE REMOVAL 1 Remove liftgate trim panel 2 Remove power lock motor 3 Disengage outside handle link from clip on lift gate latch 4 Disconnect VTSS switch from back of lock cyl inder if equipped 5 Disengage lock link if equipped 6 Remove nut attaching outside liftgate handle to liftgate Fig 61 7 Disengage retaining groove holding handle to liftgate 8 Remove outside liftgate handl...

Page 1779: ...Disengage hidden clips holding sill plate to lift gate door opening sill Fig 63 2 Remove sill plate from vehicle INSTALLATION 1 Place sill plate in position on vehicle 2 Align locator rib into recess in liftgate sill 3 Engage hidden clips to hold sill plate to liftgate door opening sill LIFTGATE STABILIZER WEDGE REMOVAL 1 Open liftgate 2 Mark outline of stabilizer wedge on liftgate to aid installa...

Page 1780: ...ding the trim panel 7 Disengage hidden clips holding trim panel to liftgate from around perimeter or liftgate Fig 66 8 Remove liftgate trim panel from vehicle INSTALLATION 1 Place liftgate trim panel in position on vehicle 2 Engage hidden clips to hold trim panel to lift gate and fasteners around perimeter of liftgate Fig 66 3 Install fasteners into trim brackets and install CHMSL cover 4 Connect ...

Page 1781: ...isengage hidden clips holding lower trim cover to B pillar 7 Remove lower B pillar trim cover from vehicle INSTALLATION 1 Place lower B pillar trim cover in position on vehicle 2 Insert seat belt through hole in lower B pillar trim 3 Engage hidden clips to hold lower trim cover to B pillar 4 Install screw to hold lower trim cover to B pil lar below seat belt retractor 5 Install access cover 6 Inst...

Page 1782: ...TION 1 Place side rail in position on vehicle 2 Install screws to attach side rail to rear riser and roof panel 3 Install screws to attach side rail to center riser and roof panel 4 Install screws to attach side rail to front riser and roof panel 5 Install crossbars 6 Install luggage rack front riser covers OVERHEAD GRAB HANDLES REMOVAL 1 Using a trim stick C 4755 remove screw access covers from g...

Page 1783: ...ol ster to quarter trim panel if applicable 3 Engage hidden clips to hold trim bolster to quarter trim panel RADIATOR CLOSURE PANEL CROSSMEMBER REMOVAL 1 Release hood latch and open hood 2 Remove bolts attaching hood latch to cross member and position latch out of the way 3 Remove radiator sight shield 4 Remove engine air inlet resonator 5 Remove bolt holding air cleaner housing to crossmember 6 R...

Page 1784: ...LLATION 1 Position rail lamp module in vehicle 2 Connect wire connector to body wiring harness 3 Position rail lamp module to headlining 4 Install screw attaching module to roof rail inside coat hook WITH REAR HVAC REMOVAL 1 Pull coat hook open 2 Remove screw attaching rail lamp module to roof rail inside coat hook Fig 77 3 Remove screws attaching rail lamp module to roof rail from behind grab han...

Page 1785: ...trim bolster on short wheel base vehicle 6 Remove screws holding trim panel to attaching bracket on short wheel base vehicle Fig 80 7 Disengage hidden clips holding trim to D pillar Fig 80 Fig 81 and Fig 82 8 Remove D pillar trim panel from D pillar 9 Disconnect speaker wire connector if equipped 10 Pass second rear seat belt if equipped through slot in trim panel on short wheel base vehicle 11 Re...

Page 1786: ...d rear seat belt through slot in trim panel on long wheel base vehicle 15 Pass first rear seat belt through slot in trim panel 16 Remove quarter trim panel from vehicle INSTALLATION 1 Position quarter trim panel on vehicle 2 Pass first rear seat belt through slot in trim panel 3 Pass second rear seat belt through access hole in trim panel on long wheel base vehicle 4 Connect wire connector into ac...

Page 1787: ...hesive removal discs are available from automotive paint suppliers Refer to instructions supplied with the discs for proper usage INSTALLATION 1 If molding is to be reused a Remove tape residue from molding b Clean back of molding with Mopart Super Kleen solvent or equivalent c Wipe molding dry with lint free cloth d Apply new body side molding two sided adhesive tape to back of molding 2 Clean bo...

Page 1788: ...t belt buckle to seat frame Fig 84 3 Remove belt from seat INSTALLATION For installation reverse the above procedures Tighten all seat belt anchor bolts to 39 N m 29 ft lbs torque SEAT BELT BUCKLE FIRST REAR QUAD BUCKET REMOVAL 1 Remove seat from vehicle Refer to Owner s Manual for proper procedures 2 Remove screws attaching inboard side cover to seat cushion Fig 82 Right Quarter and D Pillar Trim...

Page 1789: ... belt turning loop 3 Remove bolt holding turning loop to shoulder belt height adjuster Fig 86 4 Remove turning loop from B pillar 5 Remove lower B pillar trim cover or quarter trim panel on three door left side 6 Remove bolt holding seat belt retractor to B pillar Fig 86 7 Lift retractor upward and disengage arrow head retainer holding retractor to B pillar 8 Remove seat belt from vehicle INSTALLA...

Page 1790: ...r belt height adjuster 8 Close clam shell cover from over seat belt turn ing loop 9 Position anchor to floor 10 Install floor anchor bolt 11 Slide floor anchor cover over the anchor bolt 12 Install shoulder harness height adjuster knob by pushing it straight onto adjuster 13 Install first and second rear seats Refer to Owner s manual for proper procedures NOTE The tightening specification for all ...

Page 1791: ...ver from over the anchor bolt 4 Remove floor anchor bolt Fig 88 5 Remove anchor from floor 6 Open clam shell cover from over seat belt turn ing loop 7 Remove bolt attaching turning loop to shoulder belt height adjuster 8 Remove turning loop from C pillar 9 Remove B pillar upper trim cover 10 Remove C pillar upper trim cover 11 Remove lower quarter trim panel 12 Route seat belt webbing and turning ...

Page 1792: ...ching retractor to inner quar ter panel 3 Install bolt to attach retractor to inner quarter panel 4 Route seat belt webbing and turning loop through access hole in quarter trim 5 Install quarter trim bolster 6 Install D pillar trim panel 7 Position turning loop to extension bracket 8 Install bolt to hold turning loop to extension bracket above quarter glass Tightening specifications for all seat b...

Page 1793: ...or to vehi cle 2 Install screw attaching retractor to inner quarter panel 3 Pull outward on HVAC unit and install bolt attaching retractor to inner quarter panel 4 Install bolts attaching seat belt guide loop to inner quarter panel 5 Install coolant line retaining bracket holdown bolt 6 Install screws holding upper evaporator hous ing to lower evaporator housing 7 Install fasteners attaching HVAC ...

Page 1794: ...g from mirror 4 Remove bolts holding bottom of side view mir ror to A pillar 5 Remove bolt attaching top of side view mirror to A pillar Fig 96 6 If equipped disconnect power side view mirror wire connector from instrument panel harness 7 Remove side view mirror from vehicle INSTALLATION 1 Connect power side view mirror wire connector into instrument panel harness if equipped 2 Place side view mir...

Page 1795: ... the center hinge roller to contact the quarter glass Glass can break 13 Roll door rearward until lower rollers disen gage from lower channel 14 Roll the door rearward until the upper Fig 101 and center hinge rollers exit the upper and cen ter channels Fig 102 15 Remove sliding door from vehicle INSTALLATION 1 Place sliding door in position on lifting device 2 Position door rearward of the sliding...

Page 1796: ...e from sliding door 6 Roll center hinge to rear of roller channel 7 Separate center hinge from vehicle INSTALLATION NOTE Center hinge has an adjustable bolt for up down alignment Refer to Siding Door Center Hinge Adjustment 1 Place center hinge in position on vehicle 2 Roll center hinge forward in roller channel 3 Place center hinge in position on sliding door and align marks 4 Install bolts to ho...

Page 1797: ...ce hold open latch in position on vehicle 2 Connect cable to hold open latch 3 Place hold open latch in position on lower arm 4 Install nuts to hold the hold open latch to lower roller arm 5 Install sliding door sill plate 6 Verify sliding door operation SLIDING DOOR HOLD OPEN LATCH STRIKER REMOVAL 1 Open sliding door do not latch open 2 Remove sliding door sill plate 3 Remove screws holding slidi...

Page 1798: ...h handle in position on sliding door 6 Install screw to hold top of inside latch handle to sliding door 7 Install screws to hold bottom of inside latch handle to sliding door 8 Engage cable end into bellcrank assembly 9 Engage clip to hold cable end into bellcrank assembly 10 Verify sliding door operation Adjust as neces sary 11 Install sliding door trim panel 12 Install sliding door upper molding...

Page 1799: ... 8 Remove button from release mechanism INSTALLATION 1 Position button on release mechanism 2 Align and engage flats on button pivots into slots in mechanism Fig 111 3 Rotate latch release button into mechanism 4 Place release mechanism in position on handle 5 Install screws to hold release mechanism to handle Fig 110 6 Engage latch cable into handle 7 Engage cable end from release mechanism 8 Ins...

Page 1800: ...nnect wire connector from power door lock motor 20 Remove latch lock from vehicle INSTALLATION 1 Position latch lock locking lever in unlocked position 2 Engage rigging cam Fig 114 3 Place latch lock in position on vehicle 4 If equipped engage wire connector into power door lock motor 5 Insert bolt heads into slots in sliding door inner panel 6 Tighten bolts to hold latch lock control to slid ing ...

Page 1801: ... 8 Remove roller arm from sliding door 9 Disengage roller arm from lower channel Fig 117 10 Remove roller arm from vehicle INSTALLATION For installation reverse the above procedures SLIDING DOOR LOWER ROLLER ARM BRACKET REMOVAL 1 Remove access hole plug 2 Open sliding door 3 Support sliding door on a suitable lifting device 4 Remove lower roller arm 5 Mark outline of roller arm bracket on inside o...

Page 1802: ... lock control 8 Remove nuts holding outside door handle to outer door panel Fig 119 9 Remove outside door handle from vehicle INSTALLATION 1 Position outside door handle on vehicle 2 Install nuts to hold outside door handle to outer door panel 3 Insert linkage into outside door handle 4 Engage clip to hold linkage to outside door handle 5 Engage rigging cam to latch lock control mech anism 6 Move ...

Page 1803: ...VAL 1 Disengage hidden clips holding sill plate to sliding door opening sill 2 Disengage hooks holding outside edge of sill plate to door sill Fig 121 3 Remove sill plate from vehicle INSTALLATION 1 Place sill plate in position on vehicle 2 Engage hooks to hold outside edge of sill plate to door sill 3 Align guide pins to holes in door sill 4 Engage hidden clips to hold sill plate to sliding door ...

Page 1804: ... hold rear of stop bumper to door inner panel 4 Install trim panel SLIDING DOOR TRIM PANEL REMOVAL 1 Remove sliding door upper frame molding 2 If removing the left sliding door trim panel remove screw from inside ash receiver bezel 3 Remove screws holding trim panel to inner door panel Fig 126 4 Disengage push in fasteners holding trim to door panel around perimeter and upper edge of door Fig 125 ...

Page 1805: ...to hold upper roller to sliding door 6 Remove padded block from between sliding door and roof rail 7 Place stop bracket in position on vehicle 8 Install screw to hold upper stop bracket to upper roller bracket 9 Verify sliding door alignment and operation Adjust as necessary SLIDING DOOR WEATHER STRIP REMOVAL 1 Open sliding door 2 Remove door opening sill plate 3 Loosen B pillar trim covers 4 Loos...

Page 1806: ...ew body side molding two sided adhesive tape to back of molding 2 Clean body surface with Mopart Super Kleen or equivalent Wipe surface dry with lint free cloth 3 Remove protective cover from tape on back of molding 4 Apply molding to body from front to rear inserting locator pins into hole in body panel 5 Using a roller tool roll molding onto body panel with enough force to assure adhesion Do not...

Page 1807: ...Fig 130 Body Side Moldings Highline Fig 131 Body Side Moldings Premium NS BODY 23 77 REMOVAL AND INSTALLATION Continued ...

Page 1808: ...ll screw holding support to roof header Fig 135 3 Engage sun visor into support UPPER B PILLAR TRIM COVER REMOVAL 1 Remove bolt holding lower seat belt anchor to floor 2 Lower shoulder belt height adjuster to the bot tom of travel 3 Remove shoulder belt turning loop from height adjuster 4 Using Snap ont prying tool A179A or equiv alent remove shoulder belt height adjuster knob 5 Remove shoulder be...

Page 1809: ...lder belt bezel into trim cover 6 Install height adjuster knob 7 Install shoulder belt turning loop onto height adjuster 8 Place seat anchor in position on floor so web bing is pointed rearward and slightly outboard 9 Install bolt to hold lower seat belt anchor to floor Tighten seat belt bolts to 39 N m 29 in lbs torque Fig 133 Body Side Moldings with Applique Fig 134 Sun Visor Fig 135 Sun Visor S...

Page 1810: ...r height using character lines as a reference Also check roof contour as a controlling factor UP DOWN ADJUSTMENT 1 Visually inspect the sliding door for fitting low at the rear of the door by checking the alignment of the belt line of the door to quarter panel 2 Fully open the sliding door 3 Verify that all center hinge bolts are tight 4 Adjust the rear of the sliding door up by turn ing the cente...

Page 1811: ...er roller arm bracket on sliding door to assist in making adjustments d Loosen lower roller arm bracket bolts Fig 138 e Move hinge upward to raise the door f Tighten lower roller arm bracket bolts g Verify alignment Re adjust as necessary SEAL COMPRESSION 1 Check seal compression at top and bottom of B post seal 2 Adjust seal compression at the top of the B post seal a Open door to mid point of tr...

Page 1812: ...ost STABILIZER ADJUSTMENT 1 Open sliding door 2 Loosen bolts holding stabilizers to sliding door enough that the stabilizers can move with some effort 3 Close and then reopen sliding door 4 Tighten all bolts Fig 140 Sliding Door Lower Roller Arm 23 82 BODY NS ADJUSTMENTS Continued ...

Page 1813: ...seat back INSTALLATION 1 Position head restraint to seat 2 Depress lock button on side of sleeve at top of seat back 3 Insert head restraint into sleeves at top of seat back HEAD RESTRAINT ESCUTCHEON REMOVAL 1 Remove head restraint from seat 2 Remove escutcheon from head restraint sleeve Fig 2 3 Remove head restraint retainer from sleeve 4 Separate escutcheon and retainer from vehicle INSTALLATION...

Page 1814: ...ner clicks into lock position 4 Engage closure to hold bottom of trim cover together 5 Install head restraint BENCH SEAT BACK COVER REMOVAL 1 Remove screws holding the bottom of the bench seat back cover to the seat frame Fig 5 2 Disengage hooks holding top of seat back cover to seat back frame 3 Separate seat back cover from seat INSTALLATION 1 Place seat back cover in position on seat 2 Engage h...

Page 1815: ...e gearshift console 5 Separate console from vehicle INSTALLATION 1 Tilt the gearshift boot and carefully push the boot through the gearshift console 2 Install screws to hold gearshift console to gear shift mechanism 3 Install gearshift boot and carefully push the clips into the three 3 slots in the gearshift console LIFTGATE CHMSL ACCESS PANEL REMOVAL 1 Using a trim stick C 4755 disengage clip hol...

Page 1816: ...panel in position on vehicle 2 Engage hooks on CHMSL access cover to lift gate trim panel 3 Engage clip to hold CHMSL access panel to liftgate trim panel Fig 3 CHMSL Access Panel 23 4 BODY NS GS REMOVAL AND INSTALLATION Continued ...

Page 1817: ...MOTOR AND WHEEL ASSEMBLY 13 COMPRESSOR CLUTCH COIL 13 COMPRESSOR NOISE DIAGNOSIS 13 EXPANSION VALVE 13 HEATER PERFORMANCE TEST 15 HVAC CONTROL DIAGNOSTIC CONDITIONS 9 SYSTEM CHARGE LEVEL TEST 16 SERVICE PROCEDURES CHARGING REFRIGERANT SYSTEM 17 EVACUATING REFRIGERANT SYSTEM 18 R 134a REFRIGERANT 16 STICKING HVAC CONTROL MODULE PUSH BUTTONS 19 SYSTEM LEAK CHECKING 19 THERMOCOUPLE PROBE 19 REMOVAL A...

Page 1818: ... 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 UNMARKED CONTAINERS WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL KEEP OUT OF REACH OF CHILDREN AND PETS DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT RUNNING TEMPERATURE PER SONAL INJURY CAN RESULT CAUTION...

Page 1819: ...the compressor CONDENSATE DRAIN Condensation from the evaporator housing is drained through the dash panel and on to the ground This drain must be kept open to prevent water from collecting in the bottom of the housing If the drain is blocked condensate cannot drain causing water to back up and spill into the passenger compartment It is normal to see condensate drain age below the vehicle ENGINE C...

Page 1820: ... used All tools including the refrigerant dispensing manifold the manifold gauge set and test hoses should be kept clean and dry HVAC CONTROL MODULE The HVAC control module regulates the operation of the various actuator motors The actuator motors are used to move the mode blend air and RECIRC doors Fig 3 The control module is included in the A C control head located on the instrument panel The co...

Page 1821: ...rant oil of the same type should be used to service the system Do not use any other oil The oil container should be kept tightly capped until it is ready for use Tightly cap afterwards to prevent contamination from dirt and moisture Refrigerant oil will quickly absorb any moisture it comes in contact with Spe cial effort must be used to keep all R 134a system components moisture free Moisture in t...

Page 1822: ...pproximately 120 seconds If a condition is detected an error code is displayed The error code cannot be erased until the condition is repaired and the diagnostic test is performed Check wire before replacing components refer to Group 8W Wiring Diagrams CAUTION Do not remove the actuators from the Heater A C unit assembly with power applied Removal should only be done with the Ignition OFF The actu...

Page 1823: ...ed mini mum amount in less than 2 minutes CALIBRATION COOLDOWN LED DISPLAY CODES See table for definition of flashing LED s If no problems are found the control functions normally CALIBRATION DIAGNOSTICS TEST ENTRY TO INITIATE TESTS Set Blower motor ON HIGH Set Mode position to Panel Open all A C outlets Set Temperature to Cold Both slide pots if equipped Depress WASH and REAR WIPER button simul t...

Page 1824: ...at Pin 12 of the control module is high about 11 5 volts and the voltage at Pin 17 is low about 1 5 volts the door will move towards the Heat position When Pin 17 is High and Pin 12 is Low the door will move towards the Cold position When both Pins are high or both Pins are low the actuator will not move The Blend Passenger feedback signal is a voltage signal that is supplied by the actuator to th...

Page 1825: ...5 and 6 the evaporator probe and or the wiring repair needs to be completed Then press and hold the intermittent wipe button for 5 seconds Run Diagnostics Depress REAR WIPER and REAR WASH When Diagnostics is complete Cycle to Level 4 Display Sequence is as follows REAR WIPER LED will display the Level INTERMITTENT LED will display ten s digit Short Pause INTERMITTENT LED will display the one s dig...

Page 1826: ...volts to 3 5 4 5 volts If voltage is OK go to Step 3 If not OK check for loose or corroded connector open or shorted circuit and repair as nec essary 3 Remove actuator and check if gear pins are in the correct cam track or binding If OK go to Step 4 If not OK repair as necessary 4 Check for binding door if door is binding repair as necessary If gears and door are OK replace actuator 5 Once repairs...

Page 1827: ... shorted circuit and repair as necessary 3 Remove actuator and check if the gear pins are in the correct track on cam or if they are binding If OK go to Step 4 If not OK repair as necessary 4 Check for binding door if door is binding repair as necessary If gears and door are OK replace actuator 5 Once repairs are completed repeat the Calibra tion Diagnostic and Cooldown test Repeating the test is ...

Page 1828: ...e warmed up with doors and windows closed 5 Insert a thermometer in the left center A C outlet and operate the engine for five minutes The A C clutch may cycle depending on ambient condi tions 6 With the A C clutch engaged compare the dis charge air temperature to the A C Performance Tem peratures table 7 If the discharge air temperature fails to meet the specifications in the performance temperat...

Page 1829: ...tery voltage between the compressor clutch connector ter minals If voltage is detected perform A C Clutch Coil Tests TESTS 1 Verify battery state of charge Test indicator in battery should be green 2 Connect an ampmeter 0 10 ampere scale in series with the clutch coil terminal Use a voltmeter 0 20 volt scale with clip leads measuring voltage across the battery and A C clutch 3 With A C control in ...

Page 1830: ...Blower Motor Noise Vibration Diagnosis 24 14 HEATING AND AIR CONDITIONING NS DIAGNOSIS AND TESTING Continued ...

Page 1831: ...orming the following procedures Check the coolant level drive belt tension vacuum line connections radiator air flow and fan operation Start engine and allow to warm up to normal tem perature WARNING DO NOT REMOVE RADIATOR CAP WHEN ENGINE IS HOT PERSONAL INJURY CAN RESULT If vehicle has been run recently wait 15 minutes before removing cap Place a rag over the cap and turn it to the first safety s...

Page 1832: ... line temperature Refer to Thermocouple Probe in this section for more information on probe 3 The vehicle must be in the following modes Transaxle in Park Engine Idling at 700 rpm A C Controls Set to Outside Air Panel Mode Full Cool High Blower motor vehicle equipped with rear A C turn rear blower motor ON HIGH A C Button in the ON position Vehicle Windows Open Recirc button turned OFF 4 Operate s...

Page 1833: ... flow valves at the service port connector ends This will prevent refrigerant R 134a from being released into the atmosphere R 134a refrigerant requires a special type of com pressor oil When adding oil make sure to use the oil that is specified on the under hood label Due to the different characteristics of R 134a it requires all new service procedures The use of R 134a will have a positive envir...

Page 1834: ...GERANT SYSTEM NOTE Special effort must be used to prevent mois ture from entering the A C system oil Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor If a compressor designed to use R 134a refrigerant is left open to the atmosphere for an extended period of time It is recommended that the refrigerant oil be drained and replaced with new oil o...

Page 1835: ... SOME MIXTURES OF AIR R 134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE If the A C system is not cooling properly determine if the refrigerant system is fully charged with R 134a This is accomplished by performing a system Charge Level Check or Fill If while performing this t...

Page 1836: ... For installation reverse the above procedures A C SERVICE PORTS WARNING THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION The High Side service port is serviceable the Low Side is not serviceable REMOVAL 1 Disconnect the battery negative cable 2 Recover A C system refrigerant 3 Unscrew the High Side service port from the liquid line 4 Remove O ring INSTALLATI...

Page 1837: ... wiring Fig 16 Feed wir ing through blower housing Fig 17 5 Remove mounting screws for blower motor Fig 18 6 Allow the blower assembly to drop down and remove assembly from vehicle INSTALLATION For installation reverse the above procedures BLOWER MOTOR RESISTOR BLOCK REMOVAL 1 Open hood 2 Disconnect and isolate negative battery cable Fig 13 ABS Control Module Fig 14 Blend Air Actuator Fig 15 Blowe...

Page 1838: ...block and pushing inward Two guide lines are shown on the right hand edge of the resistor block to help guide the blade position This will release the clips on the side of the resistor block Pull resistor block out INSTALLATION For installation reverse the above procedures Make sure the TOP lettering is on the top of the resistor The coils on the Resistor Block should not be contacting one another...

Page 1839: ...m Disconnect compressor clutch wire lead 5 Remove refrigerant lines from compressor Fig 21 and Fig 22 6 Remove compressor nuts and bolts Fig 23 7 Remove compressor Fig 24 INSTALLATION For installation reverse the above procedures COMPRESSOR CLUTCH COIL REMOVAL 1 Remove the compressor shaft bolt Fig 25 A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal ...

Page 1840: ...r wear The pulley and front plate should be replaced if there is excessive wear or scor ing If the friction surfaces are oily inspect the shaft nose area of the compressor for oil and remove the felt from the front cover If the compressor felt is sat urated with oil the shaft seal is leaking and will have to be replaced 7 Check bearing for roughness excessive leakage or grease If grease from beari...

Page 1841: ...t plate and pulley face with feeler gauges The air gap should be between 0 5 and 0 9 mm 020 and 035 inch If proper air gap is not obtained add or subtract shims until desired air gap is obtained 8 Install compressor shaft bolt Tighten to 17 562 N m 155620 in lbs NOTE Shims may compress after tightening shaft nut Check air gap in four or more places to verify if air gap is still correct Spin pulley...

Page 1842: ...er discharge line at condenser 180 in lbs 6 20 Lower liquid line to condenser 180 in lbs 6 20 2 lower condenser mounting bolts 45 in lbs 6 10 2 upper condenser mounting bolts 45 in lbs 6 10 3 Evacuate and charge system DISCHARGE LINE REMOVAL 1 Recover A C system refrigerant 2 Remove discharge line mounting nut at com pressor Fig 34 3 Remove discharge line at the top fitting on the condenser Fig 35...

Page 1843: ...e pry tool pry the evaporator probe grommet from the HVAC housing Fig 37 4 Remove evaporator probe from evaporator Fig 38 INSTALLATION For installation reverse the above procedures Three holes are provided in evaporator for probe location When reinstalling probe use a different hole than orig inal one If a new evaporator is installed insert the probe in the uppermost hole provided Fig 34 Compresso...

Page 1844: ... Install new O rings on the refrigerant lines and evaporator seal ing plate 2 Hand start the stud into the expansion valve and torque to 7 11 N m 64 96 in lbs 3 Carefully install the expansion valve to the sealing plate Install the two screws and tighten 8 to 14 N m 70 to 130 in lbs torque 4 Carefully install the refrigerant lines and seal ing plate to the expansion valve Install the nut and tight...

Page 1845: ...REFRIGERATION SYSTEM MUST BE COM PLETELY EMPTY BEFORE PROCEEDING 1 Set parking brake 2 Disconnect battery negative cable 3 Using a refrigerant recovery machine remove refrigerant from the A C system Fig 43 4 Remove wiper module Refer to Group 8K Windshield Wipers and Washers 5 Pinch off rear heater lines if equipped 6 Drain engine coolant Remove heater hoses at the heater core Fig 44 Plug coolant ...

Page 1846: ...in coolant system 2 Remove left side lower column cover 3 Remove steering column assembly Refer to Group 19 Steering for service procedure 4 Remove ABS module bracket and wiring Fig 47 5 Remove I P to body harness interconnect and bracket Fig 48 6 Remove lower silencer boot at base of steering shaft Fig 49 7 Pinch off heater lines under the hood 8 Remove heater core cover Insert a small amount of ...

Page 1847: ...HOSES REMOVAL NOTE Review Safety Precautions and Warnings before proceeding with this operation 1 Drain engine cooling system Refer to Group 7 Engine Cooling 2 Loosen clamps at each end of heater hose to be removed Fig 54 and Fig 55 Fig 50 Heater Core Plate And Tubes Fig 51 Depress Clips Fig 52 Accelerator Pedal Fig 53 Brake Pedal Fig 54 Upper Heater Hose NS HEATING AND AIR CONDITIONING 24 31 REMO...

Page 1848: ... ducer 11 Remove liquid line mounting bracket at right frame rail 12 Using access slot between radiator crossmem ber and grille loosen liquid line mounting plate at filter drier Remove liquid line from filter drier It may be necessary to bend liquid line in half to remove line The replacement line is a two piece assembly 13 Remove the old O rings INSTALLATION For installation reverse the above pro...

Page 1849: ...isconnect the battery negative cable 2 Recover A C system refrigerant 3 Remove the accessory drive belt 4 Remove upper generator bracket 5 Remove ground wire at dash panel 6 Remove the nut retaining the refrigerant line sealing plate to the expansion valve Fig 39 7 Remove the stud from the expansion valve Fig 40 8 Remove suction line from expansion valve 9 Remove suction line mounting nut at compr...

Page 1850: ...ION Heater A C Housing must be removed from vehicle before performing this operation Refer to Heater A C Unit Housing Removal and Installation DISASSEMBLY EVAPORATOR HOUSING 1 Place HVAC unit assembly on workbench 2 Remove distribution housing mounting screws Fig 63 3 Remove blower motor cover Fig 64 4 Remove blower motor wiring grommet and feed wiring through blower housing Fig 65 5 Remove blower...

Page 1851: ...icles ASSEMBLY EVAPORATOR HOUSING 1 For reassembly of the evaporator housing reverse the above procedures 2 Perform the HVAC control Calibration Diagnos tic and Cooldown test DISASSEMBLY DISTRIBUTION HOUSING 1 Place distribution housing on workbench Fig 72 2 Remove heater core cover Fig 73 3 Remove heater core tube plate Fig 74 and Fig 75 4 Remove heater core tubes Fig 76 Fig 66 Blower Motor Screw...

Page 1852: ...ing 7 Remove driver s zone actuator from distribution housing Fig 77 8 Remove passenger zone actuator from distribu tion housing Fig 78 Fig 71 Evaporator Fig 72 Distribution Housing Fig 73 Heater Core Cover Fig 74 Heater Core Tube Plate Fig 75 Plate Removal Fig 76 Heater Core Tube Removal 24 36 HEATING AND AIR CONDITIONING NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1853: ...r and remove from the housing Fig 80 10 Remove mode door motor 11 Remove Panel door actuator gear Fig 81 12 Remove defrost door actuator gear Fig 82 Fig 77 Driver s Zone Actuator Fig 78 Passenger Zone Actuator Fig 79 Distribution Housing Fig 80 Blend Air Door Drive Gear Fig 81 Panel Door Gear Fig 82 Defrost Door Gear NS HEATING AND AIR CONDITIONING 24 37 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1854: ... distribution housing front cover Fig 87 and Fig 88 18 Remove weather strip at fresh air vent 19 Separate housing halves Fig 89 20 Pull up on separator plate and remove defrost door Fig 90 Fig 83 Cam Wheel Fig 84 Heat Door Gear Fig 85 Distribution Housing Fig 86 Distribution Housing Half Screws Fig 87 Front Cover 24 38 HEATING AND AIR CONDITIONING NS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1855: ...eparator plate from distribution housing Fig 94 25 Remove lower half of the blend air door Fig 95 26 Remove lower half of the Panel door Fig 96 Fig 88 View of Zone Control Doors Fig 89 Distribution Housing Halves Fig 90 Defrost Door Fig 91 Panel Door Fig 92 Floor Door Fig 93 Blend Air Door NS HEATING AND AIR CONDITIONING 24 39 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1856: ... gear 3 Align cam wheel slot with the post on the dis tribution housing marked 1 4 Install PANEL door actuator gear Align master spline of PANEL door actuator gear to master spline on PANEL door Position actuator gear within cam wheel track 5 Install DEFROST door actuator gear to hous ing Match master spline of DEFROST door actuator to master spline on DEFROST door Position actuator gear within ca...

Page 1857: ...e separately The resistor is integral to the blower motor If resistor is faulty it is necessary to replace the complete blower motor REAR HEATER AND A C LINES The rear heater and A C lines are all serviced as individual pieces When disconnecting any line or block ensure that the area around it is clean of any contaminations that can get in to the system Fig 1 Fig 2 Fig 4 Fig 3 and Fig 5 SYSTEM OPE...

Page 1858: ... auxiliary HVAC system airflow will come from the overhead air outlets In between 20 and 80 the airflow will remain in the last position selected In other words if the driver started out in full heat and then adjusted their tem perature lever to 30 heat as they became comfort able the rear air would come out the floor outlets the whole time Fig 2 Front Lines Connected to Rear Lines Fig 3 Rear Heat...

Page 1859: ...pillar duct to quar ter panel Pull duct up and away from unit 3 Remove screws securing duct to rear header Fig 9 4 Remove screws securing duct to right and left rails Fig 10 INSTALLATION For installation reverse the above procedures AIR DISTRIBUTION DUCT HEATER REMOVAL 1 Remove quarter trim panel and D pillar Fig 8 and Fig 11 Refer to Group 23 Body 2 Remove screws securing lower heat duct to housi...

Page 1860: ...l the evaporator and expansion valve straight out of unit Fig 14 Do not scratch the sealing surfaces with the plumbing extension tube pilots 8 Remove and discard the O rings between the plumbing extension and the expansion valve 9 Cover the plumbing extension sealing surface to prevent contamination 10 Bring evaporator and expansion valve to a clean work space 11 Remove two 1 4 20 Torx Head screws...

Page 1861: ...s with approved wax free refrigerant oil Then reverse the above procedures 2 Evacuate and recharge system REAR HEATER A C AIR OUTLETS REMOVAL Separate barrel from bezel by pulling outward INSTALLATION For installation push the outlet firmly into the opening until it locks into place REAR HEATER A C AUXILIARY CONDENSER If vehicle is equipped with a 3 3L or 3 8L engine with rear heater and air condi...

Page 1862: ...sage REAR HEATER A C UNIT NOTE Special effort must be used to keep all R 134a system components moisture free Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor REMOVAL WARNING ON VEHICLES EQUIPPED WITH REAR A C THE REFRIGERANT SYSTEM MUST BE EMP TIED BEFORE PERFORMING THE FOLLOWING OPERATION THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF A...

Page 1863: ... C duct Tilt A C unit out ward Fig 25 15 Lift the unit enough to clear floor pan Remove unit from the vehicle INSTALLATION For installation reverse the above procedures Install new O rings at refrigerant lines Evacuate and charge the refrigerant system Fill the heater core Fig 26 Test for leaks and overall performance Fig 19 Lower Heater Duct Fig 20 Heater Core Lines Fig 21 Heater Hoses Fig 22 Tri...

Page 1864: ...s are at full HEAT position Engine is at idle With rear blower motor ON HIGH Discharge air temperature measured at the dual register located on the C pillar base is between 135 and 145 F REAR HEATER CORE REMOVAL 1 Remove the lower right quarter trim panel Refer to Group 23 Body 2 Isolate and disconnect lines from heater core Fig 27 3 Remove heater core retaining screws 4 Carefully pull the heater ...

Page 1865: ...orth while tug ging slightly away from connector nipple If the hose will not come off slice the hose at the connector nip ple and peel off heater hose This method will require heater hose replacement CAUTION When removing hoses from outlet nip ples do not use excessive force Outlet nipples may become damaged and leak engine coolant 4 Compress insert in rear heater hose quick con nection and pull d...

Page 1866: ......

Page 1867: ...19 A C SERVICE PORTS 19 BLEND AIR DOOR ACTUATOR 20 BLOWER MOTOR AND WHEEL ASSEMBLY 20 BLOWER MOTOR RESISTOR BLOCK 21 BLOWER MOTOR WHEEL 22 COMPRESSOR 2 5L TURBO DIESEL 22 CONDENSER ASSEMBLY 23 DISCHARGE LINE 23 EVAPORATOR PROBE 24 EXPANSION VALVE 25 FILTER DRIER ASSEMBLY 26 HEATER A C UNIT HOUSING 26 HEATER CORE 26 HEATER HOSES 28 LIQUID LINE 28 MODE DOOR ACTUATOR 29 RECIRC DOOR ACTUATOR 30 SIDE W...

Page 1868: ...System DESCRIPTION AND OPERATION AIR DISTRIBUTION DUCTS The air distribution ducts for the A C Heater Defroster and Second Seating Air Distribution are not serviceable in vehicle The procedures for service of these ducts are covered in Group 8E Instrument Panel and Gauges The only ducts that are serviceable in the vehicle are the side window demister ducts and the ducts that feed the front door ou...

Page 1869: ...NGS Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system High pressures are pro duced in the system when it is operating Extreme care must be exercised to make sure that all connec tions are pressure tight Dirt and moisture can enter the system when it is opened for repair or replace ment of lines or components The refri...

Page 1870: ...zone control HVAC control module is available This unit has dual blend air doors that can be regu lated independently of each other The temperature set ting can be different from driver s side to passenger side After the air passes the blend air door s the air flow can then be directed from the Panel Floor and Defrost outlets Air flow velocity can be adjusted with the blower speed selector switch ...

Page 1871: ...y may be 220 ml 7 40 oz of oil 220 ml minus 90 ml 130 ml 4 40 oz CAUTION The refrigerant oil used in a R 134a A C system is unique Use only oils which were designed to work with R 134a refrigerant The oil designated for the Denso 2 5L Turbo Diesel and Denso 2 0L gas oline engine compressors is ND 8 PAG compressor oil For gasoline vehicles still using R 12 refrigerant use ND8 PAG compressor oil SER...

Page 1872: ...l repairs are completed COOLDOWN TEST This test has been designed for performance test ing of the A C system at the manufacturing facility If the HVAC control module is replaced the Cooldown test will occur during Calibration test Cooldown will not occur on Heater Only units During the Cooldown test the control will monitor the temperature of the Fin Sensor The A C system must be able to bring the...

Page 1873: ... Blend actuator s to the Heat stop first then back to Cold After the Blend actuator s have been calibrated the Mode actuator will be cycled to Defrost and then to Panel Successful calibration is defined as actuator travel falling within their min imum and maximum limits BLEND PASSENGER ACTUATOR BACKGROUND The Blend Passenger Actuator can move the tem perature door in two directions When the voltag...

Page 1874: ... Level 3 Each time the WASH button is depressed will cycle to the next level After Level 5 is reached you will cycle back to Level 1 If the Control is a Heater Only you will only cycle from Levels 1 to 3 TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS The Temperature and Mode Potentiometer can be tested after calibration is complete by pressing the WASH button and cycling to Levels 2 3 or 5 as dis ...

Page 1875: ... should change from 3 5 4 5 volts to 0 5 1 volts If voltage is OK go to Step 2 If not OK check for loose or corroded connec tor open or shorted circuit and repair as necessary 2 Remove actuator and check if the gear pins are in the correct cam track or binding If OK go to Step 3 If not OK repair as necessary 3 Check for binding door if door is binding repair as necessary If gears and door are OK r...

Page 1876: ... the hot position check Pin 4 voltage it should change from 0 5 1 5 volts 3 5 4 5 volts If voltage is OK go to Step 3 If not OK check for loose or corroded con nector open or shorted circuit and repair as neces sary 3 Remove actuator and check if the gear pins are in the correct track on cam or if they are binding If OK go to Step 4 If not OK repair as necessary 4 Check for binding doors if door a...

Page 1877: ...ods of high heat and humid ity an air conditioning system will be less effective With the instrument control set to RECIRC only air from the passenger compartment passes through the evaporator As the passenger compartment air dehu midifies A C performance levels rise PERFORMANCE TEST PROCEDURE Review Safety Precautions and Warnings in this group before proceeding with this procedure Air tem peratu...

Page 1878: ...on If voltage is detected at the pressure transducer connect pressure transducer and check for battery voltage between the compressor clutch connector ter minals If voltage is detected perform A C Clutch Coil Tests TESTS 1 Verify battery state of charge Test indicator in battery should be green 2 Connect an ampmeter 0 10 ampere scale in series with the clutch coil terminal Use a voltmeter 0 20 vol...

Page 1879: ...Blower Motor Noise Vibration Diagnosis NS GS HEATING AND AIR CONDITIONING 24 13 DIAGNOSIS AND TESTING Continued ...

Page 1880: ... for 30 seconds Use a super cold substance liquid CO2 Do not spray R 134a Refrigerant on the expansion valve for this test Suction side low pressure should drop by 10 psi If not replace expansion valve 7 Allow expansion valve to thaw The low pres sure gauge reading should stabilize at 140 kPa to 240 kPa 20 psi to 30 psig If not replace expansion valve 8 When expansion valve test is complete test A...

Page 1881: ... 134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES THESE MIXTURES ARE POTENTIALLY DANGER OUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE 1 Establish your preferred method of measuring liquid line pressure Use a manifold gauge set or a DRB scan tool 2 Attach a clamp on thermocouple Professional Service Equipment 66 324 0014 or 80PK 1A or equiv alent to the liqui...

Page 1882: ...ery recycling machine be used Fig 8 Contact an automotive service equip ment supplier for proper equipment Refer to the operating instructions provided with the equipment for proper operation A manifold gauge set Fig 9 must also be used in conjunction with the charging and or recovery recy cling device Only use gauges that have not been used for R 12 The service hoses on the gauge set should have ...

Page 1883: ...tering the A C system oil Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor If a compressor designed to use R 134a refrigerant is left open to the atmosphere for an extended period of time It is recommended that the refrigerant oil be drained and replaced with new oil or a new compres sor be used This will eliminate the possibility of con tami...

Page 1884: ...e a digital thermometer will be required If a digital thermo meter is not available an adapter is available through the Professional Service Equipment pro gram It can convert any standard digital multimeter into a thermometer This adapter is designed to accept any standard K type thermocouple If a digital multimeter is not available it to can be ordered through Professional Service Equipment pro g...

Page 1885: ...efrigerant into the evacuated refrigerant system 4 Proceed to step two of Low Refrigerant Level Leak Test LOW REFRIGERANT LEVEL LEAK TEST 1 Determine if there is any R 134a refrigerant in the system Use the scan tool DRB under the menu Systems Sensors A C Pressure test or pressure gauge liquid line temperature partial charge check See system charge level check or fill for procedure 2 Position the ...

Page 1886: ... the lower left side steering column cover Refer to Group 8E Instrument Panel and Sys tems 2 Remove ABS control module Fig 13 3 Remove blend air actuator connector 4 Remove blend air actuator Fig 14 INSTALLATION 1 For installation reverse the above procedures 2 Perform the HVAC Control Calibration Diag nostic and Cooldown test Repeating the test is nec essary to clear the fault codes BLOWER MOTOR ...

Page 1887: ...located at the back of the engine compartment on the passenger side of the vehicle under the wiper module Fig 19 NOTE It is not necessary to remove the wiper module to access the resistor block WARNING THE RESISTOR BLOCK MAY BE HOT DO NOT ATTEMPT TO SERVICE THE RESISTOR BLOCK IF THE SYSTEM HAS BEEN RUNNING RECENTLY LET THE SYSTEM COOL DOWN BEFORE REPAIRS ARE INITIATED Fig 15 Blower Motor Cover Fig...

Page 1888: ...NG PROPER RECOVERY OF THE REFRIGERANT BEFORE ATTEMPTING TO REMOVE THE COM PRESSOR 1 Disconnect negative battery cable 2 Reclaim refrigerant 3 Raise vehicle on hoist 4 Remove refrigerant lines from compressor and cap all lines Fig 10 5 Remove flex drive bolts from behind the power steering pump Fig 20 6 Remove compressor mounting bolts Fig 20 7 pry compressor off of the dowel pins and remove compre...

Page 1889: ...lts 9 Remove 2 upper mounting bolts 10 Remove condenser from vehicle Fig 22 INSTALLATION NOTE Inspect Cooling Module for presence of seals Verify seals are available for re installation 1 Before installation replace all O rings and gas kets coat all sealing surfaces with approved wax free refrigerant oil Then reverse the above procedures 2 Evacuate and charge system DISCHARGE LINE REMOVAL 1 Recove...

Page 1890: ...g a flat blade pry tool pry the evaporator probe grommet from the HVAC housing Fig 25 4 Remove evaporator probe from evaporator Fig 26 Fig 21 Filter Drier Fig 22 Condenser Removal Fig 23 Condenser Discharge Line Fig 24 Evaporator Probe Connector Fig 25 Evaporator Probe Grommet 24 24 HEATING AND AIR CONDITIONING NS GS REMOVAL AND INSTALLATION Continued ...

Page 1891: ...ing the refrigerant line sealing plate to the expansion valve Fig 27 9 Remove the stud from the expansion valve Fig 28 10 Carefully pull the refrigerant line sealing plate assembly from expansion valve towards the front of the vehicle Use care not to scratch the expansion valve sealing surfaces with pilot tubes 11 Cover the openings to prevent contamination 12 Remove two screws securing the expans...

Page 1892: ...COM PLETELY EMPTY BEFORE PROCEEDING 1 Set parking brake 2 Disconnect battery negative cable 3 Using a refrigerant recovery machine remove refrigerant from the A C system 4 Remove wiper module Refer to Group 8K Windshield Wipers and Washers 5 Drain engine coolant Remove heater hoses at the heater core refer to Heater Hoses Removal and Installation procedures Plug coolant lines 6 Remove suction and ...

Page 1893: ...35 10 Pull up on accelerator pedal and slide heater core past Fig 36 11 Depress brake pedal Fig 37 and remove heater core from HVAC housing Fig 31 ABS MODULE Fig 32 Interconnect And Bracket Fig 33 Lower Silencer Boot Fig 34 Heater Core Plate And Tubes Fig 35 Depress Clips Fig 36 Accelerator Pedal NS GS HEATING AND AIR CONDITIONING 24 27 REMOVAL AND INSTALLATION Continued ...

Page 1894: ...ures LIQUID LINE REMOVAL 1 Disconnect the battery negative cable 2 Recover A C system refrigerant 3 Remove ground wire at dash panel 4 Remove the nut retaining the refrigerant line sealing plate to the expansion valve Fig 27 5 Remove the stud from the expansion valve Fig 28 6 Remove liquid line from expansion valve 7 Cover the openings to prevent contamination 8 Disconnect wire connector at pressu...

Page 1895: ...anel To service the duct remove the I P cover and remove duct retainers fasteners Fig 43 RIGHT SIDE The demister duct on the right side is a one piece design It is one long duct that attaches to the distri bution housing The duct is located on top of the instrument panel and it is not serviceable Fig 44 SUCTION LINE REMOVAL 1 Disconnect the battery negative cable 2 Recover A C system refrigerant 3...

Page 1896: ...tua tor Fig 45 4 Remove Recirc actuator 5 Disengage actuator linkage at Recirc door 6 Remove actuator from vehicle INSTALLATION 1 For installation reverse the above procedures 2 Perform the HVAC control Calibration Diagnos tic and Cooldown test DISASSEMBLY AND ASSEMBLY HEATER A C UNIT RECONDITION Heater A C Housing must be removed from vehicle before performing this operation Refer to Heater A C U...

Page 1897: ... 50 6 Remove recirculation door cover Fig 51 7 Remove Recirc door Fig 52 8 Remove screws around the perimeter of the upper HVAC housing Fig 53 Fig 48 Blower Motor Grommet Fig 49 Blower Motor Screws Fig 50 Blower Motor Fig 51 Recirculation Door Cover Fig 52 Recirc Door Fig 53 HVAC Cover NS GS HEATING AND AIR CONDITIONING 24 31 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1898: ... ASSEMBLY EVAPORATOR HOUSING 1 For reassembly of the evaporator housing reverse the above procedures 2 Perform the HVAC control Calibration Diagnos tic and Cooldown test DISASSEMBLY DISTRIBUTION HOUSING 1 Place distribution housing on workbench Fig 55 2 Remove heater core cover Fig 56 3 Remove heater core tube plate Fig 57 and Fig 58 4 Remove heater core tubes Fig 59 Fig 54 Evaporator Fig 55 Distr...

Page 1899: ...through blend air opening on top of distribution housing Fig 62 Depress clip retaining the driver s blend air door drive gear Pull out on gear and remove from the housing Fig 63 10 Remove mode door motor 11 Remove Panel door actuator gear Fig 64 12 Remove defrost door actuator gear Fig 65 13 Remove cam wheel Fig 66 Fig 59 Heater Core Tube Removal Fig 60 Driver s Zone Actuator Fig 61 Passenger Zone...

Page 1900: ...on housing half screws Fig 69 17 Remove distribution housing front cover Fig 70 and Fig 71 Fig 64 Panel Door Gear Fig 65 Defrost Door Gear Fig 66 Cam Wheel Fig 67 Heat Door Gear Fig 68 Distribution Housing Fig 69 Distribution Housing Half Screws 24 34 HEATING AND AIR CONDITIONING NS GS DISASSEMBLY AND ASSEMBLY Continued ...

Page 1901: ... half Panel door Fig 74 22 Remove upper half of Floor door Fig 75 23 Remove upper half of the blend air door slide off of shaft Fig 76 Fig 70 Front Cover Fig 71 View of Zone Control Doors Fig 72 Distribution Housing Halves Fig 73 Defrost Door Fig 74 Panel Door Fig 75 Floor Door NS GS HEATING AND AIR CONDITIONING 24 35 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1902: ... an assembly procedure of the gears and cam is necessary ACTUATOR GEARS ALIGNMENT PROCEDURE 1 Install lower FLOOR door actuator gear to housing Match master spline of FLOOR door actua tor gear to master spline on door 2 Install cam wheel Align cam wheel track to FLOOR door actuator gear 3 Align cam wheel slot with the post on the dis tribution housing marked 1 Fig 76 Blend Air Door Fig 77 Separato...

Page 1903: ... track 5 Install DEFROST door actuator gear to hous ing Match master spline of DEFROST door actuator to master spline on DEFROST door Position actuator gear within cam wheel track 6 Reinstall housing in vehicle 7 Perform the HVAC control Calibration Diagnos tic and Cooldown test NS GS HEATING AND AIR CONDITIONING 24 37 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1904: ......

Page 1905: ...e of engine RPM engine temperature and or input voltage to the PCM The PCM might not store a DTC for a monitored circuit even though a malfunction has occurred This may happen because one of the DTC criteria for the circuit has not been met For example assume the diagnostic trouble code criteria requires the PCM to monitor the circuit only when the engine operates between 750 and 2000 RPM Suppose ...

Page 1906: ...om HIGH to LOW or LOW to HIGH assume the entire switch circuit to the PCM functions properly From the state display screen access either State Display Inputs and Outputs or State Display Sensors STATE DISPLAY INPUTS AND OUTPUTS Connect the DRB scan tool to the data link connec tor and access the State Display screen Then access Inputs and Outputs The following list contains the PCM system function...

Page 1907: ...isual indication of device operation click of relay contacts fuel spray etc Except for intermittent conditions if a device functions properly during testing assume the device its associated wiring and driver circuit work cor rectly DIAGNOSTIC TROUBLE CODES A Diagnostic Trouble Code DTC indicates the PCM has recognized an abnormal condition in the system The preferred and most accurate method of re...

Page 1908: ...d Circuits An open or shorted condition detected in the Speed Control vacuum or vent solenoid circuits 10 A C Clutch Relay Circuit An open or shorted condition detected in the A C clutch relay circuit 11 P0403 EGR Solenoid Circuit An open or shorted condition detected in the EGR transducer solenoid circuit 12 P0443 EVAP Purge Solenoid Circuit An open or shorted condition detected in the duty cycle...

Page 1909: ...um dwell time 2C No ASD Relay Output Voltage at PCM An Open condition Detected In The ASD Relay Output Circuit 2E P0401 EGR System Failure Required change in air fuel ratio not detected during diagnostic test 30 P1697 PCM Failure SRI Miles Not Stored Unsuccessful attempt to update EMR mileage in the PCM EEPROM 31 P1698 PCM Failure EEPROM Write Denied Unsuccessful attempt to write to an EEPROM loca...

Page 1910: ... in cylinder 3 6E P0304 Cylinder 4 Mis fire Misfire detected in cylinder 4 70 P0420 Right Rear or just Catalyst Efficency Failure Catalyst efficiency below required level 71 P0441 Evap Purge Flow Monitor Failure Insufficient or excessive vapor flow detected during evaporative emission system operation 72 P1899 P N Switch Stuck in Park or in Gear Incorrect input state detected for the Park Neutral ...

Page 1911: ...d to Ground O2 sensor voltage too low tested after cold start 9D P1391 Intermittent Loss of CMP or CKP Intermittent loss of either camshaft or crankshaft position sensor A0 P0442 Evap Leak Monitor Small Leak Detected A small leak has been detected by the leak detection monitor A1 P0455 Evap Leak Monitor Large Leak Detected The leak detection monitor is unable to pressurize Evap system indicating a...

Page 1912: ...r vice versa As the sen sor starts malfunctioning it could take longer to detect the changes in the oxygen content of the exhaust gas The output voltage of the O2S ranges from 0 to 1 volt A good sensor can easily generate any output voltage in this range as it is exposed to different con centrations of oxygen To detect a shift in the A F mixture lean or rich the output voltage has to change beyond...

Page 1913: ...se a catalyst to decay A meltdown of the ceramic core can cause a reduction of the exhaust passage This can increase vehicle emissions and deteriorate engine performance driveability and fuel economy The catalyst monitor uses dual oxygen sensors O2S s to monitor the efficiency of the converter The dual O2Ss strategy is based on the fact that as a cat alyst deteriorates its oxygen storage capacity ...

Page 1914: ...The cycle rate is again interrogated and when it increases due to the flow through the purge system the leak check portion of the diagnostic is complete The canister vent valve will unseal the system after completion of the test sequence as the pump diaphragm assembly moves to the full travel position Evaporative system functionality will be verified by using the stricter evap purge flow monitor A...

Page 1915: ... detect an inoperative ignition coil fouled or worn spark plugs ignition cross firing or open spark plug cables CYLINDER COMPRESSION The PCM cannot detect uneven low or high engine cylinder compression EXHAUST SYSTEM The PCM cannot detect a plugged restricted or leaking exhaust system It may set a EGR or Fuel system fault or O2S FUEL INJECTOR MECHANICAL MALFUNCTIONS The PCM cannot determine if a f...

Page 1916: ...to Trans 4 4 of Maximun Load 11 7 of Maximun Load 3 0L 4 2 of Maximun Load 11 5 of Maximun Load 3 3L 5 of Maximun Load 13 4 of Maximun Load 3 8L 4 7 of Maximun Load 13 3 of Maximun Load 25 12 EMISSION CONTROL SYSTEMS NS DESCRIPTION AND OPERATION Continued ...

Page 1917: ...ction NOTE The evaporative system uses specially man ufactured hoses If they need replacement only use fuel resistant hose ROLLOVER VALVE All vehicles have a rollover valve The valve also prevents fuel flow through the fuel tank vent valve hoses should the vehicle rollover All vehicles pass a 360 rollover The charcoal filled evaporative canister stores the vapors The rollover valve is not a servic...

Page 1918: ...vent seal During non test test conditions the vent seal is held open by the pump diaphragm assembly which pushes it open at the full travel posi tion The vent seal will remain closed while the pump is cycling This is due to the operation of the 3 port solenoid which prevents the diaphragm assem bly from reaching full travel After the brief initial ization period the solenoid is de energized allowi...

Page 1919: ...ake manifold vacuum When the engine is not operating or during an engine backfire the spring forces the plunger back against the seat This prevents vapors from flowing through the valve Fig 7 When the engine is at idle or cruising high mani fold vacuum is present At these times manifold vac uum is able to completely compress the spring and pull the plunger to the top of the valve Fig 8 In this pos...

Page 1920: ... Procedures Manual for testing procedures PCV VALVE TEST WARNING APPLY PARKING BRAKE AND OR BLOCK WHEELS BEFORE PERFORMING ANY TEST OR ADJUSTMENT WITH THE ENGINE OPERATING With the engine idling remove the PCV valve from its attaching point If the valve is operating properly a hissing noise will be heard and a strong vacuum felt when placing a finger over the valve inlet Fig 10 With the engine off...

Page 1921: ...acked or split If a hose leaks it will cause the Check Engine Lamp to illuminate 3 Install hoses to LDP 4 Plug electrical connector into LDP 5 Push connector locking tab into place 6 Using DRB scan tool verify proper operation of LDP ROLLOVER VALVES All vehicles have 2 rollover valves on top of the fuel tank The valves prevent fuel flow through the fuel tank vent valve hoses should the vehicle rol...

Page 1922: ...me temperature during combustion The EGR system consists of EGR tube connects a passage in the intake manifold to the exhaust manifold EGR valve Electronic EGR Transducer Connecting hoses The Electronic EGR Transducer contains an elec trically operated solenoid and a back pressure trans ducer Fig 3 The PCM operates the solenoid The PCM determines when to energize the solenoid Exhaust system back p...

Page 1923: ...a problem is indicated by the MIL and a DTC for the EGR system is set check for proper operation of the EGR system Use the System Test EGR Gas Flow Test If the EGR system tests properly check the system using the DRB scan tool Refer to On Board Diagnosis sections in this Group Also refer to the DRB scan tool and the appropriate Pow ertrain Diagnostics Procedure manual EGR SYSTEM TEST WARNING APPLY...

Page 1924: ...correctly The problem is in either a plugged EGR tube or plugged passages at the intake or exhaust manifolds refer to step c If the stem will not move replace the EGR valve Note The EGR valve valve control and attaching hoses are serviced as one unit Refer to EGR Valve Removal Installation in this group c Remove the EGR tube between the intake and exhaust manifolds Check and clean the EGR tube and...

Page 1925: ...roceeding to next step 11 Reconnect the rubber hose to the vacuum inlet fitting Fig 4 on the EGR valve 12 Disconnect the rubber hose at the vacuum outlet fitting Fig 4 on the EGR valve 13 Connect a vacuum gauge to this fitting 14 Disconnect the electrical connector Fig 4 at the valve control This will simulate an open circuit no ground from the PCM at the valve 15 Start the engine and bring to ope...

Page 1926: ...o electrical EGR transducer EGR TUBE SERVICE 3 0L ENGINES REMOVAL 1 Remove EGR tube flange nuts from exhaust manifold Fig 6 2 Remove EGR valve nuts at intake manifold Remove EGR tube 3 Clean all gasket surfaces and discard old gas kets Check for any signs of leakage or cracked sur faces Repair or replace as necessary INSTALLATION 1 Loosely install the EGR tube on the intake and exhaust manifolds w...

Page 1927: ...kets into place on intake and exhaust manifolds 2 Tighten mounting bolts to 22 N m 200 in lbs torque SPECIAL TOOLS EMISSION CONTROL SYSTEM Fig 8 EGR Tube 3 3 3 8L Hose Clamp Pliers 6094 NS EMISSION CONTROL SYSTEMS 25 23 REMOVAL AND INSTALLATION Continued ...

Page 1928: ......

Page 1929: ...dentified an abnormal signal in a circuit or the system A DTC may indicate the result of a failure but never identify the failed component directly There are several operating conditions that the PCM does not monitor and set a DTC for Refer to the following Monitored Circuits and Non Monitored Circuits in this section MONITORED CIRCUITS The PCM can detect certain problems in the elec trical system...

Page 1930: ...t the PCM has recognized an abnormal signal in a circuit or the system A DTC may indicate the result of a failure but most likely will not identify the failed component directly ACCESSING DIAGNOSTIC TROUBLE CODES A stored DTC can be displayed through the use of the DRB III scan tool The DRB III connects to the data link connector The data link connector is located under the instrument panel near b...

Page 1931: ...h Low Idle Switch Accelerator Pedal Sensor Signal PWG Plaus With Potentiometer P1600 Battery Voltage SRC High Exceeded P1605 Terminal 15 Plausibility After Startup P1610 Regulator Lower Regulator Limit Regulator Upper Regulator Limit P1615 Microcontroller Gate Array Monitoring Microcontroller Gate Array Watchdog Microcontroller Prepare Fuel Quantity Stop Microcontroller Recovery Was Occurred Micro...

Page 1932: ...nsor Signal High Exceeded A C System Pressure Sensor Signal Low Exceeded A C System Pressure Supply Signal High Exceeded A C System Pressure Supply Signal Low Exceeded P1703 Brake Signal Plaus With Redundant Contact P1740 Clutch Signal Plausibilty P1725 Inductive Aux Speed Sensor Dynamic Plausibilty Inductive Aux Speed Sensor Overspeed Recognition Inductive Aux Speed Sensor Plausibilty Inductive A...

Page 1933: ...tem Operation for vacuum pump informa tion Vacuum harness routing for emission related components is displayed in Fig 1 EXHAUST GAS RECIRCULATION EGR SYSTEM GENERAL INFORMATION The EGR system reduces oxides of nitrogen NOx in the engine exhaust This is accomplished by allow ing a predetermined amount of hot exhaust gas to recirculate and dilute the incoming fuel air mixture A malfunctioning EGR sy...

Page 1934: ...m the vacuum pump will be allowed to pass to the EGR valve via a connecting hose Exhaust gas recirculation will begin in this order when The PCM determines that EGR system opera tion is necessary The engine is running to operate the vacuum pump A ground signal is supplied to the EVM Vacuum passes to the EGR valve The inlet seat poppet valve at the bottom of the EGR valve opens to dilute and recirc...

Page 1935: ...MOVAL 1 Remove the rubber hose from turbocharger to metal tube 2 Disconnect vacuum line at EGR valve vacuum supply fitting Fig 2 3 Loosen the tube fitting at exhaust manifold end of EGR tube Fig 2 4 Remove the two bolts retaining the EGR tube to the side of EGR valve Fig 2 5 Remove the two EGR valve mounting bolts Fig 2 and remove EGR valve 6 Discard both of the old EGR mounting gaskets INSTALLATI...

Page 1936: ...electrical connector at EVM INSTALLATION 1 Install electrical connector to EVM 2 Install EVM and tighten mounting screws 3 Connect vacuum hoses 4 Install PDC to bracket and tighten mounting screws 5 Install battery 6 Connect battery cables positive first SPECIFICATIONS TORQUE CHART 2 5L DIESEL Description Torque EGR Valve Mounting Bolts 23 N m 204 in lbs EGR Tube Mounting Bolts 23 N m 204 in lbs E...

Page 1937: ...or 2 4 3 0 3 3 3 8L engines Refer to group 25 for more information REMOVAL AND INSTALLATION EGR VALVE If the EGR system operates incorrectly replace the entire EGR valve and transducer together The EGR valve and electrical transducer EET are calibrated together REMOVAL The EGR valve attaches to the rear of the cylinder head Fig 2 EGR transducer is attached to the air inlet duct 1 Remove EGR transd...

Page 1938: ...intake manifold Fig 3 2 Remove EGR tube to EGR valve screws 3 Remove EGR tube Clean gasket surface on the EGR valve Wipe clean the grommet on the intake manifold INSTALLATION The rubber grommet that seals the EGR tube to intake manifold connection is reusable 1 Loosely install the EGR tube and fasteners 2 Tighten the EGR tube to intake manifold ple num screws to 11 N m 95 in lbs torque 3 Tighten t...

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