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Chrysler 2000 LHS, Owner'S Manual, Page: 953 / 1591

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Chrysler 2000 LHS Owner'S Manual Download Page 953

Dial Indicator C-3339

Valve Spring Compressor 8215

Adapter 8216

Valve Spring Compressor C-3422-B

Valve Spring Adapter 6526

Valve Spring Tester C-647

Valve Spring Compressor MD-998772-A

Valve Spring Adapter 6527

Indicator Bore Size C-119

Connecting Rod Installation Guides 8189

9 - 72

2.7L ENGINE

LH

SPECIAL TOOLS (Continued)

Summary of Contents for 2000 LHS

Page 1: ...s 8L Lamps 8La Lamps 8M Passive Restraint Systems 8Ma Passive Restraint Systems 8N Electrically Heated Systems 8O Power Distribution Systems 8P Power Lock Systems 8Q Vehicle Theft Security Systems 8R Power Seat Systems 8Ra Power Seat Systems 8S Power Window Systems 8T Power Mirror Systems 8U Chime Buzzer Warning Systems 8V Overhead Console Systems 8W Wiring Diagrams 9 Engine 11 Exhaust System 13 F...

Page 2: ...ight Rating GAWR front Gross Axle Weight Rating GAWR rear and the Vehicle Identification Number VIN The Month Day and Hour of manufacture is also included All communications or inquiries regarding the vehicle should include the Month Day Hour and Vehicle Identification Number VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number VIN is located on the upper left corner of the ...

Page 3: ...00 11 Assembly Plant H Bramelea Assembly 12 through 17 Sequence Number Six digit number assigned by assembly plant VIN CHECK DIGIT DESCRIPTION To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden tification Number The check digit is used by the manufacturer and government agencies to verify the authent...

Page 4: ...alve SOHC Gasoline Aluminum Block EES 2 7 L Six Cylinder 24 Valve DOHC Gasoline Aluminum Block ECG 3 5 L Six Cylinder 24 Valve SOHC Gasoline Aluminum Block DIGIT 23 Open Space BODY CODE PLATE LINE 2 DIGITS 1 THROUGH 12 Vehicle Order Number DIGITS 13 THROUGH 15 Vinyl Roof Code DIGITS 16 AND 17 Open space DIGITS 18 AND 19 Vehicle Shell Line LH DIGITS 20 Carline C Chrysler D Dodge Fig 3 Body Code Pla...

Page 5: ...r VIN paragraph 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 CTD When a second plate is required the first four spaces of each line will not be used due to overlap of the plates INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols ...

Page 6: ...RNING USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER SONAL INJURY Figure art specifications and tightening torque ref erences in this manual are identified in metric and SAE format During any maintenance or repair procedures it is important to salvage all fasteners nuts bolts etc for reassembly If the fastener is not salvageable a fastener of equivalent specification must be us...

Page 7: ...FASTENER IDENTIFICATION 6 INTRODUCTION LH DESCRIPTION AND OPERATION Continued ...

Page 8: ...FASTENER STRENGTH LH INTRODUCTION 7 DESCRIPTION AND OPERATION Continued ...

Page 9: ... 03937 Inches Feet x 0 3048 Meters M M x 3 281 Feet Yards x 0 9144 Meters M x 1 0936 Yards mph x 1 6093 Kilometers Hr Km h Km h x 0 6214 mph Feet Sec x 0 3048 Meters Sec M S M S x 3 281 Feet Sec mph x 0 4470 Meters Sec M S M S x 2 237 mph Kilometers Hr Km h x 0 27778 Meters Sec M S M S x 3 600 Kilometers Hr Km h COMMON METRIC EQUIVALENTS 1 inch 25 Millimeters 1 Cubic Inch 16 Cubic Centimeters 1 Fo...

Page 10: ...METRIC CONVERSION CHART LH INTRODUCTION 9 DESCRIPTION AND OPERATION Continued ...

Page 11: ...TORQUE SPECIFICATIONS 10 INTRODUCTION LH DESCRIPTION AND OPERATION Continued ...

Page 12: ...lation Amendment Number Approval Number VEHICLE IDENTIFICATION NUMBER DESCRIPTION The Vehicle Identification Number VIN is located on the upper left corner of the instrument panel near the left windshield pillar Fig 2 The VIN con sists of 17 characters in a combination of letters and numbers that provide specific information about the vehicle Refer to VIN Code Breakdown table for decoding informat...

Page 13: ...o include a Check Digit at the ninth position of the Vehicle Iden tification Number The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta tion The formula to use the check digit is not released to the general public BODY CODE PLATE DESCRIPTION The Body Code Plate Fig 3 is located in the engine compartment on the battery...

Page 14: ...DIGITS 8 and 9 Open Space DIGITS 10 THROUGH 12 Secondary Paint DIGITS 13 and 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20 21 AND 22 Engine Code EER 2 7 L Six Cylinder 24 Valve DOHC Gasoline Aluminum Block EGG 3 5 L Six Cylinder 24 Valve SOHC Gasoline Aluminum Block DIGIT 23 Open Space BODY CODE PLATE LINE 1 DIGITS 1 2 AND 3 Transaxle Codes DGX 42LE four speed...

Page 15: ...irst four spaces of each line will not be used due to overlap of the plates MANUFACTURER PLATE The Manufacturer Plate is located in the engine compartment on the radiator closure panel cross member adjacent to the Body Code Plate The plate contains five lines of information 1 Vehicle Identification Number VIN 2 Gross Vehicle Mass GVM 3 Gross Train Mass GTM 4 Gross Front Axle Rating GFAR 5 Gross Re...

Page 16: ...bearing designations defined by the following organization should be used to service a DaimlerChrysler Corporation vehicle Society of Automotive Engineers SAE American Petroleum Institute API Fig 1 National Lubricating Grease Institute NLGI Fig 2 SAE VISCOSITY RATING An SAE viscosity grade is used to specify the vis cosity of engine oil Engine oils also have multiple viscosities These are specifie...

Page 17: ...ICATION LOCATIONS The fluid check fill points and lubrication locations are located in each applicable Sections LUBRICATION POINT LOCATIONS Lubrication point locations are located in each applicable Sections SPECIFICATIONS FLUID CAPACITIES Fuel Tank 68 L 18 gal Engine Oil 2 7 L Engine with Oil Filter 4 7 L 5 0 qts Engine Oil 3 2 L Engine with Oil Filter 4 7 L 5 0 qts Engine Oil 3 5 L Engine with O...

Page 18: ...ses and clamps If mileage is less than 7 500 miles 12 000 km yearly replace the engine oil filter at each oil change EMISSION CONTROL SYSTEM MAINTENANCE The scheduled emission maintenance listed in bold type on the Maintenance Schedules must be done at the mileage specified to assure the continued proper functioning of the emission control system These and all other maintenance services included i...

Page 19: ... air cleaner element fil ter and replace if required See note 1 at the end of this chart Adjust the drive belt tension Flush and replace the engine coolant at 60 months 82 500 Miles 132 000 km or at 66 months Change the engine oil Replace the engine oil filter Inspect the engine air cleaner element fil ter and replace if required See note 1 at the end of this chart 90 000 Miles 144 000 km or at 72...

Page 20: ...Inspect the CV joints and front suspension com ponents Rotate the tires every other oil change Check the coolant level hoses and clamps If mileage is less than 7 500 miles 12 000 km yearly replace the engine oil filter at each oil change 3 000 Miles 5 000 km Change the engine oil Replace the engine oil filter Inspect the engine air cleaner element fil ter and replace if required See note 1 at the ...

Page 21: ...ine oil filter Replace the engine air cleaner element fil ter See note 1 at the end of this chart Adjust the drive belt tension Change the differential fluid Inspect the front and rear brake linings and rotors 48 000 Miles 77 000 km Change the engine oil Replace the engine oil filter Inspect the engine air cleaner element fil ter and replace if required See note 1 at the end of this chart Change t...

Page 22: ...rt 87 000 Miles 139 000 km Change the engine oil Replace the engine oil filter Inspect the engine air cleaner element fil ter and replace if required See note 1 at the end of this chart 90 000 Miles 144 000 km Change the engine oil Replace the engine oil filter Replace the engine air cleaner element fil ter Adjust the drive belt tension Check and replace if necessary the PCV valve See notes 1 and ...

Page 23: ...e 2 This maintenance is not required if the component was previously replaced NOTE Operating vehicle under the following condi tions will require the transmission service indicated with an in schedule B More than 50 of vehicle operation is in stop and go traffic where the vehicle is driven regularly for more than 45 minutes of continuous operation such as in heavy city traffic or construction zone...

Page 24: ...right front fender and is accessible through the engine compartment TO JUMP START A DISABLED VEHICLE If the indicator is dark or shows a green dot pro ceed as follows 1 Wear eye protection and remove metallic jew elry worn on hands or wrists to avoid injury by acci dental arcing of battery current 2 When using another vehicle as a booster source park the booster vehicle within cable reach without ...

Page 25: ... bed towing device Fig 3 is recommended When using a wheel lift towing device be sure the rear end of disabled vehicle has at least 100 mm 4 inches 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 13 degrees for Intrepid 12 degrees for Concorde and 300M Additional ramping may be required GROUND CLEAR...

Page 26: ...REAR TOWING PROCEDURES CAUTION Do not tow vehicle with the rear end lifted If damage to the vehicle prevents front towing use a flat bed towing device CAUTION Do not push the vehicle with another vehicle as damage to the bumper fascia and tran saxle can result HOISTING RECOMMENDATIONS Refer to Owner s Manual provided with vehicle for proper emergency jacking procedures WARNING THE HOISTING AND JAC...

Page 27: ......

Page 28: ...t specifi cations recommended by DaimlerChrysler differ Typical wheel alignment angles and measurements are camber caster toe and thrust angle Camber is the number of degrees the top of the tire and wheel assembly is tilted either inward or outward Fig 1 Camber is a tire wearing angle Excessive negative camber will cause tread wear at the inside of the tire while excessive positive camber will cau...

Page 29: ... the ground while the vehicle is setting on a flat level surface DIAGNOSIS AND TESTING SUSPENSION AND STEERING DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION Front End Whine On Turns 1 Defective wheel bearing 1 Replace wheel bearing 2 Incorrect wheel alignment 2 Check and reset wheel alignment 3 Worn tires 3 Replace tires Front End Growl Or Grinding On Turns 1 Defective wheel bearing 1 Replace whe...

Page 30: ...roken C V joint 2 Replace C V joint Front End Whine When Accelerating Or Decelerating 1 Worn or defective transaxle gears or bearings 1 Replace transaxle gears or bearings Front End Clunk When Accelerating Or Decelerating 1 Worn or broken engine mount 1 Replace engine mount 2 Worn or defective transaxle gears or bearings 2 Replace transaxle gears or bearings 3 Loose lug nuts 3 Verify wheel lug nut...

Page 31: ...o determine if the lead condi tion is the result of a bad tire or is caused by the front wheel alignment SERVICE PROCEDURES PRE WHEEL ALIGNMENT INSPECTION Before any attempt is made to change or correct the wheel alignment factors The following part inspection and the necessary corrections should be made to those parts which influence the steering of the vehicle 1 Check and inflate all tires to re...

Page 32: ...LH SUSPENSION 2 5 SERVICE PROCEDURES Continued ...

Page 33: ...jouncing each end of vehicle an equal number of times The bumper should always be released when vehicle is at the bottom of the jounce cycle 4 Read the vehicle s current front and rear align ment settings Compare the vehicle s current align ment settings to the vehicle specifications for camber caster and toe in See Alignment Specifications in this group of the service manual for the required spec...

Page 34: ...ing bending or by per forming any other modification to the vehicle s front suspension components FRONT CAMBER ADJUSTMENT PROCEDURE There are camber adjustment bolts and nuts avail able to allow front suspension camber adjustment in the event the vehicle pulls even though the camber is within specifications This procedure involves replac ing the original strut clevis to knuckle attachment bolts wi...

Page 35: ...tion of the adjustment sleeve Not following this procedure could result in the Toe Setting Adjustment changing and or loosening of the inner or outer tie rod ends NOTE Use an appropriate tool on neck area of outer tie rod to maintain the correct perpendicular orientation of the tie rod end stud within the tie rod end 3 After completion of toe adjustment procedure tighten tie rod pinch bolt Fig 8 t...

Page 36: ...ide To Side Difference 0 00 0 70 CASTER 3 00 2 00 to 4 00 Cross Caster Maximum Side To Side Difference 0 00 1 00 TOTAL TOE 0 00 0 20 to 0 20 REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE CAMBER 0 20 0 70 to 0 30 TOTAL TOE 0 10 0 20 to 0 40 THRUST ANGLE 0 00 0 15 to 0 15 NOTE TOTAL TOE is the sum of both the left and right wheel toe settings TOTAL TOE must be equally split between each fr...

Page 37: ...allows each front wheel on a vehicle to adapt to different road surfaces and condi tions without affecting the control of the vehicle Each side of the front suspension is allowed to move independently from the other Both sides of the front suspension are allowed to pivot so the vehicle can be steered in the direction preferred Steering of the vehicle is provided by a rack and pinion steering gear ...

Page 38: ...ed for attachment to the front strut assembly and lower control arm ball joint Fig 1 The steering knuckle also has machined abutments on the casting to support and align the front brake caliper The knuckle also holds the hub and bearing and supports the driveshaft The hub and bearing is positioned through the center of the knuckle The driveshaft outer constant velocity C V stub shaft is splined to...

Page 39: ...mber using a bolt through the center of the pivot bushing The ten sion strut is fastened through the center of the ten sion strut bushing and lower control arm The lower control arm ball joint connects to the steering knuckle OPERATION The lower control arm supports the lower end of the steering knuckle and allows for the up and down movement of the suspension during the jounce and rebound travel ...

Page 40: ... Lift dust boot and inspect strut assembly for evidence of fluid running from the upper end of fluid reservoir Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect performance of the strut assembly Also inspect jounce bumpers for signs of damage or d...

Page 41: ...onents of the lower con trol arm are the pivot bushing and the tension strut bushing The service procedure to replace these com ponents is detailed in the specific component Service Procedures Sections in this group of the service man ual BALL JOINT Raise front of vehicle using jack stands or a frame contact type hoist until front suspension is in full rebound and tires are not in contact with the...

Page 42: ...g 7 for the installation of any metal fasteners into the shock tower Because of the minimum clear ance in this area installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring STRUT ASSEMBLY FRONT REMOVAL 1 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this man...

Page 43: ...manual for the required caliper removal procedure Support caliper assembly by hanging it from frame of vehicle with wire or some other method Fig 12 do not let caliper assembly hang by brake hose Remove front braking disc from hub Fig 8 Stabilizer Bar Link At Strut 1 OUTER TIE ROD 2 NUT 3 STABILIZER BAR ATTACHING LINK 4 STRUT ASSEMBLY 5 STEERING ARM 6 NUT Fig 9 Removing Outer Tie Rod From Steering...

Page 44: ... to shock tower attaching nuts Fig 14 Tighten the 4 strut mount to strut tower attaching nuts to a torque of 37 N m 28 ft lbs torque 2 Position steering knuckle into strut assembly CAUTION The strut assembly to steering knuckle bolts are serrated were they go through strut assembly and steering knuckle When installing bolts turn nuts onto bolts DO NOT TURN BOLTS IN STEERING KNUCKLE If bolts are tu...

Page 45: ...MOVE 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 front wheel and tire assembly from the vehicle 3 Remove the front caliper assembly from the front steering knuckle assembly Fig 15 Refer to Front Disc Brake Service in the Bra...

Page 46: ...t slide out of knuckle insert a pry bar between hub and bearing assembly and steering knuckle Fig 22 and gently pry hub and bearing from knuckle If stub shaft is frozen to hub and bearing assembly tap end of stub shaft with soft face hammer to free it from hub and bearing spline Fig 17 Speed Sensor Head Removal 1 SENSOR EAR 2 PUNCH 3 SPEED SENSOR HEAD Fig 18 Hub And Bearing Retaining Nut 1 HUB BEA...

Page 47: ...through strut assembly and steering knuckle When removing bolts turn nuts off bolts DO NOT TURN BOLTS IN STEERING KNUCKLE If bolts are turned damage to steering knuckle will result 12 Remove the strut assembly to steering knuckle attaching bolts Fig 25 13 Remove the steering knuckle from the vehicle Fig 21 Hub And Bearing Assembly Removal And Installation 1 HUB BEARING ASSEMBLY 2 STEERING KNUCKLE ...

Page 48: ...qually tighten all 3 mounting bolts until hub and bearing assembly is squarely seated against front of steering knuckle Then tighten all 3 hub and bearing assem bly mounting bolts to a torque of 110 N m 80 ft lbs CAUTION The hub and bearing assembly to stub shaft retaining nut Fig 18 is a prevailing torque nut and can not be reused A NEW retaining nut MUST be used when assembled 6 Install a NEW hu...

Page 49: ... used for this vehicle 2 Remove the front wheel and tire assembly from the vehicle 3 Remove the 2 guide pin bolts mounting the cal iper assembly to the steering knuckle Fig 28 Remove the caliper from the front steering knuckle Refer to Disc Brake Caliper in the Removal And Installation Section in the Brake Group of this ser vice manual for the caliper removal procedure 4 Remove rotor from hub by p...

Page 50: ...om hub and bearing spline CAUTION If metal seal Fig 34 on hub and bear ing assembly is seized to steering knuckle and becomes dislodged on hub and bearing assembly during bearing removal The hub and bearing assembly MUST not be reused and MUST be replaced with a new hub and bearing assembly INSTALLATION CAUTION Hub and bearing assembly mounting surfaces on steering knuckle and driveshaft Fig 35 mu...

Page 51: ... for the caliper installation pro cedure Install the caliper to steering knuckle guide pin bolts Fig 28 and tighten to a torque of 19 N m 168 in lbs 6 Install wheel and tire assembly on vehicle Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specifica tion Then repeat the tightening sequence to the full specified torque of 129 N m 95 ft lbs 7 Lower the ve...

Page 52: ... Fig 39 When removing tension strut nut keep strut from turning by holding tension strut at flat using open end wrench Fig 39 Discard tension strut to cradle retaining nut A NEW tension strut to cradle nut must be used when installing tension strut 6 Loosen and remove lower control arm pivot bushing to cradle assembly pivot bolt Fig 40 7 Separate lower control arm and tension strut from the cradle...

Page 53: ...rning by holding tension strut at flat using an open end wrench Fig 39 CAUTION Pulling steering knuckle out from vehi cle after releasing from ball joint can separate inner C V joint See Driveshafts Fig 39 Tension Strut To Cradle Mounting 1 NUT 2 WASHER 3 TENSION STRUT 4 CRADLE ASSEMBLY 5 ISOLATOR BUSHING 6 FLAT Fig 40 Lower Control Arm Pivot Bolt 1 CRADLE ASSEMBLY 2 PIVOT BOLT 3 LOWER CONTROL ARM...

Page 54: ... 1 Remove the 4 strut assembly upper mount to strut tower mounting nut and washer assemblies securing the right front strut in place Fig 43 2 Raise vehicle on jack stands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 3 Remove right front wheel and tire assembly from th...

Page 55: ...attaching bolts Fig 48 9 Remove right front strut assembly from vehi cle 10 Remove the nine bolts securing the structural collar to the engine oil pan and transaxle Fig 49 11 Remove the 4 nuts attaching the engine motor mounts to the cradle assembly Fig 50 Fig 46 Removing Outer Tie Rod From Steering Arm 1 TIE ROD END 2 STEERING ARM 3 STRUT 4 C 3894A Fig 47 Speed Sensor Cable Routing Bracket 1 STRU...

Page 56: ... thus stretching halfshaft and possibly separating inner C V joint See Driveshafts Keep knuckle in upright position INSTALLATION 1 Install stabilizer bar by reversing the manner in which it was removed Fig 53 Rotate the bar the opposite direction used when removed and move it into mounting position CAUTION Be careful not to pull knuckle outward thus stretching halfshaft and possibly separating inn...

Page 57: ...radle assembly attaching bolts to 61 N m 45 ft lbs Fig 51 8 Install left side stabilizer bar attaching link to left end of stabilizer bar Fig 45 Install attaching nut and tighten to 95 N m 70 ft lbs 9 Install right front strut assembly into shock tower Install the 4 strut assembly upper mount to shock tower attaching nuts Fig 43 Tighten the 4 strut mount to strut tower attaching nuts to a torque o...

Page 58: ... bushings 4 Inspect for broken or distorted retainers and bushings If bushing replacement is required the bushing can be removed by opening the slit in the bushing and removing the bushing from around sta bilizer bar The stabilizer bar to cradle assembly bushings must be positioned on the stabilizer bar so the slit in the bushing is positioned toward front of vehicle Fig 56 INSTALLATION 1 Install ...

Page 59: ...nce section of this manual for the required lifting procedure to be used for this vehicle 2 Remove the 2 guide pin bolts mounting the cal iper assembly to the steering knuckle Fig 58 Remove the caliper from the front steering knuckle Refer to Disc Brake Caliper in the Removal And Installation Section in the Brake Group of this ser vice manual for the caliper removal procedure 3 Remove rotor from h...

Page 60: ...sembled Refer to REMOVAL AND INSTALLATION in this section for the required procedure For the disassembly and assembly of the strut assembly use strut spring compressor Pentastar Ser vice Equipment PSE tool W 7200 or the equivalent to compress the coil spring Follow the manufactur er s instructions closely DISASSEMBLY 1 If both struts are being serviced at the same time mark the coil spring and str...

Page 61: ...uilt into the seat and upper isolator 7 Remove the seat and bearing upper spring iso lator and dust shield as an assembly from the top of the coil spring by pulling them straight up They can be separated once removed from the vehicle The jounce bumper cup may also come off when the assembly is removed Check inside the dust shield NOTE Before releasing the tension on the coil spring note the positi...

Page 62: ...st shield attached on top of the coil spring Position the step built into the seat and upper spring isolator against the coil end of the coil spring 4 Install the lower spring isolator on the lower spring seat of the strut Fig 65 The tabs on the iso lator will align it on the strut spring seat They straddle the expanded area of the lower spring seat on the strut 5 Install the jounce bumper on the ...

Page 63: ...mount and seat and bearing align properly Verify the upper mount does not bind 11 Remove the clamp from the lower end of the coil spring and strut Push back the spring compres sor upper and lower hooks then remove the strut assembly from the spring compressor 12 Install the strut assembly on the vehicle Refer to REMOVAL AND INSTALLATION in this section for the required procedure LOWER CONTROL ARM ...

Page 64: ...rol arm With an open end wrench on flat of tension strut to stop tension strut from turning Tighten the NEW tension strut to lower control retaining nut to a torque of 130 N m 95 ft lbs 5 Install lower control arm and tension strut as an assembly back on the vehicle See Lower Control Arm Installation in this section of the service manual for the required installation procedure LOWER CONTROL ARM TE...

Page 65: ...red on Receiver Special Tool MB 990799 Fig 73 Position Installer Special Tool 6644 3 with previously installed bushing inside of tension strut bushing hole in lower control arm Fig 73 Position Installer Special Tool 6644 2 on top of tension strut bushing Fig 73 Using the arbor press press the tension strut bushing into the lower control arm As the bushing is being pressed into the control arm a po...

Page 66: ...trut removal and installation procedure ASSEMBLY 1 Position tension strut in lower control as shown in Fig 75 with word FRONT stamped in tension strut positioned away from control arm Fig 75 With an open end wrench on flat of tension strut to keep tension strut from turning Tighten NEW ten sion strut to lower control retaining nut to a torque of 130 N m 95 ft lbs Fig 73 Installing Tension Strut Bu...

Page 67: ...SION STRUT CRADLE BUSHING To remove tension strut to cradle bushings from vehicle for replacement the tension strut and lower control arm first MUST be removed as an assembly from the vehicle REMOVAL 1 Remove lower control arm and tension strut as an assembly from the vehicle See Lower Control Arm in the Removal and Installation section of this service manual for the required removal procedure 2 R...

Page 68: ...el and tire assembly 5 Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 129 N m 95 ft lbs 6 Lower the vehicle to the ground so the suspen sion is supporting the full weight of the vehicle con trol arm at design height Tighten the lower control arm pivot bushing attaching bolt...

Page 69: ...Bolts 110 N m 80 ft lbs Front Stub Axle Nut 183 N m 135 ft lbs Wheel Mounting Nuts 109 150 N m 80 110 ft lbs FRONT SUSPENSION CRADLE Body Attaching Bolts 163 N m 120 ft lbs Lower Control Arm Pivot Bolt 142 N m 105 ft lbs Tension Strut Mounting Nut 130 N m 95 ft lbs STABILIZER BAR Bushing Retainer Bolts 61 N m 45 ft lbs Attaching Link Lower Nut 88 N m 65 ft lbs SPECIAL TOOLS FRONT SUSPENSION Fig 82...

Page 70: ...Installer Ball Joint MB 990800 Remover C 4150A LH SUSPENSION 2 43 SPECIAL TOOLS Continued ...

Page 71: ...the control of the vehicle Each side of the suspension is allowed to move inde pendently from the other STRUT ASSEMBLY REAR DESCRIPTION The rear strut assemblies support the weight of the vehicle using coil springs positioned around the struts Fig 1 The coil springs are contained between the upper mount of the strut assembly and a lower spring seat on the body of the strut assembly The top of each...

Page 72: ...es up and down with the tire and wheel under jounce and rebound conditions The lat eral links control lateral movement of the spindle while the trailing arm controls fore and aft move ment The spindle acts as a mount for the rear hub and bearing tire and wheel and rear brakes HUB AND BEARING REAR DESCRIPTION The rear wheel bearing and rear wheel hub of this vehicle are a one piece sealed unit or h...

Page 73: ...taches to the rear spindle through a bracket which is bolted to the bottom of the spindle The trailing arm attaches to the body using a bracket attached to the frame rail and rear torque box The trailing arm has rubber isolator bushings at each end to isolate suspension noise from the body of the vehicle OPERATION The purpose of the trailing arm is to control the fore and aft movement of the spind...

Page 74: ... hub and bearing assembly is designed for the life of the vehicle 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...

Page 75: ... be used for this vehicle 3 Remove both upper quarter trim panels from the rear of the vehicle interior Refer to Body Compo nents in the Body section of this manual for the required procedure to be used for this vehicle 4 Remove both lower quarter trim panels from the rear of the vehicle interior Refer to Body Compo nents in the Body section of this manual for the required procedure to be used for...

Page 76: ...RUT 3 WIRE HANGER 4 CALIPER ASSEMBLY Fig 5 Wheel Speed Sensor At Adapter 1 STABILIZER BAR LINK 2 STABILIZER BAR 3 LATERAL LINK 4 BOLT 5 WHEEL SPEED SENSOR 6 STRUT ASSEMBLY 7 NUT Fig 6 Lateral Links To Spindle Attachment 1 SPINDLE 2 LATERAL LINKS 3 LATERAL LINK ATTACHING BOLT HEAD 4 STRUT ASSEMBLY 5 STABILIZER BAR ATTACHING LINK 6 BRAKE CALIPER 7 LATERAL LINK ATTACHING BOLT NUT Fig 7 Link Attachmen...

Page 77: ...ve strut assembly from vehicle 19 Remove the nut washers and rubber isola tors securing the stabilizer bar attaching link to the strut 20 For disassembly and assembly of the strut assembly refer to DISASSEMBLY AND ASSEMBLY in this section of this service manual group Fig 8 Spindle To Strut Assembly Pinch Bolt 1 PINCH BOLT 2 STRUT ASSEMBLY 3 REAR SPINDLE Fig 9 Center Punch Installed In Spindle 1 LA...

Page 78: ...n rear caliper assembly to adapter mounting bolts to 22 N m 192 in lbs 9 Install wheel and tire assembly on vehicle Then torque all wheel mounting stud nuts in proper sequence until all nuts are torqued to half specifica tion Then repeat tightening sequence to full speci fied torque of 129 N m 95 ft lbs 10 Lower vehicle to the ground 11 With the weight of the vehicle on the tires tighten lateral l...

Page 79: ... arm to the bracket on the bottom of the spindle Fig 17 9 Remove the bolt Fig 18 attaching the lateral links to the spindle Fig 13 Storing Caliper 1 FLEX HOSE 2 STRUT 3 WIRE HANGER 4 CALIPER ASSEMBLY Fig 14 Hub And Bearing Retaining Nut and Washer 1 HUB RETAINING NUT 2 NUT RETAINER 3 COTTER PIN 4 SPINDLE Fig 15 Speed Sensor Head 1 STABILIZER BAR LINK 2 STABILIZER BAR 3 LATERAL LINK 4 BOLT 5 WHEEL ...

Page 80: ...ndle on the strut assembly Push and or tap spindle assembly onto strut until notch in spindle is tightly seated against locating tap on strut assembly Fig 19 Then remove center punch from hole in spindle Install the pinch bolt in the spindle Fig 19 Tighten the pinch bolt to a torque of 53 N m 40 ft lbs Fig 17 Trailing Arm To Bracket Bolt 1 SPINDLE 2 TRAILING ARM BRACKET 3 TRAILING ARM 4 BOLT Fig 1...

Page 81: ...ing stud nuts in proper sequence until all nuts are torqued to half specifica tion Then repeat the tightening sequence to the full specified torque of 129 N m 95 ft lbs 10 Lower vehicle to the ground 11 Tighten the lateral links to spindle attaching bolt to a torque of 135 N m 100 ft lbs 12 Tighten the trailing arm to spindle bracket attaching bolt to a torque of 100 N m 75 ft lbs 13 Check and res...

Page 82: ...teral link service procedure LEFT FORWARD LATERAL LINK REMOVE 1 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 2 Remove left rear wheel and tire assembly from the vehicle 3 Remove the nut and bolt attaching the left lat eral links to the spin...

Page 83: ...th stabilizer bar isolator bushing retainers to the frame rails the 2 rearward attaching bolts attach the front corners of the rear suspension crossmember in place Tighten the forward stabilizer bar isolator bushing retainer attaching bolts to 40 N m 30 ft lbs Tighten the 2 rearward stabilizer bar isolator bushing retainer attaching bolts which also serve as the front cross member attaching bolts ...

Page 84: ...g to premature failure of the lateral link bushings 3 Install the lateral links on the spindle Install but DO NOT fully tighten the attaching bolt and nut at this time Fig 26 4 Install rear wheel and tire assembly on vehicle 5 Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of ...

Page 85: ...normal riding height Tighten the attaching bolt and nut to a torque of 100 N m 75 ft lbs This bolt cannot be tightened once mounted on the vehicle 2 Position the trailing arm and forward mount ing bracket into the vehicle Attach to frame rail and torque box with the 4 attaching bolts Fig 29 Tighten the attaching bolts to 60 N m 45 ft lbs 3 Install bolt attaching trailing arm to trailing arm bracke...

Page 86: ...bar from the vehicle 5 Mount the stabilizer bar in a soft jawed vise with one of the two bushings mount just above the vise jaws 6 Carefully pry back the retainer tabs on the wider end of the upper bushing retainer away from the lower half 7 Using a hammer and a brass drift punch tap the upper half of the bushing retainer assembly for ward off of the lower half and bushing Fig 33 8 Remove the lowe...

Page 87: ...ft lbs Tighten the 2 rearward stabilizer bar iso lator bushing retainer attaching bolts which also serve as the forward rear crossmember attaching bolts to 100 N m 75 ft lbs 8 Install the screw securing the brake tubes to the left stabilizer bar isolator bushing retainer Fig 32 9 Install both stabilizer bar attaching links onto stabilizer bar Fig 31 Install both stabilizer link to stabilizer bar a...

Page 88: ...l spring in an area of the spring covered by a sleeve If the sleeve moves when com pressing the spring the spring could come move resulting in personal injury CAUTION When installing the spring compressor s hooks on the coil spring do not position the hooks of the spring compressor on the sleeve of the coil spring Positioning the spring compressor on the sleeve could cause the sleeve to dislodge f...

Page 89: ...pring could come move resulting in personal injury CAUTION When installing the spring compressor s hooks on the coil spring do not position the hooks of the spring compressor on the sleeve of the coil spring Positioning the spring compressor on the sleeve could cause the sleeve to dislodge from the coil spring when it is compressed This would result in the required replacement of the coil spring 1...

Page 90: ...ounting Nuts 25 N m 19 ft lbs Spindle Pinch Bolt 53 N m 40 ft lbs Strut Shaft Nut 75 N m 55 ft lbs Stabilizer Bar Link Upper Attaching Nut 23 N m 17 ft lbs SPINDLE Brake Support Plate Mounting Bolts 109 N m 80 ft lbs Brake Hose Bracket Bolt 23 N m 17 ft lbs Caliper Adapter Spindle Bolts 115 N m 85 ft lbs Disc Brake Caliper Bolts 22 N m 16 ft lbs HUB AND BEARING Spindle Retaining Nut 168 N m 124 ft...

Page 91: ......

Page 92: ...design Fig 2 and allow for axial and angular movement to accommo date for shifting of powertrain and suspension com ponents The inner joints incorporate a female spline which install over the transaxle stub shafts The outer joints are of a constant velocity design Fig 2 and only offer angular flexibility The outer joints incorporate a male spline which connect to the wheel hub bearing The outer jo...

Page 93: ...CTING SHAFT 3 OUTER BOOT 4 RIGHT DRIVE SHAFT 5 TONE WHEEL WHEN EQUIPPED WITH ABS 6 INNER TRIPOD JOINT 7 INTERCONNECTING SHAFT 8 OUTER C V JOINT 9 INNER BOOT 10 LEFT DRIVE SHAFT 11 OUTER BOOT 3 2 DIFFERENTIAL AND DRIVELINE LH DESCRIPTION AND OPERATION Continued ...

Page 94: ...NEEDLE 8 CLAMP SEAL RETAINING 9 BUSHING TRILOBAL TRIPOD 10 SEAL DRIVE AXLE INBOARD 11 CLAMP SEAL RETAINING 12 SHAFT AXLE RH SHOWN LH SIMILAR 13 SEAL DRIVE AXLE OUTBOARD 14 CLAMP SEAL RETAINING 15 RING RACE RETAINING 16 BALL CHROME ALLOY 17 RACE C V JOINT INNER 18 CAGE C V JOINT 19 RACE C V JOINT OUTER LH DIFFERENTIAL AND DRIVELINE 3 3 DESCRIPTION AND OPERATION Continued ...

Page 95: ...blem could be a result of 1 A worn or damaged driveshaft inner tripod joint 2 A sticking tripod joint spider assembly inner tripod joint only 3 Improper wheel alignment See Wheel Align ment in this group for alignment checking and set ting procedures and specifications VIBRATION AT HIGHWAY SPEEDS This problem could be a result of 1 Foreign material mud etc packed on the backside of the wheel s 2 O...

Page 96: ...0 on hub and bearing assembly Fig 7 using wheel lug nuts to secure it in place Fig 4 Removing Braking Disc 1 HUB 2 STEERING KNUCKLE 3 BRAKING DISC ROTOR 4 WHEEL MOUNTING STUD Fig 5 Speed Sensor Cable Routing Bracket 1 STRUT ASSEMBLY 2 ROUTING BRACKET 3 SCREW 4 SPEED SENSOR CABLE Fig 6 Hub And Bearing To Stub Axle Retaining Nut 1 HUB BEARING ASSEMBLY 2 NUT Fig 7 Puller Installed On Hub Bearing Asse...

Page 97: ...he strut assembly CAUTION When removing outer C V joint from hub and bearing assembly do not allow the flinger disk Fig 11 on hub and bearing assembly to become damaged Damage to the flinger disk will cause dirt and water intrusion into bearing Premature bearing failure will result 12 Hold outer C V joint assembly with one hand Grasp steering knuckle with other and rotate it out and to the rear of...

Page 98: ...ent around spline of inner tripod joint Fig 14 where the O ring seats against tripod joint This will spread grease onto stub shaft during tripod joint installation pre venting corrosion and help to seal the O ring Fig 11 Outer C V Joint Removal From Hub and Bearing 1 STRUT ASSEMBLY 2 OUTER C V JOINT 3 HUB BEARING ASSEMBLY 4 FLINGER DISK 5 STEERING KNUCKLE Fig 12 Inner Tripod Joint Removal From Stu...

Page 99: ...become dam aged Damage to the flinger disk can cause dirt and water intrusion into bearing and premature bearing failure 5 Hold outer C V joint assembly with one hand Grasp steering knuckle with other hand and rotate it out and to the rear of the vehicle Install outer C V joint into the hub and bearing assembly Fig 16 6 Install the top of the steering knuckle into the strut assembly Align the stee...

Page 100: ...but do not torque the hub nut at this time 9 Install speed sensor cable routing bracket on front strut assembly Install and securely tighten routing bracket screw 10 Install the braking disk on the hub and bear ing assembly Fig 19 Fig 17 Strut Assembly to Steering Knuckle Attaching Bolts 1 STRUT ASSEMBLY 2 NUTS 3 STRUT ASSEMBLY TO STEERING KNUCKLE ATTACHING BOLTS 4 STEERING KNUCKLE Fig 18 Hub And ...

Page 101: ...ed torque of 129 N m 95 ft lbs 13 Lower vehicle to the ground CAUTION When tightening hub and bearing assembly to stub shaft retaining nut do not exceed the maximum torque of 150 N m 105 ft lbs If the maximum torque is exceeded this may result in a failure of the driveshaft 14 Apply the vehicle s brakes to keep vehicle from moving Tighten the NEW stub shaft to hub and bearing assembly retaining nu...

Page 102: ...ON When removing the spider joint from the tripod joint housing Hold the rollers in place on the spider trunions to prevent the rollers and needle bearings from falling away 3 Slide the interconnecting shaft and spider assembly out of the tripod joint housing Fig 24 4 Remove snap ring which retains spider assem bly to interconnecting shaft Fig 25 Then remove the spider assembly from interconnectin...

Page 103: ...DO NOT USE ANY OTHER TYPE OF GREASE into tripod housing Put the remaining amount into the sealing boot 5 Slide the spider assembly and the interconnect ing shaft into the tripod joint housing Fig 28 6 Install inner tripod joint seal boot to intercon necting shaft clamp evenly on sealing boot 7 Clamp sealing boot onto interconnecting shaft using Crimper Special Tool C 4975 and the following procedu...

Page 104: ...le See Driveshaft Removal and Installation in this section of the service manual for the required drive shaft installation procedure Fig 28 Spider Assembly Installed In Housing 1 INTERCONNECTING SHAFT 2 SPIDER ASSEMBLY 3 TRIPOD JOINT HOUSING Fig 29 Crimping Tool Installed On Sealing Boot Clamp 1 SPECIAL TOOL C 4975 2 SEALING BOOT CLAMP 3 INTERCONNECTING SHAFT 4 SEALING BOOT Fig 30 Sealing Boot Ret...

Page 105: ...snap ring Fig 33 Slide outer C V joint assembly off end of interconnecting shaft 4 Slide failed sealing boot off interconnecting shaft 5 Thoroughly clean and inspect outer C V joint assembly and interconnecting joint for any signs of excessive wear If any parts show signs of exces sive wear the driveshaft assembly will require replacement Component parts of the driveshaft assemblies are not servic...

Page 106: ... way If seal is NOT shaped cor rectly equalize pressure in seal and shape it by hand 6 Position outer C V joint seal boot into boot retaining groove on outer C V joint housing Install seal boot to outer C V joint retaining clamp evenly on sealing boot Fig 34 Outer C V Joint Installed On Interconnecting Shaft 1 INTERCONNECTING SHAFT 2 RETAINING SNAP RING 3 OUTER C V JOINT ASSEMBLY Fig 35 Seal Boot ...

Page 107: ...driveshaft installation procedure SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION TORQUE Caliper To Knuckle Bolts 19 N m 168 in lbs Driveshaft Nut 150 N m 105 ft lbs Front Wheel Lug Nuts 135 N m 100 ft lbs Knuckle To Strut Bolt Nuts 169 N m 125 ft lbs Tie Rod End To Knuckle 61 N m 45 ft lbs SPECIAL TOOLS DRIVESHAFT Fig 38 Crimping Tool Installed On Sealing Boot Clamp 1 SPECIAL TOOL C 4975 2 SEALI...

Page 108: ...RAKE ROTOR MACHINING 23 REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS 25 BRAKE PEDAL 25 MASTER CYLINDER 26 POWER BRAKE BOOSTER 27 BRAKE TUBES AND HOSES 29 JUNCTION BLOCK 29 PROPORTIONING VALVE 30 DISC BRAKE CALIPER FRONT 30 DISC BRAKE SHOES FRONT 32 DISC BRAKE CALIPER REAR 33 DISC BRAKE SHOES REAR 35 PARKING BRAKE LEVER PEDAL AND FRONT CABLE ASSEMBLY 38 PARKING BRAKE CABLE INTERMEDIATE 41...

Page 109: ...es vacuum to ease pedal effort as force is transferred through the booster to the master cyl inder The booster s output rod pushes in the master cylinder s primary and secondary pistons applying hydraulic pressure through the chassis brake tubes junction block and proportioning valves to the brakes at each tire and wheel assembly The pedal operated parking brake operates in the following manner Wh...

Page 110: ...oster body A vacuum line connects the booster check valve to the intake manifold Depend ing on the engine combination different vacuum hose routings are required The power brake booster can be identified by the tag attached to the body of the booster assembly Fig 4 This tag contains the following information the production part number the date it was built who manufactured it NOTE The power brake ...

Page 111: ...d the front fascia The junction block mounts in the same location as the ABS integrated control unit ICU does on vehicles with ABS It has six threaded ports to which the brake tubes connect Two are for the brake tubes coming from the master cylinder The remaining four are for the brake tubes going to each brake assembly OPERATION The junction block distributes the brake fluid com ing from the mast...

Page 112: ...se no adapter The cal iper is mounted to the steering knuckle using bush ings sleeves and 2 thru bolts which thread directly into the steering knuckle Fig 9 The caliper is a one piece casting with the inboard side containing a single piston cylinder bore The front disc brake caliper phenolic piston is 60 mm 2 36 inch in diameter Fig 5 Brake Tube Nut Thread Sizes And Tube Routing 1 HOSE END RT FRON...

Page 113: ... assemblies to help pull the front disc brake shoes away from the rotor when the brakes are released Fig 7 Vehicles equipped with the performance disc brake package BR5 do not have retractor clips Fig 8 Although there are different disc brake systems available they operate and are serviced in the same manner A square cut rubber piston seal is located in a machined groove in the cylinder bore This ...

Page 114: ...BUSHING 14 SLEEVE 15 CALIPER GUIDE PIN BOLT 16 CAP 17 BLEEDER SCREW Fig 9 Disc Brake Caliper Mounting 1 BRAKE LINE 2 CALIPER GUIDE PIN BOLTS 3 STEERING KNUCKLE 4 BLEEDER SCREW 5 CALIPER ASSEMBLY Fig 10 Piston Seal Function for Automatic Adjustment Of Front Brakes 1 PISTON 2 CYLINDER BORE 3 PISTON SEAL BRAKE PRESSURE OFF 4 CALIPER HOUSING 5 DUST BOOT 6 PISTON SEAL BRAKE PRESSURE ON LH BRAKES 5 7 DE...

Page 115: ... infor mation When the parking brake is applied the parking brake shoes expand out against a braking surface hat section on the inside area of the rear disc brake rotor PARKING BRAKE DESCRIPTION The parking brake mechanism on vehicles equipped with rear disc brakes consists of a small duo servo brake which is mounted to the disc brake caliper adapter The hat center section Fig 12 of the rear rotor...

Page 116: ...EMBLY 2 HUB BEARING ASSEMBLY 3 NUT 4 NUT LOCK 5 DUST CAP 6 DISC 7 COTTER PIN 8 ANTI RATTLE WASHER 9 WASHER 10 ADAPTER 11 DISC SHIELD 12 ADJUSTER 13 RETURN SPRINGS Fig 12 Drum In Hat Braking Disc 1 REAR BRAKING DISK ROTOR 2 HAT SECTION OF REAR BRAKING DISC PARKING BRAKE BRAKING SURFACE Fig 13 Brake Lamp Switch 1 STEERING COLUMN COUPLER 2 BRAKE PEDAL 3 SWITCH LH BRAKES 5 9 DESCRIPTION AND OPERATION ...

Page 117: ...g lamp is turned on as a bulb check by the ignition switch when the ignition switch is placed in the crank posi tion OPERATION The red BRAKE warning lamp is supplied 12 volt ignition feed anytime the ignition switch is on The lamp is then illuminated by completing the ground circuit either through the parking brake warning switch mounted on the parking brake lever the brake fluid level switch moun...

Page 118: ...s out replace switch 5 Mechanical instrument cluster MIC problem 5 Refer to Chassis Diagnostic Procedures manual BRAKE NOISE CONDITION POSSIBLE CAUSES CORRECTION DISC BRAKE CHIRP 1 Excessive brake rotor runout 1 Follow brake rotor diagnosis and testing Correct as necessary 2 Lack of lubricant on brake caliper slides 2 Lubricate brake caliper slides DISC BRAKE RATTLE OR CLUNK 1 Broken or missing an...

Page 119: ...er Brake Booster in the diagnosis and testing section EXCESSIVE PEDAL EFFORT 1 Obstruction of brake pedal 1 Inspect remove or move obstruction 2 Low power brake booster assist 2 Refer to power brake booster in the diagnosis and testing section 3 Glazed brake linings 3 Reface or replace brake rotors as necessary Replace brake shoes 4 Brake shoe lining transfer to brake rotor 4 Reface or replace bra...

Page 120: ...l or brake caliper 5 Suspension problem 5 Refer to the Suspension group PARKING BRAKE EXCESSIVE LEVER TRAVEL 1 Rear parking brake shoes out of adjustment 1 Adjust rear parking brake shoes POWER BRAKE BOOSTER BASIC TEST 1 With engine off depress and release the brake pedal several times to purge all vacuum from the power brake booster 2 Depress and hold the pedal with light effort 15 to 25 lbs pres...

Page 121: ...ES CAUTION Not all components use the same type tubing flare The tube leading into the proportioning valve has an ISO flare while the flex hose coming out of the proportioning valve has a standard dou ble inverted flare Use the correct adapters when installing gauges to test proportioning valves Both vehicles with Antilock Brakes and without Antilock Brakes have two proportioning valves One valve ...

Page 122: ...ace the proportioning valve If proportioning valve is within pressure specifications do not replace proportioning valve 10 Remove the pressure gauges from the pres sure test fittings 11 Remove the proportioning valve and the Pres sure Test Fittings Special Tool 6892 2 and 8187 2 from the chassis brake tube and rear flex hose Remove the pressure test fittings from the propor tioning valve Fig 16 12...

Page 123: ... rotor thickness at the center of the brake shoe contact surface Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications CAUTION Do not machine the rotor if it will cause the rotor to fall below minimum thickness Minimum thickness specifications are cast on the rotor s unmachined surface Fig 18 Limits can also be found...

Page 124: ...tem so it contacts the hub face near the outer diameter Care must be taken to position stem outside of the stud circle but inside of the chamfer on the hub rim Fig 22 Hub runout should not exceed 0 03 mm 0 0012 inch If runout exceeds this specification the hub must be replaced Refer to the SUSPENSION group in this service manual for the hub and bearing removal and installation procedure If the hub...

Page 125: ...If fluid sepa rates into layers there is mineral oil or other fluid contamination of the brake fluid If brake fluid is contaminated drain and thor oughly flush system Replace master cylinder propor tioning valve caliper seals wheel cylinder seals Antilock Brakes hydraulic unit and all hydraulic fluid hoses BRAKE LAMP SWITCH NOTE Before proceeding with this diagnostic test verify the adjustment of ...

Page 126: ...Fig 26 In the event of low brake fluid level in the brake fluid reservoir the RED brake warning light in the instrument panel will turn on Master cylinder fluid reservoirs on both standard and antilock brake systems are marked with a FULL fill line indicating the fluid reservoirs proper fluid level Fig 26 NOTE When filling brake fluid reservoir use only MoparT brake fluid or an equivalent stored i...

Page 127: ...rubber dust caps from all 4 bleeder screws 2 Attach a clear hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid Fig 29 CAUTION Just cracking the bleeder screw often restricts fluid flow and a slow weak fluid discharge will NOT get all the air out 3 Open bleeder screw Fig 29 on caliper assem bly or wheel cylinder at least one full turn or more to o...

Page 128: ...ylinder in a vise Fig 30 NOTE The master cylinder on this vehicle uses ISO style flares and metric threads on the master cylinder outlet ports Special Tool Packages 8129 and 8305 have ISO style flares and metric threads on their bleeding tubes 2 Position the appropriate bleeding tools from packages Special Tool 8129 and 8305 on the master cylinder Place open ends in the fluid reservoir Then attach...

Page 129: ...ivalent cut off damaged seat on tubing Fig 32 Ream out any burrs or rough edges showing on inside of tubing This will make the ends of tubing square Fig 33 and ensure better seating of flared end tubing Be sure to put the tube nut on tub ing before the tubing is flared CAUTION All ISO style tubing flares are of metric dimensions When performing any service proce dures on a vehicle using ISO style ...

Page 130: ...metric ISO tubing flare BRAKE ROTOR MACHINING BRAKE ROTOR MACHINING NOTE Refacing of the rotor is not required each time the brake pads are replaced Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action If the rotor surface is deeply scored or warped or there is a complaint of brake roughness or brake pedal pulsation the roto...

Page 131: ...on of rotor turning equipment is required BRAKE ROTOR REFINISHING LIMITS Braking Rotor Rotor Thickness Minimum Rotor Thickness Rotor Thickness Variation Rotor Run Out Rotor Micro Finish Front Rotor 25 87 26 13 mm 1 019 1 029 in 24 4 mm 960 in 013 mm 0005 in 08 mm 003 in 15 80 RMS Rear Rotor 11 63 12 13 mm 458 478 in 10 4 mm 409 in 013 mm 0005 in 08 mm 003 in 15 80 RMS TIR Total Indicator Reading M...

Page 132: ...ce procedures grease or any other foreign material must be kept off the cal iper assembly surfaces of the brake rotor and external surfaces of the hub Avoid deformation scratching or nicking of the brake rotor and brake shoe linings CAUTION When handling the brake rotor and cali per be careful to avoid damaging the rotor and cal iper and scratching or nicking the brake shoe lining BRAKE PEDAL REMO...

Page 133: ...tch in the brake pedal bracket Fig 38 Install it using the following procedure Depress the brake pedal as far down as possible Then while holding brake pedal down align the index key on switch with notch in square hole of mounting bracket When the switch is fully installed into the bracket rotate the switch in a clockwise direction approximately 30 degrees until it locks into place CAUTION Do not ...

Page 134: ...vots 4 Remove the wiper module cover and cowl cover Fig 43 from the vehicle 5 Remove the 8 bolts attaching the reinforce ment Fig 44 to the strut towers and the 1 bolt Fig 44 attaching the wiper module to the reinforcement Remove the reinforcement from the vehicle 6 Disconnect the wire connector from the brake fluid level sensor on the right side of the master cyl inder reservoir 7 Remove the 2 nu...

Page 135: ...m 250 in lbs torque 3 Using lubriplate or equivalent coat the bear ing surface of brake pedal pin 4 Connect vacuum booster input rod to brake pedal pin and install a NEW retainer clip Use only a new retainer clip DO NOT USE the old clip NOTE Before installing master cylinder reposition under hood wiring harness above master cylinder mounting studs Fig 46 in front of booster Fig 44 Reinforcement At...

Page 136: ...et to the vehicle frame to minimize hose twisting Then hand start the steel brake tube fitting into the hose end fitting Tighten all attachment screws and tube fittings to specified torque The frame bracket is keyed so that it will only fit one way Vehicles equipped with rear disc brakes have brake flex hoses attached to the brake caliper on each side of vehicle The brake flex hose should be first...

Page 137: ... a bracket mounted on the back side of the crossmember INSTALL 1 Install the proportioning valve to the rear brake flex hose Tighten to a torque of 17 N m 145 in lbs 2 Install the chassis brake tube to the propor tioning valve Fig 49 Tighten the tube nut to a torque of 17 N m 145 in lbs 3 Bleed the affected brake line See Bleeding Brake System in the Service Adjustments section of the manual for p...

Page 138: ...required removal procedure Fig 51 4 Install the banjo bolt connecting the flex hose to the caliper One washer should be installed on each side of the flex hose fitting before installing the banjo bolt Tighten banjo bolt to a torque of 48 N m 35 ft lbs CAUTION When being installed extreme caution should be taken not to crossthread the caliper guide pin bolts 5 Install the caliper guide pin bolts Ti...

Page 139: ...TION Check for piston seal leaks brake fluid in and around boot area and inboard lining and for any ruptures of the piston dust boot If boot is damaged or fluid leak is visible disassemble caliper assembly and install a new seal and boot and piston if scored Refer to procedures titled Disc Brake Caliper Disassembly Check the caliper dust boot and caliper pin bush ings to determine if they are in g...

Page 140: ...d Installation found else where in this section of this service manual CAUTION Before vehicle is moved after performing a service procedure on the vehicle brake system pump the brake pedal several times to insure the vehicle has a firm brake pedal that is to adequate to stop the vehicle 8 Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the br...

Page 141: ...CTOR CLIP 12 BRAKE SHOE 13 ANTI RATTLE CLIP 14 BUSHING 15 SLEEVE 16 CALIPER GUIDE PIN BOLT 17 RETRACTOR CLIP Fig 59 Removing Caliper Guide Pin Bolts 1 CALIPER ASSEMBLY 2 ADAPTER 3 CALIPER ASSEMBLY ATTACHING BOLT 4 CALIPER ASSEMBLY ATTACHING BOLT Fig 60 Removing Installing Caliper Assembly 1 ADAPTER 2 BRAKING DISC 3 CALIPER ASSEMBLY 4 ADAPTER ABUTMENT 5 34 BRAKES LH REMOVAL AND INSTALLATION Continu...

Page 142: ...6 Install the wheel and tire assembly 7 Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 129 N m 95 ft lbs 8 Remove jackstands or lower hoist CAUTION Before moving vehicle pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehic...

Page 143: ...iston seal leaks brake fluid in and around boot area and inboard lining and for any ruptures of the piston dust boot If boot is damaged or fluid leak is visible disassemble caliper assembly and install a new seal and boot and piston if scored Refer to procedures titled Disc Brake Caliper Disassembly Check the caliper dust boot and caliper pin bush ings to determine if they are in good condition Re...

Page 144: ...ION Use care when installing the caliper assembly onto the adapter so the caliper guide pin bushings do not get damaged by the mounting bosses 7 Carefully lower caliper and brake shoes over rotor and onto adapter reversing the removal proce dure Fig 64 CAUTION When installing the caliper guide pin bolts extreme caution should be taken not to cross thread the guide pin bolts 8 Install the caliper g...

Page 145: ...ation and Maintenance group of this service manual for the required lifting procedure for this vehicle 3 Loosen the park brake tensioner adjuster nut in front of the rear crossmember until tension is removed from cables 4 Disconnect the cable connector between the front and intermediate cable 5 Lower the vehicle to the ground 6 Remove the driver s door opening sill cover 7 Remove the driver s side...

Page 146: ...lock upper edge to the instrument panel bracket These screws are installed from above the right side of the fuse junction block and mount to the left 17 Remove the dome lamp wiring harness con nector from the fuse junction block Fig 75 18 Move fuse junction block as far down and to the right as possible without causing damage to the harness or fuse junction block 19 Remove left rear door opening s...

Page 147: ... through access hole in lever assembly onto switch 3 Position the lever assembly in its mounting place Install the rear mounting bolt and tighten it to a torque of 27 N m 19 ft lbs Tighten the 2 mount ing nuts to a torque of 27 N m 19 ft lbs 4 Ensure that the park brake cable is properly routed and install the two routing bracket screws 5 Install the 2 screws securing the front park brake cable re...

Page 148: ... the rear park brake cable It should also be routed below the brake tubes at this point 2 Install the intermediate cable to the tensioner bracket by snapping it into place 3 Reinstall retainer clip on top of left side of crossmember around intermediate cable and into place 4 Connect the intermediate cable to the right rear cable connector 5 Install the intermediate cable through the hole in the bo...

Page 149: ... the rear suspension crossmember mounting hole 11 Install a new retainer clip on the end of the cable housing to secure it in place 12 Left rear cable only Connect the left rear park brake cable to the connector on the park brake cable tensioner 13 Right rear cable only Connect the right rear park brake cable to the connector on the inter mediate park brake cable 14 When repairs are complete adjus...

Page 150: ...r hub bearing assembly retaining nut and washer from the rear spindle 5 Remove rear hub and bearing assembly from rear spindle 6 Remove rear brake shoe assembly hold down clip 7 Turn brake shoe adjuster wheel until adjuster is at shortest length 8 Remove adjuster assembly from the parking brake shoe assemblies 9 Remove lower shoe to shoe spring 10 Pull rear brake shoe assembly away from anchor The...

Page 151: ...CAUTION Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch If to much force is used damage to the brake lamp switch or striker can result 4 Gently pull back on brake pedal until the pedal stops moving This will cause the switch plunger to ratchet backward to the correct position 5 Check for proper operation of the brake lamps and speed control DISASSEMB...

Page 152: ...aliper uses a sealed for life bush ing and sleeve assembly If required this assembly can be serviced using the following procedure REMOVING CALIPER GUIDE PIN BUSHINGS 1 Remove caliper from brake rotor See Brake Shoe Removal Hang caliper assembly on a wire hook away from the brake rotor 2 Push out and then pull the steel sleeve from the inside of the bushing using your fingers as shown in Fig 86 3 ...

Page 153: ...d of bushing did not come out of seal grove in sleeve 8 When the sleeve is seated properly into the bushing the sealed for life sleeve bushing can be held between your fingers and easily slid back and Fig 86 Removing Inner Sleeve From Bushing 1 CALIPER 2 SLEEVE 3 BUSHING Fig 87 Removing Bushing From Caliper 1 CALIPER 2 BUSHING Fig 88 Folded Caliper Guide Pin Bushing 1 CALIPER GUIDE PIN BUSHING Fig...

Page 154: ...ent loss of brake fluid from the master cylinder 3 If both front caliper pistons are to be removed disconnect brake tube at flexible brake hose at frame rail Plug brake tube and remove piston from oppo site caliper using the same process as above for the first piston removal 4 Disconnect the brake fluid flex hose from the caliper assembly CAUTION Do not use excessive force when clamp ing caliper i...

Page 155: ...t 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 cleared of the light scratches or corrosion using crocus cloth Bores that have deep scratches or scoring should be honed...

Page 156: ...groove Fig 96 using only your fingers until properly seated NEVER USE AN OLD PISTON SEAL Be sure that fingers are clean and seal is not twisted or rolled Fig 96 3 Coat new piston boot with clean brake fluid leaving a generous amount inside boot 4 Position dust boot over piston after coating with brake fluid CAUTION Force must be applied to the piston uni formly to avoid cocking and binding of the ...

Page 157: ...f the service manual for the required procedure The combined brake shoe and lining material thickness should be measured at the thinnest part of the assembly When a set of brake shoes are worn to a total thickness of approximately 6 5 mm 1 4 inch they should be replaced Replace both brake shoe assemblies inboard and outboard It is necessary that both front wheel sets be replaced whenever brake sho...

Page 158: ...ervice manual ADJUSTMENTS PARKING BRAKE NOTE Tensioner adjustment is only necessary when the tensioner or a cable has been replaced or disconnected for service When adjustment is nec essary perform adjustment only as described in the following procedure This is necessary to avoid faulty park brake operation 1 Raise vehicle 2 Fully back off cable tensioner adjusting nut at equalizer to create slack...

Page 159: ...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 hydraulic system...

Page 160: ...lbs Bleeder Screw 15 N m 125 in lbs ABS INTEGRATED CONTROL UNIT ICU Mounting Bracket Bolts 11 N m 97 in lbs Mounting Bracket To Frame Bolts 26 N m 230 in lbs CAB To HCU Screws 2 N m 17 in lbs PARKING BRAKE Lever Assembly Mounting Bolts 28 N m 250 in lbs REAR HUB AND BEARING Spindle Retaining Nut 168 N m 124 ft lbs WHEEL Mounting Nut 110 135 N m 85 115 ft lbs SPECIAL TOOLS BASE BRAKE SYSTEM Adapter...

Page 161: ...Installer Dust Boot C 4689 Dial Indicator C 3339 5 54 BRAKES LH SPECIAL TOOLS Continued ...

Page 162: ...k 20i Antilock Brake System that may at first seem abnormal but in fact are normal These char acteristics are described below NORMAL BRAKING Under normal braking conditions the ABS func tions the same as a standard base brake system with a diagonally split master cylinder and conventional vacuum assist ABS BRAKING ABS operation is available at all vehicle speeds above 3 5 mph If a wheel locking te...

Page 163: ...mal function of ABS as the system is performing a diag nosis check PREMATURE ABS CYCLING Symptoms of premature ABS cycling include click ing sounds from the solenoid valves pump motor running and pulsations in the brake pedal Prema ture ABS cycling can occur at any braking rate of the vehicle and on any type of road surface Neither the red BRAKE warning lamp nor the amber ABS warn ing lamp illumin...

Page 164: ...system for proper operation Detect wheel locking or wheel slipping tenden cies by monitoring the speed of all four wheels of the vehicle Control fluid modulation to the wheel brakes while the system is in an ABS mode Store diagnostic information Provide communication to the DRB scan tool while in diagnostic mode Illuminate the amber ABS warning lamp with traction control only Illuminate the TRAC O...

Page 165: ... how the different com ponents within the HCU operate VALVES AND SOLENOIDS The valve block contains four inlet valves and four outlet valves The inlet valves are spring loaded in the open position and the outlet valves are spring loaded in the closed position during normal braking The fluid is allowed to flow from the master cylinder to the wheel brakes During an ABS stop these valves cycle to mai...

Page 166: ... CONTROL UNIT in the DISASSEMBLY AND ASSEMBLY sec tion in this section of this service manual group for the procedure to remove the CAB from the HCU AMBER ABS WARNING LAMP DESCRIPTION The amber ABS warning lamp is located on the left side of the instrument panel in the instrument clus ter The purpose of the warning lamp is discussed in detail below OPERATION When the ignition key is turned to the ...

Page 167: ...m wheel slip and maximum trac tion The cycling of the build and decay valves during traction control is similar to that during antilock braking except the valves work to control wheel spin by applying the brakes whereas the ABS function is to control wheel skid by releasing the brakes HYDRAULIC SHUTTLE VALVES Two hydraulic shuttle valves allow pressure and volume to return to the master cylinder r...

Page 168: ... brake hydraulic pressure as required The pump motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits The brake fluid is routed to either the master cylinder or the wheel brake depending on the posi tion of the normally open valve NORMAL BRAKING HYDRAULIC CIRCUIT SOLENOID VALVE AND SHUTTLE VALVE FUNCTION ABS WITH TRACTION CONTROL...

Page 169: ...cuits The brake fluid is routed to either the master cylinder or the wheel brake depending on the posi tion of the normally open valve ABS TRACTION CONTROL HYDRAULIC CIRCUIT SOLENOID VALVE AND SHUTTLE VALVE FUNCTION ABS WITH TRACTION CONTROL The hydraulic diagram Fig 10 shows the vehicle in the traction control TC mode The diagram shows a drive wheel is spinning and brake pressure is required to r...

Page 170: ... this section Power should never be removed or applied to any control module with the ignition in the ON position Before removing or connecting battery cables fuses or 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 b...

Page 171: ...ference the wiring diagrams covering the antilock brake sys tem and its components For wiring diagrams refer to GROUP 8W of this service manual It will provide you with the wiring diagrams and the circuit descrip tion and operation information covering the antilock brake system ABS VEHICLE TEST DRIVE Most ABS complaints will require a test drive to properly duplicate and diagnose the condition WAR...

Page 172: ...on and then back to the ON position Note whether the amber ABS warning lamp continues to stay on If it does refer to the diagnostic manual 2 If the amber ABS warning lamp goes out shift into gear and drive the car to a speed of 25 kph 15 mph to complete the ABS start up and drive off cycles see ABS ELECTRONIC DIAGNOSIS If at this time the amber ABS warning lamp comes on refer to the diagnostic man...

Page 173: ...correct operating range is verified ONGOING TESTS While the system is operating these tests are per formed on a continuous basis solenoid continuity wheel speed sensor continuity wheel speed sensor output system voltage CAB self diagnosis PCI communication circuit sending receiving messages DIAGNOSTIC TROUBLE CODES DTC s Diagnostic trouble codes DTC s are kept in the controller s memory until eith...

Page 174: ...sult in the illumination of the amber ABS warning lamp are as follows High system voltage If high system voltage is detected by the CAB the CAB will turn on the amber ABS warning lamp If the ignition key is cycled and normal voltage is again detected by the CAB normal ABS operation resumes and the lamp remains off Any condition that interrupts electrical current to the CAB may cause the amber ABS ...

Page 175: ...parately Use the following procedure to properly bleed the brake hydraulic system including the ABS BLEEDING When bleeding the ABS system the following bleeding sequence must be followed to insure com plete and adequate bleeding 1 Make sure all hydraulic fluid lines are installed and properly torqued 2 Connect the DRB scan tool to the diagnostics connector The diagnostic connector is located under...

Page 176: ...view SERVICE WARNINGS AND CAUTIONS at the beginning of the REMOVAL AND INSTALLATION section REMOVAL 1 Remove the remote ground cable from the ground stud on the right strut tower 2 Correctly isolate remote ground cable when ser vicing vehicle by installing the ground cable insulator on the strut tower ground stud as shown in Fig 12 and installing the nut on the stud This will pre vent accidental g...

Page 177: ...ve the splash shield out of the way 14 Remove the 3 bolts attaching the ICU to the mounting bracket 15 Remove the ICU from its mounting bracket Then remove the ICU from the vehicle by pulling it out around the left side of the mounting bracket then through the wheel well Fig 13 Brake Pedal Holding Tool Installed 1 CLUTCH PEDAL IF EQUIPPED WITH MANUAL TRANSAXLE 2 THROTTLE PEDAL 3 BRAKE PEDAL HOLDIN...

Page 178: ...ystem in this section of the manual for the proper bleeding procedure 14 Road test vehicle to ensure proper operation of the base and ABS systems WHEEL SPEED SENSOR FRONT REMOVAL 1 Raise vehicle on jack stands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 2 Remove the ...

Page 179: ...efer to Seats in the Body section of this manual for the required procedure to be used for this vehicle 2 Disconnect the wheel speed sensor cable from the wire harness 3 Raise vehicle on jack stands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 4 Remove the rear wheel ...

Page 180: ...e Refer INTE GRATED CONTROL UNIT in the REMOVAL AND INSTALLATION section in this section of the service manual 2 Disconnect the pump motor wiring harness Fig 20 from the CAB 3 Remove the 4 bolts Fig 21 attaching the CAB to the HCU 4 Remove the CAB from the HCU Fig 22 INSTALLATION 1 Install the CAB Fig 22 on the HCU 2 Install the 4 bolts mounting the CAB Fig 21 to the HCU Tighten the CAB mounting b...

Page 181: ...7 in Maximum Clearance 1 71 mm 0 067 in REAR WHEEL Minimum Clearance 0 38 mm 0 015 in Maximum Clearance 1 31 mm 0 052 in WHEEL SPEED SENSOR RESISTANCE FRONT AND REAR Allowable Resistance 900 1300 ohms BRAKE FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE BRAKE TUBES Tube Nuts 17 N m 145 in lbs ABS INTEGRATED CONTROL UNIT ICU Mounting Bracket Bolts 11 N m 97 in lbs CAB To HCU Screws 2 N m 17 in l...

Page 182: ...ves Both vehicles with Antilock Brakes and without Antilock Brakes have two proportioning valves One valve is connected to each rear flex hose One propor tioning valve controls the right rear brake and the other proportioning valve controls the left rear brake On vehicles without ABS if premature wheel skid occurs on a hard brake application it could be an indication that a malfunction has occurre...

Page 183: ...s done at the pressure gauge 9 With the aid of a helper apply pressure to the brake pedal until reading on proportioning valve inlet gauge is at the pressure shown on the following chart Then check the pressure reading on the pro portioning valve outlet gauge If proportioning valve outlet pressure does not agree with value shown on the following chart when inlet pressure shown on chart is obtained...

Page 184: ... OF BRAKE DUST IF A VACUUM CLEANER IS NOT AVAILABLE CLEAN BRAKE PARTS USING ONLY WATER DAMPENED SHOP TOWELS DO NOT CREATE BRAKE LINING DUST BY SANDING THE BRAKE LININGS WHEN SERVIC ING A VEHICLE DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USE ONLY SEALED AIRTIGHT BAGS OR CONTAIN ERS FOLLOW ALL RECOMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH AD...

Page 185: ...ng knuckle so seals on cal iper guide pin bushings do not get damaged by the steering knuckle bosses 1 Completely retract the caliper piston back into the piston bore of the caliper if new brake shoes have been installed 2 If removed install rotor on hub Fig 7 3 Carefully position caliper and brake shoe assemblies over rotor using the reversed required removal procedure Fig 5 4 Install the banjo b...

Page 186: ... the REMOVAL AND INSTALLATION section REMOVAL 1 Remove caliper as described in Front Disc Brake Caliper Removal and Installation found else where in this section of this service manual 2 Remove outboard brake shoe by prying the shoe retaining clip over raised area on caliper Then slide the brake shoe off the caliper Fig 8 3 Pull inboard brake shoe away from piston until retaining clip is free from...

Page 187: ...iper piston by firmly pressing it into bore of caliper piston with thumbs Fig 9 5 Slide the new outboard brake shoe assembly onto the caliper assembly Fig 11 6 Reinstall caliper as described in Front Disc Brake Caliper Removal and Installation found else where in this section of this service manual CAUTION Before vehicle is moved after performing a service procedure on the vehicle brake system pum...

Page 188: ... 22 N m 192 in lbs Bleeder Screw 15 N m 125 in lbs ABS INTEGRATED CONTROL UNIT ICU Mounting Bracket Bolts 11 N m 97 in lbs Mounting Bracket To Frame Bolts 26 N m 230 in lbs CAB To HCU Screws 2 N m 17 in lbs PARKING BRAKE Lever Assembly Mounting Bolts 28 N m 250 in lbs REAR HUB AND BEARING Spindle Retaining Nut 168 N m 124 ft lbs WHEEL Mounting Nut 110 135 N m 85 115 ft lbs SPECIAL TOOLS BASE BRAKE...

Page 189: ...Handle Universal C 4171 Installer Dust Boot C 4689 Dial Indicator C 3339 5 8 BRAKES LH SPECIAL TOOLS Continued 2000 LHS 300M CONCORDE AND INTREPID ...

Page 190: ...PROCEDURES COOLANT SERVICE 18 COOLANT LEVEL CHECK 18 COOLANT ADDING ADDITIONAL 18 COOLING SYSTEM DRAINING 19 COOLING SYSTEM FILLING 19 REMOVAL AND INSTALLATION WATER PUMP 2 7L 21 WATER PUMP 3 2 3 5L 22 WATER OUTLET CONNECTOR 2 7L 23 HEATER SUPPLY TUBE 2 7L 24 HEATER SUPPLY TUBE 3 2 3 5L 24 THERMOSTAT 2 7L 25 THERMOSTAT 3 2 3 5L 26 RADIATOR 26 RADIATOR DRAINCOCK 27 COOLING FAN MODULE 28 TRANSMISSIO...

Page 191: ...Engine is warm Thermostat is open cool ant flows through the radiator heater core coolant bottle and by pass The cooling systems primary purpose is to main tain engine temperature in a range that will provide satisfactory engine performance and emission levels under all expected driving conditions It also provides hot coolant for heater and cooling for automatic transmission fluid It does this by ...

Page 192: ...ormula is altered when necessary additives to control boiling freezing and corrosion are added as follows Pure Water 1 btu boils at 100 C 212 F and freezes at 0 C 32 F 100 Percent ethylene glycol 7 btu can cause an engine to run hot cause detonation and will freeze at 22 C 8 F 50 50 Ethylene Glycol and Distilled Water 82 btu is the recommended combination that provides a freeze point of 37 C 35 F ...

Page 193: ...timing chain The 3 2 3 5L water pump has a die cast aluminum housing and a plastic swept vane impeller The hous ing bolts directly to the right rear timing belt cover using a O ring gasket for pump to cover sealing Fig 5 The pump is driven by the engine timing belt OPERATION The water pump is the heart of the cooling system pumping the coolant through the engine block cylin der head heater core an...

Page 194: ... and power consump tion The cooling fans will operate based on inputs to the Powertrain Control Module PCM When fan operation is determined necessary the PCM provides a ground to the fan relay control circuit The inputs provided to the PCM that influence fan operation are Coolant Temperature Sensor Intake Air Temperature Sensor Output Speed Sensor Transmission Oil Temperature Sensor A C Pressure T...

Page 195: ...e The overflow chamber should normally be empty OPERATION The pressure chamber keeps the coolant free of trapped air provides a volume for expansion and con traction and provides a convenient and safe method for checking and adjusting coolant level at atmo spheric pressure It also provides some reserve cool ant to cover minor leaks evaporation or boiling losses The overflow chamber allows coolant ...

Page 196: ...ed in the cylinder block near the right rear corner The block heater is a dry cylinder type design and is powered by 110 volt A C The power cord must be secured in its retainer clips and not positioned so it could contact linkages or exhaust manifolds and become damaged OPERATION When power is applied 110 volt A C to the block heater the heating element transfers heat through the aluminum engine b...

Page 197: ...ES only uses an engine oil cooler that is mounted inside the right radiator tank Fig 15 Oil lines connect the cooler to the engine OPERATION Engine oil travels from the engine through the supply line and into the cooler The supply line is connected to a control valve that allows engine oil flow when pressure is above 138 207 kPa 20 30 psi and an internal orifice limits oil flow to a maximum of 11 ...

Page 198: ... OIL COOLER FITTINGS 4 ENGINE OIL COOLER RETURN LINE Fig 16 Engine Oil Cooler Lines 2 7L Engine EES only 1 RETURN LINE FITTING 2 OIL COOLER RETURN LINE 3 SUPPORT BRACKET 4 OIL COOLER SUPPLY LINE 5 PRESSURE CONTROL VALVE 6 SUPPLY LINE FITTING LH COOLING SYSTEM 7 9 DESCRIPTION AND OPERATION Continued ...

Page 199: ...ve allows engine oil flow when pressure is above 138 207 kPa 20 30 psi and an internal orifice lim its oil flow to a maximum of 11 3 LPM 3 GPM The engine oil exits the cooler through the oil return line and is returned to the engine oil pan Fig 17 Fig 17 Engine Oil Cooler 3 2 3 5L 1 SUPPLY LINE TO OIL COOLER 2 FITTING 3 OIL COOLER PRESSURE CONTROL VALVE 4 OIL PRESSURE SWITCH AND CONNECTOR 5 RETAIN...

Page 200: ...he cooling system causing the thermostat to open late 5 Check and correct coolant leaks Refer to Testing Cooling System for Leaks in this section 6 Cylinder head gasket leaking allowing exhaust gas to enter cooling system causing thermostat to open late 6 a Check for cylinder head gasket leaks with a commercially available block leak tester Repair as necessary b Check for coolant in engine oil Ins...

Page 201: ...lief valve stuck Refer to Pressure cap in this section Replace as necessary b Hose between the pressure and overflow tank is plugged Clean vent and repair as necessary c Vent at coolant reserve overflow tank is plugged Clean vent and repair as necessary d Reserve overflow tank is internally blocked Clean and repair as necessary ELECTRIC RADIATOR FAN RUNS ALL THE TIME 1 Fan relay Powertrain Control...

Page 202: ... the appropriate Diagnostic manual Repair as necessary 2 Coolant level low 2 Refer to Cooling System Testing in this section Repair as necessary 3 Air Trapped in heater core 3 Improper coolant fill procedure Refer to Cooling System Filling in this section 4 Obstructions in heater hose fitting at engine or at heater core 4 Remove heater hoses at both ends and check for obstructions Repair as necess...

Page 203: ...s not necessarily an indication of adequate corrosion or temperature protection Do not rely on coolant color for determining condition of coolant 1 Check the freeze point of the coolant Refer to Coolant in this section for test procedure Adjust the ethylene glycol to water ratio as necessary and service according to maintenance schedule Refer to LUBRICATION AND MAINTENANCE COOLANT LEVEL CHANGES IN...

Page 204: ...which will activate both fans if necessary In addition to this control the fans are turned on based on coolant temperature sensor intake air temperature sensor output speed sensor and transmission oil temperature sensor output to the PCM The PCM switches the fans on through the fan relays Refer to Wiring Diagrams Manual for cir cuit and diagnostics The PCM provides fan control for the following co...

Page 205: ...or after a coolant drain flush and refill The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of 37 C 34 F to 59 C 50 F The use of a hydrometer or a refractometer can be used to test coolant concentra tion A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mix ture The higher the concentratio...

Page 206: ...ail pipe it may indicate a faulty head gasket cracked engine block or cylinder head There may be internal leaks which can be deter mined by removing the oil dipstick If water globules appear intermixed with the oil it will indicate a internal leak in the engine If there is an internal leak the engine must be disassembled for repair LOW COOLANT LEVEL Low coolant level in a cross flow radiator will ...

Page 207: ...d for continuity with a 110 volt voltmeter or 110 volt test light test heater element continuity with an ohmmeter or 12 volt test light The power cord must be secured in its retainer clips and not positioned so it could contact linkages or exhaust manifolds and become damaged SERVICE PROCEDURES COOLANT SERVICE Refer to LUBRICATION AND MAINTENANCE for engine coolant recommended service schedule COO...

Page 208: ...th clean water WARNING DO NOT REMOVE HOSE CLAMPS OR HOSES CYLINDER BLOCK DRAIN PLUGS COOL ANT BOTTLE CAP OR OPEN THE RADIATOR DRAINCOCK WHEN THE SYSTEM IS HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR 1 Open radiator drain located at the lower right side of radiator Fig 21 Drain takes place through the cooling module s lower right side insulator Do Not Use pliers to open ...

Page 209: ... valve in the outlet housing Fig 22 Route the hose away from the accessory drive belt drive pulleys and electric cooling fan Place the other end of hose into a clean container The hose will prevent coolant from contacting the accessory drive belt when bleeding the system during the refill ing operation Fig 22 Cooling System Bleeding 1 2 7L 2 3 2 3 5L 3 BLEED VALVE 4 TO COOLANT CONTAINER 5 SPECIAL ...

Page 210: ...ling Aid Funnel Install cap on coolant pressure bottle 12 Remove hose from bleed valve 13 Start engine and run until it reaches operat ing temperature NOTE The engine cooling system will push any remaining air into the coolant bottle within about an hour of normal driving As a result a drop in cool ant level in the pressure bottle may occur If the engine cooling system overheats and pushes coolant...

Page 211: ... cross member 6 Fill cooling system Refer to Cooling System Refilling in this section WATER PUMP 3 2 3 5L REMOVAL The water pump on all models can be replaced without discharging the air conditioning system WARNING DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR NOTE It is normal for the water pump to weep a small amount of coolant fro...

Page 212: ...onnector 4 Disengage tube from outlet connector only enough for connector removal 5 Remove bolts attaching water outlet connector Fig 27 6 Remove outlet connector INSTALLATION 1 Clean sealing surfaces Inspect gaskets for tears and cuts Replace as necessary 2 Install outlet connector and tighten bolts to 12 N m 105 in lbs Fig 27 3 Inspect and replace heater supply tube O ring as necessary Fig 25 Wa...

Page 213: ...N 1 Inspect heater tube O ring Replace as neces sary 2 Lubricate O ring and install heater tube by inserting tube in between cylinder heads Insert tube into water outlet housing Fig 28 3 Attach heater tube to the retaining clip at rear of engine 4 Install attaching screws and tighten to 3 N m 30 in lbs 5 Install upper radiator hose and heater hose to heater tube 6 Connect electrical connector to c...

Page 214: ...m thermostat housing 7 Remove thermostat housing bolts Fig 30 8 Remove thermostat and housing INSTALLATION 1 Clean gasket sealing surfaces NOTE Install thermostat with the bleed valve located at the 12 o clock position 2 Install thermostat and gasket into the thermo stat housing 3 Install thermostat and housing to cylinder block Tighten attaching bolts to 12 N m 105 in lbs Fig 30 4 Connect heater ...

Page 215: ...tem Refer to Cooling System Refilling in this section RADIATOR REMOVAL NOTE It is not necessary to discharge air condi tioning system when removing the radiator 1 Disconnect negative cable from remote jumper terminal WARNING DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR 2 Drain cooling system Refe...

Page 216: ... interfere with the accessory drive belt or engine Position hose clamp so it will not interfere with the hood liner 9 Install upper radiator support crossmember 10 Connect negative cable to remote jumper ter minal 11 Fill cooling system with coolant Refer to Cool ing System Filling in this section 12 Operate engine until it reaches normal oper ating temperature Check cooling system and auto matic ...

Page 217: ...all A C condenser Refer to HEATING AND AIR CONDITIONING for procedure 3 Connect cooler hoses to cooler lines and tighten hose clamps to 2 N m 18 in lbs 4 Start engine and check transmission oil level Adjust level as necessary TRANSMISSION OIL COOLER LINES REMOVAL 1 Loosen hose clamps at radiator connections and remove cooler hoses Fig 37 2 Remove lines from transmission 3 Remove lines from support...

Page 218: ...g 39 4 Remove lines Fig 39 PRESSURE CONTROL VALVE 1 Disconnect supply line to control valve 2 Remove control valve by unscrewing fitting from engine block Fig 39 INSTALLATION ENGINE OIL COOLER 1 Install radiator assembly Tighten lines to radi ator fittings to 18 N m 160 in lbs COOLER LINES 1 Connect cooler lines to radiator fittings and retainer clip Fig 38 Tighten lines to radiator fit tings to 1...

Page 219: ...RN LINE 3 SUPPORT BRACKET 4 OIL COOLER SUPPLY LINE 5 PRESSURE CONTROL VALVE 6 SUPPLY LINE FITTING Fig 38 Engine Oil Cooler 2 7L EES only 1 ENGINE OIL COOLER SUPPLY LINE 2 RETAINER 3 ENGINE OIL COOLER FITTINGS 4 ENGINE OIL COOLER RETURN LINE 7 30 COOLING SYSTEM LH REMOVAL AND INSTALLATION Continued ...

Page 220: ...ng in and out on valve 3 Connect supply line to control valve Tighten connection fitting to 30 N m 260 in lbs ENGINE OIL COOLER 3 2 3 5L ENGINE REMOVAL ENGINE OIL COOLER 1 The engine oil cooler is serviced with the radi ator Refer to Radiator Removal and Installation procedure in this section COOLER LINES 1 Disconnect cooler lines at radiator Fig 40 2 Disconnect lines at the pressure control valve...

Page 221: ...ower cord to heater CAUTION To prevent damage the power cord must be secured in its retainer clips and not posi tioned so it could contact linkages or exhaust man ifolds 5 Lower vehicle ACCESSORY DRIVE BELTS 2 7L AIR CONDITIONING BELT NOTE The A C drive belt self tensioner is NOT a dynamic tensioner After tensioner adjustment bracket bolts are tightened the torsion spring is no longer responsible ...

Page 222: ...STALLATION USED BELT NOTE A used belt is considered having more than 500 miles of service use NOTE Perform steps 1 7 to change the tensioner spring from the NEW belt position to the USED belt position 1 Insert a 1 2 drive breaker bar into the square opening on tensioner Hold counterclockwise pressure on tensioner while removing tensioner locking bolt Fig 42 2 Carefully release the tension of sprin...

Page 223: ... belt first loosen the tensioner pulley lock nut then loosen the adjusting screw to the tensioner pulley assembly until the belt can be removed Fig 46 INSTALLATION 1 Install air conditioning belt over drive pulleys Tighten the tensioner adjusting bolt until the belt is at specified tension using a Belt Tension Gauge Refer to Belt Tension Chart Tighten tensioner pulley locking nut to 54 N m 40 ft l...

Page 224: ...osits of dried glycol run ning down the pump body 3 2 3 5L pump weep pas sage 2 7L Fig 47 and components below A thin black stain below pump weep hole passage is consid ered normal operation 3 Impeller rubs inside of cylinder block 2 7L or timing belt cover 3 2 3 5L engines 4 Excessively loose or rough turning bearing NOTE It is normal for the water pump to weep a small amount of coolant from the ...

Page 225: ...cap in hand right side up Fig 49 The vent valve at the bottom of the cap should not open If the rubber gasket has swollen and prevents the valve from closing replace the cap Hold the cleaned cap in hand upside down If any light can be seen between vent valve and rubber gas ket replace cap WARNING THE WARNING WORDS DO NOT OPEN HOT ON THE COOLANT BOTTLE PRESSURE CAP IS A SAFETY PRECAUTION WHEN HOT P...

Page 226: ...ooling tubes COOLING SYSTEM CLEANING FLUSHING CLEANING CAUTION Internal radiator pressure must not exceed 138 kPa 20 psi as damage to radiator may result Reverse flushing of cooling system is the forcing of water through the cooling system This is done using air pressure in the opposite direction of normal cool ant flow It is usually only necessary with very dirty systems with evidence of partial ...

Page 227: ...2 3 5L Nut 54 40 Cooling System Bleed Screw 2 7L 12 110 3 2 3 5L 8 70 Condenser Inlet Tube Bracket Screw 5 45 Engine Oil Cooler Supply Lines to Engine 30 260 Supply Lines to Radiator 18 160 Fan Module to Radiator Screws 5 45 Fan Blade to Motor Nut 5 45 Fan Motor to Shroud Screws 3 25 Generator Power Steering Belt Tensioner Pulley Nut 54 40 Thermostat Housing 12 105 Transmission Oil Cooler Hose Cla...

Page 228: ...ON 8 REMOVAL AND INSTALLATION SAFETY PRECAUTIONS AND WARNINGS 10 BATTERY 10 SPECIFICATIONS BATTERY 10 TORQUE 11 DESCRIPTION AND OPERATION BATTERY DESCRIPTION From the factory most vehicles are equipped with a maintenance free battery and others with a low maintenance battery A Hydrometer test may be Fig 1 Maintenance Free Battery 1 POSITIVE POST 2 VENT 3 TEST INDICATOR 4 VENT 5 NEGATIVE POST 6 PLA...

Page 229: ...at tery terminals As the plate materials become more similar chemically and the electrolyte becomes less acid the voltage potential of each cell is reduced However by charging the battery with a voltage higher than that of the battery the battery discharg ing process is reversed Charging the battery gradually changes the sul fated lead plates back into sponge lead and lead oxide and the water back...

Page 230: ...quired to charge a battery will vary depending upon the following factors Size of battery Battery temperature Battery charger capacity Battery state of charge WARNING NEVER EXCEED 20 AMPS WHEN CHARGING A COLD 1 C 30 F BATTERY THE BAT TERY MAY ARC INTERNALLY AND EXPLODE PER SONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT OPERATION After proper charging time required is determined refer to the individ...

Page 231: ...ts or greater before the battery is tested or returned to use Refer to Causes of Battery Discharging in this Group for more information NOTE CLEAR COLOR Replace Battery WARNING DO NOT CHARGE ASSIST BOOST LOAD TEST OR ADD WATER TO THE BATTERY WHEN CLEAR COLOR DOT IS VISIBLE PERSONAL INJURY MAY OCCUR A clear color dot shows electrolyte level in battery is below the test indicator Fig 4 Water cannot ...

Page 232: ...SCHARGING Corroded battery posts cables or terminals Loose or worn generator drive belt Electrical loads that exceed the output of the charging system due to equipment or accessories installed after delivery Slow driving speeds in heavy traffic conditions or prolonged idling with high amperage electrical systems in use Defective electrical circuit or component causing excess Ignition Off Draw IOD ...

Page 233: ...here is a short circuit to one of the modules Refer to Group 8W Wiring Diagrams BATTERY LOAD TEST A fully charged battery must have cranking capac ity to provide the starter motor and ignition system enough power to start the engine over a broad range of ambient temperatures A battery load test will ver ify the actual cranking capability of the battery WARNING IF BATTERY SHOWS SIGNS OF FREEZ ING L...

Page 234: ...from 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 Refer to Battery Open Circuit Voltage table SERVICE PROCEDURES BATTERY CHARGING WARNING DO NOT CHARGE A BATTERY THAT HAS EXCESSI...

Page 235: ... test it must be replaced Properly clean and inspect battery hold downs tray terminals cables posts and top before completing service CHARGING COMPLETELY 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 Battery Charging Rate tablet 1 Measure the voltage at battery po...

Page 236: ...rea with bak ing soda solution 6 Clean battery posts with a battery post clean ing tool Fig 12 7 Clean battery cable clamps with a battery ter minal cleaning tool Fig 13 Replace cables that are frayed or have broken clamps Fig 11 Cleaning Battery 1 BATTERY 2 CLEANING BRUSH 3 TEST INDICATOR 4 WARM WATER AND BAKING SODA SOLUTION Fig 12 Cleaning Battery Post 1 BATTERY 2 TEST INDICATOR 3 BATTERY POST ...

Page 237: ...OFF 3 Disconnect and isolate the negative battery cable remote terminal from the remote battery post Fig 14 4 Remove air cleaner housing Refer to Group 14 Fuel for service procedures 5 Remove battery splash shield Refer to Group 23 Body for service procedures 6 Remove two short bolts to battery hold down 7 Slide battery rearward to disconnect the nega tive and positive battery terminals from batte...

Page 238: ...e length of time a battery can deliver 25 amps and maintain a minimum terminal voltage of 10 5 volts at 27 C 80 F TORQUE DESCRIPTION TORQUE Battery Hold Down Clamp Bolt 14 N m 125 in lbs LH BATTERY 8A 11 SPECIFICATIONS Continued ...

Page 239: ......

Page 240: ...s not allow the starter to be engaged if the engine is already running STARTER RELAY DESCRIPTION The Starter Relay is a micro relay located in the Power Distribution Center PDC positioned in the left front corner of the engine compartment OPERATION As battery power is applied to the relay from the ignition switch battery power is applied to the starter motor through the relay to the starter sole n...

Page 241: ...Battery Tests 2 Perform Starter Solenoid test BEFORE per forming the starter relay test 3 Raise the vehicle 4 Perform a visual inspection of the starter starter solenoid for corrosion loose connections or faulty wiring 5 Lower the vehicle 6 Locate and remove the starter relay from the Power Distribution Center PDC Refer to the PDC label for relay identification and location 7 Connect a remote star...

Page 242: ...required 4 The coil battery terminal 86 is connected to the electromagnet in the relay It is energized when the ignition switch is held in the Start position Check for battery voltage at the cavity for relay ter minal 86 with the ignition switch in the Start posi tion and no voltage when the ignition switch is released to the On position If OK go to Step 5 If not OK check for an open or short circ...

Page 243: ...ltage reads above 0 2 volt correct poor contact at battery cable to solenoid connection If reading is still above 0 2 volt after correcting poor contacts replace battery positive cable b If resistance tests do not detect feed circuit failures replace the starter motor FEED CIRCUIT TEST NOTE The following results are based upon the vehicle being at room temperature The following procedure will requ...

Page 244: ...ions of physical damage and loose or corroded wire harness connections Wiring Visually inspect the wire harness for damage Repair or replace any faulty wiring as required Check for loose or corroded wire harness connections at main engine ground and remote jump post Power Distribution Center PDC Visually inspect the B connections at the PDC for physical damage and loose or corroded harness connect...

Page 245: ...LY FAULTY 5 FAULTY TEETH ON RING GEAR 1 INSTALL STARTER TIGHTEN STARTER MOUNTING HARDWARE TO CORRECT TORQUE SPECIFICATIONS 2 REFER TO RELAY TEST IN THIS SECTION REPLACE RELAY IF NECESSARY 3 REFER TO IGNITION SWITCH TEST IN GROUP 8D IGNITION SYSTEM REPLACE SWITCH IF NECESSARY 4 IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK REPLACE STARTER ASSEMBLY 5 ROTATE FLYWHEEL 360 AND INSPECT T...

Page 246: ...y is located in the Power Distribution Cen ter PDC Refer to the PDC cover for relay location SPECIFICATIONS STARTER NOTE Engine should be up to operating tempera ture Extremely heavy oil or tight engine will increase starter amperage draw TORQUE DESCRIPTION TORQUE Starter Mounting Bolts 54 N m 40 ft lbs Starter Solenoid Battery Nut 10 N m 90 in lbs Fig 4 Starter 3 2 3 5L Engine 1 STARTER SHIELD RE...

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Page 248: ...y cycling the ground path to control the strength of the rotor magnetic field The PCM then compensates and regulates generator current output accordingly All vehicles are equipped with On Board Diagnos tics OBD All OBD sensed systems including EVR field control circuitry are monitored by the PCM Each monitored circuit is assigned a Diagnostic Trou ble Code DTC The PCM will store a DTC in elec tron...

Page 249: ...uit plug 10 Remove the B terminal nut and wire 11 Remove pivot bolt being careful not to lose spacer 12 Remove generator INSTALLATION 1 Install generator 2 Install pivot bolt leave loose 3 Connect the generator field circuit plug 4 Install the B terminal nut and wire 5 Install the generator drive belt Refer to the Cooling System section 6 Adjusting T bolt and tighten belt 7 Remove jackstand from u...

Page 250: ... mm 41 N m 30 ft lbs Generator Mounting Bolt 10 mm 54 N m 40 ft lbs Generator Pivot Bolt 10 mm 54 N m 40 ft lbs GENERATOR Part number is located on the side of the generator Type Engine Minimun Test Amperage Denso 2 7 L 105 Amp Melco 3 2 3 5 L 110 Amp Test Specification 1 Engine RPM 2500 RPM 620 RPM 2 Voltage Output 14 0 V 6 0 5 V 3 Field Current 5 amps 6 0 1 amps LH CHARGING SYSTEM 8C 3 ...

Page 251: ......

Page 252: ...The PCM deter mines crankshaft position from these sensors The PCM calculates injector sequence and ignition timing from crankshaft position For a description of both sensors refer to Camshaft Position Sensor and Crankshaft Position Sensor in this section SPARK PLUGS PLATINUM DESCRIPTION The 2 7 3 2 and 3 5L engines use platinum resis tor spark plugs They have resistance values of 6 000 to 20 000 ...

Page 253: ...ity the engine can run on crankshaft sensor input only Refer to Auto Shutdown ASD Relay PCM Output in this section for relay operation The coil s low primary resistance 0 4 0 6 ohm allows the PCM to fully charge the coil for each fir ing There is a coil capacitor added to each bank of cylinders for radio noise suppression CRANKSHAFT POSITION SENSOR DESCRIPTION The crankshaft sensor is located on t...

Page 254: ...s the last slot it determines which piston will be next at TDC from the camshaft position sensor input It may take the PCM one engine revolution to determine crankshaft position The PCM uses crankshaft position reference to determine injector sequence and ignition timing Once the PCM determines crankshaft position it begins energizing the injectors and coils in sequence The PCM uses the Crankshaft...

Page 255: ...ulses When metal aligns with the sensor voltage goes low less than 0 3 volts When a notch aligns with the sensor voltage spikes high 5 0 volts As a group of notches pass under the sensor the voltage switches from low metal to high notch then back to low The number of notches determine the amount of pulses If available an oscilloscope can display the square wave patterns of each timing event Fig 8 ...

Page 256: ...ting conditions as long as rpm is above the minimum rpm except WOT The PCM using short term memory can respond quickly to retard timing when engine knock is detected Short term memory is lost any time the ignition key is turned off NOTE Over or under tightening affects knock sen sor performance possibly causing improper spark control LOCK KEY CYLINDER DESCRIPTION The lock cylinder is inserted in t...

Page 257: ...55 in lbs 3 2 3 5L engines to 6 7 N m 60 in lbs 3 Connect the electrical connector AUTOMATIC SHUTDOWN RELAY The relay is located in the Power Distribution Cen ter PDC Fig 13 For the location of the relay within the PDC refer to the PDC cover for location Check electrical terminals for corrosion and repair as necessary CAMSHAFT POSITION SENSOR 2 7L The camshaft position sensor is mounted in the fro...

Page 258: ...ect the negative battery cable CRANKSHAFT POSITION SENSOR The crankshaft sensor is located on the passengers side of the transmission housing above the differen tial housing Fig 17 The bottom of the sensor sits above the drive plate REMOVAL 1 Disconnect electrical connector from crankshaft position sensor 2 Remove sensor mounting screw Remove sensor INSTALLATION 1 Install sensor and push sensor do...

Page 259: ... Refer to the Engine section COIL CAPACITOR REMOVAL 1 Remove the negative battery cable 2 Disconnect the electrical connector Fig 21 or Fig 20 3 Remove nut and capacitor INSTALLATION 1 Install capacitor and tighten nut 2 Attach electrical connector to capacitor 3 Install the negative battery cable IGNITION SWITCH The ignition switch attaches to the lock cylinder housing on the end opposite the loc...

Page 260: ... if equipped refer to the Power Door Locks section for installation 6 Install upper and lower cover on steering col umn 7 Install tilt lever 8 Connect negative cable to battery 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 detentes Fig 25 Accessory Off lock Unlock On Run Start When replaci...

Page 261: ...he socket is in the Run position Fig 27 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 Fig 28 4 Turn key to Off position Remove key 5 If the vehicle has column shift and a new lock cylinder was used install and adjust a new interlock cassette Refer to Ignition Interlock in this section If t...

Page 262: ...L Crankshaft Position Sensor Screw 12 N m 105 in lbs 2 7L Ignition Coil 6 2 N m 55 in lbs 3 2 3 5L Ignition Coil 6 7 N m 60 in lbs Knock Sensor 10 N m 7 ft lbs 2 7L Map Sensor 2 N m 20 in lbs 3 2 3 5L Map Sensor 2 N m 20 in lbs 2 7L Spark Plugs 17 6 N m 13 ft lbs 3 2 3 5L Spark Plugs 28 N m 20 ft lbs SPARK PLUGS Engine Spark Plug Gap Thread Size 2 7L RE10PMC5 0 048 TO 0 058 in 14mm 1 in reach 3 2L...

Page 263: ......

Page 264: ...14 INSTRUMENT PANEL AND PAD ASSEMBLY 15 INSTRUMENT PANEL END COVERS LEFT AND RIGHT 16 INSTRUMENT PANEL FLOOR BIN 16 INSTRUMENT PANEL CENTER TRIM BEZEL 16 INSTRUMENT PANEL SILENCER DUCT 16 INSTRUMENT PANEL UPPER TOP COVER 16 ODOMETER 16 RADIO 17 REMOTE KEYLESS ENTRY RKE MODULE 17 TRACTION CONTROL SWITCH 17 TRIP RESET KNOB 17 UPPER RIGHT TRIM BEZEL LHS 300M 17 DESCRIPTION AND OPERATION CIGAR LIGHTER...

Page 265: ...ROCEDURE As a quick diagnosis the cluster will perform a functional check of the odometer display transmis sion range display and warning indicators after the ignition is switched to RUN START If the cluster is not receiving any PCI bus messages the cluster will appear non functional and no bus will appear in the odometer display A self test of the cluster can also be initiated by pressing and hol...

Page 266: ...Accessories that draw higher power i e cool ers vacuum cleaners lights etc will degrade the battery even more quickly Only use these intermit tently and with greater caution After the use of high power draw accessories or long periods of the vehicle not being started with accessories still plugged in the vehicle must be driven a sufficient length of time to allow the generator to recharge the vehi...

Page 267: ...emote terminal from the remote battery post Fig 22 2 Remove the instrument upper top cover Refer to Instrument Panel Upper Top Cover Removal and Installation in this section Fig 8 Fig 9 and Fig 10 3 Remove the two sun sensor mounting screws 4 Disconnect the wire connector and remove the sensor Fig 7 INSTALLATION For installation reverse the above procedures Fig 6 ATC In Car Temperature Sensor 1 AT...

Page 268: ...Fig 8 Instrument Panel Components Intrepid LH INSTRUMENT PANEL SYSTEMS 8E 5 REMOVAL AND INSTALLATION Continued ...

Page 269: ...NEL 9 LOUVER AIR OUTLET 10 BEZEL INSTRUMENT PANEL TRIM CENTER 11 BEZEL INSTRUMENT CLUSTER 12 SWITCH HEADLAMP 13 LOUVER AIR OUTLET 14 COVER INSTRUMENT PANEL CENTER SUPPORT BIN 6 PASS ONLY 15 6 PASS ONLY 16 ASH RECEIVER 17 LEVER PARKING BRAKE 18 COVER LOWER INSTRUMENT PANEL 19 BEZEL INSTRUMENT PANEL END CAP 20 COVER UPPER INSTRUMENT PANEL 8E 6 INSTRUMENT PANEL SYSTEMS LH REMOVAL AND INSTALLATION Con...

Page 270: ...Fig 9 Instrument Panel Components Concorde LH INSTRUMENT PANEL SYSTEMS 8E 7 REMOVAL AND INSTALLATION Continued ...

Page 271: ...NSTRUMENT PANEL 8 HOUSING INSTRUMENT CLUSTER 9 RADIO 10 BEZEL INSTRUMENT CLUSTER 11 SWITCH HEADLAMP 12 LOUVER AIR OUTLET 13 COVER INSTRUMENT PANEL CENTER SUPPORT BIN 6 PASS ONLY 14 ASH RECEIVER 15 BEZEL INSTRUMENT PANEL TRIM CENTER 16 LEVER PARKING BRAKE 17 COVER LOWER INSTRUMENT PANEL 18 BEZEL INSTRUMENT PANEL END CAP 8E 8 INSTRUMENT PANEL SYSTEMS LH REMOVAL AND INSTALLATION Continued ...

Page 272: ...Fig 10 Instrument Panel Components LHS 300M LH INSTRUMENT PANEL SYSTEMS 8E 9 REMOVAL AND INSTALLATION Continued ...

Page 273: ... For installation reverse the above procedures CIGAR LIGHTER POWER OUTLET ASSEMBLY REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Fig 22 2 Look inside and note position of the retaining bosses Fig 11 3 Using external snap ring pliers with 90 degree tips Insert pliers with tips against bosses and squeeze forcing bosses out of base 4 Pull o...

Page 274: ...steering column down into the lowest position 5 Remove one screw LHS 300M to cluster bezel 6 Remove the items to expose bezel mounting screws Items vary depending on model 7 Remove two screws over upper cluster bezel in instrument panel brow area and all remaining attaching screws four on Intrepid LHS and 300M and five on Concorde 8 Using a trim stick special tool C 4755 gently pry out on the inst...

Page 275: ...negative battery cable remote terminal from the remote battery post Fig 22 2 Remove instrument cluster from vehicle Refer to procedures in this section 3 Remove two screws to mask lens Fig 17 INDICATORS BULBS INDICATOR COLOR BULB LED BATTERY RED LED BRAKE RED LED AIRBAG RED LED LOW OIL RED LED SEATBELT RED LED TEMPERATURE RED LED DOOR AJAR RED LED DECKLID AJAR RED LED HIGH BEAM BLUE 74 TURN SIGNAL...

Page 276: ...od and disconnect the negative battery cable remote terminal from the remote battery post Fig 22 2 Remove left instrument panel endcap Refer to Removal and Installation procedures in this section 3 Remove left lower instrument panel cover Refer to Instrument Panel and Pad Assembly Removal and Installation procedures in this section 4 Pinch four tabs around side of decklid release switch on the rea...

Page 277: ...ut lamp sockets are serviceable at this time Ensure that the switch is seated against the pad HEATER A C CONTROLS REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Fig 22 2 Remove the ash receiver assembly if necessary 3 Remove the instrument panel center trim bezel and remove the two electrical connectors from the back of the control head a...

Page 278: ...and remove from vehicle 11 Remove two front bracket screws and two screws inside console bin to remove console 12 Remove two nuts attaching center lower instrument panel 13 Remove four bolts to steel reinforcement from bottom of lower instrument panel cover and discon nect 16 way Diagnostic Link Connector DLC from steel reinforcement 14 Remove one screw to left floor duct silencer pad and remove f...

Page 279: ...ighter auxiliary power outlet and traction control switch 4 Remove instrument panel center trim bezel NOTE The traction control switch HVAC control head and cigar lighter auxiliary power outlet must be transferred to new bezel if being replaced INSTALLATION For installation reverse the above procedures INSTRUMENT PANEL SILENCER DUCT REMOVAL 1 Remove the retaining screw to the instrument panel 2 Ma...

Page 280: ...this section REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Fig 22 2 Remove instrument cluster from vehicle Refer to procedures in this section 3 Remove five cluster back cover retaining screws and remove the cover 4 Remove nine screws to Printed Circuit Board and remove 5 Gently pull Trip Reset Knob from the instru ment cluster housing a...

Page 281: ......

Page 282: ...TCH DESCRIPTION The headlamp leveling switch controls the headlamp leveling motor This switch is located on the instrument panel integral with the headlamp switch If this switch fails the entire headlamp switch must be replaced OPERATION The headlamp leveling switch allows remote adjustment of the vertical aim of the headlamps By rotating this switch upward the headlamp beam con centration will ri...

Page 283: ...d and disconnect the remote neg ative battery cable 2 Remove the left instrument panel end cover Grasp the molded handle and pull outward to release the three retaining clips 3 Remove the lower left instrument panel cover Remove the two cover retaining screws located on far left side of I P Pull cover straight away from I P to release retaining clips Disconnect trunk release switch and parking bra...

Page 284: ... bezel 4 Install the screw located directly above the HVAC control head opening retaining the instrument panel upper right trim bezel 5 Install the four screws retaining the instru ment panel upper right trim bezel and close the glove box door 6 Install the upper screws in cluster bezel located just above gauges 7 Connect HVAC control head and install the center trim bezel 8 Connect trunk release ...

Page 285: ...2000 LHS 300M CONCORDE AND INTREPID ...

Page 286: ...ith four output channels Two 2 5 inch round single cone speakers in the lower front corners of the front door windows Two 6 5 inch round single cone speakers in the front doors Two 6 x 9 inch coaxial speakers mounted in the rear shelf panel INFINITY l SYSTEM The Infinity l System includes AM FM stereo radio with cassette player and 4 disc in dash CD changer AM FM stereo radio with CD and cassette ...

Page 287: ...nger Pressing the individual Load Eject button for a particular chamber will eject a disc currently present in that chamber If the chamber is currently empty actuating the Load Eject button will position that chamber to receive and load a new disc in that chamber INTERFERENCE ELIMINATION DESCRIPTION Some components used on the vehicles are equipped with a capacitor to suppress radio fre quency int...

Page 288: ...F Whenever a radio malfunction occurs 1 First check FUSES in the Junction Block a Radio power b Ignition feed c Power Amplifier d Illumination e Memory feed NOTE The vehicles are shipped with the INTERIOR LAMP fuse disconnected 2 Verify the radio wire harness is properly con nected before starting normal diagnosis and repair procedures Refer to Audio Diagnostic Tables and or Group 8W Wiring Diagra...

Page 289: ...BASE 4 SPEAKER SYSTEM 8F 4 AUDIO SYSTEMS LH DIAGNOSIS AND TESTING Continued ...

Page 290: ...BASE 4 SPEAKER SYSTEM CONTINUED LH AUDIO SYSTEMS 8F 5 DIAGNOSIS AND TESTING Continued ...

Page 291: ...BASE 4 SPEAKER SYSTEM CONTINUED 8F 6 AUDIO SYSTEMS LH DIAGNOSIS AND TESTING Continued ...

Page 292: ...BASE 4 SPEAKER SYSTEM CONTINUED LH AUDIO SYSTEMS 8F 7 DIAGNOSIS AND TESTING Continued ...

Page 293: ...AMPLIFIED 8F 8 AUDIO SYSTEMS LH DIAGNOSIS AND TESTING Continued ...

Page 294: ...AMPLIFIED CONTINUED LH AUDIO SYSTEMS 8F 9 DIAGNOSIS AND TESTING Continued ...

Page 295: ...AMPLIFIED CONTINUED 8F 10 AUDIO SYSTEMS LH DIAGNOSIS AND TESTING Continued ...

Page 296: ...AMPLIFIED CONTINUED LH AUDIO SYSTEMS 8F 11 DIAGNOSIS AND TESTING Continued ...

Page 297: ...AMPLIFIED CONTINUED 8F 12 AUDIO SYSTEMS LH DIAGNOSIS AND TESTING Continued ...

Page 298: ...AMPLIFIED CONTINUED LH AUDIO SYSTEMS 8F 13 DIAGNOSIS AND TESTING Continued ...

Page 299: ...D DOESN T CHANGE DISCS 3 CD DOESN T LOAD EJECT 4 CD STOPS PLAYING 5 CD WON T PLAY AT ALL 1 CD CHANGER MECHANICAL FAILURE MECHANISM 2 INSTRUMENT PANEL TEMPERATURE NOT WITHIN CD CHANGER OPERATING RANGE 22 F TO 149 F 3 SCRATCHED DISC 4 FOCUS ERROR LASER DUE TO FOGGING MOISTURE 5 DISC INVERTED 6 WRONG OR UNKNOWN CD FORMAT CD R CD ROM CD RW OR DVD 7 LOW QUALITY CDR 1 REPLACE CD CHANGER 2 RETRY CD OPERA...

Page 300: ...ropriate pin numbers If resistance is less than two ohms test speaker for resistance If OK repair wire If not OK replace speaker ALL SPEAKERS NON OPERATIVE Check radio for being ON are the display lights on Radio not ON refer to Radio Diagnosis Check fuses amplifier connectors and wires for proper connection Check for good ground Check amplifier for battery voltage and ON OFF voltage 1 Battery vol...

Page 301: ... coil in the C pillar has a good ground 6 If not OK repair as necessary If OK go to Step 7 CAUTION Rear Window Defogger must be in the OFF position 7 Quick check of the module Place the ignition switch in the ACC position with the radio in the ON position on a appropriate station AM FM Tune to a AM station Using a grounded jumper wire momentarily short the AM lead to the grid lines Fig 5 There sho...

Page 302: ...tery post Fig 6 2 Open drivers door 3 Remove two speaker enclosure attachment screws holding the enclosure ring and grill to the door Fig 7 4 Remove two speaker retaining screws 5 Pull speaker away from door and disconnect wiring INSTALLATION For installation reverse the above procedures FIXED MAST ANTENNA INTREPID ONLY REMOVE 1 Open hood and disconnect the negative battery cable remote terminal f...

Page 303: ...nect the negative battery cable remote terminal from the remote battery post Fig 6 2 Remove instrument panel center trim bezel Refer to Group 8E Instrument Panel and Systems for Removal and Installation procedures 3 Remove four radio mounting screws 4 Pull radio from panel and disconnect wiring ground strap wires and antenna lead from radio 5 Remove radio from vehicle INSTALLATION For installation...

Page 304: ...INFINITY l SYSTEM 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Fig 6 2 Remove right under panel silencer duct Refer to Group 8E Instrument Panel and Systems for Removal and Installation procedures 3 Remove two retaining nuts to remote amplifier 4 Pull amplifier inboard and then pull downward to remove from upper retaining clips Fig 2 5 Disconne...

Page 305: ......

Page 306: ...r to Horn System Schematic DIAGNOSIS AND TESTING HORN 1 Disconnect wire connector at each horn 2 Using a voltmeter connect one lead to body ground and the other lead to the horn relay ouput pin of the horn connector Fig 2 The right horn is grounded on the front outboard side of the right frame rail The left horn is grounded on the left front fender apron 3 When the horn switch is depressed battery...

Page 307: ... horn switch or wiring as necessary Refer to Group 8W Wiring diagrams 3 Using voltmeter test voltage at a Terminal 11 and 13 test for battery voltage from fuse F30 b If voltage is incorrect repair as necessary Refer to Group 8W Wiring Diagrams 4 Insert a jumper wire between terminals 13 and 15 of the junction block a If horns sound replace relay b If the horns do not sound install horn relay and r...

Page 308: ...E AND CHECK FOR RUBBING OR LOOSE WIRE CONNECTOR REPAIR AS NECESSARY 2 REPLACE DRIVER AIRBAG MODULE 3 REPLACE DRIVER AIRBAG MODULE HORN DOES NOT SOUND 1 CHECK FUSE 18 IN THE JUNCTION BLOCK 2 NO VOLTAGE AT HORN RELAY TERMINALS 1 2 AND FUSE IS OK 3 OPEN CIRCUIT FROM TERMINAL 7 OF THE RELAY TO HORN SWITCH X3 CIRCUIT 4 DEFECTIVE OR DAMAGED HORN 5 DEFECTIVE HORN SWITCH 1 REPLACE FUSE IF BLOWN AS REPAIR ...

Page 309: ...nnect the negative battery cable remote terminal from the remote battery post Fig 4 2 Remove the two speed control switch screws from the steering wheel back cover 3 Remove the two speed control switches and dis connect the wires 4 Remove the two bolts retaining the Driver Air bag Module 5 Lift the module and disconnect the airbag horn wire connectors 6 Remove the Driver Airbag Module from the veh...

Page 310: ...m is designed to operate at speeds above 30 mph 48 km h WARNING THE USE OF SPEED CONTROL IS NOT RECOMMENDED WHEN DRIVING CONDITIONS DO NOT PERMIT MAINTAINING A CONSTANT SPEED SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT ARE WINDING ICY SNOW COVERED OR SLIPPERY OPERATION When speed control is activated by depressing the ON switch the PCM allows a set speed to be stored in RAM for speed control To stor...

Page 311: ...ed at the PCM to operate When the PCM grounds the vacuum servo solenoid the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable When the PCM breaks the ground the solenoid closes and no more vacuum is allowed to enter the servo The PCM also operates the vent sole noid via ground The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo...

Page 312: ... If the interac tive speed control is not engaged and power train loading is not reduced the driver may have to completely lift off of the throttle before an upshift will occur If the driver does lift off the throttle to induce an upshift under these conditions vehicle speed will reduce and the Overdrive to 3rd and 3rd to 2nd gear downshifts will reoccur when the throttle is reapplied If grade hun...

Page 313: ...onitored circuit is assigned a Diagnostic Trouble Code DTC The PCM will store a DTC in electronic memory for any failure it detects The PCM cannot be repaired and must be replaced if faulty USE THE DRB SCAN TOOL TO REPROGRAM THE NEW PCM WITH THE VEHICLES ORIGI NAL IDENTIFICATION NUMBER VIN AND THE VEHICLES ORIGINAL MILEAGE IF THIS STEP IS NOT DONE A DIAGNOSTIC TROUBLE CODE DTC MAY BE SET VACUUM RE...

Page 314: ...ode and No Trouble Codes refer to the Powertrain Diagnostic Manual REMOVAL AND INSTALLATION SERVO REMOVAL 1 Disconnect the negative battery cable 2 Remove three bolts from servo bracket 3 Disconnect electrical connectors and vacuum hose 4 Remove two nuts attaching speed control cable and mounting bracket to servo 5 Remove servo mounting bracket 6 Pull cable away from servo to expose retaining clip...

Page 315: ... cable to servo 8 Pull cable away from servo to expose retaining clip and remove clip attaching cable to servo 9 Remove servo mounting bracket INSTALLATION 1 Slide speed control cable into bracket and with locator positioned into notch in bracket then slide throttle cable into bracket and engage retaining tab 2 Rotate the throttle cam forward to the wide open position and install speed control cab...

Page 316: ...CRIPTION TORQUE Vacuum Resevoir Screws 12 N m 8 8 ft lbs Servo Mounting Bracket Nuts 14 N m 10 3 ft lbs Servo Mounting Bracket Bolts 14 N m 10 3 ft lbs Servo Mounting Nuts 6 7 N m 60 in lbs LH VEHICLE SPEED CONTROL SYSTEM 8H 7 ...

Page 317: ......

Page 318: ...er is combined into one unit called a Combination Flasher Combo Flasher The combo flasher controls the flashing of the hazard warning system and the turn signal system An inoperative bulb or incomplete turn signal circuit will result in an increase in flasher speed HAZARD WARNING SYSTEM DESCRIPTION The hazard warning system is actuated by a push button located on the top of the steering column bet...

Page 319: ...mps flash as described above but the switch returns to the OFF position as soon as the lever is released When the system is activated one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps indicating to the driver that the system is operating DIAGNOSIS AND TESTING MULTI FUNCTION SWITCH TESTS The multi function switch contains electrical cir cuitry...

Page 320: ...AL LAMPS 1 REPLACE FUSE 2 REPLACE FLASHER UNIT 3 REPLACE WIRING HARNESS CHECK CONNECTORS 4 REPLACE MULTI FUNCTION SWITCH 5 REPLACE WIRING HARNESS INDICATOR LAMP FLASHES AT DOUBLE NORMAL RATE EXTERNAL LAMP DOES NOT LIGHT 1 OPEN CIRCUIT IN WIRE TO EXTERNAL LAMP 2 BURNED OUT LAMP 1 REPLACE WIRING HARNESS 2 REPLACE LAMP SYSTEM DOES NOT FLASH ON EITHER SIDE 1 FAULTY FUSE 2 FAULTY FLASHER UNIT 3 LOOSE B...

Page 321: ...INDICATOR LAMP OPERATION 1 FAULTY INDICATOR LAMP IN INSTRUMENT CLUSTER 1 REPLACE LAMP Fig 3 Turn Signal and Hazard Switch Connector Pin Call Out TURN SIGNAL AND HAZARD SWITCH CONTINUITY SWITCH POSITION CONTINUITY BETWEEN TURN SIGNAL HAZARD WARNING LEFT OFF 7 AND 6 RIGHT OFF 7 AND 8 NEUTRAL ON 7 AND 8 7 AND 6 4 AND 5 Fig 4 Beam Select Switch Connector Pin Call Out BEAM SELECT SWITCH CONTINUITY SWIT...

Page 322: ...y cable remote terminal from the remote battery post 2 Remove tilt lever 3 Remove both upper and lower steering column shrouds 4 Remove multi function switch mounting screws and connectors Fig 6 INSTALLATION For installation reverse the above procedures 1 Tighten multi function switch retaining screws to 17 in lbs 2 N m torque Fig 5 Negative Battery Cable Remote Terminal 1 RIGHT STRUT TOWER 2 AIR ...

Page 323: ......

Page 324: ...y a switch located on the multi functin switch stalk The multi function switch is located on the steering col umn behind the steering wheel OPERATION The windshield wipers will operate when the igni tion switch is in the ACCESSORY or IGNITION ON position The windshield wipers will return to the parked position when the ignition switch is turned to the OFF position Fuses located in the Junction Blo...

Page 325: ... The hood mounted nozzles distribute washer fluid on the surface of the wind shield The nozzles are adjustable refer to the Washer Nozzle Adjusting Procedures The pump and reservoir are serviced as separate assemblies WIPER BLADES DESCRIPTION The wiper blades are a rubber element with a steel vertebrae that are mounted on the end of the wind shield wiper arm and sweep across the front wind shield ...

Page 326: ...mal diagnosis and repair procedures Refer to Windshield Washer Test table Fig 3 Body Control Module Location 1 JUNCTION BLOCK BCM Fig 4 Multi Function Wiper Switch 1 WINDSHIELD WASHER BUTTON 2 CONTROL STALK BEAM SELECT 3 HAZARD WARNING BUTTON 4 MULTI FUNCTION SWITCH 5 WINDSHIELD WIPER CONTROL Fig 5 Multi Function Wiper Switch Pin Call Out WINDSHIELD WIPER WASHER SWITCH RESISTANCE TEST SWITCH POSIT...

Page 327: ...R 2 SHORT CIRCUIT BETWEEN JUNCTION BLOCK FUSE 5 AND WIPER SWITCH TERMINAL 1 SHORT IN WIPER SWITCH IF NOT OK REPAIR CIRCUIT OR REFER TO WIPER WASHER SWITCH DIAGNOSTIC PROCEDURES 3 ASSURE WASHER HOSE IS NOT PINCHED LOOSE BROKEN OR DISCONNECTED IF NOT OK PROPERLY ROUTE OR REPAIR WASHER HOSE 4 PROPERLY SEAT CONNECTOR TO MOTOR 5 REPAIR TERMINALS AND PROPERLY SEAT CONNECTOR TO MOTOR 6 OPEN OR DEFECTIVE ...

Page 328: ...OD NOZZLE STREAM OVERSHOOTS WINDSHIELD 1 NOZZLE NOT SEATED IN HOOD 2 NOZZLE JET S OUT OF ADJUSTMENT 1 ASSURE NOZZLE IS SNAPPED IN PLACE 2 ADJUST NOZZLE JETS USING A SAFETY PIN WIPER WILL NOT CYCLE WHEN WASHER SWITCH IS DEPRESSED 1 OPEN OR DEFECTIVE WASHER SYSTEM CONTROL CIRCUIT 2 DEFECTIVE BODY CONTROL MODULE BCM 1 OPEN OR DEFECTIVE CIRCUIT BETWEEN WIPER WASHER SWITCH CONNECTOR TERMINAL 2 AND BCM ...

Page 329: ...nd Refer to Group 8W Wiring Diagrams for pin call outs a If fuse s are good go to Step 2 b If fuse s are defective replace and check motor operation in all switch positions c If motor is still inoperative and the fuse does not blow go to Step 2 d If replacement fuse blows go to Step 11 2 Disconnect motor wire harness connector 3 Check the wiper motor low speed Using two jumper wires connect one ju...

Page 330: ...or 2 If motor will not run on low speed connect a jumper wire between battery positive jump start ter minal and Pin 2 on the wiper motor connector Con nect a second jumper wire between ground and Pin 5 on the wiper motor wire harness connector a If motor runs go to Step 3 b If motor does not run replace the motor 3 If motor will not run on high speed connect a jumper wire between battery positive ...

Page 331: ...PARK POSITION 1 Using an ohmmeter check for ground at Pin 4 on the wiper motor connector If grounded replace motor 2 Using an ohmmeter with the wiper motor in the PARK position check for continuity between Pin 5 and Pin 4 on the wiper motor connector If contin uous continuity go to Step 3 If not OK replace motor 3 Disconnect the wiper motor wire harness con nector and the BCM C3 bone 12 way connec...

Page 332: ...E ONLY 1 DEFECTIVE WIPER SWITCH 1 REFER TO WIPER SWITCH DIAGNOSTIC PROCEDURES WIPER OPERATES IN HIGH SPEED ONLY 1 DEFECTIVE HI LO RELAY 2 DEFECTIVE CONTROL CIRCUIT TO BCM 3 DEFECTIVE BCM 4 OPEN LOW SPEED CIRCUIT 5 DEFECTIVE MOTOR 1 CHECK WIPER HI LO RELAY WITH KNOWN GOOD RELAY REPLACE IF NOT OK 2 CONTINUOUS SHORT BETWEEN HI LO RELAY CAVITY C AND BCM CONNECTOR TERMINAL 12C IF NOT OK REPAIR CIRCUIT ...

Page 333: ...HIELD 1 DEFECTIVE ON OFF RELAY 2 OPEN ON OFF RELAY GROUND CIRCUIT 1 CHECK WIPER ON OFF RELAY WITH KNOWN GOOD RELAY IF NOT OK REPLACE RELAY 2 OPEN OR DEFECTIVE CIRCUIT BETWEEN ON OFF RELAY CAVITY E9 AND LEFT HEADLAMP GROUND 5 OR ENGINE GROUND 1 OR 2 WIPER RUNS CONTINUOUSLY OR INTERMITTENTLY IN LOW SPEED WITH IGNITION OR ACCESSORY ON AND WIPER SWITCH OFF 1 DEFECTIVE ON OFF RELAY 2 DEFECTIVE CONTROL ...

Page 334: ...ODED CONNECTOR 5 OPEN OR DEFECTIVE CIRCUIT BETWEEN PDC FUSE M AND ON OFF RELAY CAVITY A OR D OPEN OR DEFECTIVE CIRCUIT BETWEEN ON OFF RELAY CAVITY B AND HI LO RELAY CAVITY B IF NOT OK REPLACE ON OFF RELAY OR REPAIR CIRCUIT S 6 CHECK BCM CONNECTORS B AND C FOR BENT LOOSE OR CORRODED CONNECTORS 7 OPEN OR DEFECTIVE CIRCUIT BETWEEN ON OFF RELAY CAVITY C9 AND BCM CONNECTOR TERMINAL 4C OPEN OR DEFECTIVE...

Page 335: ...LDINGS 1 ARM S OUT OF POSITION 1 REMOVE ARM OFF PIVOT SHAFT CYCLE MODULE TO PARK REPOSITION ARM BLADE TO LOCATION MARKS ON WINDSHIELD SECURE ARM TO PIVOT SHAFT AND TORQUE TO SPECIFICATION WIPER BLADE S STREAK 1 CONTAMINATION ON BLADE ELEMENT OR WINDSHIELD 2 BLADE ELEMENT DAMAGED 1 CLEAN BLADE ELEMENT EDGE WITH MILD SOAP OR ALCOHOL AND WATER CLEAN WINDSHIELD WITH MILD SOAP OR NON ABRASIVE CLEANSER ...

Page 336: ...able remote terminal from the remote battery post 2 Remove the Washer Reservoir Refer to Washer Reservoir Removal and Installation in this section 3 Gently pry sensor away from reservoir and out of grommet Care must be taken not to puncture res ervoir Fig 10 4 Remover rubber grommet from reservoir and throw away INSTALLATION For installation reverse the above procedures NOTE Use a new mounting gro...

Page 337: ...remote battery post 2 Hoist vehicle 3 Remove front fascia as necessary left side only and use a 2x4 to prop left edge of fascia away from body Refer to Group 23 Body for Removal and Installation procedures 4 Disconnect the wire connectors from the reser voir pump and float sensor 5 Disconnect the washer hose and block the liq uid outlet to prevent the liquid from running out of the reservoir 6 Rea...

Page 338: ...d and disconnect the negative battery cable remote terminal from the remote battery post 2 Hoist vehicle 3 Remove front fascia as necessary left side only and use a 2x4 to prop left edge of fascia away from body Refer to Group 23 Body for Removal and Installation procedures 4 Reach up behind the washer reservoir and pull the filler tube off the rear of the reservoir 5 Remove one screw attaching wa...

Page 339: ...OVAL 1 Lift wiper arm to raise blade off glass 2 Remove blade assembly from arm by pushing release tab under arm tip and slide blade away from arm tip Fig 12 and Fig 13 The vertebra is curved on the right blade only Install with the curve matching the shape of the windshield 3 Gently place wiper arm tip on glass surface INSTALLATION For installation reverse the above procedures NOTE The vertebra i...

Page 340: ... Fig 17 2 Remove one nut to crank arm and remove from motor Fig 19 3 Remove three retaining bolts from wiper motor Fig 19 4 Remove wiper motor from wiper module assem bly Install onto new wiper module assembly Refer to Wiper Motor Removal and Installation procedures in this section INSTALLATION For installation reverse the above procedures 1 Start rear outboard screw first rear inboard screw secon...

Page 341: ...ing grommets NOTE Grommet eyelet may need to be removed from rubber isolator on rear inboard and forward outboard mounting grommets only during disas sembly 6 Remove U nut from body if necessary INSTALLATION For installation reverse the above procedures NOTE When assembling master link or slave link to module frame use channel locks wrapped in cloth to prevent damage to ball and socket joint Apply...

Page 342: ...witch from inside of vehicle 3 After adjustment a final check of the spray pattern should be done by actuating the washer sys tem switch from inside the vehicle with engine idling This model is equipped with two hood mounted washer nozzles Each nozzle emits three streams into the wiper sweep pattern If nozzle performance is unsatisfactory they can be adjusted To adjust it is recommended to use a s...

Page 343: ......

Page 344: ...mp washers will spray for a preset amount of time controlled by a relay The headlamp washer system utilizes a separate high pressure pump that is attached to the wind shield washer reservoir The headlamp washer pump feeds four nozzles that are mounted behind the front fascia of the vehicle The nozzle bodies have a tele scopic action that will extend the nozzles in front of the headlamp assembly Du...

Page 345: ...VE CIRCUIT BETWEEN WIPER WASHER SWITCH CONNECTOR TERMINAL 2 AND MOTOR CONNECTOR TERMINAL 1 IF NOT OK REPAIR CIRCUIT 7 OPEN OR DEFECTIVE CIRCUIT BETWEEN WASHER MOTOR CONNECTOR GROUND TERMINAL 2 AND LEFT HEADLAMP GROUND 5 OR ENGINE GROUND 1 OR 2 8 CHECK FOR AN OPEN CIRCUIT ON MOTOR BETWEEN POWER TERMINAL 1 AND GROUND TERMINAL 2 IF NOT OK REPLACE WASHER MOTOR 9 APPLY DIRECT BATTERY VOLTAGE TO MOTOR T...

Page 346: ...ER SWITCH DIAGNOSTIC PROCEDURES 8 OPEN OR DEFECTIVE CIRCUIT BETWEEN WIPER WASHER SWITCH CONNECTOR TERMINAL 2 AND MOTOR CONNECTOR TERMINAL 1 IF NOT OK REPAIR CIRCUIT 9 OPEN OR DEFECTIVE CIRCUIT BETWEEN WASHER MOTOR CONNECTOR GROUND TERMINAL 2 AND LEFT HEADLAMP GROUND 5 OR ENGINE GROUND 1 OR 2 10 CHECK FOR AN OPEN CIRCUIT ON MOTOR BETWEEN POWER TERMINAL 1 AND GROUND TERMINAL 2 IF NOT OK REPLACE WASH...

Page 347: ...NSTALLATION 1 Connect the windshield washer pump hose headlamp washer pump hose filler tube and the wire connectors to reservoir 2 Install the reservoir retaining bolts Torque bolts to 5 to 7 N m 3 Reinstall the front fascia as necessary Refer to Group 23 Body for Removal and Installation proce dures 4 Reconnect the negative battery cable remote terminal 5 Lower vehicle from hoist 6 Refill the win...

Page 348: ...attery post HEADLAMP WASHER HOSES Removal 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post 2 Hoist vehicle 3 Remove the front fascia Refer to Group 23 Body for Removal and Installation procedures 4 Disconnect the headlamp washer hoses at the quick disconnect connectors Fig 5 Fig 6 5 Remove the headlamp washer hoses from the radiator closure panel I...

Page 349: ...Group 8L Lamps for Removal and Installation Pro cedures 4 Reinstall the front fascia as necessary Refer to Group 13 Body for Removal and Installation Proce dures 5 Lower vehicle from hoist 6 Refill the washer fluid 7 Prime the headlamp washer system Refer to the Headlamp Priming Procedure in this section Fig 5 Left Side Headlamp Washer Hoses 1 HEADLAMP WASHER HOSES QUICK DISCONNECT CONNECTORS 2 HE...

Page 350: ...headlamp washer pump from the res ervoir Installation 1 Install the headlamp washer motor in the windshield headlamp washer pump 2 Connect the headlamp washer pump hose and electrical connector 3 Install the reservoir retaining bolts Torque bolts to 5 to 7 N m 4 Reinstall the front fascia as necessary Refer to Group 23 Body for Removal and Installation proce dures 5 Lower vehicle from hoist 6 Refi...

Page 351: ...2000 LHS 300M CONCORDE AND INTREPID ...

Page 352: ...ace sockets and bulbs that are deformed from corrosion that could prevent a contin uous body ground Wire connectors can make intermittent contact or become corroded Before coupling wire connectors inspect the terminals inside the connector Male ter minals should not be bent or disengaged from the insulator Female terminals should not be sprung open or disengaged from the insulator Bent and sprung ...

Page 353: ...conds When the windshield wipers are turned OFF the Body Control Module will determine if the instru mentation and exterior illumination lamps should remain ON base upon the current ambient light level HEADLAMP SYSTEM DESCRIPTION The headlamp system is controlled completely by the Body Control Module BCM The BCM controls the Park lamps Headlamps and Front Fog Lamps using relays located in the Junc...

Page 354: ... COMPONENTS PER SONAL INJURY CAN RESULT CAUTION Do not touch the glass of halogen bulbs with fingers or other possibly oily surface reduced bulb life will result Do not use bulbs with higher candle power than indicated in the Bulb Application table at the end of this group Damage to lamp can result Do not use fuses circuit breakers or relays having greater amperage value than indicated on the fuse...

Page 355: ...of charge refer to Group 8A Battery 5 Battery is sulfated or shorted 5 Load test battery refer to Group 8A Battery 6 Poor lighting circuit Z1 ground 6 Test for voltage drop across Z1 ground locations refer to Group 8W Wiring Diagrams 7 Both headlamp bulbs defective 7 Replace both headlamp bulbs HEADLAMP BULBS BURN OUT FREQUENTLY 1 Charging system output too high 1 Test and repair charging system r...

Page 356: ...ch 5 Broken connection between BCM and headlamp parking lamp relay 5 Check Junction Block continuity Service as necessary 6 Faulty parking lamp headlamp relay 6 Replace relay 7 Faulty Body Control Module 7 Replace Body Control Module HEADLAMPS ILLUMINATE CONTINUOUSLY WITH IGNITION ON 1 Check headlamp switch circuit G52 for continuity If no continuity 1 Repair circuit 2 Check headlamp switch return...

Page 357: ...connectors and splices refer to Group 8W Wiring Diagrams FOG LAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system refer to Group 8A Battery 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations refer to Group 8W Wiring Diagrams 3 High resistance in fog lamp circuit 3 Test amperage draw of fog lamp circuit 4 B...

Page 358: ...ty fog lamp switch 3 Replace headlamp switch 4 Broken connector terminal or wire splice in fog lamp circuit 4 Repair connector terminal or wire splice 5 Broken connection between BCM and fog lamp relay 5 Test relay connectors in the Junction Block and the circuit to BCM Repair as necessary 6 Faulty fog lamp relay 6 Replace relay 7 Faulty Body Control Module 7 Replace Body Control Module LH LAMPS 8...

Page 359: ...beams should be used to verify low beam settings ALIGNMENT SCREEN PREPARATION 1 Position vehicle on a level surface perpendicu lar to a flat wall 7 62 meters 25 ft away from front of headlamp lens 2 If necessary tape a line on the floor 7 62 meters 25 ft away from and parallel to the wall 3 From the floor up 1 27 meters 5 ft tape a line on the wall at the center line of the vehicle Sight along the...

Page 360: ... 6 2 inches relative to the horizontal center line The low beams should be shielded when checking high beams Do NOT cover the headlamp s for extended periods as the heat may damage them To adjust headlamp alignment rotate the alignment screws Fig 2 and Fig 3 to achieve the specified pattern Fig 1 Headlamp Alignment Screen 1 LOW BEAM CENTER LINE TO GROUND 2 FRONT OF HEADLAMP 3 7 26 METERS 25ft 4 PR...

Page 361: ...adjust fog lamp alignment rotate the alignment screw Fig 5 Fig 6 or Fig 7 Fig 4 Fog Lamp Alignment Screen 1 HORIZONTAL CENTER LINE OF FOG LAMPS 2 TOP OF FOG LAMP BEAM PATTERN CUT OFF 6 4 INS FROM HORIZONTAL CENTER LINE 3 FRONT OF FOG LAMP 4 7 62 METERS 25 FT Fig 3 Headlamp Alignment Screws Intrepid 1 HORIZONTAL ADJUSTER 2 VERTICAL ADJUSTER Fig 5 Fog lamp Adjuster Screw Intrepid 1 FOG LAMP 2 UP DOW...

Page 362: ...Fig 6 Fog lamp Adjuster Screw LHS 1 UP DOWN ADJUSTER SCREW 2 FOG LAMP Fig 7 Fog lamp Adjuster Screw 300M 1 UP DOWN ADJUSTER SCREW 2 FOG LAMP LH LAMPS 8L 11 ADJUSTMENTS Continued ...

Page 363: ...rom headlamp housing Fig 1 3 Remove bulb from lamp wiring connector INSTALLATION CAUTION Do not touch the glass of halogen bulbs with fingers or other possibly oily surface reduced bulb life will result 1 Push bulb into lamp wiring connector 2 Place lamp socket into headlamp housing and rotate retaining ring to the lock position 3 Install headlamp housing HEADLAMP BULBS INTREPID Headlamp lens fogg...

Page 364: ...b into lamp housing 4 Hinge wire clip over bulb base 5 Engage wire clip to hold bulb in fog lamp 6 Install rear cover to fog lamp housing 7 Verify fog lamp operation and alignment 8 Install fog lamp housing screw to the front fas cia FOG LAMP BULB LHS REMOVAL 1 Remove fog lamp housing screw in front fascia and pull lamp housing from the front fascia 2 Disconnect wire connector from fog lamp socket...

Page 365: ...VAL 1 Reach under the fascia and remove the socket from the lamp housing Fig 6 2 Rotate and pull socket from lamp housing 3 Pull bulb from socket INSTALLATION 1 Push bulb into socket 2 Install socket into lamp housing 3 Verify park and turn signal lamp operation FRONT PARKING SIDE MARKER AND TURN SIGNAL LAMP BULB INTREPID REMOVAL 1 Release hood latch and open hood 2 Remove jackscrews attaching hea...

Page 366: ...e socket INSTALLATION 1 Install the bulb into the socket 2 Install socket into CHMSL housing 3 Verify CHMSL operation CHMSL AND APPLIQUE LAMP BULB S INTREPID REMOVAL 1 Release decklid latch and open decklid 2 Remove decklid cover 3 Disconnect lamp socket from housing Fig 10 4 Remove bulb from socket INSTALLATION 1 Install bulb into socket 2 Install socket into housing 3 Verify CHMSL operation 4 In...

Page 367: ... lens TAIL STOP BACK UP AND TURN SIGNAL LAMP BULB REMOVAL 1 Release decklid latch and open decklid 2 Remove trunk lining from rear closure panel as necessary to gain access to tail lamp fasteners 3 Remove nuts attaching tail lamp to rear clo sure panel 4 Remove tail lamp from rear closure panel 5 Remove socket s from tail lamp Fig 13 Fig 14 and Fig 15 6 Pull bulb from socket Fig 10 CHMSL Intrepid ...

Page 368: ...move socket from lamp Fig 16 4 Pull bulb from socket INSTALLATION 1 Push bulb into socket 2 Install socket into lamp 3 Place license plate lamp in position on rear bumper fascia 4 Install screws to attach license plate lamp to rear bumper fascia Fig 13 Tail Stop Back up and Turn Signal Lamp Bulb Concorde LHS 1 SOCKET 2 BULB Fig 14 Tail Stop Back up and Turn Signal Lamp Bulb Intrepid 1 BODY WIRE HA...

Page 369: ...uits The body controller uses input from the remote keyless entry system to switch ON the courtesy lamps Refer to Group 8W Wiring Diagrams for compo nent location and circuit information Refer to Body Systems Diagnostic Procedures Manual for complete diagnostic information ALL OTHER LIGHTING SYSTEMS Refer to Group 8W Wiring Diagrams for compo nent locations and circuit information For additional d...

Page 370: ... to upper radiator closure panel 6 Align the two fascia studs to the fender vertical attachments at the same time align the fascia groove on the horizontal flange with the fender drive pin Push fascia rearward to engage the fasteners 7 Install nut on fascia stud through the splash shield access hole 8 Verify headlamp operation and alignment Fig 1 Access Rubber Grommet 1 ACCESS RUBBER GROMMET Fig 2...

Page 371: ...mp to body 5 Verify headlamp operation and alignment FOG LAMP HOUSING REMOVAL 1 Remove screw s attaching fog lamp to fascia Fig 8 Fig 9 and Fig 10 2 Pull fog lamp forward from opening in front bumper fascia 3 Disconnect fog lamp wire connector from front lighting wire harness 4 Remove fog lamp from vehicle INSTALLATION 1 Place fog lamp in position on vehicle 2 Connect fog lamp wire connector to fr...

Page 372: ...s FRONT SIDE MARKER HOUSING LHS REMOVAL 1 Loosen fascia as necessary to access lamp 2 Remove bulb socket from lamp 3 Disconnect fasteners attaching side marker lamp to fascia Fig 11 4 Remove attaching fasteners 5 Remove lamp housing from vehicle INSTALLATION 1 Place lamp in position on fascia 2 Install lamp fasteners 3 Install bulb socket in lamp 4 Connect wire harness connector 5 Verify lamp oper...

Page 373: ...4 Connect CHMSL wire connector to body har ness 5 Verify CHMSL operation CHMSL AND APPLIQUE HOUSING INTREPID REMOVAL 1 Release decklid latch and open decklid 2 Remove decklid cover 3 Disconnect CHMSL wire connector from body harness Fig 14 4 Remove fasteners attaching CHMSL and appli que to the decklid 5 Remove CHMSL from decklid INSTALLATION 1 Place CHMSL in position on decklid 2 Install fastener...

Page 374: ...ire harness INSTALLATION 1 Connect tail lamp wire connector to body wire harness 2 Place tail lamp in position on vehicle 3 Install nuts to attach tail lamp to lower trunk and quarter panel 4 Place trunk lining in position on lower trunk panel 5 Install fasteners to attach trunk lining to lower rear trunk panel 6 Verify lamp operation Fig 14 CHMSL Housing Intrepid 1 TRUNK LID APPLIQUE AND CHMSL 2 ...

Page 375: ...vehicle INSTALLATION 1 Place license plate lamp in position on vehicle 2 Install screws to attach license plate lamp to fascia Fig 17 Tail Stop Back up and Turn Signal Intrepid Fig 18 Tail Stop Back up and Turn Signal 300M Fig 19 License Plate Lamp 1 APPLIQUE OR FASCIA 2 LICENSE PLATE LAMP 8L 24 LAMPS LH REMOVAL AND INSTALLATION Continued ...

Page 376: ...dlamp Switch 4798351 Instrument Cluster PC194 Radio ASC Analog Clock A9625 EXTERIOR LAMP BULBS CAUTION Do not use bulbs that have a higher can dle power than the bulb listed in the Bulb Applica tion Table Damage to lamp can result CAUTION Do not touch halogen bulbs with fingers or other oily surfaces Bulb life will be reduced EXTERIOR LAMP BULB CHART LAMP NAME BULB NUMBER Back up Concorde LHS 921 ...

Page 377: ...B NUMBER Air Bag LED Anti Lock Brake LED Brake Warning LED Charging System LED Check Engine LED Cruise 74 Door Open LED Engine Oil Pressure LED Engine Temperature LED High Beam 74 Low Fuel LED INDICATOR BULB NUMBER Low Washer Fluid LED Seat Belt LED Decklid Open LED Turn Signal PC194 Trac ON 74 Trac OFF LED NON DIMMER CONTROLLED INTERIOR LAMPS Service procedures for most of the lamps in the fol lo...

Page 378: ...surface reduced bulb life will result Do not use bulbs with higher candle power than indicated in the Bulb Application table at the end of this group Damage to lamp and or Daytime Run ning Lamp Module can result Do not use fuses circuit breakers or relays hav ing greater amperage value than indicated on the fuse panel or in the Owners Manual When it is necessary to remove components to ser vice an...

Page 379: ...ir 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 HEADLAMPS FLASH RANDOMLY 1 Poor lighting circuit Z1 ground 1 Test for voltage drop across Z1 ground locations refer to Group 8W 2 High resistance in headlamp circuit 2 Test amperage...

Page 380: ...NG 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 locations Refer to ...

Page 381: ...fective 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 LH DIAGNOSIS AND TESTING Continued 2000 LHS 300M...

Page 382: ...be FULL Add 2 94 kg 6 5 lbs of weight over the fuel tank for each estimated gallon of missing fuel ADJUSTMENTS HEADLAMP AND FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN NOTE 300M vehicle headlamps should be aligned using the low beams The high beams should be used to verify low beam settings ALIGNMENT SCREEN PREPARATION 1 Position vehicle on a level surface perpendicu lar to a flat wall 7 62 meters ...

Page 383: ...ce NOTE There are reference marks on the lens to assist in locating the lamp centers HEADLAMP ADJUSTMENT NOTE HEADLAMPS MUST BE ALIGNED WITH THE HEADLAMP LEVELING MOTOR IN THE 0 POSI TION Fig 1 The low beams should be aimed such that the cut off is 1 below the horizontal centerline established in step 6 of the alignment screen prepa ration For a 7 25m 25ft aiming distance this is 75mm 3in For a st...

Page 384: ...ment Screen Preparation paragraph in this section A prop erly aligned fog lamp will project a pattern on the alignment screen 100 mm 4 in below the fog lamp center line and straight ahead To adjust fog lamp alignment rotate the vertical alignment screw Fig 3 Fig 3 Fog lamp Adjuster Screw 1 FOG LAMP ADJUSTER SCREW 2 FRONT FOG LAMP Fig 2 Fog Lamp Alignment Screen 1 TOP OF FOG LAMP HIGH INTENSITY ZON...

Page 385: ...ssembly out far enough to gain access to the bulbs Fig 2 5 Twist and remove the headlamp bulb from the headlamp assembly Fig 3 6 Remove the electrical connector from the bulb INSTALLATION CAUTION Do not touch the bulb glass with fingers or other oily surfaces Reduced bulb life will result 1 Twist the new bulb into the headlamp assem bly 2 Reconnect the headlamp assembly electrical connectors and s...

Page 386: ...LB REMOVAL 1 Remove the headlamp assembly Refer to the Headlamp Assembly removal and Installation proce dure in this group 2 Twist and remove the city lamp socket from the headlamp assembly Fig 5 Fig 3 Headlamp Bulb 1 HEADLAMP ASSEMBLY 2 HEADLAMP BULB Fig 4 Front Parking Side Marker and Turn Signal Lamp Bulb 1 BULB 2 SOCKET Fig 5 City Lamp Housing 1 CITY LAMP SOCKET HOUSING 2 HEADLAMP ASSEMBLY LH ...

Page 387: ...cia and disconnect the electrical connector Fig 8 3 Remove the fog lamp assembly rear cover from the fog lamp assembly Fig 9 4 Disengage the fog lamp bulb retaining wire and remove the bulb from the fog lamp assembly Fig 10 Fig 6 City Lamp Bulb 1 CITY LAMP BULB 2 CITY LAMP HOUSING Fig 7 Front Fog Lamp 1 FRONT FOG LAMP ATTACHING SCREWS 2 FRONT FOG LAMP ASSEMBLY 3 FRONT BUMPER FASCIA Fig 8 Front Fog...

Page 388: ...ER LAMP BULB Removal 1 Insert a small flat screwdriver between the lamp and the body panel Disengage the lamp retain ing tabs Fig 11 Fig 12 Fig 9 Front Fog Lamp Assembly Rear Cover 1 FRONT FOG LAMP ASSEMBLY 2 FRONT FOG LAMP ASSEMBLY REAR COVER Fig 10 Front Fog Lamp Bulb 1 FRONT FOG LAMP ASSEMBLY 2 FRONT FOG LAMP BULB Fig 11 Side Repeater Lamp 1 SIDE REPEATER LAMP 2 FENDER Fig 12 Side Repeater Lamp...

Page 389: ...e deck lid latch and open the deck lid 2 Remove the tail lamp assembly attaching nuts Fig 14 3 Remove the tail lamp assembly from the vehi cle Fig 15 4 Disconnect the tail lamp assembly electrical connector 5 Twist and remove the bulb socket from the tail lamp assembly Fig 16 Fig 17 6 Pull the bulb from the socket Fig 13 Side Repeater Lamp Socket 1 BULB SOCKET 2 REPEATER LAMP Fig 14 Tail Lamp Asse...

Page 390: ...bumper fascia 2 Remove the license plate lamp from the rear bumper fascia Fig 10 3 Twist and remove the socket from the lamp Fig 11 Fig 16 Tail Lamp Bulbs 1 REAR TURN SIGNAL LAMP 2 REAR TAIL LAMP 3 REAR TAIL STOP LAMP 4 REAR TAIL FOG LAMP 5 BACK UP LAMP 6 TAIL LAMP ASSEMBLY Fig 17 Tail Lamp Bulb Socket 1 TAIL LAMP ASSEMBLY Fig 18 Rear License Plate Lamp 1 REAR LICENSE PLATE LAMPS Fig 19 Rear Licen...

Page 391: ...eck lid latch and open deck lid 2 Remove the trunk lid cover 3 Grasp the chmsl lamp socket and rotate coun terclockwise Separate the bulb lamp socket from the lamp assembly Fig 20 4 Remove the bulb from the socket Installation 1 Install the bulb into the socket 2 Install the socket into the lamp assembly 3 Install the deck lid cover Fig 20 CHMSL 1 CHMSL BULB SOCKET 2 CHMSL BULB 3 CHMSL 4 CHMSL FAS...

Page 392: ...he headlamp sight shield Remove pushpins and remove sight shield 2 Partially remove the front fascia to gain access to the headlamp assembly Refer to Group 13 Frame and Bumpers for Removal and Installation proce dures 3 Remove the jackscrews attaching the headlamp assembly to the body Fig 1 4 Pull the headlamp assembly out and disconnect the electrical connectors Fig 2 INSTALLATION CAUTION Do not ...

Page 393: ...d moving by hand Rotate the motor back into position to secure in place 3 Push down on outboard lamp until leveling motor ball stud snaps into place Ensure that the ball stud is fully seated 4 Connect the headlamp leveling motor wire con nector 5 Install the headlamp assembly on the vehicle Refer to the procedure in this group 6 Verify headlamp leveling motor operation 7 Align the headlamps Refer ...

Page 394: ...n the lamp into the body opening and push into place TAIL LAMP ASSEMBLY Removal 1 Release the deck lid latch and open the deck lid 2 Remove the tail lamp assembly attaching nuts Fig 8 Fig 5 Side Repeater Lamp 1 SIDE REPEATER LAMP 2 FENDER Fig 6 Side Repeater Lamp Retaining Tabs 1 RETAINING TABS 2 REPEATER LAMP 3 FENDER Fig 7 Side Repeater Lamp Socket 1 BULB SOCKET 2 REPEATER LAMP Fig 8 Tail Lamp A...

Page 395: ...Remove the license plate lamp from the rear bumper fascia Fig 10 3 Twist and remove the socket from the lamp Fig 11 Installation 1 Install the socket into the lamp 2 Place the license plate lamp in position in the rear bumper fascia 3 Install the screws attaching the rear license plate lamp to the rear bumper fascia Fig 9 Tail Lamp Assembly 1 REAR TAIL LAMP ASSEMBLY Fig 10 Rear License Plate Lamp ...

Page 396: ...mbly fasteners Fig 12 5 Remove the chmsl lamp assembly from the deck lid Installation 1 Install the chmsl lamp assembly into the deck lid 2 Install the chmsl lamp assembly fasteners 3 Install the socket into the lamp assembly 4 Install the deck lid cover Fig 12 CHMSL Lamp Assembly 1 CHMSL BULB SOCKET 2 CHMSL BULB 3 CHMSL 4 CHMSL FASTENER 5 CHMSL FASTENER LH LAMPS 8L 19 REMOVAL AND INSTALLATION Con...

Page 397: ...he lenses SPECIFICATIONS EXTERIOR LAMP BULBS LAMP BULB Back up P27 7W CHMSL W16W Front Fog Lamp H3 55W Headlamp Low Beam 9006 HB4 Headlamp High Beam 9005 HB3 License Plate W5W Front Turn Signal P27 7W Citylight W5W Side Repeater T4W Tail Stop Fog P27 7W Rear Turn Signal P27 7W Rear Tail Lamp W5W INTERIOR LAMP BULBS LAMP BULB A C Heater Control 330 Airbag LED Analog Clock A9625 Anti Lock Brake LED ...

Page 398: ...es confirmation of a crash dis criminating severity The ORC monitors the system to determine the system readiness The ORC may store sufficient energy to deploy the airbags for only two minutes after the battery is disconnected The ORC contains on board diagnostics and will illumi nate the AIRBAG warning lamp on the cluster when a fault occurs The warning equipment is tested for a few seconds every...

Page 399: ...ceeded The ORC is calibrated for a particular vehicle family and uses an advanced software algo rithm to discriminate the severity and direction of any vehicle event PASSENGER AIRBAG MODULE WARNING NEVER DISASSEMBLE THE DRIVER PASSENGER AIRBAG MODULES THERE ARE NO SERVICEABLE PARTS WITHIN THE MODULES DESCRIPTION The Passenger Airbag Module is located beneath the instrument panel and pad assembly T...

Page 400: ... time of airbag deployment operate blower motor on low speed and vacuum powder residue expelled from the heater and A C outlets Multiple vacuum cleaning may be necessary to decontaminate the interior of the vehicle Place the deployed driver and passenger airbag modules along with the instrument panel and center duct in your automotive scrap SERVICE OF DEPLOYED AIRBAG MODULE DRIVER AIRBAG After a D...

Page 401: ...ROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN PERSONAL INJURY WHEN CARRYING OR HAN DLING AN UNDEPLOYED AIRBAG MODULE THE TRIM SIDE OF THE AIRBAG SHOULD BE POINTING AWAY FROM THE BODY TO MINIMIZE POSSIBILITY OF INJURY IF ACCIDENTAL DEPLOYMENT OCCURS REPLACE AIRBAG SYSTEM COMPONENTS WITH MOPART REPLACEMENT PARTS SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE BUT INTERNAL DIFFERENCES M...

Page 402: ...ise 7 Route speed control wires under and behind the airbag module mounting tabs 8 Connect the horn lead wire and the airbag lead wire to the airbag module 9 Install the airbag module and torque bolts to 7 9 N m 65 85 in lbs torque 10 Connect the speed control wires to the switches and install switches Torque screws to 1 5 N m 13 in lbs torque 11 Do not connect the battery negative cable remote te...

Page 403: ...dule cannot be lifted out the pas senger side screw needs some additional loosen ing 14 Remove the ORC from vehicle INSTALLATION WARNING THE ORC IS A SAFETY MODULE AND FAILURE TO INSTALL AND SECURE IT PROPERLY COULD CAUSE THE MODULE TO POSSIBLY MAL FUNCTION 1 Position the ORC arrow pointing forward in vehicle on the ORC mounting bracket The mounting bosses on the module will correctly position the...

Page 404: ... and remove the glove box door 3 Remove right instrument panel endcap 4 If equipped with center console Remove the gearshift handle set screw and then remove the gear shift handle Remove the console shifter bezel Remove the right console side trim panel 5 Accessing through the glove box door remove five screws to the glove box close out assembly 20 in lbs torque Fig 6 6 Remove the left and right A...

Page 405: ...ue Fig 7 34 Remove the airbag module assembly from the instrument panel retainer 35 Remove four screws to the reinforcement brace on the old airbag module 20 in lbs torque Fig 8 INSTALLATION 1 Install the reinforcement bracket on to the new airbag module Tighten to 20 in lbs 2 3 N m For installation reverse the above procedures Refer to Diagnosis and Testing for Airbag System Test procedures DEPLO...

Page 406: ...wires through the larger opening of the hub area on the wheel Install steering wheel ensur ing the flats on hub align with the clockspring Ensure leads do not get pinched under the steering wheel 3 Install retaining nut and torque it to 61 N m 45 ft lbs 4 Route speed control wires through the slots in the steering wheel back cover 5 Connect the horn lead wire and the airbag lead wire to the airbag...

Page 407: ......

Page 408: ...5 LEFT SEAT AIRBAG WIRE HARNESS 17 RIGHT SEAT AIRBAG WIRE HARNESS 19 STEERING WHEEL 20 ADJUSTMENTS CLOCKSPRING CENTERING PROCEDURE 20 SPECIFICATIONS TORQUE SPECIFICATIONS 20 DESCRIPTION AND OPERATION SIDE IMPACT AIRBAG RESTRAINT SYSTEM DESCRIPTION Vehicles equipped with the side impact airbag restraint system utilize two airbags mounted to each front seat back frame Fig 1 This system designed to p...

Page 409: ...Fig 1 LH FRONT SEAT BACKS EQUIPPED WITH AIRBAGS 8M 2 PASSIVE RESTRAINT SYSTEMS LH DESCRIPTION AND OPERATION Continued 2000 LHS 300M CONCORDE AND INTREPID ...

Page 410: ... body B pillar Fig 2 OPERATION Each side impact airbag control module serves as the impact sensor for its seat mounted airbag The right side SIACM controls the right seat airbag Fig 3 The left side SIACM controls the left seat airbag Fig 3 Each SIACM contains two accelerometers both accelerometers must agree in order to deploy the side airbag In the event of a side impact the appropriate SIACM wil...

Page 411: ...L MODULE SIACM 2 VEHICLE BODY B PILLAR 3 RIGHT SEAT AIRBAG MODULE 4 LEFT SEAT AIRBAG MODULE 5 LEFT SIDE IMPACT AIRBAG CONTROL MODULE SIACM 6 OCCUPANT RESTRAINT CONTROLLER 8M 4 PASSIVE RESTRAINT SYSTEMS LH DESCRIPTION AND OPERATION Continued 2000 LHS 300M CONCORDE AND INTREPID ...

Page 412: ...rbag control module can deploy the seat side airbags When supplied with the proper electrical signal the seat airbag s inflator will produce a gas and discharge the bag directly between the occupant and the side of the vehicle Protecting the occupant Upon deployment the seat back trim cover will tear open and allow the side airbag to fully inflate Fig 4 Airbag Module LH PASSIVE RESTRAINT SYSTEMS 8...

Page 413: ...Fig 5 LH AIRBAG FRONT SEAT BACKS 8M 6 PASSIVE RESTRAINT SYSTEMS LH DESCRIPTION AND OPERATION Continued 2000 LHS 300M CONCORDE AND INTREPID ...

Page 414: ...ON OPERATION The driver side inflator assembly is mounted from the back of the module housing When supplied with the proper electrical signal the inflator assembly will produce a gas and discharge it directly into the cush ion A protective cover is fitted to the front of the Driver Airbag Module and forms a decorative cover in the center of the steering wheel This cover incor porates the integral ...

Page 415: ...ssembly The module is mounted to a bracket welded to the floor pan with three screws OPERATION The passenger inflator assembly is within the mod ule housing When supplied with the proper electrical signal the inflator will produce a gas and discharge it directly into the cushion Upon deployment the instrument panel upper cover will tear open and allow the passenger airbag to fully inflate DIAGNOSI...

Page 416: ...ior may contain a very small amount of sodium hydroxide powder a by product of 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...

Page 417: ...rbags should be stored in a cool dry loca tion away from excessive heat and static electrical activity with the fabric airbag facing UP or a prema ture deployment can result If the Driver Passenger Airbag Module is defective and not deployed refer to Chrysler Corporation cur rent return list for proper handling procedures OCCUPANT RESTRAINT CONTROLLER ORC WARNING THE ORC CONTAINS AN ACCELEROM ETER...

Page 418: ...t clockwise The column is locked with the ignition cylinder lock Locate the clockspring on the steering shaft and push down on the rotor until the clockspring is fully seated on the steering column Fasten clockspring to steering column using the two mounting screws and torque screws to 24 in lbs 2 7 N m 2 Connect the clockspring to the instrument panel harness ensure wiring is properly routed Then...

Page 419: ...ift handle Remove the console shifter bezel Remove the right console side trim panel 5 Accessing through the glove box door remove five screws to the glove box close out assembly 20 in lbs torque Fig 11 6 Remove the left and right A pillar trim mold ings 7 Remove the left instrument panel endcap 8 Remove the left lower instrument panel trim cover Disconnect the hood release cable and decklid relea...

Page 420: ...bag System Test procedures DEPLOYED MODULE The instrument panel must be removed for DEPLOYED Passenger Airbag Module service REMOVAL When removing a deployed module rubber gloves eye protection and a long sleeved shirt should be worn There may be deposits on the surface which could irritate the skin and eyes 1 Open hood and disconnect the negative battery cable remote terminal from the remote batt...

Page 421: ...lower and airbag side of seat back 5 Disconnect the side airbag module electrical connector Fig 15 Slide yellow locking tab down to unlock Then with two fingers push two side retain ing tabs in and pull connector straight from module 6 Remove the side airbag module retaining nuts Fig 16 7 Grasp the upper airbag side of the seat back trim cover and pull trim cover and cushion over top of seat back ...

Page 422: ... tab is in the upper locked posi tion Check to be certain connector cannot be removed once yellow locking tab is positioned 5 Position seat back trim cover and install seat back trim cover J straps on the upper lower and air bag side of seat back frame CAUTION ALWAYS INSTALL NEW PUSHPINS WHEN INSTALLING SEAT BACK PLASTIC BACK PANEL 6 Install the plastic back panel on the seat back Install new push...

Page 423: ...rim cover and pull trim cover and cushion over top of seat back frame Fig 20 This will allow room to remove side airbag module without damaging trim cover or cushion 8 Working between seat back trim cover cushion and frame unhook airbag module studs from nylon sleeve and slide module out of sleeve Be careful not to tear nylon sleeve as this will affect function of air bag system CAUTION BE CERTAIN...

Page 424: ... back cover Refer to Group 23 Body for a detailed procedure CAUTION BE CERTAIN PLASTIC BACK PANEL IS SECURELY INSTALLED ON THE SEAT BACK FAIL URE TO DO SO WILL ADVERSELY AFFECT THE AIRBAG SYSTEM 7 Connect the negative battery cable 8 Using the DRB III Scan Tool erase any stored DTC s and perform Airbag System Diagnostics LEFT SEAT AIRBAG WIRE HARNESS WARNING DISCONNECT AND ISOLATE THE NEG ATIVE BA...

Page 425: ... cannot be removed once yellow locking tab is positioned 3 Install seat back trim cover J straps on the upper lower and airbag side of seat back frame CAUTION ALWAYS INSTALL NEW PUSHPINS WHEN INSTALLING SEAT BACK PLASTIC BACK COVER 4 Install the plastic back panel on the seat back Install new pushpins in the upper mounting location of the back cover Refer to Group 23 Body for the procedure 5 Insta...

Page 426: ...the wire har ness Fig 25 from the seat assembly INSTALLATION 1 Install airbag wire harness in seat Be certain wire harness routing is correct Harness should fol low leading edge of seat back frame down into lower seat cushion Once inserted in lower cushion harness is positioned between the cushion pan and seat track and held in place with pushpin Fig 25 2 Connect the side airbag module electrical ...

Page 427: ...ft lbs 4 Route speed control wires through the slots in the steering wheel back cover 5 Connect the horn lead wire and the airbag lead wire to the airbag module 6 Install the airbag module and torque bolts to 7 to 9 N m 65 to 85 in lbs 7 Connect the speed control wires to the switches and install switches Torque screws to 1 4 to 2 0 N m 12 to 18 in lbs 8 Do not connect the battery negative cable r...

Page 428: ...s Side impact airbag control module to B pillar 7 N m 62 in lbs Occupant restraint controller to bracket 7 N m 62 in lbs Clockspring to steering column 2 7 N m 24 in lbs Steering wheel retaining nut 61 N m 45 ft lbs Front driver side airbag module 7 N m 62 in lbs Front passenger side airbag module 7 N m 62 in lbs LH PASSIVE RESTRAINT SYSTEMS 8M 21 SPECIFICATIONS Continued 2000 LHS 300M CONCORDE AN...

Page 429: ...2000 LHS 300M CONCORDE AND INTREPID ...

Page 430: ...ill only operate when the ignition switch is in the run position Once the Rear Widow Defogger button is pushed the button indica tor will light and the system will operate for a period of time and then automatically turn off Refer to the owner s manual for operation of the A C Heater or ATC control When the rear window defogger relay is ON cur rent is directed to the rear defogger grid lines The h...

Page 431: ...ehicle electrical ground 3 Touch the positive bus bar and check voltage The voltage should be above 11 volts Push the Rear Window Defogger button to turn off the indicator The measured voltage should be 0 volts If these volt ages are correct then the problem is with the Rear Window Grid or Grid ground electrical connection Go to the Grid Lines test to check the Grid and ground connection If there ...

Page 432: ... the ohm meter still indicates less than 10 ohms then the rear window defogger grid is shorting to the vehicle ground and must be replaced If the ohmmeter indi cates more than 100 ohms of resistance then go to Step 6 6 There is a problem with the circuits that con nect to the rear window defogger relay Refer to Group 8W Wiring Diagrams for circuit descriptions Check wiring with an ohmmeter to veri...

Page 433: ... CONNECTION BETWEEN PINS 1 TO 2 OF THE REAR WINDOW DEFOGGER RELAY ON MORE THAN 11 0 0 0 0 0 OPEN FUSE OR OPEN WIRING CONNECTION TO PIN 1 OF REAR WINDOW DEFOGGER RELAY ON 0 0 0 0 0 0 RELAY CONTACTS SHORTED REPLACE RELAY REAR WINDOW DEFOGGER WILL NOT TURN OFF OFF MORE THAN 11 MORE THAN 11 MORE THAN 11 MORE THAN 11 MORE THAN 11 0 SERVICE PROCEDURES REPAIR GRID LINES TERMINALS AND PIGTAILS The repair ...

Page 434: ...ONTACT WITH SKIN AND EYES FOR SKIN WASH AFFECTED AREAS WITH SOAP AND WATER DO NOT TAKE INTERNALLY IF TAKEN INTER NALLY INDUCE VOMITING CALL A PHYSICIAN IMMEDIATELY IF IN CONTACT WITH EYES FLUSH WITH PLENTY OF WATER USE WITH ADEQUATE VENTILATION DO NOT USE NEAR FIRE OR FLAME CONTENTS CONTAIN 3 PERCENT FLAMMABLE SOLVENTS KEEP OUT OF REACH OF CHILDREN REMOVAL AND INSTALLATION HEATER A C ATC CONTROL R...

Page 435: ... activated the temperature in the seat rises the Negative Temperature Coefficient NTC resistance decreases and the voltage reading detected by the MHSMM increases The seat heater output is deacti vated once the voltage reading reaches its upper threshold for either of the settings HI or LO As the temperature decreases the voltage reading decreases until the lower threshold is reached for either se...

Page 436: ...emoval and Installation DIAGNOSIS AND TESTING HEATED SEAT SYSTEM For circuit descriptions and diagrams refer to Group 8W Wiring Diagrams Before testing the individual components in the heated seat system cheek the following If the heated seat switch LED doesn t light up with the ignition in the ON position and the switch in the LO or HI position check the battery voltage If the battery is below 10...

Page 437: ...re harness connec tor If there is continuity go to Step 3 otherwise replace the faulty seat cushion cover 3 Check the continuity between one of the heated seat driver circuit cavities of the seat cushion cover half of the heated seat cushion wire harness connec tor and the seat cushion frame If there isn t any con tinuity go to the Seat Back test otherwise replace the faulty seat cushion cover SEA...

Page 438: ...ative battery cable remote terminal from the remote battery post Fig 5 2 Unscrew the side shield on the seat either driver or passenger side Fig 6 3 From the bottom disengage the switch and gently rock through the opening INSTALLATION For installation reverse the above procedures MEMORY HEATED SEAT MIRROR MODULE MHSMM Refer to Group 8R Power Seats for Removal and Installation procedures Fig 5 Nega...

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Page 440: ... control and protection fea tures including Fuses Fuse cartridges Fusible links Automatic resetting circuit breakers Relays Flashers Timers Circuit splice blocks The power distribution system for this vehicle con sists of the following components Power Distribution Center PDC Junction Block JB Accessory power outlet Following are general descriptions of the major components in the power distributi...

Page 441: ...omponents as well as to distribute electrical current to many of the accessory systems in the vehicle It eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment instrument panel and body wire harnesses The JB is positioned on a mounting bracket up and under the left instrument panel It is secured by four screws The JB i...

Page 442: ...connectors are in good condition and connectors are properly installed POWER DISTRIBUTION CENTER The Power Distribution Center PDC is serviced as a unit with the engine compartment wire harness If any internal circuit of the PDC or the PDC hous ing is faulty or damaged the entire PDC and engine compartment wire harness unit must be replaced REMOVAL 1 Disconnect and isolate the battery negative rem...

Page 443: ...ng provisions in the vehicle body and chassis compo nents Make sure to make clip attachment into the rail located behind the PDC Refer to 8W 90 Con nector Locations in Group 8W Wiring Diagrams for more information on the harness routing and retainer locations 5 Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis c...

Page 444: ...ocked by actuation of the inside remote door handle The deck lid can be unlatched by either depressing the push switch from inside the car manually by key from outside or by depressing the remote keyless entry deck lid release button two times This feature is customer programmable The customer has a choice of one or two button presses for deck lid open ing The vehicle is shipped in the button pres...

Page 445: ...yless Entry RKE system allows locking and unlocking of vehicle door s and deck lid by remote control using a hand held radio frequency RF transmitter OPERATION The ignition switch must be OFF before the trunk lid can be unlatched with the transmitter The receiver may be programmed with up to four transmitters vehicles are shipped with two Each transmitter has its own code and the code has been sto...

Page 446: ...fuse 13 in the Junction Block for a blown fuse Refer to Group 8W Wiring Diagrams for circuit information REMOVAL AND INSTALLATION DECK LID RELEASE MOTOR REMOVAL 1 Disconnect and isolate the negative battery cable remote terminal from the remote battery post 2 Raise deck lid to the full up position 3 Remove latch cover attaching screws then remove cover 4 Remove two mounting motor screws and remote...

Page 447: ... transmitter has four buttons for operation They are LOCK UNLOCK DECK LID RELEASE and PANIC The UNLOCK button will unlock the driver s door and enable illuminated entry Pushing and releasing the button once will unlock the driver s door Pushing and releasing the button two times within a five second interval will unlock all doors Upon pressing the LOCK button the horn will sound a short CHIRP if e...

Page 448: ...er terminal measures battery voltage check for an open or shorted circuit to the Junction Block repair as needed If battery voltage is still not available check the high current fuse G in the Power Distribution Center located in the engine compartment To diagnose the Remote Keyless Entry RKE Sys tem use a DRBIIIt scan tool and refer to Power Door Lock System in the proper Body Diagnostic Pro cedur...

Page 449: ...It scan tool or by the customer PROGRAMMING TRANSMITTER WITH THE DRB IIIT SCAN TOOL For procedures on programming the transmitter s with the DRB IIIt scan tool refer to the proper Body Diagnostic Procedures Manual PROGRAMMING BY CUSTOMER For a customer to be able to program RKE trans mitters themselves at least one RKE transmitter must be programmed already This procedure is to add additional tran...

Page 450: ...n the side slot of the transmitter and twist the halves should separate and the batteries are stacked on top of eachother The batteries are avail able at local retail stores Recommended batteries are Panasonic CR 2016 or equivalent Battery life is about two years Fig 1 TRANSMITTER RANGE Operation range is within 12 meters 40 ft of the module receiver LH POWER LOCK SYSTEMS 8P 7 ADJUSTMENTS Continue...

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Page 452: ...tart again The electronics for the VTSS are part of the Body Control Module BCM The system is armed when the vehicle is locked using the Power door lock switches Remote Keyless Entry transmitter For vehicles equipped with SKIS the doors do not have to be locked to enable the fuel shut off feature After the vehicle is locked and the last door is closed the set LED indicator in the top cover will fl...

Page 453: ...mits and receives RF signals through a tuned antenna enclosed within a molded plastic ring formation that is integral to the SKIM housing When the SKIM is properly installed on the steering column the antenna ring is oriented around the circumference of the ignition lock cylinder hous ing Fig 1 This antenna ring must be located within eight millimeters 0 31 inches of the Sentry Key in order to ens...

Page 454: ...le SKIM The VTSS SKIS indicator LED is hard wired directly to the BCM OPERATION The SKIM sends messages to the BCM to turn the LED on for about three seconds when the ignition switch is turned to the ON position as a bulb test After completion of the bulb test the SKIM sends bus messages to the BCM to keep the LED off for a duration of about one second Then the SKIM sends messages to the BCM to tu...

Page 455: ...NT 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 NOTE The following tests may not prove conclu sive in the diagnosis of this system The most reli able efficient and accurate means to diagnose the Sentry Key Immobilizer ...

Page 456: ... requires access to at least two of the valid Sentry Keys If two valid Sentry Keys are not available Sen try Key programming will require the use of a DRB IIIt scan tool and the proper Body Diagnostic Proce dures Manual CUSTOMER LEARN 1 Obtain the additional Sentry Key transponder blank s that are to be programmed for the vehicle Cut the additional Sentry Key transponder blanks to match the igniti...

Page 457: ...tallation reverse the above procedures LOCK CYLINDER SWITCH REMOVAL 1 Open hood disconnect and isolate the negative battery cable remote terminal from the remote bat tery post 2 Refer to Group 23 Body for door trim and water shield Removal and Installation 3 Disconnect wiring clip and pigtail wire connec tor Fig 7 4 Remove the Door Key Cylinder Switch from door lock cylinder Fig 4 Deck Lid Latch C...

Page 458: ...allation 4 Disengage the steering column wire harness from the Sentry Key Immobilizer Module SKIM 5 Remove the one screw securing the SKIM to the bottom of the steering column 6 Slide the SKIM away from the steering column to clear the SKIM antenna ring from around the ignition switch lock cylinder housing Fig 1 7 Remove the SKIM from the vehicle INSTALLATION 1 For installation reverse the above p...

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Page 460: ...rts The two single gear motor assem blies attach to the seat tracks provide the various seat movements The electrical circuit is protected by a 20 amp cir cuit breaker located on the Junction Block and a 40 amp fuse in the Power Distribution Center POSITION SENSING POWER SEAT POTENTIOMETERS DESCRIPTION A potentiometer is mounted to each seat motor to provide a sense voltage to the MHSMM that will ...

Page 461: ...MHSMM ACTIVATION The Power Seat Switch Diagnostic Test can only be activated by sending the proper PCI bus command via the DRB lll scan tool to enter diagnostic test number 2 Upon activation of the test the operator has ten seconds to activate all switches manual seat switches all 8 directions 3 memory switches and both driver and passenger heat HI and LO requests but not including the mirrors At ...

Page 462: ... PIN 3 FORWARD FORWARD PIN 3 PIN 10 REARWARD REARWARD PIN 8 PIN 7 REAR RISER UP REAR RISER DOWN PIN 7 PIN 8 REAR RISER DOWN REAR RISER UP PIN 4 PIN 2 RECLINER UP RECLINER UP PIN 2 PIN 4 RECLINER DOWN RECLINER DOWN SEAT SWITCH CONTINUITY TEST SWITCH POSITION CONTINUITY BETWEEN PINS DRIVER PASSENGER OFF PIN 5 TO 4 PIN 5 TO 3 PIN 5 TO 2 PIN 5 TO 10 PIN 5 TO 9 PIN 5 TO 8 PIN 5 TO 7 PIN 5 TO 6 PIN 5 TO...

Page 463: ...OVAL 1 Open hood disconnect and isolate the negative battery cable remote terminal from the remote bat tery post Fig 5 2 Remove cushion side shield Fig 6 3 Disconnect wiring from switch 4 Remove knobs from the switch 5 Remove four switch attaching screws 6 Remove switch from cushion side shield INSTALLATION For installation reverse the above procedure Fig 4 Seat Adjuster Removal 1 TRACK TO SEAT CU...

Page 464: ...g the power mirror switch and doesn t require the use of the module The MHSMM monitors the memory switches and has the capability to store desired positions in mem ory in response to a valid input sequence Refer to Memory Selector Switches 1 2 and S and Remote Keyless Entry RKE The memory heated seat and mirror module will activate the seat and mirror motors in response to a recall request from an...

Page 465: ...y position using the RKE is as follows 1 Press memory switch 1 and release to recall memory position 1 2 Adjust the seat recliner and side view mirrors to the desired position 3 Press momentarily and release memory switch S 4 Press momentarily and release memory switch 1 or 2 5 Press and release the UNLOCK button on one of the RKE transmitters Do NOT press any switch for 10 seconds 6 Set radio sta...

Page 466: ...gative battery cable remote terminal from the remote battery post 2 Unscrew the side shield on the seat either driver or passenger side Fig 4 3 From the bottom disengage the switch and gently rock through the opening INSTALLATION For installation reverse the above procedures Fig 3 Memory Heated Seat Mirror Module Location 1 MHSMM 2 RECLINER MOTOR 3 SEAT HEATER 4 WAY CONNECTOR 4 SEAT BACK HEATER 2 ...

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Page 468: ...TION AND OPERATION SIDE IMPACT AIRBAG RESTRAINT SYSTEM DESCRIPTION Vehicles equipped with the side impact airbag restraint system utilize two airbags mounted to each front seat back frame Fig 1 This system designed to protect occupants in the event of a side impact col lision OPERATION The side impact airbag control module SIACM controls the seat back mounted airbags If the SIACM determines the im...

Page 469: ...Fig 1 LH FRONT SEAT BACKS EQUIPPED WITH AIRBAGS 8R 2 POWER SEAT SYSTEMS LH DESCRIPTION AND OPERATION Continued 2000 LHS 300M CONCORDE AND INTREPID ...

Page 470: ... ities for responses are as follows Seat Track Rearward Seat Front Down Seat Rear Down Seat Recliner Rearward Seat Track Forward Seat Front Up Seat Rear Up Seat Recliner Forward DIAGNOSIS AND TESTING DIAGNOSTIC PROCEDURE Before any testing is attempted the battery should be carefully charged and all connections and termi nals cleaned and tightened to insure proper continu ity and grounds With dome...

Page 471: ...scribed in the Seat Motor Test table SWITCH TEST 1 Remove switch refer to Switch Removal and Installation in this section 2 Using an ohmmeter perform the Seat Switch Continuity Test table and Fig 4 If there is no con tinuity at any of the switch positions replace switch VOLTAGE The following test will determine whether or not voltage is continuous through the body harness to the seat switch NOTE P...

Page 472: ...SENGER OFF PIN 5 TO 4 PIN 5 TO 3 PIN 5 TO 2 PIN 5 TO 10 PIN 5 TO 9 PIN 5 TO 8 PIN 5 TO 7 PIN 5 TO 6 PIN 5 TO 4 PIN 5 TO 3 PIN 5 TO 2 PIN 5 TO 10 PIN 5 TO 9 PIN 5 TO 8 PIN 5 TO 7 PIN 5 TO 6 FRONT RISER UP PIN 5 TO 6 PIN 1 TO 9 PIN 5 TO 9 PIN 1 TO 6 FRONT RISER DOWN PIN 5 TO 9 PIN 1 TO 6 PIN 5 TO 6 PIN 1 TO 9 CENTER SWITCH FORWARD PIN 5 TO 3 PIN 1 TO 10 PIN 5 TO 3 PIN 1 TO 10 CENTER SWITCH REARWARD ...

Page 473: ...e negative battery cable remote terminal from the remote bat tery post Fig 7 2 Remove the seat cushion side shield Refer to Group 23 Body for the procedure 3 Disconnect wiring from switch 4 Remove knobs from the switch by gently prying straight off 5 Remove the switch attaching screws 6 Remove switch from cushion side shield INSTALLATION For installation reverse the above procedure Fig 6 Seat Adju...

Page 474: ...er side mirrors Each mirror has vertical and horizontal motors that contain potentiometers used to located the actual mirror position for recall purposes Normal electrical operation of the mirrors is accomplished by actuating the power mirror switch and doesn t require the use of the module The MHSMM monitors the memory switches and has the capability to store desired positions in mem ory in respo...

Page 475: ...r not Enable glide feature if disabled and go to Step 2 2 Turn the ignition ON and then back OFF Remove the key If seat glides rearward reinsert key and turn to ON position If seat doesn t glide for ward go to Step 3 otherwise the problem has been fixed If Learn Guard Bands test has been run and problem persists then replace MHSMM 3 Now run Learn Guard Bands Diagnostic test as shown in this sectio...

Page 476: ...OR MODULE MHSMM REMOVAL 1 Open hood disconnect and isolate the negative battery cable remote terminal from the remote bat tery post 2 Remove two module attaching screws Fig 3 3 Disconnect four module connectors 4 Remove module from vehicle INSTALLATION For installation reverse the above procedures MEMORY SELECTOR SWITCH REMOVAL 1 Disconnect and isolate the negative battery cable remote terminal fr...

Page 477: ...2000 LHS 300M CONCORDE AND INTREPID ...

Page 478: ...h the body harness to switch 1 Remove the driver door trim panel Refer to Group 23 Body for proper procedures 2 Carefully separate wiring harness connector from switch body Refer to Group 8W Wiring Dia grams 3 Using a voltmeter connect the ground lead to the Pin 10 of the wiring harness connector 4 Using the positive lead check Pin 1 of the har ness connector for battery voltage If OK go to Win do...

Page 479: ...attery cable remote terminal from the remote battery post Fig 4 3 Remove door trim panel and window regulator refer to Group 23 Body for Removal and Installation procedures WARNING FAILURE TO CLAMP THE SECTOR GEAR TO THE MOUNTING PLATE WHEN REMOV ING THE MOTOR CAN RESULT IN INJURY 4 Disconnect wiring connector from motor 5 Secure the sector gear and mounting plate with a C clamp or similar clampin...

Page 480: ...switch and remove switch from vehicle INSTALLATION For installation reverse the above procedures PASSENGER SWITCH REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Fig 4 2 Remove passenger door trim panel Refer to Group 23 Body Front Door Trim Removal and Instal lation 3 Disconnect switch wire connector 4 Remove switch from bezel and vehicle...

Page 481: ... bezel 4 Pull switch up and out of rear door trim panel 5 Using a trim stick gently pry out on retaining tabs on side of switch connector and pull connector from switch 6 Remove switch from vehicle INSTALLATION For installation reverse the above procedures 8S 4 POWER WINDOW SYSTEMS LH REMOVAL AND INSTALLATION Continued ...

Page 482: ...battery discharge during stor age when disconnected This fuse is included in the power mirror circuity and should be checked if the mirrors are inoperative HEATED MIRROR DESCRIPTION Heated mirrors are available with Memory Mirrors and Rear Window Defogger only OPERATION The heated mirror is controlled by the rear window defogger switch Only time that the heated mirror is on is when the rear window...

Page 483: ... go to Step 4 If not OK Step b b Check rear window defogger switch refer to Group 8N Electrically Heated Systems If OK go to Step c If not OK repair as necessary c If no voltage repair wire as necessary Refer to Group 8W Wiring Diagrams 4 Remove mirror glass and check wires If wires are OK replace mirror glass If not OK repair as necessary or replace mirror MIRROR MOTOR 1 Using a trim stick remove...

Page 484: ... procedures MIRROR SWITCH REMOVAL 1 Using a trim stick remove power mirror switch from mounting position 2 Disconnect wire connector 3 Remove switch INSTALLATION For installation reverse the above procedures MIRROR SWITCH TEST SWITCH POSITION MOVE BUTTON CONTINUITY BETWEEN TERMINALS MIRROR IN L POSITION UP PIN 11 TO 12 PIN 12 TO 13 PIN 9 TO 1 RIGHT PIN 11 TO 1 PIN 9 TO 7 PIN 9 TO 8 DOWN PIN 11 TO ...

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Page 486: ...SSIVE RESTRAINT SYSTEMS FOR STEERING WHEEL REMOVAL AND INSTALLATION DESCRIPTION The Chime Buzzer Warning System includes the following Exterior Lamps Left On chime An audible chime indicates the exterior lamps were left on Fasten Seat Belts chime A warning lamp on the instrument panel and an audible chime are used as the fasten seat belt warning reminder Key left in ignition chime An audible chime...

Page 487: ...terminal J1 7 and ignition feed at terminal J1 5 of the BCM connector 5 Check for tone in any other function No fasten seat belt lamp when ignition switch is turned on 1 Use DRB lllt scan tool to perform PCI bus diagnostics on BCM for battery and ignition switch input 2 Check for burned out bulb 3 Using the DRB lllt scan tool do the actuator test on cluster Refer to proper Body Diagnostic Pro cedu...

Page 488: ...agnostics on BCM for headlamp or key in ignition inputs 2 Check wiring for a grounded condition between key in switch and BCM 3 Inspect the BCM connectors and wires for proper connection EXTERIOR LAMPS LEFT ON To test the headlamps left on function remove the ignition key turn exterior lamps on with driver s door open Chime should sound until headlamps are turned off or drivers door is closed FAST...

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Page 490: ...onic packages 1 Mini Console Fig 1 has Overhead Travel Information System OTIS withoutuniversal Transmitter OTIS only Two map courtesy lamps 2 Mini Console Fig 2 has Overhead Travel Information System OTIS with Universal Transmitter Two map courtesy lamps Universal Transmitter 3 Base unit Fig 3 has two map courtesy lamps OPERATION Refer to the vehicle Owner s Manual for specific operation of each ...

Page 491: ...E BUTTON Pressing the C T button selects the Compass Tem perature display 3 US M ENGLISH METRIC MEASUREMENT BUTTON Pressing the US M button switches the display units between English and Metric readings 4 RESET BUTTON Pressing the RESET button resets the function on the display provided that function can be reset The functions which can be reset are Average fuel econ omy Trip odometer and Elapsed ...

Page 492: ...ut the PCI bus line and the BCM use the DRB lllt scan tool COMPASS DISPLAY To display the vehicle direction the OTIS processes information from a sensor internal to the module The OTIS is self calibrating and requires only vari ance adjustments dependent upon location The OTIS displays the label CAL whenever the compass is in the fast calibration mode If all three of the following conditions liste...

Page 493: ...g tool to demagnetize the roof It is important that you follow the instructions below exactly 1 Be sure the ignition switch is in the OFF posi tion before you begin the demagnetizing procedure 2 Place an 8 1 2 in X 11 in piece of paper lengthwise on the roof of vehicle directly above com pass The purpose of the paper is to protect the roof panel from scratches and define the area to be demagnetize...

Page 494: ... 3 Disconnect wire connector and lower the unit 4 Remove console from vehicle INSTALLATION For installation reverse the above procedures MAP LAMP REMOVAL 1 Open hood disconnect and isolate the negative battery cable remote terminal from the remote bat tery post Fig 5 2 Remove overhead console refer to Console Removal and Installation procedures in this section 3 Remove lamp socket from mounting 4 ...

Page 495: ...re the con sole is placed back into the headliner OVERHEAD TRAVEL INFORMATION SYSTEM OTIS LAMP REMOVAL 1 Remove overhead console refer to Console Removal and Installatioin procedures in this section 2 Using a flat blade screwdriver twist out socket lamp 3 Replace lamp s as necessary INSTALLATION For installation reverse the above procedures OVERHEAD CONSOLE BASE PLATE REMOVAL 1 Remove overhead con...

Page 496: ...UMENT CLUSTER 8W 40 1 INTERIOR LIGHTING 8W 44 1 JUNCTION BLOCK 8W 12 1 OCCUPANT RESTRAINT SYSTEM 8W 43 1 OVERHEAD CONSOLE 8W 49 1 POWER DISTRIBUTION 8W 10 1 POWER DOOR LOCKS 8W 61 1 POWER MIRRORS 8W 62 1 POWER SEATS 8W 63 1 POWER SUNROOF 8W 64 1 POWER WINDOWS 8W 60 1 REAR LIGHTING 8W 51 1 REAR WINDOW DEFOGGER 8W 48 1 SPEED PROPORTIONAL STEERING 8W 65 1 SPLICE INFORMATION 8W 70 1 SPLICE LOCATIONS 8...

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Page 498: ...hrysler 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 with the doors c...

Page 499: ...Wiring Diagram Example No 1 8W 01 2 8W 01 GENERAL INFORMATION LH DESCRIPTION AND OPERATION Continued ...

Page 500: ...Wiring Diagram Example No 2 LH 8W 01 GENERAL INFORMATION 8W 01 3 DESCRIPTION AND OPERATION Continued ...

Page 501: ...R CODE CHART COLOR CODE COLOR STANDARD TRACER COLOR BL BLUE WT BK BLACK WT 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 IDENTIFICATION CODE CHART CIRCUIT FUNCTION A BATTERY FEED B BRAKE CONTROLS C CLIMATE CONTROLS D DIAGNOSTIC CIRCUITS E DIMMING ...

Page 502: ... 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 ...

Page 503: ...Wiring Diagram Symbols 8W 01 6 8W 01 GENERAL INFORMATION LH DESCRIPTION AND OPERATION Continued ...

Page 504: ...ation 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 SPLICE LOCATIONS Splice Location charts in Section 8W 70 show the entire splice and provide references to other sections the splice serves Section 8W ...

Page 505: ...the vehicle DIAGNOSIS AND TESTING TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below Jumper Wire This is a test wire used to con nect two points of a circuit It can be used to bypass an open in a circuit WARNING NEVER USE A JUMPER WIRE ACROSS A LOAD SUCH AS A MOTOR CONNECTED BETWEEN A BATTERY ...

Page 506: ...e other lead of the voltmeter to the selected test point The vehicle ignition may need to be turned ON to check voltage Refer to the appropri ate test procedure TESTING FOR CONTINUITY 1 Remove the fuse for the circuit being checked or disconnect the battery 2 Connect one lead of the ohmmeter to one side of the circuit being tested Fig 5 3 Connect the other lead to the other end of the circuit bein...

Page 507: ...m 6 Verify proper operation For this step check for proper operation of all items on the repaired circuit Refer to the wiring diagrams SERVICE PROCEDURES WIRING REPAIR When replacing or repairing a wire it is important that the correct gage be used as shown in the wiring diagrams The wires must also be held securely in place to prevent damage to the insulation 1 Disconnect battery negative cable 2...

Page 508: ...avity on the repair connector 7 Repeat steps four through six for each wire in the connector being sure that all wires are inserted into the proper cavities For additional connector pin out identification refer to the wiring diagrams 8 Insert the connector locking wedge into the repaired connector if required 9 Connect connector to its mating half compo nent 10 Connect battery and test all affecte...

Page 509: ...e the wire harness starting 1 1 2 inches behind the connector and 2 inches past the repair 16 Re connect the repaired connector 17 Connect the battery and test all affected sys tems TERMINAL CONNECTOR REPAIR AUGAT CONNECTORS 1 Disconnect battery 2 Disconnect the connector from its mating half component 3 Push down on the yellow connector locking tab to release the terminals Fig 14 4 Using special ...

Page 510: ...osed wires 11 Push the two ends of wire together until the strands of wire are close to the insulation 12 Twist the wires together 13 Solder the connection together using rosin core type solder only Do not use acid core solder 14 Center the heat shrink tubing over the joint and heat using a heat gun Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing ...

Page 511: ...g sure current flow is correct If necessary refer to the appropriate wiring diagram for current flow 6 Solder the connection together using rosin core type solder only Do not use acid core solder 7 Tape the diode to the harness using electrical tape making sure the diode is completely sealed from the elements 8 Re connect the battery and test affected sys tems SPECIAL TOOLS WIRING TERMINAL Fig 18 ...

Page 512: ...Terminal Removing Tool 6932 Terminal Removing Tool 6934 LH 8W 01 GENERAL INFORMATION 8W 01 15 SPECIAL TOOLS Continued ...

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Page 514: ...W 63 EGR Solenoid 8W 30 Engine Coolant Temperature Sensor 8W 30 Engine Oil Pressure Switch 8W 40 Engine Starter Motor Relay 8W 21 Engine Starter Motor 8W 21 Component Page Evap Purge Solenoid 8W 30 Evaporator Temperature Sensor 8W 42 Fog Lamp Relay 8W 50 Fog Lamps 8W 50 51 Fuel Injectors 8W 30 Fuel Pump Module 8W 30 Fuel Pump Relay 8W 30 Fuses JB 8W 12 Fuses PDC 8W 10 Fusible Link 8W 20 Generator ...

Page 515: ...er Module 8W 39 Shift Interlock Solenoid 8W 30 Short Runner Valve Solenoid 8W 30 Side Impact Airbag Control Modules 8W 43 Component Page Side Marker Lamps 8W 50 51 Side Repeaters 8W 50 52 Spare Relay 8W 12 Speakers 8W 47 Speed Proportional Steering Solenoid 8W 65 Splice Information 8W 70 Standard Antenna 8W 47 Sun Sensor VTSS LED 8W 39 Sunroof Control Module 8W 64 Sunroof Limit Switch 8W 64 Sunroo...

Page 516: ...Page Fuse F PDC 8W 10 7 13 Fuse G PDC 8W 10 7 14 15 Fuse H PDC 8W 10 7 15 Fuse I PDC 8W 10 13 Fuse I PDC 8W 10 7 Fuse J PDC 8W 10 7 14 Fuse K PDC 8W 10 7 15 Fuse L PDC 8W 10 7 13 Fuse M PDC 8W 10 7 16 Fuse N PDC 8W 10 7 17 Fuse O PDC 8W 10 8 15 Fuse P PDC 8W 10 8 22 Fuse Q PDC 8W 10 8 23 Fuse R PDC 8W 10 8 24 Fuse S PDC 8W 10 8 17 Fuse T PDC 8W 10 8 17 Fusible Link 8W 10 7 G101 8W 10 16 G103 8W 10...

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Page 544: ...W 12 11 Left High Beam Headlamp 8W 12 9 Left Horn 8W 12 19 Left License Lamp 8W 12 12 Left Low Beam Headlamp 8W 12 14 Left Position Lamp 8W 12 11 Left Rear Door Courtesy Lamp 8W 12 20 Left Rear Door Lock Motor Ajar Switch 8W 12 24 Left Rear Side Marker Lamp 8W 12 12 Left Rear Turn Signal Lamp 8W 12 31 Left Side Impact Airbag Control Module 8W 12 22 Left Side Repeater 8W 12 31 Left Tail Lamp 8W 12 ...

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Page 576: ...amp 8W 15 15 16 Left Tail Stop Lamp No 1 8W 15 15 Left Tail Stop Lamp No 2 8W 15 15 Left Tail Turn Signal Lamp 8W 15 15 Left Visor Vanity Lamp 8W 15 10 License Lamp 8W 15 15 Manual Temperature Control Head 8W 15 7 Memory Heated Seat Mirror Module 8W 15 8 Memory Set Switch 8W 15 8 Occupant Restraint Controller 8W 15 9 Overhead Map Courtesy Lamp 8W 15 10 Overhead Travel Information System 8W 15 8 Ox...

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Page 594: ...elay 8W 20 2 Battery 8W 20 2 Fuse N PDC 8W 20 2 Fuse T PDC 8W 20 2 Fusible Link 8W 20 2 Component Page G108 8W 20 2 Generator 8W 20 2 Power Distribution Center 8W 20 2 Powertrain Control Module 8W 20 2 Remote Jump Post 8W 20 2 LH 8W 20 CHARGING SYSTEM 8W 20 1 ...

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Page 596: ... Motor 8W 21 2 Engine Starter Motor Relay 8W 21 2 Fuse G PDC 8W 21 2 Ignition Switch 8W 21 2 Component Page Power Distribution Center 8W 21 2 Powertrain Control Module 8W 21 2 Remote Jump Post 8W 21 2 Transmission Control Module 8W 21 2 LH 8W 21 STARTING SYSTEM 8W 21 1 ...

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Page 598: ... 8 Fuse N PDC 8W 30 2 Fuse S PDC 8W 30 3 4 6 Component Page Fuse T PDC 8W 30 2 10 11 18 G102 8W 30 2 G103 8W 30 10 11 G104 8W 30 10 11 G200 8W 30 19 G201 8W 30 19 G301 8W 30 8 G303 8W 30 8 Generator 8W 30 2 High Speed Radiator Fan Relay 8W 30 16 Idle Air Control Motor 8W 30 17 Instrument Cluster 8W 30 15 Intake Air Temperature Sensor 8W 30 12 Intake Air Temperature Manifold Absolute Pressure Senso...

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Page 618: ...Input Speed Sensor 8W 31 3 Component Page Junction Block 8W 31 2 5 8 Low Reverse Solenoid 8W 31 7 Output Speed Sensor 8W 31 3 Overdrive Solenoid 8W 31 7 Power Distribution Center 8W 31 2 6 7 Powertrain Control Module 8W 31 4 5 8 Throttle Position Sensor 8W 31 4 Transmission Control Module 8W 31 2 3 4 5 6 7 8 Transmission Control Relay 8W 31 2 6 7 Transmission Range Sensor 8W 31 3 5 Transmission So...

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Page 626: ...gaged Indicator 8W 33 2 Fuse 1 JB 8W 33 2 Fuse 20 JB 8W 33 3 G101 8W 33 3 G103 8W 33 3 Component Page G104 8W 33 3 G201 8W 33 3 Instrument Cluster 8W 33 2 Junction Block 8W 33 2 3 Powertrain Control Module 8W 33 2 3 Transmission Control Module 8W 33 2 Vehicle Speed Control Servo 8W 33 3 Vehicle Speed Control Horn Switch 8W 33 2 LH 8W 33 VEHICLE SPEED CONTROL 8W 33 1 ...

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Page 630: ...JB 8W 35 2 Fuse 20 JB 8W 35 2 Fuse H PDC 8W 35 2 Fuse K PDC 8W 35 2 Component Page G103 8W 35 2 Junction Block 8W 35 2 Left Front Wheel Speed Sensor 8W 35 3 Left Rear Wheel Speed Sensor 8W 35 3 Power Distribution Center 8W 35 2 Right Front Wheel Speed Sensor 8W 35 3 Right Rear Wheel Speed Sensor 8W 35 3 LH 8W 35 ANTI LOCK BRAKES 8W 35 1 ...

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Page 634: ...8W 39 2 Horn Relay 8W 39 5 Component Page Ignition Switch 8W 39 2 Junction Block 8W 39 2 3 5 6 Left Horn 8W 39 5 Left Rear Door Lock Motor Ajar Switch 8W 39 4 Park Lamp Relay 8W 39 5 Passenger Door Cylinder Lock Switch 8W 39 3 Passenger Door Lock Motor Ajar Switch 8W 39 3 Powertrain Control Module 8W 39 6 Right Horn 8W 39 5 Right Rear Door Lock Motor Ajar Switch 8W 39 4 Sentry Key Immobilizer Modu...

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Page 640: ...G104 8W 40 6 G200 8W 40 2 6 G201 8W 40 2 3 8 9 Component Page G303 8W 40 4 G400 8W 40 3 Headlamp Dimmer Switch 8W 40 8 High Beam Headlamp Relay 8W 40 8 Instrument Cluster 8W 40 2 3 4 5 6 7 8 9 Junction Block 8W 40 2 3 4 5 6 7 8 9 Low Washer Fluid Indicator 8W 40 3 Park Brake Switch 8W 40 6 Powertrain Control Module 8W 40 2 5 7 Seat Belt Switch 8W 40 9 Traction Control Active Indicator 8W 40 3 Trac...

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Page 650: ...1 2 Clockspring No 1 8W 41 2 Fuse 6 JB 8W 41 2 Fuse 18 JB 8W 41 2 G106 8W 41 2 G200 8W 41 2 Component Page Horn Relay 8W 41 2 Junction Block 8W 41 2 Left Horn 8W 41 2 Left Horn Switch 8W 41 2 Right Horn 8W 41 2 Right Horn Switch 8W 41 2 Vehicle Speed Control Horn Switch 8W 41 2 LH 8W 41 HORN CIGAR LIGHTER 8W 41 1 ...

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Page 652: ... 3 Fuse 17 JB 8W 42 2 4 Fuse 19 JB 8W 42 4 Fuse 21 JB 8W 42 6 7 Fuse 23 JB 8W 42 2 5 Fuse B PDC 8W 42 6 7 Component Page Fuse E PDC 8W 42 7 G100 8W 42 6 G105 8W 42 7 G200 8W 42 2 4 5 G201 8W 42 4 High Speed Radiator Fan Relay 8W 42 7 Instrument Cluster 8W 42 2 4 Junction Block 8W 42 2 4 5 6 7 Low Speed Radiator Fan Relay 8W 42 7 Manual Temperature Control Head 8W 42 2 8 Mode Door Actuator 8W 42 3 ...

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Page 660: ... 43 2 G201 8W 43 2 3 Junction Block 8W 43 2 Component Page Left Seat Airbag 8W 43 3 Left Side Impact Airbag Control Module 8W 43 3 Memory Heated Seat Mirror Module 8W 43 3 Occupant Restraint Controller 8W 43 2 Passenger Airbag 8W 43 2 Powertrain Control Module 8W 43 2 Right Seat Airbag 8W 43 3 Right Side Impact Airbag Control Module 8W 43 3 LH 8W 43 OCCUPANT RESTRAINT SYSTEM 8W 43 1 ...

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Page 664: ... 8W 44 6 Instrument Cluster 8W 44 2 6 Component Page Junction Block 8W 44 2 3 4 5 Left Rear Door Courtesy Lamp 8W 44 4 Left Rear Reading Lamp 8W 44 5 Left Rear Reading Lamp Switch 8W 44 5 Left Visor Vanity Lamp 8W 44 2 Manual Temperature Control Head 8W 44 6 Overhead Map Courtesy Lamp 8W 44 2 5 Passenger Door Courtesy Lamp 8W 44 4 PRNDL Illumination 8W 44 6 Radio 8W 44 6 Right Rear Door Courtesy L...

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Page 670: ...e Left Rear Reading Lamp Switch 8W 45 4 Left Side Impact Airbag Control Module 8W 45 15 Low Beam Headlamp Relay 8W 45 12 Manual Temperature Control Head 8W 45 13 14 Memory Heated Seat Mirror Module 8W 45 15 Mode Door Actuator 8W 45 7 Occupant Restraint Controller 8W 45 15 Overhead Map Courtesy Lamp 8W 45 4 Overhead Travel Information System 8W 45 12 Park Lamp Relay 8W 45 11 Passenger Door Courtesy...

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Page 686: ...eft Front Door Speaker 8W 47 3 4 Left Rear Door Speaker 8W 47 7 Component Page Left Rear Shelf Speaker 8W 47 3 5 Power Amplifier 8W 47 2 4 5 6 7 Radio 8W 47 2 3 4 6 Rear Window Defogger Antenna 8W 47 6 Rear Window Defogger Relay 8W 47 6 Rear Window Defogger Antenna Module 8W 47 2 6 Right Front Door Sail Speaker 8W 47 4 5 Right Front Door Speaker 8W 47 3 4 Right Rear Door Speaker 8W 47 7 Right Rear...

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Page 694: ... Mirror Fuse 8W 48 2 Manual Temperature Control Head 8W 48 2 Power Distribution Center 8W 48 2 Component Page Radio 8W 48 3 Rear Window Antenna 8W 48 3 Rear Window Defogger 8W 48 2 Rear Window Defogger Relay 8W 48 2 Rear Window Defogger Antenna Module 8W 48 3 LH 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

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Page 698: ...CONSOLE Component Page Body Control Module 8W 49 2 Fuse 14 JB 8W 49 2 Fuse 19 JB 8W 49 2 Component Page G201 8W 49 2 Junction Block 8W 49 2 Overhead Travel Information System 8W 49 2 LH 8W 49 OVERHEAD CONSOLE 8W 49 1 ...

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Page 700: ... 13 14 15 Left Fog Lamp 8W 50 11 Component Page Left Front Park Turn Signal Lamp 8W 50 7 12 14 Left Front Side Marker Lamp 8W 50 7 14 Left Headlamp Leveling Motor 8W 50 6 Left High Beam Headlamp 8W 50 9 Left Low Beam Headlamp 8W 50 10 Left Position Lamp 8W 50 6 Left Side Repeater 8W 50 12 Low Beam Headlamp Relay 8W 50 8 15 Park Brake Switch 8W 50 15 Park Lamp Relay 8W 50 4 5 13 14 Power Distributi...

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Page 716: ...1 8 Left Rear Fog Lamp 8W 51 10 Left Rear Side Marker Lamp 8W 51 9 Component Page Left Tail Lamp 8W 51 8 9 Left Tail Stop Lamp 8W 51 2 3 8 9 Left Tail Stop Lamp No 1 8W 51 2 9 Left Tail Stop Lamp No 2 8W 51 2 9 Left Tail Turn Signal Lamp 8W 51 9 License Lamp 8W 51 7 Park Lamp Relay 8W 51 7 8 9 Power Distribution Center 8W 51 10 Rear Fog Lamp Relay 8W 51 10 Right Back Up Lamp 8W 51 4 5 Right Licens...

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Page 726: ...mp 8W 52 4 Left Front Side Marker Lamp 8W 52 4 Component Page Left Rear Turn Signal Lamp 8W 52 3 Left Side Repeater 8W 52 3 Left Tail Turn Signal Lamp 8W 52 3 Power Distribution Center 8W 52 2 Right Front Park Turn Signal Lamp 8W 52 4 Right Front Side Marker Lamp 8W 52 4 Right Rear Turn Signal Lamp 8W 52 3 Right Side Repeater 8W 52 3 Right Tail Turn Signal Lamp 8W 52 3 Turn Signal Hazard Switch 8W...

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Page 730: ...8W 53 5 Headlamp Washer Pump Motor 8W 53 5 Component Page Headlamp Washer Relay 8W 53 5 Instrument Cluster 8W 53 3 Junction Block 8W 53 2 3 Power Distribution Center 8W 53 4 5 Washer Fluid Level Switch 8W 53 3 Windshield Washer Pump Motor 8W 53 2 3 Windshield Wiper Motor 8W 53 4 Wiper High Low Relay 8W 53 4 Wiper On Off Relay 8W 53 4 Wiper Switch 8W 53 2 3 LH 8W 53 WIPERS 8W 53 1 ...

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Page 736: ...witch 8W 60 2 3 G300 8W 60 2 Junction Block 8W 60 2 Left Rear Power Window Motor 8W 60 3 Component Page Left Rear Power Window Switch 8W 60 3 Passenger Power Window Motor 8W 60 2 Passenger Power Window Switch 8W 60 2 3 Right Rear Power Window Motor 8W 60 3 Right Rear Power Window Switch 8W 60 3 LH 8W 60 POWER WINDOWS 8W 60 1 ...

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Page 740: ...Switch 8W 61 3 4 Driver Door Unlock Relay 8W 61 3 Driver Power Door Lock Switch 8W 61 2 Fuse 14 JB 8W 61 2 Component Page Fuse 19 JB 8W 61 2 5 G300 8W 61 2 3 4 G301 8W 61 2 4 5 G400 8W 61 5 Instrument Cluster 8W 61 5 Junction Block 8W 61 2 3 5 Left Rear Door Lock Motor Ajar Switch 8W 61 4 Passenger Door Lock Motor Ajar Switch 8W 61 3 4 Passenger Power Door Lock Switch 8W 61 2 Right Rear Door Lock ...

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Page 746: ... 2 3 G300 8W 62 2 3 6 7 G301 8W 62 6 Heated Mirror Fuse 8W 62 6 Component Page Junction Block 8W 62 2 3 Memory Heated Seat Mirror Module 8W 62 4 5 7 Memory Set Switch 8W 62 7 Passenger Power Mirror 8W 62 2 5 6 Power Mirror Switch 8W 62 2 3 Rear Window Defogger Relay 8W 62 6 LH 8W 62 POWER MIRRORS 8W 62 1 ...

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Page 754: ...at Rear Riser Motor Sensor 8W 63 6 7 Driver Power Seat Recliner Motor 8W 63 2 4 Driver Power Seat Recliner Motor Sensor 8W 63 6 7 Component Page Driver Power Seat Switch 8W 63 2 4 Fuse 14 JB 8W 63 5 G300 8W 63 2 3 4 5 8 Junction Block 8W 63 2 3 5 8 Memory Heated Seat Mirror Module 8W 63 4 5 6 7 8 Passenger Heated Seat Back 8W 63 8 Passenger Heated Seat Cushion 8W 63 8 Passenger Heated Seat Switch ...

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Page 762: ...8W 64 2 Fuse F PDC 8W 64 2 G300 8W 64 2 Junction Block 8W 64 2 Power Distribution Center 8W 64 2 Component Page Sunroof Control Module 8W 64 2 Sunroof Limit Switch 8W 64 2 Sunroof Motor 8W 64 2 Sunroof Switch 8W 64 2 LH 8W 64 POWER SUNROOF 8W 64 1 ...

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Page 764: ...mponent Page Body Control Module 8W 65 2 Junction Block 8W 65 2 Powertrain Control Module 8W 65 2 Component Page Speed Proportional Steering Solenoid 8W 65 2 Transmission Control Module 8W 65 2 LH 8W 65 SPEED PROPORTIONAL STEERING 8W 65 1 ...

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Page 766: ...8W 10 15 S202 8W 53 2 3 S203 8W 10 9 S204 8W 70 7 S205 8W 51 2 3 S206 8W 47 2 S207 8W 44 6 S208 8W 70 5 Component Page S209 8W 12 19 S210 8W 70 4 S211 8W 42 3 S212 8W 70 5 S213 8W 45 13 S214 8W 12 22 S215 8W 30 15 S300 8W 12 16 S301 8W 12 20 S302 8W 12 29 S303 8W 12 24 S304 8W 12 24 S305 8W 60 3 S306 8W 10 9 S307 8W 44 2 S308 8W 51 2 3 S309 8W 12 12 S310 8W 12 28 S311 8W 15 17 S312 8W 15 11 S313 8...

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Page 774: ... Plug No 1 8W 80 23 Coil On Plug No 2 8W 80 23 Coil On Plug No 3 8W 80 24 Coil On Plug No 4 8W 80 24 Coil On Plug No 5 8W 80 24 Coil On Plug No 6 8W 80 24 Combination Flasher 8W 80 24 Controller Anti Lock Brake 8W 80 25 Crankshaft Position Sensor 8W 80 25 Data Link Connector 8W 80 25 Decklid Release Solenoid Ajar Switch 8W 80 25 Decklid Release Switch 8W 80 25 Driver Door Courtesy Lamp 8W 80 25 Dr...

Page 775: ...emory Heated Seat Mirror Module 8W 80 48 49 50 Memory Set Switch 8W 80 50 Mode Door Actuator 8W 80 50 Multi Function Switch 8W 80 50 Occupant Restraint Controller 8W 80 50 Output Speed Sensor 8W 80 51 Overhead Map Courtesy Lamp 8W 80 51 Overhead Travel Information System 8W 80 51 Oxygen Sensor 1 1 Right Bank Up 8W 80 51 Oxygen Sensor 1 2 Right Bank Down 8W 80 51 Oxygen Sensor 2 1 Left Bank Up 8W 8...

Page 776: ... 80 68 Seat Belt Switch 8W 80 68 Sentry Key Immobilizer Module 8W 80 69 Shift Interlock Solenoid 8W 80 69 Component Page Short Runner Valve Solenoid 8W 80 69 Speed Proportional Steering Solenoid 8W 80 69 Sun Sensor VTSS LED 8W 80 70 Sunroof Control Module 8W 80 70 Sunroof Limit Switch 8W 80 70 Sunroof Motor 8W 80 70 Sunroof Switch 8W 80 70 Throttle Position Sensor 8W 80 71 Traction Control Switch ...

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Page 848: ...wer Center of Instrument Panel 9 Automatic Day Night Mirror BK At Mirror N S Automatic Temperature Control Head BK Center of I P 9 Autostick Switch Center Console 10 Blend Door Actuator BK Right Side of HVAC N S Blower Motor Power Module BK Right Side of HVAC N S Blower Motor Resistor Block BK Right Side of HVAC N S Body Control Module C1 GY Left Side of I P 8 Body Control Module C2 BK Left Side o...

Page 849: ...cation Fig C314 Left Trunk Area 13 C316 Left B Pillar 11 C317 Right B Pillar 10 C318 NAT Under Passenger Seat 10 C319 NAT Under Drivers Seat 11 C321 300M Deck Lid 14 Camshaft Position Sensor BK Front of Engine 5 6 Capacitor 1 2 7L BK Rear of Engine N S Capacitor 2 2 7L BK Rear of Engine N S Center High Mounted Stop Lamp At Lamp N S Center Instrument Panel Speaker BK At Speaker 9 Cigar Lighter RD L...

Page 850: ...iner Motor At Driver Seat N S Connector Name Number Color Location Fig Driver Power Seat Recliner Motor Sensor BK At Driver Seat N S Driver Power Seat Switch BL At Driver Seat N S Driver Power Window Motor BK Left Front Door N S Driver Power Window Switch BL Driver Door N S Driver Sail Speaker Driver Door N S Driver Side Airbag Left B Pillar N S EGR Solenoid BK Rear of Engine 5 6 Engine Coolant Te...

Page 851: ...Color Location Fig Junction Block C1 BK Left Side of I P 8 Junction Block C2 GY Left Side of I P 8 Junction Block C3 BL Left Side of I P 8 Junction BLock C4 GN Left Side of I P 8 Junction Block C5 WT Left Side of I P 8 Junction Block C6 Left Side of I P 11 Junction Block C7 Left Side of I P 11 Junction Block C8 GN Left Side of I P 11 Junction Block C9 OR Left Side of I P 11 Junction Block C10 GY L...

Page 852: ...e of Engine 6 Manifold Tuning Valve BK Front of Engine 5 6 Connector Name Number Color Location Fig Manual Temperature Control Head C1 WT Center of I P 9 Manual Temperature Control Head C2 BK Center of I P 9 Memory Heated Seat Mirror Module C1 Under Driver Seat N S Memory Heated Seat Mirror Module C2 Under Driver Seat N S Memory Heated Seat Mirror Module C3 Under Driver Seat N S Memory Heated Seat...

Page 853: ...nger Door N S Passenger Power Window Switch BL Passenger Door N S Connector Name Number Color Location Fig Passenger Sail Speaker BK Passenger Door 15 Passenger Side Airbag Right B Pillar N S Power Amplifier C1 Front GY At Amplifier Right Cowl 10 Power Amplifier C2 Front BK At Amplifier Right Cowl 10 Power Amplifier C1 Rear Left Side Trunk Area 13 Power Amplifier C2 Rear Left Side Trunk Area 13 Po...

Page 854: ...mp At Lamp N S Right Visor Vanity Lamp At Lamp N S Connector Name Number Color Location Fig Seat Belt Switch Left B Pillar 11 Sentry Key Immobilizer Module BK Steering Column 8 Shift Interlock Solenoid WT Steering Column 8 Short Runner Valve GY Right Rear of Engine N S Sunroof Motor WT At Motor N S Sun Sensor VTSS Set LED BK Top Center of Instrument Panel N S Sunroof Control Module WT At Module N ...

Page 855: ...cation Fig Windshield Washer Pump Motor BK Left Fender Side Shield 3 Connector Name Number Color Location Fig Windshield Wiper Motor BK At Wiper Motor 4 8W 90 8 8W 90 CONNECTOR GROUND LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 856: ...Fig 1 Front of Engine Fig 2 Right Front Engine Compartment LH 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 9 DESCRIPTION AND OPERATION Continued ...

Page 857: ...Fig 3 Left Front Engine Compartment 8W 90 10 8W 90 CONNECTOR GROUND LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 858: ...Fig 4 Left Rear Engine Compartment LH 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued ...

Page 859: ...Fig 5 Engine 2 7 Liter 8W 90 12 8W 90 CONNECTOR GROUND LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 860: ...Fig 6 Engine 3 5 Liter LH 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 13 DESCRIPTION AND OPERATION Continued ...

Page 861: ...Fig 7 Transmission 8W 90 14 8W 90 CONNECTOR GROUND LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 862: ...Fig 8 Left Side of Instrument Panel LH 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued ...

Page 863: ...Fig 9 Instrument Panel 8W 90 16 8W 90 CONNECTOR GROUND LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 864: ...Fig 10 Right Side Body LH 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 17 DESCRIPTION AND OPERATION Continued ...

Page 865: ...Fig 11 Left Side Body 8W 90 18 8W 90 CONNECTOR GROUND LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 866: ...Fig 12 Shelf Panel LH 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 19 DESCRIPTION AND OPERATION Continued ...

Page 867: ...Fig 13 Tail Lamps 8W 90 20 8W 90 CONNECTOR GROUND LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 868: ...Fig 14 Deck Lid Fig 15 Right Front Door LH 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 21 DESCRIPTION AND OPERATION Continued ...

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Page 870: ... 3 4 S106 Engine Harness Front of Engine 3 4 S107 Engine Harness in T O for Powertrain Control Module 3 4 S109 Engine Harness Front of Engine 2 7L 3 S109 Engine Harness Left Side of Engine 3 5L 4 S110 Engine Harness Right Side 2 7L 3 S110 Engine Harness Front of Engine 3 5L 4 S111 Engine Harness Right Side 3 4 Splice Number Location Fig S112 Engine Harness Front of Engine 4 S114 Headlamp and Dash ...

Page 871: ...tion Center N S Splice Number Location Fig S166 Headlamp and Dash Harness in Power Distribution Center N S S167 Headlamp and Dash Harness in Power Distribution Center N S S168 Headlamp and Dash Harness in Power Distribution Center N S S170 Headlamp and Dash Harness Near T O to Front End Lighting 2 S200 Instrument Panel Left Side 6 S201 Instrument Panel Left Side 6 S202 Instrument Panel Left Side 6...

Page 872: ...y 9 S334 Body Harness Left Side Body 8 S335 Body Harness Left Side Body 8 S336 Body Harness Left Cowl 8 S337 Body Harness Body Rear N S Splice Number Location Fig S338 Body Harness Right Side Body 9 S341 Memory Seat Harness Near T O to Seat Motors N S S342 Memory Seat Harness Near Heated Seat Heater Connector N S S343 Memory Seat Harness Near Heated Seat Heater Connector N S S345 Body Harness Left...

Page 873: ...Fig 1 Right Front Lamps Fig 2 Left Front Lamps 8W 95 4 8W 95 SPLICE LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 874: ...Fig 3 2 7 Liter Engine LH 8W 95 SPLICE LOCATIONS 8W 95 5 DESCRIPTION AND OPERATION Continued ...

Page 875: ...Fig 4 3 5 Liter Engine 8W 95 6 8W 95 SPLICE LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 876: ...Fig 5 Transmission LH 8W 95 SPLICE LOCATIONS 8W 95 7 DESCRIPTION AND OPERATION Continued ...

Page 877: ...Fig 6 Instrument Panel 8W 95 8 8W 95 SPLICE LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 878: ...Fig 7 Right front Door LH 8W 95 SPLICE LOCATIONS 8W 95 9 DESCRIPTION AND OPERATION Continued ...

Page 879: ...Fig 8 Left Side Body 8W 95 10 8W 95 SPLICE LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 880: ...Fig 9 Right Side Body LH 8W 95 SPLICE LOCATIONS 8W 95 11 DESCRIPTION AND OPERATION Continued ...

Page 881: ...Fig 10 Left Rear Engine Compartment 8W 95 12 8W 95 SPLICE LOCATIONS LH DESCRIPTION AND OPERATION Continued ...

Page 882: ...S SEALERS 21 ENGINE GASKET SURFACE PREPARATION 22 REPAIR OF DAMAGED OR WORN THREADS 22 CYLINDER BORE HONING 23 HYDROSTATIC LOCKED ENGINE 23 PISTONS 23 PISTON RING FITTING 24 CONNECTING ROD BEARING INSTALLATION 25 CRANKSHAFT MAIN BEARING FITTING 26 CRANKSHAFT END PLAY CHECKING 27 VALVE AND VALVE SEAT REFACING 27 ENGINE TIMING VERIFICATION 29 INTAKE MANIFOLD VACUUM PORT REPAIR 2 7L 30 REMOVAL AND IN...

Page 883: ...NIFOLD 63 CAMSHAFT 63 CYLINDER HEAD 63 CAMSHAFT FOLLOWER 63 VALVE INSPECTION 63 OIL PUMP 64 CYLINDER BLOCK AND BORE 66 ENGINE HYDRO MOUNT ISOLATOR 66 TIMING DRIVE SYSTEM 66 SPECIFICATIONS 2 7L ENGINE 67 TORQUE 69 SPECIAL TOOLS 2 7L ENGINE 70 DESCRIPTION AND OPERATION 2 7L ENGINE Fig 1 2 7 Liter Engine 9 2 2 7L ENGINE LH ...

Page 884: ...f heat treated alumi num with cast in place iron liners Fig 4 The block is a closed deck design with the right bank forward To provide high rigidity and improved NVH the block has cast in contours and ribs along with pow dered metal 6 bolt main caps 4 vertical 2 horizon tal with a die cast aluminum structural beam windage tray mounted to the main caps The block design allows coolant flow between t...

Page 885: ...er Block and Crankshaft 1 MAIN CAP BOLT VERTICAL 2 MAIN CAP 3 MAIN BEARING LOWER 4 MAIN BEARING UPPER 5 MAIN CAP BOLT HORIZONTAL 6 CYLINDER BLOCK 7 CRANKSHAFT 9 4 2 7L ENGINE LH DESCRIPTION AND OPERATION Continued ...

Page 886: ...s to the piston with a full floating pin retained by lock rings The piston and connecting rod are serviced as an assembly Fig 5 OPERATION The piston and connecting rod is the link between the combustion force to the crankshaft CYLINDER HEAD DESCRIPTION The cylinder heads are made of an aluminum alloy Fig 6 The cylinder head features four valves per cylinder with pressed in powdered metal valve gui...

Page 887: ...e water pump is driven by the back side of the primary chain necessitating the double flexure type chain The chain is controlled by three fixed chain guides and a pivoting tensioner arm Fig 7 These guides utilize low friction and long wearing nylon plastic wear faces To tension the primary chain a fully automatic spring loaded engine oil fed hydraulic tensioner is used The tensioner is mounted in ...

Page 888: ...each cylinder head between the intake and exhaust camshafts Fig 8 The tensioner incor porates upper and lower chain guide faces The lower guide face is attached directly to the tensioner s hydraulic plunger Also the tensioner uses an inter nal oil reservoir design to prevent engine start up noise The secondary chains are lubricated via an oil passage through the upper guide face on each ten sioner...

Page 889: ...e lash adjuster socket for roller camshaft lobe lubrica tion Fig 9 OPERATION The rocker arm is the pivot point between the cam shaft lobe and the valve Fig 8 Valvetrain Components 1 CAMSHAFT BEARING CAP INTAKE 2 CAMSHAFT BEARING CAP EXHAUST 3 CAMSHAFT EXHAUST 4 ROCKER ARM 5 HYDRAULIC LIFTER 6 CYLINDER HEAD 7 CAMSHAFT SECONDARY CHAIN TENSIONER 8 CYLINDER BLOCK 9 CYLINDER HEAD 10 CAMSHAFT INTAKE 11 ...

Page 890: ...r iron Fig 10 The outlets are designed for V band clamp attachment of close cou pled catalytic converters ENGINE LUBRICATION DESCRIPTION The lubrication system is a full flow filtration pressure feed type The oil pump body is mounted to the engine block The pump inner rotor is driven by the crankshaft A structural windage tray is used to increase power by minimizing oil windage at high engine RPM ...

Page 891: ...linder Head Oil Filter Oil Filter Mounting outlet 3 Right Cylinder Head Oil Filter Mounting outlet Oil Gallery Right side of Block Crankshaft Main Bearings Connecting Rod Bearings Oil Gallery Right side of Block Oil Gallery Rear of Block and to Oil Cooler some models Left Cylinder Head Refer to Fig 12 Oil Gallery Rear of Block Main Oil Gallery Center of Block Right Cylinder Head Refer to Fig 13 Th...

Page 892: ... Left Camshaft Secondary Chain Tensioner Left Intake Camshaft Oil Passage 1 Left Intake Camshaft Journals 2 Hydraulic Valve Lash Adjusters and Rocker Arms When oil reaches the back of the cylinder head the oil gallery feeds oil into an accumulator chamber that is located towards center of the head The accumulator chamber is closed off with a pressed in core plug that has a small orifice to act as ...

Page 893: ... 3 Right Camshaft Secondary Chain Tensioner 4 Primary Timing Chain Tensioner Right Head Right Intake Camshaft Oil Passage 1 Right Intake Camshaft Journals 2 Hydraulic Valve Lash Adjusters and Rocker Arms When oil reaches the back of the cylinder head the oil gallery feeds oil into an accumulator chamber that is located towards center of the head The accumulator chamber is closed off with a pressed...

Page 894: ...Diagnosis Engine Oil Leak Inspection ENGINE DIAGNOSIS PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1 Weak battery 1 Test battery Charge or replace as necessary Refer to BATTERY 2 Corroded or loose battery connections 2 Clean and tighten battery connections Apply a coat of light mineral grease to terminals 3 Faulty starter 3 Test starting system Refer to STARTING 4 Faulty c...

Page 895: ... coil s 9 Test and replace as necessary Refer to IGNITION SYSTEM ENGINE MISSES ON ACCELERATION 1 Dirty or incorrectly gapped spark plugs 1 Clean spark plugs and set gap Refer to IGNITION SYSTEM 2 Contamination in Fuel System 2 Clean fuel system and replace fuel filter 3 Burned warped or pitted valves 3 Replace valves 4 Faulty coil s 4 Test and replace as necessary Refer to IGNITION SYSTEM ENGINE M...

Page 896: ...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 Connecting rod journal out of round 5 Replace crankshaft or grind surface 6 Misaligned connecting rods 6 Replace bent connecting r...

Page 897: ...gs 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 guide s 5 Ream guide s and replace valve s with oversize valve s and seal s 6 Valve stem seal s worn or damaged 6 Replace seal s CHECKING ENGINE OIL PRESSURE 1 Remove oil pressure sending unit and install an oil pressure ...

Page 898: ... malfunc tion is present CYLINDER COMBUSTION PRESSURE LEAKAGE TEST The combustion pressure leakage test provides an accurate means for determining engine condition Combustion pressure leakage testing will detect Exhaust and intake valve leaks improper seat ing Leaks between adjacent cylinders or into water jacket Any causes for combustion compression pressure loss WARNING DO NOT REMOVE THE RADIATO...

Page 899: ...Locating a lash adjuster tappet type noise can sometimes be difficult As a result an initial misdiagnosis may occur Refer to the following chart indicating possible lash adjuster tappet noise sources and possible sources that could lead to a misdiagnosis Refer to Lash Adjuster Tappet Noise Chart for Possible Causes and Correction of a lash adjuster tappet type noise LASH ADJUSTER TAPPET NOISE CHAR...

Page 900: ... more than 20 6 kpa 3 PSI of test pressure Gradually apply air pressure from 1 psi to 2 5 psi maximum while applying soapy water at the sus pected source Adjust the regulator to the suitable test pressure that provides the best bubbles which will pinpoint the leak source If the oil leak is detected and identified repair per service manual procedures If the leakage occurs at the crankshaft rear oil...

Page 901: ...ERVICE WARNING NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL CONTAMINANTS IN USED ENGINE OIL CAUSED BY INTERNAL COMBUSTION CAN BE HAZARDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL ...

Page 902: ...eakage while too much can result in spill over which can break off and obstruct fluid feed lines A continuous bead of the proper width is essential to obtain a leak free gasket There are numerous types of form in place gasket materials that are used in the engine area Mopart Engine RTV GEN II Mopart ATF RTV and Mopart Gasket Maker gasket materials each have different properties and can not be used...

Page 903: ... coat sprayed completely over both surfaces to be joined and both sides of a gasket Then proceed with assembly Material in a can w applicator can be brushed on evenly over the sealing surfaces Material in an aerosol can should be used on engines with multi layer steel gaskets ENGINE GASKET SURFACE PREPARATION To ensure engine gasket sealing proper surface preparation must be performed especially w...

Page 904: ...YDROSTATIC LOCKED ENGINE When an engine is suspected to be hydrostatically locked regardless of what caused the problem the following steps should be used CAUTION DO NOT use starter motor to rotate the engine severe damage may occur 1 Inspect air cleaner induction system and intake manifold to insure system is dry and clear of foreign material 2 Remove negative battery cable 3 Place a shop towel a...

Page 905: ...1 and No 2 piston rings have a differ ent cross section Insure that No 2 ring is installed with the manufacturers I D mark dot facing up towards top of the piston Fig 22 CAUTION Install piston rings in the following order 2 Oil ring expander 3 Upper oil ring side rail 4 Lower oil ring side rail 5 No 2 Intermediate piston ring 6 No 1 Upper piston ring 7 Install the side rail by placing one end betw...

Page 906: ...ing rod as engine dam age may occur Limits of taper or out of round on any crankshaft journals should be held to 0 015 mm 0 0006 in Bearings are available 0 025 mm 0 001 in and 0 250 mm 0 010 in undersize Install the bear ings in pairs Do not use a new bearing half with an old bearing half Do not file the rods or bearing caps 1 Follow procedure specified in the Standard Ser vice Procedure Section ...

Page 907: ...located on the pan rail just below the left side engine mount bracket Fig 30 These marks are read left to right corresponding to main bore 1 2 3 4 The grade marks for the crankshaft are located on the rearmost crankshaft counter weight as shown in Fig 29 The crankshaft journal grade marks are read left to right corresponding with journal number 1 2 3 4 Use the Main Bearing Selection Chart to prope...

Page 908: ... seats have a 45 to 45 5 degree face angle The valve face and valve seat angles are shown in Fig 33 Fig 29 Crankshaft Main Journal Grade Marking Location Fig 30 Cylinder Block Main Bore Grade Marking Location Fig 31 Main Bearing Grade Marks 1 LOWER MAIN BEARING 2 UPPER MAIN BEARING 3 OIL FEED HOLE AND GROOVE 4 GRADE SELECTION INK MARKS MAIN BEARING SELECTION CHART 2 7L Main Bearing Bore Grade Mark...

Page 909: ...ves have been removed for inspection reconditioning or replacement valve springs should be tested Fig 34 As an example the compression length of the spring to be tested is 38 00 mm 1 496 in Turn table of Tool C 647 until surface is in line with the 38 00 mm 1 496 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 d...

Page 910: ...on 2 Rotate engine until number one cylinder is at TDC on the EXHAUST stroke 3 View the intake camshaft sprocket timing mark The mark should be 90 from the cylinder head cover sealing surface Fig 37 on both right and left cylinder banks 4 Count chain pins from the mark on the intake camshaft towards the exhaust camshaft Engine is timed correctly when there are 12 chain pins between the timing mark...

Page 911: ...aper NOTE While performing this procedure avoid get ting the manifold material residue into the plenum chamber 1 File or sand the remaining port back until a flat surface is obtained plane normal to nipple port axis 2 Drill out the nipple port base using a 7 16 drill bit Fig 38 3 Using a 1 4 18 NPT pipe tap cut internal threads Fig 38 Use caution to start tap in a axis same as original nipple 4 Ap...

Page 912: ... 5 Install the upper attaching nuts to mount and tighten to 61 N m 45 ft lbs Fig 39 6 Lower vehicle ENGINE HYDRO MOUNT ISOLATORS Engine hydro mounts may show surface cracks this will not effect performance and hydro mount should not be replaced Only replace the engine hydro mounts when leaking fluid Driveshaft Diagnosis Refer to DIFFERENTIAL AND DRIVELINE Any front end structural damage after repa...

Page 913: ...l the horizontal collar to transmission bolts and torque to 55 N m 40 ft lbs c Starting with the center vertical bolts and work ing outward final torque bolts to 55 N m 40 ft lbs 2 Lower vehicle ENGINE ASSEMBLY REMOVAL 1 Release fuel pressure Refer to FUEL SYSTEM for procedure 2 Disconnect negative cable at remote jumper terminal located at right strut tower Fig 41 3 Mark hood position at hinges a...

Page 914: ...ec tor 23 Remove A C compressor mounting bolts and set compressor aside 24 Loosen and remove V Band clamps at exhaust manifolds 25 Disconnect throttle and speed control cables 26 Disconnect coolant hoses at coolant pressure bottle 27 Disconnect heater hoses 28 Perform fuel pressure release procedure and disconnect fuel line 29 Disconnect all vacuum lines and electrical connectors 30 Disconnect all...

Page 915: ...icle 7 Align flex plate to torque converter and install mounting bolts tighten to 75 N m 55 ft lbs 8 Install crankshaft position sensor 9 Install starter 10 Install the transaxle oil cooler lines bracket to engine 11 Install structural collar to oil pan and tran saxle Refer to procedure in this section 12 Lower vehicle 13 Install rear throttle body support bracket 14 Install electrical harness and...

Page 916: ...enter bolt while holding the damper with Special Tool 8191 Fig 46 CAUTION Before removing damper verify that A C belt tensioner is not contacting the damper as damage could occur to tensioner timing chain cover and or damper Fig 45 Engine Lifting Fixture 1 SPECIAL TOOL 8342 ENGINE LIFTING FIXTURE 2 ATTACHING LOCATION 3 ATTACHING LOCATION LH 2 7L ENGINE 9 35 REMOVAL AND INSTALLATION Continued ...

Page 917: ...ble from throttle arm and bracket 4 Remove throttle cable bracket 5 Disconnect electrical connectors from the fol lowing components Refer to FUEL SYSTEM for com ponent locations Manifold Absolute Pressure MAP Sensor Intake Air Temperature IAT Sensor Throttle Position Sensor TPS Sensor Idle Air Control IAC Motor Manifold Tuning Valve MTV if equipped 6 Disconnect Vapor Purge hose Brake Booster hose ...

Page 918: ...Temperature IAT Sensor Throttle Position Sensor TPS Sensor Idle Air Control IAC Motor Manifold Tuning Valve MTV if equipped 9 Install throttle cable bracket 10 Install throttle and speed control cables to bracket and throttle arm 11 Connect negative cable to battery remote jumper terminal INTAKE MANIFOLD LOWER REMOVAL 1 Release fuel system pressure Refer to FUEL SYSTEM for procedure 2 Remove upper...

Page 919: ...emove bolt attaching battery cable housing tube to transmission housing 4 Remove bolts attaching EGR tube from exhaust manifold and EGR valve Discard gaskets 5 Disconnect electrical connector and remove exhaust manifold mounted oxygen sensor 6 Loosen and remove the manifold to catalytic converter V Band clamp NOTE Do not reuse V Band clamp 7 Remove heat shield attaching screws and remove heat shie...

Page 920: ...atalytic converter Refer to EXHAUST SYSTEM for procedures 8 Install a new V Band clamp and tighten to 10 N m 100 in lbs 9 Install engine wiring harness support bracket to cylinder head and attach connectors to bracket 10 Install exhaust system Refer to EXHAUST SYSTEM for procedure 11 Connect negative cable CYLINDER HEAD COVERS REMOVAL 1 Remove upper intake manifold Refer to proce dure in this sect...

Page 921: ... compressed and locked position proceed to step 4 3 When the camshaft chain tensioner is removed it is necessary to compress and lock the tensioner using the following procedures a Place tensioner into a soft jaw vise Fig 55 b SLOWLY compress tensioner until fabricated lock pin or the equivalent can be inserted into the locking holes c Remove compressed and locked tensioner from the vise 4 Insert ...

Page 922: ...ion of rocker arms for reassembly in their orig inal positions 5 Repeat procedure for each rocker arm being removed INSPECTION Inspect the rocker arm for wear or damage Fig 59 Replace as necessary INSTALLATION 1 Lubricate rocker arms with clean engine oil before installation 2 Rotate engine until cam lobe is on its base cir cle heel of rocker arm being installed 3 Using Special Tools 8215 and 8216...

Page 923: ... 6 Remove crankshaft damper timing chain cover and timing chain Refer to procedures in this section 7 Remove camshafts Refer to procedure in this section 8 With air hose attached to spark plug adapter installed in the cylinder being serviced apply 620 5 689 kPa 90 100 psi air pressure This is to hold valves in place while servicing components 9 Using Special Tool MD 998772A with adapter 6779 compr...

Page 924: ...ylin der head as damage to cylinder head and or block may occur 13 Remove cylinder head bolts in reverse sequence of installation Fig 63 starting with bolts 11 9 then bolts 8 1 14 Remove cylinder head s INSTALLATION NOTE The cylinder head bolts are tightened using a torque plus angle procedure The bolts must be examined BEFORE reuse If the threads are necked down the bolts should be replaced Fig 6...

Page 925: ... TEM for procedure 15 Connect negative cable to remote jumper ter minal VALVE AND VALVE SPRINGS REMOVAL 1 With cylinder head removed compress valve springs using a Special Tool C 3422 B Valve Spring Compressor 2 Remove valve retaining locks valve spring retainers valve springs and valve spring seat stem seal assembly 3 Before removing valves remove any burrs from valve stem lock grooves to prevent...

Page 926: ...e cable from remote jumper terminal 2 Remove upper radiator support crossmember Refer to BODY for procedure 3 Remove fan module and accessory drive belts Refer to COOLING SYSTEM for procedure 4 Remove crankshaft damper Refer to procedure in this section 5 Remove power steering pump from mounting bracket 6 Remove accessory drive belt tensioner pulley and bracket 7 Remove timing chain cover attachin...

Page 927: ...all generator power steering drive belt ten sioner pulley and bracket 10 Install fan module and accessory drive belts Refer to COOLING SYSTEM for procedure 11 Install upper radiator crossmember Refer to BODY for procedure 12 Connect negative cable TIMING CHAIN AND SPROCKETS REMOVAL 1 Remove upper intake manifold Refer to proce dure in this section 2 Remove cylinder head covers crankshaft damper an...

Page 928: ...d in between the two plated timing links Fig 71 5 Lower the primary chain with left side sprocket through the left cylinder head opening NOTE The camshaft sprockets can be allowed to float on the camshaft hub during installation 6 Loosely position left side camshaft sprocket over camshaft hub 7 Align timing plated link to the crankshaft sprocket timing mark Fig 71 8 Position primary chain onto wat...

Page 929: ... MARKS 2 CHAIN GUIDE 3 CRANKSHAFT TIMING MARKS 4 CRANKSHAFT SPROCKET 5 CHAIN TENSIONER ARM 6 CHAIN TENSIONER 7 CAMSHAFT TIMING MARK 8 INTAKE CAMSHAFT SPROCKETS 9 CHAIN GUIDES 10 WATER PUMP SPROCKET 9 48 2 7L ENGINE LH REMOVAL AND INSTALLATION Continued ...

Page 930: ...check ball CAUTION Ensure the tensioner is properly reset The tensioner body must bottom against the top edge of Special Tool 8186 Failure to properly per form the resetting procedure may cause tensioner jamming Fig 72 Timing Chain Tensioner Oil Purging 1 TENSIONER 2 CHECK BALL 3 SPECIAL TOOL 8186 4 PIN LH 2 7L ENGINE 9 49 REMOVAL AND INSTALLATION Continued ...

Page 931: ...lts can be installed Tighten sprocket bolts to 28 N m 250 in lbs Fig 71 19 Rotate engine slightly clockwise to remove timing chain slack if necessary 20 To arm the timing chain tensioner Use a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly Fig 75 Then release the ten sioner arm Verify the tensioner is armed extends 21 Install the timing chain cover crankshaft dampe...

Page 932: ...048 1 5048 6 and 8539 on sprocket and crankshaft nose Fig 76 Remove sprocket using care not to rotate the crankshaft INSTALLATION 1 Install crankshaft sprocket using Special Tools 6780 1 and 8179 Fig 77 until sprocket bottoms Fig 74 Primary Timing Chain Tensioner 1 TENSIONER 2 RETAINER CAP 3 BOLT Fig 75 Timing Chain Tensioner Arming Fig 76 Crankshaft Sprocket Removal 1 SPECIAL TOOL 8539 2 SPECIAL ...

Page 933: ...179 Stud Fig 80 2 Install crankshaft damper CRANKSHAFT OIL SEAL REAR REMOVAL 1 Remove transaxle from vehicle Refer to TRAN SAXLE for procedure 2 Remove drive plate 3 Insert a 3 16 wide flat bladed screwdriver between the dust lip and the metal case of the crank shaft seal Angle the screwdriver Fig 81 through the dust lip against the metal case of the seal Pry out seal CAUTION Do not allow the scre...

Page 934: ...al is flush with housing surface 4 Install drive plate and transaxle Refer to TRANSAXLE for procedures CRANKSHAFT OIL SEAL RETAINER REAR REMOVAL 1 Remove crankshaft rear oil seal and oil pan Refer to procedures in this section 2 Remove seal retainer attaching screws Fig 83 3 Remove retainer and gasket Fig 83 Fig 81 Rear Crankshaft Oil Seal Removal Typical 1 REAR CRANKSHAFT SEAL 2 ENGINE BLOCK 3 EN...

Page 935: ... the timing cover to the oil pan as damage to the timing cover and or oil pan may occur 8 Remove oil pan attaching fasteners Remove oil pan and gasket Fig 86 INSTALLATION 1 Clean oil pan and sealing surfaces Inspect oil pan and timing chain cover gaskets Replace as nec essary 2 Apply a 1 8 inch bead of Mopart Engine RTV GEN II to the front T joints oil pan gasket to timing cover gasket interface F...

Page 936: ... timing chain cover 9 Remove primary timing chain 10 Remove crankshaft sprocket 11 Remove oil pump 12 Remove crankshaft rear oil seal retainer 13 Remove structural windage tray Fig 91 14 Turn crankshaft until connecting rod cap to be removed is accessible NOTE Connecting rod bearing caps are not inter changeable and should be marked before removing to ensure correct reassembly CAUTION DO NOT use a...

Page 937: ... bolts with engine oil before installation The main bearing cap bolts must be tightened in the proper sequence First the inner main cap bolts secondly the windage tray bolts and lastly the main cap tie horizontal bolts 7 Install the inside main bearing cap bolts and tighten to 20 N m 1 4 Turn 15 ft lbs 1 4 Turn Fig 90 8 Measure crankshaft end play Refer to Service Procedures Crankshaft Bearing Ins...

Page 938: ... new filter with clean engine oil 4 Install oil filter and tighten to 20 N m 15 ft lbs of torque after gasket contacts base Use filter wrench if necessary 5 Fill crankcase with proper engine oil to correct level if drained Start engine and check for leaks OIL PUMP REMOVAL The oil pump pressure relief valve can be serviced by removing the oil pan 1 Refer to procedures in this section for removing t...

Page 939: ... Oil Pan Crankshaft Sprocket Timing Chain Timing Chain Cover Crankshaft Damper 7 Fill Crankcase with proper engine oil to correct level PISTON AND CONNECTING ROD REMOVAL 1 Remove top ridge of cylinder 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 Pistons and con necting rods must be removed from top of...

Page 940: ...on Fig 97 CAUTION Install piston rings in the following order 2 Oil ring expander 3 Upper oil ring side rail 4 Lower oil ring side rail 5 No 2 Intermediate piston ring 6 No 1 Upper piston ring 7 Install the side rail by placing one end between the piston ring groove and the expander Hold end firmly and press down the portion to be installed until side rail is in position Do not use a piston ring e...

Page 941: ...on CAUTION Ensure the hole in bearing half aligns with hole in connecting rod as damage to engine may occur 4 Position bearing onto connecting rod Ensure that hole in bearing half is aligned to hole in con necting rod Lubricate bearing surface with clean engine oil 5 Install Special Tools 8189 Connecting Rod Guides into connecting rod Fig 96 6 The pistons are marked on top with an arrow and with a...

Page 942: ...ug With the cup plug rotated grasp firmly with pliers or other suit able tool and remove plug Fig 103 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 Mopart Stud and Bearing Mount Ma...

Page 943: ...omponents carefully for damage or wear Refer to Cleaning and Inspection Oil Pump in this section for procedures 6 Tighten cover screws to 12 N m 105 in lbs Fig 105 Tighten oil pressure relief valve retaining cap to 12 N m 105 in lbs Fig 104 Fig 103 Core Hole Plug Removal 1 CYLINDER BLOCK 2 REMOVE PLUG WITH PLIERS 3 STRIKE HERE WITH HAMMER 4 DRIFT PUNCH 5 CUP PLUG Fig 104 Oil Pressure Relief Valve ...

Page 944: ...ock mating surfaces do not use a metal scraper because the sealing surfaces could be cut or ground Instead use a wooden or plastic scraper 2 Make sure the gasket and or foreign material does not enter the oil feed hole or the oil return holes INSPECTION 1 Before cleaning check for leaks damage and cracks 2 Clean cylinder head and oil passages 3 Check cylinder head for flatness Fig 107 4 Cylinder h...

Page 945: ...der head if stem to guide clearance exceeds specifications or if guide is loose in cylinder head OIL PUMP INSPECTION AND REPAIR 1 Clean all parts thoroughly Mating surface of the oil pump housing should be smooth Replace pump cover if scratched or grooved 2 Lay a straightedge across the pump cover sur face Fig 111 If a 0 025 mm 0 001 inch feeler gauge can be inserted between cover and straight edg...

Page 946: ...s the face of the body between bolt holes If a feeler gauge of 0 077 mm 0 003 inch or more can be inserted between rotors and the straightedge replace pump assembly Fig 116 ONLY if rotors are in specs 8 Inspect oil pressure relief valve plunger for scoring and free operation in its bore Small marks may be removed with 400 grit wet or dry sandpaper 9 The relief valve spring has a free length of app...

Page 947: ... ing CYLINDER BORE INSPECTION The cylinder walls should be checked for out of round and taper with Tool C 119 as shown in Fig 117 Measure the cylinder bore at three levels in direc tions A and B Fig 117 Top measurement should be 12 mm 0 50 inch down and bottom measurement should be 12 mm 0 50 inch up from bottom of bore Refer to Engine Specifications NOTE There are no service procedures to bore th...

Page 948: ... Piston Ring Groove Diameter No 1 77 65 77 85 mm 3 0571 3 065 in Piston Ring Groove Diameter No 2 75 72 75 92 mm 2 9811 2 989 in Piston Ring Groove Diameter No 3 77 42 77 62 mm 3 0481 3 0559 in Piston Pins Type Full Floating Pin Diameter 21 997 22 000 mm 0 8661 0 8662 in Clearance in Piston 0 002 0 010 mm 0 0001 0 0004 in Clearance in Rod 0 007 0 018 mm 0 0003 0 0008 in Piston Rings Ring Gap Top C...

Page 949: ...in Bearing Clearance Max 0 13 mm 0 0051 in DESCRIPTION SPECIFICATION End Play 0 13 mm 0 0051 0 0110 in Valve Timing Intake Valve Opens ATDC 2 Closes ABDC 44 Duration 222 Valve Timing Exhaust Valve Opens BBDC 36 Closes ATDC 4 Duration 220 Valve Overlap 2 Cylinder Head Gasket Thickness Compressed 1 50 mm 60 05 0 0591 in 60 002 in Valve Seat Angle 44 5 45 Valve Seat Runout Max 0 05 mm 0 002 in Intake...

Page 950: ...tom of retainer 38 0 mm 1 4961 in Oil Pump Clearance Over Rotors Max 0 077 mm 0 003 in Cover Out of Flat Max 0 025 mm 0 001 in DESCRIPTION SPECIFICATION Inner Outer Rotor Thickness 9 475 9 500 mm 0 3731 0 3741 in Outer Rotor Clearance Max 0 39 mm 0 015 in Outer Rotor Diameter Min 89 175 mm 3 5109 in Tip Clearance Between Rotors Max 0 20 mm 0 008 in Oil Pressure Pressure Curb Idle Speed 34 7 kPa 5 ...

Page 951: ...tainer Bolts 12 105 Spark Plugs 20 15 Starter Mounting Bolts 41 30 Structural Collar Refer to Procedure Thermostat Housing Water Inlet Connector Bolts 12 105 Throttle Body Bolts 12 105 Timing Chain Cover M6 Bolts 12 105 M10 Bolts 54 40 Timing Chain Tensioner Primary 54 40 Timing Chain Guide Access Plug 20 15 Water Pump Bolts 12 105 Cooling System Bleed Screw 12 110 Water Outlet Housing Bolts 12 10...

Page 952: ...rankshaft Seal Sprocket Installer 6780 1 Crankshaft Seal Protector 6780 2 Puller 5048 Puller Adaptor 8539 Crankshaft Rear Seal Guide 6926 1 Installer 6926 2 Crankshaft Real Seal Retainer Alignment Fixture 8225 Timing Chain Tensioner Resetting Gauge 8186 LH 2 7L ENGINE 9 71 SPECIAL TOOLS Continued ...

Page 953: ...8216 Valve Spring Compressor C 3422 B Valve Spring Adapter 6526 Valve Spring Tester C 647 Valve Spring Compressor MD 998772 A Valve Spring Adapter 6527 Indicator Bore Size C 119 Connecting Rod Installation Guides 8189 9 72 2 7L ENGINE LH SPECIAL TOOLS Continued ...

Page 954: ...Main Bearing Remover Installer C 3059 Adaptor 8116 Cooling System Tester 7700 Combustion Leak Tester C 3685 A LH 2 7L ENGINE 9 73 SPECIAL TOOLS Continued ...

Page 955: ...AFT MAIN BEARING FITTING 98 CRANKSHAFT END PLAY CHECKING 99 VALVE AND VALVE SEAT REFACING 99 REMOVAL AND INSTALLATION ENGINE MOUNTS LEFT AND RIGHT 101 ENGINE MOUNT REAR 101 STRUCTURAL COLLAR 101 ENGINE ASSEMBLY 103 CRANKSHAFT DAMPER 105 INTAKE MANIFOLD UPPER 106 INTAKE MANIFOLD LOWER 107 EXHAUST MANIFOLD 110 CYLINDER HEAD COVER 111 SPARK PLUG TUBES 112 CYLINDER HEAD 112 CRANKSHAFT 115 CAMSHAFT 116...

Page 956: ...DESCRIPTION AND OPERATION 3 2 3 5L ENGINE Fig 1 3 2 3 5L Engine LH 3 2 3 5L ENGINE 9 75 ...

Page 957: ...Fig 3 CYLINDER BLOCK DESCRIPTION The cylinder block Fig 4 is made of heat treated aluminum with cast in place iron liners The block is a closed deck design with the right bank forward To provide high rigidity and improved NVH the block has cast in contours and ribs along with powdered metal 6 bolt main caps 4 vertical 2 horizontal with a die cast aluminum structural beam windage tray mounted to th...

Page 958: ...o control torsion caused vibration of the crankshaft Rubber lipped seals are used at front and rear The front seal is retained in the oil pump case and the rear seal is retained in a block mounted housing OPERATION The crankshaft transfers force generated by com bustion within the cylinder to the flywheel or flex plate Fig 4 Cylinder Block and Crankshaft 1 MAIN CAP BOLT VERTICAL 2 MAIN CAP 3 MAIN ...

Page 959: ...facilitate valve rotation OPERATION The intake valve allows the air fuel mixture to enter the combustion chamber The exhaust valve allows the burned air fuel mixture to exit the com bustion chamber Also the intake and exhaust valves seal the combustion chamber during the compression and power strokes VALVE SPRINGS DESCRIPTION Valve springs are unique for intake versus exhaust Both are made from ch...

Page 960: ...veral forged aluminum alloy pedestals which are fastened to the cylinder head Four shafts are used one for each intake and exhaust rocker arm bank on each cylinder head The shafts are hollow to provide a duct for lubricating oil flow from the cylinder head to the valve mechanisms One hollow dowel per pedestal is used to locate the pedestal to the cylinder head orient the exhaust rocker shaft and s...

Page 961: ...ir charge inertia Fig 8 An active Short Runner Valve SRV opens during certain operating conditions to improve top end performance A Manifold Tuning Valve MTV connects the plenums at specific engine speeds to maximize low RPM torque without reducing high RPM power The aluminum lower intake manifold attaches to each cylinder head and uses a gasket for sealing Fig 9 The manifold coolant passage allow...

Page 962: ...side the radiator tank OPERATION Engine oil stored in the oil pan is drawn in and discharged by a gerotor type oil pump The oil pump is directly coupled to the crankshaft Oil pressure is regulated by a relief valve The oil is fed through an oil filter and to the crankshaft journals from the oil gallery in the cylinder block This gallery also feeds oil under pressure to the cylinder heads Oil flows...

Page 963: ...osis charts Information concerning additional tests and diagno sis is provided within the following Cylinder Compression Pressure Test Cylinder Combustion Pressure Leakage Test Cylinder Head Gasket Failure Diagnosis Intake Manifold Leakage Diagnosis Fig 10 Exhaust Manifold 1 BOLT 2 HEAT SHIELD 3 EXHAUST MANIFOLD 4 BOLT 5 HEAT SHIELD Fig 11 Oil Lubrication System 1 CRANKSHAFT 2 OUTER ROTOR 3 INNER ...

Page 964: ... camshaft sprocket 3 2 3 5L ENGINE STALLS OR IDLES ROUGH 1 Idle speed too low 1 Test minimum air flow Refer to FUEL SYSTEM 2 Incorrect fuel mixture 2 Refer to FUEL SYSTEM 3 Intake manifold leakage 3 Inspect intake manifold manifold gasket and vacuum hoses 4 Faulty coil s 4 Test and replace as necessary Refer to IGNITION SYSTEM ENGINE LOSS OF POWER 1 Dirty or incorrectly gapped plugs 1 Clean plugs ...

Page 965: ... diluted oil 2 Change oil to correct viscosity 3 Low oil pressure 3 Check and correct engine oil level 4 Dirt in tappets lash adjusters 4 Replace rocker arm hydraulic lash adjuster assembly 5 Worn rocker arms 5 Inspect oil supply to rocker arms 6 Worn tappets lash adjusters 6 Install new rocker arm hydraulic lash adjuster assembly 7 Worn valve guides 7 Ream guides and install new valves with overs...

Page 966: ...scosity 7 Oil pump relief valve stuck 7 Remove valve and inspect clean or replace 8 Oil pump suction tube loose 8 Remove oil pan and install new tube or clean if necessary 9 Oil pump cover warped or cracked 9 Install new oil pump 10 Excessive bearing clearance 10 Measure bearings for correct clearance OIL LEAKS 1 Misaligned or deteriorated gaskets 1 Replace gasket s 2 Loose fastener broken or poro...

Page 967: ...measure ments are indicated on the table for finer adjust ments Refer to Specifications Section to obtain specified height and allowable tensions Replace springs that do not meet specifications INTAKE MANIFOLD LEAKAGE DIAGNOSIS An intake manifold air leak is characterized by lower than normal manifold vacuum Also one or more cylinders may not be functioning WARNING USE EXTREME CAUTION WHEN THE ENG...

Page 968: ... it attains nor mal operating temperature then turn the engine OFF Clean spark plug recesses with compressed air Remove the spark plugs Remove the oil filler cap Remove the air cleaner Calibrate the tester according to the manufactur er s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum with 552 kPa 80 psi rec ommended Perform the test p...

Page 969: ...t type noise can sometimes be difficult As a result an initial misdiagnosis may occur Refer to the following chart indicating possible lash adjuster tappet noise sources and possible sources that could lead to a misdiagnosis Refer to Lash Adjuster Tappet Noise Chart for Possible Causes and Correction of a lash adjuster tappet type noise POSSIBLE NOISE SOURCES POSSIBLE NOISE MISDIAGNOSIS SOURCES Sp...

Page 970: ...6 Ream guide s and replace valve s with oversize valves and seal s 7 Air injested into oil due to broken or cracked oil pump pickup tube 7 Inspect pickup tube and replace as necessary 8 Collapsed lash adjuster due to debris injestion 8 Clean debris from engine and replace lash adjuster rocker assembly 9 Intake rocker arm roller clevis ear s contacting camshaft bearing journal s on side 9 Inspect c...

Page 971: ...of the leak If the leakage occurs at the crankshaft rear oil seal area 1 Disconnect the battery 2 Raise the vehicle 3 Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil Use a black light to check for the oil leak If a leak is present in this area remove transmission for further inspection a Circular spray pattern generally indicates seal leakage or cranks...

Page 972: ... engines The designation of ENERGY CON SERVING is located on the label of an engine oil con tainer CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil The identifying notations are located on the label of engine oil plastic bottles and the top of engine oil cans Fig 16 ENGINE OIL CHANGE Change engine oil at mileage an...

Page 973: ...l The material cures in the absence of air when squeezed between two metallic surfaces It will not cure if left in the uncovered tube The anaerobic material is for use between two machined surfaces Do not use on flexible metal flanges MOPARt BED PLATE SEALANT Mopart Bed Plate Sealant is a unique green in color anaerobic type gasket material that is specially made to seal the area between the bedpl...

Page 974: ...e recommended tool C 823 or equivalent equipped with 220 grit stones is the best tool for this honing procedure In addition to deglazing it will reduce taper and out of round as well as removing light scuffing scoring or scratches Usually a few strokes will clean up a bore and maintain the required lim its 2 Deglazing of the cylinder walls may be done using a cylinder surfacing hone recommended to...

Page 975: ...of the cam Fig 19 Rotate engine as nec essary 4 For intake rocker arm positions a Adjust Special Tool 8351 Release Probe s gauge pin to extend approximately 20 mm 0 787 in Then carefully insert the release probe gauge pin into the lash adjuster service access hole Fig 20 CAUTION If probe tip breaks off within the lash adjuster replace the affected rocker arm b Gently unseat lash adjuster s interna...

Page 976: ...shown in Fig 21 Cylin der bores should be measured halfway down the cyl inder bore and transverse to the engine crankshaft center line Refer to Engine Specifications Pistons and cylinder bores should be measured at nor mal room temperature 70 F 21 C PISTON PINS The piston pin is full floating and is held in place by lock rings Pistons and rods are weight matched for balance Do Not switch pistons w...

Page 977: ... dot facing up towards top of the piston Fig 24 CAUTION Install piston rings in the following order 2 Oil ring expander 3 Upper oil ring side rail 4 Lower oil ring side rail 5 No 2 Intermediate piston ring 6 No 1 Upper piston ring 7 Install the side rail by placing one end between the piston ring groove and the expander Hold end firmly and press down the portion to be installed until side rail is ...

Page 978: ... half Do not file the rods or bearing caps 1 Follow procedure specified in the Standard Ser vice Procedure Section for Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance Fig 28 Refer to Engine Specifications NOTE The rod bearing bolts should be examined before reuse If the threads are necked down the bolts should be replaced Fig 29 2 Necking can be checked by holding a scale or ...

Page 979: ...roperly select the main bearings For an example if the main bore grade is 3 and the journal grade is B the proper select fit bearing would be a 2 0 003 mm 0 0002 in NOTE Service main bearings have a number from 1 5 marked in ink on the bearing surface Fig 33 For verification use the Main Bearing Selection Chart for number to size identification The upper main bearing has a oil feed hole and a cent...

Page 980: ...alve seat angles are shown in Fig 36 VALVES 1 Inspect the remaining margin after the valves are refaced Fig 35 Refer to Engine Specifications Fig 33 Main Bearing Grade Marks 1 LOWER MAIN BEARING 2 UPPER MAIN BEARING 3 OIL FEED HOLE AND GROOVE 4 GRADE SELECTION INK MARKS MAIN BEARING SELECTION CHART 3 2 3 5L Main Bearing Bore Grade Marks 1 2 3 A 3 standard 2 003 mm 0 0002 in 1 0 006 mm 0 0003 in Cr...

Page 981: ...rec tion with orange dye on the top coils and the exhaust spring is left hand coil direction with a yellow dye on the top coils Fig 37 VALVE INSTALLATION 1 Coat valve stems with clean engine oil and insert them in cylinder head 2 If valves or seats have been reground check valve tip height A Fig 38 If valve tip height is greater than 43 65 mm 1 7185 in intake or 45 98 mm 1 8102 in exhaust grind va...

Page 982: ...ing fluid Driveshaft Diagnosis Refer to DIFFERENTIAL AND DRIVELINE Any front end structural damage after repair Isolator replacement ENGINE MOUNT REAR REMOVAL 1 Raise vehicle on hoist 2 Support transaxle with a jack 3 Remove isolator nuts from the mount to tran saxle mount bracket Fig 40 4 Remove rear mount isolator bolts to crossmem ber and remove mount Fig 40 INSTALLATION 1 Position isolator ont...

Page 983: ... lbs b Install the horizontal collar to transmission bolts and torque to 55 N m 40 ft lbs c Starting with the center vertical bolts and work ing outward final torque bolts to 55 N m 40 ft lbs 2 Lower vehicle Fig 40 Engine Mounting Right Left and Rear 1 NUT 2 REAR ISOLATOR 3 BOLT 4 NUT 5 ISOLATOR 6 HEAT SHIELD 7 BOLT 8 ENGINE MOUNT BRACKET 9 NUT Fig 41 Structural Collar 1 BOLT HORIZONTAL 2 BOLT VER...

Page 984: ...diator 14 Remove power steering line bracket at left side of radiator 15 Remove fasteners attaching air conditioning condenser to radiator 16 Remove radiator 17 Remove generator 18 Remove power steering pump mounting bolts and set pump aside 19 Remove air conditioning compressor mounting bolts and set aside 20 Loosen and remove V Band clamp at right exhaust manifold 21 Remove front and rear suppor...

Page 985: ...Attach lifting device and lower engine into engine compartment 2 Align engine mounts and install fasteners but do not tighten until all mounting bolts have been installed 3 Install transmission case to engine block tighten bolts to 102 N m 75 ft lbs 4 Remove engine lifting device 5 Raise vehicle 6 Tighten engine mount fastener to 61 N m 45 ft lbs 7 Align flex plate to torque converter and install ...

Page 986: ... hose 43 Install cowl support 44 Install both cowl covers 45 Install both wiper arms 46 Install hood 47 Connect negative cable CRANKSHAFT DAMPER REMOVAL 1 Disconnect negative cable at right strut tower 2 Remove upper radiator crossmember Refer to BODY for procedure 3 Remove fan module Refer to COOLING SYS TEM for procedure 4 Remove the accessory drive belts Refer to COOLING SYSTEM for procedure 5 ...

Page 987: ...r Speed Control Reservoir Positive Crankcase Ventilation PCV Valve Proportional Purge Solenoid Power Brake Booster 6 Remove right side Fig 50 and left side Fig 51 intake manifold supports 7 Remove support brackets at intake manifold front corners and at MTV Fig 52 8 Loosen upper fastener attaching throttle body to support bracket 9 Remove clips attaching EGR tubes to intake manifold Refer to EMISS...

Page 988: ...ower Brake Booster 9 Connect electrical connectors to the following Secondary Runner Valve SRV Manifold Tuning Valve MTV Throttle Position Sensor TPS Idle Air Control IAC Intake Air Temperature Manifold Absolute Pres sure TMAP Vacuum Reservoir Solenoid 10 Install EGR tubes to intake manifold Refer to EMISSION CONTROL SYSTEM for procedure 11 Install throttle and speed control cables to bracket and ...

Page 989: ...ifold on cylin der head surfaces 4 Install fuel rail with injectors 5 Install intake manifold bolts and gradually tighten in sequence shown in Fig 56 until a torque of 28 N m 250 in lbs is obtained 6 Install screw attaching fuel rail support bracket to the throttle body support bracket 7 Connect fuel supply hose to fuel rail 8 Connect heater and coolant bottle supply hoses to coolant tube at rear ...

Page 990: ...Fig 55 Lower Intake Manifold 1 BOLT 2 HEATER SUPPLY TUBE 3 BOLT 4 BOLT 5 KNOCK SENSOR 6 GASKET 7 BOLT 8 O RING 9 INTAKE MANIFOLD LOWER LH 3 2 3 5L ENGINE 9 109 REMOVAL AND INSTALLATION Continued ...

Page 991: ...d and connect electrical connector 4 Install air conditioning compressor mounting bracket 5 Install engine oil dipstick tube 6 Install air conditioning compressor and drive belt Refer to COOLING SYSTEM for belt installa tion procedure 7 Install a new V Band clamp and tighten to 11 N m 100 in lbs 8 Raise vehicle on hoist 9 Install exhaust system Refer to EXHAUST SYSTEM for procedure 10 Install and ...

Page 992: ...and remove ignition coils Fig 59 4 Remove nuts attaching wire harness to cylin der head cover Fig 58 Move harness for cover removal clearance 5 For right cylinder head cover removal perform the following a Remove A C compressor belt Refer to COOL ING SYSTEM for procedure b Remove A C compressor mounting bolts c Move compressor aside for cylinder head cover clearance 6 Remove cylinder head cover bo...

Page 993: ... Mopart Stud and Bearing Mount to a new tube approximately 1 mm 0 039 in from the end of tube in a 3 mm 0 118 in wide area 2 Install sealer end of tube into the cylinder head Then carefully install the tube using a hard wood block and mallet Install the tube until it is seated into the bottom of the bore 3 Install cylinder head cover s Refer to proce dure in this section CYLINDER HEAD REMOVAL 1 Dr...

Page 994: ...iming belt cover has O rings to seal the water pump passages to cylinder block Fig 65 Do not reuse O rings 9 Remove cylinder head bolts and remove cylin der head s Fig 63 Servicing Spark Plug Tubes 1 SPARK PLUG TUBE 2 LOCKING PLIERS Cylinder Head Camshaft and Rocker Arms 1 SPARK PLUG TUBE 2 ROCKER ARM ASSEMBLY 3 CAMSHAFT 4 SEAL Fig 64 Rear Timing Belt Cover Attaching Bolts 1 REAR COVER TO CYLINDER...

Page 995: ... cylinder head over locating dowels 4 Before installing the bolts lubricate the threads with engine oil 5 Tighten the cylinder head bolts in the sequence shown in Fig 68 Using the 4 step torque turn method tighten according to the following torque val ues Step 1 All to 61 N m 45 ft lbs Step 2 All to 88 N m 65 ft lbs Step 3 All again to 88 N m 65 ft lbs Step 4 90 Turn Do not use a torque wrench for...

Page 996: ...l and Installation for procedure 11 Tap dowel pin out of crankshaft Refer to Front Crankshaft Oil Seal Removal and Installation for procedure 12 Remove oil pump assembly 13 Remove rear crankshaft oil seal retainer 14 Remove connecting rod bearing caps Connect ing rod bearing caps are not interchangeable and should be marked before removal to insure correct assembly Fig 69 15 Remove main bearing ca...

Page 997: ...n for procedure 14 Install crankshaft sprocket Refer to Front Crankshaft Oil Seal Removal and Installation for procedure 15 Install Timing Belt Refer to Camshaft Sprockets and Timing Procedure in this section 16 Install 3 timing belt covers 17 Install crankshaft damper Refer to procedure in this section 18 Install idler pulley for accessory drive belt 19 Install oil pickup tube and tighten bolt to...

Page 998: ...oper performance of the engine Refer to camshaft and timing belt installation in this section for proce dures TIMING PROCEDURE 3 2 3 5L CAUTION The camshaft sprockets are not inter changeable from side to side Fig 73 1 Place crankshaft sprocket to the TDC mark on the oil pump housing Fig 74 2 Install a dial indicator in number 1 cylinder to check TDC of the piston Fig 79 Rotate the crank shaft unt...

Page 999: ...y bracket 9 With number 1 piston at TDC Fig 79 hold the camshaft sprocket hex with a 36 mm 1 7 16 in wrench and tighten the camshaft bolts to 102 N m 75 ft lbs plus a 90 degree turn for the Right side and 115 N m 85 ft lbs plus a 90 degree turn for the Left side Fig 75 Camshaft Alignment Special Tools 6642 1 LEFT CAMSHAFT PILOT HOLE 2 RIGHT CAMSHAFT PILOT HOLE 3 CAMSHAFT ALIGNMENT SPECIAL TOOLS 66...

Page 1000: ...ker shaft support The rocker arm shaft assembly on the LEFT side of the engine has an oil passage hole from the cylinder head to the second rocker shaft support REMOVAL 1 Remove cylinder head covers Refer to proce dure in this section 2 Identify the rocker arm assembly and rocker arms before disassembly Fig 80 3 Remove rocker arm assembly bolts 4 Remove rocker arm assembly NOTE To prevent air inge...

Page 1001: ...lve This will allow the rocker arm shaft assembly to be tight ened into position with little or no valve spring load on it 2 Install the rocker arm and shaft assembly making sure that the identification marks face toward the front of engine for left head and toward the rear of the engine for right head 3 Tighten rocker arm shaft assembly bolts in sequence to 31 N m 275 in lbs Fig 84 VALVE STEM SEA...

Page 1002: ...e spark plug adapter tool 14 Remove Special Tool MD 998772A and install rocker arm and shaft assembly Refer to procedure in this section 15 Install cylinder head covers Refer to proce dure in this section 16 Install ignition coils and connect all electrical connectors 17 Install upper intake manifold Refer to proce dure in this section 18 Connect negative cable VALVE AND VALVE SPRINGS REMOVAL 1 Wi...

Page 1003: ...kshaft damper using Special Tools 1023 and C 4685 C2 Fig 90 6 Remove the lower belt cover located behind the crankshaft damper Fig 92 7 Remove the A C belt guide lift bracket Fig 91 8 Remove the stamped steel cover Fig 92 Do not remove the sealer on the cover it is reus able Fig 93 If some sealer is missing use Mopart Engine RTV GEN II to replace the missing sealer 9 Remove the left cast cover Fig...

Page 1004: ...ING BELT REMOVAL CAUTION The following procedure can only be used when the camshaft sprockets HAVE NOT BEEN LOOSENED or removed from the camshafts Refer to Camshaft Sprocket and Engine Timing in this Section if sprocket s or camshaft s have been loosened or removed Fig 90 Crankshaft Damper Removal 1 SPECIAL TOOL 1023 2 SPECIAL TOOL C 4685 C2 INSERT Fig 91 A C Belt Guide Lift Bracket 1 A C BELT GUI...

Page 1005: ... the exact position of the camshaft sprocket timing mark rela tive to the two timing marks on the rear timing cover NOTE When timing belt tensioner is removed from engine always store in the vertical plunger facing upward position 9 Remove the timing belt tensioner Fig 95 and remove timing belt TIMING BELT TENSIONER 10 When tensioner is removed from the engine it is necessary to compress the plung...

Page 1006: ... the timing marks on the camshafts and crank shaft The marks should line up within their respec tive locations Fig 97 If marks do not line up repeat procedure 7 Install timing belt covers and crankshaft damper Refer to procedure in this section 8 Install accessory drive belts and cooling fan module Refer to COOLING SYSTEM for procedures 9 Install upper radiator crossmember Refer to BODY for proced...

Page 1007: ...ig 99 4 Install the structural collar Fig 98 using the follow procedure a Install the vertical collar to oil pan bolts Pre torque bolts to 1 1 N m 10 in lbs b Install the horizontal collar to transmission bolts and tighten to 55 N m 40 ft lbs c Starting with center vertical bolts and work ing outward final torque all bolts to 55 N m 40 ft lbs Fig 98 Structural Collar 1 BOLT HORIZONTAL 2 BOLT VERTI...

Page 1008: ...1 Apply light coat of engine oil to the camshaft oil seal lip 2 Install the oil seal using Special Tool 6788 Seal Protector Sleeve Fig 102 and Seal Installer 6052 Fig 103 3 Install camshaft sprocket s Refer to procedure in this section Fig 100 Oil pan Sealing Fig 101 Camshaft Oil Seal Removal 1 SPECIAL TOOL C 3981B Fig 102 Camshaft Oil Seal Protector Sleeve 1 SPECIAL TOOL 6788 Fig 103 Camshaft Oil...

Page 1009: ...pecial Tool 6342 Fig 107 2 Install the dowel pin into the crankshaft to 1 2 mm 0 047 in protrusion Fig 105 NOTE To assure proper installation depth of crank shaft sprocket Special Tool 6641 must be used 3 Install crankshaft sprocket using Special Tools 6641 and C 4685 C1 Fig 108 4 Install timing belt Fig 104 Crankshaft Sprocket Removal 1 SPECIAL TOOL L 4407 A Fig 105 Crankshaft Sprocket Dowel Pin ...

Page 1010: ... 110 drive seal into the retainer hous ing until seal is flush with housing surface 4 Install drive plate and transaxle Refer to TRANSAXLE for procedures CRANKSHAFT OIL SEAL RETAINER REAR REMOVAL 1 Remove crankshaft rear oil seal and oil pan Refer to procedure in this section 2 Remove seal retainer attaching screws 3 Remove seal retainer Fig 111 NOTE Seal retainer gasket is bonded to the retainer ...

Page 1011: ...T interchangeable CRANKSHAFT MAIN JOURNALS The crankshaft journals should be checked for excessive wear taper and scoring Limits of taper or out of round on any crankshaft journals should be held to 0 015 mm 0 0006 in Journal grinding should not exceed 0 305 mm 0 012 inch under the standard journal diameter DO NOT grind thrust faces of Number 2 main bearing DO NOT nick crank pin or bearing fillets...

Page 1012: ...C 3059 Fig 115 into the oil hole of crank shaft 3 Slowly rotate crankshaft clockwise forcing out upper half of bearing shell INSTALLATION CAUTION Main bearings are select fit Refer to Crankshaft Main Bearing Fitting in this section for proper bearing selection NOTE Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened When installing a new uppe...

Page 1013: ... cap tie horizontal bolts and tighten to 28 N m 250 in lbs 11 Install oil pump pick up tube and oil pan 12 Fill engine crankcase with proper oil to cor rect level OIL FILTER NOTE When servicing the oil filter avoid deform ing the filter can Install the remove install tool band strap against the base lock seam The lock seam joining the can to the base is reinforced by the base plate 1 Using a suita...

Page 1014: ...MOVAL 1 Remove cylinder heads and oil pan Refer to procedures in this section 2 Remove top ridge of cylinder 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 Pistons and con necting rods must be removed from top of cyl inder block When removing piston and connecting rod assemblies from the engine rotate c...

Page 1015: ...r gap at least 45 from the side rail gaps but not on the piston pin cen ter or on the thrust direction Staggering ring gap is important for oil control PISTON INSTALLATION NOTE The connecting rod bearing cap bolts must be examined before reuse If the threads are necked down the bolts should be replaced 1 Check connecting rod bolts for necking by hold ing a scale or straight edge against the thread...

Page 1016: ...necting rod faces the major thrust right side of the cylinder bore Fig 128 8 Tap the piston down in cylinder bore using a hammer handle At the same time guide connecting rod into position on connecting rod journal 9 Install rod caps Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 N m 40 ft lbs Plus 1 4 turn 10 Install cylinder heads and oil pan Refer to procedures in this sectio...

Page 1017: ...ylin der block or head Be sure to remove old sealer Lightly coat inside of cup plug hole with Mopart Stud and Bearing Mount Make certain the new plug is cleaned of all oil or grease Using proper drive plug drive plug into hole so that the sharp edge of the plug is at least 0 5 mm 0 020 in inside the lead in chamfer It is not necessary to wait for curing of the sealant The cooling system can be ref...

Page 1018: ...he pin then loosen the nut on the screw This will pull the dowel out of the shaft support Do not reuse dowel pins Remove the rocker arms and pedestals in order 2 Check the rocker arm mounting portion of the shafts for wear or damage Replace if damaged or heavily worn 3 Check shaft oil holes for clogging with small wire clean as required ASSEMBLY CAUTION New dowel pins must be installed when reasse...

Page 1019: ...ean cylinder head and oil passages 3 Check cylinder head for flatness Fig 134 4 Cylinder head must be flat within Standard dimension less than 0 05 mm 0 002 inch Service Limit 0 2 mm 0 008 inch Grinding Limit Maximum of 0 2 mm 0 008 inch is permitted CAUTION 0 20 mm 0 008 in MAX is a combined total dimension of the stock removal limit from cyl inder head and block top surface Deck together CAMSHAF...

Page 1020: ...heck rocker arms for wear or damage Fig 137 Roller scuffing or wear Shaft bore scuffing or wear Swivel pad on lash adjuster missing or broken Rocker arm showing signs of fatigue or cracking Roller axle protruding from arm Replace assembly as necessary if any rocker arms shows signs of wear CAUTION Do Not remove lash adjuster from rocker arm assembly Damage to the adjuster and rocker arm will resul...

Page 1021: ...oughly Mating surface of the oil pump housing should be smooth Replace pump cover if scratched or grooved 2 Lay a straightedge across the pump cover sur face Fig 140 If a 0 025 mm 0 001 in feeler gauge can be inserted between cover and straight edge cover should be replaced 3 Measure thickness and diameter of outer rotor If outer rotor thickness measures 14 299 mm 0 563 in or less Fig 141 or if th...

Page 1022: ... 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 49 5 mm 1 95 inches it should test between 23 25 pounds when compressed to 34 mm 1 11 32 inches Replace spring that fails to meet specifications OIL PUMP ASSEMBLY 1 Assemble pump using new parts as required 2 Tighten cover screws to 12 N m 105 in lbs 3 Prime oil p...

Page 1023: ...re the cylinder bores for installation of oversized pistons ENGINE HYDRO MOUNT INSULATORS Engine hydro mounts may show surface cracks this will not effect performance and mount should not be replaced Only replace the engine hydro mounts when leaking fluid Drive shaft distress Refer to Driveshafts in Sus pension Group 2 Any front end structural damage after repair Insulator replacement TIMING BELT ...

Page 1024: ...meter No 1 83 69 83 89 mm 3 2949 3 3028 in No 2 81 12 81 32 mm 3 1937 3 2016 in No 3 82 3 82 5 mm 3 2402 3 2481 in Piston Pins Type Full Floating Clearance in Piston 0 005 0 015 mm 0 0002 0 0006 in Clearance in Rod 0 007 0 018 mm 0 0003 0 007 in Diameter 23 997 24 000 mm 0 9448 0 9449 in Piston Rings Ring Gap Top Compression Ring 0 20 0 36 mm 0 008 0 014 in Ring Gap 2nd Compression Ring 0 22 0 49 ...

Page 1025: ...iametrical Clearance 0 019 0 087 mm 0 00075 0 0034 in Out of Round Max 0 015 mm 0 0006 in Taper Max 0 015 mm 0 0006 in DESCRIPTION SPECIFICATION Camshaft Bore Diameter 43 038 43 059 mm 1 6944 1 6952 in Bearing Journal Diameter 42 939 42 960 mm 1 6905 1 6913 in Diametrical Clearance 0 078 0 12 mm 0 003 0 0047 in Max 0 15 mm 0 0059 in End Play 0 11 0 35 mm 0 004 0 014 in Valve Timing Intake Valve Op...

Page 1026: ...lve Closed 309 358 N 38 0 mm 69 5 80 5 lbs 1 4961 in Spring Force Exhaust Valve Closed 314 354 N 38 0 mm 71 79 lbs 1 4961 in DESCRIPTION SPECIFICATION Spring Force Intake Valve Open 836 907 N 29 85 mm 188 204 lbs 1 1594 in Spring Force Exhaust Valve Open 579 640 N 31 47 mm 130 144 lbs 1 239 in Number of Coils Intake 6 86 Number of Coils Exhaust 7 66 Color of Spring Top of Coils Intake Right Hand C...

Page 1027: ...ICATION Diameter 23 997 24 000 mm 0 9448 0 9449 in Piston Rings Ring Gap Top Compression Ring 0 20 0 36 mm 0 008 0 014 in Ring Gap 2nd Compression Ring 0 23 0 50 mm 0 0091 0 0197 in Ring Gap Oil Control Steel Rails 0 25 0 76 mm 0 010 0 030 in Ring Groove Clearance Top and Second Compression Ring 0 035 0 085 mm 0 0014 0 0034 in Oil Ring Steel Rails 0 038 0 184 mm 0 0015 0 0073 in Ring Width Top Com...

Page 1028: ...1 75 mm 0 0492 0 0689 in Guide Bore Diameter Std 6 975 7 00 mm 0 2746 0 2756 in Valve Guide Height 9 5 10 5 mm 0 3740 0 4134 in Measured from cylinder head surface Valves Face Angle 44 5 45 Head Diameter Intake 36 37 36 63 mm 1 4319 1 4421 in Head Diameter Exhaust 28 87 29 13 mm 1 1366 1 1469 in Length Intake Overall 114 41 114 99 mm 4 5043 4 5272 in Length Exhaust Overall 125 67 126 25 mm 4 9476 ...

Page 1029: ...e Between Rotors Max 0 20 mm 0 008 in Oil Pressure Curb Idle Speed 34 47 kPa 5 psi DESCRIPTION SPECIFICATION 3000 rpm 170 724 kPa 25 105 psi CAUTION If pressure is zero at curb idle DO NOT run engine at 3000 rpm TORQUE DESCRIPTION N m Ft Lbs In Lbs A C Compressor Bracket to Engine Bolts 54 40 A C Compressor to Bracket 28 250 Camshaft Sprocket Bolt Right Side 102 75 Camshaft Sprocket Bolt Left Side...

Page 1030: ...ostat Housing Water Inlet Connector Bolts 12 105 Throttle Body Bolts 12 105 Timing Belt Tensioner Bolts 28 250 Timing Belt Tensioner Pulley Assembly Bolt 61 45 Timing Belt Cover M6 Bolts 12 105 M8 Bolts 28 250 M10 Bolts 54 40 Water Pump Bolts 12 105 Water Outlet Bleed Screw 8 70 SPECIAL TOOLS 3 2 3 5L ENGINE Puller Damper 1023 Crankshaft Damper Remover Insert C 4685 C2 Crankshaft Damper Installer ...

Page 1031: ...ft Sprocket Installer 6641 Camshaft Alignment 6642 Camshaft Seal Protector 6788 Camshaft Seal Remover C 3981B Camshaft Seal Installer 6052 Dial Indicator C 3339 Valve Spring Compressor 7068 Valve Spring Compressor C 3422 B 9 150 3 2 3 5L ENGINE LH SPECIAL TOOLS Continued ...

Page 1032: ...r MD 998772 A Valve Spring Adapter 6527 Indicator Bore Size C 119 Main Bearing Remover Installer C 3059 Crankshaft Rear Seal Guide 6926 1 Installer 6926 2 Crankshaft Rear Seal Retainer Alignment Fixture 8225 Release Probe 8351 LH 3 2 3 5L ENGINE 9 151 SPECIAL TOOLS Continued ...

Page 1033: ...Adaptor 8116 Cooling System Tester 7700 Combustion Leak Tester C 3685 A 9 152 3 2 3 5L ENGINE LH SPECIAL TOOLS Continued ...

Page 1034: ... cat alytic converter reduces exhaust emissions CATALYTIC CONVERTERS DESCRIPTION The close coupled three way catalytic converter inlets are connected to the exhaust manifolds by the use of V Band clamps Fig 2 The left side converter outlet pipe connects to the exhaust system The right side converter connects to an extension pipe Fig 2 OPERATION The three way catalytic converter simultaneously conv...

Page 1035: ... motive problems Unleaded gasoline must be used to avoid poisoning the catalyst core Do not allow engine to operate above 1200 RPM in neutral for extended periods over 5 minutes This condition may result in excessive exhaust system floor pan temperatures because of no air movement under the vehicle CAUTION Due to exterior physical similarities of some catalytic converters with pipe assemblies extr...

Page 1036: ...nder head leak 2 Tighten manifold and or replace gasket 3 EGR tube to manifold gasket leakage 3 Tighten fasteners or replace gasket 4 EGR Valve to EGR tube gasket leakage 4 Tighten fasteners or replace gasket 5 Exhaust to manifold leak 5 Tighten or replace V Band Clamp 6 Pipe and shell noise from front exhaust pipe 6 Characteristic of single wall pipe EXCESSIVE EXHAUST NOISE 1 Leak at exhaust pipe...

Page 1037: ...moved Do not use any tools to remove the isolators remove by hand only Soapy water or silicone based spray may be used to assist removal Do Not use a petroleum based lubricant on the isolators This will damage the rubber material 4 Support exhaust system with jack stand 5 Remove screw attaching exhaust system ground strap 6 Remove the rubber isolators from the rear sus pension crossmember and supp...

Page 1038: ...should be straight when viewing from front to back of the vehi cle Working from the front of system align each component to maintain position and proper clearance with underbody parts 6 Tighten band clamps to the proper torque 7 Lower the vehicle MUFFLER AND FRONT RESONATOR REMOVAL 1 Remove exhaust system Refer to procedure in this section Fig 4 Rubber Isolator Hanger to Body Support Bracket 1 SUP...

Page 1039: ...E OPERATION TIME 1 Raise vehicle on hoist 2 Remove exhaust system Refer to procedure in this section 3 Loosen or remove nut attaching right pipe to transaxle bracket 4 Loosen extension pipe band clamp 5 Remove right side converter extension pipe Fig 7 6 Lower vehicle 7 Remove air cleaner assembly with air inlet hose Fig 6 8 Remove SRV Single Runner Valve vacuum reservoir and control valve assembly...

Page 1040: ... 4 Install downstream oxygen sensor and connect electrical connector 5 Install exhaust system 6 Lower vehicle CLEANING AND INSPECTION EXHAUST SYSTEM INSPECTION Inspect the exhaust pipes catalytic converters muffler and resonators for cracked joints broken welds and corrosion damage that would result in a leaking exhaust system Inspect the clamps support brackets and insulators for cracks and corro...

Page 1041: ...Torca Clamp 61 45 Catalytic Converter Pipe to Support Bracket Nut 47 35 V Band Clamp Exhaust Manifold to Catalytic Converter 11 100 Exhaust Support to Body Bracket Fasteners 25 215 Exhaust Support Bracket to Transmission Fasteners 47 35 11 8 EXHAUST SYSTEM LH ...

Page 1042: ...pplied against structural members The structural members provide a unibody that has great structural strength BUMPERS DESCRIPTION The bumpers are made up of bumper reinforce ment and fascia with air deflector front bumper and mounting brackets OPERATION The bumper reinforcement is fastened to the unit ized body frame rails The bumper fascia is fastened to the bumper reinforcement and the body side...

Page 1043: ...he fasteners attaching the fascia to the lower crossmember Fig 4 5 Remove the fasteners attaching the fascia to the upper radiator closure panel Fig 4 6 Disconnect wire connectors fog lamps parking turn signal side marker if equipped Fig 5 7 Remove fascia from vehicle INSTALLATION 1 Connect wire connectors 2 Place fascia in position on vehicle by fitting foam to bumper reinforcement Use care not t...

Page 1044: ...R FASCIA INTREPID REMOVAL 1 Release hood latch and open hood 2 Remove push in fasteners attaching bottom of fascia air dam to lower crossmember Fig 6 3 Remove fasteners attaching fascia to front fenders and splash shields Fig 7 Fig 2 Access Rubber Grommet 1 ACCESS RUBBER GROMMET Fig 3 Fastener Locations 1 THROUGH ACCESS REMOVE FASTENER 2 FASTENERS Fig 4 Remove Push In Fasteners 1 PUSH IN FASTENERS...

Page 1045: ...RONT BUMPER REINFORCEMENT REMOVAL 1 Remove front fascia 2 Remove end plugs in ends of bumper after removing screws in front of bumper 3 Remove attaching bolts from bumper reinforce ment to adapter plate through ends of the bumper Fig 8 4 If beam is damaged the adapter plate to rail welds will have to be cut off INSTALLATION 1 Place reinforcement in position on front of vehi cle 2 Install attaching...

Page 1046: ...5 300M only install nut on fascia stud and install tail lamp housing 6 Install trunk carpet back in position 7 Install fasteners attaching fascia to rear quar ter panel and splash shields REAR BUMPER FASCIA INTREPID REMOVAL 1 Open deck lid and remove tail lamps 2 Remove fasteners attaching fascia to rear quar ter and splash shields 3 Remove fasteners attaching fascia to tail lamp can 4 Remove fast...

Page 1047: ...nuts from attach ing bracket to rails Fig 11 INSTALLATION 1 Place reinforcement in position on rear of vehi cle 2 Install bracket to rails attaching bolts and nuts Fig 11 Rear Bumper Reinforcement 1 REAR BUMPER REINFORCEMENT 13 6 FRAMES AND BUMPERS LH REMOVAL AND INSTALLATION Continued ...

Page 1048: ...nts to spindles 10 Separate lower control arm from spindle Refer to Group 2 Suspension for proper procedures 11 Support cradle on a 10 cm by 10 cm by 90 cm 4 in by 4 in by 36 in wood beam and a jack 12 Remove bolts holding cradle to body shell Fig 1 13 Lower cradle away from body shell INSTALLATION NOTE If cradle replacement is required transfer suspension components and jounce and bounce plates t...

Page 1049: ...nt cor ners of the rear suspension crossmember in place Allow the stabilizer bar to hang down 7 Remove the parking brake cable tensioner from the intermediate parking brake cable Refer to Base Brake System in Group 5 Brakes in this manual for the required service procedure 8 Remove the parking brake cable tensioner from the left rear parking brake cable Refer to Base Brake System in Group 5 Brakes...

Page 1050: ...Install but do not fully tighten the 2 bolts attaching the rear of the crossmember to the frame rails 6 Raise the exhaust into place Reattach the 3 exhaust hangers previously removed from the muf fler and resonator 7 Remove transmission jack supporting muffler and exhaust system 8 Reinstall the fuel filler neck attaching screw and secure the fuel filler neck to the left frame rail 9 Position the r...

Page 1051: ...EMBLY REAR SUSPENSION CROSSMEMBER BUSHINGS DISASSEMBLY 1 Lay the crossmember right side up on a bench with the bushing to be removed hanging over the edge of the bench 2 Install cup Special Tool 8173 1 in well of press Special Tool C 4212F 3 Install Remover Installer Special Tool 8173 2 on end of the threaded push rod on Special Tool C 4212F 4 Install Special tool C 4212F with Special Tools 8173 1...

Page 1052: ...ips are not pinched SPECIFICATIONS FRAME DIMENSIONS Frame dimensions are listed in metric scale then converted to inch scale listed in parenthesis All dimensions are from center to center of Principal Locating Point PLP or from center to center of PLP and fastener location Vertical dimensions can be taken from the work surface to the locations indi cated Fig 8 through Fig 11 Fig 6 Special Tools 1 ...

Page 1053: ...Fig 8 Engine Compartment Top View Fig 9 Engine Compartment Side View 13 12 FRAMES AND BUMPERS LH SPECIFICATIONS Continued ...

Page 1054: ...Fig 10 Forward Frame Section and Engine Cradle LH FRAMES AND BUMPERS 13 13 SPECIFICATIONS Continued ...

Page 1055: ...Fig 11 Rear Frame Section 13 14 FRAMES AND BUMPERS LH SPECIFICATIONS Continued ...

Page 1056: ...orcement Attaching Nut 28 N m 21 ft lbs Front Suspension Crossmember Attaching Bolt Front 109 N m 80 ft lbs Attaching Bolt Rear 102 N m 75 ft lbs Radiator Support Crossmember Attaching Bolts 51 N m 45 ft lbs LH FRAMES AND BUMPERS 13 15 SPECIFICATIONS Continued ...

Page 1057: ......

Page 1058: ... the license plate bracket FRONT TOW HOOK BRACKET REMOVAL 1 Remove the tow hook from the tow hook bracket 2 Open hood and disconnect the negative battery cable remote terminal from the battery post 3 Hoist vehicle 4 Partially remove the front fascia to gain access to the windshield headlamp washer reservoir Refer to Group 23 Body for Removal and Installation pro cedures 5 Remove the tow hook brack...

Page 1059: ... to Group 0 Lubrication and Maintenance for proper lifting pro cedure 2 Remove bolts holding rear tow hook bracket to rear frame rail Fig 3 Fig 4 3 Separate rear tow hook bracket from 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 3 Rear Tow Hook Bracket 1 REAR TOW HOOK BRACKET MOUNTING SCREWS 2 ...

Page 1060: ...ER NECK 17 FUEL FILLER VENT HOSE 17 ACCELERATOR PEDAL 17 THROTTLE CABLE 18 SPECIFICATIONS TORQUE 19 FUEL SYSTEM PRESSURE 19 FUEL TANK CAPACITY 19 FUEL REQUIREMENTS 19 DESCRIPTION AND OPERATION GASOLINE OXYGENATE BLENDS DESCRIPTION Some fuel suppliers blend unleaded gasoline with materials that contain oxygen such as alcohol MTBE Methyl Tertiary Butyl Ether and ETBE Ethyl Ter tiary Butyl Ether Oxyg...

Page 1061: ... the fuel pump mod ule Refer to the Maintenance Schedules in the Intro duction section of this manual for recommended fuel filter replacement intervals OPERATION The fuel system is provided fuel pressure by an in tank pump module The PCM controls the operation of the fuel system by providing battery voltage to the fuel pump through the fuel pump relay The PCM requires only three inputs and a good ...

Page 1062: ...rols are required for all fuel tank con nections All models are equipped with either one or two rollover valves mounted into the top of the fuel tank or pump module An evaporation control system is connected to the rollover valve s to reduce emissions of fuel vapors into the atmosphere When fuel evaporates from the fuel tank vapors pass through vent hoses or tubes to a charcoal canister where they...

Page 1063: ...hanical device that is cali brated to maintain fuel system operating pressure of approximately 400 kPa 58 psi at the fuel injectors Fuel is supplied to the filter regulator by the elec tric fuel pump through an opening tube at the bot tom of filter regulator The fuel pump module contains a check valve to maintain some fuel pressure when the engine is not operating This will help to start the engin...

Page 1064: ... and enters the fuel tank Vapor or air is expelled from the tank through the control valve to the vapor canister Vapor is absorbed in the canister until vapor flow in the lines stops either following shut off or by having the fuel level in the tank rise high enough to close the control valve The control valve contains a float that rises to seal the large diameter vent path to the canister At this ...

Page 1065: ...in this system If it is necessary to replace these lines tubes hoses only those marked EFM EFI may be used If equipped The hose clamps used to secure rub ber hoses on fuel injected vehicles are of a special rolled edge construction This construction is used to prevent the edge of the clamp from cutting into the hose Only these rolled edge type clamps may be used in this system All other types of c...

Page 1066: ...l Pressure Release Procedure in this section 2 Disconnect negative cable from battery or aux iliary jumper terminal 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 fitting without the retainer being either on the fuel tube or already in the quick conne...

Page 1067: ...is discon nected The O rings and spacer will remain in quick connect fitting connector body 5 Inspect quick connect fitting body and compo nent for damage Replace as necessary CAUTION When the quick connect fitting was dis connected the plastic retainer will remain on the component being serviced If this retainer must be removed very carefully release the retainer from the component with two small...

Page 1068: ...ng serviced check condition of fitting and component Clean parts with a lint free cloth Lubricate with clean engine oil 8 Insert quick connect fitting into component being serviced until a click is felt 9 Verify a locked condition by firmly pulling on fuel tube and fitting 15 30 lbs 10 Connect negative battery cable to battery or auxiliary jumper terminal 11 Use the DRB scan tool ASD Fuel System T...

Page 1069: ...ke sure the alignment tabs on the underside of the fuel pump module flange sits in the notches on the fuel tank Fig 12 3 Position the locknut over the fuel pump mod ule 4 Tighten the locknut using Special Tool 6856 to 55 N m 40 5 ft lbs CAUTION Over tightening the pump lock ring may result in a leak 5 Raise the fuel tank on the transmission stand 6 Install fuel pump electrical connector into hole ...

Page 1070: ...eat 13 Connect the battery cable 14 Fill fuel tank Use the DRB scan tool to pres surize the fuel system Check for leaks FUEL PUMP INLET STRAINER REMOVAL 1 Remove fuel pump module Refer to Fuel Pump Module Removal in this section 2 Using a thin straight blade screwdriver pry back the locking tabs on fuel pump reservoir and remove the strainer Fig 14 3 Remove strainer O ring from the fuel pump reser...

Page 1071: ...wires through standpipe inside fuel pump module Fig 20 6 Slide level sensor out of installation channel Fig 19 INSTALLATION 1 Insert level sensor wires in bottom of stand pipe 2 Wrap wires into groove in back of level sensor Fig 21 Fig 15 Fuel Pump Level Sensor Connector 1 TAB 2 FUEL PUMP LEVEL SENSOR CONNECTOR 3 BOTTOM OF FUEL PUMP MODULE ELECTRICAL CONNECTOR Fig 16 Wire Terminal Retaining Clip 1...

Page 1072: ...tive battery cable 3 Remove intake manifold plenum Refer to the Engine section for information 4 Remove intake manifold plenum mounting bolts Lift Plenum up off of engine Cover intake manifold to prevent foreign material from entering engine 5 Disconnect fuel supply tube quick connect fit tings at the rear of intake manifold Refer to Quick Connect Fittings in the Fuel Delivery Section 6 If the inj...

Page 1073: ...on fuel injectors 3 Push injectors into fuel injector rail until clips are in the correct position 4 Position fuel rail over cylinder heads and push rail into place Tighten fuel rail mounting bolts to 11 N m 100 in lbs torque 5 Install intake manifold plenum Refer to the Engine section for information 6 Connect negative cable to battery FUEL INJECTORS 2 7L ENGINE WARNING RELEASE FUEL SYSTEM PRESSU...

Page 1074: ...Remove electrical connectors from the fuel injectors 8 Remove mounting bolts on both sides of fuel rail 9 Lift fuel rail straight up off of cylinder head 10 Remove retaining clips from fuel injectors at fuel rail 11 Remove fuel injectors INSTALLATION 1 Lightly lubricate the fuel injector O rings with a couple drops of clean engine oil 2 Install retaining clips on fuel injectors 3 Push injectors in...

Page 1075: ... 7 Lower vehicle 8 Connect the fuel pump electrical connector that is in the rear seat 9 Install the rear seat 10 Connect the battery cable 11 Fill fuel tank Use the DRB scan tool to pres surize the fuel system Check for leaks Fig 24 Battery Cable 1 BATTERY CABLE 2 SERVICE VACUUM SUPPLY TEE Fig 25 Fuel Tank Drain 1 FUEL TANK DRAIN Fig 26 Stabilizer Bar 1 FILLER TUBE 2 MUFFLER 3 FUEL TANK Fig 27 St...

Page 1076: ...k and tighten clamp 4 Lower vehicle 5 Fill fuel tank and check for leaks 6 Connect negative cable to battery ACCELERATOR PEDAL REMOVAL 1 Working from the engine compartment hold the throttle body throttle lever in the wide open posi tion Remove the throttle cable from the throttle body cam 2 From inside the vehicle hold up the pedal and remove the cable retainer and throttle cable from the upper e...

Page 1077: ...ner and throttle cable from the upper end of the pedal shaft Fig 30 3 Remove retainer clip from throttle cable and grommet at dash panel Fig 31 4 From the engine compartment pull the throttle cable out of the dash panel grommet The grommet should remain in the dash panel 5 Remove the throttle cable from throttle bracket by carefully compressing both retaining ears simulta neously Then gently pull ...

Page 1078: ...s the Worldwide Fuel Charter WWFC to define fuel properties necessary to deliver enhanced emissions performance and durability for your vehicle We rec ommend the use of gasolines that meet the WWFC specifications if they are available REFORMULATED GASOLINE Many areas of the country require the use of cleaner burning gasoline referred to as reformulat ed gasoline Reformulated gasoline contain oxyge...

Page 1079: ... detergents or other additives is not needed under normal conditions FUEL SYSTEM CAUTIONS CAUTION Follow these guidelines to maintain your vehicle s performance The use of leaded gas is prohibited by Federal law Using leaded gasoline can impair engine perfor mance damage the emission control system and could result in loss of warranty coverage An out of tune engine or certain fuel or ignition malf...

Page 1080: ...PUT 36 8 VOLT SUPPLY PCM OUTPUT 36 REMOVAL AND INSTALLATION THROTTLE BODY 2 7L ENGINE 36 THROTTLE BODY 3 2 3 5L ENGINE 36 THROTTLE POSITION SENSOR TPS 2 7L ENGINE 36 THROTTLE POSITION SENSOR TPS 3 2 3 5L ENGINE 37 IDLE AIR CONTROL MOTOR 2 7L 37 IDLE AIR CONTROL MOTOR 3 2 3 5L 37 INTAKE AIR TEMPERATURE SENSOR 38 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 2 7L 38 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 3 2...

Page 1081: ...ut tells the PCM if the calculated injector pulse width resulted in the ideal air fuel ratio of 14 7 to one By monitoring the exhaust oxygen content through the upstream heated oxygen sensor the PCM can fine tune injector pulse width Fine tuning injector pulse width allows the PCM to achieve opti mum fuel economy combined with low emissions For the PCM to enter CLOSED LOOP operation the following ...

Page 1082: ...sts injector pulse width and controls injector synchronization by turning the individual ground paths to the injectors On and Off The PCM adjusts ignition timing and engine idle speed Engine idle speed is adjusted through the idle air control motor CRUISE OR IDLE MODE When the engine is at operating temperature this is a CLOSED LOOP mode During cruising or idle the following inputs are received by...

Page 1083: ...ated oxygen sensor and both shorted diagnostics The PCM adjusts injector pulse width to supply a predetermined amount of addi tional fuel IGNITION SWITCH OFF MODE When the operator turns the ignition switch to the OFF position the following occurs All outputs are turned off unless 02 Heater Monitor test is being run Refer to the Emission sec tion for On Board Diagnostics No inputs are monitored ex...

Page 1084: ...t The process then repeats itself in the opposite direction Short term fuel correction will keep increasing or decreasing injector pulse width based upon the upstream O2 Sensor input The maximum range of authority for short term memory is 25 of base pulse width Long Term The second fuel correction program is the long term adaptive memory In order to maintain correct emission throughout all operati...

Page 1085: ...g Pressure Transducer ASD Relay Battery Voltage Brake Switch Camshaft Position Sensor Crankshaft Position Sensor Distance Sensor from transmission control mod ule EGR Position Feedback Engine Coolant Temperature Sensor Heated Oxygen Sensors Ignition sense Intake Air Temperature Sensor Knock Sensor Leak Detection Pump Feedback Manifold Absolute Pressure MAP Sensor Park Neutral from transmission con...

Page 1086: ... the camshaft position sensor crank shaft position sensor and vehicle speed sensor The PCM also provides a 5 0 volts supply for the engine coolant temperature sensor intake air temperature sensor manifold absolute pressure sensor and throt tle position sensor The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km 200 miles If the PCM is replaced aft...

Page 1087: ... maintain the same volume of fuel through the injector Charging The PCM uses sensed battery voltage to verify that target charging voltage determined by Battery Tem perature Sensor is being reached To maintain the target charging voltage the PCM will full field the generator to 0 5 volt above target then turn OFF to 0 5 volt below target This will continue to occur up to a 100 Hz frequency 100 tim...

Page 1088: ...low emission standards the PCM stores a diagnostic trouble code and illuminates the malfunction indica tor lamp MIL The O2S produce voltages from 0 to 1 volt depend ing upon the oxygen content of the exhaust gas in the exhaust manifold When a large amount of oxy gen is present caused by a lean air fuel mixture the sensors produces a low voltage When there is a lesser amount present rich air fuel m...

Page 1089: ...sts injector pulse width based on prepro grammed fixed values and inputs from other sen sors DOWNSTREAM OXYGEN SENSOR 1 2 The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration As the convertor deteriorates the input from the down stream sensor begins to match the upstream sensor input except for a slight time delay By comparing the downstream heated oxygen s...

Page 1090: ...sor signal is provided from a single piezoresistive element located in the center of a dia phragm The element and diaphragm are both made of silicone As the pressures changes the diaphragm moves causing the element to deflect which stresses the silicone When silicone is exposed to stress its resistance changes As manifold vacuum increases the MAP sensor input voltage decreases proportion ally The ...

Page 1091: ...ately 0 6 volt at minimum throttle opening idle to a maximum of 4 5 volts at wide open throttle Along with inputs from other sensors the PCM uses the TPS input to determine current engine oper ating conditions The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs VEHICLE SPEED AND DISTANCE PCM INPUT DESCRIPTION The PCM receives a signal from the TCM and the trans...

Page 1092: ...Fig 11 and then adjusts that current to achieve the desired purge flow The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold EXHAUST GAS RECIRCULATION LSEGR DESCRIPTION The EGR valve consists of three major components First there is the pintle valve seat and housing which contains and regulates the gas flow Second...

Page 1093: ...e engine during closed throttle idle The idle air control motor pintle protrudes into the air bypass passage and regulates air flow through it The PCM adjusts engine idle speed by moving the IAC motor pintle in and out of the bypass passage The adjustments are based on inputs the PCM receives The inputs are from the throttle position sensor crankshaft position sensor coolant tempera ture sensor MA...

Page 1094: ...r sensors If the PCM detects active engine misfire severe enough to cause catalyst damage it flashes the MIL At the same time the PCM also sets a Diagnostic Trouble Code DTC For signals that can trigger the MIL Check Engine Lamp refer to the On Board Diagnos tics section RADIATOR FAN RELAYS PCM OUTPUT DESCRIPTION The low speed and high speed fan relays are located in the Power Distribution Center ...

Page 1095: ...n the bolts to 27 1 N m 20 ft lbs torque 4 Hold throttle lever in wide open throttle posi tion Install throttle cable and speed control cable 5 Install throttle cable bracket and tighten bolts 6 Install EGR tube from intake manifold to EGR valve Tighten bolts 7 Install air plenum and tighten clamp 8 Connect negative cable to battery THROTTLE BODY 3 2 3 5L ENGINE REMOVAL 1 Disconnect negative cable...

Page 1096: ...other side of the tabs in the socket Tighten mounting screws to 3 N m 25 in lbs torque 2 After installing the TPS the throttle plate should be closed If the throttle plate is open install the sensor on the other side of the tabs in the socket 3 Attach electrical connector to the TPS 4 Install air plenum and tighten the clamp 5 Connect the negative battery cable IDLE AIR CONTROL MOTOR 2 7L REMOVAL ...

Page 1097: ...ne the MAP sensor mounts onto the side of the intake manifold plenum Fig 18 REMOVAL 1 Remove the negative battery cable 2 Disconnect the electrical connector from the MAP sensor 3 Remove sensor INSTALLATION 1 The sensor mounts onto intake manifold ple num Tighten screws to 4 5 N m 40 in lbs torque 2 Attach electrical connector to sensor 3 Install the negative battery cable MANIFOLD ABSOLUTE PRESSU...

Page 1098: ...t lbs torque 2 Install electrical connector 3 Connect negative battery cable MANIFOLD TUNING VALVE 3 2 3 5L ENGINE REMOVAL 1 Disconnect negative battery cable 2 Disconnect electrical connector Fig 22 3 Remove manifold tuning valve mounting screws Remove tuning valve INSTALLATION 1 Install tuning valve Tighten mounting screws to 11 9 N m 105 in lbs torque 2 Install electrical connector 3 Connect ne...

Page 1099: ...egy prevents reduced idle speeds until after the engine operates for 320 km 200 miles If the PCM is replaced after 320 km 200 miles of usage update the mileage and vehicle iden tification number VIN in the new PCM Use the DRB scan tool to change the millage and VIN in the PCM If this step is not done a diagnostic trouble code DTC may be set and SKIM must be done or car will not start if it is a SK...

Page 1100: ...manifold WARNING THE EXHAUST MANIFOLD EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR REMOVAL CAUTION When disconnecting the sensor electri cal connector do not pull directly on wire going into sensor 1 Remove the negative battery cable 2 Disconnect the heated oxygen sensor electrical connector 3 Use a socket such as ...

Page 1101: ...nal anti seize compound to the threads of a new oxygen sensor 1 Install the O2S Tighten to 30 N m 22 ft lbs torque 2 Connect the O2S wire connector 3 Lower the vehicle 4 Install the negative battery cable AIR CLEANER LH vehicles do not use a heated air inlet system The Powertrain Control Module PCM adjusts fuel injector pulse width and ignition timing to compen sate for different ambient temperatu...

Page 1102: ...N m 20 ft lbs torque 2 Attach electrical connector to sensor 3 Install the negative battery cable KNOCK SENSOR The sensors screws into the cylinder block directly below the intake manifold REMOVAL 1 Remove intake manifold plenum refer to the Engine section 2 2 7L Remove the passenger side cylinder head refer to the Engine section 3 Disconnect electrical connector from knock sen sor Fig 34 or Fig 3...

Page 1103: ...RQUE DESCRIPTION TORQUE Camshaft Position Semsor 12 N m 105 in lbs Crankshaft Position Sensor Mounting Bolts 12 N m 105 in lbs Engine Coolant Temperature Sensor 28 N m 20 ft lbs Idle Air Control Motor 2 7L 5 1 N m 45 in lbs Idle Air Control Motor 3 2 3 5L 6 2 N m 55 in lbs Air Temperature Sensor 3 2 3 5L 28 N m 20 ft lbs Knock Sensor bolt 3 2 3 5L 10 N m 7 ft lbs Knock Sensor 2 7L 10 N m 7 ft lbs ...

Page 1104: ...SPECIAL TOOLS FUEL Pressure Gauge Assembly C 4799 B Fuel Pressure Test Adapter 6539 Spanner Wrench 6856 Fuel Line Adapter 1 4 O2S Oxygen Sensor Remover Installer C 4907 LH FUEL SYSTEM 14 45 ...

Page 1105: ......

Page 1106: ...serting and rotating the ignition key to the right the cap is in the unlocked position Rotating to the left the cap is in the locked position REMOVAL AND INSTALLATION FUEL CAP TETHER For replacement of fuel cap tether refer to the dis assembly and assembly section of this group DISASSEMBLY AND ASSEMBLY LOCKING FUEL FILLER NECK CAP Ignition door deck lid and fuel cap lock cylinders are all codable ...

Page 1107: ...nt collar and tether Fig 4 4 Depress the spring loaded lock cylinder retain ing clip Fig 5 and remove the lock cylinder from the cap Fig 6 Fig 2 Removing Retaining Ring 1 RETAINING RING Fig 3 Step 2 1 O RING Fig 4 Step 3 1 TETHER Fig 5 Step 4 1 LOCK CYLINDER 2 LOCK CYLINDER RETAINING CLIP 14 2 FUEL SYSTEM LH DISASSEMBLY AND ASSEMBLY Continued 2000 LHS 300M CONCORDE AND INTREPID ...

Page 1108: ...osition lock cylinder engagement collar and tether 3 Position threaded portion of cap 4 Snap retaining ring in position Fig 6 Lock Cylinder Removed 1 LOCK CYLINDER LH FUEL SYSTEM 14 3 DISASSEMBLY AND ASSEMBLY Continued 2000 LHS 300M CONCORDE AND INTREPID ...

Page 1109: ...2000 LHS 300M CONCORDE AND INTREPID ...

Page 1110: ...he gear The internal calibra tion gives the driver a more firm feel at the steering wheel It is serviced the same as the standard steer ing gear The speed sensitive variable effort power steering system better known as speed proportional steering is an electronically controlled variable effort type power steering system The steering gear has an externally mounted control valve which in conjunc tio...

Page 1111: ...tube nut fitting with an O ring is used to connect it to the power steering gear The hose is secured to the cooler and reservoir using standard adjustable clamps OPERATION The power steering fluid hoses transfer fluid from one power steering system component to the next POWER STEERING FLUID COOLER DESCRIPTION All models of this vehicle are equipped with a cooler for the power steering system fluid...

Page 1112: ...ounting fasteners at tower 7 Tighten strut assembly fasteners to the specified torque 8 Power steering fluid pressure hose touching the body of the vehicle 8 Adjust hose to proper position by loosening repositioning and tightening fitting to specified torque Do not bend tubing 9 Internal power steering gear noise 9 Replace power steering gear 10 Damaged front suspension crossmember 10 Replace fron...

Page 1113: ...ring noisy 3 Remove clockspring Reinstall wheel If noise is gone replace clockspring 4 Steering gear internally noisy 4 Replace steering gear SCRUBBING OR KNOCKING NOISE 1 Incorrect tire or wheel size 1 Replace incorrect size tire or wheel with size used as original equipment 2 Interference between steering gear and other vehicle components 2 Check for bent or misaligned components and correct as ...

Page 1114: ...air conditioning pump head pressure and correct as necessary STEERING CATCHES STICKS IN CERTAIN POSITIONS OR IS DIFFICULT TO TURN 1 Low power steering fluid level 1 Fill power steering fluid reservoir to specified level and check for leaks 2 Tires not inflated to specified pressure 2 Inflate tires to the specified pressure 3 Lack of lubrication in front suspension control arm ball joints 3 Lubrica...

Page 1115: ...Steering System Flow and Pressure Test procedure 5 Replace the power steering pump as necessary 6 High internal leak in power steering gear Follow Power Steering System Flow and Pressure Test procedure 6 Replace power steering gear STEERING WHEEL DOES NOT RETURN TO CENTER POSITION 1 Tires not inflated properly 1 Inflate tires to specified pressure 2 Improper front wheel alignment 2 Check and adjus...

Page 1116: ...7 Inspect pinch bolt replace as necessary and tighten to specified torque 8 Front wheel bearing loose or worn 8 Replace hub and bearing or knuckle as necessary 9 Loose outer tie rod end 9 Replace outer tie rod end that has excessive free play 10 Worn inner tie rod bushing 10 Replace inner tie rod 11 Defective steering gear rotary valve 11 Replace power steering gear NOTE Steering shudder can be ex...

Page 1117: ...e power steering fluid from the system Flush the system with fresh clean power steering fluid drain then refill to the proper level NOTE Extremely cold temperatures may cause power steering fluid aeration if the power steering fluid level is low POWER STEERING SYSTEM FLOW AND PRESSURE TEST ALL ENGINES The following procedure is to be used to test the operation of the power steering system on this ...

Page 1118: ...l Tool 6959 CAUTION To prevent personal injury safety gog gles should be worn at all times when performing any test procedures on the power steering pump or power steering gear The following procedure is to be used to test the operation of the power steering system on the vehi cle 2 Check belt tension and adjust as necessary NOTE On vehicles with 3 2 and 3 5 liter engines it may be easier to acces...

Page 1119: ...eave valve closed for more than five seconds as the pump could be damaged 11 Close valve fully three times and record high est pressure indicated each time All three read ings must be above specifications and within 345 kPa 50 psi of each other NOTE Power steering pump maximum relief pres sure is 8275 to 8975 kPa 1250 to 1350 psi Power steering pump pressures above specifica tions but not within 3...

Page 1120: ...ions This will prevent the entry of foreign material into the components when power steering hoses are removed POWER STEERING FLUID HOSES PRESSURE AND RETURN NOTE On this vehicle the power steering fluid pressure and return hoses are connected together by their mounting brackets For this reason both hoses need to be removed together if either of the hoses should fail Use the procedure below for th...

Page 1121: ...t hose Fig 14 from the throttle body and air let hose com ing from the lid of the air cleaner housing NOTE When locking the steering wheel the front tires of the vehicle are to be facing straight ahead Fig 10 Correctly Isolated Remote Ground Cable 1 CABLE ISOLATOR 2 GROUND STUD 3 GROUND CABLE Fig 11 Wiper Arm Attachment To Pivot 1 WIPER ARMS 2 ATTACHING NUT 3 ATTACHING NUT Fig 12 Wiper Module And ...

Page 1122: ...from the steering col umn coupler 11 Bend back the retaining tabs on the mounting plate for the tie rod to steering gear mounting bolts Fig 17 12 Remove the bolts mounting plate and wash ers Fig 18 attaching the tie rods to the steering gear Lay the tie rods on top of the transaxle bell housing Fig 15 Steering Wheel Lock Installed Typical 1 STEERING WHEEL 2 STEERING WHEEL CLAMP Fig 16 Steering Col...

Page 1123: ...sition the vacuum hose out of the way 17 Remove the power steering fluid pressure hose and return hose Fig 20 from the steering gear 18 Remove the 2 bolts attaching the left side of the steering gear to the crossmember Fig 21 19 Remove the 2 bolts attaching the steering gears right side mounting bracket Fig 22 to the crossmember 20 Move the steering gear to clear the pressure and return lines Fig ...

Page 1124: ...all the power steering fluid return hose on the power steering fluid cooler Fig 24 Be sure the hose clamp is installed past the upset bead on the power steering fluid cooler 4 300M only Reinstall front fascia 5 Lower the vehicle until the tires are just clear of the floor 6 Install the power steering hoses onto the left frame rail Fig 23 by installing the routing clip bolts Tighten the bolts to 10...

Page 1125: ...que of 82 N m 60 ft lbs CAUTION After tie rod attaching bolts are torqued bend attaching bolt retaining tabs against heads of attaching bolts Fig 17 13 Install the vacuum hose for the vacuum booster on intake manifold vacuum port Install hose clamp on vacuum hose 14 Install the master cylinder on the vacuum booster Install the 2 nuts attaching the master cyl inder to the vacuum booster Tighten the...

Page 1126: ...edure to be used for this vehicle 3 300M only The front fascia will require removal to access the power steering cooler See Frames and Bumpers Group 13 in this service man ual for required procedure 4 Remove the hose clamp from the lower hose at the power steering fluid cooler Fig 28 Remove the lower hose from the power steering fluid cooler Drain remaining power steering fluid from the hoses and ...

Page 1127: ...ly the proper Mopar Power Steering Fluid or equivalent when filling the power steering fluid res ervoir 7 Perform Power Steering Pump Initial Opera tion procedure which can be found in the Power Steering Pump section of this group to properly refill and bleed power steering system SPECIFICATIONS POWER STEERING FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE Power Steering Gear Crossmember Bolts ...

Page 1128: ...the areas and components listed below Power steering fluid reservoirs related compo nents and attaching hardware Power steering pump pulley No repair procedures are to be done on the internal components of the power steering pump Repair of a power steering fluid leak from any area of the power steering pump is not allowed OPERATION The Power steering pump operates as follows A belt driven pulley t...

Page 1129: ...r 3 5 liter engine use a power steering pump that has a remotely mounted reservoir Fig 3 OPERATION The power steering fluid reservoir stores fluid for the power steering system SERVICE PROCEDURES POWER STEERING PUMP INITIAL OPERATION CAUTION The fluid level should be checked with engine off to prevent injury from moving compo nents Use only MoparT Power Steering Fluid Do not use automatic transmis...

Page 1130: ...ble isolator on the ground stud Fig 4 NOTE The following step should be done to pre vent excessive spilling of power steering fluid when the power steering fluid lines are removed from the power steering pump 2 Using a siphon pump remove as much power steering fluid as possible from the power steering fluid reservoir CAUTION When removing the power steering fluid supply hose from the nipple on the...

Page 1131: ...n the tensioner bracket Fig 8 Using the screwdriver push the sleeve for ward in the tensioner bracket until it is flush with the back side of the tensioner bracket Fig 8 13 Remove the power steering pump power steering fluid reservoir and pulley as an assembly from the engine Power steering pump is removed from the top of the engine 14 Transfer the required parts from the removed power steering pu...

Page 1132: ...system Only use Mopar Power Steering Fluid or equivalent 9 Perform Power Steering Pump Initial Opera tion procedure which can be found in the Power Steering Pump section of this group to properly refill and bleed power steering system POWER STEERING PUMP 3 2L 3 5L ENGINE NOTE Before proceeding review SERVICE WARN INGS AND CAUTIONS found at the beginning of the REMOVAL AND INSTALLATION section REMO...

Page 1133: ...e replacement power steer ing pump See Disassembly and Assembly in this sec tion of this group of the service manual INSTALLATION 1 Install the power steering pump back in the mounting bracket using the reverse sequence of its removal Fig 13 2 Loosely install all 3 bolts mounting the power steering pump to the mounting bracket 3 Tighten the power steering pump mounting bolts to a torque of 28 N m ...

Page 1134: ...eering fluid reservoir Let power steering fluid drain from hoses and reservoir 3 Lower the vehicle 4 Remove the power steering fluid reservoir from the mounting bracket by rotating the rear of the res ervoir toward the engine and out of the bracket INSTALLATION 1 Install the power steering fluid reservoir into the mounting bracket Be sure the retaining tab on the bracket is holding the reservoir i...

Page 1135: ... to the power steering pump Tighten bolt on pulley side to 13 N m 115 in lbs Tighten bolts on rear to 24 N m 212 in lbs 4 Install the power steering pump on the engine Refer to the procedure in the Removal And Installa tion Section in this group of the service manual POWER STEERING PUMP PULLEY DISASSEMBLE CAUTION When mounting the power steering pump in the vise do not clamp the pump in the vise b...

Page 1136: ...hrough hole in spacer Thread the Installer into the end of the power steering pump shaft Fig 20 Tighten the installer into pump shaft 4 Holding the Pulley Installer with one wrench so it will not rotate turn hex Fig 20 down threaded rod of installer pushing the pulley onto the shaft of the power steering pump Fig 20 Ensure that the tool and the pulley remain aligned with the pump shaft so pulley d...

Page 1137: ... SPECIFICATIONS DESCRIPTION TORQUE Power Steering Pump Discharge Fitting 84 N m 62 ft lbs Mounting Bolts 28 N m 250 in lbs Power Steering Fluid Hoses Hose Tube Nuts 47 N m 35 ft lbs Power Steering Fluid Reservoir Mounting Bolt 2 7L Pulley Side 13 N m 115 in lbs Mounting Bolts 2 7L Rear 24 N m 212 in lbs Mounting Screw 3 2L 3 5L 12 N m 105 in lbs SPECIAL TOOLS POWER STEERING PUMP Installer C 4063B ...

Page 1138: ...that the tie rods are connected to the steering gear via a rack guide located at the center of the gear The power steering gear is mounted on the cross member behind the engine The steering column intermediate shaft connects to the pinion shaft of the gear The outer ends of the outer tie rods attach to steering arms on the suspension s front struts Three different power steering gears are availabl...

Page 1139: ...sure thus assisting in the turning effort Manual steering control of the vehicle can be main tained if power steering assist is lost However under this condition steering effort is significantly increased DIAGNOSIS AND TESTING OUTER TIE ROD SOCKET END PLAY MEASUREMENT NOTE When measuring tie rod socket end play the total weight of the vehicle must be supported by the tires and suspension of the ve...

Page 1140: ...ground stud Fig 3 2 Position the front tires of the vehicle so that they are facing straight ahead 3 Raise the vehicle on a frame contact type hoist until the front tires of the vehicle are just off the floor See Hoisting in the Lubrication and Mainte nance section of this manual for the required lifting procedure to be used for this vehicle 4 Remove caps from both wiper arms at the attachment to ...

Page 1141: ...f the steering wheel is allowed to rotate freely after it is disconnected from the intermediated shaft the clockspring will be damaged and will need to be replaced 10 Remove the retaining pin and the coupler bolt from the steering column coupler Fig 9 Separate the intermediate steering shaft from the steering col umn coupler Fig 6 Reinforcement Attachment To Vehicle 1 RIGHT STRUT TOWER 2 WIPER MOD...

Page 1142: ...ng gear 15 If the steering gear being removed from the vehicle is a speed proportional steering gear discon nect the wiring harness connector from the solenoid control valve electrical connector located on the steer ing gear end cap below the brake master cylinder Fig 13 Fig 10 Tie Rod Attachment Bolt Retaining Tabs 1 STEERING GEAR 2 TIE RODS 3 RETAINING TABS 4 BOLTS 5 PLATE Fig 11 Tie Rod To Stee...

Page 1143: ...cessary to loosen the 2 mount ing bolts Fig 17 attaching the right mounting bracket to the steering gear in order to clear the air conditioning lines 21 Slide steering gear and intermediate shaft for ward into the engine compartment to allow access to the roll pin retaining the intermediate shaft flex cou pler to the steering gear shaft Fig 14 Master Cylinder To Vacuum Booster Mounting 1 MOUNTING ...

Page 1144: ...ntermediate steering shaft from the steering gear 24 Raise vehicle 25 Remove the right front tire wheel 26 Remove the nut Fig 19 attaching the tie rod end to the steering arm on the right strut 27 Remove the tie rod end from the steering arm of the strut using Puller Special Tool C 3894 A Fig 20 28 Remove the tie rod from the vehicle Fig 18 Steering Coupler Roll Pin Removal 1 SPECIAL TOOL 6831 A 2...

Page 1145: ...acement steering gear is being installed in vehicle be sure the tie rod attachment at the steering gear is in the center of steering gear travel 1 Install the steering gear in the vehicle using the reverse sequence of the removal steps NOTE If the vehicle is equipped with a 2 7 Liter engine position the left front tire so it is facing straight forward 2 Install the right tie rod through the tie ro...

Page 1146: ...lbs 12 Tighten the bolts mounting the left side of the steering gear to the crossmember to a torque of 58 N m 43 ft lbs 13 If previously loosened tighten the bolts mounting the steering gear mounting bracket to the right side of the steering gear Fig 17 to a torque of 37 N m 27 ft lbs CAUTION Before installing tie rods on steering gear be sure the tie rod spacer block inside the steering gear bell...

Page 1147: ...y tighten the wiper arm to pivot attaching nuts Install the caps on the wiper arms covering the pivot nuts 25 Install the battery ground cable onto the ground stud on the shock tower CAUTION Do not use automatic transmission fluid Use only the proper Mopar Power Steering Fluid or equivalent when filling the power steering fluid res ervoir 26 Perform Power Steering Pump Initial Opera tion procedure...

Page 1148: ...dure is com pleted 6 Check the front wheel toe setting on vehicle and make required changes When making front wheel toe adjustments be sure the maximum exposed thread requirements Fig 30 are not exceeded CAUTION When torquing the adjuster pinch bolt the following procedure must be followed to ensure adequate retention of the adjuster is obtained Not following this procedure could result in the Toe...

Page 1149: ...ool C 4212F and tighten the set screw Install the Driver Special Tool 8523 1 on the tip of the Ball Joint Press screw drive 2 Place the steering gear housing against the Receiver in a way that the Receiver does not come in contact with the support ribs on the gear housing Fig 32 Start the bushing in the bottom of the housing and tighten the screw drive until the Driver contacts the bushing retaine...

Page 1150: ...SPECIAL TOOLS POWER STEERING GEAR Puller C 3894 A Remover Installer Steering Shaft Roll Pin 6831A LH STEERING 19 41 ...

Page 1151: ...er steering gear mounts in the same location as the standard power steering gear It is mounted on the crossmember behind the engine Externally the main difference between a speed proportional power steering gear and a stan dard power steering gear is the presence of a sole noid control valve on the gear housing Fig 1 OPERATION The speed proportional power steering system reduces the steering effor...

Page 1152: ...ressure The pressure is con trolled by varying the size of an orifice The variable assist speed proportional solenoid con trol valve is controlled by the Body Control Module BCM The BCM receives the vehicle speed signal sent from the Powertrain Control Module PCM Upon receiving the vehicle speed signal from the PCM the BCM converts that speed signal into an electrical current usable by the solenoi...

Page 1153: ...e power steering hoses at the gear Fig 3 Tighten both hose tube nuts to 31 N m 275 in lbs 5 Route the solenoid control valve wire harness over the top of the gear and clip it into place on the gear end cap 6 Connect the wiring harness connector Be sure the wiring harness connector seal is in good condition before installing the connector in the control module 7 Road test vehicle referring to the t...

Page 1154: ...e Transaxle section in this service manual OPERATION Turning of the steering wheel mounted to the col umn shaft is transferred down the shaft through the upper coupler and intermediate shaft to the power steering gear pinion shaft The gear then moves the front strut assemblies steering the vehicle DIAGNOSIS AND TESTING STEERING COLUMN For diagnosis of conditions relating to the steering column ref...

Page 1155: ... ditions seized bearing loose bearing stake or a bearing not fully seated in the yoke of the coupler assembly the coupler can be serviced as a separate component of the steering column assembly REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS WARNING BEFORE BEGINNING ANY SERVICE PROCEDURES THAT INVOLVES REMOVING THE AIR BAG REMOVE AND ISOLATE THE NEGATIVE BATTERY CABLE GROUND FROM THE VEHI C...

Page 1156: ...HE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED AT NO TIME SHOULD ANY SOURCE OF ELECTRICITY BE PERMITTED NEAR THE INFLATOR ON THE BACK OF THE AIRBAG MOD ULE WHEN CARRYING A LIVE MODULE THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF MODULE ACCIDENTLY DEPLOYS IF AIRBAG MODULE IS PLACED ON A BENCH OR OTHER SURFACE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ...

Page 1157: ...to the instrument panel Remove the reinforcement from the instrument panel Remove the diagnostic connector Fig 8 from the reinforcement 8 Before beginning removal of steering column assembly from vehicle be sure front wheels of vehicle are in the STRAIGHT AHEAD position 9 Remove the speed control switches Fig 9 from the steering wheel The speed control switches Fig 3 Fuse Panel Cover 1 FUSE PANEL ...

Page 1158: ... OBSERVED AT NO TIME SHOULD ANY SOURCE OF ELECTRICITY BE PER MITTED NEAR THE INFLATOR ON THE BACK OF THE AIRBAG MODULE WHEN CARRYING A LIVE MODULE THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF MODULE ACCIDENTLY DEPLOYS IF AIRBAG MOD ULE IS PLACED ON A BENCH OR OTHER SUR FACE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOYMENT 10 Remove ...

Page 1159: ... hammer on steering wheel or steering column shaft when removing steering wheel from steering column 17 Remove steering wheel from steering column shaft NOTE The upper shroud on this steering column is retained to the steering column by a snap fit to the lower shroud When removing the upper shroud from the steering column lower shroud DO NOT use a hard or sharp tool This will damage the shrouds If...

Page 1160: ...ss connectors Fig 16 from the clockspring 22 Remove the 2 screws Fig 17 mounting the clockspring to the steering column Remove the clock spring from the steering column Fig 14 Tilt Lever 1 TILT LEVER 2 LOWER SHROUD Fig 15 Lower Shroud Attaching Screws 1 LOWER SHROUD 2 MOUNTING SCREWS Fig 16 Wiring Harness Connection To Clock Spring 1 WIRING HARNESS CONNECTORS 2 CLOCKSPRING Fig 17 Clockspring Mount...

Page 1161: ...fter ignition interlock cable Fig 20 and remove the cable from the key lock housing 27 If the vehicle is equipped with a steering col umn mounted shift lever remove the brake transmis sion shift interlock BTSI solenoid from the shift lever mechanism Fig 21 To do so perform the fol lowing a Disconnect the wiring harness connector from the solenoid b Remove the retainer clip from the end of the sole...

Page 1162: ... mounting bracket Fig 24 from the steering column The shift cable mount ing bracket is mounted to the steering column by the 2 mounting screws Fig 24 Fig 21 BTSI Solenoid 1 SHIFT LEVER BRACKET 2 SOLENOID 3 KEY CYLINDER Fig 22 Solenoid Retainer Clip Removal 1 SOLENOID 2 MOUNTING STUD 3 RETAINER CLIP Fig 23 Shift Cable Removal 1 STEERING COLUMN 2 SCREWDRIVER 3 PIN 4 SHIFT CABLE 5 SHIFTER MECHANISM F...

Page 1163: ...ket is seated against support bracket Tighten the 4 steering column bracket to support bracket fas teners to 12 N m 105 in lbs tightening the upper mounting nuts first then the lower mounting bolts 3 Assemble the intermediate steering shaft to the steering column flex coupler Fig 26 Tighten the coupler pinch bolt nut to a torque of 27 N m 240 in lbs Be sure to install steering coupler pinch bolt r...

Page 1164: ...nnect the wiring harness connector to the solenoid 9 Install the ignition switch on the steering col umn Install and securely tighten the 2 screws Fig 19 mounting the ignition switch to the steering col umn 10 If the vehicle is equipped with a steering col umn mounted shift lever and if a new ignition shift interlock cassette has been installed the interlock system must be adjusted Adjust the inte...

Page 1165: ...at the drive pin on clock spring rotor Engage the clockspring locking mechanism CAUTION Do not install steering wheel onto shaft of steering column assembly by driving it onto the shaft Pull steering wheel down onto steering col umn shaft using ONLY the steering wheel retaining nut 20 Feed the clockspring wiring leads through the steering wheel Fig 12 Position steering wheel on shaft of steering c...

Page 1166: ...ing the DRB scan tool read and record active fault codes Also read and record any stored fault codes Refer to the Body Diagnostic Test Manual if any faults are found Erase stored faults if there are no active fault codes If problems remain fault codes will not erase From the passenger side of the vehicle turn ignition key to OFF and then ON observing instru ment cluster airbag lamp It should go on...

Page 1167: ...ock cable from shift lever assembly Fig 38 9 Remove the interlock cassette from the steering column and discard it NOTE A new interlock cassette must be installed when a new shift lever assembly is installed INSTALLATION 1 Install new shift lever assembly on tilt housing of steering column Install and securely tighten the 3 Torx head screws attaching shift lever assembly to tilt housing 2 Install ...

Page 1168: ...terlock system by pushing in on the adjustment tab until it stops Fig 42 The adjustment tab will click as it moves into position Ensure the tab fully depressed 8 Install upper and lower shroud on steering col umn assembly Fig 35 9 Install tilt lever Fig 35 10 Install the lower instrument panel cover 11 Install the 2 screws behind the fuse panel cover attaching the lower instrument panel cover to t...

Page 1169: ...ntil correctly positioned to allow roll pin to be installed in coupler 3 Install Puller Special Tool 6831 A through center of roll pin and install knurled nut Fig 44 4 Using Puller Special Tool 6831 A Fig 44 install roll pin into the coupler until spring pin is fully installed through both sides of the coupler SPECIFICATIONS STEERING COLUMN FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE Steerin...

Page 1170: ...L AND CONDITION CHECK 29 FLUID AND FILTER SERVICE TRANSMISSION 29 FLUID DRAIN AND REFILL DIFFERENTIAL SUMP 31 ALUMINUM THREAD REPAIR 31 FLUSHING COOLERS AND TUBES 31 OIL PUMP VOLUME CHECK 32 TRANSAXLE QUICK LEARN PROCEDURE 33 PINION FACTOR PROCEDURE 33 REMOVAL AND INSTALLATION GEARSHIFT CABLE COLUMN SHIFT 33 GEARSHIFT CABLE FLOOR SHIFT 36 FLOOR SHIFTER 38 INTERLOCK CASSETTE 39 BRAKE TRANSMISSION S...

Page 1171: ...OCKET HEIGHT ADJUSTMENT PROCEDURE 145 SCHEMATICS AND DIAGRAMS 42LE TRANSAXLE HYDRAULIC SCHEMATICS 146 SPECIFICATIONS 42LE AUTOMATIC TRANSAXLE 159 42LE TRANSAXLE TORQUE SPECIFICATIONS 159 SPECIAL TOOLS 42LE AUTOMATIC TRANSAXLE 160 DESCRIPTION AND OPERATION 42LE TRANSAXLE DESCRIPTION Fig 1 42LE Transaxle 21 2 42LE TRANSAXLE LH ...

Page 1172: ...ission control relay etc The TCM also performs certain self diagnostic functions and provides comprehensive information sensor data DTC s etc which is helpful in proper diagnosis and repair This information can be viewed with the DRB scan tool TRANSAXLE IDENTIFICATION The 42LE transaxle identification code is a series of digits printed on a bar code label that is fixed to the transaxle case as sho...

Page 1173: ... than those automatic transmission fluids listed above Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks Various special additives and supplements exist that claim to improve shift feel and or quality These additives and others also claim to improve converter clutch operation and inhibit overheating oxidation varnish and sludge These claims have not been sup por...

Page 1174: ... of the soft ware provides the TCM with fine control over the LR CC solenoid There are four output logic states that can be applied as follows No EMCC Partial EMCC Full EMCC Gradual to no EMCC NO EMCC Under No EMCC conditions the L R Solenoid is OFF There are several conditions that can result in NO EMCC operations No EMCC can be initiated due to a fault in the transaxle or because the TCM does no...

Page 1175: ...ydraulic pressure in the transaxle It receives unregulated pressure from the pump which works against spring tension to maintain oil at specific pressures A system of sleeves and ports allows the regulator valve to work at one of three predetermined pressure levels Regulated oil pressure is also referred to as line pressure SOLENOID SWITCH VALVE The solenoid switch valve controls line pressure fro...

Page 1176: ...lutches from dragging Inad vertent motion of the reverse overdrive push pull piston can be caused by the unbalanced centrifugal forces in the reverse and overdrive chambers By linking the overdrive and reverse vents to the vent reservoir at the manual valve an equal residual pressure will be maintained thus balancing the cen trifugal forces in the reverse and the overdrive cham bers ACCUMULATORS D...

Page 1177: ...ch retainer Underdrive piston Overdrive reverse piston Overdrive hub Underdrive hub OPERATION The three input clutches are responsible for driving different components of the planetary geartrain NOTE Refer to the Elements In Use chart in Diagnosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever UNDERDRIVE CLUTCH The underdrive clutch is...

Page 1178: ...e case Fig 11 OPERATION NOTE Refer to the Elements In Use chart in Diagnosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever 2 4 CLUTCH The 2 4 clutch is hydraulically applied in second and fourth gears by pressurized fluid against the 2 4 clutch piston When the 2 4 clutch is applied the front sun gear assembly is held or grounded to th...

Page 1179: ...ives the differential case and the case drives the driveshafts through the differential gears The differential pinion and side gears are supported in the case by thrust washers and a pinion shaft Dif ferential pinion and side gears make it possible for front tires to rotate at different speeds while corner ing TRANSMISSION CONTROL MODULE DESCRIPTION The Transmission Control Module TCM is located i...

Page 1180: ...ponsibili ties and functions Storing and maintaining Clutch Volume Indices CVI Storing and selecting appropriate Shift Sched ules System self diagnostics Diagnostic capabilities with DRB III scan tool NOTE If the TCM has been replaced the Quick Learn Procedure must be performed Refer to Quick Learn Procedure in Service Procedures of this group CLUTCH VOLUME INDEX CVI An important function of the T...

Page 1181: ...e following chart identifies the appro priate clutch volumes and when they are monitored updated CLUTCH VOLUMES Clutch When Updated Proper Clutch Volume Shift Sequence Oil Temperature Throttle Angle L R 2 1 or 3 1 coast downshift 70 5 35 to 83 2 4 1 2 shift 110 5 54 20 to 77 OD 2 3 shift 48 to 150 UD 4 3 or 4 2 shift 5 24 to 70 SHIFT SCHEDULES As mentioned earlier the TCM has programming that allo...

Page 1182: ... Super Overheat Oil temperature above 260 F All Overheat shift schedule features apply 2nd gear PEMCC above 22 mph Above 22 mph the torque converter will not unlock unless the throttle is closed or if a wide open throttle 2nd PEMCC to 1 kickdown is made TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay is located in the Power Distribution Center PDC on the left side of the engi...

Page 1183: ...state By design this allows transaxle limp in P R N 2 in the event of an electrical failure The continuity of the solenoids and circuits are periodically tested Each solenoid is turned on or off depending on its current state An inductive spike should be detected by the TCM during this test It no spike is detected the circuit is tested again to verify the failure In addition to the periodic testin...

Page 1184: ...r that communicates transaxle tem perature to the TCM and PCM Fig 19 OPERATION The Transmission Range Sensor TRS Fig 18 communicates shift lever position SLP to the TCM as a combination of open and closed switches Each shift lever position has an assigned combination of switch states open closed that the TCM receives from four sense circuits The TCM interprets this information and determines the a...

Page 1185: ...he shift position indicator is located in the instru ment cluster It indicates the position of the manual valve lever by illuminating an LED located under the P R N D 3 or L or Autostick gear symbol OPERATION The Transmission Range Sensor TRS sends a sig nal to the Transmission Control Module TCM regarding the position of the manual valve lever The TCM converts this signal into a Shift Lever Posit...

Page 1186: ...put to the Transmission Control Module TCM OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating As the rear planetary carrier park pawl lugs pass by the sensor coil Fig 25 an AC voltage is generated and sent to the TCM The TCM interprets this information as output shaft rpm The TCM compares the input and output speed signals to determine the following Tra...

Page 1187: ...ated PARK position The following chart describes the normal operation of the Brake Transmission Shift Interlock BTSI sys tem If the expected response differs from the vehi cle s response then system repair and or adjustment is necessary BRAKE TRANSMISSION SHIFT INTERLOCK SYSTEM COLUMN SHIFT DESCRIPTION Vehicles equipped with a column shifter utilize a brake transmission shift interlock BTSI soleno...

Page 1188: ...ds the driver causes a downshift and mov ing to the right towards the passenger causes an upshift The instrument cluster will illuminate the selected gear The vehicle can be launched in 1st 2nd or 3rd gear while in the Autostick mode The speed control is operable in 3rd and 4th gear Auto stick mode Speed control will be deactivated if the transaxle is shifted to 2nd gear Shifting into OD position ...

Page 1189: ...shift cornering Elements in use when condition occurs what gear is transaxle in during condition Road and weather conditions Any other useful diagnostic information After noting all conditions check the easily acces sible variables Fluid level and condition Shift linkage adjustment Diagnostic trouble code inspection Then perform a road test to determine if the prob lem has been corrected or that m...

Page 1190: ... circuits or sticking valves HYDRAULIC PRESSURE TESTS Pressure testing is a very important step in the diagnostic procedure These tests usually reveal the cause of most transaxle problems Before performing pressure tests be certain that fluid level and condition and shift cable adjustments have been checked and approved Fluid must be at operating temperature 150 to 200 degrees F Install an engine ...

Page 1191: ...si 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 should be less than 5 psi TEST FOUR SELECTOR IN OD Fourth Gear NOTE This test checks the 2 4 clutch hydraulic cir cuit 1 Attach gauge to the 2 4 clutch tap 2 Move selector lever to the OD position 3 Allow vehicle front wheels to turn and in...

Page 1192: ...fter the valve body has been removed Use Special Tool 6599 1 and 6599 2 to perform test Fig 30 To make air pressure tests proceed as follows ALL PRESSURE SPECIFICATIONS ARE PSI ON HOIST WITH FRONT WHEELS FREE TO TURN Gear Selector Position Actual Gear PRESSURE TAPS Underdrive Clutch Overdrive Clutch Reverse Clutch Torque Converter Clutch Off 2 4 CLUTCH Low Reverse Clutch PARK 0 mph PARK 0 2 0 5 0 ...

Page 1193: ...r the piston to move forward The piston should return to its original position after the air pressure is removed FLUID LEAKAGE The 42LE is a dual sump transaxle The transaxle uses both automatic transaxle fluid ATF for the main sump and hypoid gear lube for the differential sump When diagnosing a leak it is important to dis tinguish which type of fluid is leaking Factory fill ATF is dyed red while...

Page 1194: ... actions must be taken before repair 1 Verify proper transmission fluid level 2 Verify that the leak originates from the con verter housing area and is transmission fluid 3 Determine the true source of the leak Fluid leakage at or around the torque converter area may originate from an engine oil leak Fig 33 The area should be examined closely Factory fill fluid is red and therefore can be distingu...

Page 1195: ... If the shift lever still does not move from the PARK position remove the BTSI solenoid from the shift lever assembly If the shift lever now moves freely in and out of the park position the BTSI solenoid is faulty and must be replaced If the shift lever still does not move from the park position the problem is in the shift lever assembly or the ignition interlock cassette CIRCUIT TEST 1 Check the ...

Page 1196: ... Shifter Locked In Place below If the shift lever can be shifted out of PARK without the brake pedal depressed refer to Circuit Test below SHIFTER LOCKED IN PLACE 1 Remove the instrument panel cover below the steering column then remove the steering column shrouds to gain access to the brake transmission shift interlock BTSI solenoid The solenoid is part of the interlock cable assembly 2 Disconnec...

Page 1197: ...ver Position SLP information to the BCM via the communication bus The BCM then out lines the appropriate shifter position indicator in the instrument cluster If a problem arises with the shifter position indica tor consult the following chart for diagnostic infor mation If the malfunction cannot be corrected using the chart consult the proper diagnostic manual To replace the shifter position indic...

Page 1198: ...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 air bubbles can cause overheating and or fluid oxidation and varnishing This can interfere with normal valve clutch and accumulator operation Foaming can also result in fluid escaping from th...

Page 1199: ...40 in lbs 4 Clean the oil pan and magnet Reinstall pan using new Mopar Silicone Adhesive sealant Tighten oil pan bolts to 19 N m 165 in lbs 5 Pour four quarts of Mopart ATF 4 Automatic Transmission Fluid Type 9602 through the dipstick opening 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...

Page 1200: ...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 Fig 38 9 Recheck the fluid level after the transaxle has reached normal operating temperature 180 F 10 To prevent dirt from entering transaxle make certain that dipstick is fully seated into the dipstick opening FLUID DRAIN AND REFILL DIFFERENTIAL SUMP The differential flu...

Page 1201: ...ump ON for 30 seconds to purge flush ing solution from cooler and lines Turn pump OFF 10 Place CLEAR suction line into a one quart container of Mopart ATF 4 Automatic Transmission Fluid Type 9602 11 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 12 Disconnect...

Page 1202: ...PINION FACTOR PROCEDURE The vehicle speed readings for the speedometer are taken from the output speed sensor The TCM must be calibrated to the different combinations of equip ment available Pinion Factor allows the technician to set the Transmission Control Module initial set ting so that the speedometer readings will be correct Failure to perform this procedure will cause a No Speedometer Operat...

Page 1203: ... tube to gain access to the inte grated shift cable clamp 12 Disconnect cable from routing bracket as shown in Fig 48 13 Remove shift cable retaining nut and slide cable assy off of mounting stud Fig 49 14 Disconnect shifter cable from shift lever assembly at transaxle Fig 49 15 Remove cable from vehicle Fig 42 Lower Column Cover Screw Removal Installation 1 LOWER COLUMN COVER 2 STEERING WHEEL Fig...

Page 1204: ...e cable mounting stud Install cable to transaxle and tighten nut to 28 N m 250 in lbs Fig 46 Column Gear Shift Cable Removal Installation 1 CONDUIT BRACKET 2 RETAINER CLIP 3 GEARSHIFT CABLE 4 SHIFT PIN Fig 47 Throttle Gearshift Cable Bracket 1 CABLE BRACKET 2 GEARSHIFT CABLE 3 THROTTLE CABLE Fig 48 Cable Routing Bracket 3 2L 3 5L Shown 2 7L Similar 1 BRACKET 2 CABLE Fig 49 Gearshift Cable Removal ...

Page 1205: ... cable by rotating the adjuster into lock position Fig 51 The adjuster will click when lock is fully adjusted 15 Reinstall upper and lower steering column shrouds Fig 43 Fig 45 Then install underpanel silencer duct 16 Check shifter for proper operation It should operate smoothly without binding The engine starter should crank in park or Neutral positions only GEARSHIFT CABLE FLOOR SHIFT REMOVAL 1 ...

Page 1206: ... nut and slide cable off of stud Fig 56 13 Disconnect shifter cable from shift lever assembly at transaxle Fig 56 14 Remove cable from underneath vehicle Fig 53 Shift Cable Adjust Lever Nut 1 CONSOLE 2 ACCESS HOLE 3 SHIFTER HANDLE Fig 54 Floor Gearshift Cable Removal Installation 1 CUP 2 CABLE 3 CONDUIT BRACKET 4 PIN Fig 55 Throttle Gearshift Cable Bracket 1 CABLE BRACKET 2 GEARSHIFT CABLE 3 THROT...

Page 1207: ...t lower heat duct Fig 58 and towards the gearshift mechanism 10 Route cable through hole in shifter conduit bracket and attach to cable attaching shift pin by snapping into place Fig 54 11 Install a new clip onto the cable at the shifter bracket Fig 54 12 Tighten the adjuster nut Fig 53 13 Reinstall console bezel and shifter handle Firmly press the shifter handle downward and tighten the screw Fig...

Page 1208: ...ore wire into interlock adjustment lever groove Fig 61 Make sure the interlock cable slug is seated in the groove 7 Slip interlock cable conduit end fitting into bracket and snap into place Fig 61 8 If equipped with Autostick connect the Auto stick connector 9 Adjust gear shift and interlock cables NOTE Gearshift and interlock cables MUST be adjusted Refer to the Adjustments section in this Group ...

Page 1209: ...to vehicles with steering column mounted shift levers only REMOVAL 1 Remove the fuse panel cover from the left end of the instrument panel Fig 66 2 Remove the two screws behind the fuse panel cover attaching the lower instrument panel cover to the instrument panel Fig 67 3 Remove the lower instrument panel cover The lower instrument panel cover is attached by retain ing clips along the top and rig...

Page 1210: ...ion shift interlock BTSI sole noid Fig 70 8 Remove the retainer clip from the end of the BTSI solenoid Fig 71 9 Slide the BTSI solenoid straight off the shift lever mounting stud INSTALLATION 1 Align the flat inside the brake transmission shift interlock BTSI solenoid Fig 72 with the flat on the shift lever mounting stud 2 Slide the solenoid completely onto the shift lever mounting stud aligning t...

Page 1211: ...ing brake applied try shifting the transmission shift lever out of the PARK position with and without the brake pedal being applied The shift lever should Fig 70 Solenoid Connector 1 BTSI SOLENOID 2 CONNECTOR Fig 71 Solenoid Retainer Clip Removal 1 SOLENOID 2 MOUNTING STUD 3 RETAINER CLIP Fig 72 Flat Inside BTSI Solenoid 1 GUIDES 2 SOLENOID 3 FLAT Fig 73 Guide And Flange Alignment 1 BRACKET FLANGE...

Page 1212: ...umn down and remove upper half of col umn cover Fig 78 7 Tilt the column to the uppermost position and remove the tilt lever Fig 79 8 Remove the ignition key and remove lower col umn cover Fig 80 9 Remove the interlock cable from the shifter housing Slide the cable out of the groove in the interlock lever Fig 81 10 Disconnect the BTSI solenoid connector 11 Depress the lock tab Fig 82 on the interl...

Page 1213: ...Fig 81 by pushing it down 11 If the interlock cable is being re used the lock pin will not exist Free adjustment by pulling out ward on locking clip The cable will index itself to the correct position Tighten the locking clip by pushing it down 12 Insert the ignition key and verify the ignition interlock adjustment operation Refer to Description Fig 78 Upper Column Removal Installation 1 STEERING ...

Page 1214: ...Body removal and Installation in this group 3 Remove the manual shaft seal Fig 85 4 Remove manual shaft TRS retaining screw Fig 86 5 Slide TRS off of manual valve shaft INSTALLATION 1 Install the TRS to the manual shaft Make sure TRS locating pin rests in manual valve bore slot Fig 82 Interlock Cable Locking Tab 1 TAB 2 INTERLOCK CABLE 3 LOCK CYLINDER HOUSING Fig 83 Interlock Cable Removal Install...

Page 1215: ...he speed sensor o ring and replace if necessary Fig 88 INSTALLATION 1 Verify o ring is installed into position Fig 88 2 Install and tighten input speed sensor to 27 N m 20 ft lbs torque 3 Connect speed sensor connector Fig 87 4 Connect battery negative cable OUTPUT SPEED SENSOR CAUTION When disconnecting speed sensor con nector be sure that the weather seal does not fall off or remain in the old s...

Page 1216: ...er of the 60 way connector Then disconnect the 60 way connector on transmission con trol module 6 Remove transmission control module mounting screws and lift module from vehicle Fig 91 INSTALLATION 1 Install transmission control module and tighten mounting screws 2 Install 60 way connector Tighten 60 way retaining screw to 4 N m 35 in lbs 3 Install one nut and screw holding transmission control mo...

Page 1217: ...embly and screen to the separator and transfer plates Fig 94 2 Install and tighten retaining screws Fig 93 to 6 N m 53 in lbs torque 3 Install valve body Refer to Valve Body Removal and Installation VALVE BODY REMOVAL 1 Disconnect the TRS wiring connector The sole noid wiring connector can remain attached to the case 2 Disconnect the shift cable from the shift lever at the transaxle 3 Move the shi...

Page 1218: ...verdrive and underdrive accumula tors and springs may fall out when removing the valve body INSTALLATION 1 Install valve body into position and start bolts Fig 99 2 Torque valve body to transaxle case bolts Fig 98 to 12 N m 105 in lbs torque 3 Install transaxle oil filter Fig 97 4 Make sure oil pan and case rail are clean and dry Install an 1 8 bead of RTV to the transaxle oil pan and install to c...

Page 1219: ...ove upper bell housing studs 9 Lift vehicle on hoist 10 Loosen clamps at intersection of rear exhaust system to front catalytic converter pipes 11 Separate rear exhaust from left catalytic con verter pipe and right extension pipe 12 Remove rear exhaust system Fig 99 Valve Body From Transaxle 1 VALVE BODY Fig 100 Underdrive Accumulator and Spring 1 ACCUMULATOR PISTON UNDERDRIVE 2 RETURN SPRINGS 3 S...

Page 1220: ...remove left catalytic converter pipe 25 Unbolt starter assembly Do not disconnect wiring or completely remove the starter from the vehicle Allow the starter to sit between the engine and the frame 26 Remove engine oil pan collar 27 Remove torque converter bolts The torque converter is indexed to the flex plate Mark the torque converter location to ensure that the torque converter is reinstalled co...

Page 1221: ...re 6 Refill transaxle with Mopar ATF Plus 3 Auto matic Transmission Fluid Type 7176 OIL PUMP SEAL REPLACEMENT The transaxle must be removed from the vehicle to replace this oil seal REMOVAL 1 Remove the transaxle from the vehicle 2 Remove the torque converter from the tran saxle bellhousing 3 Use special tool C 3981B to remove oil pump seal Fig 105 INSTALLATION 1 Clean and inspect oil pump seal se...

Page 1222: ...as shown in Fig 108 CAUTION If short stub shaft has corrosion use caution when removing differential cover Inspect seal and shaft for damage after removal of cover Replace shaft and or seal as required 6 Index outer adjuster Fig 109 Remove lock bracket and back out adjuster exactly one revolution Then remove differential cover 7 Remove The inner adjuster lock bracket Then remove the inner adjuster...

Page 1223: ...ransaxle from vehicle Refer to Tran saxle Removal and Installation procedure in this sec tion 2 Remove long stub shaft from transaxle Fig 110 To replace the long stub shaft bearing install stub shaft in soft jawed vise Remove the stub shaft bear ing C clip Fig 111 Install bearing splitter onto the shaft Install Special Tool P 334 under the bearing Using a shop press remove the bearing from the stu...

Page 1224: ...e short stub shaft seal without having to remove the transaxle from the vehicle If the adjuster or bearing located behind the adjuster require replacement do not use this procedure Refer to Differential Recondi tion section of this manual Fig 112 Remove Stub Shaft Bearing C clip 1 BEARING SPLITTER 2 STUB SHAFT BEARING Fig 113 Install Bearing Onto Shaft 1 TOOL 6558 2 STUB SHAFT BEARING 3 STUB SHAFT...

Page 1225: ... and tighten adjuster within 10 ft lbs of the torque read ing recorded in step five 10 Rotate ring gear three or four revolutions in both directions to seat differential bearings 11 Continue tightening outer adjuster until index marks line up original location 12 Install adjuster lock 13 Install new driveshaft retaining circlip and O ring on stub shaft Then reinstall driveshaft 14 Check fluid leve...

Page 1226: ... Fig 124 7 Remove transfer separator plate from valve body Fig 125 8 Remove separator plate to transfer plate screws Fig 126 9 Remove separator plate from transfer plate Fig 127 10 Remove oil screen Fig 128 from transfer plate Fig 120 TRS Manual Shaft Retaining Screw 1 SCREW 2 TRS Fig 121 Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER C...

Page 1227: ...te from valve body Use special tool 6301 to remove plate Fig 132 Fig 124 Transfer Plate to Valve Body Screws 1 SCREW 24 2 TRANSFER PLATE Fig 125 Transfer Plate and Valve Body 1 TRANSFER PLATE 2 VALVE BODY Fig 126 Separator Plate to Transfer Plate Screws 1 SEPARATOR PLATE 2 SCREW 2 3 TRANSFER PLATE Fig 127 Separator Plate 1 SEPARATOR PLATE 2 TRANSFER PLATE 21 58 42LE TRANSAXLE LH DISASSEMBLY AND AS...

Page 1228: ...HERMAL VALVE Fig 128 Oil Screen 1 OIL SCREEN Fig 130 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 5 BALL CHECK LOCATION 4 3 BALL CHECK LOCATION LH 42LE TRANSAXLE 21 59 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1229: ...n a suitable solvent then dried by com pressed air Do not wipe parts with shop towels All mating surfaces in the valve body are accurately machined therefore careful handling of all parts must be exercised to avoid nicks or burrs Fig 131 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 SPRINGS 5 SEALS 6 PISTON Fig 132 Remove or Install Dual Retainer Plate 1 TOOL 6301 2 RETA...

Page 1230: ... SPRING 3 BALL Fig 137 Springs and Valves Location 1 VALVE BODY 2 T C REGULATOR VALVE 3 L R SWITCH VALVE 4 VENT RESERVOIR CHECK VALVE 5 CONVERTER CLUTCH CONTROL VALVE 6 MANUAL VALVE 7 CONVERTER CLUTCH SWITCH VALVE 8 SOLENOID SWITCH VALVE 9 REGULATOR VALVE LH 42LE TRANSAXLE 21 61 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1231: ...2 4 Accumulator components as shown in Fig 143 Torque 2 4 Accumulator retainer plate to 5 N m 45 in lbs 8 Install check balls into position as shown in Fig 144 If necessary secure them with petrolatum or transmission assembly gel for assembly ease Fig 138 Install Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER Fig 139 Install Dual Retainer Plate using Tool 6301 1 TOOL 6301 2...

Page 1232: ...T SPRING 4 SPRINGS 5 SEALS 6 PISTON Fig 142 Valve Retainer Location 1 RETAINER 2 RETAINER Fig 144 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 5 BALL CHECK LOCATION 4 3 BALL CHECK LOCATION LH 42LE TRANSAXLE 21 63 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1233: ...torque to 5 N m 45 in lbs 15 Install the stiffener plate Fig 151 16 Install the solenoid pressure switch assembly and to the transfer plate Fig 152 and torque to 6 N m 53 in lbs Fig 145 Install Thermal Valve to Transfer Plate 1 THERMAL VALVE Fig 146 Install Oil Screen to Transfer Plate 1 OIL SCREEN Fig 147 Install Separator Plate to Transfer Plate 1 SEPARATOR PLATE 2 TRANSFER PLATE Fig 148 Install...

Page 1234: ...the L position Then remove the shift lever NOTE Tag all clutch pack assemblies as they are removed for reassembly identification CAUTION Do not intermix clutch discs or plates as the unit might then fail Fig 149 Install Transfer Plate to Valve Body 1 TRANSFER PLATE 2 VALVE BODY Fig 150 Install Transfer Plate to Valve Body Screws 1 SCREW 24 2 TRANSFER PLATE Fig 151 Install Stiffener Plate 1 STIFFEN...

Page 1235: ...ator reading for reference when reassembling the transaxle Remove both speed sensors from transaxle case Fig 156 CAUTION Do not handle the valve body by the manual shaft Damage could result Fig 153 Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 154 TRS Manual Shaft Retaining Screw 1 SCREW 2 TRS Fig 155 Measure Input Shaft End P...

Page 1236: ...ansaxle Oil Pan 1 TRANSAXLE OIL PAN Fig 158 Remove Transaxle Oil Filter 1 TRANSAXLE FILTER 2 FILTER RETAINING CLIPS Fig 159 Remove Valve Body Bolts 17 1 EXTENSION 2 SOCKET 3 VALVE BODY Fig 160 Remove Valve Body From Transaxle 1 VALVE BODY LH 42LE TRANSAXLE 21 67 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1237: ...RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 162 Remove Overdrive Accumulator and Springs 1 OVERDRIVE ACCUMULATOR PISTON 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 163 Accumulator Locations 1 OVERDRIVE ACCUMULATOR LOCATION 2 UNDERDRIVE ACCUMULATOR LOCATION 3 LOW REVERSE ACCUMULATOR Fig 164 Remove Low Reverse Accumulator 1 SNAP RING 2 LOW REVERSE ACCUMULATOR 21 68 42LE TRANSAXLE LH DISASSEMBLY AND ...

Page 1238: ...Remove Low Reverse Accumulator Piston 1 SEAL RINGS 2 PISTON 3 PISTON 4 PETROLATUM 5 SUITABLE TOOL Fig 167 Low Reverse Accumulator 1 ACCUMULATOR PISTON 2 SEAL RINGS 3 RETURN SPRINGS 4 NOTE NOTCH Fig 168 Remove Long Stub Shaft Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 LONG STUB SHAFT LH 42LE TRANSAXLE 21 69 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1239: ...ft From Bellhousing 1 LONG STUB SHAFT 2 SPECIAL TOOL 6669 3 SLIDE HAMMER C 3752 Fig 170 Remove Oil Pump Attaching Bolts 1 BELLHOUSING 2 OIL PUMP Fig 171 Oil Pump Pullers 1 OIL PUMP 2 PULLERS Fig 172 Remove Oil Pump 1 PUSH IN ON INPUT SHAFT WHILE REMOVING PUMP 21 70 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1240: ...all the reaction shaft to the pump housing Tighten the bolts to 27 N M 20 ft lbs 9 Remove bolts and carefully separate the hous ings Measure the Plastigage following the instruc tions supplied 10 Clearance between outer gear side and the reaction shaft support should be 0 020 0 046mm 0 008 0 0018 in Clearance between inner gear side and the reaction shaft support should be 0 020 0 046mm 0 008 0 00...

Page 1241: ...Clutch Assembly 1 INPUT CLUTCH ASSEMBLY Fig 179 Remove No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETROLATUM FOR RETENTION Fig 180 Remove Front Sun Gear Assembly 1 FRONT SUN GEAR ASSEMBLY 2 4 THRUST WASHER FOUR TABS 21 72 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1242: ...e of old sealant dirt and oil before applying new sealant Apply a 1 8 inch bead of sealant to flange of cover Fig 181 Remove Front Carrier and Rear Annulus Assembly 1 6 NEEDLE BEARING 2 FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PULL OR PUSH TO REMOVE OR INSTALL Fig 182 Remove Rear Sun Gear 1 7 NEEDLE BEARING 2 REAR SUN GEAR Fig 183 Number 7 Bearing 1 7 BEARING 2 REAR SUN GEAR Fig 184 Remov...

Page 1243: ...g 186 2 4 Clutch Retainer 1 24 CLUTCH RETAINER 2 24 CLUTCH RETURN SPRING Fig 187 Remove 2 4 Clutch Return Spring 1 24 CLUTCH RETURN SPRING Fig 188 Remove 2 4 Clutch Pack 1 CLUTCH PLATE 4 2 CLUTCH DISC 4 21 74 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1244: ... OIL PAN FACE Fig 190 Remove One Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 191 Remove Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 192 Remove Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 LH 42LE TRANSAXLE 21 75 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1245: ...ve Chain Cover 1 TRANSAXLE CASE 2 CHAIN COVER Fig 194 Remove Chain Oiler 1 CHAIN SNUBBER 2 CHAIN OILER Fig 195 Remove Chain Snubber 1 CHAIN SNUBBER Fig 196 Remove Output Shaft Sprocket Snap Ring and Wave Washer 1 WAVE WASHER 2 SNAP RING 21 76 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1246: ... stakes of the output shaft nut and transfer shaft nut will result in thread damage to the shafts during nut removal WARNING WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS Fig 197 Remove Transfer Shaft Sprocket Snap Ring and Wave Washer 1 TRANSFER SHAFT 2 WAVE WASHER 3 SNAP RING 4 SNAP RING 5 WAVE WASHER Fig 198 Install Chain Spreader 1 OUTPUT SPROCKET 2 SPECIAL TOOL 6550 3 TRANSFER SPROCKET Fig 19...

Page 1247: ...breaker bar will turn clockwise to remove the nut and counter clockwise to install the nut Use special tool 6596 to remove front output shaft bearing cup Fig 207 Fig 201 Main Sump Vent Baffle Location 1 OUTPUT SHAFT NUT 2 MAIN SUMP VENT BAFFLE 3 TRANSFER SHAFT NUT 4 TRANSFER SHAFT 5 VENT BAFFLE RETAINING SCREW 6 OUTPUT SHAFT Fig 202 Grinding Stakes 1 TRANSFER SHAFT 2 GRIND HERE 3 GRIND HERE 4 NUT ...

Page 1248: ...OOL 6497 2 SPECIAL TOOL 6498 3 BREAKER BAR Fig 206 Use Arbor Press to Remove Output Shaft from Case 1 OUTPUT SHAFT 2 ARBOR PRESS 3 TRANSAXLE CASE Fig 207 Remove Front Bearing Cup 1 ARBOR PRESS 2 SPECIAL TOOL 6596 Fig 208 Remove Rear Bearing Cup 1 SPECIAL TOOL 4171 AND 4171 2 2 SPECIAL TOOL 6597 LH 42LE TRANSAXLE 21 79 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1249: ...ol 1 TOOL 6057 2 TOOL 5059 3 TOOL 5058 3 Fig 211 Compressor Tool in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 5058A 3 4 TOOL 5059A 5 SPECIAL TOOL 6057 Fig 212 Remove Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 SPECIAL TOOL 5059A 21 80 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1250: ...ETURN SPRING 2 PISTON Fig 214 Remove Parking Sprag Pivot Retaining Screw 1 TRANSFER SHAFT 2 PARKING SPRAG PIVOT RETAINING SCREW Fig 215 Anchor Shaft Removal 1 PIN PUNCH 2 GUIDE BRACKET ASSEMBLY Fig 216 Guide Bracket Pivot Shaft 1 PIVOT PIN 2 GUIDE BRACKET ASSEMBLY LH 42LE TRANSAXLE 21 81 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1251: ...ove Low Reverse Clutch Piston 1 LOW REVERSE CLUTCH PISTON 2 LIP SEAL 3 LIP SEAL Fig 219 Remove Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 220 Remove Piston Retainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET 21 82 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1252: ...2 Remove reaction shaft support from pump housing Fig 222 3 Remove the pump gears Fig 223 and check for wear and damage 4 Re install the gears and check clearances 5 Measure the clearance between the outer gear and the pump pocket Fig 224 Clearance should be 0 045 0 141mm 0 0018 0 0056 in Fig 221 Remove Piston Retainer Gasket 1 GASKET HOLES MUST LINE UP 2 LOW REVERSE CLUTCH PISTON RETAINER GASKET ...

Page 1253: ...embly to Input Clutch Pressure Fixture Tool 8391 2 Tap down reverse clutch reaction plate to release pressure from snap ring Fig 225 3 Remove reverse clutch snap ring Fig 226 4 Pry up and remove reverse clutch reaction plate Fig 227 Fig 228 5 Remove the reverse clutch pack two fibers one steel Fig 229 NOTE Tag reverse clutch pack for reassembly identification Fig 225 Tapping Reaction Plate 1 4 THR...

Page 1254: ...EVERSE CLUTCH REACTION PLATE INSTALL FLAT SIDE DOWN Fig 229 Reverse Clutch Pack 1 REVERSE CLUTCH PLATE 2 REVERSE CLUTCH DISC Fig 230 OD Reverse Reaction Plate Snap Ring 1 OD REVERSE PRESSURE PLATE 2 SCREWDRIVER 3 OD REVERSE PRESSURE PLATE SNAP RING Fig 231 OD Reverse Reaction Plate 1 OD REVERSE PRESSURE PLATE STEP SIDE DOWN 2 STEP SIDE DOWN LH 42LE TRANSAXLE 21 85 DISASSEMBLY AND ASSEMBLY Continue...

Page 1255: ...g 1 OVERDRIVE SHAFT ASSEMBLY 2 OD REVERSE CLUTCH WAVED SNAP RING 3 SCREWDRIVER Fig 233 Remove OD Clutch Pack 1 OVERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK 2 3 THRUST PLATE 3 3 THRUST WASHER 4 UNDERDRIVE SHAFT ASSEMBLY Fig 234 Overdrive Clutch Pack 1 OVERDRIVE CLUTCH PLATE 2 OVERDRIVE SHAFT ASSEMBLY 3 OVERDRIVE CLUTCH DISC Fig 235 3 4 Thrust Washers 1 3 THRUST PLATE 3 TABS 2 OD SHAFT ASSEMBLY 3 4 T...

Page 1256: ...ep side up 14 Remove the OD UD reaction plate Fig 239 15 Remove the first UD clutch disc Fig 240 16 Remove the UD clutch flat snap ring Fig 241 Fig 236 Underdrive Shaft Assembly 1 3 THRUST WASHER 5 TABS 2 UNDERDRIVE SHAFT ASSEMBLY Fig 237 No 2 Needle Bearing 1 2 NEEDLE BEARING NOTE 3 TABS Fig 238 OD UD Reaction Plate Tapered Snap Ring 1 OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RIN...

Page 1257: ...put hub tapered snap ring Fig 246 22 Tap on input hub with soft faced hammer and separate input hub from OD Reverse piston and clutch retainer Fig 247 Fig 248 Fig 240 Remove One UD Clutch Disc 1 ONE UNDERDRIVE CLUTCH DISC Fig 241 UD Clutch Flat Snap Ring 1 UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 SCREWDRIVER Fig 242 Underdrive Clutch Pack 1 CLUTCH PLATE 2 ONE UD CLUTCH DISC 3 CLUTCH DISC ...

Page 1258: ... RING 3 SEAL 4 PISTON RETURN SPRING Fig 245 Underdrive Clutch Piston 1 PISTON Fig 246 Input Hub Tapered Snap Ring 1 INPUT SHAFT 2 INPUT HUB SNAP RING TAPERED SIDE UP WITH TABS IN CAVITY 3 SNAP RING PLIERS Fig 247 Tap on Input Hub 1 INPUT SHAFT AND HUB ASSEMBLY 2 PLASTIC HAMMER LH 42LE TRANSAXLE 21 89 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1259: ...E REVERSE PISTON Fig 249 Pull Retainer from Piston 1 OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 250 Remove Snap Ring 1 ARBOR PRESS RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNAP RING 4 SPECIAL TOOL 6057 5 OD REVERSE PISTON 6 RETURN SPRING Fig 251 Snap Ring and Return Spring 1 OD REVERSE PISTON 2 RETURN SPRING 3 SNAP RING 4 O RING 21 90 42LE T...

Page 1260: ...l 6057 Install OD Reverse piston return spring and snap ring Fig 256 Fig 257 Fig 252 Remove Input Shaft Snap Ring 1 INPUT SHAFT 2 SHARP POINTED TOOL 3 SNAP RING 4 O RINGS 5 SEALS Fig 253 Remove Input Shaft 1 ARBOR PRESS RAM 2 SOCKET 3 SEAL 4 O RINGS 5 INPUT SHAFT 6 SEAL 7 INPUT SHAFT HUB ASSEMBLY Fig 254 Install Input Shaft 1 INPUT SHAFT 2 ARBOR PRESS RAM 3 INPUT SHAFT HUB ASSEMBLY Fig 255 Install...

Page 1261: ...arbor press Install the UD spring retainer and snap ring Fig 263 Fig 264 Compress just enough to install snap ring CAUTION Compress return spring just enough to install snap ring Fig 256 Return Spring and Snap Ring 1 OD REVERSE PISTON 2 RETURN SPRING 3 SNAP RING 4 O RING Fig 257 Install Snap Ring 1 ARBOR PRESS RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SN...

Page 1262: ... 2 INPUT HUB SNAP RING TAPERED SIDE UP WITH TABS IN CAVITY 3 SNAP RING PLIERS Fig 261 Underdrive Clutch Piston 1 PISTON Fig 262 Seal Compressor Special Tool 5067 1 PISTON RETURN SPRING 2 SPECIAL TOOL 5067 3 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY Fig 263 UD Return Spring and Retainer 1 UNDERDRIVE SPRING RETAINER 2 SNAP RING 3 SEAL 4 PISTON RETURN SPRING LH 42LE TRANSAXLE 21 93 DISASSEMBLY AND ASSEM...

Page 1263: ...ng Retainer and Snap Ring 1 ARBOR PRESS RAM 2 SNAP RING PLIERS 3 SNAP RING 4 OD REVERSE PISTON 5 TOOL 5067 6 TOOL 5059A Fig 265 Underdrive Clutch Pack 1 CLUTCH PLATE 2 ONE UD CLUTCH DISC 3 CLUTCH DISC Fig 266 UD Clutch Flat Snap Ring 1 UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 SCREWDRIVER Fig 267 Install Last UD Clutch Disc 1 ONE UNDERDRIVE CLUTCH DISC 21 94 42LE TRANSAXLE LH DISASSEMBLY A...

Page 1264: ...ck indica tor reading should advance 0 005 0 010 CAUTION Do not apply more than 30 psi 206 kPa to the underdrive clutch pack 18 Apply 30 psi 206 kPa to the underdrive hose on Tool 8391 and measure UD clutch clearance Mea sure and record UD clutch pack measurement in four 4 places 90 apart Fig 268 OD UD Reaction Plate 1 OD UD CLUTCH REACTION PLATE STEP SIDE DOWN Fig 269 Tapered Snap Ring 1 OVERDRIV...

Page 1265: ... clutch pack Fig 276 24 Install OD reaction plate flat snap ring Fig 277 Fig 272 Set Up Dial Indicator to Measure UD Clutch Clearance 1 DIAL INDICATOR 2 UNDERDRIVE CLUTCH Fig 273 Press Down on UD Clutch Pack and Zero Dial Indicator 1 DIAL INDICATOR 2 UNDERDRIVE CLUTCH UNDERDRIVE REACTION PLATE THICKNESS 4659939AB 5 837 5 937 mm 0 230 0 234 in 4659940AB 6 147 6 248 mm 0 242 0 246 in 4659941AB 6 457...

Page 1266: ...pack clearance is 1 07 3 25 mm 0 042 0 128 in If not within specifications the clutch is not assembled properly There is no adjustment for the OD clutch clearance 28 Install reverse clutch pack two fibers one steel Fig 279 Fig 276 OD Reverse Reaction Plate 1 OVERDRIVE REVERSE PRESSURE PLATE 2 STEP SIDE DOWN Fig 277 Install Flat Snap Ring 1 ARBOR PRESS RAM 2 TOOL 5059A 3 FLAT SNAP RING Fig 278 Meas...

Page 1267: ...the reverse clutch hose on Tool 8391 Measure and record reverse clutch pack measurement in four 4 places 90 apart 35 Take average of four measurements and com pare with reverse clutch pack clearance specification The reverse clutch pack clearance is 0 89 1 37 mm 0 035 0 054 in Select the proper reverse clutch snap ring to achieve specifications Fig 280 Install Reaction Plate 1 REVERSE CLUTCH REACT...

Page 1268: ...verdrive shaft assembly Fig 289 42 Reinstall overdrive and reverse clutch as shown Rechecking these clutch clearances is not necessary Fig 284 Press Down on Reverse Clutch and Zero Indicator 1 DIAL INDICATOR 2 REVERSE CLUTCH REVERSE CLUTCH SNAP RING THICKNESS 4377195 1 53 1 58 mm 0 060 0 062 in 4412871 1 77 1 83 mm 0 070 0 072 in 4412872 2 02 2 07 mm 0 080 0 082 in 4412873 2 27 2 32 mm 0 090 0 091...

Page 1269: ...VERDRIVE SHAFT ASSEMBLY 2 DABS OF PETROLATUM FOR RETENTION 3 3 THRUST PLATE NOTE 3 TABS Fig 289 Install Overdrive Shaft Assembly 1 OVERDRIVE SHAFT ASSEMBLY 2 3 THRUST PLATE 3 3 THRUST WASHER Fig 290 Input Clutch Assembly 1 INPUT CLUTCH ASSEMBLY 2 OVERDRIVE SHAFT ASSEMBLY 21 100 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1270: ...INE UP 2 LOW REVERSE CLUTCH PISTON RETAINER GASKET Fig 293 Install Piston Retainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 294 Install Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 295 Install Low Reverse Clutch Piston 1 LOW REVERSE CLUTCH PISTON 2 LIP SEAL 3 LIP SEAL LH 42LE TRANSAXLE 21 101 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1271: ...CER 5 STEPPED SPACER 6 ANTIRATCHET SPRING Fig 297 Guide Bracket 1 GUIDE BRACKET 2 ANTIRATCHET SPRING MUST BE ASSEMBLED AS SHOWN 3 PAWL Fig 298 Install Guide Bracket Pivot Shaft 1 PIVOT PIN 2 GUIDE BRACKET ASSEMBLY Fig 299 Install Parking Sprag Pivot Retaining Screw 1 TRANSFER SHAFT 2 PARKING SPRAG PIVOT RETAINING SCREW 21 102 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1272: ...57 2 TOOL 5059 3 TOOL 5058 3 Fig 302 Compressor Tool in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 5058A 3 4 TOOL 5059A 5 SPECIAL TOOL 6057 Fig 303 Install Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6057 LH 42LE TRANSAXLE 21 103 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1273: ...etrolatum onto the shim to hold it in place Use the original shim as a starting point If original shim is not available use the thickest shim available Refer to Output Shaft Rear Shim Chart for available sizes 5 Install output shaft rear carrier into rear bear ing The shaft must be pressed into position Use spe cial tool MD 998911 Disc and C 4171 and C4171 2 Handle to press shaft into rear bearing...

Page 1274: ...5 17 5 19 mm 5 62 5 64 mm 5 20 5 22 mm 5 65 5 67 mm 5 23 5 25 mm 5 68 5 70 mm 5 26 5 28 mm 5 71 5 73 mm 5 29 5 31 mm 5 74 5 76 mm 5 32 5 34 mm 5 77 5 79 mm 5 35 5 37 mm 5 80 5 82 mm 5 38 5 40 mm 5 83 5 85 mm 5 41 5 43 mm 5 86 5 88 mm 5 44 5 46 mm 5 89 5 91 mm 5 47 5 49 mm 5 92 5 94 mm 5 50 5 52 mm 5 95 5 97 mm 5 53 5 55 mm 5 98 6 00 mm 5 56 5 58 mm 6 01 6 03 mm 5 59 5 61 mm 6 04 6 06 mm Output Sha...

Page 1275: ...fit onto the shafts Apply only a slight amount of pressure to the chain spreader to release the chain pressure If chain sprockets are not spread slightly installa tion will be difficult Fig 310 Staking Output Shaft Nut 1 ARBOR PRESS 2 STAKING TOOL 3 NEW NUT Fig 311 Correctly Staked Nut 1 BOTTOMED IN SLOT 2 CORRECTLY STAKED NUT Fig 312 Correctly Applied Sealant 1 SEALANT 2 BACK SIDE OF VENT BAFFLE ...

Page 1276: ...PUT SHAFT Fig 315 Install Chains and Both Sprockets as an Assembly 1 CHAINS Fig 316 Remove Chain Spreader 1 OUTPUT SPROCKET 2 SPECIAL TOOL 6550 3 TRANSFER SPROCKET Fig 317 Install Transfer Shaft Sprocket Snap Ring and Wave Washer 1 TRANSFER SHAFT 2 WAVE WASHER 3 SNAP RING 4 SNAP RING 5 WAVE WASHER LH 42LE TRANSAXLE 21 107 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1277: ...f sealant to flange of cover Fig 318 Install Output Shaft Sprocket Snap Ring and Wave Washer 1 WAVE WASHER 2 SNAP RING Fig 319 Install Chain Snubber 1 CHAIN SNUBBER Fig 320 Install Chain Oiler 1 CHAIN SNUBBER 2 CHAIN OILER Fig 321 Install Chain Cover 1 TRANSAXLE CASE 2 CHAIN COVER 21 108 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1278: ...on Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 324 Install One Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 325 Install Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP LH 42LE TRANSAXLE 21 109 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1279: ...fer to Fig 330 Fig 326 Tapered Snap Ring Instructions Fig 327 Snap Ring Installed 1 SCREWDRIVER 2 TAPERED SNAP RING INSTALL AS SHOWN Fig 328 Check Low Reverse Clutch Clearance 1 DIAL INDICATOR 2 DIAL INDICATOR TIP TOOL 6268 3 HOOK TOOL LOW REVERSE REACTION PLATE CHART PART NUMBER THICKNESS 4799846AA 5 88 mm 232 in 4799847AA 6 14 mm 242 in 4799848AA 6 40 mm 252 in 4799849AA 6 66 mm 262 in 4799855AA...

Page 1280: ...n Spring 1 24 CLUTCH RETURN SPRING Fig 332 Proper Orientation of 2 4 Clutch Retainer and Spring 1 NOTE POSITION 2 RETURN SPRING 3 2 4 CLUTCH RETAINER Fig 333 Install 2 4 Clutch Retainer 1 24 CLUTCH RETAINER 2 24 CLUTCH RETURN SPRING LH 42LE TRANSAXLE 21 111 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1281: ...tion The orientation should allow the bearing to seat flat against the rear sun gear Fig 336 A small amount of petrolatum can be used to hold the bearing to the rear sun gear Fig 334 Install 2 4 Clutch Retainer Snap Ring 1 TOOL 5058 2 SCREWDRIVER 3 SNAP RING 4 24 CLUTCH RETAINER Fig 335 Check 2 4 Clutch Clearance 1 DIAL INDICATOR 2 HOOK TOOL 3 DIAL INDICATOR TIP TOOL 6268 Fig 336 Number 7 Bearing ...

Page 1282: ...ips head screw drivers to align pump to case CAUTION Be sure to reinstall O ring on oil pump after selecting the proper No 4 thrust plate Measure the input shaft end play with the tran saxle in the vertical position This will ensure that the measurement will be accurate Fig 338 Install Front Carrier and Rear Annulus Assembly 1 6 NEEDLE BEARING 2 FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PU...

Page 1283: ...mp O Ring 1 OIL PUMP ASSEMBLY 2 O RING Fig 343 Measure Input Shaft End Play using End Play Set 8266 1 TOOL 8266 8 2 TOOL 8266 2 3 TOOL C 3339 NO 4 THRUST PLATE CHART PART NUMBER THICKNESS 4431662 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 0...

Page 1284: ...lips screwdrivers Fig 345 Install Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT Fig 346 Install By Pass Valve 1 BY PASS VALVE Fig 347 Install Oil Pump Gasket 1 BELL HOUSING 2 OIL PUMP GASKET Fig 348 Install Oil Pump 1 PUSH IN ON INPUT SHAFT WHILE REMOVING PUMP LH 42LE TRANSAXLE 21 115 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1285: ...ong Stub Shaft To Bellhousing 1 LONG STUB SHAFT 2 SPECIAL TOOL 6669 3 SLIDE HAMMER C 3752 Fig 351 Install Long Stub Shaft Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 LONG STUB SHAFT Fig 352 Install Low Reverse Accumulator 1 ACCUMULATOR PISTON 2 SEAL RINGS 3 RETURN SPRINGS 4 NOTE NOTCH 21 116 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1286: ...g 1 SNAP RING 2 PLUG Fig 355 Accumulator Locations 1 OVERDRIVE ACCUMULATOR LOCATION 2 UNDERDRIVE ACCUMULATOR LOCATION 3 LOW REVERSE ACCUMULATOR Fig 356 Install Underdrive Accumulator and Springs 1 ACCUMULATOR PISTON UNDERDRIVE 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING LH 42LE TRANSAXLE 21 117 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1287: ...VERDRIVE ACCUMULATOR PISTON 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 358 Install Valve Body To Transaxle 1 VALVE BODY Fig 359 Install Valve Body Bolts 17 1 EXTENSION 2 SOCKET 3 VALVE BODY Fig 360 Install Transaxle Oil Filter 1 TRANSAXLE FILTER 2 FILTER RETAINING CLIPS 21 118 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1288: ... valve body in place Refer to Valve Body Recondition for removal procedure If any bearings in the differential require replace ment all the bearings on the differential carrier and transfer shaft must be replaced The differential adjusters must also be replaced when differential bearings are replaced DISASSEMBLY CAUTION The chain sprockets have a slip fit onto their shafts Apply only a slight amou...

Page 1289: ... Remove Chain Oiler 1 CHAIN SNUBBER 2 CHAIN OILER Fig 366 Remove Chain Snubber 1 CHAIN SNUBBER Fig 367 Remove Output Shaft Sprocket Snap Ring and Wave Washer 1 WAVE WASHER 2 SNAP RING Fig 368 Remove Transfer Shaft Sprocket Snap Ring and Wave Washer 1 TRANSFER SHAFT 2 WAVE WASHER 3 SNAP RING 4 SNAP RING 5 WAVE WASHER 21 120 42LE TRANSAXLE LH DISASSEMBLY AND ASSEMBLY Continued ...

Page 1290: ...UTPUT SPROCKET 2 SPECIAL TOOL 6550 3 TRANSFER SPROCKET Fig 370 Remove Chains and Sprockets as an Assembly 1 CHAINS Fig 371 Remove Long Stub Shaft Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 LONG STUB SHAFT Fig 372 Remove Long Stub Shaft 1 LONG STUB SHAFT 2 SPECIAL TOOL 6669 3 SLIDE HAMMER C 3752 LH 42LE TRANSAXLE 21 121 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1291: ...Inner Differential Adjuster Lock 1 INNER DIFFERENTIAL ADJUSTER LOCK 2 INNER DIFFERENTIAL ADJUSTER Fig 374 Remove Outer Adjuster 1 OIL SEAL 2 OUTER ADJUSTER 3 STUB SHAFT 4 SOCKET 5 ADJUSTER LOCK Fig 375 Loosen Outer Adjuster 1 OUTER ADJUSTER 2 SPECIAL TOOL 6503 Fig 376 Remove Differential Side Cover Carrier and Ring Gear Assembly 1 RING GEAR 2 TRANSAXLE CASE 3 SIDE COVER 21 122 42LE TRANSAXLE LH DI...

Page 1292: ... nut because the removed stake weakens the nut flange CAUTION The transfer shaft cannot be removed from the case at this time Install special tool 6577 to remove rear transfer bearing cup Fig 383 Fig 377 Remove Inner Adjuster By Turning Clockwise 1 SPECIAL TOOL 6502 B 2 INNER DIFFERENTIAL ADJUSTER Fig 378 Remove Differential Vent Baffle 1 VENT BAFFLE RETAINING SCREWS 2 VENT BAFFLE Fig 379 Grinding...

Page 1293: ...e old seals The seals will be pulled out the rear of the case Remove the front transfer shaft bearing cup using special tool 6495 and handle C 4171 Fig 387 Use a press with special tools to remove cup Fig 381 Opening Nut Stakes 1 CHISEL 2 NUT STAKE Fig 382 Press Transfer Shaft Downward to Remove Rear Cone 1 TRANSFER SHAFT 2 ARBOR PRESS Fig 383 Transfer Bearing Cup Removal 1 SPECIAL TOOL 6577 Fig 3...

Page 1294: ...earing cup is seated in the case correctly if there is no clearance between the bot tom of the bearing cup and case If a 0 001 or 0 002 feeler gauge does not fit the bearing cup is completely seated into transaxle case 2 Install centering block special tool 6549 2 into the transaxle case Fig 390 Screw centering block into inner adjuster hole of case until it bottoms The pegs on the special tool ar...

Page 1295: ... 394 7 Hand tighten centering nut until all play in the tool has been removed Fig 389 Install Front Transfer Shaft Cup 1 SPECIAL TOOL 6494 2 BEARING CUP 3 SPECIAL TOOL 6494 Fig 390 Installing Centering Block 1 SPECIAL TOOL 6549 2 2 TOOL INSTALLATION AND REMOVAL PEGS Fig 391 Gauge Disc and Bearing 1 FRONT TRANSFER SHAFT BEARING 2 SPECIAL TOOL 6549 3 Fig 392 Installing Gauge Disc with Front Transfer...

Page 1296: ... dial face so the pointer on the dial indicator lines up with the zero Fig 397 10 Compress the dial indicator slightly and insert dial indicator pin into centering block Fig 398 11 Pivot dial indicator back and forth Fig 399 on centering pin to obtain the shortest distance mea surement This will be the lowest number read Fig 393 Disc Installation 1 SPECIAL TOOL 6494 2 Fig 394 Installing Centering ...

Page 1297: ...er on transfer shaft 2 Adjustment factor mm 0 051mm Shim size needed 0 789 0 051 0 738mm 14 Example 2 in IN Measured pinion shim depth 0 032in Adjustment number on transfer shaft 1 Adjustment factor in 0 001 Shim size needed 0 032 0 001 0 033in 15 Remove dial indicator gauge disc and center ing block from transaxle 16 Install shim selected in Step 12 of this proce dure onto the transfer shaft Fig ...

Page 1298: ... shaft seals in both adjusters using special tool 6558 Fig 403 PINION HEAD SHIM CHART Fig 400 Shim Installation 1 PINION DEPTH SHIM 2 ADJUSTMENT FACTOR 3 TRANSFER SHAFT Fig 401 Bearing Installation 1 ARBOR PRESS 2 SPECIAL TOOL 6052 3 FRONT TRANSFER SHAFT BEARING Fig 402 Outer Adjuster Removal 1 SPECIAL TOOL 6503 2 OUTER DIFFERENTIAL ADJUSTER 3 SIDE COVER LH 42LE TRANSAXLE 21 129 DISASSEMBLY AND AS...

Page 1299: ...ifferential cover Fig 406 Do not apply silicone sealant at this time All bolts should be installed and tightened 27 Install seal protector special tool 6591 as shown in Fig 407 Apply a thin film of gear oil on the protector CAUTION Lube threads and O ring on adjuster before installing Failure to due so will result in thread damage to the adjuster and transaxle case Fig 403 Axle Shaft Seal Installa...

Page 1300: ...l 6548 Record how many foot pounds were required on the outer adjuster to obtain the correct turning torque Fig 410 Record the foot pound reading The reading that you are recording will be used in Step 55 of this procedure 31 Remove the differential cover differential car rier assembly and inner adjuster 32 At this point the amount of torque required on the outer differential adjuster has been det...

Page 1301: ...e transaxle Fig 414 37 Install seal with special tool 6567A Fig 415 Use a press to install seal The installation tool will set the seal depth Do not use a hammer to install seal The seal may be damaged if installed with a hammer 38 Install rear transfer shaft seal The seal must be installed so that the spring side of the seal faces the installation tool Fig 416 Use the same special tool 6567A to i...

Page 1302: ... Fig 418 Fig 412 Transfer Shaft Support Fixture 1 SUPPORT FIXTURE 6595 Fig 413 Seal Protector Installation 1 SEAL PROTECTOR 2 TRANSFER SHAFT Fig 414 Correct Seal Orientation 1 SEAL PROTECTOR 2 FRONT TRANSFER SHAFT SEAL 3 SERRATED SIDE REARWARD Fig 415 Seal Installation 1 ARBOR PRESS 2 SEAL INSTALLER 6567A 3 TRANSAXLE CASE LH 42LE TRANSAXLE 21 133 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1303: ... special tools 6497 holder and 6498 shaft socket to tighten nut CAUTION Failure to set the transfer shaft turning torque correctly may cause transfer shaft bearings or seals to fail Be sure transfer shaft does not have end play If end play exists install a thinner preload shim 45 Check the turning torque of the transfer shaft using a torque wrench Fig 421 The turning torque Fig 416 Correct Seal Or...

Page 1304: ...Fig 422 Be sure that the tool arms line up with slots in the transfer shaft Use a press with the special tool to make the stakes in the nut CAUTION Failure to stake the transfer shaft nut correctly may allow the nut to loosen during tran saxle operation This will cause transaxle failure 47 At this point the transfer shaft new oil seals pinion depth and transfer shaft preload have been set The foll...

Page 1305: ...n the inner adjuster so that it lowers the differential assembly This will decrease backlash Recheck the backlash after each adjustment 53 Apply a 1 8 inch bead of sealant to differential cover flange Then install differential cover with seal ant Fig 427 and tighten cover bolts 54 Install seal protector special tool 6591 on shaft Fig 428 CAUTION Lube threads and O ring on adjuster before installin...

Page 1306: ...e inner adjuster should be turned in small incre ments 58 If there is not enough backlash loosen the outer adjuster with special tool 6503 Then turn the inner adjuster so that it moves towards the ring gear After adjusting the inner adjuster retighten the outer adjuster to the torque recorded in Step 30 The inner adjuster should be turned in small incre ments 59 Once backlash is with in specificat...

Page 1307: ...ide of carrier CAUTION When reassembling use a new roll pin NOTE To remove inner and outer adjuster races use Tool 6062 A To install inner and outer adjuster races use Tool 6522 and Tool C 4171 Fig 430 Dial Indicator Installation 1 DIAL INDICATOR KIT C 3339 2 ACCESS HOLE Fig 431 Remove Ring Gear Bolts 1 RING GEAR BOLTS 2 RING GEAR Fig 432 Tap Off Ring Gear 1 DIFFERENTIAL CARRIER 2 RING GEAR 3 PLAS...

Page 1308: ...DIFFERENTIAL BEARING Fig 436 Slide Out Differential Pinion Shaft and Remove Pinion Gears and Side Gears 1 DIFFERENTIAL CARRIER 2 PINION SHAFT 3 SIDE GEARS Fig 437 Carrier Bearing Removal 1 SPECIAL TOOL C 293 PA 2 WRENCH 3 DIFFERENTIAL CARRIER 4 SPECIAL TOOL JAWS 4 C 293 48 5 SPECIAL TOOL C 4496 LH 42LE TRANSAXLE 21 139 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1309: ... hole with the screwdriver BELOW the chains Fig 441 An assistant may be needed to perform this step 5 Pry the chains up at the center of the chain 6 Butt a scale against the snubber and place a second mark on the scale at the bottom of the chains Fig 442 7 Measure the distance between the two marks placed on the scale Fig 443 If the two marks on the scale are more than one inch apart replace the d...

Page 1310: ...UTION Park sprag must be engaged when adjusting linkage Rock vehicle back and forth to ensure that park sprag is fully engaged 4 Tilt the steering column to the full down posi tion 5 Place shifter in the park position with the key removed 6 Adjust by rotating adjuster into lock position Fig 445 7 Reinstall upper steering column shroud 8 Check shifter for proper operation It should operate smoothly...

Page 1311: ...heck shifter for proper operation It should operate smoothly without binding The vehicle should crank in Park or Neutral only BRAKE TRANSMISSION SHIFT INTERLOCK FLOOR 1 Remove the shifter handle 2 Remove the console bezel 3 Move the gear shifter to PARK and the ignition key to the LOCK position Fig 447 4 If the interlock cable is being replaced remove the pin to allow cable to self adjust Press lo...

Page 1312: ...e original drag torque after break in NOTE All bearing adjustments must be made with no other component interference or gear inter mesh except the transfer gear bearing Oil all bearings before checking turning torque MASTER SHIM CHART Use this chart as a reference guide when selecting the shims needed for the Transfer Shaft Output Shaft Output Sprocket Pinion Fig 448 Interlock Cable at Shifter Ass...

Page 1313: ...MASTER SHIM CHART 21 144 42LE TRANSAXLE LH ADJUSTMENTS Continued ...

Page 1314: ...stall the two sprockets with out the chain The chain sprockets are not reversible Check the height difference using a straight edge special tool 6311 or equivalent and a set of feeler gauges If the output sprocket is lower than transfer sprocket add the amount measured to the shim that was installed Fig 449 If the output sprocket is higher than transfer sprocket subtract the amount measured to the...

Page 1315: ...SCHEMATICS AND DIAGRAMS 42LE TRANSAXLE HYDRAULIC SCHEMATICS 42LE TRANSAXLE HYDRAULIC SCHEMATIC 21 146 42LE TRANSAXLE LH ...

Page 1316: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC LH 42LE TRANSAXLE 21 147 SCHEMATICS AND DIAGRAMS Continued ...

Page 1317: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC 21 148 42LE TRANSAXLE LH SCHEMATICS AND DIAGRAMS Continued ...

Page 1318: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC LH 42LE TRANSAXLE 21 149 SCHEMATICS AND DIAGRAMS Continued ...

Page 1319: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC 21 150 42LE TRANSAXLE LH SCHEMATICS AND DIAGRAMS Continued ...

Page 1320: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC LH 42LE TRANSAXLE 21 151 SCHEMATICS AND DIAGRAMS Continued ...

Page 1321: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC 21 152 42LE TRANSAXLE LH SCHEMATICS AND DIAGRAMS Continued ...

Page 1322: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC LH 42LE TRANSAXLE 21 153 SCHEMATICS AND DIAGRAMS Continued ...

Page 1323: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC 21 154 42LE TRANSAXLE LH SCHEMATICS AND DIAGRAMS Continued ...

Page 1324: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC LH 42LE TRANSAXLE 21 155 SCHEMATICS AND DIAGRAMS Continued ...

Page 1325: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC 21 156 42LE TRANSAXLE LH SCHEMATICS AND DIAGRAMS Continued ...

Page 1326: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC LH 42LE TRANSAXLE 21 157 SCHEMATICS AND DIAGRAMS Continued ...

Page 1327: ...42LE TRANSAXLE HYDRAULIC SCHEMATIC 21 158 42LE TRANSAXLE LH SCHEMATICS AND DIAGRAMS Continued ...

Page 1328: ... 457mm 6 0 018 in Differential Backlash Backlash Setting 14 to 27mm 0 0045 to 0 0105 in Clutch Pack Clearances Low Rev Clutch Select Reaction Plate 0 89 1 04 mm 0 035 0 060 in Two Four Clutch No Selection 0 76 2 64 mm 0 030 0 104 in Reverse Clutch Select Snap Ring 0 89 1 37 mm 0 035 0 054 in Overdrive Clutch No Selection 1 07 3 25 mm 0 042 0 128 in Underdrive Clutch Select Pressure Plate 0 94 1 50...

Page 1329: ... m 105 in lbs Valve Body Screw 5 N m 45 in lbs Wiring Harn Tie Down 6 N m 53 in lbs SPECIAL TOOLS 42LE AUTOMATIC TRANSAXLE Puller Press Extension C 293 3 Adapter Blocks C 293 48 Puller Press C 293 PA Pressure Gauge High C 3293SP Dial Indicator C 3339 Slide Hammer C 3752 Seal Puller C 3981B Universal Handle C 4171 21 160 42LE TRANSAXLE LH SPECIFICATIONS Continued ...

Page 1330: ...tension C 4171 2 Seal Installer C 4193A Installer C 4340 Adapter C 4996 Adapter Set L 4559 Bearing Splitter P 334 Puller Set 5048 Installer 5050A Compressor 5058A LH 42LE TRANSAXLE 21 161 SPECIAL TOOLS Continued ...

Page 1331: ...Compressor 5059 A Installer 5067 Installer 6052 Disk 6057 Tip 6268 Remover Installer 6301 Remover Installer 6302 Remover 6310 Installer 6494 21 162 42LE TRANSAXLE LH SPECIAL TOOLS Continued ...

Page 1332: ...Remover 6495 Wrench 6497 Wrench 6498 Remover 6502B Wrench 6503 Installer 6522 Puller Jaws 6545 Turning Fork 6548 Pinion Gauge Tool Set 6549 Remover 6550 LH 42LE TRANSAXLE 21 163 SPECIAL TOOLS Continued ...

Page 1333: ...aller 6558 Installer 6560 Seal Installer 6567A Remover 6577 Staking Tool 6589 Seal Protector 6591 Seal Protector 6592 Fixture 6595 Remover 6596 Remover 6597 21 164 42LE TRANSAXLE LH SPECIAL TOOLS Continued ...

Page 1334: ...Plate Set 6599 Support Plate 6618A Staking Tool 6639 Remover 6669 Cooler Flusher 6906 End Play Set 8266 Pressure Fixture 8391 LH 42LE TRANSAXLE 21 165 SPECIAL TOOLS Continued ...

Page 1335: ......

Page 1336: ...greater mileage than severe use or care less drivers A few of the driving habits 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 Operating vehicle with over or under inflated tire pressures Radial ply tires are more prone to irregular tread wear It is important to foll...

Page 1337: ... designed for emer gency use only The original tire should be repaired or replaced at the first opportunity then reinstalled Do not exceed speeds of 50 M P H when using the temporary spare tire Refer to Owner s Manual for complete details REPLACEMENT TIRES DESCRIPTION The original equipment tires provide a proper bal ance of many characteristics such as Ride Noise Handling Durability Tread life Tr...

Page 1338: ...on 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 remain constant VEHICLE LEAD DIAGNOSIS AND CORRECTION Use the following chart to ...

Page 1339: ...22 4 TIRES AND WHEELS LH DIAGNOSIS AND TESTING Continued ...

Page 1340: ...ESULTING IN LOSS OF VEHICLE CONTROL TIRE PRESSURE FOR HIGH SPEED OPERATION DESCRIPTION Where speed limits allow the vehicle to be driven at high speeds correct tire inflation pressure is very important For speeds up to and including 120 km h 75 mph tires must be inflated to the pressures shown on the tire placard For continuous speeds in excess of 120 km h 75 mph tires must be inflated to the maxi...

Page 1341: ...d and repaint if neces sary Install wheel on vehicle and progressively tighten the 5 wheel nuts to a torque of 135 N m 100 ft lbs TIRE AND WHEEL MATCH MOUNTING Wheels and tires are match mounted at the factory This means that the high spot of the tire is matched to the low spot on the wheel rim This technique is used to reduce run out in the wheel tire assembly The high spot on the tire is marked ...

Page 1342: ... AND INSPECTION CLEANING TIRES Remove the protective coating on the tires before delivery of a vehicle This coating may cause deteri oration of the tires To remove the protective coating apply warm water and let it soak for a few minutes Afterwards scrub the coating away with a soft bristle brush Steam cleaning may also be used to remove the coat ing NOTE DO NOT use gasoline mineral oil oil based ...

Page 1343: ...lance weights to fit on the rim flange of the wheel and spe cial wheel clamps for the alignment equipment The wheel studs and nuts are designed for specific wheel applications and must be replaced with equiv alent parts Do not use replacement parts of lesser quality or of a substitute design All aluminum and some steel wheels have wheel stud nuts with an enlarged nose This enlarged nose is necessa...

Page 1344: ...ge Lateral run out is the horizontal movement of the tire or wheel Radial run out of more than 1 524 mm 060 inch measured at the center line of the tread may cause the vehicle to shake Lateral run out of more than 2 032 mm 080 inch measured near the shoulder of the tire may cause the vehicle to shake Runout should always be measured off the vehicle and on a suitable balance machine Usually radial ...

Page 1345: ...of the wheel Fig 7 The radial run out of the wheel should be no more than 1 524 mm 0 060 inch Check the lateral run out of the wheel Fig 8 The lateral run out of the wheel should be no more than 0 762 mm 0 030 inch If point of the most wheel radial run out is near original chalk mark remount tire 45 degrees from its original spot Recheck run out Fig 5 Run Out Gauge Fig 6 Chalk Marking On Wheel Tir...

Page 1346: ...hould be used only when a two plane balancer is not available For static imbalance find location of heavy spot causing imbalance Counter balance wheel directly opposite the heavy spot Determine weight required to counterbalance the area of imbalance Place half of this weight on the inner rim flange and the other half on the outer rim flange Fig 10 Fig 11 Off vehicle balancing is necessary Wheel ba...

Page 1347: ...talled wheel nuts and pull straight outward from the wheel This will pop the wheel cover retaining tabs Fig 13 over the two remaining wheel nuts removing the wheel cover from the wheel Fig 11 Dynamic Unbalance Balance 1 CENTER LINE OF SPINDLE 2 ADD BALANCE WEIGHTS HERE 3 CORRECTIVE WEIGHT LOCATION 4 HEAVY SPOT WHEEL SHIMMY AND VIBRATION Fig 12 Wheel Cover Locking Nuts 1 WHEEL 2 BOLT ON WHEEL COVER...

Page 1348: ...unting nuts from the studs 3 Remove the tire and wheel from the hub INSTALLATION NOTE Never use oil or grease on studs or wheel mounting nuts 1 To install the wheel first position it properly on the hub mounting surface using the hub pilot as a guide Loosely install all 5 wheel mounting nuts All wheel nuts should then be tightened just snug Next progressively tighten them in the proper sequence Fi...

Page 1349: ...INSTALLATION NOTE The wheel nuts must be installed on the studs shown in Fig 19 to allow the installation of the wheel cover NOTE Never use oil or grease on studs or wheel mounting nuts 1 To install the wheel first position it properly on the hub mounting surface using the hub pilot as a guide Then install and lightly tighten the 2 wheel nuts on the studs as shown in Fig 19 holding the wheel to th...

Page 1350: ...are must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels Any of the DO NOT USE items listed below WILL damage chrome plated and painted aluminum wheels DO NOT USE any abrasive metal cleaner any abrasive cleaning pad or brush any cleaner that contains an acid this will immediately react with and discolor the chromium surface chrome polish...

Page 1351: ......

Page 1352: ... the fastener or the com ponent it is holding If it is not possible to remove a fastener without damaging a component or body cut or break the fastener and use a new one when installing the component Never pry or pound on a plastic or pressed board trim component Using a suitable fork type prying device pry the fastener from the retaining hole behind the component being removed When installing ver...

Page 1353: ...ane bonded glass is difficult to salvage during removal The urethane bonding is difficult to cut or clean from any surface Before removing the glass check the availability of replacement components SEATS DESCRIPTION Seat modules are made up of a seat frame seat cushion seat back cushion a covering material and the electrical components used for power operation if equipped Some seat systems also co...

Page 1354: ...sition the sunroof will stop in that position The other switch OPEN VENT is a rocker type for open ing and venting the sunroof Pressing and releasing the OPEN button once the sunroof will express open and the wind deflector will raise If the button is pressed a second time the sunroof will stop in that position To open the sunroof from the vent position push and hold the open button The sunroof wi...

Page 1355: ... finesse sanding hand buffing and polish ing If the finish has been finesse sanded in the past it cannot be repeated Finesse sanding operation should be performed by a trained automotive paint technician CAUTION Do not remove clear coat finish if equipped Base coat paint must retain clear coat for durability PAINTED SURFACE TOUCH UP When a painted metal surface has been scratched or chipped it sho...

Page 1356: ...5 59308 CHA00 XRV 34983 PXD3B Deep Slate Pearl Coat VAW 5292 B9774 54118 CHA97 VAW 73719 HMR3B Inferno Red Tinted Pearl Coat WEL 5469 5470 B9843 56090 CHA99 WEL 34461 KDR5B Light Cypress Green Pearl Coat WG2 5471 B9843 56090 CHA99 WG2 65521 KDH3B Shale Green Metallic Clear Coat XGR 5577 F9239 57765 CHA00 XGR 66088 PVJ8B Steel Blue Pearl Coat XBQ 5576 F9239 57772 CHA00 XBQ 59675 NGA5B Stone White C...

Page 1357: ...9 843 56090 CHA99 WEL 34461 KDR5B Light Cypress Green Pearl Coat WG2 5471 B9843 56090 CHA99 WG2 65521 KDH3B Shale Green Metallic Clear Coat XGR 5577 F9239 57765 CHA00 XGR 66088 PVJ8B Steel Blue Pearl Coat XBQ 5579 F9243 57761 CHA00 XBQ 59675 NGA5B Stone White Clear Coat SW1 83542 B9622 51539 CHA96 SW1 15069 8KY3B INTERIOR COLORS INTERIOR COLOR DAIMLER CHRYSLER CODE PPG DuPONT S W M S AKZO NOBEL SI...

Page 1358: ...ITH GLASS CAUTION Protect all painted and trimmed surfaces from coming in contact with urethane or primers Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield OPERATION The windshield is attached to the window frame with urethane adhesive The urethane adhesive is applied cold and seals the surface area between the window opening and the glass The ...

Page 1359: ...ed par allel 75 cm 2 5 ft apart Fig 4 WARNING DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER POOR ADHESION CAN RESULT 6 Clean inside of windshield with ammonia based glass cleaner and lint free cloth 7 Apply molding to top edge of windshield 8 Apply Glass Prep adhesion promoter 25 mm 1 in wide around perimeter of windshield and wipe with clean dry ...

Page 1360: ...FACTURER S DIRECTIONS FOR CURING TIME SPECIFICATIONS AND DO NOT USE ADHESIVE AFTER ITS EXPIRA TION DATE CAUTION Open the left front door glass before installing the rear window to avoid pressurizing the passenger compartment if a door is slammed before the urethane bonding is fully cured Water leaks can result Fig 3 Center Windshield and Mark at Support Spacers 1 A PILLAR 2 WINDSHIELD 3 MARKS 4 FO...

Page 1361: ...o the glass Allow at least three minutes drying time 4 Using a razor knife remove as much original urethane as possible Do not damage paint on rear window fence 5 Apply pinch weld primer 15 mm 75 in wide around the rear window fence Allow at least three minutes drying time 6 Apply a 10 mm 0 4 in bead of urethane to the encapsulation Fig 7 7 With the aid of a helper position the rear win dow over t...

Page 1362: ...t of the seat track to floor kick up 5 Disconnect front seat wire harness connector from body harness connector if equipped 6 Remove front seat from vehicle INSTALLATION NOTE Ensure that the seat tracks are rearward 1 Place front seat in position in vehicle 2 Connect front seat wire harness connector to body harness connector 3 Install bolts to attach front of seat track to the floor kick up Tight...

Page 1363: ... frame 2 Connect seat cushion heater element connector if equipped 3 Install track and recliner assembly 4 Install seat back Tighten pivot bolts and recliner bolts to 8 N m 71 in lbs torque 5 Connect switch wire connectors to the cushion side shield if equipped 6 Install cushion side shields 7 Install seat in vehicle FRONT SEAT CUSHION COVER HEATED SEAT COVER REMOVAL 1 Remove seat from vehicle 2 R...

Page 1364: ...ll front seat cushion side shields 9 Install seat in vehicle FRONT SEAT ARM REST 50 50 SPLIT REMOVAL 1 Move the driver seat full forward and the pas senger seat full rearward 2 Open arm rest lid Fig 9 3 Remove access retaining nut cover 4 Remove arm rest retaining nut 5 Slide arm rest off of bracket Fig 10 INSTALLATION 1 Slide arm rest on bracket 2 Install arm rest nut Tighten nut to 25 N m 18 ft ...

Page 1365: ...ue 5 Install seat cushion side shields 6 Install seat in vehicle FRONT SEAT BACK COVER REMOVAL 1 Remove seat from vehicle 2 Remove head restraint 3 Remove front seat back 4 Remove lumbar support handle if equipped 5 Disengage the J strap retainer Fig 12 6 Roll cover upward to hog rings Cut hog rings to free cover Fig 13 Fig 9 Arm Rest Access Hole 1 REMOVE ACCESS HOLE 2 NUT 3 ARM REST 4 COVER Fig 1...

Page 1366: ...ON 1 Place head restraint in position 2 Push head restraint down into the lock posi tion 3 Raise head restraint to ensure it locks at the last stop FRONT SEAT LUMBAR SUPPORT The front seat lumbar support is not service sepa rately The front seat back frame will need to be replaced FRONT SEAT TRACK AND RECLINER REMOVAL 1 Remove front seat from vehicle 2 Remove seat cushion side shield and disconnec...

Page 1367: ... cushion 2 Remove nuts attaching rear seat back and belts to floor Fig 18 3 Pull bottom of seat back out to slide rear seat back mounts off studs Push rear seat back upward to disengage hooks at top of seat back 4 Remove rear seat from vehicle INSTALLATION 1 Place rear seat in position in vehicle 2 Engage hooks at top of seat back 3 Install nuts attaching rear seat back and belts to floor Tighten ...

Page 1368: ... 3 Install retaining C clip 4 Reposition the seats REAR SEAT ARM REST WITH SKI PASS REMOVAL 1 Remove rear seat cushion 2 Remove nuts attaching rear seat back and belts to the floor 3 Push rear seat back with arm rest and ski pass upward to disengage hooks at top of seat back Fig 20 4 Remove silencer panel fasteners on the back of seat back Fig 21 5 Remove silencer panel 6 Remove fasteners attachin...

Page 1369: ...ve seat back collar assembly 5 Remove bolt attaching 40 seat section 6 Remove the 40 seat section 7 Remove bolt attaching 60 seat section Fig 27 8 Slide seat back 60 seat section off pivot bracket and remove from the collar assembly INSTALLATION 1 Install the 60 seat section on pivot bracket 2 Install bolt attaching 60 seat section Tighten bolt to 16 N m 12 ft lbs torque 3 Install the 40 seat sect...

Page 1370: ...rear seat back collar assembly 6 Remove the 60 seat section from the rear seat back collar assembly Fig 28 INSTALLATION 1 Install the 60 seat section from the rear seat back collar assembly 2 Install the 40 seat section from the rear seat back collar assembly 3 Place the rear seat back collar assembly in position in vehicle 4 Install nuts attaching rear seat back collar assembly Tighten nuts to 40...

Page 1371: ...NSTALLATION 1 Position seat cushion cover on cushion 2 Install hog rings to seat cover 3 Engage the J strap retainers 4 Steam wrinkles from seat cushion if necessary 5 Install seat cushion Fig 28 Rear Seat Back Collar 1 PIVOT BRACKET Fig 29 Rear Seat Cushion Cover J Straps 1 J STRAPS Fig 30 Rear Seat Cushion Cover Hog Rings 1 HOG RINGS 23 20 BODY LH REMOVAL AND INSTALLATION Continued ...

Page 1372: ...fuse ignition feed located in cavity 14 of the Junction Block Inspect all wiring connector pins for proper engagement and continuity Check for battery voltage at battery and ignition pins of the power sun roof express module wiring connector Refer to Group 8W Wiring Diagrams for circuit information The controller will not operate at less than 10 volts Check the ground at the sunroof express module...

Page 1373: ... vents and opens but does not close Binding cable Faulty circuit Faulty control switch Faulty sunroof express module Faulty drive motor Sunroof vents but does not open Binding linkage Faulty circuit Faulty switch Faulty sunroof controller Faulty drive motor Sunroof does not vent Binding cable Faulty circuit Faulty control switch Faulty sunroof express module Sunroof water leak Drain tubes clogged ...

Page 1374: ...Fig 1 Sunroof Assembly LH BODY 23 23 DIAGNOSIS AND TESTING Continued ...

Page 1375: ... 3 Tighten screws 4 Verify sunroof operation and alignment Check fit and adjust as necessary refer to Sunroof Glass Panel Adjustment for proper procedures SUNROOF DRIVE MOTOR REMOVAL NOTE The sunroof system is timed from the fac tory so that the motor shuts off automatically when the sunroof window reaches a certain position Extreme care must be taken when removing the motor timing may be thrown o...

Page 1376: ...unroof With the sunroof open 2 Push ends of the deflector towards the front of the vehicle to engage ends 3 Lower wind deflector to normal position 4 Push one corner to the opposite side of the vehicle until tab clears vehicle body and lower deflec tor for that corner 5 Push the side that was just installed com pletely down 6 Push the opposite corner cross vehicle until tab clears the body Then lo...

Page 1377: ...anel 11 Connect battery negative cable 12 Move both front seats into proper position 13 Test sunroof operation adjust as necessary 14 Finish installing the headliner Ensure that door weatherstrips are in position 15 Install right and left C post trim panels par tially 16 Install rear right and left grab handle lamps and let hang from headliner 17 Install right and left upper B post trim pan els 18...

Page 1378: ...necessary 4 Remove side kick cowl panel 5 Disconnect drain hose clips from body holes Fig 7 and or Fig 8 6 Drain any liquid from hose connection if nec essary 7 Hoses between trim and metal Remove old and replace with new 8 Work the hose back and forth to loosen 9 Pull the old hose down and through instrument panel dragging new hose with it until end of new hose is near grommet on side cowl 10 Rem...

Page 1379: ...of nipple 2 Connect top flair end of the drain hose to the sunroof housing drain nipple with the ratchet clamp 3 Connect the lower end of the drain tube to the rubber grommet near the rear window of the vehicle 4 Connect the drain hose to the sunroof housing and test drainage 5 Install shelf panel ensure not to pinch the rub ber grommets 6 Install headliner 7 Connect the control switch wire connec...

Page 1380: ... proper fit If not OK repeat glass panel adjustment SUNROOF GLASS PANEL TIMING Sunroof Drive Cable Timing NOTE A gage comes with the new motor 1 If the glass panel was not in the fully closed position when the sunroof drive motor was removed the sunroof glass panel needs to be timed before the new motor is installed 2 Remove sunroof glass panel 3 Set gage into the track near the rear of the openin...

Page 1381: ...51 REAR DOOR LATCH 52 REAR DOOR LATCH STRIKER 53 REAR DOOR GLASS RUN WEATHERSTRIP 54 REAR DOOR GLASS REGULATOR 54 REAR DOOR GLASS 55 REAR DOOR SAIL PANEL 55 REAR DOOR CHECK STRAP 55 REAR DOOR 56 REAR DOOR HINGE 56 REAR DOOR MOUNTED WEATHERSTRIP 57 REAR DOOR BODY MOUNTED WEATHERSTRIP 57 BODY SIDE MOLDING AND APPLIQUE 58 WHEELHOUSE SPLASH SHIELD REAR 58 DECKLID COVER 58 DECKLID LATCH 59 DECKLID LOCK...

Page 1382: ...comparable to actual conditions If a leak occurs when the vehicle is parked on an incline hoist the end or side of the vehicle to simu late this condition This method can be used when the leak occurs when the vehicle accelerates stops or turns If the leak occurs on acceleration hoist the front of the vehicle If the leak occurs when braking hoist the back of the vehicle If the leak occurs on left t...

Page 1383: ...ation of the wind noise 2 Apply 50 mm 2 in masking tape in 150 mm 6 in lengths along weatherstrips weld seams or moldings After each length is applied drive the vehi cle If noise goes away after a piece of tape is applied remove tape locate and repair defect POSSIBLE CAUSE OF WIND NOISE Moldings standing away from body surface can catch wind and whistle Gaps in sealed areas behind overhanging body...

Page 1384: ...ond line Once the pieces have been brought together do not move them until the adhesive is cured The assembly can be held together with clamps rivets etc A faster cure can be obtained by heating with a heat lamp or heat gun After the parts have been bonded and have had time to cure rough sand the seam and apply the final adhesive filler to the area being repaired Smooth the filler with a spatula w...

Page 1385: ...heet Molded Compound SMC and Resin Trans fer Molded RTM because they are composites react differently to impact that sheet metal does Compos ite materials can mask the severity of an accident Adhesive bond lines interior structure of the doors and steel structure need to be inspected carefully to get a true damage assessment Close inspection may require partial removal of interior trim or inner pa...

Page 1386: ...dhesive backed nylon mesh dry wall tape larger than the patch required Fig 9 2 Tape waxed paper or plastic sheet with mesh to a surface that has a compatible contour to the repair area 3 Apply a liberal coat of epoxy adhesive over the reinforcement mesh Fig 9 If necessary apply a sec ond or third coat of epoxy and mesh after firs coat has cured The thickness of the patch should be the same as the ...

Page 1387: ...l surface 15 Allow epoxy to cure and remove all screws 16 Using a 125 mm 5 in 24 grit disc grinder grind a 50 mm 2 in to 75 mm 3 in wide and 2 mm 0 080 in deep path across the gaps around the patch Fig 14 With compressed air blow dust from around patch 17 Apply adhesive backed nylon mesh dry wall tape over gaps around patch Fig 15 18 Mix enough epoxy to cover the entire patch area 19 Apply epoxy o...

Page 1388: ... panel 8 Disconnect hood latch cable from hood latch 9 Remove upper radiator closure panel from vehi cle 10 For replacement of upper radiator closure panel remove hood latch and any other hardware INSTALLATION 1 Place in position the upper radiator closure panel 2 Connect hood latch cable to hood latch 3 Install bolts attaching upper radiator closure panel Check bolt alignment marks Fig 13 Install...

Page 1389: ...on on crossmember 3 Install nuts to attach hood latch to crossmem ber Tighten nuts to 22 6 to 33 9 N m 200 to 300 in lbs torque 4 Verify hood latch operation before closing hood HOOD RELEASE CABLE REMOVAL 1 Release hood latch by using the inside release if still functioning If not reach up through the bot tom of the fascia opening and release the latch pawl lever Fig 17 Upper Radiator Closure Pane...

Page 1390: ...to the cowl side Tighten screws to 2 3 to 3 4 N m 20 to 30 in lbs torque 5 Install cable clips 6 Place carpet into position 7 Install left wheel splash shield 8 Install left cowl side trim panel 9 Connect hood release cable ferrule and cable end to hood latch 10 Verify hood latch operation before closing hood HOOD GAS PROPS REMOVAL 1 Open hood 2 Support hood with a suitable prop device 3 Remove ga...

Page 1391: ...L 1 Support hood on the side that requires hinge replacement 2 Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to pro vide reference marks for installation 3 Remove bolts attaching hood to hinge 4 Remove bolts attaching hood hinge to vertical wall of load beam and remove hinge from vehicle Fig 25 To gain access to the lower left hood hinge the wiper motor...

Page 1392: ...ing foam 4 Remove ten attaching grille clips 5 Remove grille INSTALLATION 1 Place grille into position on vehicle 2 Install ten attaching grille clips 3 Install two screws attaching foam 4 Install fascia 5 Close hood and check alignment of the grille GRILLE UPPER 300M REMOVAL 1 Open hood 2 Remove fascia 3 Drill out rivets attaching cross bracket to grille 4 Remove upper grille six attaching clips ...

Page 1393: ...o loosen the adhesive bond 3 With your fingernail lift up and peel away badgeing tape from panel using a heat gun as you go 4 Clean off all traces of adhesive from the pan el s with a general purpose adhesive remover INSTALLATION 1 Clean panel surface with isopropy alcohol 2 Remove paper carrier and align badgeing tape to reference points or adjacent panel 3 Install and press securely using a plas...

Page 1394: ...ill clad ding 9 Install splash shield plastic rivets to fascia 10 Install headlamp assembly 11 Check fender for flush and gap FRONT STRUT TOWER TO TOWER BRACE REMOVAL 1 Open hood 2 Remove the cowl screen 3 Mark bolt locations on front strut tower to tower brace 4 Remove attaching bolts from the brace Fig 29 5 Remove front strut tower to tower brace from vehicle 6 For replacement remove weatherstri...

Page 1395: ...Disconnect the power door lock switch wire connector 14 Disconnect the power window switch wire con nector 15 Disconnect the radio speaker wire connector 16 Disconnect wiring harness clips from trim panel 17 Disconnect the courtesy lamp 18 Remove trim panel from vehicle INSTALLATION 1 Place door trim panel in position 2 Install wire harness clips into door trim panel 3 Connect the courtesy lamp 4 ...

Page 1396: ...areas with adhesive to attach dam to inner door Ensure that the dam is sealed 4 Install trim panel FRONT DOOR LATCH REMOVAL 1 Close door glass 2 Remove door trim panel 3 Remove water shield as necessary 4 Remove rear glass channel 5 Disconnect lock button link from door latch 6 Disconnect lock cylinder link from door latch 7 Disconnect outside door handle link from door latch 8 Remove screws holdi...

Page 1397: ...h lock cylinder into socket on door handle 2 Insert link into clip on lock cylinder 3 Engage clip to fasten lock link to lock cylinder 4 Verify lock operation 5 Install water shield 6 Install door trim panel LOCK CYLINDERS Ignition door deck lid and rear hatch lock cylin ders are all codable to the key Lock barrels tum blers and tumbler springs are available to allow the technician to change repla...

Page 1398: ...e door run weatherstrip in position on win dow frame channel 3 Push door run weatherstrip into window frame channel 4 Push weatherstrip into lower front channel above door latch 5 Install door glass 6 Tighten side view mirror 7 Install pull cup support bracket water shield door trim panel and flag trim Fig 37 Door Glass Run Weatherstrip 1 FRONT DOOR MOLDING 2 GLASS RUN WEATHERSTRIP 3 REAR GLASS RU...

Page 1399: ...and out of the opening at top of door INSTALLATION 1 Lower glass into opening at top of door 2 Place glass in position against roller channel 3 Insert lift plate nuts into key hole slots in roller channel and slide channel forward to locked position 4 Tighten nuts to attach regulator roller channel to glass and lift plates 5 Install pull cup support bracket water shield door trim panel and flag co...

Page 1400: ... 1 Open front door 2 Mark location of hinge on door end frame 3 Disengage clips holding wire harness connector and boot to hinge pillar 4 Remove connector from hinge pillar 5 Disengage clip holding wire connector together on hinge pillar side of the connector 6 Remove door wire harness from instrument panel harness 7 Disengage door check stop from pin on upper door hinge 8 Support door on suitable...

Page 1401: ...nge bolt to 28 N m 250 in lbs torque 3 Install bolt and nut attaching hinge to front door Tighten the hinge bolt and nut to 28 N m 250 in lbs torque If the double ended stub is removed or replaced tighten the stud to 14 N m 120 in lbs torque 4 Verify door alignment and operation adjust as necessary DOOR HINGE DOUBLE ENDED STUD REMOVAL 1 Remove door hinge 2 To remove double ended stud double nut st...

Page 1402: ...ing FRONT DOOR MOUNTED WEATHERSTRIP REMOVAL 1 Open front door 2 Using a fork type prying tool disengage push in fasteners attaching weatherstrip to lower door Fig 46 3 Remove weatherstrip from door INSTALLATION 1 Place door mounted weatherstrip in position 2 Engage push in fasteners to attach weather strip to lower door 3 Verify door alignment and seal REAR DOOR TRIM PANEL REMOVAL CAUTION Do not p...

Page 1403: ...sealed 8 Place trim panel into channel retainer at top door 9 Insert trim panel into channel retainer at top door 10 Insert the forward four way alignment guide into position Insert the rearward two way alignment guide into position 11 Install new retaining clips to attach door trim panel to door panel 12 Engage retaining clips attach door trim panel to door panel 13 Install three screws to the bo...

Page 1404: ...illar to assist installation alignment 3 Remove bolts holding striker to C pillar Fig 50 4 Remove door latch striker from vehicle INSTALLATION 1 Place door latch striker in position on vehicle 2 Install bolts to hold striker to C pillar 3 Align striker to marked location on C pillar and tighten bolts 4 Verify alignment and operation of door adjust as necessary Fig 49 Rear Door Latch 1 TO LOCK BUTT...

Page 1405: ...REGULATOR REMOVAL 1 Remove flag cover door trim panel water shield as necessary and pull cup support bracket 2 Slide glass from regulator roller channel Fig 52 3 Disconnect power window motor wire connec tor 4 Loosen screw attaching regulator scissor chan nel to door panel 5 Remove screw and bolt heads from keyhole slots in door panel 6 Loosen bolt attaching regulator support brace to door panel 7...

Page 1406: ...nd out of the opening at top of door INSTALLATION 1 Lower glass into opening at top of door 2 Place glass in position against roller channel 3 Insert lift plate nuts into key hole slots in roller channel and slide channel forward to locked position 4 Tighten nuts to attach regulator roller channel to glass and lift plate 5 Install upper trim retainer channel 6 Install water shield 7 install door t...

Page 1407: ...If the double ended stud is loosen or replaced tighten the stud to 14 N m 120 in lbs torque 4 Install bolt and nut attaching lower hinge to door end frame 5 Verify door alignment and operation 6 Connect door wire harness to instrument panel wire harness 7 Attach check strap 8 Align door to achieve equal spacing to sur rounding body panels Panels should be flush across all gaps If door needs to be ...

Page 1408: ...DOOR BODY MOUNTED WEATHERSTRIP REMOVAL 1 Open rear door 2 Remove door opening sill plate 3 Pull body mounted weatherstrip from fence around door opening Fig 58 INSTALLATION 1 Position color dot on weatherstrip at the B pil lar upper corner 2 Engage weatherstrip on the fence at upper B pillar and work down the B pillar Fig 56 Rear Door Hinge 1 B PILLAR 2 DOOR WIRE HARNESS CONNECTOR 3 UPPER HINGE 4 ...

Page 1409: ...ver from tape on back of molding Apply molding to body below the masking tape guide 5 Remove masking tape guide and heat body and molding see step one Firmly press molding to body surface to assure adhesion WHEELHOUSE SPLASH SHIELD REAR REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove rear wheel 3 Remove fasteners attaching splash shield 4 The shock tower area will have to be cut out ...

Page 1410: ...ealing 7 Install fasteners to attach decklid lining to rear of decklid 8 Verify decklid latch operation DECKLID LOCK CYLINDER REMOVAL 1 Open decklid 2 Remove fasteners attaching decklid lining to rear of decklid 3 Remove bolts attaching decklid latch to decklid Fig 61 Fig 62 or Fig 63 4 Remove decklid latch from decklid 5 Disconnect power lock connector from latch solenoid 6 Disconnect decklid aja...

Page 1411: ...pen decklid 2 Support decklid with a suitable prop device 3 Remove gas prop lock caps on each end Fig 65 4 Remove gas prop from vehicle INSTALLATION 1 Place gas prop in position on vehicle 2 Install the lock caps on the gas prop 3 Verify decklid operation DECKLID REMOVAL 1 Release decklid latch and open decklid 2 Mark hinge locations on inside of decklid to aid installation 3 Disconnect the wire h...

Page 1412: ...1 Open decklid 2 Pull decklid weatherstrip from decklid opening fence Fig 68 3 Remove weatherstrip from vehicle INSTALLATION 1 Place weatherstrip in position on vehicle 2 Push decklid weatherstrip onto decklid opening fence with molded joint at striker location 3 Verify decklid operation and sealing DRIP RAIL WEATHERSTRIP REMOVAL 1 Open front and rear doors 2 Remove fasteners attaching drip rail w...

Page 1413: ... cap 2 Disengage clips attaching trim to A pillar by pulling on trim Fig 71 3 Slide A pillar trim rearward to disengaging from instrument panel top cover 4 Remove A pillar trim from vehicle INSTALLATION 1 Slide A pillar trim forward ensuring that the trim engages with the instrument panel top cover 2 Engage clips to attach trim to A pillar 3 Install instrument panel end cap CROSS CAR BEAM REMOVAL ...

Page 1414: ...om above seat belt slot on B pillar trim 5 Disengage clips attaching lower trim to B pil lar 6 Slide seat belt through the B pillar trim 7 Remove B pillar trim from vehicle INSTALLATION 1 Slide seat belt through the B pillar trim 2 Place B pillar trim in position on vehicle 3 Engage clips to hold lower trim to B pillar 4 Install access door above seat belt slot on B pil lar trim 5 Install bolt to ...

Page 1415: ...sengage clips holding upper quarter trim to inner quarter panel Fig 74 NOTE Start at top forward area of trim and pull inboard 2 Remove seat cushion 3 Remove lower seat belt anchor nut 4 Slide seat belt through trim panel 5 Remove upper quarter trim from vehicle INSTALLATION 1 Slide belt through trim panel 2 Place upper quarter trim in position on vehicle 3 Engage clips to attach upper quarter tri...

Page 1416: ...EMOVAL 1 Move or remove front seat as necessary to gain access to seat belt buckle anchor bolt 2 Remove bolt attaching buckle and reinforce ment to front seat track Fig 76 3 Remove seat belt buckle from vehicle INSTALLATION 1 Place seat belt buckle in position on vehicle 2 Install bolt attaching buckle and reinforcement to front seat track or floor Tighten bolt to 60 N m 44 ft lbs torque 3 Install...

Page 1417: ... on floor 2 Install rear seat belt anchor nut Tighten to 60 N m 44 ft lbs 3 Install rear seat cushion FLOOR CONSOLE ARMREST LID REMOVAL 1 Open armrest lid 2 Remove lid attaching screws 3 Remove lid from console INSTALLATION 1 Place lid in position 2 Install screws to attach lid to console 3 Check operation of lid FLOOR CONSOLE ARMREST LATCH REMOVAL 1 Open armrest lid 2 Remove latch attaching screw...

Page 1418: ...om of console storage bin to rear mounting bracket Fig 82 7 Remove floor console from vehicle INSTALLATION 1 Place center console in position on vehicle 2 Install fasteners to attach forward bracket to instrument panel 3 Install fasteners to attach bottom of console storage bin to rear mounting bracket 4 Install side panels 5 Install center console shift bezel 6 Install shift knob Fig 80 Front Flo...

Page 1419: ...OUTLET CIGAR LIGHTER CONNECTORS 4 TRANSMISSION RANGE INDICATOR ILLUMINATION CONNECTORS 5 ASH RECEIVER LAMP 6 REAR END CAP 7 FLOOR CONSOLE 8 FRONT FLOOR CONSOLE PANEL Fig 82 Floor Console 1 CONSOLE BRACKET 2 FASTENERS 3 FLOOR CONSOLE 4 FLOOR CONSOLE DUCT 5 SHIFTER ASSEMBLY 23 68 BODY LH REMOVAL AND INSTALLATION Continued ...

Page 1420: ...lips attaching bezel to floor console 5 Push gear shift knob onto gear shift 6 Tighten set screw attaching gear shift knob to gear shift FLOOR CONSOLE CUP HOLDER ASSEMBLY REMOVAL 1 Remove shift knob 2 Remove floor console shift bezel Fig 83 or Fig 84 3 Raise console armrest lid 4 Remove screws at top and bottom of cup holder assembly Fig 85 5 Lift up and forward to remove assembly INSTALLATION 1 P...

Page 1421: ...ig 84 3 To remove right side panel open glove box and remove side panel attaching screws 4 To remove left side panel remove steering col umn cover and remove side panel attaching screws 5 Disengage clips from center console 6 Remove floor console side panel INSTALLATION 1 Place front floor console side panel in position on vehicle Fig 84 Floor Console Bezel Intrepid Shown LHS 300M Similar 1 INSTRU...

Page 1422: ...tall front seats 11 Install floor mats SUN VISOR All vehicles with driver and passenger side air bags must have a colored coded five Bullet point air bag warning label applied to the sun visor verify label availability and ensure the label is installed REMOVAL 1 Remove screw attaching inboard visor retainer to over head Fig 87 2 Remove screws holding outboard visor pivot base to roof 3 Disconnect ...

Page 1423: ...ull on the headliner until the four glue bonds break free from the structural mem brane 21 x 25 cardboard The membrane is to stay as a permanently bonded member to the roof panel DO NOT apply any glue to the headliner on instal lation it is not necessary REMOVAL 1 Remove front passenger seat for ease of removal of headliner 2 Remove right and left A pillar trim panels 3 Remove right and left sun v...

Page 1424: ...l seat and return seats to up the right position 11 Engage the hook and loop patch fasteners around the sun roof opening ROOF STRUCTURAL MEMBRANE REMOVAL 1 Remove headliner 2 Remove roof support membrane using a Mold ing Removal Tool 3 M p n 08978 3 Carefully pull down corner of roof structural membrane enough to insert molding removal tool between roof panel and adhesive Activate air chisel while...

Page 1425: ...e connector if equipped 6 Remove rear shelf trim panel from vehicle INSTALLATION 1 Place rear shelf trim panel in position in vehi cle 2 Connect CHMSL wire connector 3 Push parcel shelf trim rearward toward rear glass and engage clips 4 Insert push in fasteners into position 5 Install quarter trim lower and upper panels 6 Install seat back and cushion CHILD TETHER ASSEMBLY CUP REMOVAL 1 Remove rea...

Page 1426: ... housing 3 Remove spare tire board jack and tire 4 Remove fasteners at back panel and sides 5 Remove carpet INSTALLATION 1 Fold carpet and load into position in the trunk 2 Install fasteners at back and sides panel 3 Install spare tire board jack and tire 4 Install fasteners at forward edge along wheel housing 5 Install rear seat back and cushion AIR EXHAUSTER VENT REMOVAL 1 Open decklid 2 Move tr...

Page 1427: ...door trim panel 2 Remove water shield as necessary 3 Loosen fastener attaching scissor channel to door panel at rear of access hole Fig 97 4 Position glass in run weatherstrips to achieve smooth operation and proper fit 5 Push glass aft and apply slight downward pres sure on scissor channel and tighten screw 6 Tighten all fasteners 7 Install water shield 8 Install door trim panel SPECIAL TOOLS BOD...

Page 1428: ...g a component any excess oil or grease should be removed LUBRICANT APPLICATION DOOR LOCK CYLINDERS 1 Apply a small amount of lubricant directly into the lock cylinder 2 Apply a small amount of lubricant to the key 3 Insert key into lock cylinder and cycle the mechanism from the locked to the unlocked position NOTE Do not add more lubricant 4 Cycle the lock cylinder mechanism several times to allow...

Page 1429: ...WELD LOCATIONS ENGINE COMPARTMENT 23 78 BODY LH SPECIFICATIONS Continued ...

Page 1430: ...ENGINE COMPARTMENT LH BODY 23 79 SPECIFICATIONS Continued ...

Page 1431: ...ENGINE COMPARTMENT 23 80 BODY LH SPECIFICATIONS Continued ...

Page 1432: ...ENGINE COMPARTMENT LH BODY 23 81 SPECIFICATIONS Continued ...

Page 1433: ...ENGINE COMPARTMENT 23 82 BODY LH SPECIFICATIONS Continued ...

Page 1434: ...ENGINE COMPARTMENT LH BODY 23 83 SPECIFICATIONS Continued ...

Page 1435: ...ENGINE COMPARTMENT 23 84 BODY LH SPECIFICATIONS Continued ...

Page 1436: ...ENGINE COMPARTMENT LH BODY 23 85 SPECIFICATIONS Continued ...

Page 1437: ...ENGINE COMPARTMENT 23 86 BODY LH SPECIFICATIONS Continued ...

Page 1438: ...ENGINE COMPARTMENT LH BODY 23 87 SPECIFICATIONS Continued ...

Page 1439: ...ENGINE COMPARTMENT 23 88 BODY LH SPECIFICATIONS Continued ...

Page 1440: ...DASH AND COWL LH BODY 23 89 SPECIFICATIONS Continued ...

Page 1441: ...DASH AND COWL 23 90 BODY LH SPECIFICATIONS Continued ...

Page 1442: ...DASH AND COWL LH BODY 23 91 SPECIFICATIONS Continued ...

Page 1443: ...DASH AND COWL 23 92 BODY LH SPECIFICATIONS Continued ...

Page 1444: ...DASH AND COWL LH BODY 23 93 SPECIFICATIONS Continued ...

Page 1445: ...DASH AND COWL 23 94 BODY LH SPECIFICATIONS Continued ...

Page 1446: ...ROOF PANEL AND ROOF BOWS LH BODY 23 95 SPECIFICATIONS Continued ...

Page 1447: ...ROOF PANEL AND ROOF BOWS 23 96 BODY LH SPECIFICATIONS Continued ...

Page 1448: ...ROOF PANEL AND ROOF BOWS LH BODY 23 97 SPECIFICATIONS Continued ...

Page 1449: ...ROOF PANEL AND ROOF BOWS BODY SIDE APERTURE 23 98 BODY LH SPECIFICATIONS Continued ...

Page 1450: ...BODY SIDE APERTURE LH BODY 23 99 SPECIFICATIONS Continued ...

Page 1451: ...BODY SIDE APERTURE 23 100 BODY LH SPECIFICATIONS Continued ...

Page 1452: ...BODY SIDE APERTURE LH BODY 23 101 SPECIFICATIONS Continued ...

Page 1453: ...BODY SIDE APERTURE 23 102 BODY LH SPECIFICATIONS Continued ...

Page 1454: ...BODY SIDE APERTURE LH BODY 23 103 SPECIFICATIONS Continued ...

Page 1455: ...BODY SIDE APERTURE 23 104 BODY LH SPECIFICATIONS Continued ...

Page 1456: ...BODY SIDE APERTURE LH BODY 23 105 SPECIFICATIONS Continued ...

Page 1457: ...BODY SIDE APERTURE 23 106 BODY LH SPECIFICATIONS Continued ...

Page 1458: ...BODY SIDE APERTURE LH BODY 23 107 SPECIFICATIONS Continued ...

Page 1459: ...BODY SIDE APERTURE 23 108 BODY LH SPECIFICATIONS Continued ...

Page 1460: ...BODY SIDE APERTURE LH BODY 23 109 SPECIFICATIONS Continued ...

Page 1461: ...BODY SIDE APERTURE 23 110 BODY LH SPECIFICATIONS Continued ...

Page 1462: ...FLOOR PAN LH BODY 23 111 SPECIFICATIONS Continued ...

Page 1463: ...FLOOR PAN 23 112 BODY LH SPECIFICATIONS Continued ...

Page 1464: ...FLOOR PAN LH BODY 23 113 SPECIFICATIONS Continued ...

Page 1465: ...FLOOR PAN 23 114 BODY LH SPECIFICATIONS Continued ...

Page 1466: ...FLOOR PAN LH BODY 23 115 SPECIFICATIONS Continued ...

Page 1467: ...FLOOR PAN 23 116 BODY LH SPECIFICATIONS Continued ...

Page 1468: ...FLOOR PAN LH BODY 23 117 SPECIFICATIONS Continued ...

Page 1469: ...FLOOR PAN 23 118 BODY LH SPECIFICATIONS Continued ...

Page 1470: ...FLOOR PAN LH BODY 23 119 SPECIFICATIONS Continued ...

Page 1471: ...FLOOR PAN 23 120 BODY LH SPECIFICATIONS Continued ...

Page 1472: ...FLOOR PAN LH BODY 23 121 SPECIFICATIONS Continued ...

Page 1473: ...FLOOR PAN 23 122 BODY LH SPECIFICATIONS Continued ...

Page 1474: ...FLOOR PAN LH BODY 23 123 SPECIFICATIONS Continued ...

Page 1475: ...FLOOR PAN 23 124 BODY LH SPECIFICATIONS Continued ...

Page 1476: ...FLOOR PAN LH BODY 23 125 SPECIFICATIONS Continued ...

Page 1477: ...FLOOR PAN FLOOR PAN 23 126 BODY LH SPECIFICATIONS Continued ...

Page 1478: ...REAR SHELF LH BODY 23 127 SPECIFICATIONS Continued ...

Page 1479: ...REAR SHELF 23 128 BODY LH SPECIFICATIONS Continued ...

Page 1480: ...REAR SHELF LH BODY 23 129 SPECIFICATIONS Continued ...

Page 1481: ...STRUCTURAL ADHESIVE LOCATIONS HOOD CONCORDE LHS AND 300M HOOD INTREPID 23 130 BODY LH SPECIFICATIONS Continued ...

Page 1482: ...FRONT FENDER ROOF LH BODY 23 131 SPECIFICATIONS Continued ...

Page 1483: ...SUNROOF 23 132 BODY LH SPECIFICATIONS Continued ...

Page 1484: ...DOORS LH BODY 23 133 SPECIFICATIONS Continued ...

Page 1485: ...DECKLID 23 134 BODY LH SPECIFICATIONS Continued ...

Page 1486: ...SEALER LOCATIONS METHODS OF APPLYING AUTO BODY SEALANT LH BODY 23 135 SPECIFICATIONS Continued ...

Page 1487: ...OWL AREA 1 SEALER TO BE BRUSHED INTO SEAMS 2 SEALER TO BE BRUSHED INTO SEAMS 3 SEALER TO BE BRUSHED INTO SEAMS 4 SEALER TO BE BRUSHED INTO SEAMS 5 SEALER TO BE BRUSHED INTO SEAMS 23 136 BODY LH SPECIFICATIONS Continued ...

Page 1488: ...LOAD BEAM AND COWL AREA LH BODY 23 137 SPECIFICATIONS Continued ...

Page 1489: ...BODY SIDE APERTURE 23 138 BODY LH SPECIFICATIONS Continued ...

Page 1490: ...FLOOR PAN 1 SEALER TO BE BRUSHED INTO SEAMS LH BODY 23 139 SPECIFICATIONS Continued ...

Page 1491: ...FLOOR PAN 23 140 BODY LH SPECIFICATIONS Continued ...

Page 1492: ...FLOOR PAN LH BODY 23 141 SPECIFICATIONS Continued ...

Page 1493: ...FLOOR PAN 23 142 BODY LH SPECIFICATIONS Continued ...

Page 1494: ...REAR TRUNK AREA LH BODY 23 143 SPECIFICATIONS Continued ...

Page 1495: ...INNER WHEELHOUSE 23 144 BODY LH SPECIFICATIONS Continued ...

Page 1496: ...REAR QUARTER PANEL LH BODY 23 145 SPECIFICATIONS Continued ...

Page 1497: ...DECKLID 23 146 BODY LH SPECIFICATIONS Continued ...

Page 1498: ...FRONT DOORS LH BODY 23 147 SPECIFICATIONS Continued ...

Page 1499: ...REAR DOORS 23 148 BODY LH SPECIFICATIONS Continued ...

Page 1500: ...5 0 1 0 D Rear Door to Front Door 5 0 1 5 0 1 0 E Fuel Filler Door to Quarter 3 0 0 75 0 1 0 F Fascia to Hood 5 0 2 5 0 1 5 G Front and Rear Door to Roof 5 0 2 5 0 2 0 H Deck Lid to Quarter Panel 4 0 1 5 0 1 5 I Taillamp to Applique and Deck Lid 5 0 1 5 0 2 0 J Rear Door to Quarter Panel 5 0 1 5 0 1 0 K Front Rear Door to Sill 7 0 2 0 0 2 0 LH BODY 23 149 SPECIFICATIONS Continued ...

Page 1501: ...nder 5 0 1 5 0 1 0 D Rear Door to Front Door 5 0 1 5 0 1 0 E Fuel Filler Door to Quarter 3 0 0 75 0 1 5 F Fascia to Hood 5 0 1 5 1 0 1 5 G Front and Rear Door to Roof 5 0 1 5 0 1 0 H Deck Lid to Quarter Panel 4 0 1 5 0 1 0 I Taillamp to Applique and Deck Lid 5 0 1 5 NA J Rear Door to Quarter Panel 5 0 1 5 0 1 0 23 150 BODY LH SPECIFICATIONS Continued ...

Page 1502: ...BODY OPENING DIMENSION WINDSHIELD AND FRONT DOOR OPENINGS LH BODY 23 151 SPECIFICATIONS Continued ...

Page 1503: ...ear door hinge rear bolt hole to door latch hole A Center of radius at top to door latch hole B Center of radius at bottom to center of radius at top C Center of radius at bottom to edge of quarter panel at C pillar D Upper rear door hinge rear bolt hole to door latch hole REAR DOOR OPENINGS CONCORDE LHS 300M REAR DOOR OPENINGS INTREPID 23 152 BODY LH SPECIFICATIONS Continued ...

Page 1504: ...REAR WINDOW AND TRUNK OPENING CONCORDE LHS LH BODY 23 153 SPECIFICATIONS Continued ...

Page 1505: ...REAR WINDOW AND TRUNK OPENINGS INTREPID 23 154 BODY LH SPECIFICATIONS Continued ...

Page 1506: ...REAR WINDOW AND TRUNK OPENINGS 300M LH BODY 23 155 SPECIFICATIONS Continued ...

Page 1507: ... N m 20 ft lbs Front seat rear outboard seat track to floor pan bolts 28 N m 20 ft lbs Decklid latch striker 22 N m 16 ft lbs Door hinge bolt and nut 28 N m 21 ft lbs Door hinge double ended stud 14 N m 120 in lbs Hood latch release cable handle to the cowl side 2 3 to 3 4 N m 20 to 30 in lbs Hood latch to crossmember 22 6 to 33 9 N m 200 to 300 in lbs Hood hinges 22 6 to 33 9 N m 200 to 300 in lb...

Page 1508: ...OPERATION The side impact airbag control module SIACM controls the seat back mounted airbags If the SIACM determines the impact is severe enough the appropriate airbag s will inflate tearing open the front seat back trim cover s protecting the passen ger s Once a seat back mounted airbag has been deployed all damaged parts must be replaced REMOVAL AND INSTALLATION FRONT SEAT AIRBAG EQUIPPED REMOVA...

Page 1509: ...Fig 1 LH FRONT SEAT BACKS EQUIPPED WITH AIRBAGS 23 2 BODY LH REMOVAL AND INSTALLATION Continued 2000 LHS 300M CONCORDE AND INTREPID ...

Page 1510: ...le 7 Using the DRB III Scan Tool erase all DTC s and perform airbag system diagnostics 8 Verify front seat operation FRONT SEAT CUSHION SIDE SHIELD AIRBAG EQUIPPED REMOVAL WARNING DISCONNECT AND ISOLATE THE NEG ATIVE BATTERY CABLE REMOTE TERMINAL BEFORE BEGINNING ANY FRONT SEAT REMOVAL OR INSTALLATION PROCEDURE THIS WILL DIS ABLE THE AIRBAG SYSTEM FAILURE TO DISCON NECT THE BATTERY COULD RESULT IN...

Page 1511: ...ED REMOVAL WARNING DISCONNECT AND ISOLATE THE NEG ATIVE BATTERY CABLE REMOTE TERMINAL BEFORE BEGINNING ANY FRONT SEAT REMOVAL OR INSTALLATION PROCEDURE THIS WILL DIS ABLE THE AIRBAG SYSTEM FAILURE TO DISCON NECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI BLE PERSONAL INJURY WARNING ONCE THE NEGATIVE CABLE IS DIS CONNECTED WAIT FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG SYSTEM...

Page 1512: ...Y WARNING ONCE THE NEGATIVE CABLE IS DIS CONNECTED WAIT FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG SYSTEM COMPONENTS 2 Disconnect and isolate the remote negative bat tery cable Fig 8 3 Remove the front seat from the vehicle Refer to the procedure in this group 4 Remove the front seat cushion side shields Refer to the procedure in this group 5 Disengage push pin and disconnect the yellow airbag wire ...

Page 1513: ...e bolts they are not reusable 3 Install bolts attaching recliner to seat back frame Fig 12 Tighten bolts to 8 N m 71 in lbs torque Fig 9 Seat Back Wire Connectors 1 SEAT TRACK RETAINING BOLTS 2 SEAT AIRBAG WIRE HARNESS 3 SEAT AIRBAG WIRE HARNESS CONNECTOR 4 CUSHION PAN Fig 10 Recliner Attaching Bolts 1 RECLINER BOLT Fig 11 Seat Back Wire Harness 1 FRONT SEAT BACK 2 SEAT AIRBAG WIRE HARNESS 3 FRONT...

Page 1514: ...Remove head restraint from seat back INSTALLATION 1 Place head restraint in position 2 Push head restraint down into the lock posi tion 3 Raise head restraint to ensure it locks at the last stop 1 Connect the remote negative battery cable FRONT SEAT HEAD RESTRAINT GUIDE SLEEVES AIRBAG EQUIPPED REMOVAL WARNING DISCONNECT AND ISOLATE THE NEG ATIVE BATTERY CABLE REMOTE TERMINAL BEFORE BEGINNING ANY F...

Page 1515: ...edure in this group 4 Remove the front seat back panel Fig 16 Refer to the procedure in this group 5 Remove the head restraint guide sleeves from the seat back Refer to the procedure in this group 6 Remove the front seat cushion side shield Refer to the procedure in this group 7 Release all J strap retaining clips Fig 17 8 Remove the outboard recliner attaching bolt Fig 18 This will allow access t...

Page 1516: ...rings from cover 15 Remove cover from seat back foam INSTALLATION 1 Position cover on seat back foam Fig 16 Front Seat Back Panel 1 FRONT SEAT BACK PANEL Fig 17 Seat Back J strap Position Orientation 1 TRIM COVER J STRAPS 2 SEAT HEATER WIRE HARNESS 3 SEAT AIRBAG WIRE HARNESS Fig 18 Recliner Attaching Bolt 1 RECLINER BOLT Fig 19 Seat Airbag Module Electrical Connector Location 1 AIRBAG MODULE NYLON...

Page 1517: ...age J strap retaining clips 10 Install the front seat cushion side shield Refer to the procedure in this group 11 Install the head restraint guide sleeves in the seat back Refer to the procedure in this group 12 Install the front seat back panel Refer to the procedure in this group 13 Install the front seat head restraint Refer to the procedure in this group 14 Install the front seat in the vehicl...

Page 1518: ... to cush ion pan Fig 24 4 Disconnect wire harness from cushion pan 5 Remove seat adjuster from seat cushion INSTALLATION 1 Place seat adjuster in position on seat cushion pan 2 Connect wire harness to the cushion pan 3 Install bolts attaching seat adjuster to cushion pad 4 Install seat back Refer to the procedure in this group 5 Install bolt to attach seat back recliner to seat back on each side o...

Page 1519: ...y Also replace the shoulder belt if the retractor is either damaged or inoperative REMOVAL 1 If necessary move the front seat s all the way forward for access 2 Remove turning loop adjuster knob 3 Detach the turning loop cover from the upper anchor bolt 4 Remove upper anchor bolt Fig 2 5 Remove B pillar upper trim 6 Remove lower anchor bolt 7 Remove B pillar lower trim panel 8 Remove the retractor...

Page 1520: ...que 6 Install lower quarter trim panel 7 Install upper quarter trim panels 8 Install seat back and cushion CHILD TETHER ASSEMBLY REMOVAL 1 Flip up child tether cover to allow access to child tether bracket retaining bolt 2 Remove bracket retaining bolt anchor plate cap and spacer from rear shelf INSTALLATION 1 Position spacer cap anchor plate and retaining bolt on the rear shelf 2 Be certain dog p...

Page 1521: ...elts are properly routed to avoid twisted or tangled belts and or buckles Fig 5 REAR SEAT BELT BUCKLES REMOVAL 1 Remove rear seat cushion 2 Remove seat belt anchor nut Fig 6 3 Remove seat belt buckle s from stud on floor INSTALLATION 1 Place seat belt buckle s anchor over stud on floor 2 Install rear seat belt anchor nut Tighten to 60 N m 44 ft lbs 3 Install rear seat cushion REAR SHELF TRIM PANEL...

Page 1522: ...the rear shelf retaining pushpins Fig 7 6 Install the upper and lower quarter trim pan els Refer to Group 23 Body for the procedure NOTE The rear seat back retaining nut also serves as the center seat belt anchor Be certain to torque this nut to 60 N m 44 ft lbs 7 Install the rear seat back Refer to Group 23 Body for the procedure 8 Install the rear seat cushion Refer to Group 23 Body for the proc...

Page 1523: ...liner to seat cushion frame 12 N m 9 ft lbs Front seat track to cushion frame bolt 12 N m 9 ft lbs Front seat back 40 N m 30 ft lbs Front seat back to seat cushion 30 N m 22 ft lbs Front seat back recliner to seat back 8 N m 71 in lbs Front seat rear outboard seat track to floor pan bolts 28 N m 20 ft lbs Front seat airbag module to seat back frame 7 N m 62 in lbs Rear seat center seat belt retrac...

Page 1524: ...NSER 21 CONTROL HEAD 22 DISCHARGE LINE 22 EVAPORATOR 23 EVAPORATOR TEMPERATURE SENSOR 23 EXPANSION VALVE 23 FILTER DRIER 24 HEATER CORE 24 LIQUID LINES 24 MODE DOOR ACTUATOR 25 RECIRCULATION DOOR ACTUATOR 25 SERVICE PORT VALVE CORES 26 SUCTION LINE 26 SUN SENSOR 27 TEMPERATURE DOOR ACTUATOR 28 HVAC UNIT HOUSING 28 DISASSEMBLY AND ASSEMBLY HVAC UNIT HOUSING RECONDITION 29 SPECIFICATIONS A C APPLICA...

Page 1525: ...ower motor switch in the lowest speed position the ground path for the motor is applied through all of the resistor wires Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resis tor wires increasing the blower motor speed When the blower motor switch is in the highest speed posi tion the blower motor resistor is bypassed and the blowe...

Page 1526: ...vice interval will result Refer to LUBRICATION AND MAINTENANCE for service schedules CAUTION Do not add additional inhibitors anti rust products or soluble oil sold as water pump lubricants These products may not be compatible with the engine coolant Refer to Group 7 Cooling System for cooling sys tem procedures EVAPORATOR TEMPERATURE SENSOR DESCRIPTION The evaporator temperature sensor is a tempe...

Page 1527: ...erant from the con denser flows into the filter drier A drying agent called a desiccant is used to remove any traces of moisture from the refrigerant system The filter drier also performs a filtering action to prevent foreign material in the refrigerant from contaminating the expansion valve In addition during periods of high demand air conditioner operation the filter drier acts as a reservoir to...

Page 1528: ...low when extremely hot outside ambient conditions exist This action can occur at a range of approximately 95 F to 120 F OPERATION The Body Control Module BCM receives a Pro grammable Communications Interface PCI bus mes sage from the Powertrain Control Module PCM with the feedback from the A C Pressure Transducer The BCM will force the system into the Recirculation mode reducing the A C refrigeran...

Page 1529: ...ected from the PANEL BI LEVEL panel and floor and FLOOR DEFROST outlets Air flow veloc ity can be adjusted with the blower speed selector switch on the control head Ambient air intake can be shut off by closing the recirculating air door This will recirculate the air that is already inside the vehicle See owners manual for recirculation operation DIAGNOSIS AND TESTING A C PERFORMANCE TEST The air ...

Page 1530: ...low This will make it easier to observe paper in the step Step b b Place a small piece of newspaper in front of the sensor motor opening on the ATC control If the paper sticks to the opening the In Car sensor mo tor is operating properly The piece of paper should be only large enough to cover the grille opening 2 Check if the electrical connection and connector are OK COMPRESSOR The compressor use...

Page 1531: ...sor and Sun Sensor which are not in a Manual A C system TROUBLE CODES FROM THE ATC CONTROL The trouble codes can be checked with the ATC control if a DRBIIIt scan tool is not available The control head can only be placed into the diagnostic mode while the engine is running and the vehicle is not moving Set the control to a 75 F setting so there is no confusion with the 23 51 Diagnostic Trou ble Co...

Page 1532: ... mode knob must be placed in defrost posi tion full clockwise position 5 The A C button can be ON or OFF 6 Press and hold the EBL button until the Mechanical Instrument Cluster Odometer display indicates an AC00 The body control module BCM will chime once and the Manual A C control A C but ton LED will begin blinking 7 Release the EBL button and wait until the Manual A C Control A C button LED sto...

Page 1533: ...ant is provided to the heater system by two 19 mm 3 4 inch inside diameter heater hoses With engine idling at normal running temperature set the control to maximum heat floor and high blower setting Using a test thermometer check the air temperature coming from the floor outlets Refer to Temperature Reference Table If the floor outlet air temperature is insufficient refer to Group 7 Cooling System...

Page 1534: ...w can be measured and poured into the suction port of the compressor When a line or component has ruptured and oil has escaped the receiver drier must be replaced along with the ruptured part Example On an A C system the evaporator retains 60 ml 2 oz The condenser retains 30 ml 1 oz of oil and system capacity may be 150 ml 5 00 oz of oil 150 ml minus 90 ml equals 60 ml 2 00 oz CAUTION The refriger...

Page 1535: ...pecified vacuum for at least 30 minutes start the vacuum pump open the suction and discharge valves Then allow the system to evacuate an addi tional 10 minutes 3 Close all valves Turn off and disconnect the vacuum pump 4 The refrigerant system is prepared to be charged with refrigerant R 134a REFRIGERANT This vehicle uses a refrigerant called R 134a It is a non toxic non flammable clear colorless ...

Page 1536: ...to it s zero ozone depletion and low global warming impact THERMOCOUPLE PROBE To diagnose the LH A C system a temperature probe is required to measure liquid line temperature The clamp on type K probe shown in this manual is available through the Chrysler Professional Service Equipment PSE program This probe is compatible with temperature measuring instruments that accept Type K Thermocouples and ...

Page 1537: ...e pressure Use a manifold gauge set or a scan tool 2 Attach a clamp on thermocouple P S E 66 324 0014 or 80PK 1A or equivalent to the liquid line Fig 10 It must be placed as close to the con denser outlet as possible to observe liquid line tubing 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 Engi...

Page 1538: ...frigerant system is fully charged with R 134a This is accomplished by performing a system Charge Level Check or Fill If while performing this test A C liquid line pressure is less than 207 kPa 30 psi proceed to Empty Refrigerant System Leak Test If liquid line pressure is greater than 207 kPa 30 psi proceed to low refrigerant level leak test If the refrigerant system is empty or low in refrigerant...

Page 1539: ... WHEN SER VICING THE AIR CONDITIONING REFRIGERANT SYSTEM SERIOUS EYE INJURY CAN RESULT FROM EYE CONTACT WITH REFRIGERANT IF EYE CONTACT IS MADE SEEK MEDICAL ATTENTION IMMEDIATELY DO NOT EXPOSE REFRIGERANT TO OPEN FLAME POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED AN ELECTRONIC TYPE LEAK DETECTOR IS RECOMMENDED LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXY...

Page 1540: ... This sensor will inform the ATC system of the ambi ent temperature outside the vehicle This sensor is used by the ATC system to adjust blower speed tem perature offsets evaporator temperatures and mode control The ambient sensor is not serviceable and must be replaced if found to be defective The ambient temperature sensor is used on all LH vehicles with or without ATC systems To test Ambient Tem...

Page 1541: ... Module is used on ATC systems only 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Fig 13 2 Remove lower right underpanel silencer duct 3 Disconnect wiring connectors on blower motor resistor 4 Remove blower motor resistor retaining screws 5 Pull blower motor resistor out of heater hous ing INSTALLATION For installation reverse the above procedur...

Page 1542: ...charge the refrigerant system Torque 5 8 Hex to 13 5 N m 10 ft lbs COMPRESSOR CLUTCH COIL ASSEMBLY REMOVAL Compressor assembly must be removed from mounting Although refrigerant discharge is not nec essary 1 Remove the compressor shaft bolt Fig 18 A band type oil filter removal tool can be placed around the clutch plate to aid in bolt removal 2 Tap the clutch plate with a plastic hammer and remove...

Page 1543: ...of grease Replace bearing as required INSTALLATION 1 Align pin in back of field coil with hole in com pressor end housing and position field coil into place Fig 18 Compressor Shaft Bolt and Clutch Plate 1 COMPRESSOR SHAFT BOLT 2 COMPRESSOR CLUTCH PLATE Fig 19 Clutch Plate and Shim s 1 COMPRESSOR SHAFT 2 CLUTCH PLATE 3 CLUTCH PLATE SHIM Fig 20 Removing Pulley Snap Ring 1 SNAP RING Fig 21 Clutch Coi...

Page 1544: ...late energize the clutch and record the amount of movement c The readings should be 0 35 to 0 65 mm 0 014 to 0 026 in If proper reading is not obtained add or subtract shims until desired read ing is obtained 8 Install compressor shaft bolt Tighten to 17 5 62 N m 155 620 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 cor...

Page 1545: ...tube when lifting radiator condenser assembly from the vehicle INSTALLATION For installation reverse the above procedures CONTROL HEAD The Heater A C Control Head is located in the instrument panel center bezel Refer to Group 8E Instrument Panel and System for Removal and Installation procedures DISCHARGE LINE REMOVAL 1 Remove refrigerant from the A C system using a refrigerant recovery machine 2 ...

Page 1546: ...OR The Evaporator Temperature Sensor is located on the lower right side of the heater housing REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Fig 13 2 Remove right under panel silencer 3 Disconnect wiring connector for evaporator probe 4 At center of heater housing locate evaporator probe access plate Using a flat blade pry tool pull back ...

Page 1547: ...arts and lines together before individually tightening them to prevent damage Torque filter drier plumbing fasten ers to 10 ft lbs HEATER CORE The HVAC unit housing must be removed from the vehicle to service the heater core REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Fig 13 2 Remove the HVAC unit housing from vehicle Refer to Unit Hou...

Page 1548: ...er floor heat adaptor duct 5 Remove rear seat heat forward adaptor duct 6 Loosen center support bracket and pry rear ward to gain access to the actuator 7 Remove actuator retaining screws Then pull actuator straight down Upon removal note the shaft position of the actuator because the shaft on this motor is keyed When installing new actuator its shaft must be positioned in the same location 8 Remo...

Page 1549: ...andard valve core tool remove the valve core Be careful to prevent any dirt debris from entering the valve core opening or getting on the replacement valve core CAUTION A valve that is not fully seated can lead to damage to the valve during evacuation and charge This can result in system refrigerant dis charge while uncoupling the charge adapters INSTALLATION For installation reverse the above pro...

Page 1550: ...ost Fig 13 2 Remove instrument panel top cover 3 Remove two Sun Sensor mounting screws 4 Lift sensor out of instrument panel and discon nect wiring 5 Remove sensor from vehicle INSTALLATION CAUTION The sun sensor must protrude approxi mately 1 4 inch above the instrument panel top cover This will ensure proper operation For installation reverse the above procedures Fig 31 A C Refrigerant Lines and...

Page 1551: ... reverse the above procedures HVAC UNIT HOUSING REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Fig 13 This must be done to prevent accidental air bag deployment 2 Remove instrument panel from vehicle Refer to Group 8E Instrument Panel and Systems for Removal and Installation procedures 3 Using an A C recovery unit remove all R 134a refrig...

Page 1552: ...mode door actuating cam 23 Remove screw at defrost door actuating arm Remove defrost door link from arm 24 Remove defrost door arm from lower housing 25 Remove link and defrost door from housing 26 Remove vent door actuating arm from lower housing ASSEMBLE 1 Install vent door actuating arm to lower hous ing 2 Install defrost door link to defrost door 3 Install door and link into A C housing 4 Inst...

Page 1553: ...ays Clutch Control relay PCM Draw 2 2 amps 12 V 60 5V Gap 0 014 0 0269 DRB IIIT Reads TPS RPM A C switch test Actuators mode doors clutch and fan relays Item Description Notes Vehicle LH Intrepid Concorde 300M LHS manual A C control System R134a w expansion valve Compressor Nippondenso 10PA17 ND 8 PAG oil Freeze up Control 2 wire evaporator temp probe BCM controlled clutch OFF 33 F resets 37 F Low...

Page 1554: ...e cific range of engine RPM engine temperature and or input voltage to the PCM The PCM might not store a DTC for a monitored circuit even though a malfunction has occurred This may happen because one of the DTC criteria for the circuit has not been met For example assume the diagnostic trouble code criteria requires the PCM to monitor the circuit only when the engine operates between 750 and 2000 ...

Page 1555: ...ng engine operation if this Diagnostic Trouble Code was recorded G Generator Lamp Illuminated GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE P0106 M Barometric Pressure Out of Range MAP sensor input voltage out of an acceptable range detected during reading of barometric pressure at key on P0107 M Map Sensor Voltage Too Low MAP sensor input below minimum accept...

Page 1556: ... shorted condition detected in the ASD or CNG shutoff relay control ckt P0137 M 1 2 O2 Sensor Shorted To Ground Oxygen sensor input voltage maintained below normal operating range P0138 M 1 2 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal operating range P0139 M 1 2 O2 Sensor Slow Response Oxygen sensor response not as expected P0140 M 1 2 O2 Sensor Stays at Cente...

Page 1557: ... System Lean A lean air fuel mixture has been indicated by an abnormally rich correction factor P0175 M 2 1 Fuel System Rich A rich air fuel mixture has been indicated by an abnormally lean correction factor P0178 Water in Fuel Sensor Voltage Too Low Flex fuel sensor input below minimum acceptable voltage P0179 Flex Fuel Sensor Volts Too High Flex fuel sensor input above maximum acceptable voltage...

Page 1558: ...tected in cylinder 8 P0309 M CYLINDER 9 MISFIRE Misfire detected in cylinder 9 P0310 M CYLINDER 10 MISFIRE Misfire detected in cylinder 10 P0320 No Crank Referance Signal at PCM No reference signal crankshaft position sensor detected during engine cranking P0325 Knock Sensor 1 Circuit Knock sensor 1 signal above or below minimum acceptable threshold voltage at particular engine speeds P0330 Knock ...

Page 1559: ... 1 efficiency below required level P0441 M Evap Purge Flow Monitor Insufficient or excessive vapor flow detected during evaporative emission system operation P0442 M Evap Leak Monitor Medium Leak Detected A small leak has been detected in the evaporative system P0443 M Evap Purge Solenoid Circuit An open or shorted condition detected in the EVAP purge solenoid control circuit P0455 M Evap Leak Mon...

Page 1560: ...sor No Temp Rise After Start Relationship between the transmission temperature and overdrive operation and or TCC operation indicates a failure of the Transmission Temperature Sensor OBD II Rationality P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below acceptable voltage P0713 Trans Temp Sensor Voltage Too High Transmission fluid temperature sensor input abov...

Page 1561: ... Low Radiator coolant temperature sensor input below the minimum acceptable voltage P1281 Engine is Cold Too Long Engine coolant temperature remains below normal operating temperatures during vehicle travel Thermostat P1282 Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel pump relay control circuit P1288 Intake Manifold Short Runner Solenoid Circuit An open or shor...

Page 1562: ...ry air injection detected during aspirator test was P0411 P1477 Too Much Secondary Air Excessive flow of secondary air injection detected during aspirator test was P0411 P1478 M Battery Temp Sensor Volts Out of Limit Internal temperature sensor input voltage out of an acceptable range P1479 Transmission Fan Relay Circuit An open or shorted condition detected in the transmission fan relay circuit P...

Page 1563: ...peed radiator fan control relay P1594 G Charging System Voltage Too High Battery voltage sense input above target charging voltage during engine operation P1595 Speed Control Solenoid Circuits An open or shorted condition detected in either of the speed control vacuum or vent solenoid control circuits P1596 Speed Control Switch Always High Speed control switch input above maximum acceptable voltag...

Page 1564: ... Circuit An open or shorted condition detected in the transmission 2 3 gear lock out solenoid control circuit P1756 GOV Press Not Equal to Target 15 20 PSI The requested pressure and the actual pressure are not within a tolerance band for the Governor Control System which is used to regulate governor pressure to control shifts for 1st 2nd and 3rd gear Mid Pressure Malfunction P1757 GOV Press Not E...

Page 1565: ...ctioning 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 a threshold value A malfunctioning senso...

Page 1566: ...ity and its efficiency are both reduced By monitoring the oxy gen storage capacity of a catalyst its efficiency can be indirectly calculated The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic converter The PCM calculates the A F mixture from the output of the O2S A low voltage indicates high oxygen content lean mixture A high voltage indi...

Page 1567: ...ll be clocked up from some small value in an attempt to see a shift in the 02 control system If fuel vapor indicated by a shift in the 02 control is present the test is passed If not it is assumed that the purge system is not functioning in some respect The LDP is again turned off and the test is ended TRIP DEFINITION OPERATION A Trip means vehicle operation following an engine off period of durat...

Page 1568: ...nsor Crankshaft Position CKP Sensor Intake Air Temperature IAT Sensor Throttle Position TPS Sensor Ambient Battery Temperature Sensors Power Steering Switch Oxygen Sensor Heater Engine Controller Brake Switch Leak Detection Pump Switch P N Switch Trans Controls Output Functionality PCM outputs are tested for functionality in addition to testing for opens and shorts When the PCM provides a voltage ...

Page 1569: ...ined speed Engine run time at a predetermined speed and throttle opening Transmission in gear automatic only Fuel system in Closed Loop Long Term Adaptive within parameters Power Steering Switch in low PSI no load Engine at idle Fuel level above 15 Ambient air temperature Barometric pressure Engine RPM within acceptable range of desired idle Closed throttle speed Pending Conditions The Task Manage...

Page 1570: ...rformance driveability and fuel economy The catalyst monitor uses dual oxygen sensors O2S s to monitor the efficiency of the converter The dual O2S strategy is based on the fact that as a cat alyst deteriorates its oxygen storage capacity and its efficiency are both reduced By monitoring the oxy gen storage capacity of a catalyst its efficiency can be indirectly calculated The upstream O2S is used...

Page 1571: ...d electrical All PCM self test faults All CMP and CKP sensor faults All injector and ignition electrical faults Idle Air Control IAC motor functionality Vehicle Speed Sensor Brake switch Intake air temperature Conflict The catalyst monitor does not run if any of the following are conditions are present EGR Monitor in progress Fuel system rich intrusive test in progress EVAP Monitor in progress Tim...

Page 1572: ...se a high idle condition PCM SYSTEM GROUND The PCM cannot determine a poor system ground However one or more diagnostic trouble codes may be generated as a result of this condition The mod ule should be mounted to the body at all times also during diagnostic PCM CONNECTOR ENGAGEMENT The PCM may not be able to determine spread or damaged connector pins However it might store diagnostic trouble code...

Page 1573: ...ional purge solenoid sys tem The PCM controls vapor flow by operating the purge solenoid Refer to Proportional Purge Solenoid in this section NOTE The evaporative system uses specially man ufactured hoses If they need replacement only use fuel resistant hose Also the hoses must be able to pass an Ozone compliance test NOTE For more information on Onboard Refueling Vapor Recovery ORVR refer to the ...

Page 1574: ...f fuel vapors from the vapor canister and fuel tank to the engine intake manifold LEAK DETECTION PUMP DESCRIPTION The leak detection pump is a device used to detect a leak in the evaporative system The pump contains a 3 port solenoid a pump that contains a switch a spring loaded canister vent valve seal 2 check valves and a spring diaphragm Fig 1 ORVR System Schematic 1 FUEL CAP 2 RECIRCULATION TU...

Page 1575: ...E SWITCH DESCRIPTION The primary components within the leak detection pump assembly are a three port leak detection sole noid valve a pump assembly that includes a spring loaded diaphragm a reed switch which is used to monitor the pump diaphragm movement position two check valves and a spring loaded vent seal valve OPERATION The leak detection pump LDP assembly incorpo rates two primary functions ...

Page 1576: ... neck This will allow the technician to cycle the LDP and to watch switch state changes After passing the leak detection phase of the test system pressure is maintained until the purge sys tem is activated in effect creating a leak If the dia phragm falls as is expected causing the reed switch to change state then the diagnostic test is completed When of the evaporative system leak monitor begins ...

Page 1577: ...TION WARNING APPLY PARKING BRAKE AND OR BLOCK WHEELS BEFORE PERFORMING ANY TEST OR ADJUSTMENT WITH THE ENGINE OPERATING 1 With engine idling remove the hose from the PCV valve If the valve is not plugged a hissing noise will be heard as air passes through the valve A strong vacuum should also be felt when a finger is placed over the valve inlet 2 Install hose on PCV valve Remove the make up air ho...

Page 1578: ... REMOVAL 1 Disconnect the negative battery cable 2 Remove fuel tank refer to the Fuel Delivery section 3 Disconnect the hoses from the EVAP canister Fig 9 4 Remove 2 nuts from the upper bracket of the EVAP canister Fig 10 5 Remove EVAP canister from bracket Fig 12 6 Remove LDP from EVAP canister upper bracket Fig 13 INSTALLATION 1 Install LDP to EVAP Canister Fig 13 2 Install EVAP canister to Brac...

Page 1579: ...y 6 Connect negative battery cable PROPORTIONAL PURGE SOLENOID VALVE The solenoid attaches to a bracket near the air cleaner Fig 14 The solenoid will not operate unless it is installed correctly REMOVAL 1 Disconnect electrical connector from solenoid 2 Disconnect vacuum tubes from solenoid 3 Remove solenoid from bracket INSTALLATION The top of the solenoid has TOP printed on it The solenoid will n...

Page 1580: ...e attaches to the rear of the right cylinder head 1 Disconnect negative battery cable 2 Remove air inlet tube and resonator and bracket 3 Disconnect electrical connector from solenoid 4 Remove EGR upper tube screws at EGR valve 5 Remove EGR valve mounting screws 6 Remove screws from EGR lower tube at exhaust manifold 7 Remove EGR valve and lower tube as an assembly 8 Clean gasket surfaces Discard ...

Page 1581: ...PER 2 7L The EGR tube attaches to the intake manifold ple num on both sides of the throttle body and the EGR valve REMOVAL 1 Disconnect negative battery cable 2 Remove air inlet tube and resonator 3 Remove throttle cable bracket and reposition 4 Remove EGR tube mounting screws at intake manifold plenum Fig 4 5 Remove EGR tube mounting screws at EGR valve 6 Remove EGR upper tube Fig 1 EGR Valve 2 7...

Page 1582: ...d resonator and bracket 3 Remove EGR tube mounting screws at EGR valve Fig 5 4 Remove EGR tube mounting screws at exhaust manifold INSTALLATION 1 Install new gasket between the EGR valve and tube and loosely install bolts 2 Install new gasket between the exhaust mani fold and tube and loosely install bolts 3 Tighten the EGR tube to EGR valve bolts to 11 N m 95 in lbs torque 4 Tighten the EGR tube ...

Page 1583: ... EGR tube into the intake manifold and loosely install EGR tube to EGR valve 3 Tighten the EGR tube to EGR valve screws to 11 N m 95 in lbs torque 4 Install clips for the EGR tube to intake mani fold plenum Fig 9 5 Install transmission to throttle body bracket 6 Install air inlet tube and resonator 7 Connect negative battery cable SPECIFICATIONS TORQUE Description Torque EGR valve to cyl head 31 N...

Page 1584: ...TC in memory The criteria may be a spe cific range of engine RPM engine temperature and or input voltage to the PCM The PCM might not store a DTC for a monitored circuit even though a malfunction has occurred This may happen because one of the DTC criteria for the circuit has not been met For example assume the diagnostic trouble code criteria requires the PCM to monitor the circuit only when the ...

Page 1585: ...T ACTUATION TEST MODE OPERATION The Circuit Actuation Test Mode checks for proper operation of output circuits or devices the Powertrain Control Module PCM may not internally recognize The PCM attempts to activate these outputs and allow an observer to verify proper operation Most of the tests provide an audible or visual indication of device operation click of relay contacts fuel spray etc Except...

Page 1586: ... EVAP Purge Solenoid Circuit An open or shorted condition detected in the duty cycle purge solenoid circuit 13 P0203 Injector 3 Control Circuit Injector 3 output driver does not respond properly to the control signal 14 P0202 Injector 2 Control Circuit Injector 2 output driver does not respond properly to the control signal 15 P0201 Injector 1 Control Circuit Injector 1 output driver does not resp...

Page 1587: ...ge Low Intake air temperature sensor input below the maximum acceptable voltage 3A P0113 Intake Air Temp Sensor Voltage High Intake air temperature sensor input above the minimum acceptable voltage 3B P0325 Knock Sensor Circuit Sensor is either shorted to ground or 12 volts Will not detect open circuit 3C P0106 Baro Pressure Out of Range Barometric pressure out of out of range 3D P0204 Injector 4 ...

Page 1588: ...e fuel pump relay control circuit 67 P0135 1 1 O2S Heater Failure Upstream oxygen sensor heating element circuit malfunction 69 P0141 1 2 O2S Heater Failure Oxygen sensor heating element circuit malfunction 72 P1899 P N Switch Stuck in Park or in Gear Incorrect input state detected for the Park Neutral switch auto trans only 73 P0551 Pwr steering sw perf Incorrect input state detected for the powe...

Page 1589: ...e sensor input voltage below an acceptable range 9A P1492 Ambient Batt Temp Sensor Volts Too High Battery temperature sensor input voltage above an acceptable range 9B P0131 1 1 O2S Shorted to Ground O2 sensor voltage too low tested after cold start 9C P0137 1 2 O2S Shorted to Ground O2 sensor voltage too low tested after cold start 9D P1391 Intermittent Loss of CMP or CKP Intermittent loss of eit...

Page 1590: ..._____________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ What comments or suggestions do you have ________________________________________ __________________________________________________________________________...

Page 1591: ...DaimlerChrysler International Operations Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills MI 48326 2757 ...

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