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Chrysler 2004 Concorde, Service Manual

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Chrysler 2004 Concorde Service Manual Download Page 949

(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 out the base through mounting ring by

gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 3).

(5) Disconnect the base wires.
(6) Set base aside and remove base mount ring.

INSTALLATION

(1) Install base mount ring.
(2) Connect the base wires.
(3) Firmly snap base into position inside of instru-

ment panel.

(4) Connect the negative battery cable remote ter-

minal to the remote battery post.

IOD FUSE

DESCRIPTION

All vehicles are equipped with an Ignition-Off

Draw (IOD) fuse that is disconnected within the
Junction Block when the vehicle is shipped from the
factory. Dealer personnel are to reconnect the IOD
fuse in the junction block as part of the preparation
procedures performed just prior to new vehicle deliv-
ery.

The left end of the instrument panel cover has a

snap-fit fuse access panel that can be removed to pro-
vide service access to the fuses in the junction block.
An adhesive-backed fuse layout map is secured to the
instrument panel side of the access panel to ensure
proper fuse identification. The IOD fuse is a 15
ampere mini blade-type fuse, located in fuse cavity #
19.

CIRCUITS INCLUDED WITH IOD FUSE

•

Cluster

•

Body Control Module

•

Diagnostic Connector

•

Map Lamps

•

Glove Box Lamp

•

Courtesy Lamps

•

Compass Mini-Trip Computer

•

Radio

OPERATION

The term ignition-off draw identifies a normal con-

dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position.
The only reason the IOD fuse is disconnected is to
reduce the normal IOD of the vehicle electrical sys-
tem during new vehicle transportation and pre-deliv-
ery storage to reduce battery depletion, while still
allowing vehicle operation so that the vehicle can be
loaded, unloaded and moved as needed by both vehi-
cle transportation company and dealer personnel.

The IOD fuse is disconnected from JB fuse cavity

#19 when the vehicle is shipped from the assembly
plant. Dealer personnel must reconnect the IOD fuse
when the vehicle is being prepared for delivery in
order to restore full electrical system operation. Once
the vehicle is prepared for delivery, the IOD function
of this fuse becomes transparent and the fuse that
has been assigned the IOD designation becomes only
another Fused B(+) circuit fuse.

The IOD fuse can be used by the vehicle owner as

a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that disconnecting the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged.

REMOVAL

The Ignition-Off Draw (IOD) fuse is disconnected

from Junction Block fuse cavity # 19 when the vehi-
cle is shipped from the assembly plant. Dealer per-
sonnel must reconnect the IOD fuse when the vehicle
is being prepared for delivery in order to restore full
electrical system operation.

(1) Turn the ignition switch to the Off position.

Fig. 3 Tool For Cigar Lighter / Power Outlet

Removal

1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)

LH

8W-97 POWER DISTRIBUTION

8W - 97 - 3

CIGAR LIGHTER/POWER OUTLET (Continued)

Summary of Contents for 2004 Concorde

Page 1: ... 8H Horn 8I Ignition Control 8J Instrument Cluster 8L Lamps 8M Message Systems 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers Washers 8W Wiring 9 Engine 11 Exhaust System 13 Frame Bumpers 14 Fuel System 19 Steering 21 Transaxle 22 Tires Wheels 23 Body 24 Heating Air Conditioning 25 Emissions Control Component and System Index Service Manual Comment Forms Rear o...

Page 2: ......

Page 3: ... 7 are not used to define service information Information reads from left to right starting with line 3 in the center of the plate to line 1 at the bottom of the plate BODY CODE PLATE LINE 3 DIGITS 1 2 AND 3 Paint procedure DIGIT 4 Open Space DIGITS 5 THROUGH 7 Primary Paint Refer to 23 BODY PAINT SPEC IFICATIONS DIGIT 8 AND 9 Open Space DIGITS 10 THROUGH 12 Secondary Paint DIGIT 13 AND 14 Open Sp...

Page 4: ...n 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 FASTENER IDENTIFICATION DESCRIPTION The SAE bolt strength grades range from grade 2 to gr...

Page 5: ...Fig 3 FASTENER IDENTIFICATION LH INTRODUCTION 3 FASTENER IDENTIFICATION Continued ...

Page 6: ...Fig 4 FASTENER STRENGTH 4 INTRODUCTION LH FASTENER IDENTIFICATION Continued ...

Page 7: ... procedures INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart Fig 5 are used to identify various instrument con trols The symbols correspond to the controls and dis plays that are located on the instrument panel Fig 5 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 1 High Beam 13 Rear Window Washer 2 Fog Lamps 14 Fuel 3 Hea...

Page 8: ...s x 25 4 Millimeters mm mm x 0 03937 Inches Feet x 0 3048 Meters M M x 3 281 Feet Yards x 0 9144 Meters M x 1 0936 Yards mph x 1 6093 Kilometers Hr Km h Km h x 0 6214 mph Feet Sec x 0 3048 Meters Sec M S M S x 3 281 Feet Sec mph x 0 4470 Meters Sec M S M S x 2 237 mph Kilometers Hr Km h x 0 27778 Meters Sec M S M S x 3 600 Kilometers Hr Km h COMMON METRIC EQUIVALENTS 1 inch 25 Millimeters 1 Cubic ...

Page 9: ...Fig 6 METRIC CONVERSION CHART LH INTRODUCTION 7 METRIC SYSTEM Continued ...

Page 10: ...ION Individual Torque Charts appear within many or the Groups Refer to the Standard Torque Specifications Chart for torque references not listed in the individual torque charts Fig 7 Fig 7 TORQUE SPECIFICATIONS 8 INTRODUCTION LH ...

Page 11: ... Active Driver and Side Airbags H Restraint System Active Driver and Passenger Airbags 5 Car Line D Concord U S Canada Mexico Bux D Intrepid U S Mexico E 300M U S Canada Mexico Bux H Intrepid Canada 6 Series 3 Medium 4 High Line 5 Premium 6 Sport 7 Special Transmission Table For Bux W DGL DGX B 4 Speed Automatic 7 Body Style 6 4 Door Sedan 8 Engine G 3 5L V6 Cyl 24 Valve SOHC MPI K 3 5L V6 Cyl 24 ...

Page 12: ...included All communications or inquiries regarding the vehicle should include the Month Day Hour and Vehicle Identification Number E MARK LABEL DESCRIPTION An E mark Label Fig 10 is located on the rear shut face of the driver s door The label contains the following information Date of Manufacture Month Day Hour MDH Vehicle Identification Number VIN Country Codes Regulation Number Regulation Amendm...

Page 13: ...partment on the passenger side rear cor ner of the hood The plate contains five lines of infor mation 1 Vehicle Identification Number VIN 2 Gross Vehicle Mass GVM 3 Gross Train Mass GTM 4 Gross Front Axle Rating GFAR 5 Gross Rear Axle Rating GRAR Fig 11 MANUFACTURER PLATE LH INTRODUCTION 11 ...

Page 14: ......

Page 15: ...N DESCRIPTION ENGINE OIL AND LUBRICANTS 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 PO...

Page 16: ...ied engine oil Engine oil additives supplements should not be used to enhance engine oil perfor mance Engine oil additives supplements should not be used to extend engine oil change intervals No additive is known to be safe for engine durability and can degrade emission components Additives can con tain undesirable materials that harm the long term durability of engines by Doubling the level of Ph...

Page 17: ...corrosion inhibitors called HOAT for Hybrid Organic Additive Technology is recommended This coolant offers the best engine cooling without corrosion when mixed with 50 Ethylene Glycol and 50 distilled water to obtain a freeze point of 37 C 35 F If it loses color or becomes contaminated drain flush and replace with fresh properly mixed coolant solu tion The green coolant MUST NOT BE MIXED with the ...

Page 18: ...y of transmission seals DESCRIPTION FUEL REQUIREMENTS Your engine is designed to meet all emissions reg ulations and provide excellent fuel economy and per formance when using high quality unleaded gasoline having an octane rating of 87 The uses of midgrade octane rating of 89 gasoline is recommended for the 3 5L H O engine The use of premium gasoline is not recommended The use of premium gasoline...

Page 19: ...cs system section MATERIALS ADDED TO FUEL All gasoline sold in the United States and Canada are required to contain effective detergent additives Use of additional 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...

Page 20: ...t best describes your driving conditions Where time and mileage are listed follow the interval that occurs first NOTE Under no circumstances should oil change intervals exceed 6000 miles 10 000 km or 6 months whichever comes first CAUTION Failure to perform the required mainte nance items may result in damage to the vehicle At Each Stop for Fuel Check the engine oil level about 5 minutes after a f...

Page 21: ...00 18 000 Kilometers 5 000 10 000 14 000 19 000 24 000 29 000 Change engine oil and engine oil filter X X X X X X Inspect the air cleaner filter and replace if required X X X X X Replace the air cleaner filter X Inspect the front and rear brake linings and rotors X X Adjust the drive belt tension X Miles 21 000 24 000 27 000 30 000 33 000 36 000 Kilometers 34 000 38 000 43 000 48 000 53 000 58 000...

Page 22: ... rear brake linings and rotors X X Check and replace if necessary the PCV valve X Miles 93 000 96 000 99 000 100 000 102 000 105 000 Kilometers 149 000 154 000 158 000 160 000 163 000 168 000 Change engine oil and engine oil filter X X X X X Inspect the air cleaner filter and replace if required X X X X Replace the air cleaner filter X Inspect the front and rear brake linings and rotors X Flush an...

Page 23: ... and engine oil filter X X X X X X Inspect the air cleaner filter and replace if required X X X X X Replace the air cleaner filter X Replace the drive belts X Inspect the front and rear brake linings and rotors X X Flush and replace engine coolant at 60 months or 100 000 miles X Check and replace if necessary the PCV valve X Miles 78 000 84 000 90 000 96 000 102 000 Kilometers 125 000 134 000 144 ...

Page 24: ...les 16 km More than 50 of your driving is at sustained high speeds during hot weather above 90 F 32 C L Trailer towing L Taxi police or delivery service commercial ser vice L Off road or desert operation If equipped for and operating with E 85 ethanol fuel NOTE If ANY of these apply to you then change your engine oil every 3 000 miles 5 000 km or 3 months whichever comes first and follow schedule ...

Page 25: ...0 60 000 67 500 75 000 82 500 90 000 Months 42 48 54 60 66 72 Change engine oil and engine oil filter X X X X X X Inspect the air cleaner filter and replace if required X X X X Replace the air cleaner filter X X Replace the drive belts X Adjust drive belt tension X Inspect the front and rear brake linings and rotors X X Flush and replace engine coolant at 60 months or 160 000 km X Check and replac...

Page 26: ...000 9 000 12 000 15 000 18 000 Change engine oil and engine oil filter X X X X X X Inspect the air cleaner filter and replace if required X X X X X Replace the air cleaner filter X Inspect the front and rear brake linings and rotors X X Adjust the drive belt tension X Kilometers 34 000 38 000 43 000 48 000 53 000 58 000 Miles 21 000 24 000 27 000 30 000 33 000 36 000 Change engine oil and engine o...

Page 27: ...00 100 000 102 000 105 000 Change engine oil and engine oil filter X X X X X Inspect the air cleaner filter and replace if required X X X X Replace the air cleaner filter X Inspect the front and rear brake linings and rotors X Change the automatic transaxle fluid and filter X Flush and replace the engine coolant X Replace the engine timing belt Federal Emissions X Replace the engine timing belt Ca...

Page 28: ...DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS TAKE CARE TO AVOID THE RADIATOR COOLING FAN WHENEVER THE HOOD IS RAISED THE FAN CAN START AT ANYTIME THE IGNITION SWITCH IS ON YOU CAN BE HURT BY THE FAN BATTERY FLUID IS A CORROSIVE ACID SOLUTION DO NOT ALLOW BATTERY FLUID TO CONTACT EYES SKIN OR CLOTHING IF ACID SPLASHES IN EYES OR ON SKIN FLUSH THE CONTAMINATED AREA IMMEDIATELY WITH LARGE QUANTITI...

Page 29: ...sitive clamp from dis able battery start attachment Disconnect jumper cable positive clamp from booster battery start attachment TOWING STANDARD PROCEDURE TOWING WARNING Do NOT tow vehicle with front wheels on the ground The transaxle can be damaged Secure loose and protruding parts from a dis abled vehicle Always use a safety chain system that is inde pendent of the lifting and towing equipment D...

Page 30: ...ling type towing device Damage to bumper fascia will result Always tow vehicle with front wheels off the ground as shown Fig 9 Use a flat bed towing device when wheel lift tow ing device is not available 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 ...

Page 31: ...ER CONTROL ARM 12 DISASSEMBLY DISASSEMBLY LOWER CONTROL ARM PIVOT BUSHING 14 DISASSEMBLY LOWER CONTROL ARM TENSION STRUT BUSHING 14 ASSEMBLY ASSEMBLY LOWER CONTROL ARM PIVOT BUSHING 15 ASSEMBLY LOWER CONTROL ARM TENSION STRUT BUSHING 15 INSTALLATION LOWER CONTROL ARM 16 STABILIZER BAR DESCRIPTION 16 OPERATION 17 DIAGNOSIS AND TESTING STABILIZER BAR FRONT 17 REMOVAL STABILIZER BAR FRONT 17 INSTALLA...

Page 32: ... 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 through a rack and pinion steer ing gear that is connected to a fixed steering arm on each front strut WARNING WARNING DO NOT REMOVE THE STRUT ASSEM BLY S SHAFT NUT AT ANY TIME UNLESS THE COI...

Page 33: ...r in the area shown Fig 2 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 SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE DESCRIPTION N m Ft Lbs In Lbs Ball Joint Pinch Bolt Nut 55 40 Hub And Bearing Mounting Bolts 110 81...

Page 34: ...r the life of the vehicle and requires no type of periodic maintenance The following procedure may be used for diagnosing the condition of the front hub bearing With the wheel disc brake caliper and brake rotor removed rotate the wheel hub Any roughness or resistance to rotation may indicate dirt intrusion or a failed hub bearing If the hub bearing exhibits any of these conditions during diagnosis...

Page 35: ...ecomes damaged hub and bear ing assembly MUST not be used and MUST be replaced with a new hub and bearing assembly 7 Remove hub and bearing assembly from steer ing knuckle by sliding it straight out of steering knuckle and off end of stub axle Fig 7 If hub and bearing assembly will not slide out of knuckle insert Fig 3 Disc Brake Caliper Mounting 1 BRAKE LINE 2 CALIPER GUIDE PIN BOLTS 3 STEERING K...

Page 36: ...N Hub and bearing assembly mounting surfaces on steering knuckle and driveshaft Fig 10 must be smooth and completely free of foreign material or nicks Fig 7 Hub And Bearing Removal And Installation 1 HUB BEARING ASSEMBLY 2 STEERING KNUCKLE Fig 8 Prying Hub And 1 INSERT PRY BAR HERE 2 PRY BAR 3 KNUCKLE 4 HUB BEARING ASSEMBLY Fig 9 Hub And Bearing Assembly Seal 1 SEAL CAN MUST REMAIN TIGHT AGAINST H...

Page 37: ... sequence until all nuts are torqued to half specifica tion Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs 8 Lower the vehicle to the ground 9 Check the wheel alignment toe setting on the vehicle and reset if not within specifications KNUCKLE DESCRIPTION STEERING KNUCKLE The steering knuckle is a single casting with legs machined for attachment to the front ...

Page 38: ...d damage to speed sensor by outer C V joint when hub and bearing is removed 6 Carefully remove sensor head from steering knuckle If the sensor has seized due to corrosion DO NOT USE PLIERS ON SENSOR HEAD Use a hammer and punch Fig 14 to tap edge of sensor ear rocking sensor side to side until free 7 Remove the hub and bearing to stub axle retaining nut Fig 15 8 Remove the 3 steering knuckle to hub...

Page 39: ...nuckle 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 10 Remove the ball joint stud to steering knuckle attaching nut and bolt Fig 20 CAUTION When lower control arm is separated from steering knuckle do not let ball joint seal hit up against steering knuckle If ball joint seal hits steering knuckle seal damage ...

Page 40: ...ng bolt and nut into steering knuckle Fig 20 Tighten the attaching bolt to a torque of 55 N m 40 ft lbs 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 turned damage to steering knuck...

Page 41: ...15 Do not torque the hub nut at this time 7 Coat speed sensor head with High Temperature Multipurpose E P Grease before installing into the steering knuckle Install speed sensor head into steering knuckle Install screw and tighten to a torque of 7 N m 60 in lbs 8 Install the brake rotor back on the hub and bearing assembly Fig 13 9 Install front brake caliper on steering knuckle Refer to Disc Brak...

Page 42: ...arm is bolted to the cradle crossmember 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 du...

Page 43: ...dle and then sliding tension strut out of isolator bushing Fig 28 Fig 29 8 Remove tension strut to control arm retaining nut and washer from end of tension strut Fig 29 While removing nut keep strut from turning by hold ing tension strut at flat using an open end wrench Discard the retaining nut A NEW nut must be used when installing tension strut 9 Separate the tension strut from the lower con tr...

Page 44: ...de Receiver Special Tool MB 990799 as shown Fig 31 Position Remover Special Tool 6644 4 on top of tension strut bushing Fig 31 4 Lower the arbor press ram pressing Remover Special Tool 6644 4 down through the tension strut bushing until the arbor press can push it no farther This action will cut the bushing into two pieces 5 Remove lower control arm from arbor press Remove pieces of tension strut ...

Page 45: ...nstallation Lube or an equivalent 2 By hand install tension strut bushing into large end of Installer Special Tool 6644 3 Press bushing into installer as far as it will go by hand 3 Position lower control arm in arbor press so tension strut hole in lower control arm is centered on Receiver Special Tool MB 990799 Fig 34 Position Installer Special Tool 6644 3 with previously installed bushing inside...

Page 46: ...sing an open end wrench Fig 26 CAUTION Pulling steering knuckle out from vehicle after releasing from ball joint can separate inner C V joint See Driveshafts CAUTION When ball joint stud is installed into steering knuckle do not let ball joint seal hit up against steering knuckle If ball joint seal hits steer ing knuckle seal damage may occur If ball joint seal becomes torn replace seal before ass...

Page 47: ...nting nut and washer assemblies securing the right front strut in place Fig 37 2 Raise vehicle on jack stands or centered on a frame contact hoist See Hoisting in Lubrication and Maintenance 3 Remove right front wheel and tire assembly from the vehicle 4 Remove the right stabilizer bar link nut at the strut assembly Remove the link from the strut assembly Fig 38 5 Remove the left stablizer bar lin...

Page 48: ...ve right front strut assembly from vehi cle 10 Remove the nine bolts securing the structural collar to the engine oil pan and transaxle Fig 43 11 Remove the 4 nuts attaching the engine motor mounts to the cradle assembly Fig 44 Fig 39 Stabilizer Bar At Left Link 1 LINK 2 STABILIZER BAR 3 LOWER ARM 4 NUT 5 KNUCKLE Fig 40 Removing Outer Tie Rod From Steering Arm 1 TIE ROD END 2 STEERING ARM 3 STRUT ...

Page 49: ...removed structural collar area between the engine and trans axle assembly Remove the stabilizer bar out the right wheel opening by routing it in front of the right halfshaft then behind the right knuckle Fig 47 Fig 43 Structural Collar 1 TRANSAXLE 2 MOUNTING BOLTS 3 ENGINE OIL PAN 4 STRUCTURAL COLLAR 5 STABILIZER BAR Fig 44 Motor Mount To Cradle Assembly Attachment 1 ENGINE OIL PAN 2 MOTOR MOUNT A...

Page 50: ... stabilizer bar isolator bushings onto sta bilizer bar with slits facing forward and flat side fac ing downward The stabilizer bar to cradle assembly bushings must be positioned on the stabilizer bar so the slit in the bushing is posi tioned toward front of vehicle Fig 48 6 Install the isolator bushing retainers onto the stabilizer bar isolator bushings Fig 45 CAUTION When stabilizer bar is instal...

Page 51: ...on and Maintenance 2 Remove the 2 bolts attaching each of the 2 sta bilizer bushing retainers and bushings to the cradle assembly Fig 49 3 Remove the stabilizer bar isolator bushing retainers from the isolator 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 fr...

Page 52: ...d type of vehicle service The components of the strut assembly listed below are serviceable if found to be defective Fig 52 Strut shaft retainer nut Upper mount Seat and bearing Dust shield Jounce bumper Jounce bumper cup Coil spring Upper spring isolator Lower spring isolator Strut OPERATION STRUT ASSEMBLY FRONT The strut assembly cushions the ride of the vehicle controlling vibration jounce and ...

Page 53: ...osition when observing rubber tab positioning whether a left or right mount is being observed Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service Be sure that the springs meet the correct load rating for the vehicle and its specific options REMOVAL STRUT ASSEMBLY FRONT WARNING DO NOT REMOVE THE STRUT ASSEM BLY S SHAFT...

Page 54: ...TIE ROD 2 NUT 3 STABILIZER BAR ATTACHING LINK 4 STRUT ASSEMBLY 5 STEERING ARM 6 NUT Fig 56 Removing Outer Tie Rod From Steering Arm 1 TIE ROD END 2 STEERING ARM 3 SPECIAL TOOL C 3894A 4 STRUT Fig 57 Speed Sensor Cable Routing Bracket 1 STRUT ASSEMBLY 2 ROUTING BRACKET 3 SCREW 4 SPEED SENSOR CABLE Fig 58 Caliper Guide Pin Bolts 1 BRAKE LINE 2 CALIPER GUIDE PIN BOLTS 3 STEERING KNUCKLE 4 BLEEDER SCR...

Page 55: ...blies Fig 61 11 Remove the strut assembly from the vehicle 12 For disassembly of the strut assembly refer to Disassembly DISASSEMBLY STRUT ASSEMBLY FRONT The Strut assembly must be removed from the vehicle for it to be disassembled and assembled Refer to Removal in this section For the disassembly and assembly of the strut assembly use strut spring compressor Pentastar Ser vice Equipment PSE tool ...

Page 56: ...is removed from the upper mount 4 Install Strut Nut Socket Special Tool 6864 on the strut shaft retaining nut Fig 63 Next install a socket on the hex on the end of the strut shaft While holding the strut shaft from turning remove the nut from the strut shaft 5 Remove the upper mount from the strut shaft 6 Remove the clamp from the bottom of the coil spring and remove the strut out through the bott...

Page 57: ...d distortion Check for binding of the seat and bearing pivot bearing Inspect the dust shield for rips and deteriora tion Inspect the upper and lower spring isolators for material deterioration Inspect the coil spring for any sign of damage to the coating ASSEMBLY STRUT ASSEMBLY FRONT For the disassembly and assembly of the strut assembly use strut spring compressor Pentastar Ser vice Equipment PSE...

Page 58: ...the 10 o clock position when observing rubber tab positioning whether a left or right mount is being observed Once this hole is located in the 10 o clock position the tabs should be in the posi tions as shown Fig 66 and Fig 67 The right upper mount should also have a white dot painted on its mounting face 8 Install the strut upper mount over the strut shaft and onto the top of the seat and bearing...

Page 59: ...ied torque of 135 N m 100 ft lbs 10 Lower vehicle TENSION STRUT DESCRIPTION This vehicle uses a steel tension strut on each side of the vehicle s front suspension between the lower control arm and front suspension cradle crossmember Fig 1 The strut has rubber isolator bushings retainer washers and nuts at each end where it mounts OPERATION The tension strut controls longitudinal fore and aft movem...

Page 60: ...seated against cradle Fig 69 2 Install isolator bushing halve on tension strut until it is seated against retaining washer as shown Fig 68 3 Reinstall the tension strut and lower control arm as an assembly back in the vehicle Refer to 2 SUSPENSION FRONT LOWER CONTROL ARM INSTALLATION Fig 69 Bushing In Cradle 1 CRADLE ISOLATOR BUSHING 2 CRADLE 3 TENSION STRUT TO CRADLE ISOLATOR BUSHING 2 30 FRONT S...

Page 61: ...EAR 45 ASSEMBLY STRUT ASSEMBLY REAR 46 INSTALLATION STRUT ASSEMBLY REAR 47 TRAILING ARM LINK DESCRIPTION TRAILING ARM 47 OPERATION TRAILING ARM 47 DIAGNOSIS AND TESTING TRAILING ARM 47 REMOVAL TRAILING ARM 48 INSTALLATION TRAILING ARM 48 REAR SUSPENSION DESCRIPTION REAR SUSPENSION The rear suspension used on this vehicle is a fully independent rear suspension Fig 1 Each side of the rear suspension...

Page 62: ...itched rotated or replaced the TPM System needs to be retrained Refer to 22 TIRES WHEELS TIRE PRESSURE MONITORING SENSOR STANDARD PROCEDURE CAUTION If a rear suspension component becomes bent damaged or fails no attempt should be made to straighten or repair it Always replace with a new component Fig 1 Rear Suspension 1 STRUT ASSEMBLY 2 REAR SUSPENSION CROSSMEMBER 3 REAR SUSPENSION CROSSMEMBER BUS...

Page 63: ...ear wheel speed sensor is pressed onto the hub and bearing OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the tire and wheel The five wheel mounting studs mount the tire and wheel and disc brake rotor to the vehicle DIAGNOSIS AND TESTING HUB AND BEARING REAR The rear hub and bearing assembly is designed for the life of the vehicle and should require no mainte...

Page 64: ...n crossmember and the spindle using a bolt and nut assembly at each end The rear lateral link incorporates a threaded wheel alignment toe adjustment sleeve OPERATION The lateral movement of the rear spindle is con trolled by the lateral links connecting the front and rear centerline of the spindle to the rear suspension crossmember The threaded adjustment sleeve of the rear link allows for setting...

Page 65: ...bilizer bar isolator bushing retainers to the frame rails the 2 rearward attaching bolts also attach the front cor ners of the rear suspension crossmember in place Allow the stabilizer bar to hang down out of the way 7 Remove the screw securing the fuel filler neck to the left frame rail 8 Position a transmission jack under the fuel tank 9 Remove the attaching bolts securing both fuel tank mountin...

Page 66: ...s to 100 N m 75 ft lbs 7 Install the screw securing the brake tubes to the left stabilizer bar isolator bushing retainer 8 Install the lateral links on the spindle Install but DO NOT fully tighten the attaching bolt and nut at this time Fig 4 CAUTION Tightening the lateral link attaching bolt at this point will cause the bushing to contort when the vehicle is at curb riding height thus contribut i...

Page 67: ...servicing the vehicle no attempt is to be made to repair or to straighten the spindle THE SPINDLE MUST BE REPLACED IF FOUND TO BE DAMAGED IN ANY WAY REMOVAL SPINDLE 1 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting in Lubrication and Maintenance 2 Remove the rear wheel and tire assembly from the vehicle 3 Remove the rear caliper assembly from the adapter Refer to...

Page 68: ...point of center punch does not puncture strut assembly 11 Insert a center punch into the hole on the spindle Fig 13 Center punch must be tapped into the hole in the spindle until jammed into place This will spread the spindle casting allowing it to be removed from strut assembly Fig 8 Speed Sensor Head 1 STABILIZER BAR LINK 2 STABILIZER BAR 3 LATERAL LINK 4 BOLT 5 WHEEL SPEED SENSOR 6 STRUT ASSEMB...

Page 69: ...apter Fig 8 Tighten the speed sensor head attaching bolt to a torque of 7 N m 60 in lbs 6 Install the rear hub and bearing assembly on the rear spindle Install hub and bearing assembly retaining washer and nut on spindle Fig 7 Tighten the hub and bearing retaining nut to a torque of 168 N m 124 ft lbs 7 Install the rear brake disc on the hub 8 Carefully place rear brake caliper over rotor and inst...

Page 70: ...ching links Verify all fastener bolts are properly tightened Inspect the bushings and sleeves on the stabilizer bar links for damage or deterioration Inspect the links lower ball stud for excessive looseness and damage Inspect the stabilizer bar link to ensure it is not bent or broken If any of these conditions are present when inspecting the links replace the stabi lizer bar links as required REM...

Page 71: ...ner half on until the mounting holes line up with the ones in the lower half 5 Using a pair of pliers bend the retainer tabs on the upper retainer half around the lower retainer half securing the two halves together 6 Remove the stabilizer bar from the vise and repeat the preceding 5 steps to install the second bushing and retainer on the other side of the stabi lizer bar 7 Position the rear stabi...

Page 72: ...ng vibration jounce and rebound of the suspen sion The coil spring controls ride quality and maintains ride height The jounce bumper limits suspension travel and metal to metal contact under full jounce The strut dampens jounce and rebound motions of the coil spring and suspension DIAGNOSIS AND TESTING STRUT ASSEMBLY REAR 1 Inspect for damaged or broken coil springs Fig 19 2 Inspect for torn or da...

Page 73: ...ion and Maintenance 8 Remove the rear wheel and tire assembly from the vehicle 9 Remove the rear caliper assembly from the adapter Refer to Brakes Disc Brake Caliper After removing the caliper assembly store the caliper by hanging it from the underside of the vehicle Fig 20 Do not let the rear caliper assembly hang by flexible brake hose 10 If loose on wheel mounting studs remove rear brake rotor ...

Page 74: ...strut assembly Fig 26 17 Let the rear spindle and assembled compo nents hang from the trailing arm while the strut assembly is out of the vehicle Fig 22 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 23 Link Attachment To Stabilizer Bar 1 STABILIZ...

Page 75: ...from the coil spring when it is compressed This would result in the required replacement of the coil spring 2 Position the strut assembly in the strut coil spring compressor following the manufacturers instructions Position the strut assembly so the out board side of the strut is outward away from the compressor Grasp the upper and lower coils of the spring with the upper and lower hooks of the co...

Page 76: ... the upper end of assembly Before compress ing the spring rotate the spring to the position noted in disassembly for ease of strut assembly compo nents 2 Install the lower spring isolator on strut matching the step in the isolator to the step in the strut lower spring seat 3 Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil sprin...

Page 77: ...en to 7 N m 60 in lbs 8 Install rear braking disc on hub Carefully install rear brake caliper over braking disc and install on adapter Tighten 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 t...

Page 78: ...ight This angle cannot be set once the trailing arm and bracket are installed on the vehicle 1 Install the trailing arm to the mounting bracket so the length wise opening in the arm points downward Align the plane of the arm at a 5 degree angle to the mounting bracket mounting surface to the vehicle Fig 32 This can be accomplished by using a simple magnetic base protractor Fig 32 Verify the mounti...

Page 79: ...s in proper sequence until all nuts are torqued to half specifica tion Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs 5 Lower vehicle to the ground 6 Tighten the trailing arm to spindle bracket attaching bolt to a torque of 100 N m 75 ft lbs 7 Check and reset rear wheel toe to specifications if required Refer to Wheel Alignment LH REAR SUSPENSION 2 49 TRAILI...

Page 80: ...acy of the alignment except when DaimlerChrysler Corporation s wheel alignment specifications differ On this vehicle the suspension angles that can be adjusted are as follows Front Camber Toe Rear Toe Check the wheel alignment and make all wheel align ment adjustments with the vehicle standing at its proper curb height specification Curb height is the nor mal riding height of the vehicle It is mea...

Page 81: ...ear a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster CROSS CASTER Cross caster is the difference between left and right caster TOE Toe is the inward or outward angle of the wheels as viewed from above the vehicle Fig 3 Toe in is produced when the front edges of the wheels on the same axle are closer together than the rear edge...

Page 82: ...ot necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehi cle has been damaged STEERING AXIS INCLINATION S A I Steering axis inclination is the angle between a true vertical line starting at the center of the tire at the road contact point and a line drawn throu...

Page 83: ... Negative thrust angle means the rear tires are tracking to the left of the front tires Positive thrust angle means the rear tires are tracking to the right of the front tires Improper tracking can cause undue tire wear a lead or pull and a crooked steering wheel Excessive thrust angle can usually be corrected by adjusting the rear wheel toe so that each wheel has one half of the total toe measure...

Page 84: ...nt 3 Worn or loose tie rod 3 Tighten or replace tie rod end 4 Worn or loose ball joint 4 Tighten or replace ball joint 5 Worn loose control arm bushing 5 Replace control arm bushing 6 Loose stabilizer bar 6 Tighten stabilizer bar to specified torque 7 Loose strut mount to body attachment 7 Tighten strut attachment to specified torque 8 Loose crossmember bolts 8 Tighten crossmember bolts to specifi...

Page 85: ...t upper bearing 7 Replace strut bearing Lateral Pull 1 Unequal tire pressure 1 Inflate all tires to recommended pressure 2 Radial tire lead 2 Perform lead correction procedure 3 Incorrect front wheel camber 3 Check and reset front wheel camber 4 Power steering gear imbalance 4 Replace power steering gear 5 Wheel braking 5 Correct braking condition causing lateral pull Excessive Steering Free Play ...

Page 86: ... is designed to be used in conjunc tion with Diagnosis And Testing Vehicle Lead Pull Refer to 2 SUSPENSION WHEEL ALIGNMENT DIAGNOSIS AND TESTING Proceed with the Caster Bias procedure before attempting the Camber Bias procedure CASTER BIAS On a vehicle that leads left create more caster on the left than on the right On a right lead vehicle the procedure is opposite Try to get at least 0 8 degree o...

Page 87: ...ior to reading the vehicle s alignment readouts the front and rear of vehicle should be jounced Induce jounce rear first then front by grasping the center of the bumper and 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 3 Read the vehicle s current front and rear align ment settings Compare the vehicle s ...

Page 88: ...ber is within specifications This procedure involves replac ing the original strut clevis to knuckle attachment bolts with special undersized bolts 1 Raise the front of vehicle by the frame until the tires are not supporting the weight of the vehicle 2 Remove the tire and wheel assembly from the location on the vehicle requiring camber adjustment CAUTION When removing the strut to knuckle bolts fr...

Page 89: ...allowed alignment specification STANDARD PROCEDURE CURB HEIGHT MEASUREMENT The wheel alignment is to be checked and all align ment adjustments made with the vehicle at its required curb height specification Vehicle height is to be checked with the vehicle on a flat level surface preferably a vehicle alignment rack The tires are to be inflated to the recommended pressure All tires are to be the sam...

Page 90: ...BLE RANGE CAMBER 0 00 0 60 to 0 60 Cross Camber Maximum Side 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 20 20 to 0 20 REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE CAMBER 20 20 20 70 to 0 30 TOTAL TOE 0 10 20 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...

Page 91: ...ter joint is fastened to the hub to ensure that there is no axial movement end play Both inner and outer joints utilize flexible boots Fig 1 Fig 2 which maintain grease within the joints protect the joints from the environment ele ments and facilitate the axial and angular move ment of the joints The inner joint boots are constructed of silicone rubber The outer boots are made of Hytrel plastic NO...

Page 92: ...or worn halfshaft C V joint SHUDDER OR VIBRATION DURING ACCELERATION This problem could be a result of 1 A worn or damaged halfshaft inner tripod joint 2 A sticking tripod joint spider assembly inner tripod joint only 3 Improper wheel alignment Refer to 2 SUS PENSION WHEEL ALIGNMENT STANDARD PROCEDURE VIBRATION AT HIGHWAY SPEEDS This problem could be a result of 1 Foreign material mud snow etc pac...

Page 93: ...OINT 13 SEAL DRIVE AXLE OUTBOARD 4 RING RETAINING 14 CLAMP SEAL RETAINING 5 RETAINER BALL ROLLER 15 RING RACE RETAINING 6 BALL TRIPOD JOINT 16 BALL CHROME ALLOY 7 ROLLER NEEDLE 17 RACE C V JOINT INNER 8 CLAMP SEAL RETAINING 18 CAGE C V JOINT 9 BUSHING TRILOBAL TRIPOD 19 RACE C V JOINT OUTER 10 SEAL DRIVE AXLE INBOARD LH HALFSHAFT 3 3 HALFSHAFT Continued ...

Page 94: ...e inner tripod joint from the trans mission stub shaft at this time CAUTION The strut assembly to steering knuckle bolts are serrated where they go 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 8 Remove the strut assembly to steering knuckle attaching bolts Fig 8 9...

Page 95: ... from the stub shaft the retaining circlip and O ring seal MUST BE REPLACED The retaining circlip and O ring seal is included in all service kits requiring removal of the inboard tripod joint from the stub shaft Fig 6 Hub And Bearing To Stub Axle Retaining Nut 1 HUB BEARING ASSEMBLY 2 NUT Fig 7 Inner Tripod Joint Removal from Stub Shaft 1 TRANSMISSION STUB SHAFT 2 INNER TRIPOD JOINT 3 PRY BAR 4 TR...

Page 96: ...e visible when inner tripod joint is fully installed on stub shaft To check that inner tripod joint retaining circlip is locked into tri pod joint grasp inner tripod joint and pull on it by hand If circlip is locked into tripod joint tripod joint will not move on stub shaft CAUTION When installing outer C V joint into the hub and bearing assembly do not allow the flinger disk on hub and bearing as...

Page 97: ...bearing assembly to stub shaft retaining nut is a prevailing torque nut and can not be re used A NEW retaining nut MUST be used when assembled 8 Install a NEW retaining nut Fig 16 Tighten 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 i...

Page 98: ...5 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 nut to 142 N m 105 ft lbs Fig 20 Fig 17 Installing Brake Rotor 1 HUB 2 STEERING KNUCKLE 3 BRAKE ROTOR DISC 4 WHEEL MOUNTING STUD Fig 18 Disc Brake Caliper Mounting 1 BRAKE SHOES 2 STEERIN...

Page 99: ...t 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 22 4 Remove snap ring which retains spider assem bly to interconnecting shaft Fig 23 Then remove the spider assembly from interconnecting shaft If spider assembly will not come off interconn...

Page 100: ...ss drift Do not hit the outer tripod bearings in an attempt to install spider assembly on intercon necting shaft 3 Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of inter connecting shaft Fig 25 Verify the snap ring is fully seated into groove on interconnecting shaft 4 Distribute 1 2 the amount of grease provided in the seal boot service package DO NOT...

Page 101: ...oot retaining clamp evenly on sealing boot 9 Clamp sealing boot onto tripod housing using Crimper Special Tool C 4975 and the following pro cedure Place crimping tool C 4975 over bridge of clamp Tighten nut on crimping tool C 4975 until jaws on tool are closed completely together face to face Fig 25 Spider Assembly Retaining Snap Ring 1 SNAP RING 2 SEALING BOOT 3 SPIDER ASSEMBLY 4 SNAP RING PLIERS...

Page 102: ... retaining ring Spread ears apart on C V joint assembly to interconnecting shaft retaining snap ring Fig 31 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 halfshaft ass...

Page 103: ...ing shaft so only the thinnest sight groove on interconnecting shaft is visible Fig 33 5 Clamp sealing boot on interconnecting shaft using Crimper Special Tool C 4975 and the following procedure Place crimping tool C 4975 over bridge of clamp Fig 34 Tighten nut on crimping tool C 4975 until jaws on tool are closed completely together face to face Fig 35 CAUTION Seal must not be dimpled stretched o...

Page 104: ...all the driveshaft requiring boot replace ment back on the vehicle Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT INSTALLATION Fig 35 Sealing Boot Retaining Clamp Installed 1 SEALING BOOT 2 SPECIAL TOOL C 4975 3 CLAMP BRIDGE Fig 36 Crimping Tool Installed On Sealing Boot Clamp 1 SPECIAL TOOL C 4975 2 SEALING BOOT 3 CLAMP BRIDGE Fig 37 Sealing Boot Retaining Clamp Installed 1 BOOT CLAMP 2 SPECIAL TO...

Page 105: ...ISC BRAKE SHOES 15 REMOVAL FRONT DISC BRAKE SHOES EXPORT 16 CLEANING DISC BRAKE SHOES 16 INSPECTION DISC BRAKE SHOES 17 INSTALLATION INSTALLATION FRONT DISC BRAKE SHOES 17 INSTALLATION FRONT DISC BRAKE SHOES EXPORT 18 BRAKE PADS SHOES REAR REMOVAL REAR DISC BRAKE SHOES 18 CLEANING DISC BRAKE SHOES 20 INSPECTION DISC BRAKE SHOES 20 INSTALLATION REAR DISC BRAKE SHOES 20 DISC BRAKE CALIPER FRONT REMO...

Page 106: ...DIAGNOSIS AND TESTING PROPORTIONING VALVE 46 ROTOR DIAGNOSIS AND TESTING BRAKE ROTOR 48 STANDARD PROCEDURE BRAKE ROTOR MACHINING 51 REMOVAL REMOVAL BRAKE ROTOR FRONT 52 REMOVAL BRAKE ROTOR REAR 52 INSTALLATION INSTALLATION BRAKE ROTOR FRONT 53 INSTALLATION BRAKE ROTOR REAR 53 PARKING BRAKE DESCRIPTION 53 OPERATION 53 ADJUSTMENTS ADJUSTMENT PARKING BRAKE 53 PARKING BRAKE CABLE TENSIONER REMOVAL 54 ...

Page 107: ... valves to the brakes at each tire and wheel assembly The pedal operated parking brake operates in the following manner When applied the parking brake lever pulls on cables that actuate parking brake shoes at each rear wheel For more information on the operation of any indi vidual base brake component refer to that compo nent elsewhere in this section WARNING WARNING DUST AND DIRT ACCUMULATING ON ...

Page 108: ...g process This will only increase the amount of air in the system and make additional bleeding necessary NOTE Do not allow the master cylinder reservoir to run out of brake fluid while bleeding the system An empty reservoir will allow additional air into the brake system Check the fluid level frequently and add fluid as needed The following wheel circuit sequence for bleeding the brake hydraulic s...

Page 109: ...lp is required 1 Remove rubber duct caps from all 4 bleeder screws 2 Attach a clear hose to the bleeder screw at one wheel and feed the other end of the hose into a clear jar containing fresh brake fluid Fig 2 3 Have an assistant pump the brake pedal three or four times and hold it down before the bleeder screw is opened CAUTION Open the bleeder screw at least one full turn when instructed Some ai...

Page 110: ...res Master Cylinder Type with ABS Center Valve Port Master Cylinder Type without ABS Vent Port Master Cylinder Bore Stroke 23 8 mm x 39 4 mm 0 937 in x 1 55 in Master Cylinder Split 50 50 Master Cylinder Outlet Port Primary Tube Nut Thread M 12 Master Cylinder Outlet Port Secondary Tube Nut Thread W ABS M 10 Master Cylinder Outlet Port Secondary Tube Nut Thread W O ABS M 12 Power Brake Booster Typ...

Page 111: ...e Pressure Test 6892 Adapters Brake Pressure Test 8187 Gauge Set C 4007 A Tubes Master Cylinder Bleed 8358 Handle Universal C 4171 Installer Dust Boot C 4689 Dial Indicator C 3339 LH BRAKES BASE BRAKE SYSTEM 5 7 BRAKES BASE BRAKE SYSTEM Continued ...

Page 112: ...se no adapter The caliper is mounted to the steering knuckle using bushings sleeves and two thru bolts which thread directly into the steering knuckle Fig 6 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 There are two brake shoes pads mounted to the brake caliper Fig 5 One...

Page 113: ... PISTON 15 GUIDE PIN BOLT 7 DUST SEAL 16 CAP 8 WEAR INDICATOR 17 BLEEDER SCREW 9 ANTI RATTLE CLIP Fig 6 Disc Brake Caliper Mounting 1 BRAKE LINE 2 CALIPER GUIDE PIN BOLTS 3 STEERING KNUCKLE 4 BLEEDER SCREW 5 CALIPER ASSEMBLY Fig 7 Externally And Internally Vented Rotors Cross Sectional View 1 EXTERNAL VENTS 2 INTERNAL VENTS LH BRAKES BASE BRAKE SYSTEM 5 9 HYDRAULIC MECHANICAL Continued ...

Page 114: ...to mount the brake shoes and actuating cables for the parking brake system The adapter also mounts the rear caliper assembly to the vehicle The adapter has two machined abutments which are used to position and align the caliper and brake shoes for movement inboard and outboard This vehicle uses a 14 inch solid non vented rear disc brake rotor Fig 8 It is a drum in hat style It serves a dual purpos...

Page 115: ... the piston is pushed back into the recessed position An audible wear indicator Fig 5 is mounted on the outboard pad of the front disc brake assemblies Upon contact with the brake rotor this indicator emits a sound signaling that brake shoes may need inspection or replacement OPERATION REAR DISC BRAKES Rear disc brakes operate similarly to front disc brakes Refer to Front Disc Brakes for additiona...

Page 116: ...S DRAG FRONT OR ALL 1 Contaminated brake fluid 1 Check for swollen seals Replace all system components containing rubber 2 Binding caliper pins or bushings 2 Replace pins and bushings 3 Binding master cylinder 3 Replace master cylinder 4 Binding brake pedal 4 Replace brake pedal BRAKES DRAG REAR ONLY 1 Parking brake cables binding or froze up 1 Check cable routing Replace cables as necessary 2 Par...

Page 117: ...agnosis and testing section PREMATURE REAR WHEEL LOCKUP 1 Contaminated brake shoe linings 1 Inspect and clean or replace shoes Repair source of contamination 2 Inoperative proportioning valve 2 Test proportioning valves folowing procedure listed in diagnosis and testing section Replace valves as necessary 3 Improper power brake booster assist 3 Refer to power brake booster in the diagnosis and tes...

Page 118: ... the master cylinder to the wheel brakes of the vehicle The flex hoses are made of rubber to allow for the move ment of the vehicle s steering and suspension INSPECTION BRAKE TUBES AND HOSES Flexible rubber hose is used at both front and rear brakes Inspection of brake hoses should be performed whenever the brake system is serviced and every 7 500 miles or 12 months whichever comes first every eng...

Page 119: ...hen lifting caliper off bottom machined abutment on steering knuckle Fig 12 Take care not to lose the two rail shims 5 Hang the caliper off to the side using wire or bungee cord Fig 13 Do not allow the caliper to be supported by the flexible brake hose Damage to the flexible brake hose may result Fig 11 Caliper Guide Pin Bolts 1 CALIPER ASSEMBLY 2 GUIDE PIN BOLT 3 GUIDE PIN BOLT 4 STEERING KNUCKLE...

Page 120: ...piston until retaining clip is free from cavity in piston Fig 15 8 Repeat steps 3 through 7 on opposite side of vehicle to remove that sides brake shoes CLEANING DISC BRAKE SHOES WARNING DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CON TAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY ...

Page 121: ...ring knuckle abutments with a liberal amount of Mopart Brake Grease For Caliper Slides Lubricant or equivalent 3 Remove the protective paper from the noise suppression gasket on both the inner and outer brake shoe assemblies if equipped NOTE The inboard and outboard brake shoes are not common refer to Fig 16 for inboard and out board brake shoe assembly identification NOTE When installing inboard ...

Page 122: ...board brake shoe assembly onto the caliper assembly Fig 17 6 Carefully position caliper and brake shoes over rotor by reversing the removal procedure Fig 12 CAUTION When being installed extreme caution should be taken not to crossthread the caliper guide pin bolts 7 Install the caliper guide pin bolts Fig 11 Tighten guide pin bolts to a torque of 22 N m 192 in lbs 8 Repeat the preceding steps on t...

Page 123: ...he wheel mounting studs Fig 21 7 Remove outboard brake shoe by prying brake shoe retaining clip over raised area on caliper and sliding the shoe off the caliper Fig 22 Fig 19 Removing Installing Caliper 1 ADAPTER 2 BRAKING DISC 3 CALIPER ASSEMBLY 4 ADAPTER ABUTMENT Fig 20 Storing Caliper 1 FLEX HOSE 2 STRUT 3 WIRE HANGER 4 CALIPER ASSEMBLY Fig 21 Removing Installing Rear Rotor 1 BRAKE ROTOR DISC 2...

Page 124: ...o a thickness of approximately 7 95 mm 5 16 inch they should be replaced For rear disc brake shoes when a set of brake shoes are worn to a thickness of approximately 7 0 mm 9 32 inch they should be replaced Typically if front shoes are worn out both fronts and rears need to be replaced Make sure to check rears Replace both disc brake shoes inboard and out board on each caliper It is necessary to r...

Page 125: ...will isolate the master cylinder reser voir from the brake hydraulic system not allowing the brake fluid to drain out of the reservoir 2 Raise vehicle on jackstands or centered on a hoist See Hoisting in Lubrication and Maintenance 3 Remove front wheel and tire assembly from vehicle 4 Remove the banjo bolt connecting the brake flex hose to the caliper There will be two washers one on each side of ...

Page 126: ...knuckle Fig 25 7 If required remove rotor from hub by pulling it straight off wheel mounting studs Fig 26 DISASSEMBLY DISASSEMBLY CALIPER GUIDE PIN BUSHINGS Before disassembling the brake caliper clean and inspect it Refer to CLEANING or INSPECTION in this section 1 With one hand push the guide pin bushing sleeve towards the back of the caliper and at the same time pull the sleeve out the back of ...

Page 127: ...om completely draining out 3 Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle CAUTION Do not use excessive force when clamp ing caliper in vise Excessive vise pressure will cause bore distortion 4 Mount the caliper in a vise equipped with pro tective jaws 5 Remove the piston dust boot from the caliper and discard Fig 29 NOTE Do not use a screw driver or...

Page 128: ...G EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM EXERCISE CARE WHEN SERVICING BRAKE PARTS DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CON TAIN THE DUST RESIDUE DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER THEN WIPING THE BRAKE COMPONENTS CLEAN...

Page 129: ...he bushing is fully seated into the caliper housing The bushing flanges should be seated evenly on both sides of the bushing hole Fig 34 4 Lubricate the inside surfaces of the bushing using Mopart Dielectric Grease or an equivalent Fig 32 Folded Caliper Guide Pin Bushing 1 CALIPER GUIDE PIN BUSHING Fig 33 Installing Caliper Guide Pin Bushing 1 CALIPER 2 BUSHING Fig 34 Bushing Correctly Installed I...

Page 130: ...CALIPER PISTON AND SEAL NOTE Never use an old piston seal 1 Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore The seal should be started at one area of the groove and gently worked around and into the groove Fig 37 using only your clean fingers to seat it 2 Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot 3 Positi...

Page 131: ...on the shims are positioned toward the abutments 5 Carefully position caliper and brake shoes over rotor by reversing removal procedure Fig 25 CAUTION When being installed extreme caution should be taken not to crossthread the caliper guide pin bolts 6 Install the caliper guide pin bolts Tighten guide pin bolts to a torque of 22 N m 192 in lbs 7 Install the banjo bolt connecting the flex hose to t...

Page 132: ...mbly 8 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 135 N m 100 ft lbs 9 Lower vehicle CAUTION After performing any service to the vehi cle brake system be sure to obtain a firm brake pedal before moving vehicle 10 Remove the brake pedal holding tool 11 Bleed the base bra...

Page 133: ...t Refer to CLEANING or INSPECTION in this section 1 With one hand push the guide pin bushing sleeve towards the back of the caliper and at the same time pull the sleeve out the back of the caliper and bushing Fig 44 Fig 42 Storing Caliper 1 FLEX HOSE 2 STRUT 3 WIRE HANGER 4 CALIPER ASSEMBLY Fig 43 Removing Installing Rear Rotor 1 BRAKE ROTOR DISC 2 DISC SHIELD 3 HUB 4 DRUM IN HAT PARKING BRAKE Fig...

Page 134: ...a brake pedal holding tool This will prevent the fluid in the master cylinder reservoir from completely draining out 3 Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle CAUTION Do not use excessive force when clamp ing caliper in vise Excessive vise pressure will cause bore distortion 4 Mount the caliper in a vise equipped with pro tective jaws 5 Remove ...

Page 135: ... WITH COMPRESSED AIR OR BY DRY BRUSHING CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN ING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL FOL LOW PRACTICES PRESCRIBED BY THE OCCUPA TIONAL SAFETY AND HEALTH ADMINISTRATION OSHA AND THE ENV...

Page 136: ...the bushing is fully seated into the caliper housing The bushing flanges should be seated evenly on both sides of the bushing hole Fig 51 4 Lubricate the inside surfaces of the bushing using Mopart Dielectric Grease or an equivalent Fig 49 Folded Caliper Guide Pin Bushing 1 CALIPER GUIDE PIN BUSHING Fig 50 Installing Caliper Guide Pin Bushing 1 CALIPER 2 BUSHING Fig 51 Bushing Correctly Installed ...

Page 137: ...CALIPER PISTON AND SEAL NOTE Never use an old piston seal 1 Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore The seal should be started at one area of the groove and gently worked around and into the groove Fig 54 using only your clean fingers to seat it 2 Coat the new piston boot with clean brake fluid leaving a generous amount inside the boot 3 Positi...

Page 138: ...er so the caliper guide pin bushings do not get damaged by the mounting bosses 4 Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse proce dure for removal Fig 41 CAUTION When installing guide pin bolts extreme caution should be taken not to crossthread the cal iper guide pin bolts 5 Install the caliper guide pin bolts Tighten the guide pin bolts to a torque o...

Page 139: ...e fluid reservoir Fig 57 In the event of low brake fluid level in the brake fluid reservoir the RED brake warning indicator lamp in the instrument cluster will turn on SPECIFICATIONS BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards No other type of brake fluid is recommended or approved for usage in the vehicle brake system Use only Mopa...

Page 140: ...RAULIC MECHANICAL PROPORTION ING VALVE OPERATION REMOVAL 1 Disconnect and isolate the negative battery connection at the right front strut tower 2 Using a brake pedal holding tool such as shown Fig 59 depress brake pedal past its first 1 inch of travel and secure in this position This will isolate the master cylinder reservoir from the brake hydrau lic system not allowing the brake fluid to drain ...

Page 141: ...ion block and bracket forward on the remaining mounting bolt and remove the junc tion block and bracket from the vehicle INSTALLATION 1 If not already installed install but do not tighten the one bolt in the junction block bracket Fig 63 2 Install the junction block with mounting bracket onto the engine cradle crossmember guiding the installed bolt into the slot in the engine cradle crossmember 3 ...

Page 142: ...ylinder are machined to accept 12 mm tube nuts The master cylinder is mounted to the face of the power brake booster on the left side of the dash Fig 64 It has the brake fluid reservoir mounted on top and the brake fluid level switch is mounted in the side of that reservoir OPERATION When the brake pedal is pressed the master cylin der primary and secondary pistons apply brake pres sure through th...

Page 143: ...valent conforming to DOT 3 specifications Make sure fluid level is above tips of bleeder tubes in res ervoir 4 Using a wooden dowel as a pushrod Fig 65 slowly depress master cylinder pistons then release pressure allowing pistons to return to released posi tion Repeat several times until all air bubbles are expelled Make sure fluid level stays above tips of bleeder tubes in reservoir while bleedin...

Page 144: ... sealing grommets using a rocking motion while pushing down on reservoir 3 Make sure bottom of reservoir touches the top of both sealing grommets 4 Install the 2 fluid reservoir to master cylinder retaining pins Fig 67 5 Bleed and install master cylinder on vehicle Refer to 5 BRAKES HYDRAULIC MECHANICAL MASTER CYLINDER STANDARD PROCEDURE INSTALLATION CAUTION If the master cylinder is being replace...

Page 145: ...from the brake pedal pin securing the power brake booster to the pedal using following procedure Fig 71 Position a small screwdriver between the center tang on the retaining clip and the brake pedal pin Rotate blade of screw driver enough so center tang on retaining clip can pass over end of brake pedal pin then pull retaining clip off brake pedal pin 4 Remove the booster input rod from the brake ...

Page 146: ... fully installed into the bracket rotate the switch in a clockwise direction approximately 30 degrees until it locks into place CAUTION Do not use excessive force when pulling back on brake pedal to adjust the brake lamp switch If to much force is used damage to the brake lamp switch or striker can result 11 Gently release pull back the brake pedal until it stops moving This will cause the switch ...

Page 147: ...tly then hold Less effort should be needed to apply the pedal at this time If the pedal fell as indicated perform the VACUUM LEAK TEST listed after the BASIC TEST If the pedal did not fall continue on with this BASIC TEST 3 Disconnect the vacuum hose on the side of the vacuum check valve that leads to the speed control then connect a vacuum gauge to the open vacuum port on the valve 4 Start the en...

Page 148: ...m the ground stud on the right strut tower Then correctly isolate the ground cable by installing the cable isola tor on the ground stud Fig 74 2 Remove caps from both wiper arms at the attachment to the pivots to expose the wiper arm attaching nut Remove the nut attaching each wiper arm to its pivot Fig 75 3 Remove the wiper arms from the pivots Wiper arms are removed from the pivots by rocking th...

Page 149: ... lever until the crank lever points in the 12 o clock position Fig 80 14 Slide the power brake booster out of the dash panel and remove from vehicle CAUTION Do not attempt to disassemble the power brake vacuum booster It is serviced ONLY as a complete assembly INSTALLATION POWER BRAKE BOOSTER 1 Position power brake vacuum booster on dash panel 2 Install and tighten the 4 power brake booster to das...

Page 150: ... brakes This pre vents premature rear wheel skid If hydraulic pressure is lost in one half of the diag onally split brake hydraulic system the operation of the proportioning valve in the remaining half is not affected DIAGNOSIS AND TESTING PROPORTIONING VALVE Vehicles without Antilock Brakes have two propor tioning valves One proportioning valve controls the right rear brake and the other proporti...

Page 151: ...shown on the chart once inlet pressure shown on chart is obtained replace the junction block with internal proportioning valves Refer to 5 BRAKES BASE HYDRAULIC MECHANICAL JUNCTION BLOCK REMOVAL If pressure is within specifications do not replace pro portioning valve and perform the following steps 18 Remove the Pressure Gauge and Adapter Special Tool 8494 3 or 8494 4 from junction block 19 Reinst...

Page 152: ... MECHANICAL ROTORS STANDARD PROCEDURE Excessive wear and scoring of the rotor can cause improper lining contact on the rotor s braking sur face If the ridges on the rotor are not removed before new brake shoes are installed improper wear of the shoes will result If a vehicle has not been driven for a period of time the rotor s braking surface will rust in the areas not covered by the brake shoes a...

Page 153: ...ll the wheel mounting nuts on the studs tightening the rotor to the hub Mount the Dial Indicator Special Tool C 3339 with Mounting Adaptor Special Tool SP 1910 on steering arm The dial indicator plunger should contact braking surface of rotor approximately 25 mm one inch from outer edge of rotor Fig 86 Check lateral runout on both sides of the rotor marking the low and high spots on both Runout li...

Page 154: ...otor with a wheel mounting stud two studs apart from the original stud Fig 89 Tighten nuts in the proper sequence and torque to specifications Recheck brake rotor runout to see if the runout is now within specifications If runout is not within specifications reface or replace the brake rotor Refer to 5 BRAKES BASE HYDRAULIC MECHANICAL ROTORS STANDARD PROCEDURE BRAKE ROTOR LIMITS Braking Rotor Roto...

Page 155: ... rotor machined surface may be cut to CAUTION Do not machine the rotor if it will cause the rotor to fall below minimum thickness Before installation verify the brake rotor face and the hub adapters are free of any chips rust or con tamination When mounting and using the brake lathe strict attention to the brake lathe manufacturer s operating instructions is required Machine both sides of the brak...

Page 156: ...L 2 Remove any clips retaining the brake rotor to the wheel mounting studs 3 Remove brake rotor from hub by pulling it straight off wheel mounting studs Fig 93 REMOVAL BRAKE ROTOR REAR 1 Remove disc brake caliper and store hang it out of the way following the procedure found in Brake Pads Shoes Refer to 5 BRAKES BASE HY DRAULIC MECHANICAL BRAKE PADS SHOES REMOVAL 2 Remove any clips retaining the b...

Page 157: ... The rear cables are joined at an equalizer bracket and cable tensioner which is attached to the intermediate cable The opposite end of the intermediate cable is attached to the front cable which leads to the foot operated lever mounted inside the passenger compartment OPERATION When the parking brake foot lever is pressed the cables are pulled thus actuating the parking brake shoes The shoes expa...

Page 158: ...the park brake tensioner from the left rear parking brake cable Fig 97 4 Remove the park brake tensioner with its iso lator from the vehicle INSTALLATION 1 Mark tensioner rod 6 35 mm 1 4 in from edge of tensioner bracket Fig 98 2 Install the park brake tensioner with its iso lator in the vehicle with the threaded adjustment stud pointed towards the right side of the vehicle Fig 97 3 Connect the le...

Page 159: ...diate cable retainer to the body torque box Fig 99 5 Remove the intermediate cable from the body torque box Fig 99 6 Remove the connector from the intermediate cable at the right rear park brake cable 7 Remove the intermediate cable from the ten sioner bracket using the box end of a 1 2 inch wrench 8 Release the latch on the routing clip for the intermediate cable mounted above the left rear cable...

Page 160: ...EAR CABLE NOTE This procedure can be used to install either rear parking brake cable 1 Install the rear parking brake cable by routing the leading end above the intermediate cable then between the frame crossmember and stabilizer bar 2 Install the other end of the cable into the disc brake adapter allowing the retainer tabs to lock into place in the adapter 3 Install the park brake actuator lever ...

Page 161: ...ossmember 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 kick panel 8 Remove the fuse panel cover from the left end of the instrument panel Fig 102 9 Remove the 2 screws behind the fuse panel cover attaching the lower instrument ...

Page 162: ...ews securing fuse junction block 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 107 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 Re...

Page 163: ...le 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 retainer bracket to ...

Page 164: ... 10 Pull rear brake shoe assembly away from anchor then remove rear brake shoe and upper spring 11 Remove front brake shoe hold down clip then remove front brake shoe assembly INSTALLATION PARKING BRAKE SHOES 1 Install front brake shoe and hold down clip 2 Install rear brake shoe and the upper brake shoe to shoe return spring 3 Pull rear brake shoe over anchor block until properly located on adapt...

Page 165: ... 79 INSTALLATION ICU 79 BRAKES ANTILOCK BRAKE SYSTEM DESCRIPTION DESCRIPTION ANTILOCK BRAKES This section covers the physical and operational descriptions and the on car service procedures for vehicles equipped with the Mark 20e Antilock Brake System and the Mark 20e Antilock Brake System with traction control The purpose of this four channel design antilock brake system is to prevent wheel lockup...

Page 166: ...n signals generated by the wheel speed sensors WSS at each wheel and received at the controller antilock brake CAB NOISE AND BRAKE PEDAL FEEL During ABS braking some brake pedal movement may be felt In addition ABS braking will create ticking popping or groaning noises heard by the driver This is normal and is due to pressurized fluid being transferred between the master cylinder and the brakes If...

Page 167: ...rakes This back and forth process will con tinue until the required slip difference is obtained At the end of EVBP braking brakes released the fluid in the LPA drains back to the master cylinder by switching on the outlet valve and draining through the inlet valve check valve At the same time the inlet valve is switched on in case of another brake application The EVBP will remain functional during...

Page 168: ...y components of the ABS System are not serviceable and must be replaced as an assembly Do not disassemble any component which is not designed to be serviced CAUTION Only the recommended jacking or hoist ing positions for this vehicle are to be used when ever it is necessary to lift a vehicle Failure to raise a vehicle from the recommended locations could result in lifting a vehicle by the hydrauli...

Page 169: ...ro priate Diagnostic Information 8 If the amber ABS warning indicator lamp goes out at any time drive the vehicle a short distance Accelerate the vehicle to a speed of at least 64 km h 40 mph Bring the vehicle to a complete stop brak ing hard enough to cause the ABS to cycle Repeat this action several times Using the DRBIIIt read and record any Diagnostic Trouble Codes DTCs If any DTCs are present...

Page 170: ...two wire wheel speed sensors known as active wheel speed sensors One wheel speed sensor WSS and one tone wheel is located at each front and rear wheel Each front wheel speed sensor is attached to a boss in the steering knuckle Fig 2 The front tone wheel is part of the outboard constant velocity joint OPERATION The CAB sends 12 volts to power an Integrated Circuit IC in the sensor The IC supplies a...

Page 171: ...bles resulting in an open circuit 1 Connect the wheel speed sensor cable connector to the vehicle wiring harness 2 Install the speed sensor cable assembly grom met into the front inner fender Install speed sensor cable grommet and retainer bracket on the inner fender of the vehicle and install and securely tighten attaching bolt CAUTION When installing the wheel speed sensor cable routing bracket ...

Page 172: ... signal is interpreted by the ABS CAB as the wheel speed REMOVAL NOTE When removing rear wheel speed sensor from vehicle access to the wire harness connector is through the passenger compartment of the vehi cle 1 Remove the rear seat cushion and the rear seat back from the interior of the car Refer to Seats in the Body section of this manual for the required procedure to be used for this vehicle 2...

Page 173: ...tallation If wheel speed sensor to tone wheel contact is evi dent determine the cause and correct it before replacing the wheel speed sensor or tone wheel Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications Refer to SPECIFICATIONS in this section Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals Refer to SPECI FICATION...

Page 174: ... The driver is applying the brake pedal which builds pres sure in the brake hydraulic system to engage the brakes and stop the vehicle Fig 7 Normal Braking Hydraulic Circuit W O Traction Control 1 OUTLET VALVE 2 PUMP PISTON 3 PUMP MOTOR OFF 4 LOW PRESSURE ACCUMULATOR 5 NORMALLY CLOSED VALVE OFF 6 TO RIGHT FRONT WHEEL 7 NORMALLY OPEN VALVE OFF 8 MASTER CYLINDER PRESSURE 9 FROM MASTER CYLINDER 10 NO...

Page 175: ...rake 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 Fig 8 ABS Mode Hydraulic Circuit W O Traction Control 1 OUTLET VALVE 2 PUMP PISTON 3 PUMP MOTOR ON 4 LOW PRESSURE ACCUMULATOR PRESSURE 5 LOW PRESSURE ACCUMULATOR 6 NORMALLY CLOSED V...

Page 176: ...rakes and stop the vehicle The hydraulic shuttle valve closes with every brake pedal application so pressure is not created at the inlet to the pump motor Fig 9 ABS With Traction Control Normal Braking Hydraulic Circuit 1 OUTLET VALVE 2 PUMP PISTON 3 PUMP MOTOR OFF 4 SUCTION VALVE 5 LOW PRESSURE ACCUMULATOR 6 NORMALLY CLOSED VALVE OFF 7 TO RIGHT FRONT WHEEL 8 NORMALLY OPEN VALVE OFF 9 NORMALLY OPE...

Page 177: ... build decay the 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 Fig 10 ABS With Traction Control ABS Braking Hydraulic Circuit 1 OUTLET VALVE 2 PUMP...

Page 178: ...er at a fixed pressure setting The normally open and normally closed valves modulate build decay the brake pressure as required to the spinning wheel Fig 11 Traction Control Hydraulic Circuit 1 OUTLET VALVE 2 PUMP PISTON 3 PUMP MOTOR ON 4 LOW PRESSURE ACCUMULATOR PRESSURE 5 LOW PRESSURE ACCUMULATOR 6 NORMALLY CLOSED VALVE MODULATING 7 TO RIGHT FRONT WHEEL SPINNING 8 NORMALLY OPEN VALVE MODULATING ...

Page 179: ...trol system Refer to 5 BRAKES ABS TRACTION CONTROL OPERATION BRAKE FLUID ACCUMULATORS There are two fluid accumulators in the HCU one for the primary hydraulic circuit and one for the sec ondary hydraulic circuit Each hydraulic circuit uses a 5 cc accumulator The fluid accumulators temporarily store brake fluid that is removed from the wheel brakes during an ABS cycle This stored fluid is used by ...

Page 180: ...nents the CAB eight build decay solenoid valves four inlet valves and four outlet valves two traction control ASR valves two hydraulic shuttle valves valve block fluid accumula tors a pump and an electric motor The replaceable components of the ICU are the HCU and the CAB No attempt should be made to service any individual components of the HCU or CAB OPERATION For information of the ICU refer to ...

Page 181: ... to the speed control servo move it aside out of the way 5 Remove the screw attaching the washer bottle filler neck to the vehicle Move neck to the side with out loosening the filler tube Fig 16 6 Remove the nut and bolt holding the transmis sion controller and bracket to vehicle Fig 16 Lift transmission controller up and move away from mounting position 7 Using Mopart Brake Parts Cleaner or an eq...

Page 182: ...racket 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 NOTE To separate the CAB from the HCU Refer to 5 BRAKES ABS HYDRAULIC MECHANICAL ICU INTEGRATED CONTROL UNIT DISASSEMBLY DISASSEMBLY ICU NOTE To replace the hydraulic control unit HCU or the controller antilock brake CAB ...

Page 183: ... CAB socket push in the connector lock Fig 18 as far as it will go This will pull the 24 way connec tor into the socket on the CAB and lock it in the installed position 6 Install the 4 chassis brake tubes on the HCU Fig 17 Tighten the chassis brake tubes to 17 N m 145 in lbs 7 Install the primary and secondary brake lines from the master cylinder on the HCU Fig 17 Tighten the primary and secondary...

Page 184: ......

Page 185: ...uxiliary transmission oil cooler if equipped OPERATION ENGINE COOLING SYSTEM CAUTION The cooling system is designed to func tion with a 50 50 mixture of MoparT Antifreeze Cool ant 5 Year 100 000 Mile Formula MS 9769 or equivalent and distilled water Higher concentra tions may result in poor cooling performance and premature water pump seal failure This antifreeze coolant may not be mixed or substi...

Page 186: ...UPPLY HOSE 7 RADIATOR LOWER OUTLET HOSE 2 PRESSURE BOTTLE 8 THERMOSTAT LOCATION 3 HEATER SUPPLY TUBE 9 BOTTLE RETURN 4 RADIATOR UPPER INLET HOSE 10 HEATER RETURN TUBE 5 RADIATOR 11 HEATER CORE 6 DRAIN COCK 7 2 COOLING LH COOLING Continued ...

Page 187: ...en 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 Inspect for white steam emitting from exhaust sys...

Page 188: ...LING ENGINE RADIATOR PRESSURE CAP INSPECTION Replace as necessary b Hose between the pressure and overflow container is plugged Clean vent and repair as necessary c Vent at coolant reserve overflow container is plugged Clean vent and repair as necessary d Reserve overflow container is internally blocked Clean and repair as necessary ELECTRIC RADIATOR FAN RUNS ALL THE TIME 1 Fan relay Powertrain Co...

Page 189: ... as necessary 2 Low Coolant level 2 Refer to 7 COOLING DIAGNOSIS AND TESTING Repair as necessary 3 Air Trapped in heater core 3 Improper coolant fill procedure Refer to 7 COOLING STANDARD PROCEDURE 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 necessary 5 Heater hose kinked or obstructed 5 Locate kinked or ...

Page 190: ...r is 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 7 COOLING ENGINE COOLANT DIAGNOSIS AND TESTING Adjust the ethylene glycol to water ratio as necessary and service according to maintenance schedule Refer to LUBRICATION MAINTENANCE MAINTENANCE SCHEDULES...

Page 191: ...e water pump resulting in the follow ing High reading shown on the temperature gauge Loss of coolant flow through the heater core Corrosion in the cooling system Transmission oil will become hotter Water pump seal may run dry increasing the risk of premature seal failure Combustion gas leaks into the coolant can also cause the above problems DIAGNOSIS AND TESTING COOLING SYSTEM DEAERATION As air i...

Page 192: ...e cooling system normally operates at 97 124 kPa 14 18 psi pressure Exceeding this pressure may damage the radiator or hoses STANDARD PROCEDURE COOLING SYSTEM FILLING WARNING MAKE SURE ENGINE COOLING SYSTEM IS COOL BEFORE REMOVING PRESSURE CAP OR ANY HOSE SEVERE PERSONAL INJURY MAY RESULT FROM ESCAPING HOT COOLANT THE COOLING SYSTEM IS PRESSURIZED WHEN HOT CAUTION Do not use well water or suspect ...

Page 193: ... COOLING SYSTEM BLEEDING 1 2 7L ENGINE 6 COOLANT CONTAINER 2 3 5L ENGINE 7 HOSE 3 BLEED VALVE 8 TO COOLANT CONTAINER 4 TO COOLANT CONTAINER 9 BLEED VALVE 5 SPECIAL TOOL 8195 LH COOLING 7 9 COOLING Continued ...

Page 194: ...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 cool ant into the overflow side of the coolant bottle this coolant will be sucked back into the cooling system ONLY IF...

Page 195: ... on the cap and turn to the second stop Remove cap Fig 7 NOTE If the coolant pressure bottle is completely empty Refer to 7 COOLING STANDARD PROCE DURE COOLING SYSTEM FILLING 3 If there is some coolant in coolant pressure bot tle slowly fill coolant pressure bottle SPECIFICATIONS TORQUE DESCRIPTION N m Ft Lbs In Lbs A C Condenser to Radiator Bolts 5 45 A C Belt Tensioner Pulley 2 7L Bolts 28 250 A...

Page 196: ...PECIAL TOOLS COOLING Belt Tension Gauge 7198 Hose Clamp Pliers 8495 Hose Clamp Pliers 6094 Filling Aid Funnel 8195 Coolant Refractometer 8286 Cooling System Tester 7700 7 12 COOLING LH COOLING Continued ...

Page 197: ...crankshaft and the engine driven accesso ries DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT CONDITION POSSIBLE CAUSE CORRECTION INSUFFICIENT ACCESSORY OUTPUT DUE TO BELT SLIPPAGE 1 Belt too loose 1 Adjust belt tension 2 Belt excessively glazed or worn 2 Replace and tighten as specified BELT SQUEAL WHEN ACCELERATING ENGINE 1 Belts too loose 1 Adjust belt tension 2 Belts glazed 2 Replace belts BELT CHI...

Page 198: ...nsioner Rotate tensioner counterclock wise until belt can be removed from pulleys Fig 2 4 Slowly rotate tensioner clockwise to relieve spring load CLEANING Clean all foreign debris from belt pulley grooves The belt pulleys must be free of oil grease and cool ants before installing the drive belt INSPECTION Belt replacement under any or all of the following conditions is required Excessive wear Fra...

Page 199: ...ockwise pressure until locking bolt can be installed 8 Install the NEW belt by rotating the tensioner counterclockwise until the NEW belt can be installed on pulleys See Fig 5 for belt routing 9 Release tensioner and remove breaker bar Belt is automatically adjusted with the tensioner s torsion spring 10 Tighten tensioner locking bolt and pivot bolt to 28 N m 250 in lbs Fig 2 11 Install generator ...

Page 200: ... 3 5L ENGINES POLY V BELT GAUGE Generator Power Steering Belt all engines New Belt 836 44 N 190 10 lbs Used Belt 534 N 120 lbs V BELT GAUGE Air Conditioning Belt 3 5L only New Belt 667 44 N 160 10 lbs Used Belt 534 N 120 lbs DRIVE BELTS 3 5L REMOVAL GENERATOR POWER STEERING BELT The Poly V generator power steering belt has an adjustable tensioner pulley located on the front tim ing belt cover 1 Lo...

Page 201: ...ront tim ing belt cover 1 Install generator power steering belt 2 Tighten adjusting bolt until the specified ten sion is obtained Fig 6 Refer to 7 COOLING AC CESSORY DRIVE DRIVE BELTS ADJUSTMENTS 3 Install lower air shield and attaching push clips 4 Lower vehicle 5 Tighten tensioner pulley locking nut to 54 N m 40 ft lbs Fig 6 ADJUSTMENTS BELT TENSION Use belt tension gauge Special Tool 7198 for c...

Page 202: ...LLATION 26 HOSE CLAMPS DESCRIPTION 26 OPERATION 26 RADIATOR REMOVAL 27 CLEANING 28 INSPECTION 28 INSTALLATION 28 RADIATOR DRAINCOCK REMOVAL 28 INSTALLATION 28 PRESSURE CAP DESCRIPTION 29 OPERATION 29 INSPECTION 29 RADIATOR FAN DESCRIPTION 30 OPERATION 30 DIAGNOSIS AND TESTING RADIATOR FAN CONTROL 30 REMOVAL 32 INSTALLATION 32 RADIATOR FAN RELAY DESCRIPTION 32 OPERATION 33 WATER PUMP DIAGNOSIS AND ...

Page 203: ... or becomes contaminated drain flush and replace with fresh properly mixed coolant solu tion The green coolant MUST NOT BE MIXED with the orange or magenta coolants When replacing cool ant the complete system flush must be performed before using the replacement coolant CAUTION MoparT Antifreeze Coolant 5 Year 100 000 Mile Formula MS 9769 may not be mixed with any other type of antifreeze Doing so ...

Page 204: ... Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION 6 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE COOLANT RECOVERY PRESSURE CONTAINER DESCRIPTION The coolant bottle consists of a pressure chamber and a overflow chamber Fig 2 that is mounted in the engine compartment Fig 3 The overflow hose connects the pressure chamber to the overflow cham ber NOTE Coolant will normally be in t...

Page 205: ...L 1 Raise vehicle on hoist 2 Detach power cord plug from heater Fig 4 3 Remove block heater attaching screw located below heater terminals 4 Remove block heater from cylinder block INSTALLATION 1 Thoroughly clean cylinder block heater cavity 2 Insert heater assembly into block such that mounting hole is located below heater terminals 3 Install mounting screw and tighten to 12 N m 105 in lbs 4 Atta...

Page 206: ...ig 8 The thermostat on both engines are on the inlet side of the water pump The thermostats have an air bleed located in the thermo stat flange The air bleed allows internal trapped air during cooling system filling to be released OPERATION The engine cooling thermostat is a wax pellet driven reverse poppet type The thermostat is located in the inlet side of the engine to provide fast warm up and ...

Page 207: ...T THERMOSTAT 2 7L REMOVAL 1 Disconnect negative cable from remote jumper terminal WARNING DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR 2 Drain cooling system Refer to 7 COOLING STANDARD PROCEDURE 3 Remove the engine oil dipstick and tube To prevent coolant from entering engine cover the dip stick tube opening in crankcase with a sui...

Page 208: ...5 Disconnect radiator and heater hoses from thermostat housing 6 Remove thermostat housing bolts Fig 10 7 Remove housing thermostat and gasket NOTE The OEM thermostat is staked in place at the factory To ensure proper seating of replacement thermostat carefully remove the bulged metal from the thermostat housing using a suitable hand held grinder It is not necessary to restake the replace ment the...

Page 209: ...stall the heater tube by inserting tube in be tween cylinder heads Insert tube into water outlet housing Fig 11 4 Attach heater tube to the retaining clip at rear of engine 5 Install attaching screws and tighten to 3 N m 30 in lbs 6 Install radiator upper and heater hoses to heater tube 7 Connect electrical connector to coolant temper ature sensor 8 Install radiator upper crossmember Refer to 23 B...

Page 210: ...imeters has been stamped on each clamp Fig 13 Refer to HOSE CLAMP USAGE CHART for proper size and location of hose clamps HOSE CLAMP USAGE CHART SPRING CLAMP LOCATION 2 7L 3 5L Upper Radiator Hose engine 39 mm 47 mm radiator 39 mm 39 mm Lower Radiator Hose engine 40 mm 39 mm radiator 39 mm 39 mm Heater Hoses 3 49 27 mm 27 mm 3 89 17 mm 17 mm OPERATION The worm type hose clamp uses a specified torq...

Page 211: ...equipped Fig 15 7 Disconnect the radiator fan electrical connector Fig 16 8 Remove radiator fan Fig 16 CAUTION Avoid bending the condenser inlet tube Care should be taken not to damage radiator or condenser cooling fins or water tubes during removal 9 Remove the air conditioning condenser attach ing screws located at the front of the radiator Fig 17 or Fig 18 10 Remove fastener attaching transmiss...

Page 212: ...ose clamps to 3 N m 28 in lbs 5 Install the radiator fan Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 6 Connect radiator fan motor electrical connector 7 Connect engine oil cooler lines if equipped Torque lines to 18 N m 160 in lbs 8 Install the radiator upper hose Align hose so it does not interfere with the accessory drive belt or engine Position hose clamp so it will not interfere with ...

Page 213: ...ant loss and overheating INSPECTION WARNING IF VEHICLE HAS BEEN RUN RECENTLY WAIT 15 MINUTES BEFORE REMOVING CAP THEN PLACE A SHOP TOWEL OVER THE CAP AND WITH OUT PUSHING DOWN ROTATE IT COUNTERCLOCK WISE TO THE FIRST STOP ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING OUT COOL ANT AND STEAM AND PRESSURE DROPS REMOVE THE CAP COMPLETELY SQUEEZING THE RADIATOR INLE...

Page 214: ...erature Sensor Intake Air Temperature Sensor Output Speed Sensor Transmission Oil Temperature Sensor A C Pressure Transducer For more information Refer to 7 COOLING EN GINE RADIATOR FAN RELAY OPERATION DIAGNOSIS AND TESTING RADIATOR FAN CONTROL Radiator fan control can be accomplished five ways A pressure transducer on the air conditioning compressor discharge line sends a signal to the Pow ertrai...

Page 215: ...After Low Fan On for 8 minutes Fan Off 102 C 216 F 107 C 225 F 102 C 216 F 106 C 223 F Fan on time 4 minutes 105 C 221 F 64 C 147 F if coolant 92 C 197 F 60 C 140 F if coolant 104 C 219 F Fan on time 4 minutes Minimum fan on time 90 seconds Note If low fan is on for 8 minutes fan turns on high speed for 4 minutes then goes back to low speed A C PRESSURE TRANSMISSION OIL TEMPERATURE Fan Speed Low H...

Page 216: ...ator fan motor electrical connec tor 3 Partially drain cooling system below the level of the upper radiator hose 4 Disconnect upper radiator hose from radiator 5 Remove radiator fan attaching fasteners and upper clip Fig 23 6 Remove radiator fan by lifting upward to clear radiator INSTALLATION 1 Install radiator fan 2 Install upper clip and fasteners Fig 23 3 Connect upper radiator hose to radiato...

Page 217: ...both fan motors in a series circuit High speed radiator fan function is achieved by running both fan motors in a parallel circuit Refer to WIRING DIAGRAMS WATER PUMP DIAGNOSIS AND TESTING WATER PUMP A quick test to determine water pump operation is to check for proper heater system performance Refer to 24 HEATING AIR CONDITIONING DIAG NOSIS AND TESTING A defective pump will not circulate heated co...

Page 218: ...iming chain 5 Remove the timing chain and all chain guides Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 6 Remove bolts attaching water pump to block Fig 27 7 Remove water pump and gasket INSPECTION 2 7L Inspect and replace the water pump if it has any of the following defects 1 Damage or cracks on the pump body 2 Coolant leaks If the shaft seal is leaking this will be evi...

Page 219: ...d timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLA TION 4 Install the timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 5 Install the crankshaft damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 6 Install the accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 7 Install the ra...

Page 220: ...E The water pump is driven by the timing belt 3 Remove engine timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS REMOVAL 4 Remove water pump mounting bolts Fig 31 Note position of longer bolt for proper re installation 5 Remove water pump body from engine Fig 31 INSPECTION Inspect and replace the water pump if it has any of the following defects 1 Damage or cracks on the pump bod...

Page 221: ...er pump to engine 4 Install mounting bolts and tighten to 12 N m 105 in lbs 5 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS INSTALLATION 6 Install accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 7 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE Fig 32 WATER PUMP 3 5L 1 O RING 2 IMPELLER 3 WATER PUMP BODY LH ENGINE 7 37 WATE...

Page 222: ... mounted to the front of the air conditioning condenser Fig 1 OPERATION Transmission oil is supplied to the internal in tank transmission cooler Fig 1 The oil is then routed to the external cooler mounted to the front side of the A C condenser Oil is then returned to the transmission from the external oil cooler Fig 1 Fig 1 TRANSMISSION OIL COOLER 1 RADIATOR 4 TRANSMISSION OIL RETURN LINE 2 TRANSM...

Page 223: ...g 2 CLEANING Check the external cooler for debris on the cooling fin surfaces Clean as necessary INSPECTION Inspect all hoses tubes clamps and connections for leaks cracks or damage Replace as necessary Use only approved transmission oil cooler hoses that are molded to fit the space available Inspect external coolers for leaks loose mounts or damage Replace as necessary INSTALLATION For in tank tr...

Page 224: ...et and screw Fig 4 11 Install the retaining strap locks and tighten to secure the cooler to the condenser Trim off the excess strap material 12 Connect the cooler hoses to cooler lines and tighten hose clamps to 3 N m 28 in lbs 13 Install radiator side air shields 14 Install the front fascia Refer to 13 FRAMES BUMPERS BUMPERS FRONT FASCIA INSTAL LATION 15 Install the front wheels 16 Install the ra...

Page 225: ...e flare nuts at transmission to 30 N m 260 in lbs 2 Connect cooler lines to supports 3 Connect cooler hoses to radiator Fig 5 Tighten hose clamps to 3 N m 28 in lbs 4 Start engine and check transmission fluid level Adjust as necessary Fig 5 TRANSMISSION OIL COOLER 1 RADIATOR 4 TRANSMISSION OIL RETURN LINE 2 TRANSMISSION OIL COOLER SUPPLY LINE TO IN TANK COOLER 5 TRANSMISSION OIL SUPPLY LINE TO IN ...

Page 226: ......

Page 227: ...TESTING REMOTE SWITCHES 11 REMOVAL 12 INSTALLATION 13 SATELLITE RECEIVER MODULE DESCRIPTION 13 OPERATION 13 REMOVAL 14 INSTALLATION 14 SPEAKER DESCRIPTION 14 OPERATION 14 DIAGNOSIS AND TESTING SPEAKER 15 REMOVAL 15 INSTALLATION 16 AUDIO SYSTEM DESCRIPTION An audio system is standard factory installed equipment on this model unless the radio delete option is specified Several combinations of radio ...

Page 228: ...dio system components operate on battery current received through a fuse in the Junction Block JB on a fused ignition switch output run acc cir cuit so that the system will only operate when the ignition switch is in the On or Accessory positions DIAGNOSIS AND TESTING AUDIO Any diagnosis of the Audio system should begin with the use of the DRB IIIt diagnostic tool For information on the use of the...

Page 229: ... Draw IOD fuse in the Junction Block JB Replace fuse if required 2 Radio connector faulty 2 Check for loose or corroded radio connector Repair if required 3 Wiring faulty 3 Check for battery voltage at radio connector Repair wiring if required 4 Radio ground faulty 4 Check for continuity between radio chassis and a known good ground There should be continuity Repair ground if required 5 Radio faul...

Page 230: ...ors splices and grounds REMOVAL MIDLINE INFINITY l SYSTEM 1 Disconnect and isolate the negative battery cable 2 Remove right under panel silencer duct 3 Remove mounting fastener to remote amplifier Fig 1 4 Pull amplifier inboard and then pull downward to remove from upper retaining clips 5 Disconnect two wiring connectors 6 Remove remote amplifier from vehicle INFINITY ll SYSTEM 1 Disconnect and i...

Page 231: ...are connected to the body harness above the headliner OPERATION The satellite radio antenna receives signals from orbiting satellites and sends these signals to the sat ellite receiver module The satellite radio antenna must have open space in which to operate Items car ried on the roof parking inside etc can have an effect on the antenna s ability to receive signals REMOVAL 1 Disconnect and isola...

Page 232: ... negative cable ANTENNA CABLE SATELLITE RADIO DESCRIPTION The satellite radio antenna connects the roof mounted antenna to the satellite receiver module It has two connectors at each end and is routed above the headliner then down the right side of the vehicle floor below the carpet REMOVAL 1 Disconnect and isolate the battery negative cable 2 Lower the rear portion of the headliner as nec essary ...

Page 233: ...eiver if applicable 3 Using a trim stick special tool C 4755 gently pry out on center trim bezel Disconnect wiring con nectors to HVAC controls cigar lighter auxiliary power outlet and traction control switch 4 Remove instrument panel center trim bezel 5 Remove two retaining screws to in dash CD changer 6 Pull CD changer out of instrument panel dis connect wiring and remove from vehicle INSTALLATI...

Page 234: ...2 Remove instrument panel center trim bezel Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL CENTER BEZEL REMOVAL 3 Remove four radio mounting screws 4 Pull radio from panel and disconnect wiring from radio CAUTION Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio 5 Disconnect the antenna cable by pulling the loc...

Page 235: ... upper quarter trim panel Refer to 23 BODY INTERIOR UPPER QUARTER TRIM INSTALLATION REAR WINDOW ANTENNA MODULE DESCRIPTION The integrated rear window antenna incorporates the rear window defogger and a electronic module to receive radio signals The module is located in the right C pillar behind the trim panel Fig 7 OPERATION The AM and FM signals are received via isolated unheated lines along the ...

Page 236: ... information 6 Ensure that the rear window defogger ground wire with integral coil in the C pillar has a good ground 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 ...

Page 237: ...ss with the vehicle speed control switches The steering wheel wire harness is connected to the instrument panel wire harness through the clockspring OPERATION The six switches in the two remote radio switch units are normally open resistor multiplexed momentary switches that are hard wired to the Body Control Module BCM through the clockspring The BCM sends a five volt reference signal to both swi...

Page 238: ...rted radio control mux circuit to the Body Control Module BCM as required 4 Disconnect and isolate the battery negative cable Disconnect the 22 way instrument panel wire harness connector from the BCM Check for continu ity between the remote radio switch ground circuit cavities of the steering wheel wire harness connec tors for both remote radio switches and a good ground There should be no contin...

Page 239: ...osition the remote radio switch to the mount ing hole on the outside of the steering wheel rear trim cover Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel 2 Press firmly and evenly on the remote radio switch until each of the switch snap features is fully engaged in the mounting hole of the steering wheel rear...

Page 240: ...el INFINITY l SYSTEM The Infinity l System includes A 240 watt Infinity power amplifier with six out put channels One 2 5 inch round single cone spatial imaging speaker in the center of the instrument panel Two 2 5 inch round single cone spatial imaging speakers in the lower corners of the front door win dows Two 6 5 inch round single cone speakers in the front doors Two 6 x 9 inch single cone spe...

Page 241: ...formance of each individual speaker Note the speaker locations that are not performing correctly Go to Step 4 4 Turn the radio receiver OFF Turn the ignition OFF Disconnect and isolate the battery negative cable If vehicle is not equipped with a amplifier remove the radio receiver If vehicle is equipped with an amplifier disconnect wire harness connector at output side of amplifier Go to Step 5 5 ...

Page 242: ...ace speaker grille into place and firmly press into place 4 Connect battery negative cable FRONT DOOR UPPER 1 Connect wiring and place speaker in door speaker opening 2 Install two speaker retaining screws 3 Install two speaker enclosure attachment screws holding the enclosure ring and grill to the door 4 Connect battery negative cable INSTRUMENT PANEL 1 Place speaker into position on instrument p...

Page 243: ... the Body Control Module BCM for battery ignition and seat belt switch input 3 Use a DRB lllt scan tool to perform actuator diagnostics on BCM chime 4 Check for battery feed at 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...

Page 244: ...key turn exterior lamps on with driver s door open Chime should sound until headlamps are turned off or drivers door is closed Refer to Electrical Lamps Lighting Exterior Headlamp Switch Removal and Installation for ser vice procedures DIAGNOSIS AND TESTING FASTEN SEAT BELTS To test the fasten seat belt function start with the ignition switch in the OFF position Turn the ignition switch to the ON ...

Page 245: ...at retains the analog clock 4 Disconnect the one wire connector to the clock 5 Remove bezel from vehicle 6 On the bench remove two retaining screws to analog clock and remove from bezel Fig 2 INSTALLATION 1 On the bench place the clock into place on the bezel and install the two retaining screws to analog clock Fig 2 2 Connect the one wire connector to the clock 3 Place bezel into place and firmly...

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Page 247: ...efore replacing the PCM for a failed driver control circuit or ground circuit be sure to check the related component circuit integrity for failures not detected due to a double fault in the circuit Most PCM driver control circuit failures are caused by internal component failures i e relay and sole noids and shorted circuits i e pull ups drivers and switched circuits These failures are difficult t...

Page 248: ...ing Not Attempted The DRB III attempts to read the programmed key status and there are no keys programmed into SKIM memory Programming Key Failed Possible Used Key From Wrong Vehicle SKIM is unable to program key due to one of the following faulty ignition key transponder ignition key is programmed to another vehicle 8 Keys Already Learned Programming Not Done SKIM transponder ID memory is full 5 ...

Page 249: ...read9 these sensor inputs Multiplexing reduces wire harness complexity sensor current loads and controller hardware because each sensing device is connected to only one controller which reads and distributes the sensor information to the other controllers over the data bus Also because each controller on the data bus can access the con troller sensor inputs to every other controller on the data bu...

Page 250: ...t the same time to ensure message integrity When a collision is detected the module that transmitted the one bit stops sending messages over the bus until the bus becomes idle Each module is capable of transmitting and receiv ing data simultaneously The typical PCI bus mes sage has the following four components Message Header One to three bytes in length The header contains information identifying...

Page 251: ... or all of the hydraulic circuits The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present The CAB contains a self diagnostic program that monitors the antilock brake system for system faults When a fault is detected the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code DTC is then stored in a diagnostic ...

Page 252: ...eated Seat Mirror Module receives hard wired inputs from the heated seat switches and the heated seat sensors located on each of the front seats The programmed software in the MHSMM allows it to know the temperature of the seat by a resistance reading generated from the seat cushion element mounted thermistor Heated Seat Tempera ture Sensor When a heated seat switch is depressed the module will po...

Page 253: ...attempting to replace the memory heated seat module For complete circuit wiring diagrams refer to Wir ing WARNING REFER TO THE RESTRAINTS SECTION OF THIS MANUAL BEFORE ATTEMPTING ANY SEAT STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAU TIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY PRELIMINARY TEST...

Page 254: ... Engine Coolant Temperature Sensor Heated Oxygen Sensors Ignition sense Intake Air Temperature Sensor Knock Sensor Manifold Absolute Pressure MAP Sensor Natural Vacuum Leak Detection PCI Bus Power Steering Pressure Switch Proportional Purge Sense SCI Receive Speed Control Throttle Position Sensor Torque Management Input Integral to PCM Transmission Control Relay Switched B Transmission Range Senso...

Page 255: ...System self diagnostics Diagnostic capabilities with DRB III scan tool The automatic shut down ASD and fuel pump relays are mounted externally but turned on and off by the powertrain control module The camshaft and crankshaft signals are sent to the powertrain control module If the PCM does not receive both signals within approximately two second of engine cranking it deactivates the ASD and fuel ...

Page 256: ...e Input Out put Speed Sensors and wiring can cause these conditions The 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 ...

Page 257: ...48 mph 3rd gear FEMCC from 30 48 mph 3rd gear PEMCC from 27 31 mph Super Overheat Oil temperature above 260 F All 9Overheat9 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 OPERATION SENSOR RETURN PCM INPUT The sensor return circuit provides a low ele...

Page 258: ... are taken from the output speed sensor The PCM must be calibrated to the different combinations of equip ment available Pinion Factor allows the technician to set the Powertrain Control Module initial setting so that the speedometer readings will be correct This procedure must be performed if the Powertrain Control Module has been replaced Failure to perform this procedure will result in an inope...

Page 259: ...e 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 SKIM equipped car If a SKIM car you must do a secret key transfer also Refer to the appropriate Powertrain Diagnostic Man ual and the DRBIIIt scan tool To avoid possible voltage spike damage to PCM ignition key must be off and the negative battery cable must...

Page 260: ...mory the codes of at least two but no more than eight electronically coded Sentry Key transponders The SKIS programming also enables the SKIM to communicate over the Programmable Communication Interface PCI bus network with the Powertrain Control Module PCM and or the DRB IIIt scan tool OPERATION The SKIM transmits and receives RF signals through a tuned antenna enclosed within a molded plastic ri...

Page 261: ...turn the LED on or off based upon the results of the SKIS self tests If the VTSS indicator LED comes on and stays on after the bulb test it indicates that the SKIM has detected a system malfunction and or that the SKIS has become inoperative If the SKIM detects an invalid key when the igni tion switch is turned to the ON position it sends messages to flash the VTSS indicator LED The SKIM can also ...

Page 262: ...l and the proper Body Diagnostic Procedures Manual MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders 1 Slide the SKIM toward the steering column making sure the SKIM antenna ring is around the ignition cylinder housing Fig 11 2 Install the one screw securing the SKIM to the bottom of the steering column 3 Engage the steering column wire harness to the Sent...

Page 263: ...15 BATTERY TRAY DESCRIPTION 15 OPERATION 15 BATTERY HEATER BLANKET DESCRIPTION 15 OPERATION 16 DIAGNOSIS AND TESTING BATTERY HEATER BLANKET 16 REMOVAL 16 INSTALLATION 16 BATTERY SYSTEM DESCRIPTION A single 12 volt battery is standard factory in stalled equipment on this model All of the compo nents of the battery system are located in the front of the vehicle just in front of the right front wheel...

Page 264: ...maintain its charge properly all of the components that are used in these systems must perform within specifications It is important that the battery starting and charging systems be thor oughly tested and inspected any time a battery needs to be charged or replaced The cause of abnormal bat tery discharge overcharging or early battery failure must be diagnosed and corrected before a battery is re...

Page 265: ...tions are loose or corroded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Clean and tighten the battery terminal connections as required 5 The battery has an incorrect size or rating for this vehicle 5 Refer to Battery System Specifications for the proper size and rating Replace an incorrect battery as required 6 The battery is faulty 6 Determine the batte...

Page 266: ...m as required 7 Electrical loads exceed the output of the charging system 7 Inspect the vehicle for aftermarket electrical equipment which might cause excessive electrical loads 8 Slow driving or prolonged idling with high amperage draw systems in use 8 Advise the vehicle operator as required THE BATTERY WILL NOT ACCEPT A CHARGE 1 The battery is faulty 1 Test the battery using the Micro 420 batter...

Page 267: ...d that these procedures be performed any time the battery or related compo nents must be removed for vehicle service 1 Inspect the battery cable terminals for damage Replace any battery cable that has a damaged or deformed terminal 2 Inspect the battery tray and battery holddown hardware for damage Replace any damaged parts 3 If equipped slide the heater blanket off of the battery case Inspect the...

Page 268: ...hours with the volt age in the battery not falling below 10 5 volts This rating is also sometimes identified as the twenty hour discharge rating BATTERY CLASSIFICATIONS RATINGS Part Number BCI Group Size Classification Cold Cranking Amperage Reserve Capacity Ampere Hours Load Test Amperage N A N A 500 110 Minutes 60 250 N A N A 600 120 Minutes 60 300 SPECIAL TOOLS BATTERY SYSTEM SPECIAL TOOLS BATT...

Page 269: ...ed to release excess hydrogen gas that is created when the battery is being charged or discharged However even with these vents hydrogen gas can collect in or around the battery If hydrogen gas is exposed to flame or sparks it may ignite If the electrolyte level is low the battery may arc internally and explode If the battery is equipped with removable cell caps add distilled water when ever the e...

Page 270: ...ing for your area see menu The tester will then run its self programmed test of the battery and display the results Refer to the test result table noted below CAUTION If REPLACE BATTERY is the result of the test this may mean a poor connection between the vehicle s cables and battery exists After discon necting the vehicle s battery cables from the bat tery retest the battery using the OUT OF VEHI...

Page 271: ...y to service If the battery will not endure a load test it is faulty and must be replaced Clean and inspect the battery hold downs tray terminals posts and top before completing battery service Refer to Battery System Cleaning for the proper battery system cleaning procedures and Bat tery System Inspection for the proper battery system inspection procedures CHARGING A COMPLETELY DISCHARGED BATTERY...

Page 272: ...erage 5 Amps 10 Amps 20 Amps Open Circuit Voltage Hours Charging 21 C 70 F 12 25 to 12 49 6 hours 3 hours 1 5 hours 12 00 to 12 24 10 hours 5 hours 2 5 hours 10 00 to 11 99 14 hours 7 hours 3 5 hours Below 10 00 18 hours 9 hours 4 5 hours STANDARD PROCEDURE OPEN CIRCUIT VOLTAGE TEST A battery open circuit voltage no load test will show the approximate state of charge of a battery This test can be ...

Page 273: ... ELECTRONIC MODULE IGNITION OFF DRAW IOD TABLE Module Time Out If Yes Interval And Wake Up Input IOD IOD After Time Out Radio No 1 to 3 milliamperes N A Audio Power Amplifier No up to 1 milliampere N A Central Timer Module CTM No 4 75 milliamperes max N A Powertrain Control Module PCM No 0 95 milliampere N A ElectroMechanical Instrument Cluster EMIC No 0 44 milliampere N A Combination Flasher No 0...

Page 274: ...e 5 Remove battery splash shield Refer to the Body section of the service manual for the procedure 6 Disconnect the heater blanket cord if equipped 7 Remove the two short bolts from the battery hold down and remove the hold down 8 Disconnect the positive battery cable from the battery 9 Slide the battery toward rear of vehicle 10 Disconnect the negative battery cable from the battery 11 Remove bat...

Page 275: ...he battery terminal posts The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery The eyelet terminals secured to the opposite ends of the battery cable wires from the female battery terminal clamps pro vide secure and reliable connection of the battery cables to the vehicle electrical system The battery positive cable term...

Page 276: ... correct the poor con nection between the battery negative cable terminal clamp and the battery negative terminal post 2 Connect the positive lead of the voltmeter to the battery positive terminal post Connect the nega tive lead of the voltmeter to the battery positive cable terminal clamp Fig 7 Rotate and hold the ignition switch in the Start position Observe the voltmeter If voltage is detected ...

Page 277: ...ttery in the vehicle Refer to the procedure in this group 4 Connect the remote battery negative cable ter minal BATTERY TRAY DESCRIPTION The battery is placed in a steel tray located in the right front corner of the vehicle The battery tray is permanently attached to the front end sheet metal and cannot be removed from the vehicle Refer to Charging System for information on the battery tem peratur...

Page 278: ... feel the heater blanket on the inside it should be warm to the touch If warm the heater is OK if not OK proceed 8 Disconnect the heater blanket from the vehicles electrical system Using an Ohmmeter connect the leads across the two wire terminals coming from the heater blanket A resistance value of 220 to 280 ohms should be present If not replace the blanket If OK proceed 9 Ensure that the 110 vol...

Page 279: ...r is driven by the engine through a serpentine belt and pulley or decoupler pulley arrangement The amount of DC current produced by the gener ator is controlled by the EVR field control circuitry contained within the PCM This circuitry is con nected in series with the second rotor field terminal and ground An Ambient air temperature sensor is mounted on the bumper used to calculate the temperature...

Page 280: ... battery is often caused by accessories being left on with the engine not running a faulty or improperly adjusted switch that allows a lamp to stay on Refer to Ignition Off Draw Test Refer to 8 ELECTRICAL BATTERY SYSTEM BATTERY STANDARD PROCEDURE loose generator belt INSPECTION The Powertrain Control Module PCM monitors critical input and output circuits of the charging sys tem making sure they ar...

Page 281: ...a complete assembly If the genera tor fails for any reason the entire assembly must be replaced The generator produces DC voltage OPERATION As the energized rotor begins to rotate within the generator the spinning magnetic field induces a cur rent into the windings of the stator coil The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectif...

Page 282: ... 10 Remove the B terminal nut and wire 11 Remove pivot bolt being careful not to lose spacer 12 Remove generator REMOVAL 3 5L 1 Disconnect negative battery cable Fig 2 2 Loosen lower mounting bolt do not remove 3 Remove the upper radiator support and relo cate 4 Loosen the lower mounting bolt but do not remove 5 Loosen pivot bolt but do not remove 6 Loosen belt adjustment bolt 7 Remove the generat...

Page 283: ...ION The Electronic Voltage Regulator EVR is not a separate component It is actually a voltage regulat ing circuit located within the Powertrain Control Module PCM The EVR is not serviced separately If replacement is necessary the PCM must be replaced OPERATION The amount of DC current produced by the gener ator is controlled by EVR circuitry contained within the PCM This circuitry is connected in ...

Page 284: ...ect operation of starting charging systems all components used in these 3 systems must perform within specifications When attempting to diagnose any of these systems it is important that you keep their interdependency in mind The diagnostic procedures used in each of these groups include the most basic conventional diagnostic methods to the more sophisticated On Board Diag nostics OBD built into t...

Page 285: ...ge and loose or corroded harness connections STARTING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS TO ENGAGE 1 BATTERY DISCHARGED OR FAULTY 1 REFER TO THE BATTERY SECTION FOR MORE INFORMATION CHARGE OR REPLACE BATTERY IF REQUIRED 2 STARTING CIRCUIT WIRING FAULTY 2 REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED CIRCUIT TEST IN THIS SECTION 3 STARTER RELAY FAULTY 3 REFER TO REL...

Page 286: ...TARTS 1 BROKEN TEETH ON STARTER RING GEAR 1 REMOVE STARTER INSPECT RING GEAR AND REPLACE IF NECESSARY 2 STARTER ASSEMBLY FAULTY 2 IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK REPLACE STARTER ASSEMBLY STARTER DOES NOT DISENGAGE 1 STARTER IMPROPERLY INSTALLED 1 INSTALL STARTER TIGHTEN STARTER MOUNTING HARDWARE TO CORRECT TORQUE SPECIFICATIONS 2 STARTER RELAY FAULTY 2 REFER TO RELAY ...

Page 287: ... starter solenoid is good Go to the Starter Relay Test b If engine does not crank or solenoid chatters check wiring and connectors from starter relay to starter solenoid and from the battery positive ter minal to starter post for loose or corroded connec tions Particularly at starter terminals c Repeat test If engine still fails to crank prop erly trouble is within starter or starter mounted solen...

Page 288: ...ar zero engine speed rpm To diagnose the Park Neutral switch of the trans range sensor refer to the transaxle section Check for conti nuity to ground while the ignition switch is in the start position and if equipped the clutch pedal depressed If not OK and the vehicle has an auto matic trans verify Park Neutral switch operation If that checks OK check for continuity between PCM and the terminal 8...

Page 289: ...nal Hold the ignition switch key in the START position If voltage reads above 0 2 volt correct poor starter to engine ground a Connect the positive voltmeter lead to the battery positive terminal and negative lead to bat tery cable terminal on starter solenoid Rotate and hold the ignition switch in the START position If voltage reads above 0 2 volt correct poor contact at battery cable to solenoid...

Page 290: ...t engine mount mounting bolts from engine block 8 Jack engine up slightly to give more room to maneuver starter assembly 9 Slide rear of starter motor out between catalyst and engine mount 10 Disconnect posi lock starter solenoid connec tor 11 Remove the starter from vehicle INSTALLATION 1 Connect battery positive feed wire to starter 2 Connect posi lock starter solenoid connector 3 Jack engine up...

Page 291: ...2 The relay normally closed terminal 87A is connected to terminal 30 in the de energized position but is not used for this application Go to Step 3 3 The relay normally open terminal 87 is con nected to the common feed terminal 30 in the ener gized position This terminal supplies battery voltage to the starter solenoid field coils There should be continuity between the cavity for relay terminal 87...

Page 292: ... 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 starter switch or a jumper wire between the remote battery positive post and terminal 87 of t...

Page 293: ...STALLATION 6 REAR WINDOW DEFOGGER SWITCH DESCRIPTION 7 OPERATION 7 DIAGNOSIS AND TESTING REAR WINDOW DEFOGGER SWITCH 7 REMOVAL 7 HEATED GLASS DESCRIPTION WINDOW DEFOGGER The Rear Window Defogger electrical system involves the operation of the Manual Temperature Control MTC or Automatic Temperature Control ATC head the Body Control Module BCM and the rear window defogger relay and wiring The sys te...

Page 294: ... rags or toweling is recom mended DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING WINDOW DEFOGGER Electrically Heated Rear Window Defogger opera tion can be easily checked in three steps 1 Use ATC or MTC self diagnostics or the DRB IIIt scan tool to check fault codes and control button operation Refer to 24 HEATING AIR CONDI TIONING DIAGNOSIS AND TESTING SELF DIAGNOSTICS Note this does not check the E...

Page 295: ...n 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 with the grid voltage feed wire disconnected then go to Step 6 6 There is a problem with the circuits that con nect to the rear window defogger relay Refer to the appropriate wiring information for circuit descrip tions Check wiring with an...

Page 296: ... the terminal and place terminal on desired location To prevent the terminal from moving while the epoxy is curing it must be wedged or clamped 8 Carefully remove the masking tape from the grid line CAUTION Do not allow the glass surface to exceed 204 C 400 F glass may fracture 9 Allow epoxy to cure 24 hours at room tempera ture or use a heat gun with a 260 371 C 500 700 F range for 15 minutes Hol...

Page 297: ...de energized spring pressure returns the movable contact to the normally closed position The resistor or diode is con nected in parallel with the electromagnetic coil in the relay and helps to dissipate voltage spikes that are produced when the coil is de energized DIAGNOSIS AND TESTING REAR WINDOW DEFOGGER RELAY 1 Stop the engine Connect the negative lead of a 0 15 volt range voltmeter to a known...

Page 298: ...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 REMOVAL 1 Disconnect the battery negative remote cable from the remote ground post Fig 6 2 Open the trunk Remove the carpeting fasten ers from the right rear panel and pull the trunk car peting away 3 Remove the relay fastener screw and unplug...

Page 299: ... relay Energizing the rear window defogger relay provides electrical current to the rear window defogger grid and to the LED indicator in the switch which lights to indicate when the defog ger system is turned on A dedicated fuse in the junc tion block protects the rear window defogger relay output circuit to the LED indicator DIAGNOSIS AND TESTING REAR WINDOW DEFOGGER SWITCH For instructions on h...

Page 300: ...d is operating as designed Refer to 8 ELECTRICAL HEATED MIRRORS DIAGNO SIS AND TESTING for diagnosis of the outside mir ror heating grids The heating grid behind each outside mirror glass cannot be repaired and if faulty or damaged the entire power mirror unit must be replaced Refer to Power Mirrors for the procedures DIAGNOSIS AND TESTING HEATED MIRRORS 1 Check the heated mirror fuse and repair a...

Page 301: ...tory On some models replacement seat heating elements sensor are available without having to replace the entire seat cushion or trim cover Refer to heated seat element later in this sec tion for additional information Memory Heated Seat Mirror Module also referred to as the MHSMM this module contains the solid state electronic control and diagnostic logic cir cuitry for the heated seat and memory ...

Page 302: ... about 36 C 97 F and the High heat posi tion set point is about 41 C 105 F The module and the heated seat elements operate on non switched battery current supplied through the power seat circuit breaker in the junction block The module will automatically turn off the heating ele ments if it detects an open or a HI LOW short in the sensor circuit or a open or LOW short in the heating element circui...

Page 303: ...ion block If OK refer to Heated Seat Element Diagnosis and Testing in this section If not OK replace the faulty circuit breaker DRIVER HEATED SEAT SWITCH DESCRIPTION The heated seat switches are located on the out board seat cushion side shield of the driver and pas senger front seats The momentary bidirectional rocker type heated seat switch Fig 1 provides a resistor multiplexed signal to the Mem...

Page 304: ... meter check the ground circuit cavity of the heated seat switch electrical connector for a good continuity to ground If OK go to Step 3 If not OK repair the open ground circuit as required 3 Turn the ignition switch to the RUN position Using an volt meter check the 12v B circuit cavity of the heated seat switch electrical connector for 12v If OK go to Step 4 If not OK repair the open or shorted 1...

Page 305: ...ty or damaged the complete heated seat switch must be replaced OPERATION The heated seat switches receive battery current through a fused ignition switch output run circuit when the ignition switch is in the On position Depressing the heated seat switch rocker to its momentary High or Low position provides a hard wired resistance signal to the Memory Heated Seat Mirror Module MHSMM This signal tel...

Page 306: ...th the chart below Fig 5 If the readings do not correspond to those in the Heated Seat Switch Continuity table replace the heated seat switch HEATED SEAT SWITCH PIN IDENTIFICATION PIN FUNCTION 1 LO LED 2 OPEN 3 GROUND 4 IGNITION FEED 5 HI LED 6 REQUEST LINE HEATED SEAT SWITCH TESTING CONTINUITY BETWEEN SWITCH POSITION READING PIN 4 AND 6 OFF 2200 OHMS PIN 4 AND 6 LO 415 OHMS PIN 4 AND 6 HI 33 OHMS...

Page 307: ...rises the resistance of the sensor decreases The Memory Heated Seat Mirror Module supplies five volts to one side of each sensor and monitors the voltage drop through the sensor on a signal return circuit The Memory Heated Seat Mirror Module uses this tem perature sensor input to monitor the temperature of the seat and regulates the current flow to the heated seat elements accordingly DIAGNOSIS AN...

Page 308: ...time If NOT OK trace the element wire harness until the short is found CAUTION Be certain to properly re attach the Mem ory Heated Seat Mirror Module and wire harness under the seat cushion pan Failure to do so could result in the wire harness coming in contact with the moving components under the seat and future problems REMOVAL Some LH models have heating elements that can not be replaced withou...

Page 309: ...age is not within specifi cation replace the heated seat element 3 If using a voltmeter backprobe the sensor return signal circuit at the module and compare the voltage reading with the table shown Refer to heated seat element diagnosis and testing for additional instructions If the voltage is not within specification replace the heated seat element TEMP LO SET POINT HI SET POINT COLD SEAT RT LT S...

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Page 311: ... STEERING COLUMN SEAT BELT TENSIONER SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR ...

Page 312: ...HE JUNCTION BLOCK 1 REPLACE FUSE IF BLOWN AS REPAIR AS NECESSARY 2 NO VOLTAGE AT HORN RELAY TERMINALS 1 2 AND FUSE IS OK 2 NO VOLTAGE REPLACE JUNCTION BLOCK OR REPAIR AS NECESSARY 3 OPEN CIRCUIT FROM TERMINAL 7 OF THE RELAY TO HORN SWITCH X3 CIRCUIT 3 REPAIR CIRCUIT AS NECESSARY 4 FAULTY OR DAMAGED HORN 4 VOLTAGE AT HORN WHEN HORN SWITCH IS PRESSED REPLACE HORN 5 FAULTY HORN SWITCH 5 REPLACE DRIVE...

Page 313: ...gative cable 2 Disconnect wire connector 3 Remove the horn bracket mounting bolt and remove horn NOTE Do not disconnect horn from horn bracket INSTALLATION 1 Position both horns and the mounting bracket onto the vehicle as a unit 2 Install and tighten the screw that secures the horn mounting bracket to vehicle Tighten the screw to 11 3 N m 100 in lbs 3 Connect the wire connector 4 Connect the batt...

Page 314: ...ER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Using ohmmeter connect one lead to ground wire and the other lead to the positive wire Fig 4 2 Depress horn switch continuity should be present Repeat for other switch If no continuity replace switches Fi...

Page 315: ...CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY The horn switch is serviced with the driver airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL LH...

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Page 317: ... not adjustable All spark advance is determined by the Powertrain Control Module PCM The distributorless ignition system used on these engines is referred to as the Direct Ignition System DIS The system s three main components are the coils crankshaft position sensor and camshaft posi tion sensor If equipped with the coil on plug ignition system it utilizes an ignition coil for every cylinder it i...

Page 318: ...haft Position Sensor Screw 12 105 2 7L Ignition Coil 6 2 55 3 5L Ignition Coil 6 7 60 Knock Sensor 10 83 2 7L Map Sensor 2 20 3 5L Map Sensor 2 17 7 2 7L Spark Plugs 17 6 13 155 3 5L Spark Plugs 28 20 Capacitor Nut 12 8 8 106 SPARK PLUGS Engine Spark Plug Gap Thread Size 2 7L RE10PMC5 0 048 TO 0 058 in 14mm 1 in reach 3 5L ZFR5LP 13G 0 048 TO 0 053 in 14 mm 3 4 in reach 8I 2 IGNITION CONTROL LH IG...

Page 319: ...hicles the ASD relay also provides a sense circuit to the PCM for diagnos tic purposes If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay it sets a Diagnostic Trouble Code DTC The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value typically about 50 rpm The ASD relay can also be energized after the engine h...

Page 320: ...ft position sensor is mounted in the front of the head 1 Disconnect electrical connector from sensor 2 Remove camshaft position sensor screw 3 Without pulling on the connector pull the sen sor out of the chain case cover REMOVAL 3 5L The camshaft position sensor is installed in the timing belt housing cover above the left camshaft sprocket 1 Disconnect the negative battery cable 2 Loosen the upper...

Page 321: ... igni tion system Fig 7 or Fig 8 Each cylinder has a dedicated coil that sits atop each plug No secondary wires are required and connection from the coil to plug is made with a boot that is attached to the coil The combination of the coil boot and fasteners is known as the ignition coil assembly The Powertrain Control Module PCM determines which coil to charge and fire at the correct time OPERATIO...

Page 322: ...PACITOR DESCRIPTION The Auto Shutdown ASD relay provides battery voltage to the ignition coil The PCM provides a ground contact circuit for energizing the coil When the PCM breaks the contact the energy in the coil primary transfers to the secondary causing the spark The PCM will de energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs For...

Page 323: ...not a selective cylinder retard The PCM ignores knock sensor input during engine idle conditions Once the engine speed exceeds a specified value knock retard is allowed Knock retard uses its own short term and long term memory program Long term memory stores previous detonation information in its battery backed RAM The maxi mum authority that long term memory has over tim ing retard can be calibra...

Page 324: ...15 and ceramic insula tor damage during plug removal and installation CAUTION Cleaning of the platinum plug may dam age the platinum tip REMOVAL Always remove the ignition coil assembly by grasp ing at the spark plug boot turning the assembly 1 2 turn and pulling straight back in a steady motion 1 Prior to removing the spark plug spray com pressed air around the coil area and spark plug 2 Remove e...

Page 325: ...e Programmable Communication Interface PCI bus There are three types of clusters Fig 1 and Fig 2 The Instrument Cluster for the Intrepid and Con corde Fig 1 are almost identical The gauge and warning lamp location and functionality are identi cal The difference being the Intrepid has white gauges with black numbers and the Concorde has black gauges with white numbers and chrome rings around the ga...

Page 326: ...rew Limited 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 Limited and 300M and five on Concorde 8 Using a trim stick special tool C 4755 gently pry out on the instrument panel cluster bezel discon nect headlamp switc...

Page 327: ...cable remote terminal from the remote battery post 2 Remove the instrument panel left end cap 3 Remove steering column shroud cover 4 Tilt the steering column down into the lowest position 5 Remove one screw Limited 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 al...

Page 328: ...Cluster Removal and Installation 3 Remove five cluster back cover retaining screws and remove the cover 4 Unplug connectors from printed circuit board 5 Remove cluster mask lens from instrument cluster Refer to Mask Lens Removal and Installa tion 6 Remove two screws to Vacuum Fluorescent VF display Odometer and remove from cluster INSTALLATION 1 Install the two screws to Vacuum Fluorescent VF disp...

Page 329: ...DISPLAY LIGHTS 9ON9 IN P N GEAR POSITIONS Check wiring and connectors Faulty TRS Faulty manual lever ALL DISPLAY LIGHTS 9ON9 IN ALL GEAR POSITIONS Check wiring connectors Faulty trans range sensor Faulty manual lever Communication bus malfunction CONDITION POSSIBLE CAUSE ALL DISPLAY LIGHTS 9OFF9 Normal transient condition between P R and R N gear positions Check shift lever linkage BCM malfunction...

Page 330: ......

Page 331: ...CENTER HIGH MOUNTED STOP LAMP UNIT REMOVAL 8 INSTALLATION 9 COMBINATION FLASHER DESCRIPTION 9 OPERATION 9 DIAGNOSIS AND TESTING COMBINATION FLASHER 9 REMOVAL 9 INSTALLATION 10 DAYTIME RUNNING LAMP MODULE DESCRIPTION 10 OPERATION 10 DIAGNOSIS AND TESTING DAYTIME RUNNING LAMP MODULE 10 DECKLID TRUNK LAMP REMOVAL 10 INSTALLATION 10 FOG LAMP DIAGNOSIS AND TESTING FOG LAMP 10 REMOVAL 12 INSTALLATION 13...

Page 332: ...NSTALLATION 32 MULTI FUNCTION SWITCH DESCRIPTION 32 OPERATION 33 DIAGNOSIS AND TESTING MULTI FUNCTION SWITCH 33 REMOVAL 35 INSTALLATION 35 PARK TURN SIGNAL LAMP REMOVAL 36 INSTALLATION 36 REAR FOG LAMP EXPORT DESCRIPTION 37 OPERATION 37 DIAGNOSIS AND TESTING REAR FOG LAMP EXPORT 37 REMOVAL 37 INSTALLATION 37 REAR FOG LAMP SWITCH EXPORT DESCRIPTION 37 OPERATION 38 REMOVAL 38 INSTALLATION 38 SIDE RE...

Page 333: ...r ACCESSORY positions The hazard warning system operates on non switched battery voltage received on a fused B circuit so that the hazard warning remains operational regardless of the ignition switch position When the turn signal system is activated the turn signal switch and the combination flasher will cause the selected turn signal indicator front park turn signal lamp and rear tail stop turn s...

Page 334: ...nel wire harness connector for the multi function switch There should be continuity If OK go to Step 9 If not OK repair the open hazard flasher signal circuit between the combination flasher and the multi function switch as required 9 Check for continuity between the right turn switch sense circuit in the instrument panel wire harness connector and the instrument panel wire harness connector for t...

Page 335: ...s to hold back up lamp unit to bumper 6 Connect the battery negative cable BACK UP LAMP UNIT REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove screws holding back up lamp unit to rear bumper 3 Disconnect the wire connector 4 Separate lamp unit from vehicle INSTALLATION 1 Connect the one wire connector 2 Place back up lamp unit into opening in bumper on vehicle 3 Install screws t...

Page 336: ...he released position plung er extended use an ohmmeter to test each of the three internal switches as shown Fig 2 You should achieve the results as listed in the figure 3 Gently push the plunger on the brake lamp switch in until it stops 4 With the switch in the depressed position plunger pushed in use an ohmmeter to test each of the three internal switches as shown Fig 3 You should achieve the re...

Page 337: ...has ratcheted out to its fully extended position 4 Mount the brake lamp switch into the bracket as follows Depress the brake pedal as far down as possible Install the switch in it s bracket by aligning the index key on switch with the notch in the square mounting hole of the mounting bracket Fig 4 Once the switch is fully seated rotate the switch clockwise approximately 30 to lock the switch into ...

Page 338: ...H MOUNTED STOP LAMP UNIT REMOVAL CONCORDE 1 Open hood disconnect and isolate the battery negative cable 2 Release decklid latch and open decklid 3 From under rear shelf panel disconnect CHMSL wire connector from body harness 4 Remove rear shelf upper panel 5 Remove fasteners attaching the CHMSL to rear shelf upper panel Fig 8 6 Remove CHMSL from rear shelf upper panel INTREPID 1 Release decklid la...

Page 339: ... Junction Block The flasher can be removed by pulling in a rearward direction The left under panel silencer duct must be removed to access the flasher The combo flasher is black in color for ease of identification OPERATION The Turn Signal and Hazard Warning Flasher is combined into one unit called a Combination Flasher Combo Flasher The combo flasher controls the flashing of the hazard warning sy...

Page 340: ...e running lamps will go out when the headlamp switch is turned ON The passing light feature will flash bright high beams while the daytime running lamps are activated DIAGNOSIS AND TESTING DAYTIME RUNNING LAMP MODULE The Daytime Running Lamp Module DRL Module is controlled by inputs received from the ignition switch and High or Low Beam Headlamp relays Park Brake switch and the Brake Fluid Level s...

Page 341: ...nd repair all connectors and splices refer to 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 Electrical Battery 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations refer to Wiring Diagrams 3 High resistance in fog lamp circuit 3 Test amperage draw of fog lamp circuit 4 Bot...

Page 342: ...odule REMOVAL INTREPID 300M 1 Remove fog lamp housing screw in front fascia and pull lamp housing from the fascia 2 Remove rear cover from fog lamp housing 3 Disengage wire clip holding bulb in fog lamp 4 Hinge wire clip out of bulb removal path 5 Pull bulb from lamp housing Fig 11 or Fig 12 6 Disengage wire connector from fog lamp wire harness CONCORDE 1 Remove fog lamp housing screw in front fas...

Page 343: ... 2 Connect wire connector to the socket 3 Verify fog lamp operation and alignment 4 Install fog lamp housing into fascia 5 Install fog lamp screw to the front fascia FOG LAMP UNIT STANDARD PROCEDURE FOG LAMP UNIT ALIGNMENT Prepare an alignment screen Fig 14 Refer to Electrical Lamps Lighting Exterior Headlamp Adjustments for Alignment Screen Preparation A properly aligned fog lamp will project a p...

Page 344: ... connector to front light ing wire harness 2 Insert fog lamp rearward into opening in front bumper fascia 3 Install screw s attaching fog lamp to fascia 4 Connect the battery negative cable and close hood Fig 16 FOG LAMP UNIT ADJUSTER SCREW CONCORDE 1 UP DOWN ADJUSTER SCREW 2 FOG LAMP UNIT Fig 17 FOG LAMP UNIT ADJUSTER SCREW 300M 1 UP DOWN ADJUSTER SCREW 2 FOG LAMP UNIT Fig 18 FOG LAMP INTREPID 1 ...

Page 345: ...n connector pin out information and location views for the various wire harness connectors splices and grounds NOTE Battery must be completely charged 12v prior to testing It may also be necessary to install battery charger on the vehicles electrical system when performing this test Refer to the Battery sec tion of the service manual for detailed information 1 Remove the front position lamp bulb a...

Page 346: ... body ground to the lamp socket Lamp sockets that are exposed to moisture should be coated with Mopart Multi pur pose Grease or equivalent to avoid corrosion If a socket has become corroded clean socket and bulb base with abrasive fiber sanding pad or metallic bris tle brush Replace sockets and bulbs that are deformed from corrosion that could prevent a contin uous body ground Wire connectors can ...

Page 347: ...s The automatic headlamps will only function when the engine is running When the headlamp switch is in the AUTO position the Headlamp Time Delay system will function when the ignition is switched OFF HIGH INTENSITY DISCHARGE HEADLAMPS 300M SPECIAL High Intensity Discharge Headlamps HID rely on an electrical charge to ignite xenon gas contained in a sealed beam lamp The HID lamps are similar in ope...

Page 348: ...arm up time to reach full operation The light appears blue during warm up and then turns to white DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING HEADLAMP When a vehicle experiences problems with the headlamp system verify the condition of Battery connections Charging system Headlamp bulbs Head lamp relay High beam dimmer switch Headlamp switch Body Control Module Wire connectors Refer to Wiring Diagr...

Page 349: ...als or splices in circuit 2 Inspect and repair all connectors and splices refer to Wiring Diagrams HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system refer to Electrical Battery 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations refer to Wiring Diagrams 3 High resistance in headlamp circuit 3 Test am...

Page 350: ...er to Wiring Diagrams 3 Faulty dimmer switch 3 Replace dimmer switch DIAGNOSIS AND TESTING HIGH INTENSITY DISCHARGE HEADLAMPS 300M SPECIAL The High Intensity Discharge HID headlamps are supplied B voltage and ground by the same connec tor used to power the normal halogen low beam lamp The low beam system is different from there forward The ballast module is mounted to the bot tom of the headlamp u...

Page 351: ...spring retainer to the igniter lamp assembly 6 Pull assembly straight out of headlamp unit The igniter and lamp are an assembly and will be replaced as such The water shield will also come with a new assembly BALLAST MODULE 1 Remove headlamp unit Refer to 8 ELECTRI CAL LAMPS LIGHTING EXTERIOR HEADLAMP UNIT REMOVAL 2 Disconnect the igniter lamp assembly connector from ballast module Fig 28 3 Remove...

Page 352: ... shield in the groove making sure it is positioned properly and then press down on the edge to fully seat the lip in the retaining groove 4 Position the retaining ring over the water shield and install Remove three screws 5 Connect the igniter assembly connector into the ballast module 6 Install the headlamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR HEAD LAMP UNIT INSTALLATION BALLAST MO...

Page 353: ...amp alignment HEADLAMP LEVELING MOTOR Vehicles equipped with the remote headlamp level ing system utilize headlamp leveling motors Two leveling motors are used per vehicle one for each headlamp These leveling motors are attached to the rear of the headlamp modules They can be described as a small semi square shaped module with a electri cal connector attached to one side Due to vehicle design thes...

Page 354: ...lb access panel found in the appro priate front wheel well splash shield 3 Check PIN 1 for battery voltage If not present trace the circuit until the open or short is found 4 Check PIN 2 for ground If not present trace the circuit until the open or short is found 5 Check PIN 3 for headlamp leveling sense volt age 2 83 8 60v If not present trace circuit until open or short is found 6 If no open or ...

Page 355: ...on of the headlamp leveling switch control knob voltage is adjusted at the headlamp lev eling switch rheostat This signals the headlamp leveling motors headlamp module mounted to adjust the vertical headlamp beam pattern accord ingly The headlamps must be ON in order for the leveling system to function Refer to the appropriate wiring information The wiring information includes wiring diagrams prop...

Page 356: ...nimum dimming level The Body Control Module BCM must be flashed with a special police package for the stealth mode to work A security provision may require the unique engine controller to broadcast a code to allow the BCM to be flashed with the police package program OPERATION POLICE APPROACH MODE To place the vehicle s lighting system into Approach mode turn the switch counterclockwise to the A o...

Page 357: ...changed except in the case of body damage or tam pering 1 Verify headlamp dimmer switch and high beam indicator operation 2 Inspect and correct damaged or defective com ponents that could interfere with proper headlamp alignment 3 Verify proper tire inflation 4 Clean headlamp lenses 5 Verify that luggage area is not heavily loaded 6 Fuel tank should be FULL Add 2 94 kg 6 5 lbs of weight over the f...

Page 358: ... of the aiming screen Occasional stray filament images should be disregarded while verifying aim Verify the vertical adjustment by checking the high beams to ensure they are centered within 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 alignmen...

Page 359: ... of vehicle centerline Use these lines for left right adjustment reference this should be 1338 5 mm 52 7 in HEADLAMP UNIT ADJUSTMENT A properly aimed low beam headlamp will project a high intensity light pattern on the screen with the horizontal cut off line aligned with the tape line 100 mm 4 in below the headlamp centerline Fig 34 The intersection of the horizontal and 15 degree cut off lines in...

Page 360: ... lamps if replacing unit INTREPID 1 Release hood latch and open hood 2 Disconnect and isolate the battery negative cable 3 Remove jackscrews attaching headlamp to body Fig 35 4 Remove headlamp from body 5 Disconnect wire connector from headlamp and parking side marker and turn signal lamps 6 Remove headlamp housing from vehicle Fig 34 HEADLAMP ALIGNMENT SCREEN EXPORT 1 CENTER OF VEHICLE 5 10 METER...

Page 361: ...flush with the fenders INTREPID NOTE Headlamp lens fogging is a normal condition and does not require service unless excessive or continual Moisture will vent from tubes or vents located on the back of the lamp 1 Place headlamp unit in position on vehicle 2 Connect wire connectors to headlamp parking side marker and turn signal lamps 3 Place headlamp unit in position on body 4 Install screws to at...

Page 362: ...teners attaching side marker lamp to fascia Fig 38 4 Remove attaching fasteners 5 Remove lamp unit 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 operation 6 Attach fascia to vehicle MULTI FUNCTION SWITCH DESCRIPTION MULTI FUNCTION SWITCH The turn signals are part of the multi functi...

Page 363: ... operating HAZARD WARNING SYSTEM Push and release the button to turn the hazard function ON or OFF The button will move out from the steering column in the ON position and will remain in toward the column in the OFF position DIAGNOSIS AND TESTING MULTI FUNCTION SWITCH The multi function switch contains electrical cir cuitry for turn signal hazard warning headlamp beam select headlamp optical horn ...

Page 364: ... TIGHTEN CONNECTOR 4 LOOSE OR FAULTY REAR WIRING HARNESS OR TERMINALS 4 REPLACE WIRING HARNESS 5 OPEN CIRCUIT TO FLASHER UNIT 5 CHECK CONNECTORS REPLACE WIRING HARNESS 6 OPEN CIRCUIT IN FEED WIRE TO TURN SIGNAL SWITCH 6 CHECK CONNECTORS REPLACE WIRING HARNESS 7 FAULTY SWITCH CONNECTION IN SWITCH 7 REPLACE SWITCH 8 OPEN OR GROUNDED CIRCUIT IN WIRING TO EXTERNAL LAMPS 8 REPLACE WIRING HARNESS 9 BURN...

Page 365: ...ove both upper and lower steering column shrouds Refer to Body Instrument Panel Steering Column Shrouds Removal 4 Remove multi function switch mounting screws and connectors Fig 42 INSTALLATION 1 Install the multi function switch connectors and mounting screws Fig 42 2 Tighten multi function switch retaining screws to 17 in lbs 2 N m torque 3 Install both upper and lower steering column shrouds Re...

Page 366: ... Disconnect wire connector from back of lamp socket s 3 Rotate socket and pull lamp socket from head lamp housing 4 Remove bulb from lamp socket INSTALLATION INTREPID 1 Push bulb into socket Fig 43 2 Install the lamp socket into lamp housing 3 Install the lamp housing 4 Install the jack screws attaching headlamp to crossmember 5 Connect the negative battery cable and close hood Fig 42 MULTI FUNCTI...

Page 367: ...y charger on the vehicles electrical system when performing this test Refer to the Battery sec tion of the service manual for detailed information 1 Remove the rear fog lamp bulb and check for burned out condition replace bulb if necessary 2 If bulb appears OK reinstall the bulb in its socket and turn fog lamps ON and check for proper operation If lamp is still inoperative proceed to Step 3 3 Remo...

Page 368: ...LAMP SWITCH INSTALLATION SIDE REPEATER LAMP EXPORT DESCRIPTION One Side Repeater Lamp can be found on each side of the vehicle just behind the front wheel Fig 47 The side repeater lamp utilizes an amber colored housing and clear bulb OPERATION The side repeater lamps are turned ON or OFF with the turn signal lamps These lamps are con trolled by the steering column mounted multi func tion switch DI...

Page 369: ...ATION 1 Install the side repeater lamp socket into the lamp unit 2 Install the side repeater lamp in the front fender Fig 48 Be certain lamp is secure within the fender 3 Install the front wheelhouse liner 4 Verify lamp operation SPOT LAMP POLICE REMOVAL 1 Remove the PDC cover and pull either the X or Y fuse depending on which spot lamp is being ser viced 2 Raise the spot lamp from the stowed to t...

Page 370: ... LP RT UNDERHOOD 20 amp The parts available for service are Complete spot lamp assembly H3 100 watt halogen bulb Inside control handle w switch OPERATION Use this switch to turn the spot lamp assembly ON and OFF Rotate and twist the handle to adjust the position of the spot lamp assembly Fig 52 DIAGNOSIS AND TESTING SPOT LAMP ASSEMBLY POLICE IF SPOT LAMP DOES NOT LIGHT 1 If both spot lamps are ino...

Page 371: ...lamp head and cause damage REMOVAL CAUTION Make sure that fuse F master spot lamp feed or either fuse X or Y left or right spot lamp feed are removed from the Power Distribution Cen ter PDC before performing service on the spot lamps 1 Remove the fuse cover and pull either the X or Y fuse depending on which spot lamp is being ser viced 2 Raise the spot lamp from the stowed to the operating positio...

Page 372: ...ndshield pillar to expose the spot lamp outer tube and apply a small amount of clear silicone sealer to the base of the outer tube 4 Carefully install the spot lamp head with the intermediate and inner shafts to the outer tube and mounting bracket until the head assembly bottoms out on the outer tube Fig 56 5 Tighten the clamp screw at the base of the spot lamp head assembly in small incriments wh...

Page 373: ...otate 360 degrees on its axis 14 If the spot lamp head does not rotate 360 degrees on its axis or if excessive effort is required to rotate the lamp head on its axis perform the fol lowing a Remove the handle and inspect for damage to the inner shaft and the gears in the handle Repair or replace as necessary b If no damage is present to the inner shaft or the gears in the handle reinstall the hand...

Page 374: ...ower 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 TURN SIGNAL LAMP UNIT CONCORDE 300M REMOVAL 1 Open hood disconnect and isolate the battery negative cable 2 Remove headlamp unit to access lamp housing 3 Rotate and pull socket from lamp unit 4 Disconnect fastener attaching ...

Page 375: ... lamp base and press into place 4 Connect the battery negative remote cable or reinsert fuse Y in the PDC 5 Verify system and vehicle operation UNDERHOOD LAMP UNIT POLICE REMOVAL 1 Open hood disconnect and isolate the battery negative remote terminal or pull fuse Y in the PDC 2 Disconnect the wire harness connector from lamp unit 3 Remove the push pin fastener attaching under hood lamp unit to inn...

Page 376: ... Install the lamp unit and press into place 4 Connect the wire harness connector 5 Connect the battery negative remote cable or reinsert fuse Y in the PDC 6 Verify system and vehicle operation 7 Close hood Fig 66 UNDERHOOD LAMP UNIT LOCATION TYPICAL POLICE 1 CONNECTOR 2 UNDERHOOD LAMP UNIT 8L 46 LAMPS LIGHTING EXTERIOR LH UNDERHOOD LAMP UNIT POLICE Continued ...

Page 377: ...enter ASC after the compo nent is removed from the vehicle Contact local dealer for location of nearest ASC DIMMER CONTROLLED LAMP APPLICATION TABLE LAMP BULB A C HEATER CONTROL 330 INSTRUMENT CLUSTER PC194 RADIO ASC ANALOG CLOCK A9625 INDICATOR LAMPS Service procedures for most of the lamps in the instrument cluster are located in Electrical Instru ment Cluster CAUTION Do not use bulbs other than...

Page 378: ...or lamps that ARE replace able are called out on the back cover of the instru ment cluster All other indicators are Light Emitting Diodes LED s and are serviced with the cluster assembly If a LED is non functional the entire instrument cluster must be replaced Refer to the INDICATORS BULBS table for applications INDICATORS BULBS INDICATOR COLOR BULB LED BATTERY RED LED BRAKE RED LED AIRBAG RED LED...

Page 379: ...ing Fig 4 3 Disconnect the wire connector INSTALLATION 1 Connect the electrical connector to the new glove box lamp switch 2 Place glove box lamp switch assembly into posi tion firmly snap into place Fig 4 and close the glove box door 3 Connect the negative battery cable remote ter minal to the remote battery post ILLUMINATED ENTRY DESCRIPTION The Illuminated Entry System is available on vehi cles...

Page 380: ...MISSION RANGE INDICATOR ILLUMINATION DESCRIPTION The floor console mounted Transmission Range Indicator Lamp display utilizes electroluminescent technology as the light source The only diagnostics that should be performed is to check for the presence of 12 volts on the mating wire harness connector The electroluminescent lamp requires a 120 volt AC sig nal that is provided by a power converter inc...

Page 381: ... overhead consoles on LH models can include the Electronic Vehicle Information Center EVIC system Fig 2 or the Overhead Travel Information System OTIS Fig 1 All overhead consoles are equipped with two reading and courtesy lamps Vehi cles equipped with a power sunroof will have the sunroof control switch located between the two read ing and courtesy lamps The overhead console is mounted with one sc...

Page 382: ...r the open circuit or compo nent as required Refer to the Wiring section for detailed schematics 2 Check the IGN RUN B circuit in the over head console electrical connector If OK go to Step 3 If not OK repair the open IGN RUN B circuit as required 3 Check the Ground circuit in the overhead con sole electrical connector If OK go to Step 4 If not OK repair the open ground circuit as required 4 If th...

Page 383: ...r bridges or near overhead or underground power lines NOTE Whenever an EVIC module is replaced the variance number must also be reset Refer to Com pass Variation Adjustment in this group Calibrate the compass manually as follows 1 Turn the ignition switch to the On position If the compass temperature data is not currently being displayed momentarily depress and release the C T push button to reach...

Page 384: ... Contact the roof panel with the plastic coated tip of the degaussing tool Be sure that the template is in place to avoid scratching the roof panel Using a slow back and forth sweeping motion and allowing 13 millimeters 0 50 inch between passes move the tool at least 11 centimeters 4 inches to each side of the roof center line and 28 centimeters 11 inches back from the windshield header 10 With th...

Page 385: ...on 2 Depress and release the Menu push button The first item in the programmable features menu list will appear in the EVIC display 3 Momentarily depress and release the Menu push button to step through the programmable fea tures list Each programmable feature and its cur rently selected option will appear on the EVIC display in the sequence shown in the Programmable Features list that follows 4 M...

Page 386: ...KE receiver recognizes a valid Unlock signal from an RKE transmitter When No is selected no lamp flash will occur with the RKE Lock or Unlock event This feature may be selected inde pendent of the SOUND HORN ON LOCK pro grammable feature HEADLAMP DELAY The options include Off 30 Sec 60 Sec and 90 Sec The default is 90 Sec When a time interval is selected the headlamps will remain on for that lengt...

Page 387: ...iated with a memory setting When you have finished training the trans mitters press the menu button again and the EVIC will display TRAIN DONE X TRAINED If no transmitters are trained within approx 30 seconds the EVIC will display TRAIN TIMEOUT RETRAIN TIRE SENSORS This programma ble feature only applies to vehicles equipped with the optional Tire Pressure Monitoring System The options include Yes...

Page 388: ...n resets the function currently on the display provided that function can be reset The functions which can be reset are Aver age fuel economy Trip odometer and Elapsed time The RESET button is also used to set the variance and or calibrate the compass Refer to the Variance Procedure and Calibration Procedure in this section DIAGNOSIS AND TESTING COMPASS MINI TRIP COMPUTER TEMPERATURE The Compass M...

Page 389: ...and to set the variance refer to Variance Procedure both within this section If the compass portion of the display is still blank replace the Compass Mini Trip Computer COMPASS MINI TRIP COMPUTER SELF DIAGNOSTIC TEST 1 With the ignition switch in the OFF position simultaneously press the C T and STEP buttons and hold 2 Turn ignition switch ON then release C T and STEP buttons 3 Compass Mini Trip C...

Page 390: ...is transmitting and when the transceiver is cleared If the vehicle is equipped with the optional Tire Pressure Monitoring System the EVIC will also display messages and an icon indicating when the tire air pressure falls below a given set point and which of the five tires is transmitting the low pres sure warning and when the condition is cleared Refer to the Tires Wheels section of this manual fo...

Page 391: ... compass tempera ture trip computer display mode from any other mode While in the compass temperature trip com puter display mode momentarily depressing and releasing the Step push button will step through the available trip computer display options The EVIC trip computer features several functions that can be reset The functions that can be reset are average fuel economy trip odometer and elapsed...

Page 392: ...rking properly FAILED SELF TEST The EVIC module has an internal failure The EVIC module is faulty and must be replaced NOT RECEIVING J1850 MESSAGE The EVIC module is not receiving proper message input through the PCI data bus This can result from one or more faulty electronic modules in the vehicle or from a faulty PCI data bus The use of a DRB scan tool and the proper Diagnostic Procedures manual...

Page 393: ...ressure tire specified For this rea son anytime a evic module is removed or replaced a DRB IIIT scan tool must be used to set verify that the correct tire pressure set point is programmed in the evic module Failure to do so could result in incorrect tire pressure monitoring set points UNIVERSAL TRANSMITTER DESCRIPTION On some LH models a Universal Transmitter is standard factory installed equipmen...

Page 394: ... good transmitter as instructed in the owner s manual and test the Transmitter operation again If the unit is still inoperative test the universal transmitter with Radio Frequency Detector special tool Fig 9 If both the Transmitter and the EVIC module are inopera tive refer to Electronic Vehicle Information Cen ter Diagnosis and Testing in this group for further diagnosis For complete circuit diag...

Page 395: ...oltage to the PCM Based upon the resistance in the sensor the PCM senses a specific voltage on the temperature sensor signal circuit which it is pro grammed to correspond to a specific temperature The PCM then sends the proper ambient tempera ture messages to the EVIC over the PCI data bus The thermometer function is supported by the ambient temperature sensor a wiring circuit the Powertrain Contr...

Page 396: ...Connect the ambient temperature sensor elec trical connector 2 Install the ambient temperature sensor retain ing screw 3 Connect the negative battery cable 8M 16 MESSAGE SYSTEMS LH AMBIENT TEMPERATURE SENSOR Continued ...

Page 397: ...ock relay All doors can be locked or unlocked mechanically and independently with their respective locking knobs On police vehicles the rear doors must be locked or unlocked using the knob located in the front portion of each rear door panel These are accessible only when the front doors are open The right and left front door can be locked or unlocked mechanically from the outside with the key or ...

Page 398: ...ock switch is pressed for longer than eight consecutive seconds the BCM will de en ergize the door lock relay The system includes an Automatic Door Locking feature The vehicle is shipped with the system enabled When the system is disabled the door locks will work by use of the door lock switches and the Remote Keyless Entry System only When the Auto matic Door Lock System is enabled the BCM will a...

Page 399: ...ter the opposite state of its current programmed state by receiving this operation code The BCM is responsible for keep ing track of the horn chirp status DIAGNOSIS AND TESTING POWER LOCKS The most reliable efficient and accurate means to diagnose the power lock system requires the use of a DRBIIIt scan tool and the proper Diagnostic Procedures manual STANDARD PROCEDURE TOGGLING CUSTOMER PREFERENC...

Page 400: ...ylinder INSTALLATION 1 Install the Door Cylinder Lock Switch onto the door lock cylinder 2 Connect the wiring clip and pigtail wire con nector Fig 2 3 Refer to Body Door Front for Door Trim and Water Shield Installation 4 Connect the negative battery cable remote ter minal onto the remote battery post DOOR LOCK MOTOR DIAGNOSIS AND TESTING DOOR LOCK MOTOR Make certain battery is in normal condition...

Page 401: ...ers 1 inch for Asian transmitters and 30 5 centimeters 12 inches for all others To test position the transmitter as shown Fig 4 Press any transmitter button then test each button individually The tool will beep if a radio signal strength that lights five or more LED s is detected Repeat this test three times If transmitter fails any of the test refer to the Diagnostic Procedures manual STANDARD PR...

Page 402: ...ries are stacked on top of each other 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 RANGE Operation range is within 12 meters 40 ft of the module receiver REMOTE KEYLESS ENTRY MODULE REMOVAL The Remote Keyless Entry RKE Module is located between the junction block and body control module Refer to ...

Page 403: ...er the vehicle is being driven in reverse Refer to the owner s manual for more information on the features use and operation of the automatic day night mirror system OUTSIDE REAR VIEW MIRROR The power mirrors receive a non switched battery feed through a fuse in the junction block so that the system will remain operational regardless of the ignition switch position DIAGNOSIS AND TESTING POWER MIRR...

Page 404: ... proceed with power mirror motor test Refer to the appropri ate wiring information The wiring information includes wiring diagrams proper wire and connector repair procedures details of wire harness routing and retention connector pin out information and location views for the various wire harness connec tors splices and grounds 1 Remove the power mirror switch 2 Disconnect wire harness connector ...

Page 405: ...K repair the open circuit to the ignition switch as required 3 Turn the ignition switch to the Off position Disconnect and isolate the battery negative cable Unplug the wire harness connector from the auto matic day night mirror Connect the battery negative cable Turn the ignition switch to the On position Check for battery voltage at the fused ignition switch output run start circuit cavity of th...

Page 406: ...or Switch Test table 4 If test results are not obtained as shown in the Mirror Switch Test table replace the switch MIRROR SWITCH TEST SWITCH POSITION MOVE BUTTON CONTINUITY BETWEEN TERMINALS MIRROR IN 9L9 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 1 PIN 9 TO 12 PIN 9 TO 13 LEFT PIN 11 TO 7 PIN 11 TO 8 PIN 9 TO 1 MIRROR IN 9R9 POSITION U...

Page 407: ...t is standard on highline models and optional on others This option includes a six way adjustable seat cushion track and a two way power seat back The eight way power seat is also available with the heated seat and mem ory seat system that automatically positions the power seat for two different drivers Refer to Heated Seat System for more information on the heated seat option Refer to Memory Syst...

Page 408: ...luded in the memory seat mirror and heated seat systems The memory system includes the following compo nents Memory Heated Seat Mirror Module MHSMM This module contains the solid state electronic control and diagnostic logic circuitry for the heated seat and memory seat mirror systems One module is used per vehicle and is mounted under the drivers front seat cushion Refer to the Electronic Control...

Page 409: ...tion on the EVIC DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING POWER SEATS The following tests will help to diagnose the hard wired components and circuits of the power seat sys tem However if the vehicle is also equipped with the optional memory system these tests may not prove conclusive in the diagnosis of the driver side power seat In order to obtain conclusive testing of the driver side power s...

Page 410: ... the proper hard wired inputs and relaying the proper hard wired out puts to perform its functions STANDARD PROCEDURE MEMORY SYSTEM PROGRAMMING The Memory Heated Seat Mirror Module MHSMM interfaces with the RKE vial the Pro grammable Communication Interface PCI bus The proper procedure of setting and recalling a memory position using the RKE is as follows 1 Press memory switch 1 and release to rec...

Page 411: ...TEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE THEN WAIT TWO MIN UTES FOR THE SYSTEM CAPACITOR TO DIS CHARGE BEFORE FURTHER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 2 Remove the drivers seat...

Page 412: ... 12v It should be present If OK go to Step 4 If NOT OK repair the open voltage supply circuit as required 4 Using an ohmmeter verify the Seat Switch Continuity Test table using the seat switch connec tor Fig 3 If there is no continuity at any of the switch positions replace the power seat switch DRIVER SEAT SWITCH TEST SWITCH POSITION CONTINUITY BETWEEN PINS DRIVER OFF PIN 5 4 PIN 5 3 PIN 5 2 PIN ...

Page 413: ... applied through the switch contacts to the power seat track or recliner adjuster motor The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direc tion until the switch is released or until the travel limit of the adjuster is reached When the switch is moved in the opposite direction the battery feed and ground path to the motor are reverse...

Page 414: ...FORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE THEN WAIT TWO MIN UTES FOR THE SYSTEM CAPACITOR TO DIS CHARGE BEFORE FURTHER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 2 Remove seat cush...

Page 415: ...y two separate vertical adjustment motors These motors can be operated independently of each other tilting the entire seat assembly forward or rearward or they can be operated in unison by selecting the proper power seat switch functions which will raise or lower the entire seat assembly The third motor is the horizontal adjustment motor which moves the seat track in the forward and rear ward dire...

Page 416: ...k mounting bolts and also remove two seat back recliner bolts Fig 10 3 Remove four seat track mounting bolts from cushion pan 4 Remove the seat track from seat INSTALLATION 1 Position the seat track and install the retaining bolts in the seat cushion pan Torque the bolts to 45 60 N m 2 Install the two seat back mounting bolts Torque the bolts to 45 60 N m 3 Install the two seat back recliner bolts...

Page 417: ...r terminals will cause the motor to rotate in one direction Reversing current through these same two connec tions will cause the motor to rotate in the opposite direction Each individual motor is grounded through the master switch DIAGNOSIS AND TESTING POWER WINDOWS WIRING VOLTAGE TEST The following circuit test sequence determines whether or not voltage is continuous through the body harness to s...

Page 418: ...te terminal from the remote battery post 3 Remove door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL or Refer to 23 BODY DOORS REAR TRIM PANEL REMOVAL 4 Remove window regulator Refer to 23 BODY DOOR FRONT WINDOW REGULATOR REMOVAL or Refer to 23 BODY DOORS REAR REMOVAL WARNING FAILURE TO CLAMP THE SECTOR GEAR TO THE MOUNTING PLATE WHEN REMOVING THE MOTOR CAN RESULT IN INJURY 5 Disconnec...

Page 419: ... mounting screws 4 Remove switch and disconnect wire connector LHS and 300M 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post 2 Using a trim stick special tool C 4755 or equivalent gently pry up on switch trim bezel and lift up and out of trim panel 3 Disconnect wire connector from rear of switch and remove switch from vehicle PASSENGER SWITCH 1 Ope...

Page 420: ...E 1 Install switch and wire connector 2 Install three mounting screws 3 Install drivers door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLA TION 4 Connect negative battery cable remote termi nal LHS and 300M 1 Install wire connector to switch 2 Install switch to trim panel 3 Connect negative battery cable remote termi nal PASSENGER SWITCH 1 Install switch and wire connector 2 Install d...

Page 421: ...M COVER REMOVAL 11 INSTALLATION 11 FRONT SEAT BELT RETRACTOR REMOVAL 14 INSTALLATION 15 IMPACT SENSOR DESCRIPTION 15 OPERATION 15 OCCUPANT RESTRAINT CONTROLLER DESCRIPTION 15 OPERATION 15 OCCUPANT RESTRAINT CONTROLLER 5 PASSENGER VEHICLES REMOVAL 15 INSTALLATION 16 OCCUPANT RESTRAINT CONTROLLER 6 PASSENGER VEHICLES REMOVAL 16 INSTALLATION 17 PASSENGER AIRBAG DESCRIPTION 17 OPERATION 17 REMOVAL 18 ...

Page 422: ...S RUBBER GLOVES AND LONG SLEEVED CLOTHING WHEN CLEANING POWDER RESIDUE FROM THE VEHICLE AFTER AN AIRBAG DEPLOYMENT SODIUM HYDROXIDE POW DER RESIDUE EMITTED FROM A DEPLOYED AIR BAG CAN CAUSE SKIN IRRITATION FLUSH AFFECTED AREA WITH COOL WATER IF IRRITA TION IS EXPERIENCED IF NASAL OR THROAT IRRITATION IS EXPERIENCED EXIT THE VEHICLE FOR FRESH AIR UNTIL THE IRRITATION CEASES IF IRRITATION CONTINUES ...

Page 423: ...Fig 1 SIDE AIRBAG LOCATION TYPICAL LH RESTRAINTS 8O 3 RESTRAINTS Continued ...

Page 424: ...VER AIRBAG STEERING WHEEL SPECIFICATIONS DRIVER AIRBAG CUSHION POSITION DAB DIAMETER WHEN FULL 28 INCHES DAB DEPTH WHEN FULL 12 INCHES MAXIMUM REARWARD DISPLACEMENT DURING FILL 13 8 INCHES STEERING WHEEL TILT POSITION RANGE 10 4 DEGREES 29 6 DEGREES FROM VERTICAL 20 0 DEGREES FROM VERTICAL IS THE NOMINAL POSITION 1 FRONT SEAT BACK PANEL 5 SEAT BACK TRIM COVERS 2 LEFT SEAT AIRBAG MODULE 6 SEAT BACK...

Page 425: ...est the airbag warning lamp bulb opera tion in the cluster refer to Electrical Instrument Cluster Diagnosis and Testing Instrument Cluster Refer to the proper Body Diagnostic Procedures man ual for any other system problems Fig 3 DRIVER AIRBAG LATERAL DEPLOYMENT ZONE 1 SEATING REFERENCE 2 DRIVER AIRBAG CUSHION LATERAL DEPLOYMENT ZONE Fig 4 PASSENGER AIRBAG DEPLOYMENT ZONE 1 WINDSHIELD 2 PASSENGER ...

Page 426: ...airbag will propel into the air if accidental deployment occurs STANDARD PROCEDURE SERVICE AFTER AN AIRBAG DEPLOYMENT DRIVER AIRBAG After a Driver Airbag has been deployed due to a collision the following MUST be replaced Driver Airbag Clock Spring Assembly Steering Wheel Complete Steering Column Assembly with Lower Steering Column Coupler All other airbag and vehicle components should be closely ...

Page 427: ...with a fixed position child restraint upper tether anchor and child restraint lower anchors for the two outboard seating positions only Vehicles manufactured for sale outside of North America are equipped with a fixed position child restraint upper tether anchor for both the cen ter and the two outboard seating positions but does not have the child restraint lower anchors Vehicles manufactured for...

Page 428: ...til the cover detaches from the cup INSTALLATION 1 Place the Child Tether Cup cover into position on top of the rear shelf trim panel 2 Push downward on the Child Tether Cup Cover until it locks into position you will hear it click into place CLOCK SPRING DESCRIPTION The clock spring is mounted to the steering column behind the steering wheel Fig 9 The clock spring is used to maintain a continuous...

Page 429: ...pring and the steering wheel wiring harness 7 Remove the steering wheel Refer to 19 STEERING COLUMN STEERING WHEEL REMOVAL 8 Remove the tilt lever Fig 10 from the steer ing column if equipped 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 sha...

Page 430: ... the steering wheel back cover 8 Connect the horn lead wire and the airbag lead wire to the airbag module 9 Install the airbag 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 WARNING DO NOT CONNECT THE BATTERY NEG ATIVE CABLE REMOTE TERMINAL REFER TO ELECTRICAL RESTRAINTS DIAGNOSIS AND...

Page 431: ...tighten to 7 to 9 N m 65 to 85 in lbs torque 3 Connect the wire connectors to the speed con trol switches and install switches Tighten speed con trol screws to 1 5 N m 13 in lbs a If equipped with remote radio switches only the 4 way connector between the steering wheel and wire harness and the clock spring needs to be connected Dock the 4 way connector in the tab at the 12 o clock position of the...

Page 432: ...2 HORN SWITCH GROUND WIRE 5 WIRE RETAINER 3 TRIM COVER RETAINER BRACKET Fig 14 DRIVER AIRBAG TRIM COVER INSULATOR CONNECTOR REMOVAL 1 HORN SWITCH FEED WIRE 4 NUTS 2 HORN SWITCH GROUND WIRE 5 WIRE RETAINER 3 TRIM COVER RETAINER BRACKET 8O 12 RESTRAINTS LH DRIVER AIRBAG TRIM COVER Continued ...

Page 433: ...OUSING AND INFLATOR 1 INFLATOR 2 DRIVER AIRBAG HOUSING Fig 16 DRIVER AIRBAG TRIM COVER 1 LOCKING BLOCKS 3 HORN GROUND WIRE 2 TRIM COVER RETAINER BRACKET 4 LOCKING BLOCKS LH RESTRAINTS 8O 13 DRIVER AIRBAG TRIM COVER Continued ...

Page 434: ...RONT SEAT BELT RETRACTOR REMOVAL WARNING INSPECT THE CONDITION OF THE SHOULDER LAP BELT REPLACE THE RETRACTOR IF THE BELT IS CUT FRAYED TORN OR DAM AGED IN ANY WAY 1 If necessary move the front seat all the way forward for access 2 Remove the turning loop adjuster knob 3 Detach the turning loop cover from the upper anchor bolt 4 Remove the upper anchor bolt Fig 18 5 Remove the B pillar upper trim ...

Page 435: ...LER DESCRIPTION The Occupant Restraint Controller ORC is also sometimes referred to as the Airbag Control Module ACM The ORC contains the accelerometer and energy reserve capacitor The ORC is mounted on the tunnel floor pan forward of the center console OPERATION The accelerometer is located inside the ORC The accelerometer provides confirmation of a crash dis criminating severity The ORC monitors...

Page 436: ...nd install the center bezel into vehicle 12 Install the two screws to shifter bezel 13 Install the one screw to shift knob WARNING DO NOT CONNECT THE BATTERY NEG ATIVE CABLE REMOTE TERMINAL REFER TO ELECTRICAL RESTRAINTS DIAGNOSIS AND TEST ING AIRBAG SYSTEM FIRST OCCUPANT RESTRAINT CONTROLLER 6 PASSENGER VEHICLES REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from th...

Page 437: ...rument panel and pad assembly Fig 19 The airbag is mounted to a bracket welded to the floor pan with three screws The instrument panel top cover pad is the most visible part of the passenger airbag system Located under the instrument panel top pad are the airbag door the passenger airbag cushion and the airbag cushion supporting components The passenger airbag includes an extruded housing within w...

Page 438: ...stribution ducts 16 Disconnect the brake switch electrical connec tor 17 Remove the bulkhead connector mounting screw NOTE It is not necessary to disconnect the bulk head connector 18 Disconnect the Occupant Restraint Controller ORC electrical connector 19 Disconnect the two center instrument panel ground eyelets on the left side of the floor tunnel 20 Remove the four steering column nuts and lowe...

Page 439: ...the instrument panel retainer 3 Install the five screws attaching the passenger airbag assembly to retainer Torque screws to 2 N m 20 in lbs Fig 21 4 Install the four 10 mm hex head screws to the deployment door reinforcement two screws per side Torque screws to 8 5 N m 75 in lbs Fig 21 5 Connect the instrument panel wiring harness to the airbag reinforcement bracket 6 Install the right and left p...

Page 440: ... m 20 in lbs torque 2 Install the four screws to the airbag reinforce ment brace on the airbag Torque screws to 2 N m 20 in lbs Fig 22 3 Install the airbag assembly into the instrument panel retainer 4 Install the five screws attaching the passenger airbag assembly to retainer Torque screws to 2 N m 20 in lbs Fig 21 5 Install the four 10 mm hex head screws to the deployment door reinforcement two ...

Page 441: ...r shelf Fig 24 3 Remove the center rear seat belt retractor assembly from the vehicle INSTALLATION WARNING INSPECT THE CONDITION OF THE SHOULDER LAP BELT REPLACE THE RETRACTOR IF THE BELT IS CUT FRAYED TORN OR DAM AGED IN ANY WAY 1 Install the center rear seat belt retractor assembly on the rear shelf Torque the bolt to 40 N m 30 ft lbs 2 Install the rear shelf trim panel WARNING THE REAR SEAT BAC...

Page 442: ...DISCON NECTED WAIT 2 MINUTES BEFORE REMOVING ANY AIRBAG SYSTEM COMPONENT 1 Position the front seat in the full forward posi tion 2 Disconnect and isolate the battery negative cable remote terminal 3 Wait two minutes for the system reserve capac itor to discharge before servicing any airbag compo nents 4 Remove the plastic back panel from the seat back Fig 27 Refer to Body Seats Seat Back Removal 5...

Page 443: ...yellow locking tab is positioned 5 Position the seat back trim cover and install the seat back trim cover J straps on the upper lower and airbag side of seat back frame CAUTION Always install new push pins when installing the seat back plastic panel 6 Install the plastic back panel on the seat back Be sure to use new push pins in the upper mounting location of the back cover Refer to Body Seats Se...

Page 444: ... removed once yellow locking tab is positioned 3 Install the seat back trim cover J straps on the upper lower and airbag side of the seat back frame CAUTION Always install new push pins when installing the seat back plastic panel 4 Install the plastic back panel on the seat back Install new push pins in the upper mounting location of the back cover Refer to Body Seats Front Seat Back Cover Install...

Page 445: ... seat as necessary to gain access to seat belt buckle anchor bolt 2 Remove the bolt attaching buckle and rein forcement to front seat track Fig 31 3 Remove the seat belt buckle from vehicle INSTALLATION 1 Place the seat belt buckle in position in the vehicle 2 Install the buckle attaching bolt and reinforce ment to the front seat track or floor Tighten bolt to 40 N m 30 ft lbs torque 3 Install the...

Page 446: ...nal to its airbag deploying the airbag The SIACM communicates with the occupant restraint controller via the PCI bus circuit REMOVAL 1 Disconnect and isolate the battery negative cable remote terminal 2 Wait two minutes for the system reserve capac itor to discharge before servicing any airbag compo nents 3 Remove the lower B pillar trim from the appro priate side of the vehicle Refer to Body Inte...

Page 447: ...n WARNING DO NOT CONNECT THE BATTERY NEG ATIVE CABLE REMOTE TERMINAL REFER TO ELECTRICAL RESTRAINTS DIAGNOSIS AND TEST ING AIRBAG SYSTEM FIRST Fig 33 SIDE IMPACT AIRBAG SYSTEM COMPONENT LOCATION 1 RIGHT SIDE IMPACT AIRBAG CONTROL MODULE SIACM 4 LEFT SEAT AIRBAG MODULE 2 VEHICLE BODY B PILLAR 5 LEFT SIDE IMPACT AIRBAG CONTROL MODULE SIACM 3 RIGHT SEAT AIRBAG MODULE 6 OCCUPANT RESTRAINT CONTROLLER L...

Page 448: ......

Page 449: ...ST buttons are located on the right side of the airbag module Fig 1 The system 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 SLIP PERY OPERATION OPERATION When speed control is activated by depressin...

Page 450: ...ade the interactive speed con trol tries to maintain the set speed by increasing the throttle opening while inhibiting delaying down shifts OPERATION If opening the throttle alone cannot maintain the set speed and the vehicle speed drops more than three mph below the set speed the transmission will downshift to third gear If the vehicle continues to lose speed by more than 6 mph the transmission w...

Page 451: ...uld be smooth and without flut ter at all speeds Flutter in the speedometer indicates a problem which might cause surging in the speed control sys tem The cause of any speedometer problems should be corrected before proceeding Refer to the Instru ment Cluster for speedometer diagnosis If a road test verifies an inoperative system and the speedometer operates properly check for A Diagnostic Trouble...

Page 452: ...e retaining clip and remove clip attaching cable to servo 9 Remove servo mounting bracket INSTALLATION INSTALLATION 2 7L 1 Slide cable into throttle cable bracket and engage retaining tabs 2 Rotate the throttle cam forward to the wide open position and install speed control cable clasp Fig 2 3 Rotate the throttle cam forward to the wide open position and install throttle cable clasp 4 Install reta...

Page 453: ... and mounting bracket to servo 5 Remove servo mounting bracket 6 Pull cable away from servo to expose retaining clip and remove clip attaching cable to servo INSTALLATION 1 With throttle in full open position align hole in speed control cable sleeve with hole in servo pin and install retaining clip 2 Connect vacuum hose to servo 3 Connect electrical connector 4 Insert servo studs through holes in ...

Page 454: ...ter to maintain the highest available vacuum level in the servo reservoir and vacuum hoses When engine vacuum drops as in climbing a grade while driving the reservoir supplies the vacuum needed to maintain proper speed control operation The vacuum reservoir cannot be repaired and must be replaced if faulty REMOVAL 1 Disconnect the negative battery cable 2 Remove the Powertrain Control Module PCM r...

Page 455: ...passive protection against unau thorized vehicle use by preventing the engine from operating The components of this system are the Sentry Key Immobilizer Module SKIM Fig 1 Body Control Module BCM Sentry Key transpon der VTSS indicator LED and the Powertrain Con trol Module PCM The SKIM is installed on the steering column near the ignition lock cylinder The transponder is located under the molded r...

Page 456: ...manually override the system For Door Cylinder Lock Switch Removal and Installation refer to Electrical Power Locks Door Cylinder Lock Switch SENTRY KEY IMMOBILIZER SYSTEM The SKIS includes two valid Sentry Key transpon ders from the factory These two Sentry Keys can be used to program additional non coded blank Sentry Keys These blank keys can be cut to match a valid ignition key but the engine w...

Page 457: ...uired DIAGNOSIS AND TESTING VEHICLE THEFT SECURITY SYSTEM Using a DRB IIIt scan tool and the proper Body Diagnostic Procedures manual each switch input can be checked using this method For complaints about the Theft Alarm going off on it s own use the DRB IIIt scan tool and select Theft Alarm VTSS then Monitor Display and read the Alarm Tripped By status DECKLID SECURITY SWITCH REMOVAL 1 Open hood...

Page 458: ... BCM to flash the VTSS indi cator LED The SKIM can also send messages to the BCM to flash the LED and to generate a single audible chime tone These functions serve as an indication to the customer that the SKIS has been placed in its Cus tomer Learn programming mode See Sentry Key Immobilizer System Transponder Programming in this section for more information on the Customer Learn programming mode...

Page 459: ... blanks to match the ignition lock cylinder mechanical key codes 2 Insert one of the two valid Sentry Key tran sponders into the ignition switch and turn the igni tion switch to the ON position 3 After the ignition switch has been in the ON position for about three seconds but no more than fifteen seconds cycle the ignition switch back to the OFF position Replace the first valid Sentry Key in the ...

Page 460: ...messages to the BCM to flash the VTSS indi cator LED The SKIM can also send messages to the BCM to flash the LED and to generate a single audible chime tone These functions serve as an indication to the customer that the SKIS has been placed in its Cus tomer Learn programming mode See Sentry Key Immobilizer System Transponder Programming in this section for more information on the Customer Learn p...

Page 461: ...WASHER FLUID LEVEL SWITCH INTREPID REMOVAL 15 INSTALLATION 15 WASHER HOSES REMOVAL 15 INSTALLATION 16 WASHER NOZZLE REMOVAL 16 INSTALLATION 16 WASHER PUMP MOTOR REMOVAL 16 INSTALLATION 16 WASHER PUMP MOTOR INTREPID REMOVAL 16 INSTALLATION 16 WASHER RESERVOIR REMOVAL 17 INSTALLATION 17 WASHER RESERVOIR INTREPID REMOVAL 18 INSTALLATION 18 WASHER RESERVOIR FILLER TUBE REMOVAL 18 INSTALLATION 18 WIPER...

Page 462: ...an tool refer to the proper Body Diagnostic Procedures Manual for Diag nosis and Testing WASHER SYSTEM The wash function can be accessed in the OFF position of the wiper control switch Wash switch must be pressed for at least 0 5 second to get the wipe after wash Holding the wash button depressed when the switch is in the OFF position will operate the wipers and washer motor pump continuously unti...

Page 463: ...WN 1 CHECK FUSE 5 REPLACE IF NOT OK BLOWN FUSE WHEN WASHER SWITCH IS DEPRESSED 1 SHORT IN WIPER WASHER SWITCH 1 DEFECTIVE WASHER SWITCH REFER TO WIPE WASHER SWITCH DIAGNOSTIC PROCEDURES 2 SHORT IN MOTOR POWER CIRCUIT 2 SHORT OR DEFECTIVE CIRCUIT BETWEEN WIPER WASHER SWITCH CONNECTOR TERMINAL 2 AND MOTOR CONNECTOR TERMINAL 1 IF NOT OK REPAIR CIRCUIT 3 SHORT IN WASHER MOTOR 3 CONNECT AN OHMMETER ACR...

Page 464: ...ND WASHER SWITCH CONNECTOR TERMINAL 1 IF NOT OK REPAIR CIRCUIT 7 OPEN OR DEFECTIVE WIPER WASHER SWITCH 7 CONNECT AN OHMMETER ACROSS WIPER WASHER SWITCH TERMINAL 1 AND 2 AND DEPRESS WASHER BUTTON AND CHECK FOR CONTINUITY IF NOT OK REFER TO WIPER WASHER SWITCH DIAGNOSTIC PROCEDURES 8 OPEN POWER CIRCUIT TO MOTOR 8 OPEN OR DEFECTIVE CIRCUIT BETWEEN WIPER WASHER SWITCH CONNECTOR TERMINAL 2 AND MOTOR CO...

Page 465: ...SED CIRCUIT TO PUMP IF NOT OK REPAIR CIRCUIT HOOD NOZZLE STREAM OVERSHOOTS WINDSHIELD 1 NOZZLE NOT SEATED IN HOOD 1 ASSURE NOZZLE IS SNAPPED IN PLACE WIPER WILL NOT CYCLE WHEN WASHER SWITCH IS DEPRESSED 1 OPEN OR DEFECTIVE WASHER SYSTEM CONTROL CIRCUIT 1 OPEN OR DEFECTIVE CIRCUIT BETWEEN WIPER WASHER SWITCH CONNECTOR TERMINAL 2 AND BCM C2 BLACK CONNECTOR TERMINAL 7 IF NOT OK REPAIR CIRCUIT 2 DEFEC...

Page 466: ...ys tem problems and tests that are to be performed to locate the faulty part and the corrective action to be taken When installing harness connector to motor connector on vehicle assure motor terminals are not bent causing an open circuit to motor MOTOR WILL NOT RUN IN ANY SWITCH POSITION 1 Check fuse 5 in the Junction Block and fuse M in the Power Distribution Center and Refer to Wir ing Diagrams...

Page 467: ...wiper motor Remove wiper arms and blades Disconnect motor drive link from motor Connect an amp meter between battery negative jump start terminal and Pin 5 on the wiper motor connector Connect battery positive wire to Pin 2 on the wiper motor connector When replacing motor crank nut tighten to 15 20 N m 130 177 in lbs torque a If average amp meter reading is more than 10 amps with a hot motor and ...

Page 468: ... to ter minal 8 of the C3 black 12 way connector a If voltmeter reads 10 to 15 volts check the circuit for short to battery or ignition b If the voltmeter reads 0 volts replace the BCM WIPER WILL RUN CONTINUOUSLY WITH SWITCH IN THE INTERMITTENT POSITION WHEN COLUMN SWITCH IS TURNED OFF WIPERS STOP WHEREVER THEY ARE WITHOUT RETURNING TO PARK POSITION 1 Using an ohmmeter check for ground at Pin 4 on...

Page 469: ...r malfunction occurs first verify that the windshield washer wire harness is properly connected to all connectors before starting normal diagnosis and repair procedures Refer to Windshield Headlamp Washer Test table WINDSHIELD HEADLAMP WASHER TEST CONDITION POSSIBLE CAUSE CORRECTION WASHER POWER FEED FUSE OPEN 1 JUNCTION BLOCK FUSE 5 BLOWN 1 CHECK FUSE 5 REPLACE IF NOT OK BLOWN FUSE WHEN WASHER SW...

Page 470: ...OR GROUND 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 OPEN CIRCUIT IN MOTOR 8 CHECK FOR AN OPEN CIRCUIT ON MOTOR BETWEEN POWER TERMINAL 1 AND GROUND TERMINAL 2 IF NOT OK REPLACE WASHER MOTOR 9 SEIZED MOTOR BEARINGS 9 APPLY DIRECT BATTERY VOLTAGE TO MOTOR TERMINALS IF MOTOR DOES NOT RUN REPLACE MOTOR 10 PI...

Page 471: ...L 7 IF NOT OK REPAIR CIRCUIT 2 DEFECTIVE BODY CONTROL MODULE BCM 2 REFER TO BCM DIAGNOSTIC PROCEDURES WASHER FLUID LEVEL INDICATOR INOPERATIVE 1 LOOSE FLUID LEVEL SENSOR CONNECTOR 1 PROPERLY SEAT CONNECTOR TO SWITCH 2 FLUID LEVEL SENSOR SWITCH OPEN OR DEFECTIVE 2 ASSURE SENSOR FLOAT SWITCH IS CLOSED DOWN POSITION APPLY OHMMETER TO SWITCH TO CHECK FOR COMPLETE CIRCUIT IF NOT OK REPLACE SWITCH LH WI...

Page 472: ...R SWITCH TERMINAL 1 AND 2 AND DEPRESS WASHER BUTTON AND CHECK FOR CONTINUITY IF NOT OK REFER TO WIPER WASHER SWITCH DIAGNOSTIC PROCEDURES 8 OPEN POWER CIRCUIT TO MOTOR 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 MOTOR GROUND CIRCUIT 9 OPEN OR DEFECTIVE CIRCUIT BETWEEN WASHER MOTOR CONNECTOR...

Page 473: ...ADLAMP WASHER HOSES EXPORT 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 Body for Removal procedures 4 Disconnect the headlamp washer hoses at the quick disconnect connectors Fig 3 and Fig 4 5 Remove the headlamp washer hoses from the radiator closure panel INSTALLATION 1 Install the hea...

Page 474: ... the headlamp washer system Refer to the Electrical Wipers Washerr Headlamp Washers Standard Procedures Headlamp Washer System Priming HEADLAMP WASHER PUMP EXPORT REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the battery post 2 Hoist vehicle 3 Drain washer fluid into a clean container 4 Partially remove the front fascia to gain access to the windshield headlamp...

Page 475: ...ecessary Refer to Body for Installation 5 Lower vehicle from hoist 6 Connect the negative battery cable remote ter minal to the remote battery post WASHER FLUID LEVEL SWITCH INTREPID REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post 2 Remove the Washer Reservoir Refer to Electri cal Wipers and Washers Washer Reservoir Removal 3 Gently pry se...

Page 476: ...rvoir and out of grommet Care must be taken not to puncture res ervoir Fig 8 6 Remover rubber grommet from reservoir and throw away INSTALLATION 1 Install new rubber grommet in reservoir 2 Carefully install pump motot into reservoir Care must be taken not to puncture reservoir Fig 8 3 Connect the wire connectors to the reservoir pump 4 Install the front fascia as necessary left side only and use a...

Page 477: ... reser voir Fig 7 8 Remove washer reservoir from vehicle 9 Transfer fluid level sensor pump and washer fluid to new reservoir Fig 8 INSTALLATION 1 Transfer fluid level sensor pump and washer fluid to new reservoir Fig 8 2 Place washer reservoir into vehicle into the mounting position 3 Install the four mounting bolts to the washer reservoir Fig 7 4 Reach up behind the washer reservoir and place th...

Page 478: ...er reservoir Fig 7 7 Install the left headlamp assembly Refer to Electrical Lamps Lighting Exterior Headlamp Unit Intrepid Installation 8 Connect the negative battery cable remote ter minal to the remote battery post WASHER RESERVOIR FILLER TUBE REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post 2 Hoist vehicle 3 Remove front fascia as necess...

Page 479: ...per pivot 2 Install the retaining nut to the wiper arm pivot 3 Install the wiper arm retaining nut cap 4 Cycle the wiper arm blades to make sure the arms are positions correctly Refer to Electrical Wipers and Washers Wiper Arms Standard Procedures for adjustments if neces sary WIPER BLADES DESCRIPTION The wiper blades are a rubber element with a steel vertebrae that are mounted on the end of the w...

Page 480: ...d anytime the module is removed from the vehi cle Replace module mounting grommets if they are broken cracked deteriorated or defective 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post 2 Remove wiper module from vehicle Refer to Electrical Wipers and Washers Wiper Module Removal 3 Disconnect wiper module slave link from pivot levers by carefully us...

Page 481: ...r to tower beam 5 Remove eight bolts to Tower to Tower crosscar support Fig 14 Refer to Body for Removal 6 Remove three retaining bolts to windshield wiper module Fig 15 7 Lift wiper module away from vehicle body 8 Disconnect one wire connector 9 Remove windshield wiper module from vehicle 10 If replacing module transfer wiper module grommets to new module assembly Fig 16 11 Remove one nut to cran...

Page 482: ...GNOSIS AND TESTING WIPER MOTOR Whenever a wiper motor malfunction occurs dis connect motor wire harness and clean the terminals Ensure the wire harness is properly connected before starting diagnosis and repair procedures Refer to Wiper Motor Test table WIPER MOTOR TEST CONDITION POSSIBLE CAUSE CORRECTION WIPER OPERATES IN LOW SPEED OR INTERMITTENT ONLY 1 HI LO RELAY DEFECTIVE 1 CHECK HI LO RELAY ...

Page 483: ... TO BCM DIAGNOSTIC PROCEDURES WIPER WILL NOT PARK 1 OPEN WIPER MOTOR PARK CIRCUIT 1 OPEN OR DEFECTIVE CIRCUIT BETWEEN WIPER MOTOR CONNECTOR TERMINAL 4 AND BCM TERMINAL 3C IF NOT OK REPAIR CIRCUIT 2 DEFECTIVE BCM 2 REFER TO BCM DIAGNOSTIC PROCEDURES 3 DEFECTIVE WIPER MOTOR 3 APPLY BATTERY JUMPER POWER TO WIPER TERMINAL 2 LOW SPEED AND GROUND TERMINAL 5 COMMON GROUND POSITION AN OHMMETER ACROSS MOTO...

Page 484: ...UIT BETWEEN PDC FUSE 9M9 AND ON OFF RELAY CAVITY 9A9 OR 9D9 OR HI LO RELAY CAVITY 9A9 SHORT CIRCUIT IN ON OFF RELAY OR HI LO RELAY SHORT CIRCUIT BETWEEN ON OFF RELAY CAVITY 9B9 AND HI LO RELAY CAVITY 9B9 IF NOT OK REPLACE ON OFF RELAY OR REPAIR CIRCUIT S 2 JUNCTION BLOCK FUSE 5 BLOWN 2 SHORT CIRCUIT BETWEEN JUNCTION BLOCK FUSE 5 AND WIPER SWITCH TERMINAL 1 SHORT IN WIPER SWITCH IF NOT OK REPAIR CI...

Page 485: ...LY BATTERY VOLTAGE TO MOTOR HI SPEED OR LO SPEED CIRCUIT IF MOTOR RUNS AND OUTPUT CRANK RUNS INTERMITTENTLY OR DOES NOT RUN REPLACE MOTOR 11 SEIZED MOTOR BEARINGS 11 APPLY BATTERY VOLTAGE TO MOTOR HI SPEED OR LO SPEED CIRCUIT IF MOTOR DOES NOT RUN REPLACE MOTOR WIPER SYSTEM MAKES REVERSAL NOISE 1 LOOSE ARM TO BLADE CONNECTION 1 INSPECT CONNECTION FOR DAMAGE BENDING EXCESSIVE WARE REPLACE ARM OR BL...

Page 486: ...DSHIELD DEFROSTER FOR PROPER FUNCTION AND PERFORMANCE 3 PERMANENT HI OR LO TEMPERATURE SET OF BLADE ELEMENT EDGE 3 INSPECT RUBBER ELEMENT FOR PERMANENT SET IF NOT OK REPLACE RUBBER ELEMENT 4 LOW ARM FORCE 4 CHECK FOR PROPER ARM FORCE IF NOT OK REPLACE ARM REMOVAL The Wiper Module Assembly must be removed to service the wiper motor 1 Open hood and disconnect the negative battery cable remote termin...

Page 487: ...e OFF position the next six positions are for the DELAY wipe LOW is the next detent position and HIGH is the full counterclockwise detent position In any wiper switch position if the control stalk end cap is depressed the washer circuit will be com pleted Fig 17 WIPER MOTOR RETAINING BOLTS 1 CRANK ARM NUT 2 WIPER MOTOR RETAINING BOLTS Fig 18 WIPER SWITCH LOCATION 1 WINDSHIELD WASHER BUTTON 2 CONTR...

Page 488: ... K OHMS 1 PINS 1 TO 3 9 72 K OHMS DELAY 2 PINS 1 TO 3 8 22 K OHMS LEVEL 3 PINS 1 TO 3 6 61 K OHMS 4 PINS 1 TO 3 5 12K OHMS 5 PINS 1 TO 3 3 67K OHMS 6 PINS 1 TO 3 2 22K OHMS LOW PINS 1 TO 3 1 02 K OHMS HIGH PINS 1 TO 3 0 51K OHMS WASH PINS 1 TO 2 0 OHMS 8R 28 WIPERS WASHERS LH WIPER SWITCH Continued ...

Page 489: ...INSTRUMENT CLUSTER 8W 40 1 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 AIR CONDITIONING HEATER 8W 42 1 OCCUPANT RESTRAINT SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 BODY CONTROL MODULE 8W 45 1 AUDIO SYSTEM 8W 47 1 REAR WINDOW DEFOGGER 8W 48 1 OVERHEAD CONSOLE 8W 49 1 FRONT LIGHTING 8W 50 1 REAR LIGHTING 8W 51 1 TURN SIGNALS 8W 52 1 WIPERS 8W 53 1 POWER WINDOWS 8W 60 1 POWER DOOR LOCKS 8W 61 1 POWER MIRR...

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Page 491: ...wiring content In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles it is important to understand all of their features and characteris tics 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 Fig 1 All switches components ...

Page 492: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMATION LH WIRING DIAGRAM INFORMATION Continued ...

Page 493: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 LH 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 WIRING DIAGRAM INFORMATION Continued ...

Page 494: ...Fig 3 WIRING DIAGRAM SYMBOLS 8W 01 4 8W 01 WIRING DIAGRAM INFORMATION LH WIRING DIAGRAM INFORMATION Continued ...

Page 495: ...rt Vehicles Built For Sale In North America DESCRIPTION CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit part of the main circuit gage of wire and color Fig 4 WIRE COLOR CODE CHART COLOR CODE COLOR BL BLUE BK BLACK BR BROWN DB DARK BLUE DG DARK GREEN GY GRAY LB LIGHT BLUE LG LIGHT GREEN OR ORANGE PK PINK RD RED TN TAN VT VIOLET WT WHITE YL YELLO...

Page 496: ...ar group it will be shown complete all wires connectors and pins within that group For exam ple the Auto Shutdown Relay is most likely to be found in Group 30 so it is shown there complete It can however be shown partially in another group if it contains some associated wiring Splice diagrams in Section 8W 70 show the entire splice and provide references to other sections the splices serves Sectio...

Page 497: ...f general warnings that should be followed any time a vehicle is being serviced WARNING ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION WARNING USE SAFETY STANDS ANYTIME A PRO CEDURE REQUIRES BEING UNDER A VEHICLE WARNING BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION UNLESS THE PROCEDURE REQUIRES IT TO BE ON WARNING SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE AN AUTOMATIC TRAN...

Page 498: ... for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify these add on items are not the cause of the problem 1 Verify the problem 2 Verify any related symptoms Do this by per forming operational checks on components that are in the same circuit Refer to the wiring diagrams 3 Analyze the symptoms Use the wiring dia ...

Page 499: ...er lead to the other end of the circuit being tested Low or no resistance means good continuity STANDARD PROCEDURE TESTING FOR A SHORT TO GROUND 1 Remove the fuse and disconnect all items involved with the fuse 2 Connect a test light or a voltmeter across the terminals of the fuse 3 Starting at the fuse block wiggle the wiring harness about six to eight inches apart and watch the voltmeter test la...

Page 500: ...ground has been isolated STANDARD PROCEDURE TESTING FOR A VOLTAGE DROP 1 Connect the positive lead of the voltmeter to the side of the circuit closest to the battery Fig 9 2 Connect the other lead of the voltmeter to the other side of the switch component or circuit 3 Operate the item 4 The voltmeter will show the difference in volt age between the two points SPECIAL TOOLS WIRING TERMINAL Fig 9 TE...

Page 501: ...emoved terminal in the same cavity on the repair connector 2 Repeat steps for each terminal in the connec tor being sure that all wires are inserted into the proper cavities For additional connector pin out identification refer to the wiring diagrams 3 When the connector is re assembled the sec ondary terminal lock must be placed in the locked position to prevent terminal push out 4 Replace dress ...

Page 502: ...Fig 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 Secondary Terminal Lock 8W 01 12 8W 01 WIRING DIAGRAM INFORMATION LH CONNECTOR Continued ...

Page 503: ...3 APEX CONNECTOR 4 PICK FROM SPECIAL TOOL KIT 6680 5 AUGAT CONNECTOR 6 SPECIAL TOOL 6932 7 MOLEX CONNECTOR 8 SPECIAL TOOL 6742 9 THOMAS AND BETTS CONNECTOR 10 SPECIAL TOOL 6934 11 TYCO CONNECTOR 12 SPECIAL TOOL 8638 LH 8W 01 WIRING DIAGRAM INFORMATION 8W 01 13 CONNECTOR Continued ...

Page 504: ...fected sys tems TERMINAL REMOVAL 1 Follow steps for removing terminals described in the connector removal section 2 Cut the wire 6 inches from the back of the con nector INSTALLATION 1 Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired 2 Cut the repair wire to the proper length and remove one half 1 2 inch of insulation 3 Splice the repair wi...

Page 505: ...e of the splice clip Fig 14 4 Using crimping tool Mopar p n 05019912AA crimp the splice clip and wires together Fig 15 5 Solder the connection together using rosin core type solder only Fig 16 CAUTION DO NOT USE ACID CORE SOLDER 6 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...

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Page 507: ...at Sensors 8W 63 Engine Coolant Temperature Sensor 8W 30 Engine Oil Pressure Switch 8W 40 EVAP Purge Solenoid 8W 30 Evaporator Temperature Sensor 8W 42 Component Page Fog Lamp Relay 8W 50 Fog Lamps 8W 50 51 Front Washer Pump Motor 8W 53 Front Wiper High Low Relay 8W 53 Front Wiper Motor 8W 53 Front Wiper On Off Relay 8W 53 Fuel Injectors 8W 30 Fuel Pump Module 8W 30 Fuel Pump Relay 8W 30 Fuses 8W ...

Page 508: ...8W 47 Satellite Radio Multiplexer 8W 47 Satellite Receiver Module 8W 47 Seat Airbags 8W 43 Seat Belt Switch 8W 40 Component Page Sentry Key Immobilizer Module 8W 39 Short Runner Valve Solenoid 8W 30 Side Impact Airbag Control Modules 8W 43 Side Marker Lamps 8W 50 51 Side Repeater Lamps 8W 52 Spare Relay 8W 12 Speakers 8W 47 Speed Control Servo 8W 33 Speed Control Switches 8W 33 Speed Proportional ...

Page 509: ...omponent Page Fuse K 8W 10 8 18 Fuse L 8W 10 8 15 Fuse M 8W 10 8 19 Fuse N 8W 10 8 9 20 Fuse O 8W 10 8 9 20 Fuse P 8W 10 9 24 30 Fuse Q 8W 10 9 25 Fuse R 8W 10 9 26 30 Fuse S 8W 10 9 20 Fuse T 8W 10 9 20 21 Fuse U 8W 10 10 16 Fuse V 8W 10 10 25 Fuse W 8W 10 10 20 Fuse X 8W 10 10 15 16 Fuse Y 8W 10 10 15 16 Fusible Link 8W 10 7 G101 8W 10 19 G103 8W 10 19 G104 8W 10 19 G201 8W 10 17 Generator 8W 10...

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Page 539: ...e P 8W 11 6 Fuse R 8W 11 6 Fuse U 8W 11 6 G301 8W 11 5 Component Page ISO Relay No 1 8W 11 4 5 ISO Relay No 2 8W 11 4 5 Junction Block 8W 11 4 Police Accessory 8W 11 6 Power Distribution Center 8W 11 6 Radio 8W 11 4 Rear Fuse Block 8W 11 2 5 6 Remote Power Post 8W 11 5 LH 8W 11 FUSE BLOCK 8W 11 1 ...

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Page 545: ...rker Lamp 8W 12 11 34 Left Headlamp Leveling Motor 8W 12 12 Left High Beam Headlamp 8W 12 9 Left Horn 8W 12 20 Left License Lamp 8W 12 13 Left Low Beam Headlamp 8W 12 15 Left Rear Door Lock Motor Ajar Switch 8W 12 26 Left Rear Reading Courtesy Lamp 8W 12 23 Left Rear Reading Courtesy Lamp Switch 8W 12 32 Left Rear Side Marker Lamp 8W 12 13 Left Rear Turn Signal Lamp 8W 12 34 Left Side Impact Airba...

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Page 579: ...8W 15 10 Left Side Repeater Lamp 8W 15 4 Left Tail Lamp 8W 15 16 17 Left Tail Stop Lamp 8W 15 16 17 Left Tail Stop Lamp No 1 8W 15 16 Left Tail Stop Lamp No 2 8W 15 16 Left Tail Turn Signal Lamp 8W 15 16 Left Visor Vanity Lamp 8W 15 12 License Lamp 8W 15 16 Manifold Tuning Valve 8W 15 21 Manual Temperature Control Head 8W 15 8 Memory Heated Seat Mirror Module 8W 15 9 Memory Set Switch 8W 15 9 Natu...

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Page 601: ...18 2 G200 8W 18 2 G201 8W 18 2 Instrument Cluster 8W 18 3 Component Page Junction Block 8W 18 2 Left Side Impact Airbag Control Module 8W 18 3 Memory Heated Seat Mirror Module 8W 18 3 Overhead Travel Information System 8W 18 2 Powertrain Control Module 8W 18 2 3 Radio 8W 18 3 4 Right Side Impact Airbag Control Module 8W 18 3 Satellite Radio Multiplexer 8W 18 4 Satellite Receiver Module 8W 18 4 Sen...

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Page 605: ...W 20 3 Fuse W 8W 20 3 Fusible Link 8W 20 2 4 G102 8W 20 2 G108 8W 20 2 Component Page Generator 8W 20 2 ISO Relay No 1 8W 20 4 ISO Relay No 2 8W 20 4 Power Distribution Center 8W 20 2 3 Powertrain Control Module 8W 20 2 3 Remote Jump Post 8W 20 2 3 Remote Power Post 8W 20 4 LH 8W 20 CHARGING SYSTEM 8W 20 1 ...

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Page 609: ...use G 8W 21 2 Fuse V 8W 21 2 G108 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 Starter Motor 8W 21 2 Starter Motor Relay 8W 21 2 LH 8W 21 STARTING SYSTEM 8W 21 1 ...

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Page 611: ...8 Fuse N 8W 30 2 Fuse Q 8W 30 21 Fuse S 8W 30 3 4 6 Fuse T 8W 30 2 Component Page Fuse V 8W 30 21 Fuse W 8W 30 2 G101 8W 30 21 G102 8W 30 20 21 23 G103 8W 30 10 11 21 G104 8W 30 10 11 21 G301 8W 30 8 16 Generator 8W 30 20 High Speed Radiator Fan Relay 8W 30 16 Idle Air Control Motor 8W 30 17 Input Speed Sensor 8W 30 22 Intake Air Temperature Sensor 8W 30 12 13 Junction Block 8W 30 8 15 16 21 24 Kn...

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Page 637: ... 4 G103 8W 31 2 G104 8W 31 2 Component Page G300 8W 31 8 Input Speed Sensor 8W 31 3 Junction Block 8W 31 2 5 8 Output Speed Sensor 8W 31 3 Power Distribution Center 8W 31 2 6 7 Powertrain 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 Solenoid Pressure Switch Assembly 8W 31 6 7 LH 8W 31 TRANSMISSION CONTROL SYSTEM 8W 31 1 ...

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Page 645: ...k Brake 8W 33 3 Fuse 1 8W 33 2 Fuse 20 8W 33 3 G101 8W 33 3 G103 8W 33 3 G104 8W 33 3 Component Page G201 8W 33 3 Instrument Cluster 8W 33 2 Junction Block 8W 33 2 3 Left Speed Control Switch 8W 33 2 Powertrain Control Module 8W 33 2 3 Right Speed Control Switch 8W 33 2 Speed Control Servo 8W 33 3 LH 8W 33 VEHICLE SPEED CONTROL 8W 33 1 ...

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Page 649: ...use 17 8W 35 2 Fuse 20 8W 35 2 Fuse H 8W 35 2 Fuse K 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 ANTILOCK BRAKES 8W 35 1 ...

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Page 653: ...W 39 3 4 G310 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 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 Module 8W 39 6 Sun Sensor VTSS LED...

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Page 659: ... 3 10 Fuse 19 8W 40 3 10 G101 8W 40 6 7 G103 8W 40 6 7 G104 8W 40 6 7 G200 8W 40 2 6 Component Page G201 8W 40 2 3 9 10 G300 8W 40 10 G301 8W 40 4 G310 8W 40 3 Headlamp Dimmer Switch 8W 40 9 High Beam Headlamp Relay 8W 40 9 Instrument Cluster 8W 40 2 3 4 5 6 7 8 9 10 Junction Block 8W 40 2 3 4 5 6 7 8 9 10 Park Brake Switch 8W 40 6 7 Powertrain Control Module 8W 40 2 5 8 Seat Belt Switch 8W 40 10 ...

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Page 669: ...1 2 Fuse 6 8W 41 2 Fuse 18 8W 41 2 Fuse F 8W 41 3 Fuse Y 8W 41 3 G103 8W 41 3 G106 8W 41 2 Component Page G200 8W 41 2 Horn Relay 8W 41 2 Junction Block 8W 41 2 Left Horn 8W 41 2 Left Horn Switch 8W 41 2 Power Distribution Center 8W 41 3 Power Outlet 8W 41 3 Right Horn 8W 41 2 Right Horn Switch 8W 41 2 LH 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 ...

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Page 673: ...2 6 7 Fuse 23 8W 42 2 5 Fuse B 8W 42 6 7 Fuse E 8W 42 7 G100 8W 42 6 Component Page G105 8W 42 7 8 G200 8W 42 2 4 5 G201 8W 42 4 High Speed Radiator Fan Relay 8W 42 7 8 Instrument Cluster 8W 42 2 4 Junction Block 8W 42 2 4 5 6 7 Low Speed Radiator Fan Relay 8W 42 7 8 Manual Temperature Control Head 8W 42 2 9 Mode Door Actuator 8W 42 3 Power Distribution Center 8W 42 6 7 Powertrain Control Module 8...

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Page 683: ...use 1 8W 43 2 Fuse 8 8W 43 2 Fuse 22 8W 43 2 G201 8W 43 2 Component Page G300 8W 43 3 Instrument Cluster 8W 43 2 Junction Block 8W 43 2 Left Seat Airbag 8W 43 3 Left Side Impact Airbag Control Module 8W 43 3 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 687: ...Instrument Cluster 8W 44 2 6 Component Page Junction Block 8W 44 2 3 4 5 Left Rear Reading Courtesy Lamp 8W 44 5 Left Rear Reading Courtesy 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 Overhead Travel Information System 8W 44 2 3 Power Distribution Center 8W 44 7 Radio 8W 44 6 Right Rear Reading Courtesy Lamp 8W 44 ...

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Page 695: ...2 13 Left Horn Switch 8W 45 11 Left Rear Door Lock Motor Ajar Switch 8W 45 10 Component Page Left Rear Reading Courtesy Lamp 8W 45 4 Left Rear Reading Courtesy Lamp Switch 8W 45 4 Left Remote Radio Switch 8W 45 5 Left Side Impact Airbag Control Module 8W 45 15 Low Beam Headlamp Relay 8W 45 12 Manual Temperature Control Head 8W 45 5 14 Memory Heated Seat Mirror Module 8W 45 15 Mode Door Actuator 8W...

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Page 711: ... 8W 47 6 Left Rear Shelf Speaker 8W 47 4 8 Component Page Left Remote Radio Switch 8W 47 7 Power Amplifier 8W 47 2 3 4 5 6 Radio 8W 47 2 3 5 8 9 10 11 12 Rear Window Defogger Antenna 8W 47 5 Rear Window Defogger Relay 8W 47 5 Rear Window Defogger Antenna Module 8W 47 2 5 Right Front Door Sail Speaker 8W 47 4 Right Front Door Speaker 8W 47 3 8 Right Rear Door Speaker 8W 47 6 Right Rear Shelf Speake...

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Page 725: ...3 Heated Mirror Fuse 8W 48 2 4 Manual Temperature Control Head 8W 48 2 Component Page Passenger Power Mirror 8W 48 4 Power Distribution Center 8W 48 2 Radio 8W 48 3 Rear Window Defogger 8W 48 2 Rear Window Defogger Antenna 8W 48 3 Rear Window Defogger Relay 8W 48 2 3 Rear Window Defogger Antenna Module 8W 48 2 3 LH 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

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Page 729: ...AD CONSOLE Component Page Body Control Module 8W 49 2 Fuse 14 8W 49 2 Fuse 19 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 731: ...amp Relay 8W 50 8 14 15 Instrument Cluster 8W 50 14 Junction Block 8W 50 2 3 4 5 7 8 9 10 11 12 13 14 15 Left Fog Lamp 8W 50 11 Left Front Park Turn Signal Lamp 8W 50 7 13 Left Front Position Lamp 8W 50 6 Left Front Side Marker Lamp 8W 50 13 Left Headlamp Leveling Motor 8W 50 6 Left High Beam Headlamp 8W 50 8 9 15 Left Low Beam Headlamp 8W 50 8 10 Low Beam Headlamp Relay 8W 50 8 14 Park Brake Swit...

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Page 747: ...License Lamp 8W 51 9 Left Rear Fog Lamp 8W 51 10 Component Page Left Rear Side Marker Lamp 8W 51 8 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 8 Left Tail Stop Lamp No 2 8W 51 2 8 Left Tail Turn Signal Lamp 8W 51 8 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...

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Page 757: ...ront Park Turn Signal Lamp 8W 52 3 5 6 Component Page Left Front Side Marker Lamp 8W 52 5 Left Rear Turn Signal Lamp 8W 52 3 4 Left Side Repeater Lamp 8W 52 4 Power Distribution Center 8W 52 2 Right Front Park Turn Signal Lamp 8W 52 3 5 6 Right Front Side Marker Lamp 8W 52 5 Right Rear Turn Signal Lamp 8W 52 3 4 Right Side Repeater Lamp 8W 52 4 Turn Signal Hazard Switch 8W 52 2 3 4 LH 8W 52 TURN S...

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Page 763: ...4 Front Wiper On Off Relay 8W 53 4 Fuse 5 8W 53 2 Fuse M 8W 53 4 Fuse P 8W 53 5 G104 8W 53 3 4 Component Page G106 8W 53 5 Headlamp Washer Pump Motor 8W 53 5 Headlamp Washer Relay 8W 53 5 Instrument Cluster 8W 53 3 Junction Block 8W 53 2 Power Distribution Center 8W 53 4 5 Washer Fluid Level Sensor 8W 53 3 Wiper Switch 8W 53 2 LH 8W 53 WIPERS 8W 53 1 ...

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Page 769: ...60 2 3 4 G300 8W 60 2 Junction Block 8W 60 2 Left Rear Power Window Motor 8W 60 3 4 Component Page Left Rear Power Window Switch 8W 60 3 4 Passenger Power Window Motor 8W 60 2 Passenger Power Window Switch 8W 60 2 3 4 Right Rear Power Window Motor 8W 60 3 4 Right Rear Power Window Switch 8W 60 3 4 LH 8W 60 POWER WINDOWS 8W 60 1 ...

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Page 773: ...iver Door Lock Motor Ajar Switch 8W 61 3 4 Driver Door Unlock Relay 8W 61 3 Driver Power Door Lock Switch 8W 61 2 Fuse 6 8W 61 5 Component Page Fuse 19 8W 61 2 5 G300 8W 61 3 4 G301 8W 61 4 G310 8W 61 5 Instrument Cluster 8W 61 5 Junction Block 8W 61 2 3 4 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 ...

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Page 779: ... 19 8W 62 2 3 4 G300 8W 62 2 3 4 7 8 G301 8W 62 7 Heated Mirror Fuse 8W 62 7 Component Page Junction Block 8W 62 2 3 4 6 7 Memory Heated Seat Mirror Module 8W 62 5 6 8 Memory Set Switch 8W 62 8 Passenger Power Mirror 8W 62 2 3 6 7 Power Mirror Switch 8W 62 2 3 4 5 Rear Window Defogger Relay 8W 62 7 LH 8W 62 POWER MIRRORS 8W 62 1 ...

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Page 787: ... Driver Power Seat 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 8W 63 5 G300 8W 63 2 4 5 8 G301 8W 63 3 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 P...

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Page 795: ... Fuse F 8W 64 2 Fuse X 8W 64 2 G300 8W 64 2 Junction Block 8W 64 2 Component Page Power Distribution Center 8W 64 2 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 797: ...ED PROPORTIONAL STEERING Component Page Body Control Module 8W 65 2 Fuse 19 8W 65 2 Component Page Junction Block 8W 65 2 Speed Proportional Steering Solenoid 8W 65 2 LH 8W 65 SPEED PROPORTIONAL STEERING 8W 65 1 ...

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Page 799: ...S209 8W 12 20 S210 8W 70 4 S211 8W 42 3 S212 8W 70 4 S214 8W 12 24 S215 8W 30 15 S216 8W 47 7 S217 8W 47 7 Component Page S218 8W 33 2 S219 8W 33 2 S220 8W 42 2 S221 8W 41 2 S230 8W 41 2 S231 8W 11 4 S232 8W 40 7 S300 8W 12 17 S301 8W 12 21 S303 8W 12 26 S304 8W 12 26 S305 8W 60 3 S306 8W 10 11 S307 8W 44 2 S308 8W 51 2 3 S309 8W 12 13 S310 8W 12 31 S311 8W 15 18 S312 8W 15 13 S313 8W 12 23 S314 8...

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Page 803: ...17 C120 Police Package Special Service 8W 80 17 C200 8W 80 17 C200 8W 80 18 C201 8W 80 18 C201 8W 80 19 C202 MTC 8W 80 19 C202 MTC 8W 80 19 C203 ATC 8W 80 20 C203 ATC 8W 80 20 C204 8W 80 21 Component Page C204 8W 80 21 C205 Except Police Package 8W 80 21 C205 Except Police Package 8W 80 21 C206 Except Police Package 8W 80 22 C206 Except Police Package 8W 80 22 C300 8W 80 22 C300 8W 80 23 C301 8W 8...

Page 804: ...Motor 8W 80 45 Driver Power Seat Rear Riser Motor Sensor Memory 8W 80 46 Driver Power Seat Recliner Motor 8W 80 46 Component Page Driver Power Seat Recliner Motor Sensor Memory 8W 80 46 Driver Power Seat Switch 8W 80 46 Driver Power Window Motor 8W 80 47 Driver Power Window Switch 8W 80 47 Engine Coolant Temperature Sensor 8W 80 47 Engine Oil Pressure Switch 8W 80 47 EVAP Purge Solenoid 8W 80 48 E...

Page 805: ...68 Memory Heated Seat Mirror Module C2 8W 80 68 Memory Heated Seat Mirror Module C3 8W 80 69 Memory Heated Seat Mirror Module C4 8W 80 69 Memory Set Switch 8W 80 69 Component Page Mode Door Actuator 8W 80 69 Multi Function Switch 8W 80 70 Natural Vacuum Leak Detection Assembly 8W 80 70 Output Speed Sensor 8W 80 70 Overhead Map Courtesy Lamp 8W 80 70 Overhead Travel Information System Premium 8W 80...

Page 806: ...Side Impact Airbag Control Module 8W 80 91 Component Page Right Side Repeater Lamp Export 8W 80 91 Right Speed Control Switch 8W 80 91 Right Tail Lamp 300M Export 8W 80 92 Right Tail Lamp Concorde 8W 80 92 Right Tail Stop Lamp Concorde 8W 80 92 Right Tail Stop Lamp No 1 300M 8W 80 92 Right Tail Stop Lamp No 1 Dodge 8W 80 93 Right Tail Stop Lamp No 2 300M 8W 80 93 Right Tail Stop Lamp No 2 Dodge 8W...

Page 807: ...GNAL 4 AIRBAG CONTROL MODULE ORC YELLOW RED 23 WAY CAV CIRCUIT FUNCTION 1 2 3 4 5 R42 18BK YL PASSENGER SQUIB 1 LINE 1 6 R44 18DG YL PASSENGER SQUIB 1 LINE 2 7 8 9 10 11 R45 18DG LB DRIVER SQUIB 1 LINE 1 12 R43 18BK LB DRIVER SQUIB 1 LINE 2 13 14 F14 18LG YL FUSED IGNITION SWITCH OUTPUT RUN START 15 F23 18DB YL FUSED IGNITION SWITCH OUTPUT RUN 16 Z2 18BK LG GROUND 17 18 19 20 21 D25 20VT YL PCI BU...

Page 808: ...SWITCH OUTPUT RUN START 2 Z2 20BK LG GROUND 3 L1 20VT BK BACK UP LAMP FEED 4 P112 18BK TN AUTO DAY NIGHT MIRROR 5 P114 18BK YL AUTO DAY NIGHT MIRROR 6 7 AUTOMATIC TEMPERATURE CONTROL HEAD BLACK 12 WAY CAV CIRCUIT FUNCTION 1 Z2 20BK LG GROUND 2 D25 20VT YL PCI BUS ATC 3 Z1 20BK GROUND 4 E2 20OR PANEL LAMPS DRIVER 5 6 7 C10 22RD TN IN CAR TEMPERATURE SENSOR SIGNAL ATC 8 C57 20DB GY SENSOR GROUND 9 1...

Page 809: ...ND 3 C36 22RD WT BLEND DOOR FEEDBACK SIGNAL 4 C26 22PK DB 5 VOLT SUPPLY 5 C34 22BR WT COMMON DOOR DRIVER BLOWER MOTOR POWER MODULE ATC BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 Z1 12BK GROUND 3 C56 22RD LG BLOWER MOTOR CONTROL 4 C1 12DG FUSED IGNITION SWITCH OUTPUT RUN BLOWER MOTOR RESISTOR BLOCK BLACK 6 WAY CAV CIRCUIT FUNCTION 1 C7 12BK TN HIGH BLOWER MOTOR DRIVER 2 C6 16LB M2 BLOWER MOTOR DRIVER 3 4...

Page 810: ...VE TCM 5 C9 22YL DG ATC ASPIRATOR MOTOR DRIVER 6 C56 22RD LG ATC BLOWER MOTOR CONTROL 7 V10 20BR FRONT WASHER PUMP MOTOR CONTROL 8 V52 20DG RD FRONT WIPER MUX SWITCH SIGNAL 9 C37 22YL WT MODE DOOR FEEDBACK SIGNAL 10 C38 20DB EXCEPT BASE SUN SENSOR SIGNAL 11 L99 20GY BK POLICE PACKAGE FUSED B 12 C82 20YL OR MTC TEMPERATURE SELECT 13 E17 20YL BK POLICE PACKAGE EX PORT PARK LAMP RELAY OUTPUT 14 C48 2...

Page 811: ...20TN RD DOOR AJAR SWITCH SENSE PASS 3 4 G75 20TN DRIVER DOOR AJAR SWITCH SENSE 5 P97 20WT DG DRIVER DOOR SWITCH MUX 6 7 G4 20DB FUEL LEVEL SENSOR SIGNAL 8 G71 22VT WT DECKLID SECURITY SWITCH SENSE 9 D25 20VT YL EXCEPT MEMORY PCI BUS SIACM 9 D25 20VT YL MEMORY PCI BUS MHSMM 10 G74 20TN RD DOOR AJAR SWITCH SENSE RR 11 12 P96 20WT LG PASSENGER DOOR SWITCH MUX 13 G73 20LG OR DRIVER CYLINDER LOCK SWITC...

Page 812: ...SMISSION SHIFT INTERLOCK SOLENOID WHITE 2 WAY CAV CIRCUIT FUNCTION 1 K29 20WT PK BRAKE SWITCH SIGNAL 2 G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START C101 BLACK ENGINE SIDE CAV CIRCUIT 1 F42 16DG LG 2 K236 18GY PK 3 5L H O 3 Z12 14BK TN 2 7L 3 Z12 18BK TN 3 5L 4 5 6 7 C2 14DB BK 8 Z1 14BK 9 T40 12LG 10 G6 20GY 11 Z1 18BK 12 C18 20DB 13 K4 18BK LB 2 7L 13 K4 20BK LB 3 5L 14 K4 18BK LB 2 7L 14 K4...

Page 813: ... 4 K29 20WT PK 5 G29 20BK TN 6 G6 20GY 7 D21 20PK TN 8 D20 20LG 9 G9 20GY BK POLICE PACKAGE SPE CIAL SERVICE 10 K4 20BK LB 11 12 L96 18LG RD EXPORT 12 A101 16RD TN POLICE PACKAGE 13 A105 18DB RD 300M EXPORT 13 A102 16RD OR POLICE PACKAGE 14 Z1 18BK EXCEPT POLICE PACKAGE 14 A103 16RD YL POLICE PACKAGE 15 D15 20WT DG 16 F13 20DB 17 D19 20VT OR 18 SL1 18LB WT POLICE PACKAGE 19 SL2 18DB WT POLICE PACK...

Page 814: ...3 A105 18DB RD EXCEPT POLICE PACK AGE 13 A102 16RD OR POLICE PACKAGE 14 Z1 18BK EXCEPT POLICE PACKAGE 14 A103 16RD YL POLICE PACKAGE 15 D15 20WT DG 16 F13 20DB 17 D19 20VT OR 18 SL1 18WT POLICE PACKAGE 19 SL2 18WT DB POLICE PACKAGE 20 A15 18PK 21 L50 16WT TN 22 V10 20BR C104 ORANGE HEADLAMP DASH SIDE CAV CIRCUIT 1 A1 12RD 2 A2 12PK BK 3 A41 12YL 4 C104 ORANGE INSTRUMENT PANEL SIDE CAV CIRCUIT 1 A1...

Page 815: ... 18LG 2 B3 18LG DB 3 B2 18YL 4 B1 18YL DB 5 K106 18WT DG 6 K107 20OR RD 7 8 Z1 18BK EXCEPT EXPORT BASE 8 L95 16DG YL EXPORT 9 T44 20YL LB 10 T5 20LG RD C106 NATURAL HEADLAMP DASH SIDE CAV CIRCUIT 1 B4 18LG ABS 2 B3 18LG DB ABS 3 B2 18YL ABS 4 B1 18YL DB ABS 5 K106 18WT DG 6 K107 18OR RD 7 F18 20LG BK 8 Z1 18BK EXCEPT EXPORT 8 L95 18DG YL EXPORT 9 T44 20YL 10 T5 20LG RD LH 8W 80 CONNECTOR PIN OUTS ...

Page 816: ...T C107 LT GRAY TRANSMISSION SIDE CAV CIRCUIT 1 K399 18BR GY 2 L1 20VT BK 3 F20 20WT 4 T1 20LG BK 5 T3 20VT 6 T42 20VT WT 7 T41 20BR YL 8 T54 20VT PK 9 T13 20DB BK 10 K904 18DB DG 11 K341 20PK WT 12 K141 20TN WT 13 T52 20RD BK 14 T14 20LG WT C108 LT GRAY HEADLAMP DASH SIDE CAV CIRCUIT 1 T9 16OR BK 2 T19 16WT 3 Z1 18BK 4 T60 16BR 5 T59 16PK 6 T50 16DG 7 T47 16YL BK 8 K199 18BR VT 9 T20 16LB 10 T16 1...

Page 817: ...60 18TN 300M EXPORT 1 L60 20TN EXCEPT 300M EXPORT 2 L7 20BK YL 3 L61 18LG 300M EXPORT 3 L61 20LG EXCEPT 300M EXPORT 4 5 L39 20LB 6 Z1 20BK C109 BLACK HEADLAMP DASH SIDE CAV CIRCUIT 1 L60 18TN 2 L7 18BK YL EXCEPT 300M EXPORT 3 L61 18LG 4 5 L39 20LB 6 Z1 18BK C111 EXPORT GRAY HEADLAMP LEVELING SIDE CAV CIRCUIT 1 L43 16VT 2 L7 20BK YL 3 Z1 16BK 4 5 L13 20BR YL 6 L33 20RD LH 8W 80 CONNECTOR PIN OUTS 8...

Page 818: ...P MODULE SIDE CAV CIRCUIT 1 L44 16VT RD 2 L7 20BK YL 3 Z1 16BK 4 5 L13 20BR YL 6 L34 20RD OR C112 EXPORT GRAY HEADLIGHT LEVELING SIDE CAV CIRCUIT 1 L44 20VT 2 L7 20BK YL 3 Z1 20BK 4 5 L13 20BR YL 6 L34 20RD C115 EXCEPT 2 7L BASE BLACK ENGINE SIDE CAV CIRCUIT 1 Z1 12BK 2 Z1 12BK 3 C23 12DG 4 C25 12YL 8W 80 16 8W 80 CONNECTOR PIN OUTS LH ...

Page 819: ... 20GY BK EXCEPT SPECIAL SER VICE CANADIAN POLICE PACKAGE A G9 20GY BK SPECIAL SERVICE CANA DIAN POLICE PACKAGE B C200 BLUE BODY SIDE CAV CIRCUIT 1 G78 20TN BK 2 Z2 20BK LG 3 L13 18BR YL 4 L95 16DG YL EXPORT 5 F14 20LG YL EXCEPT POLICE PACK AGE 6 7 8 X60 20DG RD EXCEPT DODGE 9 P112 18TN OR EXCEPT DODGE 10 X12 18RD POLICE PACKAGE 11 G9 20GY BK POLICE PACKAGE 12 13 14 P114 18TN WT EXCEPT DODGE 15 C80...

Page 820: ...E PACKAGE 12 13 14 P114 18TN WT EXCEPT DODGE 15 C80 20DB WT 16 17 18 19 F101 16YL TN POLICE PACKAGE 20 F102 16YL OR POLICE PACKAGE 21 F103 16YL RD POLICE PACKAGE 22 L50 16WT TN C201 NATURAL BODY SIDE CAV CIRCUIT 1 F62 16RD 2 X51 18BR YL 3 X52 18DB WT 4 X53 18DG 5 X54 18VT 6 X55 18BR RD 7 X57 18BR LB 8 X58 18DB OR 9 X56 18DB RD 10 X88 18PK RD EXCEPT BASE 11 X89 18PK BK EXCEPT BASE 12 X60 20DG RD 13...

Page 821: ...AV CIRCUIT 1 C34 20BR WT 2 C35 22DG YL 3 C33 22DB RD 4 C32 20GY DB 5 C57 20DB GY 6 C26 22PK DB 7 C7 12BK TN 8 C1 12DG 9 C12 20LG BK 10 C36 22RD WT 11 C37 22YL WT 12 C4 18TN 13 C5 16LG 14 C6 16LB 15 16 C202 MTC NATURAL INSTRUMENT PANEL SIDE CAV CIRCUIT 1 C34 22BR WT 2 C35 22DG YL 3 C33 22DB RD 4 C32 22GY DB 5 C57 20DB GY 6 C26 22PK DB 7 C7 12BK TN 8 C1 12DG 9 C12 22LG BK 10 C36 22RD WT 11 C37 22YL ...

Page 822: ...C12 20LG BK 10 C36 22RD WT 11 C37 22YL WT 12 13 Z1 12BK 14 15 C56 22RD LG 16 C203 ATC NATURAL INSTRUMENT PANEL SIDE CAV CIRCUIT 1 C34 22BR WT 2 C35 22DG YL 3 C33 22DB RD 4 C32 22GY DB 5 C57 20DB GY 6 C26 22PK DB 7 8 C1 12DG 9 C12 22LG BK 10 C36 22RD WT 11 C37 22YL WT 12 13 Z1 12BK 14 15 C56 22RD LG 16 8W 80 20 8W 80 CONNECTOR PIN OUTS LH ...

Page 823: ...AV CIRCUIT 1 Q41 20WT 2 A130 16VT RD 3 Z1 16BK 4 G5 20DB WT 5 Q43 20VT 6 Q42 20LB C205 EXCEPT POLICE PACKAGE NATURAL INSTRUMENT PANEL SIDE CAV CIRCUIT 1 E2 20OR 2 Z1 20BK 3 A105 18DB RD 4 Z1 18BK C205 EXCEPT POLICE PACKAGE NATURAL POWERPOINT SIDE CAV CIRCUIT 1 E2 20OR 2 Z1 20BK 3 A105 18DB RD 4 Z1 18BK LH 8W 80 CONNECTOR PIN OUTS 8W 80 21 ...

Page 824: ...X81 18YL BK 3 P33 16OR 4 Q26 14VT WT 5 6 Q18 14GY BK 7 X87 18LG VT EXCEPT POLICE PACK AGE 7 X53 18DG POLICE PACKAGE 8 X83 18YL RD 9 P55 16DB 10 11 12 Q16 14BR WT 13 M2 20YL EXCEPT DODGE 14 F21 14TN 15 Q27 14RD BK 16 X85 18LG BK EXCEPT POLICE PACK AGE 16 X55 18BR RD POLICE PACKAGE 17 Q28 14DG WT 18 19 20 P112 18TN OR EXCEPT DODGE 21 Q1 14YL 22 Z1 14BK 23 P114 18TN WT EXCEPT DODGE 24 L61 16LG EXCEPT...

Page 825: ... 14RD BK 16 X85 18LG BK 17 Q28 14DG WT 18 19 20 P112 18TN OR 21 Q1 14YL 22 Z1 14BK 23 P114 18TN WT 24 L61 18LG C301 NATURAL BODY SIDE CAV CIRCUIT 1 G5 20DB WT 2 C16 20LB YL 3 M1 20PK 4 P72 20YL BK 5 P70 20WT 6 P74 20DB 7 G73 20LG OR 8 P97 20WT DG 9 P64 20YL OR 10 P65 20DB YL 11 P69 20WT RD 12 P71 20YL MEMORY 13 P75 20BK WT MEMORY 14 P73 20YL PK MEMORY 15 G75 20TN 16 P161 20GY LB LH 8W 80 CONNECTOR...

Page 826: ... 13 P75 20BK WT MEMORY 14 P73 20YL PK MEMORY 15 G75 20TN 16 P161 20GY LB C302 NATURAL BODY SIDE CAV CIRCUIT 1 2 X84 18OR BK 3 P33 16OR 4 Q26 14VT WT 5 6 X80 18LB BK EXCEPT POLICE PACK AGE 6 X56 18DB RD POLICE PACKAGE 7 8 9 X86 18OR RD 10 P34 16PK BK 11 Q16 14BR WT 12 M2 20YL 13 Q1 14YL 14 Z1 20BK 15 X82 18LB RD EXCEPT POLICE PACK AGE 15 X54 18VT POLICE PACKAGE 16 L60 16TN 8W 80 24 8W 80 CONNECTOR ...

Page 827: ...BK 7 8 9 X86 18OR RD 10 P34 16PK BK 11 Q16 14BR WT 12 M2 22YL 13 Q1 14YL 14 Z1 20BK 15 X82 18LB RD 16 L60 18TN C303 NATURAL BODY SIDE CAV CIRCUIT 1 2 C16 20LB YL 3 M1 20PK MEMORY 4 P72 20YL BK 5 P70 20WT 6 P74 20DB 7 8 P96 20WT LG 9 10 11 12 13 14 15 G74 20TN RD 16 LH 8W 80 CONNECTOR PIN OUTS 8W 80 25 ...

Page 828: ...E CAV CIRCUIT 1 Z1 20BK 2 X95 18WT VT PREMIUM II 3 P33 16OR 4 X97 18WT DG PREMIUM II 5 P34 16PK BK 6 7 Q27 14RD BK 8 G74 20TN RD 9 Q1 14YL 10 Q17 14DB WT C304 NATURAL REAR DOOR SIDE CAV CIRCUIT 1 Z1 20BK 2 X95 18WT VT PREMIUM II AUDIO 3 P33 16OR 4 X97 18WT DG PREMIUM II AUDIO 5 P34 16PK BK 6 7 Q27 14DG WT 8 G74 20TN RD 9 Q1 14YL 10 Q17 14GY BK 8W 80 26 8W 80 CONNECTOR PIN OUTS LH ...

Page 829: ...PACKAGE 10 Q18 14GY BK C305 NATURAL REAR DOOR SIDE CAV CIRCUIT 1 Z1 20BK 2 X98 18TN VT PREMIUM II AUDIO 3 P33 16OR 4 X96 18TN DG PREMIUM II AUDIO 5 P34 16PK BK 6 7 Q28 14DG WT 8 G74 20TN RD 9 Q1 14YL EXCEPT POLICE PACKAGE 10 Q18 14GY BK C306 BLACK BODY SIDE CAV CIRCUIT 1 Z1 16BK 2 F35 16RD C306 GREEN POWER SEAT SIDE CAV CIRCUIT 1 Z1 16BK 2 F35 16RD LH 8W 80 CONNECTOR PIN OUTS 8W 80 27 ...

Page 830: ... C308 BLACK BODY SIDE CAV CIRCUIT 1 K106 18WT DG 2 Z1 12BK 3 G4 20DB 4 K107 20OR RD 5 A141 12DG WT 6 C308 BLACK FUEL TANK JUMPER SIDE CAV CIRCUIT 1 K106 18WT DG EXPORT 2 Z1 12BK 3 G4 18DB 4 K107 18OR EXPORT 5 A141 12DG WT 6 C309 YELLOW SAB JUMPER SIDE CAV CIRCUIT 1 R31 20LG OR 2 R33 20LG WT 8W 80 28 8W 80 CONNECTOR PIN OUTS LH ...

Page 831: ...ELLOW SAB OVERLAY SIDE CAV CIRCUIT 1 R32 20LB OR 2 R34 20LB WT C311 RED BODY SIDE CAV CIRCUIT 1 G78 20TN BK 2 P2 20BK WT 3 G71 22VT WT 4 Z1 16BK 5 L50 16WT TN EXCEPT LHS CON CORDE 6 C311 RED DECKLID SIDE CAV CIRCUIT 1 G78 20TN BK 2 P2 20BK WT VTA 3 G71 20VT YL 4 Z1 16BK 5 L50 16WT TN EXCEPT LHS CON CORDE 6 LH 8W 80 CONNECTOR PIN OUTS 8W 80 29 ...

Page 832: ...AV CIRCUIT 1 L7 18BK YL 2 Z1 18BK C313 CONCORDE DODGE 300M GRAY BODY SIDE CAV CIRCUIT 1 L50 16WT TN 2 L60 16TN 3 4 L7 18BK YL 5 L1 20VT BK 6 Z1 16BK C313 CONCORDE DODGE 300M GRAY TAIL LAMP SIDE CAV CIRCUIT 1 L50 18WT TN 2 L60 18LG TN 3 4 L7 18BK YL 5 L1 18VT BK 6 Z1 18BK 8W 80 30 8W 80 CONNECTOR PIN OUTS LH ...

Page 833: ...UIT 1 L50 18WT TN 2 L60 18LG TN 3 L95 18DG YL EXPORT 4 L7 18BK YL 5 L1 18VT BK EXPORT 6 Z1 18BK C314 CONCORDE DODGE 300M GRAY BODY SIDE CAV CIRCUIT 1 L50 16WT TN 2 L61 16LG 3 4 L7 18BK YL 5 L1 20VT BK 6 Z1 16BK C314 CONCORDE DODGE 300M GRAY TAIL LAMP SIDE CAV CIRCUIT 1 L50 16WT TN 2 L61 18LG TN 3 4 L7 18BK YL 5 L1 18VT BK 6 Z1 18BK LH 8W 80 CONNECTOR PIN OUTS 8W 80 31 ...

Page 834: ... 4 L7 18BK YL 5 L1 18VT BK EXPORT 6 Z1 18BK C315 CONCORDE LTD BLACK BODY SIDE CAV CIRCUIT 1 L1 18VT BK 2 Z1 18BK 3 L7 18BK YL C315 CONCORDE LTD BLACK REAR FASCIA SIDE CAV CIRCUIT 1 L1 18VT BK 2 Z1 18BK 3 L7 18BK YL C316 BLACK BODY SIDE 12 WAY CAV CIRCUIT 1 X160 18YL 2 X112 22RD 3 Z140 18BK OR 4 X480 22DG LB 5 6 X17 22GY OR 7 D25 22BK 8 9 X481 22DG YL 10 11 X917 22DG WT 12 X166 22GY WT 8W 80 32 8W ...

Page 835: ... X917 22DG WT 12 X166 22GY WT C318 MEMORY NATURAL BODY SIDE CAV CIRCUIT 1 P130 16RD TN 2 P142 20TN DB 3 G5 20DB WT 4 5 P138 20VT LG 6 P140 20VT BK 7 P134 20TN LG 8 P144 20BK LG C318 MEMORY NATURAL POWER SEAT SIDE CAV CIRCUIT 1 P130 16RD TN 2 P142 20TN DB 3 G5 20DB WT 4 5 P138 20VT LG 6 P140 20VT BK 7 P134 20TN LG 8 P144 20BK LG LH 8W 80 CONNECTOR PIN OUTS 8W 80 33 ...

Page 836: ...0YL PK 15 P64 20YL OR 16 P65 20DB YL 17 P161 20GY LB 18 P69 20WT RD 19 20 21 22 C319 MEMORY NATURAL POWER SEAT SIDE CAV CIRCUIT 1 D25 20VT YL 2 G5 20DB WT 3 P70 20WT 4 P72 20YL BK 5 P74 20DB 6 P142 20TN DB 7 P130 16RD TN 8 P144 20BK LG 9 P134 20TN LG 10 P140 20VT BK 11 P138 20VT LG 12 P71 20YL 13 P75 20BK WT 14 P73 20YL PK 15 P64 20YL OR 16 P65 20DB YL 17 P161 20GY LB 18 P69 20WT RD 19 20 21 22 8W...

Page 837: ...TURAL CHMSL SIDE CAV CIRCUIT 1 L50 18WT TN 2 Z1 18BK C321 300M BLACK CHMSL SIDE CAV CIRCUIT 1 L50 18WT TN 2 Z1 18BK C321 300M NATURAL DECKLID SIDE CAV CIRCUIT 1 L50 18WT TN 2 Z1 18BK C322 BLACK BODY SIDE CAV CIRCUIT 1 F14 20LG YL 2 Z2 20BK LG 3 D25 20VT YL LH 8W 80 CONNECTOR PIN OUTS 8W 80 35 ...

Page 838: ...CAV CIRCUIT 1 M1 20PK 2 Z1 20BK C360 POLICE PACKAGE SPECIAL SERVICE BLACK INSTRUMENT PANEL SIDE CAV CIRCUIT 1 A101 16RD TN 2 A102 16RD OR 3 A103 16RD YL 4 F101 16YL TN 5 F102 16YL OR 6 F103 16YL RD C360 POLICE PACKAGE SPECIAL SERVICE BLACK POLICE ACCESSORY SIDE CAV CIRCUIT 1 A101 16RD TN 2 A102 16RD OR 3 A103 16RD YL 4 F101 16YL TN 5 F102 16YL OR 6 F103 16YL RD 8W 80 36 8W 80 CONNECTOR PIN OUTS LH...

Page 839: ...CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L50 18WT TN BRAKE LAMP SWITCH OUTPUT CENTER HIGH MOUNTED STOP LAMP NO 1 CONCORDE LTD GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 2 Z1 18BK GROUND CENTER HIGH MOUNTED STOP LAMP NO 1 DODGE WHITE 2 WAY CAV CIRCUIT FUNCTION 1 L50 16WT TN BRAKE LAMP SWITCH OUTPUT 2 Z1 16BK GROUND LH 8W 80 CONNECTOR PIN OUTS 8W 80 37 ...

Page 840: ...PANEL SPEAKER PREMIUM BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X89 18PK BK AMPLIFIED CENTER INSTRUMENT PANEL SPEAKER 2 X88 18PK RD AMPLIFIED CENTER INSTRUMENT PANEL SPEAKER CIGAR LIGHTER NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 F30 18RD EXCEPT POLICE PACKAGE BATTERY POSITION FUSED B 1 F30 18RD EXCEPT POLICE PACKAGE IGNITION POSITION FUSED IGNITION SWITCH OUTPUT RUN 1 F30 18PK POLICE PACKAGE IGNITION POSITIO...

Page 841: ...G LB DRIVER SQUIB 1 LINE 1 CLOCKSPRING C3 4 WAY CAV CIRCUIT FUNCTION 1 V37 22RD LG S C SWITCH SIGNAL 2 K4 22BK LB SENSOR GROUND 3 X920 22GY OR RADIO CONTROL MUX RETURN 4 X20 22GY WT RADIO CONTROL MUX COIL ON PLUG NO 1 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 16DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K91 16TN RD COIL CONTROL NO 1 COIL ON PLUG NO 2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 16DG LG...

Page 842: ... CIRCUIT FUNCTION 1 F42 16DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K95 16TN DG COIL CONTROL NO 5 COIL ON PLUG NO 6 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 16DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K96 16TN LB COIL CONTROL NO 6 COMBINATION FLASHER BLACK 9 WAY CAV CIRCUIT FUNCTION 1 2 L32 18RD COMBINATION FLASHER OUTPUT 3 4 Z1 20BK GROUND 5 L91 22DB PK COMBINATION FLASHER SWITCHED GROUND...

Page 843: ... 1 Z1 12BK GROUND 2 B1 18YL DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL 3 B2 18YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY 4 5 D25 18VT YL PCI BUS CAB 6 B6 18WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 7 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 8 9 A20 12RD DB FUSED B 10 F20 18WT VT FUSED IGNITION SWITCH OUTPUT RUN 11 12 13 14 15 16 Z1 12BK GROUND 17 18 L50 18WT TN BRAKE LAMP SWITCH ...

Page 844: ... OR SCI RECEIVE TCM 10 11 12 D20 20LG SCI RECEIVE PCM 13 14 15 D15 20WT DG SCI TRANSMIT TCM 16 F62 18RD FUSED B DECKLID RELEASE SOLENOID AJAR SWITCH BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 G78 20TN BK DECKLID AJAR SWITCH SENSE 3 P2 20BK WT DECKLID RELEASE CONTROL DECKLID RELEASE SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 P1 20BK WT DECKLID RELEASE SWITCH OUTPUT 2 M1 20PK FUSED B 2 F30 2...

Page 845: ... CYLINDER LOCK SWITCH MUX 2 M1 20PK FUSED B DRIVER DOOR LOCK MOTOR AJAR SWITCH BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G75 20TN DRIVER DOOR AJAR SWITCH SENSE 2 Z1 20BK GROUND 3 P55 16DB DRIVER DOOR UNLOCK RELAY OUTPUT 4 P33 16OR DOOR LOCK RELAY OUTPUT DRIVER HEATED SEAT BACK GREEN 2 WAY CAV CIRCUIT FUNCTION A P88 16BR BK HEATED SEAT DRIVER B Z1 20BK GROUND LH 8W 80 CONNECTOR PIN OUTS 8W 80 43 ...

Page 846: ...K SWITCH NATURAL 4 WAY CAV CIRCUIT FUNCTION 1 M1 20PK FUSED B 2 3 4 P97 20WT DG DRIVER DOOR SWITCH MUX DRIVER POWER MIRROR EXCEPT MEMORY NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 P71 20YL DRIVER MIRROR UP DRIVER 2 P73 20YL PK DRIVER MIRROR COMMON DRIVER RIGHT DOWN 3 P75 20BK WT DRIVER MIRROR LEFT DRIVER DRIVER POWER MIRROR MEMORY WHITE 12 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 P73 20YL PK DRIVER M...

Page 847: ...SEATS DRIVER SEAT HORIZONTAL REARWARD DRIVER 1 P115 16YL DB MEMORY SEATS DRIVER SEAT HORIZONTAL FORWARD DRIVER 2 P17 16RD LB EXCEPT MEMORY SEATS DRIVER SEAT HORIZONTAL FORWARD DRIVER 2 P117 16RD LB MEMORY SEATS DRIVER SEAT HORIZONTAL REARWARD DRIVER DRIVER POWER SEAT HORIZONTAL MOTOR SENSOR MEMORY BLACK 3 WAY CAV CIRCUIT FUNCTION A P28 20BR RD SEAT POSITION SENSOR GROUND B P25 20VT RD SEAT HORIZON...

Page 848: ...48 20GY WT MEMORY SEATS RECLINER DOWN SWITCH SENSE 3 P17 16RD LB EXCEPT MEMORY SEATS DRIVER SEAT HORIZONTAL REARWARD 3 P17 18RD LB MEMORY SEATS SEAT HORIZONTAL REARWARD SWITCH SENSE 4 P43 16GY LB EXCEPT MEMORY SEATS DRIVER SEAT RECLINER SWITCH DOWN 4 P40 20GY LB MEMORY SEATS DRIVER SEAT RECLINER UP 5 Z1 16BK EXCEPT MEMORY SEATS GROUND 5 Z1 18BK MEMORY SEATS GROUND 6 P21 16RD LG EXCEPT MEMORY SEATS...

Page 849: ...INDOW DRIVER UP 5 Q1 14YL WINDOW SWITCH FEED 6 7 Q11 16LB DRIVER WINDOW DRIVER UP 8 Q21 16WT DRIVER WINDOW DRIVER DOWN 9 Q28 14DG WT RIGHT REAR WINDOW DRIVER DOWN 10 Z1 14BK GROUND 11 Q26 14VT WT MASTER WINDOW SWITCH PASSENGER DOWN 12 Q16 14BR WT MASTER WINDOW SWITCH PASSENGER UP ENGINE COOLANT TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K2 20TN BK ECT SIGNAL 2 K4 20BK LB SENSOR GROUND E...

Page 850: ...RATURE SENSOR SIGNAL 2 C57 20DB GY SENSOR GROUND FRONT WASHER PUMP MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 V10 20BR FRONT WASHER PUMP MOTOR CONTROL FRONT WIPER MOTOR BLACK 5 WAY CAV CIRCUIT FUNCTION 1 V4 14RD YL FRONT WIPER RELAY HIGH SPEED OUTPUT 2 V3 14BR WT FRONT WIPER RELAY LOW SPEED OUTPUT 3 4 V55 20TN RD FRONT WIPER PARK SWITCH SENSE 5 Z1 14BK GROUND 8W 80 48 8W 80 CONNECTO...

Page 851: ... RELAY OUTPUT FUEL INJECTOR NO 3 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K13 18YL WT INJECTOR CONTROL NO 3 2 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 4 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K14 18LB BR INJECTOR CONTROL NO 4 2 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO 5 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K38 18GY INJECTOR CONTROL NO 5 2 F42 18DG LG FUSED...

Page 852: ...V CIRCUIT FUNCTION 1 Z12 14BK TN 2 7L GROUND 1 Z12 18BK TN 3 5L GROUND 2 K20 18DG GEN FIELD CONTROL GLOVE BOX LAMP LTD 300M BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 M1 20PK FUSED B HEADLAMP FLASHER POLICE PACKAGE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 L33 20RD FUSED LEFT HIGH BEAM OUTPUT 2 L34 20OR WT FUSED RIGHT HIGH BEAM OUTPUT 3 L33 20RD FUSED LEFT HIGH BEAM OUTPUT 4 L34 20RD OR FUSED RI...

Page 853: ...4 Z1 20BK GROUND 5 L95 18DG YL EXPORT REAR FOG LAMP RELAY CONTROL 6 L80 20WT HEADLAMP SWITCH RETURN 7 8 L13 18BR YL EXPORT HEADLAMP ADJUST SIGNAL 9 10 L96 18LG RD EXPORT REAR FOG LAMP SWITCH GROUND 11 L39 20LB FOG LAMP RELAY OUTPUT 12 G52 20YL HEADLAMP SWITCH MUX 13 HEADLAMP WASHER PUMP MOTOR 300M EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION A Z1 14BK GROUND B V53 14RD OR HEADLAMP WASHER RELAY OUTPUT H...

Page 854: ... RUN ACC 7 A2 12PK BK FUSED B 8 9 A41 14YL FUSED IGNITION OUTPUT START 10 A22 12BK OR FUSED IGNITION SWITCH OUTPUT RUN INPUT SPEED SENSOR GRAY 2 WAY CAV CIRCUIT FUNCTION 1 T13 20DB BK SPEED SENSOR GROUND 2 T52 20RD BK INPUT SPEED SENSOR SIGNAL INSTRUMENT CLUSTER C1 GREEN 10 WAY CAV CIRCUIT FUNCTION 1 F33 18PK RD FUSED B 2 F11 22RD WT FUSED IGNITION SWITCH OUTPUT OFF RUN START 3 M1 20PK FUSED B 4 E...

Page 855: ... RD IAT SIGNAL 2 K4 20BK LB SENSOR GROUND JUNCTION BLOCK BODY CONTROL MODULE JB 20 WAY CAV CIRCUIT FUNCTION 1 Z20 GROUND 2 M2 COURTESY LAMPS DRIVER 3 S76 SPEED PROPORTIONAL STEERING SOLENOID 4 S77 SPEED PROPORTIONAL STEERING SOLENOID 5 G5 FUSED IGNITION SWITCH OUTPUT RUN START 6 L7 PARK LAMP RELAY OUTPUT 7 M1 FUSED B 8 P2 DECKLID RELEASE CONTROL 9 10 D25 PCI BUS OTIS 11 12 13 P109 DRIVER DOOR UNLO...

Page 856: ...GNITION SWITCH OUTPUT RUN START 11 L5 22BK YL FUSED IGNITION SWITCH OUTPUT RUN 12 L40 18BR WT FUSED LOW BEAM RELAY OUTPUT 13 L60 22TN RIGHT TURN SIGNAL 14 L60 22TN RIGHT TURN SIGNAL 15 L61 22LG LEFT TURN SIGNAL 16 L61 22LG LEFT TURN SIGNAL JUNCTION BLOCK C3 BLUE 15 WAY CAV CIRCUIT FUNCTION 1 A81 14DG RD IGNITION SWITCH OUTPUT OFF RUN START 2 X12 20RD FUSED IGNITION SWITCH OUTPUT RUN ACC 3 4 Z2 18B...

Page 857: ...Y CONTROL JUNCTION BLOCK C5 NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 A1 12RD FUSED B 2 A22 12BK OR FUSED IGNITION SWITCH OUTPUT RUN JUNCTION BLOCK C6 BROWN 12 WAY CAV CIRCUIT FUNCTION 1 2 3 P33 16OR LOCK RELAY OUTPUT 4 P33 16OR LOCK RELAY OUTPUT 5 P33 16OR LOCK RELAY OUTPUT 6 7 P55 16DB DRIVER DOOR UNLOCK RELAY OUTPUT 8 M2 20YL COURTESY LAMPS DRIVER 9 F11 20RD WT DODGE 300M FUSED IGNITION SWITCH OUTPU...

Page 858: ... GREEN 6 WAY CAV CIRCUIT FUNCTION 1 A3 14RD TN FUSED B 2 A130 16VT RD EXCEPT POLICE PACKAGE FUSED B 3 L44 16VT RD FUSED RIGHT LOW BEAM OUTPUT 4 F12 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 5 L33 20RD FUSED LEFT HIGH BEAM OUTPUT 6 L39 20LB FOG LAMP RELAY OUTPUT JUNCTION BLOCK C9 ORANGE 8 WAY CAV CIRCUIT FUNCTION 1 A13 12PK WT FUSED B 2 A34 12LB RD FUSED B 3 A7 14RD BK FUSED B 4 F20 20WT FUSED...

Page 859: ...OUTPUT RUN START 13 L43 16VT FUSED LEFT LOW BEAM OUTPUT JUNCTION BLOCK C11 NATURAL 8 WAY CAV CIRCUIT FUNCTION 1 Z1 16BK SUNROOF GROUND 2 G5 20DB WT SUNROOF FUSED IGNITION SWITCH OUTPUT RUN START 3 Z2 20BK LG PREMIUM GROUND 4 M2 20YL COURTESY LAMPS DRIVER 5 A130 16VT RD SUNROOF FUSED B 6 M1 20PK FUSED B 7 L1 20BK VT PREMIUM BACK UP LAMP FEED 8 D25 20VT YL PREMIUM PCI BUS KNOCK SENSOR BLACK 2 WAY CA...

Page 860: ...D LEFT FOG LAMP CONCORDE LTD BLACK 2 WAY CAV CIRCUIT FUNCTION A L39 20LB FOG LAMP RELAY OUTPUT B Z1 20BK GROUND LEFT FOG LAMP DODGE 300M EXPORT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L39 20LB FOG LAMP RELAY OUTPUT 2 Z1 20BK GROUND LEFT FRONT DOOR SAIL SPEAKER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X83 18YL RD AMPLIFIED LEFT DOOR SAIL SPEAKER 2 X81 18YL BK AMPLIFIED LEFT DOOR SAIL SPEAKER 8W 80 58 8W 80 CON...

Page 861: ... RELAY OUTPUT 3 Z1 18BK GROUND LEFT FRONT PARK TURN SIGNAL LAMP DODGE BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L7 18BK YL PARK LAMP RELAY OUTPUT 3 L61 18LG LEFT TURN SIGNAL LEFT FRONT POSITION LAMP GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L7 20BK YL PARK LAMP RELAY OUTPUT 2 Z1 20BK GROUND LEFT FRONT SIDE MARKER LAMP CONCORDE LTD NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 L7 20BK YL PARK LAMP RELAY O...

Page 862: ... YL PARK LAMP RELAY OUTPUT 2 L13 20BR YL HEADLAMP ADJUST SIGNAL 3 Z1 20BK GROUND LEFT HIGH BEAM HEADLAMP EXCEPT EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION A L33 20RD FUSED LEFT HIGH BEAM OUTPUT B Z1 20BK GROUND LEFT HORN BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 X2 18DG RD HORN RELAY OUTPUT LEFT LICENSE LAMP EXPORT NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 L7 18BK YL PARK LAMP RELAY OUTPUT 2 Z1 ...

Page 863: ...R AJAR SWITCH SENSE 2 Z1 20BK GROUND 3 P34 16PK BK UNLOCK RELAY OUTPUT 4 P33 16OR LOCK RELAY OUTPUT LEFT REAR DOOR SPEAKER PREMIUM BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X97 18TN DG AMPLIFIED LOW LEFT REAR SPEAKER 2 X95 18TN VT AMPLIFIED LOW LEFT REAR SPEAKER LEFT REAR FOG LAMP EXPORT NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 L95 18DG YL REAR FOG LAMP RELAY OUTPUT 2 3 Z1 18BK GROUND LH 8W 80 CONNECTOR PIN ...

Page 864: ...COURTESY LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 M1 20PK FUSED B 2 M52 20LG EXCEPT BASE COURTESY LAMPS DRIVER LEFT REAR READING COURTESY LAMP SWITCH WHITE 3 WAY CAV CIRCUIT FUNCTION A Z1 20BK GROUND B M52 20LG LEFT REAR READING LAMP SWITCH CONTROL C M2 20YL COURTESY LAMPS DRIVER LEFT REAR SHELF SPEAKER BLACK 3 WAY CAV CIRCUIT FUNCTION 1 X91 18WT BK EXCEPT POLICE PACK AGE AMPLIFIED HIGH LEFT REAR S...

Page 865: ...ND LEFT REAR TURN SIGNAL LAMP CONCORDE GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L61 18LG TN LEFT TURN SIGNAL 2 Z1 18BK GROUND LEFT REAR TURN SIGNAL LAMP DODGE BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L61 18LG TN LEFT TURN SIGNAL 2 Z1 18BK GROUND LEFT REAR WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B4 18LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY 2 B3 18LG DB LEFT REAR WHEEL SPEED SENSOR SIGNAL L...

Page 866: ...UIT FUNCTION 1 F14 20LG YL FUSED IGNITION SWITCH OUTPUT RUN START 2 D25 20VT YL EXCEPT MEMORY PCI BUS SIACM 2 D25 20VT YL MEMORY PCI BUS MHSMM 3 R31 20LG OR LEFT SEAT SQUIB 1 LINE 1 4 R33 20LG WT LEFT SEAT SQUIB 1 LINE 2 5 Z2 20BK LG GROUND 6 Z2 20BK LG GROUND LEFT SIDE REPEATER LAMP EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L61 20LG LEFT TURN SIGNAL 2 Z1 20BK GROUND LEFT SPEED CONTROL SWITCH LT G...

Page 867: ...CAV CIRCUIT FUNCTION 1 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 2 L7 18BK YL PARK LAMP RELAY OUTPUT 3 Z1 18 BK DRIVER LEFT TAIL STOP LAMP NO 1 DODGE 300M BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 2 L7 18BK YL PARK LAMP RELAY OUTPUT 3 Z1 18BK GROUND LEFT TAIL STOP LAMP NO 2 300M GREEN 3 WAY CAV CIRCUIT FUNCTION 1 Z1 18WT TN GROUND 2 L7 18BK YL PARK LAMP RELAY OUTPUT 3 L50 ...

Page 868: ...TCH OUTPUT 2 L7 18BK YL PARK LAMP RELAY OUTPUT 3 Z1 18BK GROUND LEFT VISOR VANITY LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 M1 20PK FUSED B 2 Z1 20BK GROUND LICENSE LAMP EXCEPT EXPORT NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 L7 18BK YL PARK LAMP RELAY OUTPUT 2 Z1 18BK GROUND MANIFOLD ABSOLUTE PRESSURE SENSOR GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K1 20DG RD MAP SIGNAL 2 K4 18BK LB SENSOR GROUND 3 K6 20VT WT ...

Page 869: ...ROUND 4 C57 20DB GY SENSOR GROUND 5 F20 20WT FUSED IGNITION SWITCH OUTPUT RUN 6 E17 20YL BK PARK LAMP RELAY OUTPUT 7 8 9 C82 20YL OR TEMPERATURE SELECT 10 C58 22RD TN A C MODE SWITCH MUX 11 12 E2 20OR PANEL LAMPS DRIVER MANUAL TEMPERATURE CONTROL HEAD C2 BLACK 10 WAY CAV CIRCUIT FUNCTION 1 2 C4 18TN LOW BLOWER MOTOR DRIVER 3 C6 16LB M2 BLOWER MOTOR DRIVER 4 5 Z1 12BK GROUND 6 7 C5 16LG M1 BLOWER M...

Page 870: ... 21 P19 18YL LG SEAT FRONT UP SWITCH SENSE 22 P11 18YL WT SEAT REAR UP SWITCH SENSE 23 P17 18RD LB SEAT HORIZONTAL REARWARD SWITCH SENSE 24 P48 20GY WT DRIVER SEAT RECLINER DOWN 25 P24 18PK WT MEMORY POSITION 2 SWITCH SENSE 26 D25 20VT YL PCI BUS MEMORY HEATED SEAT MIRROR MODULE C2 GRAY 16 WAY CAV CIRCUIT FUNCTION 1 P139 20VT WT DRIVER SEAT HIGH HEAT LED DRIVER 2 P140 20VT BK PASSENGER SEAT HIGH H...

Page 871: ...11 P117 16RD LB SEAT HORIZONTAL REARWARD DRIVER 12 P131 16RD DG DRIVER SEAT HEATER B DRIVER MEMORY HEATED SEAT MIRROR MODULE C4 GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z1 16BK GROUND 2 F35 16RD FUSED B MEMORY SET SWITCH 6 WAY CAV CIRCUIT FUNCTION 1 2 3 Z1 18BK GROUND 4 P24 18PK WT MEMORY POSITION 2 SWITCH SENSE 5 P22 18PK BK MEMORY SET SWITCH SENSE 6 P23 18PK RD MEMORY POSITION SWITCH SENSE MODE DOOR AC...

Page 872: ...EAM RELAY CONTROL NATURAL VACUUM LEAK DETECTION ASSEMBLY BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 K107 18OR NVLD SWITCH SIGNAL 3 K106 18WT DG NVLD SOLENOID CONTROL OUTPUT SPEED SENSOR GRAY 2 WAY CAV CIRCUIT FUNCTION 1 T13 20DB BK SPEED SENSOR GROUND 2 T14 20LG WT OUTPUT SPEED SENSOR SIGNAL OVERHEAD MAP COURTESY LAMP BLACK 3 WAY CAV CIRCUIT FUNCTION A M1 20PK FUSED B B M2 20YL COURTESY L...

Page 873: ... K99 18BR OR O2 1 1 HEATER CONTROL 3 K902 18BR DG O2 RETURN UP 4 K41 20BK DG O2 1 1 SIGNAL OXYGEN SENSOR 1 2 RIGHT BANK DOWN BLACK 4 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 K199 18BR VT O2 1 2 HEATER CONTROL 3 K904 18DB DG O2 RETURN DOWN 4 K141 20TN WT O2 1 2 SIGNAL OXYGEN SENSOR 2 1 LEFT BANK UP GRAY 4 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 K299 18BR WT O2 2 1 HEATER CONTROL 3 K902 18BR ...

Page 874: ...UIT FUNCTION 1 R42 18BK YL PASSENGER SQUIB 1 LINE 1 2 R44 18DG YL PASSENGER SQUIB 1 LINE 2 PASSENGER DOOR LOCK MOTOR AJAR SWITCH BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G74 20TN RD DOOR AJAR SWITCH SENSE 2 Z1 20BK GROUND 3 P34 16PK BK UNLOCK RELAY OUTPUT 4 P33 16OR LOCK RELAY OUTPUT PASSENGER HEATED SEAT BACK GREEN 2 WAY CAV CIRCUIT FUNCTION A P88 16BR BK HEATED SEAT DRIVER B Z1 20BK GROUND 8W 80 72 8W...

Page 875: ...EATER MUX SWITCH PASSENGER POWER DOOR LOCK SWITCH NATURAL 4 WAY CAV CIRCUIT FUNCTION 1 M1 20PK FUSED B 2 3 Z1 20BK MEMORY GROUND 4 P96 20WT LG PASSENGER DOOR MUX SWITCH PASSENGER POWER MIRROR EXCEPT HEATED NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 P70 20WT PASSENGER MIRROR COMMON DRIVER RIGHT DOWN 2 P72 20YL BK PASSENGER MIRROR UP 3 P74 20DB PASSENGER MIRROR LEFT PASSENGER POWER MIRROR NATURAL 10 WAY C...

Page 876: ...MOTOR GREEN 2 WAY CAV CIRCUIT FUNCTION 1 P42 16GY BK PASSENGER SEAT RECLINER SWITCH DOWN 2 P44 16GY DB PASSENGER SEAT RECLINER SWITCH UP PASSENGER POWER SEAT SWITCH BLUE 10 WAY CAV CIRCUIT FUNCTION 1 F35 16RD FUSED B 2 P42 16GY BK PASSENGER SEAT RECLINER SWITCH DOWN 3 P16 16RD LB PASSENGER SEAT HORIZONTAL FORWARD 4 P44 16GY DB PASSENGER SEAT RECLINER SWITCH UP 5 Z1 16BK GROUND 6 P18 16YL LG PASSEN...

Page 877: ...FUNCTION 1 X87 18LG VT AMPLIFIED LEFT DOOR SPEAKER 2 X82 18LB RD AMPLIFIED RIGHT DOOR SPEAKER 3 X83 18YL RD AMPLIFIED LEFT DOOR SAIL SPEAKER 4 X86 18OR RD AMPLIFIED RIGHT DOOR SAIL SPEAKER 5 X95 18WT VT PREMIUM II AUDIO AMPLIFIED LOW LEFT REAR SPEAKER 6 X98 18TN VT PREMIUM II AUDIO AMPLIFIED LOW RIGHT REAR SPEAKER 7 X85 18LG BK AMPLIFIED LEFT DOOR SPEAKER 8 X80 18LB BK AMPLIFIED RIGHT DOOR SPEAKER...

Page 878: ...AKER 16 X55 18BR RD LEFT FRONT SPEAKER 17 X58 18DB OR RIGHT REAR SPEAKER 18 X57 18BR LB LEFT REAR SPEAKER 19 20 X89 18PK BK AMPLIFIED CENTER INSTRUMENT PANEL SPEAKER 21 X91 18WT BK AMPLIFIED HIGH LEFT REAR SPEAKER 22 X92 18TN BK AMPLIFIED HIGH RIGHT REAR SPEAKER POWER MIRROR SWITCH BLACK 13 WAY CAV CIRCUIT FUNCTION 1 P73 20YL PK DRIVER MIRROR COMMON DRIVER RIGHT DOWN 2 3 4 5 G5 20DB WT FUSED IGNIT...

Page 879: ...FF RUN START 13 14 15 16 K236 18GY PK 3 5L HIGH OUTPUT SRV CONTROL 17 18 Z12 18BK TN GROUND 19 20 21 C18 20DB A C PRESSURE SIGNAL 22 23 24 25 D20 20LG SCI RECEIVE PCM 26 D19 20VT OR SCI RECEIVE TCM 27 28 29 A209 20RD FUSED B 30 T751 20YL BK FUSED IGNITION SWITCH OUTPUT START 31 K141 20TN WT O2 1 2 SIGNAL 32 K904 18DB DG O2 RETURN DOWN 33 K341 20PK WT O2 2 2 SIGNAL 34 35 36 D21 20PK TN SCI TRANSMIT...

Page 880: ...NO 2 14 K11 18WT DB INJECTOR CONTROL NO 1 15 16 K36 18VT RD MTV CONTROL 17 K299 18BR WT O2 2 1 HEATER CONTROL 18 K99 18BR OR O2 1 1 HEATER CONTROL 19 K20 18DG GEN FIELD CONTROL 20 K2 20TN BK ECT SIGNAL 21 K22 20OR DB TP SIGNAL 22 23 K1 20DG RD MAP SIGNAL 24 K45 20BK VT KS RETURN 25 K42 20DB LG KS SIGNAL 26 27 K4 18BK LB SENSOR GROUND 28 K60 18YL BK IAC RETURN 29 K6 20VT WT 5 VOLT SUPPLY 30 K21 20B...

Page 881: ...ELAY CONTROL 12 V36 18TN RD S C VACUUM CONTROL 13 14 15 16 17 18 F142 16OR DG ASD RELAY OUTPUT 19 F142 16OR DG ASD RELAY OUTPUT 20 K52 18PK BK EVAP PURGE CONTROL 21 22 23 K29 20WT PK BRAKE SWITCH SIGNAL 24 25 26 T44 20YL AUTOSTICK AUTOSTICK DOWNSHIFT SWITCH SENSE 27 T5 20LG RD AUTOSTICK AUTOSTICK UPSHIFT SWITCH SIGNAL 28 F142 16OR DG ASD RELAY OUTPUT 29 K108 18DG LG EVAP PURGE RETURN 30 31 32 K25 ...

Page 882: ...ROL RELAY CONTROL 19 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT 20 21 22 T9 16OR BK OVERDRIVE PRESSURE SWITCH SENSE 23 24 25 26 27 T41 20BK WT TRS T41 SENSE 28 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT 29 T50 16DG LOW REVERSE PRESSURE SWITCH SENSE 30 T47 16YL BK 2 4 PRESSURE SWITCH SENSE 31 32 T14 20LG WT OUTPUT SPEED SENSOR SIGNAL 33 T52 20RD BK INPUT SPEED SENSOR SIGNAL 34 T13 20DB BK SPEED SEN...

Page 883: ...IATOR FAN MOTOR NO 2 EXCEPT 2 7L BASE 2 WAY CAV CIRCUIT FUNCTION A 12BK GROUND B C23 12RD LOW SPEED RADIATOR FAN RELAY OUTPUT RADIATOR FAN RELAY NO 1 AT FAN EXCEPT 2 7L BASE CAV CIRCUIT FUNCTION 30 12RD RADIATOR FAN MOTOR NO 1 CONTROL 30 12RD RADIATOR FAN MOTOR NO 1 CONTROL 85 C25 12RD HIGH SPEED RADIATOR FAN RELAY OUTPUT 85 C25 12RD HIGH SPEED RADIATOR FAN RELAY OUTPUT 86 Z1 12BK GROUND 86 Z1 12B...

Page 884: ...AY CAV CIRCUIT FUNCTION 1 2 X12 20RD FUSED IGNITION SWITCH OUTPUT RUN ACC 3 E2 20OR PANEL LAMPS DRIVER 4 5 6 7 X54 18VT RIGHT FRONT SPEAKER 8 X56 18DB RD RIGHT FRONT SPEAKER 9 X55 18BR RD LEFT FRONT SPEAKER 10 X53 18DG LEFT FRONT SPEAKER 11 Z1 18BK GROUND 12 M1 20PK FUSED B 13 X60 20DG RD RADIO 12 VOLT OUTPUT 14 D25 20VT YL PCI BUS RADIO 15 16 17 18 X51 18BR YL LEFT REAR SPEAKER 19 X57 18BR LB LEF...

Page 885: ...IRCUIT FUNCTION 1 X416 22GY WT AUDIO MUX RIGHT 2 X916 22DG WT AUDIO RETURN 3 X407 22BK RADIO MULTIPLEXER SHIELD 4 D25 22VT YL PCI BUS MULTIPLEXER 5 X112 22RD FUSED IGNITION SWITCH OUTPUT RUN ACC 6 X417 22GY OR AUDIO MUX LEFT 7 Z140 18BK OR GROUND 8 X481 22DG YL AUDIO BUS 1 9 E14 22OR TN PANEL LAMPS DIMMER SIGNAL 10 X160 18YL FUSED B REAR WINDOW DEFOGGER RELAY NATURAL 9 WAY CAV CIRCUIT FUNCTION 1 2...

Page 886: ...1 C32 20GY DB RECIRCULATION DOOR DRIVER 2 3 4 5 C34 20BR WT COMMON DOOR DRIVER RIGHT BACK UP LAMP 300M EXPORT NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK 300M GROUND 1 L1 18VT BK EXPORT BACK UP LAMP FEED 2 3 L1 18VT BK 300M BACK UP LAMP FEED 3 Z1 18BK EXPORT GROUND RIGHT BACK UP LAMP CONCORDE LTD NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 L1 18VT BK BACK UP LAMP FEED 2 Z1 18BK GROUND 8W 80 84 8W 80 CON...

Page 887: ...E 300M EXPORT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L39 20LB FOG LAMP SWITCH OUTPUT 2 Z1 20BK GROUND RIGHT FRONT DOOR SAIL SPEAKER BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X86 18OR RD AMPLIFIED RIGHT DOOR SAIL SPEAKER 2 X84 18OR BK AMPLIFIED RIGHT DOOR SAIL SPEAKER RIGHT FRONT DOOR SPEAKER BLACK 3 WAY CAV CIRCUIT FUNCTION 1 X82 18LB RD AMPLIFIED RIGHT DOOR SPEAKER 3 X80 18LB BK AMPLIFIED RIGHT DOOR SPEAKER ...

Page 888: ...P RELAY OUTPUT 3 Z1 18BK GROUND RIGHT FRONT POSITION LAMP GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L7 20BK YL PARK LAMP RELAY OUTPUT 2 Z1 20BK GROUND RIGHT FRONT SIDE MARKER LAMP CONCORDE LTD NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 L7 20BK YL PARK LAMP RELAY OUTPUT 2 L60 20TN RIGHT TURN SIGNAL RIGHT FRONT WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B7 18WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SU...

Page 889: ...SED RIGHT HIGH BEAM OUTPUT A L34 20OR WT POLICE PACKAGE FUSED RIGHT HIGH BEAM OUTPUT B Z1 20BK GROUND RIGHT HORN BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 X2 18DG RD HORN RELAY OUTPUT RIGHT LICENSE LAMP EXPORT NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 L7 18BK YL PARK LAMP RELAY OUTPUT 2 Z1 18BK GROUND RIGHT LOW BEAM HEADLAMP EXCEPT EXPORT GRAY 2 WAY CAV CIRCUIT FUNCTION A L44 16VT RD FUSED RI...

Page 890: ...UM BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X96 18TN DG AMPLIFIED LOW RIGHT REAR SPEAKER 2 X98 18TN VT AMPLIFIED LOW RIGHT REAR SPEAKER RIGHT REAR FOG LAMP EXPORT NATURAL 3 WAY CAV CIRCUIT FUNCTION 1 L95 18DG YL REAR FOG LAMP RELAY OUTPUT 2 3 Z1 18BK GROUND RIGHT REAR POWER WINDOW MOTOR RED 2 WAY CAV CIRCUIT FUNCTION 1 Q24 16DG WINDOW RIGHT REAR B DOWN 2 Q14 16GY WINDOW RIGHT REAR B UP 8W 80 88 8W 80 CO...

Page 891: ... 2 M42 20LG EXCEPT BASE COURTESY LAMPS DRIVER RIGHT REAR READING COURTESY LAMP SWITCH WHITE 3 WAY CAV CIRCUIT FUNCTION A Z1 20BK COURTESY LAMPS DRIVER B M42 20LG COURTESY LAMPS DRIVER C M2 20YL GROUND RIGHT REAR SHELF SPEAKER BLACK 3 WAY CAV CIRCUIT FUNCTION 1 X92 18TN BK EXCEPT POLICE PACK AGE AMPLIFIED HIGH RIGHT REAR SPEAKER 1 X58 18DB OR POLICE PACKAGE RIGHT REAR SPEAKER 2 3 X94 18TN RD EXCEPT...

Page 892: ... RIGHT REAR TURN SIGNAL LAMP CONCORDE GRAY 2 WAY CAV CIRCUIT FUNCTION 1 L60 18LG TN RIGHT TURN SIGNAL 2 Z1 18BK GROUND RIGHT REAR TURN SIGNAL LAMP DODGE BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L60 18LG TN RIGHT TURN SIGNAL 2 Z1 18BK GROUND RIGHT REAR WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B2 18YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY 2 B1 18YL DB RIGHT REAR WHEEL SPEED SENSOR SIG...

Page 893: ... CAV CIRCUIT FUNCTION 1 F14 20LG YL FUSED IGNITION SWITCH OUTPUT RUN START 2 D25 20VT YL EXCEPT MEMORY PCI BUS SIACM 2 D25 20VT YL MEMORY PCI BUS MHSMM 3 R32 20LB OR RIGHT SEAT SQUIB 1 LINE 1 4 R34 20LB WT RIGHT SEAT SQUIB 1 LINE 2 5 6 Z2 20BK LG GROUND RIGHT SIDE REPEATER LAMP EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 L60 20TN RIGHT TURN SIGNAL 2 Z1 20BK GROUND RIGHT SPEED CONTROL SWITCH LT GREEN...

Page 894: ...ROUND 2 L7 18BK YL PARK LAMP RELAY OUTPUT RIGHT TAIL STOP LAMP CONCORDE BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 2 L7 18BK YL PARK LAMP RELAY OUTPUT 3 Z1 18BK GROUND RIGHT TAIL STOP LAMP NO 1 300M BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L7 18BK YL PARK LAMP RELAY OUTPUT 3 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 8W 80 92 8W 80 CONNECTOR PIN OUTS LH ...

Page 895: ...Y CAV CIRCUIT FUNCTION 1 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 2 L7 18BK YL PARK LAMP RELAY OUTPUT 3 Z1 18BK GROUND RIGHT TAIL STOP LAMP NO 2 DODGE BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 2 L7 18BK YL PARK LAMP RELAY OUTPUT 3 Z1 18BK GROUND RIGHT VISOR VANITY LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 M1 20PK FUSED B 2 Z1 20BK GROUND LH 8W 80 CONNECTOR PIN OUTS 8W 80 93...

Page 896: ... 22DG LB AUDIO MUX ENABLE 14 X481 22DG YL AUDIO BUS 1 15 Z140 18BK OR GROUND 16 E14 22OR TN PANEL LAMPS DIMMER SIGNAL 17 X160 18YL FUSED B 18 D25 22BK PCI BUS SATELLITE RECEIVER 19 Z140 18BK OR GROUND 20 X481 22DG YL AUDIO BUS 2 21 X160 18YL FUSED B 22 SATELLITE RADIO MULTIPLEXER C2 10 WAY CAV CIRCUIT FUNCTION 1 X40 22GY WT AUDIO OUT RIGHT 2 Z4 22WT BK GROUND 3 C235 WT LB MULTIPLEXER COMPACT DISC ...

Page 897: ...MON 12 X166 22GY WT AUDIO SIGNAL RIGHT SEAT BELT SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 G10 20LG RD SEAT BELT SWITCH SENSE 2 Z2 20BK LG GROUND SENTRY KEY IMMOBILIZER MODULE BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 D25 20VT YL PCI BUS SKIM 3 4 G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 5 Z2 20BK LG GROUND 6 M1 20PK FUSED B SHORT RUNNER VALVE SOLENOID 3 5L HIGH OUTPUT BLACK 2 WAY CAV CIRCUIT F...

Page 898: ... SPEED PROPORTIONAL STEERING SOLENOID LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 S76 18LG PK SPEED PROPORTIONAL STEERING SOLENOID 2 S77 18VT OR SPEED PROPORTIONAL STEERING SOLENOID SPOT LAMP NO 1 POLICE PACKAGE BLACK 2 WAY CAV CIRCUIT FUNCTION A SL1 18WT FUSED B B SPOT LAMP NO 2 POLICE PACKAGE BLACK 2 WAY CAV CIRCUIT FUNCTION A SL2 18WT DB FUSED B B 8W 80 96 8W 80 CONNECTOR PIN OUTS LH ...

Page 899: ...OR B 3 G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 4 A130 16 VT RD FUSED B 5 Z1 16BK GROUND 6 Q42 20LB SUNROOF CLOSE 7 Q41 20WT SUNROOF OPEN 8 Q42 20LB SUNROOF CLOSE 9 Q43 20VT SUNROOF VENT 10 Q46 20OR SUNROOF LIMIT SWITCH SUNROOF LIMIT SWITCH BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 Q46 20OR SUNROOF LIMIT SWITCH 3 SUNROOF MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q6 16DB SUNROOF M...

Page 900: ...GNAL 3 K4 20BK LB SENSOR GROUND THROTTLE POSITION SENSOR 3 5L GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K6 20VT WT 5 VOLT SUPPLY 2 K22 20OR DB TP SIGNAL 3 K4 20BK LB SENSOR GROUND TRACTION CONTROL SWITCH NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 Z2 22BK LG GROUND 2 B27 20RD YL TRACTION CONTROL SWITCH SENSE TRANSMISSION RANGE INDICATOR ILLUMINATION PRNDL 2 WAY CAV CIRCUIT FUNCTION 1 E2 20OR PANEL LAMPS FEED 2 Z...

Page 901: ... CIRCUIT FUNCTION 1 T9 16OR BK OVERDRIVE PRESSURE SWITCH SENSE 2 T50 16DG LOW REVERSE PRESSURE SWITCH SENSE 3 T47 16YL BK 2 4 PRESSURE SWITCH SENSE 4 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT 5 T19 16WT 2 4 SOLENOID CONTROL 6 T20 16LB LOW REVERSE SOLENOID CONTROL 7 T60 16BR OVERDRIVE SOLENOID CONTROL 8 T59 16PK UNDERDRIVE SOLENOID CONTROL TRUNK KNOCK OUT SWITCH NATURAL 2 WAY CAV CIRCUIT FUNCTION ...

Page 902: ...BK GROUND WASHER FLUID LEVEL SENSOR GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 G29 20BK TN WASHER FLUID LEVEL SWITCH SENSE WINDSHIELD WASHER PUMP MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 V10 20BR FRONT WASHER PUMP MOTOR CONTROL WINDSHIELD WIPER MOTOR BLACK 5 WAY CAV CIRCUIT FUNCTION 1 V4 14RD YL FRONT WIPER RELAY HIGH SPEED OUTPUT 2 V3 14BR WT FRONT WIPER RELAY LOW SPEED O...

Page 903: ...ssory No 1 Police Behind center of front bumper 6 Accessory No 2 Police Behind Park Brake Lever 20 Airbag Control Module ORC YL RD Lower Center of Instrument Panel 12 Ambient Temperature Sensor BK Front Grille Area 1 Analog Clock NAT At Clock N S Antenna Coax Right Side C Pillar 28 35 Automatic Day Night Mirror BK At Mirror N S Auto Shut Down Relay In the Power Distribution Center N S Automatic Te...

Page 904: ... Service Package Between JB C3 and Splice S232 N S C200 BL Left Side Instrument Panel 11 23 C201 NAT Right Side Instrument Panel 12 21 C202 MTC NAT Center of Instrument Panel 12 13 C203 ATC NAT Center of Instrument Panel 12 13 C204 NAT At Headliner N S C205 Except Police Package NAT Near Cigar Lighter 12 C206 Except Police Package NAT Left Side of Instrument Panel N S C300 NAT Left Cowl 23 C301 NA...

Page 905: ...ng C1 NAT Rear of Clockspring 11 15 Clockspring C2 YL Rear of Clockspring 11 15 Clockspring C3 At Steering Wheel 15 Coil On Plug No 1 BK At Plug 8 9 Coil On Plug No 2 BK At Plug 8 9 Coil On Plug No 3 BK At Plug 8 9 Coil On Plug No 4 BK At Plug 8 9 Coil On Plug No 5 BK At Plug 8 9 Coil On Plug No 6 BK At Plug 8 9 Combination Flasher BK Left Side Instrument Panel 11 23 Compact Disc Changer BK At Rea...

Page 906: ...ecliner Motor Sensor BK At Driver Seat N S Driver Power Seat Switch BL At Driver Seat N S Driver Power Window Motor RD Left Front Door N S Driver Power Window Switch BL Driver Door 26 Engine Coolant Temp Sensor BK Front of Engine 8 9 Engine Oil Pressure Switch LTGN Right Side of Engine 8 9 EVAP Purge Solenoid BK Left Rear of Engine Compartment 7 Evaporator Temperature Sensor BK Lower Center of Hea...

Page 907: ... 9 ISO Relay No 1 Police On Rear Fuse Block Right side of trunk 34 ISO Relay No 2 Police On Rear Fuse Block Right side of trunk 34 Junction Block C1 BK Left Side of Instrument Panel 11 Junction Block C2 GY Left Side of Instrument Panel 11 Junction Block C3 BL Left Side of Instrument Panel 11 Junction Block C4 GN Left Side of Instrument Panel 11 Junction Block C5 NAT Left Side of Instrument Panel 1...

Page 908: ...oor Lock Motor Ajar Switch BK At Left Rear Door N S Left Rear Door Speaker BK At Left Rear Door Panel 27 Left Rear Fog Lamp 300M Export NAT At Lamp 36 Left Rear Power Window Motor RD At Left Rear Door N S Left Rear Power Window Switch BL At Left Rear Door Panel 27 Left Rear Reading Courtesy Lamp BK At Lamp N S Left Rear Reading Courtesy Lamp Switch WT At Lamp N S Left Rear Shelf Speaker BK At Spea...

Page 909: ...ld Absolute Pressure Sensor 2 7L BK Top Left of Engine 8 Manifold Absolute Pressure Sensor 3 5L GY Top Left of Engine 9 Manifold Tuning Valve 3 5L High Output BK Front of Engine 8 9 Manual Temperature Control Head C1 NAT Center of Instrument Panel 12 Manual Temperature Control Head C2 BK Center of Instrument Panel 12 Memory Heated Seat Mirror Module C1 Under Driver Seat N S Memory Heated Seat Mirr...

Page 910: ...mory NAT Passenger Door N S Passenger Power Seat Front Riser Motor RD At Passenger Seat N S Passenger Power Seat Horizontal Motor BK At Passenger Seat N S Passenger Power Seat Rear Riser Motor RD At Passenger Seat N S Passenger Power Seat Recliner Motor GN At Passenger Seat N S Passenger Power Seat Switch BL At Seat N S Passenger Power Window Motor RD Passenger Door N S Passenger Power Window Swit...

Page 911: ...35 Recirculation Door Actuator NAT On HVAC Unit 13 Remote Jump Post Right Front Engine Compartment 2 Remote Keyless Entry Antenna Export WT Near Body Control Module 11 Remote Rear Power Post In Trunk at Right Side Panel 34 Right Back Up Lamp 300M Export NAT At Lamp Same as Left shown in Figure 36 Right Back Up Lamp Concorde LTD NAT At Lamp in Fascia N S Right Back Up Lamp Dodge GY At Lamp 36 Right...

Page 912: ...6 Right Rear Turn Signal Lamp Dodge BK At Lamp 36 Right Rear Wheel Speed Sensor BK Right Side Trunk Area 21 Right Remote Radio Switch BK Steering Wheel 15 Right Seat Airbag Squib YL At Seat N S Right Side Impact Airbag Control Module YL Right B Pillar 24 Right Side Repeater Lamp BK Right Fender Side Shield 1 5 Right Speed Control Switch LG Steering Wheel 15 Right Tail Lamp 300M Export NAT At Lamp ...

Page 913: ...9 10 Starter Motor Relay In Power Distribution Center N S Sun Sensor VTSS Set LED BK Top Center of Instrument Panel N S Sunroof Control Module WT At Module N S Sunroof Limit Switch BK At Switch N S Sunroof Motor BK At Motor N S Sunroof Switch NAT Headliner N S Throttle Position Sensor 2 7L BK On Throttle Body 8 Throttle Position Sensor 3 5L GY On Throttle Body 9 Traction Control Switch NAT Center ...

Page 914: ...ne Harness in T O for Powertrain Control Module 9 S109 2 7L Engine Harness Between Fuel Injector No 1 and Fuel Injector No 4 8 S109 3 5L Engine Harness Left Side of Engine 9 S110 2 7L Engine Harness Near Idle Air Control Motor T O 8 S110 3 5L Engine Harness Front of Engine 9 S111 2 7L Engine Harness Between Fuel Injector No 3 and Fuel Injector No 5 8 S111 3 5L Engine Harness Between Fuel Injector ...

Page 915: ...t Fascia Harness Between Right and Left Headlamps N S S164 Headlamp and Dash Harness Near T O for Left Front Wheel Speed Sensor 7 S165 Headlamp and Dash Harness in Power Distribution Center N S 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 S171 Headlamp ...

Page 916: ...ight Side Body 21 S304 Body Harness Right Side Body 21 S305 Body Harness Under Drivers Seat 23 S306 Body Harness Right Trunk 34 S307 Body Harness Left Body Rear 22 S308 Body Harness Left Body Rear 22 S309 Body Harness Left Body Rear 22 S310 Body Harness Left Body Rear 22 S311 Right Front Door Harness 25 S312 Left Front Door Harness N S S313 Right Front Door Harness 25 S314 Left Front Door Harness ...

Page 917: ...ness Left Front Sill 23 S348 In T O For Fuel Pump Module N S S349 In T O to Left Airbag Module N S S350 Body Harness Left Front Sill N S S351 Body Harness Left Front Sill 23 S353 Police Body Harness Right Trunk 34 S354 Police Body Harness Right Trunk 35 S360 Rear Fascia Harness N S S361 Rear Fascia Harness N S S362 Taillamp Harness Left Tail Lamps N S S363 Taillamp Harness Left Tail Lamps N S S364...

Page 918: ...Fig 1 RIGHT FRONT BATTERY COMPARTMENT 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 919: ...Fig 2 RIGHT FRONT FENDER SIDE LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 17 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 920: ...Fig 3 RIGHT FRONT LAMPS Fig 4 RIGHT FRONT WHEEL SPEED SENSOR 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 921: ...Fig 5 RIGHT REPEATER LAMP LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 19 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 922: ...Fig 6 LEFT FRONT LAMPS 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 923: ...Fig 7 LEFT REAR ENGINE COMPARTMENT LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 21 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 924: ...Fig 8 ENGINE 2 7 LITER 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 925: ...Fig 9 ENGINE 3 5 LITER LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 23 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 926: ...Fig 10 TRANSMISSION 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 927: ...Fig 11 LEFT SIDE OF INSTRUMENT PANEL LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 25 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 928: ...Fig 12 INSTRUMENT PANEL 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 929: ...Fig 13 HVAC CONNECTIONS Fig 14 LEFT INSTRUMENT PANEL END CAP LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 27 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 930: ...Fig 15 CLOCK SPRING CONNECTIONS 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 931: ...Fig 16 ACCESSORY EQUIPMENT CONNECTOR Fig 17 SATELLITE RADIO CONNECTORS LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 29 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 932: ...Fig 18 SATELLITE RADIO MUX 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 933: ...Fig 19 SATELLITE RADIO RECEIVER LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 31 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 934: ...Fig 20 HEADLAMP FLASHER POLICE 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 935: ...Fig 21 RIGHT SIDE BODY LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 33 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 936: ...Fig 22 LEFT SIDE BODY REAR 8W 91 34 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 937: ...Fig 23 LEFT SIDE BODY LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 35 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 938: ...Fig 24 SIDE IMPACT AIRBAGS 8W 91 36 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 939: ...Fig 25 RIGHT FRONT DOOR Fig 26 RIGHT FRONT DOOR PANEL LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 37 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 940: ...Fig 27 RIGHT REAR DOOR PANEL Fig 28 SHELF PANEL 8W 91 38 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 941: ...Fig 29 AUXILIARY LIGHT CONNECTOR Fig 30 DECK LID LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 39 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 942: ...Fig 31 LICENSE LAMP Fig 32 CENTER HIGH MOUNTED STOP LAMP 300M 8W 91 40 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 943: ...Fig 33 CENTER HIGH MOUNTED STOP LAMP DODGE Fig 34 RIGHT TRUNK REAR POWER AND ACCESSORIES LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 41 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 944: ...Fig 35 TAIL LAMPS 8W 91 42 8W 91 CONNECTOR GROUND SPLICE LOCATION LH CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 945: ...Fig 36 TAIL LAMP ASSEMBLY LH 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 43 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 946: ......

Page 947: ... The wiring is routed to an area just below the instrument panel in a six cavity connector to provide three fused ignition feeds Three fused battery feeds in the PDC also are provided to the center stack area of the instrument panel within the same six cavity connector Only the police package has both fused ignition and battery circuits below the instrument panel Spe cial service vehicles have onl...

Page 948: ...arge sufficiently to degrade battery life and or prevent engine starting 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 drive...

Page 949: ...e Off position The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical sys tem during new vehicle transportation and pre deliv ery storage to reduce battery depletion while still allowing vehicle operation so that the vehicle can be loaded unloaded and moved as needed by both vehi cle transportation company and dealer personnel The IOD fuse is disconnecte...

Page 950: ...eceptacles molded into the JB housing The JB houses blade type fuses blade type automatic resetting circuit breakers full International Standards Organization ISO relays and ISO micro relays Internal connection of all the JB circuits is accomplished by an intricate network of hard wiring and bus bars Refer to the appropriate wiring information The wiring information includes wiring diagrams proper...

Page 951: ...uds OPERATION All of the PDC outputs are through the integral engine compartment wire harness which exits from the front of the PDC housing All of the current from the battery generator cable connection enters the PDC that is secured with nuts just inside the left end of the PDC housing The PDC houses up to fourteen maxi fuse cartridges which replace all in line fusible links The PDC also houses u...

Page 952: ...ion center to the proper cavities of the new power distribution center Refer to Electrical Wiring Diagram Informa tion for the proper power distribution center cavity assignments 1 Position the PDC over the mounting bracket in the engine compartment 2 Align the PDC mounting slots with the blades on the PDC mounting bracket 3 Push down firmly and evenly on the PDC hous ing until it snaps into place...

Page 953: ...EMOVAL 22 INSTALLATION 22 CYLINDER HEAD DESCRIPTION 23 DIAGNOSIS AND TESTING CYLINDER HEAD GASKET 23 REMOVAL 23 CLEANING 24 INSPECTION 24 INSTALLATION 24 CAMSHAFT OIL SEAL S REMOVAL 26 INSTALLATION 26 CAMSHAFT S DESCRIPTION 26 OPERATION 26 STANDARD PROCEDURE MEASURING CAMSHAFT END PLAY 26 REMOVAL 27 CLEANING 27 INSPECTION 27 INSTALLATION 27 CYLINDER HEAD COVER S REMOVAL 28 INSTALLATION 28 INTAKE E...

Page 954: ...INSTALLATION 55 STRUCTURAL COLLAR COVER REMOVAL 56 INSTALLATION 56 VIBRATION DAMPER REMOVAL 56 INSTALLATION 57 ENGINE MOUNTING DESCRIPTION 57 INSPECTION 58 LEFT MOUNT REMOVAL 58 INSTALLATION 58 REAR MOUNT REMOVAL 59 INSTALLATION 59 RIGHT MOUNT REMOVAL 59 INSTALLATION 59 LUBRICATION DESCRIPTION 60 OPERATION 60 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE OIL LEAK INSPECTION 60 DIAGNOSIS AND T...

Page 955: ...LLATION INSTALLATION TENSIONER PULLEY ASSEMBLY 82 INSTALLATION TENSIONER 83 TIMING BELT AND SPROCKETS REMOVAL REMOVAL TIMING BELT 83 REMOVAL CAMSHAFT SPROCKETS 84 REMOVAL CRANKSHAFT SPROCKET 86 INSPECTION TIMING BELT 86 INSTALLATION INSTALLATION TIMING BELT 86 INSTALLATION CAMSHAFT SPROCKETS 87 INSTALLATION CRANKSHAFT SPROCKET 89 ENGINE 3 5L DESCRIPTION The 3 5 Liter 214 Cubic Inches 60 degree V 6...

Page 956: ...Fig 1 3 5L Engine 9 4 ENGINE LH ENGINE 3 5L Continued ...

Page 957: ...r to 9 ENGINE DIAGNOSIS AND TESTING PERFORMANCE For fuel system diagnosis Refer to 14 FUEL SYSTEM FUEL DELIVERY DIAGNOSIS AND TESTING Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts Information concerning additional tests and diagno sis is provided within the following Cylinder Compression Press...

Page 958: ...mbly 8 Worn valve guides 8 Ream guides and install new valves with oversize stems 9 Excessive runout of valve seats on valve faces 9 Grind valve seats and valves 10 Missing adjuster pivot 10 Replace rocker arm hydraulic lash adjuster assembly CONNECTING ROD NOISE 1 Insufficient oil supply 1 Check engine oil level 2 Low oil pressure 2 Check engine oil level Inspect oil pump relief valve and spring ...

Page 959: ...oil level 1 Check engine oil level 2 Faulty oil pressure sending unit 2 Install new sending unit 3 Low oil pressure 3 Check sending unit and main bearing oil clearance 4 Clogged oil filter 4 Install new oil filter 5 Worn parts in oil pump 5 Replace worn parts or pump 6 Thin or diluted oil 6 Change oil to correct viscosity 7 Oil pump relief valve stuck 7 Remove valve and inspect clean or replace 8 ...

Page 960: ...L NOT START 1 Weak battery 1 Test battery Charge or replace as necessary Refer to 8 ELECTRICAL BATTERY SYSTEM BATTERY DESCRIPTION 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 8 ELECTRICAL STARTING DIAGNOSIS AND TESTING 4 Faulty coil s or control unit 4 Test and repl...

Page 961: ... Test compression of each cylinder 7 Burned warped or pitted valves 7 Replace valves 8 Plugged or restricted exhaust system 8 Check exhaust system restriction Replace parts as necessary 9 Faulty coil s 9 Test and replace as necessary Refer to Appropriate Diagnostic Information ENGINE MISSES ON ACCELERATION 1 Dirty or incorrectly gapped spark plugs 1 Set gap as needed or replace plug s 2 Contaminat...

Page 962: ...akage 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 PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR Che...

Page 963: ...is recommended during assembly to prevent smear ing material off the location Mopart Engine RTV GEN II or ATF RTV gasket material should be applied in a continuous bead approximately 3 mm 0 120 in in diameter All mounting holes must be circled For corner sealing a 3 17 or 6 35 mm 1 8 or 1 4 in drop is placed in the center of the gasket contact area Uncured sealant may be removed with a shop towel ...

Page 964: ...rt 8 Install new spark plugs 9 Drain engine oil and remove oil filter 10 Install a new oil filter 11 Fill engine with specified amount of approved oil 12 Connect negative battery cable 13 Start engine and check for any leaks STANDARD PROCEDURE ENGINE CORE AND OIL GALLERY PLUGS Using a blunt tool such as a drift and a hammer strike the bottom edge of the cup plug With the cup plug rotated grasp fir...

Page 965: ...other is a metric scale NOTE Plastigage is available in a variety of clear ance ranges Use the most appropriate range for the specifications you are checking 4 Install the proper crankshaft bearings to achieve the specified bearing clearances REMOVAL ENGINE ASSEMBLY 1 Release fuel pressure Refer to 14 FUEL SYSTEM FUEL DELIVERY STANDARD PROCE DURE 2 Disconnect negative cable at right strut tower Fi...

Page 966: ... MANIFOLDS INTAKE MANIFOLD REMOVAL 30 Disconnect heater hoses 31 Remove rear throttle body support bracket 32 Remove fastener for water pipe at transmis sion to block bolt 33 Remove four upper transmission to block bolts 34 Disconnect all electrical connections 35 Hoist vehicle 36 Drain engine oil 37 Remove structural collar and mark flex plate to torque converter position 38 Remove bolts holding ...

Page 967: ...all and tighten right side catalytic con verter down pipe support bracket fastener at trans axle mount 29 Install air conditioning compressor and tighten fasteners to 28 N m 250 in lbs 30 Install power steering pump and tighten fas teners to 28 N m 250 in lbs 31 Install generator Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 32 Install radiator Refer to 7 COOLING EN GINE RADIATOR INSTALLAT...

Page 968: ... Ring 0 04 0 08 mm 0 0016 0 0031 in Oil Ring Steel Rails 0 038 0 184 mm 0 0015 0 0073 in DESCRIPTION SPECIFICATION Ring Width Top Compression Ring 1 17 1 19 mm 0 0461 0 0469 in 2nd Compression Ring 1 47 1 49 mm 0 058 0 059 in Oil Ring Steel Rings 0 445 0 470 mm 0 0176 0 0186 in Connecting Rods Bearing Clearance 0 019 0 081 mm 0 0007 0 0031 in Piston Pin Bore Diameter 24 0076 24 0153 mm 0 9452 0 94...

Page 969: ...SPECIFICATION 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 4 9705 in Stem Diameter Intake 6 935 6 953 mm 0 2730 0 2737 in Stem Diameter Exhaust 6 906 6 924 mm 0 2719 0 2726 in Stem to Guide Clearance Intake 0 022 0 065 mm 0 0009 0 0026 in Max Rocking Method 0 29 mm 0 0114 in Stem to Guid...

Page 970: ...n 5 psi Min Pressure 3000 RPM 300 724 kPa 45 105 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 1 4 Turn 75 1 4 Turn Camshaft Sprocket Bolt Left Side 115 1 4 Turn 85 1 4 Turn Camshaft Thrust Plate Bolts 28 250 Connectin...

Page 971: ...INE ENGINE BLOCK STRUCTURAL COVER INSTALLATION Thermostat 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 SPECIAL TOOLS 3 5L ENGINE Puller Damper 1023 Crankshaft Damper Remover Insert C 4685 C2 Crankshaft Damper Sprocket Install...

Page 972: ...kshaft 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 C 3422 D Valve Spring Adapter 6526 9 20 ENGINE LH ENGINE 3 5L Continued ...

Page 973: ...ve Spring Adapter 6527 Indicator Bore Size C 119 Main Bearing Remover Installer C 3059 Crankshaft Rear Seal Guide 6926 1 Installer 6926 2 Driver Handle C 4171 Crankshaft Rear Seal Retainer Alignment Fixture 8225 Release Probe 8351 LH ENGINE 9 21 ENGINE 3 5L Continued ...

Page 974: ... of the air cleaner housing 2 Install new filter element Fig 9 3 Place lid over air cleaner housing Pressure Gauge C 3292 Adapter 8406 DRB IIIT with PEP Module OT CH6010A Pressure Transducer CH7059 Adaptor 8116 Cooling System Tester 7700 Combustion Leak Tester C 3685 A Fig 9 Air Cleaner Housing and Element 1 AIR FILTER ELEMENT 9 22 ENGINE LH ENGINE 3 5L Continued ...

Page 975: ...ession pressure leak exists bubbles will be visible in the coolant COOLING SYSTEM TESTER METHOD WARNING WITH COOLING SYSTEM TESTER IN PLACE PRESSURE WILL BUILD UP FAST EXCES SIVE PRESSURE BUILT UP BY CONTINUOUS ENGINE OPERATION MUST BE RELEASED TO A SAFE PRESSURE POINT NEVER PERMIT PRES SURE TO EXCEED 138 kPa 20 psi Install Cooling System Tester 7700 or equivalent to pressure cap neck Start the en...

Page 976: ...08 in MAX is a combined total dimension of the stock removal limit from cyl inder head and block top surface Deck together INSTALLATION 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 must be replaced Fig 13 Necking can be checked by holding a scale or straight edge against the threads If all...

Page 977: ...1 Lubricate new O rings with Mopart Dielectric Grease or equivalent to facilitate assembly 8 Install rear timing belt covers Fig 10 and Fig 11 Tighten bolts to specified torque M10 54 N m 40 ft lbs M8 28 N m 20 ft lbs M6 12 N m 105 in lbs 9 Install camshaft sprockets and timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 10 Install front timing belt covers Refe...

Page 978: ...d Right and left camshaft driving sprockets are not interchangeable because of the cam sensor pick up wheel on the left sprocket Camshaft bearing lubrication is provided via oil feed passage through each rocker shaft pedestal dowel OPERATION The camshaft is driven by the crankshaft via drive sprockets and belt The camshaft has precisely machined lobes to provide accurate valve timing and duration ...

Page 979: ...camshaft with a suitable solvent INSPECTION 1 Inspect camshaft bearing journals for damage and binding Fig 21 If journals are binding check the cylinder head for damage Also check cylinder head oil holes for clogging 2 Check the cam lobe and bearing surfaces for abnormal wear and damage Replace camshaft if defective NOTE If camshaft is replaced due to lobe wear or damage always replace the rocker ...

Page 980: ...over Fig 22 Move harness for cover removal clearance 6 For right cylinder head cover removal perform the following a Remove A C compressor belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL b Remove A C compressor mounting bolts c Move compressor aside for cylinder head cover clearance 7 Remove cylinder head cover bolts and remove cover Fig 24 INSTALLATION 1 Clean cylinder head and cover ...

Page 981: ...r valves two intake and two exhaust employ a three groove lock design to help facilitate valve rotation STANDARD PROCEDURE VALVE AND VALVE SEAT REFACING The valve face and valve seat angles are shown in Fig 28 VALVES 1 Inspect the remaining margin after the valves are refaced Fig 27 Refer to 9 ENGINE SPEC IFICATIONS VALVE SEATS 1 When refacing valve seats it is important that the correct size valv...

Page 982: ...valve stem 3 Install valve seal spring seat assembly over valve guides on all valve stems Fig 31 Ensure that the garter spring is intact around the top of the rub ber seal 4 Place valve spring color coded end facing up Fig 30 and valve retainer into position on spring seat Fig 31 5 Compress valve springs with valve spring com pressor C 3422 D and adapter 6526 Refer to 9 ENGINE SPECIAL TOOLS instal...

Page 983: ... IFICATIONS NOTE Replace cylinder head if stem to guide clear ance exceeds specifications or if guide is loose in cylinder head 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 34 If valve tip height is greater than 43 65 mm 1 7185 in intake or 45 98 mm 1 8102 in exhaust grind valve tip until...

Page 984: ...l per pedestal is used to locate the pedestal to the cylinder head orient the exhaust rocker shaft and serve as a cam bearing oil feed pas sage DIAGNOSIS AND TESTING LASH ADJUSTER TAPPET NOISE DIAGNOSIS Proper noise diagnosis is essential in locating the source of a NVH complaint Locating a lash adjuster tappet type noise can sometimes be difficult As a result an initial misdiagnosis may occur Ref...

Page 985: ...r trapped in lash adjuster after 1 hour run time 3 See below a Check lash adjusters for sponginess while installed in cylinder head Depress part of rocker arm over adjuster Normal adjusters should feel very firm Very spongy adjusters can be bottomed out easily b Before proceeding perform Lash Adjuster Bleeding procedure c If lash adjuster s are still spongy replace with new adjuster rocker arm ass...

Page 986: ...m s 5 For exhaust rocker arm positions a Adjust Special Tool 8351 Release Probe gauge pin to extend approximately 20 mm 0 787 in Then using two release probes carefully insert gauge pins into the lash adjuster service access holes Fig 38 CAUTION If probe tip breaks off within the lash adjuster replace the affected rocker arm b Gently unseat BOTH lash adjuster s internal check ball at the same time...

Page 987: ...aged or heavily worn 4 Check shaft oil holes for clogging with small wire clean as required INSPECTION The rocker arm shafts are hollow and are used as lubrication oil ducts The rocker arm and shaft assembly on the right side of the engine has an oil passage hole from the cylinder head located at the third rocker shaft support pedestal The rocker arm and shaft assembly on the left side of the engi...

Page 988: ... Refer to 9 ENGINE CYLINDER HEAD ROCKER ARM ADJUSTER ASSY INSTALLATION INSTALLATION NOTE Rocker arm and shaft assembly can be installed either prior to or after preferred cylinder head installation 1 Rotate camshafts to the position shown in Fig 44 With the camshafts in these positions the lobes are in a neutral position no load to the valve This will allow the rocker arm shaft assembly to be tigh...

Page 989: ...CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 4 Install cylinder head cover s Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION VALVE STEM SEALS REMOVAL 1 Remove valve spring Refer to 9 ENGINE CYLINDER HEAD VALVE SPRINGS REMOVAL 2 Remove valve stem seals by using a valve stem seal tool Fig 47 INSTALLATION 1 The valve stem seal valve spring seat should be pushed firmly and squarely o...

Page 990: ...ON 1 Perform fuel system pressure release procedure before attempting any repairs Refer to 14 FUEL SYSTEM FUEL DELIVERY STANDARD PROCEDURE 2 Disconnect negative cable from battery 3 Remove air cleaner housing and hose assembly 4 Remove upper intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD REMOVAL 5 Remove cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVA...

Page 991: ...NSTALLATION INSTALLATION CYLINDER HEAD OFF 1 Install valves if removed 2 Install valve stem seal spring seat assembly over valve guides on all valve stems Fig 52 Ensure that the garter spring is intact around the top of the rubber seal 3 Place valve spring color coded end facing up and valve retainer into position 4 Compress valve spring with valve spring com pressor Install locks and release tool...

Page 992: ...num 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 the main caps STANDARD PROCEDURE CYLINDER BORE HONING 1 Used carefully the cylinder bore ...

Page 993: ...d the parts then thoroughly dried The bore can be considered clean when it can be wiped clean with a white cloth and cloth remains clean Oil the bores after cleaning to prevent rusting CLEANING Clean cylinder block thoroughly using a suitable cleaning solvent INSPECTION ENGINE BLOCK 1 Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking 2 If new core plugs are to b...

Page 994: ... the nuts the threads should be oiled with engine oil 3 Install nuts on each bolt finger tight Then alternately torque each nut to assemble the cap prop erly 4 Tighten the connecting rod cap nuts to specifi cations Refer to 9 ENGINE SPECIFICATIONS CONNECTING ROD SIDE CLEARANCE 1 Mount a dial indicator to a stationary point on engine Locate probe perpendicular to and resting against the connecting ...

Page 995: ... CRANK SHAFT REAR OIL SEAL RETAINER REMOVAL 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 60 15 Remove main bearing caps Main bearing caps are not interchangeable and are marked to insure correct assembly Fig 61 16 Remove crankshaft from cylinder block Fig 62 NOTE Before installing crank...

Page 996: ...ankshaft forward to limit of travel Lubricate and install the front thrust washer by roll ing the washer onto the machined shelf between the No 2 upper main bulk head and crankshaft thrust surface Fig 64 4 Move crankshaft rearward to limit of travel Lubricate and install the rear thrust washer by roll ing the washer onto the machined shelf between the No 2 upper main bulk head and crankshaft thrus...

Page 997: ...3 Install oil pump assembly Refer to 9 ENGINE LUBRICATION OIL PUMP INSTALLA TION 14 Install dowel pin in crankshaft Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL FRONT INSTALLATION 15 Install crankshaft sprocket Refer to Front Crankshaft Oil Seal Removal and Installation for procedure 16 Install camshaft sprockets and timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS ...

Page 998: ...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 67 For verification refer to the MAIN BEARING SELEC TION CHART 3 2 3 5L for number to size identifica tion The upper main bearing has a oil feed hole and a center groove to allow lubrication of the main journa...

Page 999: ...alf of bearing by inserting Special Main Bear ing Tool C 3059 Fig 69 into the oil hole of crank shaft 5 Slowly rotate crankshaft clockwise forcing out upper half of bearing shell INSTALLATION Bearing caps are not interchangeable and are marked to insure correct assembly Upper and lower bearing halves are NOT interchangeable Fig 70 CAUTION Main bearings are select fit Refer to 9 ENGINE ENGINE BLOCK...

Page 1000: ...ce The main bearing cap bolts must be tightened in the proper sequence First the inner main cap bolts secondly the windage tray bolts lastly the main cap tie horizontal bolts 6 Install each main bearing cap and tighten inner bolts finger tight 7 Tighten inner main bearing cap bolts to 20 N m 1 4 turn 15 ft lbs 1 4 turn 8 Measure crankshaft end play Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT STAN DA...

Page 1001: ...r Fig 75 through the dust lip against the metal case of the seal Pry out seal CAUTION Do not allow the screwdriver blade to contact the crankshaft seal surface Contact of the screwdriver blade against crankshaft edge cham fer is permitted INSTALLATION CAUTION If a burr or scratch is present on the crankshaft edge chamfer clean surface using 400 grit sand paper to prevent seal damage during install...

Page 1002: ... and must be replaced as an assembly INSTALLATION 1 Clean all sealing surfaces Replace retainer assembly if gasket is torn or damaged 2 Install seal retainer to block but do not tighten attaching screws at this time NOTE The following steps must be performed to prevent oil leaks at sealing joints 3 Attach Special Tools 8225 to pan rail using the oil pan fasteners Fig 78 NOTE Make sure the marking ...

Page 1003: ... are coated with a solid lubri cant for scuff resistance Connecting rod is forged steel with a squirt hole and attaches to the piston with a full floating pin retained by lock rings STANDARD PROCEDURE FITTING PISTONS The pistons are machined to two different weight specifications and matched to rods based on weight All piston and rod assemblies weigh the same to maintain engine balance Piston and ...

Page 1004: ... careful not to nick crankshaft journals 6 After removal install bearing cap on the mat ing rod INSTALLATION 1 Install the piston rings Refer to 9 ENGINE ENGINE BLOCK PISTON RINGS INSTALLA TION NOTE The connecting rod bearing cap bolts must be examined before reuse If the threads are necked down the bolts must be replaced 2 Check connecting rod bolts for necking by hold ing a scale or straight edg...

Page 1005: ...rdering a ser vice piston rod assembly that valve reliefs are present These may be used in the engine and will not affect engine operation 7 The arrow on top of piston must be pointing toward front of engine Fig 86 and oil squirt hole on connecting rod faces the major thrust right side of the cylinder bore Fig 87 8 Tap the piston down in cylinder bore using a hammer handle At the same time guide c...

Page 1006: ...m bottom of cylinder bore Check gap with feeler gauge Fig 88 For clearance specifications Refer to 9 ENGINE SPECIFICATIONS 2 Check piston ring to groove clearance Fig 89 For clearance specifications Refer to 9 ENGINE SPECIFICATIONS Fig 87 Piston and Connecting Rod Positioning Front View of Engine 1 MAJOR THRUST SIDE OF PISTON 2 OIL SQUIRT HOLE Fig 88 Check Gap on Piston Rings 1 FEELER GAUGE 9 54 E...

Page 1007: ...ing is installed with manufacturers I D mark dot facing up towards top of the piston Fig 90 CAUTION Install piston rings in the following order Oil ring expander Upper oil ring side rail Lower oil ring side rail No 2 Intermediate piston ring No 1 Upper piston ring 2 Install oil ring expander 3 Install the side rail by placing one end between the piston ring groove and the expander Hold end firmly ...

Page 1008: ...e procedure as damage to collar and or oil pan may occur 1 Install structural collar Fig 94 using the fol lowing tightening sequence a Install the vertical collar to oil pan bolts Torque bolts initially to 1 1 N m 10 in 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 working outward final torque bolts to 55 N m ...

Page 1009: ... 4 Install upper radiator crossmember Refer to 23 BODY EXTERIOR GRILLE OPENING REIN FORCEMENT INSTALLATION 5 Connect negative cable ENGINE MOUNTING DESCRIPTION The engine mounting system consist of three mounts two hydro type mounts are attached to the right and left side of the engine block and one molded rubber type rear mount is attached to the transaxle Fig 99 All three mounts attach to the su...

Page 1010: ... nuts from the bot tom of the isolator to the frame Fig 98 5 Raise engine carefully with jack enough to remove the isolator with heat shield from its mount INSTALLATION 1 Install isolator mount with heat shield onto the frame 2 Lower the engine onto the isolator mount 3 Remove jack from vehicle 4 Tighten the isolator to frame nuts to 61 N m 45 ft lbs Fig 98 5 Install the upper attaching nuts to mo...

Page 1011: ...uts from top of the mounting bracket Fig 99 3 Support the engine with a jack and a block of wood across the full width of the oil pan 4 Remove the lower attaching nuts from the bot tom of the isolator to the frame Fig 99 5 Raise engine carefully with jack enough to remove the isolator with heat shield from its mount INSTALLATION 1 Install isolator mount with heat shield onto the frame 2 Lower the ...

Page 1012: ...horough visual inspection of the engine particularly at the area of the suspected leak If an oil leak source is not readily identifiable the following steps should be followed 1 Do not clean or degrease the engine at this time because some solvents may cause rubber to swell temporarily stopping the leak 2 Add an oil soluble dye use as recommended by manufacturer Start the engine and let idle for a...

Page 1013: ...ea 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 crankshaft damage b Where leakage tends to run straight down possible caus...

Page 1014: ... stands Refer to LUBRICATION MAINTENANCE HOIST ING STANDARD PROCEDURE 4 Remove oil fill cap 5 Place a suitable drain pan under crankcase drain 6 Remove drain plug from crankcase and allow oil to drain into pan Inspect drain plug threads for stretching or other damage Replace drain plug and gasket if damaged 7 Remove oil filter Refer to 9 ENGINE LUBRI CATION OIL FILTER REMOVAL 8 Install drain plug ...

Page 1015: ...by unscrewing fitting INSTALLATION ENGINE OIL COOLER 1 Install radiator assembly Refer to 7 COOL ING ENGINE RADIATOR INSTALLATION Tighten lines to radiator fittings to 18 N m 160 in lbs Fig 102 COOLER LINES 1 Position cooler lines and connect lines to radia tor fittings Tighten lines to radiator fittings to 18 N m 160 in lbs Fig 102 2 Connect lines to pressure control valve and oil pan fitting Tig...

Page 1016: ...from base and discard Fig 103 INSTALLATION 1 Wipe base clean then inspect gasket contact surface 2 Lubricate gasket of new filter with clean engine oil 3 Install and tighten filter to 16 N m 12 ft lbs of torque after gasket contacts base Fig 103 Use filter wrench if necessary 4 Start engine and check for leaks OIL PAN REMOVAL 1 Disconnect negative cable from remote jumper terminal 2 Remove dipstic...

Page 1017: ...cal 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 5 Lower vehicle and install dipstick and tube 6 Fill engine crankcase with proper oil to correct level 7 Connect negative cable Fig 105 OIL PAN 1 ...

Page 1018: ...cated on the lower left front side of the engine Fig 108 It screws into the engine oil cooler adapter fitting that is installed into the engine main oil gallery The nor mally closed switch provides an input through a sin gle wire to the low pressure indicator light on the instrument cluster OPERATION The oil pressure switch provides a ground for the instrument cluster low oil pressure indicator li...

Page 1019: ...AL 7 Remove the oil pickup tube 8 Remove the oil pump fasteners Remove pump and gasket from engine Fig 109 DISASSEMBLY 1 To remove the relief valve proceed as follows 2 Remove cotter pin Drill a 3 175 mm 1 8 inch hole into the relief valve retainer cap and insert a self threading sheet metal screw into cap 3 Clamp screw into a vise and while supporting oil pump body remove cap by tapping oil pump ...

Page 1020: ...rs and measure clearance between rotor and body Fig 115 If measurement is 0 39 mm 0 015 inch or more replace body only if outer rotor is in specifications 7 Install inner rotor into body If clearance between inner and outer rotors Fig 116 is 0 20 mm 0 008 inch or more replace both rotors 8 Place a straightedge across the face of the body between bolt holes If a feeler gauge of 0 077 mm 0 003 in or...

Page 1021: ...in lbs Fig 111 3 Prime oil pump before installation by filling rotor cavity with engine oil 4 If oil pressure is low and pump is within spec ifications inspect for worn engine bearings or other reasons for oil pressure loss Fig 115 Measuring Outer Rotor Clearance in Housing 1 FEELER GAUGE 2 OUTER ROTOR Fig 116 Measuring Clearance Between Rotors 1 FEELER GAUGE 2 OUTER ROTOR 3 INNER ROTOR Fig 117 Me...

Page 1022: ...ve belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 11 Install the radiator fan Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 12 Fill the cooling system Refer to 7 COOL ING STANDARD PROCEDURE 13 Fill engine crankcase with proper oil to the correct level INTAKE MANIFOLD DESCRIPTION The composite upper intake manifold is a cross flow type with long runners to improve air char...

Page 1023: ...NTAKE MANIFOLD UPPER REMOVAL 1 Disconnect negative cable from remote jumper terminal 2 Disconnect the Inlet Air Temperature IAT Sensor connector Remove air cleaner housing and inlet hose Fig 121 3 Remove throttle and speed control cables from throttle arm and bracket Refer to 14 FUEL SYS TEM FUEL INJECTION THROTTLE CONTROL CABLE REMOVAL 4 Disconnect electrical connectors from the fol lowing sensor...

Page 1024: ... front corners and at MTV Fig 124 8 Loosen upper fastener attaching throttle body to support bracket 9 Remove bolts attaching intake manifold and remove manifold Fig 125 Fig 121 AIR CLEANER WITH INLET HOSE 1 AIR CLEANER ASSEMBLY WITH AIR INLET HOSE 2 THROTTLE BODY Fig 122 INTAKE MANIFOLD SUPPORT RIGHT 1 SUPPORT BRACKET Fig 123 INTAKE MANIFOLD SUPPORT LEFT 1 SUPPORT BRACKET Fig 124 INTAKE MANIFOLD ...

Page 1025: ...ont cor ners and at MTV Fig 124 7 Tighten fastener attaching throttle body to sup port bracket 8 Connect vacuum lines to the following Speed Control Reservoir Positive Crankcase Ventilation PCV Valve Proportional Purge Solenoid Power Brake Booster 9 Connect electrical connectors to the following Short Runner Valve SRV If Equipped Manifold Tuning Valve MTV If Equipped Throttle Position Sensor TPS I...

Page 1026: ...aged fuel injector ports If the manifold exihibits any of these conditions replace the manifold INSTALLATION 1 Clean all sealing surfaces NOTE Gaskets can be reused provided they are free of tears or cuts 2 Inspect gaskets for tears or cuts Replace as necessary 3 Position gaskets and intake manifold on cylin der head surfaces 4 Install fuel rail with injectors 5 Install intake manifold bolts and g...

Page 1027: ...Fig 128 LOWER INTAKE MANIFOLD 1 BOLT 6 GASKET 2 HEATER SUPPLY TUBE 7 BOLT 3 BOLT 8 O RING 4 BOLT 9 INTAKE MANIFOLD LOWER 5 KNOCK SENSOR LH ENGINE 9 75 INTAKE MANIFOLD LOWER Continued ...

Page 1028: ...ystem Refer to 11 EXHAUST SYSTEM REMOVAL 4 Loosen converter pipe support attaching bolt at transaxle mount 5 Loosen the A C belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 6 Lower vehicle 7 Remove air cleaner housing and air inlet tube 8 Loosen and remove V Band clamp at exhaust manifold connector Fig 129 LOWER INTAKE MANIFOLD TIGHTENING Fig 130 EXHAUST MANIFOLD 1 BOLT HEAT SHIELD 2 HE...

Page 1029: ...en bolts starting at the center working outward to 23 N m 200 in lbs Fig 131 2 Install heat shields and tighten attaching bolts to 12 N m 105 in lbs Fig 130 3 Install oxygen sensor to manifold and connect electrical connector 4 Install the A C compressor mounting bracket 5 Install engine oil dipstick tube 6 Install the A C compressor and drive belt For belt installation procedure Refer to 7 COOLIN...

Page 1030: ...en bolts starting at the center working outward to 23 N m 200 in lbs Fig 132 2 Install heat shields and tighten bolts to 12 N m 105 in lbs Fig 132 3 Install oxygen sensor to manifold and connect electrical connector 4 Attach electrical connector bracket to brace 5 Install a new V Band clamp and tighten to 11 N m 100 In lbs 6 Raise vehicle on hoist 7 Install and or tighten nut attaching converter p...

Page 1031: ... to 7 COOL ING ENGINE RADIATOR FAN REMOVAL 4 Remove the accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove crankshaft vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL Fig 133 TIMING DRIVE SYSTEM 1 TIMING BELT COVER RIGHT REAR 8 BOLT CRANKSHAFT DAMPER 2 TENSIONER TIMING BELT 9 TIMING BELT COVER LOWER 3 CAMSHAFT SPROCKET 10 TIMING BELT COVER...

Page 1032: ...RY DRIVE DRIVE BELTS INSTALLATION 7 Install the radiator fan Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 8 Install upper radiator crossmember Refer to 23 BODY EXTERIOR GRILLE OPENING REIN FORCEMENT INSTALLATION 9 Connect negative cable to remote jumper termi nal TIMING BELT COVER S REAR REMOVAL 1 Remove camshaft sprocket s Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REM...

Page 1033: ...ngs on cover Fig 139 Fig 137 Rear Timing Belt Cover Bolts 1 REAR COVER TO CYLINDER HEAD BOLTS 2 APPLY SEALANT TO BOLT THREADS 3 REAR COVER TO CYLINDER BLOCK BOLTS Fig 138 TIMING COVER REAR SEALS 1 REAR COVER RIGHT SIDE 3 REAR COVER LEFT SIDE 2 FOAM SEAL 4 FOAM SEALS Fig 139 Right Side Timing Belt Cover O Rings 1 O RINGS 2 WATER PUMP IMPELLER LH ENGINE 9 81 TIMING BELT COVER S REAR Continued ...

Page 1034: ...ULLEY ASSEMBLY NOTE The tensioner pulley bracket and pivot bolt is serviced as an assembly 1 Inspect pulley for free movement Fig 142 Replace if pulley is loose seized or rough turning 2 Inspect pulley bearing and seal Fig 142 Replace if damaged 3 Inspect pivot bolt for free movement in ten sioner bracket Fig 142 Replace assembly if seized or excessive looseness INSPECTION TENSIONER 1 Inspect hydr...

Page 1035: ...23 BODY EXTERIOR GRILLE OPENING REIN FORCEMENT REMOVAL 3 Remove the radiator fan Refer to 7 COOL ING ENGINE RADIATOR FAN REMOVAL 4 Remove the accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 5 Remove the crankshaft vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 6 Remove the front timing belt covers Refer to 9 ENGINE VALVE TIMING TIMING BELT CHA...

Page 1036: ... orientation when tensioner is installed on the engine a Place the tensioner into a vise and SLOWLY compress the plunger Fig 146 Total bleed down of tensioner should take about 5 minutes b When plunger is compressed into the ten sioner body install a pin through the body and plunger to retain plunger in place until tensioner is installed REMOVAL CAMSHAFT SPROCKETS CAUTION The 3 2 3 5L engines are ...

Page 1037: ... interchangeable between cylinder banks 5 Install Special Tools 6642 Camshaft Alignment tools to the rear of each cylinder head by inserting pin on the alignment tool to the pilot hole on the camshaft Attach tools using the retainer plate bolts Fig 149 NOTE If the alignment tools do not properly line up to install attaching bolts first remove the timing belt tensioner then slowly rotate camshaft w...

Page 1038: ...nail b Cracks on rubber back c Cracks or peeling of canvas d Cracks on rib root e Cracks on belt sides f Missing teeth g Abnormal wear of belt sides The sides are normal if they are sharp as if cut by a knife h Vehicle mileage or time at component main tenance requirement Refer to LUBRICATION MAINTENANCE MAINTENANCE SCHEDULES DESCRIPTION 3 If none of the above conditions are seen on the belt the b...

Page 1039: ... Refer to 7 COOL ING ENGINE RADIATOR FAN INSTALLATION 11 Install upper radiator crossmember Refer to 23 BODY EXTERIOR GRILLE OPENING REIN FORCEMENT INSTALLATION 12 Connect negative cable to remote jumper ter minal INSTALLATION CAMSHAFT SPROCKETS CAUTION The camshaft sprockets are not inter changeable from side to side Fig 153 1 Install camshaft sprockets onto the camshafts Install NEW sprocket att...

Page 1040: ...tall spark plug 9 Remove Special Tools 6642 10 Install cam retainer thrust plates and O rings Fig 157 Tighten bolts to 28 N m 250 in lbs 11 Install timing belt covers Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 12 Install crankshaft vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION Fig 154 Camshaft Sprocket Timing Marks 1 ALIGN CAMSHAFT SPROCKE...

Page 1041: ...ation depth of crankshaft sprocket Special Tool 6641 must be used 1 Install crankshaft sprocket using Special Tools 6641 and C 4685 C1 Fig 158 2 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION Fig 158 CRANKSHAFT SPROCKET INSTALLATION 1 INSTALL WITH SPECIAL TOOL 6641 WITH 12mm SCREW C 4685 C1 AND THRUST BEARING AND WASHER LH ENGINE 9 89 TIMING BELT AN...

Page 1042: ......

Page 1043: ...ESONATOR ASSEMBLY REMOVAL 10 INSTALLATION 10 RESONATOR LEFT REAR REMOVAL 10 INSTALLATION 10 RESONATOR RIGHT REAR 300M SPECIAL REMOVAL 11 INSTALLATION 11 EXHAUST SYSTEM DESCRIPTION The exhaust system Fig 1 or Fig 2 consists of two front close coupled catalytic converters Both con verters attach directly to the exhaust manifold using a V Band clamp The exhaust down pipes exit the converters and conn...

Page 1044: ...AR RESONATOR PIPE ASSEMBLY 8 CATALYTIC CONVERTERS Fig 2 Exhaust System 300M Special 1 V BAND CLAMPS 2 BAND CLAMPS 3 FRONT RESONATOR 4 MUFFLER 5 NUTS 28 N m 250 in lbs 6 RIGHT REAR RESONATOR PIPE ASSEMBLY 7 BAND CLAMP 8 LEFT REAR RESONATOR PIPE ASSEMBLY 9 CATALYTIC CONVERTERS 11 2 EXHAUST SYSTEM LH EXHAUST SYSTEM Continued ...

Page 1045: ...CK Exhaust system restriction can be checked by mea suring back pressure using the DRB IIIt and PEP module pressure tester WARNING THE NORMAL OPERATING TEMPERA TURE OF THE EXHAUST SYSTEM IS VERY HIGH THEREFORE NEVER WORK AROUND OR ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CONVERTER THE TEMPERATURE OF THE CON VE...

Page 1046: ...n the isolators This will damage the rubber material 5 Support exhaust system with jack stand 6 Remove the rubber isolators from the rear sus pension crossmember and support brackets on body Fig 3 and Fig 4 7 Lower exhaust system and lay on the ground NOTE When replacement is required on any com ponent of the exhaust system it is most important that original equipment parts be used for the follow ...

Page 1047: ...rackets Replace or tighten as necessary It is important that exhaust system clear ances and alignment be maintained Perform the following procedures to align the exhaust system 1 Loosen clamps and support brackets 2 Align the exhaust system starting at the front working rearward 3 Tighten all clamps and brackets once align ment and clearances are achieved SPECIFICATIONS TORQUE DESCRIPTION N m Ft L...

Page 1048: ...the catalyst can become totally depleted When this occurs the catalyst fails to convert the gases This is known as catalyst 9punch through 9 Catalyst operation is dependent on its ability to store and release the oxygen needed to complete the emissions reducing chemical reactions As a catalyst deteriorates its ability to store oxygen is reduced Since the catalyst s ability to store oxygen is some ...

Page 1049: ...lytic converter for a flow restriction Refer to 11 EXHAUST SYSTEM DIAGNOSIS AND TESTING Exhaust System Restriction Check for procedure Visually inspect the catalytic converter element by using a borescope or equivalent Remove oxygen sen sor s and insert borescope If borescope is not avail able remove converter and inspect element using a flashlight Inspect element for cracked or melted sub strate ...

Page 1050: ...5 Support front of engine cradle on both sides with suitable jack stands Fig 7 16 Support transmission oil pan with suitable transmission jack Fig 7 17 Loosen front engine cradle bolts two to three turns Fig 8 18 Remove rear engine cradle bolts Fig 8 19 Lower the rear of the engine cradle 76 mm 3 in with the transmission jack to allow removal of catalytic converter from engine compartment Fig 7 Su...

Page 1051: ...ce to underbody and engine compartment components before tightening clamps 9 Tighten V Band clamp to 11 N m 100 in lbs 10 Install downstream oxygen sensor and connect electrical connector Refer to 14 FUEL SYSTEM FUEL INJECTION O2 SENSOR INSTALLATION 11 Install air cleaner resonator support bracket to right cylinder head 12 Connect ground strap at right frame rail shock tower area 13 Install air cl...

Page 1052: ...separate left rear resonator pipe from muffler front resonator assembly Fig 1 or Fig 2 3 300M Special Remove nuts securing right rear resonator pipe to muffler front resonator assem bly Fig 2 INSTALLATION 1 Install left rear resonator pipe onto new muf fler front resonator Fig 1 or Fig 2 but do not tighten clamp until exhaust system is installed on vehicle 2 300M Special Install right rear resonat...

Page 1053: ...ne based spray may be used to assist removal Do Not use a petroleum based lubricant on the iso lators This will damage the rubber material 3 Remove the rubber isolator from the rear sup port bracket on body 4 Remove right rear resonator pipe nuts Fig 2 5 Remove right rear resonator pipe assembly INSTALLATION 1 Position right rear resonator pipe assembly into mounting position Loosely install attac...

Page 1054: ......

Page 1055: ...0 OPERATION 10 REMOVAL 10 DISASSEMBLY 12 ASSEMBLY 12 INSTALLATION 13 REAR TOW EYE REMOVAL 15 INSTALLATION 15 FRONT 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 1 4 If beam is damaged the adapter plate to rail welds w...

Page 1056: ... equipped Fig 5 8 Remove fascia from vehicle REMOVAL INTREPID 1 Release hood latch and open hood 2 Remove push pin fasteners attaching bottom of fascia air dam to lower crossmember Fig 6 3 Remove fasteners attaching fascia to splash shields Fig 7 4 Remove push pin fasteners attaching the fascia to upper radiator closure panel 5 Pull the sides of the fascia outwards to disen gage fascia from drive ...

Page 1057: ...o the lower crossmember INSTALLATION INTREPID 1 Connect fog lamp wire connectors if equipped 2 Place fascia pin position on vehicle by fitting foam to bumper beam 3 Snap sides of fascia over drive pin fasteners on fenders 4 Install fasteners to upper radiator closure 5 Install fasteners attaching fascia to splash shields 6 Install fasteners attaching bottom of fascia to lower crossmember REAR BUMP...

Page 1058: ... attaching fascia to rear quar ter panel and splash shields REAR FASCIA INTREPID REMOVAL INTREPID 1 Open deck lid 2 Remove fasteners attaching fascia to rear quar ter and splash shields 3 Remove fasteners attaching fascia to lower trunk panel 4 Pull sides of fascia outwards to disengage snaps to quarter panel attaching bracket Fig 10 5 Pull fascia rearward to expose license plate lamp wire connect...

Page 1059: ... VIEW 11 ENGINE COMPARTMENT SIDE VIEW 12 FORWARD FRAME SECTION AND ENGINE CRADLE 13 REAR FRAME SECTION 14 Fig 11 ENGINE COMPARTMENT TOP VIEW LH FRAME BUMPERS 13 5 FRAME Continued 2004 LH Service Manual Publication No 81 270 04027 04LH13 5 June 2003 ...

Page 1060: ...Fig 12 ENGINE COMPARTMENT SIDE VIEW 13 6 FRAME BUMPERS LH FRAME Continued ...

Page 1061: ...Fig 13 FORWARD FRAME SECTION AND ENGINE CRADLE LH FRAME BUMPERS 13 7 FRAME Continued ...

Page 1062: ...Fig 14 REAR FRAME SECTION 13 8 FRAME BUMPERS LH FRAME Continued ...

Page 1063: ... 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 15 13 Lower cradle away from body shell INSTALLATION NOTE If cradle replacement is required transfer suspension components and jounce and bounce plates to replacement cradle 1 Support cradle on wood beam and a jack 2 Position cradle under body shell...

Page 1064: ...ig 18 It is isolated from the frame rails with the use of rubber isolator bushings These bushings may be replaced separate ly The rear suspension crossmember has 4 rubber iso lator bushings which are replaceable OPERATION The purpose of the rear suspension crossmember is to support the lower end of the rear suspension through the use of four lateral links Two lateral links are mounted on each end ...

Page 1065: ...diate 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 in this manual for the required service procedure 9 Remove the right rear parking brake cable from the intermediate parking brake cable Refer to Base Br...

Page 1066: ...e 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 and 8173 2 on bushing Fig 22 5 Turn the threaded rod pushing bushing down through crossmember and into cup 8173 1 6 Remove special tools and bushin...

Page 1067: ...is time CAUTION The bolts attaching the forward lateral links to the crossmember must be installed with the bolts pointing rearward Fig 19 to prevent damage to the fuel tank and or fuel tubes Also when installing the bolt attaching the left rear lateral link install the bolt pointing forward to prevent damage to the fuel filler tube 5 Raise the crossmember up against the frame rails Install but do...

Page 1068: ...r The forward lateral arm mounting bolts must point rearward and the rearward lateral arm mounting bolts must point for ward CAUTION The bolts attaching the forward lateral links to the crossmember must be installed with the bolts pointing rearward Fig 19 to prevent damage to the fuel tank and or fuel tubes The bolt attaching the left rear lateral link must be installed with the bolt pointing forw...

Page 1069: ...e bracket to rear frame rail Fig 25 3 Remove rear tow eye bracket from vehicle INSTALLATION 1 Position rear tow eye bracket on vehicle 2 Install bolts to hold rear tow eye bracket to rear frame rail Torque bolts to 48 N m 3 Lower vehicle Fig 25 REAR TOW EYE ASSEMBLY 1 REAR TOW EYE BRACKET MOUNTING SCREWS 2 REAR TOW EYE BRACKET LH FRAME BUMPERS 13 15 ...

Page 1070: ......

Page 1071: ...MOVAL 4 INSTALLATION 4 FUEL LINES DESCRIPTION FUEL LINES HOSES AND CLAMPS 5 STANDARD PROCEDURE HOSES AND CLAMP 5 FUEL PRESSURE REGULATOR DESCRIPTION 6 OPERATION 6 FUEL PUMP DESCRIPTION 6 OPERATION 6 FUEL PUMP MODULE DESCRIPTION 7 OPERATION 7 REMOVAL 7 INSTALLATION 7 FUEL RAIL DESCRIPTION 8 OPERATION 8 REMOVAL 2 7 3 5L 8 INSTALLATION INSTALLATION 2 7L 9 INSTALLATION 3 5L 9 FUEL TANK DESCRIPTION 9 O...

Page 1072: ...GNOSIS AND TESTING FUEL DELIVERY SYSTEM Refer to Appropriate Diagnostic Information STANDARD PROCEDURE FUEL SYSTEM PRESSURE RELEASE PROCEDURE 1 Remove Fuel Pump relay from Power Distribu tion Center PDC For location of relay refer to label on underside of PDC cover 2 Start and run engine until it stalls 3 Attempt restarting engine until it will no longer run 4 Turn ignition key to OFF position 5 R...

Page 1073: ...NG UNIT SENSOR DESCRIPTION The fuel gauge level sending unit is attached to the side of fuel pump module The level sensor is a vari able resistor OPERATION Its resistance changes with the amount of fuel in the tank The float arm attached to the sensor moves as the fuel level changes The fuel level input is used as an input for OBD II If the fuel level is below 15 or above 85 of total tank capacity...

Page 1074: ... the level sensor housing Fig 5 Push level sensor down slightly 5 Slide level sensor wires through standpipe inside fuel pump module Fig 6 6 Slide level sensor out of installation channel Fig 5 INSTALLATION 1 Insert level sensor wires in bottom of stand pipe Fig 1 Fuel Pump Level Sensor Connector 1 TAB 2 FUEL PUMP LEVEL SENSOR CONNECTOR 3 BOTTOM OF FUEL PUMP MODULE ELECTRICAL CONNECTOR Fig 2 Wire ...

Page 1075: ...RESSURE RELEASE PROCEDURE IN THIS GROUP The lines tubes hoses used on fuel injected vehicles are of a special construction This is due to the higher fuel pressures and the possibility of contami nated fuel 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 ...

Page 1076: ...ains a diaphragm calibrated springs and a fuel return valve OPERATION Fuel Pressure Regulator Operation The pres sure regulator is a mechanical 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 regulator by the electric fuel pump through an opening tube at the bottom of reg ulator The fuel pump module...

Page 1077: ... the tank The maximum deadhead pressure is approximately 880 kPa 130 psi The regulator adjusts fuel system pressure to approximately 400 34 kPa 58 5 psi REMOVAL 1 Release fuel pressure Refer to Fuel System Pressure Release Procedure in the Fuel Delivery sec tion 2 Remove Fuel Tank refer to the Fuel Tank Removal Installation in this group WARNING THE FUEL RESERVOIR OF THE FUEL PUMP MODULE DOES NOT ...

Page 1078: ... Fuel Delivery System section of this group for information The fuel rail is not repairable REMOVAL 2 7 3 5L WARNING RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL RAIL SERVICE VEHI CLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES NEVER SMOKE WHILE SER VICING THE VEHICLE 1 Release fuel system pressure Refer to Fuel System Pressure Release Procedure in this section 2 Disconnect the nega...

Page 1079: ...Polyethylene HDPE material If equipped with ORVR Onboard Refueling Vapor Recovery it has been added to the fuel tank to con trol refueling vapor emissions OPERATION All models pass a full 360 degree rollover test without fuel leakage To accomplish this fuel and vapor flow controls are required for all fuel tank con nections All models are equipped with either one or two rollover valves mounted int...

Page 1080: ...nection and drain fuel tank 7 Loosen the rear stabilizer bar brackets from body Swing stabilizer bar toward rear of vehicle Fig 16 and Fig 17 8 Disconnect fuel and EVAP lines Fig 18 9 Position transmission jack under fuel tank assembly 10 Remove fuel tank straps bolts Passenger side first 11 Lower fuel tank and remove the purge line and vent line Fig 14 Electrical Connector Fig 15 Fuel Filler Tube...

Page 1081: ...e purge and vent lines Fig 18 6 Raise tank into position and install tank straps 7 Install the fuel filler tube and tighten the clamp Fig 15 8 Reposition the stabilizer bar and install bolts 9 Lower vehicle 10 Connect the fuel pump electrical connector that is under the rear seat Fig 14 11 Install the rear seat refer to the Body section for more information 12 Connect the battery cable Fig 13 13 F...

Page 1082: ...screwdriver pry back the locking tabs on fuel pump reservoir and remove the strainer Fig 22 3 Remove strainer O ring from the fuel pump reservoir body 4 Remove any contaminants in the fuel tank by washing the inside of the fuel tank INSTALLATION 1 Lubricate the strainer O ring with clean engine oil 2 Insert strainer O ring into outlet of strainer so that it sits evenly on the step inside the outle...

Page 1083: ...plied for disconnecting the quick connect fitting from component being serviced CAUTION The interior components O rings spac ers of this type of quick connect fitting are not ser viced separately but new plastic retainers are available Do not attempt to repair damaged fittings or fuel lines tubes If repair is necessary replace the complete fuel tube assembly WARNING THE FUEL SYSTEM IS UNDER A CON ...

Page 1084: ...EASE PROCEDURE IN THIS GROUP DISCONNECTION CONNECTION 1 Perform fuel pressure release procedure Refer to Fuel Pressure Release Procedure in this section 2 Disconnect negative battery cable from battery or auxiliary jumper terminal 3 Clean fitting of any foreign material before dis assembly 4 To release fuel system component from quick connect fitting firmly push fitting towards compo nent being se...

Page 1085: ... 3 5L 26 INSTALLATION INSTALLATION 2 7L 26 INSTALLATION 3 5L 26 INLET AIR TEMPERATURE SENSOR REMOVAL 27 INSTALLATION 27 MANIFOLD TUNE VALVE REMOVAL 3 5L 27 INSTALLATION 3 5L 27 MAP SENSOR DESCRIPTION 27 OPERATION 27 REMOVAL REMOVAL 2 7L 29 REMOVAL 3 5L 29 INSTALLATION INSTALLATION 2 7L 29 INSTALLATION 3 5L 29 O2 SENSOR DESCRIPTION 29 OPERATION 30 REMOVAL REMOVAL UPSTREAM 1 1 or 2 1 31 REMOVAL DOWN...

Page 1086: ...tored dur ing OPEN LOOP modes except for heated oxygen sensor diagnostics they are checked for shorted con ditions at all times During CLOSED LOOP modes the PCM monitors the inputs from the upstream and downstream heated oxygen sensors The upstream heated oxygen sensor input tells the PCM if the calculated injector pulse width resulted in the ideal air fuel ratio of 14 7 to one By monitoring the e...

Page 1087: ...the PCM maintains ignition tim ing at 9 BTDC ENGINE WARM UP MODE This is an OPEN LOOP mode The following inputs are received by the PCM Manifold Absolute Pressure MAP Crankshaft position engine speed Engine coolant temperature Inlet Intake air temperature IAT Camshaft position Knock sensor Throttle position A C switch status Battery voltage Vehicle speed Speed control O2 sensors The PCM adjusts in...

Page 1088: ...OOP mode During wide open throttle operation the following inputs are used by the PCM Inlet Intake air temperature Engine coolant temperature Engine speed Knock sensor Manifold absolute pressure Throttle position When the PCM senses a wide open throttle condi tion through the Throttle Position Sensor TPS it de energizes the A C compressor clutch relay This disables the air conditioning system and ...

Page 1089: ...un time This is done to prevent any transitional temperature or start up compensations from corrupting long term fuel correction Long term adaptive memory can change the pulse width by as much as 25 which means it can correct for all of short term It is possible to have a problem that would drive long term to 25 and short term to another 25 for a total change of 50 away from base pulse width calcu...

Page 1090: ...ives the input when the transmission shifts gears In response the PCM shuts off a number of fuel injectors when the transmission shifts gears SPECIFICATIONS TORQUE DESCRIPTION N m Ft Lbs In Lbs Camshaft Position Semsor 12 8 8 105 Crankshaft Position Sensor Mounting Bolts 12 8 8 105 Engine Coolant Temperature Sensor 28 20 Idle Air Control Motor 2 7L 5 5 49 Idle Air Control Motor 3 5L 7 3 65 Knock S...

Page 1091: ... the vehicle hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft Fig 1 and Fig 2 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 O2S Oxygen Sensor Remover Installer 8439 Fig 1 ACCELERATOR PEDAL AND THROTTLE CABLE LH FUEL INJECTION 14 21 FUEL INJ...

Page 1092: ... hold the throt tle body lever in the wide open position and install the throttle cable CRANKSHAFT POSITION SENSOR DESCRIPTION The crankshaft sensor is located on the passengers side of the transmission housing above the differen tial housing Fig 5 The bottom of the sensor is posi tioned next to the drive plate The sensor is a hall effect device combined with an internal magnet It is also sensitiv...

Page 1093: ...screw Remove sensor INSTALLATION The crankshaft sensor is located on the passengers side of the transmission housing above the differen tial housing The bottom of the sensor sits above the drive plate 1 Install sensor and push sensor down until con tact is made with the transmission case While hold ing the sensor in this position install and tighten the retaining bolt to 12 N m 105 in lbs torque 2...

Page 1094: ...reign 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 injector connectors are not tagged with their cylinder number tag them to identify the cor rect cylinder 7 Remove electrical connectors from the fuel injectors 8 Remove fuel rail mounting bolts 9 Lift fuel rai...

Page 1095: ... clean engine oil 2 Install retaining clips on fuel injectors 3 Push injectors into fuel injector rail until clips are in the correct position 4 Position fuel rail over cylinder head and push rail into place Tighten fuel rail mounting bolts to 28 N m 250 in lbs torque 5 Connect fuel supply tube quick connect fittings at the rear of the fuel rail Refer to Quick Connect Fittings in the Fuel Delivery...

Page 1096: ...engaged so that the engine rpm does not dip down when the compressor engages Target Idle Target idle is determined by the following inputs Gear position ECT Sensor Battery voltage Ambient Battery Temperature Sensor VSS TPS MAP Sensor REMOVAL REMOVAL 2 7L 1 Disconnect the negative battery cable 2 Disconnect the IAC electrical connector 3 Remove the IAC mounting screws 4 Remove the IAC REMOVAL 3 5L ...

Page 1097: ...NSOR DESCRIPTION The MAP sensor mounts to the driver side of the intake manifold plenum Fig 14 or Fig 15 OPERATION The MAP serves as a PCM input using a silicon based sensing unit to provide data on the manifold vacuum that draws the air fuel mixture into the com bustion chamber The PCM requires this information to determine injector pulse width and spark advance When MAP equals Barometric pressur...

Page 1098: ...e is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated Any time the PCM sees Wide Open throttle based upon TPS angle and RPM it will update barometric pres sure in the MAP memory cell With periodic updates the PCM can make its calculations more effectively The PCM uses the MAP sensor to aid in calculat ing the following Barometr...

Page 1099: ...ble 2 Disconnect the electrical connector from the MAP sensor 3 Remove bolts from sensor 4 Remove sensor INSTALLATION INSTALLATION 2 7L 1 The sensor mounts onto intake manifold ple num Fig 17 Tighten screws to 4 5 N m 40 in lbs torque 2 Attach electrical connector to sensor Fig 16 3 Install the negative battery cable INSTALLATION 3 5L 1 Bolt sensor to intake and tighten the bolts to 4 N m 35 in lb...

Page 1100: ... higher voltage By monitoring the oxy gen content and converting it to electrical voltage the sensors act as a rich lean switch The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner Also it allows the sys...

Page 1101: ... and inputs from other sen sors DOWNSTREAM OXYGEN SENSOR 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 sensor input to the input from the upstream sensor the PCM calcula...

Page 1102: ...t the outlet ends of the catalytic converter Threads of new oxygen sensors are factory coated with anti seize compound to aid in removal DO NOT add any additional anti seize compound to the threads of a new oxygen sensor 1 Install the O2 sensor Tighten to 28 N m 20 ft lbs torque 2 Connect the O2 sensor wire connector 3 Lower the vehicle 4 Install the negative battery cable SHORT RUNNER VALVE DESCR...

Page 1103: ...the engine idle speed using this screw All idle speed functions are controlled by the PCM REMOVAL REMOVAL 2 7L 1 Disconnect negative cable from battery 2 Disconnect air plenum from throttle body 3 Hold throttle lever in wide open position Remove throttle cable and speed control cables from throttle arm 4 Remove throttle cable bracket 5 Disconnect electrical connectors from throttle body 6 Remove t...

Page 1104: ...mmet 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 the throttle cable from throttle bracket INSTALLATION 1 From the engine compartment push the hous ing end fitting into the dash panel grommet 2 Install the cable housing throttle body end into the cable mounting bracket on the engine 3...

Page 1105: ...ottle 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 the negative battery cable INSTALLATION 3 5L 1 The throttle shaft end of the throttle body slides into a socket in the TPS The socket has two tabs inside it The throttle shaft rests against the tabs When indexed correctly the T...

Page 1106: ......

Page 1107: ...steering system consists of these major components Power Steering Pump Power Steering Gear Power Steering Fluid Reservoir Power Steering Fluid Supply Hose Power Steering Fluid Pressure Hose Power Steering Fluid Return Hose Power Steering Fluid Cooler For information on the fluid cooler reservoir and hoses refer to POWER STEERING PUMP in this section OPERATION POWER STEERING SYSTEM Turning of the s...

Page 1108: ...mble hoses on Power Steering Analyzer Special Tool 6815 as shown Install Pressure Hose Special Tool 6905 in 6893 kit in the inlet fitting on Power Steering Analyzer Install Pressure Hose Spe cial Tool 6713 in 6815 kit on Pressure Hose Special Tool 6905 Install Pressure Hose Special Tool 6959 in the outlet fitting on Power Steering Analyzer Install the following adapters from Adapter Set Special To...

Page 1109: ...nlet gauge end of Power Steering Analyzer to the pres sure fitting on the power steering pump Fig 6 Fig 3 Pressure Hose Connection To Power Steering Pump 2 7L Engine 1 POWER STEERING FLUID PRESSURE HOSE Fig 4 Pressure Hose Connection To Power Steering Pump 3 5L Engine 1 POWER STEERING PUMP 2 POWER STEERING FLUID PRESSURE HOSE Fig 5 Analyzer Connected To Power Steering Pump 2 7L Engine 1 POWER STEE...

Page 1110: ...ns 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 345 kPa 50 psi of each other replace pump Pressures within 345 kPa 50 psi of each other but below specifications replace pump CAUTION Do not force the pump to operate against the stops for more than 2 to...

Page 1111: ...ontrol arm mounting bolts to the specified torques 5 Lower control arm pivot bushing worn 5 Replace lower control arm pivot bushing 6 Lower control arm tension strut bushing worn 6 Replace lower control arm tension strut bushing 7 Loose strut assembly mounting fasteners at tower 7 Tighten strut assembly fasteners to the specified torque 8 Power steering fluid pressure hose touching the body of the...

Page 1112: ...fluid reservoir and power steering pump 4 Replace power steering pump with reservoir SQUEAK OR RUBBING SOUND 1 Steering column shroud rubbing 1 Realign shrouds as necessary 2 Steering column shaft rubbing 2 Move or realign item rubbing shaft 3 Clockspring noisy 3 Remove clockspring Reinstall wheel If noise is gone replace clockspring 4 Steering gear internally noisy 4 Replace steering gear SCRUBBI...

Page 1113: ...essure 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 Lubricate ball joints if ball joints...

Page 1114: ...ow 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 adjust wheel alignment as necessary 3 Lack of lubrication binding in front lower control arm ball joints 3 Lubricate ball joints if ball joints are n...

Page 1115: ... 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 expected in new vehicles and vehicles with recent steering system repairs Shudder should dissipate after the vehi...

Page 1116: ...ntamination 1 Drain the 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 DIAGNOSIS AND TESTING SPEED PROPORTIONAL POWER STEERING Electronic diagnosis of the variable effort speed proportional power steerin...

Page 1117: ...240 Steering Column Mounting Bolts 12 105 Steering Column Mounting Nuts 12 105 Steering Wheel Retaining Nut 61 45 SPECIAL TOOLS POWER STEERING Power Steering Analyzer 6815 Adapters Power Steering Analyzer 6893 Installer C 4063B Puller C 4333 Puller C 3894 A Remover Installer Steering Shaft Roll Pin 6831A Remover Installer Bushing 8523 LH STEERING 19 11 STEERING Continued ...

Page 1118: ...be serviced without removing the steering column from the vehicle BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID Column shift vehicles have a brake transmission shift interlock BTSI solenoid mounted on the steer ing column The BTSI solenoid works in conjunction with the brake lamp switch and will not allow the steering column shift lever to be moved out of the PARK position without the brake pedal be...

Page 1119: ...N EQUIPPED WITH AN AIR BAG Refer to 8 ELEC TRICAL RESTRAINTS WARNING WARNING WHEN HANDLING AN UNDEPLOYED AIRBAG MODULE DURING SERVICING OF THE STEERING COLUMN THE FOLLOWING PRECAU TIONS SHOULD BE 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 MIN...

Page 1120: ... steering column It is written to reflect that objective If the column is to be removed as one assembly or without removing the steering wheel the steering wheel must be turned from the straight ahead position to the RIGHT 180 and locked in place Lock the column in this position by removing the key from the key cylinder This MUST be per formed before the steering coupler to the gear is disconnecte...

Page 1121: ... bolts Fig 7 mounting the rein forcement Fig 7 to the instrument panel Remove the reinforcement from the instrument panel Remove the diagnostic connector Fig 8 from the reinforcement Fig 4 Lower Instrument Panel Cover Mounting Screws 1 MOUNTING SCREWS 2 INSTRUMENT PANEL BRACKET 3 LOWER INSTRUMENT PANEL COVER Fig 5 Trunk Release Wiring 1 WIRING HARNESS CONNECTOR 2 TRUNK RELEASE SWITCH 3 LOWER INSTR...

Page 1122: ...G MODULE WHEN CARRYING A LIVE MODULE THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF MODULE ACCI DENTLY DEPLOYS IF AIRBAG MODULE IS PLACED ON A BENCH OR OTHER SURFACE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVE MENT IN CASE OF ACCIDENTAL DEPLOYMENT 10 Remove the 2 bolts attaching the driver air bag to the steering wheel Fig 10 11 Remove the driver airbag from the ste...

Page 1123: ...per shroud from the steering column lower shroud DO NOT use a hard or sharp tool This will damage the shrouds If a tool must be used use a soft tool such as a trim stick 18 Remove the steering column upper shroud from the steering column using the following proce dure First on the right seam between the upper and lower shrouds push in on seam at the forward end When the upper shroud unsnaps pull t...

Page 1124: ... the key cylinder halo bezel 24 Remove the wiring harness from the routing clip on the top of the multi function switch Remove the 2 screws Fig 18 mounting the multi function switch to the steering column Remove the multi function switch with the wiring harness attached from the steering column Fig 15 Lower Shroud Attaching Screws 1 LOWER SHROUD 2 MOUNTING SCREWS Fig 16 Wiring Harness Connection T...

Page 1125: ...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 solenoid Fig 22 c Slide the solenoid straight off the shift lever mounting stud Fig 19 Ignition Switch Mounting Screws 1 IGNITION SWITCH 2 MOUNTING SCREW 3 STEERING COLUMN 4 MOUNTING SCREW 5 MULTIFUNCTION SWITCH Fig 20 Shifter I...

Page 1126: ... ducts Fig 25 from under the steering column 31 Remove retaining pin in steering column cou pler pinch bolt Fig 26 Remove the pinch bolt from the steering column coupler The pinch bolt nut is caged to coupler and is not removable Separate the steering column flex coupler from steering intermedi ate shaft Fig 23 Shift Cable Removal 1 STEERING COLUMN 2 SCREWDRIVER 3 PIN 4 SHIFT CABLE 5 SHIFTER MECHA...

Page 1127: ...ure to install steering coupler pinch bolt retaining pin 4 Install the two air ducts under the steering col umn Fig 25 5 If the vehicle is equipped with a floor shifter install the shifter ignition interlock cable Fig 20 in the lock cylinder housing 6 Install the shift cable mounting bracket Fig 24 on the steering column The shift cable mounting bracket is mounted to the steering column by the two...

Page 1128: ... two screws Fig 18 mounting the multi function switch to the steering column Install the clockspring wiring harness on the routing clip on the top of the multi function switch 12 If the vehicle is equipped clip the SKIM mod ule over the key cylinder halo bezel and attach it to the steering column with its mounting screw Con nect the wiring harness to the module 13 Install the clockspring on the st...

Page 1129: ...ec trical connector from clockspring is securely latched into driver airbag connector 25 If optional audio control switches are present on the rear of the steering wheel connect the 4 way connector lead from the clockspring to the steering wheel wiring harness lead Once connected place the connector in back cover formation located at the 12 O clock position CAUTION The fasteners screws and bolts o...

Page 1130: ...he lock cylinder For ignition switch terminal and circuit identification refer to the Wiring Diagrams section 1 Disconnect negative cable from battery 2 Remove tilt lever attaching screw Remove lever 3 Remove upper and lower cover from steering column 4 Remove Sentry Key Immobilizer Module SKIM if equipped Refer to the Power Door Locks section for removal 5 Remove multi function switch 6 Disconnec...

Page 1131: ...ions Seized bearing Loose bearing stake Bearing not seated properly The steering column intermediate shaft MUST be replaced as an entire assembly if a problem condition is found KEY LOCK CYLINDER DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch OPERATION The ignition key rotates the cylinder to 5 different detents Fig 35 Accessory Off lock Unlock On ...

Page 1132: ...ylinder is replaced Refer to the Floor Shift Interlock Adjustment procedure in the Transmission section 6 Install upper and lower cover on steering col umn 7 Install tilt lever 8 Connect negative cable to battery LOCK CYLINDER HOUSING REMOVAL 1 Disconnect remote battery ground cable at right strut tower and isolate 2 Remove tilt lever upper and lower steering col umn shrouds Refer to 19 STEERING C...

Page 1133: ...er to 19 STEER ING COLUMN IGNITION SWITCH INSTALLA TION 5 Install multi function switch Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR MULTI FUNCTION SWITCH INSTALLATION 6 Attach wiring harness in place on left side of column using nut 7 Install a new shift interlock cassette If the vehicle has a floor shift reconnect and adjust the shift cable as necessary 8 If equipped with Sentry Key Imobilizer ...

Page 1134: ...ru ment panel cover Fig 45 Lay the cover and handle out of the way CAUTION The upper shroud is retained to the steering column by a snap fit to the lower shroud When removing the upper shroud from the lower shroud DO NOT use a hard or sharp tool This will damage the shrouds If a tool must be used use a soft tool such as a trim stick Fig 42 Fuse Panel Cover 1 FUSE PANEL COVER 2 INSTRUMENT PANEL Fig...

Page 1135: ... panel cover Fig 45 5 Connect the wiring harness to the trunk release switch in the lower instrument panel cover Fig 44 6 Install the lower instrument panel cover using the retaining clips along the top and right edge 7 Install the two screws behind the fuse panel cover attaching the lower instrument panel cover to the instrument panel Fig 43 8 Install the fuse panel cover on the left end of the i...

Page 1136: ...nurled nut Fig 48 4 Using Puller Special Tool 6831 A Fig 48 install roll pin into the coupler until spring pin is fully installed through both sides of the coupler STEERING WHEEL REMOVAL 1 Place the front road wheels in the straight ahead position then a Rotate the steering wheel one half turn 180 degrees to the right clockwise b Lock column in place with the ignition cylin der lock NOTE The steer...

Page 1137: ...ng 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 module 6 If optional audio control switches are present on the rear of the steering wheel connect the 4 way connector lead from the clockspring to the steering wheel wiring harness lead ...

Page 1138: ...ad screws attaching the shift lever assembly to the steering column tilt hous ing Fig 54 then remove shift lever assembly from tilt housing and unhook the ignition interlock cable from shift lever assembly Fig 54 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 Fig 52 BTSI 1 SHIFT LE...

Page 1139: ...mechanism bracket Fig 56 c Install the retainer clip until it snaps into place in the slot cut into the shift lever mounting stud Fig 57 d Verify the solenoid is locked in place and will not slide off the mounting stud e Connect the wiring harness connector to the solenoid 5 Install cable from the new ignition interlock cassette onto the interlock lever of the shift lever assembly Fig 54 6 With th...

Page 1140: ...y Fig 51 9 Install tilt lever Fig 51 10 Install the lower instrument panel cover 11 Install the 2 screws behind the fuse panel cover attaching the lower instrument panel cover to the instrument panel Fig 50 12 Install the fuse panel cover on the left end of the instrument panel Fig 49 Fig 58 Ignition Interlock Adjustment Tab 1 LOCK CYLINDER HOUSING 2 INTERLOCK CASSETTE 3 ADJUSTMENT TAB 19 34 COLUM...

Page 1141: ...ing 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 available A base gear A firm feel gear and A speed proportional gear The base gear and firm feel gear are serviced the same The speed proportional steering gear is physi cally very similar to th...

Page 1142: ...NNER TIE ROD 8 ADJUSTMENT SLEEVE 9 TIE ROD END 10 CLAMP Fig 2 Variable Assist Speed Proportional Power Steering Gear 1 STEERING GEAR FLUID LINES 2 STEERING GEAR BOOT 3 RACK AND PINION STEERING GEAR 4 SOLENOID CONTROL VALVE 5 CLAMP 6 TIE ROD END 7 ADJUSTMENT SLEEVE 8 INNER TIE ROD 9 ADJUSTMENT SLEEVE 10 TIE ROD END 11 CLAMP 19 36 GEAR LH GEAR Continued ...

Page 1143: ...e vehicle speed between 0 km h 0 mph and approximately 32 km h 20 mph minimum steering effort is required Between approximately 32 km h 20 mph and 100 km h 60 mph power steering effort will gradually increase based upon vehicle speed Above approximately 100 km h 60 mph maximum steering effort is provided by the speed proportional steering system Variable effort power steering is provided by con tr...

Page 1144: ...m attaching nut Remove the nut attaching each wiper arm to its pivot Fig 6 7 Remove the wiper arms from the pivots Wiper arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled off the pivots 8 Remove the wiper module cover and cowl cover from the vehicle Fig 7 9 Remove the eight bolts attaching the cowl rein forcement to the strut towers and the one ...

Page 1145: ...e master cylinder in an upright position on the left side valve cover of the engine CAUTION Do not allow brake fluid to leak onto painted surfaces Paint damage may occur 15 Remove the vacuum supply hose to the power brake vacuum booster at the check valve in the vacuum booster Position the vacuum hose out of the way 16 Bend back the retaining tabs on the mounting plate for the tie rod to steering ...

Page 1146: ...he two bolts attaching the left side of the steering gear to the crossmember Fig 15 21 Remove the two bolts attaching the steering gear s right side mounting bracket to the crossmem ber Fig 16 Fig 13 Tie Rod To Steering Gear Attaching Bolts 1 TIE RODS 2 BOLTS 3 MOUNTING PLATE 4 WASHERS 5 STEERING GEAR Fig 14 Power Steering Hose Connections At Steering Gear 1 POWER STEERING FLUID RETURN HOSE 2 STEE...

Page 1147: ...f Remover through center of roll pin then install and hand tighten knurled nut c Position sleeve of removal tool on flex joint as shown Fig 18 d While holding threaded shaft of tool from turning tighten nut pulling roll pin out of flex joint 24 Separate the intermediate steering shaft from the steering gear 25 Raise vehicle 26 Remove the right front tire wheel 27 Remove the nut Fig 19 attaching th...

Page 1148: ...ender Fig 22 Steering gear needs to be slid through tie rod hole until about half of the steering gear is through the hole Fig 22 b Lift the left end of the steering gear upward with the steering gear positioned as shown between the back of the engine and the front of the cowl Fig 23 c To remove the steering gear from the vehicle pull the steering gear toward the passenger side of the vehicle out ...

Page 1149: ...s the bushing retainer washer Fig 25 Slowly tighten the screw drive until the bushing bot toms in the recessed area of the steering gear hous ing 3 Back off the Ball Joint Press screw drive and remove the power steering gear from the press 4 Repeat the above procedure on the other power steering gear housing bushing INSTALLATION POWER STEERING GEAR NOTE When the original or a replacement steering ...

Page 1150: ... steering gear to the cross member Fig 16 Tighten the mounting bolts to a torque of 58 N m 43 ft 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 in...

Page 1151: ...pinch bolt nut retaining pin in pinch bolt 25 Remove the holding clamp from the steering wheel Fig 4 26 Install the battery ground cable onto the ground stud on the shock tower 27 Perform Power Steering Pump Initial Opera tion procedure to properly refill and bleed power steering system Refer to 19 STEERING PUMP STANDARD PROCEDURE 28 Lower vehicle 29 Adjust front toe Refer to 2 SUSPENSION WHEEL AL...

Page 1152: ... the steer ing gear by hand until it is fully seated into the steering gear 3 Using the 1 5 16 inch crow foot as shown Fig 32 tighten the solenoid control valve to a torque of 14 N m 124 in lbs Fig 29 Wiring Harness 1 SPEED PROPORTIONAL STEERING SOLENOID CONNECTOR 2 MASTER CYLINDER RESERVOIR Fig 30 Power Steering Hose Connections At Steering Gear 1 POWER STEERING FLUID RETURN HOSE 2 STEERING GEAR ...

Page 1153: ...ttachment to the pivots to expose the wiper arm attaching nut Remove the nut attaching each wiper arm to its pivot Fig 34 3 Remove the wiper arms from the pivots Wiper arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled off the pivots 4 Remove the wiper module cover and cowl cover from the vehicle Fig 35 5 Remove the 8 bolts attaching the reinforc...

Page 1154: ...he strut using Puller Special Tool C 3894 A Fig 39 11 Turn the steering wheel all the way to the full right position 12 Bend back the retaining tabs on the mounting plate for the tie rod to steering gear mounting bolts Fig 40 Fig 37 In Line Resonator And Air Inlet Hose 1 AIR INLET HOSE 2 THROTTLE BODY 3 AIR INLET HOSE 4 AIR CLEANER HOUSING LID 5 RESONATOR 6 IN LINE RESONATOR Fig 38 Tie Rod End Att...

Page 1155: ...wn in Fig 42 If the maxi mum distance is exceeded inadequate retention of either the adjuster or the outer tie rod can result This condition can cause separation of the outer tie rod end from the inner tie rod Ensure that adjust ment sleeve pinch bolts are torqued to the required specification when Toe setting procedure is com pleted 2 Install the tie rod assembly through the tie rod hole in the w...

Page 1156: ...screws 13 Install the wiper arms on the pivots Fig 34 Install and securely tighten the wiper arm to pivot attaching nuts Install the caps on the wiper arms covering the pivot nuts 14 Install the battery ground cable onto the ground stud on the shock tower and install nut 15 Adjust front toe Refer to Wheel Alignment in Suspension TIE ROD OUTER DIAGNOSIS AND TESTING OUTER TIE ROD SOCKET END PLAY NOT...

Page 1157: ...into the steering arm on front strut Install tie rod to steering arm attach ing nut Fig 47 Tighten the attaching nut a torque of 37 N m 27 ft lbs 3 Install the tire and wheel assembly 4 Install and tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs 5 Lower vehicle...

Page 1158: ...d bushings replacement of both inner tie rod bushings is rec ommended 1 Remove the battery ground cable from the ground stud on the shock tower and isolate the ground cable by installing the cable isolator on the ground stud Fig 50 2 Remove caps from both wiper arms at the attachment to the pivots to expose the wiper arm attaching nut Remove the nut attaching each wiper arm to its pivot Fig 51 3 R...

Page 1159: ...n Lubrication And Maintenance 8 Remove front wheel and tire assembly from side requiring repair both sides are recommended 9 Remove the nut attaching the outer tie rod end to the steering arm on the strut Fig 55 Fig 52 Wiper Module And Cowl Cover 1 COWL COVER 2 WIPER MODULE COVER Fig 53 Reinforcement Attachment To Vehicle 1 RIGHT STRUT TOWER 2 WIPER MODULE 3 LEFT STRUT TOWER 4 ATTACHING BOLTS 5 AT...

Page 1160: ...as shown Fig 59 b Place Remover Installer Special Tool 8438 4 with the small end down on top of the bushing Fig 59 c Insert Screw Special Tool 8438 3 though the Remover Installer and tie rod bushing until it threads into the bottom of the Receiver d Using hand tools tighten the Screw until it bottoms out The bushing is now removed from the inner tie rod 19 Remove the Screw then remove the Remover ...

Page 1161: ...ing downward c Place Remover Installer Special Tool 8438 4 with the small end down on top of the bushing Fig 61 d Insert Screw Special Tool 8438 3 through the Remover Installer bushing in Sizer and tie rod until it threads into the bottom of the Receiver e Using hand tools tighten the Screw pushing the bushing out of Sizer into the inner tie rod end Tighten the Screw until it bottoms in the tool D...

Page 1162: ...ear be sure the tie rod spacer block inside the steering gear bellows boot is correctly aligned with the bolt holes in the rack of the steering gear and the steer ing gear bellows Fig 63 8 Align the inner tie rod with the mounting hole in the center take off on steering gear Rotate the mount ing plate into position over the tie rod Install tie rod attaching bolt through tie rod and washer into ste...

Page 1163: ... inlet hose on the throttle body and air inlet hose coming from the lid of the air cleaner housing Fig 54 16 Install the reinforcement on the vehicle Fig 53 Install the eight bolts attaching the cowl rein forcement to the strut towers Install the bolt attach ing the wiper module to the reinforcement 17 Install the covers over the wiper module and the cowl Fig 52 Install and securely tighten the at...

Page 1164: ...n of the power steering system is provided by a belt driven rotary power steering pump The power steering pump is a constant flow rate and displacement vane type pump Vehicles equipped with the 2 7 liter engine use a power steering pump that has an integral reservoir for the power steering fluid Fig 1 Vehicles equipped with the 3 5 liter engine use a power steer ing pump Fig 2 that has a remotely ...

Page 1165: ... opens and allows the oil to return to the intake side of the pump This action limits maximum pressure output of the pump to a safe level Under normal power steering pump operating con ditions the pressure requirements of the pump are below maximum causing the pressure relief valve to remain closed In the event of a power steering pump drive belt failure manual steering control of the vehicle can ...

Page 1166: ...roken off of the power steering fluid reservoir 3 Remove the power steering fluid return hose from the power steering fluid reservoir Fig 4 4 Let power steering fluid drain from the power steering fluid reservoir and power steering pump 5 Install a cap on the open nipple of the power steering fluid reservoir to prevent power steering fluid from spilling when removing the power steering pump 6 Remo...

Page 1167: ... side of the tensioner bracket Fig 7 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 pump to the replacement power steer ing pump See Disassembly and Assembly in this sec tion REMOVAL PUMP 3 5L ENGINE 1 Remove the batter...

Page 1168: ...d drain from the power steering pump 9 Loosen the lock nut Fig 11 on the front of the pulley for the serpentine drive belt tensioner 10 Using the adjustment bolt Fig 11 remove the tension from the drive belt for the power steering pump 11 Remove the drive belt from the power steering pump pulley NOTE Access for the power steering pump mount ing bolts is through the holes in the face of the power s...

Page 1169: ...n an attempt to install the pulley This will damage the internal components of the power steering pump 1 Place the power steering pump pulley on the end of the power steering pump shaft Make sure the pulley is installed squarely on the end of the shaft CAUTION When installing the pulley on the power steering pump Spacer Special Tool 6936 MUST be used The spacer provides for the correct pulley loca...

Page 1170: ...uid pressure hose tube nut to a torque of 47 N m 35 ft lbs 7 Install the power steering fluid return hose on the power steering fluid reservoir When installing the hose clamp on the power steering fluid return hose be sure the clamp is installed past the upset bead on the nipple of the power steer ing fluid reservoir 8 Connect the battery ground cable onto the ground stud located on the strut towe...

Page 1171: ...for the power steering system fluid Fig 18 The power steering fluid cooler is located at the front of the vehicle It is mounted to the radiator lower support just forward of the air conditioning con denser and just rearward of the front fascia Fig 18 The cooler is positioned so it is in the air flow through the front fascia of the vehicle OPERATION The purpose of the power steering fluid cooler is...

Page 1172: ...per hose Fig 20 from the power steering fluid cooler 6 Remove the 6 clips Fig 21 mounting the air dam to the radiator lower support 7 Remove the 2 nuts Fig 22 attaching the power steering fluid cooler to the radiator lower crossmember 8 Remove the power steering fluid cooler from the radiator lower crossmember INSTALLATION 1 Install the power steering fluid cooler on the radiator lower crossmember...

Page 1173: ...se 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 REMOVAL PRESSURE AND RETURN HOSES 1 Remove the battery ground cable from the ground stud on the shock tower and isolate the ground cable by installing the cable isolator on the ground stud Fig 23 2 Position the front...

Page 1174: ...ting Fig 28 If 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 29 Separate the intermediate steering shaft from the steering col umn coupler Fig 26 Reinforcement Attachment To Vehicle 1 RIGHT STRUT TO...

Page 1175: ...vacuum booster Carefully position the master cylinder in an upright position on the left side valve cover of the engine 16 Remove the vacuum supply hose to the vac uum booster at the check valve in the vacuum booster Position the vacuum hose out of the way 17 Remove the power steering fluid pressure hose and return hose from the steering gear Fig 33 Fig 33 Power Steering Hose Connections At Steeri...

Page 1176: ...eturn hose from the power steering fluid cooler Fig 37 Let the remaining power steering fluid drain out of the return hose and the power steering fluid cooler Fig 34 Steering Gear Attachment To Crossmember Left Side 1 MOUNTING BOLTS 2 CORSSMEMBER 3 STEERING GEAR Fig 35 Steering Gear Attachment To Crossmember Right Side 1 STEERING GEAR 2 CROSSMEMBER 3 MOUNTING BRACKET 4 MOUNTING BOLTS Fig 36 Power ...

Page 1177: ...g holes with its mounting holes in crossmem ber 8 Loosely install the bolts mounting the left side of the steering gear to the crossmember Fig 34 CAUTION Tightening the steering gear to cross member mounting bolts to the proper torque is very important 9 Install the bolts mounting the right side mounting bracket for the steering gear to the cross member Fig 35 Tighten the mounting bolts to a torqu...

Page 1178: ...ng the wiper module to the reinforcement 18 Install the in line resonator and inlet hose on the throttle body and air let hose coming from the lid of the air cleaner housing Fig 27 19 Install the covers over the wiper module and the cowl Fig 25 Install and securely tighten the attaching screws 20 Install the wiper arms on the pivots Fig 24 Install and securely tighten the wiper arm to pivot attach...

Page 1179: ...ible out of the reservoir Fig 44 2 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 3 Remove the power steering return hose from the side of the power steering fluid reservoir Remove the power steering fluid supply hose going to the power steering pump from the bottom of the power steering fluid reservoir Let power steering fluid drain from hoses and reservoir 4 Lower th...

Page 1180: ...power steering fluid reservoir into the mounting bracket Be sure the retaining tab on the bracket is holding the reservoir in the bracket Fasten screw to 12 N m 105 in lbs 2 Raise vehicle 3 Install the power steering return hose onto the nipple on the side of the power steering fluid reser voir Install the power steering fluid supply hose going to the power steering pump on the bottom nip ple of t...

Page 1181: ...PERATION 74 DISASSEMBLY 74 ASSEMBLY ASSEMBLY BEARING ADJUSTMENT PROCEDURE 82 FLUID STANDARD PROCEDURE STANDARD PROCEDURE FLUID LEVEL AND CONDITION CHECK 96 STANDARD PROCEDURE FLUID FILTER SERVICE 97 STANDARD PROCEDURE DIFFERENTIAL SUMP DRAIN AND REFILL 98 GEAR SHIFT CABLE COLUMN REMOVAL 99 INSTALLATION 101 ADJUSTMENTS ADJUSTMENT 102 GEAR SHIFT CABLE FLOOR REMOVAL 103 INSTALLATION 104 ADJUSTMENTS A...

Page 1182: ...luid fluid passages hydraulic valves and various line pressure control components An input clutch assembly which houses the underdrive overdrive and reverse clutches is used It also utilizes separate holding clutches 2nd 4th gear and Low Reverse The primary mechanical components of the transaxle con sist of the following Three multiple disc input clutches Two multiple disc holding clutches Four hy...

Page 1183: ...EED SENSOR 14 INPUT SPEED SENSOR 3 TRANSFER GEAR 9 LOW REVERSE CLUTCH 15 CONVERTER CLUTCH 4 FRONT PLANET CARRIER 10 2 4 CLUTCH 16 OIL PUMP 5 REAR PLANET CARRIER 11 REVERSE CLUTCH 17 INPUT SHAFT 6 OUTPUT SHAFT 12 OVERDRIVE CLUTCH 18 TORQUE CONVERTER LH TRANSAXLE 21 3 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1184: ...00 1 Overdrive 0 69 1 Reverse 2 21 1 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING 42LE GENERAL DIAGNOSIS CAUTION Before attempting any repair on the 42LE Four Speed Automatic Transaxle always check for proper shift linkage adjustment Also check for diagnostic trouble codes with the DRB scan tool and the 42LE Transaxle Diagnostic Procedure Man ual 42LE automatic transaxle malfunctions may be caused ...

Page 1185: ...needed to maintain highway speeds the converter stator clutch may have seized Both of these stator defects require replacement of the torque converter and thorough transaxle cleaning Slipping clutches can be isolated by comparing the Elements in Use chart with clutch operation encountered on a road test This chart identifies which clutches are applied at each position of the selector lever A slipp...

Page 1186: ...ssure should read 110 to 145 psi TEST TWO A SELECTOR IN OD Fourth Gear NOTE This test checks the underdrive clutch hydraulic circuit as well as the shift schedule 1 Attach gauge to the underdrive clutch tap 2 Move selector lever to the OD position 3 Allow wheels to rotate freely and increase throttle opening to achieve an indicated speed of 40 mph 4 Underdrive clutch pressure should read below 5 p...

Page 1187: ... pressure is found in any one test the pump and pressure regulator are working properly 2 Low pressure in all positions indicates a defec tive pump a clogged filter or a stuck pressure regu lator valve 3 Clutch circuit leaks are indicated if pressures do not fall within the specified pressure range 4 If the overdrive clutch pressure is greater than 5 psi in Step 6 of Test Three a worn reaction sha...

Page 1188: ...xt apply air pressure to the underdrive clutch Fig 6 The input shaft should not rotate with hand torque Release the air pressure and confirm that the input shaft will rotate REVERSE CLUTCH Apply air pressure to the reverse clutch apply pas sage and watch for the push pull piston to move rear ward The piston should return to its starting position when the air pressure is removed 2 4 CLUTCH Apply ai...

Page 1189: ...can be distinguished from engine oil Some suspected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter housing or excess fluid spilled during factory fill or fill after repair Converter housing leaks have several potential sources Through careful observation a leak source can be identified before removing the transmission for repair...

Page 1190: ...MISSION STANDARD PROCE DURE The cooler bypass valve in the transaxle must be inspected and or replaced also The torque converter must also be replaced with an exchange unit This will ensure that metal particles or sludged oil are not later transferred back into the recondi tioned or replaced transaxle NOTE If the Torque Converter is being replaced it is necessary to restart the TCC Break In Strate...

Page 1191: ...e transaxle Secure the transaxle to the jack 29 Raise transaxle slightly to relieve the weight on the rear transaxle mount NOTE Bolts for the crossmember bridge are differ ent lengths side to side 30 Remove rear crossmember bridge bolts 31 Remove rear mount adapter plate mounting bolts 32 Remove the rear crossmember bridge mount and adapter plate as an assembly 33 Lower the rear of the transaxle t...

Page 1192: ...pan Fig 14 4 Remove transaxle oil filter Fig 15 Fig 12 Measure Input Shaft End Play Using Tool 8266 Typical 1 TOOL 8266 8 2 TOOL 8266 2 3 TOOL C 3339 Fig 13 Remove Input and Output Speed Sensors 1 OUTPUT SPEED SENSOR 2 INPUT SPEED SENSOR Fig 14 Remove Transaxle Oil Pan 1 TRANSAXLE OIL PAN Fig 15 Remove Transaxle Oil Filter 1 TRANSAXLE FILTER 2 FILTER RETAINING CLIPS 21 12 TRANSAXLE LH 42LE AUTOMAT...

Page 1193: ...umulator and spring Fig 18 Fig 20 8 Remove overdrive accumulator and springs Fig 19 Fig 20 Fig 16 Remove Valve Body Bolts 17 1 EXTENSION 2 SOCKET 3 VALVE BODY Fig 17 Remove Valve Body From Transaxle 1 VALVE BODY Fig 18 Remove Underdrive Accumulator and Springs 1 ACCUMULATOR PISTON UNDERDRIVE 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 19 Remove Overdrive Accumulator and Springs 1 OVERDRIVE ACCUMU...

Page 1194: ...ulator piston and springs Fig 23 Fig 24 Fig 20 Accumulator Location 1 OVERDRIVE ACCUMULATOR LOCATION 2 UNDERDRIVE ACCUMULATOR LOCATION 3 LOW REVERSE ACCUMULATOR Fig 21 Remove Low Reverse Accumulator 1 SNAP RING 2 LOW REVERSE ACCUMULATOR Fig 22 Remove Low Reverse Accumulator Plug 1 ADJUSTABLE PLIERS 2 PLUG Fig 23 Remove Low Reverse Accumulator Piston 1 SEAL RINGS 2 PISTON 3 PISTON 4 PETROLATUM 5 SU...

Page 1195: ...e Accumulator Components 1 ACCUMULATOR PISTON 2 SEAL RINGS 3 RETURN SPRINGS 4 NOTE NOTCH Fig 25 Remove Long Stub Shaft Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 LONG STUB SHAFT Fig 26 Remove Long Stub Shaft From Bellhousing 1 LONG STUB SHAFT 2 SPECIAL TOOL 8420A 3 SLIDE HAMMER C 3752 Fig 27 Remove Oil Pump Attaching Bolts 1 BELLHOUSING 2 OIL PUMP LH TRANSAXLE 21 15 42LE AUTOMATIC TRANSAXLE Contin...

Page 1196: ...e must be replaced if trans mission failure occurs 18 Remove cooler by pass valve Fig 31 Fig 28 Oil Pump Pullers 1 OIL PUMP 2 PULLERS Fig 29 Remove Oil Pump 1 PUSH IN ON INPUT SHAFT WHILE REMOVING PUMP Fig 30 Remove Oil Pump Gasket 1 BELL HOUSING 2 OIL PUMP GASKET Fig 31 Remove By Pass Valve 1 BYPASS VALVE 21 16 TRANSAXLE LH 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1197: ...move No 1 Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT Fig 33 Remove Input Clutch Assembly 1 INPUT CLUTCH ASSEMBLY Fig 34 Remove 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETROLATUM FOR RETENTION Fig 35 Remove Front Sun Gear Assembly 1 FRONT SUN GEAR ASSEMBLY 2 4 THRUST WASHER FOUR TABS LH TRANSAXLE 21 17 42LE AUTOMATIC TRANSAXLE Continue...

Page 1198: ...trola tum can be used to hold the bearing to the rear sun gear 25 Install and load Tool 5058 to remove 2 4 clutch retainer snap ring Fig 39 Fig 36 Remove Front Carrier Rear Annulus 1 6 NEEDLE BEARING 2 FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PULL OR PUSH TO REMOVE OR INSTALL Fig 37 Remove Rear Sun Gear 1 7 NEEDLE BEARING 2 REAR SUN GEAR Fig 38 Number 7 Bearing 1 7 BEARING 2 REAR SUN GEAR...

Page 1199: ...g 43 Fig 40 Remove 2 4 Clutch Retainer 1 2 4 CLUTCH RETAINER Fig 41 2 4 Clutch Retainer 1 24 CLUTCH RETAINER 2 24 CLUTCH RETURN SPRING Fig 42 Remove 2 4 Clutch Return Spring 1 24 CLUTCH RETURN SPRING Fig 43 Remove 2 4 Clutch Pack 1 CLUTCH PLATE 4 2 CLUTCH DISC 4 LH TRANSAXLE 21 19 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1200: ... REVERSE CLUTCH REACTION PLATE 2 LONG TAB 3 SCREWDRIVER 4 LOW REVERSE TAPERED SNAP RING TAPERED SIDE UP 5 OIL PAN FACE Fig 45 Remove Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP Fig 46 Remove One Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 47 Remove Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE 2...

Page 1201: ... the chain snubber and chain oiler when reassembling 37 Remove chain snubber Fig 51 Fig 48 Remove Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 49 Remove Chain Cover 1 TRANSAXLE CASE 2 CHAIN COVER Fig 50 Remove Chain Oiler 1 CHAIN SNUBBER 2 CHAIN OILER Fig 51 Remove Chain Snubber 1 CHAIN SNUBBER LH TRANSAXLE 21 21 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1202: ...moval difficult 39 Install Tool 6550 and apply a light amount of pressure to facilitate removal Fig 54 40 Remove transfer chain and sprockets as an assembly Fig 55 Fig 52 Remove Output Shaft Sprocket Snap Ring and Wave Washer 1 WAVE WASHER 2 SNAP RING Fig 53 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 54 Install ...

Page 1203: ...he shaft nuts as shown in Fig 58 Fig 59 Do not grind all the way through the nut and into the shaft There are two stakes on each nut Fig 56 Output Sprocket Spacer 1 OUTPUT SPROCKET SPACER 2 VENT BAFFLE 3 OUTPUT SHAFT Fig 57 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 58 Grinding Sta...

Page 1204: ... tool 6596 with a shop press to remove front output shaft bearing cup Fig 63 Fig 60 Opening Nut Stakes 1 CHISEL 2 NUT STAKE Fig 61 Remove Output Shaft Nut 1 SPECIAL TOOL 6497 2 SPECIAL TOOL 6498 3 BREAKER BAR Fig 62 Use Arbor Press to Remove Output Shaft from Case 1 OUTPUT SHAFT 2 ARBOR PRESS 3 TRANSAXLE CASE Fig 63 Remove Front Bearing Cup 1 ARBOR PRESS 2 SPECIAL TOOL 6596 21 24 TRANSAXLE LH 42LE...

Page 1205: ... 1 SPECIAL TOOL 4171 AND 4171 2 2 SPECIAL TOOL 6597 Fig 65 Remove Rear Carrier Front Bearing Cone 1 SPECIAL TOOL 5048 1 2 SPECIAL TOOL 6545 3 REAR CARRIER 4 SPECIAL TOOL 5048 Fig 66 Low Reverse Spring Compressor Tool 1 TOOL 6057 2 TOOL 5059 3 TOOL 5058 3 Fig 67 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 LH ...

Page 1206: ... 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 SPECIAL TOOL 5059A Fig 69 Low Reverse Piston Belleville Spring 1 LOW REVERSE PISTON RETURN SPRING 2 PISTON Fig 70 Remove Parking Sprag Pivot Retaining Screw 1 TRANSFER SHAFT 2 PARKING SPRAG PIVOT RETAINING SCREW Fig 71 Anchor Shaft Removal 1 PIN PUNCH 2 GUIDE BRACKET ASSEMBLY 21 26 TRANSAXLE LH 42LE AUTOMATIC TRANSAXL...

Page 1207: ... Pivot Shaft 1 PIVOT PIN 2 GUIDE BRACKET ASSEMBLY Fig 73 Guide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE 4 SPACER 5 PAWL 6 STEPPED SPACER Fig 74 Remove Low Reverse Clutch Piston 1 LOW REVERSE CLUTCH PISTON 2 D RING SEAL 3 D RING SEAL Fig 75 Remove Piston Retainer to Case Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS LH TRANSAXLE 21 27 42...

Page 1208: ...cups use Special Tool 5050A Fig 78 2 Install low reverse piston retainer gasket Fig 79 3 Install low reverse piston retainer Fig 80 Fig 76 Remove Piston Retainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 77 Remove Piston Retainer Gasket 1 GASKET HOLES MUST LINE UP 2 LOW REVERSE CLUTCH PISTON RETAINER GASKET Fig 78 Bearing Cup Installation Special Tool 5050A Fig 79 Install Piston Retainer G...

Page 1209: ...ws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 82 Install Low Reverse Clutch Piston 1 LOW REVERSE CLUTCH PISTON 2 D RING SEAL 3 D RING SEAL Fig 83 Guide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE 4 SPACER 5 PAWL 6 STEPPED SPACER Fig 84 Guide Bracket 1 GUIDE BRACKET 2 ANTIRATCHET SPRING MUST BE ASSEMBLED AS SHOWN 3 PAWL LH TRANSAXLE 21 29 4...

Page 1210: ...itate snap ring installation Fig 88 Low Reverse Spring Compressor Tool 1 TOOL 6057 2 TOOL 5059 3 TOOL 5058 3 Fig 89 Compressor Tool Installed 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 5058A 3 4 TOOL 5059A 5 SPECIAL TOOL 6057 Fig 85 Install Guide Bracket Pivot Shaft 1 PIVOT PIN 2 GUIDE BRACKET ASSEMBLY Fig 86 Install Parking Sprag Pivot Retaining Screw 1 TRANSFER SHAFT ...

Page 1211: ...crews should be below the plate surface but do not snug screws c Turn case over on arbor press so that the plate is resting on the press base CAUTION The output shaft will extend through the hole of tool 6618A Ensure your press table has clear ance for the output shaft Fig 92 Bearing Installation 1 SPECIAL TOOL 6618 A 2 REAR OUTPUT SHAFT BEARING Fig 93 Special Tool Installed 1 SPECIAL TOOL 6618 A ...

Page 1212: ... the removed stake weakens the nut flange Using special tools 6497 and 6498 install new output shaft nut Do not reuse old output shaft nut Tighten new output shaft nut to 271 N m 200 ft lbs g Check the turning torque of the output shaft Fig 96 The shaft should have 1 to 8 in lbs of turning torque If the turning torque is higher than 8 in lbs install a thicker shim If turning torque is less than 1 ...

Page 1213: ... Install main sump baffle to transaxle case Fig 100 and torque screw to 5 N m 45 in lbs Fig 97 Staking Output Shaft Nut 1 ARBOR PRESS 2 STAKING TOOL 3 NEW NUT Fig 98 Properly Staked Nut 1 BOTTOMED IN SLOT 2 CORRECTLY STAKED NUT Fig 99 Properly Applied Sealant 1 SEALANT 2 BACK SIDE OF VENT BAFFLE Fig 100 Main Sump Vent Baffle Location 1 OUTPUT SHAFT NUT 2 MAIN SUMP VENT BAFFLE 3 TRANSFER SHAFT NUT ...

Page 1214: ...o trans fer shaft and output shaft Fig 102 17 Remove chain spreader Fig 103 18 Install transfer shaft sprocket snap rings and wave washers Fig 104 Fig 105 Fig 101 Output Sprocket Spacer 1 OUTPUT SPROCKET SPACER 2 VENT BAFFLE 3 OUTPUT SHAFT Fig 102 Install Chains and Both Sprockets as an Assembly 1 CHAINS Fig 103 Remove Chain Spreader 1 OUTPUT SPROCKET 2 SPECIAL TOOL 6550 3 TRANSFER SPROCKET Fig 10...

Page 1215: ...l chain cover Fig 108 Chain cover must be free of old sealant dirt and oil before applying new sealant Apply a 1 8 inch bead of Mopart ATF RTV MS GF41 to flange of cover Fig 105 Install Output Shaft Sprocket Snap Ring and Wave Washer 1 WAVE WASHER 2 SNAP RING Fig 106 Install Chain Snubber 1 CHAIN SNUBBER Fig 107 Install Chain Oiler 1 CHAIN SNUBBER 2 CHAIN OILER Fig 108 Install Chain Cover 1 TRANSA...

Page 1216: ...ate with flat side up Fig 112 Fig 109 Install Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 110 Install Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 111 Install One Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 112 Install Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP 21 36 TRA...

Page 1217: ...60 inch 29 Select the proper low reverse reaction plate to achieve specifications 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 6 92 mm 273 in Fig 113 Tapered Snap Ring Instructions Fig 114 Snap Ring Installed 1 SCREWDRIVER 2 TAPERED SNAP RING INSTALL AS SHOWN Fig 115 Check Low Re...

Page 1218: ...t align refer to Fig 117 31 Install 2 4 clutch belleville spring Fig 118 Fig 119 Fig 116 Install 2 4 Clutch Pack 1 CLUTCH PLATE 4 2 CLUTCH DISC 4 Fig 117 Stagger 2 4 Clutch Plate Pads 1 PILOT PADS 2 LUGS Fig 118 Install 2 4 Clutch Return Spring 1 24 CLUTCH RETURN SPRING Fig 119 Proper Orientation of 2 4 Clutch 1 NOTE POSITION 2 RETURN SPRING 3 2 4 CLUTCH RETAINER 21 38 TRANSAXLE LH 42LE AUTOMATIC ...

Page 1219: ...ance 35 Install the 7 needle bearing to the rear sun gear Fig 123 The number 7 needle bearing has three antireversal tabs and is common with the number 5 and number 2 position The orienta tion should allow the bearing to seat flat against the rear sun gear A small amount of petrolatum can be used to hold the bearing to the rear sun gear Fig 120 Install 2 4 Clutch Retainer 1 24 CLUTCH RETAINER 2 24...

Page 1220: ...g 127 using petro latum to hold into position Fig 124 Install Rear Sun Gear 1 7 NEEDLE BEARING 2 REAR SUN GEAR Fig 125 Install Front Carrier Rear Annulus Assy 1 6 NEEDLE BEARING 2 FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PULL OR PUSH TO REMOVE OR INSTALL Fig 126 Install Front Sun Gear Assembly 1 FRONT SUN GEAR ASSEMBLY 2 4 THRUST WASHER FOUR TABS Fig 127 No 4 Thrust Plate 1 OVERDRIVE SHAF...

Page 1221: ...No 4 Thrust Plate which is 0 071 to 0 074 thick This should provide an input shaft end play reading of 0 020 inch which is within specifications h See chart to select the proper No 4 thrust plate NO 4 THRUST PLATE CHART PART NUMBER THICKNESS 3836237AB 1 73mm 0 068 in 4431666AB 1 80mm 0 071 in 3836238AB 1 96mm 0 077 in 4431667AB 2 03mm 0 080 in 3836239AB 2 16mm 0 085 in 4431668AB 2 24mm 0 088 in 38...

Page 1222: ...urs NOTE To align oil pump gasket and case during installation use threaded dowels or phillips screw drivers 43 Install oil pump gasket Fig 134 Fig 131 Install Input Clutch Assembly 1 INPUT CLUTCH ASSEMBLY Fig 132 Install Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT Fig 133 Install By Pass Valve 1 BYPASS VALVE Fig 134 Install Oil Pump Gasket 1 BELL HOUSING 2 OIL PUMP GASKET...

Page 1223: ...s 47 Install low reverse accumulator as shown in Fig 138 Fig 135 Install Oil Pump Attaching Bolts 1 BELLHOUSING 2 OIL PUMP Fig 136 Install Long Stub Shaft To Bellhousing 1 LONG STUB SHAFT 2 SPECIAL TOOL 8420A 3 SLIDE HAMMER C 3752 Fig 137 Install Long Stub Shaft Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 LONG STUB SHAFT Fig 138 Install Low Reverse Accumulator 1 ACCUMULATOR PISTON 2 SEAL RINGS 3 RE...

Page 1224: ...ccumulator Plug Cover 1 ADJUSTABLE PLIERS 2 PLUG Fig 140 Install Low Reverse Accumulator Snap Ring 1 SNAP RING 2 PLUG Fig 141 Accumulator Locations 1 OVERDRIVE ACCUMULATOR LOCATION 2 UNDERDRIVE ACCUMULATOR LOCATION 3 LOW REVERSE ACCUMULATOR Fig 142 Install Underdrive Accumulator and Springs 1 ACCUMULATOR PISTON UNDERDRIVE 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING 21 44 TRANSAXLE LH 42LE AUTOMATIC T...

Page 1225: ...ansaxle measure the input shaft end play This will indicate when a 4 thrust plate change is required The number 4 thrust plate is located behind the overdrive clutch hub Attach a dial indicator to transaxle bell housing with its plunger seated against end of input shaft Fig 149 Move input shaft in and out to obtain end play Fig 143 Install Overdrive Accumulator and Springs 1 OVERDRIVE ACCUMULATOR ...

Page 1226: ...rein stalling transaxle If any cracks are found replace the drive plate Do not attempt to repair a cracked drive plate CAUTION The bolts for the torque converter are a new short headed design Bolts from previous year vehicles cannot be used 4 Always use new torque converter to drive plate bolts NOTE If the transaxle assembly PCM solenoid pack or clutch plates have been replaced perform the Quick L...

Page 1227: ...SCHEMATICS AND DIAGRAMS 42LE TRANSAXLE Park Neutral Speed Under 8 mph LH TRANSAXLE 21 47 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1228: ...Neutral Speed Over 8 mph 21 48 TRANSAXLE LH 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1229: ...Reverse LH TRANSAXLE 21 49 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1230: ...Reverse Block Shift to Reverse w Speed Over 8 mph 21 50 TRANSAXLE LH 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1231: ...First Gear LH TRANSAXLE 21 51 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1232: ...Second Gear 21 52 TRANSAXLE LH 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1233: ...Second Gear EMCC LH TRANSAXLE 21 53 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1234: ...Direct Gear 21 54 TRANSAXLE LH 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1235: ...Direct Gear EMCC LH TRANSAXLE 21 55 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1236: ...Direct Gear CC On 21 56 TRANSAXLE LH 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1237: ...Overdrive LH TRANSAXLE 21 57 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1238: ...Overdrive EMCC 21 58 TRANSAXLE LH 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1239: ...Overdrive CC On LH TRANSAXLE 21 59 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1240: ...tion Metric Standard Differential Assembly 0 8 3 4 N m 7 30 in lbs Output Shaft 0 22 0 903 N m 1 8 in lbs Transfer Shaft 0 22 0 903 N m 1 8 in lbs Overall Drag at Output Hub 1 12 6 77 N m 10 60 in lbs CLUTCH PACK Description Metric Standard Low Reverse Clutch Select Reaction Plate 0 89 1 04 mm 0 035 0 060 in Two Four Clutch No Select 0 76 2 64 mm 0 030 0 104 in Reverse Clutch Select Snap Ring 0 89...

Page 1241: ...mm 0 005 0 025 in OIL PUMP CLEARANCES DESCRIPTION METRIC STANDARD Outer Gear to Crescent 0 060 0 298 mm 0 0023 0 0117 in Inner Gear to Crescent 0 093 0 385 mm 0 0036 0 0151 in Outer Gear to Pocket 0 089 0 202 mm 0 0035 0 0079 in Outer Gear Side Clearance 0 020 0 046 mm 0 0008 0 0018 in Inner Gear Side Clearance 0 020 0 046 mm 0 0008 0 0018 in TRANSFER SYSTEM Description Metric Standard Sprocket He...

Page 1242: ...Bolt Oil Pan to Case 23 17 Bolt Oil Pump to Case 28 250 Bolt Park Sprag Retainer 5 45 Bolt Reaction Shaft Support Halves 28 250 Bolt Snubber 5 45 Bolt Solenoid Pressure Switch Assy to Valve Body 6 53 Bolt Valve Body to Case 12 105 Bolt Valve Body to Transfer Plate 5 45 Connector Solenoid Pressure Switch Assembly 6 53 Fitting Cooler Line 18 155 Nut Output Shaft 271 200 Nut Transfer Shaft Stake 271 ...

Page 1243: ...ller 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 LH TRANSAXLE 21 63 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1244: ...sion 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 21 64 TRANSAXLE LH 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1245: ...Compressor 5059 A Installer 5067 Installer 6052 Disk 6057 Tip 6268 Remover Installer 6301 Remover Installer 6302 Remover 6310 Installer 6494 LH TRANSAXLE 21 65 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1246: ...mover 6495 Wrench 6497 Wrench 6498 Remover 6502B Wrench 6503 Installer 6522 Puller Jaws 6545 Turning Fork 6548 Pinion Gauge Tool Set 6549 Remover 6550 21 66 TRANSAXLE LH 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1247: ...ler 6558 Installer 6560 Seal Installer 6567A Remover 6577 Staking Tool 6589 Seal Protector 6591 Seal Protector 6592 Fixture 6595 Remover 6596 Remover 6597 LH TRANSAXLE 21 67 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1248: ...Plate Set 6599 Support Plate 6618A Staking Tool 6639 Cooler Flusher 6906 End Play Set 8266 Pressure Fixture 8391 Remover 8420A 21 68 TRANSAXLE LH 42LE AUTOMATIC TRANSAXLE Continued ...

Page 1249: ...ver and retaining screws Fig 152 OPERATION The function of an accumulator is to cushion the application of a frictional clutch element When pres surized fluid is applied to a clutch circuit the appli cation force is dampened by fluid collecting in the respective accumulator chamber against the piston and spring s The intended result is a smooth firm clutch application Fig 150 Accumulator Assembly ...

Page 1250: ...resumes the OD shift schedule DEACTIVATION The autostick feature will be deactivated if one of the following conditions occur DTC P0706 Check Shifter Signal usually accompanied by all PRNDL lights turning on in Park and Neutral This will result in a DTC P0706 if three such errors are detected after any one key on DTC P0951 Autostick Input Circuit DTC P1797 Manual Shift Overheat Transmis sion oil t...

Page 1251: ...ting or heat distress If distress is seen on either the cup or bearing roll ers both cup and cone must be replaced NOTE Bearing end play and drag torque specifica tions must be maintained to avoid premature bear ing failures Used original bearing may lose up to 50 percent of the original drag torque after break in NOTE All bearing adjustments must be made with no other component interference or ge...

Page 1252: ...Fig 153 Master Shim Chart 21 72 TRANSAXLE LH BEARINGS Continued ...

Page 1253: ...nderdrive hub drives the rear sun gear OVERDRIVE CLUTCH The overdrive clutch is hydraulically applied in third direct and overdrive gears by pressurized fluid against the overdrive reverse piston When the over drive clutch is applied the overdrive hub drives the front planet carrier REVERSE CLUTCH The reverse clutch is hydraulically applied in reverse gear only by pressurized fluid against the ove...

Page 1254: ...r ing DISASSEMBLY The valve body and solenoid wiring connector must be removed from the transaxle in order to service the transaxle differential The transfer shaft cannot be removed with the valve body in place Remove the valve body assembly from the transaxle Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 42LE VALVE BODY REMOVAL 1 Remove transfer chain cover Fig 156 2 Remove chain oiler Fig 157 3 R...

Page 1255: ...pand to facilitate sprocket and chain removal Fig 161 7 Remove chains and sprockets as an assembly Fig 162 CAUTION To ensure proper gear ratio verify that the correct chain and sprocket ratio is selected CAUTION When reinstalling drive chains the blue link must face outward Fig 159 Remove Output Shaft Sprocket Snap Ring and Wave Washer 1 WAVE WASHER 2 SNAP RING Fig 160 Remove Transfer Shaft Sprock...

Page 1256: ...ial adjuster lock Fig 165 11 Remove differential outer adjuster lock Fig 166 Fig 163 Remove Long Stub Shaft Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 LONG STUB SHAFT Fig 164 Remove Long Stub Shaft 1 LONG STUB SHAFT 2 SPECIAL TOOL 8420A 3 SLIDE HAMMER C 3752 Fig 165 Remove Inner Differential Adjuster Lock 1 INNER DIFFERENTIAL ADJUSTER LOCK 2 INNER DIFFERENTIAL ADJUSTER Fig 166 Remove Outer Adjuste...

Page 1257: ...9 2 Using a plastic or soft tipped hammer tap ring gear off of carrier Fig 170 Fig 167 Loosen Outer Adjuster 1 OUTER ADJUSTER 2 SPECIAL TOOL 6503 Fig 168 Remove Differential Side Cover Carrier and Ring Gear Assembly 1 RING GEAR 2 TRANSAXLE CASE 3 SIDE COVER Fig 169 Remove Ring Gear Bolts 1 RING GEAR BOLTS 2 RING GEAR Fig 170 Tap Off Ring Gear 1 DIFFERENTIAL CARRIER 2 RING GEAR 3 PLASTIC MALLET LH ...

Page 1258: ...74 Fig 171 Pry Differential Carrier Apart 1 DIFFERENTIAL CARRIER 2 PRY TOOL 3 PRY TOOL Fig 172 Remove C Clip 1 SIDE GEAR 2 STUB SHAFT 3 C CLIP Fig 173 Remove Pinion Shaft Roll Pin 1 HAMMER 2 PIN PUNCH 3 PINION SHAFT 4 DIFFERENTIAL CARRIER 5 DIFFERENTIAL BEARING Fig 174 Slide Out Differential Pinion Shaft and Remove Pinion Gears and Side Gears 1 DIFFERENTIAL CARRIER 2 PINION SHAFT 3 SIDE GEARS 21 7...

Page 1259: ...ind the stakes in the shoulder of the shaft nut as shown in Fig 178 and Fig 179 Do not grind through the transfer shaft nut into the shaft There are two stakes on the nut Fig 175 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 4996 Fig 176 Remove Inner Adjuster By Turning Clockwise 1 SPECIAL TOOL 6502 B 2 INNER DIFFERE...

Page 1260: ... cannot be removed from the case at this time 19 Install special tool 6577 to remove rear trans fer bearing cup Fig 182 Fig 179 Stake Grinding Pattern 1 TRANSFER SHAFT 2 TRANSFER SHAFT NUT Fig 180 Opening Nut Stakes 1 CHISEL 2 NUT STAKE Fig 181 Press Transfer Shaft Downward to Remove Rear Cone 1 TRANSFER SHAFT 2 ARBOR PRESS Fig 182 Transfer Bearing Cup Removal 1 SPECIAL TOOL 6577 21 80 TRANSAXLE L...

Page 1261: ...t 6310 9 Fig 185 Do not reuse old seals The seals will be pulled out the rear of the case 23 Remove the front transfer shaft bearing cup using special tool 6495 and handle C 4171 Fig 186 Use a press with special tools to remove cup Fig 183 Preload Shim Removal 1 TRANSFER SHAFT PRELOAD SHIM 2 TRANSFER SHAFT Fig 184 Remove Transfer Shaft Assembly From Case 1 TRANSFER SHAFT Fig 185 Transfer Shaft Sea...

Page 1262: ...earing cup CAUTION The bearing 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 189 Screw centering block into inner adjuster hole of case until it bottoms The peg...

Page 1263: ...s been removed 8 Install dial indicator into locating block Tool 6549 1 Then screw extension rod onto dial indicator Fig 194 Fig 190 Gauge Disc and Bearing 1 FRONT TRANSFER SHAFT BEARING 2 SPECIAL TOOL 6549 3 Fig 191 Installing Gauge Disc with 1 FRONT TRANSFER SHAFT BEARING 2 SPECIAL TOOL 6549 3 Fig 192 Disc Installation 1 SPECIAL TOOL 6494 2 Fig 193 Installing Centering Nut 1 CENTERING NUT 2 CENT...

Page 1264: ...back and forth Fig 198 on centering pin to obtain the shortest distance measurement This will be the lowest number reading on dial indicator Record the number obtained Now rotate the gauge disc clockwise 1 3 of a turn and recheck readings Record number obtained Rotate the gauge disc another 1 3 of a turn clockwise and take another reading Average the three readings Record this pinion depth measure...

Page 1265: ...sfer shaft pinion head and the front transfer shaft bear ing Refer to the following examples for further explanation 13 Example 1 in MM Measured pinion shim depth 0 789mm Adjustment number 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 s...

Page 1266: ...lure 20 Remove outer adjuster with special tool 6503 Fig 201 21 Remove old stub shaft seals Press inner adjuster seal out with special tool 6502B Press outer adjuster seal out with special tool 6558 22 Install new stub shaft seals in both adjusters using special tool 6558 Fig 202 NOTE To remove inner and outer adjuster races use Tool 6062 A To install inner and outer adjuster races use Tool 6522 a...

Page 1267: ...nd side gears and pinion shaft Fig 205 CAUTION Use a new roll pin upon reassembly 3 Install pinion shaft roll pin Fig 206 Fig 203 Inner Adjuster Installation 1 SPECIAL TOOL 6502 B 2 INNER DIFFERENTIAL ADJUSTER Fig 204 Carrier Bearing Installation 1 ARBOR PRESS 2 HANDLE C 4171 3 SPECIAL TOOL C 4340 Fig 205 Install Differential Pinion Shaft and Remove Pinion Gears and Side Gears 1 DIFFERENTIAL CARRI...

Page 1268: ...to 95 N m 70 ft lbs Fig 208 25 Install differential assembly into the transaxle case Fig 209 26 Install differential cover Fig 210 Do not apply silicone sealant at this time All bolts should be installed and tightened Fig 207 Install Side Gear Stub Shaft and C Clip 1 SIDE GEAR 2 STUB SHAFT 3 C CLIP Fig 208 Install Ring Gear Bolts 1 RING GEAR BOLTS 2 RING GEAR Fig 209 Differential Assembly Installa...

Page 1269: ...w many foot pounds were required on the outer adjuster to obtain the correct turning torque Fig 214 Record the foot pound reading The reading that you are recording will be used in Step 54 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 deter mined The tra...

Page 1270: ...FT LBS TORQUE WRENCH 2 SPECIAL TOOL 6548 3 IN LBS TORQUE WRENCH 4 SPECIAL TOOL 6503 Fig 215 Transfer Shaft Installation 1 TRANSFER SHAFT Fig 216 Transfer Shaft Support Fixture 1 SUPPORT FIXTURE 6595 21 90 TRANSAXLE LH FINAL DRIVE Continued ...

Page 1271: ...ammer 38 Install rear transfer shaft seal The seal must be installed so that the spring side of the seal faces the installation tool Fig 220 Use the same special tool 6567A to install the seal The installation tool will set the seal depth Use a press to install this seal Do not use a hammer Fig 217 Seal Protector Installation 1 SEAL PROTECTOR 2 TRANSFER SHAFT Fig 218 Correct Seal Orientation 1 SEA...

Page 1272: ...Trans fer Shaft Rear Shim Chart for available sizes 42 Install rear transfer shaft cone Press cone on transfer shaft using Tool 6560 43 Remove transfer shaft support fixture special tool 6595 CAUTION Always use a new transfer shaft nut Do not reuse old transfer shaft nut Fig 221 Rear Transfer Bearing Cup 1 REAR TRANSFER BEARING CUP 2 TRANSFER SHAFT Fig 222 Rear Transfer Shaft Cup Installation 1 AR...

Page 1273: ...ecial tool 6589 must be used when staking the transfer shaft nut Do not use a hammer and the special tool to stake nut If a hammer is used seal bearing and or tool damage may result Also the stake will not be seated against the shaft correctly This will allow the nut to loosen 46 After the correct turning torque is obtained use special tool 6589 to stake the new transfer shaft nut Fig 226 Fig 227 ...

Page 1274: ...klash should be 0 0069 to 0 0099 thousands of an inch To get the backlash close enough to measure perform the fol lowing steps Hold the transfer shaft with one hand and rock the ring gear back and forth Fig 230 You should feel some backlash between the gears If no backlash is felt use special tool 6502B to turn the inner adjuster so that it raises the differential assembly This will increase backl...

Page 1275: ...e recorded in Step 30 Again reseat bearings Repeat this sequence until correct adjuster torque is maintained 55 To check and or adjust backlash remove the inspection plug from the top of the differential Install dial indicator as shown in Fig 234 The tip of the dial indicator must be perpendicular against one of the ring gear teeth Hold transfer shaft with locking pliers Move ring gear back and fo...

Page 1276: ...SSION SUMP FLUID LEVEL CHECK The transmission sump has a dipstick to check oil similar to most automatic transmissions It is located on the left side of the engine Be sure to wipe all dirt from dipstick handle before removing The torque converter fills in both the P Park and N Neutral positions Place the selector lever in P Park to be sure that the fluid level check is accurate The engine should b...

Page 1277: ... odor that may change with age Conse quently odor and color cannot be used to indi cate the fluid condition or the need for a fluid change After the fluid has been checked seat the dipstick fully to seal out water and dirt DIFFERENTIAL SUMP The differential sump is checked separately from the transmission A fill plug located on the side of the transaxle must be removed to check fluid level The flu...

Page 1278: ...EDURE 9 To prevent dirt from entering transaxle make certain that dipstick is fully seated into the dipstick opening DIPSTICK TUBE FLUID SUCTION METHOD 1 When performing the fluid suction method make sure the transaxle is at full operating temper ature 2 To perform the dipstick tube fluid suction method use a suitable fluid suction device Vacula or equivalent 3 Insert the fluid suction line into t...

Page 1279: ...om the differential vent 3 Install differential fill plug Tighten fill plug to 47 N m 35 ft lbs GEAR SHIFT CABLE COLUMN REMOVAL 1 Place vehicle in park and turn ignition key to the LOCK position Fig 238 2 Remove under panel silencer duct assembly Fig 239 3 Remove column cover screws Fig 240 4 Tilt column down and remove upper half of col umn cover Fig 241 Fig 241 Upper Column Removal Installation ...

Page 1280: ...p 9 Raise hood From inside the engine compart ment remove the gear shift cable from the cable bracket Fig 245 Fig 242 Tilt Lever Screw Removal Install 1 STEERING WHEEL 2 TURN SIGNAL LEVER 3 TILT LEVER 4 SCREWDRIVER Fig 243 Lower Column Cover Removal Installation 1 LOWER COLUMN COVER Fig 244 Column Gear Shift Cable 1 CONDUIT BRACKET 2 RETAINER CLIP 3 GEARSHIFT CABLE 4 SHIFT PIN Fig 245 Throttle Gea...

Page 1281: ...saxle and tighten nut to 28 N m 250 in lbs 4 Rotate fill tube to original location Install and tighten fill tube bracket bolt 5 Install cable push pin into bracket as shown in Fig 246 6 Route transaxle shift cable through hole in dash panel Fig 247 Fig 248 7 Lubricate cable grommet with a synthetic lubricant or equivalent and secure to hole Verify that it is seated by pulling outward on cable 8 In...

Page 1282: ...he ignition If the key can be removed with the shifter in reverse When the key cannot be removed with the shifter in the park position 1 Remove upper steering column shroud 2 Rotate cable adjuster into unlock position Use a straight blade screwdriver to unlock adjuster Fig 250 3 Make sure that the transaxle shift lever at transaxle is in the Park position This is the most rearward position Verify ...

Page 1283: ...ble attach stud pin Fig 254 7 Remove cable from center console routing Leave flat on floor for ease of removal 8 Raise hood Remove gearshift cable from throt tle gearshift cable bracket Fig 255 Fig 255 Throttle Gearshift Cable Bracket 1 CABLE BRACKET 2 GEARSHIFT CABLE 3 THROTTLE CABLE Fig 252 Shift Handle Retaining Screw 1 GEARSHIFT KNOB 2 HEX WRENCH Fig 253 Shift Cable Adjust Lever Nut 1 CONSOLE ...

Page 1284: ...and tighten nut to 28 N m 250 in lbs 4 Rotate fill tube to original location Install and tighten fill tube bracket bolt 5 Install cable push pin into bracket as shown in Fig 255 6 Route transaxle shift cable through hole in dash panel Fig 256 Fig 258 7 Lubricate cable grommet with a synthetic lubricant or equivalent and secure to hole Verify that it is seated by gently pulling outward on cable 8 I...

Page 1285: ...le adjuster Fig 259 3 Make sure that the transaxle shift lever at transaxle is in the Park position This is the most rearward position Verify park sprag is fully engaged CAUTION Park sprag must be engaged when adjusting linkage Rock vehicle back and forth to ensure that park sprag is fully engaged 4 Place shifter in park position 5 Place ignition in lock with key removed 6 Tighten adjuster nut at ...

Page 1286: ...ly is held or grounded to the transaxle case INPUT CLUTCH ASSEMBLY DISASSEMBLY 1 Mount input clutch assembly to Input Clutch Pressure Fixture Tool 8391 2 Tap down reverse clutch reaction plate to release pressure from snap ring Fig 261 3 Remove reverse clutch snap ring Fig 262 4 Pry up and remove reverse clutch reaction plate Fig 263 Fig 264 Fig 261 Tapping Reaction Plate 1 4 THRUST PLATE SELECT 2...

Page 1287: ...e snap ring Fig 268 Fig 265 Reverse Clutch Pack 1 REVERSE CLUTCH PLATE 2 REVERSE CLUTCH DISC Fig 266 OD Reverse Pressure Plate Snap Ring 1 OD REVERSE PRESSURE PLATE 2 SCREWDRIVER 3 OD REVERSE PRESSURE PLATE SNAP RING Fig 267 OD Reverse Reaction Plate 1 OD REVERSE PRESSURE PLATE STEP SIDE DOWN 2 STEP SIDE DOWN Fig 268 Waved Snap Ring 1 OVERDRIVE SHAFT ASSEMBLY 2 OD REVERSE CLUTCH WAVED SNAP RING 3 ...

Page 1288: ...VERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK 2 3 THRUST PLATE 3 3 THRUST WASHER 4 UNDERDRIVE SHAFT ASSEMBLY Fig 270 Overdrive Clutch Pack 1 OVERDRIVE CLUTCH PLATE 2 OVERDRIVE SHAFT ASSEMBLY 3 OVERDRIVE CLUTCH DISC Fig 271 3 and 4 Thrust Washers 1 3 THRUST PLATE 3 TABS 2 OD SHAFT ASSEMBLY 3 4 THRUST PLATE 3 SLOTS Fig 272 Underdrive Shaft Assembly 1 3 THRUST WASHER 5 TABS 2 UNDERDRIVE SHAFT ASSEMBLY 2...

Page 1289: ...de up 14 Remove the OD UD reaction plate Fig 275 15 Remove the first UD clutch disc Fig 276 16 Remove the UD clutch flat snap ring Fig 277 Fig 273 No 2 Needle Bearing 1 2 NEEDLE BEARING NOTE 3 TABS Fig 274 Tapered Snap Ring 1 OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 SCREWDRIVER DO NOT SCRATCH REACTION PLATE Fig 275 OD UD Reaction Plate 1 OD UD CLUTCH REACTION PLATE STEP SID...

Page 1290: ...279 Fig 280 19 Remove spring retainer Fig 280 20 Remove UD clutch piston Fig 281 Fig 278 Underdrive Clutch Pack 1 CLUTCH PLATE 2 ONE UD CLUTCH DISC 3 CLUTCH DISC Fig 279 UD Spring Retainer Snap Ring 1 SNAP RING PLIERS 2 ARBOR PRESS RAM 3 SNAP RING 4 SPECIAL TOOL 5059A Fig 280 UD Return Spring and Retainer 1 UNDERDRIVE SPRING RETAINER 2 SNAP RING 3 SEAL 4 PISTON RETURN SPRING Fig 281 Underdrive Clu...

Page 1291: ... Hub Tapered Snap Ring 1 INPUT SHAFT 2 INPUT HUB SNAP RING TAPERED SIDE UP WITH TABS IN CAVITY 3 SNAP RING PLIERS Fig 283 Tap on Input Hub 1 INPUT SHAFT AND HUB ASSEMBLY 2 PLASTIC HAMMER Fig 284 Input Hub Removed 1 INPUT SHAFT AND HUB ASSEMBLY 2 INPUT CLUTCH RETAINER 3 O RING 4 SEAL 5 OVERDRIVE REVERSE PISTON Fig 285 Pull Retainer from Piston 1 OVERDRIVE REVERSE PISTON 2 INPUT CLUTCH RETAINER LH T...

Page 1292: ... 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 287 Return Spring and Snap Ring 1 OD REVERSE PISTON 2 RETURN SPRING 3 SNAP RING 4 O RING Fig 288 Remove Input Shaft Snap Ring 1 INPUT SHAFT 2 SHARP POINTED TOOL 3 SNAP RING 4 O RINGS 5 SEALS Fig 289 Remove Input Shaft 1 ARBOR PRESS...

Page 1293: ...1 INPUT SHAFT 2 ARBOR PRESS RAM 3 INPUT CLUTCH HUB Fig 291 Install Input Shaft Snap Ring 1 INPUT SHAFT 2 SCREWDRIVER DO NOT SCRATCH BEARING SURFACE 3 SNAP RING 4 O RINGS 5 SEALS Fig 292 Return Spring and Snap Ring 1 OD REVERSE PISTON 2 RETURN SPRING 3 SNAP RING 4 O RING Fig 293 Install Snap Ring 1 ARBOR PRESS RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNA...

Page 1294: ...lutch piston Fig 297 Fig 294 Install OD Reverse Piston 1 PUSH DOWN TO INSTALL OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 295 Install Input Shaft Hub Assembly 1 PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY ROTATE TO ALIGN SPLINES 2 OD REV PISTON Fig 296 Install 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 297...

Page 1295: ... top disc out until after the snap ring is installed Fig 298 Seal Compressor Special Tool 5067 1 PISTON RETURN SPRING 2 SPECIAL TOOL 5067 3 INPUT CLUTCH RETAINER Fig 299 UD Return Spring and Retainer 1 UNDERDRIVE SPRING RETAINER 2 SNAP RING 3 SEAL 4 PISTON RETURN SPRING Fig 300 Install UD Spring Retainer and Snap Ring 1 ARBOR PRESS RAM 2 SNAP RING PLIERS 3 SNAP RING 4 OD REVERSE PISTON 5 TOOL 5067...

Page 1296: ...ction plate tapered step side up Fig 302 UD Clutch Flat Snap Ring 1 UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 SCREWDRIVER Fig 303 Install Last UD Clutch Disc 1 ONE UNDERDRIVE CLUTCH DISC Fig 304 OD UD Reaction Plate 1 OD UD CLUTCH REACTION PLATE STEP SIDE DOWN Fig 305 Tapered Snap Ring 1 OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 SCREWDRIVER DO NOT SCRATCH REACTION PL...

Page 1297: ...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 19 Take average of four measurements and com pare with UD clutch pack clearance specification Underdrive clutch pack clearance must be 0 94 1 50 mm 0 037 0 059 in 20 If n...

Page 1298: ...ch pack Fig 312 Fig 309 Press Down on UD Clutch Pack and Zero Dial Indicator 1 DIAL INDICATOR 2 UNDERDRIVE CLUTCH Fig 310 Install OD Clutch Pack 1 OVERDRIVE CLUTCH PACK Fig 311 Install Waved Snap Ring 1 OVERDRIVE REACTION PLATE WAVED SNAP RING 2 SCREWDRIVER Fig 312 OD Reverse Reaction Plate 1 OVERDRIVE REVERSE PRESSURE PLATE 2 STEP SIDE DOWN 21 118 TRANSAXLE LH INPUT CLUTCH ASSEMBLY Continued ...

Page 1299: ... 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 315 29 Install reverse clutch reaction plate with the flat side down towards reverse clutch Fig 316 Fig 313 Install Flat Snap Ring 1 ARBOR PRESS RAM 2 TOOL 5059A 3 FLAT SNAP RING Fig 314 Measure ...

Page 1300: ...nce 0 005 0 010 as clutch pack relaxes 34 Apply 30 psi 206 kPa air pressure to the reverse clutch hose on Tool 8391 Measure and record reverse clutch pack measurement in four 4 places 90 apart Fig 317 Install Reverse Clutch Snap Ring 1 REVERSE CLUTCH SNAP RING SELECT 2 SCREWDRIVER 3 REVERSE CLUTCH REACTION PLATE Fig 318 Pry Up Reaction Plate 1 SCREWDRIVER 2 SNAP RING 3 SCREWDRIVER 4 MUST RAISE REV...

Page 1301: ...erdrive shaft assembly Be sure five tabs are seated properly Fig 323 40 Install the 3 thrust plate to the bottom of the overdrive shaft assembly Retain with petrolatum or transmission assembly gel Fig 324 Fig 321 Install No 2 Needle Bearing 1 2 NEEDLE BEARING NOTE 3 SMALL TABS 2 TABS UP Fig 322 Install Underdrive Shaft Assembly 1 UNDERDRIVE SHAFT ASSEMBLY 2 2 NEEDLE BEARING Fig 323 Install No 3 Th...

Page 1302: ... rotate the clearance between the gear teeth increases in the crescent area and creates a suction at the inlet side of the pump This suction draws fluid through the pump inlet from the oil pan As the clearance between the gear teeth in the crescent area decreases it forces pressurized fluid into the pump outlet and to the valve body Fig 325 Install Overdrive Shaft Assembly 1 OVERDRIVE SHAFT ASSEMB...

Page 1303: ...n an appropriate piece of Plastigage across both pump gears 9 Align the Plastigage to a flat area on the reac tion shaft support housing 10 Install the reaction shaft to the pump hous ing Tighten the bolts to 27 N m 20 ft lbs 11 Remove bolts and carefully separate the hous ings Measure the Plastigage following the instruc tions supplied 12 Clearance between outer gear side and the reaction shaft s...

Page 1304: ... seal This procedure will allow the replacement of the seals without having to set back lash and measure differential bearing turning torque CAUTION The differential bearings and the differ ential adjusters must be reused in order to use this procedure If any of the items listed above require replacement this procedure cannot be used Refer to Differential Recondition section of this manual 1 Remov...

Page 1305: ...stub shaft into shop press Position Special Tool 6558 above bear ing Press bearing onto shaft Fig 336 3 Index the inner differential adjuster with a cross hair as shown in Fig 337 Fig 334 Stub Shaft Bearing C clip 1 C CLIP 2 LONG STUB SHAFT 3 STUB SHAFT BEARING Fig 335 Remove Stub Shaft Bearing C clip 1 BEARING SPLITTER 2 STUB SHAFT BEARING Fig 336 Install Bearing Onto Shaft 1 TOOL 6558 2 STUB SHA...

Page 1306: ...ier three or four turns in both directions Finish tightening the adjuster 1 4 turn to its index mark original location 5 Reinstall long stub shaft fill differential with fluid and reinstall transaxle 6 After installing transaxle check transmission side fluid level SEAL STUB SHAFT SHORT REMOVAL The following procedure can be used to replace the short stub shaft seal without having to remove the tra...

Page 1307: ...est and recheck for leaks as required SEAL TRANSFER SHAFT REMOVAL If it has been diagnosed that one or both of the transfer shaft seals are leaking the following proce dure can be used to replace failed seals This proce dure will allow the technician to replace the seals without having to set backlash and measure differen tial bearing turning torque CAUTION The transfer shaft rear shim bearing cup...

Page 1308: ...ft seals oil baffle rear cup rear shim rear cone and a new nut Refer to appropriate procedures within this section for detailed removal and installation procedures if required 2 Install a new o ring onto the inner adjuster 3 Lube inner adjuster threads and o ring with gear oil and reinstall to the cross haired index marks 4 Reinstall the inner adjuster locking bracket 5 Install the differential ca...

Page 1309: ...gine drive plate for cracks If any cracks are found replace the drive plate Do not attempt to repair a cracked drive plate Always use new torque converter to drive plate bolts 3 Apply a light film of transmission oil to the torque converter hub and oil seal lips Then install torque converter into transaxle Be sure that the hub lugs mesh with the front pump lugs when installing 4 Reinstall the tran...

Page 1310: ...erlock cable from the shifter housing Slide the cable out of the groove in the interlock lever Fig 352 Fig 349 Panel Removal Installation 1 SILENCER DUCT ASSEMBLY Fig 350 Tilt Lever Screw Removal Installation 1 STEERING WHEEL 2 TURN SIGNAL LEVER 3 TILT LEVER 4 SCREWDRIVER Fig 351 Lower Column Cover Removal Installation 1 LOWER COLUMN COVER Fig 352 Interlock Cable Removal Installation 1 LOCKING CLI...

Page 1311: ...ng column to the full UP posi tion 10 If the interlock cable is being replaced remove the lock pin Allow the cable to adjust itself to the correct position Tighten the locking clip Fig 352 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 locki...

Page 1312: ...Shifter CANNOT be shifted out of park 3 Turn key to the 9ON RUN9 position and depress the brake pedal 3 Shifter CAN be shifted out of park 4 Leave shifter in any gear and try to return key to the 9LOCK9 or 9ACC9 position 4 Key cannot be returned to the 9LOCK9 or 9ACC9 position 5 Return shifter to 9PARK9 and try to remove the key 5 Key can be removed after returning to 9LOCK9 position 6 With the ke...

Page 1313: ...shifter mechanism The column shift interlock system is only adjusted after installing a new cassette It can t be adjusted more than once If the system operates incorrectly install and adjust a new interlock cassette 1 Ensure the latch rotates freely on the shifter gate Fig 359 2 With the shifter in Park and the key removed install the cable over the hook on locking arm of the shifter mechanism 3 S...

Page 1314: ...damage the shrouds If a tool must be used use a soft tool such as a trim stick 4 Remove the steering column upper shroud from the steering column using the following procedure First on the right seam between the upper and lower shrouds push in on seam at the forward end When the upper shroud unsnaps pull the upper shroud upward away from the lower Repeat this procedure on the opposite side of the ...

Page 1315: ...e BTSI solenoid straight off the shift lever mounting stud INSTALLATION 1 Align the flat inside the brake transmission shift interlock BTSI solenoid Fig 367 with the flat on the shift lever mounting stud Fig 364 Lower Shroud Attaching Screws 1 LOWER SHROUD 2 MOUNTING SCREWS Fig 365 Solenoid Connector 1 BTSI SOLENOID 2 CONNECTOR Fig 366 Solenoid Retainer Clip 1 SOLENOID 2 MOUNTING STUD 3 RETAINER C...

Page 1316: ... lower shroud to the steering column 8 Install the tilt lever Fig 363 on the steering column 9 Install the upper shroud on the steering col umn by snapping it onto the lower shroud 10 Install the lower instrument panel cover 11 Install the two screws behind the fuse panel cover attaching the lower instrument panel cover to the instrument panel Fig 362 12 Install the fuse panel cover on the left en...

Page 1317: ...ition 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 ACTION EXPECTED RESPONSE 1 Turn key to the 9OFF9 position 1 Shifter CAN be shifted out of park 2 Turn key to the 9ON RUN9 position 2 Shifter CANNOT be shifted out of park 3 Tur...

Page 1318: ...and turn it to the ON position 4 With the brakes applied try moving the shifter out of the PARK position If the lever now moves freely in and out of PARK perform the Circuit Test below 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 an...

Page 1319: ...3 Insert the ignition key and turn it to the ON position 4 With the brakes applied try shifting the trans mission shift lever out of the PARK position If the lever now moves freely in and out of PARK perform the Circuit Test below 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 th...

Page 1320: ...NSTALLATION 1 Install shifter assembly Fig 378 2 Install five shifter cable bracket to floor pan nuts and tighten to 31 N m 23 ft lbs 3 Make sure shift lever and transaxle are in Park CAUTION Park sprag must be engaged when adjusting linkage Rock vehicle back and forth to ensure that park sprag is fully engaged 4 With the ignition in the lock position attach shift cable eyelet to shift pin Fig 376...

Page 1321: ...rough a single wire The PCM energizes or operates the solenoids individ ually by grounding the return wire of the solenoid needed When a solenoid is energized the solenoid valve shifts and a fluid passage is opened or closed vented or applied depending on its default operat ing state The result is an apply or release of a fric tional element The 2 4 and UD solenoids are normally applied which allo...

Page 1322: ...sn t close it is tested again If the switch fails to close the second time the appropriate Diagnostic Trouble Code DTC will set REMOVAL NOTE If the Solenoid Pressure Switch Assembly is being replaced the Quick Learn Procedure must be performed Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE STANDARD PROCEDURE 1 Raise vehicle on hoist 2 Remove valve body assembly from tra...

Page 1323: ...and sent to the PCM The PCM interprets this information as input shaft rpm The PCM compares the input speed signal with output speed signal to determine the following Transmission gear ratio Speed ratio error detection CVI calculation The PCM also compares the input speed signal and the engine speed signal to determine the following Torque converter clutch slippage Torque converter element speed r...

Page 1324: ...peed Sensor is a two wire magnetic pickup device that generates an AC voltage signal as rotation occurs It is threaded into the transaxle case Fig 387 sealed with an o ring Fig 388 and is considered a primary input to the Powertrain Control Module PCM Fig 385 Speed Sensor Connector Location 1 MANUAL SHIFT LEVER 2 OUTPUT SPEED SENSOR 3 LONG STUB SHAFT 4 INPUT SPEED SENSOR Fig 386 O Ring Location 1 ...

Page 1325: ...M The PCM in turn sends the vehicle speed message across the PCI bus to the Instrument Cluster to dis play vehicle speed to the driver REMOVAL 1 Disconnect the output speed sensor connector Fig 390 2 Unscrew and remove the output speed sensor 3 Inpsect the speed sensor o ring and replace if necessary Fig 391 INSTALLATION 1 Verify o ring is installed into position Fig 391 2 Install and tighten outp...

Page 1326: ...sts of a pis ton and a frictional disc that form a direct mechanical link between the impeller and turbine when slippage is inefficient or unnecessary The torque converter hub drives the transmission oil pump REMOVAL NOTE If torque conveter assembly is being replaced it is necessary to restart the TCC Break In Strategy Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE ST...

Page 1327: ...8 Install the transmission in the vehicle Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 42LE INSTALLATION 9 Fill the transmission with the recommended fluid 10 If torque conveter was replaced it is neces sary to reset the TCC Break In Strategy Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE TRANSFER SYSTEM INSPECTION The need to replace the transfer ...

Page 1328: ...cket is used to position the output sprocket in line with the transfer sprocket The sprocket must be within 0 0159 of each other In order to do this operation install original spacer over the output shaft If original spacer is not available use the thickest available shim as a start ing point Refer to Output Sprocket Spacer Chart for available sizes Then install the two sprockets with out the chai...

Page 1329: ...e sole noid pack when the transmission is in normal oper ating mode When the relay is off no power is supplied to the solenoid pack and the transmission is in limp in mode After a controller reset ignition key turned to the run position or after cranking engine the PCM energizes the relay Prior to this the PCM verifies that the contacts are open by check ing for no voltage at the switched battery ...

Page 1330: ...ated to gear position and three are recognized as between gear codes This results in six codes which should never occur These are called invalid codes An invalid code will result in a DTC and the PCM will then determine the shift lever position based on pressure switch data This allows reasonably normal transmission operation with a TRS failure TRS SWITCH STATES SLP T42 T41 T3 T1 P CL CL CL OP R C...

Page 1331: ...Install the TRS manual shaft retaining screw and torque to 5 N m 45 in lbs torque Fig 405 3 Install the manual shaft seal Fig 404 4 Install valve body to transaxle Refer to Valve Body Removal and Installation in this group VALVE BODY DESCRIPTION The valve body assembly Fig 406 consists of a cast aluminum valve body a separator plate and transfer plate The valve body contains valves and check balls...

Page 1332: ... 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 from the LR CC solenoid In one position it allows the low reverse clutch to be pressurized In the other it dire...

Page 1333: ...lected The low reverse switch valve alternates positions depending on from which direc tion fluid pressure is applied By design when the valve is shifted by fluid pressure from one channel the opposing channel is blocked The switch valve alienates the possibility of a sticking ball check thus providing consistent application of the low reverse clutch under these operating conditions REMOVAL NOTE I...

Page 1334: ...lve body assembly from transaxle Fig 412 Fig 415 CAUTION The overdrive and underdrive accumula tors and springs may fall out when removing the valve body Fig 413 Fig 414 Fig 415 Fig 410 Transaxle Oil Filter 1 TRANSAXLE FILTER 2 FILTER RETAINING CLIPS Fig 411 Valve Body Bolts 1 EXTENSION 2 SOCKET 3 VALVE BODY Fig 412 Valve Body From Transaxle 1 VALVE BODY Fig 413 Accumulator Assembly Typical 1 ACCU...

Page 1335: ...n Range Sensor TRS and manual shaft Fig 417 Fig 414 Overdrive Accumulator and Springs 1 OVERDRIVE ACCUMULATOR PISTON 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 415 Overdrive Underdrive and Low Reverse Accumulator Location 1 OVERDRIVE ACCUMULATOR LOCATION 2 UNDERDRIVE ACCUMULATOR LOCATION 3 LOW REVERSE ACCUMULATOR Fig 416 Manual Shaft Retaining Screw 1 SCREW 2 TRS Fig 417 Manual Shaft Rooster Com...

Page 1336: ... 420 7 Remove transfer separator plate from valve body Fig 421 Fig 418 Solenoid Retaining Screws 1 SOLENOID PRESSURE SWITCH ASSEMBLY 2 RETAINING SCREWS Fig 419 Remove Stiffener Plate 1 STIFFENER PLATE Fig 420 Remove Transfer Plate to Valve Body Screws 1 SCREW 24 2 TRANSFER PLATE Fig 421 Remove Transfer Plate to Valve Body 1 TRANSFER PLATE 2 VALVE BODY 21 156 TRANSAXLE LH VALVE BODY Continued ...

Page 1337: ... valve Fig 425 from transfer plate Fig 422 Remove Separator Plate to Transfer Plate Screws 1 SEPARATOR PLATE 2 SCREW 2 3 TRANSFER PLATE Fig 423 Remove Separator Plate to Transfer Plate 1 SEPARATOR PLATE 2 TRANSFER PLATE Fig 424 Remove Oil Screen to Transfer Plate 1 OIL SCREEN Fig 425 Remove Thermal Valve to Transfer Plate 1 THERMAL VALVE LH TRANSAXLE 21 157 VALVE BODY Continued ...

Page 1338: ...tor assembly as shown in Fig 427 Fig 426 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 5 BALL CHECK LOCATION 4 3 BALL CHECK LOCATION Fig 427 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 SPRINGS 5 SEALS 6 PISTON 21 158 TRANSAXLE LH VALVE BODY Continued ...

Page 1339: ...ng retainer Fig 429 16 Remove remaining retainers as shown in Fig 430 Fig 428 Remove Dual Retainer Plate using Tool 6301 1 TOOL 6301 2 RETAINER Fig 429 Remove Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER Fig 430 Valve Retainer Location 1 RETAINER 2 RETAINER LH TRANSAXLE 21 159 VALVE BODY Continued ...

Page 1340: ...TE If the valve body assembly is being recondi tioned or replaced it is necessary to perform the Quick Learn Procedure using the DRBIIIT Scan Tool Refer to 8 ELECTRICAL ELECTRONIC CON TROL MODULES POWERTRAIN CONTROL MODULE STANDARD PROCEDURE 1 Install valves and springs as shown in Fig 432 2 Install regulator valve spring retainer Fig 433 3 Install dual retainer plate using Tool 6301 Fig 434 Fig 4...

Page 1341: ...ONTROL VALVE 5 MANUAL VALVE 6 CONVERTER CLUTCH SWITCH VALVE 7 SOLENOID SWITCH VALVE 8 REGULATOR VALVE Fig 433 Install Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER Fig 434 Install Dual Retainer Plate using Tool 6301 1 TOOL 6301 2 RETAINER LH TRANSAXLE 21 161 VALVE BODY Continued ...

Page 1342: ...all check balls into position as shown in Fig 437 If necessary secure them with petrolatum or transmission assembly gel for assembly ease 7 Install thermal valve to the transfer plate Fig 438 8 Install oil screen to transfer plate Fig 439 Fig 435 Valve Retainer Location 1 RETAINER 2 RETAINER Fig 436 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 SPRINGS 5 SEALS 6 PISTON 2...

Page 1343: ... LOCATION 2 2 BALL CHECK LOCATION 3 5 BALL CHECK LOCATION 4 3 BALL CHECK LOCATION Fig 438 Install Thermal Valve to Transfer Plate 1 THERMAL VALVE Fig 439 Install Oil Screen to Transfer Plate 1 OIL SCREEN LH TRANSAXLE 21 163 VALVE BODY Continued ...

Page 1344: ...rews Fig 443 and torque to 5 N m 45 in lbs Fig 440 Install Separator Plate to Transfer Plate 1 SEPARATOR PLATE 2 TRANSFER PLATE Fig 441 Install Separator Plate to Transfer Plate Screws 1 SEPARATOR PLATE 2 SCREW 2 3 TRANSFER PLATE Fig 442 Install Transfer Plate to Valve Body 1 TRANSFER PLATE 2 VALVE BODY Fig 443 Install Transfer Plate to Valve Body Screws 1 SCREW 24 2 TRANSFER PLATE 21 164 TRANSAXL...

Page 1345: ...ll the TRS manual shaft retaining screw Fig 447 and torque to 5 N m 45 in lbs 17 Install manual shaft seal Fig 444 Install Stiffener Plate 1 STIFFENER PLATE Fig 445 Solenoid Retaining Screws 1 SOLENOID PRESSURE SWITCH ASSEMBLY 2 RETAINING SCREWS Fig 446 Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 447 Manual Shaft Retaining S...

Page 1346: ...ctor 6 Lower vehicle 7 Fill transaxle with ATF 4 Automatic Trans mission Fluid Type MS 9602 Verify proper fluid level Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 42LE FLUID STANDARD PROCE DURE NOTE If the valve body has been reconditioned or replaced it is necessary to perform the Quick Learn Procedure Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE STANDARD PROCEDURE F...

Page 1347: ...NG TIRE PRESSURE SENSOR 11 STANDARD PROCEDURE TIRE PRESSURE SENSOR RETRAIN 11 REMOVAL 12 INSTALLATION 13 TIRES DESCRIPTION DESCRIPTION TIRE 14 DESCRIPTION RADIAL PLY TIRES 15 DESCRIPTION REPLACEMENT TIRES 15 DESCRIPTION SPARE TIRE TEMPORARY 16 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING TIRE NOISE 16 DIAGNOSIS AND TESTING TIRE VEHICLE LEAD 16 DIAGNOSIS AND TESTING TIRE WEAR PATTERNS 16 DIAGNOSIS A...

Page 1348: ...d wheel assem blies For brake vibrations Refer to 5 BRAKES BASE HYDRAULIC MECHANICAL ROTORS DIAGNOSIS AND TESTING For powertrain vibrations Refer to 3 DIFFER ENTIAL DRIVELINE DIAGNOSIS AND TEST ING For tire and wheel assembly vibrations continue with this diagnosis and testing procedure TIRE AND WHEEL BALANCE 1 Balance the tire and wheel assemblies as nec essary following the wheel balancer manufa...

Page 1349: ...t exceeds limits the tire will need to be dismounted from the wheel to verify wheel vs tire contribution Refer to Wheel Runout below 3 Lateral Runout Lateral runout for the vehi cle system as well as the tire and wheel assembly should be less than 0 76 mm 0 030 inch The same procedure and theory described for radial runout can also be applied to identify and reduce lateral runout 4 Wheel Runout Th...

Page 1350: ...ig 7 Break down the tire and remount it 90 degrees on rim in that direction then re measure runout This will normally reduce the runout to an acceptable amount Fig 4 Checking Radial Runout Of Wheel 1 MOUNTING CONE 2 SPINDLE SHAFT 3 WING NUT 4 PLASTIC CUP 5 DIAL INDICATOR 6 WHEEL 7 DIAL INDICATOR Fig 5 Checking Lateral Runout Of Wheel 1 MOUNTING CONE 2 SPINDLE SHAFT 3 WING NUT 4 PLASTIC CUP 5 DIAL ...

Page 1351: ...N SPECIFICATION Total Radial Force Variation RFV Less Than 22 Lbs 2 Lbs Radial First Harmonic R1H Less Than 16 Lbs 2 Lbs Radial Second Harmonic R2H Less Than 12 Lbs 2 Lbs STANDARD PROCEDURE STANDARD PROCEDURE TIRE AND WHEEL BALANCE NOTE Balance equipment must be calibrated and maintained per equipment manufacturer s specifica tions Wheel balancing can be accomplished with either on vehicle or off ...

Page 1352: ...NTER LINE OF SPINDLE 5 TIRE OR WHEEL TRAMP OR WHEEL HOP 3 ADD BALANCE WEIGHTS HERE Fig 9 Dynamic Unbalance Balance 1 CENTER LINE OF SPINDLE 3 CORRECTIVE WEIGHT LOCATION 2 ADD BALANCE WEIGHTS HERE 4 HEAVY SPOT WHEEL SHIMMY AND VIBRATION 22 6 TIRES WHEELS LH TIRES WHEELS Continued ...

Page 1353: ...ROCEDURE NON DIRECTIONAL TREAD PATTERN TIRES Tires on the front and rear axles operate at differ ent loads and perform different functions For these reasons they wear at unequal rates and tend to develop irregular wear patterns These effects can be reduced by timely rotation of tires The benefits of rotation are especially worthwhile Rotation will increase tread life help to maintain mud snow and ...

Page 1354: ...aining tabs over the two remain ing wheel nuts removing the wheel cover from the vehicle 4 Remove the two remaining wheel mounting nuts from the hub s studs 5 Remove the wheel and tire from the hub DISASSEMBLY TIRE AND WHEEL ASSEMBLY WITH TPM Refer to 22 TIRES WHEELS TIRE PRESSURE MONITORING SENSOR REMOVAL ASSEMBLY TIRE AND WHEEL ASSEMBLY WITH TPM Refer to 22 TIRES WHEELS TIRE PRESSURE MONITORING ...

Page 1355: ...e notch in the wheel cover with the valve stem on the wheel b At the same time align the two holes in the wheel cover having the retaining tabs with the two installed wheel nuts Fig 15 c Press in on center of wheel cover until wheel cover retaining tabs push past and engage rear of previously installed wheel mounting nuts Fig 15 This will hold the wheel cover in place 4 Install and lightly tighten...

Page 1356: ...d a chime It will then go into the tire pressure display screen and flash the pressure value of the tire that is low or high This will be displayed for the rest of the ignition cycle or until either the C T MENU STEP or RESET button is pressed If a road tire is replaced by the spare the TPM system will detect the swap automatically after the ignition has been cycled and display 9SPARE SWAP DETECTE...

Page 1357: ...n original style factory wheels only CAUTION Do not reuse the original Sensor To Wheel Grommet when installing a pressure sensor Always use a new grommet and properly torque the sensor nut to specifications Refer to 22 TIRES WHEELS TIRE PRESSURE MONITORING SENSOR INSTALLATION DIAGNOSIS AND TESTING TIRE PRESSURE SENSOR NOTE Tire pressure may increase from 2 to 6 psi 14 to 41 kPa during normal drivi...

Page 1358: ...rn will chirp indicating training complete for that particular sensor Remove the mag net 7 Repeat step 6 on remaining sensors as indi cated by EVIC until all five TPM sensors positions are trained 8 Once EVIC displays 9TRAINING COMPLETE9 pressing either STEP C T RESET or MENU button will exit training routine REMOVAL 1 Remove tire and wheel assembly from vehicle Refer to 22 TIRES WHEELS REMOVAL CA...

Page 1359: ...sor valve stem approximately 210 from the head of the changer in a clockwise direction before rotat ing the wheel also in a clockwise direction to mount the tire Fig 20 Use this procedure on both the upper and lower tire beads b Rotating Tool Tire Changers Position the wheel on the changer so that the sensor valve stem is located approximately 210 clockwise from the installation end of the mountin...

Page 1360: ...e to irregular tread wear It is important to follow the tire rotation inter val shown in the section on Tire Rotation This will help to achieve a greater tread life potential TIRE IDENTIFICATION Tire type size load index and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire Refer to the Tire Identification chart to decipher the code For example purposes the...

Page 1361: ...e drive train fail ure This could also cause inaccurate wheel speed signals when the vehicle is equipped with Antilock Brakes The use of tires from different manufactures on the same vehicle is NOT recommended The proper tire pressure should be maintained on all four tires DESCRIPTION REPLACEMENT TIRES WARNING FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN S...

Page 1362: ...nusual tire noise can be associated with tire and wheel vibration or irregular tire wear For vibration Refer to 22 TIRES WHEELS DIAGNOSIS AND TESTING For irregular tire wear Refer to 22 TIRES WHEELS TIRES DIAGNOSIS AND TEST ING DIAGNOSIS AND TESTING TIRE VEHICLE LEAD Refer to 2 SUSPENSION WHEEL ALIGNMENT DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING TIRE WEAR PATTERNS Under inflation will cause wear...

Page 1363: ...ease from 2 to 6 pounds per square inch psi during operation Do not reduce this normal pressure buildup Improper inflation can cause Uneven wear patterns Reduced tread life Reduced fuel economy Unsatisfactory ride The vehicle to drift WARNING OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING THE TIRE CAN FAIL SUDDENLY RESULTING IN LOSS OF VEHICLE CONTROL Under inflation causes rapid shoulde...

Page 1364: ... with a soft bristle brush Steam cleaning may also be used to remove the coating CAUTION DO NOT use gasoline mineral oil oil based solvent or a wire brush for cleaning WHEELS DESCRIPTION Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity All models use steel or cast aluminum drop center wheels Every wheel has raised sections betwee...

Page 1365: ...inum 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 unless it is buffed off immedi ately after application oven cleaner a car wash that uses carbide tipped wheel clean ing brushes SPECIFICATIONS WHEEL SPECIFICATIONS DESCRIPTION SPECIFICATION Wheel Moun...

Page 1366: ...ge rear of previously installed wheel mounting nuts Fig 31 This will hold the wheel cover in place 2 Install and lightly tighten the three remain ing wheel mounting nuts securing the wheel cover in place Fig 29 3 Tighten all five wheel mounting nuts in the proper sequence Fig 32 Tighten wheel nuts to a torque of 135 N m 100 ft lbs Fig 29 Wheel Mounting Nuts Securing Wheel Cover 1 VALVE STEM 2 BOLT...

Page 1367: ...g assembly Fig 35 so the threads on stud are even with end of lug nut Install Remover Special Tool C 4150 on hub and bearing assembly flange and wheel stud Fig 35 5 Tighten down on special tool to push wheel stud out of the hub and bearing assembly When shoulder of wheel stud is past flange remove special tool from hub and bearing assembly Remove lug nut from stud and remove wheel stud from flange...

Page 1368: ...peat the tightening sequence to the full specified torque of 129 N m 95 ft lbs 6 Lower the vehicle to the ground WHEEL MOUNTING STUDS REAR REMOVAL CAUTION DO NOT hammer studs out of the hub flange If a stud is removed by hammering it out of the bearing flange damage to the hub and bearing assembly will occur leading to premature bearing failure 1 Remove the hub and bearing from the vehicle Refer t...

Page 1369: ... face down with stud pointing down into the well of the 21 mm socket The hydraulic press ram must line up with the stud Fig 38 3 Press the stud into the hub flange until it bot toms 4 Remove the hub and bearing assembly from the press 5 Install the hub and bearing on the vehicle Refer to 2 SUSPENSION REAR HUB BEARING INSTALLATION Fig 38 Wheel Stud Installation 1 HUB AND BEARING ASSEMBLY 2 PRESS RA...

Page 1370: ......

Page 1371: ...N RESULT DO NOT STAND UNDER A HOISTED VEHICLE THAT IS NOT PROPERLY SUPPORTED ON SAFETY STANDS PERSONAL INJURY CAN RESULT CAUTION When holes must be drilled or punched in an inner body panel verify depth of space to the outer body panel electrical wiring or other compo nents Damage to vehicle can result Do not weld exterior panels unless combustible material on the interior of vehicle is removed fr...

Page 1372: ...ne help do the water test Some water leaks must be tested for a considerable length of time to become apparent When a leak appears find the highest point of the water track or drop The highest point usually will show the point of entry After leak point has been found repair the leak and water test to verify that the leak has stopped Locating the entry point of water that is leaking into a cavity b...

Page 1373: ...stic identification and repair procedures Rigid Plastics Examples of rigid plastic use Fascias Hoods Doors and other Body Panels which include SMC ABS and Polycarbonates Semi Rigid Plastics Examples of semi rigid plastic use Interior Panels Under Hood Panels and other Body Trim Panels Flexible Plastics Examples of flexible plastic use Fascias Body Moldings and upper and lower Fascia Covers Repair ...

Page 1374: ...IC POLYESTER RYNITE TRIM PBT PPO PBT PPO ALLOY GERMAX CLADDINGS PBTP POLYBUTYLENE THEREPTHALATE PBT PBTP POCAN VALOX WHEEL COVERS FENDERS GRILLES PBTP EEBC POLYBUTYLENE THEREPTHALATE EEBC ALLOY BEXLOY 9M9 PBTP EEBC FASCIAS ROCKER PANEL MOLDINGS PC POLYCARBONATE LEXAN MERLON CALIBRE MAKROLON PC TAIL LIGHT LENSES IP TRIM VALANCE PANELS PC ABS PC ABS ALLOY GERMAX BAY BLENDS PULSE DOORS INSTRUMENT PAN...

Page 1375: ... DYLON PRAVEX INNER FENDER SPOILERS KICK PANELS PP EPDM PP EPDM ALLOY PP EPDM SPOILERS GRILLES PUR POLYURETHANE COLONELS PUR PU FASCIAS BUMPERS PUR PC PUR PC ALLOY TEXIN BUMPERS PVC POLYVINYL CHLORIDE APEX GEON VINYLITE BODY MOLDINGS WIRE INSULATION STEERING WHEELS RIM REACTION INJECTED MOLDED POLYURETHANE RIM BAYFLEX FRONT FASCIAS MODULAR WINDOWS RRIM REINFORCED REACTION INJECTED MOLDED PUR RRIM ...

Page 1376: ...ons of glass cloth saturated with structural adhesive Semi rigid or flexible repair materials should be used for semi rigid or flexible backing reinforcement Fig 2 and Fig 3 Open meshed fiberglass dry wall tape can be used to form a reinforcement The dry wall tape allows the resin to penetrate through and make a good bond between the panel and the adhesive Struc turally the more dry wall tape used...

Page 1377: ...b cracks leading away from a damaged area must be stopped or removed To stop a running crack in a panel drill a 6 mm 0 250 in hole at the end of the crack farthest away from the damage If spider web cracks can not be stopped the panel would require replacement The sur faces around the damaged area should be stripped of paint and freed from wax and oil Scuff surfaces around repair area with 360 gri...

Page 1378: ...0 in holes 13 mm 0 5 in in from edge of cutout hole Fig 7 6 Drill 4 mm 0 160 in holes 13 mm 0 5 in away from edge of patch across from holes drilled around cutout 7 Drill 3 mm 0 125 in holes in the support squares 13 mm 0 5 in from the edge in the center of one side 8 Scuff the backside of the body panel around the cutout hole with a scuff pad or sandpaper 9 Mix enough adhesive to cover one side o...

Page 1379: ...h grinding Use two to three layers of mesh and adhesive to create a stronger repair Fig 15 Fig 10 POSITION PATCH IN CUTOUT AND ALIGN 1 CUTOUT 2 SUPPORT SQUARES Fig 11 APPLY ADHESIVE TO SUPPORT SQUARES 1 APPLICATOR 2 SUPPORT SQUARES 3 ADHESIVE Fig 12 INSTALL SCREWS 1 PATCH 2 GAP Fig 13 GRIND SURFACE 1 PATCH 2 GAP 3 DISC GRINDER LH BODY 23 9 BODY Continued ...

Page 1380: ... the repaired area to cool and verify the repair 5 Install trim panel SPECIFICATIONS BODY LUBRICATION LUBRICATION REQUIREMENTS Body mechanisms and linkages should be inspected cleaned and lubricated as required to maintain ease of operation and to provide protection against rust and wear When performing other under hood services the hood latch release mechanism and safety catch should be inspected...

Page 1381: ...ont arm rest 50 50 split 25 18 DESCRIPTION N m Ft Lbs In Lbs Front seat back recliner to seat back 12 9 Front seat belt buckle anchor nut 40 29 Front seat belt retractor bolt 38 28 Front seat belt buckle anchor bolt 40 29 Front door hinge to hinge pillar bolt 28 21 Front door hinge to door nuts and bolt 28 21 Front door latch striker 28 20 Front seat rear outboard seat track to floor pan bolts 28 ...

Page 1382: ...SPECIAL TOOLS BODY Stick Trim C 4755 Remover Moldings C 4829 Pliers Headliner Clip C 6967 23 12 BODY LH BODY Continued ...

Page 1383: ...ove decklid latch cover from vehicle INSTALLATION INTREPID CONCORDE 1 Place decklid latch cover in position on vehicle Fig 1 2 Install push pin fasteners attaching decklid cover to decklid 3 Install grab handle if equipped DECKLID REMOVAL 1 Release decklid latch and open decklid 2 Mark hinge locations on inside of decklid to aid installation 3 Disconnect the wire harness connector if equipped 4 Re...

Page 1384: ...OVAL 1 Open decklid 2 Remove fasteners attaching decklid lining or latch cover to rear of decklid as necessary 3 Remove bolts attaching decklid latch to decklid Fig 4 Fig 5 or Fig 6 4 Remove decklid latch from decklid 5 Disconnect power lock connector from latch solenoid 6 Disconnect decklid ajar switch connector from latch 7 Remove latch from vehicle Fig 2 DECKLID 1 REMOVE BOLTS 2 DECKLID 3 WIRE ...

Page 1385: ...id 2 Remove fasteners attaching decklid lining to rear of decklid 3 Remove bolts attaching decklid latch to decklid Fig 4 Fig 5 or Fig 6 4 Remove decklid latch from decklid 5 Disconnect power lock connector from latch solenoid 6 Disconnect decklid ajar switch connector from latch 7 Remove latch from vehicle 8 Remove decklid lock set 9 Remove decklid lock cylinder INSTALLATION 1 Install decklid loc...

Page 1386: ...E COVER INSTALLATION SLAM BUMPER REMOVAL 1 Open decklid 2 Pull slam bumper from decklid 3 Remove slam bumper from decklid INSTALLATION 1 Place slam bumper in position on decklid 2 Push slam bumper into decklid 3 Verify decklid alignment SUPPORT CYLINDER REMOVAL 1 Open decklid 2 Support decklid with a suitable prop device 3 Remove gas prop lock caps on each end Fig 9 4 Remove gas prop from vehicle ...

Page 1387: ...LLATION 22 LATCH STRIKER REMOVAL 22 INSTALLATION 22 LOCK CYLINDER REMOVAL 22 INSTALLATION 23 SIDE VIEW MIRROR FLAG REMOVAL 23 INSTALLATION 23 SIDE VIEW MIRROR FLAG REMOVAL WITH SPEAKER 23 INSTALLATION WITH SPEAKER 23 TRIM PANEL REMOVAL 23 INSTALLATION 24 TRIM PANEL WOOD TRIM REMOVAL WOOD TRIM 25 INSTALLATION WOOD TRIM 25 WATERDAM REMOVAL 25 INSTALLATION 25 WINDOW REGULATOR REMOVAL 26 INSTALLATION ...

Page 1388: ...y door on lifting device and remove bolt and nut attaching upper hinge to door end frame 11 Remove door from vehicle INSTALLATION 1 Place door in position on vehicle 2 Engage door onto stud on upper door hinge 3 Steady door on lifting device and install bolt and nut attaching upper hinge to door end frame Tighten the hinge bolt and nut to 28 N m 21 ft lbs torque If the double ended stud is loosen ...

Page 1389: ...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 cover Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION ADJUSTMENTS ADJUSTMENT 1 Remove door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 2 Remove watershield as necessary 3 Loosen fastener attaching scissor channel to door pane...

Page 1390: ... Install door glass 7 Install water shield 8 Install door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL INSTALLATION HINGE REMOVAL REMOVAL 1 Mark location of hinge on hinge pillar 2 Remove bolt and nut attaching hinge to front door 3 Remove bolts attaching hinge to hinge pillar Fig 6 4 Remove hinge from vehicle REMOVAL DOOR HINGE DOUBLE ENDED STUD 1 Remove door hinge 2 To remove double ended s...

Page 1391: ...ation adjust as necessary INSIDE HANDLE ACTUATOR BEZEL REMOVAL 1 Remove the door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 2 Place door trim panel on a clean work surface 3 Drill the heat stakes attaching handle to exist ing door handle bezel Fig 8 4 Remove the door handle bezel from door trim panel INSTALLATION 1 Clean the back of trim panel of plastic fillings 2 Seat the new hand...

Page 1392: ...DOOR FRONT TRIM PANEL INSTALLATION LATCH STRIKER REMOVAL 1 Open front door 2 Mark location of door latch striker on B pillar to assist installation alignment 3 Remove bolts holding striker to B pillar Fig 11 4 Remove door latch striker from vehicle INSTALLATION 1 Place door latch striker in position on vehicle 2 Install bolts attaching striker to B pillar 3 Verify alignment and operation of door a...

Page 1393: ...NSTALLATION WITH SPEAKER 1 Install fasteners attaching the front door flag enclosure plate to front door 2 Install speaker to front door flag enclosure cover if necessary 3 Install fasteners attaching the front door flag enclosure cover to the door TRIM PANEL REMOVAL CAUTION Do not pry on door trim panel damage to trim panel will result 1 Remove speaker flag and housing 2 Remove speaker grille by ...

Page 1394: ...d 4 Connect the radio speaker wire connector 5 Connect the power window switch wire connec tor 6 Connect the power door lock switch wire con nector 7 Connect the power mirror switch wire connec tor 8 Connect the linkage to the handle assembly 9 Hook door trim panel over the sheet metal flange 10 Insert the forward four way alignment guide into position Insert the rearward two way alignment guide i...

Page 1395: ... Remove door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 2 Carefully remove by pulling water dam from door inner panel 3 Pull watershield around umbrella clips in sheet metal inner panel INSTALLATION 1 Position watershield on door inner panel Ensure that the water dam locator holes align and watershield is over the umbrella clips 2 Press inward on areas with adhesive to attach dam to...

Page 1396: ...end of roller channel through access hole in door panel Fig 19 INSTALLATION 1 Insert roller channel through access hole in door panel 2 Insert bolt heads on regulator through key hold slots in door panel 3 Tighten bolts attaching regulator to door panel 4 Tighten bolt to attach regulator support brace to door panel 5 Tighten screw to attach regulator scissor chan nel to door panel 6 Connect power ...

Page 1397: ...and rear door on all LH models require the same basic service procedures regardless of door trim configuration The art used in this section is typical and features only one of the current produc tion models CHECK STRAP REMOVAL 1 Raise door glass 2 Remove door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL REMOVAL 3 Remove watershield as necessary 4 Remove bolt and nut attaching check strap to d...

Page 1398: ...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 aligned damages or hinge replacement and can not be achieved may be necessary to remove the double ended stud and replaced it with a bolt This may allow extra move ment to achieve the proper alignment DOOR GLASS REMOVAL 1 Remove door trim panel Refer to 23...

Page 1399: ...Fig 5 4 Remove hinge from door INSTALLATION 1 Align hinge to marks on door end frame 2 Place hinge in position on door 3 Install nut and bolt attaching hinge to door end frame 4 Align hinge to marks on B pillar 5 Install nut and bolt attaching hinge to B pillar 6 Verify door alignment and operation adjust as necessary LATCH REMOVAL 1 Close door glass 2 Remove door trim panel Refer to 23 BODY DOORS...

Page 1400: ...r to C pillar Fig 7 4 Remove door latch striker from vehicle INSTALLATION 1 Place door latch striker in position on vehicle 2 Install bolts attaching 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 6 REAR DOOR LATCH 1 TO LOCK BUTTON 2 CLIPS 3 WIRE CONNECT 4 REAR DOOR LATCH 5 TO DOOR HANDLE Fig 7 R...

Page 1401: ...connect power window switch wire connec tor 10 Disconnect wiring harness clips from the trim panel 11 Remove trim panel from door INSTALLATION 1 Place trim panel in position on door 2 Connect the wiring harness clips to the trim panel 3 Connect the power window switch wire harness connector 4 Connect the rear door speaker wire connect 5 Connect the remote handle linkage 6 Hook the trim panel over ...

Page 1402: ...el Fig 11 2 Install new retainer clips and seat fully Fig 10 3 Install the door trim panel Refer to 23 BODY DOORS REAR TRIM PANEL INSTALLA TION SAIL PANEL REMOVAL 1 Open the rear door 2 Using a trim stick release clip attaching sail panel to the door 3 Remove sail panel INSTALLATION 1 Position sail panel on door 2 Press on sail panel to engage clips Fig 10 WOOD TRIM CLIPS TYPICAL 1 RETAINER CLIPS ...

Page 1403: ...oor glass on to regulator roller channel 8 Align glass and verify operation 9 Install pull cup support bracket water shield door trim panel and flag cover CABLE REMOTE LOCK ACTUATOR REMOVAL 1 Open the front door 2 Loosen the actuator knob lock nut 3 Remove the lock actuator knob and lock nut 4 Remove the cable housing nut 5 Remove the trim panel and watershield Refer to 23 BODY DOORS REAR TRIM PAN...

Page 1404: ... REMOVAL 1 Warm the effected stick on molding and body metal to approximately 38 C 100 F using a suit able heat lamp or heat gun 2 Pull stick on molding from painted surface 3 Remove adhesive tape residue from painted surface of vehicle INSTALLATION 1 If molding is to be reused remove tape residue from molding Clean back of molding with Mopart Super Kleen solvent or equivalent Wipe molding dry wit...

Page 1405: ...e from the panel with a general purpose adhesive remover REMOVAL ADHESIVES 1 Mark reference points before removing 2 Using a heat gun gently apply heat in a circu lar motion to 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 INSTALLA...

Page 1406: ... grille clips 3 Install two screws attaching foam 4 Install fascia 5 Close hood and check alignment of the grille INSTALLATION 300 M UPPER 1 Place grille into position on vehicle 2 Install six attaching grille clips 3 Install rivets attaching cross bracket to grille 4 Install two screws attaching foam 5 Install fascia 6 Close hood and check alignment of the grille INSTALLATION 300 M LOWER 1 Place ...

Page 1407: ... panel 9 Support the hood and disconnect hood prop rod 10 From inside engine compartment remove bolts attaching fender to upper rail 11 Remove fender from vehicle Fig 5 INSTALLATION 1 Place fender in position on vehicle 2 From inside engine compartment install bolts to attach fender to upper rail 3 Connect hood prop rod and support the hood 4 Install fender bolts to lower radiator closure panel 5 ...

Page 1408: ...sor bracket 5 Install strut assemble Refer to 2 SUSPEN SION FRONT STRUT INSTALLATION 6 Install front wheel 7 Lower vehicle REAR WHEELHOUSE SPLASH SHIELD REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove rear wheel 3 Remove fasteners attaching splash shield Fig 7 4 The shock tower area will have to be cut out of the splash shield This will ease the removal or Installation of the slash s...

Page 1409: ... CAUTION It is important to make sure the motor is square to the glass holder attaching fingers prior to glass holder attachment otherwise the glass holder could be installed incorrectly causing poor retention and possible repeat failure 1 Position the new mirror glass holder to the mirror assembly NOTE Position the mirror glass holder so that the moisture drain hole on the mirror glass holder ass...

Page 1410: ...IPER MOTOR REMOVAL INSTALLATION 1 If necessary paint new hinge before installa tion 2 Place hinge in position on vehicle 3 Install bolts attaching hood hinge to vertical wall of load beam 4 Install bolts attaching hood to hinge When installing hood hinge align all marks and secure bolts The hood should be aligned to 4 mm 0 160 in gap to the front fenders and flush across the top sur faces along fe...

Page 1411: ...inger tight 2 Install top bolts to attach hood to hinge finger tight When installing hood align all marks and secure bolts The hood should be aligned to 4 mm 0 160 in gap to the front fenders and flush across the top surfaces along fenders 3 Position bolts at marks and tighten bolts to 22 6 to 33 9 N m 200 to 300 in lbs torque The hood should be aligned to 4 mm 0 160 in gap to the front fenders an...

Page 1412: ...nd from hood latch assembly Fig 5 or Fig 6 3 Remove left cowl side trim panel 4 Remove screws attaching hood latch release cable handle to the cowl side 5 Remove left wheel splash shield 6 Disengage release cable from routing clips 7 Roll carpet back to expose cable 8 Release taped on cable clip from dash liner Fig 7 9 Release the rubber grommet from the dash panel Pull cable through the dash pane...

Page 1413: ...wl side trim panel 9 Connect hood release cable ferrule and cable end to hood latch 10 Verify hood latch operation before closing hood SUPPORT CYLINDER REMOVAL 1 Open hood 2 Support hood with a suitable prop device 3 Remove gas prop lock caps on each end Fig 8 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 hood l...

Page 1414: ...pen hood and disconnect the negative battery cable remote terminal from the remote battery post Fig 1 2 Remove the instrument panel left end cap 3 Remove steering column shroud cover 4 Tilt the steering column down into the lowest position 5 Remove one screw Concorde 300M to cluster bezel 6 Remove the items to expose bezel mounting screws Items vary depending on model 7 Remove two screws over uppe...

Page 1415: ...ON ACCELERATOR PEDAL REMOVAL Refer to 23 BODY INTERIOR CROSS CAR BEAM REMOVAL and etc 2 Feed electrical wires back through the silencer wiring pass through holes Fig 2 3 Remove fasteners attaching silencer to the dash and side cowls 4 Remove silencer from vehicle INSTALLATION 1 Position silencer to dash panel and cowl panels Fig 2 2 Push retainers over previously installed studs on the dash panel ...

Page 1416: ...ment panel 6 Install the four screws at bottom of glove box door to instrument panel GLOVE BOX LATCH REMOVAL 1 Remove the four screws at bottom of glove box door 2 Open the glove box door and slide sidewalls inboard to remove the door box assembly from instru ment panel 3 Place the glove box on a cloth to protect the door surface 4 Remove the nine screws from backside of the door 5 Separate the in...

Page 1417: ...leasing clips Remove cable to brake release handle Pull rearward and remove cover from vehicle 8 On six passenger vehicles remove the lower floor bin and proceed with Step 14 Refer to 23 BODY INSTRUMENT PANEL STORAGE BIN REMOVAL 9 On five passenger vehicles use trim stick or equivalent to gently remove center bezel Refer to 23 BODY INSTRUMENT PANEL STORAGE BIN REMOVAL 10 Disconnect wire connectors...

Page 1418: ...ar of vehicle Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL TOP COVER REMOVAL 22 Remove one screw retaining each left and right scuff plate Using a trim stick or equivalent gently pry up on left and right scuff plates and remove from vehicle 23 Remove three screws to right and left side cowl side kick panels and remove from vehicle Fig 5 24 Remove right side under dash silencer pad 25 Disconn...

Page 1419: ...INSTRUMENT PANEL REMOVAL 1 INSTRUMENT PANEL 2 ATTACHING SCREWS 3 CROSS CAR BEAM 4 STEERING COLUMN MOUNTING PLATE 5 INSTRUMENT PANEL COLUMN BRACKET LH INSTRUMENT PANEL 23 49 INSTRUMENT PANEL ASSEMBLY Continued ...

Page 1420: ...Fig 6 INSTRUMENT PANEL COMPONENTS 300M 23 50 INSTRUMENT PANEL LH INSTRUMENT PANEL ASSEMBLY Continued ...

Page 1421: ...INSTRUMENT CLUSTER 4 LOUVER DEMISTER SIDE WINDOW 12 STORAGE COMPARTMENT CUBBY BOX 5 MODULE PASSENGER SIDE AIRBAG 13 LEVER PARKING BRAKE 6 BEZEL INSTRUMENT PANEL END CAP 14 COVER LOWER INSTRUMENT PANEL LEFT SIDE 7 GLOVE BOX ASSEMBLY INSTRUMENT PANEL 15 INSTRUMENT PANEL ASSEMBLY 8 BEZEL INSTRUMENT PANEL UPPER RIGHT TRIM LH INSTRUMENT PANEL 23 51 INSTRUMENT PANEL ASSEMBLY Continued ...

Page 1422: ...Fig 7 INSTRUMENT PANEL COMPONENTS INTREPID 23 52 INSTRUMENT PANEL LH INSTRUMENT PANEL ASSEMBLY Continued ...

Page 1423: ... PANEL CENTER SUPPORT BIN 6 PASS ONLY 5 HOUSING INSTRUMENT CLUSTER 15 6 PASS ONLY 6 GLOVE BOX ASSEMBLY 16 ASH RECEIVER 7 RADIO 17 LEVER PARKING BRAKE 8 CONTROL ASSEMBLY INSTRUMENT PANEL 18 COVER LOWER INSTRUMENT PANEL 9 LOUVER AIR OUTLET 19 BEZEL INSTRUMENT PANEL END CAP 10 BEZEL INSTRUMENT PANEL TRIM CENTER 20 COVER UPPER INSTRUMENT PANEL LH INSTRUMENT PANEL 23 53 INSTRUMENT PANEL ASSEMBLY Contin...

Page 1424: ...Fig 8 INSTRUMENT PANEL COMPONENTS CONCORDE 23 54 INSTRUMENT PANEL LH INSTRUMENT PANEL ASSEMBLY Continued ...

Page 1425: ...all the two nuts attaching center lower instrument panel to floor tunnel bracket On six pas senger vehicles go to Step 25 Fig 3 19 Install the two front bracket screws and two screws inside console storage bin to console 20 Place the right console side cover into position and firmly snap into place Install the two screws to right console side cover 21 Raise glove box door to by pinching sides toge...

Page 1426: ... left door and pull on the access han dle to disengage the end cap clips Fuse diagram is located inside the left end cap Fuse Access is under the left end cap Fig 10 2 Open the right door and remove the right end cover by inserting a trim stick special tool C 4755 between cap and instrument panel to disengage clips INSTALLATION 1 Pull body mounted weatherstrip form fence along the side of the inst...

Page 1427: ...k special tool C 4755 or equivalent gently pry out on center instrument panel bezel 3 Open glove box and remove four screws along bottom edge of trim bezel 4 Remove one screw in center bezel area 5 Loosen the lower right edge of steering column cover then loosen upper right corner of steering col umn cover 6 Using a trim stick or equivalent gently pry bezel away from the instrument panel and disco...

Page 1428: ...ble 6 Connect the negative battery cable remote ter minal to the remote battery post Fig 1 STORAGE BIN 6 PASSENGER VEHICLES REMOVAL 1 Remove one screw and one push pin to the lower instrument panel Fig 13 2 Pull rearward and remove the floor bin INSTALLATION 1 Place the instrument panel bin into position and firmly snap into place 2 Install one screw and one push pin to the lower instrument panel ...

Page 1429: ... reinforcement from vehicle INSTALLATION 1 Place steering column cover reinforcement in position 2 Connect diagnostic connector to the steering column cover reinforcement 3 Install the four bolts attaching steering column cover reinforcement Fig 15 4 Install steering column cover Refer to 23 BODY INSTRUMENT PANEL STEERING COLUMN OPENING COVER INSTALLATION Fig 15 STEERING COLUMN COVER REINFORCEMENT...

Page 1430: ... 66 INSTALLATION 66 CENTER CONSOLE SIDE PANELS REMOVAL REMOVAL CONCORD 67 REMOVAL 67 INSTALLATION INSTALLATION CONCORD 67 INSTALLATION 67 DOOR SILL TRIM REMOVAL 67 INSTALLATION 67 FLOOR CONSOLE REMOVAL 67 INSTALLATION 68 FRONT DOOR WINDOW FRAME MOLDING REMOVAL 69 INSTALLATION 69 HEADLINER REMOVAL 69 INSTALLATION 70 ROOF STRUCTURAL MEMBRANE REMOVAL 70 INSTALLATION 71 LOWER QUARTER TRIM REMOVAL 71 I...

Page 1431: ...le in position on vehicle 2 Install screws to attach assist handle to roof BODY VENT REMOVAL 1 Open decklid 2 Move trunk carpet to access the air exhauster in the right left rear corner of the trunk Fig 3 3 From inside trunk push the air exhauster out ward to release clips 4 Reach under fascia and pull air exhauster out ward from trunk side panel 5 Remove air exhauster from vehicle INSTALLATION 1 ...

Page 1432: ...4 6 Remove B pillar trim from vehicle INSTALLATION 1 Place B pillar trim in position on vehicle 2 Engage clips attaching upper trim to B pillar 3 Place shoulder belt turning loop in position on adjuster 4 Install adjuster knob 5 Install bolt attaching turning loop to shoulder belt height adjuster 6 Install shoulder belt turning loop cover 7 Refit weatherstrip CROSS CAR BEAM REMOVAL 1 Remove steeri...

Page 1433: ...roper position on floor of vehi cle 2 Install carpet fasteners 3 Using double back tape or hook and loop secure carpet strap behind the instrument panel cen ter support bracket 4 Install cowl side trim covers 5 Install door sill trim covers 6 Install rear seat cushion 7 Install gas pedal bracket 8 Install center console if equipped 9 Install bolts to attach seat belt lower anchors to floor below B...

Page 1434: ...ift knob from gear shift 5 Disengage clips attaching bezel to floor console Fig 7 or Fig 8 6 Disconnect the power outlet if equipped 7 Disconnect the transmission range indicator illumination connector 8 Remove bezel from vehicle INSTALLATION 1 Connect the transmission range indicator illu mination connector 2 Connect power outlet if equipped 3 Place bezel in position on vehicle 4 Engage clips att...

Page 1435: ...nstall the center console bezel Refer to 23 BODY INTERIOR CENTER CONSOLE BEZEL INSTALLATION Fig 8 FRONT FLOOR CONSOLE SIDE PANELS INTREPID SHOWN 300M SIMILAR 1 INSTRUMENT PANEL 2 FLOOR CONSOLE BEZEL 3 POWER OUTLET CIGAR LIGHTER CONNECTORS 4 TRANSMISSION RANGE INDICATOR ILLUMINATION CONNECTORS 5 REAR END CAP 6 FLOOR CONSOLE 7 FRONT FLOOR CONSOLE PANEL Fig 9 CONSOLE BEZEL WOOD TRIM 1 CENTER CONSOL B...

Page 1436: ...H REMOVAL 1 Open armrest lid 2 Remove latch attaching screws 3 Remove latch from console INSTALLATION 1 Place latch in position 2 Install screws attaching latch to console 3 Check operation of latch CENTER CONSOLE REAR BEZEL REMOVAL 1 Disengage tabs on sides at bottom Fig 12 2 Open arm rest lid and remove rear end cap attaching screws 3 Remove rear bezel INSTALLATION 1 Align rear end cap in positi...

Page 1437: ...side panel s screws 4 Install floor console shift bezel 5 Install shift knob INSTALLATION 1 Place front floor console side panel in position on vehicle 2 Press on the side panel to seat clips 3 Install attaching screws 4 Install floor console shift bezel 5 Install shift knob DOOR SILL TRIM REMOVAL The door sills are attached with push pin fasten ers 1 Disengage fasteners attaching door sill trim t...

Page 1438: ... fasteners attaching bottom of console storage bin to rear mounting bracket 6 Connect the electrical connectors 7 Install side panels 8 Install center console shift bezel 9 Install shift knob Fig 14 FRONT FLOOR CONSOLE SIDE PANELS CONCORDE 1 INSTRUMENT PANEL 2 FASTENERS 3 CLIPS 4 SIDE PANEL Fig 15 FRONT FLOOR CONSOLE SIDE PANELS 1 INSTRUMENT PANEL 2 FLOOR CONSOLE BEZEL 3 POWER OUTLET CIGAR LIGHTER...

Page 1439: ...ssenger seat for ease of removal of headliner 2 Remove right and left A pillar trim panels 3 Remove right and left sun visors Do not remove sun visor retainers at this time 4 Remove overhead console or front interior lights 5 Disconnect wire harness along A pillar and wire connector to the fuse panel 6 Remove upper B pillar trim panels 7 Remove front and rear assist handles if equipped 8 Remove qu...

Page 1440: ...es if equipped 5 Install right and left sun visors and retainers 6 Install upper right and left B pillar trim pan els 7 Install wire harness along A pillar and connect wire connector to the fuse panel 8 Install overhead console or front interior lights 9 Install right and left A pillar trim panels 10 Install seat and return seats to up the right position 11 Engage the hook and loop patch fasteners...

Page 1441: ... MEMBRANE THE SHAPE AND STIFFNESS OF THE HEADLINER WILL PROVIDE PROPER PRESSURE TO ALLOW THE ADHESIVE TO CURE PROPERLY LOWER QUARTER TRIM REMOVAL 1 Remove rear seat cushion and back 2 Pull upper quarter trim from panel Fig 21 3 Remove sill trim as necessary to clear quarter trim removal path 4 Disengage clips attaching lower quarter trim to inner quarter trim from vehicle 5 Remove quarter trim fro...

Page 1442: ...ol Finally clean the glass with a paper towel dampened with alcohol 3 Sand the surface on the support bracket with fine grit sandpaper Wipe the bracket surface clean with a paper towel 4 Apply accelerator to the surface on the bracket according to the following instructions a Crush the vial to saturate the felt applicator b Remove the paper sleeve c Apply accelerator to the contact surface on the ...

Page 1443: ...n position on roof 5 Pull and hold assist handle down 6 Install front screw attaching assist handle to roof 7 Install screw behind coat hook attaching assist handle to roof SUN VISOR REMOVAL 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 1 Rem...

Page 1444: ...rea 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 attaching upper quarter trim to inner quarter panel NOTE Start at lower attachments first and work up 4 Install seat belt anc...

Page 1445: ...taching silencer to wheel house 5 Remove silencer from vehicle Fig 27 INSTALLATION 1 Place silencer into position on the wheel house Fig 27 2 Install fasteners attaching silencer to wheel house 3 Install lower quarter trim Refer to 23 BODY INTERIOR LOWER QUARTER TRIM INSTALLA TION 4 Install rear seat back Refer to 23 BODY SEATS REAR SEAT BACK INSTALLATION Fig 27 WHEELHOUSE SILENCER 1 WHEEL HOUSE 2...

Page 1446: ...AT BB8 DEEP LAVA RED PEARLCOAT ZMQ ONYX GREEN PEARLCOAT YJR GRAPHITE METALLIC CLEARCOAT ZDP STONE WHITE CLEARCOAT SW1 INTERIOR COLORS INTERIOR COLOR DAIMLERCHRYSLER CODE INTERIOR COLOR DAIMLERCHRYSLER CODE DARK SLATE GREY DV SANDSTONE T5 DARK SLATE GREY DV TAUPE L5 BASECOAT CLEARCOAT FINISH DESCRIPTION On most vehicles a two part paint application basecoat clearcoat is used Color paint that is app...

Page 1447: ...onto good sur face finish The applicator brush should be wet enough to puddle fill the scratch or chip without run ning Do not stroke brush applicator on body surface Allow the filler primer to dry hard 4 Cover the filler primer with color touch up paint Do not overlap touch up color onto the original color coat around the scratch or chip Butt the new color to the original color if possible Do not...

Page 1448: ...N AIRBAG EQUIPPED 88 FRONT SEAT CUSHION REMOVAL 88 INSTALLATION 88 FRONT SEAT CUSHION COVER REMOVAL HEATED 88 INSTALLATION HEATED 89 SEAT SIDE SHIELD REMOVAL REMOVAL NON AIRBAG 90 REMOVAL AIRBAG EQUIPPED 90 INSTALLATION INSTALLATION NON AIRBAG 90 INSTALLATION AIRBAG EQUIPPED 90 LUMBAR SUPPORT REMOVAL 90 SEAT TRACK RECLINER ASSEMBLY REMOVAL 91 INSTALLATION 91 REAR ARMREST REMOVAL REMOVAL 60 40 91 R...

Page 1449: ...at airbag module to seat back frame 7 62 Rear seat center seat belt retractor to shelf 60 44 FRONT ARMREST REMOVAL 50 50 SPLIT 1 Move the driver seat full forward and the pas senger seat full rearward 2 Open arm rest lid Fig 1 3 Remove access retaining nut cover 4 Remove arm rest retaining nut 5 Slide arm rest off of bracket Fig 2 INSTALLATION 50 50 SPLIT 1 Slide arm rest on bracket 2 Install arm ...

Page 1450: ...ING ANY AIRBAG SYSTEM COMPONENTS 1 Disconnect the remote negative battery cable 2 If fully extended lower head restraint slightly 3 Insert a stiff wire into the hole on the right hand side head restraint sleeve guide and push to release latch Fig 4 4 At the same time press the button on the head restraint sleeve guide and pull upward to release the head restraint 5 Remove head restraint from seat ...

Page 1451: ... and out of the seat back INSTALLATION AIRBAG EQUIPPED NOTE The head restraint guide sleeve equipped with height adjustment button is always installed on the left side of the seat back 1 Install guides in seat back making sure they are snapped in place 2 Install J strap retainer 3 Install the back panel on the seat back 4 Install the head restraint on the seat back Refer to 23 BODY SEATS HEADREST ...

Page 1452: ...e INSTALLATION 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 Tighten bolts to 61 N m 45 ft lbs torque 4 Move seat forward and install bolts attaching rear of seat track to the floor Tighten bolts to 61 N m 45...

Page 1453: ...ion seat forward enough to allow removal of the rear seat track to floor pan bolts 2 Disconnect and isolate the remote negative bat tery cable Fig 11 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 harness connector located on th...

Page 1454: ...t reuse recliner assembly attaching bolts Due to the nylon coating on these 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 4 Connect airbag wire harness connector and secure push pin Be certain connector is securely con nected 5 Connect heated seat element connector and secure push pin 6 Install seat cushion side shi...

Page 1455: ...shion side shield Refer to the procedure in this group 7 Release all J strap retaining clips Fig 16 8 Remove the outboard recliner attaching bolt Fig 17 This will allow access to the seat back heat ing element wire harness 9 Disconnect heating element wire connector 10 Disconnect seat airbag module electrical con nector at the module Slide the yellow locking tab down to release lock function Then ...

Page 1456: ... 4 Position seat back foam and cover on frame CAUTION Seat Airbag Module Must Be Installed IN Nylon Sleeve Failure To Do So Will Adversely Affect Function Of Airbag System Fig 15 NEGATIVE BATTERY CABLE REMOTE TERMINAL 1 RIGHT STRUT TOWER 2 AIR CLEANER INLET TUBE 3 REMOTE TERMINAL Fig 16 SEAT BACK J STRAP POSITION ORIENTATION 1 TRIM COVER J STRAPS 2 SEAT HEATER WIRE HARNESS 3 SEAT AIRBAG WIRE HARNE...

Page 1457: ...ocedure in this group 15 Connect the negative battery cable 16 Using the DRB IIIt Scan Tool erase all DTC s and perform airbag system diagnostics 17 Check trim cover fit and finish and verify seat operation SEAT BACK PANEL REMOVAL AIRBAG EQUIPPED WARNING DISCONNECT AND ISOLATE THE NEGA TIVE BATTERY CABLE REMOTE TERMINAL BEFORE BEGINNING ANY FRONT SEAT REMOVAL OR INSTALLATION PROCEDURE THIS WILL DI...

Page 1458: ...e track and recliner assembly Refer to 23 BODY SEATS SEAT TRACK RECLINER ASSEMBLY REMOVAL 2 Remove front seat back Refer to 23 BODY SEATS FRONT SEAT BACK REMOVAL 3 Disconnect seat cushion heater element connec tor if equipped 4 Disconnect wire harness fasteners from cushion frame Fig 21 5 Remove seat cushion Fig 22 INSTALLATION 1 Install wire harness fasteners to cushion frame Fig 21 2 Connect sea...

Page 1459: ...o sition seat anti squeak sheet to frame if equipped 2 Route seat function switches through access hole on outboard side of seat cushion Fig 25 3 Align seat cover with cushion alignment inden tations 4 Engage seat cushion heater element connector 5 Install hog rings 6 Engage J strap attaching seat cover to front of seat cushion frame 7 Install seat back Refer to 23 BODY SEATS FRONT SEAT BACK INSTA...

Page 1460: ... bottom and side of seat cushion Fig 26 and Fig 27 4 Remove shield from seat 5 Disconnect switch wire connectors if equipped 6 Remove seat switches if equipped INSTALLATION INSTALLATION NON AIRBAG 1 Transfer seat switches if equipped 2 Connect switch wire connectors to cushion side shield if equipped 3 Place shield in position on seat cushion 4 Install screws attaching seat cushion side shield Tig...

Page 1461: ... adjuster to cush ion pan Fig 29 4 Disconnect wire harness fasteners 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 fasteners to the cushion pan 3 Install bolts attaching seat adjuster to cushion pad 4 Install seat back 5 Install bolt attaching seat back recliner to seat back on each side of seat T...

Page 1462: ...N m 9 ft lbs torque 3 Install retaining C clip 4 Reposition the seats INSTALLATION REAR SKI PASS 1 Place arm rest into position 2 Install fasteners attaching arm rest to seat back Tighten fasteners to 5 N m 45 in lbs torque 3 Install silencer fasteners Use new fasteners 4 Install seat back Refer to 23 BODY SEATS REAR SEAT BACK REMOVAL Fig 31 ARM REST WITH SKI PASS 1 SKI PASS 2 DOOR Fig 32 REAR SEA...

Page 1463: ...23 BODY SEATS REAR SEAT BACK COLLAR ASSEM BLY REMOVAL 2 Remove bolt attaching 40 seat section 3 Remove the 40 seat section 4 Remove bolt attaching 60 seat section Fig 39 5 Slide seat back 60 seat section off pivot bracket and remove from the collar assembly REMOVAL 60 40 SEAT COLLAR ASSEMBLY 1 Remove rear seat cushion Refer to 23 BODY SEATS SEAT CUSHION REAR REMOVAL 2 Remove nuts attaching rear se...

Page 1464: ...ll the 40 seat section on pin 4 Install bolt attaching 40 seat section Tighten bolt to 16 N m 12 ft lbs torque 5 Install seat back collar assembly Refer to 23 BODY SEATS REAR SEAT BACK COLLAR ASSEM BLY INSTALLATION INSTALLATION 60 40 SEAT COLLAR ASSEMBLY 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 Pla...

Page 1465: ...OVAL 1 Pull upward at forward edge of cushion each retainer loop of the rear seat cushion to disengage retainer loops from cups in floor Fig 41 2 Remove rear seat cushion from vehicle INSTALLATION 1 Place rear seat cushion in position 2 Engage retainer loops into cup on floor kick up 3 Push downward at forward edge at each retainer loop of the rear seat cushion to engage retainers REAR SEAT CUSHIO...

Page 1466: ...ck Refer to the proce dure in this group 3 Remove bolts attaching seat adjuster to cush ion pan Fig 44 4 Disconnect wire harness from cushion pan 5 Remove seat adjuster from seat cushion INSTALLATION AIRBAG EQUIPPED 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 ...

Page 1467: ... 1 in wide around perimeter of rear window encapsu lation not to the glass and wipe with clean dry lint free cloth until no streaks are visible 3 Apply Glass Primer 25 mm 1 in wide around perimeter of rear window encapsulation not to 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...

Page 1468: ... window frame with urethane adhesive The urethane adhesive is applied cold and seals the surface area between the window opening and the glass The primer adheres the urethane adhesive to the windshield It is difficult to salvage a windshield during the removal operation The windshield is part of the structural support for the roof The urethane bonding used to secure the windshield to the fence is ...

Page 1469: ...nce for installation Fig 4 5 Remove replacement windshield from wind shield opening 6 Position the windshield inside up on a suitable work surface with two padded wood 10 cm by 10 cm by 50 cm 4 in by 4 in by 20 in blocks placed par allel 75 cm 2 5 ft apart Fig 5 WARNING DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER POOR ADHESION CAN RESULT 7 Clean...

Page 1470: ...W MIRROR INSTALLATION 21 Install inside rear view mirror Refer to 23 BODY INTERIOR REAR VIEW MIRROR INSTAL LATION 22 After urethane has cured remove tape strips and water test windshield to verify repair Fig 4 Center Windshield and Mark at Support Spacers 1 A PILLAR 2 WINDSHIELD 3 MARKS 4 FOAM BLOCK 3 5 COWL Fig 5 Work Surface Set up and Molding 1 WINDSHIELD AND MOULDINGS 2 URETHANE BEAD AROUND GL...

Page 1471: ...ctor 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 will not express open until you have passed through the full closed position The OPEN button may be released and the sunroof will continue to open in the express open feature If the VENT button is pressed and held while t...

Page 1472: ...nroof drive motor Faulty sunroof express module Faulty sunroof drive motor connector Audible whine when switch is depressed sunroof does not operate Faulty sunroof drive motor Binding cable Audible clicking or ratcheting when switch is pressed sunroof does not operate Broken or worn drive cable Worn drive motor gear Mechanisms not synchronized Sunroof vents and opens but does not close Binding cab...

Page 1473: ...Fig 1 SUNROOF ASSEMBLY 1 SUNSHADE 2 EXPRESS MODULE 3 DRIVE MOTOR 4 FRAME ASSEMBLY 5 WIND DEFLECTOR 6 GLASS PANEL 7 DRAIN CHANNEL LH SUNROOF 23 103 SUNROOF Continued ...

Page 1474: ...Fig 2 SUNROOF HOUSING ASSEMBLY REMOVAL 1 DRAIN HOSE 2 DRAIN HOSE 3 SUN ROOF FRAME ASSEMBLY 4 DRAIN HOSE 5 A PILLAR 23 104 SUNROOF LH SUNROOF Continued ...

Page 1475: ...y when the sunroof window reaches a certain position Extreme care must be taken when removing the motor tim ing may be thrown off causing possible damage to the sunroof system Anytime the motor is removed from the sunroof assembly the sunroof glass panel must be in the FULLY CLOSED POSITION or the unit will be out of time The drive motor cannot be reset to the park position after being removed Ref...

Page 1476: ... the front two screws 6 Loosen the rear screws on each side enough to make the rear adjustment 7 Adjust the rear of the sunroof glass panel 1 mm 1 32 inch above the top surface of the roof panel 8 Tighten the rear two screws 9 Check for proper fit If not OK repeat glass panel adjustment ADJUSTMENT SUNROOF GLASS PANEL TIMING Sunroof Drive Cable Timing NOTE A gage comes with the new motor 1 If the g...

Page 1477: ...or 3 Remove headliner as necessary Refer to 23 BODY INTERIOR HEADLINER REMOVAL 4 Remove rear shelf panel Refer to 23 BODY INTERIOR REAR SHELF TRIM PANEL REMOV AL 5 Disconnect the end of the drain tube from the rubber grommet at the end of the drain tube closest to the rear window of the vehicle Fig 8 6 Drain any liquid from hose connection if nec essary 7 Disconnect the top end of the drain hose f...

Page 1478: ...emove express module from the keyway by sliding module towards the center of the vehicle INSTALLATION 1 Insert sunroof express module in the keyway located in the sunroof module and slide the module outward to lock it into position 2 Install the sunroof express module screw 3 Connect the wire connectors to the sunroof express module 4 Install the headliner into position Refer to 23 BODY INTERIOR H...

Page 1479: ...e clears the body Then raise the corner up 4 Repeat the procedure to the other corner 5 Lift wind deflector to 90 of the way 6 Push the attaching ends of the deflector to the rear of the vehicle to disengage the deflector INSTALLATION 1 Place wind deflector at 90 in the vertical posi tion to the sunroof With the sunroof open 2 Push ends of the deflector towards the front of the vehicle to engage e...

Page 1480: ...o 23 BODY INTERIOR DOOR SILL TRIM REMOVAL 2 Pull body mounted weatherstrip from fence around door opening Fig 1 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 3 Engage weatherstrip along the header and down the A pillar 4 Engage weatherstrip along the sill There may be slack material wo...

Page 1481: ...trip from window frame channel Fig 3 INSTALLATION 1 Clean butyl material from door flange area 2 Place 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 Refer to 23 BODY DOOR FRONT DOOR GLASS INSTALLATION 6 Tighten side view mirror Fig 3 DOOR GLASS RUN ...

Page 1482: ...e around door opening Fig 5 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 3 Engage weatherstrip along the header and down the C pillar 4 Engage weatherstrip along the sill There may be slack material work the slack material to the front of the opening 5 Install the door opening sill pl...

Page 1483: ...yl material from door flange area 2 Place door run weatherstrip in position on win dow frame channel 3 Push door run weatherstrip in position on win dow frame channel 4 Push weatherstrip into lower rear channel above door latch 5 Install door glass Refer to 23 BODY DOORS REAR DOOR GLASS INSTALLATION Fig 6 REAR DOOR GLASS RUN 1 REAR DOOR MOLDING 2 GLASS RUN 3 REAR GLASS RUN CHANNEL 4 REAR DOOR 5 FR...

Page 1484: ...o lower door 3 Verify door alignment and seal TRUNK OPENING WEATHERSTRIP REMOVAL 1 Open decklid 2 Pull decklid weatherstrip from decklid opening fence Fig 8 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 Fig 7 REAR DOOR MOU...

Page 1485: ... 118 SEALER LOCATIONS SPECIFICATIONS SEALER LOCATIONS 124 STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS 139 WELD LOCATIONS SPECIFICATIONS WELD LOCATIONS 144 GAP AND FLUSH SPECIFICATIONS BODY GAP AND FLUSH MEASUREMENTS INDEX DESCRIPTION FIGURE BODY GAP AND FLUSH INTREPID 1 BODY GAP AND FLUSH CONCORDE AND 300M 2 LH BODY STRUCTURE 23 115 ...

Page 1486: ...or 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 23 116 BODY STRUCTURE LH GAP AND FLUSH Continued ...

Page 1487: ... 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 Tail lamp to Applique and Deck Lid 5 0 1 5 NA J Rear Door to Quarter Panel 5 0 1 5 0 1 0 LH BODY STRUCTURE 23 117 GAP AND FLUSH Continued ...

Page 1488: ...ESCRIPTION FIGURE WINDSHIELD AND FRONT DOOR OPENINGS 3 REAR DOOR OPENINGS CONCORDE 300M 4 REAR DOOR OPENINGS INTREPID 5 REAR WINDOW AND TRUNK OPENING CONCORDE 6 REAR WINDOW AND TRUNK OPENINGS INTREPID 7 REAR WINDOW AND TRUNK OPENINGS 300M 8 23 118 BODY STRUCTURE LH ...

Page 1489: ...Fig 3 WINDSHIELD AND FRONT DOOR OPENINGS LH BODY STRUCTURE 23 119 OPENING DIMENSIONS Continued ...

Page 1490: ... panel at C pillar D Upper rear door hinge rear bolt hole to door latch hole Fig 5 REAR DOOR OPENINGS INTREPID 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 23 120 BODY STRUCTURE LH OPENING DIMENSIONS Continued ...

Page 1491: ...Fig 6 REAR WINDOW AND TRUNK OPENING CONCORDE LH BODY STRUCTURE 23 121 OPENING DIMENSIONS Continued ...

Page 1492: ...Fig 7 REAR WINDOW AND TRUNK OPENINGS INTREPID 23 122 BODY STRUCTURE LH OPENING DIMENSIONS Continued ...

Page 1493: ...Fig 8 REAR WINDOW AND TRUNK OPENINGS 300M LH BODY STRUCTURE 23 123 OPENING DIMENSIONS Continued ...

Page 1494: ...F APPLYING AUTO BODY SEALANT 9 STRUT TOWER AND COWL AREA 10 LOAD BEAM AND COWL AREA 11 BODY SIDE APERTURE 12 FLOOR PAN 13 FLOOR PAN 14 FLOOR PAN 15 FLOOR PAN 16 REAR TRUNK AREA 17 INNER WHEELHOUSE 18 REAR QUARTER PANE 19 DECKLID 20 FRONT DOORS 21 REAR DOORS 22 23 124 BODY STRUCTURE LH ...

Page 1495: ...Fig 9 METHODS OF APPLYING AUTO BODY SEALANT LH BODY STRUCTURE 23 125 SEALER LOCATIONS Continued ...

Page 1496: ...L 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 23 126 BODY STRUCTURE LH SEALER LOCATIONS Continued ...

Page 1497: ...Fig 11 LOAD BEAM AND COWL AREA LH BODY STRUCTURE 23 127 SEALER LOCATIONS Continued ...

Page 1498: ...Fig 12 BODY SIDE APERTURE 23 128 BODY STRUCTURE LH SEALER LOCATIONS Continued ...

Page 1499: ...Fig 13 FLOOR PAN 1 SEALER TO BE BRUSHED INTO SEAMS LH BODY STRUCTURE 23 129 SEALER LOCATIONS Continued ...

Page 1500: ...Fig 14 FLOOR PAN 23 130 BODY STRUCTURE LH SEALER LOCATIONS Continued ...

Page 1501: ...Fig 15 FLOOR PAN LH BODY STRUCTURE 23 131 SEALER LOCATIONS Continued ...

Page 1502: ...Fig 16 FLOOR PAN 23 132 BODY STRUCTURE LH SEALER LOCATIONS Continued ...

Page 1503: ...Fig 17 REAR TRUNK AREA LH BODY STRUCTURE 23 133 SEALER LOCATIONS Continued ...

Page 1504: ...Fig 18 INNER WHEELHOUSE 23 134 BODY STRUCTURE LH SEALER LOCATIONS Continued ...

Page 1505: ...Fig 19 REAR QUARTER PANE LH BODY STRUCTURE 23 135 SEALER LOCATIONS Continued ...

Page 1506: ...Fig 20 DECKLID 23 136 BODY STRUCTURE LH SEALER LOCATIONS Continued ...

Page 1507: ...Fig 21 FRONT DOORS LH BODY STRUCTURE 23 137 SEALER LOCATIONS Continued ...

Page 1508: ...Fig 22 REAR DOORS 23 138 BODY STRUCTURE LH SEALER LOCATIONS Continued ...

Page 1509: ...IONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS INDEX DESCRIPTION FIGURE HOOD CONCORDE AND 300M 23 HOOD INTREPID 24 FRONT FENDER 25 ROOF 26 SUNROOF 27 DOORS 28 DECKLID 29 Fig 23 HOOD CONCORDE AND 300M LH BODY STRUCTURE 23 139 ...

Page 1510: ...Fig 24 HOOD INTREPID Fig 25 FRONT FENDER 23 140 BODY STRUCTURE LH STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1511: ...Fig 26 ROOF Fig 27 SUNROOF LH BODY STRUCTURE 23 141 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1512: ...Fig 28 DOORS 23 142 BODY STRUCTURE LH STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1513: ...Fig 29 DECKLID LH BODY STRUCTURE 23 143 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1514: ... COWL 42 DASH AND COWL 43 DASH AND COWL 44 DASH AND COWL 45 DASH AND COWL 46 ROOF PANEL AND ROOF BOWS 47 ROOF PANEL AND ROOF BOWS 48 ROOF PANEL AND ROOF BOWS 49 ROOF PANEL AND ROOF BOWS 50 BODY SIDE APERTURE 51 BODY SIDE APERTURE 52 BODY SIDE APERTURE 53 BODY SIDE APERTURE 54 BODY SIDE APERTURE 55 BODY SIDE APERTURE 56 BODY SIDE APERTURE 57 BODY SIDE APERTURE 58 BODY SIDE APERTURE 59 BODY SIDE APE...

Page 1515: ...FLOOR PAN 69 FLOOR PAN 70 FLOOR PAN 71 FLOOR PAN 72 FLOOR PAN 73 FLOOR PAN 74 FLOOR PAN 75 FLOOR PAN 76 FLOOR PAN 77 FLOOR PAN 78 FLOOR PAN 79 FLOOR PAN 80 REAR SHELF 81 REAR SHELF 82 REAR SHELF 83 LH BODY STRUCTURE 23 145 WELD LOCATIONS Continued ...

Page 1516: ...Fig 30 ENGINE COMPARTMENT 23 146 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1517: ...Fig 31 ENGINE COMPARTMENT LH BODY STRUCTURE 23 147 WELD LOCATIONS Continued ...

Page 1518: ...Fig 32 ENGINE COMPARTMENT 23 148 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1519: ...Fig 33 ENGINE COMPARTMENT LH BODY STRUCTURE 23 149 WELD LOCATIONS Continued ...

Page 1520: ...Fig 34 ENGINE COMPARTMENT 23 150 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1521: ...Fig 35 ENGINE COMPARTMENT LH BODY STRUCTURE 23 151 WELD LOCATIONS Continued ...

Page 1522: ...Fig 36 ENGINE COMPARTMENT 23 152 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1523: ...Fig 37 ENGINE COMPARTMENT LH BODY STRUCTURE 23 153 WELD LOCATIONS Continued ...

Page 1524: ...Fig 38 ENGINE COMPARTMENT 23 154 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1525: ...Fig 39 ENGINE COMPARTMENT LH BODY STRUCTURE 23 155 WELD LOCATIONS Continued ...

Page 1526: ...Fig 40 ENGINE COMPARTMENT 23 156 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1527: ...Fig 41 DASH AND COWL LH BODY STRUCTURE 23 157 WELD LOCATIONS Continued ...

Page 1528: ...Fig 42 DASH AND COWL 23 158 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1529: ...Fig 43 DASH AND COWL LH BODY STRUCTURE 23 159 WELD LOCATIONS Continued ...

Page 1530: ...Fig 44 DASH AND COWL 23 160 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1531: ...Fig 45 DASH AND COWL LH BODY STRUCTURE 23 161 WELD LOCATIONS Continued ...

Page 1532: ...Fig 46 DASH AND COWL 23 162 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1533: ...Fig 47 ROOF PANEL AND ROOF BOWS LH BODY STRUCTURE 23 163 WELD LOCATIONS Continued ...

Page 1534: ...Fig 48 ROOF PANEL AND ROOF BOWS 23 164 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1535: ...Fig 49 ROOF PANEL AND ROOF BOWS LH BODY STRUCTURE 23 165 WELD LOCATIONS Continued ...

Page 1536: ...Fig 50 ROOF PANEL AND ROOF BOWS Fig 51 BODY SIDE APERTURE 23 166 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1537: ...Fig 52 BODY SIDE APERTURE LH BODY STRUCTURE 23 167 WELD LOCATIONS Continued ...

Page 1538: ...Fig 53 BODY SIDE APERTURE 23 168 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1539: ...Fig 54 BODY SIDE APERTURE LH BODY STRUCTURE 23 169 WELD LOCATIONS Continued ...

Page 1540: ...Fig 55 BODY SIDE APERTURE 23 170 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1541: ...Fig 56 BODY SIDE APERTURE LH BODY STRUCTURE 23 171 WELD LOCATIONS Continued ...

Page 1542: ...Fig 57 BODY SIDE APERTURE 23 172 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1543: ...Fig 58 BODY SIDE APERTURE LH BODY STRUCTURE 23 173 WELD LOCATIONS Continued ...

Page 1544: ...Fig 59 BODY SIDE APERTURE 23 174 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1545: ...Fig 60 BODY SIDE APERTURE LH BODY STRUCTURE 23 175 WELD LOCATIONS Continued ...

Page 1546: ...Fig 61 BODY SIDE APERTURE 23 176 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1547: ...Fig 62 BODY SIDE APERTURE LH BODY STRUCTURE 23 177 WELD LOCATIONS Continued ...

Page 1548: ...Fig 63 BODY SIDE APERTURE 23 178 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1549: ...Fig 64 FLOOR PAN LH BODY STRUCTURE 23 179 WELD LOCATIONS Continued ...

Page 1550: ...Fig 65 FLOOR PAN 23 180 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1551: ...Fig 66 FLOOR PAN LH BODY STRUCTURE 23 181 WELD LOCATIONS Continued ...

Page 1552: ...Fig 67 FLOOR PAN 23 182 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1553: ...Fig 68 FLOOR PAN LH BODY STRUCTURE 23 183 WELD LOCATIONS Continued ...

Page 1554: ...Fig 69 FLOOR PAN 23 184 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1555: ...Fig 70 FLOOR PAN LH BODY STRUCTURE 23 185 WELD LOCATIONS Continued ...

Page 1556: ...Fig 71 FLOOR PAN 23 186 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1557: ...Fig 72 FLOOR PAN LH BODY STRUCTURE 23 187 WELD LOCATIONS Continued ...

Page 1558: ...Fig 73 FLOOR PAN 23 188 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1559: ...Fig 74 FLOOR PAN LH BODY STRUCTURE 23 189 WELD LOCATIONS Continued ...

Page 1560: ...Fig 75 FLOOR PAN 23 190 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1561: ...Fig 76 FLOOR PAN LH BODY STRUCTURE 23 191 WELD LOCATIONS Continued ...

Page 1562: ...Fig 77 FLOOR PAN 23 192 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1563: ...Fig 78 FLOOR PAN LH BODY STRUCTURE 23 193 WELD LOCATIONS Continued ...

Page 1564: ...Fig 79 FLOOR PAN Fig 80 FLOOR PAN 23 194 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1565: ...Fig 81 REAR SHELF LH BODY STRUCTURE 23 195 WELD LOCATIONS Continued ...

Page 1566: ...Fig 82 REAR SHELF 23 196 BODY STRUCTURE LH WELD LOCATIONS Continued ...

Page 1567: ...Fig 83 REAR SHELF LH BODY STRUCTURE 23 197 WELD LOCATIONS Continued ...

Page 1568: ......

Page 1569: ...er to 7 COOLING OPERATION Coolant temperature can be checked using the scan tool DRBIIIt When additional coolant is needed it should be added to the coolant pressure bottle Use only 50 50 mix of Mopart Antifreeze Coolant 5 Year 100 000 Mile Formula orange in color or the equivalent and distilled water This coolant must not be mixed with other green in color coolants If this occurs a reduc tion in ...

Page 1570: ...5 C 90 F 37 C 100 F 43 C 110 F MAXIMUM ALLOWABLE AIR TEMPERATURE AT CENTER LEFT PANEL OUTLET 6 C 42 F 7 C 45 F 10 C 50 F 12 C 54 F 15 C 59 F COMPRESSOR DISCHARGE PRESSURE 1379 1585 kPa 200 230 psi 1448 1723 kPa 210 250 psi 1654 1930 kPa 240 280 psi 1930 2206 kPa 280 320 psi 2206 2516 kPa 320 365 psi COMPRESSOR SUCTION PRESSURE 103 172 kPa 15 25 psi 139 208 kPa 20 30 psi 172 241 kPa 25 35 psi 208 2...

Page 1571: ...he vehicles own control head display Refer to the DRBIIIt menu for checking Diagnostic Trouble Codes DTC s Note that there are three DTC tables The ATC and MTC DTC table contain faults that are common to both the ATC and the MTC system The same diagnosis can be used for both systems The DTC s cover operation of the climate control unit actuators doors evaporator temperature sensor ambient temperat...

Page 1572: ...ehicle is not moving Set the control to a 75 F setting so there is no confusion with the 23 51 Diagnostic Trou ble Codes DTC s Fig 1 To place the system into it s diagnostic mode press and hold the Floor Mix and Defrost buttons at the same time The ATC head display will begin to blink Release the Floor Mix and Defrost buttons Once the control head enters the diagnostic mode the display on the cont...

Page 1573: ... more than one diagnos tic trouble code could be in the memory To scroll through any additional diagnostic trouble codes press the A C button on the MTC head The BCM will beep each time the A C button is pushed Con tinue pushing the A C button and recording the trou ble code numbers until the odometer returns to normal operation note the letters AC will disappear It is important that no other knob...

Page 1574: ...ntrepid Concorde 300M LHS Automatic Temperature Control ATC System R134a w expansion valve Compressor Nippondenso 10PA17 ND 8 PAG oil Freeze up Control 2 wire evaporator temp sensor BCM controlled clutch OFF 33 F resets 37 F Low psi Control A C pressure transducer line mounted opens 29 4 psi PCM input High psi Control opens 431 0 psi PCM input Item Description Notes Forced Recirc Mode System force...

Page 1575: ...CM Draw 2 2 amps 12 V 0 5V Gap 0 0149 0 0269 DRB IIIT Reads TPS RPM A C switch test Actuators Mode doors clutch and fan relays TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs A C COMPRESSOR SHAFT BOLT 17 5 2 13 2 155 20 A C COMPRESOR LINE MANIFOLD FASTENERS 23 17 204 A C COMPRESSOR TO ENGINE BLOCK BOLTS 28 21 252 A C CONDENSER TO REFRIG LINES 23 17 204 A C EXPANSION VALVE...

Page 1576: ... 19 INSTALLATION 20 RECIRCULATION DOOR ACTUATOR REMOVAL 20 INSTALLATION 20 SUN SENSOR DESCRIPTION 21 OPERATION 21 DIAGNOSIS AND TESTING SUN SENSOR 21 REMOVAL 21 INSTALLATION 22 A C COMPRESSOR CLUTCH DESCRIPTION The compressor clutch assembly consists of a sta tionary electromagnetic coil a hub bearing and pul ley assembly and a clutch plate The electromagnetic coil unit and the hub bearing and pul...

Page 1577: ... more the coil is shorted and should be replaced b If the clutch coil current reading is zero the coil is open and should be replaced STANDARD PROCEDURE INSPECTION Examine the friction surfaces of the clutch pulley and the front plate for wear The pulley and front plate should be replaced if there is excessive wear or scoring If the friction surfaces are oily inspect the shaft and nose area of the...

Page 1578: ...compressor housing Fig 4 Slide field coil off of compressor housing Fig 1 COMPRESSOR SHAFT BOLT AND CLUTCH PLATE 1 COMPRESSOR SHAFT BOLT 2 COMPRESSOR CLUTCH PLATE Fig 2 CLUTCH PLATE AND SHIM S 1 COMPRESSOR SHAFT 2 CLUTCH PLATE 3 CLUTCH PLATE SHIM Fig 3 REMOVING PULLEY SNAP RING 1 SNAP RING Fig 4 CLUTCH COIL SNAP RING 1 SNAP RING PLIERS 2 CLUTCH COIL 3 SNAP RING 4 COMPRESSOR 24 10 CONTROLS LH A C C...

Page 1579: ...t be checked Use the following procedure a Attach a dial indicator to front plate so that movement of the plate can be measured b With the dial indicator zeroed on the front plate 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 compre...

Page 1580: ...ty between this cavity and the A C compres sor clutch relay output circuit cavity of the compressor clutch coil wire harness connector If OK go to Step 4 If not OK repair the open circuit as required 4 The relay coil battery terminal 86 is connected to the fused ignition switch output run start circuit There should be battery voltage at the cavity for relay terminal 86 with the ignition switch in ...

Page 1581: ...ove from the bezel INSTALLATION 1 Place the control into place on the back of the instrument panel center bezel and install the six retaining screws to the a c heater control 2 Connect the two electrical connectors to the back of the control head and traction control switch if equipped 3 Install the instrument panel center bezel 4 Install the ash receiver assembly if necessary 5 Connect the negati...

Page 1582: ...side of the HVAC unit housing and is controlled by the Body Control Module BCM OPERATION The power module receives pulse width modulated PWM signals from the BCM The power module varies voltage to the blower motor for different blower speeds based on the ATC software There are 14 selectable speeds while the Auto mode provides 256 variations REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABL...

Page 1583: ...assed and the blower motor receives a direct path to ground DIAGNOSIS AND TESTING BLOWER MOTOR RESISTOR BLOCK For circuit descriptions and diagrams Refer to Appropriate Wiring Information WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEG...

Page 1584: ... becomes too cold The PCM will then turn OFF the A C Compressor Clutch before evaporator freeze up occurs The DRBIIIt scan tool can be used to monitor this operation The tem perature set point at which the clutch is turned OFF varies with the outside ambient temperature The temperature at which the clutch is turned ON is pre set to 2 F above the OFF setpoint mentioned above Refer to Evaporator Tem...

Page 1585: ... temperature sensor thermistor is part of the ATC Control and not a separate serviceable part One must replace the ATC Control if the ATC self diag nostics indicates a fault code Refer to 24 HEAT ING AIR CONDITIONING DIAGNOSIS AND TESTING SELF DIAGNOSTICS OPERATION Air drawn from the passenger compartment by the in car sensor aspirator motor assembly and flows over the thermistor The in car sensor...

Page 1586: ...ual and ATC systems to know the exact position of the blend door at all times The blend door actuator is not serviceable and must be replaced if found to be defective REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND ...

Page 1587: ...RY 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Refer to 8 ELECTRICAL BATTERY SYSTEM CA BLES REMOVAL 2 Remove the left and right underpanel ducts 3 Remove the floor console Refer to 23 BODY INTERIOR FLOOR CONSOLE REMOVAL Refer to Body for the procedures 4 Remove the center floor heat adaptor duct 5 Remove the rear seat heat forward adaptor duct...

Page 1588: ...AG DEPLOYMENT AND POSSIBLE PERSONAL INJURY The recirculation door actuator is located on the right side of the heater housing Fig 18 1 Open the hood and disconnect the negative bat tery cable remote terminal from the remote battery post 2 Remove the instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 3 Remove the actuator retaining screws Pull the actuator straight...

Page 1589: ...the sensor Top cover which is not properly installed The sun sensor should be 1 4 inch above the top cover Caps or papers which might cover the sensor Some ATC equipped vehicles may exhibit a lack of passenger comfort in sunny weather such as in the early afternoon Verify that the ATC system is func tioning properly Inspect the location of the sun sen sor The sun sensor must protrude approximately...

Page 1590: ... SYSTEM CABLES INSTALLATION CAUTION The sun sensor must protrude approxi mately 1 4 inch above the instrument panel top cover This will ensure proper operation If the sensor does not protrude 1 4 inch perform the following procedure Confirm that the top cover is properly installed Remove the top cover Remove fasteners from sun sensor Install one 1 4 20 nut per fastener under the sun sensor so that...

Page 1591: ...ater control Ambient air intake can be shut off by closing the recirculation door This will recirculate the air that is already inside the vehicle See owners manual for recirculation operation BLOWER MOTOR DESCRIPTION The blower motor and blower wheel are located in the passenger side end of the HVAC housing below the glove box module The blower motor controls the velocity of the air flowing throu...

Page 1592: ...O DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY WARNING REVIEW THE WARNINGS IN THE FRONT OF PLUMBING BEFORE PERFORMING THE FOL LOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING WARNING 1 Open the hood an...

Page 1593: ... 21 Using a flat blade screwdriver pinch in the retaining tab at the base of the vent door Pull up on door and remove it from the HVAC housing 22 Remove the mode door actuating cam 23 Remove the screw at defrost door actuating arm Remove the defrost door link from the arm 24 Remove the defrost door arm from the lower HVAC housing 25 Remove the link and defrost door from the HVAC housing 26 Remove ...

Page 1594: ...the HVAC housing to the dash panel Tighten to 4 5 N m 40 in lbs 6 Position the defrost duct and install the two retainer screws Tighten to 2 2 N m 20 in lbs 7 Install the nuts on the HVAC housing mount ing studs on the engine compartment side of the dash panel Tighten to 7 N m 60 in lbs 8 Unplug or remove the tape from liquid and suc tion lines and the expansion valve Connect the lines to the expa...

Page 1595: ...EMOVAL 41 INSTALLATION 41 REFRIGERANT DESCRIPTION 42 OPERATION 42 REFRIGERANT OIL DESCRIPTION 42 OPERATION 42 STANDARD PROCEDURE REFRIGERANT OIL LEVEL 42 SERVICE PORT VALVE CORE REMOVAL 43 INSTALLATION 44 PLUMBING DESCRIPTION REFRIGERANT LINE The refrigerant lines and hoses are used to carry the refrigerant between the various air conditioning system components A barrier hose design with a nylon t...

Page 1596: ...N CONTACT WITH ETHYLENE GLYCOL KEEP OUT OF REACH OF CHILDREN AND PETS DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT RUNNING TEMPERATURE PER SONAL INJURY CAN RESULT CAUTION REFRIGERANT SYSTEM PRECAUTIONS CAUTION The system must be completely empty before opening any fitting or connection in the refrigeration system Open fittings with caution even after the system has been emptied If any pressu...

Page 1597: ...ll windows CAUTION A leak detector designed for R 12 refrig erant may not detect leaks in a R 134a refrigerant system Check specifications on leak detector 4 Shut off the vehicle and wait 2 to 7 minutes Then use an Electronic Leak Detector that is designed to detect R 134a type refrigerant and search for leaks Fittings lines or components that appear to be oily usually indicates a refrigerant leak...

Page 1598: ...sor be used This will eliminate the possibility of con taminating the refrigerant system If the refrigerant system has been open to the atmosphere it must be evacuated before the system can be filled Moisture and air mixed with the refrig erant will raise the compressor head pressure above acceptable operating levels This will reduce the per formance of the air conditioner and damage the com press...

Page 1599: ...ugh the compressor CAUTION A 10PA17 R 12 compressor looks identi cal to a 10PA17 R134a and will bolt up to this vehi cle It is extremely important that a R 134a compressor is identified prior to using compressor in question Check tag located on compressor for model number OPERATION The compressor is driven by the engine through an electric clutch drive pulley and belt arrangement The compressor is...

Page 1600: ...duce the capacity of the entire air condi tioning system Kinks and sharp bends reduce the flow of refrigerant in the system A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose In addition the flexible hose refrigerant lines should be routed so they are at least 80 millimeters 3 inches from the exhaust manifold High pres...

Page 1601: ...ING PLUMBING WARNING The condenser is located between the radiator and the front bumper The condenser can be serviced without having to drain the cooling system or remove the radiator 1 Open the hood and disconnect the negative bat tery cable remote terminal from the remote battery post 2 Recover the refrigerant from the system Refer to 24 HEATING AIR CONDITIONING PLUMB ING STANDARD PROCEDURE REFR...

Page 1602: ...ings and lubricate with refrigerant oil 4 Connect the liquid line to the condenser inlet Tighten the retaining nut to 23 N m 17 ft lbs 5 Connect the discharge line to the condenser outlet Tighten the retaining nut to 23 N m 17 ft lbs 6 Install the retainer bracket and screw for the auxiliary transmission cooler lines 7 Connect the auxiliary transmission cooler hose fittings 8 Install the upper rad...

Page 1603: ...c pres sure transducer 5 Connect the negative battery cable remote ter minal to the remote battery post 6 Evacuate the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 7 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE LIQUID LINE REMOVAL WARNING REVIEW THE WARNI...

Page 1604: ...ree It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed 1 Place the liquid line in the vehicle 2 Install the liquid line fitting to the receiver drier Tighten the fastener to 13 6 N m 10 ft lbs 3 Install the liquid line mounting clamp fastener located near the service port Tighten the fastener to 6 8 ...

Page 1605: ...SION VALVE 3 2 3 5 L 1 A C COMPRESSOR 2 EXPANSION VALVE 3 SUCTION LINE 4 RECEIVER DRIER 5 DISCHARGE LINE 6 A C PRESSURE TRANSDUCER 7 LIQUID LINE Fig 11 A C REFRIGERANT LINES AND EXPANSION VALVE 2 7L 1 A C PRESSURE TRANSDUCER 2 SERVICE PORT 3 EXPANSION VALVE 4 RECEIVER DRIER 5 A C COMPRESSOR 6 LIQUID LINE 7 DISCHARGE LINE 8 SUCTION LINES Fig 12 SUCTION LINE 3 2L 3 5L 1 SUCTION LINE 2 EXPANSION VALV...

Page 1606: ...TING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAGNOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEP...

Page 1607: ...ATION High pressure high temperature liquid refrigerant from the liquid line passes through the expansion valve orifice converting it into a low pressure low temperature mixture of liquid and gas before it enters the evaporator coil A temperature sensor in the expansion valve control head monitors the tem perature of the refrigerant leaving the evaporator coil through the suction line and adjusts ...

Page 1608: ...e retaining nut to 8 N m 6 ft lbs 3 Tighten the bolt at the receiver drier to 13 6 N m 10 ft lbs 4 Install the engine air inlet tube and the air dis tribution duct on vehicles equipped with 3 2 3 5 L engine Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER ELEMENT INSTALLATION 5 Evacuate the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACU...

Page 1609: ...om vehicle 8 Remove the small line from the receiver drier to the expansion valve to install on the new receiver drier NOTE Always install new O rings when replacing filter drier 9 Plug or cap liquid line fittings while system is open to prevent moisture intrusion INSTALLATION WARNING REVIEW THE WARNINGS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR...

Page 1610: ...forming any refrigerant recovery or recy cling operation always replenish the refrigerant sys tem with the same amount of the recommended refrigerant oil as was removed Too little refrigerant oil can cause compressor damage and too much can reduce air conditioning system performance PAG refrigerant oil is much more hygroscopic than mineral oil and will absorb any moisture it comes into contact wit...

Page 1611: ...ompressor This is not to exceed 150 ml 5 00 oz in total 6 Install the compressor and connect the refriger ant lines Then evacuate and charge refrigerant sys tem Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PRO CEDURE REFRIGERANT SYSTEM EVACUATE Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIG ERANT SYSTEM CHARGE 7 Most reclaim recycling equipment will measure the l...

Page 1612: ...e core into the fitting 2 Evacuate the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 3 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE 4 Install the valve caps 24 44 PLUMBING LH SERVICE PORT VALVE CORE Continued ...

Page 1613: ...ed limp in will set a fault after 1 trip with the malfunction present Refer to the Diagnostic Trouble Codes Description Charts in this section and the appropriate Power train Diagnostic Procedure Manual for diagnostic procedures The following is a list of the monitored compo nents Catalyst Monitor Comprehensive Components EGR if equipped Fuel Control rich lean Oxygen Sensor Monitor Oxygen Sensor H...

Page 1614: ...st and Fuel Monitors and purge The O2S may fail in any or all of the following manners Slow response rate Big Slope Reduced output voltage Half Cycle Heater Performance Slow Response Rate Big Slope Response rate is the time required for the sensor to switch from lean to rich signal output once it is exposed to a richer than optimum A F mixture or vice versa As the PCM adjusts the air fuel ratio th...

Page 1615: ...engine is started The same O2S heater return pin used to read the heater resis tance is capable of detecting an open circuit a shorted high or shorted low condition OXYGEN SENSOR HEATER MONITOR SBEC DESCRIPTION If there is an oxygen sensor O2S DTC as well as a O2S heater DTC the O2S heater fault MUST be repaired first After the O2S fault is repaired verify that the heater circuit is operating corr...

Page 1616: ...ty to store oxygen the condition can be detected from the behavior of the downstream O2S When the efficiency drops no chemical reaction takes place This means the con centration of oxygen will be the same downstream as upstream The output voltage of the downstream O2S copies the voltage of the upstream sensor The only difference is a time lag seen by the PCM between the switching of the O2S s To m...

Page 1617: ...ontains the vehicle s emission specifica tions and vacuum hose routings All hoses must be connected and routed according to the label DESCRIPTION TRIP DEFINITION A Trip means vehicle operation following an engine off period of duration and driving mode such that all components and systems are monitored at least once by the diagnostic system The monitors must successfully pass before the PCM can ve...

Page 1618: ...ystem devices However these could cause the PCM to store a MAP sensor diagnostic trouble code and cause 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 including when diagnostics are performed PCM CONNECTOR ENGAGEME...

Page 1619: ...he sensor properly The O2S circuit is monitored for a drop in voltage The sensor output is used to test the heater by iso lating the effect of the heater element on the O2S output voltage from the other effects EGR MONITOR if equipped The Powertrain Control Module PCM performs an on board diagnostic check of the EGR system The EGR monitor is used to test whether the EGR system is operating within ...

Page 1620: ...inated NATURAL VACUUM LEAK DETECTION NVLD if equipped The Natural Vacuum Leak Detection NVLD sys tem is the next generation evaporative leak detection system that will first be used on vehicles equipped with the Next Generation Controller NGC This new system replaces the leak detection pump as the method of evaporative system leak detection This is to detect a leak equivalent to a 0 0209 0 5 mm ho...

Page 1621: ...ent circuits in the fuel injection ignition emission and engine systems If the PCM senses a problem with a monitored circuit often enough to indicate an actual problem it stores a Diagnostic Trouble Code DTC in the PCM s memory If the code applies to a non emissions related component or system and the problem is repaired or ceases to exist the PCM cancels the code after 40 warmup cycles Diagnostic...

Page 1622: ...e between a selected switch position versus an open circuit a short circuit or a defective switch If the State Display screen shows the change from HIGH to LOW or LOW to HIGH assume the entire switch circuit to the PCM functions properly From the state display screen access either State Display Inputs and Outputs or State Display Sensors 25 10 EMISSIONS CONTROL LH EMISSIONS CONTROL Continued ...

Page 1623: ...el tank vapors into the atmosphere When fuel evaporates in the fuel tank the vapors pass through vent hoses or tubes to an activated carbon filled evaporative canister The canister temporarily holds the vapors The Powertrain Control Module PCM allows intake manifold vacuum to draw vapors into the combustion chambers during certain operating conditions Fig 1 All engines use a proportional purge sol...

Page 1624: ... REMOVAL The solenoid attaches to a bracket near the air cleaner The solenoid will not operate unless it is installed correctly 1 Disconnect electrical connector from solenoid 2 Disconnect vacuum tubes from solenoid 3 Remove solenoid from bracket INSTALLATION The solenoid attaches to a bracket near the air cleaner The solenoid will not operate unless it is installed correctly Fig 1 ORVR System Sch...

Page 1625: ...he valve returns to the normally closed position CAUTION Remove the fuel filler cap to release fuel tank pressure before disconnecting any fuel system component NATURAL VAC LEAK DETECTION ASSY DESCRIPTION The natural Vacuum Leak detection NVLD sys tem is mounted on top of the EVAP canister Fig 3 that is mounted on the fuel tank REMOVAL 1 Disconnect the negative battery cable 2 Remove fuel tank ref...

Page 1626: ...ured by the canister the vehicle s computer controlled purge system draws vapor out of the canister for the engine to burn The vapors flow is metered by the purge solenoid so that there is no or minimal impact on driveability or tailpipe emissions As fuel starts to flow through the fill tube it opens the normally closed check valve and enters the fuel tank Vapor or air is expelled from the tank th...

Page 1627: ...ube PCV HOSE DESCRIPTION The PCV system has a heat exchanger in the PCV hose that works with the cooling system of the vehi cle Fig 8 or Fig 9 REMOVAL 1 Drain the Cooling system refer to the Cooling system for more information 2 Remove hose from PCV valve 3 Remove hose from valve cover 4 Remove the 2 heater hoses from heat exchanger in PCV hose Fig 7 ORVR System Schematic 1 FUEL TANK PLASTIC 2 FUE...

Page 1628: ... PCV VALVE DESCRIPTION The PCV valve contains a spring loaded plunger The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum Fig 10 or Fig 11 Fig 8 PCV 2 7L Fig 9 PCV 3 2 3 5L Fig 10 PCV Valve 2 7L 1 PCV VALVE 2 THROTTLE BODY 3 EGR TUBE Fig 11 PCV Valve 3 2 3 5L 1 THROTTLE BODY 2 PCV VALVE 25 16 EVAPORATIVE EMISSIONS LH PCV HOSE Continu...

Page 1629: ... Remove the PCV valve from intake manifold The valve should rattle when shaken 5 Replace the PCV valve and retest the system if it does not operate as described in the preceding tests Do not attempt to clean the old PCV valve If the valve rattles apply a light coating of Loctitet Pipe Sealant With Teflon to the threads Thread the PCV valve into the manifold plenum and tighten to 7 N m 60 in lbs to...

Page 1630: ... mounting tab Fig 17 and Fig 18 INSTALLATION 1 Install the EVAP canister to the upper mount ing bracket Fig 17 and Fig 18 2 Swing EVAP canister into the lower mounting and snap into place Fig 16 3 Install the hoses to the top of the EVAP canis ter Fig 15 4 Connect the electrical connector 5 Install the fuel tank refer to the fuel tank installation section 6 Connect the negative battery cable Fig 1...

Page 1631: ...nd regulates the gas flow Second there is the armature return spring and solenoid coil to provide the operating force to regulate the flow by changing the pintle position The solenoid coil assembly is in parallel with a diode and connects to the two connectors in the connector assembly The third major component which senses pintle position and is connected to the three connectors in the elec trica...

Page 1632: ...nstall screws to lower EGR tube to exhaust manifold use new gasket between tube and exhaust manifold 4 Install new gasket between the EGR valve and upper tube and install bolts 5 Tighten EGR valve to cylinder head screws to 31 N m 275 in lbs torque 6 Tighten the EGR tube s to EGR valve bolts to 11 N m 95 in lbs torque 7 Tighten EGR lower tube to exhaust manifold screws to 31 N m 275 in lbs torque ...

Page 1633: ...oose dirt can lodge between the pintle and the seat and cause valve leakage that will give a rough idle and depressed manifold vacuum REMOVAL 2 7L LOWER TUBE 1 Disconnect negative battery cable 2 Remove air inlet tube and resonator and brack et 3 Remove EGR tube mounting screws at EGR valve Fig 5 4 Remove EGR tube mounting screws at exhaust manifold INSTALLATION INSTALLATION 2 7L UPPER TUBE The EG...

Page 1634: ...lbs torque 5 Install air inlet tube and resonator and bracket 6 Connect negative battery cable EGR TUBE 3 5L REMOVAL 3 5L The EGR tube attaches to the bottom of the intake manifold plenum beside the throttle body Fig 8 1 Disconnect negative battery cable 2 Remove air inlet tube and resonator 3 Remove EGR tube mounting clips at intake manifold plenum Fig 7 4 Loosen transmission to throttle body bra...

Page 1635: ...2 Using a new gasket loosely install the 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 Fig 9 EGR tube Seal 1 SILIC...

Page 1636: ...of the test suspend Pending Under some situations the Task Manager will not run a monitor if the MIL is illuminated and a fault is stored from another monitor In these situations the Task Manager postpones monitors pending resolu tion of the original fault The Task Manager does not run the test until the problem is remedied For example when the MIL is illuminated for an Oxygen Sensor fault the Tas...

Page 1637: ...utive trips for MIL illumination Upon failure of the first test the Task Manager enters a maturing code If the component fails the test for a second time the code matures and a DTC is set After three good trips the MIL is extinguished and the Task Manager automatically switches the trip counter to a warm up cycle counter DTCs are auto matically erased following 40 warm up cycles if the component d...

Page 1638: ... by disconnecting the battery also clears all Freeze Frame data Similar Conditions Window The Similar Conditions Window displays informa tion about engine operation during a monitor Abso lute MAP engine load and Engine RPM are stored in this window when a failure occurs There are two different Similar conditions Windows Fuel System and Misfire FUEL SYSTEM Fuel System Similar Conditions Window An i...

Page 1639: ...re Occurred The stored RPM reading at the time of failure Informs the user at what engine RPM the failure occurred Engine RPM A live reading of engine RPM to aid the user in accessing the Similar Conditions Window Adaptive Memory Factor The PCM utilizes both Short Term Compensation and Long Term Adap tive to calculate the Adaptive Memory Factor for total fuel correction 200 Rev Counter Counts 0 10...

Page 1640: ......

Page 1641: ...22 AIRBAG CONTROL MODULE DESCRIPTION SIDE IMPACT 8O 26 AIRBAG CONTROL MODULE INSTALLATION SIDE IMPACT 8O 27 AIRBAG CONTROL MODULE OPERATION SIDE IMPACT 8O 26 AIRBAG CONTROL MODULE REMOVAL SIDE IMPACT 8O 26 AIRBAG DEPLOYMENT STANDARD PROCEDURE SERVICE AFTER AN 8O 6 AIRBAG DEPLOYMENT ZONES POLICE WARNING 8O 4 AIRBAG EQUIPPED INSTALLATION 23 80 23 81 23 82 23 84 23 86 23 88 23 90 23 96 AIRBAG EQUIPPE...

Page 1642: ... SPECIAL TOOLS 8F 6 BATTERY TESTER STANDARD PROCEDURE USING MICRO 420 8F 8 BATTERY TRAY DESCRIPTION 8F 15 BATTERY TRAY OPERATION 8F 15 BEAM INSTALLATION CROSS CAR 23 62 BEAM REMOVAL CROSS CAR 23 62 BEARING DESCRIPTION HUB 2 33 2 4 BEARING OPERATION HUB 2 33 2 4 BEARING ADJUSTMENT PROCEDURE ASSEMBLY ASSEMBLY 21 82 BEARING ADJUSTMENT PROCEDURES ADJUSTMENTS 21 71 BEARING CLEARANCE USING PLASTIGAGE ST...

Page 1643: ...URE BASE 5 4 BRAKE BOOSTER DESCRIPTION POWER 5 42 BRAKE BOOSTER DIAGNOSIS AND TESTING POWER 5 43 BRAKE BOOSTER INSTALLATION POWER 5 45 BRAKE BOOSTER OPERATION POWER 5 43 BRAKE BOOSTER REMOVAL POWER 5 44 BRAKE CABLE TENSIONER INSTALLATION PARKING 5 54 BRAKE CABLE TENSIONER REMOVAL PARKING 5 54 BRAKE COMPONENTS SPECIFICATIONS 5 6 BRAKE FASTENER TORQUE SPECIFICATIONS 5 6 BRAKE FLUID CONTAMINATION DIA...

Page 1644: ...ONVERTER S INSPECTION 11 7 CATALYTIC CONVERTER S OPERATION 11 6 CAUTION REFRIGERANT SYSTEM HOSES LINES TUBES PRECAUTIONS 24 28 CAUTION REFRIGERANT SYSTEM PRECAUTIONS 24 28 CAUTION BRAKES BASE BRAKE SYSTEM 5 3 CAUTION FRONT SUSPENSION 2 3 CAUTION REAR SUSPENSION 2 31 CAUTION SENSOR TPM 22 11 CAUTION STEERING 19 1 CAUTION TIRE PRESSURE MONITORING TPM 22 10 CD CHANGER DESCRIPTION 8A 7 CD CHANGER INST...

Page 1645: ...TEERING 19 11 COLUMN GEAR SHIFT LEVER INSTALLATION STEERING 19 33 COLUMN GEAR SHIFT LEVER REMOVAL STEERING 19 31 COLUMN INTERMEDIATE SHAFT DIAGNOSIS AND TESTING STEERING 19 25 COLUMN SHAFT UPPER COUPLER DIAGNOSIS AND TESTING STEERING 19 30 COMBINATION FLASHER DESCRIPTION 8L 9 COMBINATION FLASHER DIAGNOSIS AND TESTING 8L 9 COMBINATION FLASHER INSTALLATION 8L 10 COMBINATION FLASHER OPERATION 8L 9 CO...

Page 1646: ...LANT THERMOSTAT 3 5L REMOVAL ENGINE 7 24 COOLANT THERMOSTAT DESCRIPTION ENGINE 7 22 COOLANT THERMOSTAT DIAGNOSIS AND TESTING ENGINE 7 23 COOLANT THERMOSTAT OPERATION ENGINE 7 22 COOLER CLEANING TRANSMISSION OIL 7 39 COOLER DESCRIPTION FLUID 19 65 COOLER DESCRIPTION TRANSMISSION OIL 7 38 COOLER INSPECTION TRANSMISSION OIL 7 39 COOLER INSTALLATION FLUID 19 66 COOLER INSTALLATION TRANSMISSION OIL 7 3...

Page 1647: ...DIAGNOSIS AND TESTING 8L 10 DAYTIME RUNNING LAMP MODULE OPERATION 8L 10 DEAERATION DIAGNOSIS AND TESTING COOLING SYSTEM 7 7 DECK LID RELEASE DIAGNOSIS AND TESTING 8N 3 DECK LID RELEASE SOLENOID INSTALLATION 8N 4 DECK LID RELEASE SOLENOID REMOVAL 8N 3 DECK LID RELEASE SWITCH INSTALLATION 8N 4 DECK LID RELEASE SWITCH REMOVAL 8N 4 DECKLID INSTALLATION 23 13 DECKLID REMOVAL 23 13 DECKLID SECURITY SWIT...

Page 1648: ...CRIPTION 25 19 EGR VALVE OPERATION 25 19 ELECTRICAL SHORT TEST DIAGNOSIS AND TESTING FUSE 8G 3 ELECTRONIC VARIABLE BRAKE PROPORTIONING DESCRIPTION 5 62 ELECTRONIC VARIABLE BRAKE PROPORTIONING OPERATION 5 63 ELECTRONIC VEHICLE INFO CENTER DESCRIPTION 8M 10 ELECTRONIC VEHICLE INFO CENTER INSTALLATION 8M 13 ELECTRONIC VEHICLE INFO CENTER OPERATION 8M 11 ELECTRONIC VEHICLE INFO CENTER REMOVAL 8M 13 EL...

Page 1649: ...EMOVAL HEADLAMP WASHER HOSES 8R 13 EXPORT REMOVAL HEADLAMP WASHER NOZZLE 8R 14 EXPORT REMOVAL HEADLAMP WASHER PUMP 8R 14 EXPORT REMOVAL REAR FOG LAMP 8L 37 EXPORT REMOVAL REAR FOG LAMP SWITCH 8L 38 EXPORT REMOVAL SIDE REPEATER LAMP 8L 38 EXPORT REMOVAL SIDE REPEATER LAMP UNIT 8L 39 EXPORT STANDARD PROCEDURE HEADLAMP UNIT ALIGNMENT 8L 29 EXPORT STANDARD PROCEDURE HEADLAMP WASHER SYSTEM PRIMING 8R 1...

Page 1650: ...TIONS 2 3 FRONT SUSPENSION SPECIAL TOOLS 2 3 FRONT TOW EYE INSTALLATION 13 10 FRONT TOW EYE REMOVAL 13 9 FRONT TOW HOOK BRACKET INSTALLATION 13 10 FRONT TOW HOOK BRACKET REMOVAL 13 10 FRONT WHEEL SPEED SENSOR DESCRIPTION 5 66 FRONT WHEEL SPEED SENSOR INSTALLATION 5 67 FRONT WHEEL SPEED SENSOR OPERATION 5 66 FRONT WHEEL SPEED SENSOR REMOVAL 5 67 FUEL CORRECTION OR ADAPTIVE MEMORIES OPERATION 14 18 ...

Page 1651: ...MP UNIT ALIGNMENT EXPORT STANDARD PROCEDURE 8L 29 HEADLAMP UNIT ALIGNMENT STANDARD PROCEDURE 8L 27 HEADLAMP WASHER EXPORT DIAGNOSIS AND TESTING 8R 9 HEADLAMP WASHER HOSES EXPORT INSTALLATION 8R 13 HEADLAMP WASHER HOSES EXPORT REMOVAL 8R 13 HEADLAMP WASHER NOZZLE EXPORT INSTALLATION 8R 14 HEADLAMP WASHER NOZZLE EXPORT REMOVAL 8R 14 HEADLAMP WASHER PUMP EXPORT INSTALLATION 8R 15 HEADLAMP WASHER PUMP...

Page 1652: ...EMOVAL 8I 6 IGNITION SENSE PCM INPUT OPERATION 8E 11 IGNITION SWITCH INSTALLATION 19 24 IGNITION SWITCH REMOVAL 19 24 IGNITION SYSTEM DESCRIPTION 8I 1 IGNITION SYSTEM OPERATION 8I 1 IGNITION OFF DRAW TEST STANDARD PROCEDURE 8F 11 ILLUMINATED ENTRY DESCRIPTION 8L 49 ILLUMINATED ENTRY DIAGNOSIS AND TESTING 8L 50 ILLUMINATED ENTRY OPERATION 8L 49 ILLUMINATION DESCRIPTION TRANSMISSION RANGE INDICATOR ...

Page 1653: ...LINDER INSTALLATION 19 26 KEY LOCK CYLINDER OPERATION 19 25 KEY LOCK CYLINDER REMOVAL 19 25 KNOB INSTALLATION TRIP ODOMETER RESET 8J 5 KNOB REMOVAL TRIP ODOMETER RESET 8J 5 KNOCK SENSOR DESCRIPTION 8I 7 KNOCK SENSOR INSTALLATION 8I 8 KNOCK SENSOR OPERATION 8I 7 KNOCK SENSOR REMOVAL 8I 7 KNUCKLE DESCRIPTION STEERING 2 7 KNUCKLE DIAGNOSIS AND TESTING STEERING 2 7 KNUCKLE INSTALLATION STEERING 2 10 K...

Page 1654: ... 5 8 LEVEL SWITCH REMOVAL WASHER FLUID 8R 15 LEVELING MOTOR EXPORT DESCRIPTION HEADLAMP 8L 23 LEVELING MOTOR EXPORT DIAGNOSIS AND TESTING HEADLAMP 8L 24 LEVELING MOTOR EXPORT OPERATION HEADLAMP 8L 23 LEVELING SWITCH EXPORT DESCRIPTION HEADLAMP 8L 25 LEVELING SWITCH EXPORT DIAGNOSIS AND TESTING HEADLAMP 8L 25 LEVELING SWITCH EXPORT INSTALLATION HEADLAMP 8L 26 LEVELING SWITCH EXPORT OPERATION HEADLA...

Page 1655: ...TION OR ADAPTIVE 14 18 MEMORY HEATED SEAT MIRROR MODULE DESCRIPTION 8E 6 MEMORY HEATED SEAT MIRROR MODULE DIAGNOSIS AND TESTING 8E 6 MEMORY HEATED SEAT MIRROR MODULE INSTALLATION 8E 8 MEMORY HEATED SEAT MIRROR MODULE OPERATION 8E 6 MEMORY HEATED SEAT MIRROR MODULE REMOVAL 8E 7 MEMORY SEAT SYSTEM DESCRIPTION 8N 12 MEMORY SEAT SYSTEM DIAGNOSIS AND TESTING 8N 14 MEMORY SEAT SYSTEM OPERATION 8N 13 MEM...

Page 1656: ...EXER INSTALLATION 8A 7 MULTIPLEXER REMOVAL 8A 7 NATURAL VAC LEAK DETECTION ASSY DESCRIPTION 25 13 NATURAL VAC LEAK DETECTION ASSY INSTALLATION 25 14 NATURAL VAC LEAK DETECTION ASSY REMOVAL 25 13 NAVIGATION RADIO INSTALLATION ANTENNA 8A 6 NAVIGATION RADIO REMOVAL ANTENNA 8A 6 NIGHT MIRROR DESCRIPTION AUTOMATIC DAY 8N 9 NIGHT MIRROR OPERATION AUTOMATIC DAY 8N 9 NOISE DIAGNOSIS AND TESTING COMPRESSOR...

Page 1657: ...SSENGER POWER SEAT SWITCH DESCRIPTION 8N 17 PASSENGER POWER SEAT SWITCH DIAGNOSIS AND TESTING 8N 17 PASSENGER POWER SEAT SWITCH INSTALLATION 8N 18 PASSENGER POWER SEAT SWITCH OPERATION 8N 17 PASSENGER POWER SEAT SWITCH REMOVAL 8N 18 PASSENGER VEHICLES INSTALLATION OCCUPANT RESTRAINT CONTROLLER 5 8O 16 PASSENGER VEHICLES INSTALLATION OCCUPANT RESTRAINT CONTROLLER 6 8O 17 PASSENGER VEHICLES INSTALLA...

Page 1658: ...RENCES STANDARD PROCEDURE TOGGLING CUSTOMER 8N 3 PREPARATION STANDARD PROCEDURE ENGINE GASKET SURFACE 9 11 PRESSURE DIAGNOSIS AND TESTING CHECKING ENGINE OIL 9 61 PRESSURE AND RETURN HOSES INSTALLATION 19 71 PRESSURE AND RETURN HOSES REMOVAL 19 67 PRESSURE CAP DESCRIPTION 7 29 PRESSURE CAP INSPECTION 7 29 PRESSURE CAP OPERATION 7 29 PRESSURE CONTAINER DESCRIPTION COOLANT RECOVERY 7 20 PRESSURE CON...

Page 1659: ...NSTALLATION 23 113 REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 23 113 REAR DOOR MOUNTED WEATHERSTRIP INSTALLATION 23 114 REAR DOOR MOUNTED WEATHERSTRIP REMOVAL 23 114 REAR FASCIA INSTALLATION 13 4 REAR FASCIA REMOVAL 13 3 REAR FOG LAMP EXPORT DESCRIPTION 8L 37 REAR FOG LAMP EXPORT DIAGNOSIS AND TESTING 8L 37 REAR FOG LAMP EXPORT INSTALLATION 8L 37 REAR FOG LAMP EXPORT OPERATION 8L 37 REAR FOG LAMP EX...

Page 1660: ...IL PRESSURE 9 66 REMOTE KEYLESS ENTRY MODULE INSTALLATION 8N 6 REMOTE KEYLESS ENTRY MODULE REMOVAL 8N 6 REMOTE LOCK ACTUATOR INSTALLATION CABLE 23 33 REMOTE LOCK ACTUATOR REMOVAL CABLE 23 33 REMOTE SWITCHES DESCRIPTION 8A 11 REMOTE SWITCHES DIAGNOSIS AND TESTING 8A 11 REMOTE SWITCHES INSTALLATION 8A 13 REMOTE SWITCHES OPERATION 8A 11 REMOTE SWITCHES REMOVAL 8A 12 REPEATER LAMP EXPORT DESCRIPTION S...

Page 1661: ...RBAG WIRING HARNESS INSTALLATION 8O 24 SEAT AIRBAG WIRING HARNESS REMOVAL 8O 23 SEAT BACK COVER INSTALLATION REAR 23 95 SEAT BACK COVER REMOVAL REAR 23 95 SEAT BELT RETRACTOR CENTER INSTALLATION REAR 8O 21 SEAT BELT RETRACTOR CENTER REMOVAL REAR 8O 21 SEAT BELT RETRACTOR INSTALLATION FRONT 8O 15 SEAT BELT RETRACTOR INSTALLATION REAR 8O 20 SEAT BELT RETRACTOR REMOVAL FRONT 8O 14 SEAT BELT RETRACTOR...

Page 1662: ...SENSOR OUTPUT DESCRIPTION SPEED 21 144 SENSOR OUTPUT INSTALLATION SPEED 21 145 SENSOR OUTPUT OPERATION SPEED 21 145 SENSOR OUTPUT REMOVAL SPEED 21 145 SENSOR REMOVAL AMBIENT TEMP 24 14 SENSOR REMOVAL AMBIENT TEMPERATURE 8M 15 SENSOR REMOVAL CRANKSHAFT POSITION 14 23 SENSOR REMOVAL ENGINE COOLANT TEMPERATURE 7 22 SENSOR REMOVAL EVAPORATOR TEMPERATURE 24 16 SENSOR REMOVAL FRONT WHEEL SPEED 5 67 SENS...

Page 1663: ...CONTROL VALVE DESCRIPTION 19 45 SOLENOID CONTROL VALVE INSTALLATION 19 46 SOLENOID CONTROL VALVE OPERATION 19 45 SOLENOID CONTROL VALVE REMOVAL 19 45 SOLENOID PRESSURE SWITCH ASSY DESCRIPTION 21 141 SOLENOID PRESSURE SWITCH ASSY INSTALLATION 21 142 SOLENOID PRESSURE SWITCH ASSY OPERATION 21 141 SOLENOID PRESSURE SWITCH ASSY REMOVAL 21 142 SPARE TIRE TEMPORARY DESCRIPTION 22 16 SPARK PLUG INSTALLAT...

Page 1664: ...MOVAL ROOF 23 70 STRUT DESCRIPTION TENSION 2 29 STRUT INSTALLATION TENSION 2 29 STRUT OPERATION TENSION 2 29 STRUT REMOVAL TENSION 2 29 STRUT ASSEMBLY FRONT ASSEMBLY 2 27 STRUT ASSEMBLY FRONT DESCRIPTION 2 22 STRUT ASSEMBLY FRONT DIAGNOSIS AND TESTING 2 23 STRUT ASSEMBLY FRONT DISASSEMBLY 2 25 STRUT ASSEMBLY FRONT INSTALLATION 2 28 STRUT ASSEMBLY FRONT OPERATION 2 22 STRUT ASSEMBLY FRONT REMOVAL 2...

Page 1665: ...42 SWITCH ASSY OPERATION SOLENOID PRESSURE 21 141 SWITCH ASSY REMOVAL SOLENOID PRESSURE 21 142 SWITCHES DESCRIPTION REMOTE 8A 11 SWITCHES DIAGNOSIS AND TESTING REMOTE 8A 11 SWITCHES INSTALLATION REMOTE 8A 13 SWITCHES OPERATION REMOTE 8A 11 SWITCHES REMOVAL REMOTE 8A 12 SYMBOLS DESCRIPTION INTERNATIONAL Intro 5 SYMBOLS DESCRIPTION INTERNATIONAL 0 1 TACHOMETER DESCRIPTION 8J 4 TACHOMETER OPERATION 8...

Page 1666: ... SPECIFICATIONS 5 66 TOOLS 3 5L ENGINE SPECIAL 9 19 TOOLS 42LE AUTOMATIC TRANSAXLE SPECIAL 21 63 TOOLS BASE BRAKE SYSTEM SPECIAL 5 7 TOOLS BATTERY SYSTEM SPECIAL TOOLS SPECIAL 8F 6 TOOLS BODY SPECIAL 23 12 TOOLS COOLING SPECIAL 7 12 TOOLS DRIVELINE SPECIAL 3 9 TOOLS EXHAUST SYSTEM SPECIAL 11 6 TOOLS FRONT SUSPENSION SPECIAL 2 3 TOOLS FUEL SPECIAL 14 21 14 3 TOOLS POWER STEERING SPECIAL 19 11 TOOLS...

Page 1667: ...TAIL LAMP 8L 44 UNIT POLICE INSTALLATION UNDERHOOD LAMP 8L 46 UNIT POLICE REMOVAL UNDERHOOD LAMP 8L 45 UNIT REMOVAL BACK UP LAMP 8L 5 UNIT REMOVAL CENTER HIGH MOUNTED STOP LAMP 8L 8 UNIT REMOVAL FOG LAMP 8L 14 UNIT REMOVAL LICENSE PLATE LAMP 8L 31 UNIT REMOVAL TAIL LAMP 8L 44 UNIT SENSOR DESCRIPTION FUEL LEVEL SENDING 14 3 UNIT SENSOR INSTALLATION FUEL LEVEL SENDING 14 4 UNIT SENSOR OPERATION FUEL...

Page 1668: ...LLATION 8R 16 WASHER PUMP MOTOR INTREPID INSTALLATION 8R 16 WASHER PUMP MOTOR INTREPID REMOVAL 8R 16 WASHER PUMP MOTOR REMOVAL 8R 16 WASHER RESERVOIR INSTALLATION 8R 17 WASHER RESERVOIR INTREPID INSTALLATION 8R 18 WASHER RESERVOIR INTREPID REMOVAL 8R 18 WASHER RESERVOIR REMOVAL 8R 17 WASHER RESERVOIR FILLER TUBE INSTALLATION 8R 18 WASHER RESERVOIR FILLER TUBE REMOVAL 8R 18 WASHER SYSTEM PRIMING EX...

Page 1669: ...TOR INSTALLATION 23 26 23 33 WINDOW REGULATOR REMOVAL 23 26 23 33 WINDOW SWITCH DIAGNOSIS AND TESTING 8N 23 WINDOW SWITCH INSTALLATION 8N 24 WINDOW SWITCH REMOVAL 8N 23 WINDOWS DESCRIPTION POWER 8N 21 WINDOWS DIAGNOSIS AND TESTING POWER 8N 21 WINDOWS OPERATION POWER 8N 21 WINDSHIELD DESCRIPTION 23 98 WINDSHIELD INSTALLATION 23 99 WINDSHIELD REMOVAL 23 98 WINDSHIELD WASHERS DIAGNOSIS AND TESTING 8R...

Page 1670: ......

Page 1671: ...______________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Dealership Technician Dealer Code Retail Customer Manual Title Year Number and Page _________________________________________________ _____________________________________________...

Page 1672: ...DaimlerChrysler Corporation Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills MI 48326 2757 8 ...

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