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Chrysler 2005 Sebring, Service Manual, Page: 2071 / 3204

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Chrysler 2005 Sebring Service Manual Download Page 2071

Fig. 232 INNER REAR WHEELHOUSE TO REAR FLOOR PAN

Fig. 233 SILL EXTENSION, INNER REAR WHEELHOUSE TO REAR FLOOR PAN

23 - 296

BODY STRUCTURE

JR

WELD LOCATIONS (Continued)

Summary of Contents for 2005 Sebring

Page 1: ...Welcome 2005 JR Sebring Stratus Sedan and Sebring Convertible Technical Publications Click on the icon for the desired manual Service Manual Powertrain Body Chassis Transmission ...

Page 2: ...IC PINION FACTOR IF APPLICABLE 4 3 4 USING THE DRBIII 5 3 5 DRBIII ERROR MESSAGES 5 3 5 1 DRBIII DOES NOT POWER UP BLANK SCREEN 5 3 5 2 DISPLAY IS NOT VISIBLE 5 3 5 3 SOME DISPLAY ITEMS READ 5 3 6 TRANSMISSION SIMULATOR MILLER TOOL 8333 AND FWD ADAPTER MILLER TOOL 8333 1A 5 4 0 DISCLAIMERS SAFETY AND WARNINGS 6 4 1 DISCLAIMERS 6 4 2 SAFETY 6 4 2 1 TECHNICIAN SAFETY INFORMATION 6 4 2 2 VEHICLE PREP...

Page 3: ...RCUIT 72 P0755 2 4 SOLENOID CIRCUIT 76 P0760 OD SOLENOID CIRCUIT 80 P0765 UD SOLENOID CIRCUIT 84 P0841 LR PRESSURE SWITCH SENSE CIRCUIT 88 P0845 2 4 HYDRAULIC PRESSURE TEST FAILURE 92 P0846 2 4 PRESSURE SWITCH SENSE CIRCUIT 97 P0870 OD HYDRAULIC PRESSURE TEST FAILURE 101 P0871 OD PRESSURE SWITCH SENSE CIRCUIT 106 P0884 POWER UP AT SPEED 110 P0888 RELAY OUTPUT ALWAYS OFF 111 P0890 SWITCHED BATTERY ...

Page 4: ...TIONS 166 9 0 CONNECTOR PINOUTS 167 AUTOSTICK SWITCH NATURAL 4 WAY 167 DATA LINK CONNECTOR BLACK 16 WAY 167 INPUT SPEED SENSOR GRAY 2 WAY 167 LEFT BACK UP LAMP BLACK 2 WAY 167 FUSES PDC 169 POWERTRAIN CONTROL MODULE C1 BLACK BLACK 38 WAY 170 POWERTRAIN CONTROL MODULE C2 BLACK ORANGE 38 WAY 171 POWERTRAIN CONTROL MODULE C3 BLACK NATURAL 38 WAY 172 10 0 SCHEMATIC DIAGRAMS 173 10 1 EATX 40 41TE 173 1...

Page 5: ...NOTES iv ...

Page 6: ... may be enhanced READ THIS MANUAL BEFORE TRYING TO DIAGNOSE A VEHICLE TROUBLE CODE It is recommended that you review the entire manual to become familiar with all new and changed diagnostic procedures This book reflects many suggested changes from readers of past issues After using this book if you have any comments or recommendations please fill out the form at the back of the book and mail it ba...

Page 7: ...cle operation Vehicles using calculated oil tem perature are reasonably accurate during normal operation However if a transmission is overfilled a transmission oil cooler becomes restricted or if a customer drives aggressively in low gear the calcu lated oil temperature will be inaccurate Conse quently the shift schedule selected may be inappro priate for the current conditions 3 3 DIAGNOSTIC TROU...

Page 8: ...les A warm up cycle is defined as sufficient vehicle operation such that the coolant temperature has risen by at least 22 C 40 F from engine starting and reaches a minimum temperature of 71 C 160 F The Malfunction Indicator Lamp MIL will turn off after 3 good trips or when the DTC s are cleared from the control module 3 3 6 QUICK LEARN The Quick Learn function customizes adaptive parameters of the...

Page 9: ...when doing a 4 3 or 4 2 shift The transmission temperature must be above 43 C 110 F The clutch volume should be between 24 and 70 Transmission Effects These CVIs that are out of range are usually set with other DTC s which indicates an internal transmission problem Possible Causes Clutch pack clearance out of spec Snap ring out of position or broken Broken return spring Hydraulic leak into clutch ...

Page 10: ...the vehicle or other devices and the vehicle battery is fully charged an inoperative DRBIII may be the result of faulty cable or vehicle wiring For a blank screen refer to the appropriate Body Diagnostic manual 3 5 2 DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display Adjust the contrast to compensate for this condition 3 5 3 SOME DISPLAY ITEMS READ This is caused by ...

Page 11: ...uid at high pressure Before disconnecting any hydraulic tubes hoses and fittings be sure that the system is fully depres surized When servicing a vehicle always wear eye protection and remove any metal jewelry such as watchbands or bracelets that might make an inad vertent electrical contact When diagnosing a Transmission system prob lem it is important to follow approved procedures where applicab...

Page 12: ...cated may result in a dangerous electrical system over load If a properly rated fuse continues to blow it indicates a problem in the circuit that must be corrected 4 3 2 ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure The purpose of the test drive is to try to duplicate the diagnostic DTC or symptom condition CAUTION Before ro...

Page 13: ...ted that depend on speed information 4 4 4 BULLETINS AND RECALLS Always perform all Safety Recalls and Technical Service Bulletins that are applicable to the prob lem 5 0 REQUIRED TOOLS AND EQUIPMENT DRBIII diagnostic read out box Must be at latest release level Transmission Simulator Miller 8333 Adapter harness panel overlay kit for Transmis sion Simulator Miller 8333 1A for FWD vehi cles J umper...

Page 14: ...tch or Pres sure Switch 6 2 DEFINITIONS OBDII EURO STAGE III OBD Trip A vehicle start and drive cycle such that all once per trip diagnostic monitors have run Key Start A vehicle start and run cycle of at least 20 seconds Warm up Cycle A vehicle start and run cycle such that the engine coolant must rise to at least 71 C 160 F and must rise by at least 4 4 C 40 F from initial start up To count as a...

Page 15: ...NOTES 10 ...

Page 16: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 11 ...

Page 17: ...e DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC s s...

Page 18: ...the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 The conditions necessary to set thi...

Page 19: ...the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC s...

Page 20: ...e schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 The conditions necessary to set this ...

Page 21: ...rforming any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gea...

Page 22: ... Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 NOTE Due to the integration of the Pow ertrain and Transmission Control Modules communication betw een the modules is internal Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Repl...

Page 23: ...ymptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and rec...

Page 24: ...to aid the Technician in diagnosing shift quality complaints This DTC indicates that the transmission has been operating in the Overheat shift schedule which may generate a customer complaint The customer driving patterns may indicate the need for an additional transmission oil cooler With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set View repair opt...

Page 25: ...radually falling battery voltage or a resistive connection s to the PCM The DTC will also set if the battery voltage sensed at the PCM is less than 6 5v for 200ms or where Transmission Control Relay Output circuits is less than 7 2v for 200ms POSSIBLE CAUSES RELATED CHARGING SYSTEM DTC S GROUND CIRCUIT OPEN OR HIGH RESISTANCE FUSED B CIRCUIT TO RELAY HIGH RESISTANCE FUSED B CIRCUIT TO PCM HIGH RES...

Page 26: ... that all diagnostic monitors have run NOTE Verify flash level of Pow ertrain Control Module Some problems are corrected by softw are upgrades to the Transmission and Engine softw are NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIII read the Engine DTC s Are there any Charging System related DTC s presen...

Page 27: ...ning CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Using a 12 volt test light connected to ground check the Fused B circuit in the appropriate terminal of special tool 8815 NOTE The Test light must illuminate brightly Compare the bri...

Page 28: ...n Control Relay Output circuit for an open or high resistance Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 8 Turn the ignition off to the lock position Install a substitute Relay in place of the Transmission Control Relay Start the engine Using a voltmeter measure the battery voltage With the DRBIII monitor the Transmission Switched Battery Voltage Compare the DRBIII Transmission Switc...

Page 29: ... this circuit Wiggle the wiring and connectors while checking for shorts and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 24 TRANSMISSION NGC P0562 LOW BATTERY VOLTAGE Continued ...

Page 30: ...al the technician that the controller still has generic software installed TEST ACTION APPLICABILITY 1 NOTE Controller is programmed w ith generic softw are and w ill not allow the correct vehicle Pow ertrain management Record the vehicles controller part number Select Use Controller Part Number under the Flash Tab Flash the controller with the correct software Test complete All Yes Test Complete ...

Page 31: ... ERROR TEST ACTION APPLICABILITY 1 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module WITH THE DRBIII PERFORM QUICK LEARN AND REPROGRAM PINION FAC TOR Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VE...

Page 32: ...ing in park or neutral if a problem exists POSSIBLE CAUSES SHIFTER OUT OF ADJ USTMENT TRS T1 SENSE CIRCUIT OPEN TRS T3 SENSE CIRCUIT OPEN TRS T41 SENSE CIRCUIT OPEN TRS T42 SENSE CIRCUIT OPEN TRS T1 SENSE CIRCUIT SHORT TO GROUND TRS T3 SENSE CIRCUIT SHORT TO GROUND TRS T41 SENSE CIRCUIT SHORT TO GROUND TRS T42 SENSE CIRCUIT SHORT TO GROUND TRS T1 SENSE CIRCUIT SHORT TO VOLTAGE TRS T3 SENSE CIRCUIT...

Page 33: ...y flash level of Pow ertrain Control Module Some problems are corrected by softw are upgrades to the Transmission and Engine softw are NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIII erase Transmission DTCs Cycle the ignition off then start the vehicle Firmly apply the brakes and shift into Overdrive NO...

Page 34: ...r Position Test pass All Yes Go To 5 No Go To 6 NOTE After completion of this procedure make sure to disconnect the Transmission Simulator Miller tool 8333 and FWD adaptor cable kit Miller tool 8333 1A and reconnect all connectors 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Range Sensor per the Service Informa tion Perform 40 41TE NGC TRANSMISSION VE...

Page 35: ...CTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T1 Sense circuit Is the resistance below 5 0 ohms All Yes Repair the TRS T1 Sense circuit for a short to ground Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 9 9 Turn the ignition off to the lock position Disconnect the TRS harness connector Disconnect the PCM harness c...

Page 36: ...NG IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T3 Sense circuit Is the resistance below 5 0 ohms All Yes Repair the TRS T3 Sense circuit for a short to ground Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 12 12 Turn the ignition off to the lock position Disconnect the TRS harness conn...

Page 37: ...G IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T41 Sense circuit Is the resistance below 5 0 ohms All Yes Repair the TRS T41 Sense circuit for a short to ground Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 15 15 Turn the ignition off to the lock position Disconnect the TRS harness con...

Page 38: ...G IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the TRS T42 Sense circuit Is the resistance below 5 0 ohms All Yes Repair the TRS T42 Sense circuit for a short to ground Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 18 18 Turn the ignition off to the lock position Disconnect the TRS harness con...

Page 39: ...nformation Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 21 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits Check the Shift Linkage and cable for proper operation per the Service Information With the...

Page 40: ...evel per the Service Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram ...

Page 41: ...h the Transmission Simulator turn the Input Output switch to OFF With the DRBIII monitor the TRANS TEMP VOLTS while turning the Thermistor Voltage switch to all three positions on the Transmission Simulator Compare the DRBIII readings with the numbers listed on the Transmission Simulator Do the readings on the Transmission Simulator match the DRBIII readings 0 2 volts All Yes Go To 5 No Go To 6 5 ...

Page 42: ... circuit Wiggle the wires while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 37 TRANSMISSION NGC P0711 TRANSMISSION TEMPERATURE SENSOR PERFORMANCE Continued ...

Page 43: ...s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter S...

Page 44: ...o the readings on the Transmission Simulator match the DRBIII readings 0 2 volts All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace Transmission Solenoid TRS assembly per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM C4 harness connector Disconnect t...

Page 45: ...RANSMISSION VERIFICATION TEST VER 1 8 The conditions necessary to set this DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Re...

Page 46: ...s perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and ...

Page 47: ...nsmission Simulator Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Note Check connectors Clean repair as necessary Ignition on engine not running With the Transmission Simulator turn the Input Output switch to OFF With the DRBIII monitor the TRANS TEMP VOLTS while turning the Thermistor Voltage switch to all three positions on the Transmission Simulator Compare the DRBIII re...

Page 48: ...epair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Connect a jumper wire between the Fused B circuit and the Transmission Control Relay Output circuit in the Transmission Control Relay connector Ignition on engine not r...

Page 49: ...this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 44 TRANSMISSION NGC P0713 TRANSMISSION TEMPERATURE SENSOR HIGH Continued ...

Page 50: ...mission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s chec...

Page 51: ...eading 0 2 volts All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace Transmission Solenoid TRS assembly per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no...

Page 52: ...NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the ...

Page 53: ...o 4 No Go To 5 4 If there are no possible causes remaining view repair All Repair Replace the Input Speed Sensor per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Input Speed Sensor harness connector Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE...

Page 54: ...OOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the Input Speed Sensor Signal circuit Is the resistance Below 5 0 ohms All Yes Repair the Input Speed Sensor Signal circuit for a short to ground Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 8 8 Turn the ignition off to the lock position Disconnect the...

Page 55: ...voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN AND REPR...

Page 56: ...ion NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect ...

Page 57: ...With the DRBIII read the Input and Output RPM Does the Input RPM read 3000 and the Output RPM read 1250 within 50 RPM All Yes Go To 4 No Go To 5 4 If there are no possible causes remaining view repair All Repair Replace the Output Speed Sensor per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 Turn the ignition off to the lock position Disconnect the PCM harness...

Page 58: ...POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the Output Speed Sensor Signal circuit Is the resistance below 5 0 ohms All Yes Repair the Output Speed Sensor Signal circuit for a short to ground Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 8 8 Turn the ignition off to the lock position Disconnect ...

Page 59: ...C TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perfor...

Page 60: ...DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC s set on start up but some mus...

Page 61: ...ule per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 5 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With t...

Page 62: ...II read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not...

Page 63: ...ill sets Gear Ratio DTC check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Check the wiring and connectors for the Speed Sensors for a good connection then perform a wiggle test using the Transmission Simulator Miller tool 8333 and the Electronic Transmission Adapter k...

Page 64: ...e symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position T...

Page 65: ... Test and still sets Gear Ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Check the Speed Sensor wiring and connectors for good connection then perform a wiggle test using the Transmission Simulator Miller tool 8333 and the Electronic Transmission Adapte...

Page 66: ... internal transmission per the Service Information Check all of the components related to the UD and 2 4 clutches Inspect the Oil Pump and repair or replace per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 61 TRANSMISSION NGC P0732 GEAR RATIO ERROR IN 2ND Continued ...

Page 67: ...e symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position T...

Page 68: ... vehicle passes the clutch test and still sets gear ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Check the speed sensor wiring and connectors for good connection then perform a wiggle test using the Transmission Simulator Miller tool 8333 and the Elec...

Page 69: ... internal transmission per the Service Information Check all of the components related to the UD and OD clutches Inspect the Oil Pump and repair or replace per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 64 TRANSMISSION NGC P0733 GEAR RATIO ERROR IN 3RD Continued ...

Page 70: ...e symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position T...

Page 71: ...uits If the vehicle passes the clutch test and still sets gear ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Check the Speed Sensor wiring and connectors for good connection then perform a wiggle test using the Transmission Simulator Miller tool 8333 a...

Page 72: ... internal transmission per the Service Information Check all of the components related to the OD and 2 4 clutches Inspect the Oil Pump and repair or replace per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 67 TRANSMISSION NGC P0734 GEAR RATIO ERROR IN 4TH Continued ...

Page 73: ...DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does...

Page 74: ... test and still sets gear ratio DTC s check the Speed Sensors for proper operation Remove the Starter Relay With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Check the Speed Sensor wiring and connectors for good connection then perform a wiggle test using the Transmission Simulator Miller tool 8333 and Electronic Transmission Adapter kit Miller tool...

Page 75: ...the leak then check and adjust the fluid level per the Service Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a f...

Page 76: ...itions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits This DTC can also be set under extreme temperature conditions this is usually caused by an internal problem Verify if the problem is only experienced under extreme hot or...

Page 77: ...hen check and adjust the fluid level per the Service Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matur...

Page 78: ...the L R Solenoid LED on the Transmission Simulator blink on and off during actuation All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harness conne...

Page 79: ...CTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the LR Solenoid Control circuit Is the voltage above 0 5 volts All Yes Repair the LR Solenoid Control circuit for a short to voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 9 9 Tur...

Page 80: ... Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any pro...

Page 81: ...e fluid level per the Service Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring...

Page 82: ...the Transmission Simulator blink on and off during actuation All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Tran...

Page 83: ...E PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the 2 4 Solenoid Control circuit Is the voltage above 0 5 volts All Yes Repair the 2 4 Solenoid Control circuit for a short to voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST V...

Page 84: ... 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there...

Page 85: ...e fluid level per the Service Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring...

Page 86: ...nsmission Simulator blink on and off during actuation All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Transmissio...

Page 87: ...HE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the OD Solenoid Control circuit Is the voltage above 0 5 volts All Yes Repair the OD Solenoid Control circuit for a short to voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VE...

Page 88: ... 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there...

Page 89: ...luid level per the Service Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring di...

Page 90: ...the Transmission Simulator blink on and off All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Transmission Solenoid...

Page 91: ...HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the UD Solenoid Control circuit Is the voltage above 0 5 volts All Yes Repair the UD Solenoid Control circuit for a short to voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No ...

Page 92: ... 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there...

Page 93: ...Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide ...

Page 94: ...nition off to the lock position Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Install the Transmission Simulator Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Note Check connectors Clean repair as necessary Ignition on engine not running With the Transmission Simulator turn the Pressu...

Page 95: ...NNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the L R Pressure Switch Sense circuit Is the resistance below 5 0 ohms All Yes Repair the L R Pressure Switch Sense circuit for a short to ground Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 9 9 Tur...

Page 96: ... sure to check for a short to ground Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUI...

Page 97: ...ily turns on element pressure to the clutch circuits that don t have pressure to verify that the correct pressure switch closes If the pressure switch does not close 2 times the DTC sets POSSIBLE CAUSES LOSS OF PRIME P0944 PRESENT TRANSMISSION CONTROL RELAY OUTPUT CIRCUIT OPEN 2 4 PRESSURE SWITCH SENSE CIRCUIT OPEN 2 4 PRESSURE SWITCH CIRCUIT SHORT TO GROUND INTERNAL TRANSMISSION 2 4 PRESSURE SWIT...

Page 98: ...ing the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Pow ertrain Control Module Some problems are corrected by softw are upgrades to the Transmission and Engine softw are NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIII check for other Transmission DTC s Is the DTC P0944 ...

Page 99: ... and inspect the Valve Body per the Service Informa tion and repair or replace as necessary If no problems are found in the Valve Body replace the Transmission Solenoid Pressure Switch Assembly Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Transmission Solenoid Pressure Switch Assembly harne...

Page 100: ...ONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the 2 4 Pressure Switch Sense circuit Is the voltage above 0 5 volts All Yes Repair the 2 4 Pressure Switch Sense circuit for a short to voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Turn the ignition of...

Page 101: ... 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 12 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems fo...

Page 102: ...OTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the w...

Page 103: ...he Transmission Simulator Did the state of the 2 4 Pressure Switch change while pressing the Pressure Switch Test button All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock posit...

Page 104: ... CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the 2 4 Pressure Switch Sense circuit Is the voltage above 0 5 volts All Yes Repair the 2 4 Pressure Switch Sense circuit for a short to voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER ...

Page 105: ...form 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were any problems foun...

Page 106: ... on element pressure to the clutch circuits that don t have pressure to verify that the correct pressure switch closes If the pressure switch does not close 2 times the DTC sets POSSIBLE CAUSES LOSS OF PRIME P0944 PRESENT TRANSMISSION CONTROL RELAY OUTPUT CIRCUIT OPEN OD PRESSURE SWITCH SENSE CIRCUIT SHORT TO GROUND OD PRESSURE SWITCH SENSE CIRCUIT OPEN OD PRESSURE SWITCH SENSE CIRCUIT SHORT TO VO...

Page 107: ... by driving the vehicle such that all diagnostic monitors have run NOTE Verify flash level of Pow ertrain Control Module Some problems are corrected by softw are upgrades to the Transmission and Engine softw are NOTE Check for applicable TSB s related to the problem Perform this procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIII check for other Transmission DTC s Is the DT...

Page 108: ...nforma tion and repair or replace as necessary If no problems are found in the Valve Body replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Transmission Solenoid Pressure Switch Assembly harness connector Note...

Page 109: ...NG THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the OD Pressure Switch Sense circuit Is the voltage above 0 5 volts All Yes Repair the OD Pressure Switch Sense circuit for a short to voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Tu...

Page 110: ... 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 12 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems fo...

Page 111: ... ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring a...

Page 112: ...Switch test button Did the OD Pressure Switch state change while pressing the Pressure Switch test button All Yes Go To 5 No Go To 6 5 If there are no possible causes remaining view repair All Repair Replace the Solenoid Pressure Switch Assembly per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 6 Turn the ignition off to the lock position Disconnect the PCM harne...

Page 113: ...CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the voltage of the OD Pressure Switch Sense circuit Is the voltage above 0 5 volts All Yes Repair the OD Pressure Switch Sense circuit for a short to voltage Perform 40 41TE NGC T...

Page 114: ...E NGC TRANSMISSION VERIFICATION TEST VER 1 11 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any pr...

Page 115: ...s of power to the Transmission portion of the PCM CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS NOTE Due to the integration of the Pow ertrain and Transmission Control Modules the transmission part of the PCM has its ow n specific po...

Page 116: ...n and Transmission Control Modules the transmission part of the PCM has its own specific power and ground circuits POSSIBLE CAUSES FUSED B CIRCUIT OPEN TRANSMISSION CONTROL RELAY OUTPUT CIRCUIT OPEN TRANSMISSION CONTROL RELAY TRANSMISSION CONTROL RELAY CONTROL CIRCUIT OPEN TRANSMISSION CONTROL RELAY GROUND CIRCUIT OPEN TRANSMISSION CONTROL RELAY CONTROL CIRCUIT SHORT TO GROUND TRANSMISSION CONTROL...

Page 117: ...procedure prior to Symptom diagnosis All Continue Go To 2 2 With the DRBIII Check the STARTS SINCE SET counter for P0888 Note This counter only applies to the last DTC set Is the STARTS SINCE SET counter equal to 0 All Yes Go To 3 No Go To 13 3 Turn the ignition off to the lock position Remove the Transmission Control Relay Note Check connectors Clean repair as necessary Using a 12 volt test light...

Page 118: ...s the test light illuminate brightly All Yes Go To 7 No Repair the Transmission Control Relay Ground circuit for an open Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 Turn the ignition off to the lock position Remove the Transmission Control Relay Disconnect the PCM harness connector Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBIN...

Page 119: ...ular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 10 Turn the ignition off to the lock position Remove the Transmission Control Relay Disconnect the ...

Page 120: ...IFICATION TEST VER 1 No Go To 12 12 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Transmission Solenoid Pressure Switch Assembly per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 13 The cond...

Page 121: ...s low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnos...

Page 122: ... the voltage above 0 5 volt All Yes Repair the OD Pressure Switch Sense circuit for a short to voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Transmission Solenoid Pressure Switch Assembly harness connector Remove the Transmission Control Relay Note Check connectors Clean r...

Page 123: ... short to voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 6 6 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN ...

Page 124: ...n problems If the fluid level is low locate and repair the leak then check and adjust the fluid level per the Service Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s a...

Page 125: ...circuit in the Transmission Control Relay connector Is the voltage above 0 5 volts All Yes Repair the Transmission Control Relay Output circuit for a short to voltage Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off to the lock position Remove the Transmission Control Relay Note Check connectors Clean repair as necessary Ignition on engine not running NOT...

Page 126: ... 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wiring and connectors while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any...

Page 127: ... DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to...

Page 128: ... and adjust the fluid per the Service Information With the DRBIII perform a Battery Disconnect NOTE The Battery Disconnect must be done to re enable EMCC during an A C Clutch engagement NOTE The vehicle may exhibit intermittent shudder during the first few hundred miles The new Transmission Fluid w ill gradually penetrate the Torque Convertor Clutch friction material and the shudder should disap p...

Page 129: ...ce Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a gui...

Page 130: ...g and connectors specific to this circuit Wiggle the wiring while checking for shorted and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 5 With the DRBIII perform a Shift Lever Position test Follow the...

Page 131: ... there are no possible causes remaining view repair All Repair Replace the Transmission Oil Pump per the Service Information Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 126 TRANSMISSION NGC P0944 LOSS OF PRIME Continued ...

Page 132: ... INTERMITTENT WIRING AND CONNECTORS TEST ACTION APPLICABILITY 1 With the DRBIII Check the STARTS SINCE SET counter for P0951 Note This counter only applies to the last DTC set Is the Starts Since Set counter set at 0 All Yes Go To 2 No Go To 6 2 Turn the ignition off to the lock position Disconnect the AutoStick Switch harness connector Note Check connectors Clean repair as necessary Ignition on e...

Page 133: ...O NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the AutoStick Upshift Sense circuit Is the resistance below 5 0 ohms All Yes Repair the AutoStick Upshift Sense circuit for a short to ground Perform 40 4...

Page 134: ... to this circuit Wiggle the wires while checking for shorts and open circuits With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 129 TRANSMISSION NGC P0952 AUTOSTICK INPUT CIRCUIT LOW Continued ...

Page 135: ...form diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and conne...

Page 136: ...ostics for both P0870 and P0845 to determine which switch is the cause of the DTC With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set If there are no possible causes remaining view repair All Repair Refer to the Transmission category and perform the symptoms for P0845 and P0870 Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 131 TRANSMISSION ...

Page 137: ...y Engine Communication DTC s present All Yes Refer to the Powertrain category and perform the appropriate symptom Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIII erase Transmission DTC s Start the Engine in Park With the DRBIII read Transmission DTCs NOTE The Engine must run for at least 20 seconds to reset this DTC Did the DTC reset after the engine was start...

Page 138: ...trollers on the bus on this vehicle If there is a bus problem refer to the Communication Category for diagnosis With the DRBIII check the EATX EVENT DATA to help identify the conditions in which the DTC was set Were there any problems found All Yes Repair as necessary Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Test Complete 133 TRANSMISSION NGC P1652 SERIAL COMMUNICATION LINK MALF...

Page 139: ...and adjust the fluid level per the Service Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Usi...

Page 140: ...To 5 5 Turn the ignition off to the lock position Disconnect the PCM harness connector Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Using a 12 volt test light connected to ground check...

Page 141: ...ightness to that of a direct connection to the battery Does the test light illuminate brightly for all the ground circuits All Yes Go To 7 No Repair the Ground circuits for an open Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 7 The conditions necessary to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit ...

Page 142: ...om diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record ...

Page 143: ...e Communications category and perform test for MIC MESSAGES NOT RECEIVED Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 5 5 Ignition on engine not running With the DRBIII erase Transmission DTC s Start the engine in park With the DRBIII read Transmission DTC s Is the DTC P1687 NO COMMUNICATION WITH THE MIC present All Yes Replace the Powertrain Control Module WITH THE DRBIII PER...

Page 144: ... 3 2 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER ...

Page 145: ...rvice Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a ...

Page 146: ...Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Ignition on engine not running With the Transmission Simulator turn the Pressure Switch selector switch to L R With the DRBIII monitor the L R Pressure Switch State while pressing the Pressure Switch Test button Did the Pressure Switch state change from open to closed when the test button was pressed All Yes Go To 5 No Go To 6 5...

Page 147: ... TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the L R Pressure Switch Sense circuit Is the resistance below 5 0 ohms All Yes Repair the L R Pressure Switch Sense circuit for a short to ground Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 8 8 Turn the ignition off to the lo...

Page 148: ...rol Relay Output circuit for an open Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 No Go To 10 10 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII...

Page 149: ...en check and adjust the fluid level per the Service Information NOTE Alw ays perform diagnostics w ith a fully charged battery to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully mature...

Page 150: ... With the DRBIII Check the STARTS SINCE SET counter for P1776 NOTE This counter only applies to the last DTC set Is the STARTS SINCE SET counter 2 or less All Yes Go To 5 No Go To 11 5 Turn the ignition off to the lock position CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Install the Transmission Simulator Miller tool 8333 and the ...

Page 151: ...ROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the L R Pressure Switch Sense circuit from the Pinout Box to the Transmission Solenoid Pressure Switch Assembly harness connector Is the resistance above 5 0 ohms All Yes Repair...

Page 152: ...ION TEST VER 1 No Go To 10 10 Using the schematics as a guide inspect the wiring and connectors Repair as necessary Pay particular attention to all power and ground circuits If there are no possible causes remaining view repair All Repair Replace the Powertrain Control Module per the Service Informa tion WITH THE DRBIII PERFORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 40 41TE NGC TRANSMISSI...

Page 153: ...y matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the test does not pass refer to Symptom test for P0706 Check Shifter Signal For Gear Ratio DTC s check and record all CVI s Most DTC s set on start up but some must be set by driving the vehicle such that all diagnostic monitors have run NOTE Ve...

Page 154: ...quent torque reduction messages to the Powertrain Control Module PCM and does not receive a confirmation from the PCM Note Due to the integration of the Powertrain and Transmission Control Modules bus communication between the modules is internal POSSIBLE CAUSES POWERTRAIN CONTROL MODULE TEST ACTION APPLICABILITY 1 NOTE Due to the integration of the Engine and Transmission controllers into one mod...

Page 155: ... With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Lever Position Test If the...

Page 156: ...CATION TEST VER 1 No Test Complete 4 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the Input and Output Speed Sensor harness connectors Note Check connectors Clean repair as necessary CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILL...

Page 157: ... to avoid false symptoms With the DRBIII read Engine DTC s Check and repair all Engine DTC s prior to performing any transmission symptom diagnostics With the DRBIII read Transmission DTC s Record all DTC s and 1 Trip Failures NOTE Diagnose 1 Trip Failures as a fully matured DTC Using the wiring diagram schematic as a guide inspect the wiring and connectors Repair as necessary Perform the Shift Le...

Page 158: ...the Service Information Make sure it is not overfilled NOTE Aggressive driving or driving in low for extended periods of time in AutoStick mode w ill set this DTC If there are no possible causes remaining view repair All Repair If the Transmission Fluid is low repair any Transmission Fluid leak as necessary and adjust the Transmission Fluid Level per the Service Information Refer to Service Inform...

Page 159: ...erased before returning the vehicle to the customer Did the Backup Lamps go out when the TRS harness connector was disconnected All Yes Go To 3 No Go To 4 3 If there are no possible causes remaining view repair All Repair Replace Transmission Range Sensor per the Service Information 4 Turn the ignition off to the lock position Disconnect the TRS harness connector Ignition on engine not running Mea...

Page 160: ...ng for shorted and open circuits View repair options All Repair Repair as necessary 3 Turn the ignition off to the lock position Remove the Starter Relay CAUTION Removal of the Starter Relay is to prevent a Transmission NO RESPONSE condition and disable the starter Install the Transmission Simulator Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Ignition on engine not runnin...

Page 161: ...sure to check for a short to ground 6 Turn the ignition off to the lock position Install the Transmission Simulator Miller tool 8333 and the Electronic Transmis sion Adapter kit 8333 1A Remove the Backup Lamp bulb s Ignition on engine not running Note Check connectors Clean repair as necessary Using a 12 volt test light connected to ground check the Backup Lamp Supply circuit in both Backup Lamp s...

Page 162: ...or Note Check connectors Clean repair as necessary Measure the resistance between ground and the AutoStick Ground circuit at the AutoStick harness connector Is the resistance above 5 0 ohms All Yes Repair the AutoStick Ground circuit for an open No Go To 3 3 Turn the ignition off to the lock position Disconnect the PCM harness connector Disconnect the AutoStick Switch harness connector Note Check ...

Page 163: ... and the AutoStick Switch harness connector Is the resistance above 5 0 ohms All Yes Repair the AutoStick Downshift Sense circuit for an open No Go To 5 5 Ignition on engine not running With the DRBIII monitor the AutoStick Switch status Firmly apply the brake and shift into AutoStick Push the shift lever to the right several times to actuate the AutoStick Upshift Switch and then to the left sever...

Page 164: ...east three times pausing momentarily in each gear NOTE If all the PRNDL lights box individually then the error w as cleared Shift into park and turn the ignition off to the lock position Ignition on engine not running With the DRBIII read Transmission DTCs Does the DTC P0706 reset or do all the PRNDL indicators remain boxed in park or neutral All Yes Return to the symptom list and perform diagnost...

Page 165: ... engine speed and listen to the noise NOTE THE RADIO MUST BE TURNED OFF Alternator noise can come through the speakers and be misinterpreted as Transmission Pump Whine This can happen even w ith the volume turned dow n Does the noise get louder or change pitch while the engine speed is changing All Yes Go To 3 No Go To 4 3 If there are no possible causes remaining view repair All Repair Repair int...

Page 166: ...ry to set the DTC are not present at this time Using the schematics as a guide inspect the wiring and connectors specific to this circuit Wiggle the wires while checking for shorts and open circuits Although it takes two occurences of a missed TRD link message to set the DTC P1793 one missed message will cause the transmission to short shift until the next start up If the vehicle has any indicatio...

Page 167: ...on Control Relay can cause the Trans mission Simulator to not Pow er up NOTE If the Transmission Simulator Miller tool 8333 and the Electronic Transmission Adapter kit 8333 1A w ill not pow er up make sure to check all connectors and the ground cable for proper installation If there are no possible causes remaining view repair All Repair Check and repair these symptoms before having the Transmissi...

Page 168: ...tor 9 Road test the vehicle With the DRBIII monitor the engine RPM Make 15 to 20 1 2 2 3 3 4 upshifts Perform these shifts from a standing start to 45 MPH with a constant throttle opening of 20 to 25 degrees 10 Below 25 MPH make 5 to 8 wide open throttle kickdowns to 1st gear Allow at least 5 seconds each in 2nd and 3rd gear between each kickdown 11 For a specific DTC drive the vehicle to the Symp...

Page 169: ...NOTES 164 ...

Page 170: ...8 0 COMPONENT LOCATIONS 8 1 AUTOSTICK IF EQUIPPED 8 2 CONTROL MODULE LOCA TIONS EATX NGC 8 3 PRESSURE PORT LOCA TIONS C O M P O N E N T L O C A T I O N S 165 COMPONENT LOCATIONS ...

Page 171: ...8 4 TRANSMISSION COMPONENT LOCA TIONS C O M P O N E N T L O C A T I O N S 166 COMPONENT LOCATIONS ...

Page 172: ...UIT FUNCTION 1 2 D25 20VT YL PCI BUS DLC 3 4 Z305 20BK YL GROUND 5 Z306 20BK VT GROUND 6 7 D21 20PK SCI TRANSMIT 8 F11 20RD WT FUSED IGNITION SWITCH OUTPUT OFF RUN START 9 D6 20PK LB SCI RECEIVE TCM 10 11 12 D20 20LG SCI RECEIVE 13 14 15 D15 20WT DG SCI TRANSMIT TCM 16 M1 20PK FUSED B INPUT SPEED SENSOR GRA Y 2 WA Y CAV CIRCUIT FUNCTION 1 T13 18DB BK SPEED SENSOR GROUND 2 T52 18RD BK INPUT SPEED S...

Page 173: ...C O N N E C T O R P I N O U T S 168 CONNECTOR PINOUTS ...

Page 174: ...F235 16RD FUSED B 14 30A A14 14RD TN FUSED B 15 40A A10 12RD DG ABS FUSED B 16 40A A13 12PK WT FUSED B 17 40A A25 12DB JR27 FUSED B 18 40A A5 12RD GY FUSED B 19 20A A45 18BR JR27 FUSED B 20 20A A15 16PK FUSED B 21 SPARE 22 20A A20 12RD DB ABS FUSED B 23 20A F12 18DB WT FUSED IGNITION SWITCH OUTPUT RUN START 23 20A F12 18DB WT HEATED SEATS FUSED IGNITION SWITCH OUTPUT RUN START 24 20A F42 16DG LG 2...

Page 175: ... 22 23 24 25 D20 20LG SCI RECEIVE PCM 26 D6 20PK LB EATX SCI RECEIVE TCM 27 K7 18OR MTX EXPORT 5 VOLT SUPPLY 28 K62 18BK OR 2 4L PZEV AIR PUMP MOTOR RELAY CONTROL 29 A14 16RD TN FUSED B 30 A41 16YL FUSED IGNITION SWITCH OUTPUT START 31 K141 20TN WT 2 7L O2 SENSOR 1 2 SIGNAL 32 K904 18DB DG O2 RETURN DOWN 33 K341 20PK WT 2 7L O2 SENSOR 2 2 SIGNAL 34 35 36 D21 20PK SCI TRANSMIT PCM 37 D15 20WT DG EA...

Page 176: ...ROL NO 2 14 K11 18WT DB INJECTOR CONTROL NO 1 15 16 17 K199 18BR VT 2 0L 2 4L O2 1 2 HEATER CONTROL 17 K299 18BR WT 2 7L 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 K235 20LG PK 2 4L PZEV 2 7L EGR SENSOR SIGNAL 23 K1 20DG RD MAP SIGNAL 24 K45 20BK VT KS RETURN 25 K42 20DB LG KS SIGNAL 26 K57 20DB 2 4L...

Page 177: ...13 14 15 16 17 K4 18BK LB SENSOR GROUND 1 18 19 F142 16OR DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 20 K52 20PK BK EVAP PURGE CONTROL 21 T26 20DG OR CLUTCH INTERLOCK UPSTOP SWITCH OUTPUT 22 23 K29 20WT PK BRAKE SWITCH SIGNAL 24 25 26 T44 20YL AUTOSTICK DOWNSHIFT SWITCH SIGNAL 27 T5 20LG AUTOSTICK UPSHIFT SWITCH SIGNAL 28 F142 16OR DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 29 K108 20WT TN EVAP PURG...

Page 178: ...10 0 SCHEMATIC DIAGRAMS 10 1 EA TX 40 41TE S C H E M A T I C D I A G R A M S 173 SCHEMATIC DIAGRAMS ...

Page 179: ...10 2 NGC 40 41TE S C H E M A T I C D I A G R A M S 174 SCHEMATIC DIAGRAMS ...

Page 180: ...11 0 CHARTS AND GRAPHS 11 1 TRANSMISSION RANGE SENSOR STA TES 11 2 PRESSURE SWITCH STA TES C H A R T S A N D G R A P H S 175 CHARTS AND GRAPHS ...

Page 181: ...11 3 SOLENOID APPLICA TION CHART 11 4 SHIFT LEVER ERROR CODES 11 5 TRANSMISSION TEMPERA TURE SENSOR C H A R T S A N D G R A P H S 176 CHARTS AND GRAPHS ...

Page 182: ...ystems 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 ...

Page 183: ......

Page 184: ...ion on the body code plate Lines 4 5 6 and 7 are not used to define ser vice 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 2 DIGITS 1 2 AND 3 Paint procedure DIGIT 4 Open Space DIGITS 5 THROUGH 7 Primary paint Refer to 23 BODY PAINT SPECIFICATIONS for Body Color Codes DIGIT 8 AND 9 Open Spa...

Page 185: ... 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 grade 8 The higher the grade number the greater the bolt strength Identification is determined by the line marks on the top of each bolt head The actual bolt strength grade corresponds to the number of line marks plus 2 The most co...

Page 186: ... 16 24 26 240 33 300 3 8 16 40 30 55 40 3 8 24 47 35 60 45 7 16 14 68 50 88 65 7 16 20 74 55 95 70 1 2 13 101 75 135 100 1 2 20 115 85 150 110 9 16 12 135 105 182 135 9 16 18 155 115 202 150 5 8 11 202 150 263 195 5 8 18 215 160 284 210 3 4 10 230 170 297 220 3 4 16 236 175 304 225 7 8 14 405 300 540 400 Inch Lbs JR INTRODUCTION 3 FASTENER IDENTIFICATION Continued ...

Page 187: ...Fig 2 FASTENER STRENGTH 4 INTRODUCTION JR FASTENER IDENTIFICATION Continued ...

Page 188: ...Display Symbols Chart are used to identify various instrument controls The symbols correspond to the controls and displays that are located on the instrument panel METRIC SYSTEM DESCRIPTION The metric system is based on quantities of one ten one hundred one thousand and one million The following chart will assist in converting metric units to equivalent English and SAE units or vise versa INTERNAT...

Page 189: ...METRIC CONVERSION CHART 6 INTRODUCTION JR METRIC SYSTEM Continued ...

Page 190: ...h x 1 6093 Kilometers Hr Km h Km h x 0 6214 mph Feet Sec x 0 3048 Meters Sec M S M S x 3 281 Feet Sec mph x 0 4470 Meters Sec M S M S x 2 237 mph Kilometers Hr Km h x 0 27778 Meters Sec M S M S x 3 600 Kilometers Hr Km h COMMON METRIC EQUIVALENTS 1 inch 25 Millimeters 1 Cubic Inch 16 Cubic Centimeters 1 Foot 0 3 Meter 1 Cubic Foot 0 03 Cubic Meter 1 Yard 0 9 Meter 1 Cubic Yard 0 8 Cubic Meter 1 Mi...

Page 191: ...CRIPTION Individual Torque Charts appear within many or the Groups Refer to the Standard Torque Specifica tions Chart for torque references not listed in the individual torque charts TORQUE SPECIFICATIONS 8 INTRODUCTION JR ...

Page 192: ...TION INTERPRETATION CODE DESCRIPTION 1 Country of Origin 1 Manufacture By DaimlerChrysler Corporation 2 Make B Dodge C Chrysler 3 Vehicle Type 3 Passenger Car 4 Passenger Safety A Active Front and Side Airbag D Without Airbags E Active Driver and Passenger Airbag 5 Car Line J Stratus Cirrus L Sebring 6 Series 3 M Medium 4 H High line 5 P Premium 6 S Sport 7 X Special 6 Export Series B 4 Speed Auto...

Page 193: ...eck digit is not released to the general public VEHICLE CERTIFICATION LABEL DESCRIPTION A vehicle certification label is attached to the rear shutface of the driver s door Fig 4 This label indi cates date of manufacture month and year Gross Vehicle Weight Rating GVWR Gross Axle Weight Rating GAWR front Gross Axle Weight Rating GAWR rear and the Vehicle Identification Number VIN The Month Day and H...

Page 194: ...onnected and routed according to the label MANUFACTURER PLATE DESCRIPTION The Manufacturer Plate Fig 6 is located in the engine compartment 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 5 E MARK LABEL 1 C...

Page 195: ......

Page 196: ...LES DESCRIPTION MAINTENANCE SCHEDULES 7 MAINTENANCE SCHEDULES EXPORT 15 HOISTING STANDARD PROCEDURE HOISTING 20 JUMP STARTING STANDARD PROCEDURE JUMP STARTING 21 TOWING STANDARD PROCEDURE TOWING 22 INTERNATIONAL SYMBOLS DESCRIPTION DaimlerChrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations Fig 1 PARTS LUBRICANT RECOMMENDA...

Page 197: ...NGINE OIL CAN BE IRRITATING TO THE SKIN AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL CONTAMINANTS IN USED ENGINE OIL CAUSED BY INTERNAL COMBUSTION CAN BE HAZARDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL PROPERLY CONTACT YOUR DEALER...

Page 198: ...ils that are cer tified by the American Petroleum Institute API to display the Certification Mark and show SAE vis cosity grade recommended for each vehicle Follow the service schedule that describes your driving type ENGINE OIL ADDITIVES SUPPLEMENTS The manufacturer does not recommend the addi tion of any engine oil additives supplements to the specified engine oil Engine oil additives supplement...

Page 199: ...CAUTION Mopar Antifreeze Coolant 5 Year 100 000 Mile Formula MS 9769 may not be mixed with any other type of antifreeze Doing so will reduce the corrosion protection and may result in premature water pump seal failure If non HOAT coolant is introduced into the cooling system in an emergency it should be replaced with the specified coolant as soon as possible FLEXIBLE FUEL VEHICLES 2 7L ENGINES ONL...

Page 200: ...ransmission Fluid is required in the 41TE automatic and T350 T850 man ual transaxles Substitute fluids can induce torque converter clutch shudder or premature geartrain failure Mopar ATF 4 Automatic Transmission Fluid when new is red in color The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze The red color is not permanent and is not ...

Page 201: ...LINE If you live in the northeast United States your vehicle may have been designed to meet California low emission standards with Cleaner Burning Cali fornia reformulated gasoline with low sulfur If such fuels are not available in states adopting California emission standards your vehicles will operate satis factorily on fuels meeting federal specifications but emission control system performance...

Page 202: ...TIONS DESCRIPTION The fluid check fill point locations are located in each applicable service manual section LUBRICATION POINTS DESCRIPTION Lubrication point locations are located in each applicable Sections MAINTENANCE SCHEDULES DESCRIPTION MAINTENANCE SCHEDULES There are two maintenance schedules that show the required service for your vehicle First is Schedule B It is for vehicles that are oper...

Page 203: ... front and rear suspen sion components Check the automatic transmission fluid level Check the brake master cylinder fluid level Check the coolant level hoses and clamps NOTE In 2 7L Engines equipped with Flex Fuel Engine FFV change engine oil every 5 months or 5 000 miles whichever comes first This applies to both Maintenance Schedule A and B SCHEDULE B Follow schedule B if you usually operate you...

Page 204: ...place if required X X X X X Replace the air cleaner filter X Inspect and check tension for power steering belt 2 4 Liter Engine Adjust or replace if required X Inspect the front and rear brake pads linings rotors rear drums and shoes X X Check and replace if necessary the PCV valve X Replace the spark plugs on 2 4 liter engine X Rotate the tires X X X Miles 39 000 42 000 45 000 48 000 51 000 54 00...

Page 205: ...PCV valve X Change the automatic transmission fluid and filter X Rotate the tires X X X Flush and replace engine coolant at 60 months if not done at 100 000 miles X Miles 75 000 78 000 81 000 84 000 87 000 90 000 Kilometers 120 000 125 000 130 000 134 000 139 000 144 000 Change engine oil and engine oil filter if not replaced at 3 months X X X X X X Inspect the air cleaner filter and replace if ne...

Page 206: ... the engine coolant if not replaced at 60 months X Miles 108 000 111 000 114 000 117 000 120 000 123 000 Kilometers 174 000 179 000 183 000 188 000 193 000 198 000 Change engine oil and engine oil filter if not replaced at 3 months X X X X X X Inspect the air cleaner filter and replace if necessary X X X X X Replace the air cleaner filter X Replace the spark plugs on the 2 4 liter engine X Replace...

Page 207: ... linings rotors rear drums and shoes X Check and replace if necessary the PCV valve X Rotate the tires X This maintenance is recommended by the manu facture to the owner but is not required to maintain the emissions warranty Except for the 2 4 liter Partial Zero Emissions Vehicle PZEV 2 4 liter PZEV only This maintenance is not required if previously replaced Inspection and service should also be ...

Page 208: ...bles on 2 4 liter engine X Replace the accessory drive belts in 2 7 liter engine X Rotate the tires X X X X X X Miles 78 000 84 000 90 000 96 000 100 000 102 000 105 000 Kilometers 125 000 134 000 144 000 154 000 160 000 163 000 168 000 Months 78 84 90 96 102 105 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...

Page 209: ... X Replace the spark plugs on 2 4 liter engine X Check and replace if necessary the PCV valve X Replace the engine timing belt on 2 4 liter engine X Replace the accessory drive belts in 2 7 liter engine X Replace the ignition cables on 2 4 liter engine X Flush and replace engine coolant at 120 months if not done at 100 000 miles X Rotate the tires X X X X X X Miles 144 000 150 000 Kilometers 232 0...

Page 210: ...dule B of the Maintenance Schedules section of this manual NOTE If ANY of these apply to you then flush and replace the engine coolant every 160 000 km 100 000 miles or 60 months whichever comes first and follow schedule B of the Maintenance Schedules section of this manual Use the schedule that best describes your driving conditions Where time and mileage are listed follow the interval that occur...

Page 211: ...hs 36 42 48 54 60 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 and check tension for power steering belt 2 4 Liter Engine Adjust or replace if required X Inspect the front and rear brake pads linings rotors rear drums and shoes X X Replace the spark plugs on 2 0 and 2 4 liter engines X Flus...

Page 212: ... observed or suspected Retain all receipts SCHEDULE B Follow schedule B if you usually operate your vehicle under one or more of the following conditions Change the automatic transmission fluid and filter every 96 000 km 60 000 miles if the vehicle is usu ally operated under one or more of the conditions marked with an Day or night temperatures are below 0 C 32 F Stop and go driving Extensive engi...

Page 213: ... X X X X Replace the air cleaner filter X Inspect the front and rear brake pads linings rotors rear drums and shoes X X Inspect and check tension for power steering belt 2 4 Liter Engine Adjust or replace if required X Check and replace if necessary the PCV valve X Replace the spark plugs on 2 0 and 2 4 liter engines X Rotate the tires X X X Kilometers 62 000 67 000 72 000 77 000 82 000 86 000 Mil...

Page 214: ...ransmission fluid and filter X Rotate the tires X X X Flush and replace engine coolant at 60 months if not done at 160 000 km X Kilometers 120 000 125 000 130 000 134 000 139 000 144 000 Miles 75 000 78 000 81 000 84 000 87 000 90 000 Change engine oil and engine oil filter X X X X X X Inspect the air cleaner filter and replace if necessary X X X X X Replace the air cleaner filter X Inspect and ch...

Page 215: ...ll receipts WARNING You can be badly injured working on or around a motor vehicle Do only that service work for which you have the knowledge and the right equipment If you have any doubt about your ability to perform a service job take your vehicle to a competent mechanic HOISTING STANDARD PROCEDURE HOISTING Refer to Owner s Manual provided with vehicle for proper emergency jacking procedures WARN...

Page 216: ...ries set the parking brake place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF 3 On disabled vehicle place gear selector in park or neutral and set park brake Turn off all accesso ries 4 Connect jumper cables to booster battery RED clamp to positive terminal BLACK clamp to neg ative terminal DO NOT allow clamps at opposite end of cables to touch...

Page 217: ... of disabled vehicle has at least 100 mm 4 in ground clearance If minimum ground clearance cannot be reached use a towing dolly If a flat bed device is used the approach angle should not exceed 15 degrees GROUND CLEARANCE CAUTION If vehicle is towed with wheels removed install lug nuts to retain brake drums or rotors A towed vehicle should be raised until the lifted wheels are a minimum 100 mm 4 i...

Page 218: ...poration recommends that a vehicle be towed with the front end lifted whenever possible A 90 cm 36 in length of 4x4 wood beam can be placed between the wheel lift device and the bottom of the fascia to prevent damage to vehicle during the lifting operation The beam can removed after lifting the front of the vehicle TOWING REAR WHEEL LIFT If a vehicle cannot be towed with the front wheels lifted th...

Page 219: ......

Page 220: ...ND TESTING HUB AND BEARING 6 REMOVAL 6 INSTALLATION 7 KNUCKLE DESCRIPTION 7 OPERATION 7 DIAGNOSIS AND TESTING STEERING KNUCKLE 7 REMOVAL 8 INSTALLATION 9 LOWER BALL JOINT DESCRIPTION 10 DIAGNOSIS AND TESTING LOWER BALL JOINT 10 LOWER BALL JOINT SEAL BOOT REMOVAL 11 INSTALLATION 11 LOWER CONTROL ARM DESCRIPTION 14 OPERATION 14 DIAGNOSIS AND TESTING LOWER CONTROL ARM 14 REMOVAL 14 DISASSEMBLY DISASS...

Page 221: ...ALLATION UPPER CONTROL ARM 31 FRONT SUSPENSION DESCRIPTION FRONT SUSPENSION This vehicle s front suspension is a short long arm SLA design used in conjunction with a gas pressur ized shock absorber and coil spring assembly Fig 1 SLA offers three advantages over the customary MacPherson strut system for front wheel drive vehi cles Better handling through geometry that keeps the tires more perpendic...

Page 222: ...e other Both sides of the front suspension are allowed to pivot so the vehicle can be steered in the direction preferred Steering of the vehicle is provided by a rack and pinion steering gear which is connected directly to each steering knuckle by an outer tie rod WARNING WARNING DO NOT REMOVE A SHOCK ROD NUT WHILE THE SHOCK ASSEMBLY IS INSTALLED IN VEHICLE OR BEFORE THE SHOCK ASSEMBLY SPRING IS C...

Page 223: ... Control Arm Ball Joint Stud Nut 27 N m 20 ft lbs Shock Bracket Bolt 90 N m 66 ft lbs Lower Control Arm Ball Joint Stud Castle Nut 74 N m 55 ft lbs Crossmember Front Pivot Bolt 142 N m 104 ft lbs Crossmember Rear Bolt 75 N m 55 ft lbs Ball Joint Heat Shield Attaching Bolts 10 N m 89 in lbs Stabilizer Bar Bushing Clamp Bolts 61 N m 45 ft lbs Link Nuts 105 N m 77 ft lbs SPECIAL TOOLS FRONT SUSPENSIO...

Page 224: ...66 Receiver Ball Joint 6756 Installer Bushing 6760 Remover Installer Control Arm Clevis Bushing 6877 Installer Ball Joint Seal Boot Retainer 6875 Remover Tie Rod Remover Lower Ball Joint C 4150A JR FRONT SUSPENSION 2 5 FRONT SUSPENSION Continued ...

Page 225: ...e bearing is not service able Damaged bearing seals and the resulting excessive grease loss may also require bearing replacement Moderate grease weapage from the bearing is consid ered normal and should not require replacement of the wheel bearing To diagnose a bent hub Refer to 2 BRAKES HY DRAULIC MECHANICAL ROTOR DIAGNOSIS AND TESTING REMOVAL 1 Raise vehicle Refer to LUBRICATION MAINTENANCE JUMP...

Page 226: ...to 5 BRAKES HYDRAU LIC MECHANICAL ROTOR INSTALLATION 9 Clean all foreign matter from threads of outer C V joint stub axle 10 Install hub nut on C V joint stub axle threads With vehicle brakes applied to keep stub axle from turning tighten hub nut to 203 N m 150 ft lbs torque 11 Install wheel and tire assembly Install wheel mounting nuts and progressively tighten in crisscross sequence Tighten nuts...

Page 227: ...he tie rod end from the steering knuckle using Remover Special Tool C 3894 A 7 Remove ABS wheel speed sensor cable routing bracket from steering knuckle Fig 7 8 Remove cotter pin and castle nut from lower ball joint stud Fig 8 CAUTION No tool is to be inserted between the steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle The steering knuckle i...

Page 228: ...ring knuckle away from outer C V joint Fig 10 12 Remove nut from upper ball joint stud 13 Remove upper ball joint stud from steering knuckle using Puller Special Tool C 3894 A Fig 11 14 Remove steering knuckle from vehicle 15 If necessary remove lower ball joint grease seal heat shield on steering knuckle 16 If steering knuckle is being replaced and hub and bearing is found to be in usable conditi...

Page 229: ...SION WHEEL ALIGN MENT STANDARD PROCEDURE LOWER BALL JOINT DESCRIPTION The ball joint used in the lower control arm of this vehicle is a sealed for life ball joint The ball joint can not be replaced as a separate component of the lower control arm assembly If the ball joint is deter mined to be defective it will require replacement of the complete lower control arm assembly The lower ball joint con...

Page 230: ...Wrap a shop towel around the ball joint and seal boot This is to prevent dirt and cleaning solvent to enter ball joint when cleaning area around ball joint 3 Using ONLY a solvent such as Mopar Foamy Engine Degreaser or an equivalent thoroughly clean lower control arm in area around ball joint and seal Then using a shop towel saturated with the engine degreaser carefully wipe off the ball joint sea...

Page 231: ...r control arm 3 Carefully position ball joint seal boot in seal retaining groove on lower control arm After install ing seal boot in retaining groove carefully bleed air out of sealing boot without getting grease pushed into seal boot retaining groove in lower control arm 4 Place Retaining Ring Installer Special Tool 6875 1 over ball joint seal boot Fig 15 Using adjusting knob adjust tool so botto...

Page 232: ... upper sealing ring is on seal boot and correctly installed Fig 19 Check seal boot for damage before installing back on car 10 Install lower control arm assembly back on vehicle Refer to 2 SUSPENSION FRONT LOWER CONTROL ARM INSTALLATION Fig 16 Retaining Ring And Expandable Collar Installed On Tool 1 SPECIAL TOOL 6875 2 LOWER CONTROL ARM 3 SEAL BOOT RETAINING RING Fig 17 Installing Seal Boot Retain...

Page 233: ...l and the control arm bushings Inspect both control arm bushings for severe deterioration and replace if required Inspect the lower ball joint for wear Use the wear inspection procedure in the diagnosis and testing sec tion in this group of service manual to determine if the wear is excessive and ball joint lower control arm replacement is required Service procedures to replace these components ar...

Page 234: ...grease seal CAUTION Pulling the steering knuckle outward from the vehicle after releasing it from the ball joint can separate driveshaft inner C V joint thus damag ing it Refer to 2 DRIVELINE AND DRIVESHAFT HALFSHAFT REMOVAL 7 Remove shock absorber clevis to lower control arm bushing nut and thru bolt Separate clevis from lower control arm Fig 23 8 Remove nut attaching stabilizer bar link to lower...

Page 235: ...member first then remove rear of lower control arm from suspension crossmember When removing rear of lower control arm from crossmem ber keep control arm as level as possible This will keep rear bushing from binding on crossmember making it easier to remove control arm from cross member Fig 25 Stabilizer Bar Bushing Clamp Attachment To Vehicle 1 STABILIZER BAR BUSHING CLAMP 2 FRONT SUSPENSION CROS...

Page 236: ...he lower control arm isolator bushings the lower control arm must be removed from the vehicle 1 Remove lower control arm assembly from vehi cle Refer to 2 SUSPENSION FRONT LOWER CONTROL ARM REMOVAL 2 Install Bushing Remover Special Tool 6756 and Bushing Receiver Special Tool C 4366 2 on Special Tool C 4212 F Fig 29 3 Install Special Tools assembled for removal of the rear isolator bushing on the l...

Page 237: ...ower control arm by hand making sure it is square w ith its mount ing hole in the low er control arm Bushing is to be installed in lower control arm from the machined surface side of lower control arm bushing hole 3 Install lower control arm on Special Tools assembled for installation of front isolator bushing into lower control arm Fig 31 Be sure Special Tool 6758 is square on lower control arm a...

Page 238: ...ue pressing rear bushing into lower control arm until bushing is sitting flush on the machined surface Fig 33 of the lower control arm This will correctly position rear bushing in lower control arm 5 Install lower control arm assembly back on vehicle Refer to 2 SUSPENSION FRONT LOWER CONTROL ARM INSTALLATION ASSEMBLY CLEVIS BUSHING To perform removal and replacement of the lower control arm clevis...

Page 239: ...astle nut Fig 21 Do not tighten nut at this time CAUTION When installing tie rod on steering knuckle the heat shield Fig 35 must be installed If heat shield is not installed tie rod seal boot can fail due to excessive heat from brake rotor 3 Install outer tie rod stud into steering knuckle Start outer tie rod to steering knuckle attaching nut onto tie rod stud While holding stud of tie rod end sta...

Page 240: ...prings positioned around shock absorbers The springs are contained between an upper seat located in the upper mounting bracket and a lower spring seat on the shock absorber The top of each shock absorber is bolted to a cast shock absorber upper control arm bracket which is bolted to the shock tower of the vehicle using 4 mounting bolts The bottom of the shock absorber attaches to a cle vis bracket...

Page 241: ...ff the lower end of the shock absorber A slight amount of seepage between the shock absorber rod and the seal is not unusual and does not affect per formance of the shock absorber Also inspect jounce bumpers for signs of damage or deterioration Fig 38 REMOVAL SHOCK ASSEMBLY NOTE Before proceeding Refer to 2 SUSPEN SION FRONT WARNING 1 Loosen wheel nuts 2 Raise vehicle Refer to LUBRICATION MAINTENA...

Page 242: ...m the vehicle The shock assembly is removed out through the front area of the front wheel well 13 For disassembly of the shock assembly Refer to 2 SUSPENSION FRONT SHOCK DISASSEM BLY Fig 39 Wheel Speed Sensor Cable Routing Bracket 1 WHEEL SPEED SENSOR CABLE 2 SPEED SENSOR CABLE ROUTING BRACKET 3 STEERING KNUCKLE 4 ATTACHING BOLT 5 BRAKE CALIPER FLEX HOSE Fig 40 Ball Joint Stud Removal From Steerin...

Page 243: ...d from 2 Position the shock assembly in the strut coil spring compressor following the manufacturer s instructions Set the lower hooks and install the clamp on the lower end of the coil spring so the shock is held in place once the shock shaft nut is removed Fig 44 Rotate the shock assembly so the upper control arm ball joint sits directly below the front upper hook as shown Fig 45 Position the up...

Page 244: ...mpressor The coil spring will need to be in this position on reassem bly for proper coil spring to shock absorber and upper mounting bracket orientation 7 Release the tension from the coil spring by backing off the compressor drive fully Push back the compressor upper hooks and remove the upper mounting bracket and upper control arm from the coil spring 8 Note the position of the coil spring in th...

Page 245: ...assembly of the shock assembly use strut spring compressor Pentastar Ser vice Equipment PSE tool W 7200 or the equivalent to compress the coil spring Follow the manufactur er s instructions closely NOTE If the coil spring upper mounting bracket rod bushings upper coil spring isolator and upper control arm have been removed from the spring compressor proceed with the next step otherwise proceed wit...

Page 246: ...unting bracket on top of the coil spring matching the coil spring tip to the built in step in the isolator on the upper mounting bracket Position the upper control arm ball joint so it lies directly below the front upper hook as shown Fig 45 6 Position the upper hooks on top of the upper mounting bracket as shown Fig 45 7 Compress the coil spring 8 Install the lower spring isolator on the lower sp...

Page 247: ...e split of the clevis Fig 54 3 Install the pinch bolt retaining the shock clevis to the shock absorber Fig 41 Tighten the pinch bolt to a torque of 88 N m 65 ft lbs 4 Install the clevis bracket to lower control arm thru bolt Fig 42 Do not tighten the thru bolt at this time 5 Install upper ball joint into steering knuckle Install nut on ball joint stud Tighten nut to a torque of 27 N m 20 ft lbs 6 ...

Page 248: ... 2 Remove nuts and stabilizer bar attaching link assemblies from the front lower control arms Fig 56 When removing attaching link nut keep stud from turning by installing an allen wrench in the end of the stud Fig 56 3 Remove the 4 bolts attaching the stabilizer bar bushing retainers to the front suspension crossmem ber and body Fig 57 Then remove the stabilizer bar assembly from the vehicle STABI...

Page 249: ...ball joint stud is attached and locked into the steering knuckle using a special nut The ball joint is a sealed for life type and requires no maintenance If the ball joint is defective it will require replacement of the entire upper control arm DIAGNOSIS AND TESTING UPPER BALL JOINT 1 Raise and support vehicle so that tires clear floor Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCEDURE 2...

Page 250: ...l arm is serviced only as a complete component Inspect the upper control arm for any signs of damage If control arm shows any sign of damage the upper control arm must be replaced Do not attempt to repair or straighten a broken or bent upper control arm INSTALLATION UPPER CONTROL ARM 1 Install the upper control arm on the upper shock absorber upper control arm mounting bracket 2 Install the 2 bolt...

Page 251: ...RIPTION 45 OPERATION 45 DIAGNOSIS AND TESTING TRAILING LINK 45 REMOVAL 45 INSTALLATION 46 UPPER BALL JOINT DESCRIPTION 47 DIAGNOSIS AND TESTING UPPER BALL JOINT 47 UPPER CONTROL ARM DESCRIPTION 47 OPERATION 47 REMOVAL 47 DISASSEMBLY UPPER BALL JOINT 50 INSPECTION 50 ASSEMBLY UPPER BALL JOINT 50 INSTALLATION 51 REAR SUSPENSION DESCRIPTION REAR SUSPENSION The rear suspension used on this vehicle is ...

Page 252: ...ckle Brake Adapter Mounting Bolts 61 N m 45 ft lbs Hub And Bearing Knuckle Retaining Nut 250 N m 185 ft lbs Wheel Mounting Nuts 135 N m 100 ft lbs Upper Control Arm Pivot Bar To Crossmember 95 N m 70 ft lbs Lateral Links To Knuckle Nuts 122 N m 90 ft lbs Jam Nuts 95 N m 70 ft lbs To Suspension Crossmember Nuts 88 N m 65 ft lbs Trailing Link Shaft Nuts Front And Rear 115 N m 85 ft lbs Bracket To Bo...

Page 253: ...rom rear hub and bearing assembly by prying it off 6 Remove hub and bearing retaining nut 7 Remove rear hub and bearing from the spindle by pulling it straight off the spindle INSTALLATION 1 Install the hub and bearing assembly on the knuckle spindle Install a NEW retaining nut Tighten the retaining nut to a torque of 250 N m 185 ft lbs 2 Install the hub and bearing dust cap using a soft faced ham...

Page 254: ...ly 8 If equipped with rear drum brakes remove parking brake cable from parking brake actuating lever then remove cable from drum brake support plate Refer to 5 BRAKES PARKING BRAKE CA BLES REMOVAL 9 Remove four bolts attaching drum brake sup port plate disc brake adapter to knuckle Fig 3 Fig 1 Rear Wheel Speed Cable Routing And Attachment 1 UPPER CONTROL ARM 2 SHOCK ABSORBER 3 SPEED SENSOR CABLE R...

Page 255: ...on will protect threads from damage during next step 13 Release ball joint stud from knuckle using Puller Special Tool CT 1106 Fig 6 14 Remove nut retaining upper control arm ball joint to knuckle 15 Remove nut and washer attaching trailing link to rear knuckle Use a wrench on the flat of the trailing link to keep it from turning when removing nut Fig 7 Fig 4 Correctly Stored Rear Brake Support Pl...

Page 256: ...s and nuts to 122 N m 90 ft lbs torque 5 Install rear drum brake assembly disc brake adapter onto knuckle Install four mounting bolts Fig 3 Tighten mounting bolts to 61 N m 45 ft lbs torque 6 If equipped with rear drum brakes install parking brake cable into support plate and attach to parking brake actuating lever Refer to 5 BRAKES PARKING BRAKE CABLES INSTALLATION 7 Install rear hub and bearing ...

Page 257: ...nks for signs of contact with the ground or road debris which has bent or caused other damage to the lateral link If the lateral link is bent or damaged the lateral link will require replacement Do not attempt to repair or straighten a lateral link CAUTION Do not apply heat to the lateral link adjusting screws or to the jam nuts for any reason REMOVAL CAUTION Do not attempt to straighten or repair...

Page 258: ...lizer bar attaching link isolator bushings and attaching nut on the forward lateral link Fig 11 Tighten the attaching nut to 31 N m 23 ft lbs torque 5 Install the wheel and tire assembly Progres sively tighten the wheel mounting nuts in crisscross Fig 11 Stabilizer Bar To Lateral Link Attachment 1 WASHER 2 BOLT AND WASHER 3 KNUCKLE 4 STABILIZER BAR 5 FORWARD LATERAL LINK 6 STABILIZER BAR ATTACHING...

Page 259: ...ber assembly attaches to the rear knuckle using a thru bolt The rear coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service Coil springs come in a various rates be sure the correct spring is in use The components of the shock assembly listed below are serviceable Shock rod nut Shock mount Shock rod bushings Upper spring ...

Page 260: ...spring was removed from 2 Position the shock assembly in the strut coil spring compressor following the manufacturer s instructions Set the lower hooks and install the clamp on the lower end of the coil spring so the shock is held in place once the shock shaft nut is removed Lower the upper hooks and position them on the coil spring near the top 3 Compress the coil spring until all coil spring ten...

Page 261: ...ring from the compressor ASSEMBLY SHOCK ASSEMBLY 1 If the coil spring has been removed from the compressor place the lower end smaller diameter of the coil spring in the spring compressor supported by the lower hooks at the same position as in disassem bly following the manufacturer s instructions 2 Position the upper hooks of the spring compres sor on the coil spring near the top as in disassembl...

Page 262: ...mpressor 18 Install shock assembly on the vehicle Refer to 2 SUSPENSION REAR SHOCK INSTALLA TION INSTALLATION SHOCK ASSEMBLY 1 Install shock assembly back in vehicle using the reverse sequence of removal 2 Install upper shock mount into the mounting holes in rear shock tower 3 Push down on rear knuckle to obtain clearance and then install shock absorber clevis bracket on rear knuckle 4 Align clevi...

Page 263: ...ching the stabilizer bar bushing clamps to the rear suspension crossmember Fig 22 5 Remove the rear stabilizer bar to crossmember bushing clamps and bushings from the stabilizer bar 6 Remove stabilizer bar from vehicle Stabilizer bar will come out of vehicle between the exhaust pipe and the rear suspension crossmember STABILIZER BAR BUSHING INSPECTION Inspect for broken or distorted retainers and ...

Page 264: ...trailing link DIAGNOSIS AND TESTING TRAILING LINK Inspect the trailing link bushings and retainers for signs of deterioration or damage If the trailing link bushings are deteriorated or the retainers are dam aged replacement of the trailing link bushings and or the retainers will be required The bushings and retainers are serviceable as separate components of the trailing link Inspect the trailing...

Page 265: ...ng link retainer and bushing on the hanger bracket Fig 27 Then install the outer bushing gold outer bushing retainer and nut Fig 27 on the trailing link Using a large adjustable wrench on flat of trailing link to keep it from rotating tighten the trailing link retaining nut to a torque of 115 N m 85 ft lbs 2 Install the black inner bushing retainer and inner bushing Fig 27 on the trailing link 3 I...

Page 266: ...top of tire noting if any movement of ball joint occurs 3 If movement is noted replace upper control arm ALTERNATE METHOD 1 Raise and support vehicle Refer to LUBRICA TION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Remove tire and wheel assembly Refer to 22 TIRES WHEELS REMOVAL 3 Push inward and pull outward on neck of knuckle near ball joint while observing ball joint for movement Holding a finger...

Page 267: ...brakes remove routing clips for wheel speed sensor cable from brackets on both upper control arms Fig 32 Fig 29 Shock Absorber To Knuckle Attaching 1 ATTACHING BOLT 2 REAR KNUCKLE 3 SHOCK ABSORBER CLEVIS BRACKET 4 LATERAL LINK Fig 30 Muffler Support Bracket 1 REAR FASCIA 2 MUFFLER SUPPORT BRACKET 3 ATTACHING BOLTS 4 MUFFLER Fig 31 Exhaust Pipe Hanger At Rear Suspension Crossmember 1 BOLT 2 REAR SU...

Page 268: ...nuckle in the following step b Remove ball joint stud from knuckle using Puller Special Tool CT 1106 Fig 33 c Remove nut retaining upper control arm ball joint to knuckle 11 Position a transmission jack and wooden block under the center of the rear suspension crossmember to support and lower crossmember during removal Fig 34 12 Remove the 4 bolts Fig 35 attaching rear suspension crossmember to rea...

Page 269: ...ings and pivot bar are serviced as a complete assembly on this vehicle Do not attempt to disassemble the control arm from the pivot bar to service the rear control arm bushings The only component on the upper control arm that is serviceable is the rear upper ball joint and its seal ASSEMBLY UPPER BALL JOINT 1 By hand position ball joint assembly into ball joint bore of control arm Be sure ball joi...

Page 270: ...KES HYDRAULIC MECHANICAL BRAKE PADS SHOES INSTALLATION 7 If vehicle is equipped with antilock brakes attach wheel speed sensor heads to both rear knuck les Tighten sensor mounting bolts to a torque of 8 N m 75 in lbs 8 If vehicle is equipped with antilock brakes install routing clips for wheel speed sensor cables onto brackets on both upper control arms Fig 32 Securely tighten routing clip attachi...

Page 271: ... Corporation s wheel alignment spec ifications differ On this vehicle the suspension angles that can be adjusted are as follows Front Camber using special procedure Toe Rear Camber Toe Check the wheel alignment and make all wheel alignment adjustments with the vehicle standing at its proper curb height specification Curb height is the normal riding height of the vehicle It is mea sured from a cert...

Page 272: ...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 273: ...preset by the factory at the time the vehicle is assembled It is not 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 c...

Page 274: ... Wheel Alignment 2 Check And Reset Wheel Alignment 3 Worn Tires 3 Replace Tires Front End Growl Or Grinding On Turns 1 Defective Wheel Bearing 1 Replace Wheel Bearing 2 Engine Mount Grounding Against Frame Or Body Of Vehicle 2 Check For Motor Mount Hitting Frame Rail And Reposition Engine As Required 3 Worn Or Broken C V Joint 3 Replace C V Joint 4 Loose Wheel Lug Nuts 4 Verify Wheel Lug Nut Torqu...

Page 275: ...ten Crossmember Bolts To Specified Torque Road Wander 1 Incorrect Tire Pressure 1 Inflate Tires To Recommended Pressure 2 Incorrect Front Or Rear Wheel Toe 2 Check And Reset Front Wheel Toe 3 Worn Wheel Bearings 3 Replace Wheel Bearing 4 Worn Control Arm Bushings 4 Replace Control Arm Bushing 5 Excessive Friction In Steering Gear 5 Replace Steering Gear 6 Excessive Friction In Steering Shaft Coupl...

Page 276: ... joints and all steering linkage for looseness and any sign of wear or damage 7 Inspect the rubber bushings on all the suspen sion components for signs of wear or deterioration If any bushings show signs of wear or deterioration they should be replaced prior to aligning the vehicle 8 Check vehicle curb height to verify it is within specifications Refer to 2 SUSPENSION WHEEL ALIGNMENT STANDARD PROC...

Page 277: ...ations proceed to FRONT TOE NOTE Rear Caster on this vehicle is not adjustable and is not shown as an alignment specification Rear Camber is not adjustable on some vehicles CAUTION Do not attempt to adjust the vehicle s wheel alignment by heating bending or modifying any component of the suspension REAR CAMBER AND TOE Rear Camber is adjustable on earlier production vehicles To verify whether rear ...

Page 278: ...se a crows foot wrench on a torque wrench and tighten all lateral link adjusting screw jam nuts to 92 N m 68 ft lbs torque This will securely hold the adjusting screws from turning 5 Proceed to FRONT CASTER AND CAMBER or FRONT TOE if front caster and camber are within specifications FRONT CAMBER AND CASTER Camber and caster settings on this vehicle are determined at the time the vehicle is designe...

Page 279: ... 2 SUSPENSION WHEEL ALIGN MENT SPECIFICATIONS 10 If front toe readings obtained are not within the required specification range adjust front toe to meet the preferred specification setting Proceed to FRONT TOE FRONT TOE 1 Center the steering wheel and lock in place using a steering wheel clamp CAUTION Do not twist front inner tie rod to steer ing gear rubber boots during front wheel Toe adjustment...

Page 280: ...side difference 0 0 1 0 TOE RIGHT OR LEFT 0 12 0 02 to 0 22 TOTAL TOE 0 24 0 04 to 0 44 REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE CAMBER 0 5 1 1 to 0 1 TOE RIGHT OR LEFT 0 05 0 05 to 0 15 TOTAL TOE 0 10 0 10 to 0 30 THRUST ANGLE 0 00 0 15 to 0 15 Positive toe is toe in negative toe is toe out Total toe is the arithmetic sum of the left and right wheel toe settings Total Toe must be e...

Page 281: ......

Page 282: ... and Rzeppa joints are true constant velocity C V joint assemblies The inner tripod joint allows for the changes in halfshaft length through the jounce and rebound travel of the front suspen sion On vehicles equipped with ABS brakes the outer C V joint is equipped with a tone wheel used to determine vehicle speed for ABS brake operation The inner tripod joint of both halfshafts is splined into the...

Page 283: ...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 etc packed on the backside of the wheel s 2 Out of balance fr...

Page 284: ...t Fig 4 7 Separate tie rod end from steering knuckle arm using Tool MB 991113 Fig 5 Fig 2 Properly Supported Brake Caliper Typical 1 ABS SPEED SENSOR CABLE 2 STEERING KNUCKLE 3 ROTOR 4 UPPER CONTROL ARM 5 DISC BRAKE CALIPER ASSEMBLY 6 WIRE HANGER Fig 3 Brake Rotor Removal Typical 1 BRAKING DISC 2 STEERING KNUCKLE 3 DISC BRAKE CALIPER ASSEMBLY STORED Fig 4 Removing Tie Rod End to Knuckle Nut 1 TIE ...

Page 285: ...a hammer strike steer ing knuckle boss until steering knuckle separates from stud of lower ball joint Fig 8 When striking steering knuckle care MUST be taken not to hit low er control arm or ball joint grease seal NOTE Care must be taken not to separate the inner C V joint during this operation Do not allow drive shaft to hang by inner C V joint Driveshaft must be supported Fig 6 Halfshaft Retaini...

Page 286: ...ransaxle case 12 Support the outer end of the halfshaft assem bly Insert a pry bar between inner tripod joint and transaxle case Fig 11 Pry against inner tripod joint until tripod joint retaining snap ring is disen gaged from transaxle side gear Fig 9 Separating Halfshaft from Steering Knuckle 1 HUB BEARING ASSEMBLY 2 HALFSHAFT 3 LOWER CONTROL ARM 4 STEERING KNUCKLE 5 BALL JOINT Fig 10 Separating ...

Page 287: ...e gear by attempting to remove tripod joint from transaxle by hand If snap ring is fully engaged w ith side gear tripod joint w ill not be removable by hand 4 Clean all debris and moisture out of steering knuckle in the area were outer C V joint will be installed into steering knuckle 5 Ensure that front of outer C V joint which fits against the face of the hub and bearing is free of debris and mo...

Page 288: ...tall caliper adapter bracket assembly on steering knuckle Install and torque caliper adapter to knuckle bolts to 88 N m 65 ft lbs Fig 15 Lower Ball Joint to Steering Knuckle Attachment 1 CASTLE NUT 2 BALL JOINT STUD 3 STEERING KNUCKLE 4 COTTER PIN 5 LOWER CONTROL ARM Fig 16 Installing Tie Rod End Nut 1 TIE ROD 2 HEAT SHIELD 3 STEERING KNUCKLE 4 TIE ROD STUD 5 NUT Fig 17 Torquing Tie Rod End Nut 1 ...

Page 289: ...N m 110 ft lbs Fig 20 12 Install front wheel and tire assembly Install front wheel lug nuts and tighten in the correct sequence Fig 21 Tighten lug nuts to 135 N m 100 ft lbs 13 Lower vehicle Fig 19 Halfshaft Retaining Nut Typical 1 HUB BEARING ASSEMBLY 2 NUT Fig 20 Torquing Front Hub Nut Typical 1 TORQUE WRENCH 2 HUB 3 BRAKING DISC Fig 21 Wheel Lug Torquing Sequence Typical 3 8 HALF SHAFT JR HALF ...

Page 290: ...ng boot to interconnecting shaft and discard Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft CAUTION When removing the tripod joint housing from the spider assembly hold the bearings in place on the spider trunions to prevent the bearings from falling away 2 Slide the tripod joint housing off the spider assembly and the interconnecting shaft Fig 22 Pulle...

Page 291: ...riveshaft assemblies are not serviceable INSTALLATION 1 Slide inner tripod joint seal boot retaining clamp onto interconnecting shaft Then slide the replacement inner tripod joint sealing boot onto the interconnecting shaft Inner tripod joint seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the seal boot is in groove on interconnecting shaft Fig 25 Fig 23 S...

Page 292: ...e 1 2 the amount of grease provided in the seal boot service package DO NOT USE ANY OTHER TYPE OF GREASE into tripod housing Put the remaining amount into the sealing boot 5 Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft Fig 29 Fig 26 Spider Assembly Installation on Interconnecting Shaft 1 SPIDER ASSEMBLY 2 INTERCONNECTING SHA...

Page 293: ... tripod joint assembly use care so inner tripod sealing boot does not get punctured or in any other way dam aged If sealing boot is punctured or damaged in any way while being vented the sealing boot can not be used 9 Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly Fig 32 When inserting trim stick betw een tri pod housing and sealing boot ensur...

Page 294: ... A Place crimping tool C 4975 A over bridge of clamp Fig 33 Tighten nut on crimping tool C 4975 A until jaws on tool are closed completely together face to face Fig 34 LATCHING TYPE BOOT CLAMP If seal boot uses low profile latching type boot clamp Clamp sealing boot onto tripod housing using clamp locking tool Snap On YA3050 or an equiva lent Place prongs of clamp locking tool in the holes of the ...

Page 295: ...ousing from internal circlip on inter connecting shaft Fig 38 Then slide outer C V joint off end of interconnecting shaft joint may have to be tapped off shaft using a soft faced hammer 4 Remove large circlip Fig 39 from the inter connecting shaft before attempting to remove outer C V joint sealing boot Fig 36 Sealing Boot Clamp Properly Installed 1 INNER TRIPOD JOINT HOUSING 2 TOP BAND OF CLAMP M...

Page 296: ... interconnecting shaft 3 Install outer C V joint assembly onto intercon necting shaft by using a soft faced hammer and tapping end of stub axle with nut installed until outer C V joint is fully seated on interconnecting shaft Fig 41 4 Outer C V joint assembly must be installed on interconnecting shaft until cross of outer C V joint assembly is seated against circlip on interconnecting shaft Fig 42...

Page 297: ...sealing boot onto outer C V joint hous ing using Crimper Special Tool C 4975 A and the fol lowing procedure Place crimping tool C 4975 A over bridge of clamp Fig 45 Tighten nut on crimping tool C 4975 A until jaws on tool are closed completely together face to face Fig 46 Fig 43 Crimping Tool Installed on Sealing Boot Clamp 1 SPECIAL TOOL C 4975A 2 INTERCONNECTING SHAFT 3 CLAMP 4 SEALING BOOT Fig ...

Page 298: ...DISC BRAKE SHOES 12 BRAKE PADS SHOES REAR DRUM REMOVAL 12 CLEANING 13 INSPECTION 14 INSTALLATION 14 ADJUSTMENTS ADJUSTMENT DRUM BRAKE SHOES 14 DISC BRAKE CALIPER FRONT REMOVAL FRONT DISC BRAKE CALIPER 15 DISASSEMBLY DISASSEMBLY CALIPER GUIDE PIN BUSHINGS DISC DISC BRAKES 16 DISASSEMBLY CALIPER PISTON AND SEAL 16 CLEANING CALIPER 17 INSPECTION CALIPER 18 ASSEMBLY ASSEMBLY CALIPER GUIDE PIN BUSHINGS...

Page 299: ...ERS 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 WITH A DAMPENED CLOTH DISPOSE OF CLOTH AN...

Page 300: ... 4 Once the brake pedal has dropped close the bleeder screw After the bleeder screw is closed release the brake pedal 5 Repeat the above steps until all trapped air is removed from that wheel circuit usually four or five times 6 Bleed the remaining wheel circuits in the same manner until all air is removed from the brake sys tem Monitor the fluid level in the master cylinder reservoir to make sure...

Page 301: ...Sensor Mounting Bolt 8 75 Brake Tube Nuts 17 145 Brake Hose To Caliper Banjo Bolt 35 26 Disc Brake Caliper Guide Pin Bolts 35 26 DESCRIPTION N m Ft Lbs In Lbs Disc Brake Caliper Bleeder Screw 15 125 Front Brake Hose Intermediate Bracket Bolt 12 105 Front Caliper Adapter Mounting Bolts 108 80 Junction Block Non ABS Brakes Mounting Bolts 28 21 250 Master Cylinder Mounting Nuts 26 19 230 Power Brake ...

Page 302: ...OLS BASE BRAKE SYSTEM Adapters Brake Pressure Test 8187 Gauge Set Handle Universal C 4171 Installer Dust Boot C 4689 Dial Indicator C 3339 Tubes Master Cylinder Bleed 8358 JR BRAKES BASE 5 5 BRAKES BASE Continued ...

Page 303: ...from valve and remove valve from vehicle INSTALLATION 1 Install smaller port on brown half of aspirator valve in hose leading to air cleaner housing 2 Install open port on black half of valve in hose leading to power brake booster 3 Install larger port on brown half of valve in hose leading from vacuum source BRAKE LINES DESCRIPTION BRAKE TUBES AND HOSES The brake tubes are steel with a corrosion ...

Page 304: ...ubing must be inspected for kinks fraying and contact with other com ponents or with the body of the vehicle BRAKE PADS SHOES FRONT REMOVAL FRONT DISC BRAKE SHOES 1 Raise the vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 2 Remove both front wheel and tire assemblies NOTE Using this procedure begin on one side of the vehicle 3 Remove the anti rattle spring from the out board...

Page 305: ...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 ENVIRONMENTAL PROTECTION AGENCY EPA FOR THE HANDLING PROCESSING AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS INSPECTION DISC BRAKE SHOES Visually inspect brake shoes pads for uneven lin...

Page 306: ...he lining up against the outside of the brake rotor CAUTION Use care when installing the caliper assembly onto the caliper adapter so the caliper guide pin bushings do not get damaged by the adapter bosses 7 Carefully position the brake caliper over the brake rotor and adapter 8 Install the caliper guide pin bolts and tighten to a torque of 35 N m 26 ft lbs Extreme caution should be taken not to c...

Page 307: ...rake shoes and parking brake braking surface on rotor for any signs of excessive wear or damage Replace parking brake shoes if required 7 Remove outboard brake pad from caliper by prying brake pad retaining clip over raised area on Fig 10 Caliper Guide Pin Bolts 1 DISC BRAKE CALIPER 2 CALIPER GUIDE PIN BOLTS Fig 11 Caliper Removal Installation 1 BRAKING DISC 2 CALIPER ADAPTER 3 CALIPER 4 LOWER MAC...

Page 308: ... INSPECTION DISC BRAKE SHOES Visually inspect brake shoes pads for uneven lin ing wear Also inspect for excessive lining deteriora tion Check the clearance between the tips of the wear indicators on the shoes if equipped and the brake rotors If a visual inspection does not adequately deter mine the condition of the lining a physical check will be necessary To check the amount of lining wear remove...

Page 309: ...dapter Fig 10 Tighten the guide pin bolts to a torque of 22 N m 192 in lbs 9 Install the wheels and tires 10 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 11 Lower vehicle 12 Check brake fluid level NOTE Before vehicle is moved after any brake ser vice w...

Page 310: ...AKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN 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 COMPO NENTS CLEAN WITH A DAMPENED CLOTH DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBES TOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL F...

Page 311: ...e assembly on brake support plate Fig 18 4 Install lower return spring Fig 18 5 Install both shoe hold down pins from rear through support plate and shoes Compress and install shoe hold down springs on pins Fig 18 6 Compress parking brake cable return spring then install cable on parking brake lever Fig 20 Release spring guiding it beneath retaining tab on lever 7 Insert cable into cable guide att...

Page 312: ...release the parking brake lever one time after the adjustment process is completed so the parking brakes can readjust themselves to the new brake shoe adjustment 13 Road test vehicle stopping in both forward and reverse directions Automatic adjuster will con tinue to adjust brakes as necessary during road test DISC BRAKE CALIPER FRONT REMOVAL FRONT DISC BRAKE CALIPER 1 Depress the brake pedal past...

Page 313: ...rocedure on the remaining bush ing DISASSEMBLY CALIPER PISTON AND SEAL WARNING UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PIS TON FROM A CALIPER BORE PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE NOTE Before disassembling the brake caliper clean and inspect it Refer to CLEANING AND INSPECTION in this section NOTE The safest way to remove the piston from the caliper bo...

Page 314: ...scoring or pitting Bores that show light scratches or corrosion can usu ally be cleared of the light scratches or corrosion using crocus cloth CLEANING CALIPER 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 HARM EXERCISE CARE ...

Page 315: ...en dowel until the bushing is fully seated into the caliper housing The bushing flanges should be seated evenly on both sides of the bushing hole 4 Lubricate inside surfaces of bushing using Mopar Dielectric Grease or equivalent 5 Repeat the procedure for remaining bushing ASSEMBLY CALIPER PISTON AND SEAL NOTE Never use an old piston seal 1 Dip the new piston seal in clean brake fluid and install ...

Page 316: ...refully position the brake caliper with inboard shoe over the brake rotor outboard shoe and adapter For proper positioning of shoes when install ing caliper Refer to 5 BRAKES HYDRAULIC ME CHANICAL BRAKE PADS SHOES INSTALLATION 4 Install the caliper guide pin bolts and tighten to a torque of 35 N m 26 ft lbs Fig 25 Extreme caution should be taken not to cross thread the caliper guide pin bolts 5 In...

Page 317: ...e hose fitting that will come off with the banjo bolt Discard these washers 5 Remove the 2 guide pin bolts mounting the cal iper to the adapter Fig 32 6 Remove caliper from adapter and rotor by first rotating top of caliper away from the adapter then lifting the caliper off lower machined abutment on adapter Fig 33 DISASSEMBLY DISASSEMBLY CALIPER GUIDE PIN BUSHINGS DISC DISC BRAKES Before disassem...

Page 318: ...iper 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 34 NOTE Do not use a screw driver or other metal tool for seal removal Using such tools can scratch the bore or leave burrs on the seal groove edges 6 Using a soft tool such as a plastic trim stick work the pisto...

Page 319: ...rake fluid leaks in and around boot area and inboard lining Ruptures brittleness or damage to the piston dust boot Damaged dry or brittle guide pin dust boots If caliper fails inspection disassemble and recondi tion caliper replacing the seals and dust boots ASSEMBLY ASSEMBLY CALIPER GUIDE PIN BUSHINGS DISC DISC BRAKES 1 Fold the guide pin bushing in half lengthwise NOTE To avoid damage to the bus...

Page 320: ...this section INSTALLATION REAR DISC BRAKE CALIPER 1 Completely retract caliper piston back into pis ton bore of caliper assembly 2 Lubricate both adapter abutments with a lib eral amount of Mopar Multipurpose Lubricant or equivalent 3 If removed install the rotor on the hub making sure it is squarely seated on the face of the hub Fig 39 CAUTION Use care when installing caliper assem bly onto adapt...

Page 321: ...ent is not within specification reface or replace the drum Refer to 5 BRAKES HYDRAULIC MECHANICAL DRUM STANDARD PROCEDURE Always replace the drum if machining will cause the diameter to exceed drum maximum diameter All brake drums are marked with the maximum allowable brake drum diameter Fig 40 RUNOUT A runout measurement can be done along with the out of round measurement 1 Mount the drum on an o...

Page 322: ...t from adjuster star wheel teeth Fig 43 rotate star wheel downward to back off adjust ment using a small screwdriver or brake adjuster tool e Once adjuster screw is backed off a sufficient amount drum should slide off wheel studs f Remove tools and reinstall plug in support plate INSTALLATION NOTE Before installing drum inspect brake shoe linings for wear alignment and contamination Repair or repl...

Page 323: ...ed level is FULL If necessary adjust the brake fluid level bringing it to the FULL mark on the side of the mas ter cylinder brake fluid reservoir 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 Mopar brake fluid or an eq...

Page 324: ...shown Fig 45 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 out of the reservoir 3 Remove the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM 4 Clean any debris away from the fittings on top of the junction block 5 Remove the two brake tube...

Page 325: ... brake fluid when reser voir is filled to its proper level 3 Fill brake fluid reservoir with Mopar brake fluid or equivalent conforming to DOT 3 specifica tions 4 Using a wooden dowel depress push rod slowly and then allow pistons to return to released position Repeat several times until all air bubbles are expelled from master cylinder 5 Remove bleeding tubes from master cylinder outlet ports and...

Page 326: ...ed repeat the BASIC TEST VACUUM LEAK TEST 1 Disconnect the vacuum hose on the side of the power brake booster vacuum check valve that leads to the speed control then connect a vacuum gauge to the open vacuum port on the valve 2 Remove the remaining hose on the vacuum check valve that is not the vacuum supply hose com ing from the intake manifold Cap off the open port on the check valve 3 Start the...

Page 327: ...ace only w ith a new retaining clip w hen assembled 9 Remove the 4 nuts attaching power brake vac uum booster to dash panel Nuts are accessible from under dash panel in area of the steering column and pedal bracket assembly Fig 52 10 Slide power brake vacuum booster straight forward until mounting studs clear dash panel and remove from vehicle CAUTION Do not attempt to disassemble the power brake ...

Page 328: ...vel split point On light pedal applications equal brake pres sure is transmitted to both the front and rear brakes On heavier pedal applications through the use of proportioning valves the pressure transmitted to the rear will be lower than the front 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 operati...

Page 329: ...HANICAL JUNCTION BLOCK REMOVAL If pressure is within specifications do not replace pro portioning valve and perform the following steps 15 Remove the Pressure Gauges and Adapters from the junction block 16 Reinstall the brake tubes to the junction block ports Tighten tube nuts fitting to 17 N m 145 in lbs torque 17 Bleed the affected brake lines Refer to 5 BRAKES BASE STANDARD PROCEDURE 18 If no p...

Page 330: ... surface is normal and does not require resurfacing when lin ings are replaced If cracks or burned spots are evi dent the rotor must be replaced ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications CAUTION Do not machine ...

Page 331: ...l runout of the hub face Before removing the rotor from the hub place a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken This way the original mounting spot of the rotor on the hub is indexed Fig 57 Remove the rotor from the hub NOTE Clean the hub face surface before checking runout This provides a clean surface to get an accurate indic...

Page 332: ... 0 900 0 911 in 21 4 mm 0 843 in 0 013 mm 0 0005 in 0 10 mm 0 004 in 15 80 RMS Rear Rotor 8 87 9 13 mm 0 350 0 360 in 7 25 mm 0 285 in 0 013 mm 0 0005 in 0 10 mm 0 004 in 15 80 RMS TIR Total Indicator Reading Measured On Vehicle STANDARD PROCEDURE BRAKE ROTOR MACHINING NOTE Refacing the rotor is not required each time the brake pads are replaced only when the need is foreseen Any servicing of the ...

Page 333: ... Rotor Thickness Variation Rotor Runout Rotor Micro Finish Front Rotor 22 87 23 13 mm 0 900 0 911 in 21 4 mm 0 843 in 0 013 mm 0 0005 in 0 10 mm 0 004 in 15 80 RMS Rear Rotor 8 87 9 13 mm 0 350 0 360 in 7 25 mm 0 285 in 0 013 mm 0 0005 in 0 10 mm 0 004 in 15 80 RMS TIR Total Indicator Reading Measured On Vehicle REMOVAL REMOVAL FRONT ROTOR 1 Raise the vehicle Refer to LUBRICATION MAINTENANCE HOIST...

Page 334: ...g 63 2 Install caliper and shoes on vehicle Refer to 5 BRAKES HYDRAULIC MECHANICAL BRAKE PADS SHOES INSTALLATION 3 Install wheel and tire assembly 4 Lower vehicle SUPPORT PLATE REMOVAL NOTE Before proceeding Refer to 5 BRAKES WARNING Refer to 5 BRAKES CAUTION NOTE Make sure parking brake is in released position before raising vehicle 1 Depress brake pedal past its first inch of travel and hold it ...

Page 335: ...g bracket to support plate Fig 64 Tighten routing bracket screw to 13 N m 115 in lbs torque 11 Thread flex hose tube nut into wheel cylinder port Fig 64 Tighten tube nut to 17 N m 145 in lbs torque 12 Install tire and wheel assembly Tighten wheel mounting nuts to 135 N m 100 ft lbs torque 13 Slowly rotate wheel and verify that brake drum lightly drags on shoes 14 Lower vehicle 15 Remove brake peda...

Page 336: ...g tool 10 Bleed affected wheel cylinder circuit as neces sary Refer to 5 BRAKES STANDARD PROCE DURE 11 Road test vehicle stopping in both forward and reverse directions Automatic adjuster will con tinue to adjust brakes as necessary during road test PARKING BRAKE ADJUSTMENTS ADJUSTMENT PARKING BRAKE This vehicle uses a bent nail type park brake cable tension equalizer Fig 67 The bent nail tension ...

Page 337: ...d when adjusting park brake cable tension 6 Install a NEW park brake cable tension equal izer on the park brake lever output cable and rear park brake cables Fig 70 CAUTION A new park brake lever output cable retainer must be used when installing output cable on cable tension equalizer Cable retainer usage is required to ensure output cable can not separate from tension equalizer Fig 68 Park Brake...

Page 338: ...e tension has been properly adjusted check for free play in park brake lever Park brake hand lever should feel firm at all clicks with a maximum of 15 clicks of lever travel possible 11 Install the center floor console Refer to 23 BODY INTERIOR FLOOR CONSOLE INSTALLA TION CABLES PARKING BRAKE REMOVAL For servicing either the left or right rear parking brake cable follow the procedure as listed bel...

Page 339: ... under carpet grasp park brake cable housing and pull cable straight out of console bracket 9 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 10 Remove rear wheel and tire assembly 11 On vehicles with rear disc brakes remove cal iper rotor hub and bearing and parking brake shoes Refer to 5 BRAKES PARKING BRAKE SHOES REMOVAL 12 On vehicles with rear drum brakes remove hu...

Page 340: ...g retainer are expanded NOTE Parking brake cable routing and routing clips are different on right and left sides of vehicle Be sure correct routing clips are installed on cor rect side of vehicle 3 Attach two parking brake cable routing clips on rear frame rail Install and securely tighten routing clip attaching screws 4 Install end of cable on parking brake actuating lever Fig 79 Guide spring ben...

Page 341: ...81 unlatch the parking brake output cable retainer Then remove cable retainer and park brake cable tension equalizer from park brake lever output cable and discard components CAUTION A new cable tension equalizer must be installed when replacing a rear park brake cable The new cable tension equalizer is required to cor rectly adjust park brake cable tension after install ing a new rear park brake ...

Page 342: ...stment nut will yield stretch the bent nail por tion of the tension equalizer approximately 1 4 inch This process will correctly set the parking brake cable tension 16 Check rear wheels of vehicle with parking brake lever fully released they should rotate freely without dragging 17 After parking brake cable tension has been properly adjusted check for free play in parking brake lever Parking brake...

Page 343: ...park brake lever mechanism bracket Fig 87 9 Remove the park brake lever mechanism from the vehicle INSTALLATION 1 Place the parking brake lever mechanism on the console bracket Install the 4 bolts mounting the park brake lever mechanism to the console bracket Fig 87 Tighten the 4 mounting bolts to a torque of 28 N m 250 in lbs 2 Install the wiring harness on the park brake mechanism bracket 3 Inst...

Page 344: ...ied position one time after tightening the adjustment nut will yield stretch the bent nail por tion of the tension equalizer approximately 1 4 inch This process will correctly set the parking brake cable tension 7 Check the rear wheels of the vehicle with the park brake lever fully released they should rotate freely without dragging 8 After the park brake cable tension has been properly adjusted c...

Page 345: ...ckle 6 Remove hold down clip from rear park brake shoe Fig 91 7 Turn park brake shoe adjuster wheel until adjuster is at its shortest length 8 Remove the park brake shoe adjuster from the park brake shoes Fig 92 9 Remove the lower return spring Fig 93 between the park brake shoes Fig 91 Rear Park Brake Shoe Hold Down Clip 1 HOLD DOWN CLIP Fig 92 Park Brake Shoe Adjuster 1 ADJUSTER Fig 93 Brake Sho...

Page 346: ...ster must be installed with the star wheel toward the rear of the vehicle Fig 92 6 Install hold down clip on rear park brake shoe Fig 91 7 Adjust park brake shoes to an outside diameter of 171 mm 6 75 inch 8 Install hub bearing on knuckle 9 Install A NEW hub bearing retaining nut Tighten the hub bearing retaining nut to a torque of 250 N m 185 ft lbs 10 Install dust cap on hub bearing 11 Install r...

Page 347: ...nnel design antilock brake system is to prevent wheel lockup under braking condi tions on virtually any type of road surface Antilock brak ing is desirable because a vehicle that is stopped without locking the wheels retains directional stability and some steering capability This allows the driver to retain greater control of the vehicle during braking This ABS system has ABS Plus and Electronic V...

Page 348: ...id being transferred between the master cylinder and the brakes If ABS operation occurs during hard braking some pulsation may be felt in the vehicle body due to fore and aft movement of the suspension as brake pressures are modulated At the end of an ABS stop ABS is turned off when the vehicle is slowed to a speed of 5 7 km h 3 4 mph There may be a slight brake pedal drop any time that the ABS is...

Page 349: ...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 many ABS fault modes If both the red BRAKE and amber ABS warning indicators are illuminated the EVBP may not be fu...

Page 350: ...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 hoisting positions for this vehicle are to be used whenever it is necessary to lift a vehicle Failure to raise a vehicle from the recommended locations could result in lifting a vehicle by the hydraulic control unit mou...

Page 351: ...ed when the HCU is replaced or removed from the vehicle The ABS must always be bled anytime it is suspected that the HCU has ingested air Under most circumstances that require the bleeding of the brakes hydraulic system only the base brake hydraulic system needs to be bled It is important to note that excessive air in the brake system will cause a soft or spongy feeling brake pedal During the brak...

Page 352: ...he steering knuckle Remove the wiring harness sealing grommet retainer and speed sensor routing bracket from the inner fender 4 Remove speed sensor sealing grommet from the inner fender Fig 2 Then unplug the speed sensor cable from the vehicle wiring harness Fig 2 5 Remove bolt Fig 3 attaching speed sensor to steering knuckle Then remove speed sensor head from steering knuckle CAUTION If speed sen...

Page 353: ... assembly grom met into the front inner fender Fig 2 Install speed sensor cable grommet retainer routing bracket on the inner fender of the vehicle and install and securely tighten attaching bolt Fig 1 CAUTION When installing the wheel speed sensor cable routing bracket on the steering knuckle Fig 1 the speed sensor cable must be looped toward the shock absorber as shown in Fig 5 If speed sensor c...

Page 354: ...ck Refer to 23 BODY SEATS REAR SEAT BACK REMOVAL 2 Roll back the main silencer pad along the side to expose the wheel speed sensor harness connector located behind the wheel house silencer Fig 7 3 Pull the wheel speed sensor harness connector out from behind the wheel house silencer It should have a foam sleeve covering it Fig 8 Fig 6 Installing Speed Sensor Head In Steering Knuckle 1 SPEED SENSOR...

Page 355: ...seat back 3 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 4 Remove rear tire and wheel assembly from vehicle 5 Remove speed sensor harness sealing grommet retainer from the rear frame rail of the vehicle Fig 10 6 Remove speed sensor harness sealing grommet and harness from hole in body of vehicle 7 Remove speed sensor routing clips from the rear upper control arm 8 Re...

Page 356: ...s sealing grommet into hole Install the sealing grommet retainer and attaching bolt Fig 10 Securely tighten retainer attaching bolt 5 Install the tire and wheel assembly on vehicle 6 Lower vehicle 7 Connect speed sensor harness connector to vehicle wiring harness behind rear seat back Install sleeve back over the speed sensor harness con nection to prevent rattling 8 Road test vehicle to ensure pr...

Page 357: ...witch from upper shroud Fig 14 INSTALLATION 1 Install switch through top of upper shroud and snap into place Fig 14 2 Install the upper and lower steering column shrouds onto the lock housing of the steering column As upper shroud is installed guide traction control OFF switch wiring pigtail down right side of col umn and connect wiring connector to column har ness 3 Install and securely tighten s...

Page 358: ...S AND VALVES The hydraulic fluid control valves within the HCU control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking The following paragraphs explain how this works For purposes of explanation only it is assumed that only the right front wheel is experienc ing antilock braking the following diagrams show only the right front wheel in an antilock ...

Page 359: ... the brakes 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 16 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 NORMA...

Page 360: ...dulate 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 17 ABS With Traction Control ABS Braking Hydraulic Circuit 1 OUTLET VALVE ...

Page 361: ...cylinder 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 18 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 MODUL...

Page 362: ...he ICU refer to these individ ual components of the ICU ANTILOCK BRAKE MODULE ABM Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES ANTILOCK BRAKE MODULE OPERA TION HYDRAULIC CONTROL UNIT HCU Refer to 5 BRAKES ABS HYDRAULIC MECHANICAL HCU HYDRAULIC CONTROL UNIT OPERA TION REMOVAL 1 Remove the remote ground cable from the ground stud on the left strut tower 2 Correctly isolate remote ground cable w...

Page 363: ...e module ABM by depressing the tabs on each side of the connector cover Fig 24 then pulling outward and upward on the lower half of the cover until it locks into position pointing straight outward The connector can then be pulled straight outward off the ABM Fig 25 Fig 21 Primary Secondary And Left Front Brake Tubes 1 PRIMARY BRAKE TUBE 2 SECONDARY BRAKE TUBE 3 LEFT FRONT CHASSIS BRAKE TUBE 4 ICU ...

Page 364: ...Fig 27 then slide the ICU s mounting pins out of the grommets in the bracket Remove the mounting pins from the ICU as necessary 2 Remove the four screws attaching the ABM to the HCU Fig 28 Fig 25 Wiring Connector At ABM 1 WIRING CONNECTOR 2 ABM ON ICU Fig 26 ICU Mounting 1 ICU 2 UPPER MOUNTING SCREW 3 LOWER RADIATOR SUPPORT 4 LOWER MOUNTING SCREW Fig 27 ICU Mounting Bolt 1 ICU 2 MOUNTING BOLT 3 MO...

Page 365: ...ing pins into the grommets mounted in the bracket then install the single mounting bolt Fig 27 Tighten the mounting bolt to 11 N m 97 in lbs torque 6 Install the ICU in the vehicle Refer to 5 BRAKES HYDRAULIC MECHANICAL ICU INTE GRATED CONTROL UNIT INSTALLATION INSTALLATION 1 Install the ICU with bracket in position on lower radiator support Fig 26 2 Install two upper mounting screws and one lower...

Page 366: ...l the two brake tubes coming from the primary and secondary master cylinder ports at the ICU Fig 21 Tighten the tube nuts to 17 N m 145 in lbs torque with the aid of a crowsfoot wrench 9 Install the air cleaner housing Refer to 9 ENGINE AIR INTAKE SYSTEM AIR CLEANER HOUSING INSTALLATION 10 Remove the brake pedal holding tool 11 Install the remote ground cable onto the ground stud located on left s...

Page 367: ......

Page 368: ...OPERATION 8 REMOVAL 9 INSTALLATION 9 CLUTCH RELEASE CABLE DESCRIPTION 10 REMOVAL 10 INSTALLATION 10 MODULAR CLUTCH DESCRIPTION 11 REMOVAL 11 INSTALLATION 11 CLUTCH DESCRIPTION Manual transaxle equipped models utilize a modu lar clutch assembly The clutch system consists of a modular clutch assembly Fig 1 a sleeve type release bearing a self adjusting clutch cable and a clutch pedal that is part of...

Page 369: ...cable which compensates for clutch disc wear The preload spring maintains tension on the cable This tension keeps the clutch release bearing Fig 4 continuously loaded against the fingers of the clutch cover assembly The cable requires no maintenance or lubrication DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING CLUTCH SYSTEM Clutch problem diagnosis will generally require a road test to determine the ...

Page 370: ...S CORRECTION DISC FACING WORN OUT Normal wear Replace modular clutch assembly Driver frequently rides slips clutch results in rapid wear overheating Replace modular clutch assembly Insufficient clutch cover diaphragm spring tension Replace modular clutch assembly CLUTCH DISC FACING CONTAMINATED WITH OIL OR GREASE Leak at rear main oil seal or transaxle input shaft seal Replace leaking seals Replac...

Page 371: ...ull on cable conduit at transaxle as if disconnecting cable to check adjuster operation SERVICE DIAGNOSIS CLUTCH PEDAL NOISE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH PEDAL SQUEAKS WHEN DEPRESSED TO FLOOR Pedal bushings worn out or inadequate lubrication Replace or lubricate bushings Clutch pedal return spring worn out Lubricate or replace return spring CLUTCH PEDAL SQUEAKS DURING OPERATION Clut...

Page 372: ...mbly if necessary DIAGNOSIS AND TESTING CLASH INTO REVERSE COMPLAINTS All T350 manual transaxles are equipped with a reverse brake It prevents clash when shifting into reverse but only if the vehicle is not moving 1 Depress clutch pedal to floor and hold After three seconds shift to reverse If clash is present clutch has excessive spin time and the reverse brake may not be functioning 2 Remove tra...

Page 373: ... N m 23 ft lbs torque 3 Install clutch cable upstop spacer to clutch pedal pin Fig 5 An audible click should be heard Verify upstop spacer retainer is intact and secures spacer 4 Install clutch pedal return spring Fig 5 Install to pedal blade first then slip into position at pedal bracket using suitable pliers 5 Verify proper clutch pedal operation as well as proper interlock switch contact 6 Inst...

Page 374: ...pedal fully depressed and the vehicle IN GEAR turn the key to the start position and hold it there Slowly depress the clutch pedal and feel for any vehicle motion when the starter is energized If there is no motion the switch is working properly If motion is felt check to see if the switch is mak ing contact when the pedal is between 25 mm 1 0 in and 6 mm 0 25 in from the floor If this condi tion ...

Page 375: ...ves the bearing into contact with the clutch cover diaphragm spring OPERATION The release bearing is operated by the release lever Fig 8 Pressure applied to the clutch pedal transmits force through the clutch cable causing the release lever to move the release bearing into contact with the diaphragm spring As additional force is applied the bearing presses the diaphragm spring fingers inward on th...

Page 376: ...condition of the pivot stud spring clips on the back side of the clutch release lever If the clips are broken or distorted replace the release lever NOTE Remove release lever pivot ball only if replacement is necessary 7 Remove pivot ball using slide hammer C 3752 and remover installer 6891 Fig 10 INSTALLATION 1 If removed install new release lever pivot ball s using slide hammer C 3752 and remove...

Page 377: ...e clutch cable strand Disconnect the cable up stop spacer from the pedal pivot pin by removing the retaining clip at the top of the clutch pedal Wedge a flat blade pry tool between the pin and the retaining tab While holding the tab slightly sepa rated from the pin pull the upstop spacer off the pedal Now remove the cable end from the upstop spacer 8 Remove clutch release cable core from upstop sp...

Page 378: ...e the modular clutch drive plate and or clutch release bearing and lever The modular clutch assembly used in this vehicle consists of a single dry type clutch disc a diaphragm style clutch cover and an integrated flywheel The clutch cover is riveted to the flywheel containing the clutch disc within The modular clutch can only be serviced as an assembly The clutch disc has cushion springs riveted t...

Page 379: ...Fig 15 Modular Clutch Removal Installation 1 MODULAR CLUTCH ASSEMBLY 2 CLIP 3 TRANSAXLE 4 CLUTCH MODULE BOLT 4 6 12 CLUTCH JR MODULAR CLUTCH Continued ...

Page 380: ...on Air Conditioning Compressor Generator Dynamic Tensioned Power Steering Pump New 120 180 lbs 160 223 Hz Used 70 115 lbs 114 179 Hz A belt is considered used after 15 minutes of run in time 2 7L Accessory Drive Belt Belt Tension Air Conditioning Compressor Generator New 185 235 lbs 204 230 Hz Used 110 160 lbs 157 190 Hz Power Steering Pump New 120 180 lbs 122 170 Hz Used 70 115 lbs 94 136 Hz A be...

Page 381: ...ector Bolts 12 105 Cooling System Bleed Valve 12 105 Fan Module to Radiator Fasteners 5 45 Fan Motor to Shroud Fasteners 5 45 Thermostat Housing to cylinder head 2 0L 2 4L Bolts 28 250 Thermostat Housing 2 7L Bolts 12 105 Transmission Cooler Tube Bracket Fastener 5 45 Transmission Cooler Tube Fastener 9 80 Transmission Cooler Hose Clamps 3 2 28 Water Pump Mounting 2 0L 2 4L 2 7L Bolts 12 105 Water...

Page 382: ...TEM DRB III with PEP Module OT CH6010A Belt Tension Gauge Adapter 8371 Hose Clamp Pliers 8495 Hose Clamp Pliers 6094 Filling Aid Funnel 8195 Cooling System Tester 7700 Coolant Refractometer 8286 JR COOLING 7 3 COOLING Continued ...

Page 383: ...TS DESCRIPTION The accessory drive consists of two Poly V type belts Fig 1 or Fig 2 One belt drives the power steering pump the other drives the generator and air conditioning compressor Both belts on the 2 7L engine are manually tensioned The power steering belt on the 2 0L 2 4L engine is manually tensioned The air conditioning generator belt on the 2 0L 2 4L engine has an automatic belt tensione...

Page 384: ...oo loose or too tight 2 Adjust belt tension 3 Misaligned pulleys 3 Align accessories 4 Non uniform grooves or eccentric pulley 4 Replace pulley s STANDARD PROCEDURE CHECKING ACCESSORY DRIVE BELT TENSION 2 7L WARNING DO NOT CHECK BELT TENSION WITH ENGINE RUNNING Accessory drive belt tension can be measured with Special Tool 8371 Belt Tension Gauge Adapter and the DRBIII using the following procedur...

Page 385: ...nsioner clockwise until the belt tensioner bottoms out and the belt can be removed from pulleys Fig 4 or Fig 5 5 Remove belt 6 Gently release tensioner POWER STEERING PUMP BELT 1 Raise vehicle on hoist 2 Remove right front wheel and belt splash shield 3 Remove air conditioning compressor generator belt 4 Loosen pivot bolt and locking bolt nut 5 Release tension on belt by moving pump assembly inwar...

Page 386: ...t dressing or restorer on Poly V Belts INSTALLATION INSTALLATION 2 0L 2 4L NOTE When installing drive belt onto pulleys make sure that belt is properly routed and all V grooves make proper contact with pulley AIR CONDITIONING COMPRESSOR GENERATOR BELT 1 Install belt over all pulleys except for the air conditioning compressor pulley Fig 7 2 Insert a 3 8 drive breaker bar into the square opening of ...

Page 387: ...r steering belt on pulleys Fig 8 2 Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS ADJUSTMENTS for proper drive belt tension adjustment 3 Install air conditioning compressor generator belt 4 Install belt splash shield and right front wheel 5 Lower vehicle ADJUSTMENTS ADJUSTMENT 2 7L ACCESSORY DRIVE BELTS NOTE A belt is considered used after 15 minutes of run time AIR CONDITIONING COMPRESSOR GENERAT...

Page 388: ...wrench from tensioner bracket and torque lower tensioner bracket fastener to 28 N m 250 in lbs 4 Verify proper belt tension Refer to 7 COOL ING ACCESSORY DRIVE DRIVE BELTS STAN DARD PROCEDURE CHECKING ACCESSORY DRIVE BELT TENSION 2 7L POWER STEERING PUMP BELT TENSIONING 1 Insert a 1 2 drive breaker bar into the square opening on the power steering pump bracket 2 Hold clockwise pressure on power st...

Page 389: ...29 INSTALLATION 29 ENGINE BLOCK HEATER DESCRIPTION DESCRIPTION 2 0L 2 4L 30 DESCRIPTION 2 7L 30 OPERATION OPERATION 2 0L 2 4L 30 OPERATION 2 7L 30 DIAGNOSIS AND TESTING ENGINE BLOCK HEATER TESTING 30 REMOVAL REMOVAL 2 0L 2 4L 30 REMOVAL 2 7L 30 INSTALLATION INSTALLATION 2 0L 2 4L 31 INSTALLATION 2 7L 31 ENGINE COOLANT TEMPERATURE SENSOR DESCRIPTION 31 OPERATION 31 REMOVAL 31 INSTALLATION 32 ENGINE...

Page 390: ...LET TUBE REMOVAL REMOVAL 2 0L 45 REMOVAL 2 4L 45 INSTALLATION INSTALLATION 2 0L 45 INSTALLATION 2 4L 45 ENGINE DESCRIPTION COOLING SYSTEM The cooling system consists of an engine cooling module thermostat coolant recovery reserve system 2 0L 2 4L or coolant pressure container 2 7L cool ant hoses and a water pump to circulate the cool ant The engine cooling module consists of a radiator electric fa...

Page 391: ...TOR 6 TRANSMISSION COOLER TUBE FASTENER 7 TRANSMISSION COOLER TUBE INLET 8 CONDENSER TO RADIATOR FASTENER 9 COMBINATION A C CONDENSER AND TRANSMISSION OIL COOLER 10 CONDENSER TO RADIATOR FASTENER 11 TRANSMISSION COOLER TUBE OUTLET 12 TRANSMISSION COOLER TUBE FASTENER 13 RADIATOR 14 CLIP 15 RADIATOR DRAINCOCK 7 12 ENGINE JR ENGINE Continued ...

Page 392: ... 2 Cooling System Operation 2 0L 2 4L 1 HEATER 2 HEAT UP 3 COOL DOWN 4 PRESSURE CAP 5 COOLANT OUTLET CONNECTOR 6 WATER PUMP 7 ENGINE 8 COOLANT RECOVERY CONTAINER 9 RADIATOR JR ENGINE 7 13 ENGINE Continued ...

Page 393: ...Fig 3 Cooling System Operation 2 7L 1 HEATER CORE 2 COOLANT PRESSURE CONTAINER 3 COOLANT OUTLET CONNECTOR 4 ENGINE 5 WATER PUMP 6 THERMOSTAT 7 RADIATOR 7 14 ENGINE JR ENGINE Continued ...

Page 394: ...l being climbed vehicle being operated in slow moving traffic or engine idling during high ambient outside temperatures with air conditioning on High altitudes could cause these conditions 1 This may be a temporary condition and repair is not necessary Turn off the air conditioning and drive the vehicle without any of the previous conditions Observe the temperature gauge The gauge should return to...

Page 395: ...c Check condition of hose from filler neck to coolant container It should be tight at both ends without any kinks or tears Replace hose as necessary d Check coolant recovery container and hose for blockage Repair as necessary 9 Freeze point of coolant not correct Mixture ratio may be too rich 9 Check coolant concentration Refer to 7 COOLING ENGINE COOLANT DIAGNOSIS AND TESTING Adjust glycol to wat...

Page 396: ...ions 1 A normal condition No correction is necessary If gauge cycling is going into the hot zone check electric fan operation and repair as necessary Refer to 7 COOLING ENGINE RADIATOR FAN DIAGNOSIS AND TESTING 2 During cold weather operation with the heater blower in the high position the gauge reading may drop slightly 2 A normal condition No correction is necessary 3 Temperature gauge or engine...

Page 397: ...Y BE ABOVE NORMAL BUT NOT HIGH COOLANT LEVEL MAY BE HIGH IN RECOVERY CONTAINER 1 Pressure relief valve in pressure cap defective or wrong pressure cap installed 1 Verify proper pressure cap part number Check condition of pressure cap and seals Replace as necessary Refer to 7 COOLING ENGINE RADIATOR PRESSURE CAP DIAGNOSIS AND TESTING COOLANT LOSS TO THE GROUND WITHOUT PRESSURE CAP BLOWOFF GAUGE IS ...

Page 398: ...mation Repair as necessary 2 Check for low coolant level 2 Refer to 7 COOLING STANDARD PROCEDURE Repair as necessary ELECTRIC RADIATOR FAN WILL NOT OPERATE GAUGE READING HIGH OR HOT 1 Radiator fan motor defective 1 Refer to the Appropriate Diagnostic Information Repair as necessary 2 Radiator fan relay powertrain control module PCM or engine coolant temperature sensor defective 2 Refer to the Appr...

Page 399: ... and check for obstructions Repair as necessary 4 Heater hose kinked 4 Locate kinked area and repair as necessary 5 Water pump is not pumping coolant to heater core When the engine is fully warmed up both heater hoses should be hot to the touch 5 Refer to 7 COOLING ENGINE WATER PUMP DIAGNOSIS AND TESTING Repair as necessary HEAT ODOR 1 Various heat shields are used at certain driveline components ...

Page 400: ...OOLING ENGINE COOLANT DIAGNOSIS AND TESTING Adjust the glycol to water ratio as required COOLANT LEVEL CHANGES IN COOLANT RECOVERY CONTAINER 1 Level changes are to be expected as coolant volume fluctuates with engine temperature If the level in the container was between the MIN and MAX marks when the engine was cold the level should return to within that range after operation at elevated temperatu...

Page 401: ...operating tem perature in order to open the thermostat and allow the coolant to expand Reattach the tester If the nee dle on the dial fluctuates it indicates a combustion leak and is usually a head gasket leak WARNING WITH TOOL IN PLACE PRESSURE BUILDS UP FAST ANY EXCESSIVE AMOUNT OF PRESSURE BUILT UP BY CONTINUOUS ENGINE OPERATION MUST BE RELEASED TO A SAFE PRESSURE POINT NEVER PERMIT PRESSURE TO...

Page 402: ...f the wrong cooling system pressure cap is installed Ensure proper cooling system pressure cap is used Verify proper pressure cap part number 2 7L This engine has a premium system to remove air from the engine cooling system Removal of air from the engine cooling system occurs continuously when the engine is run at speeds above idle Thirty minutes of normal driving after a properly completed servi...

Page 403: ...at heater tube located at the right front inner frame rail and direct coolant flow into container COOLING SYSTEM FILLING CAUTION Do not use well water or suspect water supply in cooling system A 50 50 mixture of the recommended ethylene glycol and distilled water is recommended NOTE COOLING SYSTEM FILL PROCEDURE IS CRITICAL TO OVERALL COOLING SYSTEM PER FORMANCE NOTE Make sure all hoses are connec...

Page 404: ...w air to escape 7 Slowly continue filling until a steady stream of coolant flows from attached hose on bleed valve 8 Close bleed valve and continue filling system to top of Filling Aid Funnel 9 Remove clip from overflow hose 10 Allow coolant in Filling Aid Funnel to drain into overflow chamber of pressure container 11 Remove Special Tool 8195 Filling Aid Funnel and install pressure cap on pressure...

Page 405: ...ylinder heads and water pumps requires special corrosion protection Mopar Antifreeze Coolant 5 Year 100 000 Mile Formula MS 9769 or the equiva lent ethylene glycol base coolant with hybrid organic 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 wa...

Page 406: ...re container 2 7L Use only 50 50 con centration of ethylene glycol type antifreeze and distilled water STANDARD PROCEDURE COOLANT SERVICE For engine coolant recommended service schedule Refer to LUBRICATION MAINTENANCE MAIN TENANCE SCHEDULES DESCRIPTION COOLANT OUTLET CONNECTOR REMOVAL WARNING DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN ...

Page 407: ... 2 4L DESCRIPTION The coolant recovery system consists of a container and an overflow hose that is connected to the coolant outlet connector Fig 13 The coolant recovery con tainer is mounted in the right side engine compart ment OPERATION This system works in conjunction with the pres sure cap to utilize thermal expansion and contraction of the coolant to keep the coolant free of trapped air It pr...

Page 408: ...ting coolant level at atmo spheric pressure It also provides some reserve cool ant to cover minor leaks evaporation or boiling losses The overflow chamber allows coolant recovery in case of an overheat REMOVAL 1 Drain coolant below the coolant pressure con tainer level 2 Remove the power steering reservoir attaching screw 3 Remove the air conditioning receiver dryer attaching screw 4 Unsnap washer...

Page 409: ... transferred to the engine coolant This pro vides easier engine starting and faster warm up when vehicle is operated in areas having extremely low temperatures OPERATION 2 7L When power is applied 110 volt A C to the block heater the heating element transfers heat through the aluminum engine block and into the coolant without directly penetrating the cooling system DIAGNOSIS AND TESTING ENGINE BLO...

Page 410: ...L 2 4L ENGINE The Engine Coolant Temperature ECT Sensor threads into the thermostat housing just below the coolant outlet connector Fig 17 The ECT Sensor is a negative thermal coefficient sensor 2 7L ENGINE The Engine Coolant Temperature ECT Sensor threads into the coolant outlet connector Fig 18 The ECT Sensor is a negative thermal coefficient sensor OPERATION The ECT sensor provides an input to ...

Page 411: ...perated by a wax filled con tainer pellet which is sealed When heated coolant reaches a predetermined temperature the wax pellet expands enough to overcome the closing spring and water pump pressure which forces the valve to open Coolant leakage into the pellet will cause a thermo stat to fail open Do not attempt to free up a thermo stat with a screwdriver The thermostat that opens too soon type f...

Page 412: ...ew thermostat assembly into the coolant outlet connector Align air bleed with notch on the coolant outlet connector Fig 21 3 Install coolant outlet connector onto thermostat housing and tighten bolts to 12 5 N m 110 in lbs Fig 19 4 Connect hoses to coolant outlet connector 5 Fill cooling system Refer to 7 COOLING EN GINE STANDARD PROCEDURE Fig 19 Coolant Outlet Connector 2 0L 2 4L 1 PRESSURE CAP 2...

Page 413: ...LAMPS The cooling system uses constant tension spring type hose clamps If a spring type clamp replacement is necessary replace with the original Mopar equip ment spring type clamp Vehicles equipped with a 2 7L engine use unique Low Profile type constant tension hose clamps at the coolant outlet connector hoses CAUTION A number or letter is stamped into the tongue of constant tension clamps If repl...

Page 414: ... Remove screw that holds support bracket for transmission cooler tubes at left side of radiator if equipped CAUTION Avoid bending the condenser inlet tube Care should be taken not to damage radiator or condenser cooling fins 8 Remove the air conditioning condenser attach ing screws located at the front of the radiator Fig 26 Disengage AC condenser from radiator It is not necessary to discharge the...

Page 415: ...se of pliers on draincock is not recom mended Damage may occur to radiator or drain cock NOTE It is not necessary to remove draincock dur ing a routine coolant drain 1 Drain the cooling system Refer to 7 COOL ING ENGINE STANDARD PROCEDURE 2 Open the draincock by turning it counterclock wise until it stops 3 Turn the draincock back clockwise 1 8 turn 4 Pull the draincock Fig 27 from the radiator ta...

Page 416: ...oes not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool Add water to the tool Turn tool upside down and recheck pressure cap to confirm that cap is bad If the pressure cap tests properly while positioned on Cooling System Tester Fig 29 but will not hold pressure or vacuum when positioned on the filler neck Inspect the filler neck and ca...

Page 417: ... cap part num ber 2 0L 2 4L Hold the cap in your hand right side up Fig 31 The vent valve at the bottom of the cap should fall open Turn the cap upside down The vent valve should close Replace the cap for any of the following conditions Rubber gasket has swollen preventing the valve from opening Any light can be seen between the vent valve and the rubber gasket with cap upside down Gasket on the b...

Page 418: ...y the coolant temperature sen sor which sends the message to the Powertrain Control Module PCM The PCM turns on the fan through a fan relay On models equipped with auto matic transmission a transmission fluid thermister may have some influences on fan operation See Wir ing Diagrams Manual for circuity and diagnostics provided The Powertrain Control Module PCM provides fan control for the following...

Page 419: ...E Radiator Fan Control A C Pressure A C Off Low High Fan On 104 C 220 F 110 C 230 F Fan Off 98 C 208 F 105 C 221 F A C On Low High Low High Fan On 99 C 210 F 110 C 230 F 1 448 Kpa 210 psi 1 718 Kpa 249 psi Fan Off 93 C 199 F 105 C 221 F 1 207 Kpa 175 psi 1 585 kpa 229 psi EATX Fluid Temperature Low Speed High Speed Fan On 109 C 228 F 111 C 232 F Fan Off 104 C 220 F 109 C 228 F DIAGNOSIS AND TESTIN...

Page 420: ...STAT REMOVAL 3 Disconnect engine coolant temperature sensor connector 4 Disconnect heater supply hose 5 Remove housing attaching bolts Fig 34 6 Remove housing and gasket Fig 34 INSTALLATION INSTALLATION 2 0L 1 Clean all gasket sealing surfaces 2 Install gasket and housing Fig 34 Tighten bolts to 28 N m 20 ft lbs 3 Reconnect heater supply hose 4 Reconnect engine coolant temperature sensor connector...

Page 421: ...of the engine s primary timing chain DIAGNOSIS AND TESTING WATER PUMP To determine whether coolant is flowing through the cooling system use one of the following proce dures PREFERRED METHOD WARNING DO NOT REMOVE THE COOLING SYS TEM PRESSURE CAP OR ANY HOSE WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR 2 0L 2 4L Remove pressure cap when engine is cold Remove s...

Page 422: ... 1 Disconnect negative battery cable 2 Drain cooling system Refer to 7 COOLING ENGINE STANDARD PROCEDURE NOTE The water pump is driven by the primary timing chain 3 Remove the timing chain cover timing chain and all chain guides Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 4 Remove bolts attaching water pump to block Fig 38 5 Remove water pump and gasket CLEANING Clean ga...

Page 423: ...t may leak from the second ary weep passage and fill the valley of the engine Fig 39 and Fig 41 If this condition is found clean the primary weep passage of debris Be sure to perform a thorough analysis before replacing water pump INSTALLATION INSTALLATION 2 0L 2 4L 1 Install new O ring gasket in water pump body O ring groove Fig 42 CAUTION Make sure O ring is properly seated in water pump groove ...

Page 424: ...e fasteners that hold the inlet tube to the block 5 Rotate inlet tube while removing from the engine block Fig 43 INSTALLATION INSTALLATION 2 0L 1 Inspect the O ring for damage before installing the tube into the cylinder block Fig 43 2 Lube O ring with coolant and install tube into the cylinder block opening 3 Install fasteners and tighten to 12 N m 105 in lbs 4 Reconnect lower radiator hose and ...

Page 425: ...mission oil leaks TRANSMISSION OIL COOLER DESCRIPTION An external oil to air type automatic transmission oil cooler is mounted to the front of the radiator and is integral to the A C condenser Fig 1 The six upper tubes are used for transaxle oil cooling and the remaining tubes below are for the A C system The cooler uses tubes and rubber hoses to feed oil to and from the automatic transaxle The re...

Page 426: ...em rely upon resources shared with other electronic modules in the vehicle over the Programmable Com munication Interface PCI bus network The data bus network allows the sharing of sensor informa tion For diagnosis of these electronic modules or of the data bus network the use of a DRB III scan tool and the proper Diagnostic Procedures manual are recommended Refer to the appropriate wiring informa...

Page 427: ...equipped 3 Verify radio on off input to amplifier and verify battery and ground connections Repair wiring as necessary 4 Amplifier faulty if equipped 4 Replace amplifier NO AUDIO AT SOME SPEAKERS RADIO DISPLAY AND CONTROLS ARE OPERATIONAL 1 Radio faulty 1 Refer to appropriate Diagnostic Service Manual 2 Speaker s faulty 2 Refer to speaker diagnostics 3 Wiring faulty between radio and speaker 3 Che...

Page 428: ...onnector faulty 2 Check for loose or corroded radio connector Repair if required CLOCK WILL NOT KEEP SET TIME 1 Fuse faulty 1 Check Ignition Off 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 faul...

Page 429: ...a with an ohmmeter Test 1 Coax cable at back of radio to ground test Test 2 Tip of mast to tip of conductor test Test 3 Body ground to battery ground test Test 4 Body ground to antenna coaxial cable shield test WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN SEAT BELT TENSIONER SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO ...

Page 430: ...not OK isolate and test each of the individual antenna conductor components Replace only the faulty antenna conductor component TEST 3 Test 3 checks the condition of the vehicle body ground connection To begin this test proceed as fol lows 1 This test must be performed with the battery positive cable disconnected from the battery Discon nect and isolate both battery cables negative cable first 2 R...

Page 431: ...ject functions which are controlled by buttons located on the front of the CD changer All features you would expect such as Disc Up Down Track Up Down Random and Scan are controlled by the radio which also displays all relevant CD changer information on the radio display On JR27 models the CD changer will not operate with the ignition in the OFF position With the igni tion OFF CD s can not be remo...

Page 432: ...panel INSTALLATION 1 Push antenna up through grommet in quarter panel 2 Install mounting bolts to antenna Tighten to 12 N m 110 in lbs 3 Connect antenna cable 4 Connect electrical connector to antenna 5 Connect drain tube 6 Install ground strap if equipped and fastener Tighten to 12 N m 110 in lbs 7 Connect battery negative cable REMOTE SWITCHES DESCRIPTION Remote radio control switches are rocker...

Page 433: ...ess routing and retention connector pin out information and location views for the various wire harness connectors splices and grounds WARNING DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL 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 ...

Page 434: ...he steering wheel as the remote radio switch that is being serviced Refer to 8 ELECTRI CAL SPEED CONTROL SWITCH REMOVAL 4 Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch Fig 6 5 From the inside of the steering wheel rear trim cover press firmly and evenly outward on the back of the switch to disengage the four snap features that secure ...

Page 435: ... radio repair stations OPERATION The radio receiver operates on ignition switched battery current that is available only when the igni tion switch is in the On or Accessory positions The electronic digital clock function of the radio operates on fused battery current supplied through the IOD fuse regardless of the ignition switch position For more information on the features setting pro cedures an...

Page 436: ...SIDE AIRBAG OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MIN UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAG NOSIS OR SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI BLE PERSONAL IN...

Page 437: ... PANEL TOP PAD REMOVAL 4 Remove speaker screws 5 Disconnect wire harness connector from speaker 6 Remove speaker Fig 11 REAR SPEAKER JR41 1 Disconnect and isolate the battery negative cable 2 Fold down the rear seat backs 3 Remove C pillar trim 4 Remove lower quarter trim behind rear seat backs 5 Remove fasteners from rear shelf trim Pull out trim to access speaker 6 Remove speaker screws 7 Discon...

Page 438: ...l speaker screws Tighten to 3 N m 30 in lbs 3 Install instrument panel top cover 4 Install A pillar trim 5 Connect battery negative cable REAR SPEAKER JR41 1 Connect wire harness connector to speaker 2 Position speaker into opening 3 Install speaker screws Tighten to 4 N m 35 in lbs 4 Install rear shelf trim 5 Install lower quarter trim panel 6 Install C pillar trim 7 Raise seat backs 8 Connect ba...

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Page 440: ...d seat belt feature is not initiated or if the feature is disabled the seat belt indicator will be turned ON continuously until the driver seat belt is buckled In the same ignition cycle if the seat belt is again unbuckled for more than ten seconds with the vehicle speed greater than five mph 8 km h the enhanced seat belt reminder feature will again be initiated The enhanced seat belt reminder fea...

Page 441: ...air as necessary NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON 1 At power up the cluster will turn ON the seat belt warning indicator for 6 1 seconds as required regardless of the driver side seat belt buckle status If the warning indicator does not turn ON verify if the socketed red LED is seated properly and good contact with the PC board is present If not seated properly then seat ...

Page 442: ... Remove BCM from Junction Block Check for battery voltage at terminal JB 12 and ignition feed at terminal JB 6 of BCM Refer to the appropriate wiring information 6 If voltage not OK repair as necessary CHIMES CONTINUE WHEN HEADLAMPS ARE TURNED OFF AND OR KEY IS REMOVED FROM IGNITION 1 Use DRB III scan tool to perform PCI data bus diagnostics on BCM for headlamp or key in igni tion inputs 2 Check w...

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Page 444: ...ntrol 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 to detect when a double fault has occurred and ...

Page 445: ... the secret key the PCM will send the secret key to the SKIM 8 Program ignition keys to SKIM NOTE If the PCM and the SKIM are replaced at the same time all vehicle keys will need to be replaced and programmed to the new SKIM PROGRAMMING IGNITION KEYS TO THE SKIM 1 Turn the ignition switch on transmission in park neutral 2 Use the scan tool and select THEFT ALARM SKIM then MISCELLANEOUS 3 Select PR...

Page 446: ...the wheel speed sensors to determine if any wheel is beginning to lock When a wheel locking tendency is detected the ABM commands the ABM command coils to actu ate The ABM command coils then open and close the valves in the HCU that modulate brake fluid pres sure in some or all of the hydraulic circuits The ABM continues to control pressure in individual hydraulic circuits until a locking tendency...

Page 447: ...accessory systems in the vehicle The BCM monitors its own internal circuitry as well as many of its input and output circuits and will store a Diagnostic Trouble Code DTC in elec tronic memory for any failure it detects These DTCs can be retrieved and diagnosed using a scan tool Refer to the appropriate diagnostic information REMOVAL The Junction Block and Body Control Module BCM are attached to e...

Page 448: ...set point is about 38 C 100 4 F and the High heat set point is about 42 C 107 6 F If the seat cushion surface temperature input is below the temperature set point for the selected tem perature setting the heated seat module energizes an N channel Field Effect Transistor N FET within the module which energizes the heated seat elements in the selected seat cushion and back When the sen sor input to ...

Page 449: ...ule Inputs Based on these inputs the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs NOTE PCM Inputs Air Conditioning Pressure Transducer ASD Relay Battery Voltage Brake Switch Camshaft Position Sensor Crankshaft Position Sensor Distance Sensor from transmission control mod ule EGR Position Feedback if equipped Engine Coolant Tempe...

Page 450: ...camshaft position sensor and crankshaft position sensor The PCM also provides a regulated 5 0 volts supply for the manifold absolute pressure sensor throttle position sensor and EGR if equipped The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km 200 miles If the PCM is replaced after 320 km 200 miles of usage update the mileage in new PCM Use the...

Page 451: ...priate clutch vol umes 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 Fig 4 Example of CVI Calculation 1 OUTPUT SPEED SENSOR 2 OUTPUT SHAFT 3 CLUTCH PACK 4 SEPARATOR PLATE 5 FRIC...

Page 452: ...shift approximately 30 mph Early 3 2 coastdown shift approximately 17 mph High speed 4 2 3 2 2 1 kickdown shifts are prevented No EMCC Warm Oil temperature at start up above 36 F and below 80 degree F Normal operation upshift kickdowns and coastdowns No EMCC Hot Oil temperature at start up above 80 F Normal operation upshift kickdowns and coastdowns Full EMCC no PEMCC except to engage FEMCC except...

Page 453: ...LY PCM OUTPUT The PCM supplies 5 volts to the following sensors A C pressure transducer Ambient Temperature sensor Battery temperature Camshaft Position Sensor NGC Crankshaft Position Sensor NGC Engine coolant temperature sensor Inlet Air Temperature Sensor Knock sensor Linear EGR solenoid if equipped Manifold absolute pressure sensor Oil Pressure Switch Throttle position sensor STANDARD PROCEDURE...

Page 454: ...he calculated oil temperature must be above 60 and below 200 1 Plug the scan tool into the diagnostic connector The connector is located under the instrument panel 2 Go to the Transmission screen 3 Go to the Miscellaneous screen 4 Select Quick Learn Procedure Follow the instructions of the scan tool to perform the Quick Learn Procedure REMOVAL NGC CONTROLLER USE THE SCAN TOOL TO REPROGRAM THE NEW ...

Page 455: ...er Module SKIM con tains a Radio Frequency RF transceiver and a microprocessor The SKIM retains in memory the ID numbers of any Sentry Key that is programmed to it The maximum number of keys that may be pro grammed to each module is eight 8 The SKIM also communicates over the PCI bus with the Powertrain Control Module PCM the Body Control Module BCM and the scan tool The SKIM transmits and receive...

Page 456: ...elated fault exists the indicator light will flash following the indicator light test The SKIM may also request an audible chime if the customer key programming fea ture is available and the procedure is being utilized Refer to Electrical Vehicle Theft Security Transpon der Key Standard Procedure Transponder Program ming REMOVAL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM ...

Page 457: ...rews Fig 8 4 Connect the wire harness connector 5 Install the steering column upper and lower shrouds Refer to 23 BODY INSTRUMENT PANEL STEERING COLUMN OPENING COVER INSTAL LATION 6 Install the knee bolster Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 7 Connect the battery negative remote cable 8E 14 ELECTRONIC CONTROL MODULES JR SENTRY KEY IMMOBILIZER MODULE Continued ...

Page 458: ...L 15 INSTALLATION 15 BATTERY TRAY DESCRIPTION 15 OPERATION 15 REMOVAL 16 INSTALLATION 16 BATTERY HEATER BLANKET DESCRIPTION 16 OPERATION 17 DIAGNOSIS AND TESTING BATTERY HEATER BLANKET 17 REMOVAL 17 INSTALLATION 17 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 v...

Page 459: ...vehicle operate with one another and must be tested as a single complete system In order for the engine to start and the battery to charge properly all of the components that are used in these systems must per form within specifications It is important that the battery starting and charging systems be thoroughly tested and inspected any time a battery needs to be charged or replaced The cause of a...

Page 460: ... Standard Procedures for the proper test procedures Charge the faulty battery as required 5 The electrical system ignition off draw is excessive 5 Refer to Standard Procedures for the proper test procedures Repair the faulty electrical system as required 6 The battery is faulty 6 Determine the battery cranking capacity Refer to Standard Procedures for the test procedures Replace the faulty battery...

Page 461: ...tem as required 7 The charging system is faulty 7 Determine if the charging system is performing to specifications Refer to Charging System for the proper charging system diagnosis and testing procedures Repair the faulty charging system as required 8 Electrical loads exceed the output of the charging system 8 Inspect the vehicle for aftermarket electrical equipment which might cause excessive ele...

Page 462: ...ion from the battery terminals with a wire brush or terminal cleaner and a sodium bicarbonate baking soda and warm water cleaning solution INSPECTION The following information details the recommended inspection procedures for the battery and related components In addition to the maintenance sched ules found in this service manual and the owner s manual it is recommended that these procedures be pe...

Page 463: ...lts This rating is also sometimes identified as the twenty hour discharge rating BATTERY SPECIFICATIONS RATINGS Part Number BCI Group Size Classification Cold Cranking Amperage Reserve Capacity Ampere Hours Load Test Amperage N A 75 510 110 Minutes 57 260 SPECIAL TOOLS BATTERY SYSTEM SPECIAL TOOLS BATTERY DESCRIPTION Maintenance free batteries have non removable battery vent caps Fig 2 Water canno...

Page 464: ...attery cell caps cannot be removed the battery must be replaced if the electrolyte level becomes low DIAGNOSIS AND TESTING BATTERY The battery must be completely charged and the terminals should be properly cleaned and inspected before diagnostic procedures are performed Refer to Battery System Cleaning for the proper cleaning pro cedures and Battery System Inspection for the proper battery inspec...

Page 465: ...EHICLE test before replacing 6 While viewing the battery test result press the CODE button and the tester will prompt you for the last 4 digits of the VIN Use the UP DOWN arrow buttons to scroll to the correct character then press ENTER to select and move to the next digit Then press the ENTER button to view the SERVICE CODE Pressing the CODE button a second time will return you to the test result...

Page 466: ...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 The following procedure should be used to recharge a completely discharged battery Unless this proce dure is properly followed a good battery may be needlessly replaced 1 Measure the voltage at...

Page 467: ... 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 used in place of the hydrometer test when...

Page 468: ...ntrol Module Yes 1 min Ignition Key Up To 3 0 amps N A 2 If equipped determine that the underhood lamp is operating properly then disconnect the lamp wire harness connector or remove the lamp bulb 3 Disconnect the battery negative cable 4 Set an electronic digital multi meter to its highest amperage scale Connect the multi meter between the disconnected battery negative cable ter minal clamp and t...

Page 469: ...cables from the battery 8 Slide the battery toward rear of vehicle and lift out of the battery tray 9 Remove battery from vehicle INSTALLATION 1 Position the battery in the battery tray 2 Connect the positive and negative battery cables Torque to 16 N m 150 in lbs 3 Connect the heater blanket cord if equipped 4 Install the battery hold down and install the hold down bolt Torque to 16 N m 150 in lb...

Page 470: ... clamp The battery cables cannot be repaired and if dam aged or faulty they must be replaced Both the bat tery positive and negative cables are available for service replacement only as a unit with the battery wire harness which may include portions of the wir ing circuits for the generator and other components on some models Refer to the appropriate wiring information in this service manual for t...

Page 471: ... terminal clamp to terminal post connection and the battery positive cable VOLTAGE DROP TEST The following operation will require a voltmeter accurate to 1 10 0 10 volt Before performing this test be certain that the following procedures are accomplished The battery is fully charged and load tested Refer to Standard Procedures for the proper battery charging and load test procedures Fully engage t...

Page 472: ...battery cable in the vehicle 2 One at a time install the battery cable retain ing pushpins fasteners and routing clips until the cable is installed exactly in the factory installed loca tion in the vehicle Refer to the Wiring Diagram sec tion of the service manual for reference 3 Connect the battery negative cable terminal BATTERY TRAY DESCRIPTION The battery is placed in a steel tray located in t...

Page 473: ...Fig 13 and remove the battery tray from the vehicle INSTALLATION 1 Install the battery tray and retaining bolts Torque the bolts to 14 N m 160 in lbs 2 Install the battery in the vehicle Refer to 8 ELECTRICAL BATTERY SYSTEM BATTERY INSTALLATION 3 Install the left headlamp assembly in the vehi cle Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR HEADLAMP UNIT INSTALLATION 4 Connect the remote negative...

Page 474: ...lanket 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 volt AC power cord is...

Page 475: ...nt 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 used to cal culate the temperature near the battery This tem perature data along with data from monitored line voltage battery voltage sense circuit is used by the PCM to v...

Page 476: ... 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 are operational A Diagnostic Trouble Code DTC is assigned to each input and output circuit monitored by the On Board Diagnostic OBD system So...

Page 477: ...coil The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification From the diodes rectified DC current is delivered to the vehicles electrical system through the generator battery and ground terminals Noise emitting from the generator may be caused by Worn loose or defective bearings Loose or defective drive pulley Incorrect worn damage...

Page 478: ...enerator from vehicle Fig 4 Fig 1 Remove Battery Cable at Shock Tower Fig 2 Wiring Connections 1 B TERMINAL 2 CASE GROUND 3 FEED 4 TO PCM Fig 3 GENERATOR AND MAP SENSOR 1 Generator 2 MAP Sensor Fig 4 GENERATOR JR CHARGING 8F 21 GENERATOR Continued ...

Page 479: ...r to the Cooling section for more information 6 Install the accessory drive splash shield 7 Lower vehicle 8 Install the B terminal wire and nut Fig 2 9 Install B terminal cover 10 Plug in the field circuit to generator 11 Install belt cover 12 Install the negative battery cable INSTALLATION 2 7L 1 Install generator Fig 6 2 Install the 2 upper bolts but do not tighten 3 Install the engine dip stick...

Page 480: ...The EVR circuitry monitors system line voltage at the PDC and calculated battery temperature or inlet air temperature sensor refer to Inlet Air Tem perature Sensor if equipped for more information It then determines a target charging voltage If sensed battery voltage is lower than the target volt age the PCM feeds the field winding until sensed battery voltage is at the target voltage A circuit in...

Page 481: ...nose 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 the Powertrain Control Mod ule PCM Use of an induction type milliampere ammeter volt ohmmeter battery charger carbon pile rheostat load teste...

Page 482: ...s within starter or starter mounted solenoid and replace starter Inspect the ring gear teeth STARTER RELAY WARNING CHECK TO ENSURE THAT THE TRANS MISSION IS IN THE PARK NEUTRAL POSITION WITH THE PARKING BRAKE APPLIED RELAY TEST The starter relay is located in the Power Distribu tion Center PDC in the engine compartment Refer to the PDC label for relay identification and location Remove the starter...

Page 483: ...l 86 Repair open circuit as required Also check the clutch interlock switch operation if equipped with a manual transmission If OK the PCM may be defective SAFETY SWITCHES For diagnostics of the Transmission Range Sensor refer to the Transaxle section for more information If equipped with Clutch Interlock Upstop Switch refer to Diagnosis and Testing in the Clutch section IGNITION SWITCH After test...

Page 484: ... INFORMATION REPLACE SWITCH IF NECESSARY 6 CLUTCH INTERLOCK SWITCH MAN TRANS FAULTY 6 REFER TO CLUTCH PEDAL POSITION SWITCH TEST IN THE CLUTCH SECTION REPLACE SWITCH IF NECESSARY 7 STARTER SOLENOID FAULTY 7 REFER TO SOLENOID TEST IN THIS SECTION REPLACE STARTER ASSEMBLY IF NECESSARY 8 STARTER ASSEMBLY FAULTY 8 IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK REPLACE STARTER ASSEMBLY 9...

Page 485: ...and Fuel systems dis connect the Automatic Shutdown Relay ASD The ASD relay is located in the Power Distribution Cen ter PDC Refer to the PDC cover for proper relay location 2 Gain access to battery terminals 3 With all wiring harnesses and components properly connected perform the following a Connect the negative lead of the voltmeter to the battery negative post and positive lead to the battery ...

Page 486: ... not overheat the starter motor or draw the battery voltage below 9 6 volts during cranking operations 5 Rotate and hold the ignition switch in the START position Observe the volt ampere tester Fig 1 If voltage reads above 9 6 volts and amperage draw reads above 280 amps check for engine seizing or faulty starter If voltage reads 12 4 volts or greater and amper age reads 0 to 10 amps check for cor...

Page 487: ...sensor from the exhaust mani fold Fig 4 6 Remove the front mount through bolt 7 Remove the front mount bracket from engine block 8 Remove the battery cable from starter Fig 5 9 Remove the lower starter bolt and remove starter Fig 6 Fig 2 STARTER 4 CYLINDER Fig 3 STARTER REMOVAL 4 CYLINDER Fig 4 O2 SENSOR Fig 5 STARTER MOTOR 8F 30 STARTING JR STARTER MOTOR Continued ...

Page 488: ...wer and torque bolt to 54 N m 40 ft lbs 9 Install the front mount through bolt and torque bolt to 61 N m 45 ft lbs 10 Install the O2 sensor and torque to 27 N m 20 ft lbs 11 Lower vehicle 12 Connect the negative battery cable STARTER MOTOR RELAY DESCRIPTION The Starter Relay is a micro relay located in the Power Distribution Center PDC positioned in the left front corner of the engine compartment ...

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Page 490: ...moving foreign materials decals or stickers Normal glass cleaning solvents or hot water used with rags or toweling is recom mended The rear window defogger system also known as electric backlight EBL consists of two vertical bus bars linked by a series of grid lines fired onto the inside surface of the rear window Fig 1 The EBL system is turned On and Off by a switch in the A C heater control loca...

Page 491: ...PAIR DIAGNOSIS AND TESTING ELECTRIC BACKLIGHT EBL SYSTEM NOTE Illumination of the defogger switch indicator lamp does not necessary mean that electrical cur rent is reaching the rear glass heating grid lines NOTE For circuit descriptions and diagrams of the rear window defogger system refer to 8W WIRING DIAGRAM INFORMATION Operation of the electric backlight EBL system can be confirmed by the foll...

Page 492: ...electromechanical switch that uses a low current input controlled by the body control module BCM to control the high current output to the rear window defogger grid lines The movable common feed relay contact is held against the fixed normally closed relay contact by spring pressure When the electromagnetic relay coil is energized it draws the movable common feed relay contact away from the fixed ...

Page 493: ...he rear window defogger EBL relay from the junction block JB Fig 5 INSTALLATION 1 Position the EBL relay into the proper recepta cle of the junction block JB 2 Align the EBL relay terminals with the termi nal cavities in the JB receptacle and push down firmly on the relay until the terminals are fully seated 3 Install the instrument panel end cap Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ...

Page 494: ...0 ohms 10 If not OK replace the A C heater control If OK check for the following Faulty rear window defogger EBL relay Faulty fuse in the junction block JB Open circuit Short circuit Faulty connection Faulty body control module BCM REAR WINDOW DEFOGGER GRID LINES STANDARD PROCEDURE GRID LINE AND TERMINAL REPAIR REAR WINDOW DEFOGGER GRID LINE REPAIR WARNING Materials contained in the Repair Kit Par...

Page 495: ...ry or death Repair of the rear glass heating grid terminal s on hard top models can be accomplished using the Mopar Rear Window Defogger Repair Kit Part Number 04549275 or equivalent 1 If the grid terminal s is broken and a portion of the terminal is still attached to the heating grid remove the portion of the clip remaining in the wire harness connector s 2 Mask the areas so the conductive epoxy ...

Page 496: ... 000 Extra Fine Steel Wool or an equivalent NOTE The terminal attaching clip s must face out board Failure to reorient the terminal s may result in an additional failure 4 Properly orient the new terminal s with the attaching clip facing outboard in the original loca tion s on the grid bus bar and hold the terminal s with a metal pick or other suitable pointed tool CAUTION Do not allow the glass s...

Page 497: ... the ignition switch is turned to the Off position or it can be shut off manually by pressing the rear window defogger switch a second time OPERATION When the rear window defogger switch is pressed the rear window defogger EBL system becomes acti vated and an electric heater grid located behind the glass of each of the outside rear view mirrors is ener gized When energized each of these heater gri...

Page 498: ...trol and diagnostic logic cir cuitry for the entire heated seat system Each heated seat module is mounted under each of the front seat cushions Refer to the Electronic Control Modules section of the service manual for additional heated seat module information Heated Seat Elements Four heated seat ele ments are used per vehicle one in each front seat cushion and one in each front seat back These el...

Page 499: ...h outboard seating position of the front seat and it is located in the center insert area of the seat cushion cover The heated seat sensors and their pigtail wires are also captured between the leather trim cover and the foam rubber backing on the underside of their respective seat cushion trim cover assemblies The heated seat sensors are Negative Thermal Coefficient NTC thermistors The sensors fo...

Page 500: ...nuity If OK test the heated seat control module as described in this section If not OK replace the faulty seat back cover and element assembly REMOVAL Do not remove the original heating element from the seat or seat back cushion trim covers The origi nal element is permanently attached and cannot be removed without permanent damage Models with replaceable heating elements are designed to be applie...

Page 501: ... Diodes LED s in the heated seat switch The first LED illuminates the heated seat symbol on the switch anytime the igni tion switch is in the On position The remaining LED s illuminate the numbers on the switch indicat ing that the system is on DIAGNOSIS AND TESTING HEATED SEAT SWITCH Refer to Wiring Diagrams for the location of com plete heated seat system wiring diagrams WARNING DISABLE THE AIRB...

Page 502: ...ce the heated seat switch CHECKING PASSENGER HEATED SEAT SWITCH SWITCH POSITION RESISTANCE VALUE BETWEEN PINS PF 86F 0 OPEN 1 4 OHM 2 100 OHMS 3 200 OHMS 4 300 OHMS 5 400 OHMS 6 500 K OHMS 500 OHMS REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the center console Refer to the Body section of this manual for the procedure 3 Disconnect the center console wire harness con nector...

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Page 504: ...unded at the shock tower through the headlamp and dash har ness Refer to the appropriate 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 connectors splices and grounds DIAGNOSIS AND TESTING HORN SYSTEM CAUTION Con...

Page 505: ...N BLOCK 1 REPLACE FUSE IF BLOWN AS REPAIR AS NECESSARY 2 NO VOLTAGE AT HORN RELAY TERMINALS 6 8 AND FUSE IS OK 2 NO VOLTAGE REPAIR OR REPLACE JUNCTION BLOCK AS NECESSARY 3 FAULTY OR DAMAGED HORN 3 VOLTAGE AT HORN WHEN HORN SWITCH IS PRESSED REPLACE HORN 4 FAULTY HORN SWITCH 4 REPLACE DRIVER AIRBAG MODULE TRIM FUSE BLOWS WHEN HORN IS BLOWN 1 SHORT CIRCUIT IN HORN OR HORN WIRING OR FAULTY RELAY 1 RE...

Page 506: ...nected test continuity of the X2 cavity of the horn relay to ground If continuity is detected the circuit is grounded between the Junction Block and the horns Locate and repair pinched harness If the amperage draw does not drop to 0 amps repair short at the Junction Block FUSE OK 1 Remove the horn relay from the Junction Block 2 Using a continuity tester Depress horn switch and test continuity fro...

Page 507: ...iring 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 connectors splices and grounds 1 Remove horn relay from the Junction Block 2 Using ohmmeter test between the Junction Block relay terminal 7 and ground for continuity a When the horn contac...

Page 508: ...INSTALLATION 2 0 2 4L 8 IGNITION CONTROL DESCRIPTION IGNITION SYSTEM NOTE All engines use a fixed ignition timing sys tem Basic ignition timing is 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 po...

Page 509: ...WN RELAY DESCRIPTION The relay is located in the Power Distribution Cen ter PDC For the location of the relay within the PDC refer to the PDC cover for location Check elec trical terminals for corrosion and repair as necessary OPERATION The ASD sense circuit SBEC vehicles or the engine switched battery NGC vehicles informs the PCM when the ASD relay energizes A 12 volt signal at this input indicat...

Page 510: ... cylinder identification to the Powertrain Con trol Module PCM The sensor generates pulses as groups of notches on the camshaft sprocket or cam shaft target magnet pass underneath it The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket When metal aligns with the sensor voltage goes low less than 0 3 volts When a not...

Page 511: ...ach electrical connector to sensor IGNITION COIL DESCRIPTION The ignition coil assembly for the 4 cylinder engines consists of 2 independent coils molded together The coil assembly for the 4 cylinder engines is mounted on the cylinder head cover Spark plug cables route to each cylinder from the coil The coil assemblies for the 2 7L are mounted on the head cover It is a coil on plug assembly and ea...

Page 512: ...embly Fig 8 INSTALLATION INSTALLATION 4 CYLINDER The electronic ignition coil pack attaches directly to the valve cover Fig 5 1 Install coil pack on valve cover 2 Install bolts and tighten bolts to N m 11 8 105 in lbs 3 Connect the electrical connector Fig 6 4 Transfer spark plug cables to new coil pack The coil pack towers are numbered with the cylinder identification Be sure the ignition cables ...

Page 513: ...ed by the knock sensor increases with the amplitude of vibration The PCM receives as an input the knock sensor voltage signal If the signal rises above a predetermined level the PCM will store that value in memory and retard ignition timing to reduce engine knock If the knock sensor voltage exceeds a preset value the PCM retards ignition timing for all cylinders It is not a selective cylinder reta...

Page 514: ...cts knock sensor performance possibly causing improper spark control 2 Attach electrical connector to knock sensor INSTALLATION 2 7L The sensors screws into the cylinder block directly below the intake manifold 1 Install knock sensor Fig 11 Tighten knock sensor to 10 N m 7 ft lbs torque Over or under tightening effects knock sensor performance resulting in possible improper spark control 2 Install...

Page 515: ...ression of radio frequency emissions from the ignition system Check the spark plug cable connections for good contact at the coil and spark plugs Terminals should be fully seated The insulators should be in good con dition and should fit tightly on the coil and spark plugs Spark plug cables with insulators that are cracked or torn must be replaced Clean Spark Plug cables with a cloth moistened wit...

Page 516: ...ant Restraint Control ler ORC via the PCI data bus Upon receipt of information the cluster will determine the gauge position and whether the PCI bus controlled warn ings should be turned ON or OFF The ABS is a learned feature by receiving an ABS message on the bus Once learned the ABS must be unlearned manually by sending a diagnostic message using a DRB III scan tool The AIRBAG light is always su...

Page 517: ...p Computer CMTC Traveler disconnect the module and then remove the cluster bezel assembly 10 For better access and prevention of scratching the cluster lens tilt the steering column to its lowest position and depress the hazard switch 11 Remove the cluster attaching screws 12 Pull the cluster rearward to disconnect the 26 way self docking connector and then carefully tilt cluster downward slightly...

Page 518: ...rd 7 Remove two screws from the back of the dial assembly to remove the VF display 8 Remove the VF display from the cluster INSTALLATION 1 Position the VF display onto the dial assembly and install the two screws 2 Carefully push the dial assembly into the hous ing to make the connection with the PC board 3 Install the six attachment screws and then install cluster mask lens to the instrument clus...

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Page 520: ...icle Sight along the centerline of the vehicle from rear of vehi cle forward to verify accuracy of the line placement 5 Rock vehicle side to side three times and allow suspension to stabilize 6 Jounce front suspension three times by pushing downward on front bumper and releasing 7 Measure the distance from the center of head lamp lens to the floor Transfer measurement to the alignment screen with ...

Page 521: ...MP ALIGNMENT SCREEN EXPORT 1 CENTER OF VEHICLE 5 10 METERS 32 8 ft 2 CENTER OF HEADLAMPS 6 HORIZONTAL CUT OFF LINE 3 15 CUT OFF LINE 7 130mm 4 FRONT OF HEADLAMP Fig 2 HEADLAMP ALIGNMENT SCREWS 1 HEADLAMP ADJUSTER VERTICAL 2 HEADLAMP ADJUSTER HORIZONTAL 3 HEADLAMP RETAINING BOLTS 8L 2 LAMPS JR HEADLAMP UNIT EXPORT Continued ...

Page 522: ...sconnect the wiring harness from the lamps 8 Disconnect electrical connector from headlamp leveling motor 9 Remove the headlamp unit Fig 4 INSTALLATION 1 Connect the position lamp to the reflector 2 Carefully reinstall the rubber boot making sure to get a full perimeter seal aroung the back of the reflector and the headlamp unit 3 Connect the wire harness 4 Connect wire harness to headlamp levelin...

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Page 524: ...s on the Programmable Communication Interface PCI Data Bus Circuit The information that is available via activation of the STEP button follows Compass and Temperature Average Fuel Economy Distance to Empty Instantaneous Fuel Economy Trip Odometer Elapsed Time Blank Screen The only information that can be reset includes Average Fuel Economy Trip Odometer and Elapsed Time To reset the display press ...

Page 525: ... may be performed using a DRB lll scan tool and the proper Body Diagnostic Procedures Man ual or by the following procedure 1 With the ignition switch in the OFF position press both the US M and STEP button 2 Turn ignition switch to the ON position The Compass Mini Trip Computer will perform internal checks while lighting all segments of the vacuum florescent display Upon completion of the interna...

Page 526: ... variance zone 1 15 If the variance needs to be changed use the STEP button to select the correct zone number from the figure below Fig 3 After selecting the desired variance zone the CMTC will return to nor mal operation after 5 seconds or by pressing the STEP and US M buttons simultaneously Fig 3 Variance Settings Fig 2 Compass Calibration 1 RADIUS 15 45 SPEED 7 10 mph JR COMPASS MINI TRIP COMPU...

Page 527: ...taining clip Fig 4 and remove Compass Mini Trip Computer Traveler from the cluster bezel INSTALLATION 1 Snap the Compass Mini Trip Computer on the cluster bezel and install the retaining screws 2 Install the Instrument Cluster Bezel Refer to 23 BODY INSTRUMENT PANEL CLUSTER BEZEL INSTALLATION 3 Connect the battery negative remote cable Fig 4 Compass Mini Trip Computer Retaining Screws 1 COMPASS MI...

Page 528: ...unit If any part of the component is faulty or damaged the complete assembly must be replaced OPERATION The universal transmitter operates on a non switched source of battery current so the unit will remain functional regardless of the ignition switch position For more information on the features pro gramming procedures and operation of the universal transmitter see the owner s manual in the vehic...

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Page 530: ...ESS ENTRY MODULE REMOVAL 6 INSTALLATION 6 POWER LOCKS DESCRIPTION POWER DOOR LOCKS The power lock system allows all doors to be locked or unlocked electrically by operating the switch on either front door trim panel The power lock system operates on non switched battery current supplied through a fuse in the junction block so that the sys tem remains functional regardless of the ignition switch po...

Page 531: ...r respective locking knobs The front doors can be locked or unlocked mechan ically with the locking knob regardless of electrical locking and unlocking actuation with the front door knobs The right and left front door on all vehicles can be locked or unlocked mechanically from the outside with the key or electrically as described above The left and right front doors can also be unlocked by actuati...

Page 532: ...is responsible for keep ing track of the horn chirp status DIAGNOSIS AND TESTING REMOTE KEYLESS ENTRY When trouble shooting problems with the Remote Keyless Entry System always verify that the power door lock unlock switches are functional If the doors do not lock unlock with the power switches the fol lowing components should be analyzed Door Lock Switches Body Control Module Lock and unlock rela...

Page 533: ...cuit information DOOR LOCK SWITCH Remove the switch from its mounting location Using an ohmmeter refer to the DOOR LOCK SWITCH CONTINUITY table to determine if the continuity is correct in the LOCK and UNLOCK switch positions If these results are not obtained replace the switch DOOR LOCK SWITCH CONTINUITY SWITCH POSITION CONTINUITY BETWEEN RESISTANCE VALUE LOCK 1 AND 4 2700 10 UNLOCK 1 AND 4 620 1...

Page 534: ...r is available The DRBIII scan tool can provide confirmation that the PCI data bus is functional and that all of the electronic modules are sending and receiving the proper messages on the PCI data bus The following procedure can be used as long as one functioning transmitter is available 1 Turn ignition to the RUN position allow igni tion chimes to stop 2 Using any original working transmitter pr...

Page 535: ... the remote keyless entry module from the BCM NOTE The Remote Keyless Entry RKE module is attached to the BCM This must be transferred if equipped to the new BCM if being replaced NOTE If BCM is replaced the VTSS must be enabled in the new BCM via the DRB lll in order to start the vehicle INSTALLATION 1 Snap the remote keyless entry module onto the BCM 2 Connect BCM to the Junction Block 3 Connect...

Page 536: ...automatic dimming feature is operational When the automatic day night mirror is turned on the mirror switch is lighted by an integral Light Emitting Diode LED The mirror will auto matically disable its self dimming feature whenever the vehicle is being driven in reverse OUTSIDE REAR VIEW MIRROR The power mirrors receive a non switched battery feed through a fuse in the junction block so that the s...

Page 537: ...ug 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 the automatic day night mirror wire harness connector If OK go to Step 4 If not OK repair the open circuit to the junc tion block as required 4 Turn the ignition sw...

Page 538: ...ND 7 RIGHT 7 AND 1 3 AND 2 8 AND 3 SWITCH POSITION CONTINUITY BETWEEN MIRROR SELECT SWITCH IN RIGHT POSITION UP 10 AND 3 9 AND 7 7 AND 4 DOWN 10 AND 7 9 AND3 4 AND 3 LEFT 10AND 3 7 AND 2 8 AND 7 RIGHT 10 AND 7 3 AND 2 8 AND 3 REMOVAL 1 Disconnect and isolate the battery negative cable 2 Using a trim stick pry the trim bezel from the instrument panel 3 Disconnect wire harness connector from switch ...

Page 539: ...RY NEGATIVE CABLE THEN WAIT TWO MINUTES FOR THE SYS TEM CAPACITOR TO DISCHARGE BEFORE FUR THER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY The power seat system allows the seating position to be adjusted forward rearward up down front up front down rear up or rear down A eight way ...

Page 540: ...cuit breaker terminals still contact terminals in fuse block Connect ground wire of voltmeter to a good ground With probe of voltmeter positive wire check both terminals of cir cuit breaker for battery voltage If only one terminal checks at battery voltage circuit breaker is defective and must be replaced If neither terminal shows bat tery voltage check for open or shorted circuit to cir cuit brea...

Page 541: ...the switch positions replace switch HARD TOP POWER SEAT SWITCH CONTINUITY TEST SWITCH POSITION CONTINUITY BETWEEN OFF 1 2 1 3 1 4 1 6 1 7 1 8 1 9 1 10 SEATBACK RECLINER UP 5 2 1 4 SEATBACK RECLINER DOWN 5 4 1 2 SEAT BACKWARD 5 3 1 6 SEAT FORWARD 5 6 1 3 FRONT RISER UP 7 5 1 10 FRONT RISER DOWN 5 10 1 7 REAR RISER UP 5 8 1 9 REAR RISER DOWN 5 9 1 8 CONVERTIBLE POWER SEAT SWITCH CONTINUITY TEST SWIT...

Page 542: ...s include a single electrically operated power seat track unit located under the drivers seat The power seat track unit replaces the standard equipment manual seat track There are three reversible motors that operate the power seat adjuster The motors are connected to worm drive gearboxes that move the seat adjuster through a combination of screw type drive units The lower half of the power seat t...

Page 543: ... assembly The third motor is the horizontal adjustment motor which moves the seat track in the forward and rearward directions DIAGNOSIS AND TESTING POWER SEAT TRACK 1 Remove power seat switch from seat 2 Disconnect wire harness connector 3 Check Pin 1 for battery voltage and Pin 5 for ground On convertible models refer to step 5 4 To test the seat motors refer to the and verify proper seat respon...

Page 544: ...e the appropriate front seat from the vehicle Once the front seat is removed lay it on a clean surface upside down to expose the underside of the seat assembly 3 Remove the seat cushion side shields from the seat assembly Refer to the Body section of this man ual for the Seat Cushion Side Shield Removal and Installation procedure 4 Disconnect the necessary power seat electrical connectors 5 Remove...

Page 545: ...operative the complete assembly must be replaced Refer to 23 BODY CONVERTIBLE TOP HYDRAULIC PUMP MOTOR REMOVAL OPERATION The power top switch is hard wired to the Body Control Module BCM through the Power Top Switch Mux circuit The BCM supplies a multiplexed voltage of approximately 90 of ignition voltage to the power top switch Through a series of resistors the power top switch switches the circu...

Page 546: ...ould light in both directions If OK replace the inoperative motor hydraulic pump assem bly Refer to 23 BODY CONVERTIBLE TOP HY DRAULIC PUMP MOTOR REMOVAL If not OK go to Step 5 5 Disconnect the power top relay assembly With the ignition switch in the RUN position check for Battery voltage at the B terminal of the harness connector If OK go to Step 6 If not OK repair the open B circuit as necessary...

Page 547: ...f approximately 90 of ignition voltage to the power top switch Through a series of resistors the power top switch switches the circuit to ground The circuit resistance is varied depending on the switch position When a top operation input is received by the BCM it will ground the respective power top relay control circuit which in turn will operate the power top motor If the power top switch is pre...

Page 548: ...ng diag nosed is an inoperative power top up or down perform the following 1 Disconnect and isolate the battery negative cable 2 Remove the power top switch Refer to 8 ELECTRICAL POWER TOP SWITCH REMOVAL 3 Disconnect the power top switch wire harness connector 4 Using an ohmmeter test the resistances of the power top switch in each switch position Refer to Fig 4 and the POWER TOP SWITCH TEST CHART...

Page 549: ... equipped 3 Reinstall the switch bezel into the floor console opening Line up the two lower locating tabs with the console and push the top of the bezel in until the retaining tab is fully seated Fig 7 4 Connect the battery negative cable 5 Verify power top system operation Fig 5 POWER TOP SWITCH 1 FLOOR CONSOLE SWITCH PLATE 2 HEATED SEAT SWITCH 3 HEATED SEAT SWITCH CONNECTOR 4 FLOOR CONSOLE ASSEM...

Page 550: ...e sunroof to the vent position only The other switch OPEN CLOSED is a rocker type switch for opening and closing the sun roof Pressing and releasing the open button once the sunroof will express open and the wind deflector will raise If the button is pressed a second time the sunroof will stop in that position Pressing and hold ing the close button will close the sunroof If the close button is rel...

Page 551: ... Refer to 8 ELECTRICAL POWER TOP MOTOR REMOVAL Audible whine when switch is depressed sunroof does not operate Inoperative sunroof motor module Replace the sunroof motor module Refer to 8 ELECTRICAL POWER TOP MOTOR REMOVAL Binding cable Repair or replace binding cable as necessary Audible clicking or ratcheting when switch is pressed sunroof does not operate Broken or worn drive cable Repair or re...

Page 552: ...ectors splices and grounds If the power top is completely inoperative perform the following diagnostic steps 1 Check the Accessory delay 30 amp Circuit breaker in the Junction Block If OK go to Step 2 If not OK repair the shorted circuit or component as required and replace the inoperative circuit breaker 2 Partially remove the headliner to access the sunroof motor module 3 Disconnect the motor mo...

Page 553: ...TOP MOTOR STANDARD PROCEDURE STANDARD PROCEDURE RE INITIALIZATION NOTE If for some reason the sunroof is not oper ating normally it may be necessary to re initialize the sunroof assembly This procedure should be attempted prior to any diagnosis of the sunroof system NOTE The re initialization procedure is not com plete if any one of the following conditions occurs before the re initialization proc...

Page 554: ...VAL 6 Remove sunroof opening trim lace Refer to 23 BODY SUNROOF OPENING TRIM LACE REMOVAL 7 Remove headliner as necessary to gain access to sunroof motor module Refer to 23 BODY INTE RIOR HEADLINER REMOVAL 8 Disconnect the motor module wire harness con nectors 9 Remove the motor module attaching screws 10 Remove motor module from the sunroof hous ing assembly INSTALLATION NOTE Before installing a ...

Page 555: ...tor repair procedures details of wire harness routing and retention connector pin out information and location views for the various wire harness con nectors splices and grounds DIAGNOSIS AND TESTING SUNROOF SWITCH For complete circuit diagrams refer to the appropriate w iring information The wiring infor mation includes wiring diagrams proper wire and connector repair procedures details of wire h...

Page 556: ...n the sunroof switch in the vehicle 2 Connect the switch electrical connector to the connector receptacle Fig 4 3 Position the sunroof switch against the head liner and push the switch to properly seat the retain ing clips Fig 4 4 Connect the battery negative cable 5 Confirm proper sunroof system operation Fig 2 SUNROOF SWITCH PINOUT Fig 3 SUNROOF SWITCH LOCATION 1 POWER SUNROOF SWITCH BEZEL 2 HEA...

Page 557: ...mage The power window system includes the power win dow switches on each door trim panel the circuit breaker in the junction block and the power window motors inside each door For service of mechanical components such as the regulator lift plate window tracks or glass refer to Group 23 Body OPERATION Front and rear door window lift motors are of the permanent magnet type A battery positive and neg...

Page 558: ...w should now move If window does not move replace motor 5 If window moved completely up or down the test leads should be reversed one more time to com plete a full window travel inspection 6 If window does not move check to make sure that it is free 7 It is necessary that the window be free to slide up and down in the glass channels If the window is not free to move up and down the window lift mot...

Page 559: ...11 RIGHT FRONT DOWN 1 AND 11 10 AND 12 LEFT REAR UP 3 AND 10 1 AND 2 LEFT REAR DOWN 3 AND 1 2 AND 10 SWITCH POSITION CONTINUITY BETWEEN RIGHT REAR UP 1 AND 4 9 AND 10 RIGHT REAR DOWN 1 AND 9 4 AND 10 LOCKOUT SWITCH SWITCH NOT DEPRESSED 1 AND 5 PASSENGER WINDOW SWITCH TEST SWITCH POSITION CONTINUITY BETWEEN OFF 2 AND 5 1 AND 4 UP 1 AND 4 5 AND 6 DOWN 2 AND 5 1 AND 6 REMOVAL 1 Disconnect and isolate...

Page 560: ...RESTRAINT CONTROLLER DESCRIPTION 9 OPERATION 9 REMOVAL 10 INSTALLATION 10 PASSENGER AIRBAG DESCRIPTION 10 OPERATION 10 REMOVAL 10 INSTALLATION 10 REAR SEAT BELT BUCKLE JR27 ONLY REMOVAL 11 INSTALLATION 11 REAR SEAT BELT RETRACTOR JR27 ONLY REMOVAL 11 INSTALLATION 11 SATELLITE ACCELERATION SENSOR DESCRIPTION 12 OPERATION 12 REMOVAL 12 INSTALLATION 12 SEAT BELT CINCH BAR STANDARD PROCEDURE SEAT BELT...

Page 561: ...RS USE ONLY ORIGINAL EQUIPMENT FAS TENERS LISTED IN THE PARTS CATALOG WHEN FASTENER REPLACEMENT IS REQUIRED AIRBAGS SHOULD BE STORED IN A COOL DRY LOCATION AWAY FROM EXCESSIVE HEAT AND STATIC ELECTRICAL ACTIVITY WITH THE FABRIC AIRBAG FACING UP IF NOT STORED PROPERLY A PREMATURE DEPLOYMENT COULD HAPPEN AND RESULT IN PERSONAL INJURY OR DEATH CAUTION Deployed and Nondeployed Air Bags may or may not ...

Page 562: ...ent Panel and Pad Assembly All other airbag and vehicle components including wiring should be closely inspected following any air bag deployment and should be replaced when visible damage is incurred CURTAIN AIRBAG After a Curtain Airbag has been deployed due to a collision the following MUST be replaced Curtain Airbag Assembly Headliner A B and C Pillar Trim on deployed side Satellite Acceleratio...

Page 563: ...anufactured for sale in North America also have two lower anchors for each rear outboard seating position Fig 2 These anchors are mounted on a bracket and secured to the floor pan They are each accessed from the front of their respective seats at each side where the seat back meets the seat cushion These lower anchors cannot be adjusted or repaired and if faulty or damaged they must be replaced as...

Page 564: ...een two narrow strips of plastic film Like the clock spring in a timepiece the clock spring tape has travel limits and can be damaged by being wound too tightly To prevent this from occur ring the clock spring is centered when it is installed on the steering column Centering the clock spring indexes the clock spring tape to other steering com ponents so that it can operate within its designed trav...

Page 565: ...he event of a side impact collision OPERATION The Occupant Restraint Controller ORC controls the curtain airbags For side impacts the ORC senses the impact severity through Satellite Acceler ation Sensors SAS If the ORC determines the impact is severe enough it will send an electrical sig nal to inflate the appropriate curtain airbag The air bag will inflate dropping down from the ceiling between ...

Page 566: ...charges it directly into the pillow The airbag will deploy and the pillow will fully inflate REMOVAL 1 Open hood and disconnect the negative battery cable remote terminal from the remote battery post Wait two minutes for the system reserve capacitor to discharge before servicing any airbag components 2 Remove speed control switch screws from steer ing wheel back cover remove switches and disconnec...

Page 567: ...nstall the airbag mounting plate to the airbag Be certain that the four studs pass through the mounting plate holes Ensure that the mounting plate side flanges are positioned outside the trim cover ribbing 3 Install the four nuts on the airbag Torque nuts to 9 1 N m 80 10 in lbs 4 Secure the horn switch feed wire red connec tor to the airbag mounting plate 5 Secure the horn switch ground black con...

Page 568: ...wire connector to seat belt retractor 3 Install new bolts to hold seat belt retractor to seat frame Tighten the retractor bolts to 16 2 N m 12 ft lbs torque 4 Install seat belt retractor cover 5 Install seat cover Refer to Body Seats Front Seat Cover Installation 6 Attach lower seat belt anchor to bolt on seat adjuster 7 Verify that seat belt is routed such that it will not be twisted when engaged...

Page 569: ...st above the front right side of the instrument panel The passenger airbag is mounted to the instrument panel assembly The passenger inflator assembly is within the airbag housing The airbag is mounted to the instrument panel retainer and support structure The Passenger Airbag consists of Dual Initiator Inflator Assembly Reaction Canister Airbag Pillow Passenger Airbag Cover Door OPERATION When su...

Page 570: ...and isolate the battery negative cable 2 Remove rear seat cushion Refer to Body Seats Rear Seat Cushion Removal 3 Remove rear seat back Refer to Body Seats Rear Seat Back Removal 4 Remove quarter trim panel Refer to Body Interior Lower Quarter Trim Panel Removal 5 Remove bolt attaching seat belt anchor to floor pan Fig 4 6 Remove bolt attaching seat belt retractor to rear seat support assembly 7 R...

Page 571: ... SAS retaining screws and remove the sensor from the vehicle INSTALLATION 1 Position the satellite acceleration sensor SAS in B pillar electrical connector facing forward in vehicle and install the retaining screws Torque the screws to 7 N m 62 in lbs 2 Connect the SAS electrical connector 3 Install the lower B pillar trim Refer to Body Interior B Pillar Lower Trim Installation WARNING DO NOT CONN...

Page 572: ...ntain proper lap belt adjustment while the latch plate is buckled a seat belt cinch bar repair is required Refer to 8 ELEC TRICAL RESTRAINTS SEAT BELT CINCH BAR REMOVAL REMOVAL Before removing the cinch bar verify that the cinch bar holds the belt from sliding through the latch plate Refer to 8 ELECTRICAL RE STRAINTS SEAT BELT CINCH BAR STANDARD PROCEDURE SEAT BELT CINCH BAR VERIFI CATION TEST If ...

Page 573: ...ound the latch plate bar Fig 9 2 Install two of the three springs provided in the repair package by positioning them over the dimples on the latch plate bar then into the second slot from each end of the cinch bar Fig 10 The springs might not be exactly perpendicular to the cinch bar This is acceptable Fig 8 CINCH BAR REMOVE 1 CINCH BAR COVER 2 LATCH PLATE BAR 3 SPRING 2 4 CINCH BAR Fig 9 CINCH BA...

Page 574: ...ot be used in the retractor Instead a solenoid inside the retractor is used to lock and unlock the seat belt when electrically signaled by a g sensor The seat belt retractor solenoid is located in the seat back and is serviced with the seat back as an assembly When the solenoids are powered the seat belt can be moved When the solenoids are not powered the seat belts cannot be extracted This is nec...

Page 575: ...to ground Solenoid open Solenoid shorted to battery Internal fault No acceleration within the last 10 timer cycles one timer cycle key ON plus 30 minute minimum key OFF The seat belts themselves can demonstrate prob lems such as Both locked all the time Both locked with the ignition OFF but not timed out Both seat belts function properly when the igni tion is ON or the driver door is opened but no...

Page 576: ...rly from the effected door BOTH SEAT BELTS LOCK AND UNLOCK WITH THE IGNITION SWITCH ON OR WHEN THE DRIVER DOOR AJAR SWITCH IS ACTIVATED BUT NOT WHEN THE PASSENGER DOOR AJAR SWITCH IS ACTIVATED Using a DVOM check from the SCTM to the pas senger door ajar switch circuit for an open or short to ground Check pin 3 of the SCTM 13 way connector to ground for continuity If no continuity check for open or...

Page 577: ...ly bolt torque and deform the tapping plate back flush with the B pillar inner SEAT BELT REAR INBOARD REMOVAL 1 Remove rear seat cushion 2 Remove nut attaching seat belt to floor Fig 12 3 Remove seat belt from vehicle INSTALLATION 1 Place seat belt in position 2 Install nut attaching seat belt to floor Tighten nut to 61 5 N m 83 5 ft lbs torque 3 Install rear seat cushion SEAT BELT REAR OUTBOARD R...

Page 578: ...all bolt attaching retractor and anchor to lower B pillar Torque bolt to 40 8 N m 29 5 6 ft lbs 5 Install the upper B pillar trim and bolt that attaches the turning loop to the height adjuster Torque bolt to 55 5 N m 40 5 ft lbs 6 Install the turning loop cover and adjuster knob WARNING DO NOT CONNECT THE BATTERY NEG ATIVE CABLE REMOTE TERMINAL REFER TO ELECTRICAL RESTRAINTS DIAGNOSIS AND TEST ING...

Page 579: ...er ORC monitors the seat belt tensioner circuit resistance and reports active and stored Diagnostic Trouble Codes DTC s if any problem is found WARNING WHEN THE FRONT AIRBAG IS DEPLOYED THE TENSIONER WILL HAVE DEPLOYED AND MUST BE REPLACED THIS WILL REQUIRE THE ENTIRE FRONT SEAT BELT RETRACTOR ASSEMBLY TO BE REPLACED FAIL URE TO DO SO COULD RESULT IN OCCUPANT PERSONAL INJURY OR DEATH JR27 At the o...

Page 580: ...R ON ROADS THAT ARE WINDING ICY SNOW COVERED OR SLIP PERY INTERACTIVE SPEED CONTROL DESCRIPTION Interactive means that communication between the PCM and the TCM is taking place this communica tion is internal to the PCM on NGC vehicles Inter active speed control avoids unnecessary shifting for smoother quieter operation and when downshifts are required makes the shifts smoother CLIMBING A GRADE DE...

Page 581: ...e damage may result AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION DESCRIPTION Transmission control software includes an auto matic speed control overspeed reduction feature This maintains vehicle speed at the selected set point when descending a grade OPERATION The TCM on SBEC vehicles PCM on NGC vehi cles first senses that the speed control is set If the set speed is exceeded by more than 4 mph 6 5...

Page 582: ... each momentary switch activation of the coast switch SPECIFICATIONS TORQUE DESCRIPTION N m Ft Lbs In Lbs Servo Mounting Bracket Nuts 5 1 45 Servo Mounting Nuts 6 7 60 Vacuum Reservoir Screws 10 2 90 SERVO DESCRIPTION The servo unit consists of a solenoid valve body and a vacuum chamber The solenoid valve body con tains three solenoids Vacuum Vent Dump The vacuum chamber contains a diaphragm with ...

Page 583: ...and mounting bracket Fig 3 5 Install nuts tighten to 6 7 N m 60 in lbs 6 Install servo and bracket to stud plate in shocktower and tighten nuts 7 Connect negative battery cable Fig 2 SWITCH REMOVAL The speed control switches is mounted in the steer ing wheel and wired through the clock spring device under the airbag module Fig 4 WARNING IF REMOVAL OF AIRBAG MODULE IS NECESSARY REFER TO THE RESTRAI...

Page 584: ...om the brake booster check valve The speed control vacuum supply hose has a check valve at the source brake booster 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...

Page 585: ...yhole slots in the frame rail and slide down to lock it into place 2 Install the vacuum reservoir Fig 7 3 Install bolt through to reservoir to frame rail 4 Install the front fascia refer to the Frames and Bumper Front Fascia section for more information 8P 6 SPEED CONTROL JR VACUUM RESERVOIR Continued ...

Page 586: ...cation to the Powertrain Control Module PCM the PCM will shut off fuel after two seconds of run time The engine will not start on the key cycle that the failure occurred a full key down sequence must be performed for the engine to crank again After six consecutive fuel shut offs the engine will no longer crank on subsequent key cycles The failure must be corrected and a valid communication process...

Page 587: ...or decklid key input CAUTION The VTSS indicator LED will trigger and engine will continue to run if the vehicle is equipped with SKIS and the proper key is used to start the vehicle This condition will occur if the VTSS has been triggered If valid key is used VTSS will disarm SENTRY KEY IMMOBILIZER SYSTEM The SKIS includes keys from the factory which are pre programmed Each SKIM will recognize a m...

Page 588: ...SKIS uses a transponder chip that is integral to each ignition key Fig 1 to communicate with the Sentry Key Immo bilizer Module SKIM Ignition keys are supplied with the vehicle when it is shipped from the factory The transponder chip is undermolded within the head of the key This undermold is hidden beneath an overmolded rubber cap OPERATION Each Sentry Key has a unique transponder identi fication...

Page 589: ...ter an Erase All Keys function is executed Programming Key Failed is displayed if fur ther diagnosis is required To learn additional keys turn the ignition OFF remove the learned key insert the next new blank key and repeat the steps from the beginning CUSTOMER LEARN MODE This feature is only available on domestic vehicles or those which have a U S country code designator This procedure requires a...

Page 590: ...ule BCM based upon messages it receives from the Sentry Key Immobilizer Module SKIM on the PCI bus OPERATION When the ignition is turned ON the Body Control Module BCM performs a four second bulb check regardless of Sentry Key Immobilizer Module SKIM messages After the bulb check the indicator is con trolled according to SKIM messages Then the SKIM sends messages to the BCM to operate the indicato...

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Page 592: ...7 INSTALLATION 7 WIPERS WASHERS DESCRIPTION WIPER SYSTEM The wiper washer switch is mounted on the right side of the multi function switch Fig 1 on the steer ing column behind the steering wheel The wiper switch is a resistive multiplexed network that pro vides an input to the Body Control Module BCM which then opens closes the wiper relay The wiper system has LOW HIGH and INTER MITTENT switch pos...

Page 593: ...in the junction block This pro tects the circuitry of the wiper system and the vehi cle The wiper motor has permanent magnet fields The intermittent wiper delay mode has a range of 1 0 5 to 18 0 5 seconds Pulse wipe is accom plished by holding stalk lever in the WASH position momentarily The wiper blades then sweep once or twice after the WASH at low speed and then return to the previous wiper swi...

Page 594: ... CHECK FLOW THROUGH HOSE CONNECTION 2 HOSE BLOCKED 2 DISCONNECT HOSE AT NOZZLE AND Y CONNECTOR CHECK FOR FLOW REPLACE AS NECESSARY WASHER NOZZLE REMOVAL To replace nozzle disconnect washer fluid hose Using needle nose pliers squeeze together the lock ing tabs on the nozzle and remove INSTALLATION For installing make sure that both locking tabs are securely snapped into position Connect washer flui...

Page 595: ...t the battery negative remote cable WIPER ARMS REMOVAL 1 Place the wiper arm blades in the PARK posi tion and turn ignition OFF 2 Unsnap nut cover By hand rock gently side to side and slide away from arm pivot To remove the left side raise hood for clearance 3 Loosen retention nut 4 Remove the arm from the pivot by using a uni versal claw puller or by hand rock gently side to side and slide Raise ...

Page 596: ...e Wiper Arm Alignment paragraph of this group INSTALLATION 1 Gently lift the wiper arm tip off windshield 2 The driver s side wiper blade has a air foil on it and the air foil points downward 3 Install the blade assembly onto the wiper arm by firmly snapping it onto the arm tip Fig 4 and Fig 5 4 Lower blade to glass 5 When complete turn ignition switch ON Turn wiper switch OFF allowing the wiper b...

Page 597: ...Align the crank with the linkage arm so it is parallel Fig 6 The linkage arm will cover the hole in the crank when aligned properly Fig 6 Place the crank on the motor shaft and start the nut Torque the nut to 18 2 N m 159 18 in lbs 8 Install the wiper motor assembly Refer to 8 ELECTRICAL WIPERS WASHERS WIPER MOTOR ASSEMBLY INSTALLATION 9 Connect the battery negative cable 10 Close hood 11 Verify v...

Page 598: ...connector at motor and remove assembly INSTALLATION 1 Connect wire connector at motor 2 Connect harness clip to the forward mounting leg 3 Place assembly into position install the two mounting bolts and tighten the mounting bolts to 10 to 12 N m 89 to 106 in lbs torque 4 Install the cowl screen 5 Install the wiper arms and blades 6 Connect the battery negative remote cable 7 Verify vehicle and sys...

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Page 600: ...TEM 8W 39 1 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 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 MIRRORS 8W 62 1 P...

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Page 602: ...e 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 and modules are shown in the at rest position...

Page 603: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMATION JR WIRING DIAGRAM INFORMATION Continued ...

Page 604: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 JR 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 WIRING DIAGRAM INFORMATION Continued ...

Page 605: ...Fig 3 WIRING DIAGRAM SYMBOLS 8W 01 4 8W 01 WIRING DIAGRAM INFORMATION JR WIRING DIAGRAM INFORMATION Continued ...

Page 606: ...IPTION 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 YELLOW WITH TRACER Fig 4 WIRE CODE IDENTIFICATION 1 CO...

Page 607: ...cular 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 Sec...

Page 608: ...neral 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 TRANSMIS...

Page 609: ... 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 610: ...est 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 lamp 4 If the voltmeter registers voltage or the test lamp glows there is a short to ground in that gen eral area of the wiring harness STANDARD PROCEDURE TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1 Refer t...

Page 611: ...er 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 TESTING FOR VOLTAGE DROP PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 8W 01 10 8W 01 WIRING DIAGRAM INFORMATION JR WIRING DIAGRAM INFORMATION Continued...

Page 612: ...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 613: ...Fig 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 Secondary Terminal Lock 8W 01 12 8W 01 WIRING DIAGRAM INFORMATION JR CONNECTOR Continued ...

Page 614: ...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 JR 8W 01 WIRING DIAGRAM INFORMATION 8W 01 13 CONNECTOR Continued ...

Page 615: ...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 616: ...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 618: ...oid Ajar Switch 8W 45 Decklid Release Switch 8W 45 Dome Lamp 8W 44 Door Lock Motor Ajar Switches 8W 61 Door Lock Switches 8W 61 EGR Solenoid 8W 30 Component Page Engine Coolant Temp Sensor 8W 30 EVAP Purge Solenoid 8W 30 Fog Lamp Relay 8W 50 Fog Lamps 8W 50 51 Front Fog Lamp Switch 8W 50 Front Vertical Motor 8W 63 Front Washer Pump Motor 8W 53 Front Wiper High Low Relay 8W 53 Front Wiper Motor 8W ...

Page 619: ... Recline Motor 8W 63 Remote Keyless Entry Antenna 8W 61 Remote Radio Switches 8W 47 Seat Belt Control Module 8W 43 Component Page Seat Belt Solenoids 8W 43 Seat Belt Switch 8W 43 Seat Belt Tensioners 8W 43 Sentry Key Immobilizer Module 8W 39 Side Impact Sensors 8W 43 Speakers 8W 47 Speed Control Switches 8W 33 Splices 8W 70 Starter Motor 8W 21 Starter Motor Relay 8W 21 Sun Sensor 8W 42 Sunroof Con...

Page 620: ... 18 27 Fuse 15 8W 10 8 22 27 Fuse 16 8W 10 8 22 27 Fuse 17 8W 10 8 22 27 Fuse 18 8W 10 8 23 Fuse 19 8W 10 8 9 23 Component Page Fuse 20 8W 10 8 9 24 Fuse 22 8W 10 9 24 Fuse 23 8W 10 9 25 27 Fuse 24 8W 10 9 18 20 Fuse 25 8W 10 9 18 21 Fusible Link 8W 10 7 G100 8W 10 7 G103 8W 10 23 G203 8W 10 26 Generator 8W 10 7 Headlamp Delay Relay 8W 10 11 Headlamp Washer Pump Motor 8W 10 10 Headlamp Washer Rela...

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Page 648: ... 26 27 Component Page Left Fog Lamp 8W 12 25 Left Headlamp 8W 12 9 16 Left Lavalier Module 8W 12 9 16 21 24 Left License Lamp 8W 12 22 23 Left Park Turn Signal Lamp 8W 12 21 24 Left Power Mirror 8W 12 14 Left Rear Power Window Switch 8W 12 26 Left Tail Side Marker Lamp 8W 12 22 Left Tail Stop Lamp 8W 12 22 25 Left Tail Turn Signal Lamp 8W 12 22 24 Left Turn Lamp 8W 12 24 Left Visor Vanity Lamps 8W...

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Page 676: ...Mirror 8W 15 11 Left Rear Door Lock Motor Ajar Switch 8W 15 23 Left Rear Fog Lamp 8W 15 16 18 Left Speed Control Switch 8W 15 12 Left Tail Side Marker Lamp 8W 15 16 19 Left Tail Stop Lamp 8W 15 16 19 Left Tail Turn Signal Lamp 8W 15 19 Left Turn Lamp 8W 15 16 Left Visor Vanity Lamps 8W 15 21 License Lamp 8W 15 18 Master Power Window Switch 8W 15 11 Multi Function Switch 8W 15 10 11 Natural Vacuum ...

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Page 700: ...Control Module 8W 18 2 3 Cd Changer 8W 18 3 Compass Mini Trip Computer 8W 18 3 Data Link Connector 8W 18 2 Fuse 5 8W 18 2 Fuse 11 8W 18 2 Component Page G203 8W 18 2 G301 8W 18 2 Instrument Cluster 8W 18 3 Junction Block 8W 18 2 Powertrain Control Module 8W 18 2 Radio 8W 18 3 Sentry Key Immobilizer Module 8W 18 3 JR 8W 18 BUS COMMUNICATIONS 8W 18 1 ...

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Page 704: ... 8W 20 2 Battery 8W 20 2 Fuse 14 8W 20 2 Fuse 25 8W 20 2 Fusible Link 8W 20 2 G100 8W 20 2 Component Page G103 8W 20 2 Generator 8W 20 2 Power Distribution Center 8W 20 2 Powertrain Control Module 8W 20 2 Starter Motor 8W 20 2 JR 8W 20 CHARGING SYSTEM 8W 20 1 ...

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Page 706: ...tch 8W 21 2 Fuse 8 8W 21 2 3 Fusible Link 8W 21 2 3 G103 8W 21 2 Generator 8W 21 2 3 Component Page Ignition Switch 8W 21 2 3 Power Distribution Center 8W 21 2 3 Powertrain Control Module 8W 21 2 3 Starter Motor 8W 21 2 3 Starter Motor Relay 8W 21 2 3 JR 8W 21 STARTING SYSTEM 8W 21 1 ...

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Page 710: ... 8 8W 30 3 Fuse 11 8W 30 16 Fuse 14 8W 30 2 13 22 Fuse 23 8W 30 2 3 5 Component Page Fuse 24 8W 30 22 Fuse 25 8W 30 10 20 G103 8W 30 2 5 7 10 20 25 G108 8W 30 2 13 G300 8W 30 3 G302 8W 30 3 Generator 8W 30 2 High Speed Radiator Fan Relay 8W 30 5 Idle Air Control Motor 8W 30 2 Ignition Coil Pack 8W 30 11 Ignition Switch 8W 30 3 Inlet Air Temp Sensor 8W 30 8 17 Junction Block 8W 30 16 Knock Sensor 8...

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Page 736: ...1 3 Heated Seat Switch 8W 31 3 Component Page Input Speed Sensor 8W 31 6 Junction Block 8W 31 3 4 9 Left Back Up Lamp 8W 31 5 Output Speed Sensor 8W 31 6 Power Distribution Center 8W 31 2 7 8 Powertrain Control Module 8W 31 2 3 4 6 7 8 9 Right Back Up Lamp 8W 31 5 Transmission Control Relay 8W 31 2 7 8 Transmission Range Sensor 8W 31 4 5 6 Transmission Solenoid Pressure Switch Assembly 8W 31 2 7 8...

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Page 746: ...ockspring 8W 33 4 Compass Mini Trip Computer 8W 33 2 Fuse 7 8W 33 2 G103 8W 33 3 Component Page G203 8W 33 4 G204 8W 33 4 Instrument Cluster 8W 33 2 Junction Block 8W 33 2 3 Left Speed Control Switch 8W 33 4 Powertrain Control Module 8W 33 3 4 Right Speed Control Switch 8W 33 4 Vehicle Speed Control Servo 8W 33 3 JR 8W 33 VEHICLE SPEED CONTROL 8W 33 1 ...

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Page 750: ...11 8W 35 3 5 Fuse 15 8W 35 2 Fuse 22 8W 35 2 Fuse 23 8W 35 2 G103 8W 35 5 Component Page G113 8W 35 2 Instrument Cluster 8W 35 5 Junction Block 8W 35 2 3 5 Left Front Wheel Speed Sensor 8W 35 4 Left Rear Wheel Speed Sensor 8W 35 4 Park Brake Switch 8W 35 5 Power Distribution Center 8W 35 2 3 Right Front Wheel Speed Sensor 8W 35 4 Right Rear Wheel Speed Sensor 8W 35 4 JR 8W 35 ANTI LOCK BRAKES 8W 3...

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Page 756: ...5 G302 8W 39 3 G310 8W 39 3 Headlamp Delay Relay 8W 39 6 Component Page Horn Relay 8W 39 6 Ignition Switch 8W 39 3 Instrument Cluster 8W 39 7 Junction Block 8W 39 2 3 6 7 Left Lavalier Module 8W 39 6 Left Park Turn Signal Lamp 8W 39 6 Left Rear Door Lock Motor Ajar Switch 8W 39 5 Passenger Door Lock Motor Ajar Switch 8W 39 4 5 Power Distribution Center 8W 39 3 Powertrain Control Module 8W 39 7 Rig...

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Page 764: ...t Belt Tensioner 8W 40 4 Fuel Pump Module 8W 40 4 Fuse 4 8W 40 8 Fuse 5 8W 40 8 Fuse 7 8W 40 2 6 Fuse 11 8W 40 2 5 Component Page G103 8W 40 5 G203 8W 40 4 5 7 8 G300 8W 40 4 G301 8W 40 2 6 G302 8W 40 4 Instrument Cluster 8W 40 2 3 4 5 6 7 8 Junction Block 8W 40 2 5 6 7 8 Multi Function Switch 8W 40 7 Oil Pressure Switch 8W 40 5 Park Brake Switch 8W 40 5 Powertrain Control Module 8W 40 3 Radio 8W ...

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Page 772: ...er Outlet 8W 41 3 Clockspring 8W 41 2 Fuse 2 8W 41 3 Fuse 8 8W 41 2 G106 8W 41 2 G202 8W 41 3 Component Page G301 8W 41 3 Horn 8W 41 2 Horn Relay 8W 41 2 Horn Switch 8W 41 2 Junction Block 8W 41 2 Power Distribution Center 8W 41 3 Power Outlet 8W 41 3 JR 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 ...

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Page 776: ...k 8W 42 3 Body Control Module 8W 42 2 3 4 5 6 7 9 Fuse 1 8W 42 3 5 Fuse 4 8W 42 4 Fuse 5 8W 42 4 Fuse 6 8W 42 2 Fuse 11 8W 42 2 Component Page Fuse 12 8W 42 8 9 Fuse 23 8W 42 8 9 G108 8W 42 8 G202 8W 42 3 4 G203 8W 42 5 High Speed Radiator Fan Relay 8W 42 8 Junction Block 8W 42 2 3 4 5 Low Speed Radiator Fan Relay 8W 42 8 Mode Door Actuator 8W 42 7 Power Distribution Center 8W 42 8 9 Powertrain Co...

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Page 786: ...W 43 2 6 Fuse 19 8W 43 10 G201 8W 43 2 6 G203 8W 43 5 11 G301 8W 43 10 11 Component Page G302 8W 43 8 Instrument Cluster 8W 43 2 5 6 8 Junction Block 8W 43 2 6 10 Left Curtain Airbag Squib 8W 43 9 Left Side Impact Sensor 1 8W 43 9 Multi Function Switch 8W 43 10 Passenger Airbag 8W 43 3 7 Passenger Door Lock Motor Ajar Switch 8W 43 5 11 Passenger Seat Belt Solenoid 8W 43 11 Passenger Seat Belt Tens...

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Page 798: ... 7 Fuse 5 8W 44 2 3 4 5 Fuse 11 8W 44 6 G301 8W 44 3 4 5 6 7 Garage Door Opener 8W 44 4 Component Page Instrument Cluster 8W 44 6 7 Junction Block 8W 44 2 3 4 5 6 7 Left Visor Vanity Lamps 8W 44 4 Multi Function Switch 8W 44 6 7 Overhead Map Courtesy Lamps 8W 44 3 Power Antenna 8W 44 2 Rear Floor Courtesy Lamp 8W 44 2 3 Right Visor Vanity Lamps 8W 44 4 Transmission Range Indicator Illumination 8W ...

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Page 806: ...use 14 8W 45 2 Fuse 15 8W 45 16 17 Fuse 17 8W 45 2 Fuse 18 8W 45 2 Fuse 23 8W 45 17 Component Page G108 8W 45 2 G203 8W 45 2 11 G301 8W 45 3 G302 8W 45 11 Headlamp Delay Relay 8W 45 4 Headlamp Washer Relay 8W 45 2 Heated Seat Relay 8W 45 17 Horn Relay 8W 45 3 Ignition Switch 8W 45 2 11 Instrument Cluster 8W 45 6 7 Junction Block 8W 45 2 3 4 5 16 17 Left Rear Door Lock Motor Ajar Switch 8W 45 12 13...

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Page 824: ...ft Front Door Speaker 8W 47 3 4 9 10 Left Front Instrument Panel Speaker 8W 47 3 7 8 Component Page Left Rear Speaker 8W 47 3 4 9 10 Left Remote Radio Switch 8W 47 12 Power Amplifier 8W 47 5 6 7 8 9 10 11 Power Antenna 8W 47 5 11 Radio 8W 47 2 3 4 5 7 8 11 12 Rear Floor Courtesy Lamp 8W 47 5 11 Right Front Door Speaker 8W 47 3 4 9 10 Right Front Instrument Panel Speaker 8W 47 3 7 8 Right Rear Spea...

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Page 836: ... Body Control Module 8W 48 2 3 Fuse 6 8W 48 2 3 Fuse 15 8W 48 2 3 G202 8W 48 3 G203 8W 48 4 Component Page G303 8W 48 2 3 Junction Block 8W 48 2 3 Left Power Mirror 8W 48 2 3 4 Rear Window Defogger 8W 48 2 3 Rear Window Defogger Relay 8W 48 2 3 Right Power Mirror 8W 48 2 3 4 JR 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

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Page 840: ...15 16 G301 8W 50 11 12 Component Page Headlamp Beam Select Switch 8W 50 6 Headlamp Delay Relay 8W 50 2 4 9 13 Headlamp Leveling Switch 8W 50 12 Headlamp Switch 8W 50 6 Instrument Cluster 8W 50 7 9 10 16 Junction Block 8W 50 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Left Fog Lamp 8W 50 9 10 16 Left Headlamp 8W 50 2 3 4 5 Left Lavalier Module 8W 50 12 13 14 15 Left Park Turn Signal Lamp 8W 50 7 8 Multi F...

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Page 856: ...0 11 Left Back Up Lamp 8W 51 2 Left License Lamp 8W 51 4 8 10 Component Page Left Rear Fog Lamp 8W 51 6 11 Left Tail Side Marker Lamp 8W 51 8 10 Left Tail Stop Lamp 8W 51 3 Left Tail Turn Signal Lamp 8W 51 4 License Lamp 8W 51 4 Multi Function Switch 8W 51 3 5 7 9 11 Power Distribution Center 8W 51 5 Rear Fog Lamp Relay 8W 51 5 6 Right Back Up Lamp 8W 51 2 Right License Lamp 8W 51 4 8 10 Right Rea...

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Page 868: ...k 8W 52 2 3 4 Left Lavalier Module 8W 52 2 4 Component Page Left Park Turn Signal Lamp 8W 52 2 3 Left Tail Turn Signal Lamp 8W 52 3 Left Turn Lamp 8W 52 3 Multi Function Switch 8W 52 2 Power Distribution Center 8W 52 2 Right Lavalier Module 8W 52 2 4 Right Park Turn Signal Lamp 8W 52 2 3 Right Tail Turn Signal Lamp 8W 52 3 Right Turn Lamp 8W 52 3 JR 8W 52 TURN SIGNALS 8W 52 1 ...

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Page 872: ...iper Motor 8W 53 3 Front Wiper On Off Relay 8W 53 3 Fuse 3 8W 53 4 Fuse 15 8W 53 2 3 Fuse 18 8W 53 3 Component Page G103 8W 53 3 G106 8W 53 2 G108 8W 53 2 4 Headlamp Washer Pump Motor 8W 53 4 Headlamp Washer Relay 8W 53 4 Junction Block 8W 53 2 3 Multi Function Switch 8W 53 2 Power Distribution Center 8W 53 3 4 JR 8W 53 WIPERS 8W 53 1 ...

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Page 876: ...tor 8W 60 2 4 6 Fuse 4 8W 60 5 G203 8W 60 2 4 Component Page Junction Block 8W 60 2 3 4 5 6 7 Left Rear Power Window Motor 8W 60 3 7 Left Rear Power Window Switch 8W 60 3 Master Power Window Switch 8W 60 2 3 4 6 Passenger Power Window Motor 8W 60 2 7 Passenger Power Window Switch 8W 60 2 7 Right Rear Power Window Motor 8W 60 3 7 Right Rear Power Window Switch 8W 60 3 Window Drop Relay Assembly 8W ...

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Page 884: ...h 8W 61 2 3 Fuse 5 8W 61 2 G203 8W 61 3 5 6 G301 8W 61 4 Junction Block 8W 61 2 Component Page Left Rear Door Lock Motor Ajar Switch 8W 61 4 Passenger Door Lock Motor Ajar Switch 8W 61 5 6 Passenger Door Lock Switch 8W 61 2 3 Remote Keyless Entry Antenna 8W 61 5 6 Right Rear Door Lock Motor Ajar Switch 8W 61 4 Seat Belt Control Module 8W 61 6 JR 8W 61 POWER DOOR LOCKS 8W 61 1 ...

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Page 890: ...62 5 Fuse 4 8W 62 5 6 Fuse 5 8W 62 2 3 5 Fuse 6 8W 62 4 G203 8W 62 4 Component Page G301 8W 62 2 3 5 6 Junction Block 8W 62 2 3 4 5 6 Left Power Mirror 8W 62 2 3 4 Power Mirror Switch 8W 62 2 3 Rear Window Defogger Relay 8W 62 4 Right Power Mirror 8W 62 2 3 4 Transmission Range Sensor 8W 62 5 6 JR 8W 62 POWER MIRRORS 8W 62 1 ...

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Page 896: ...63 2 3 Fuse 11 8W 63 4 Fuse 13 8W 63 5 Fuse 23 8W 63 5 G301 8W 63 2 3 6 Component Page Heated Seat Relay 8W 63 5 Heated Seat Switch 8W 63 4 Horizontal Motor 8W 63 2 3 Junction Block 8W 63 2 3 4 5 Passenger Heated Seat Back 8W 63 6 Passenger Heated Seat Cushion 8W 63 6 Passenger Heated Seat Module 8W 63 6 Power Distribution Center 8W 63 5 Power Seat Switch 8W 63 2 3 Rear Vertical Motor 8W 63 2 3 Re...

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Page 902: ...8W 64 POWER SUNROOF Component Page Circuit Breaker No 2 JB 8W 64 2 G301 8W 64 2 Junction Block 8W 64 2 Component Page Sunroof Control Module 8W 64 2 Sunroof Switch 8W 64 2 JR 8W 64 POWER SUNROOF 8W 64 1 ...

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Page 904: ...8W 66 2 3 Fuse 4 8W 66 2 Fuse 17 8W 66 3 G301 8W 66 2 G302 8W 66 3 Component Page Junction Block 8W 66 2 Power Distribution Center 8W 66 3 Power Top Pump Motor 8W 66 3 Power Top Switch 8W 66 2 Power Top Up Down Relays 8W 66 3 JR 8W 66 POWER TOP 8W 66 1 ...

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Page 908: ...8W 45 11 S203 8W 12 15 S207 8W 51 5 11 S208 8W 50 12 S209 8W 12 12 S210 8W 12 18 S211 8W 12 12 Component Page S212 8W 45 10 S214 8W 42 3 S215 8W 12 7 S216 8W 47 12 S217 8W 47 12 S218 8W 15 12 S219 8W 33 4 S220 8W 12 11 S221 8W 18 3 S222 8W 15 11 S223 8W 15 11 S224 8W 50 6 S225 8W 12 15 S226 8W 50 8 S227 8W 50 10 S228 8W 50 6 S301 8W 15 17 24 S302 8W 12 13 S303 8W 15 21 S304 8W 15 16 S305 8W 15 16 ...

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Page 914: ... 16 C101 8W 80 16 C104 EATX 8W 80 17 C104 EATX 8W 80 17 C105 EATX 8W 80 17 C105 EATX 8W 80 18 C111 8W 80 18 C111 8W 80 18 C121 8W 80 19 C121 8W 80 19 C169 2 0L MTX 8W 80 20 C169 2 0L MTX 8W 80 20 C170 2 4L PZEV 8W 80 20 C170 2 4L PZEV 8W 80 20 C171 2 4L PZEV 8W 80 21 C171 2 4L PZEV 8W 80 21 C200 ATC 8W 80 21 C200 ATC 8W 80 22 C200 MTC 8W 80 22 C200 MTC 8W 80 23 Component Page C225 8W 80 23 C225 8W...

Page 915: ... Switch Export 8W 80 51 Headlamp Washer Pump Motor JR41 Export 8W 80 51 Heated Seat Switch 8W 80 51 Horizontal Motor JR27 8W 80 52 Component Page Horizontal Motor JR41 8W 80 52 Horn 8W 80 52 Idle Air Control Motor 8W 80 52 Ignition Coil Pack 2 0L 2 4L 8W 80 52 Ignition Switch C1 8W 80 53 Ignition Switch C2 8W 80 53 Ignition Switch C3 8W 80 53 Inlet Air Temp Sensor 8W 80 53 Input Speed Sensor 8W 80...

Page 916: ...W 80 82 Radio C1 8W 80 82 Radio C2 8W 80 83 Rear Floor Courtesy Lamp 8W 80 83 Rear Vertical Motor JR27 8W 80 83 Rear Vertical Motor JR41 8W 80 83 Recirculation Door Actuator 8W 80 84 Component Page Recline Motor JR41 8W 80 84 Right Back Up Lamp 8W 80 84 Right Curtain Airbag Squib JR41 8W 80 84 Right Fog Lamp JR27 8W 80 84 Right Fog Lamp JR41 8W 80 85 Right Front Door Speaker 8W 80 85 Right Front I...

Page 917: ... 1 C3 14DB BK A C COMPRESSOR CLUTCH RELAY OUTPUT 2 A C EVAPORATOR TEMPERATURE SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 C12 20LG BK EVAPORATOR TEMPERATURE SENSOR SIGNAL 2 C57 20DB GY SENSOR GROUND A C PRESSURE TRANSDUCER GRAY 4 WAY CAV CIRCUIT FUNCTION 1 K4 20BK LB SENSOR GROUND 1 2 K6 20VT WT 5 VOLT SUPPLY 3 C18 20DB A C PRESSURE SIGNAL 4 8W 80 4 8W 80 CONNECTOR PIN OUTS JR ...

Page 918: ...SIGNAL A C HEATER CONTROL C2 MTC BLACK 10 WAY CAV CIRCUIT FUNCTION 1 2 C4 16TN LOW BLOWER MOTOR DRIVER 3 C6 14LB M2 BLOWER MOTOR DRIVER 4 5 Z119 14BK GY GROUND 6 7 C5 16LG M1 BLOWER MOTOR DRIVER 8 9 10 C7 12BK TN BLOWER MOTOR DRIVER AIR PUMP MOTOR 2 4L PZEV BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z14 10TN GROUND 2 A161 10RD AIR PUMP MOTOR RELAY OUTPUT AIR PUMP MOTOR RELAY 2 4L PZEV BLACK 4 WAY CAV CIRC...

Page 919: ... PASSENGER SQUIB 1 LINE 2 7 R55 20LG DG DRIVER SEAT BELT TENSIONER LINE 1 8 R53 20LG YL DRIVER SEAT BELT TENSIONER LINE 2 9 R61 20OR LB DRIVER SQUIB 2 LINE 1 10 R63 20TN LB DRIVER SQUIB 2 LINE 2 11 R43 20BK LB DRIVER SQUIB 1 LINE 1 12 R45 20DG LB DRIVER SQUIB 1 LINE 2 13 14 F14 20LG YL FUSED IGNITION SWITCH OUTPUT RUN START 15 F23 20DB YL FUSED IGNITION SWITCH OUTPUT RUN 16 Z100 18BK GROUND 17 18 ...

Page 920: ...6 20LB DG PASSENGER SEAT BELT TENSIONER LINE 1 4 R54 20LB YL PASSENGER SEAT BELT TENSIONER LINE 2 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 R77 20LB BR LEFT CURTAIN SQUIB 1 LINE 2 26 R75 20LB OR LEFT CURTAIN SQUIB 1 LINE 1 27 R74 20LB YL RIGHT CURTAIN SQUIB 1 LINE 1 28 R76 20LB WT RIGHT CURTAIN SQUIB 1 LINE 2 29 30 31 32 JR 8W 80 CONNECTOR PIN OUTS 8W 80 7 ...

Page 921: ... LINE 2 9 10 11 12 R16 20BR LG RIGHT SIDE IMPACT SENSOR 1 GROUND 13 14 15 D25 20VT YL JR27 PCI BUS 15 D25 20VT JR41 PCI BUS 16 F14 20LG YL FUSED IGNITION SWITCH OUTPUT RUN START 17 18 19 20 R15 20LG BR LEFT SIDE IMPACT SENSOR 1 GROUND 21 22 Z100 20BK GROUND 23 24 F23 20DB YL FUSED IGNITION SWITCH OUTPUT RUN 25 R13 20LG TN LEFT SIDE IMPACT SENSOR 1 SIGNAL 26 R14 20TN LG RIGHT SIDE IMPACT SENSOR 1 S...

Page 922: ...VALVE 33 B6 20WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 34 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 35 36 B4 20LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY 37 B3 20LG DB LEFT REAR WHEEL SPEED SENSOR SIGNAL 38 39 40 41 42 B1 20YL DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL 43 B2 20YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY 44 45 B9 20RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP ...

Page 923: ...D 3 L1 18BK VT JR27 BACK UP LAMP FEED 3 L1 20BK VT JR41 BACK UP LAMP FEED 4 5 6 M2 18BK YL JR27 COURTESY LAMPS DRIVER 7 M1 20BK RD JR27 FUSED B AUTOMATIC TEMPERATURE CONTROL HEAD BLACK 12 WAY CAV CIRCUIT FUNCTION 1 Z116 20BK GROUND 2 D25 20VT LG PCI BUS 3 Z117 20BK GROUND 4 E2 20OR PANEL LAMPS DRIVER 5 6 7 C10 20RD TN IN CAR TEMPERATURE SENSOR SIGNAL 8 C57 20DB GY SENSOR GROUND 9 10 F20 20WT YL FU...

Page 924: ...BACK UP LAMP SWITCH 2 0L MTX GRAY 2 WAY CAV CIRCUIT FUNCTION A F20 18WT FUSED IGNITION SWITCH OUTPUT RUN B L1 18VT BK BACK UP LAMP FEED BACK UP LAMP SWITCH 2 7L MTX BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F20 18WT FUSED IGNITION SWITCH OUTPUT RUN 2 L1 18VT BK BACK UP LAMP FEED BLEND DOOR ACTUATOR NATURAL 5 WAY CAV CIRCUIT FUNCTION 1 C33 20DB RD BLEND AIR DOOR DRIVER 2 C57 20DB GY SENSOR GROUND 3 C36 20...

Page 925: ... C56 20RD LG BLOWER MOTOR CONTROL 4 C1 12DG FUSED IGNITION SWITCH OUTPUT RUN BLOWER MOTOR POWER MODULE C2 ATC BLACK 2 WAY CAV CIRCUIT FUNCTION 1 C72 12GY BLOWER MOTOR SUPPLY 2 C71 12DB BLOWER MOTOR GROUND BLOWER MOTOR RESISTOR BLOCK MTC BLACK 10 WAY CAV CIRCUIT FUNCTION 1 C7 12BK BLOWER MOTOR DRIVER 2 C7 12BK TN HIGH BLOWER MOTOR DRIVER 3 C6 16LB M2 BLOWER MOTOR DRIVER 4 C5 16LG M1 BLOWER MOTOR DR...

Page 926: ...FUNCTION 1 C26 20PK DB 5 VOLT SUPPLY 2 Z132 16BK GY GROUND 3 P1 20BK WT DECKLID RELEASE SWITCH SENSE 4 V52 20DG RD FRONT WIPER SWITCH MUX 5 C7 18BK TN MTC BLOWER MOTOR DRIVER 6 C21 20DB OR BASE A C SWITCH SENSE 7 C37 20YL MODE DOOR FEEDBACK SIGNAL 8 C36 18RD WT BLEND DOOR FEEDBACK SIGNAL 9 C12 20LG BK EVAPORATOR TEMPERATURE SENSOR SIGNAL 10 C57 20DB GY SENSOR GROUND 11 E2 18OR BR PANEL LAMPS DRIVE...

Page 927: ... RD PASSENGER DOOR AJAR SWITCH SENSE 7 G77 20TN OR JR41 LEFT REAR DOOR AJAR SWITCH SENSE 8 G76 20TN YL JR41 RIGHT REAR DOOR AJAR SWITCH SENSE 9 P175 20OR BK DRIVER LOCK RELAY OUTPUT 10 P179 20OR BR JR41 LEFT REAR LOCK RELAY OUTPUT 11 P180 20OR TN JR41 RIGHT REAR LOCK RELAY OUTPUT 12 P176 20PK BK PASSENGER LOCK RELAY OUTPUT 13 P177 20DB WT DRIVER UNLOCK RELAY OUTPUT 14 G38 18GY JR27 GARAGE DOOR OPE...

Page 928: ...EED CONTROL BRAKE SWITCH OUTPUT 5 L50 16WT TN BRAKE LAMP SWITCH OUTPUT 6 A7 18RD BK FUSED B BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID WHITE 2 WAY CAV CIRCUIT FUNCTION 1 K29 20WT PK BRAKE SWITCH SIGNAL 2 F20 20WT YL FUSED IGNITION SWITCH OUTPUT RUN C100 INSTRUMENT PANEL SIDE CAV CIRCUIT 1 A15 16PK BASE EXPORT 1 A15 16PK LB PREMIUM 2 A51 20RD WT 2 A51 20RD WT SKIM 3 D6 20PK LB EATX 3 D6 20PK LB EA...

Page 929: ...2 F12 20DB WT 3 A41 16YL 3 A41 16YL 4 A2 12PK BK 5 F20 20WT YL EXCEPT JR27 MTX EXPORT 5 F20 18WT YL JR27 MTX EXPORT 6 F30 16RD 7 V10 18BR 7 V10 18BR 8 V37 20RD LG 9 L36 18LG JR27 EXPORT 10 D15 20WT DG C101 LT GRAY INSTRUMENT PANEL SIDE CAV CIRCUIT 1 A1 18RD 2 F12 20DB WT EXCEPT SKIM 3 A41 18YL 4 A2 12PK BK 5 F20 20WT YL 5 F20 20WT EXCEPT ATC 6 F30 18RD 6 F30 16RD 7 V10 18BR 8 V37 20RD LG 9 L36 18L...

Page 930: ...T GRAY AUTOMATIC TRANS MISSION SIDE CAV CIRCUIT 1 T9 18OR BK 2 T54 18VT YL 3 T41 20BK WT 4 5 T16 16RD 6 T19 18WT 7 T41 20BK LB 8 T50 18DG 9 T59 18PK 10 T60 18BR C105 EATX BLACK HEADLAMP AND DASH SIDE CAV CIRCUIT 1 F20 18 WT 2 T1 20LG BK 3 T3 20VT 4 T13 20DB BK 5 T14 20LG WT 6 T20 20LB 7 T42 20VT WT 8 T47 20YL BK 9 T52 20RD BK 10 L1 18VT BK JR 8W 80 CONNECTOR PIN OUTS 8W 80 17 ...

Page 931: ...0 12BR 2 7L 6 F42 18DG LG 7 K199 18BR VT 2 7L 8 G6 20GY 9 C18 20DB 10 11 K10 20DB LG 2 0L 12 K399 18BR GY 2 7L 13 K341 20TN WT 2 7L 14 Z88 16BK LG 2 7L C111 BLACK HEADLAMP AND DASH SIDE CAV CIRCUIT 1 Z186 20BK 2 C3 14DB BK 3 K904 18DB DG 4 K57 20DB 2 4L PZEV 4 K141 20TN WT 2 7L 5 T40 16BR 2 0L 2 4L 5 T40 12BR 2 7L 6 F42 16LG DG 7 K199 18BR VT 2 7L 8 G6 18GY 9 C18 20DB 10 F142 16OR DG EXCEPT 2 4L P...

Page 932: ... 18VT BK 15 B3 20LG DB ABS 16 B4 20LG ABS C121 NATURAL UNIBODY SIDE CAV CIRCUIT 1 K106 20WT DG 2 K107 20OR 3 L95 18DG YL JR27 EXPORT 4 A45 18BR JR27 EXPORT 5 B1 20YL DB ABS 6 B2 20YL ABS 7 P86 16PK BK HEATED SEAT 8 A25 12DB JR27 9 10 T44 20YL JR27 AUTOSTICK 10 T44 20YL LB JR41 AUTOSTICK 11 T5 20LG JR27 AUTOSTICK 11 T5 20LG LB JR41 AUTOSTICK 12 F12 20DB WT 13 A141 16DG WT 14 L1 20VT BK 14 L1 20VT B...

Page 933: ...K MTX HARNESS SIDE CAV CIRCUIT 1 K7 18OR WT 2 K4 20BK LB 3 G7 18WT OR 4 F20 18WT 5 L1 18VT BK 6 C170 2 4L PZEV DK GRAY ASSEMBLY SIDE CAV CIRCUIT 1 K57 16WT 2 K4 16LB 3 A142 16YL 4 K62 16RD C170 2 4L PZEV DK GRAY HEADLAMP AND DASH SIDE CAV CIRCUIT 1 K57 20DB 2 K4 18BK LB 3 A142 16DG OR 4 K62 18BK OR 8W 80 20 8W 80 CONNECTOR PIN OUTS JR ...

Page 934: ...P AND DASH SIDE CAV CIRCUIT 1 Z14 16BK YL 2 A161 14LB WT C200 ATC HVAC SIDE CAV CIRCUIT 1 C34 20DB WT 2 C35 20DG YL 3 C33 20DB RD 4 C32 20GY DB 5 C57 20DB GY 6 C26 20PK DB 7 C1 12DG 8 C7 18BK TN 9 C12 20LG BK 10 C36 20RD WT 11 C37 20YL 12 Z118 12BK 13 C56 20RD LG 14 JR 8W 80 CONNECTOR PIN OUTS 8W 80 21 ...

Page 935: ... C7 18BK TN 9 C12 20LG BK 10 C36 18RD WT 11 C37 20YL 12 Z118 12BK 13 C56 20RD LG 14 C200 MTC NATURAL HVAC SIDE CAV CIRCUIT 1 C34 20DB WT 2 C35 20DG YL 3 C33 20DB RD 4 C4 14TN 5 C57 20DB GY 6 C26 20PK DB 7 C7 12BK TN 8 C1 12DG 9 C12 20LG BK 10 C36 20RD WT 11 C37 20YL 12 C5 16LG 13 14 15 C6 16LB 16 C32 20GY DB 8W 80 22 8W 80 CONNECTOR PIN OUTS JR ...

Page 936: ...20GY DB C225 BLACK JUMPER SIDE CAV CIRCUIT 1 P86 16PK BK 2 F11 20RD WT 3 Z260 16BK C225 BLACK UNIBODY SIDE CAV CIRCUIT 1 P86 16PK BK 2 F11 20RD WT 2 F11 20RD WT 3 Z260 20BK C300 BLACK UNIBODY SIDE CAV CIRCUIT 1 L1 20VT BK 1 L1 20VT BK 2 L50 18WT TN 2 L50 18WT TN 3 L61 20LG 4 L7 20BK YL 4 L7 20BK YL 5 Z150 18BK 5 Z151 18BK JR27 5 Z143 18BK JR41 6 L95 18DG YL JR27 EXPORT 6 L36 18LG JR41 EXPORT JR 8W...

Page 937: ...N 4 L7 20BK YL 5 Z151 18BK 6 C301 BLACK RIGHT REAR LAMP SIDE CAV CIRCUIT 1 L1 18VT BK 2 L50 18WT TN 3 L60 18LG CHRYSLER EXPORT 3 L60 18TN DODGE 3 L60 18LG JR27 4 L7 18BK YL 5 Z151 18BK 6 C302 BLACK INSTRUMENT PANEL SIDE CAV CIRCUIT 1 F30 18RD 2 G9 20GY BK 3 G73 20LG OR VTSS 4 L36 18LG REAR FOG LAMPS 5 6 P97 20WT DG 7 P175 20OR BK 8 P177 20DB WT 9 Q1 14YL WT JR41 10 Q1 14YL TN JR41 8W 80 24 8W 80 C...

Page 938: ... 20RD WT EXCEPT BASE 2 F13 18DB JR27 2 G75 20TN JR41 3 4 P96 20WT LG 5 P176 20OR WT JR27 5 P176 20PK BK JR41 6 P178 20PK LB 7 Q13 14DB JR27 7 Q17 14DB WT JR41 8 Q14 14GY JR27 8 Q18 14GY BK JR41 9 Q23 14RD WT JR27 9 Q27 14RD BK JR41 10 Q24 14DG JR27 10 Q28 14DG WT JR41 11 Q37 20OR WT JR27 11 G74 20TN RD JR41 12 G74 20TN JR27 12 F14 18LG YL JR41 13 G10 20LG RD JR41 EXCEPT EXPORT 14 G75 20TN RD JR27 ...

Page 939: ...28 14DG WT JR41 11 Q37 20OR WT JR27 11 G74 20TN RD JR41 12 G74 20TN RD JR27 EXPORT 12 G74 20TN RD JR27 13 G10 20LG RD JR41 EXCEPT EXPORT 14 G75 20TN JR27 EXPORT 14 G75 20TN JR27 C304 JR41 YELLOW INSTRUMENT PANEL SIDE CAV CIRCUIT 1 R53 20LG YL EXCEPT SIDE AIRBAG 1 R13 20LG TN SIDE AIRBAG 2 R55 20LG DG EXCEPT SIDE AIRBAG 2 R15 20LG BR SIDE AIRBAG 3 R54 20LB YL EXCEPT SIDE AIRBAG 3 R14 20TN LG SIDE A...

Page 940: ...AG 4 R16 20BK LG SIDE AIRBAG C305 JR41 BLACK CHMSL SIDE CAV CIRCUIT 1 Z1 18BK 2 L50 18BK TN C305 JR41 BLACK UNIBODY SIDE CAV CIRCUIT 1 Z143 18BK 2 L50 18WT TN C306 BLACK INSTRUMENT PANEL SIDE CAV CIRCUIT 1 2 3 4 5 X51 20BR YL BASE 5 X93 20WT RD PREMIUM 6 X52 20DB WT BASE 6 X94 20TN VT PREMIUM 7 X57 20BR LB BASE 7 X91 20WT BK PREMIUM 8 X58 20DB OR BASE 8 X92 20TN BK PREMIUM 9 X60 20DG RD 9 X60 20DG...

Page 941: ...MIRROR 3 G38 18GY JR27 4 L1 18BK VT JR27 AUTOMATIC DAY NIGHT MIRROR 4 L1 20BK VT JR41 AUTOMATIC DAY NIGHT MIRROR C307 NATURAL UNIBODY SIDE CAV CIRCUIT 1 M2 18YL EXCEPT JR41 BASE 2 F20 20WT 3 G38 18GY JR27 4 L1 20VT BK AUTOMATIC DAY NIGHT MIRROR C308 JR41 BLUE REAR DOOR SIDE CAV CIRCUIT 1 P179 18OR TN 2 P181 18PK DB 3 Q1 14YL 4 Q17 14GY BK 5 Q27 14DG WT 6 G77 20TN YL 7 Z317 18BK 8 9 10 11 12 8W 80 ...

Page 942: ... 6 G77 20TN OR 7 Z317 20BK VT 8 9 10 11 12 C309 JR27 POWER SEAT GRAY POWER SEAT JUMPER SIDE CAV CIRCUIT 1 F35 16RD 2 Z1 16BK C309 JR27 POWER SEAT GRAY UNIBODY SIDE CAV CIRCUIT 1 F35 16RD 2 Z238 20BK C309 JR41 POWER SEAT GRAY UNIBODY SIDE CAV CIRCUIT 1 F35 16RD 2 Z238 20BK JR 8W 80 CONNECTOR PIN OUTS 8W 80 29 ...

Page 943: ... Q18 14GY BK JR41 9 Q37 20OR WT JR27 10 P175 20OR BK 11 P177 20DB WT 12 P93 22YL BK 13 G75 20TN RD JR27 13 G75 20TN JR41 14 15 16 C310 BROWN LEFT FRONT DOOR SIDE CAV CIRCUIT 1 2 M1 20PK 3 P97 20WT DG 4 P91 22WT BK 4 P91 22WT BK 5 P95 22DB 6 7 Q16 14BR WT 8 Q14 14GY JR27 8 Q18 14GY BK JR41 9 Q37 20OR WT JR27 10 P175 20OR BK 11 P177 20DB WT 12 P93 22YL BK 13 G75 20TN 14 15 16 8W 80 30 8W 80 CONNECTO...

Page 944: ... 20LG DG JR27 BASE 9 X85 20LG DG JR27 BASE 9 X53 20DG JR41 BASE 9 X87 18LG VT PREMIUM 10 G73 20LG OR VTSS 11 F20 20WT YL JR27 EXCEPT ATC 11 F20 20WT YL JR27 12 C16 20LB YL POWER MIRRORS C311 BLUE LEFT FRONT DOOR SIDE CAV CIRCUIT 1 Q1 14YL JR41 2 Q23 14RD WT JR27 3 Q13 14DB JR27 3 Q17 14DB WT JR41 4 F21 14TN 5 Q26 14VT WT 6 Z314 14BK JR27 6 Z243 14BK JR41 7 Q28 14DG WT EXCEPT JR27 7 Q24 14DG JR27 8...

Page 945: ...ASE BLACK UNIBODY SIDE CAV CIRCUIT 1 F20 20WT JR27 2 Q31 20WT BK JR27 3 Z316 14BK JR27 3 Z316 18BK JR41 4 5 6 Z249 18BK JR27 7 M1 18PK VT 7 M1 18PK EXPORT 8 M2 18YL 9 10 F30 18RD C315 BROWN INSTRUMENT PANEL SIDE CAV CIRCUIT 1 2 M1 20PK 3 P96 20WT LG 4 P90 22LG BK 5 P92 22YL 6 7 8 9 10 C16 20LB OR PREMIUM 11 P94 22WT YL 12 13 G74 20TN JR27 13 G74 20TN RD JR41 14 15 16 8W 80 32 8W 80 CONNECTOR PIN O...

Page 946: ... PANEL SIDE CAV CIRCUIT 1 P176 20OR WT JR27 1 P176 20PK BK JR41 2 P178 20PK LB 3 Q1 14YL VT JR41 4 Q16 14BR WT 5 Q26 14VT WT 6 Z237 20BK JR27 EXCEPT EXPORT 6 Z315 18BK BR JR27 6 Z242 18BK BR JR41 7 8 X82 20LB VT JR27 BASE 8 X82 20LB VT JR27 BASE 8 X56 20DB RD JR41 BASE 8 X80 18LB BK PREMIUM 9 X80 20LB BK JR27 BASE 9 X80 20LB BK JR27 BASE 9 X54 20VT JR41 BASE 9 X82 18LB VT PREMIUM 10 F21 14TN JR27 ...

Page 947: ... 18LB VT 10 F21 14TN JR27 11 12 C318 JR41 BLUE RIGHT REAR DOOR SIDE CAV CIRCUIT 1 P180 18OR TN 2 P182 18PK DB 3 Q1 14YL 4 Q18 14GY BK 5 Q28 14DG WT 6 G76 20TN YL 7 Z318 18BK 8 9 10 11 12 C318 JR41 BLUE UNIBODY SIDE CAV CIRCUIT 1 P180 20OR TN 2 P182 20PK DB 3 Q1 14YL WT 4 Q18 14GY BK 5 Q28 14DG WT 6 G76 20TN YL 7 Z318 20BK 8 9 10 11 12 8W 80 34 8W 80 CONNECTOR PIN OUTS JR ...

Page 948: ... YL EXPORT 2 Z150 18BK 3 L36 18LG REAR FOG LAMPS C320 JR41 BLACK UNIBODY SIDE CAV CIRCUIT 1 L7 18BK YL EXPORT 2 Z150 18BK 3 L36 18LB REAR FOG LAMPS C321 BLACK FUEL PUMP SIDE CAV CIRCUIT 1 A141 14RD 2 G4 18DB 3 Z211 14BK 4 Z12 20BK 2 4L LEAK DETECTION 4 F12 20DG BK 2 7L LEAK DETECTION 5 K106 20WT DG LEAK DETECTION 6 K107 20OR LEAK DETECTION JR 8W 80 CONNECTOR PIN OUTS 8W 80 35 ...

Page 949: ...0OR LEAK DETECTION C322 JR27 EXPORT BLACK FOG LAMP HARNESS SIDE CAV CIRCUIT 1 Z149 18BK 2 L36 18LG C322 JR27 EXPORT BLACK LEFT TAIL STOP TURN HARNESS SIDE CAV CIRCUIT 1 Z149 18BK 2 L36 18LB C323 BLACK JUMPER SIDE CAV CIRCUIT 1 P7 20LB BK 2 F11 20RD WT 3 P8 20LB WT 4 F99 20RD WT 5 F98 20RD WT 6 Z260 20BK 8W 80 36 8W 80 CONNECTOR PIN OUTS JR ...

Page 950: ...K C324 BLACK JUMPER SIDE CAV CIRCUIT 1 P86 16PK BK 2 Z121 16BK 3 4 P7 20LB BK 5 6 F99 20RD WT C324 BLACK SEAT SIDE CAV CIRCUIT 1 P86 16PK BK 2 Z121 16BK 3 4 P7 20LB BK 5 6 F99 20RD WT C325 BLACK JUMPER SIDE CAV CIRCUIT 1 P86 16PK BK 2 Z122 16BK 3 4 P8 20LB WT 5 6 F98 20RD WT JR 8W 80 CONNECTOR PIN OUTS 8W 80 37 ...

Page 951: ... CD CHANGER BLACK 8 WAY CAV CIRCUIT FUNCTION 1 X40 22GY WT AUDIO OUT RIGHT 2 E14 22OR TN PANEL LAMPS DIMMER SIGNAL 3 D25 22VT YL PCI BUS 4 X112 22RD IGNITION SWITCH OUTPUT RUN ACC 5 X41 22DG WT AUDIO OUT LEFT 6 Z4 22BK OR GROUND 7 Z140 22BK TN GROUND 8 X160 22GY YL B CENTER HIGH MOUNTED STOP LAMP JR27 RED 3 WAY CAV CIRCUIT FUNCTION 1 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 2 3 Z143 18BK GROUND 8W 80 ...

Page 952: ... LINE 2 5 R61 20OR LB DRIVER SQUIB 2 LINE 1 CLOCKSPRING C2 YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R43 20BK LB DRIVER SQUIB 1 LINE 1 2 R45 20DG LB DRIVER SQUIB 1 LINE 2 CLOCKSPRING C3 4 WAY CAV CIRCUIT FUNCTION 1 V37 22RD LG S C SWITCH SIGNAL 2 Z123 22BK LB GROUND 3 Z123 22BK OR GROUND 4 X3 22BK RD HORN RADIO CONTROL MUX CLUTCH INTERLOCK UPSTOP SWITCH MTX BLACK 2 WAY CAV CIRCUIT FUNCTION 1 T26 20DG OR...

Page 953: ...F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K92 18TN PK COIL CONTROL NO 2 COIL ON PLUG NO 3 2 7L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K93 18TN OR COIL CONTROL NO 3 COIL ON PLUG NO 4 2 7L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K94 18TN LG COIL CONTROL NO 4 8W 80 40 8W 80 CONNECTOR PIN OUTS J...

Page 954: ...USED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K96 18TN LB COIL CONTROL NO 6 COMPASS MINI TRIP COMPUTER BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 D25 20VT RD PCI BUS 3 M1 20PK FUSED B 4 Z104 20BK GROUND 5 F20 20WT FUSED IGNITION SWITCH OUTPUT RUN 6 CRANKSHAFT POSITION SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K6 20VT WT 5 VOLT SUPPLY 2 K4 20BK LB SENSOR GROUND 1 3 K24 20GY BK CKP SIGNAL JR 8W 80 CONNECTOR PIN...

Page 955: ...IVE 13 14 15 D15 20WT DG SCI TRANSMIT TCM 16 M1 20PK FUSED B DECKLID CYLINDER LOCK SWITCH VTSS 2 WAY CAV CIRCUIT FUNCTION 1 Z236 20BK GROUND 2 G71 20VT YL DECKLID SECURITY SWITCH SENSE DECKLID RELEASE SOLENOID AJAR SWITCH BLACK 3 WAY CAV CIRCUIT FUNCTION 1 Z217 20BK JR27 GROUND 1 Z217 20BK VT JR41 GROUND 2 G78 18TN BK DECKLID AJAR SWITCH SENSE 2 G78 18TN BK DECKLID AJAR SWITCH SENSE 3 P2 20BK WT D...

Page 956: ...COURTESY LAMPS DRIVER DRIVER AIRBAG SQUIB 1 GRAY 2 WAY CAV CIRCUIT FUNCTION 1 R45 20DG LB DRIVER SQUIB 1 LINE 2 2 R43 20BK LB DRIVER SQUIB 1 LINE 1 DRIVER AIRBAG SQUIB 2 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 R63 20DG LB DRIVER SQUIB 2 LINE 2 2 R61 20BK LB DRIVER SQUIB 2 LINE 1 DRIVER CYLINDER LOCK SWITCH VTSS GRAY 2 WAY CAV CIRCUIT FUNCTION 1 G73 20LG OR DRIVER CYLINDER LOCK SWITCH MUX 2 M1 20PK FUSE...

Page 957: ...1 20PK FUSED B 2 3 Z314 20BK JR27 GROUND 3 Z243 20BK JR41 GROUND 4 P97 20WT DG DRIVER DOOR SWITCH MUX DRIVER HEATED SEAT MODULE BLACK 6 WAY CAV CIRCUIT FUNCTION 15 P86 16PK BK HEATED SEAT RELAY OUTPUT 31 Z121 16BK GROUND 86 F99 20RD WT DRIVER HEATED SEAT FEED H P P7 20LB BK DRIVER HEATED SEAT SWITCH OUTPUT T DRIVER POWER WINDOW MOTOR JR27 BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q21 14WT LEFT FRONT POWE...

Page 958: ...T SOLENOID CONTROL 2 Z220 18BK GROUND DRIVER SEAT BELT SWITCH JR41 EXCEPT EXPORT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z237 20BK GROUND 2 G10 20LG RD SEAT BELT SWITCH SENSE DRIVER SEAT BELT TENSIONER JR27 YELLOW 4 WAY CAV CIRCUIT FUNCTION 1 Z237 20BK EXCEPT EXPORT GROUND 2 G10 20LG RD EXCEPT EXPORT SEAT BELT SWITCH SENSE 3 R53 20LG YL DRIVER SEAT BELT TENSIONER LINE 2 4 R55 20LG DG DRIVER SEAT BELT TE...

Page 959: ...20LG PK EGR SENSOR SIGNAL 2 K6 20VT WT 5 VOLT SUPPLY 3 K4 20BK LB SENSOR GROUND 1 4 Z12 20BK TN 2 4L PZEV GROUND 4 Z12 16BK TN 2 7L GROUND 5 6 K35 20GY YL EGR SOLENOID CONTROL ENGINE COOLANT TEMP SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K2 20TN BK ECT SIGNAL 2 K4 20BK LB SENSOR GROUND 1 EVAP PURGE SOLENOID 2 WAY CAV CIRCUIT FUNCTION 1 K52 20PK BK EVAP PURGE CONTROL 2 K108 20WT TN EVAP PURGE RETUR...

Page 960: ... VERTICAL MOTOR JR27 BLACK 2 WAY CAV CIRCUIT FUNCTION A P19 18YL LG LEFT SEAT FRONT DOWN B P21 18RD LG LEFT SEAT FRONT UP FRONT VERTICAL MOTOR JR41 RED 2 WAY CAV CIRCUIT FUNCTION 1 P19 16YL LG LEFT SEAT FRONT UP 2 P21 16RD LG LEFT SEAT FRONT DOWN FRONT WASHER PUMP MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z216 18BK GROUND 2 V10 18BR FRONT WASHER PUMP MOTOR CONTROL JR 8W 80 CONNECTOR PIN OUTS 8W 80 ...

Page 961: ...BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K11 18WT DB INJECTOR CONTROL NO 1 FUEL INJECTOR NO 1 2 7L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K11 18WT DB INJECTOR CONTROL NO 1 FUEL INJECTOR NO 2 2 7L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K12 18TN INJECTOR CONTROL NO 2 8W 80 4...

Page 962: ...ON 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K13 18YL WT INJECTOR CONTROL NO 3 FUEL INJECTOR NO 3 2 7L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K13 18YL WT INJECTOR CONTROL NO 3 FUEL INJECTOR NO 4 2 7L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K14 18LB BR INJECTOR CONTROL NO 4 JR 8W 80 CONNECTOR PIN OUTS 8W 80 ...

Page 963: ...F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K38 18GY INJECTOR CONTROL NO 5 FUEL INJECTOR NO 6 2 7L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K58 18BR DB INJECTOR CONTROL NO 6 FUEL PUMP MODULE 4 WAY CAV CIRCUIT FUNCTION 1 Z211 12BK GROUND 2 Z211 18BK GROUND 3 G4 18DB FUEL LEVEL SENSOR SIGNAL 4 A141 14RD FUEL PUMP RELAY OUTPUT 8W 80 50 8W 80 CONNECTOR PIN O...

Page 964: ...JUST SIGNAL HEADLAMP WASHER PUMP MOTOR JR41 EXPORT 2 WAY CAV CIRCUIT FUNCTION 1 V53 14RD YL HEADLAMP WASHER RELAY OUTPUT 2 Z216 14BK GROUND HEATED SEAT SWITCH WHITE 7 WAY CAV CIRCUIT FUNCTION 1 Z260 20BK GROUND 2 3 F99 20RD BK DRIVER HEATED SEAT FEED 4 F98 20RD WT PASSENGER HEATED SEAT FEED 5 P7 20LB BK DRIVER HEATED SEAT SWITCH OUTPUT 6 F11 20RD FUSED IGNITION SWITCH OUTPUT OFF RUN START 7 P8 20L...

Page 965: ... 16RD LB LEFT SEAT HORIZONTAL FORWARD HORN BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z307 20BK GROUND 2 X2 20DG RD HORN RELAY OUTPUT IDLE AIR CONTROL MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K39 18GY RD IAC MOTOR CONTROL 2 K60 18YL BK IAC RETURN IGNITION COIL PACK 2 0L 2 4L BLACK 3 WAY CAV CIRCUIT FUNCTION 1 K17 18DB TN COIL CONTROL NO 2 2 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 3 K19 18BK GY COIL C...

Page 966: ...RD FUSED B 8 A31 16BK WT FUSED IGNITION SWITCH OUTPUT RUN ACC 8 A31 18BK LB FUSED IGNITION SWITCH OUTPUT RUN ACC 9 A21 16DB FUSED IGNITION SWITCH OUTPUT RUN START 10 A41 18YL FUSED IGNITION SWITCH OUTPUT START IGNITION SWITCH C3 GREEN 2 WAY CAV CIRCUIT FUNCTION 1 Z233 20BK WT GROUND 2 G26 20LB KEY IN IGNITION SWITCH SENSE INLET AIR TEMP SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K21 20BK RD IAT SIG...

Page 967: ...9 10 Z105 20BK LB GROUND 11 Z106 18BK OR GROUND 12 E2 20OR PANEL LAMPS DRIVER 13 L36 18LG REAR FOG LAMPS REAR FOG LAMP INDICATOR 14 G6 20GY ENGINE OIL PRESSURE SWITCH SENSE 15 F11 20RD WT FUSED IGNITION SWITCH OUTPUT OFF RUN START 16 17 18 L61 18LG TN LEFT TURN SIGNAL 19 L60 18TN BR RIGHT TURN SIGNAL 20 21 F33 20PK WT FUSED B 22 G9 18GY BK BRAKE WARNING INDICATOR DRIVER 23 Z104 20BK GROUND 24 G10 ...

Page 968: ...USED RIGHT HIGH BEAM OUTPUT 4 L60 20TN RIGHT TURN SIGNAL 5 L61 16LG LEFT TURN SIGNAL 6 L33 20LG BR FUSED LEFT HIGH BEAM OUTPUT 7 8 L7 20BK YL HEADLAMP SWITCH OUTPUT 9 L7 20BK BR HEADLAMP SWITCH OUTPUT 10 L39 20LB OR FRONT FOG LAMPS FOG LAMP SWITCH OUTPUT 11 L39 20LB FRONT FOG LAMPS FOG LAMP SWITCH OUTPUT 12 L43 18VT FUSED LEFT LOW BEAM OUTPUT JUNCTION BLOCK C2 10 WAY CAV CIRCUIT FUNCTION 1 L50 20W...

Page 969: ...15 16BK RD PREMIUM GROUND 10 Z126 16BK LG JR41 PREMIUM GROUND JUNCTION BLOCK C5 GRAY 16 WAY CAV CIRCUIT FUNCTION 1 F75 16VT PREMIUM FUSED B 2 3 L7 16BK YL HEADLAMP SWITCH OUTPUT 4 5 L39 20LB WT FOG LAMP SWITCH OUTPUT 6 G9 18GY BK BRAKE WARNING INDICATOR DRIVER 7 8 9 A21 16DB FUSED IGNITION SWITCH OUTPUT RUN START 10 L39 18LB FOG LAMP SWITCH OUTPUT 11 12 M1 18PK FUSED B 13 M1 20PK DB FUSED B 14 A31...

Page 970: ...E FUSED RIGHT LOW BEAM OUTPUT 5 C16 20LB YL MTC FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 6 X12 18RD WT FUSED IGNITION SWITCH OUTPUT RUN ACC 7 L61 20LG LEFT TURN SIGNAL 8 L60 16TN RIGHT TURN SIGNAL 9 L61 18LG TN LEFT TURN SIGNAL 10 F11 18RD WT FUSED IGNITION SWITCH OUTPUT OFF RUN START 11 F33 20PK WT FUSED B 12 F33 16PK RD FUSED B JUNCTION BLOCK C8 BLACK 8 WAY CAV CIRCUIT FUNCTION 1 Q1 14YL JR41 POW...

Page 971: ... 20BK YL HEADLAMP SWITCH OUTPUT 10 L7 20BK YL JR27 HEADLAMP SWITCH OUTPUT 11 12 M1 18PK FUSED B JUNCTION BLOCK C10 NATURAL 6 WAY CAV CIRCUIT FUNCTION 1 M2 18YL JR27 COURTESY LAMPS DRIVER 1 M2 18BK YL JR27 COURTESY LAMPS DRIVER 1 M2 20YL JR41 COURTESY LAMPS DRIVER 1 M2 20YL JR41 COURTESY LAMPS DRIVER 2 3 F21 18TN JR41 PREMIUM FUSED IGNITION SWITCH OUTPUT RUN 4 Z312 20BK JR27 GROUND 4 Z312 20BK JR27...

Page 972: ...K42 20DB LG KS SIGNAL LEFT BACK UP LAMP BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z149 18BK JR27 GROUND 1 Z150 18BK JR41 GROUND 2 L1 18VT BK BACK UP LAMP FEED LEFT CURTAIN AIRBAG SQUIB JR41 YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R77 20LB BR LEFT CURTAIN SQUIB 1 LINE 2 2 R75 20LB OR LEFT CURTAIN SQUIB 1 LINE 1 LEFT FOG LAMP EXCEPT JR27 BLACK 2 WAY CAV CIRCUIT FUNCTION A L39 20LB OR FOG LAMP RELAY OUTPUT B Z1...

Page 973: ...FUNCTION 1 X87 20LG VT LEFT INSTRUMENT PANEL SPEAKER 2 X85 20LG DG LEFT INSTRUMENT PANEL SPEAKER LEFT FRONT INSTRUMENT PANEL SPEAKER JR27 PREMIUM BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X81 18YL BK AMPLIFIED LEFT INSTRUMENT PANEL SPEAKER 2 X83 18YL RD AMPLIFIED LEFT INSTRUMENT PANEL SPEAKER LEFT FRONT INSTRUMENT PANEL SPEAKER JR41 PREMIUM 3 WAY CAV CIRCUIT FUNCTION 1 X81 18YL BK AMPLIFIED LEFT INSTRUME...

Page 974: ...141 20BK GROUND 3 L33 20LG BR FUSED LEFT HIGH BEAM OUTPUT LEFT LAVALIER MODULE EXPORT BLACK 6 WAY CAV CIRCUIT FUNCTION 1 Z163 16BK GROUND 2 L101 18RD HEADLAMP ADJUST SIGNAL 3 L33 20LG BR FUSED LEFT HIGH BEAM OUTPUT 4 L61 16LG LEFT TURN SIGNAL 5 L7 20BK BR HEADLAMP SWITCH OUTPUT 6 L43 18VT FUSED LEFT LOW BEAM OUTPUT LEFT LICENSE LAMP JR27 NATURAL 2 WAY CAV CIRCUIT FUNCTION 1 L7 18BK YL FUSED PARK L...

Page 975: ...D REAR WINDOW DEFOGGER RELAY OUTPUT 2 Z314 20BK JR27 GROUND 2 Z243 20BK JR41 GROUND 3 C16 20LB YL JR27 FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 3 P95 22DB JR41 LEFT MIRROR HORIZONTAL 4 P91 22WT BK LEFT RIGHT MIRROR HORIZONTAL SUPPLY 5 P91 22WT BK JR27 LEFT RIGHT MIRROR VERTICAL SUPPLY 6 P93 22YL BK LEFT MIRROR VERTICAL LEFT REAR DOOR LOCK MOTOR AJAR SWITCH JR41 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G7...

Page 976: ...1 Q23 14RD WT JR27 LEFT REAR WINDOW DRIVER DOWN 1 Q23 14DG JR41 LEFT REAR WINDOW DRIVER DOWN 2 Q13 14DB JR27 LEFT REAR WINDOW DRIVER UP 2 Q13 14GY JR41 LEFT REAR WINDOW DRIVER UP LEFT REAR POWER WINDOW SWITCH JR41 BLUE 6 WAY CAV CIRCUIT FUNCTION 1 Q23 14DG LEFT REAR WINDOW DRIVER DOWN 2 Q17 14DB WT MASTER WINDOW SWITCH LEFT REAR UP 3 4 Q27 14RD BK MASTER WINDOW SWITCH LEFT REAR DOWN 5 Q13 14GY LEF...

Page 977: ... WHEEL SPEED SENSOR 12 VOLT SUP PLY 2 B3 20LG DB LEFT REAR WHEEL SPEED SENSOR SIGNAL LEFT REMOTE RADIO SWITCH 2 7L 2 WAY CAV CIRCUIT FUNCTION 1 X3 22BK RD HORN RADIO CONTROL MUX 2 Z123 22BK OR GROUND LEFT SIDE IMPACT SENSOR 1 GRAY 2 WAY CAV CIRCUIT FUNCTION 1 R15 20LG BR LEFT SIDE IMPACT SENSOR 1 GROUND 2 R13 20LG TN LEFT SIDE IMPACT SENSOR 1 SIGNAL LEFT SPEED CONTROL SWITCH LT GREEN 2 WAY CAV CIR...

Page 978: ...E LAMP SWITCH OUTPUT LEFT TAIL TURN SIGNAL LAMP JR41 DODGE GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z150 18BK GROUND 2 L7 18BK YL FUSED PARK LAMP RELAY OUTPUT 3 L61 18LG LEFT TURN SIGNAL LEFT TURN LAMP CHRYSLER EXCEPT JR41 DODGE TAN 2 WAY CAV CIRCUIT FUNCTION 1 L61 18LG LEFT TURN SIGNAL 2 Z149 18BK JR27 GROUND 2 Z150 18BK JR41 GROUND LEFT VISOR VANITY LAMPS BLACK 2 WAY CAV CIRCUIT FUNCTION A M1 20PK FUSE...

Page 979: ...SOLUTE PRESSURE SENSOR GRAY 3 WAY CAV CIRCUIT FUNCTION 1 K1 20DG RD MAP SIGNAL 2 K4 20BK LB SENSOR GROUND 1 3 K6 20VT WT 5 VOLT SUPPLY MASS AIR FLOW SENSOR 2 4L PZEV BLACK 6 WAY CAV CIRCUIT FUNCTION 1 2 K4 16BL SENSOR GROUND 1 3 4 A142 16YL AUTOMATIC SHUT DOWN RELAY OUTPUT 5 K57 16WT MAF SENSOR SIGNAL 6 8W 80 66 8W 80 CONNECTOR PIN OUTS JR ...

Page 980: ...W SWITCH RIGHT REAR DOWN 9 Q28 14DG WT JR41 MASTER WINDOW SWITCH RIGHT REAR DOWN 10 Z314 14BK JR27 GROUND 10 Z243 14BK JR41 GROUND 11 Q38 14OR LB JR27 MASTER WINDOW SWITCH RIGHT FRONT DOWN 11 Q26 14VT WT JR41 MASTER WINDOW SWITCH RIGHT FRONT DOWN 12 Q16 14BR WT MASTER WINDOW SWITCH RIGHT FRONT UP MODE DOOR ACTUATOR BLACK 5 WAY CAV CIRCUIT FUNCTION 1 C35 20DG YL MODE DOOR DRIVER 2 C57 20DB GY SENSO...

Page 981: ...20WT EXCEPT EXPORT FUSED IGNITION SWITCH OUTPUT 10 L36 18LG EXPORT REAR FOG LAMP CONTROL 11 L44 20VT RD BASE FUSED RIGHT LOW BEAM OUTPUT 11 L25 20BR EXPORT FUSED FOG LAMP SWITCH FEED 11 F33 18PK RD PREMIUM FUSED B 12 L39 20LB WT EXCEPT PREMIUM FRONT FOG LAMP INDICATOR DRIVER 12 L35 20BR WT PREMIUM FOG LAMP SWITCH SENSE NATURAL VACUUM LEAK DETECTION ASSEMBLY EXCEPT EXPORT BLACK 3 WAY CAV CIRCUIT FU...

Page 982: ...USED B C M2 20YL COURTESY LAMPS DRIVER OXYGEN SENSOR 1 1 RIGHT BANK UP 2 7L 4 WAY CAV CIRCUIT FUNCTION 1 Z192 20BK GROUND 2 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 1 UPSTREAM 2 0L 2 4L 4 WAY CAV CIRCUIT FUNCTION 1 Z228 20BK GROUND 2 K99 18BR OR O2 1 1 HEATER CONTROL 3 K902 18BR DG O2 RETURN UP 4 K41 20BK DG O2 1 1 SIGNAL JR 8W 80 CO...

Page 983: ...R 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 2 7L 4 WAY CAV CIRCUIT FUNCTION 1 Z193 20BK GROUND 2 K299 18BR WT O2 2 1 HEATER CONTROL 3 K902 18BR DG O2 RETURN UP 4 K241 20LG RD O2 2 1 SIGNAL OXYGEN SENSOR 2 2 LEFT BANK DOWN 2 7L 4 WAY CAV CIRCUIT FUNCTION 1 Z186 20BK GROUND 2 K399 18BR GY O2 2 2 HEATER CONTROL 3 K904 18DB DG O2...

Page 984: ... 2 3 R62 20OR YL PASSENGER SQUIB 2 LINE 1 4 R64 20TN YL PASSENGER SQUIB 2 LINE 2 PASSENGER DOOR LOCK MOTOR AJAR SWITCH BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G74 20TN RD PASSENGER DOOR AJAR SWITCH SENSE 2 Z315 20BK JR27 GROUND 2 Z242 20BK JR41 GROUND 3 P178 20PK LB PASSENGER UNLOCK RELAY OUTPUT 4 P176 20PK BK PASSENGER LOCK RELAY OUTPUT PASSENGER DOOR LOCK SWITCH NATURAL 4 WAY CAV CIRCUIT FUNCTION 1 M...

Page 985: ...JR41 LT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Q22 16VT RIGHT FRONT WINDOW DRIVER DOWN 2 Q12 16BR RIGHT FRONT WINDOW DRIVER UP PASSENGER POWER WINDOW SWITCH BLUE 6 WAY CAV CIRCUIT FUNCTION 1 Q22 14VT JR27 RIGHT FRONT WINDOW DRIVER DOWN 1 Q22 16VT JR41 RIGHT FRONT WINDOW DRIVER DOWN 2 Q16 14BR WT MASTER WINDOW SWITCH RIGHT FRONT UP 3 4 Q26 14VT WT MASTER WINDOW SWITCH RIGHT FRONT DOWN 5 Q12 14BR JR27 RI...

Page 986: ...NER LINE 1 POWER AMPLIFIER C1 JR27 PREMIUM WHITE 12 WAY CAV CIRCUIT FUNCTION 1 X82 18LB VT AMPLIFIED RIGHT FRONT SPEAKER 2 X87 18LG VT AMPLIFIED LEFT FRONT SPEAKER 3 X92 20TN BK AMPLIFIED RIGHT REAR SPEAKER 4 X86 18OR RD AMPLIFIED RIGHT INSTRUMENT PANEL SPEAKER 5 X83 18YL RD AMPLIFIED LEFT INSTRUMENT PANEL SPEAKER 6 X80 18LB BK AMPLIFIED RIGHT FRONT SPEAKER 7 X85 18LG DG AMPLIFIED LEFT FRONT SPEAK...

Page 987: ... 20BR RD LEFT FRONT SPEAKER 17 X58 20DB OR RIGHT REAR SPEAKER 18 X57 20BR LB LEFT REAR SPEAKER 19 20 21 X91 20WT BK AMPLIFIED LEFT REAR SPEAKER 22 X92 20TN BK AMPLIFIED RIGHT REAR SPEAKER POWER AMPLIFIER C2 JR27 PREMIUM WHITE 18 WAY CAV CIRCUIT FUNCTION 1 F75 16VT FUSED B 2 3 4 5 X52 20DB WT RIGHT REAR SPEAKER 6 X51 20BR YL LEFT REAR SPEAKER 7 X54 20VT RIGHT FRONT SPEAKER 8 X53 20DG LEFT FRONT SPE...

Page 988: ...MPLIFIED LEFT INSTRUMENT PANEL SPEAKER 10 X84 18OR BK AMPLIFIED RIGHT INSTRUMENT PANEL SPEAKER 11 12 POWER ANTENNA EXPORT BROWN 2 WAY CAV CIRCUIT FUNCTION 1 M1 18PK FUSED B 2 X60 20DG RD RADIO 12V OUTPUT POWER MIRROR SWITCH BLACK 10 WAY CAV CIRCUIT FUNCTION 1 P91 22WT BK LEFT RIGHT MIRROR HORIZONTAL SUPPLY 2 P94 22WT YL RIGHT MIRROR HORIZONTAL 3 Z239 20BK LB GROUND 4 P93 22YL BK LEFT MIRROR VERTIC...

Page 989: ...T SEAT HORIZONTAL REARWARD M P13 18RD WT LEFT SEAT REAR UP N P11 18YL WT LEFT SEAT REAR DOWN POWER SEAT SWITCH JR41 BLUE 10 WAY CAV CIRCUIT FUNCTION 1 F35 16RD FUSED B 2 P43 16GY LB LEFT SEAT RECLINER SWITCH DOWN 3 P17 16RD LB LEFT SEAT HORIZONTAL FORWARD 4 P41 16GY WT LEFT SEAT RECLINER SWITCH UP 5 Z1 16BK GROUND 6 P21 16RD LG LEFT SEAT FRONT DOWN 7 P13 16RD WT LEFT SEAT REAR DOWN 8 P11 16YL WT L...

Page 990: ...P DOWN RELAY OUTPUT POWER TOP SWITCH JR27 3 WAY CAV CIRCUIT FUNCTION 1 F20 20YL BK FUSED IGNITION SWITCH OUTPUT RUN 2 Z249 20BK GROUND 3 Q31 20OR DB CONVERTIBLE TOP SWITCH MUX POWER TOP UP DOWN RELAYS JR27 6 WAY CAV CIRCUIT FUNCTION A P6 20RD WT TOP UP RELAY CONTROL B P3 12YL TOP UP RELAY OUTPUT C A25 12DB FUSED B D Z253 12BK GROUND E P4 12RD TOP DOWN RELAY OUTPUT F P5 20YL BK TOP DOWN RELAY CONTR...

Page 991: ...E SIGNAL 22 23 24 25 D20 20LG SCI RECEIVE PCM 26 D6 20PK LB EATX SCI RECEIVE TCM 27 K7 18OR MTX EXPORT 5 VOLT SUPPLY 28 K62 18BK OR 2 4L PZEV AIR PUMP MOTOR RELAY CONTROL 29 A14 16RD TN FUSED B 30 A41 16YL FUSED IGNITION SWITCH OUTPUT START 31 K141 20TN WT 2 7L O2 SENSOR 1 2 SIGNAL 32 K904 18DB DG O2 RETURN DOWN 33 K341 20PK WT 2 7L O2 SENSOR 2 2 SIGNAL 34 35 36 D21 20PK SCI TRANSMIT PCM 37 D15 20...

Page 992: ...TOR CONTROL NO 2 14 K11 18WT DB INJECTOR CONTROL NO 1 15 16 17 K199 18BR VT 2 0L 2 4L O2 1 2 HEATER CONTROL 17 K299 18BR WT 2 7L 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 K235 20LG PK 2 4L PZEV 2 7L EGR SENSOR SIGNAL 23 K1 20DG RD MAP SIGNAL 24 K45 20BK VT KS RETURN 25 K42 20DB LG KS SIGNAL 26 K57 2...

Page 993: ...ONTROL 13 14 15 16 17 K4 18BK LB SENSOR GROUND 1 18 19 F142 16OR DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 20 K52 20PK BK EVAP PURGE CONTROL 21 T26 20DG OR CLUTCH INTERLOCK UPSTOP SWITCH OUTPUT 22 23 K29 20WT PK BRAKE SWITCH SIGNAL 24 25 26 T44 20YL AUTOSTICK DOWNSHIFT SWITCH SIGNAL 27 T5 20LG AUTOSTICK UPSHIFT SWITCH SIGNAL 28 F142 16OR DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 29 K108 20WT TN EV...

Page 994: ...OL RELAY CONTROL 19 T16 20RD TRANSMISSION CONTROL RELAY OUTPUT 20 21 22 T9 20OR BK OD PRESSURE SWITCH SENSE 23 24 25 26 27 T41 20BK WT TRS T41 SENSE 28 T16 20RD TRANSMISSION CONTROL RELAY OUTPUT 29 T50 20DG L R PRESSURE SWITCH SENSE 30 T47 20YL 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 SENSOR GROUND 35 T5...

Page 995: ...20DB RD EXCEPT JR27 BASE RIGHT FRONT SPEAKER 8 X82 20LB VT JR27 BASE RIGHT INSTRUMENT PANEL SPEAKER 9 X55 20BR RD EXCEPT JR27 BASE LEFT FRONT SPEAKER 9 X87 20LG VT JR27 BASE LEFT INSTRUMENT PANEL SPEAKER 10 X53 20DG EXCEPT JR27 BASE LEFT FRONT SPEAKER 10 X85 20LG DG JR27 BASE LEFT INSTRUMENT PANEL SPEAKER 11 Z1 18BK GROUND 12 M1 20PK FUSED B 13 X60 20DG RD EXCEPT JR27 BASE RADIO 12V OUTPUT 14 D25 ...

Page 996: ...E14 22OR TN PANEL LAMPS DIMMER SIGNAL 10 X160 22GY YL B REAR FLOOR COURTESY LAMP WHITE 2 WAY CAV CIRCUIT FUNCTION 1 M1 18PK FUSED B 2 M2 18YL COURTESY LAMPS DRIVER REAR VERTICAL MOTOR JR27 BLACK 2 WAY CAV CIRCUIT FUNCTION A P13 16RD WT LEFT SEAT REAR UP B P11 16YL WT LEFT SEAT REAR UP REAR VERTICAL MOTOR JR41 RED 2 WAY CAV CIRCUIT FUNCTION 1 P11 16YL WT LEFT SEAT REAR UP 2 P13 16RD WT LEFT SEAT RE...

Page 997: ...6GY LB LEFT SEAT RECLINER SWITCH DOWN RIGHT BACK UP LAMP GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z151 18BK GROUND 2 L1 18VT BK BACK UP LAMP FEED RIGHT CURTAIN AIRBAG SQUIB JR41 YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R76 20LB WT RIGHT CURTAIN SQUIB 1 LINE 2 2 R74 20LB YL RIGHT CURTAIN SQUIB 1 LINE 1 RIGHT FOG LAMP JR27 GRAY 2 WAY CAV CIRCUIT FUNCTION A L39 20LB FOG LAMP RELAY OUTPUT B Z144 20BK GROUND 8W 80...

Page 998: ...SE RIGHT FRONT SPEAKER 3 X82 18LB VT PREMIUM AMPLIFIED RIGHT FRONT SPEAKER RIGHT FRONT INSTRUMENT PANEL SPEAKER JR27 BASE WHITE 2 WAY CAV CIRCUIT FUNCTION 1 X82 20LB VT RIGHT INSTRUMENT PANEL SPEAKER 2 X80 20LB BK RIGHT INSTRUMENT PANEL SPEAKER RIGHT FRONT INSTRUMENT PANEL SPEAKER JR27 PREMIUM BLACK 2 WAY CAV CIRCUIT FUNCTION 1 X84 18OR BK AMPLIFIED RIGHT INSTRUMENT PANEL SPEAKER 2 X86 18OR RD AMP...

Page 999: ... 20WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL RIGHT HEADLAMP EXCEPT EXPORT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L44 20VT RD FUSED RIGHT LOW BEAM OUTPUT 2 Z142 20BK GROUND 3 L34 18RD OR FUSED RIGHT HIGH BEAM OUTPUT RIGHT LAVALIER MODULE EXPORT BLACK 6 WAY CAV CIRCUIT FUNCTION 1 Z162 16BK GROUND 2 L101 18RD HEADLAMP ADJUST SIGNAL 3 L34 18RD OR FUSED RIGHT HIGH BEAM OUTPUT 4 L60 20TN RIGHT TURN SIGNAL...

Page 1000: ...GNAL 2 L7 20BK YL HEADLAMP SWITCH OUTPUT 3 Z147 20BK GROUND RIGHT POWER MIRROR NATURAL 6 WAY CAV CIRCUIT FUNCTION 1 P94 22WT YL JR27 RIGHT MIRROR VERTICAL 1 C16 20LB OR JR41 PREMIUM FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 2 Z315 20BK JR27 GROUND 2 Z242 20BK JR41 PREMIUM GROUND 3 C16 20LB YL JR27 FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 3 P94 22WT YL JR41 RIGHT MIRROR VERTICAL 4 P90 22LG BK RIGHT PO...

Page 1001: ...Y OUTPUT RIGHT REAR FOG LAMP JR27 EXPORT GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z149 18BK GROUND 2 L36 18LG REAR FOG LAMP RELAY OUTPUT RIGHT REAR FOG LAMP JR41 EXPORT GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z150 18BK GROUND 2 3 L36 18LG REAR FOG LAMP CONTROL RIGHT REAR POWER WINDOW MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q24 14DG RIGHT REAR WINDOW DRIVER DOWN 2 Q14 14GY RIGHT REAR WINDOW DRIVER UP 8W 80 88 ...

Page 1002: ...IRCUIT FUNCTION 1 X92 18TN BK BASE RIGHT REAR SPEAKER 1 X92 18TN BK PREMIUM AMPLIFIED RIGHT REAR SPEAKER 2 3 X94 18TN VT BASE RIGHT REAR SPEAKER 3 X94 18TN VT PREMIUM AMPLIFIED RIGHT REAR SPEAKER RIGHT REAR WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B2 20YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP PLY 2 B1 20YL DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL RIGHT REMOTE RADIO SWITCH 2 7L 2 WA...

Page 1003: ...EN 2 WAY CAV CIRCUIT FUNCTION A V37 22RD LG S C SWITCH SIGNAL B Z123 22BK LB GROUND RIGHT TAIL SIDE MARKER LAMP 2 WAY CAV CIRCUIT FUNCTION 1 Z151 18BK GROUND 2 L7 18BK YL FUSED PARK LAMP RELAY OUTPUT RIGHT TAIL STOP LAMP GRAY 3 WAY CAV CIRCUIT FUNCTION 1 Z151 18BK GROUND 2 L7 18BK YL FUSED PARK LAMP RELAY OUTPUT 3 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 8W 80 90 8W 80 CONNECTOR PIN OUTS JR ...

Page 1004: ...VANITY LAMPS BLACK 2 WAY CAV CIRCUIT FUNCTION A M1 20PK FUSED B B Z312 20BK GROUND SEAT BELT CONTROL MODULE JR27 EXPORT NATURAL 13 WAY CAV CIRCUIT FUNCTION 1 2 G75 20TN DRIVER DOOR AJAR SWITCH SENSE 3 G74 20TN RD PASSENGER DOOR AJAR SWITCH SENSE 4 F13 18DB FUSED IGNITION SWITCH OUTPUT RUN ACC 5 A45 18BR FUSED B 6 Z128 18BK GROUND 7 R7 18OR BK DRIVER SEAT BELT SOLENOID CONTROL 8 R8 18OR RD PASSENGE...

Page 1005: ...GROUND 4 C38 20DB SUN SENSOR SIGNAL SUNROOF CONTROL MODULE JR41 WHITE 6 WAY CAV CIRCUIT FUNCTION 1 Z312 18BK GROUND 2 F21 18TN FUSED IGNITION SWITCH OUTPUT RUN 3 Q43 20VT SUNROOF VENT 4 Q44 20BR SUNROOF SWITCH GROUND 5 Q42 20LB SUNROOF CLOSE 6 Q41 20WT SUNROOF OPEN SUNROOF SWITCH JR41 NATURAL 4 WAY CAV CIRCUIT FUNCTION 1 Q41 20WT SUNROOF OPEN 2 Q43 20VT SUNROOF VENT 3 Q44 20BR SUNROOF SWITCH GROUN...

Page 1006: ...T FUNCTION 1 K6 20VT WT 5 VOLT SUPPLY 2 K22 20OR DB TP SIGNAL 3 K4 20BK LB SENSOR GROUND 1 TRACTION CONTROL SWITCH 2 WAY CAV CIRCUIT FUNCTION 1 Z2 20BK LG GROUND 2 B27 20RD YL TRACTION CONTROL SWITCH SENSE TRANSMISSION RANGE INDICATOR ILLUMINATION PRNDL BROWN 2 WAY CAV CIRCUIT FUNCTION 1 E2 20OR PANEL LAMPS DRIVER 2 Z157 18BK JR27 GROUND 2 Z157 20BK JR41 GROUND JR 8W 80 CONNECTOR PIN OUTS 8W 80 93...

Page 1007: ...10 T41 20BK WT TRS T41 SENSE TRANSMISSION SOLENOID PRESSURE SWITCH ASSEMBLY BLACK 8 WAY CAV CIRCUIT FUNCTION 1 T47 18YL BK 2 4 PRESSURE SWITCH SENSE 2 T50 18DG L R PRESSURE SWITCH SENSE 3 T9 18OR BK OD PRESSURE SWITCH SENSE 4 T16 16RD TRANSMISSION CONTROL RELAY OUTPUT 5 T59 18PK UD SOLENOID CONTROL 6 T60 18BR OD SOLENOID CONTROL 7 T20 18LB L R SOLENOID CONTROL 8 T19 18WT 2 4 SOLENOID CONTROL TRUNK...

Page 1008: ...UNCTION 1 Q19 14OR YL MASTER WINDOW SWITCH LEFT FRONT DOWN 2 Q290 14YL OR MASTER WINDOW SWITCH LEFT REAR DOWN 3 Q38 14OR LB MASTER WINDOW SWITCH RIGHT FRONT DOWN 4 Q32 14LB OR MASTER WINDOW SWITCH RIGHT REAR DOWN 5 F20 20WT FUSED IGNITION SWITCH OUTPUT RUN 6 Q37 20OR WT WINDOW DROP RELAY CONTROL 7 Q21 14WT LEFT FRONT WINDOW DRIVER DOWN 8 Q23 14RD WT LEFT REAR WINDOW DRIVER DOWN 9 Q26 14VT WT WINDO...

Page 1009: ......

Page 1010: ...trument Panel 21 28 A C Heater Control C2 MTC BK Rear of Control Center of Instrument Panel 21 28 A C Pressure Transducer GY Top of A C Compressor 16 Airbag Control Module ORC BASE GY Center Body Near Shifter Assembly 21 39 Airbag Control Module C1 ORC Premium YL Front Center Body Connector 39 Airbag Control Module C2 ORC Premium YL Front Center Body Connectors and Instruments Panel Harness Connec...

Page 1011: ... Steering Column 21 23 C100 LT GN Lower Left Side Instrument Panel 21 22 24 C101 LT GY Lower Left Side Instrument Panel 21 22 24 C104 EATX LT GY Left Front Engine Compartment 4 10 12 C105 EATX BK Left Front Engine Compartment 4 10 12 C111 BK Left Side Engine Compartment 5 C121 BK Left Side Cowl Panel 41 C169 MTX BK Left Front Engine Compartment 4 11 12 C170 DK GY On Air Pump Assy near Starter 4 13...

Page 1012: ... Cigar Lighter Power Outlet BK Lower Center Instrument Panel 21 27 Cigar Lighter Power Outlet Feed Lower Center Instrument Panel 21 27 Cigar Lighter Power Outlet Ground Lower Center Instrument Panel 21 27 Clockspring C1 NAT Rear of Clockspring 21 23 Clockspring C2 YL Rear of Clockspring 21 23 Clockspring C3 Front Side of Clockspring N S Clutch Interlock Upstop Switch MTX BK At Switch N S Coil On P...

Page 1013: ...YL Under Driver Seat 21 39 43 45 Driver Seat Belt Tensioner JR41 YL Near Belt Real N S EGR Solenoid BK At Left Rear of Engine Head 14 Engine Coolant Temperature Sensor 2 0L 2 4L BK At Sensor 14 Engine Coolant Temperature Sensor 2 7L BK At Sensor 15 Engine Starter Motor BK At Engine Starter Motor 15 EVAP Purge Solenoid BK Left Side Engine Compartment 5 Fog Lamp Relay Premium NAT Lower Left Side I P...

Page 1014: ...3 Inlet Air Temperature Sensor BK On Intake 13 17 Input Speed Sensor GY Left Front of Transmission 10 Instrument Cluster NAT Rear of Cluster 21 29 Junction Block Body Control Module JB Left Front Kick Panel 31 Junction Block C1 BR Left Front Kick Panel 32 Junction Block C2 NAT Left Front Kick Panel 32 Junction Block C3 WT Left Front Kick Panel 32 Junction Block C4 BL Left Front Kick Panel 21 32 Ju...

Page 1015: ...Rear Wheel Speed Sensor BK Left Quarter Panel 42 43 Left Remote Radio Switch Under Horn Pad 30 Left Side Impact Sensor YL At B Post N S Left Speed Control Switch BK Under Horn Pad 30 Left Tail Side Marker Lamp BK At Lamp N S Left Tail Stop Lamp GY At Lamp N S Left Tail Turn Signal Lamp GY At Lamp N S Left Turn Lamp TN At Lamp N S Left Visor Vanity Lamps BK At Lamp 38 52 Licence Lamp Except Export ...

Page 1016: ...nger Door Lock Motor Ajar Switch BK In Passenger Door 50 51 Passenger Door Lock Switch NAT In Passenger Door 50 51 Passenger Heated Seat Module Under Passenger Seat N S Passenger Power Window Motor LT GY In Passenger Door 50 51 Passenger Power Window Switch BL In Passenger Door 50 51 Passenger Seat Belt Solenoid Export BK Under Passenger Seat 21 39 Passenger Seat Belt Tensioner YL Under Passenger ...

Page 1017: ...w Defogger Feed Left Side Shelf Panel 42 43 Rear Window Defogger Ground Right Side of Rear Window Defogger N S Rear Window Defogger Relay In Junction Block 31 Recirculation Door Actuator BK At Actuator Right end of HVAC 35 Recline Motor Power Seat GN Under Driver Seat N S Remote Keyless Entry Receiver On Junction Block Body Control Module 31 Right Back Up Lamp GY At Lamp N S Right Curtain Airbag Y...

Page 1018: ...eat Belt Control Module Export NAT Under Driver Seat N S Sentry Key Immobilizer Module BK At Steering Column 21 23 Starter Lower Front of Engine 10 Sunroof Control Module WT In Left Headliner 52 Sunroof Switch NAT In Left Headliner 52 Sun Sensor ATC BK Center I P 21 26 Throttle Position Sensor 2 0L 2 4L NAT On Throttle Body 13 Throttle Position Sensor 2 7L BK On Throttle Body 15 Traction Control S...

Page 1019: ...on Center 5 S103 Internal to the Power Distribution Center 5 S104 Internal to the Power Distribution Center 5 S105 Internal to the Power Distribution Center 5 S106 Internal to the Power Distribution Center 5 S108 Internal to the Power Distribution Center 5 S109 Internal to the Power Distribution Center 5 S110 Left Side Engine Compartment 5 S111 Left Front Engine Compartment 4 S112 ATX Internal to ...

Page 1020: ...out for Data Link Connector N S S207 Left Side of Instrument Panel 21 22 S208 Export Left Side of Instrument Panel 21 22 S209 Left Center of Instrument Panel 21 22 S210 Left Center of Instrument Panel 21 22 S211 Left Center of Instrument Panel 21 22 S212 Left Center of Instrument Panel 21 22 S214 Right Center of Instrument Panel 21 22 S215 Left Side of Instrument Panel 21 S216 Under Horn Pad 30 S2...

Page 1021: ...9 Near T O for Right Tail Stop Lamp N S S320 In Driver Door 50 S321 In Passenger Door 50 S324 In Rear Fog Lamp Harness N S S326 Near Fuel Pump Module N S S327 JR27 In Driver Door 50 S327 JR41 Driver Door Forward From Take out for Power Window and Power Mirror Switches N S S330 In Driver Door 50 S331 Between T O for C320 T O For License Lamp N S S332 Near Left License Lamp N S S333 JR27 Between Lef...

Page 1022: ...Fig 1 RIGHT HEADLAMP CONNECTORS Fig 2 RIGHT FRONT LIGHTING CONNECTORS JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 13 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1023: ...Fig 3 RIGHT SIDE ENGINE COMPARTMENT CONNECTORS Fig 4 LEFT FRONT ENGINE COMPARTMENT CONNECTORS 8W 91 14 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1024: ...Fig 5 LEFT SIDE ENGINE COMPARTMENT CONNECTORS JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 15 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1025: ...Fig 6 LEFT REAR ENGINE COMPARTMENT CONNECTORS Fig 7 LEFT FOG LAMP 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1026: ...Fig 8 POWER DISTRIBUTION CENTER Fig 9 BATTERY CABLE CONNECTORS JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 17 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1027: ...Fig 10 AUTOMATIC TRANSMISSION CONNECTORS 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1028: ...Fig 11 MANUAL TRANSMISSION CONNECTORS JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 19 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1029: ...Fig 12 TRANSMISSION INLINE CONNECTORS 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1030: ...Fig 13 ENGINE FRONT CONNECTORS 2 0L 2 4L JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 21 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1031: ...Fig 14 FUEL INJECTOR CONNECTORS 2 0L 2 4L 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1032: ...Fig 15 ENGINE CONNECTORS 2 7L JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 23 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1033: ...Fig 16 GENERATOR AND A C CONNECTORS 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1034: ...Fig 17 INLET AIR TEMPERATURE SENSOR 2 7L Fig 18 REAR ENGINE CONN 2 0L 2 4L JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 25 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1035: ...Fig 19 OXYGEN SENSORS 2 0L 2 4L Fig 20 OXYGEN SENSORS 2 7L 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1036: ...Fig 21 INSTRUMENT PANEL HARNESS CONNECTORS JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 27 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1037: ...Fig 22 LEFT SIDE INSTRUMENT PANEL REAR VIEW 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1038: ...Fig 23 LEFT SIDE INSTRUMENT PANEL FRONT VIEW JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 29 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1039: ...Fig 24 LEFT INSTRUMENT PANEL INLINES Fig 25 BRAKE LAMP SWITCH 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1040: ...Fig 26 RIGHT SIDE INSTRUMENT PANEL JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 31 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1041: ...Fig 27 CENTER INSTRUMENT PANEL REAR Fig 28 CENTER INSTRUMENT PANEL CONNECTORS 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1042: ...Fig 29 INSTRUMENT CLUSTER Fig 30 STEERING COLUMN JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 33 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1043: ...Fig 31 JUNCTION BLOCK 8W 91 34 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1044: ...Fig 32 LEFT FRONT KICK PANEL JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 35 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1045: ...Fig 33 GLOVE BOX CONNECTORS Fig 34 HVAC CONNECTORS MTC 8W 91 36 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1046: ...Fig 35 HVAC RIGHT ATC Fig 36 BLOWER MOTOR POWER MODULE JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 37 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1047: ...Fig 37 HVAC LEFT ATC Fig 38 HEADER CONNECTORS 8W 91 38 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1048: ...Fig 39 FRONT CENTER BODY CONNECTORS JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 39 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1049: ...Fig 40 CENTER BODY CONNECTORS 8W 91 40 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1050: ...Fig 41 LEFT FRONT BODY CONNECTORS JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 41 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1051: ...Fig 42 LEFT SIDE BODY CONNECTORS JR 27 8W 91 42 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1052: ...Fig 43 LEFT SIDE BODY CONNECTORS JR 41 JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 43 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1053: ...Fig 44 DRIVER POWER SEAT SWITCH Fig 45 DRIVER POWER SEAT MOTORS 8W 91 44 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1054: ...Fig 46 REAR BODY CONNECTORS JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 45 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1055: ...Fig 47 RIGHT REAR QUARTER PANEL 8W 91 46 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1056: ...Fig 48 REAR BODY LIGHTING CONNECTORS JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 47 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1057: ...Fig 49 REAR DOOR CONNECTORS 8W 91 48 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1058: ...Fig 50 PASSENGER DOOR CONNECTORS JR 27 JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 49 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1059: ...Fig 51 PASSENGER DOOR CONNECTORS JR 41 8W 91 50 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1060: ...Fig 52 ROOF CONNECTORS JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 51 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1061: ...Fig 53 TRUNK CONNECTORS JR 27 Fig 54 TRUNK CONNECTORS JR 41 8W 91 52 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1062: ...Fig 55 CENTER HIGH MOUNTED STOP LAMP Fig 56 DECKLID CONNECTORS JR 27 JR 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 53 CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1063: ...Fig 57 DECKLID CONNECTORS JR 41 8W 91 54 8W 91 CONNECTOR GROUND SPLICE LOCATION JR CONNECTOR GROUND SPLICE LOCATION Continued ...

Page 1064: ...te all of the many standard and optional factory installed electrical and electronic powertrain chassis safety comfort and convenience systems At the same time these systems were designed to provide centralized locations for conduct ing diagnosis of faulty circuits and for sourcing the additional current requirements of many aftermarket vehicle accessory and convenience items These power distribut...

Page 1065: ...me 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 including the clock The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehi cle electrical system during new vehicle transporta tion and pre delivery storage to reduce battery depletion while still allowing vehic...

Page 1066: ... numerous electrical compo nents as well as to distribute electrical current to many of the accessory systems in the vehicle It elim inates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment instrument panel and body wire harnesses The JB is positioned on a mounting bracket up and under the left instrument panel Fig 3 It is s...

Page 1067: ...rs to Junction Block 7 Install silencer 8 Install instrument cluster hood 9 Install center bezel 10 Install end cap 11 Connect battery negative cable POWER DISTRIBUTION CENTER DESCRIPTION All of the electrical current distributed throughout this vehicle is directed through the standard equip ment Power Distribution Center PDC The molded plastic PDC housing is located in the left front corner of th...

Page 1068: ...mounting bracket 3 Install the mounting nut onto the PDC 4 Route the wire harness from the PDC through the engine compartment engaging each of the har ness retainers to the mounting provisions in the vehicle body and chassis components 5 Install and tighten the fasteners that secure each of the engine compartment wire harness ground eyelets to the vehicle body and chassis components 6 Reconnect ea...

Page 1069: ......

Page 1070: ...ORQUE 20 SPECIAL TOOLS 2 0L DOHC ENGINE 21 AIR CLEANER ELEMENT REMOVAL 25 INSTALLATION 25 AIR CLEANER HOUSING REMOVAL 25 INSTALLATION 25 CYLINDER HEAD DESCRIPTION 26 DIAGNOSIS AND TESTING CYLINDER HEAD GASKET 26 REMOVAL CYLINDER HEAD 26 CLEANING 27 INSPECTION 27 INSTALLATION CYLINDER HEAD 28 CAMSHAFT OIL SEAL S REMOVAL 29 INSTALLATION 30 CAMSHAFT S DESCRIPTION 30 OPERATION 30 STANDARD PROCEDURE CA...

Page 1071: ...R MOUNT REMOVAL 54 INSTALLATION 54 LUBRICATION DESCRIPTION 55 OPERATION 55 DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE 56 OIL STANDARD PROCEDURE ENGINE OIL LEVEL CHECK 56 STANDARD PROCEDURE ENGINE OIL AND FILTER CHANGE 56 OIL FILTER REMOVAL 57 INSTALLATION 58 OIL FILTER ADAPTER REMOVAL 58 INSTALLATION 58 OIL PAN REMOVAL 58 INSTALLATION 58 OIL PRESSURE SENSOR SWITCH REMOVAL 59 INSTALLATION 5...

Page 1072: ...cu in in line four cylinder engine is a dual over head camshaft with hydraulic lash adjusters and four valves per cylinder design Fig 1 The engine does not have provisions for a free wheeling valvetrain Fig 1 2 0L DOHC Engine JR ENGINE 2 0L DOHC 9 3 ...

Page 1073: ...ssible causes and corrections of malfunctions Refer to 9 ENGINE DIAGNOSIS AND TESTING MECHANICAL Refer 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 c...

Page 1074: ...ct spark plug gap 5 Set gap Refer to 8 ELECTRICAL IGNITION CONTROL SPECIFICATIONS 6 Contamination in fuel system 6 Clean system and replace fuel filter 7 Faulty fuel pump 7 Test fuel pump and replace as needed Refer to Appropriate Diagnostic Information 8 Incorrect engine timing 8 Check for a skipped timing belt chain ENGINE STALLS OR IDLES ROUGH 1 Idle speed too low 1 Test minimum air flow Refer ...

Page 1075: ...ry 9 Faulty ignition 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 Clean spark plugs and set gap 2 Contamination in Fuel System 2 Clean fuel system and replace fuel filter 3 Burned warped or pitted valves 3 Replace valves 4 Faulty ignition coil s 4 Test and replace as necessary Refer to A...

Page 1076: ...uides 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 3 Thin or diluted o...

Page 1077: ...w 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 ...

Page 1078: ...ully open during the compression check 6 Insert compression gauge adaptor Special Tool 8116 or the equivalent into the 1 spark plug hole in cylinder head Connect the 0 500 psi Blue pressure transducer Special Tool CH7059 with cable adap tors to the DRBIII For Special Tool identification Refer to 9 ENGINE SPECIAL TOOLS 7 Crank engine until maximum pressure is reached on gauge Record this pressure a...

Page 1079: ...PCV valve nipple on the cover Attach an air hose with pressure gauge and reg ulator to the dipstick tube CAUTION Do not subject the engine assembly to more than 20 6 kpa 3 PSI of test pressure Gradually apply air pressure from 1 psi to 2 5 psi maximum while applying soapy water at the sus pected source Adjust the regulator to the suitable test pressure that provides the best bubbles which will pin...

Page 1080: ...ecting rods pistons valves etc 7 Repair engine or components as necessary to prevent this problem from re occurring CAUTION Squirt approximately one teaspoon of oil into the cylinders rotate engine to lubricate the cyl inder walls to prevent damage on restart 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 appro...

Page 1081: ... 10 minutes The usage of a locating dowel is recommended during assembly to prevent smearing material off the location Mopar Gasket Sealant in an aerosol can should be applied using a thin even coat sprayed completely over both surfaces to be joined and both sides of a gasket Then proceed with assembly Material in a can w applicator can be brushed on evenly over the sealing surfaces Material in an...

Page 1082: ...hole in cylin der block or head Be sure to remove old sealer Lightly coat inside of cup plug hole with Mopar Stud and Bearing Mount Make certain the new plug is cleaned of all oil or grease Using proper drive plug drive plug into hole so that the sharp edge of the plug is at least 0 5 mm 0 020 in inside the lead in chamfer It is not necessary to wait for curing of the sealant The cooling system ca...

Page 1083: ...TAKE MANIFOLD REMOVAL 38 Remove generator 39 Remove A C suction line at compressor Cap suction port and line 40 Remove A C compressor 41 Raise vehicle enough to allow engine dolly 6135 and cradle 6710 with posts 6848 to be installed under vehicle Fig 6 42 Loosen cradle engine mounts to allow move ment for positioning onto engine locating holes on the engine bedplate compressor and support bracket ...

Page 1084: ...ning Engine Cradle Support Post Mounts 1 SPECIAL TOOLS POST 6848 2 SPECIAL TOOLS POST 6848 WITH ADAPTERS 6909 3 SPECIAL TOOL 6135 DOLLY 4 SPECIAL TOOL 6710 CRADLE JR ENGINE 2 0L DOHC 9 15 ENGINE 2 0L DOHC Continued ...

Page 1085: ... Manual Transmission equipped vehicles Connect clutch cable Connect transmission shift cables Connect back up lamp switch connector Connect speed sensor connector 36 Automatic Transmission equipped vehicles Connect transmission shift cable Connect transmission electrical connectors C104 C105 Refer to 8 ELECTRICAL CONNECTOR GROUND LOCATIONS DESCRIPTION Connect transmission oil cooler lines using se...

Page 1086: ...c Standard Ring Gap Top Compression Ring 0 23 0 52 mm 0 009 0 020 in Wear Limit 0 8 mm 0 031 in Ring Gap 2nd Compression Ring 0 49 0 78 mm 0 019 0 031 in Wear Limit 0 8 mm 0 031 in Ring Gap Oil Control Steel Rails 0 23 0 66 mm 0 009 0 026 in Wear Limit 1 0 mm 0 039 in Ring Side Clearance Compression Rings 0 025 0 065 mm 0 0010 0 0026 in Wear Limit 0 10 mm 0 004 in Ring Side Clearance Oil Ring Pack...

Page 1087: ...HAFT BEARING BORE DIAMETER DESCRIPTION SPECIFICATION Metric Standard Journals No 1 6 26 020 26 041 mm 1 024 1 025 in CAMSHAFT DESCRIPTION SPECIFICATION Metric Standard Journal Diameter No 1 6 25 976 25 995 mm 1 022 1 023 in Bearing Clearance Diametrical 0 025 0 065 mm 0 0009 0 0025 in End Play 0 05 0 15 mm 0 002 0 006 in Lift Zero Lash Intake 8 65 mm 0 340 in Exhaust 7 95 mm 0 312 in Intake Valve ...

Page 1088: ...4 1 375 in Head Diameter Exhaust 28 32 28 52 mm 1 114 1 122 in Valve Length Overall Intake 112 76 113 32 mm 4 439 4 461 in DESCRIPTION SPECIFICATION Metric Standard Exhaust 110 89 111 69 mm 4 365 4 397 in Valve Stem Diameter Intake 5 934 5 952 mm 0 2337 0 2344 in Exhaust 5 906 5 924 mm 0 2326 0 2333 in VALVE MARGIN DESCRIPTION SPECIFICATION Metric Standard Intake 1 200 1 700 mm 0 047 0 066 Service...

Page 1089: ...O NOT run engine at 3000 rpm TORQUE DESCRIPTION N m Ft Lbs In Lbs Camshaft Sprocket Bolt 115 85 Connecting Rod Cap Bolts 27 1 4 turn 20 1 4 turn Crankshaft Main Bearing Cap Bed plate M8 Bolts 34 25 M11 Bolts 81 60 Crankshaft Damper 136 100 Cylinder Head Bolts Refer to Procedure Cylinder Head Cover Bolts 12 105 Drive Plate to Crankshaft 95 70 Engine Mount Bracket Right Bolts 61 45 Engine Mount Fron...

Page 1090: ...6827 A Crankshaft Damper Sprocket Installer 6792 Dolly 6135 Cradle 6710 Post Kit Engine Cradle 6848 Camshaft Sprocket Remover Installer C 4687 Camshaft Sprocket Remover Installer Adapter C 4687 1 Camshaft Seal Remover C 4679A JR ENGINE 2 0L DOHC 9 21 ENGINE 2 0L DOHC Continued ...

Page 1091: ...8215 A Adaptor 8436 Valve Spring Compressor MD 998772 A Valve Spring Compressor Adapter 6779 Valve Spring Compressor C 3422 D Spring Compressor Adaptor 6526 Valve Spring Tester C 647 Cylinder Bore Gage C 119 9 22 ENGINE 2 0L DOHC JR ENGINE 2 0L DOHC Continued ...

Page 1092: ...er Insert C 4685 C2 Crankshaft Seal Remover 6771 Oil Pressure Gage C 3292 Adaptor 8406 Rear Crankshaft Seal Guide and Installer 6926 1 and 6926 2 Driver Handle C 4171 Front Crankshaft Oil Seal Installer 6780 Cooling System Tester 7700 JR ENGINE 2 0L DOHC 9 23 ENGINE 2 0L DOHC Continued ...

Page 1093: ...Combustion Leak Tester C 3685 A DRB III with PEP Module OT CH6010A Pressure Transducer CH7059 Cylinder Compression Pressure Adaptor 8116 9 24 ENGINE 2 0L DOHC JR ENGINE 2 0L DOHC Continued ...

Page 1094: ...d 6 Connect fresh air makeup hose 7 Connect inlet air temperature sensor electrical connector 8 Connect negative battery cable AIR CLEANER HOUSING REMOVAL 1 Disconnect negative battery cable 2 Disconnect inlet air temperature sensor electri cal connector 3 Disconnect fresh air makeup hose from throttle body air inlet hose 4 Loosen hose clamp at throttle body air inlet hose Remove hose from throttl...

Page 1095: ...e Test Refer to 9 ENGINE DIAGNOSIS AND TESTING An engine cylinder head gasket leaking between adja cent cylinders will result in approximately a 50 70 reduction in compression pressure CYLINDER TO WATER JACKET LEAKAGE TEST WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES SURE CAP REMOVED VISUAL TEST METHOD With the engine cool remove the coolant pressure cap Start the eng...

Page 1096: ...ER HEAD COVER S REMOVAL 19 Remove camshafts and rocker arms Refer to 9 ENGINE CYLINDER HEAD CAMSHAFT S REMOVAL 20 Remove cylinder head bolts and remove cyl inder head from engine block 21 Inspect and clean cylinder head Refer to 9 ENGINE STANDARD PROCEDURE CLEANING To ensure engine gasket sealing proper surface preparation must be performed especially with the use of aluminum engine components and...

Page 1097: ...ence shown in Fig 15 Using the 4 step torque turn method tighten according to the following values First All bolts to 34 N m 25 ft lbs Second Bolts 1 6 to 68 N m 50 ft lbs Bolts 7 10 to 49 N m 35 ft lbs Third Bolts 1 6 to 68 N m 50 ft lbs Bolts 7 10 to 49 N m 35 ft lbs Tighten all bolts in the specified sequence an additional 90 1 4 Turn CAUTION Do not use a torque wrench for the Fourth step Fig 1...

Page 1098: ...ition sensor electrical connector 15 Connect EGR solenoid electrical connector If equipped 16 Install heater tube support bracket to cylinder head 17 Connect heater hose to thermostat housing 18 Install intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLA TION 19 Install throttle body air inlet hose and air cleaner housing assembly 20 Fill cooling system Refer to 7 COOLING ENGINE S...

Page 1099: ...aft 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 STANDARD PROCEDURE CAMSHAFT END PLAY 1 Oil camshaft journals and install camshaft WITHOUT cam follower assemblies Install rear cam caps and tighten screws to specified torque 2 Using a suitable tool move camshaft as far rearward...

Page 1100: ... journals for damage and binding Fig 23 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 arms 3 Measure the lobe actual wear unworn area wear zone actual wear ...

Page 1101: ...ION 9 Install timing belt and front timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLA TION CYLINDER HEAD COVER REMOVAL 1 Remove ignition coil and plug wires 2 Disconnect PCV and make up air hoses from cylinder head cover 3 Remove the cylinder head cover fasteners 4 Remove cylinder head cover from cylinder head CLEANING Clean cylinder head and cover mating su...

Page 1102: ...he two 2 bolts containing the sealing washer are located in the cen ter locations of cover Tighten bolts in sequence shown in Fig 30 Using a 3 step torque method as follows a Tighten all bolts to 4 5 N m 40 in lbs b Tighten all bolts to 9 0 N m 80 in lbs c Tighten all bolts to 12 N m 105 in lbs 5 Connect PCV and make up air hoses to cylin der head cover 6 Install ignition coil and plug wires Tight...

Page 1103: ... This procedure is for in vehicle service with camshafts installed 1 Remove cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 2 Remove rocker arm Refer to 9 ENGINE CYL INDER HEAD ROCKER ARMS REMOVAL 3 Remove hydraulic lifter Fig 31 4 Repeat removal procedure for each hydraulic lifter 5 If reusing mark each hydraulic lifter for reas sembly in original position Lifter...

Page 1104: ... be installed on the hydraulic lifter and valve stem Fig 32 3 Repeat installation procedure for each rocker arm 4 Install spark plugs 5 Install cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 6 Connect negative battery cable VALVE SPRINGS AND SEALS REMOVAL CYLINDER HEAD ON 1 Disconnect negative battery cable 2 Remove timing belt Refer to 9 ENGINE VALVE TIMING...

Page 1105: ...D 998772 A with adapter 6779 to compress valve springs only enough to install locks Fig 34 Correct alignment of tool is necessary to avoid nick ing valve stems 3 Remove air hose and install spark plugs 4 Install camshafts Refer to 9 ENGINE CYL INDER HEAD CAMSHAFT S INSTALLATION 5 Install cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 6 Install timing belt Re...

Page 1106: ...ing scoring or scratches Usually a few strokes will clean up a bore and maintain the required lim its 2 Deglazing of the cylinder walls may be done using a cylinder surfacing hone recommended tool C 3501 or equivalent equipped with 280 grit stones if the cylinder bore is straight and round 20 60 strokes depending on the bore condition will be suf ficient to provide a satisfactory surface Use a lig...

Page 1107: ...t be within service limit of 0 1 mm 0 004 in CYLINDER BORE NOTE The cylinder bores should be measured at normal room temperature 21 C 70 F The cylinder walls should be checked for out of round and taper with Tool C119 or equivalent Fig 40 Refer to 9 ENGINE SPECIFICATIONS If the cylinder walls are badly scuffed or scored the cylinder block should be replaced and new pistons and rings fitted Measure...

Page 1108: ...and timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS REMOVAL 9 Remove the timing belt tensioner and pulley bracket Refer to 9 ENGINE VALVE TIMING TIM ING BELT TENSIONER PULLEY REMOVAL 10 Remove camshaft sprockets and rear timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT COVER S REMOVAL 11 Remove crankshaft sprocket Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL ...

Page 1109: ...et ring mounting screws and discard 24 Remove the target ring from the crankshaft INSPECTION The crankshaft journals should be checked for excessive wear taper and scoring Fig 45 Limits of taper or out of round on any crankshaft journals should be held to 0 025 mm 0 001 in Journal grinding should not exceed 0 305 mm 0 012 in under the standard journal diameter DO NOT grind thrust faces of No 3 mai...

Page 1110: ...et ring mounting holes are free from oil and lock patch debris NOTE Always use NEW mounting screws whether installing original or new target ring 4 Install NEW mounting screws finger tight starting with the 1 location Fig 48 Make sure engagment occurs with the shoulder of the screw and mounting hole before starting all other screws 5 Torque all mounting screws with T30 torx bit to 13 Nm 110 in lbs...

Page 1111: ... Move crankshaft rearward to limits of travel Step 3 Then move crankshaft forward to limits of travel Step 4 Wedge an appropriate tool between the rear of the cylinder block NOT BED PLATE and the rear crankshaft counterweight This will hold the crankshaft in it s furthest forward position Step 5 Install and tighten bolts 1 10 in sequence shown in Fig 50 to 41 N m 30 ft lbs Step 6 Remove wedge tool...

Page 1112: ...tand and position on Special Tools 6135 and 6710 Engine Dolly and Cradle Install safety straps around the engine to cradle and tighten and lock them into position 33 Install the crankshaft rear oil seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR INSTALLATION 34 Install drive plate flex plate Apply Mopar Lock Seal Adhesive to bolt threads and tighten to 95 N m 70 ft lbs 35 Attach trans...

Page 1113: ... accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION CRANKSHAFT OIL SEAL REAR REMOVAL 1 Remove the transaxle Refer to 21 TRANS AXLE REMOVAL for procedure 2 Remove the flex plate Refer to 9 ENGINE ENGINE BLOCK FLEX PLATE REMOVAL Fig 52 Crankshaft Key 1 CRANKSHAFT KEY Fig 53 Front Crankshaft Oil Seal Removal 1 SPECIAL TOOL 6771 Fig 54 Front Crankshaft Oil Seal Installat...

Page 1114: ... may cause an oil leak 3 Drive the seal into the block using Special Tool 6926 2 and handle C 4171 Fig 58 until the tool bot toms out against the block Fig 59 4 Install the flex plate Refer to 9 ENGINE ENGINE BLOCK FLEX PLATE INSTALLATION 5 Install the transaxle Refer to 21 TRANS AXLE INSTALLATION PISTON CONNECTING ROD DESCRIPTION NOTE The engine DOES NOT have provisions for a free wheeling valve ...

Page 1115: ...nd economical operation REMOVAL 1 Remove the cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL 2 Remove the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN REMOVAL 3 Remove top ridge of cylinder bores with a reli able ridge reamer before removing pistons from cyl inder block Be sure to keep tops of pistons covered during this operation Mark piston with matching cylinder number Fig 62 CAUTION DO...

Page 1116: ...cting rod bolts CAUTION Care must be taken not to damage the fractured rod and cap joint surfaces as engine damage many occur 8 To protect crankshaft journal and fractured rod surfaces install Special Tool 8189 connecting rod guides onto connecting rod Fig 64 Carefully push each piston and rod assembly out of cylinder bore 9 Remove Special Tool 8189 connecting rod guides and re install bearing cap...

Page 1117: ...ore installing the NEW bolts the threads should be coated with clean engine oil 12 Install connecting rod lower bearing half into connecting rod cap Install connecting rod cap 13 Install each bolt finger tight then alternately torque each bolt to assemble the cap properly 14 Tighten the connecting rod bolts using the 2 step torque turn method Tighten according to the following values CAUTION Do no...

Page 1118: ...ations Refer to 9 ENGINE SPEC IFICATIONS 2 Check piston ring to groove side clearance Fig 68 For piston ring specifications Refer to 9 ENGINE SPECIFICATIONS REMOVAL 1 Using a suitable ring expander remove upper and intermediate piston rings Fig 69 2 Remove the upper oil ring side rail lower oil ring side rail and then oil ring expander from piston 3 Clean ring grooves of any carbon deposits INSTAL...

Page 1119: ...l No 2 piston ring and then No 1 piston ring Fig 70 4 Position piston ring end gaps as shown in Fig 72 5 Position oil ring expander gap at least 45 from the side rail gaps but not on the piston pin center or on the thrust direction Staggering ring gap is impor tant for oil control STRUCTURAL COLLAR REMOVAL 1 Raise vehicle on hoist NOTE To remove transaxle dust cover the front bending strut must be...

Page 1120: ...r to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 10 Remove crankshaft damper bolt 11 Remove damper using Special Tool 8454 Puller and Insert 6827 A Fig 75 INSTALLATION 1 Install crankshaft vibration damper using M12 1 75 x 150 mm bolt washer thrust bearing and nut from Special Tool 6792 Fig 76 2 Install crankshaft vibration damper bolt and tighten to 136 N m 100 ft lbs 3 Install accessory drive ...

Page 1121: ... Suspension and Driveshaft for driveshaft identification and related assembly length measur ing 5 Tighten right engine support assembly vertical bolts to 61 N m 45 ft lbs and tighten left engine support assembly bolts to 61 N m 45 ft lbs 6 Recheck drive shaft length LEFT MOUNT REMOVAL 1 Disconnect negative battery cable 2 Remove throttle body air inlet hose and air cleaner housing assembly 3 Remov...

Page 1122: ...ngine mount INSTALLATION 1 Position right engine mount and install frame rail to mount bolts Tighten bolts to 61 N m 45 ft lbs Fig 78 2 Install the mount to engine support bracket bolts and tighten to 61 N m 45 ft lbs Fig 78 3 Raise vehicle on a hoist 4 Install heater tube rear attaching screw 5 Install inner splash shield and lower vehicle 6 Install heater tube front attaching screw 7 Install coo...

Page 1123: ... attaching bolts 9 Remove rear mount INSTALLATION 1 Position rear mount on suspension crossmem ber and loosely install bolts 2 Position mount bracket on transaxle and install bolts Tighten to 95 N m 70 ft lbs Fig 80 3 Tighten rear mount to crossmember bolts to 61 N m 45 ft lbs Fig 80 NOTE Be sure the weight of the engine is static and in rest position 4 Install rear mount to bracket through bolt a...

Page 1124: ...s pressurized oil through a restrictor and up past a cylinder head bolt to an oil gallery running the length of the cylinder head The restrictor an integral part of the cylinder head gasket provides increased oil flow to the main oil gallery The cam shaft journals are partially slotted to allow a prede termined amount of pressurized oil to pass into the bearing cap cavities with small holes direct...

Page 1125: ...age and time intervals described in the Maintenance Schedule Refer to LUBRICATION MAINTENANCE MAINTE NANCE SCHEDULES DESCRIPTION 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 WAS...

Page 1126: ... Fig 85 avoid deforming the filter Use an appropriate oil fil ter removing tool Position filter wrench strap close the seam at the base of the filter The oil filter seam that joins the can to the base is reinforced by the base plate 1 Turn filter counterclockwise to remove Fig 85 Fig 83 Fluid Level Check 2 0 2 4L 1 COOLANT RECOVERY CONTAINER 2 COOLANT PRESSURE CAP 3 ENGINE OIL FILL 4 ENGINE OIL DI...

Page 1127: ...Remove oil filter adaptor from engine block Fig 86 Refer to 9 ENGINE LUBRICATION OIL FILTER ADAPTER REMOVAL 5 Remove structural collar Fig 87 6 Remove lateral bending brace 7 Remove transaxle dust cover 8 Remove oil pan bolts 9 Remove oil pan INSTALLATION 1 Clean oil pan and all sealing surfaces 2 Apply Mopar Silicone Rubber Adhesive Seal ant at the oil pump to engine block parting line Fig 88 3 P...

Page 1128: ...onnect negative cable from battery 2 Remove crankshaft vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL 3 Remove the front timing belt cover Refer to 9 ENGINE VALVE TIMING TIMING BELT COVER S REMOVAL 4 Remove the timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS REMOVAL 5 Remove the timing belt tensioner pulley bracket Refer to 9 ENGINE VALVE TIMING TIM I...

Page 1129: ...traightedge across the pump cover sur face Fig 94 If a 0 076 mm 0 003 in feeler gauge can be inserted between cover and straight edge cover should be replaced 3 Measure thickness and diameter of outer rotor If outer rotor thickness measures 7 64 mm 0 301 in or less Fig 95 or if the diameter is 79 95 mm 3 148 in or less replace outer rotor 4 If inner rotor measures 7 64 mm 0 301 in or less replace ...

Page 1130: ... its bore Small marks may be removed with 400 grit wet or dry sandpaper 9 The relief valve spring has a free length of approximately 60 7 mm 2 39 in it should test between 18 and 19 pounds when compressed to 40 5 mm 1 60 in Replace spring that fails to meet spec ifications Fig 92 Oil Pressure Relief Valve 1 RETAINER CAP 2 GASKET 3 OIL PUMP BODY 4 RELIEF VALVE 5 SPRING Fig 93 Oil Pump 1 OIL PUMP BO...

Page 1131: ...l surfaces are clean and free of oil and dirt 2 Apply Mopar Gasket Maker to oil pump as shown in Fig 100 Install oil ring into oil pump body discharge passage 3 Prime oil pump before installation 4 Align oil pump rotor flats with flats on crank shaft as you install the oil pump to the block NOTE Front crankshaft seal MUST be out of pump to align or damage may result 5 Torque all oil pump attaching...

Page 1132: ... lower than normal manifold vacuum Also one or more cylinders may not be functioning WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN DO NOT WEAR LOOSE CLOTHING 1 Start the engine 2 Spray a small stream of water Spray Bottle at the suspected leak area 3 If engine RPM S change the area of the ...

Page 1133: ...l new intake manifold and gasket Grad ually tighten fasteners to 28 N m 250 in lbs in sequence shown in Fig 104 2 Install coolant outlet connector Refer to 7 COOLING ENGINE COOLANT OUTLET HOUSING INSTALLATION 3 Install fuel rail 4 Install fuel rail support bracket Fig 103 5 Connect previously disconnected electrical con nectors 6 Install fastener holding fuel rail bracket to side of cylinder head ...

Page 1134: ...rtion Replace manifold as necessary INSTALLATION 1 Install new exhaust manifold gasket DO NOT APPLY SEALER 2 Position exhaust manifold in place Gradually tighten fasteners in sequence shown in Fig 106 to 23 N m 200 in lbs 3 Install exhaust manifold heat shield 4 Connect oxygen sensor electrical connector 5 Install rear engine mount and transaxle bracket 6 Install exhaust system Refer to 11 EXHAUST...

Page 1135: ...gine weight 10 Remove the right engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT REMOVAL 11 Remove front engine mount bracket Fig 108 12 Remove the front timing belt cover Fig 108 REAR COVER 1 Remove front timing belt cover CAUTION Camshaft s or crankshaft should not be rotated after timing belt is removed Damage to valve components may occur Always align timing marks before removing tim...

Page 1136: ...s to 12 N m 105 in lbs 2 Install engine front engine mount bracket Fig 108 3 Install right side engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT INSTALLATION 4 Remove jack from under engine 5 Install generator bracket and generator Recon nect generator connectors 6 Install accessory drive belt automatic tensioner 7 Install the crankshaft damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DA...

Page 1137: ...nt timing belt cover Fig 110 Refer to 9 ENGINE VALVE TIMING TIMING BELT COVER S REMOVAL CAUTION Align camshaft and crankshaft timing marks before removing the timing belt by rotating the engine with the crankshaft Fig 110 Timing Belt System 2 0L DOHC 1 FRONT TIMING BELT COVER 2 CAMSHAFT SPROCKETS 3 REAR TIMING BELT COVER 4 IDLER PULLEY 5 WATER PUMP 6 OIL PUMP 7 CRANKSHAFT SPROCKET 8 TIMING BELT 9 ...

Page 1138: ...sconnect negative battery cable 2 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS REMOVAL 3 Hold camshaft sprockets with Special Tools C 4687 and Adaptor C 4687 1 Fig 114 while removing attaching bolts Remove camshaft sprock ets CRANKSHAFT SPROCKET 1 Disconnect negative battery cable 2 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS REMOVAL F...

Page 1139: ...NGINE VALVE TIMING TIMING BELT AND SPROCKETS INSTALLATION 3 Connect negative battery cable CAMSHAFT SPROCKETS 1 Install camshaft sprockets Hold camshaft sprockets with Special Tools C 4687 and Adaptor C 4687 1 while tightening center bolts to 115 N m 85 ft lbs Fig 114 2 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS INSTALLATION 3 Connect negative battery cable INSTAL...

Page 1140: ...Repositioning the crankshaft to the TDC position must be done only during the CLOCKWISE rotation movement If TDC is missed rotate a fur ther two revolutions until TDC is achieved DO NOT rotate crankshaft counterclockwise as this will make verification of proper tensioner setting impos sible 8 Rotate the crankshaft CLOCKWISE two com plete revolutions manually for seating of the belt until the crank...

Page 1141: ...ngine To ensure proper alignment of tensioner to engine block temporarily install the engine mount bracket bolts into the upper holes of the timing belt tensioner Install timing belt tensioner lower mount ing bolts Tighten lower mounting bolts to 31 N m 23 ft lbs Remove temporarily installed engine mount bracket bolts 2 Install the timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKE...

Page 1142: ...PECTION 99 INSTALLATION CYLINDER HEAD 99 CAMSHAFT OIL SEAL S REMOVAL 100 INSTALLATION 100 CAMSHAFT S DESCRIPTION 101 OPERATION 101 STANDARD PROCEDURE MEASURING CAMSHAFT END PLAY 102 REMOVAL 102 CLEANING 102 INSPECTION 102 INSTALLATION 103 CYLINDER HEAD COVER REMOVAL 103 CLEANING 103 INSPECTION 103 INSTALLATION 104 HYDRAULIC LASH ADJUSTERS DIAGNOSIS AND TESTING HYDRAULIC LASH ADJUSTER NOISE DIAGNOS...

Page 1143: ...K 127 STANDARD PROCEDURE ENGINE OIL AND FILTER CHANGE 127 OIL FILTER DESCRIPTION 129 REMOVAL 129 INSTALLATION 129 OIL PAN REMOVAL 129 INSTALLATION 130 OIL PRESSURE SENSOR SWITCH REMOVAL 131 INSTALLATION 131 OIL PUMP REMOVAL 131 DISASSEMBLY 131 CLEANING 131 INSPECTION 133 ASSEMBLY 133 INSTALLATION 134 INTAKE MANIFOLD DIAGNOSIS AND TESTING INTAKE MANIFOLD LEAKS 135 REMOVAL 135 CLEANING 136 INSPECTIO...

Page 1144: ...g a strange noise or performance e g engine idles rough and stalls Refer to the Engine Mechanical and the Engine Performance diagnostic charts for possible causes and corrections of malfunctions Refer to 9 ENGINE DIAGNOSIS AND TESTING MECHANICAL Refer to 9 ENGINE DIAGNOSIS AND TESTING PERFORMANCE For fuel system diagnosis Refer to 14 FUEL SYSTEM FUEL DELIVERY DIAGNOSIS AND TESTING Additional tests...

Page 1145: ...ct spark plug gap 5 Set gap Refer to 8 ELECTRICAL IGNITION CONTROL SPECIFICATIONS 6 Contamination in fuel system 6 Clean system and replace fuel filter 7 Faulty fuel pump 7 Test fuel pump and replace as needed Refer to Appropriate Diagnostic Information 8 Incorrect engine timing 8 Check for a skipped timing belt chain ENGINE STALLS OR IDLES ROUGH 1 Idle speed too low 1 Test minimum air flow Refer ...

Page 1146: ...y 9 Faulty ignition 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 Clean spark plugs and set gap 2 Contamination in Fuel System 2 Clean fuel system and replace fuel filter 3 Burned warped or pitted valves 3 Replace valves 4 Faulty ignition coil s 4 Test and replace as necessary Refer to Ap...

Page 1147: ...ides 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 3 Thin or diluted oi...

Page 1148: ...w 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 ...

Page 1149: ...lly open during the compression check 6 Insert compression gauge adaptor Special Tool 8116 or the equivalent into the 1 spark plug hole in cylinder head Connect the 0 500 psi Blue pressure transducer Special Tool CH7059 with cable adap tors to the DRBIII For Special Tool identification Refer to 9 ENGINE SPECIAL TOOLS 7 Crank engine until maximum pressure is reached on gauge Record this pressure as...

Page 1150: ...PCV valve nipple on the cover Attach an air hose with pressure gauge and reg ulator to the dipstick tube CAUTION Do not subject the engine assembly to more than 20 6 kpa 3 PSI of test pressure Gradually apply air pressure from 1 psi to 2 5 psi maximum while applying soapy water at the sus pected source Adjust the regulator to the suitable test pressure that provides the best bubbles which will pin...

Page 1151: ...ecting rods pistons valves etc 7 Repair engine or components as necessary to prevent this problem from re occurring CAUTION Squirt approximately one teaspoon of oil into the cylinders rotate engine to lubricate the cyl inder walls to prevent damage on restart 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 appro...

Page 1152: ... 10 minutes The usage of a locating dowel is recommended during assembly to prevent smearing material off the location Mopar Gasket Sealant in an aerosol can should be applied using a thin even coat sprayed completely over both surfaces to be joined and both sides of a gasket Then proceed with assembly Material in a can w applicator can be brushed on evenly over the sealing surfaces Material in an...

Page 1153: ... remove old sealer Lightly coat inside of cup plug hole with Mopar Stud and Bearing Mount Make certain the new plug is cleaned of all oil or grease Using proper drive plug drive plug into hole so that the sharp edge of the plug is at least 0 5 mm 0 020 in inside the lead in chamfer It is not necessary to wait for curing of the sealant The cooling system can be refilled and the vehicle placed in se...

Page 1154: ...e engine mounts to allow move ment for positioning onto engine locating holes on the engine bedplate compressor and support bracket Install adapters 6909 to the two post at rear of engine Lower vehicle and position cradle mounts until the engine is resting on posts Tighten post mounts to cradle frame This will keep mounts from moving when removing or installing engine transmis sion assembly Secure...

Page 1155: ...ning Engine Cradle Support Post Mounts 1 SPECIAL TOOLS POST 6848 2 SPECIAL TOOLS POST 6848 WITH ADAPTERS 6909 3 SPECIAL TOOL 6135 DOLLY 4 SPECIAL TOOL 6710 CRADLE 9 86 ENGINE 2 4L DOHC JR ENGINE 2 4L DOHC Continued ...

Page 1156: ...EC TOR GROUND LOCATIONS DESCRIPTION 36 Install cooling module assembly radiator fan module and condenser Connect A C lines to con denser 37 Connect transmission oil cooler lines using service splice kit Refer to instructions provided with kit 38 Connect upper and lower radiator hoses 39 Install upper radiator crossmember 40 Install throttle body air inlet hose and air cleaner housing assembly 41 F...

Page 1157: ...007 in Diameter Non Turbo 21 99822 003 mm 0 8660 0 8662 in Turbo 21 997 22 000 mm 0 8660 0 8661 in End Play Non Turbo None DESCRIPTION SPECIFICATION Metric Standard Turbo 0 34 1 44 mm 0 0133 0 0566 in Length Non Turbo 72 75 73 25 mm 2 864 2 883 in Turbo 65 41 65 85 mm 2 575 2 592 in PISTON RINGS DESCRIPTION SPECIFICATION Metric Standard Ring Gap Top Compression Ring 0 25 0 51 mm 0 0098 0 020 in We...

Page 1158: ...metrical Clearance 0 018 0 062 mm 0 0007 0 0024 in HYDRAULIC LASH ADJUSTER DESCRIPTION SPECIFICATION Metric Standard Body Diameter 15 901 15 913 mm 0 626 0 6264 in DESCRIPTION SPECIFICATION Metric Standard Plunger Travel Minimum Dry 3 0 mm 0 118 in CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER DSECRIPTION SPECIFICATION Metric Standard Journals No 1 6 26 020 26 041 mm 1 024 1 025 in CAMSHAFT DESCRIP...

Page 1159: ... in Guide Height spring seat to guide tip 13 25 13 75 mm 0 521 0 541 in VALVES DESCRIPTION SPECIFICATION Metric Standard Face Angle Intake and Exhaust 44 5 45 Head Diameter Intake 34 67 34 93 mm 1 364 1 375 in Head Diameter Exhaust 28 32 28 52 mm 1 114 1 122 in Valve Length Overall Intake 112 76 113 32 mm 4 439 4 461 in Exhaust 110 89 111 69 mm 4 365 4 397 in Valve Stem Diameter Intake 5 934 5 952...

Page 1160: ... 421 in Outer Rotor Clearance Max 0 039 mm 0 015 in Outer Rotor Diameter Min 85 924 mm 3 383 in DESCRIPTION SPECIFICATION Metric Standard Tip Clearance Between Rotors Max 0 20 mm 0 008 in OIL PRESSURE DESCRIPTION SPECIFICATION Metric Standard At Curb Idle Speed 25 kPa 4 psi At 3000 rpm 170 550 kPa 25 80 psi CAUTION If pressure is ZERO at curb idle DO NOT run engine at 3000 rpm TORQUE DESCRIPTION N...

Page 1161: ...0 Oil Pump Cover Plate Bolts 12 105 Oil Pump Pick up Tube Bolt 23 200 Oil Pump Relief Valve Cap 41 30 Spark Plugs 18 13 Structural Collar Refer to 9 ENGINE ENGINE BLOCK STRUCTURAL COLLAR INSTALLATION Timing Belt Covers Front Covers to Rear Cover Screws 6 50 Rear Cover M6 Bolts 12 105 M8 Bolts 28 250 Timing Belt Idler Pulley 61 45 Timing Belt Tensioner Lock Bolt 25 220 Timing Belt Tensioner Assembl...

Page 1162: ...ft Seal Remover C 4679A Camshaft Seal Installer MD 998306 Crankshaft Damper Sprocket Installer 6792 Valve Spring Compressor 8215 A Adaptor 8436 Valve Spring Compressor MD998772A Valve Spring Compressor Adapter 6779 JR ENGINE 2 4L DOHC 9 93 ENGINE 2 4L DOHC Continued ...

Page 1163: ...es 8189 Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Remover Insert C 4685 C2 Front Crankshaft Oil Seal Remover 6771 Oil Pressure Gauge C 3292 Adapter 8406 Rear Crankshaft Oil Seal Installer 6926 Driver Handle C 4171 9 94 ENGINE 2 4L DOHC JR ENGINE 2 4L DOHC Continued ...

Page 1164: ...ankshaft Oil Seal Installer 6780 Cooling System Tester 7700 Combustion Leak Tester C 3685 A DRB III with PEP Module OT CH6010A Pressure Transducer CH7059 Cylinder Compression Pressure Adaptor 8116 JR ENGINE 2 4L DOHC 9 95 ENGINE 2 4L DOHC Continued ...

Page 1165: ...d 6 Connect fresh air makeup hose 7 Connect inlet air temperature sensor electrical connector 8 Connect negative battery cable AIR CLEANER HOUSING REMOVAL 1 Disconnect negative battery cable 2 Disconnect inlet air temperature sensor electri cal connector 3 Disconnect fresh air makeup hose from throttle body air inlet hose 4 Loosen hose clamp at throttle body air inlet hose Remove hose from throttl...

Page 1166: ...et leak can be located between adjacent cylinders or between a cylinder and the adjacent water jacket Possible indications of the cylinder head gasket leaking between adjacent cylinders are Loss of engine power Engine misfiring Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are Engine overheating Loss of coolant Excessive ...

Page 1167: ...support bracket from cyl inder head 8 Disconnect camshaft position sensor electrical connector 9 Disconnect EGR solenoid electrical connector 10 Disconnect connector tube from the one way check valve Fig 11 11 Raise vehicle on hoist 12 Disconnect exhaust pipe from exhaust mani fold 13 Remove accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 14 Remove crankshaft damper Re...

Page 1168: ...he threads If all the threads do not contact the scale the bolt should be replaced 1 Before installing the bolts the threads should be coated with engine oil 2 Position cylinder head gasket on block 3 Install cyllinder head on block 4 On Non PZEV equiped engines tighten the cylinder head bolts in the sequence shown in Fig 16 Using the 4 step torque turn method tighten according to the following va...

Page 1169: ...t manifold Torque fasteners to 28 N m 250 in lbs 15 Connect air injection connector tube to check valve 16 Connect camshaft position sensor electrical connector 17 Connect EGR solenoid electrical connector 18 Install heater tube support bracket to cylinder head 19 Connect heater hose to thermostat housing 20 Install intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLA TION 21 Insta...

Page 1170: ... rear of the cylinder head A hydro dynamic oil seal is used for oil control at the front of the camshaft 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 Fig 17 Camshaft Sprocket Removal Installation 1 SPECIAL TOOL 6847 Fig 18 Camshaft Oil Seal Removal With C 4679A 1 SPECIAL TOOL ...

Page 1171: ...MOVAL 5 Bearing caps are identified for location Remove the outside bearing caps first Fig 22 6 Loosen the camshaft bearing cap attaching fasteners in sequence shown Fig 23 one camshaft at a time CAUTION Camshafts are not interchangeable The intake cam number 6 thrust bearing face spacing is wider 7 Identify the camshafts before removing from the head The camshafts are not interchangeable 8 Remove...

Page 1172: ...l seals Refer to 9 ENGINE CYLINDER HEAD CAMSHAFT OIL SEAL S INSTALLATION 6 Install camshaft target magnet and camshaft position sensor 7 Install cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER INSTALLATION 8 Install timing belt rear cover and camshaft sprockets Refer to 9 ENGINE VALVE TIMING TIMING BELT COVER S INSTALLATION 9 Install timing belt Refer to 9 ENGINE VALVE TIMI...

Page 1173: ...o high or too low This may cause aerated oil to enter the adjusters and cause them to be spongy 2 Insufficient running time after rebuilding cylin der head Low speed running up to 1 hour may be required 3 During this time turn engine off and let set for a few minutes before restarting Repeat this several times after engine has reached normal operating temperature 4 Low oil pressure 5 The oil restr...

Page 1174: ...seals are integral with the spring seats The valves have three bead lock keepers to retain springs and to promote valve rotation OPERATION The four valves per cylinder two intake and two exhaust are opened by using roller rocker arms which pivot on hydraulic lash adjusters CLEANING 1 Clean all valves thoroughly and discard burned warped and cracked valves ROCKER ARMS REMOVAL NOTE This procedure is...

Page 1175: ...ter 6779 Fig 33 compress valve springs and remove valve locks 8 Remove valve spring s 9 Remove valve stem seal s by a using valve stem seal tool Fig 35 CYLINDER HEAD OFF 1 With cylinder head removed from cylinder block compress valve springs using a universal valve spring compressor 2 Remove valve retaining locks valve spring retainers valve stem seals and valve springs 3 Before removing valves re...

Page 1176: ...r to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 6 Install timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION 7 Connect negative battery cable CYLINDER HEAD OFF 1 Coat valve stems with clean engine oil and insert in cylinder head 2 Install new valve stem seals on all valves using a valve stem seal tool Fig 35 The valve stem seals should be pushed ...

Page 1177: ...ition to deglazing it will reduce taper and out of round as well as removing light scuffing scoring or scratches Usually a few strokes will clean up a bore and maintain the required lim its 2 Deglazing of the cylinder walls may be done using a cylinder surfacing hone recommended tool C 3501 or equivalent equipped with 280 grit stones if the cylinder bore is straight and round 20 60 strokes dependi...

Page 1178: ... and cylinder bores for cracks or fractures 4 Check block deck surfaces for flatness Deck surface must be within service limit of 0 1 mm 0 004 in CYLINDER BORE NOTE The cylinder bores should be measured at normal room temperature 21 C 70 F The cylinder walls should be checked for out of round and taper with Tool C119 or equivalent Fig 39 Refer to 9 ENGINE SPECIFICATIONS If the cylinder walls are b...

Page 1179: ...SHAFT REMOVAL 16 Remove crankshaft position sensor NOTE If piston connecting rod replacement is nec essary remove cylinder head Refer to 9 ENGINE CYLINDER HEAD REMOVAL 17 Using a permanent ink or paint marker iden tify cylinder number on each connecting rod cap Fig 41 CAUTION DO NOT use a number stamp or a punch to mark connecting rods Damage to connecting rod could occur 18 Remove all connecting ...

Page 1180: ... end play is controlled by a flanged bearing on the number three main bearing journal 1 Install the main bearing upper shells with the lubrication groove and oil hole in the engine block Fig 45 2 Make certain oil holes in block line up with oil hole in bearings and bearing tabs seat in the block tab slots NOTE If the crankshaft is sent out for machine work it must be balenced as an assembly with t...

Page 1181: ... Mopar Bed Plate Sealant to the bed plate as shown in Fig 47 Install the main bearing bed plate into engine block 9 Before installing the bolts the threads should be oiled with clean engine oil wipe off any excess oil 10 Install main bearing bed plate to engine block bolts 11 17 and 20 finger tight Tighten these bolts down together until the bed plate contacts the cylin der block Fig 48 11 To ensu...

Page 1182: ...N 25 Install the timing belt rear cover Refer to 9 ENGINE VALVE TIMING TIMING BELT COVER S INSTALLATION 26 Install crankshaft sprocket Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS INSTALLATION 27 Install the timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS INSTALLATION 28 Install the timing belt front covers Refer to 9 ENGINE VALVE TIMING TIMING BELT COV ER S INSTAL...

Page 1183: ... transaxle Refer to 21 TRANSMIS SION TRANSAXLE AUTOMATIC 41TE REMOVAL 2 Remove flex plate Refer to 9 ENGINE EN GINE BLOCK FLEX PLATE REMOVAL 3 Insert a 3 16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft seal Angle the screwdriver Fig 53 through the dust lip against metal case of the seal Pry out seal CAUTION Do not permit the screwdriver blade to contact cranksh...

Page 1184: ... into the block past flush this may cause an oil leak 3 Drive the seal into the block using Special Tool 6926 2 and handle C 4171 Fig 55 until the tool bot toms out against the block Fig 56 Fig 53 Rear Crankshaft Oil Seal Removal 1 REAR CRANKSHAFT SEAL 2 ENGINE BLOCK 3 ENGINE BLOCK 4 REAR CRANKSHAFT SEAL METAL CASE 5 PRY IN THIS DIRECTION 6 CRANKSHAFT 7 SCREWDRIVER 8 REAR CRANKSHAFT SEAL DUST LIP ...

Page 1185: ...ex head cap screws are used to provide alignment and durability in the assembly The pistons and connecting rods are ser viced as an assembly STANDARD PROCEDURE PISTON TO CYLINDER BORE FITTING NOTE Pistons and cylinder bores should be mea sured at normal room temperature 21 C 70 F Piston and cylinder wall must be clean and dry Piston diameter should be measured 90 degrees to piston pin Piston measu...

Page 1186: ...ed rod and cap joint surfaces as engine damage many occur 9 To protect crankshaft journal and fractured rod surfaces install Special Tool 8189 connecting rod guides onto connecting rod Fig 62 Carefully push each piston and rod assembly out of cylinder bore 10 Remove Special Tool 8189 connecting rod guides and re install bearing cap on the mating rod NOTE Piston and rods are serviced as an assem bl...

Page 1187: ...used 10 Before installing the NEW bolts the threads should be coated with clean engine oil 11 Install connecting rod lower bearing half into connecting rod cap Install connecting rod cap 12 Install each bolt finger tight then alternately torque each bolt to assemble the cap properly 13 Tighten the connecting rod bolts using the 2 step torque turn method Tighten according to the following values CA...

Page 1188: ...bolts using the 2 step torque turn method Tighten according to the following values CAUTION Do not use a torque wrench for the sec ond step 1 Tighten the bolts to 27 N m 20 ft lbs 2 Tighten the connecting rod bolts an additional 1 4 TURN 5 Using a feeler gauge check connecting rod side clearance Fig 66 Refer to clearance specifications Refer to 9 ENGINE SPECIFICATIONS PISTON RINGS STANDARD PROCEDU...

Page 1189: ... top of piston Install rings with manufacturers identification mark facing up to the top of the piston Fig 70 CAUTION Install piston rings in the following order 1 Oil ring expander 2 Upper oil ring side rail 3 Lower oil ring side rail 4 No 2 Intermediate piston ring 5 No 1 Upper piston ring Fig 68 Piston Ring Side Clearance 1 FEELER GAUGE Fig 69 Piston Rings Removing and Installing Fig 70 Piston ...

Page 1190: ...pport engine under oil pan with wooden block and floor jack 3 Remove three right side engine mount vertical bolts to front engine bracket 4 Raise vehicle on hoist 5 Remove right front wheel and belt splash shield 6 Support engine under oil pan with a wooden block and screw jack Fig 73 7 Remove front and rear engine mount through bolts 8 Slowly lower engine down with screw jack 9 Remove accessory d...

Page 1191: ...engine mount through bolt 3 Remove bolts attaching torque reaction bracket to engine and transaxle Fig 76 Remove torque reaction bracket 4 Remove bolts attaching structural collar to oil pan and transaxle Fig 76 Remove structural collar INSTALLATION CAUTION Torque procedure for structural collar and torque reaction bracket must be followed or damage could occur to oil pan collar and or bracket 1 P...

Page 1192: ...entification and related assembly length measur ing 5 Tighten right engine support assembly vertical bolts to 61 N m 45 ft lbs and tighten left engine support assembly bolts to 61 N m 45 ft lbs 6 Recheck drive shaft length LEFT MOUNT REMOVAL 1 Disconnect negative battery cable 2 Remove throttle body air inlet hose and air cleaner housing assembly 3 Remove two nuts securing speed control servo brac...

Page 1193: ... 55 ft lbs Fig 80 6 Lower vehicle Install throttle body air inlet hose and air cleaner housing assembly RIGHT MOUNT REMOVAL 1 Remove coolant recovery container Refer to 7 COOLING ENGINE COOLANT RECOVERY CON TAINER REMOVAL 2 Remove heater tube front attaching screw 3 Raise vehicle on a hoist and remove inner splash shield 4 Remove heater tube rear attaching screw 5 Remove the right engine support a...

Page 1194: ...rtical bolts Fig 80 6 Remove front mo unt INSTALLATION 1 Position front mount on lower radiator cross member 2 Loose install front mount to bracket through bolt 3 Install front mount vertical bolts Tighten bolts to 61 N m 45 ft lbs Fig 80 NOTE Be sure the weight of the engine is static and in rest position 4 Tighten rear horizontal through bolt to 75 N m 55 ft lbs Fig 78 5 Install the AIR pump 6 T...

Page 1195: ...ant The lubrication system is a full flow filtration pressure feed type The oil pump Fig 81 is mounted in the front engine cover and driven by the crank shaft Fig 81 Lubrication Components Typical 1 OIL PAN GASKET 2 O RING 3 OIL PUMP BODY 4 FILTER 5 OIL PICK UP TUBE 6 DRAIN PLUG 7 OIL PAN 9 126 ENGINE 2 4L DOHC JR ...

Page 1196: ...e connecting rod thrust collars Fig 82 DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE 1 Disconnect and remove oil pressure switch Refer to 9 ENGINE LUBRICATION OIL PRES SURE SENSOR SWITCH REMOVAL 2 Install Special Tools C 3292 Gauge with 8406 Adaptor fitting 3 Start engine and record oil pressure Refer to Specifications for correct oil pressure requirements Refer to 9 ENGINE SPECIFICATIONS CAU...

Page 1197: ... Place a suitable drain pan under crankcase drain 5 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 6 Remove oil filter Refer to 9 ENGINE LUBRI CATION OIL FILTER REMOVAL 7 Install and tighten drain plug in crankcase 8 Install new oil filter Refer to 9 ENGINE LU BRICATION OIL FILTER I...

Page 1198: ... check filter mounting surface The surface must be smooth flat and free of debris or pieces of gasket 2 Lubricate new oil filter gasket with clean engine oil 3 Screw oil filter Fig 85 on until the gasket contacts base Tighten to 11 N m 8 ft lbs OIL PAN REMOVAL 1 Disconnect negative battery cable 2 Raise vehicle on hoist and drain engine oil 3 Remove structural collar Refer to 9 ENGINE ENGINE BLOCK...

Page 1199: ...rom the chamfer on the inner edge of the oil pan Fig 89 5 Position oil pan on bedplate 6 Install oil pan attatching bolts and tighten to 12 N m 105 in lbs 7 Install air conditioning compressor bracket to oil pan bolt 8 Install structural collar Refer to 9 ENGINE ENGINE BLOCK STRUCTURAL COVER INSTAL LATION 9 Lower vehicle and fill engine crankcase with proper oil to correct level 10 Connect negativ...

Page 1200: ...ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 4 Remove Oil Pan Refer to 9 ENGINE LUBRI CATION OIL PAN REMOVAL 5 Remove Crankshaft Sprocket using Special Tool 6793 and insert C 4685 C2 Fig 91 6 Remove oil pick up tube 7 Remove oil pump Fig 92 and front crank shaft seal DISASSEMBLY 1 To remove the relief valve proceed as follows a Remove the threaded plug and gasket from the oil pump F...

Page 1201: ...Fig 92 Oil Pump and Pick up Tube 1 OIL PAN GASKET 2 O RING 3 OIL PUMP BODY 4 FILTER 5 OIL PICK UP TUBE 6 DRAIN PLUG 7 OIL PAN 9 132 ENGINE 2 4L DOHC JR OIL PUMP Continued ...

Page 1202: ...lt holes If a feeler gauge of 0 102 mm 0 004 in or more can be inserted between rotors and the straightedge replace pump assembly Fig 99 ONLY if rotors are in specifica tions 8 Inspect oil pressure relief valve plunger for scoring and free operation in its bore Small marks may be removed with 400 grit wet or dry sandpaper 9 The relief valve spring has a free length of approximately 60 7 mm 2 39 in...

Page 1203: ...il ring into oil pump body discharge passage 3 Prime oil pump before installation 4 Align oil pump rotor flats with flats on crank shaft as you install the oil pump to the block Fig 96 Measuring Fig 97 Measuring Outer Rotor Clearance in Housing 1 FEELER GAUGE 2 OUTER ROTOR Fig 98 Measuring Clearance Between Rotors 1 FEELER GAUGE 2 INNER ROTOR 3 OUTER ROTOR Fig 99 Measuring Clearance Over Rotors 1 ...

Page 1204: ...or more cylinders may not be functioning WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN DO NOT WEAR LOOSE CLOTHING 1 Start the engine 2 Spray a small stream of water Spray Bottle at the suspected leak area 3 If engine RPM S change the area of the sus pected leak has been found 4 Repair as r...

Page 1205: ...asket for surface damage or excessive swelling Replace gaskets as necessary INSTALLATION 1 Install new intake manifold and gasket Grad ually tighten fasteners to 28 N m 250 in lbs in sequence shown in Fig 104 2 Install coolant outlet connector Refer to 7 COOLING ENGINE COOLANT OUTLET HOUSING INSTALLATION 3 Install fuel rail 4 Install fuel rail support bracket Fig 103 5 Connect previously disconnec...

Page 1206: ...ig 107 7 Disconnect oxygen sensor electrical connector 8 Remove exhaust manifold retaining fasteners and remove exhaust manifold 9 Remove and discard manifold gasket CLEANING 1 Discard gasket if equipped and clean all sur faces of manifold and cylinder head Fig 104 Intake Manifold Tightening Sequence Fig 105 CONNECTOR TUBE QUICK CONNECT Fig 106 PZEV Manifold and Check Valve 1 Check Valve 2 Exhaust...

Page 1207: ...over check valve 6 Connect oxygen sensor electrical connector 7 Install rear engine mount and transaxle bracket 8 Install exhaust system Refer to 11 EXHAUST SYSTEM INSTALLATION Tighten fas teners to 28 N m 250 in lbs 9 Lower vehicle 10 Connect negative battery cable TIMING BELT COVER S REMOVAL FRONT COVER UPPER 1 Remove upper timing belt cover fasteners Fig 110 and remove cover FRONT COVER LOWER 1...

Page 1208: ...teners and remove cover from engine Fig 113 Fig 110 Front Timing Belt Covers 1 UPPER TIMING BELT COVER FASTENERS 2 ENGINE SUPPORT BRACKET FASTENERS 3 LOWER TIMING BELT COVER FASTENERS Fig 111 Timing Belt Idler Pulley 1 IDLER PULLEY 2 BOLT Fig 112 Camshaft Sprocket Removal Installation 1 SPECIAL TOOL 6847 Fig 113 Rear Timing Belt Cover Fasteners 1 M6 BOLTS 12 N m 105 in lbs 2 M8 BOLTS 28 N m 250 in...

Page 1209: ...MING BELT COVER S REMOVAL Fig 110 9 Remove coolant recovery container Refer to 7 COOLING ENGINE COOLANT RECOVERY CON TAINER REMOVAL 10 Remove right engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT REMOVAL 11 Remove engine support bracket Fig 110 CAUTION When aligning crankshaft and camshaft timing marks always rotate engine from crankshaft Camshaft should not be rotated after timing belt...

Page 1210: ...e replaced Clean all sprockets using a suitable solvent Clean all sprocket grooves of any debris Fig 114 Crankshaft and Camshaft Timing 1 CAMSHAFT TIMING MARKS 2 CRANKSHAFT TDC MARKS 3 TRAILING EDGE OF SPROCKET TOOTH Fig 115 Timing Belt Tensioner 1 LOCK BOLT 2 TOP PLATE Fig 116 Camshaft Sprocket Removal Installation 1 SPECIAL TOOL 6847 Fig 117 Crankshaft Sprocket Removal 1 SPECIAL TOOL 6793 2 SPEC...

Page 1211: ... and take up belt slack 5 Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley Rotate the top plate COUNTERCLOCK WISE The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise Watching the movement of the setting notch continue rotating the top plate counterclockwise until the setting...

Page 1212: ...15 Install right engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT INSTALLATION 16 Install coolant recovery container Refer to 7 COOLING ENGINE COOLANT RECOVERY CON TAINER INSTALLATION 17 Install accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 18 Install belt splash shield 19 Install right front wheel 20 Connect negative battery cable Fig 120 Timing Belt ...

Page 1213: ...nstall lower mounting bolt but do not tighten Fig 127 To properly align tensioner assembly in stall one of the engine bracket mounting bolts M10 5 to 7 turns into the tensioner s upper mounting loca tion Fig 127 2 Torque the tensioner s lower mounting bolt to 61 N m 45 ft lbs Remove the upper bolt used for tensioner alignment 3 Install rear timing belt cover and fasteners Torque fasteners to value...

Page 1214: ...r to 9 ENGINE VALVE TIMING TIMING BELT AND SPROCKETS INSTALLATION Fig 125 Camshaft Sprocket Removal Installation 1 SPECIAL TOOL 6847 Fig 126 Rear Timing Belt Cover Fasteners 1 M6 BOLTS 12 N m 105 in lbs 2 M8 BOLTS 28 N m 250 in lbs 3 TIMING BELT TENSIONER Fig 127 Timing Belt Tensioner Bracket Assembly 1 BOLT 2 TENSIONER ASSEMBLY 3 BOLT INSTALL FOR PROPER ALIGNMENT JR ENGINE 2 4L DOHC 9 145 TIMING ...

Page 1215: ...ain cover guide and tensioner Dis card pivot screw and adjuster screw Fig 129 5 Remove screw retaining balance shaft drive sprocket Fig 130 Remove chain and sprocket 6 Using two wide pry bars work the crankshaft sprocket back and forth until it is off the crankshaft shaft 7 Remove gear cover retaining stud double ended to also retain chain guide Remove cover and balance shaft gears Fig 131 8 Remov...

Page 1216: ...NER ADJUSTER 3 GEAR COVER 4 ADJUSTER SCREW 5 SHOULDERED PIVOT SCREW 6 CHAIN COVER CUTAWAY 7 GUIDE Fig 130 Drive Chain and Sprockets 1 NICKEL PLATED LINK AND MARK 2 GEAR SPROCKET SCREWS 3 NICKEL PLATED LINK AND DOT Fig 131 Gear Cover and Gears 1 STUD DOUBLE ENDED 2 DRIVE GEAR 3 DRIVEN GEAR 4 CARRIER DOWEL 5 GEAR S 6 GEAR COVER Fig 132 Balance Shaft Removal Installation 1 REAR COVER 2 CARRIER 3 BALA...

Page 1217: ...until number 1 cylinder is at top dead center TDC The timing marks on the chain sprocket should line up with the parting line on the left side of number one main bearing cap Fig 136 7 Place chain over crankshaft sprocket so that the plated link of the chain is over the number 1 cyl inder timing mark on the balance shaft crankshaft sprocket Fig 136 8 Place balance shaft sprocket into the timing cha...

Page 1218: ...g 5 5 6 6 lbs directly behind the adjustment slot to take up all slack Chain must have shoe radius contact as shown in Fig 137 d With the load applied tighten top tensioner bolt first then bottom pivot bolt Tighten bolts to 12 N m 105 in lbs Remove shim e Install carrier covers and tighten screws to 12 N m 105 in lbs 12 If removed install oil pump Refer to 9 ENGINE LUBRICATION OIL PUMP INSTALLA TI...

Page 1219: ...ery Cup Plug Service 176 REMOVAL 177 CLEANING 179 INSPECTION 179 INSTALLATION 179 CAMSHAFT S DESCRIPTION 180 OPERATION 180 REMOVAL 180 INSPECTION 181 INSTALLATION 181 CYLINDER HEAD COVER LEFT REMOVAL 183 INSTALLATION 183 CYLINDER HEAD COVER RIGHT REMOVAL 184 INSTALLATION 184 INTAKE EXHAUST VALVES SEATS DESCRIPTION 184 STANDARD PROCEDURE VALVE AND VALVE SEAT REFACING 184 REMOVAL 185 INSPECTION 186 ...

Page 1220: ...DURE ENGINE OIL LEVEL CHECK 214 OIL COOLER LINES DESCRIPTION 215 OPERATION 215 REMOVAL 216 INSTALLATION 218 OIL FILTER REMOVAL 219 INSTALLATION 219 OIL PAN REMOVAL 220 INSTALLATION 220 OIL PRESSURE RELIEF VALVE REMOVAL 221 INSTALLATION 221 OIL PRESSURE SWITCH DESCRIPTION 221 REMOVAL 221 INSTALLATION 221 OIL PUMP REMOVAL 221 DISASSEMBLY 222 CLEANING 222 INSPECTION 222 ASSEMBLY 224 INSTALLATION 224 ...

Page 1221: ...r a free wheel ing valve train The cylinders are numbered from front to rear with the right bank odd numbered and the left bank even numbered Fig 2 The firing order is 1 2 3 4 5 6 The engine identification number is located on the rear of the cylinder block just below the left cylinder head Fig 3 Fig 1 2 7 Liter Engine Fig 2 Cylinder Numbering and Firing Order Fig 3 Engine Identification 9 152 ENG...

Page 1222: ...ONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL 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 ...

Page 1223: ...lty 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 Contamination in Fuel System 2 Clean fuel system and replace fuel filter 3 Burned warped or pitted valves 3 Replace valves 4 Faulty coil s 4 Test and replace as necessary Refer to Appropriate Diagnosti...

Page 1224: ...rn 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 3 Thin or...

Page 1225: ...vel 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 Oil pu...

Page 1226: ...ducer Special Tool CH7059 with cable adap tors to the DRBIII For Special Tool identification Refer to 9 ENGINE SPECIAL TOOLS 7 Crank engine until maximum pressure is reached on gauge Record this pressure as 1 cylin der pressure 8 Repeat the previous step for all remaining cyl inders 9 Compression should not be less than 689 kPa 100 psi and not vary more than 25 percent from cyl inder to cylinder 1...

Page 1227: ...the suitable test pressure that provides the best bubbles which will pinpoint the leak source If the oil leak is detected and identified repair per service manual procedures If the leakage occurs at the crankshaft rear oil seal area refer to the section Inspection for Rear Seal Area Leak 6 If no leaks are detected turn off the air supply Remove the air hose all plugs and caps Install the PCV valve...

Page 1228: ...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 FORM IN PLACE GASKETS AND SEALERS There are numerous places where form in place gaskets are used on the engine Care must be taken when applying form in place gaskets to assure obtaining the desired results Do not use form in place gasket material unless sp...

Page 1229: ... gasket Then proceed with assembly Material in a can w applicator can be brushed on evenly over the sealing surfaces Material in an aerosol can should be used on engines with multi layer steel gaskets ENGINE GASKET SURFACE PREPARATION To ensure engine gasket sealing proper surface preparation must be performed especially with the use of aluminum engine components and multi layer steel cylinder hea...

Page 1230: ...mp switch connector 17 Disconnect A C lines at condenser Remove cooling module fan radiator A C condenser 18 Disconnect engine electrical harness from PCM and bulkhead connectors 19 Remove fasteners attaching ABS brake mod ule to lower radiator crossmember Support module with a suitable retaining strap 20 Disconnect brake line from retaining clips that attach to lower radiator crossmember 21 Raise...

Page 1231: ... in short length spans Inspect at each interval for potential engine or trans axle contact to vehicle components Move the cradle dolly fixture as necessary to allow for removal clearance INSTALLATION ENGINE ASSEMBLY 1 Position engine transaxle assembly under vehi cle and slowly lower vehicle in short length spans Inspect at each interval for potential engine or trans axle contact to vehicle compon...

Page 1232: ...ed with kit 32 Manual Transmission Equipped Vehicles Connect transmission shift cables Connect back up lamp switch connector 33 Install cooling module fan radiator A C con denser Connect A C lines to condenser 34 Connect upper and lower radiator hoses to radiator 35 Install upper radiator crossmember 36 Raise vehicle 37 Ensure oil pan drain plug is tight Install new oil filter 38 Install front bum...

Page 1233: ... 0 014 in Ring Gap 2nd Compression Ring 0 37 0 63 mm 0 0146 0 0249 in Ring Gap Oil Control Steel Rails 0 25 0 76 mm 0 010 0 030 in PISTON RING SIDE CLEARANCE Description Specification Metric Standard Compression Ring Top 0 035 0 083 mm 0 0013 0 0032 in Compression Ring Second 0 040 0 080 mm 0 0016 0 0031 in Oil Ring Steel Rails 0 058 0 204 mm 0 0022 0 0080 in PISTON RING WIDTH Description Specific...

Page 1234: ... Diameter 24 000 23 981 0 9449 0 9441 in Bearing Clearance 0 05 0 09 mm 0 0020 0 0035 in Bearing Clearance Max 0 13 mm 0 0051 in End Play 0 13 mm 0 0051 0 0110 in VALVE TIMING INTAKE VALVES Description Specification Opens ATDC 2 Closes ABDC 44 Duration 222 VALVE TIMING EXHAUST VALVES Description Specification Opens BBDC 36 Closes ATDC 4 Duration 220 Valve Overlap 2 CYLINDER HEAD Description Specif...

Page 1235: ...120 0 467 mm 1 8551 0 00184 in Valve Stem Tip Height Exhaust 48 672 0 467 mm 1 9162 0 00184 in VALVE SPRING Description Specification Metric Standard Free Length Intake Exhaust Approx 45 63 mm 1 7965 in Spring Force Intake Exhaust Valve Closed 249 284 N 38 0 mm 56 0 64 0 lbs 1 4961 in Spring Force Intake Valve Open 658 721 N 29 0 mm 147 9 162 1 lbs 1 1417 in Spring Force Exhaust Valve Open 614 671...

Page 1236: ... Bolts 27 1 4 Turn 20 1 4 Turn Crankshaft Main Bearing Cap Inner Cap Bolts 20 1 4 Turn 15 1 4 Turn Crankshaft Damper Bolt 170 125 Cylinder Head Bolts Refer to 9 ENGINE CYLINDER HEAD INSTALLATION Cylinder Head Cover Bolts 12 105 Exhaust Manifold Bolts 23 200 Exhaust Manifold Heat Shield Bolts 12 105 Exhaust Manifold to Catalytic Converter V Band Clamp 11 100 Engine Mount Bracket to Block Bolts 61 4...

Page 1237: ...dy Bolts 12 105 Timing Chain Cover M6 Bolts 12 105 Timing Chain Cover M10 Bolts 54 40 Timing Chain Tensioner Primary 12 105 Timing Chain Guide Access Plug 20 15 Water Pump Bolts 12 105 Cooling System Bleed Screw 12 110 Water Outlet Housing Bolts 12 105 SPECIAL TOOLS 2 7L ENGINE Dolly 6135 Cradle 6710 Post Kit Engine Cradle 6848 Disconnect Tool 6638A 9 168 ENGINE 2 7L DOHC JR ENGINE 2 7L DOHC Conti...

Page 1238: ...shaft Damper Installer Screw 8179 Crankshaft Damper Installer 6792 1 Crankshaft Seal Remover 6771 Crankshaft Seal Sprocket Installer 6780 1 Crankshaft Seal Protector 6780 2 Puller 5048 Puller Adaptor 8539 JR ENGINE 2 7L DOHC 9 169 ENGINE 2 7L DOHC Continued ...

Page 1239: ...rankshaft Real Seal Retainer Alignment Fixture 8225 Timing Chain Tensioner Resetting Gauge 8186 Dial Indicator C 3339 Valve Spring Compressor 8215 A Adaptor 8216 A Valve Spring Compressor C 3422 D Valve Spring Adapter 6526 9 170 ENGINE 2 7L DOHC JR ENGINE 2 7L DOHC Continued ...

Page 1240: ...772 A Valve Spring Adapter 6527 Indicator Bore Size C 119 Connecting Rod Installation Guides 8189 Main Bearing Remover Installer C 3059 Pressure Gauge C 3292 Adapter 8406 DRB III with PEP Module OT CH6010A JR ENGINE 2 7L DOHC 9 171 ENGINE 2 7L DOHC Continued ...

Page 1241: ...Pressure Transducer CH7059 Adaptor 8116 Cooling System Tester 7700 Combustion Leak Tester C 3685 A 9 172 ENGINE 2 7L DOHC JR ENGINE 2 7L DOHC Continued ...

Page 1242: ... body Fig 9 Remove hose from throttle body 5 Push in on locking tabs to disengage air inlet hose from air cleaner housing Pull air inlet hose out far enough to disengage air cleaner element from hose with screwdriver Fig 10 6 Remove throttle body air inlet hose 7 Remove air cleaner element from air cleaner housing Fig 7 INLET AIR TEMPERATURE SENSOR Fig 8 MAKE UP AIR HOSE Fig 9 HOSE CLAMP Fig 10 AI...

Page 1243: ...nnect inlet air temperature sensor electrical sensor Fig 7 7 Connect negative battery cable AIR CLEANER HOUSING REMOVAL 1 Disconnect negative battery cable 2 Disconnect inlet air temperature sensor electri cal connector Fig 12 3 Disconnect fresh air makeup hose from throttle body air inlet hose Fig 13 Loosen clamp at throttle body Fig 14 4 Remove hose from throttle body 5 Remove nut on bracket tha...

Page 1244: ...termine if an engine cylinder head gasket is leaking between adjacent cylinders follow the proce dures in Cylinder Compression Pressure Test Refer to 9 ENGINE DIAGNOSIS AND TESTING An engine cylinder head gasket leaking between adja cent cylinders will result in approximately a 50 70 reduction in compression pressure CYLINDER TO WATER JACKET LEAKAGE TEST WARNING USE EXTREME CAUTION WHEN THE ENGINE...

Page 1245: ...ecessary to gain access to the oil gallery cup plug requiring service NOTE SOME OF THE OIL GALLERY CUP PLUGS ARE SERVICEABLE WITH THE HEAD INSTALLED ON THE ENGINE AND THE ENGINE IN THE VEHI CLE WHILE OTHERS REQUIRE REMOVING THE AFFECTED CYLINDER HEAD FROM THE ENGINE IN EITHER CASE ONLY REPLACE THE CUP PLUG REQUIRING SERVICE 2 Clean the cup plug bore with brake cleaner and compressed air It is not ...

Page 1246: ...EAD CYLINDER HEAD COVER S REMOVAL 13 Disconnect camshaft position sensor and crankshaft position sensor connectors 14 Reposition engine wiring harness to left side of vehicle 15 Remove coolant outlet connector Fig 17 Refer to 7 COOLING ENGINE COOLANT OUT LET HOUSING REMOVAL 16 Remove timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING CHAIN COVER REMOVAL 17 Rotate crankshaft until crankshaft ...

Page 1247: ...inder head bolts in reverse sequence of installation Fig 20 starting with bolts 11 9 then bolts 8 1 Fig 19 Camshaft Valvetrain Components 1 CAMSHAFT BEARING CAP INTAKE 7 CAMSHAFT SECONDARY CHAIN TENSIONER 2 CAMSHAFT BEARING CAP EXHAUST 8 CYLINDER BLOCK 3 CAMSHAFT EXHAUST 9 CYLINDER HEAD 4 ROCKER ARM 10 CAMSHAFT INTAKE 5 HYDRAULIC LIFTER 11 CAMSHAFT SECONDARY TIMING CHAIN 6 CYLINDER HEAD Fig 18 Cam...

Page 1248: ...replaced Fig 22 Necking can be checked by holding a straight edge against the threads If all the threads do not contact the scale the bolt must be replaced Fig 22 CAUTION When cleaning cylinder head and cylin der block surfaces DO NOT use a metal scraper because the surfaces could be cut or ground Use ONLY a wooden or plastic scraper 1 Clean sealing surfaces of cylinder head and block Refer to 9 E...

Page 1249: ...o 7 COOLING ENGINE STANDARD PROCEDURE 21 Connect negative cable to remote jumper ter minal CAMSHAFT S DESCRIPTION The assembled fabricated camshafts are composed of five bearing journals machined into a hollow steel tube Fig 25 Six steel lobes a secondary timing drive sprocket and a primary sprocket thrust flange are pressed onto the camshaft tube using a unique assembly process Camshaft end play ...

Page 1250: ...ing the proper crankshaft position Failure to do so will result in valve and or piston damage 1 Assemble camshaft chain on the cams Ensure that plated links are facing toward the front Align the plated links to the dot on the camshaft sprockets Fig 29 2 If camshaft chain tensioner is already in the compressed and locked position proceed to step 4 3 When the camshaft chain tensioner is removed it i...

Page 1251: ...me position as removed 8 Tighten cam bearing cap bolts gradually in sequence shown in Fig 26 to 12 N m 105 in lbs 9 Install secondary chain tensioner bolts and tighten to 12 N m 105 in lbs 10 Remove locking pin from secondary tension ers 11 Measure camshafts end play Refer to 9 ENGINE CYLINDER HEAD CAMSHAFT S STAN DARD PROCEDURE 12 Install the primary timing chain Refer to 9 ENGINE VALVE TIMING TI...

Page 1252: ...efore attempting to remove cover Fig 30 9 Remove cylinder head cover INSTALLATION 1 Clean cylinder head cover and both sealing sur faces Inspect and replace gaskets as necessary Fig 31 2 Install cylinder head cover and hand start all fasteners Verify that all double ended studs are in the correct locations as shown in Fig 30 3 Tighten cylinder head cover attaching bolts and double ended studs to 1...

Page 1253: ... clips 9 Install upper intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION INTAKE EXHAUST VALVES SEATS DESCRIPTION The valves are made of heat resistant steel and have chrome plated stems to prevent scuffing Fig 15 The four valves per cylinder two intake and two exhaust are actuated by roller rocker arms which pivot on stationary lash adjusters All valves use three bead lock k...

Page 1254: ...ct around the top of the rub ber seal 4 Position valve springs and retainer on spring seat Fig 34 5 Compress valve spring with a valve spring compressor 6 Install retainer locks and release tool 7 If valves and or seats are refaced measure the installed height of springs B Fig 33 Measure ment is taken from top of spring seat to the bottom surface of spring retainer If height is greater than 38 75 ...

Page 1255: ... SPECIFI CATIONS 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 37 If valve tip height for intake valve is greater than 47 59 mm 1 8737 in or 49 14 mm 1 9347 in for exhaust va...

Page 1256: ...overs Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL 6 Remove crankshaft vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER REMOVAL timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL and timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 7 Remove camshafts and rocker arms Refer to 9 ENGINE CYLINDER HEAD ...

Page 1257: ... Engine Specifications to obtain specified height and allowable tensions Refer to 9 ENGINE SPECIFICATIONS Replace any springs that do not meet specifications INSTALLATION INSTALLATION IN VEHICLE 1 The valve stem seal valve spring seat should be pushed firmly and squarely over the valve guide using the valve stem as guide Do Not Force seal against top of guide When installing the valve retainer loc...

Page 1258: ... tool If valves and or seats are reground measure the installed height of springs B Fig 40 make sure measurements are taken from top of spring seat to the bottom surface of spring retainer If height is greater than 38 75 mm 1 5256 in install a 0 762 mm 0 030 in spacer in head counterbore under the valve spring seat to bring spring height back within specification VALVE STEM SEALS REMOVAL 1 Remove ...

Page 1259: ...e adjusters and cause them to be spongy 1 Check and correct engine oil level 2 Insufficient running time after rebuilding cylinder head 2 Low speed running of up to 1 hour may be required to fully evacuate trapped air from the valve train system During this time turn engine off and let set for a few minutes before restarting Repeat this several times after engine has reached normal operating tempe...

Page 1260: ...ER HEAD COVER S INSTALLATION ROCKER ARMS DESCRIPTION The rocker arms are composed of steel stampings with an integral roller bearing Fig 43 The rocker arms incorporate a 0 5 mm 0 0197 in oil hole in the lash adjuster socket for roller camshaft lobe lubrica tion Fig 43 REMOVAL 1 Remove cylinder head cover s Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S REMOVAL CAUTION Always rotate engine b...

Page 1261: ...stat STANDARD PROCEDURE CYLINDER BORE HONING 1 Used carefully the cylinder bore resizing hone recommended tool C 823 or equivalent equipped with 220 grit stones is the best tool for this honing procedure In addition to deglazing it will reduce taper and out of round as well as removing light scuffing scoring or scratches Usually a few strokes will clean up a bore and maintain the required lim its ...

Page 1262: ...a brush and 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 Fig 46 ENGINE BLOCK AND CRANKSHAFT 1 MAIN CAP BOLT VERTICAL 2 MAIN CAP 3 MAIN BEARING LOWER 4 MAIN BEARING UPPER 5 MAIN CAP BOLT H...

Page 1263: ...e may occur The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps Also assure that the hole in upper bearing half aligns with oil squirt hole in rod Install cap with the tangs on the same side as the rod CAUTION Assure that hole in upper bearing half aligns with hole in connecting rod as engine dam age may occur Limits of taper or out of round ...

Page 1264: ...g as the thrust washer location Fig 46 The select fit identification mark ings will be on the rear side of the number nine rearmost counterweight The six separate connect ing rod throws are an even firing design which reduces torque fluctuations while a vibration damper is used to control torsional vibration The crankshaft oil seals are a one piece design The front seal is retained by the timing c...

Page 1265: ...e tray Fig 53 14 Turn crankshaft until connecting rod cap to be removed is accessible NOTE Connecting rod bearing caps are not inter changeable and should be marked before removing to ensure correct reassembly CAUTION DO NOT use a number stamp or a punch to mark connecting rods Damage to connecting rod could occur 15 Mark connecting rod bearing cap positions using a permanent ink marker or scribe ...

Page 1266: ...es on the crankshaft 2 Install crankshaft Fig 55 NOTE Make sure that the coated and oil groove side of crankshaft thrust washer faces the crank shaft thrust surface 3 Push crankshaft forward Lubricate and install the front thrust washer by rolling the thrust washer Fig 55 CYLINDER BLOCK AND CRANKSHAFT 1 MAIN CAP BOLT VERTICAL 2 MAIN CAP 3 MAIN BEARING LOWER 4 MAIN BEARING UPPER 5 MAIN CAP BOLT HOR...

Page 1267: ...LVE TIMING TIMING CHAIN AND SPROCKETS INSTALLATION 15 Install timing chain Refer to 9 ENGINE VALVE TIMING TIMING CHAIN AND SPROCKETS INSTALLATION 16 Install timing chain cover Refer to 9 ENGINE VALVE TIMING TIMING CHAIN COVER INSTALLATION 17 Install cylinder head covers Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER S INSTALLATION 18 Install idler pulley bracket for accessory drive belt 19 In...

Page 1268: ... there is only one piston size MAIN BEARING SELECTION CHART 2 7L Main Bearing Bore Grade Mark 1 2 3 Crankshaft Main Journal Grade Mark 1 3 standard 2 0 003 mm 0 0002 in 1 0 006 mm 0 0003 in 2 4 0 003 mm 0 0002 3 standard 2 0 003 mm 0 0002 in 3 5 0 006 mm 0 0003 in 4 0 003 mm 0 0002 in 3 standard Fig 58 Crankshaft Main Journal Grade Marking Location Fig 59 Cylinder Block Main Bore Grade Marking Fig...

Page 1269: ...f 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 installation 1 Place Special Tool 6926 1 Guide on crankshaft ...

Page 1270: ...TE 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 NOTE Make sure that the 2 7L stamped on the special tool is facing the cylinder block flat side of tools against pan rail Fig 63 Rear Crankshaft Oil Seal Removal Typical 1 REAR CRANKSHAFT SEAL 2 ENGINE BLOCK 3 ENGINE BLOCK 4 REAR CRANKSHAFT SEAL METAL ...

Page 1271: ... piston and rod assemblies are matched to weigh the same for engine balance Piston and cylinder wall must be clean and dry Piston diameter should be measured 90 degrees to piston pin at size location shown in Fig 68 Cylin der bores should be measured halfway down the cyl inder bore and transverse to the engine crankshaft center line Refer to Engine Specifications Refer to 9 ENGINE SPECIFICATIONS P...

Page 1272: ...ATION 1 Install the piston rings Refer to 9 ENGINE ENGINE BLOCK PISTON RINGS INSTALLA TION 2 Before installing piston and connecting rod assemblies into the bore ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap 3 Before installing the ring compressor make sure the oil ring expander ends are butted and the rail gaps located as shown in Fig 78 4 Immer...

Page 1273: ...0 50 inch from bottom of cylinder bore Check gap with feeler gauge Fig 73 Refer to Refer to 9 ENGINE SPECIFICA TIONS for clearance measurements 2 Check piston ring to groove clearance Fig 74 For clearance specifications Refer to 9 ENGINE SPECIFICATIONS REMOVAL 1 Remove piston and connecting rod Refer to 9 ENGINE ENGINE BLOCK PISTON CONNECT ING ROD REMOVAL 2 Remove No 1 and No 2 piston rings Fig 76...

Page 1274: ... Lower oil ring side rail Fig 72 Piston and Connecting Rod Positioning Front View of Engine 1 MAJOR THRUST SIDE OF PISTON 2 OIL SQUIRT HOLE Fig 73 CHECK GAP ON PISTON RINGS 1 FEELER GUAGE Fig 74 Measuring Piston Ring Side Clearance 1 FEELER GAUGE JR ENGINE 2 7L DOHC 9 205 PISTON RINGS Continued ...

Page 1275: ...manufacturers I D mark dot facing up towards top of the piston Fig 76 4 Install No 2 piston ring and then No 1 piston ring Fig 77 5 Position piston ring end gaps as shown in Fig 78 6 Position oil ring expander gap at least 45 from the side rail gaps but not on the piston pin center or on the thrust direction Staggering ring gap is impor tant for oil control Fig 75 SIDE RAIL INSTALLATION 1 SIDE RAI...

Page 1276: ...125 ft lbs 3 Install accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 4 Install belt splash shield and right front wheel 5 Lower vehicle 6 Connect negative battery cable STRUCTURAL COLLAR REMOVAL 1 Raise vehicle on hoist 2 Remove bolts attaching structural collar to oil pan and transmission housing Fig 81 3 Remove collar Fig 81 Fig 79 Vibration Damper Removal 1 SPE...

Page 1277: ...shaft identification and related assembly length measur ing 5 Tighten right engine support assembly vertical bolts to 61 N m 45 ft lbs and tighten left engine support assembly bolts to 61 N m 45 ft lbs 6 Recheck drive shaft length LEFT MOUNT REMOVAL 1 Disconnect negative battery cable 2 Remove throttle body air inlet hose and air cleaner housing assembly 3 Remove two nuts securing speed control se...

Page 1278: ...sing assembly RIGHT MOUNT REMOVAL 1 Remove coolant pressure container Refer to 7 COOLING ENGINE COOLANT RECOVERY PRESS CONTAINER REMOVAL 2 Remove heater tube front attaching screw 3 Raise vehicle on a hoist and remove inner splash shield 4 Remove heater tube rear attaching screw 5 Remove the right engine support assembly ver tical fasteners from frame rail Fig 84 6 Lower vehicle Remove the load on...

Page 1279: ...hten the front mount horizontal through bolts to 75 N m 55 ft lbs Fig 85 6 Install the starter solenoid heat shield 7 Lower vehicle LUBRICATION DESCRIPTION The lubrication system is a full flow filtration pressure feed type The oil pump body is mounted to the engine block The pump inner rotor is driven by the crankshaft A structural windage tray is used to increase power by minimizing oil windage ...

Page 1280: ...gs Oil Gallery Right side of Block Oil Gallery Rear of Block and to Oil Cooler some models Left Cylinder Head Refer to 87 Oil Gallery Rear of Block Main Oil Gallery Center of Block Right Cylinder Head Refer to 88 The cylinder head gaskets have an oil restrictor to control oil flow to the cylinder heads Fig 86 Cylinder Block Oil Lubrication System 1 TO RIGHT CYLINDER HEAD 5 OIL FILTER 2 TO LEFT CYL...

Page 1281: ...the cylinder head the oil gallery feeds oil into an accumulator chamber that is located towards center of the head The accumulator chamber is closed off with a pressed in core plug that has a small orifice to act as a vent Oil then travels down at a 45 degree angle from the accumulator into two passages one for the intake and one for the exhaust side of the cylinder head The secondary camshaft cha...

Page 1282: ...of the cylinder head the oil gallery feeds oil into an accumulator chamber that is located towards center of the head The accumulator chamber is closed off with a pressed in core plug that has a small orifice to act as a vent Oil then travels down at a 45 degree angle from the accumulator into two passages one for the intake and one for the exhaust side of the cylinder head The timing primary chai...

Page 1283: ...NGINE OIL 1 Run engine until achieving normal operating temperature 2 Position the vehicle on a level surface and turn engine off 3 Hoist and support vehicle on safety stands Refer to LUBRICATION MAINTENANCE HOIST ING STANDARD PROCEDURE 4 Remove oil fill cap Fig 89 5 Place a suitable drain pan under crankcase drain 6 Remove drain plug from crankcase and allow oil to drain into pan Inspect drain pl...

Page 1284: ...he cooler The supply line is connected to a control valve that allows engine oil flow when pressure is above 138 207 kPa 20 30 psi and an internal orifice limits oil flow to a maximum of 11 3 LPM 3 GPM The engine oil exits the cooler through the oil return line and is returned to the engine oil pan Fig 91 Fig 89 Fluid Level Check 2 7L 1 COOLANT PRESSURE CONTAINER 2 COOLANT PRESSURE CAP 3 ENGINE OI...

Page 1285: ...ssembly only design To remove cooler lines unscrew the fittings from block and oil pan 2 Disconnect lines at the engine block and oil pan by unscrewing the fittings 3 Disconnect lines from support bracket and retainer Fig 92 and Fig 93 4 Remove lines Fig 93 Fig 90 ENGINE OIL COOLER 2 7L ENGINE 1 ENGINE OIL COOLER SUPPLY LINE 2 RETAINER 3 ENGINE OIL COOLER FITTINGS 4 ENGINE OIL COOLER RETURN LINE 9...

Page 1286: ...ol valve by unscrewing fitting from engine block Fig 93 Fig 91 ENGINE OIL COOLER LINES 2 7L 1 RETURN LINE FITTING 2 OIL COOLER RETURN LINE 3 SUPPORT BRACKET 4 OIL COOLER SUPPLY LINE 5 PRESSURE CONTROL VALVE 6 SUPPLY LINE FITTING JR ENGINE 2 7L DOHC 9 217 OIL COOLER LINES Continued ...

Page 1287: ...l pan Fig 93 Tighten fittings to 30 N m 260 in lbs b Position lines to fittings Push line into fit ting until it locks in place Ensure proper connec tion is made by pulling in and out on line c Connect lines to support bracket Fig 93 3 Installation of the original cooler lines a Position cooler lines to engine block and oil pan Fig 93 Tighten fittings to 30 N m 260 in lbs b Connect lines to suppor...

Page 1288: ...ilter wrench Fig 94 Dispose of oil filter following envi romental guidelines INSTALLATION 1 Wipe filter base clean then inspect gasket seal ing surface 2 Lubricate gasket of new filter with clean engine oil 3 Install oil filter Fig 94 and tighten to 16 N m 12 ft lbs of torque after gasket contacts base Use filter wrench if necessary 4 Fill crankcase with proper engine oil to correct level if drain...

Page 1289: ...nt oil leaks at oil pan to timing chain cover the following tightening sequence pro cedure must be performed 4 Install oil pan and fasteners Fig 96 using the following tightening sequence a Install oil pan bolts and nuts finger tight only just tight enough to compress the gas ket s rubber seal b Install timing chain cover to pan bolts and tighten to 12 N m 105 in lbs c Tighten oil pan bolts to 28 ...

Page 1290: ...re switch electrical con nector 4 Position an oil collecting container under switch location 5 Remove switch by unscrewing from the engine block INSTALLATION 1 Apply Mopar Thread Sealant to the switch threads 2 Install oil pressure switch 3 Connect electrical connector 4 Install oil pressure switch heat shield 5 Lower vehicle 6 Start engine and check for leaks 7 Check engine oil level and adjust a...

Page 1291: ... Clean all parts thoroughly in a suitable sol vent INSPECTION 1 Disassemble the oil pump Refer to 9 ENGINE LUBRICATION OIL PUMP DISASSEM BLY 2 Clean all oil pump components Refer to 9 ENGINE LUBRICATION OIL PUMP CLEANING 3 Inspect mating surface of the oil pump housing and cover Replace oil pump if deeply scratched or grooved minor surface scratches and polishing is normal Fig 98 Crankshaft Positi...

Page 1292: ...08 in or more replace both rotors 9 Place a straightedge across the face of the body between bolt holes If a feeler gauge of 0 077 mm 0 003 in or more can be inserted between rotors and the straightedge replace pump assembly Fig 107 ONLY if rotors are in specification 10 Inspect oil pressure relief valve plunger for scoring and free operation in its bore Small marks may be removed with 400 grit we...

Page 1293: ...carefully over crankshaft and into position 4 Install oil pump attaching bolts Tighten bolts to 28 N m 250 in lbs Fig 99 5 Install oil pick up tube with new O ring Lubri cate O ring before installation Tighten attaching bolts to 28 N m 250 in lbs Fig 99 6 Install oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN INSTALLATION 7 Install timing chain and sprockets Refer to 9 ENGINE VALVE TIMING TIMING B...

Page 1294: ...1 File or sand the remaining port back until a flat surface is obtained plane normal to nipple port axis 2 Drill out the nipple port base using a 7 16 drill bit Fig 108 3 Using a 1 4 18 NPT pipe tap cut internal threads Fig 108 Use caution to start tap in a axis same as original nipple 4 Apply Mopar Thread Sealant to threads of repair nipple s 5 Install repair nipple s Do not over torque repair ni...

Page 1295: ...vacuum port is damaged a repair procedure can be performed Refer to 9 ENGINE MANI FOLDS INTAKE MANIFOLD STANDARD PROCE DURE INSPECTION INTAKE MANIFOLD LOWER Check manifold for Damage and cracks Gasket surface damage or warpage Damaged fuel injector ports If the manifold exihibits any of these conditions replace the manifold INSTALLATION INSTALLATION INTAKE MANIFOLD UPPER 1 Clean and inspect sealin...

Page 1296: ...o the throttle body support bracket 7 Connect fuel supply hose to fuel rail Refer to 14 FUEL SYSTEM FUEL DELIVERY FUEL LINES STANDARD PROCEDURE 8 Install upper intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION EXHAUST MANIFOLD REMOVAL FRONT EXHAUST MANIFOLD 1 Disconnect negative battery cable 2 Disconnect and remove oxygen sensor 3 Raise vehicle on hoist 4 Remove exhaust cro...

Page 1297: ...xure inverted tooth type chain The primary chain drives both of the intake camshafts directly from a sprocket mounted on the crankshaft In addition the water pump is driven by the back side of the primary chain necessitating the double flexure type chain The chain is controlled by three fixed chain guides and a pivoting tensioner arm Fig 112 These guides utilize low friction and long wearing nylon...

Page 1298: ... EQUIPPED 7 CHAIN GUIDE 2 CHAIN GUIDE 8 CHAIN TENSIONER ARM 3 ACCESS PLUG 9 CHAIN TENSIONER 4 CAMSHAFT POSITION SENSOR 10 CAMSHAFT SPROCKETS 5 PRIMARY TIMING CHAIN 11 CHAIN GUIDE 6 CRANKSHAFT SPROCKET JR ENGINE 2 7L DOHC 9 229 VALVE TIMING Continued ...

Page 1299: ...ft Fig 113 5 If marks are not correctly aligned proceed to Timing Chain and Sprockets for service procedures Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL TIMING CHAIN COVER REMOVAL 1 Disconnect negative battery cable 2 Drain cooling system Refer to 7 COOLING ENGINE STANDARD PROCEDURE 3 Remove coolant pressure container Refer to 7 COOLING ENGINE COOLANT RECOVERY PRESS CONT...

Page 1300: ...eal using Special Tool 6780 2 sleeve and 6780 1 installer 5 Lower vehicle 6 Install right engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT INSTALLATION 7 Install screws attaching heater supply tube to right front frame rail area 8 Raise vehicle on hoist 9 Connect heater hose to supply tube at right front frame rail area 10 Install AC Generator belt tensioner bracket assembly 11 Install c...

Page 1301: ...osition Failure to do so will result in valve and or piston damage 6 Remove power steering pump and bracket as an assembly Do not disconnect power steering lines from pump Reposition pump and support with suit able retaining strap 7 Remove primary timing chain tensioner retainer cap and tensioner from right cylinder head Fig 117 8 Disconnect and remove camshaft position sen sor from left cylinder ...

Page 1302: ...crankshaft sprocket installation procedures Refer to 9 ENGINE ENGINE BLOCK CRANK SHAFT INSTALLATION 3 If removed install right and left side short chain guides Fig 118 Tighten attaching bolts to 28 N m 250 in lbs 4 Align crankshaft sprocket timing mark to the mark on oil pump housing Fig 120 NOTE Lubricate timing chain and guides with engine oil before installation 5 Place left side primary chain ...

Page 1303: ...l was not first purged from the tensioner use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the tensioner s check ball CAUTION Ensure the tensioner is properly reset The tensioner body must bottom against the top edge of Special Tool 8186 Failure to properly per form the resetting procedure may cause tensioner jamming 16 Install the reset chain tensioner into t...

Page 1304: ...NG MARKS 6 CHAIN TENSIONER 2 CHAIN GUIDE 7 CAMSHAFT TIMING MARK 3 CRANKSHAFT TIMING MARKS 8 INTAKE CAMSHAFT SPROCKETS 4 CRANKSHAFT SPROCKET 9 CHAIN GUIDES 5 CHAIN TENSIONER ARM 10 WATER PUMP SPROCKET JR ENGINE 2 7L DOHC 9 235 TIMING CHAIN AND SPROCKETS Continued ...

Page 1305: ...Install upper intake manifold Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD INSTALLATION NOTE After installation of a reset tensioner engine noise will occur after initial start up This noise will normally disappear within 5 10 seconds 26 Fill cooling system Refer to 7 COOLING ENGINE STANDARD PROCEDURE 27 Connect negative battery cable Fig 121 TIMING CHAIN TENSIONER OIL PURGING 1 TENSIONER 3 SPECIAL...

Page 1306: ...80 1 and 8179 Fig 124 until sprocket bottoms against crankshaft step flange Use care not to rotate crankshaft Fig 122 TIMING CHAIN TENSIONER RESETTING 1 TENSIONER 2 SPECIAL TOOL 8186 Fig 123 TIMING CHAIN TENSIONER ACTIVATING JR ENGINE 2 7L DOHC 9 237 TIMING CHAIN AND SPROCKETS Continued ...

Page 1307: ...t should read 39 05 0 50 mm 1 5374 0 020 in 3 Install primary timing chain Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS INSTALLATION Fig 124 Crankshaft Sprocket Installation 1 SPECIAL TOOL 6780 1 2 SPECIAL TOOL 8179 Fig 125 Crankshaft Sprocket Depth Measurement 9 238 ENGINE 2 7L DOHC JR TIMING CHAIN AND SPROCKETS Continued ...

Page 1308: ...VAL 12 INSTALLATION 13 RESONATOR PIPE ASSEMBLY REMOVAL 13 INSTALLATION 13 HEAT SHIELDS DESCRIPTION 14 OPERATION 14 EXHAUST SYSTEM DESCRIPTION The exhaust system on the 2 0L 2 4L engine mod els consists of a front mounted catalytic converter resonator pipe assembly muffler pipe assembly band clamps and support isolators The upstream oxygen sensor is located in the exhaust manifold The down stream o...

Page 1309: ...UFFLER SUPPORT ISOLATORS Fig 1 EXHAUST SYSTEM 1 FLEX JOINT 2 BAND CLAMP 3 RESONATOR ALIGNMENT PIN 4 RESONATOR PIPE ASSEMBLY 5 BAND CLAMP 6 MUFFLER PIPE ASSEMBLY 7 REAR MUFFLER SUPPORTS 8 MIDPIPE SUPPORT 9 OXYGEN SENSOR 10 CATALYTIC CONVERTOR 2 0L 2 4L 11 CONNECTOR PIPE 2 7L 11 2 EXHAUST SYSTEM JR EXHAUST SYSTEM Continued ...

Page 1310: ...int 7 Replace catalytic converter assembly 8 Pipe and shell noise from front exhaust pipe 8 Characteristic of single wall pipe EXCESSIVE EXHAUST NOISE 1 Leak at exhaust pipe joints 1 Tighten clamps at leaking joints 2 Burned or rusted out muffler assembly or exhaust pipe 2 Replace muffler resonator tailpipe assembly or exhaust pipe with catalytic converter assembly 3 Burned or rusted out resonator...

Page 1311: ...YSTEM NOTE Some service procedures require the removal of the entire exhaust system in order to gain better access to certain components for removal and installation The following procedure explains how to remove the entire exhaust system Refer to specific procedures if replacing individual exhaust components WARNING THE NORMAL OPERATING TEMPERA TURE OF THE EXHAUST SYSTEM IS VERY HIGH THEREFORE NE...

Page 1312: ...t ground strap to muffler 6 Lower vehicle 7 Start the engine and inspect for exhaust leaks Repair exhaust leaks as necessary 8 Check the exhaust system for contact with the body panels Make the necessary ajustments if needed ADJUSTMENTS A misaligned exhaust system is usually indicated by a vibration rattling noise or binding of exhaust system components These noises are sometimes hard to distingui...

Page 1313: ...roper operation oxygen storage can be used as an indicator of catalyst performance Refer to the appropriate Diagnostic Information for diagnosis of a catalyst related Diagnostic Trouble Code DTC The combustion reaction caused by the catalyst releases additional heat in the exhaust system caus ing temperature increases in the area of the reactor under severe operating conditions Such conditions can...

Page 1314: ...ck catalytic 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 ...

Page 1315: ...g converter to exhaust manifold 7 Remove catalytic converter 8 Remove and discard gasket INSPECTION WARNING THE NORMAL OPERATING TEMPERA TURE OF THE EXHAUST SYSTEM IS VERY HIGH THEREFORE NEVER ATTEMPT TO SERVICE ANY PART OF THE EXHAUST SYSTEM UNTIL IT IS COOLED SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CON VERTER THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHO...

Page 1316: ...e body panels Make the necessary ajustments if needed CATALYTIC CONVERTER REAR 2 7L REMOVAL 1 Disconnect negative battery cable 2 Raise vehicle on hoist 3 Remove entire exhaust system from vehicle Refer to 11 EXHAUST SYSTEM REMOVAL 4 Remove exhaust cross under pipe Refer to 11 EXHAUST SYSTEM CROSS UNDER PIPE REMOVAL 5 Disconnect upstream oxgen sensor 6 Remove nuts attaching converter to exhaust ma...

Page 1317: ...nder pipe Refer to 11 EXHAUST SYSTEM CROSS OVER PIPE INSTAL LATION 8 Install exhaust system on vehicle Refer to 11 EXHAUST SYSTEM INSTALLATION 9 Lower vehicle 10 Connect negative battery cable 11 Start the engine and inspect for exhaust leaks Repair exhaust leaks as necessary 12 Check the exhaust system for contact with the body panels Make the necessary ajustments if needed Fig 6 CATALYTIC CONVER...

Page 1318: ...NSTALLATION 1 Install new gasket to lower part of rear cata lytic converter If installing new cross under pipe transfer oxygen sensors to new pipe Fig 7 2 Loosely install cross under pipe to catalytic converters Fig 7 Snug nuts up equally using hand pressure 3 Tighten 2 nuts for cross under pipe to rear cat alytic converter to 28 N m 250 in lbs Fig 7 4 Tighten 2 nuts for cross under pipe to front ...

Page 1319: ...work from the front to rear of exhaust system when aligning and tightening exhaust system components 1 Loosely attach exhaust pipe to cross under pipe 2 Loosely install resonator pipe and muffler pipe assembly to exhaust pipe 3 Install support isolators to muffler supports 4 Align exhaust pipe and resonator muffler pipe assembly to maintain position and proper clearance with underbody parts All su...

Page 1320: ...THE TEMPERATURE OF THE CON VERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME 1 Raise vehicle on hoist and apply penetrating oil to band clamps of components being removed Fig 1 2 Remove muffler pipe assembly Refer to 11 EXHAUST SYSTEM MUFFLER REMOVAL 3 Loosen band clamp for resonator pipe assembly 4 Remove resonator pipe assembly NOTE Band clamps are spot welded to exhaust...

Page 1321: ...c converter Avoid application of rust prevention com pounds or undercoating materials to exhaust system floor pan heat shields on cars so equipped Light over spray near the edges is permitted Application of coating w ill greatly reduce the efficiency of the heat shields result ing in excessive floor pan temperatures and objectionable fumes Fig 8 Heat Shields 1 GROUND STRAP 2 MUFFLER 3 HEAT SHIELD ...

Page 1322: ...Radiator Support Crossmember Attaching Bolts 115 N m 85 ft lbs FRONT FASCIA REMOVAL REMOVAL JR 41 It is not necessary to remove the headlamp assem blies to remove the front bumper fascia 1 Release hood latch and open hood 2 Remove fasteners attaching fascia to front splash shields Fig 1 3 Hoist and support vehicle on safety stands Refer to LUBRICATION MAINTENANCE HOIST ING STANDARD PROCEDURE for p...

Page 1323: ... lamp wire connector to body wire harness if equipped 3 Place fascia on position on vehicle Fig 1 4 Install fasteners attaching fascia to front fend ers 5 Install fasteners attaching bottom of fascia to radiator closure panel and brake ducts 6 Install fasteners attaching top of fascia to upper crossmember 7 Install front wheelhouse splash shields INSTALLATION JR 27 1 Ensure that energy management ...

Page 1324: ...forcement to frame rail Use marks made previously to properly position bumper reinforcement 3 Tighten nuts to 28 N m 250 in lbs torque 4 Install rear fascia Fig 2 FRONT FASCIA JR 27 1 PUSH PIN S TO UPPER RADIATOR CROSSMEMBER 2 SCREW WASHER FRONT FASCIA TO FRONT FENDER 3 SCREW WASHER FRONT FASCIA TO SPLASH SHIELD 4 PUSH PIN S FRONT FASCIA TO LOWER CROSSMEMBER 5 FRONT FASCIA Fig 3 Front Bumper Energ...

Page 1325: ...rews attaching fascia to quarter panel at the wheelhouse opening 7 Slide fascia rearward to disengage hooks hold ing fascia to bottom of quarter panel 8 Remove fascia from vehicle INSTALLATION INSTALLATION JR 41 1 Ensure that the energy management foam is properly installed in rear fascia 2 Position fascia on vehicle 3 Slide fascia forward to engage hooks attaching fascia to bottom of quarter pane...

Page 1326: ...to left tail lamp 8 Install tail lamps Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP INSTALLATION FRAME SPECIFICATIONS FRAME DIMENSIONS Frame dimensions are listed in metric scale All dimensions are from center to center of Principal Locating Point PLP or from center to center of PLP and fastener location VEHICLE PREPARATION Position the vehicle on a level work surface Using screw or bot...

Page 1327: ...NE COMPARTMENT TOP VIEW 8 ENGINE COMPARTMENT SIDE VIEW 9 FORWARD FRAME SECTION BOTTOM VIEW 10 REAR FRAME SECTION SIDE VIEW 11 REAR FRAME SECTION BOTTOM VIEW 12 Fig 8 ENGINE COMPARTMENT TOP VIEW 13 6 FRAME BUMPERS JR FRAME Continued ...

Page 1328: ...Fig 9 ENGINE COMPARTMENT SIDE VIEW Fig 10 FORWARD FRAME SECTION BOTTOM VIEW JR FRAME BUMPERS 13 7 FRAME Continued ...

Page 1329: ...Fig 11 REAR FRAME SECTION SIDE VIEW Fig 12 REAR FRAME SECTION BOTTOM VIEW 13 8 FRAME BUMPERS JR FRAME Continued ...

Page 1330: ... allow steering gear to hang by the pressure or return hoses damage to hoses can result 10 Using mechanics wire tie steering gear to structure above 11 Raise crossmember back into position 12 Remove bolts attaching rear of crossmember to frame rail torque boxes 13 Lower front suspension crossmember away from bottom of vehicle INSTALLATION 1 Raise front suspension crossmember into posi tion on vehi...

Page 1331: ... 16 5 Remove the rear exhaust pipe hanger from the rear suspension crossmember Fig 17 Let exhaust system drop down as far as possible 6 Position a transmission jack and wooden block under the center of the rear suspension crossmember to support and lower crossmember during removal Fig 18 7 If vehicle is equipped with antilock brakes remove routing clips for wheel speed sensor cable from brackets o...

Page 1332: ...that the head of the bolt will be toward the front of the vehicle when the crossmember is installed Install the rear lateral link to crossmember bolts so that the threaded end of the bolt will be facing toward the front of the vehicle when the crossmember is installed Fig 18 Lowering And Supporting Rear Suspension Crossmember 1 WOODEN BLOCK 2 TRANSMISSION JACK 3 REAR SUSPENSION CROSSMEMBER Fig 19 ...

Page 1333: ...ion crossmember side to side and front to rear in the body of the vehicle Then tighten the 4 crossmember to frame rail attaching bolts to 95 N m 70 ft lbs torque Remove drifts from rear suspen sion crossmember 7 Align lateral links with knuckles and install the lateral arm to knuckle attaching bolts Tighten the 4 lateral arm to spindle attaching bolts to 95 N m 70 ft lbs torque 8 Remove transmissi...

Page 1334: ...ig 24 3 Remove tow hook from vehicle INSTALLATION 1 Place tow in position 2 Install bolts Fig 24 Tighten to 55 to 115 N m 55 to 85 ft lbs torque 3 Remove safety stands and lower vehicle Fig 24 FRONT TOW HOOK 1 FRONT SUB DECKING PALLET 2 TOW HOOK RECOVERY BRACKET JR FRAME BUMPERS 13 13 ...

Page 1335: ......

Page 1336: ...INSTALLATION 7 FUEL RAIL REMOVAL REMOVAL 4 CYLINDER 7 REMOVAL 2 7L 8 INSTALLATION INSTALLATION 4 CYLINDER 8 INSTALLATION 2 7L 9 FUEL TANK DESCRIPTION 9 OPERATION 9 REMOVAL 10 INSTALLATION 10 FUEL TANK FILLER TUBE REMOVAL 11 INSTALLATION 11 FUEL TANK VENT TUBE REMOVAL 11 INSTALLATION 11 QUICK CONNECT FITTING STANDARD PROCEDURE QUICK CONNECT FITTINGS 11 FUEL DELIVERY DESCRIPTION The front wheel driv...

Page 1337: ...ll it back into the fuel line from body Check the O ring and make sure that it is in place and not damaged Attach end of special test hose tool number 6539 at fuel line con nection from the body line Position opposite end of this hose tool to an approved gasoline draining sta tion Activate fuel pump and drain tank until empty When done remove the special test hose tool number 6539 from the body li...

Page 1338: ...ake Manifold 4 Cylinder 11 9 105 Fuel Rail to Cylinder Head 4 Cylinder 22 195 Fuel Rail to Intake Manifold 2 7L 11 9 105 FUEL SYSTEM PRESSURE 400 kpa 34 kpa 58 psi 5 psi SPECIAL TOOLS FUEL Pressure Gauge Assembly C 4799 B Fuel Pressure Test Adapter 6539 Spanner Wrench 6856 Fuel Line Adapter 1 4 O2S Oxygen Sensor Remover Installer C 4907 JR FUEL DELIVERY 14 3 FUEL DELIVERY Continued ...

Page 1339: ...d terminals out of connector Fig 4 4 Use screwdriver to move locking tab on level sensor and move level sensor down channel to remove Fig 5 and Fig 6 5 Slide level sensor out of installation channel in module INSTALLATION 1 Insert level sensor wires into bottom of opening in module 2 Wrap wires into groove in back of level sensor 3 While feeding wires into guide grooves slide level sensor up into ...

Page 1340: ...ered engine REMOVAL The fuel pressure regulator is part of the fuel pump module Remove the fuel pump module from the fuel tank to access the fuel pressure regulator Refer to the Fuel Pump Module removal in this sec tion 1 Spread tangs on pressure regulator retainer 2 Pry fuel pressure regulator out of housing 3 Ensure both upper and lower O rings were removed with regulator INSTALLATION The fuel p...

Page 1341: ...nd pressure regu lator The pump is driven by a 12 volt DC motor any time the fuel pump relay is energized Serviceable components on the module include Inlet strainer Fuel level sensor Pressure regulator The pump draws fuel through a strainer and pushes it through the motor to the outlet The pump contains two check valves One valve relieves inter nal fuel pump pressure and regulates maximum pump ou...

Page 1342: ...tion Refer to 14 FUEL SYSTEM FUEL DELIV ERY FUEL TANK INSTALLATION 8 Lower vehicle 9 Connect the battery cable 10 Fill fuel tank Use the DRB III scan tool to pressurize the fuel system Check for leaks FUEL RAIL REMOVAL REMOVAL 4 CYLINDER 1 Perform fuel system pressure release procedure before servicing or starting repairs Refer to Fuel System Pressure Release Procedure in this sec tion 2 Disconnec...

Page 1343: ...g them to identify the cor rect cylinder Fig 13 7 Remove electrical connectors from the fuel injectors 8 Remove mounting bolts on both sides of fuel rail 9 Lift fuel rail straight up off of cylinder head 10 Remove retaining clips from fuel injectors at fuel rail 11 Remove fuel injector from fuel rail INSTALLATION INSTALLATION 4 CYLINDER 1 Ensure injector holes are clean Replace O rings if damaged ...

Page 1344: ...the fuel injectors 7 Install intake manifold plenum Refer to the Engine section for information 8 Connect negative cable to battery FUEL TANK DESCRIPTION The fuel tank is constructed of a plastic material Its main functions are for fuel storage and for place ment of the fuel pump module The tank is made from High density Polyethylene HDPE material If equipped with ORVR Onboard Refueling Vapor Reco...

Page 1345: ...s from fuel tank straps 6 Lower tank slightly 7 Disconnect the fuel filler vent tube 8 Disconnect fuel line and vapor line 9 Disconnect the vacuum line from the LDP 10 Disconnect fuel filler tube by loosing the clamp and removing hose 11 Slide fuel pump module electrical connector lock to unlock The fuel pump module electrical connector has a retainer that locks it in place 12 Push down on connect...

Page 1346: ...ction 6 Remove vent hose from top of tank 7 Remove vent hose from fuel filler neck INSTALLATION 1 Install vent hose and tighten clamp 2 Install fuel tank refer to Fuel Tank Removal Installation in this section 3 Install vent hose to fuel filler neck and tighten clamp 4 Lower vehicle 5 Fill fuel tank and check for leaks 6 Connect negative cable to battery QUICK CONNECT FITTING STANDARD PROCEDURE QU...

Page 1347: ...eplace the complete fuel tube assembly WARNING THE FUEL SYSTEM IS UNDER A CON STANT PRESSURE EVEN WITH THE ENGINE OFF BEFORE SERVICING ANY FUEL SYSTEM HOSES FITTINGS OR LINES THE FUEL SYSTEM PRES SURE MUST BE RELEASED REFER TO THE FUEL PRESSURE RELEASE PROCEDURE IN THIS GROUP THIS MAY RESULT IN PERSONAL INJURY OR DEATH DISCONNECTION CONNECTION 1 Perform fuel pressure release procedure Refer to Fue...

Page 1348: ...rocedure 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 serviced while firmly pushing plastic retainer ring into fitting Fig 17 With plastic ring depressed pull fitting from component Th...

Page 1349: ... 27 REMOVAL 2 7L 27 INSTALLATION INSTALLATION 4 CYLINDER 27 INSTALLATION 2 7L 27 INLET AIR TEMPERATURE SENSOR DESCRIPTION 28 MAP SENSOR DESCRIPTION 28 OPERATION 28 REMOVAL REMOVAL 4 CYLINDER 29 REMOVAL 2 7L 29 INSTALLATION INSTALLATION 4 CYLINDER 29 INSTALLATION 2 7L 30 O2 SENSOR DESCRIPTION 30 OPERATION 30 REMOVAL REMOVAL DOWNSTREAM 1 2 4 CYLINDER 31 REMOVAL Downstream 1 2 2 2 2 7L 32 REMOVAL Ups...

Page 1350: ...nputs from the upstream and down stream heated oxygen sensors are not monitored 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 wid...

Page 1351: ...re IAT Throttle position The number of engine revolutions since cranking was initiated During Start up 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 Thrott...

Page 1352: ...ROTTLE MODE This is an OPEN LOOP 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...

Page 1353: ...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 1354: ...NSOR 4 CYLINDER 4 5 40 MAP SENSOR 2 7L 4 5 40 POWER STEERING RESERVOIR PLASTIC MANIFOLD 5 7 50 POWER STEERING RESERVOIR ALUMINUM MANIFOLD 11 9 105 THROTTLE CABLE BRACKET 4 CYLINDER 14 1 125 THROTTLE CABLE BRACKET 2 7L 13 6 120 THROTTLE BODY BOLTS 4 CYLINDER 13 6 120 THROTTLE BODY BOLTS 2 7L 13 6 120 LOWER SUPPORT BRACKET 2 7L 31 1 23 O2 Sensors 27 20 The composite manifolds uses special Plastic sc...

Page 1355: ...dal retainer and throttle cable from the upper end of the pedal lever Fig 2 3 Remove nuts from accelerator pedal attaching studs Remove assembly from vehicle Fig 3 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 THROTTLE CABLE RELEASE 14 20 FUEL INJEC...

Page 1356: ...he throt tle body lever in the wide open position and install the throttle cable Fig 1 CRANKSHAFT POSITION SENSOR DESCRIPTION The 4 cylinder crankshaft sensor is located on the front of the engine below the starter Fig 4 The 2 7L crankshaft sensor is located on the rear of the transmission housing above the differential housing Fig 5 The bottom of the sensor is positioned next to the drive plate F...

Page 1357: ...red to as pulse width The faster the engine is operating the smaller the pulse width on the oscilloscope For SBEC vehicles each group of timing reference notches the first notch represents 69 degrees before top dead center BTDC The second notch represents 49 degrees BTDC The third notch represents 29 degrees The last notch in each set represents 9 degrees before top dead center TDC There is also a...

Page 1358: ...t 5 Remove sensor INSTALLATION INSTALLATION 4 CYLINDER 1 Install the crankshaft sensor 2 Install crankshaft sensor bolt and tighten 3 Connect the electrical connector Fig 4 4 Lower vehicle 5 Connect the negative battery cable INSTALLATION 2 7L 1 Install crankshaft sensor Fig 9 2 Tighten bolt 3 Install air cleaner box 4 Connect the negative battery cable Fig 7 Crankshaft Position Sensor 2 7L 1 CRAN...

Page 1359: ...ctor the armature and needle move a short distance against a spring allowing fuel to flow out the orifice Because the fuel is under high pressure a fine spray is developed in the shape of a hollow cone or two streams The spraying action atomizes the fuel adding it to the air entering the combustion chamber Fuel injectors are not inter changeable between engines The PCM provides battery voltage to ...

Page 1360: ... Remove fuel injectors 12 Repeat for remaining injectors 13 Check injector O ring for damage If O ring is damaged it must be replaced Replace the injector clip if it is damaged INSTALLATION INSTALLATION 4 CYLINDER 1 Before installing an injector the rubber O ring must be lubricated with a drop of clean engine oil to aid in installation 2 Install injector clip by sliding open end into the top slot ...

Page 1361: ...ximately one second IDLE AIR CONTROL MOTOR DESCRIPTION The idle air control valve IAC attaches to the throttle body Fig 15 or Fig 16 It is a linear sole noid valve on the NGC vehicles OPERATION The PCM adjusts engine idle speed through the idle air control valve to compensate for engine load coolant temperature or barometric pressure changes The throttle body has an air bypass passage that provide...

Page 1362: ...screw 4 Remove the IAC INSTALLATION INSTALLATION 4 CYLINDER When servicing throttle body components always reassemble components with new O rings Fig 18 and seals where applicable 1 The new idle air control valve has a new O ring installed on it 2 Carefully place idle air control valve into throt tle body Fig 15 3 Install mounting screw Tighten screw to 4 5 N m 40 in lbs torque 4 Connect electrica...

Page 1363: ...tude It will also help to correct for varying weather conditions If a hurricane was coming through the pressure would be very very low or there could be a real fair weather high pressure area This is important because as air pressure changes the barometric pres sure changes Barometric pressure and altitude have a direct inverse correlation as altitude goes up baro metric pressure goes down The fir...

Page 1364: ... to as low as 0 3 volts at 26 in of Hg Barometric pressure is the pressure exerted by the atmosphere upon an object At sea level on a standard day no storm barometric pressure is 29 92 in Hg For every 100 feet of altitude barometric pres sure drops 10 in Hg If a storm goes through it can either add high pressure or decrease low pressure from what should be present for that altitude You should make...

Page 1365: ... pipe at the rear of the catalytic convertor Fig 26 OPERATION A seperate upstream and downstream grounds are used on the NGC vehicles 4 Cyl As vehicles accumulate mileage the catalytic con vertor deteriorates The deterioration results in a less efficient catalyst To monitor catalytic convertor deterioration the fuel injection system uses two Fig 23 MAP SENSOR O RING Fig 24 O2 SENSOR UPSTREAM 1 1 4...

Page 1366: ...ew O2 sensor The cus tomer may experience driveability issues if this is not performed UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas Based on this input the PCM fine tunes the air fuel ratio by adjusting injector pulse width The sensor input switches from 2 5 to 3 5 volt depending upon the oxygen content of the exhaust g...

Page 1367: ...ing the sensor the exhaust mani fold threads must be cleaned with an 18 mm X 1 5 6E tap If reusing the original sensor coat the sensor threads with an anti seize compound such as Loctite 771 64 or equivalent New sensors have compound on the threads and do not require an additional coat ing 2 Install the O2S Tighten to 28 N m 20 ft lbs torque 3 Connect the O2S wire connector 4 Lower the vehicle 5 I...

Page 1368: ...y contains an air control passage controlled by an Idle Air Control IAC motor The air control passage is used to supply air for idle conditions A throttle valve plate is used to supply air for above idle conditions Certain sensors are attached to the throttle body The accelerator pedal cable speed control cable are connected to the throttle body cam A factory adjusted set screw is used to mechani ...

Page 1369: ...move throttle cable and speed control cables from throttle arm Fig 32 6 Remove throttle cable bracket 7 Remove the throttle body support bracket from the bottom of the throttle body Fig 33 8 Remove remaining 2 throttle body bolts Fig 34 9 Remove throttle body 10 Clean mating surfaces Fig 29 THROTTLE CABLE BRACKET Fig 30 TPS AND INLET AIR TEMP SENSOR 2 7L 1 Throttle Position Sensor 2 Inlet Air Temp...

Page 1370: ...ottle cable bracket 3 Install the third throttle body bolt and the throttle body support bracket to the bottom of the throttle body Fig 33 Tighten the lower support bracket bolts to 31 1 N m 23 ft lbs torque 4 Tighten throttle body bolts to 13 6 N m 120 in lbs torque 5 Hold throttle lever in wide open throttle posi tion Install throttle cable and speed control cable Fig 32 6 Install the throttle c...

Page 1371: ...ine compartment push the pedal end fitting through the dash panel seat the grom met then push the cable dash fitting into the grom ment 2 Install the cable s throttle body end fitting into the cable mounting bracket on the engine 3 On 4 cylinder engines install throttle cable routing clip to bracket on fuel rail Fig 38 and other clip to the shocktower 4 From inside the vehicle hold up the pedal an...

Page 1372: ...he 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 TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into posi tion If it is difficult to rotate the TPS into position install the sensor with t...

Page 1373: ......

Page 1374: ...in tained if power steering assist is lost However under this condition steering effort is significantly increased WARNING WARNING POWER STEERING FLUID ENGINE COMPONENTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING DO NOT START ENGINE WITH ANY LOOSE OR DIS CONNECTED HOSES OR DRIVE BELTS DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANI FOLD OR CATALYST CAUTION CAUTION During repai...

Page 1375: ...of the fluid Shut off engine 4 Check power steering fluid level and add fluid as necessary Start engine again and let idle 5 The analyzer gauge should read below 862 kPa 125 psi If above inspect the hoses for restrictions and repair as necessary The initial pressure should be in the range of 345 552 kPa 50 80 psi The flow meter should read between 1 3 and 1 6 GPM CAUTION The following test procedu...

Page 1376: ...ting bolts at front suspension crossmember 4 Tighten control arm mounting bolts to the specified torques 5 Loose shock assembly mounting fasteners at shock tower 5 Tighten shock assembly fasteners to the specified torques 6 Power steering fluid pressure hose touching the body of the vehicle 6 Adjust hose to proper position by loosening repositioning and tightening fitting to specified torque Do no...

Page 1377: ...ar 3 Replace steering gear NOTE There is some noise in all power steering systems One of the most common is a hissing sound evident when turning the steering wheel when at a standstill or when parking and the steer ing wheel is at the end of its travel Hiss is a very high frequency noise similar to that experienced while slowly closing a water tap The noise is present in every valve and results wh...

Page 1378: ...ation in front suspension control arm ball joints 3 Lubricate ball joints if ball joints are not a lubricated for life type ball joint If ball joint is a lubricated for life ball joint replace ball joint or control arm 4 Worn upper or lower control arm ball joint 4 Replace ball joint or control arm 5 Lack of lubrication in steering gear outer tie rod ends 5 Lubricate tie rod ends if they are not a...

Page 1379: ...nment as necessary 3 Lack of lubrication in front suspension control arm ball joints 3 Lubricate ball joints if ball joints are not a lubricated for life type of ball joint If ball joint is a lubricated for life ball joint replace ball joint or control arm 4 Steering wheel rubbing 4 Adjust steering column shrouds to eliminate rubbing condition 5 Damaged mis positioned or un lubricated steering col...

Page 1380: ...wing Before disconnecting coupling place tires in the straight ahead position and center steer ing wheel Once disconnected DO NOT rotate steering wheel more than one revolution in either direction and place steering wheel in original loca tion before reconnecting coupling If this position is lost the steering column clockspring must be recentered following the procedure found within the procedure ...

Page 1381: ...ischarge Fitting 75 55 Pump Front Mounting Bolts 54 40 Pump Rear Mounting Bolts 54 40 Pump Bracket To Engine Mounting Bolts 54 40 Reservoir Mounting Screw 6 53 Tie Rod Adjustment Jam Nuts 75 55 Tie Rod Steering Knuckle Nut 55 40 SPECIAL TOOLS POWER STEERING Power Steering Analyzer 6815 Adapters Power Steering Analyzer 6893 Hose Power Steering Analyzer 6959 Puller C 3894 A Puller C 4333 Installer C...

Page 1382: ...witches and driver airbag mounted on the steering wheel are also serviced sep arately OPERATION Turning of the steering wheel is transferred through the steering column and intermediate shaft to the power steering gear pinion shaft The gear then moves the steering knuckles steering the vehi cle The steering column used on vehicles equipped with a manual transaxle has an anti theft provision With t...

Page 1383: ... THE AIRBAG MODULE WHEN CARRYING A LIVE MODULE THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF MODULE ACCIDENTLY DEPLOYS IF AIRBAG MOD ULE IS PLACED ON A BENCH OR OTHER SUR FACE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOYMENT WARNING SAFETY GOGGLES SHOULD BE WORN AT ALL TIMES WHEN WORKING ON STEERING COLUMNS CAUTION CAUTIONS CAUTION D...

Page 1384: ...w each switch which are accessible from back side of steering wheel Disconnect wire connector from each switch WARNING WHEN HANDLING AN UNDEPLOYED AIRBAG DURING SERVICING OF THE STEERING COLUMN THE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED AT NO TIME SHOULD ANY SOURCE OF ELECTRICITY BE PERMITTED NEAR THE INFLATOR ON THE BACK OF THE AIR BAG MODULE WHEN CARRYING A LIVE MODULE THE TRIM COVER SHOULD BE...

Page 1385: ...ge to the clockspring may result 17 Install puller on steering wheel as shown Fig 8 CAUTION Do not bump or hammer on steering wheel or steering column shaft when removing steering wheel from steering column 18 While holding steering wheel firmly in the straight ahead position loosen steering wheel from steering column shaft using wheel puller 19 Remove puller from steering wheel then remove steeri...

Page 1386: ...move the cable from the key lock housing 26 Under the instrument panel disconnect the intermediate shaft from the steering gear shaft To do so remove the pinch bolt from the intermediate shaft coupler Fig 13 then slide the intermediate shaft up and off the steering gear shaft 27 Remove the 2 upper steering column mount ing bracket to support bracket nuts Then remove the 2 lower steering column mou...

Page 1387: ...e sure both break away capsules are still fully seated in slots of upper steering column mounting bracket and mounting studs are centered fore and aft in plas tic capsules Then equally tighten both steering col umn mounting nuts until upper steering column mounting bracket is seated against support bracket Tighten 4 steering column bracket to support bracket nuts to 17 N m 150 in lbs 4 If a new st...

Page 1388: ...ighten until steering wheel is fully installed on shaft Tighten steering wheel retaining bolt to a torque of 54 N m 40 ft lbs 16 Turn key cylinder to unlock position 17 If equipped with remote audio control switches connect 4 way connector between clock spring and steering wheel wiring harness Fig 6 Store connection behind tab in steering wheel hous ing 18 Connect horn switch wiring connector from...

Page 1389: ... shaft fastens to the steering column s splined shaft using a roll pin It uses a pinch bolt to secure the shafts to one another at the steering gear Fig 15 OPERATION The steering column intermediate shaft connects the steering column shaft to the power steering gear s pinion shaft It s flexible joints allow the shaft to universal when rotating DIAGNOSIS AND TESTING STEERING COLUMN INTERMEDIATE SHA...

Page 1390: ...aft on steering column shaft Install roll pin into just far enough to square roll pin to hole in universal joint If roll pin is installed too far universal joint will not slid onto steering column shaft 2 Install intermediate shaft on steering shaft until correctly positioned to allow roll pin to be installed in coupler 3 Install Remover Installer Special Tool 6831 A through center of roll pin and...

Page 1391: ...nd dis connect wire connectors 4 Remove Driver Airbag attaching bolts from steering wheel 5 Lift airbag and disconnect airbag squib connec tors using finger grip Fig 18 Use care not to pull on wires Never use a metallic tool to pry on the con nector 6 Disconnect horn wire connector from airbag mounting bracket Fig 18 Remove driver airbag 7 If equipped with remote audio control switches disconnect ...

Page 1392: ...ng bolt Fig 20 to 54 N m 40 ft lbs torque 6 If equipped with remote audio control switches connect 4 way connector between clockspring and steering wheel wiring harness Fig 19 Store connec tion behind tab in steering wheel housing 7 Connect horn lead wiring connector at driver airbag bracket Fig 18 8 Route speed control wires under mechanism and through speed control switch pockets 9 Connect airba...

Page 1393: ...ing knuckle to steer the vehicle OPERATION Turning of the steering wheel is converted into lin ear travel through the meshing of the helical pinion teeth with the rack teeth Power assist steering is provided by an open center rotary type control valve which directs fluid from the pump to either side of the integral rack piston Road feel is controlled by the diameter of a torsion bar This movement ...

Page 1394: ...his position using a steering wheel holder 4 Under instrument panel disconnect intermedi ate shaft from steering gear shaft To do so remove pinch bolt from intermediate shaft coupler Fig 3 then slide intermediate shaft up and off steering gear shaft 5 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 6 Remove both front wheel and tire assemblies 7 Remove fasteners attachi...

Page 1395: ... to side location where front suspension crossmember is mounted against body This type line should be scribed at all locations where the crossmember is mounted to the vehicle on each side of the vehicle 11 Remove stabilizer bar bushing clamp to body attaching bolts Fig 5 Stabilizer bar bushing clamp to crossmember bolts do not need to be removed 12 Remove bolts attaching shock absorber clevis to l...

Page 1396: ...ear to front suspension crossmember 24 Remove power steering gear from front sus pension crossmember 25 Transfer required parts from removed gear to replacement gear if a new gear is being installed DISASSEMBLY 1 Using a screwdriver pry the sleeve out of the mounting bolt isolator Fig 11 2 Pry the mounting bolt isolator bushing from the steering gear mounting bracket ASSEMBLY 1 Lubricate replaceme...

Page 1397: ...ur mounting points Tighten bolts to approximately 2 N m 20 in lbs torque to hold front suspension crossmember in position Do not over tighten 5 Using a soft face hammer tap front suspension crossmember into position until it is aligned with previously scribed positioning marks on body of vehi cle 6 Once front suspension crossmember is correctly positioned tighten two rear crossmember mounting bolt...

Page 1398: ...rber clevis to lower control arm bushing thru bolts to a torque of 92 N m 68 ft lbs 20 Raise vehicle and remove jack stands 21 Install wheel and tire assemblies Progres sively tighten wheel nuts in a criss cross tightening sequence to 135 N m 100 ft lbs torque CAUTION Before connecting the steering column intermediate shaft coupler to the steering gear shaft position the front wheels STRAIGHT AHEA...

Page 1399: ...ION When tightening the power steering pressure switch after installation in steering gear do not exceed the torque specification shown in step 1 below Over tightening may result in strip ping the threads out of the pressure switch port on the steering gear 1 Install power steering pressure switch into power steering gear by hand until fully seated Then using a crow foot and extension tighten powe...

Page 1400: ...e attaching nut onto tie rod stud While holding tie rod stud stationary using a socket use a crowfoot on a torque wrench to tighten tie rod nut to 55 N m 40 ft lbs torque Fig 19 CAUTION During the following step do not allow the steering gear boot to become twisted 4 Tighten tie rod jam nut Fig 17 to 75 N m 55 ft lbs torque 5 Install tire and wheel assembly Progressively tighten the wheel nuts in ...

Page 1401: ...flow control lev els or pump displacements power steering pumps may be used only on specific vehicle applications Be sure that the power steering pump is only replaced with a pump that is the correct replacement for that specific application OPERATION Hydraulic pressure is provided for operation of the power steering gear by the belt driven power steering pump The power steering pump is connected ...

Page 1402: ...nents Use only Mopar ATF 4 Automatic Transmis sion Fluid MS 9602 Do not overfill 1 Wipe the reservoir fill cap clean before removal 2 Fill the pump fluid reservoir to the proper level The fluid level should be within the FILL RANGE listed on the exterior of the reservoir when the fluid is at normal ambient temperature approxi mately 21 C to 27 C 70 F to 80 F 3 Let the fluid settle in the system fo...

Page 1403: ...AS BEEN RUNNING DO NOT START ENGINE WITH ANY LOOSE OR DIS CONNECTED HOSES OR ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST 1 Remove battery cable from negative post on battery and isolate cable 2 Siphon as much power steering fluid as possi ble out of power steering fluid reservoir 3 Remove power steering fluid supply hose from power steering pump supply fitting Fig 4 4 Raise vehicle Refer...

Page 1404: ...ing pump in a vise Fig 6 This will keep shaft of power steering pump from turning while removing pulley 3 Tighten puller and remove pulley from shaft of power steering pump NOTE Replace power steering pump pulley if bent cracked or loose ASSEMBLY PUMP PULLEY CAUTION Do not hammer on power steering pump pulley or shaft to install power steering pump pul ley This will damage the pulley and the power...

Page 1405: ...oosely install the nut mounting the power steering pump to its rear mounting bracket adjust ment slot 5 Install power steering pump drive belt on power steering pump pulley Install a 1 2 in breaker bar in the square adjusting hole in the front power steering pump mounting bracket and adjust belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS ADJUSTMENTS 6 When correct drive belt tension is obtaine...

Page 1406: ...t battery cable back on negative post of battery 17 Fill power steering reservoir to correct fluid level and perform Power Steering Pump Initial Oper ation standard procedure Refer to 19 STEERING PUMP STANDARD PROCEDURE 18 Check for leaks at all hose connections and power steering pump FLUID STANDARD PROCEDURE POWER STEERING FLUID LEVEL CHECKING WARNING FLUID LEVEL SHOULD BE CHECKED WITH THE ENGIN...

Page 1407: ...id and bleed system using Power Steering Pump Initial Operation stan dard procedure Refer to 19 STEERING PUMP STANDARD PROCEDURE 12 Check for leaks HOSE RETURN REMOVAL WARNING POWER STEERING FLUID ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING DO NOT START ENGINE WITH ANY LOOSE OR DIS CONNECTED HOSES DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST NOTE...

Page 1408: ...r Isolate ground cable from vehicle by placing isolator on stud as shown Fig 10 2 Siphon power steering fluid from power steer ing fluid reservoir 3 Remove screw fastening power steering fluid reservoir to engine coolant recovery bottle Fig 12 4 Lift reservoir off guide on engine coolant recov ery bottle 5 Remove hose clamp attaching power steering fluid return hose to reservoir Fig 12 6 Remove po...

Page 1409: ...Pro gressively tighten all wheel lug nuts using a criss cross pattern to 135 N m 100 ft lbs torque 14 Lower vehicle 15 Install remote battery ground cable on ground stud located on left shock tower 16 Fill reservoir with fluid and bleed system using Power Steering Pump Initial Operation stan dard procedure Refer to 19 STEERING PUMP STANDARD PROCEDURE 17 Check for leaks RETURN HOSE TO RESERVOIR 1 I...

Page 1410: ...und cable on ground stud located on left shock tower 6 Fill power steering pump fluid reservoir to the proper level 7 Start the engine and let run for a few seconds then turn the engine off 8 Fill power steering pump fluid reservoir to the proper level and perform Power Steering Pump Ini tial Operation standard procedure Refer to 19 STEERING PUMP STANDARD PROCEDURE 9 Check for leaks RESERVOIR DESC...

Page 1411: ... sure both hose clamps are installed on hose past upset bead on pow er steering reser voir fittings 2 Slide reservoir down over guide on engine cool ant recovery bottle 3 Install power steering fluid reservoir mounting screw and tighten to 6 N m 53 in lbs 4 Install remote battery ground cable on ground stud located on left shock tower 5 Fill power steering pump fluid reservoir to the proper level ...

Page 1412: ...NDARD PROCEDURE FLUID DRAIN AND FILL 28 GEAR SHIFT CABLE REMOVAL 29 INSTALLATION 30 GEAR SHIFT MECHANISM REMOVAL 30 INSTALLATION 31 INPUT BEARING AND SLEEVE REMOVAL 31 INSTALLATION 31 INPUT SHAFT DISASSEMBLY 32 ASSEMBLY 36 OUTPUT BEARING AND RACE REMOVAL 38 INSTALLATION 38 OUTPUT SHAFT DISASSEMBLY 39 REAR BEARING OIL FEED TROUGH REMOVAL 39 INSTALLATION 40 SHIFT CROSSOVER SHAFT REMOVAL 40 INSTALLAT...

Page 1413: ...mation is also shown on a bar code label that is attached to the front of the transaxle Fig 3 NOTE Transaxles use various final drive gear ratios in different vehicle applications Therefore it is nec essary that the correct transaxle assembly number is used when ordering service parts GEAR RATIOS CAUTION All gears and shafts must not be inter changed with other transaxles they will not func tion c...

Page 1414: ...Misassembled synchronizer components also cause shifting problems Incorrectly installed synchronizer sleeves struts or springs can cause shift problems Worn damaged missassembled or leaking hydrau lic system components can also cause difficult shift ing or gear clash NOISY OPERATION Transaxle noise is most often a result of worn or damaged components Chipped broken gear or syn chronizer teeth and ...

Page 1415: ...bly at this location and be sure to align marks upon reassembly 24 Position screw jack and wood block to oil pan 25 Remove transaxle upper mount through bolt 26 Lower engine transaxle assembly 27 Remove transaxle upper mount 28 Obtain helper and transmission jack 29 Remove transaxle to engine block bolts 30 Remove transaxle from engine DISASSEMBLY The T350 transaxle internal components can be serv...

Page 1416: ... Case Halves 1 PRY TOOL 2 CASE HALVES 3 PRY SLOT Fig 8 Bellhousing Case Half Removed 1 INPUT SHAFT 2 OUTPUT SHAFT 3 DIFFERENTIAL ASSEMBLY 4 GEARTRAIN HOUSING Fig 9 Differential Removal Installation 1 INPUT SHAFT 2 OUTPUT SHAFT 3 DIFFERENTIAL ASSEMBLY 4 GEARTRAIN HOUSING Fig 10 Reverse Idler Shaft 1 CASE 2 REVERSE IDLER SHAFT 3 REVERSE IDLER SHAFT BOLT JR T350 MANUAL TRANSAXLE 21 5 T350 MANUAL TRAN...

Page 1417: ...t assembly Fig 14 Fig 11 Reverse Idler Shaft Removal 1 REVERSE IDLER SHAFT 2 SPACER Fig 12 Reverse Idler Gear and Spacer 1 SPACER 2 REVERSE IDLER GEAR Fig 13 Screws Retaining Reverse Fork Bracket 1 SCREWS 2 2 REVERSE FORK BRACKET Fig 14 Remove Reverse Fork Bracket 1 REVERSE FORK BRACKET 2 REVERSE CAM BLOCKOUT 3 SHIFT BLOCKER ASSEMBLY 21 6 T350 MANUAL TRANSAXLE JR T350 MANUAL TRANSAXLE Continued ...

Page 1418: ...way Fig 16 15 Remove transaxle end cover Fig 17 Fig 18 Fig 15 Remove Selector Shaft Spacer 1 SHIFT BLOCKER ASSEMBLY 2 SELECTOR SHAFT SPACER PLASTIC 3 SNAP RING PLIERS Fig 16 Selector Shaft 1 SHIFT ASSEMBLY 2 SELECTOR SHAFT Fig 17 Transaxle Cover Removal 1 TRANSAXLE CASE 2 END COVER Fig 18 End Cover 1 END COVER 2 CASE JR T350 MANUAL TRANSAXLE 21 7 T350 MANUAL TRANSAXLE Continued ...

Page 1419: ...y aligned to input and output shafts CAUTION The oil dams in the input and output shafts can be damaged while pressing on the shafts if the bearing fixture is not used properly 19 Install transaxle gear case into shop press Press output and input shaft assemblies out of case Fig 22 Fig 19 Snap Rings Retaining Bearings 1 SNAP RING PLIERS 2 SNAP RINGS Fig 20 Bench Fixture 1 SHIMS 2 TRANSAXLE 3 6785 ...

Page 1420: ...the reverse brake friction cone and blocking ring from the input shaft assembly Fig 25 Fig 26 Fig 23 Transaxle Case Removal 1 TRANSAXLE CASE 2 BENCH FIXTURE 3 GEARTRAIN Fig 24 Oil Feed Trough 1 OIL FEED TROUGH Fig 25 Reverse Brake Friction Cone 1 REVERSE BRAKE FRICTION CONE Fig 26 Reverse Brake Blocking Ring 1 REVERSE BRAKE BLOCKING RING JR T350 MANUAL TRANSAXLE 21 9 T350 MANUAL TRANSAXLE Continue...

Page 1421: ... distorted Replace the thrust washers if cracked chipped or worn Replace the gears if the teeth are chipped cracked or worn thin Inspect the synchronizers Replace the sleeve if worn or damaged in any way Replace the stop rings if the friction material is burned flaking off or worn Check the condition of the synchro keys and springs Replace these parts if worn cracked or distorted ASSEMBLY The T350...

Page 1422: ...assembly into bench fix ture Fig 32 4 Install reverse brake blocking ring Fig 33 Fig 30 Bench Fixture 1 BENCH FIXTURE 2 GEARTRAIN Fig 31 Shift Rail Installation 1 6785 BENCH FIXTURE 2 1 2 SHIFT FORK Fig 32 Shift Blocker Installation 1 6785 BENCH FIXTURE 2 SHIFT BLOCKER ASSEMBLY Fig 33 Reverse Brake Blocking Ring Installation 1 REVERSE BRAKE BLOCKING RING JR T350 MANUAL TRANSAXLE 21 11 T350 MANUAL ...

Page 1423: ...s Using Miller tool C 4992 1 press on input and output shaft bearings until they bottom into the case and against the shafts Fig 37 Fig 34 Reverse Brake Friction Cone Installation 1 REVERSE BRAKE FRICTION CONE Fig 35 Gear Case Half 1 TRANSAXLE CASE 2 BENCH FIXTURE 3 GEARTRAIN Fig 36 Friction Cone Lugs 1 CASE 2 FRICTION CONE LUGS 3 INPUT SHAFT Fig 37 Installing Input and Output Bearings 1 INPUT AND...

Page 1424: ...er facing down 13 Turn selector shaft into slot on blocker assem bly Fig 40 14 Push selector shaft spacer clip onto selector shaft Install shift levers 15 Install reverse idler gear and spacer as shown in Fig 41 Fig 38 Snap Rings Retaining Bearings 1 SNAP RING PLIERS 2 SNAP RINGS Fig 39 Transaxle End Cover 1 TRANSAXLE CASE 2 END COVER Fig 40 Selector Shaft 1 SHIFT ASSEMBLY 2 SELECTOR SHAFT Fig 41 ...

Page 1425: ...torque Fig 44 Fig 45 Fig 42 Reverse Idler Shaft Installation 1 REVERSE IDLER SHAFT 2 SPACER Fig 43 Reverse Idler Shaft Bolt 1 CASE 2 REVERSE IDLER SHAFT 3 REVERSE IDLER SHAFT BOLT Fig 44 Reverse Fork Bracket 1 REVERSE FORK BRACKET 2 REVERSE CAM BLOCKOUT 3 SHIFT BLOCKER ASSEMBLY Fig 45 Reverse Fork Screws 1 SCREWS 2 2 REVERSE FORK BRACKET 21 14 T350 MANUAL TRANSAXLE JR T350 MANUAL TRANSAXLE Continu...

Page 1426: ...ring turning torque readings can be obtained only with the geartrain removed from the case 1 Remove bearing cup and existing shim from clutch bellhousing case 2 Press in new bearing cup into bellhousing case or use a cup that has been ground down on the outer edge for ease of measurement 3 Press in new bearing cup into gear case side 4 Oil differential bearings with transmission fluid Install diff...

Page 1427: ...nsaxle upper mount to bracket bolts to 61 N m 45 ft lbs 7 Remove screw jack and wood block 8 Install four 4 modular clutch to driveplate bolts Align drive plate and modular clutch alignment marks placed upon disassembly Start with tight tol erance slotted hole install and torque bolts to 88 N m 65 ft lbs torque 9 Install bellhousing dust cover 10 Install structural collar 11 Install left wheel hou...

Page 1428: ...Left Mount Through Bolt 108 80 Left Mount to Transaxle 54 40 Output Bearing Race Ret Strap 11 96 Reverse Fork Bracket 11 96 Reverse Idler Shaft Bolt 29 19 Shift Cable Bracket to Transaxle 28 250 Transaxle Case Bolts 29 21 Transaxle to Engine Bolt 95 70 Vehicle Speed Sensor 7 60 Vertical Bending Strut to Engine 108 80 Vertical Bending Strut to Trans 108 80 NV T350 A 578 MANUAL TRANSAXLE FLUID FILL ...

Page 1429: ...C 3717 Slide Hammer C 3752 Universal Handle C 4171 Bearing Installer C 4628 Seal Remover C 4680 Seal Installer C 4992 Torque Tool C 4995 Adapter C 4996 Installer L 4410 21 18 T350 MANUAL TRANSAXLE JR T350 MANUAL TRANSAXLE Continued ...

Page 1430: ...et L 4518 Bearing Splitter 1130 Driver 6342 Disconnect Tool 6638A Seal Installer 6709 Bearing Remover 6768 Bench Fixture 6785 Remover 6786 Remover 6787 JR T350 MANUAL TRANSAXLE 21 19 T350 MANUAL TRANSAXLE Continued ...

Page 1431: ...y back up lamp operation DIFFERENTIAL DISASSEMBLY 1 Remove differential bearing cones ring gear and diff case side using Tool C 293 PA Adapters C 293 45 and Tool 4996 Fig 50 Fig 51 Fig 49 BACK UP LAMP SWITCH 1 CONNECTOR 2 BACK UP LAMP SWITCH Fig 50 Remove Differential Bearing Cone from Diff Case Side 1 TOOL C 293 2 TOOL C 4996 3 TOOL C 293 45 4 DIFFERENTIAL CASE Fig 51 Remove Differential Bearing ...

Page 1432: ...inion shaft retainer Fig 55 Dis card and use NEW bolts upon assembly Fig 52 Pry off Speedometer Drive Gear 1 SPEEDOMETER GEAR 2 SCREWDRIVER Fig 53 Speedometer Drive Gear 1 SPEEDOMETER GEAR Fig 54 Differential Ring Gear to Case Bolts 1 DIFFERENTIAL CASE 2 BOLT 12 3 RING GEAR 4 PINION SHAFT RETAINER 2 Fig 55 Pinion Shaft Retainer 1 PINION SHAFT RETAINER JR T350 MANUAL TRANSAXLE 21 21 DIFFERENTIAL Co...

Page 1433: ...ide gears and thrust washers Fig 58 Fig 59 Fig 60 Fig 56 Differential Ring Gear and Case 1 DIFFERENTIAL CASE 2 RING GEAR Fig 57 Pinion Shaft Removal Installation 1 PINION SHAFT 2 DIFFERENTIAL CASE 3 PINION GEAR 2 Fig 58 Pinion Gear and Washer 1 WASHER 2 PINION GEAR Fig 59 Side Gear and Washer 1 SIDE GEAR 2 WASHER 21 22 T350 MANUAL TRANSAXLE JR DIFFERENTIAL Continued ...

Page 1434: ...nts 1 DIFFERENTIAL CASE 2 SIDE GEAR WASHER 2 3 SIDE GEAR 2 4 PINION GEAR WASHER 2 5 PINION GEAR 2 6 PINION SHAFT 7 PINION SHAFT RETAINER 2 8 SPEEDOMETER DRIVE GEAR 9 RING GEAR JR T350 MANUAL TRANSAXLE 21 23 DIFFERENTIAL Continued ...

Page 1435: ...y removed install ring gear to dif ferential case Fig 64 Fig 61 Side Gear and Washer 1 SIDE GEAR 2 WASHER Fig 62 Pinion Gear and Washer 1 WASHER 2 PINION GEAR Fig 63 Pinion Shaft Removal Installation 1 PINION SHAFT 2 DIFFERENTIAL CASE 3 PINION GEAR 2 Fig 64 Differential Ring Gear and Case 1 DIFFERENTIAL CASE 2 RING GEAR 21 24 T350 MANUAL TRANSAXLE JR DIFFERENTIAL Continued ...

Page 1436: ... L 4440 press speedometer drive gear into position Fig 68 Fig 65 Pinion Shaft Retainer 1 PINION SHAFT RETAINER Fig 66 Differential Ring Gear to Case Bolts 1 DIFFERENTIAL CASE 2 BOLT 12 3 RING GEAR 4 PINION SHAFT RETAINER 2 Fig 67 Speedometer Drive Gear 1 SPEEDOMETER GEAR Fig 68 Press Gear onto Differential 1 STEEL STOCK 2 TOOL L 4440 3 SPEEDOMETER GEAR 4 DIFFERENTIAL CASE JR T350 MANUAL TRANSAXLE ...

Page 1437: ... checked using the same procedure CAUTION Side gear end play must be within 0 001 to 0 013 inch Five select thrust washers are avail able 0 027 0 032 0 037 0 042 and 0 047 inch Fig 69 Install Differential Bearing Cone to Ring Gear Side 1 ARBOR PRESS RAM 2 BEARING CONE 3 SPECIAL TOOL HANDLE C 4171 4 SPECIAL TOOL L 4410 5 DIFFERENTIAL ASSEMBLY Fig 70 Install Bearing Cone to Differential Case Side 1 ...

Page 1438: ... downward direction Roll differential assembly back and forth a number of times This will settle the bearings Zero the dial indicator To obtain end play readings apply a medium load in an upward direction while rolling differential assembly back and forth Fig 73 Record end play 7 The shim required for proper bearing preload is the total of end play plus constant preload of 0 18 mm 0 007 in Never c...

Page 1439: ...uipped with a fill plug The fill plug is located on the left side of the trans axle differential area Fig 77 The fluid level should be within 3 16 inch from the bottom of the transaxle fill hole vehicle must be level when checking All T350 transaxles are equipped with a drain plug The drain plug is located on the lower right side of the transaxle differential housing Fig 78 Tighten drain plug to 2...

Page 1440: ... cleaner assembly 7 Disconnect crossover and selector cables from transaxle Fig 81 8 Remove retainer clips and disengage cables from bracket Fig 81 9 Raise vehicle on hoist 10 Remove cable grommet from floor pan 11 Pull cables forward and remove from under vehicle Fig 78 Drain Plug Location 1 DRAIN PLUG Fig 79 Center Console Assembly Typical 1 CENTER CONSOLE 2 SCREW 3 IF EQUIPPED 4 IF EQUIPPED 5 P...

Page 1441: ...lever is in the proper position place the shifter in 3rd or 4th gear if necessary Torque adjustment screw to 8 N m 70 in lbs Care must be taken to avoid moving the shift mechanism off center during screw tighten ing c Perform functional check by shifting trans axle into all gears 9 Install center console assembly Fig 79 10 Install gearshift knob boot assembly Ensure knob retaining tabs are secured...

Page 1442: ...ng the shift mechanism off center during screw tighten ing c Perform functional check by shifting trans axle into all gears 4 Install center console assembly Fig 83 5 Install gearshift knob boot assembly Ensure knob retaining tabs are secured to shift lever Snap boot to console at retainer locations INPUT BEARING AND SLEEVE REMOVAL The input bearing is a one piece bearing and sleeve unit Fig 87 Th...

Page 1443: ... 2 208 mm 0 021 0 087 in 3rd 0 73 1 53 mm 0 029 0 060 in 4th 0 77 1 57 mm 0 030 0 062 in 5th 0 73 1 53 mm 0 029 0 060 in Reverse Brake 0 505 1 74 mm 0 020 0 068 in The reverse brake measurement is taken between the stop ring and case Fig 87 Input Bearing And Sleeve 1 DIFFERENTIAL BEARING 2 OUTPUT BEARING 3 INPUT BEARING 4 BEARING RETAINER Fig 88 Input Bearing Removal 1 SPECIAL TOOL 6342 2 BELLHOUS...

Page 1444: ...nizer hub on input shaft Fig 92 2 Remove synchronizer and gear using shop press Fig 93 3 Remove caged needle bearing Fig 94 Fig 91 Input Shaft 1 INPUT SHAFT 2 STOP RING 3 SLEEVE 4 5TH SPEED GEAR 5 STOP RING 6 SLEEVE 7 4TH SPEED GEAR 8 STOP RING 9 3RD SPEED GEAR Fig 92 5th Synchro and Hub Snap Ring Removal 1 SNAP RING PLIERS 2 INPUT SHAFT 3 BEARING SPLITTER 4 SNAP RING Fig 93 Remove Synchronizer Us...

Page 1445: ...ve 4th gear Fig 98 Fig 95 Split Thrust Washer Ring 1 SPLIT THRUST WASHER RING 2 INPUT SHAFT Fig 96 Split Thrust Washer Removal 1 INPUT SHAFT 2 SPLIT THRUST WASHER Fig 97 Split Thrust Washer Separation Pin 1 SEPARATION PIN 2 INPUT SHAFT 3 PLIERS Fig 98 4th Gear Removal 1 INPUT SHAFT 2 4TH GEAR 21 34 T350 MANUAL TRANSAXLE JR INPUT SHAFT Continued ...

Page 1446: ...t needle bearing for a broken retention spring 12 Inspect the input shaft for worn or damaged bearing races or chipped gear teeth Replace as nec essary Fig 99 Caged Needle Bearing Removal 1 INPUT SHAFT 2 CAGED NEEDLE BEARING Fig 100 3 4 Synchronizer Hub Snap Ring 1 SNAP RING PLIERS 2 SYNCHRO SNAP RING 3 SYNCHRONIZER ASSEMBLY Fig 101 3rd Gear Removal 1 PRESS RAM 2 INPUT SHAFT 3 3RD GEAR 4 SYNCHRONI...

Page 1447: ...tall blocking ring into 3 4 synchronizer Install 4th gear caged needle bearing 6 Install 4th gear onto input shaft 7 Install 4 5 split thrust washer separation pin Fig 105 8 Install split thrust washer onto input shaft Fig 106 Fig 103 3rd Gear Caged Needle Bearing 1 INPUT SHAFT 2 3RD GEAR CAGED NEEDLE BEARING Fig 104 Press On 3rd Gear Synchronizer Hub 1 PRESS RAM 2 SPECIAL TOOL C 3717 3 BEARING SP...

Page 1448: ... facing upward 12 Install 5th gear synchronizer snap ring Fig 110 Fig 107 Retaining Ring Installation 1 SPLIT THRUST WASHER RING 2 INPUT SHAFT Fig 108 Caged Needle Bearing Installation 1 INPUT SHAFT 2 CAGED NEEDLE BEARING Fig 109 5th Speed Gear Installation 1 PRESS RAM 2 SPECIAL TOOL C 3717 3 SYNCHRONIZER ASSEMBLY 4 BEARING SPLITTER 5 5TH SPEED GEAR Fig 110 5th Gear Synchronizer Snap Ring Installa...

Page 1449: ...mmer remove output bearing race INSTALLATION 1 Line up output bearing race to race bore 2 Insert tool 4628 with C 4171 into output bear ing race Fig 114 Tap race into bore Install output bearing into race Verify that the larger diameter cage is facing outward Position bearing retaining strap Tighten bolts to 11 N m 96 in lbs Fig 111 Output Roller Bearing 1 INPUT BEARING 2 OUTPUT BEARING 3 LARGER D...

Page 1450: ...If a stop ring gap does not fall within the specifi cations it must be inspected for wear and replaced If the 1st or 2nd synchronizer stop ring is worn beyond specifications the complete output shaft assembly must be replaced The output shaft incorporates the 1st and 2nd gears and synchronizers on the assembly Fig 115 REAR BEARING OIL FEED TROUGH REMOVAL The bearing oil feed trough is retained in ...

Page 1451: ...ne up replacement bushing in bore 2 Using tool MD998343 tap bushing into bore until flush with the chamfer in the case SHIFT SELECTOR SHAFT REMOVAL 1 Disassemble transaxle 2 With the transaxle disassembled remove the selector shaft by pushing on the shaft from the out side Pull shaft out from the inside INSTALLATION 1 Pull selector shaft into position from the out side 2 Assemble transaxle SHIFT S...

Page 1452: ...in a suitable holder and clean with solvent Air dry INSPECTION INSPECT Proper inspection of components involve Teeth for wear scuffed nicked burred or bro ken teeth Keys for wear or distortion Balls and springs for distortion cracks or wear If any of these conditions exist in these compo nents replace as necessary ASSEMBLY 1 Position synchronizer hub onto a suitable hold ing fixture input shaft Th...

Page 1453: ...ol circuitry to determine vehicle speed and to maintain speed control set speed REMOVAL 1 Raise vehicle on hoist 2 Disconnect the speed sensor connector Fig 125 CAUTION Clean area around speed sensor before removing to prevent dirt from entering the transaxle during speed sensor removal 3 Remove speed sensor retaining bolt Fig 125 4 Remove speed sensor from transaxle CAUTION Carefully remove vehic...

Page 1454: ...g 125 3 Install the bolt and torque to 7 N m 60 in lbs 4 Connect speed sensor connector Fig 125 5 Lower vehicle and road test to verify proper speedometer operation Fig 125 Speed Sensor and Pinion Removal Installation 1 CONNECTOR 2 SENSOR 3 O RING 4 SPEEDO PINION JR T350 MANUAL TRANSAXLE 21 43 VEHICLE SPEED SENSOR Continued ...

Page 1455: ...DARD PROCEDURE FLUID LEVEL AND CONDITION CHECK 126 STANDARD PROCEDURE FLUID AND FILTER SERVICE 128 GEAR SHIFT CABLE REMOVAL 129 INSTALLATION 131 ADJUSTMENTS GEARSHIFT LINKAGE ADJUSTMENT 131 GEARSHIFT MECHANISM REMOVAL 132 INSTALLATION 134 HOLDING CLUTCHES DESCRIPTION 134 OPERATION 134 INPUT CLUTCH ASSEMBLY DISASSEMBLY 135 ASSEMBLY 144 OIL PUMP DESCRIPTION 159 OPERATION 159 DISASSEMBLY 159 ASSEMBLY...

Page 1456: ...ule TCM The PCM TCM is the heart of the electronic control system and relies on information from various direct and indirect inputs sensors switches etc to deter mine driver demand and vehicle operating condi tions With this information the PCM TCM can calculate and perform timely and quality shifts through various output or control devices solenoid pack transmission control relay etc The PCM TCM ...

Page 1457: ...IER 14 TRANSFER SHAFT GEAR 3 OIL PUMP 9 2 4 CLUTCH 15 TRANSFER SHAFT 4 INPUT SPEED SENSOR 10 L R CLUTCH 16 DIFFERENTIAL 5 UNDERDRIVE CLUTCH 11 OUTPUT SPEED SENSOR 17 CONVERTER DRIVE PLATE 6 OVERDRIVE CLUTCH 12 REAR PLANET CARRIER OUTPUT SHAFT 18 INPUT SHAFT 21 46 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1458: ...e transaxle should be oper ated in each position to check for slipping and any variation in shifting If the vehicle operates properly at highway speeds but has poor acceleration the converter stator over running clutch may be slipping If acceleration is nor mal but high throttle opening is needed to maintain highway speeds the converter stator clutch may have seized Both of these stator defects re...

Page 1459: ...sticking valves DIAGNOSIS AND TESTING HYDRAULIC PRESSURE TESTS Pressure testing is a very important step in the diagnostic procedure These tests usually reveal the cause of most hydraulic transaxle problems Before performing pressure tests be certain that fluid level and condition and shift cable adjustments have been checked and approved Fluid must be at operating temperature 150 to 200 degrees F...

Page 1460: ...st checks the overdrive clutch hydraulic circuit as well as the shift schedule TEST FOUR SELECTOR IN OVERDRIVE 4th Gear 1 Attach gauge to the 2 4 clutch tap 2 Move selector lever to the OD position 3 Allow vehicle front wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 30 mph Vehicle should be in 4th gear 4 The 2 4 clutch pressure should read 75 to 95 psi 5 This...

Page 1461: ... turning at the same speed DIAGNOSIS AND TESTING CLUTCH AIR PRESSURE TESTS Inoperative clutches can be located using a series of tests by substituting air pressure for fluid pressure Fig 5 Fig 6 The clutches may be tested by apply ing air pressure to their respective passages The valve body must be removed and Tool 6056 installed To make air pressure tests proceed as follows NOTE The compressed ai...

Page 1462: ...D TESTING TORQUE CONVERTER HOUSING FLUID LEAKAGE When diagnosing converter housing fluid leaks three actions must be taken before repair 1 Verify proper transmission fluid level 2 Verify that the leak originates from the con verter housing area and is transmission fluid 3 Determine the true source of the leak Fluid leakage at or around the torque converter area may originate from an engine oil lea...

Page 1463: ...body support bracket 12 Disconnect Oxygen Sensor harness retainer from transaxle case 13 Remove rear mount bracket to transaxle case bolts 14 Remove starter upper bracket to block bolt 15 Raise vehicle 16 Remove halfshafts Refer to Differential and Driveline 17 Remove rear mount bracket lower bolt 18 Remove rear mount thru bolt 19 Remove rear mount to cross member bolts 20 Remove rear mount and br...

Page 1464: ...emove input and output speed sensors 2 Remove three 3 solenoid pressure switch assembly to case bolts 3 Remove solenoid pressure switch assembly and gasket Fig 9 4 Remove oil pan to case bolts Fig 10 5 Remove oil pan Fig 11 Fig 9 Solenoid Pressure Switch Assembly and Gasket 1 SOLENOID PRESSURE SWITCH ASSEMBLY 2 GASKET Fig 10 Remove Oil Pan Bolts 1 OIL PAN BOLTS USE RTV UNDER BOLT HEADS Fig 11 Remo...

Page 1465: ...cation some accumulators will have two springs and others will have one spring The springs are color coded according to application and year When disassem bling mark accumulator spring location to ease assembly Fig 12 Remove Filter and O Ring 1 OIL FILTER 2 O RING Fig 13 Remove Valve Body to Case Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY Fig 14 Push Park Rod Rollers from Guide Bracket 1 P...

Page 1466: ...ers Fig 19 Remove piston and springs Fig 20 Fig 16 Underdrive and Overdrive Accumulators 1 OVERDRIVE PISTON AND SPRING 2 UNDERDRIVE PISTON AND SPRING Fig 17 Remove Low Reverse Accumulator Snap Ring 1 SNAP RING 2 PLUG Fig 18 Remove Low Reverse Accumulator Plug 1 ADJUSTABLE PLIERS 2 PLUG Fig 19 Low Reverse Accumulator Piston 1 ACCUMULATOR PISTON JR 40TE AUTOMATIC TRANSAXLE 21 55 40TE AUTOMATIC TRANS...

Page 1467: ...15 Remove oil pump to case bolts Fig 22 CAUTION Be sure input speed sensor is removed before removing oil pump 16 Install pullers Tool C 3752 as shown in Fig 23 Fig 20 Low Reverse Accumulator 1 PISTON 2 RETURN SPRINGS Fig 21 Measure Input Shaft End Play Using Tool 8266 Typical 1 TOOL 8266 8 2 TOOL 8266 2 3 TOOL C 3339 Fig 22 Remove Oil Pump to Case Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 2...

Page 1468: ...aced Do not re use or attempt to clean valve 19 Remove cooler bypass valve Fig 27 Fig 24 Remove Oil Pump 1 PUSH IN ON INPUT SHAFT WHILE REMOVING PUMP Fig 25 Oil Pump Removed 1 OIL PUMP 2 GASKET Fig 26 Remove Oil Pump Gasket 1 PUMP GASKET Fig 27 Remove Bypass Valve 1 COOLER BYPASS VALVE JR 40TE AUTOMATIC TRANSAXLE 21 57 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1469: ...ring 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT Fig 29 Remove Input Clutch Assembly 1 INPUT CLUTCH ASSEMBLY 2 4 THRUST WASHER Fig 30 No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETROLATUM FOR RETENTION Fig 31 Remove Front Sun Gear Assembly 1 FRONT SUN GEAR ASSEMBLY 2 4 THRUST WASHER FOUR TABS 21 58 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Conti...

Page 1470: ... snap ring and remove snap ring NOTE Verify that Tool 5058 is centered properly over the 2 4 clutch retainer before compressing If necessary fasten the 5058 bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly Fig 32 Remove Front Carrier Rear Annulus Assembly 1 6 NEEDLE BEARING 2 FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PULL OR PUSH TO...

Page 1471: ...assembly identification 30 Remove tapered snap ring Fig 39 Fig 36 2 4 Clutch Retainer 1 2 4 CLUTCH RETAINER 2 2 4 CLUTCH RETURN SPRING Fig 37 Remove 2 4 Clutch Return Spring 1 2 4 CLUTCH RETURN SPRING Fig 38 Remove 2 4 Clutch Pack 1 CLUTCH DISC 2 CLUTCH PLATE Fig 39 Remove Tapered Snap Ring 1 LOW REVERSE CLUTCH REACTION PLATE 2 SCREWDRIVER 3 LOW REVERSE TAPERED SNAP RING TAPERED SIDE UP 4 OIL PAN ...

Page 1472: ...e Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP Fig 41 Remove One Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 42 Remove Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 43 Remove Low Reverse Clutch 1 CLUTCH PLATE 2 CLUTCH DISC JR 40TE AUTOMATIC TRANSAXLE 21 61 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1473: ...over Bolts 1 REAR COVER BOLTS 2 REAR COVER 3 USE SEALANT ON BOLTS Fig 45 Remove Rear Cover 1 REAR COVER 2 1 8 INCH BEAD OF MOPAR ATF RTV MS GF41 AS SHOWN Fig 46 Remove Transfer Shaft Gear Nut 1 TRANSFER SHAFT GEAR 2 OUTPUT GEAR 3 SPECIAL TOOL 6259 Fig 47 Transfer Shaft Gear Nut and Coned Washer 1 TRANSFER SHAFT 2 LOCK WASHER 3 NUT 21 62 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Continue...

Page 1474: ...L L4407 6 2 TRANSFER SHAFT GEAR 3 SPECIAL TOOL L4407A Fig 49 Remove Transfer Shaft Gear and Select Shim 1 TRANSFER SHAFT GEAR 2 BEARING CUP RETAINER 3 SHIM SELECT Fig 50 Remove Bearing Cup Retainer 1 ALIGN INDEXING TAB TO SLOT 2 BEARING CUP RETAINER Fig 51 Remove Transfer Gear Bearing Cone 1 WRENCHES 2 TOOL 5048 WITH JAWS TOOL 5048 4 AND BUTTON TOOL L 4539 2 3 TRANSFER SHAFT GEAR JR 40TE AUTOMATIC...

Page 1475: ...g 52 Remove Transfer Shaft Bearing Cup 1 WRENCHES 2 TOOL 6062 3 TRANSFER SHAFT BEARING CUP RETAINER Fig 53 Remove Transfer Shaft Bearing Snap Ring 1 SNAP RING PLIERS TOOL 6051 2 TRANSFER SHAFT BEARING SNAP RING 3 TRANSFER SHAFT Fig 54 Remove Transfer Shaft 1 SPECIAL TOOL 5049 A 2 TRANSFER SHAFT 3 OUTPUT GEAR Fig 55 Bearing Cup Removed 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT 4 OIL BAFFLE 5 O ...

Page 1476: ... Fig 59 remove output shaft gear to shaft bolt and washer Fig 60 Fig 56 Remove Transfer Shaft Bearing Cone 1 ARBOR PRESS RAM 2 TRANSFER SHAFT 3 TOOL P 334 4 BEARING CONE Fig 57 Remove Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING STRAP BOLTS Fig 58 Remove Stirrup Strap 1 OUTPUT GEARBOLT 2 RETAINING STRAP 3 STIRRUP Fig 59 Remove Output Gear Bolt 1 OUTPUT GEAR 2 TOOL 6259 JR 40TE AUTOMATIC TRA...

Page 1477: ... and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED LOCK WASHER Fig 61 Remove Output Gear 1 OUTPUT GEAR 2 BUTTON TOOL 6055 3 WRENCHES 4 TOOL L4407A 5 BOLTS TOOL L4407 6 Fig 62 Output Gear and Select Shim 1 REAR CARRIER ASSEMBLY 2 SHIM SELECT 3 OUTPUT GEAR Fig 63 Remove Bearing Cone 1 TOOL 5048 WITH JAWS 5048 5 AND BUTTON L 4539 2 2 WRENCHES 3 OUTPUT GEAR 21 66 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANS...

Page 1478: ...sembly 1 REAR CARRIER ASSEMBLY Fig 65 Remove Rear Carrier Bearing Cone 1 TOOL 5048 WITH JAWS 5048 3 AND BUTTON 6055 2 WRENCHES 3 REAR CARRIER ASSEMBLY 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 6057 4 TOOL 5059 5 TOOL 5058 3 JR 40TE AUTOMATIC TRANSAXLE 21 67 40T...

Page 1479: ...aft and guide bracket assembly Fig 71 Fig 68 Install Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6057 Fig 69 Low Reverse Piston 1 LOW REVERSE PISTON RETURN SPRING 2 PISTON Fig 70 Remove Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 PIVOT SHAFT 3 ANCHOR SHAFT PLUG Fig 71 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIV...

Page 1480: ...screws Fig 74 64 Remove low reverse piston retainer Fig 75 Fig 72 Guide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE 4 SPACER 5 PAWL 6 STEPPED SPACER Fig 73 Remove Low Reverse Clutch Piston 1 LOW REVERSE CLUTCH PISTON 2 BONDED SEAL 3 BONDED SEAL Fig 74 Remove Piston Retainer to Case Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 75 Remov...

Page 1481: ... PCM Quick Learn procedure must be performed Refer to 8 ELEC TRICAL ELECTRONIC CONTROL MODULES TRANS MISSION CONTROL MODULE STANDARD PROCEDURE 1 Install both output bearing cups using Tool 5050 Fig 79 Fig 76 Remove Piston Retainer Gasket 1 GASKET HOLES MUST LINE UP 2 LOW REVERSE CLUTCH PISTON RETAINER GASKET Fig 77 Remove Output Bearing Inner Cup 1 OUTPUT BEARING CUPS REPLACE IN PAIRS 2 HAMMER 3 B...

Page 1482: ... replacement of the piston assembly 5 Install low reverse clutch piston Fig 83 Fig 80 Install Piston Retainer Gasket 1 GASKET HOLES MUST LINE UP 2 LOW REVERSE CLUTCH PISTON RETAINER GASKET Fig 81 Install Piston Retainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 82 Install Piston Retainer to Case Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 83 Install Low ...

Page 1483: ...ide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE 4 SPACER 5 PAWL 6 STEPPED SPACER Fig 85 Guide Bracket 1 GUIDE BRACKET 2 ANTIRATCHET SPRING MUST BE ASSEMBLED AS SHOWN 3 PAWL Fig 86 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 87 Install Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 PIVOT SHAFT 3 ANCHOR SHAFT PLUG 21 7...

Page 1484: ...ring 1 LOW REVERSE PISTON RETURN SPRING 2 PISTON Fig 89 Compressor Tool in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 90 Install Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6057 Fig 91 Install Rear Carrier Bearing Cone 1 ARBOR PRESS RAM 2 TOOL 6053 3 NEW BEARING CONE 4 REAR CARRIER...

Page 1485: ...sure output gear end play as shown in Fig 94 f Refer to the output gear bearing shim chart for the required shim to obtain proper bearing set ting g Use Tool 6259 to remove the output gear retaining bolt and washer To remove the output gear use Tool L4407A h Remove the gauging shim and install the proper shim determined by the chart Use grease to hold the shim in place Fig 92 Install Rear Carrier ...

Page 1486: ...n 4412813AB 0 25mm 0 010 in 4 22mm 0 166 in 4412825AB 0 74mm 0 029 in 3 74mm 0 147 in 4412813AB 0 28mm 0 011 in 4 18mm 0 165 in 4412824AB 0 76mm 0 030 in 3 70mm 0 146 in 4412812AB 0 30mm 0 012 in 4 14mm 0 163 in 4412823AB 0 79mm 0 031 in 3 66mm 0 144 in 4412811AB 0 33mm 0 013 in 4 14mm 0 163 in 4412823AB 0 81mm 0 032 in 3 66mm 0 144 in 4412811AB 0 36mm 0 014 in 4 10mm 0 161 in 4412822AB 0 84mm 0 0...

Page 1487: ...ll a 0 04 mm 0 0016 in thicker shim If the turning torque is too low install a 0 04 mm 0 0016 in thinner shim Repeat until the proper turning torque of 3 8 in lbs is obtained Fig 96 Install Output Gear 1 WRENCHES 2 TOOL 6261 WITH STUD 3 OUTPUT GEAR Fig 97 Output Gear Bolt and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED LOCK WASHER Fig 98 Tighten Output Gear to 271 N m 200 ft lbs 1 OUTPUT GEAR 2 TORQUE WRE...

Page 1488: ...rup strap bolts to 23 N m 200 in lbs Fig 103 Fig 100 Install Stirrup 1 STIRRUP 2 OUTPUT GEAR RETAINING BOLT Fig 101 Install Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING STRAP BOLTS Fig 102 Turn Stirrup Clockwise Against Flats Of Output Gear Retaining Bolt 1 RETAINING STRAP 2 STIRRUP Fig 103 Tighten Stirrup Strap Bolts to 23 N m 200 in lbs 1 RETAINING STRAP 2 STIRRUP JR 40TE AUTOMATIC TRANSA...

Page 1489: ... On Strap Up Against Flats Of Bolts 1 RETAINING STRAP TABS 2 RETAINING STRAP 3 STIRRUP Fig 105 Install Transfer Shaft Bearing Cone 1 TOOL 6052 2 NEW BEARING CONE 3 TRANSFER SHAFT 4 ARBOR PRESS RAM Fig 106 Install Bearing Cup to Shaft 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT 4 OIL BAFFLE 5 O RING Fig 107 Install Transfer Shaft 1 SPECIAL TOOL 5049 A 2 TRANSFER SHAFT 3 OUTPUT GEAR 21 78 40TE AUT...

Page 1490: ...IERS TOOL 6051 2 TRANSFER SHAFT BEARING SNAP RING 3 TRANSFER SHAFT Fig 109 Install Transfer Shaft Bearing Cup Into Retainer 1 ARBOR PRESS RAM 2 HANDLE C 4171 3 TOOL 6061 4 TRANSFER SHAFT BEARING CUP RETAINER 5 USE REMOVED BEARING CUP TO SUPPORT RETAINER Fig 110 Install Bearing Cup Retainer 1 ALIGN INDEXING TAB TO SLOT 2 BEARING CUP RETAINER Fig 111 Install Transfer Gear Bearing Cone 1 ARBOR PRESS ...

Page 1491: ...n 4505588AB 0 76mm 0 030 in 3 94mm 0 155 in 4412818AB 0 08mm 0 003 in 4 62mm 0 182 in 4412835AB 0 79mm 0 031 in 3 90mm 0 154 in 4412817AB 0 10mm 0 004 in 4 58mm 0 180 in 4412834AB 0 81mm 0 032 in 3 90mm 0 154 in 4412817AB 0 13mm 0 005 in 4 58mm 0 180 in 4412834AB 0 84mm 0 033 in 3 86mm 0 152 in 4412816AB 0 15mm 0 006 in 4 54mm 0 178 in 4412833AB 0 86mm 0 034 in 3 82mm 0 150 in 4412815AB 0 18mm 0 0...

Page 1492: ... in 4412806AB 0 53mm 0 021 in 4 18mm 0 165 in 4412824AB 1 24mm 0 049 in 3 46mm 0 136 in 4412806AB 0 56mm 0 022 in 4 14mm 0 163 in 4412823AB 1 27mm 0 050 in 3 42mm 0 135 in 4412805AB 0 58mm 0 023 in 4 10mm 0 161 in 4412822AB 1 30mm 0 051 in 3 38mm 0 133 in 4412804AB 0 61mm 0 024 in 4 10mm 0 161 in 4412822AB 1 32mm 0 052 in 3 38mm 0 133 in 4412804AB 0 64mm 0 025 in 4 06mm 0 160 in 4412821AB 1 35mm 0...

Page 1493: ...ner shim Repeat until 0 05 0 10 mm 0 002 0 004 in end play is obtained 36 Install a bead of Mopar ATF RTV MS GF41 to transfer gear cover Fig 115 37 Install transfer gear cover to case bolts and torque to 20 N m 175 in lbs torque Fig 116 Fig 113 Install Transfer Shaft Gear 1 WRENCHES 2 SPECIAL TOOL 6261 3 OUTPUT GEAR 4 TRANSFER SHAFT GEAR Fig 114 Tighten Nut to 271 N m 200 ft lbs 1 TRANSFER SHAFT G...

Page 1494: ...ate with flat side up Fig 120 Fig 117 Install Low Reverse Clutch 1 CLUTCH PLATE 2 CLUTCH DISC Fig 118 Install Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 119 Install One Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 120 Install Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP JR 40TE AUTOMATIC TR...

Page 1495: ...eaction plate to achieve specifications LOW REVERSE REACTION PLATE CHART PART NUMBER THICKNESS 4799846AA 5 88 mm 0 232 in 4799847AA 6 14 mm 0 242 in 4799848AA 6 40 mm 0 252 in 4799849AA 6 66 mm 0 262 in 4799855AA 6 92 mm 0 273 in 44 Install 2 4 clutch pack Fig 124 Fig 121 Tapered Snap Ring Instructions Fig 122 Snap Ring Installed 1 SCREWDRIVER 2 TAPERED SNAP RING INSTALL AS SHOWN Fig 123 Check Low...

Page 1496: ...h pack clearance is 0 76 2 64 mm 0 030 0 104 in Set up indicator and record mea surement in four 4 places Take average of read ings If clearance is outside this range the clutch is assembled improperly There is no adjustment for 2 4 clutch clearance Fig 125 Proper Orientation of 2 4 Clutch Retainer and Spring 1 NOTE POSITION 2 RETURN SPRING 3 2 4 CLUTCH RETAINER Fig 126 2 4 Clutch Retainer 1 2 4 C...

Page 1497: ...ear annulus assembly and 6 needle bearing Fig 131 51 Install front sun gear assembly and 4 thrust washer Fig 132 Fig 129 Number 7 Bearing 1 7 NEEDLE BEARING 2 REAR SUN GEAR Fig 130 Install Rear Sun Gear and 7 Needle Bearing 1 7 NEEDLE BEARING 2 REAR SUN GEAR Fig 131 Install Front Carrier Rear Annulus Assembly 1 6 NEEDLE BEARING 2 FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PULL OR PUSH TO RE...

Page 1498: ...ndicator Set C3339 and End Play Set 8266 as shown in Fig 136 f Measure the input shaft end play with the transaxle in the vertical position Input shaft end play must be w ithin 0 005 to 0 025 inch For example if end play reading is 0 055 inch select No 4 Thrust Plate which is 0 071 to 0 074 thick This should provide an input shaft end play read ing of 0 020 inch which is within specifications g Re...

Page 1499: ...4 in 53 Install input clutch assembly Fig 137 54 Install 1 caged needle bearing Fig 138 CAUTION The cooler bypass valve must be replaced if transaxle failure has occurred Do not attempt to reuse or clean old valve Fig 136 Measure Input Shaft End Play Using Tool 8266 Typical 1 TOOL 8266 8 2 TOOL 8266 2 3 TOOL C 3339 Fig 137 Install Input Clutch Assembly 1 INPUT CLUTCH ASSEMBLY 2 4 THRUST WASHER Fig...

Page 1500: ...tall oil pump to case bolts and torque to 27 N m 20 ft lbs Fig 142 Fig 139 Install Cooler Bypass Valve 1 COOLER BYPASS VALVE Fig 140 Install Oil Pump Gasket 1 PUMP GASKET Fig 141 Install Oil Pump 1 OIL PUMP 2 GASKET Fig 142 Install Pump to Case Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING JR 40TE AUTOMATIC TRANSAXLE 21 89 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1501: ...r coded for application and year 62 Install underdrive and overdrive accumulators and springs Fig 146 Fig 143 Low Reverse Accumulator 1 PISTON 2 RETURN SPRINGS Fig 144 Install Low Reverse Accumulator Plug 1 ADJUSTABLE PLIERS 2 PLUG Fig 145 Install Low Reverse Accumulator Snap Ring 1 SNAP RING 2 PLUG Fig 146 Underdrive and Overdrive Accumulators 1 OVERDRIVE PISTON AND SPRING 2 UNDERDRIVE PISTON AND...

Page 1502: ...an 1 8 bead of Mopar ATF RTV MS GF41 to oil pan and immediately install to case Fig 150 67 Install oil pan to case bolts and torque to 19 N m 165 in lbs Fig 147 Valve Body Removal Installation 1 VALVE BODY Fig 148 Install Valve Body to Case Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY Fig 149 Install Oil Filter and O Ring 1 OIL FILTER 2 O RING Fig 150 Install Oil Pan 1 OIL PAN 2 1 8 INCH BEA...

Page 1503: ...alfshafts Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT INSTALLA TION 11 Lower vehicle 12 Install starter upper bracket to block bolt 13 Connect oxygen sensor harness connector 14 Install throttle body support bracket if equipped 15 Connect crankshaft position sensor connector if equipped 16 Connect gearshift cable to manual valve lever 17 Connect output speed sensor connector 18 Connect input spe...

Page 1504: ...SCHEMATICS AND DIAGRAMS 4XTE TRANSAXLE HYDRAULIC SCHEMATICS Park Neutral Speed Under 8 MPH JR 40TE AUTOMATIC TRANSAXLE 21 93 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1505: ...Neutral Speed Over 8 MPH 21 94 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1506: ...Reverse JR 40TE AUTOMATIC TRANSAXLE 21 95 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1507: ...Reverse Block Shift to Reverse W Speed Over 8 mph 21 96 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1508: ...First Gear JR 40TE AUTOMATIC TRANSAXLE 21 97 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1509: ...Second Gear 21 98 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1510: ...Second Gear EMCC JR 40TE AUTOMATIC TRANSAXLE 21 99 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1511: ...Direct Gear 21 100 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1512: ...Direct Gear CC On JR 40TE AUTOMATIC TRANSAXLE 21 101 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1513: ...Overdrive 21 102 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1514: ...Overdrive EMCC JR 40TE AUTOMATIC TRANSAXLE 21 103 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1515: ...Overdrive CC On 21 104 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1516: ... 004 in Overall Drag At Output Hub 0 3 1 9 N m 3 16 in lbs CLUTCH CLEARANCES DESCRIPTION METRIC STANDARD Low Rev Clutch Select Reaction Plate 0 89 1 47 mm 0 035 0 058 in Two Four Clutch No Selection 0 76 2 64 mm 0 030 0 104 in Reverse Clutch Select Snap Ring 0 89 1 37 mm 0 035 0 054 in Overdrive Clutch No Selection 1 07 3 25 mm 0 042 0 128 in Underdrive Clutch Select Pressure Plate 0 94 1 50 mm 0 ...

Page 1517: ... Gear Stirrup Strap 23 17 Bolt Oil Pump to Case 27 20 Bolt Reaction Support to Case 27 20 Bolt Solenoid Pressure Switch Assy to Case 12 110 Bolt Torque Converter to Driveplate 75 55 Bolt Transfer Gear Cover 20 175 Bolt Valve Body to Case 12 105 Fitting Oil Cooler Line 12 105 Nut Tranfer Gear 271 200 Tap Transaxle Pressure 5 45 Screw L R Clutch Retainer 5 45 Screw Solenoid Pressure Switch Assy Conn...

Page 1518: ...7 Pressure Gauge High C 3293SP Dial Indicator C 3339 Oil Pump Puller C 3752 Seal Puller C 3981B Universal Handle C 4171 Seal Installer C 4193A Adapter C 4996 JR 40TE AUTOMATIC TRANSAXLE 21 107 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1519: ... Puller L 4407A Bearing Installer L 4410 Gear Checking Plate L 4432 Bearing Puller L 4435 Differential Tool L 4436A Special Jaw Set L 4518 Installer L 4520 21 108 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1520: ...tton L 4539 2 Adapter L 4559 Adapter L 4559 2 Bearing Splitter P 334 Puller Set 5048 Remover Installer 5049 A Installer 5050A Installer 5052 JR 40TE AUTOMATIC TRANSAXLE 21 109 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1521: ...Compressor 5058A Compressor 5059 A Installer 5067 Pliers 6051 Installer 6052 Installer 6053 Button 6055 Plate 6056 21 110 40TE AUTOMATIC TRANSAXLE JR 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1522: ...Disk 6057 Installer 6061 Remover 6062 A Holder 6259 Bolt 6260 Installer 6261 Tip 6268 Remover Installer 6301 JR 40TE AUTOMATIC TRANSAXLE 21 111 40TE AUTOMATIC TRANSAXLE Continued ...

Page 1523: ...153 The low reverse accumulator Fig 154 is also located within the transaxle case but the assembly is retained by a cover and a snap ring The 2 4 accumulator is located in the valve body It is retained by a cover and retaining screws Fig 155 Remover Installer 6302 Installer 6536 A Puller 7794 A End Play Socket Set 8266 Input Clutch Pressure Fixture 8391 Fig 153 Underdrive and Overdrive Accumulator...

Page 1524: ...strument cluster will illumi nate the selected gear The vehicle can be launched in 1st 2nd or 3rd gear while in the Autostick mode The speed control is operable in 3rd and 4th gear Autostick mode Speed control will be deactivated if the transaxle is shifted to 2nd gear Shifting into OD position cancels the Autostick mode and the trans axle resumes the OD shift schedule AUTOMATIC OVERRIDES For safe...

Page 1525: ... nosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first second and third direct gears by pressurized fluid against the underdrive piston When the under drive clutch is applied the underdrive hub drives the rear sun gear OVERDRIVE CLUTCH The overdrive clutch is hydr...

Page 1526: ...The differential pinion and side gears are supported in the case by thrust washers and a pinion shaft Dif ferential pinion and side gears make it possible for front tires to rotate at different speeds while corner ing DISASSEMBLY NOTE The transfer shaft should be removed for dif ferential repair and bearing turning torque check ing 1 Remove the differential cover and bolts Fig 158 Fig 159 Fig 157 ...

Page 1527: ...to measure side gear end play Side gear end play must be w ithin 0 001 0 013 in Fig 160 Differential Retainer Bolts 1 DIFFERENTIAL RETAINER BOLTS Fig 161 Remove Bearing Retainer 1 DIFFERENTIAL BEARING RETAINER 2 TOOL L 4435 Fig 162 Checking Side Gear End Play Extension Housing Side 1 SPECIAL TOOL C 4996 NOTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY 4 SIDE GEAR Fig 163 Checking Side Ge...

Page 1528: ...tall Button L 4539 2 as shown Fig 166 9 Install 5048 as shown Fig 167 Remove and discard bearing cone Fig 164 Button L 4539 2 and Collets 5048 4 1 COLLETS 5048 4 2 BUTTON L 4539 2 3 BEARING CONE Fig 165 Side Bearing Removal Using Tool 5048 Ring Gear Side 1 TOOL 5048 2 COLLETS 5048 4 3 SLEEVE 5048 Fig 166 Install Button L 4539 2 1 BUTTON L 4539 2 Fig 167 Side Bearing Removal Using Tool 5048 1 TOOL ...

Page 1529: ...Rotate pinion gears about case and remove w washer Fig 171 Fig 168 Remove Install Retainer Ring Gear Bolt 1 PINION SHAFT RETAINER Fig 169 Pinion Shaft Retainer 1 PINION SHAFT RETAINER Fig 170 Pinion Shaft Removal Installation 1 PINION SHAFT Fig 171 Pinion Gear and Washer 1 WASHER 2 PINION GEAR 21 118 40TE AUTOMATIC TRANSAXLE JR FINAL DRIVE Continued ...

Page 1530: ... 174 17 Using a soft faced hammer remove ring gear from case Fig 175 Fig 172 Side Gear Removal Installation 1 SIDE GEAR Fig 173 Side Gear Washer 1 SIDE GEAR THRUST WASHER Fig 174 Ring Gear Bolt Removal Installation 1 RING GEAR BOLTS Fig 175 Ring Gear Removal 1 SOFT FACED HAMMER 2 RING GEAR JR 40TE AUTOMATIC TRANSAXLE 21 119 FINAL DRIVE Continued ...

Page 1531: ...ension Housing Seal 7794 A C 637 Slide Hammer L 4520 C 4171 Bearing Retainer Seal 794 A C 637 Slide Hammer L 4520 C 4171 ASSEMBLY NOTE Use Mopar Silicone Rubber Adhesive Seal ant or equivalent on retainer and extension hous ing adapter plate to seal to transaxle case 1 Position differential case to ring gear Install ring gear to differential case bolts and draw ring gear into position Fig 178 Torq...

Page 1532: ... position ensuring the anti rotate tabs are located into the differential case as shown Fig 182 Fig 179 Side Gear Washer 1 SIDE GEAR THRUST WASHER Fig 180 Side Gear Removal Installation 1 SIDE GEAR Fig 181 Pinion Gear and Washer 1 WASHER 2 PINION GEAR Fig 182 Pinion Washer Anti Rotate Tab 1 ANTI ROTATE TAB 2 POCKET JR 40TE AUTOMATIC TRANSAXLE 21 121 FINAL DRIVE Continued ...

Page 1533: ...ferential side bearing cone onto dif ferential as shown Fig 186 Fig 183 Pinion Shaft Removal Installation 1 PINION SHAFT Fig 184 Pinion Shaft Retainer 1 PINION SHAFT RETAINER Fig 185 Remove Install Retainer Ring Gear Bolt 1 PINION SHAFT RETAINER Fig 186 Position Bearing Cone Onto Differential 1 DIFFERENTIAL ASSEMBLY 2 DIFFERENTIAL BEARING 21 122 40TE AUTOMATIC TRANSAXLE JR FINAL DRIVE Continued ...

Page 1534: ...21 TRANSMISSION TRANSAXLE AUTOMATIC 41TE FINAL DRIVE ADJUSTMENTS 15 Install differential assembly to case Install extension housing adapter plate and bearing retainer 16 Install bearing retainer with a bead of Mopar Silicone Rubber Adhesive Sealant and torque bolts Fig 190 to 28 N m 250 in lbs Fig 187 Side Bearing Installation Ring Gear Side 1 C 4171 2 INSTALLER 5052 Fig 188 Side Bearing Installat...

Page 1535: ...ainer side up 2 Install Tool L 4436A into the differential and onto the pinion mate shaft Fig 193 3 Rotate the differential at least one full revolu tion to ensure the tapered roller bearings are fully seated 4 Using Tool L 4436A and an inch pound torque wrench check the turning torque of the differential Fig 194 The turning torque should be betw een 5 and 18 inch pounds Fig 191 Install Differenti...

Page 1536: ...ial bearing retainer using Tool 5052 and C 4171 Seal the retainer to the housing with MOPAR Adhesive Sealant and torque bolts to 28 N m 250 in lbs 7 Using Tool L 4436A and an inch pound torque wrench recheck the turning torque of the differential Fig 194 The turning torque should be betw een 5 and 18 inch pounds Shim thickness need be determined only if any of the following parts are replaced Tran...

Page 1537: ...Torque bolts to 28 N m 250 in lbs 13 Using Miller Special Tool L 4436 A and an inch pound torque wrench check the turning torque of the differential Fig 194 The turning torque should be between 5 18 inch pounds NOTE If turning torque is too high install a 0 05mm 0 002 inch thicker shim If the turning torque is too low install a 0 05mm 0 002 inch thinner shim Repeat until 5 18 inch pounds of turnin...

Page 1538: ... a leak FLUID CONDITION Along with fluid level it is important to check the condition of the fluid When the fluid smells burned and is contaminated with metal or friction material particles a complete transaxle recondition is proba bly required Be sure to examine the fluid on the dip stick closely If there is any doubt about its condition drain out a sample for a double check Mopar ATF 4 Automatic...

Page 1539: ...ngine and allow to idle for at least one minute Then with parking and service brakes applied move selector lever momentarily to each position ending in the park or neutral position 7 Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm 1 8 in below the lowest mark on the dip stick Fig 198 8 Recheck the fluid level after the transaxle has reached n...

Page 1540: ...ering transaxle make certain that dipstick is fully seated into the dipstick opening GEAR SHIFT CABLE REMOVAL 1 Place transaxle in PARK 2 Disconnect battery negative cable at left strut tower 3 Remove air cleaner assembly 4 Using a pry tool pry up on cable at manual valve lever and remove cable from lever Fig 199 5 Remove the screw from the cable bracket at the transaxle Fig 199 6 Remove the gears...

Page 1541: ...e cable grommet from the floor pan area Fig 205 14 Carefully remove the cable from the under body by unfolding the cable retainer clip Fig 205 as you go along Fig 202 Center Console Assembly 1 CENTER CONSOLE 2 SCREW 3 IF EQUIPPED 4 IF EQUIPPED 5 PARK BRAKE HANDLE Fig 203 Shift Cable Adjust Lever Nut Typical 1 ACCESS HOLE Fig 204 Gearshift Cable at Floor Shifter 1 CLIP 2 CABLE 3 CONDUIT BRACKET 4 S...

Page 1542: ...s a quick check to confirm proper link age adjustment Move the selector level slowly forward until it clicks into the P Park position The starter should operate After checking the P position move selector slowly toward the N Neutral position until lever is in the N position If the starter will also operate at this point the gearshift linkage is properly adjusted If the starter fails to operate in ...

Page 1543: ...ool remove the shifter cable core end from the shift lever pin Fig 210 7 Using a flat blade pry tool pry the cable con duit clip up from the shifter bracket Pull up on the cable conduit and remove from bracket Fig 210 Fig 207 Gearshift Knob 1 GEARSHIFT KNOB 2 SET SCREW 3 GEARSHIFT MECHANISM Fig 208 Gearshift Bezel 1 CENTER CONSOLE ASSEMBLY 2 GEARSHIFT BEZEL 3 LAMP CONNECTOR Fig 209 Center Console ...

Page 1544: ...nector if equipped Fig 213 10 Remove the five nuts at the base of the shifter assembly Remove assembly from vehicle Fig 214 Fig 210 Gearshift Cable at Floor Shifter Typical 1 CLIP 2 CABLE 3 CONDUIT BRACKET 4 SHIFT PIN Fig 211 Release Cable from Bracket at Retainer Lock 1 RELEASE CABLE HERE Fig 212 Interlock Cable at Floor Shifter Assembly 1 SHIFTER ASSEMBLY 2 INTERLOCK CABLE Fig 213 Autostick Conn...

Page 1545: ...hten set screw Fig 207 to 2 N m 20 in lbs 11 Connect the battery negative cable HOLDING CLUTCHES DESCRIPTION Two hydraulically applied multi disc clutches are used to hold planetary geartrain components station ary while the input clutches drive others The 2 4 and Low Reverse clutches are considered holding clutches and are contained at the rear of the trans axle case Fig 215 OPERATION NOTE Refer ...

Page 1546: ...from snap ring Fig 216 3 Remove reverse clutch snap ring Fig 217 4 Pry up and remove reverse clutch reaction plate Fig 218 5 Remove reverse clutch pack Fig 219 Tag components for assembly identification Fig 216 Tapping Reaction Plate 1 4 THRUST PLATE SELECT 2 TAP DOWN REVERSE CLUTCH REACTION PLATE TO REMOVE OR INSTALL SNAP RING 3 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY 4 REVERSE CLUTCH REACTION PLA...

Page 1547: ...Fig 219 Reverse Clutch Assembly 1 SNAP RING 2 REACTION PLATE 3 CLUTCH DISC 2 4 CLUTCH PLATE 1 5 INPUT CLUTCH ASSEMBLY 21 136 40TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1548: ...ssure plate wave snap ring Fig 220 9 Remove OD clutch pack Fig 220 Tag com ponents for assembly identification Fig 220 Overdrive Clutch Assembly 1 SNAP RING 2 OD REVERSE PRESSURE PLATE 3 SNAP RING WAVE 4 CLUTCH DISC 3 5 CLUTCH STEEL 2 6 INPUT CLUTCH ASSEMBLY JR 40TE AUTOMATIC TRANSAXLE 21 137 INPUT CLUTCH ASSEMBLY Continued ...

Page 1549: ...plate and 2 needle bearing Fig 221 Fig 221 Overdrive Underdrive Shafts 1 OVERDRIVE SHAFT 2 3 THRUST PLATE 3 TABS 3 3 THRUST WASHER 5 TABS 4 UNDERDRIVE SHAFT 5 2 NEEDLE BEARING 3 TABS 6 INPUT CLUTCH ASSEMBLY 21 138 40TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1550: ...ation CAUTION Compress return spring just enough to remove or install snap ring 13 Using Tool 5059A and an arbor press com press UD clutch piston spring enough to remove snap ring Fig 223 Fig 224 Fig 222 Underdrive Clutch Assembly 1 SNAP RING TAPERED 2 OD UD REACTION PLATE 3 CLUTCH DISC 3 4 SNAP RING FLAT 5 CLUTCH PLATE 3 6 INPUT CLUTCH ASSEMBLY JR 40TE AUTOMATIC TRANSAXLE 21 139 INPUT CLUTCH ASSE...

Page 1551: ... ton Fig 227 18 Using Tool 6057 and an arbor press compress return OD Reverse piston return spring just enough to remove snap ring Fig 228 Fig 224 Underdrive Clutch Piston Spring and Retainer 1 SNAP RING 2 SPRING RETAINER 3 SPRING 4 UD CLUTCH PISTON 5 SEAL OUTER 6 SEAL INNER 7 INPUT CLUTCH ASSEMBLY Fig 223 UD Spring Retainer Snap Ring 1 SNAP RING PLIERS 2 ARBOR PRESS RAM 3 SNAP RING 4 SPECIAL TOOL...

Page 1552: ...B ASSEMBLY 2 PLASTIC HAMMER Fig 227 Pull Retainer from Piston 1 OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 228 Install Snap Ring 1 ARBOR PRESS RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNAP RING 4 SPECIAL TOOL 6057 5 OD REVERSE PISTON 6 RETURN SPRING JR 40TE AUTOMATIC TRANSAXLE 21 141 INPUT CLUTCH ASSEMBLY Continued ...

Page 1553: ... input shaft from input shaft hub Fig 230 Fig 229 Remove Input Shaft Snap Ring 1 INPUT SHAFT 2 SHARP POINTED TOOL 3 SNAP RING 4 O RINGS 5 SEALS Fig 230 Remove Input Shaft 1 ARBOR PRESS RAM 2 SOCKET 3 SEAL 4 O RINGS 5 INPUT SHAFT 6 SEAL 7 INPUT SHAFT HUB ASSEMBLY 21 142 40TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1554: ...ston 1 SNAP RING INPUT SHAFT 2 SNAP RING 3 CLUTCH RETAINER 4 SEAL OUTER 5 SEAL INNER 6 OD REVERSE PISTON 7 SEAL INPUT SHAFT 8 SHAFT INPUT 9 HUB 10 SEAL 11 SNAP RING 12 BELLEVILLE SPRING JR 40TE AUTOMATIC TRANSAXLE 21 143 INPUT CLUTCH ASSEMBLY Continued ...

Page 1555: ...FT 2 ARBOR PRESS RAM 3 INPUT SHAFT HUB ASSEMBLY Fig 233 Install Input Shaft Snap Ring 1 INPUT SHAFT 2 SCREWDRIVER DO NOT SCRATCH BEARING SURFACE 3 SNAP RING 4 O RINGS 5 SEALS Fig 234 Return Spring and Snap Ring 1 OD REVERSE PISTON 2 RETURN SPRING 3 SNAP RING 4 O RING Fig 235 Install Snap Ring 1 ARBOR PRESS RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNAP R...

Page 1556: ...ig 236 Install OD Reverse Piston 1 PUSH DOWN TO INSTALL OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 237 Install Input Shaft Hub Assembly 1 PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY ROTATE TO ALIGN SPLINES 2 OD REV PISTON Fig 238 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 JR 40TE AUTOMATIC TRANSAXLE 2...

Page 1557: ...ston 1 SNAP RING INPUT SHAFT 2 SNAP RING 3 CLUTCH RETAINER 4 SEAL OUTER 5 SEAL INNER 6 OD REVERSE PISTON 7 SEAL INPUT SHAFT 8 SHAFT INPUT 9 HUB 10 SEAL 11 SNAP RING 12 BELLEVILLE SPRING 21 146 40TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1558: ...stall snap ring Fig 240 Underdrive Clutch Piston 1 PISTON Fig 241 Seal Compressor Special Tool 5067 1 PISTON RETURN SPRING 2 SPECIAL TOOL 5067 3 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY Fig 242 UD Return Spring and Retainer 1 UNDERDRIVE SPRING RETAINER 2 SNAP RING 3 SEAL 4 PISTON RETURN SPRING Fig 243 Install UD Spring Retainer and Snap Ring 1 ARBOR PRESS RAM 2 SNAP RING PLIERS 3 SNAP RING 4 OD REVE...

Page 1559: ...drive Clutch Piston Spring and Retainer 1 SNAP RING 2 SPRING RETAINER 3 SPRING 4 UD CLUTCH PISTON 5 SEAL OUTER 6 SEAL INNER 7 INPUT CLUTCH ASSEMBLY 21 148 40TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1560: ...ocated within one finger of the input clutch hub Be sure that snap ring is fully seated by pushing with screwdriver into snap ring groove all the way around 14 Seat tapered snap ring to ensure proper installation Fig 250 Fig 251 Fig 245 Install Underdrive Clutch Pack 1 CLUTCH DISC 2 CLUTCH PLATE Fig 246 UD Clutch Flat Snap Ring 1 UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 SCREWDRIVER Fig 24...

Page 1561: ...TE Fig 250 Seating Tapered Snap Ring 1 OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 SCREWDRIVER Fig 251 Underdrive Clutch Assembly 1 SNAP RING TAPERED 2 OD UD REACTION PLATE 3 CLUTCH DISC 3 4 SNAP RING FLAT 5 CLUTCH PLATE 3 6 INPUT CLUTCH ASSEMBLY 21 150 40TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1562: ... 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 necessary select the proper reaction plate to achieve specifications UNDERDRIVE REACTION PLATE THICKNESS 4659939AB 5 837 5 937 mm 0 230 0 234 in 4659940AB 6 147 6 248 mm 0 242 0 246 in 4659941AB 6 457 6 5...

Page 1563: ...lat snap ring Fig 258 Fig 259 Fig 255 Install Overdrive Clutch Pack 1 CLUTCH DISC 2 CLUTCH PLATE Fig 256 Install Waved Snap Ring 1 OVERDRIVE PRESSURE PLATE WAVED SNAP RING 2 SCREWDRIVER Fig 257 OD Reverse Reaction Plate 1 OVERDRIVE REVERSE PRESSURE PLATE 2 STEP SIDE DOWN Fig 258 Install Flat Snap Ring 1 ARBOR PRESS RAM 2 TOOL 5059A 3 FLAT SNAP RING 21 152 40TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH A...

Page 1564: ...9 Overdrive Clutch Assembly 1 SNAP RING 2 OD REVERSE PRESSURE PLATE 3 SNAP RING WAVE 4 CLUTCH DISC 3 5 CLUTCH STEEL 2 6 INPUT CLUTCH ASSEMBLY JR 40TE AUTOMATIC TRANSAXLE 21 153 INPUT CLUTCH ASSEMBLY Continued ...

Page 1565: ...ance 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 frictions one steel Fig 261 29 Install reverse clutch reaction plate with the flat side down towards reverse clutch Fig 262 Fig 260 Measure OD Clutch Pack Clearance 1 DIAL INDICATOR 2 OD REVERSE REACTION PLATE Fi...

Page 1566: ... Reverse Clutch Snap Ring 1 REVERSE CLUTCH SNAP RING SELECT 2 SCREWDRIVER 3 REVERSE CLUTCH REACTION PLATE Fig 264 Reverse Clutch Assembly 1 SNAP RING 2 REACTION PLATE 3 CLUTCH DISC 2 4 CLUTCH PLATE 1 5 INPUT CLUTCH ASSEMBLY Fig 265 Pry Up Reaction Plate 1 SCREWDRIVER 2 SNAP RING 3 SCREWDRIVER 4 MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP RING JR 40TE AUTOMATIC TRANSAXLE 21 155 INPUT CLUTCH ASS...

Page 1567: ...tion The reverse clutch pack clearance is 0 89 1 37 mm 0 035 0 054 in Select the proper reverse clutch snap ring to achieve specifications REVERSE CLUTCH SNAP RING THICKNESS 4377195 1 53 1 58 mm 0 060 0 062 in 4412871 1 77 1 83 mm 0 070 0 072 in 4412872 2 02 2 07 mm 0 080 0 082 in 4412873 2 27 2 32 mm 0 090 0 091 in 36 To complete the assembly reverse clutch and overdrive clutch must be removed 37...

Page 1568: ...erdrive shaft assembly Fig 272 Fig 273 Fig 269 Install Underdrive Shaft Assembly 1 UNDERDRIVE SHAFT ASSEMBLY 2 2 NEEDLE BEARING Fig 270 Install No 3 Thrust Washer 1 3 THRUST WASHER NOTE 5 TABS 2 UNDERDRIVE SHAFT ASSEMBLY Fig 271 Install No 3 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 DABS OF PETROLATUM FOR RETENTION 3 3 THRUST PLATE NOTE 3 TABS Fig 272 Install Overdrive Shaft Assembly 1 OVERDRIVE S...

Page 1569: ...lutch clearances is not necessary Fig 273 Overdrive Underdrive Shafts 1 OVERDRIVE SHAFT 2 3 THRUST PLATE 3 TABS 3 3 THRUST WASHER 5 TABS 4 UNDERDRIVE SHAFT 5 2 NEEDLE BEARING 3 TABS 6 INPUT CLUTCH ASSEMBLY 21 158 40TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1570: ...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 DISASSEMBLY When disassembling the transaxle it is necessary to inspect the oil pump for wear and damage 1 Remove the reaction shaft support to pump body bolts Fig 275 2 Remove reaction shaft support from pump housing Fig 276 Fig 274 Oil Pum...

Page 1571: ...17 in 7 Measure clearance between inner gear and crescent Fig 280 Clearance should be 0 093 0 385 mm 0 0036 0 0151 in Fig 277 Oil Pump Assembly 1 PUMP BODY 2 OUTER GEAR 3 INNER GEAR 4 REACTION SHAFT SUPPORT 5 SEAL RINGS 4 6 REACTION SHAFT 7 CRESCENT Fig 278 Measuring Outer Gear to Pocket 1 FEELER GAUGE 2 OUTER GEAR 3 PUMP BODY Fig 279 Measuring Outer Gear to Crescent 1 FEELER GAUGE 2 OUTER GEAR 3 ...

Page 1572: ...ed between the input clutch assembly and the rear of the transaxle case The planetary geartrain consists of two sun gears two planetary carriers two annulus ring gears and one output shaft Fig 283 OPERATION The planetary geartrain utilizes two planetary gear sets that connect the transmission input shaft to the output shaft Input and holding clutches drive or lock different planetary members to ch...

Page 1573: ...ion Fig 286 An additional electrically activated feature will prevent shifting out of the PARK position unless the brake pedal is depressed at least one half inch A magnetic holding device integral to the interlock cable is ener gized when the ignition is in the ON RUN position When the key is in the ON RUN position and the brake pedal is depressed the shifter is unlocked and will move into any po...

Page 1574: ...6 Shifter cannot be shifted out of PARK NOTE Any failure to meet these expected responses requires system adjustment or repair REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the gearshift knob set screw and knob Fig 287 3 Remove gearshift bezel Fig 288 4 Remove center console assembly Fig 289 5 Release interlock cable adjuster end by insert ing pointed object into shift brack...

Page 1575: ...ng column shroud 10 Disconnect interlock solenoid connector 11 Disconnect nylon cable retainer from lower column mounting stud 12 Place the ignition key in the ON RUN position Fig 294 Grasp the interlock cable clip and connec tor Remove the cable from the interlock housing Fig 295 Fig 290 Release Cable from Bracket at Retainer Lock 1 RELEASE CABLE HERE Fig 291 Interlock Cable at Floor Shifter Asse...

Page 1576: ... to 21 TRANSMISSION TRANSAXLE AUTO MATIC 41TE SHIFT INTERLOCK CABLE ADJUST MENTS 8 Install center console assembly Fig 289 9 Install gearshift bezel Fig 287 10 Install the gearshift knob and tighten set screw Fig 287 to 2 N m 20 in lbs 11 Tilt wheel to full down position and install upper steering column shroud 12 Install steering column lower shroud Fig 293 13 Install lower knee bolster screws an...

Page 1577: ...eturning to LOCK position 6 With the key removed try to shift out of PARK 6 Shifter cannot be shifted out of PARK NOTE Any failure to meet these expected responses requires system adjustment or repair ADJUSTMENT 1 Disconnect and isolate the battery negative cable 2 Remove the gearshift knob set screw and knob Fig 298 3 Remove the gearshift bezel to gain access to the interlock cable adjuster lock ...

Page 1578: ...tive cable SHIFT INTERLOCK MECHANISM REMOVAL 1 Remove steering column upper and lower shrouds 2 Grasp the interlock cable and connector firmly Remove the interlock cable 3 Remove the two interlock mechanism to steer ing column attaching screws Fig 302 Remove the interlock mechanism INSTALLATION 1 Position the interlock housing at steering col umn Install the two interlock mechanism to steering col...

Page 1579: ...sted again to verify the failure In addition to the periodic testing the solenoid circuits are tested if a speed ratio or pressure switch error occurs PRESSURE SWITCHES The PCM TCM relies on three pressure switches to monitor fluid pressure in the L R 2 4 and OD hydraulic circuits The primary purpose of these switches is to help the PCM TCM detect when clutch circuit hydraulic failures occur The r...

Page 1580: ...nerated and sent to the PCM TCM The PCM TCM interprets this informa tion as input shaft rpm The PCM TCM compares the input speed signal with output speed signal to determine the following Transmission gear ratio Speed ratio error detection CVI calculation The PCM TCM also compares the input speed sig nal and the engine speed signal to determine the fol lowing Torque converter clutch slippage Torqu...

Page 1581: ...Install and tighten input speed sensor to 27 N m 20 ft lbs Fig 308 3 Connect speed sensor connector Fig 307 4 Connect battery negative cable Fig 307 Transmission Connectors 1 SOLENOID PACK CONNECTOR 2 INPUT SPEED SENSOR CONNECTOR 3 OUTPUT SPEED SENSOR CONNECTOR 4 TRANSMISSION RANGE SENSOR CONNECTOR Fig 308 Input Turbine Speed Sensor 1 INPUT SPEED SENSOR Fig 309 O ring Location 1 INPUT SPEED SENSOR...

Page 1582: ...r detection CVI calculation VEHICLE SPEED SIGNAL The vehicle speed signal is taken from the Output Speed Sensor The PCM converts this signal into a pulse per mile signal and sends the vehicle speed message across the communication bus to the BCM The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver The vehicle speed signal pulse is roughly 8000 pulses per mile ...

Page 1583: ...13 4 Connect battery negative cable Fig 313 Transmission Connectors 1 SOLENOID PACK CONNECTOR 2 INPUT SPEED SENSOR CONNECTOR 3 OUTPUT SPEED SENSOR CONNECTOR 4 TRANSMISSION RANGE SENSOR CONNECTOR Fig 314 Output Speed Sensor 1 OUTPUT SPEED SENSOR Fig 315 O ring Location 1 OUTPUT SPEED SENSOR 2 O RING 21 172 40TE AUTOMATIC TRANSAXLE JR SPEED SENSOR OUTPUT Continued ...

Page 1584: ...nverter clutch pro vides reduced engine speed and greater fuel economy when engaged Clutch engagement also provides reduced transmission fluid temperatures The con verter clutch engages in third gear The torque con verter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is serviced as an assembly Fig 316 Torque Converter Assembly 1 ...

Page 1585: ...of the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving member of the system Fig 317 Impeller 1 ENGINE FLEXPLATE 4 ENGINE ROTATION 2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE SECTION 5 ENGINE ROTATION 3 IMPELLER VANES AND COVER ARE INTEGRAL 21 174 40TE AUTOMATIC TRANSAXLE JR TORQUE CONVERTER Continued ...

Page 1586: ...ed through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 318 Turbine 1 TURBINE VANE 2 ENGINE ROTATION 3 INPUT SHAFT 4 PORTION OF TORQUE CONVERTER COVER 5 ENGINE ROTATION 6 OIL FLOW WITHIN TURBINE SECTION JR 40TE AUTOMATIC TRANSAXLE 21 175 TORQUE CONVERTER Continu...

Page 1587: ... is lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impel ler and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction mate rial was added to the inside of the front cover to pro vide this ...

Page 1588: ...eed The converter turbine driven member which reacts from fluid pressure generated by the impeller rotates and turns the transmission input shaft Fig 322 Torque Converter Fluid Operation 1 APPLY PRESSURE 3 RELEASE PRESSURE 2 THE PISTON MOVES SLIGHTLY FORWARD 4 THE PISTON MOVES SLIGHTLY REARWARD JR 40TE AUTOMATIC TRANSAXLE 21 177 TORQUE CONVERTER Continued ...

Page 1589: ...direct 1 1 mechanical link between the engine and the transmission The engagement and disengagement of the TCC are automatic and controlled by the Powertrain Con trol Module PCM The engagement cannot be acti vated in the lower gears because it eliminates the torque multiplication effect of the torque converter necessary for acceleration Inputs that determine clutch engagement are coolant temperatu...

Page 1590: ...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 TCM energizes the relay Prior to this the PCM TCM verifies that the contacts are open by checking for no voltage at the switched bat tery terminals After this is verified the voltage at the solenoid pack pressure switche...

Page 1591: ...he PCM TCM uses to monitor the transmis sion s sump temperature Since fluid temperature can affect transmission shift quality and convertor lock up the PCM TCM requires this information to determine which shift schedule to operate in The PCM also monitors this temperature data so it can energize the vehicle cooling fan s when a transmis sion overheat condition exists If the thermistor cir cuit fai...

Page 1592: ...pressure switch assembly and fric tional clutches The valve body contains the following components Fig 329 Regulator valve Solenoid switch valve Manual valve Converter clutch switch valve Converter clutch control valve Torque converter regulator valve Low Reverse switch valve In addition the valve body also contains the ther mal valve 2 3 4 check balls the 5 overdrive check valve and the 2 4 accum...

Page 1593: ...noids The valve has three operating ranges or positions CONVERTER CLUTCH SWITCH VALVE The main responsibility of the converter clutch switch valve is to control hydraulic pressure applied to the front off side of the converter clutch piston Line pressure from the regulator valve is fed to the torque converter regulator valve where it passes through the valve and is slightly regulated The pressure ...

Page 1594: ...iding consistent application of the low reverse clutch under all operating conditions REMOVAL NOTE If valve body is replaced or reconditioned the PCM Quick Learn Procedure must be per formed Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Disconnect battery negative cable 2 Remove air cleaner assembly 3 Disconnect gearshift cable from manual valve ...

Page 1595: ... 336 CAUTION The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped Fig 333 Valve Body to Case Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY Fig 334 Push Park Rod Rollers from Guide Bracket 1 PARK SPRAG ROLLERS 2 SCREWDRIVER 3 PARK SPRAG GUIDE BRACKET Fig 335 Valve Body Removal Installation 1 VALVE BODY Fig 336 Underdrive and Overdri...

Page 1596: ...ansmission Range Sensor retaining screw Fig 338 3 Remove Manual Shaft Rooster Comb and Transmission Range Sensor Fig 339 Fig 337 Manual Shaft Seal 1 SEAL 2 MANUAL SHAFT Fig 338 Remove Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL VALVE CONTROL PIN 3 RETAINING SCREW Fig 339 Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER ...

Page 1597: ...ware of loose check balls Fig 340 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLATE 2 DETENT SPRING Fig 341 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 RETURN SPRINGS 5 PISTON Fig 342 Remove Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE 3 VALVE BODY Fig 343 Remove Transfer Plate 1 TRANSFER PLATE 21 186 40TE AUTOMATIC TRANSAXLE JR VALVE...

Page 1598: ...rmal valve Fig 347 12 Remove check balls Fig 348 Fig 344 Remove Oil Screen 1 OIL SCREEN Fig 345 Remove Overdrive Clutch 5 Check Valve 1 OVERDRIVE CLUTCH 5 CHECK VALVE Fig 346 Remove Separator Plate 1 SEPARATOR PLATE 2 VALVE BODY Fig 347 Remove Thermal Valve 1 THERMAL VALVE JR 40TE AUTOMATIC TRANSAXLE 21 187 VALVE BODY Continued ...

Page 1599: ...Fig 351 16 Remove valves and springs as shown in Fig 352 NOTE Refer to Valve Body Cleaning and Inspection for cleaning procedures Fig 348 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VALVE Fig 349 Remove Dual Retainer Plate using Tool 6301 1 TOOL 6301 2 RETAINER 21 188 40TE AUTOMATIC TRANSAXLE JR VALVE...

Page 1600: ...ainer Location 1 RETAINER 2 RETAINER Fig 352 Springs and Valves Location 1 VALVE BODY 5 MANUAL VALVE 2 T C REGULATOR VALVE 6 CONVERTER CLUTCH SWITCH VALVE 3 L R SWITCH VALVE 7 SOLENOID SWITCH VALVE 4 CONVERTER CLUTCH CONTROL VALVE 8 REGULATOR VALVE JR 40TE AUTOMATIC TRANSAXLE 21 189 VALVE BODY Continued ...

Page 1601: ...6301 Fig 354 4 Verify that all retainers are installed as shown in Fig 355 Retainers should be flush or below valve body surface 5 Install check balls into position as shown in Fig 356 If necessary secure them with petrolatum or transmission assembly gel for assembly ease Fig 353 Install Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER Fig 354 Install Dual Retainer Plate usin...

Page 1602: ...all Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VALVE Fig 357 Install Thermal Valve 1 THERMAL VALVE Fig 358 Install Separator Plate 1 SEPARATOR PLATE 2 VALVE BODY JR 40TE AUTOMATIC TRANSAXLE 21 191 VALVE BODY Continued ...

Page 1603: ...t bind Fig 361 11 Install twenty four transfer plate to valve body screws Fig 362 and torque to 5 N m 45 in lbs Fig 359 Install Overdrive Clutch 5 Check Valve 1 OVERDRIVE CLUTCH 5 CHECK VALVE Fig 360 Install Oil Screen 1 OIL SCREEN Fig 361 Install Transfer Plate 1 TRANSFER PLATE Fig 362 Install Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE 3 VALVE BODY 21 192 40TE AUTOMATIC TRANS...

Page 1604: ...6 and torque to 5 N m 45 in lbs Fig 363 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 RETURN SPRINGS 5 PISTON Fig 364 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLATE 2 DETENT SPRING Fig 365 Install Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 366 Install Transmission Range Sensor R...

Page 1605: ... 3 Install transaxle oil filter Fig 371 Inspect the o ring and replace if necessary 4 Ensure the transaxle oil pan and transaxle case sealing surfaces are clean and dry Install an 1 8 bead of Mopar ATF RTV MS GF41 to the oil pan and install Fig 372 Torque oil pan to transaxle case bolts Fig 373 to 19 N m 165 in lbs Fig 367 Manual Shaft Seal 1 SEAL 2 MANUAL SHAFT Fig 368 Underdrive and Overdrive Ac...

Page 1606: ... 10 Fill transaxle with Mopar ATF 4 Transmis sion fluid Refer to 21 TRANSMISSION TRANS AXLE AUTOMATIC 41TE FLUID STANDARD PROCEDURE Fig 371 Install Oil Filter and O Ring 1 OIL FILTER 2 O RING Fig 372 Oil Pan 1 OIL PAN 2 1 8 INCH BEAD OF MOPAR ATF RTV MS GF41 3 OIL FILTER Fig 373 Oil Pan Bolts 1 OIL PAN BOLTS USE RTV UNDER BOLT HEADS JR 40TE AUTOMATIC TRANSAXLE 21 195 VALVE BODY Continued ...

Page 1607: ...ARD PROCEDURE FLUID LEVEL AND CONDITION CHECK 278 STANDARD PROCEDURE FLUID AND FILTER SERVICE 279 GEARSHIFT CABLE REMOVAL 280 INSTALLATION 282 ADJUSTMENTS GEARSHIFT LINKAGE ADJUSTMENT 283 GEARSHIFT MECHANISM REMOVAL 283 INSTALLATION 285 HOLDING CLUTCHES DESCRIPTION 286 OPERATION 286 INPUT CLUTCH ASSEMBLY DISASSEMBLY 287 ASSEMBLY 294 OIL PUMP DESCRIPTION 311 OPERATION 311 STANDARD PROCEDURE OIL PUM...

Page 1608: ...l Module PCM or Transmission Control Mod ule TCM The PCM TCM is the heart of the electronic control system and relies on information from various direct and indirect inputs sensors switches etc to deter mine driver demand and vehicle operating condi tions With this information the PCM TCM can calculate and perform timely and quality shifts through various output or control devices solenoid pack tr...

Page 1609: ...ER 14 TRANSFER SHAFT GEAR 3 OIL PUMP 9 2 4 CLUTCH 15 TRANSFER SHAFT 4 INPUT SPEED SENSOR 10 L R CLUTCH 16 DIFFERENTIAL 5 UNDERDRIVE CLUTCH 11 OUTPUT SPEED SENSOR 17 CONVERTER DRIVE PLATE 6 OVERDRIVE CLUTCH 12 REAR PLANET CARRIER OUTPUT SHAFT 18 INPUT SHAFT 21 198 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1610: ...e transaxle should be oper ated in each position to check for slipping and any variation in shifting If the vehicle operates properly at highway speeds but has poor acceleration the converter stator over running clutch may be slipping If acceleration is nor mal but high throttle opening is needed to maintain highway speeds the converter stator clutch may have seized Both of these stator defects re...

Page 1611: ...ticking valves DIAGNOSIS AND TESTING HYDRAULIC PRESSURE TESTS Pressure testing is a very important step in the diagnostic procedure These tests usually reveal the cause of most hydraulic transaxle problems Before performing pressure tests be certain that fluid level and condition and shift cable adjustments have been checked and approved Fluid must be at operating temperature 150 to 200 degrees F ...

Page 1612: ...st checks the overdrive clutch hydraulic circuit as well as the shift schedule TEST FOUR SELECTOR IN OVERDRIVE 4th Gear 1 Attach gauge to the 2 4 clutch tap 2 Move selector lever to the OD position 3 Allow vehicle front wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 30 mph Vehicle should be in 4th gear 4 The 2 4 clutch pressure should read 75 to 95 psi 5 This...

Page 1613: ... WITH TCC 0 2 75 95 0 2 0 5 75 95 0 2 50 mph Engine speed at 1500 rpm CAUTION Both front wheels must be turning at the same speed DIAGNOSIS AND TESTING CLUTCH AIR PRESSURE TESTS Inoperative clutches can be located using a series of tests by substituting air pressure for fluid pressure Fig 5 Fig 6 The clutches may be tested by apply ing air pressure to their respective passages The valve body must ...

Page 1614: ...tate with hand torque Release the air pressure and confirm that the input shaft will rotate DIAGNOSIS AND TESTING TORQUE CONVERTER HOUSING FLUID LEAKAGE When diagnosing converter housing fluid leaks three actions must be taken before repair 1 Verify proper transmission fluid level 2 Verify that the leak originates from the con verter housing area and is transmission fluid 3 Determine the true sour...

Page 1615: ...ove rear mount to cross member bolts 20 Remove rear mount and bracket 21 Remove front mount thru bolt 22 Remove front mount to radiator lower cross member bolts 23 Remove front mount bracket to block and transaxle 24 Remove front mount bracket and mount 25 Remove starter lower bolt and starter motor assembly 26 Remove converter dust shield 27 Remove torque converter bolts 28 Support engine transax...

Page 1616: ...BLY 2 GASKET Fig 10 Remove Oil Pan Bolts 1 OIL PAN BOLTS USE RTV UNDER BOLT HEADS Fig 11 Remove Oil Pan 1 OIL PAN 2 1 8 INCH BEAD OF MOPAR ATF RTV MS GF41 3 OIL FILTER Fig 12 Remove Oil Filter 1 OIL FILTER 2 O RING JR 41TE AUTOMATIC TRANSAXLE 21 205 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1617: ...oded according to application and year When disassem bling mark accumulator spring location to ease assembly 10 Remove underdrive and overdrive accumula tors Fig 16 Fig 13 Remove Valve Body Attaching Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY Fig 14 Push Park Rod Rollers from Guide Bracket 1 PARK SPRAG ROLLERS 2 SCREWDRIVER 3 PARK SPRAG GUIDE BRACKET Fig 15 Remove Valve Body 1 VALVE BODY F...

Page 1618: ...le pliers Fig 19 Fig 20 Fig 17 Remove Low Reverse Accumulator Snap Ring 1 SNAP RING 2 PLUG Fig 18 Remove Low Reverse Accumulator Plug Cover 1 ADJUSTABLE PLIERS 2 PLUG Fig 19 Low Reverse Accumulator Piston 1 ACCUMULATOR PISTON Fig 20 Low Reverse Accumulator 1 PISTON 2 RETURN SPRINGS JR 41TE AUTOMATIC TRANSAXLE 21 207 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1619: ... bolts Fig 22 CAUTION Be sure input speed sensor is removed before removing oil pump 16 Install pullers Tool C 3752 as shown in Fig 23 17 Remove oil pump assembly Fig 24 Fig 25 Fig 21 Measure Input Shaft End Play Using End Play Set 8266 1 TOOL 8266 8 2 TOOL 8266 2 3 TOOL C 3339 Fig 22 Remove Pump Attaching Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 23 Install Tool C 3752 1 PULLERS TOOL C 3752...

Page 1620: ...9 Remove cooler bypass valve Fig 27 20 Remove 1 needle bearing Fig 28 Fig 25 Oil Pump Removed 1 OIL PUMP 2 GASKET Fig 26 Remove Oil Pump Gasket 1 PUMP GASKET Fig 27 Remove Bypass Valve 1 COOLER BYPASS VALVE Fig 28 Remove Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT JR 41TE AUTOMATIC TRANSAXLE 21 209 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1621: ...ASSEMBLY 2 4 THRUST WASHER Fig 30 No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETROLATUM FOR RETENTION Fig 31 Remove Front Sun Gear Assembly 1 FRONT SUN GEAR ASSEMBLY 2 4 THRUST WASHER FOUR TABS Fig 32 Remove Front Carrier and Rear Annulus Assembly 1 6 NEEDLE BEARING 2 FRONT CARRIER AND REAR ANNULUS ASSEMBLY TWIST AND PULL OR PUSH TO REMOVE OR INSTALL 21 210 41...

Page 1622: ...2 4 clutch retainer before compressing If necessary fasten the 5058 bar to the bellhousing flange with any combination of locking pliers and bolts to center the tool properly NOTE The 2 4 Clutch Piston has bonded seals which are not individually serviceable Seal replace ment requires replacement of the piston assembly 27 Remove 2 4 clutch retainer Fig 36 Fig 33 Remove Rear Sun Gear 1 7 NEEDLE BEAR...

Page 1623: ... 4 Clutch Return Spring 1 2 4 CLUTCH RETURN SPRING Fig 38 Remove 2 4 Clutch Pack 1 CLUTCH PLATE 4 2 CLUTCH DISC 4 Fig 39 Remove Tapered Snap Ring 1 LOW REVERSE CLUTCH REACTION PLATE 2 SCREWDRIVER 3 LOW REVERSE TAPERED SNAP RING TAPERED SIDE UP 4 OIL PAN FACE 5 LONG TAB Fig 40 Remove Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP 21 212 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMAT...

Page 1624: ...e Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 42 Remove Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 43 Remove Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 44 Remove Rear Cover Bolts 1 REAR COVER BOLTS 2 REAR COVER 3 USE SEALANT ON BOLTS JR 41TE AUTOMATIC TRANSAXLE 21 213 41TE AUTOMATIC TRANSAXLE ...

Page 1625: ... REAR COVER 2 1 8 INCH BEAD OF MOPAR ATF RTV MS GF41 AS SHOWN Fig 46 Remove Transfer Shaft Gear Nut 1 TRANSFER SHAFT GEAR 2 OUTPUT GEAR 3 SPECIAL TOOL 6259 Fig 47 Transfer Shaft Gear Nut and Coned Washer 1 TRANSFER SHAFT 2 LOCK WASHER 3 NUT Fig 48 Remove Transfer Shaft Gear 1 SPECIAL TOOL L4407 6 2 TRANSFER SHAFT GEAR 3 SPECIAL TOOL L4407A 21 214 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMATIC TRANSAXL...

Page 1626: ...elect Shim 1 TRANSFER SHAFT GEAR 2 BEARING CUP RETAINER 3 SHIM SELECT Fig 50 Remove Bearing Cup Retainer 1 ALIGN INDEXING TAB TO SLOT 2 BEARING CUP RETAINER Fig 51 Remove Transfer Gear Bearing Cone 1 WRENCHES 2 TOOL 5048 WITH JAWS TOOL 5048 4 AND BUTTON TOOL L 4539 2 3 TRANSFER SHAFT GEAR Fig 52 Remove Transfer Shaft Bearing Cup 1 WRENCHES 2 TOOL 6062 3 TRANSFER SHAFT BEARING CUP RETAINER JR 41TE ...

Page 1627: ...53 Remove Transfer Shaft Bearing Snap Ring 1 SNAP RING PLIERS TOOL 6051 2 TRANSFER SHAFT BEARING SNAP RING 3 TRANSFER SHAFT Fig 54 Remove Transfer Shaft 1 SPECIAL TOOL 5049 A 2 TRANSFER SHAFT 3 OUTPUT GEAR Fig 55 Bearing Cup Removed 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT 4 OIL BAFFLE 5 O RING Fig 56 Remove Transfer Shaft Bearing Cone 1 ARBOR PRESS RAM 2 TRANSFER SHAFT 3 TOOL P 334 4 BEARING...

Page 1628: ...haft gear to shaft bolt and washer Fig 60 Fig 57 Remove Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING STRAP BOLTS Fig 58 Remove Stirrup Strap 1 OUTPUT GEARBOLT 2 RETAINING STRAP 3 STIRRUP Fig 59 Remove Output Gear Bolt 1 OUTPUT GEAR 2 TOOL 6259 Fig 60 Output Gear Bolt and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED LOCK WASHER JR 41TE AUTOMATIC TRANSAXLE 21 217 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1629: ...axle Fig 64 Fig 61 Remove Output Gear 1 OUTPUT GEAR 2 BUTTON TOOL 6055 3 WRENCHES 4 TOOL L4407A 5 BOLTS TOOL L4407 6 Fig 62 Output Gear and Select Shim 1 REAR CARRIER ASSEMBLY 2 SHIM SELECT 3 OUTPUT GEAR Fig 63 Remove Bearing Cone 1 TOOL 5048 WITH JAWS 5048 5 AND BUTTON L 4539 2 2 WRENCHES 3 OUTPUT GEAR Fig 64 Remove Rear Carrier Assembly 1 REAR CARRIER ASSEMBLY 21 218 41TE AUTOMATIC TRANSAXLE JR ...

Page 1630: ...5048 WITH JAWS 5048 3 AND BUTTON 6055 2 WRENCHES 3 REAR CARRIER ASSEMBLY 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 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 68 Remove Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6057 J...

Page 1631: ...ear and replace if necessary Fig 72 Fig 69 Low Reverse Piston Return Spring 1 LOW REVERSE PISTON RETURN SPRING 2 PISTON Fig 70 Remove Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 PIVOT SHAFT 3 ANCHOR SHAFT PLUG Fig 71 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 72 Guide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE 4...

Page 1632: ... suitable drift drive out inner output bearing cup Fig 77 67 Using tool 6062 remove outer output bearing cup Fig 78 Fig 73 Remove Low Reverse Clutch Piston 1 LOW REVERSE CLUTCH PISTON 2 BONDED SEAL 3 BONDED SEAL Fig 74 Remove Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 75 Remove Piston Retainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GAS...

Page 1633: ...e 3 Install low reverse piston retainer Fig 81 4 Install low reverse piston retainer to case bolts Fig 82 and torque to 5 N m 45 in lbs NOTE The Low Reverse Clutch Piston has bonded seals which are not individually serviceable Seal replacement requires replacement of the piston assembly Fig 77 Remove Output Bearing Inner Cup 1 OUTPUT BEARING CUPS REPLACE IN PAIRS 2 HAMMER 3 BRASS DRIFT Fig 78 Remo...

Page 1634: ...l Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 83 Install Low Reverse Clutch Piston 1 LOW REVERSE CLUTCH PISTON 2 BONDED SEAL 3 BONDED SEAL Fig 84 Guide Bracket Disassembled 1 ANTIRATCHET SPRING 2 GUIDE BRACKET 3 SPLIT SLEEVE 4 SPACER 5 PAWL 6 STEPPED SPACER JR 41TE AUTOMATIC TRANSAXLE 21 223 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1635: ...ig 88 Fig 85 Guide Bracket 1 GUIDE BRACKET 2 ANTIRATCHET SPRING MUST BE ASSEMBLED AS SHOWN 3 PAWL Fig 86 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 87 Install Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 PIVOT SHAFT 3 ANCHOR SHAFT PLUG Fig 88 Low Reverse Piston Return Spring 1 LOW REVERSE PISTON RETURN SPRING 2 PISTON 21 224 41TE AUTOMATIC TR...

Page 1636: ...ol in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 90 Install Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNAP RING PLIERS 3 TOOL 6057 Fig 91 Install Rear Carrier Bearing Cone 1 ARBOR PRESS RAM 2 TOOL 6053 3 NEW BEARING CONE 4 REAR CARRIER ASSEMBLY Fig 92 Install Rear Carrier Assembly 1 REAR CARRIER ASSEMBL...

Page 1637: ...asure output gear end play as shown in Fig 94 f Refer to the output gear bearing shim chart for the required shim to obtain proper bearing set ting g Use Tool 6259 to remove the output gear retaining bolt and washer To remove the output gear use Tool L4407A h Remove the gauging shim and install the proper shim determined by the chart Use grease to hold the shim in place Fig 93 Install Output Gear ...

Page 1638: ...n 4412813AB 0 25mm 0 010 in 4 22mm 0 166 in 4412825AB 0 74mm 0 029 in 3 74mm 0 147 in 4412813AB 0 28mm 0 011 in 4 18mm 0 165 in 4412824AB 0 76mm 0 030 in 3 70mm 0 146 in 4412812AB 0 30mm 0 012 in 4 14mm 0 163 in 4412823AB 0 79mm 0 031 in 3 66mm 0 144 in 4412811AB 0 33mm 0 013 in 4 14mm 0 163 in 4412823AB 0 81mm 0 032 in 3 66mm 0 144 in 4412811AB 0 36mm 0 014 in 4 10mm 0 161 in 4412822AB 0 84mm 0 0...

Page 1639: ...l a 0 04 mm 0 0016 in thicker shim If the turning torque is too low install a 0 04 mm 0 0016 in thinner shim Repeat until the proper turning torque of 3 8 in lbs is obtained Fig 96 Install Output Gear 1 WRENCHES 2 TOOL 6261 WITH STUD 3 OUTPUT GEAR Fig 97 Output Gear Bolt and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED LOCK WASHER Fig 98 Tighten Output Gear to 271 N m 200 ft lbs 1 OUTPUT GEAR 2 TORQUE WREN...

Page 1640: ...que stirrup strap bolts to 23 N m 200 in lbs Fig 103 Fig 100 Install Stirrup 1 STIRRUP 2 OUTPUT GEAR RETAINING BOLT Fig 101 Install Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING STRAP BOLTS Fig 102 Turn Stirrup Clockwise Against Bolt Flats 1 RETAINING STRAP 2 STIRRUP Fig 103 Tighten Stirrup Strap Bolts To 23 N m 200 in lbs 1 RETAINING STRAP 2 STIRRUP JR 41TE AUTOMATIC TRANSAXLE 21 229 41TE A...

Page 1641: ...On Strap Up Against Flats Of Bolts 1 RETAINING STRAP TABS 2 RETAINING STRAP 3 STIRRUP Fig 105 Install Transfer Shaft Bearing Cone 1 TOOL 6052 2 NEW BEARING CONE 3 TRANSFER SHAFT 4 ARBOR PRESS RAM Fig 106 Install Bearing Cup to Shaft 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT 4 OIL BAFFLE 5 O RING Fig 107 Install Transfer Shaft 1 SPECIAL TOOL 5049 A 2 TRANSFER SHAFT 3 OUTPUT GEAR 21 230 41TE AUT...

Page 1642: ...IERS TOOL 6051 2 TRANSFER SHAFT BEARING SNAP RING 3 TRANSFER SHAFT Fig 109 Install Transfer Shaft Bearing Cup Into Retainer 1 ARBOR PRESS RAM 2 HANDLE C 4171 3 TOOL 6061 4 TRANSFER SHAFT BEARING CUP RETAINER 5 USE REMOVED BEARING CUP TO SUPPORT RETAINER Fig 110 Remove Bearing Cup Retainer 1 ALIGN INDEXING TAB TO SLOT 2 BEARING CUP RETAINER Fig 111 Install Transfer Gear Bearing Cone 1 ARBOR PRESS R...

Page 1643: ... 4505588AB 0 76mm 0 030 in 3 94mm 0 155 in 4412818AB 0 08mm 0 003 in 4 62mm 0 182 in 4412835AB 0 79mm 0 031 in 3 90mm 0 154 in 4412817AB 0 10mm 0 004 in 4 58mm 0 180 in 4412834AB 0 81mm 0 032 in 3 90mm 0 154 in 4412817AB 0 13mm 0 005 in 4 58mm 0 180 in 4412834AB 0 84mm 0 033 in 3 86mm 0 152 in 4412816AB 0 15mm 0 006 in 4 54mm 0 178 in 4412833AB 0 86mm 0 034 in 3 82mm 0 150 in 4412815AB 0 18mm 0 00...

Page 1644: ... in 4412806AB 0 53mm 0 021 in 4 18mm 0 165 in 4412824AB 1 24mm 0 049 in 3 46mm 0 136 in 4412806AB 0 56mm 0 022 in 4 14mm 0 163 in 4412823AB 1 27mm 0 050 in 3 42mm 0 135 in 4412805AB 0 58mm 0 023 in 4 10mm 0 161 in 4412822AB 1 30mm 0 051 in 3 38mm 0 133 in 4412804AB 0 61mm 0 024 in 4 10mm 0 161 in 4412822AB 1 32mm 0 052 in 3 38mm 0 133 in 4412804AB 0 64mm 0 025 in 4 06mm 0 160 in 4412821AB 1 35mm 0...

Page 1645: ...m Repeat until 0 05 0 10 mm 0 002 0 004 in end play is obtained 36 Install a bead of Mopar ATF RTV MS GF41 to transfer gear cover Fig 115 37 Install transfer gear cover to case bolts and torque to 20 N m 175 in lbs torque Fig 116 Fig 113 Install Transfer Shaft Gear 1 WRENCHES 2 SPECIAL TOOL 6261 3 OUTPUT GEAR 4 TRANSFER SHAFT GEAR Fig 114 Tighten Transfer Gear Nut to 271 N m 200 ft lbs 1 TRANSFER ...

Page 1646: ...th flat side up Fig 120 Fig 117 Install Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 118 Install Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 119 Install One Disc 1 ONE DISC FROM LOW REVERSE CLUTCH Fig 120 Install Low Reverse Reaction Plate 1 LOW REVERSE REACTION PLATE FLAT SIDE UP JR 41TE AUTOMAT...

Page 1647: ... NUMBER THICKNESS 4799846AA 5 88 mm 0 232 in 4799847AA 6 14 mm 0 242 in 4799848AA 6 40 mm 0 252 in 4799849AA 6 66 mm 0 262 in 4799855AA 6 92 mm 0 273 in 44 Install 2 4 clutch pack Fig 124 NOTE The 2 4 Clutch Piston has bonded seals which are not individually serviceable Seal replace ment requires replacement of the piston assembly Fig 121 Tapered Snap Ring Instructions Fig 122 Snap Ring Installed ...

Page 1648: ...rd mea surement in four 4 places Take average of read ings If clearance is outside this range the clutch is assembled improperly There is no adjustment for 2 4 clutch clearance Fig 125 Proper Orientation of 2 4 Clutch Retainer and Spring 1 NOTE POSITION 2 RETURN SPRING 3 2 4 CLUTCH RETAINER Fig 126 2 4 Clutch Retainer 1 2 4 CLUTCH RETAINER 2 2 4 CLUTCH RETURN SPRING Fig 127 Install 2 4 Clutch Reta...

Page 1649: ...petrolatum to retain b Install input clutch assembly into position and verify that it is completely seated by viewing through input speed sensor hole If view through input speed sensor hole is not as shown in Fig 134 the input clutch assembly is not seated prop erly c Remove oil pump o ring Fig 135 Be sure to reinstall oil pump o ring after selecting the proper 4 thrust plate Fig 129 Number 7 Bear...

Page 1650: ...t plate chart to select the proper No 4 thrust plate NO 4 THRUST PLATE CHART PART NUMBER THICKNESS 4431665AB 1 60mm 0 063 in 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 Fig 133 Select Thinnest No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETROLATUM FOR RETENTION Fig 134 View Th...

Page 1651: ...saxle failure has occurred Do not attempt to reuse or clean old valve 55 Install cooler bypass valve with o ring end towards rear of case Fig 139 56 Install oil pump gasket Fig 140 Fig 137 Install Input Clutch Assembly 1 INPUT CLUTCH ASSEMBLY 2 4 THRUST WASHER Fig 138 Install Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT Fig 139 Install Cooler Bypass Valve 1 COOLER BYPASS VA...

Page 1652: ...ll low reverse accumulator plug Fig 144 Fig 141 Install Oil Pump 1 OIL PUMP 2 GASKET Fig 142 Install Pump to Case Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 143 Low Reverse Accumulator 1 PISTON 2 RETURN SPRINGS Fig 144 Install Low Reverse Accumulator Plug Cover 1 ADJUSTABLE PLIERS 2 PLUG JR 41TE AUTOMATIC TRANSAXLE 21 241 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1653: ... clockwise to ease installation Make sure park rod rollers are posi tioned within park guide bracket 64 Install and torque valve body to case bolts to 12 N m 105 in lbs Fig 148 Fig 145 Install Low Reverse Accumulator Snap Ring 1 SNAP RING 2 PLUG Fig 146 Underdrive and Overdrive Accumulators 1 OVERDRIVE PISTON AND SPRING 2 UNDERDRIVE PISTON AND SPRING Fig 147 Install Valve Body 1 VALVE BODY Fig 148...

Page 1654: ...embly to transaxle case bolts to 12 N m 110 in lbs Fig 152 70 Install and torque input and output speed sensors to case to 27 N m 20 ft lbs Fig 149 Install Oil Filter 1 OIL FILTER 2 O RING Fig 150 Install Oil Pan 1 OIL PAN 2 1 8 INCH BEAD OF MOPAR ATF RTV MS GF41 3 OIL FILTER Fig 151 Solenoid Pressure Switch Assembly and Gasket 1 SOLENOID PRESSURE SWITCH ASSEMBLY 2 GASKET Fig 152 Solenoid Pack to ...

Page 1655: ...LF SHAFT INSTALLA TION 11 Lower vehicle 12 Install starter upper bracket to block bolt 13 Connect oxygen sensor harness connector 14 Install throttle body support bracket if equipped 15 Connect crankshaft position sensor connector if equipped 16 Connect gearshift cable to manual valve lever 17 Connect output speed sensor connector 18 Connect input speed sensor connector 19 Connect transmission ran...

Page 1656: ...SCHEMATICS AND DIAGRAMS 4XTE TRANSAXLE HYDRAULIC SCHEMATICS Park Neutral Speed Under 8 MPH JR 41TE AUTOMATIC TRANSAXLE 21 245 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1657: ...Neutral Speed Over 8 MPH 21 246 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1658: ...Reverse JR 41TE AUTOMATIC TRANSAXLE 21 247 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1659: ...Reverse Block Shift to Reverse W Speed Over 8 mph 21 248 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1660: ...First Gear JR 41TE AUTOMATIC TRANSAXLE 21 249 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1661: ...Second Gear 21 250 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1662: ...Second Gear EMCC JR 41TE AUTOMATIC TRANSAXLE 21 251 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1663: ...Direct Gear 21 252 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1664: ...Direct Gear CC On JR 41TE AUTOMATIC TRANSAXLE 21 253 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1665: ...Overdrive 21 254 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1666: ...Overdrive EMCC JR 41TE AUTOMATIC TRANSAXLE 21 255 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1667: ...Overdrive CC On 21 256 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1668: ... 004 in Overall Drag At Output Hub 0 3 1 9 N m 3 16 in lbs CLUTCH CLEARANCES DESCRIPTION METRIC STANDARD Low Rev Clutch Select Reaction Plate 0 89 1 47 mm 0 035 0 058 in Two Four Clutch No Selection 0 76 2 64 mm 0 030 0 104 in Reverse Clutch Select Snap Ring 0 89 1 37 mm 0 035 0 054 in Overdrive Clutch No Selection 1 07 3 25 mm 0 042 0 128 in Underdrive Clutch Select Pressure Plate 0 94 1 50 mm 0 ...

Page 1669: ...lt Oil Pump to Case 27 20 Bolt Reaction Support to Case 27 20 Bolt Solenoid Pressure Switch Assy to Case 12 110 Bolt Torque Converter to Driveplate 75 55 Bolt Transfer Gear Cover 20 175 Bolt Valve Body to Case 12 105 Fitting Oil Cooler Line 12 105 Nut Tranfer Gear 271 200 Tap Transaxle Pressure 5 45 Screw L R Clutch Retainer 5 45 Screw Solenoid Pressure Switch Assy Connector 4 35 Screw Valve Body ...

Page 1670: ...3339 Oil Pump Puller C 3752 Seal Puller C 3981B Universal Handle C 4171 Seal Installer C 4193A Adapter C 4996 Remover Kit L 4406 Gear Puller L 4407A JR 41TE AUTOMATIC TRANSAXLE 21 259 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1671: ...0 Gear Checking Plate L 4432 Bearing Puller L 4435 Differential Tool L 4436A Special Jaw Set L 4518 Installer L 4520 Thrust Button L 4539 2 Adapter L 4559 21 260 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1672: ... L 4559 2 Bearing Splitter P 334 Puller Set 5048 Remover Installer 5049 A Installer 5050A Installer 5052 Compressor 5058A Compressor 5059 A JR 41TE AUTOMATIC TRANSAXLE 21 261 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1673: ...Installer 5067 Pliers 6051 Installer 6052 Installer 6053 Button 6055 Plate 6056 Disk 6057 Installer 6061 21 262 41TE AUTOMATIC TRANSAXLE JR 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1674: ...over 6062 A Holder 6259 Bolt 6260 Installer 6261 Tip 6268 Remover Installer 6301 Remover Installer 6302 Installer 6536 A Puller 7794 A JR 41TE AUTOMATIC TRANSAXLE 21 263 41TE AUTOMATIC TRANSAXLE Continued ...

Page 1675: ... the valve body It is retained by a cover and retaining screws Fig 155 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 app...

Page 1676: ...ear Shifting into OD position cancels the Autostick mode and the trans axle resumes the OD shift schedule AUTOMATIC OVERRIDES For safety durability and driveability some shifts are executed automatically or prevented AUTOMATIC SHIFTS WILL OCCUR UNDER THE FOLLOWING CONDITIONS TYPE OF SHIFT APPROXIMATE SPEED 4 3 coast downshift 13 mph 3 2 coast downshift 9 mph 2 1 coast downshift 5 mph 1 2 upshift 6...

Page 1677: ...derdrive 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 over...

Page 1678: ...should be removed for dif ferential repair and bearing turning torque check ing 1 Remove the differential cover and bolts Fig 158 Fig 159 2 Remove the differential bearing retainer and bolts Fig 160 Fig 161 3 Using a plastic hammer remove extension housing adapter plate on the right side of the trans axle WARNING HOLD ONTO DIFFERENTIAL ASSEMBLY TO PREVENT IT FROM ROLLING OUT OF HOUSING Fig 158 Dif...

Page 1679: ...164 Fig 161 Remove Bearing Retainer 1 DIFFERENTIAL BEARING RETAINER 2 TOOL L 4435 Fig 162 Checking Side Gear End Play Extension Housing Side 1 SPECIAL TOOL C 4996 NOTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY 4 SIDE GEAR Fig 163 Checking Side Gear End Play Ring Gear Side 1 SPECIAL TOOL C 4996 NOTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY Fig 164 Button L 4539 2 and Collet...

Page 1680: ...d discard bearing cone 10 Remove pinion shaft retainer plate bolts Fig 168 Fig 165 Side Bearing Removal Using Tool 5048 Ring Gear Side 1 TOOL 5048 2 COLLETS 5048 4 3 SLEEVE 5048 Fig 166 Install Button L 4539 2 1 BUTTON L 4539 2 Fig 167 Side Bearing Removal Using Tool 5048 1 TOOL 5048 2 COLLET 5048 3 2 SLEEVE 5048 Fig 168 Remove Install Retainer Ring Gear Bolt 1 PINION SHAFT RETAINER JR 41TE AUTOMA...

Page 1681: ...move w washer Fig 171 14 Remove differential side gears Fig 172 Fig 169 Pinion Shaft Retainer 1 PINION SHAFT RETAINER Fig 170 Pinion Shaft Removal Installation 1 PINION SHAFT Fig 171 Pinion Gear and Washer 1 WASHER 2 PINION GEAR Fig 172 Side Gear Removal Installation 1 SIDE GEAR 21 270 41TE AUTOMATIC TRANSAXLE JR FINAL DRIVE Continued ...

Page 1682: ...using adapter plate 19 Using Miller Special Tool 6062A remove the differential bearing race from the bearing retainer Fig 176 Fig 177 Fig 173 Side Gear Washer 1 SIDE GEAR THRUST WASHER Fig 174 Ring Gear Bolt Removal Installation 1 RING GEAR BOLTS Fig 175 Ring Gear Removal 1 SOFT FACED HAMMER 2 RING GEAR Fig 176 Position Bearing Cup Remover Tool in Retainer 1 SPECIAL TOOL 6062A 2 DIFFERENTIAL BEARI...

Page 1683: ... 4520 C 4171 ASSEMBLY NOTE Use Mopar Silicone Rubber Adhesive Seal ant or equivalent on retainer and extension hous ing adapter plate to seal to transaxle case 1 Position differential case to ring gear Install ring gear to differential case bolts and draw ring gear into position Fig 178 Torque bolts to 95 N m 70 ft lbs 2 Install side gear thrust washers Fig 179 Fig 177 Remove Bearing Cup 1 SPECIAL...

Page 1684: ...are located into the differential case as shown Fig 182 6 Install pinion shaft Fig 183 Fig 180 Side Gear Removal Installation 1 SIDE GEAR Fig 181 Pinion Gear and Washer 1 WASHER 2 PINION GEAR Fig 182 Pinion Washer Anti Rotate Tab 1 ANTI ROTATE TAB 2 POCKET Fig 183 Pinion Shaft Removal Installation 1 PINION SHAFT JR 41TE AUTOMATIC TRANSAXLE 21 273 FINAL DRIVE Continued ...

Page 1685: ...ols 5052 and C 4171 install differen tial bearing to differential ring gear side Fig 187 Fig 184 Pinion Shaft Retainer 1 PINION SHAFT RETAINER Fig 185 Remove Install Retainer Ring Gear Bolt 1 PINION SHAFT RETAINER Fig 186 Position Bearing Cone Onto Differential 1 DIFFERENTIAL ASSEMBLY 2 DIFFERENTIAL BEARING Fig 187 Side Bearing Installation Ring Gear Side 1 C 4171 2 INSTALLER 5052 21 274 41TE AUTO...

Page 1686: ...ainer with a bead of Mopar Silicone Rubber Adhesive Sealant and torque bolts Fig 190 to 28 N m 250 in lbs 17 Install extension housing adapter plate with a bead of Mopar Silicone Rubber Adhesive Sealant and torque bolts to 28 N m 250 in lbs 18 Install differential cover with a bead of Mopar Silicone Rubber Adhesive Sealant Fig 191 and torque bolts Fig 192 to 28 N m 250 in lbs Fig 188 Side Bearing ...

Page 1687: ...ring retainer using Tool 6062A c Remove the existing shim from under the cup d Measure the existing shim e If the turning torque was too high when mea sured install a 0 05 mm 0 002 inch thinner shim If the turning torque is was too low install a 0 05 mm 0 002 inch thicker shim Repeat until 5 to 18 inch pounds turning torque is obtained Oil Baffle is not required to be installed when making shim se...

Page 1688: ...g Miller special Tool 6062A 2 Remove existing shim from under bearing cup 3 Reinstall the bearing cup into the retainer using Miller Special Tool 6061 and C 4171 NOTE Oil baffle is not required when making the shim calculation 4 Install the bearing retainer into the case Torque bolts to 28 N m 250 in lbs 5 Position the transaxle assembly vertically on the support stand and install Miller Special T...

Page 1689: ...LD region of the dip stick at 27 C 80 F fluid temperature FLUID LEVEL CHECK USING DRB NOTE Engine and Transaxle should be at normal operating temperature before performing this proce dure 1 Start engine and apply parking brake 2 Hook up DRB scan tool and select transmis sion 3 Select sensors 4 Read the transmission temperature value 5 Compare the fluid temperature value with the fluid temperature ...

Page 1690: ...time of the transmission oil change The magnet on the inside of the oil pan should also be cleaned with a clean dry cloth NOTE If the transaxle is disassembled for any rea son the fluid and filter should be changed FLUID FILTER SERVICE RECOMMENDED 1 Raise vehicle on a hoist Refer to LUBRICA TION and MAINTENANCE for proper procedures Place a drain container with a large opening under transaxle oil ...

Page 1691: ... 6 Pour four quarts of Mopar ATF 4 Automatic Transmission Fluid through the dipstick opening 7 Start engine and allow to idle for at least one minute Then with parking and service brakes applied move selector lever momentarily to each position ending in the park or neutral position 8 Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm 1 8 in belo...

Page 1692: ... 1 GEARSHIFT KNOB 2 SET SCREW 3 GEARSHIFT MECHANISM Fig 201 Gearshift Bezel 1 CENTER CONSOLE ASSEMBLY 2 GEARSHIFT BEZEL 3 LAMP CONNECTOR Fig 202 Center Console Assembly 1 CENTER CONSOLE 2 SCREW 3 IF EQUIPPED 4 IF EQUIPPED 5 PARK BRAKE HANDLE JR 41TE AUTOMATIC TRANSAXLE 21 281 GEARSHIFT CABLE Continued ...

Page 1693: ...stall cable to transaxle and tighten screw to 14 N m 125 in lbs Fig 199 5 Install cable to transaxle shift lever Fig 199 6 Connect cable to shifter conduit bracket and shift pin Install cable retaining clip Fig 204 7 Verify transaxle shift lever and floor shifter lever are in the PARK position 8 Tighten cable adjuster nut Fig 203 to 23 N m 200 in lbs 9 Install center console assembly Fig 202 10 In...

Page 1694: ...Fig 206 7 Move the gearshift lever on the transaxle to the park position 8 Verify the shift lever and transaxle are in park position Tighten the gearshift cable adjuster nut at the shifter assembly The gearshift linkage should now be properly adjusted 9 Check adjustment as follows Detent position for neutral and drive should be within limits of hand lever gate stops Key start must occur only when ...

Page 1695: ...bracket and disconnect cable core from shifter assembly Fig 212 9 Disconnect Autostick connector if equipped Fig 213 10 Remove the five nuts at the base of the shifter assembly Remove assembly from vehicle Fig 214 Fig 208 Gearshift Bezel 1 CENTER CONSOLE ASSEMBLY 2 GEARSHIFT BEZEL 3 LAMP CONNECTOR Fig 209 Center Console Assembly 1 CENTER CONSOLE 2 SCREW 3 IF EQUIPPED 4 IF EQUIPPED 5 PARK BRAKE HAN...

Page 1696: ...ment lever groove Make sure the interlock cable slug is seated in the groove Fig 212 5 Insert interlock cable adjuster end into bracket and snap into place Fig 212 Fig 211 Release Cable from Bracket at Retainer Lock 1 RELEASE CABLE HERE Fig 212 Interlock Cable at Floor Shifter Assembly 1 SHIFTER ASSEMBLY 2 INTERLOCK CABLE Fig 213 Autostick Connector if equipped 1 AUTOSTICK CONNECTOR Fig 214 Shifte...

Page 1697: ...f the trans axle case Fig 215 OPERATION NOTE Refer to the Elements In Use chart in Diag nosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever 2 4 CLUTCH The 2 4 clutch is hydraulically applied in second and fourth gears by pressurized fluid against the 2 4 clutch piston When the 2 4 clutch is applied the front sun gear assembly is held ...

Page 1698: ...verse clutch pack Fig 219 Tag components for assembly identification Fig 216 Tapping Reaction Plate 1 4 THRUST PLATE SELECT 2 TAP DOWN REVERSE CLUTCH REACTION PLATE TO REMOVE OR INSTALL SNAP RING 3 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY 4 REVERSE CLUTCH REACTION PLATE Fig 217 Reverse Clutch Snap Ring 1 REACTION PLATE 2 SCREWDRIVER 3 REVERSE CLUTCH SNAP RING SELECT Fig 218 Pry Reverse Clutch Reacti...

Page 1699: ...Fig 219 Reverse Clutch Assembly 1 SNAP RING 2 REACTION PLATE 3 CLUTCH DISC 2 4 CLUTCH PLATE 1 5 INPUT CLUTCH ASSEMBLY 21 288 41TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1700: ...ssure plate wave snap ring Fig 220 9 Remove OD clutch pack Fig 220 Tag com ponents for assembly identification Fig 220 Overdrive Clutch Assembly 1 SNAP RING 2 OD REVERSE PRESSURE PLATE 3 SNAP RING WAVE 4 CLUTCH DISC 4 5 CLUTCH STEEL 3 6 INPUT CLUTCH ASSEMBLY JR 41TE AUTOMATIC TRANSAXLE 21 289 INPUT CLUTCH ASSEMBLY Continued ...

Page 1701: ...plate and 2 needle bearing Fig 221 Fig 221 Overdrive Underdrive Shafts 1 OVERDRIVE SHAFT 2 3 THRUST PLATE 3 TABS 3 3 THRUST WASHER 5 TABS 4 UNDERDRIVE SHAFT 5 2 NEEDLE BEARING 3 TABS 6 INPUT CLUTCH ASSEMBLY 21 290 41TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1702: ... remove or install snap ring 13 Using Tool 5059A and an arbor press com press UD clutch piston spring enough to remove snap ring Fig 223 Fig 224 14 Remove spring retainer spring and piston Fig 224 15 Remove input hub tapered snap ring Fig 225 Fig 231 Fig 222 Underdrive Clutch Assembly 1 SNAP RING TAPERED 2 OD UD REACTION PLATE 3 CLUTCH DISC 4 SNAP RING FLAT 5 CLUTCH PLATE 6 INPUT CLUTCH ASSEMBLY J...

Page 1703: ...ch Piston Spring and Retainer 1 SNAP RING 2 SPRING RETAINER 3 SPRING 4 UD CLUTCH PISTON 5 SEAL OUTER 6 SEAL INNER 7 INPUT CLUTCH ASSEMBLY Fig 225 Input Hub Tapered Snap Ring 1 INPUT SHAFT 2 INPUT HUB SNAP RING TAPERED SIDE UP WITH TABS IN CAVITY 3 SNAP RING PLIERS 21 292 41TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1704: ... snap ring Fig 229 Fig 231 Fig 226 Tap on Input Hub 1 INPUT SHAFT AND HUB ASSEMBLY 2 PLASTIC HAMMER Fig 227 Pull Retainer from Piston 1 OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 228 Remove Snap Ring 1 ARBOR PRESS RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNAP RING 4 SPECIAL TOOL 6057 5 OD REVERSE PISTON 6 RETURN SPRING Fig 229 Remove Input S...

Page 1705: ... press install input shaft to input shaft hub Fig 232 2 Install input shaft snap ring Fig 233 3 Using an arbor press and Tool 6057 Install OD Reverse piston return spring and snap ring Fig 234 Fig 235 Fig 230 Remove Input Shaft 1 ARBOR PRESS RAM 2 SOCKET 3 SEAL 4 O RINGS 5 INPUT SHAFT 6 SEAL 7 INPUT SHAFT HUB ASSEMBLY 21 294 41TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1706: ...ston 1 SNAP RING INPUT SHAFT 2 SNAP RING 3 CLUTCH RETAINER 4 SEAL OUTER 5 SEAL INNER 6 OD REVERSE PISTON 7 SEAL INPUT SHAFT 8 SHAFT INPUT 9 HUB 10 SEAL 11 SNAP RING 12 BELLEVILLE SPRING JR 41TE AUTOMATIC TRANSAXLE 21 295 INPUT CLUTCH ASSEMBLY Continued ...

Page 1707: ...E 3 SNAP RING 4 O RINGS 5 SEALS Fig 234 Return Spring and Snap Ring 1 OD REVERSE PISTON 2 RETURN SPRING 3 SNAP RING 4 O RING Fig 235 Install Snap Ring 1 ARBOR PRESS RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNAP RING 4 SPECIAL TOOL 6057 5 OD REVERSE PISTON 6 RETURN SPRING 21 296 41TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1708: ...on return spring and Tool 5067 as shown in Fig 241 Fig 236 Install OD Reverse Piston 1 PUSH DOWN TO INSTALL OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 237 Install Input Shaft Hub Assembly 1 PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY ROTATE TO ALIGN SPLINES 2 OD REV PISTON Fig 238 Install Input Hub Tapered Snap Ring 1 INPUT SHAFT 2 INPUT HUB SNAP RING TAPERED SIDE UP WITH TABS IN CAV...

Page 1709: ...ston 1 SNAP RING INPUT SHAFT 2 SNAP RING 3 CLUTCH RETAINER 4 SEAL OUTER 5 SEAL INNER 6 OD REVERSE PISTON 7 SEAL INPUT SHAFT 8 SHAFT INPUT 9 HUB 10 SEAL 11 SNAP RING 12 BELLEVILLE SPRING 21 298 41TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1710: ...PISTON Fig 241 Seal Compressor Special Tool 5067 1 PISTON RETURN SPRING 2 SPECIAL TOOL 5067 3 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY Fig 242 UD Return Spring and Retainer 1 UNDERDRIVE SPRING RETAINER 2 SNAP RING 3 SEAL 4 PISTON RETURN SPRING Fig 243 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 6 TOOL 5059A JR 41TE AUTOMAT...

Page 1711: ...drive Clutch Piston Spring and Retainer 1 SNAP RING 2 SPRING RETAINER 3 SPRING 4 UD CLUTCH PISTON 5 SEAL OUTER 6 SEAL INNER 7 INPUT CLUTCH ASSEMBLY 21 300 41TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1712: ... within one finger of the input clutch hub Be sure that snap ring is fully seated by pushing with screwdriver into snap ring groove all the way around 14 Seat tapered snap ring to ensure proper installation Fig 250 Fig 251 Fig 245 Underdrive Clutch Pack 1 CLUTCH PLATE 2 ONE UD CLUTCH DISC 3 CLUTCH DISC Fig 246 UD Clutch Flat Snap Ring 1 UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 SCREWDRIVER...

Page 1713: ...LATE Fig 250 Seating Tapered Snap Ring 1 OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 SCREWDRIVER Fig 251 Underdrive Clutch Assembly 1 SNAP RING TAPERED 2 OD UD REACTION PLATE 3 CLUTCH DISC 4 SNAP RING FLAT 5 CLUTCH PLATE 6 INPUT CLUTCH ASSEMBLY 21 302 41TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1714: ...e 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 necessary select the proper reaction plate to achieve specifications UNDERDRIVE REACTION PLATE THICKNESS 4659939AB 5 837 5 937 mm 0 230 0 234 in 4659940AB 6 147 6 248 mm 0 242 0 246 in 4659941AB 6 457 6 557 mm 0 254 0 258 in 21 Install t...

Page 1715: ... Fig 258 Fig 259 Fig 255 Install OD Clutch Pack 1 OVERDRIVE CLUTCH PACK Fig 256 Install Waved Snap Ring 1 OVERDRIVE PRESSURE PLATE WAVED SNAP RING 2 SCREWDRIVER Fig 257 OD Reverse Pressure Plate 1 OVERDRIVE REVERSE PRESSURE PLATE 2 STEP SIDE DOWN Fig 258 Install Flat Snap Ring 1 ARBOR PRESS RAM 2 TOOL 5059A 3 FLAT SNAP RING 21 304 41TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1716: ...9 Overdrive Clutch Assembly 1 SNAP RING 2 OD REVERSE PRESSURE PLATE 3 SNAP RING WAVE 4 CLUTCH DISC 4 5 CLUTCH STEEL 3 6 INPUT CLUTCH ASSEMBLY JR 41TE AUTOMATIC TRANSAXLE 21 305 INPUT CLUTCH ASSEMBLY Continued ...

Page 1717: ...ance 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 frictions one steel Fig 261 29 Install reverse clutch reaction plate with the flat side down towards reverse clutch Fig 262 Fig 260 Measure OD Clutch Pack Clearance 1 DIAL INDICATOR 2 OD REVERSE REACTION PLATE Fi...

Page 1718: ...ch Snap Ring 1 REVERSE CLUTCH SNAP RING SELECT 2 SCREWDRIVER 3 REVERSE CLUTCH REACTION PLATE Fig 264 Reverse Clutch Assembly 1 SNAP RING 2 REACTION PLATE 3 CLUTCH DISC 2 4 CLUTCH PLATE 1 5 INPUT CLUTCH ASSEMBLY Fig 265 Pry Up Reaction Plate to Seat Against Snap Ring 1 SCREWDRIVER 2 SNAP RING 3 SCREWDRIVER 4 MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP RING JR 41TE AUTOMATIC TRANSAXLE 21 307 INP...

Page 1719: ...tion The reverse clutch pack clearance is 0 89 1 37 mm 0 035 0 054 in Select the proper reverse clutch snap ring to achieve specifications REVERSE CLUTCH SNAP RING THICKNESS 4377195 1 53 1 58 mm 0 060 0 062 in 4412871 1 77 1 83 mm 0 070 0 072 in 4412872 2 02 2 07 mm 0 080 0 082 in 4412873 2 27 2 32 mm 0 090 0 091 in 36 To complete the assembly reverse clutch and overdrive clutch must be removed 37...

Page 1720: ...overdrive and reverse clutch as shown Rechecking these clutch clearances is not necessary Fig 269 Install Underdrive Shaft Assembly 1 UNDERDRIVE SHAFT ASSEMBLY 2 2 NEEDLE BEARING Fig 270 Install No 3 Thrust Washer 1 3 THRUST WASHER NOTE 5 TABS 2 UNDERDRIVE SHAFT ASSEMBLY Fig 271 Install No 3 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 DABS OF PETROLATUM FOR RETENTION 3 3 THRUST PLATE NOTE 3 TABS Fig...

Page 1721: ...Underdrive Shafts 1 OVERDRIVE SHAFT 2 3 THRUST PLATE 3 TABS 3 3 THRUST WASHER 5 TABS 4 UNDERDRIVE SHAFT 5 2 NEEDLE BEARING 3 TABS 6 INPUT CLUTCH ASSEMBLY 21 310 41TE AUTOMATIC TRANSAXLE JR INPUT CLUTCH ASSEMBLY Continued ...

Page 1722: ...off flush with the cooler inlet fitting and place a collection container under the open line CAUTION With the fluid set at the proper level fluid collection should not exceed 1 quart or inter nal damage to the transmission may occur 2 Start engine and run at curb idle speed with the shift selector in neutral 3 If one quart of ATF is collected in 20 seconds or less flow is within acceptable limits ...

Page 1723: ...p Body Bolts 1 BOLT 6 2 PUMP BODY 3 REACTION SHAFT SUPPORT Fig 277 Reaction Shaft Support 1 PUMP BODY 2 PUMP GEARS 3 REACTION SHAFT SUPPORT Fig 278 Oil Pump Assembly 1 PUMP BODY 2 OUTER GEAR 3 INNER GEAR 4 REACTION SHAFT SUPPORT 5 SEAL RINGS 4 6 REACTION SHAFT 7 CRESCENT Fig 279 Measuring Outer Gear to Pocket 1 FEELER GAUGE 2 OUTER GEAR 3 PUMP BODY 21 312 41TE AUTOMATIC TRANSAXLE JR OIL PUMP Conti...

Page 1724: ... hous ings Measure the Plastigage following the instruc tions supplied 12 Clearance between both gear end faces and the reaction shaft support should be 0 020 0 046 mm 0 0008 0 0018 in ASSEMBLY 1 Assemble oil pump as shown in Fig 282 2 Install and torque reaction shaft support to oil pump housing bolts to 28 N m 20 ft lbs torque Fig 283 Fig 280 Measuring Outer Gear to Crescent 1 FEELER GAUGE 2 OUT...

Page 1725: ...OIL PUMP REMOVAL 1 Remove transaxle from vehicle Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 41TE REMOVAL 2 Using Tool C 3981 B remove oil pump seal Fig 285 INSTALLATION 1 Using Tool C 4193 install oil pump seal Fig 286 2 Install transaxle to vehicle Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 41TE INSTALLATION Fig 283 Reaction Support to Pump Body Bolts 1 BOLT 6 2 PUMP BODY 3 REACTION SHAFT SUP...

Page 1726: ...hi cle s response then system repair and or adjustment is necessary ACTION EXPECTED RESPONSE 1 Turn key to the OFF position 1 Shifter CAN be shifted out of park 2 Turn key to the ON RUN position 2 Shifter CANNOT be shifted out of park 3 Turn key to the ON RUN 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 LOCK or A...

Page 1727: ...ENTER CONSOLE ASSEMBLY 2 GEARSHIFT BEZEL 3 LAMP CONNECTOR Fig 290 Center Console Assembly 1 CENTER CONSOLE 2 SCREW 3 IF EQUIPPED 4 IF EQUIPPED 5 PARK BRAKE HANDLE Fig 291 Release Cable from Bracket at Retainer Lock 1 RELEASE CABLE HERE 21 316 41TE AUTOMATIC TRANSAXLE JR SHIFT INTERLOCK CABLE Continued ...

Page 1728: ...or Remove the cable from the interlock housing Fig 296 13 Remove interlock cable from underside of instrument panel INSTALLATION CAUTION When installing interlock cable assembly care must be taken not to bend exposed cable wire and slug at shifter end of cable 1 Route interlock cable into lower dash panel and towards console as removed Fig 292 Interlock Cable at Floor Shifter Assembly 1 SHIFTER AS...

Page 1729: ...ll steering column lower shroud Fig 294 13 Install lower knee bolster screws and knee bolster 14 Install fuse panel cover Fig 293 15 Connect the battery negative cable ADJUSTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK CABLE VERIFICATION AND ADJUSTMENT VERIFICATION The following chart describes the normal operation of the Brake Transmission Shift Interlock BTSI sys tem If the expected response differs...

Page 1730: ...screw and knob Fig 299 5 Place the shift lever in PARK Move the Igni tion key to the LOCK position Fig 298 and remove the key 6 If the interlock cable is being replaced remove the lock pin Fig 301 This will allow the cable to self adjust to the correct position Tighten the lock ing clip by pushing it down Fig 302 7 If the interlock cable is not being replaced the lock pin will not exist Pull outwa...

Page 1731: ...external to the transaxle and mounted to the transaxle case The assembly consists of four sole noids that control hydraulic pressure to the LR CC 2 4 OD and UD friction elements The reverse clutch is controlled by line pressure from the manual valve in the valve body The solenoids are contained within the Solenoid Pressure Switch Assembly and can only be serviced by replacing the assembly The sole...

Page 1732: ...17 psi The switches are continuously monitored by the PCM TCM for the correct states open or closed in each gear as shown in the following chart PRESSURE SWITCH STATES GEAR L R 2 4 OD R OP OP OP P N CL OP OP 1st CL OP OP 2nd OP CL OP D OP OP CL OD OP CL CL OP OPEN CL CLOSED A Diagnostic Trouble Code DTC will set if the PCM TCM senses any switch open or closed at the wrong time in a given gear The ...

Page 1733: ... 2 INPUT SPEED SENSOR CONNECTOR 3 OUTPUT SPEED SENSOR CONNECTOR 4 TRANSMISSION RANGE SENSOR CONNECTOR Fig 306 Input Speed Sensor 1 INPUT SPEED SENSOR Fig 307 Solenoid Pressure Switch Assembly to Case Bolts 1 BOLTS 2 SOLENOID AND PRESSURE SWITCH ASSEMBLY Fig 308 Solenoid Pressure Switch Assembly and Gasket 1 SOLENOID PRESSURE SWITCH ASSEMBLY 2 GASKET 21 322 41TE AUTOMATIC TRANSAXLE JR SOLENOID PRES...

Page 1734: ...4 N m 35 in lbs Fig 305 6 Install air cleaner assembly 7 Connect battery negative cable 8 If solenoid pressure switch assembly was replaced perform the Quick Learn procedure Refer to 8 ELECTRICAL ELECTRONIC CON TROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE SPEED SENSOR INPUT DESCRIPTION The Input Speed Sensor is a two wire magnetic pickup device that generates AC signals as rotation ...

Page 1735: ...gine speed signal to determine the fol lowing Torque converter clutch slippage Torque converter element speed ratio REMOVAL 1 Disconnect battery negative cable 2 Disconnect input speed sensor connector Fig 312 3 Unscrew and remove input speed sensor Fig 313 4 Inspect speed sensor o ring Fig 314 and replace if necessary Fig 311 Sensor Relation to Input Clutch Hub 1 INPUT SPEED SENSOR 2 TRANSAXLE CA...

Page 1736: ... park pawl lugs pass by the sensor coil Fig 317 an AC voltage is generated and sent to the PCM TCM The PCM TCM interprets this infor mation as output shaft rpm The PCM TCM compares the input and output speed signals to determine the following Transmission gear ratio Fig 314 O ring Location 1 INPUT SPEED SENSOR 2 O RING Fig 315 Output Speed Sensor 1 OUTPUT SPEED SENSOR Fig 316 O Ring Location 1 OUT...

Page 1737: ... Disconnect output speed sensor connector Fig 318 4 Unscrew and remove output speed sensor Fig 319 5 Inspect speed sensor o ring Fig 320 and replace if necessary INSTALLATION 1 Verify o ring is installed into position Fig 320 2 Install and tighten input speed sensor to 27 N m 20 ft lbs 3 Connect speed sensor connector Fig 318 4 Connect battery negative cable Fig 318 Transmission Connectors 1 SOLEN...

Page 1738: ...nverter clutch pro vides reduced engine speed and greater fuel economy when engaged Clutch engagement also provides reduced transmission fluid temperatures The con verter clutch engages in third gear The torque con verter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is serviced as an assembly Fig 321 Torque Converter Assembly 1 ...

Page 1739: ...of the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving member of the system Fig 322 Impeller 1 ENGINE FLEXPLATE 4 ENGINE ROTATION 2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE SECTION 5 ENGINE ROTATION 3 IMPELLER VANES AND COVER ARE INTEGRAL 21 328 41TE AUTOMATIC TRANSAXLE JR TORQUE CONVERTER Continued ...

Page 1740: ...ed through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 323 Turbine 1 TURBINE VANE 2 ENGINE ROTATION 3 INPUT SHAFT 4 PORTION OF TORQUE CONVERTER COVER 5 ENGINE ROTATION 6 OIL FLOW WITHIN TURBINE SECTION JR 41TE AUTOMATIC TRANSAXLE 21 329 TORQUE CONVERTER Continu...

Page 1741: ... is lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impel ler and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction mate rial was added to the inside of the front cover to pro vide this ...

Page 1742: ...eed The converter turbine driven member which reacts from fluid pressure generated by the impeller rotates and turns the transmission input shaft Fig 327 Torque Converter Fluid Operation 1 APPLY PRESSURE 3 RELEASE PRESSURE 2 THE PISTON MOVES SLIGHTLY FORWARD 4 THE PISTON MOVES SLIGHTLY REARWARD JR 41TE AUTOMATIC TRANSAXLE 21 331 TORQUE CONVERTER Continued ...

Page 1743: ...direct 1 1 mechanical link between the engine and the transmission The engagement and disengagement of the TCC are automatic and controlled by the Powertrain Con trol Module PCM The engagement cannot be acti vated in the lower gears because it eliminates the torque multiplication effect of the torque converter necessary for acceleration Inputs that determine clutch engagement are coolant temperatu...

Page 1744: ...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 TCM energizes the relay Prior to this the PCM TCM verifies that the contacts are open by checking for no voltage at the switched bat tery terminals After this is verified the voltage at the solenoid pack pressure switche...

Page 1745: ...he PCM TCM uses to monitor the transmis sion s sump temperature Since fluid temperature can affect transmission shift quality and convertor lock up the PCM TCM requires this information to determine which shift schedule to operate in The PCM also monitors this temperature data so it can energize the vehicle cooling fan s when a transmis sion overheat condition exists If the thermistor cir cuit fai...

Page 1746: ...c tional clutches The valve body contains the following components Fig 334 Regulator valve Solenoid switch valve Manual valve Converter clutch switch valve Converter clutch control valve Torque converter regulator valve Low Reverse switch valve In addition the valve body also contains the ther mal valve 2 3 4 check balls the 5 overdrive check valve and the 2 4 accumulator assembly Refer to 21 TRAN...

Page 1747: ... fluid to the torque converter LOW REVERSE SWITCH VALVE The low reverse clutch is applied from different sources depending on whether low 1st gear or reverse is selected 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...

Page 1748: ...NOTE To ease removal of the valve body turn the manual valve lever fully clockwise to low or first gear Fig 335 Oil Pan Bolts 1 OIL PAN BOLTS USE RTV UNDER BOLT HEADS Fig 336 Oil Pan 1 OIL PAN 2 1 8 INCH BEAD OF RTV SEALANT 3 OIL FILTER Fig 337 Oil Filter 1 OIL FILTER 2 O RING Fig 338 Valve Body to Case Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY JR 41TE AUTOMATIC TRANSAXLE 21 337 VALVE BOD...

Page 1749: ...ed the PCM TCM Quick Learn Procedure must be performed Refer to 8 ELECTRICAL ELEC TRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Remove manual shaft seal Fig 342 Fig 339 Push Park Rod Rollers from Guide Bracket 1 PARK SPRAG ROLLERS 2 SCREWDRIVER 3 PARK SPRAG GUIDE BRACKET Fig 340 Valve Body Removal Installation 1 VALVE BODY Fig 341 Underdrive and Overdrive Accumulators 1 O...

Page 1750: ...sion Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL VALVE CONTROL PIN 3 RETAINING SCREW Fig 344 Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 345 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLATE 2 DETENT SPRING Fig 346 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 RETURN SPRINGS 5...

Page 1751: ...351 11 Remove thermal valve Fig 352 12 Remove check balls Fig 353 NOTE Tag all valve spring assemblies for reassem bly identification Fig 347 Remove Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE 3 VALVE BODY Fig 348 Remove Transfer Plate 1 TRANSFER PLATE Fig 349 Remove Oil Screen 1 OIL SCREEN Fig 350 Remove Overdrive Clutch 5 Check Valve 1 OVERDRIVE CLUTCH 5 CHECK VALVE 21 340 41...

Page 1752: ...ODY Fig 352 Remove Thermal Valve 1 THERMAL VALVE Fig 353 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VALVE JR 41TE AUTOMATIC TRANSAXLE 21 341 VALVE BODY Continued ...

Page 1753: ...earn Procedure must be per formed Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Install valves and springs as shown in Fig 357 2 Install regulator valve spring retainer Fig 358 3 Install dual retainer plate using Tool 6301 Fig 359 Fig 354 Remove Dual Retainer Plate using Tool 6301 1 TOOL 6301 2 RETAINER Fig 355 Remove Regulator Valve Spring Retai...

Page 1754: ...LVE 3 L R SWITCH VALVE 7 SOLENOID SWITCH VALVE 4 CONVERTER CLUTCH CONTROL VALVE 8 REGULATOR VALVE Fig 358 Install Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER Fig 359 Install Dual Retainer Plate using Tool 6301 1 TOOL 6301 2 RETAINER JR 41TE AUTOMATIC TRANSAXLE 21 343 VALVE BODY Continued ...

Page 1755: ...alls into position as shown in Fig 361 If necessary secure them with petrolatum or transmission assembly gel for assembly ease 6 Install thermal valve into transfer plate Fig 362 7 Install separator plate to valve body Fig 363 Fig 360 Valve Retainer Location 1 RETAINER 2 RETAINER 21 344 41TE AUTOMATIC TRANSAXLE JR VALVE BODY Continued ...

Page 1756: ...L CHECK LOCATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VALVE Fig 362 Install Thermal Valve 1 THERMAL VALVE Fig 363 Install Separator Plate 1 SEPARATOR PLATE 2 VALVE BODY JR 41TE AUTOMATIC TRANSAXLE 21 345 VALVE BODY Continued ...

Page 1757: ...t bind Fig 366 11 Install twenty four transfer plate to valve body screws Fig 367 and torque to 5 N m 45 in lbs Fig 364 Install Overdrive Clutch 5 Check Valve 1 OVERDRIVE CLUTCH 5 CHECK VALVE Fig 365 Install Oil Screen 1 OIL SCREEN Fig 366 Install Transfer Plate 1 TRANSFER PLATE Fig 367 Install Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE 3 VALVE BODY 21 346 41TE AUTOMATIC TRANS...

Page 1758: ... m 45 in lbs 16 Install manual shaft seal Fig 372 Fig 368 2 4 Accumulator Assembly 1 VALVE BODY 2 RETAINER PLATE 3 DETENT SPRING 4 RETURN SPRINGS 5 PISTON Fig 369 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLATE 2 DETENT SPRING Fig 370 Install Manual Shaft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 371 Install Transmiss...

Page 1759: ...g 373 2 Install valve body assembly to transaxle Fig 374 Install and torque valve body to transaxle case bolts Fig 375 to 12 N m 105 in lbs Fig 372 Manual Shaft Seal 1 SEAL 2 MANUAL SHAFT Fig 373 Underdrive and Overdrive Accumulators 1 OVERDRIVE PISTON AND SPRING 2 UNDERDRIVE PISTON AND SPRING Fig 374 Valve Body Removal Installation 1 VALVE BODY Fig 375 Valve Body to Case Bolts 1 VALVE BODY ATTACH...

Page 1760: ...nsmission range sensor connector 7 Install manual valve lever to manual shaft 8 Install gearshift cable to manual valve lever 9 Connect battery negative cable 10 Fill transaxle with Mopar ATF 4 Transmis sion fluid Refer to 21 TRANSMISSION TRANS AXLE AUTOMATIC 41TE FLUID STANDARD PROCEDURE Fig 376 Install Oil Filter and O Ring 1 OIL FILTER 2 O RING Fig 377 Oil Pan 1 OIL PAN 2 1 8 INCH BEAD OF MOPAR...

Page 1761: ......

Page 1762: ...exhibit steering wheel vibration VISUAL INSPECTION Visual inspection of the vehicle is recommended prior to road testing or performing any other proce dure Raise vehicle on a suitable hoist Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCEDURE Inspect for the following Verify correct OEM wheel and tire as well as correct wheel weights Aluminum wheels require unique wheel weights They are de...

Page 1763: ...re and wheel System radial runout should not exceed 0 76 mm 0 030 inch with no tread dips or steps Tread dips and steps can be identified by spikes of the dial indicator gauge Tread dips Rapid decrease then increase in dial indicator reading over 101 6 mm 4 0 inch of tread circumference Tread steps Rapid decrease or increase in dial indicator reading over 101 6 mm 4 0 inch of tread circumference d...

Page 1764: ...out of the wheel at the tire bead seat Fig 4 Runout should not exceed 0 254 mm 0 010 inch for aluminum wheels and 0 508 mm 020 inch for steel wheels Replace the wheel if it exceeds the limit d Measure lateral runout of the wheel at the tire bead seat Fig 5 Runout should not exceed 0 762 mm 0 030 inch for all wheels Replace the wheel if it exceeds the limit 5 Match Mounting If the wheel runout is w...

Page 1765: ... the radial force variation of an assembly through re indexing of the tire to wheel The equipment manufacturer or DaimlerChrysler Corporation may supply reference values as guide lines Radial force measurements above the reference value may not always result in a ride disturbance nor do they automatically mean the assembly compo nents are out of specification Do not replace compo nents based on ra...

Page 1766: ...imbalance Place half of this weight on the inner rim flange and the other half on the outer rim flange Fig 8 For dynamic balancing the balance equipment is designed to indicate the location and amount of weight to be applied to both the inner and outer rim flanges Fig 9 The aluminum wheels on this vehicle use a unique wheel weight Fig 10 This wheel weight is designed to fit the contoured surface o...

Page 1767: ... items 2 through 5 within Diagnosis And Testing Tire And Wheel Vibration Refer to 22 TIRES WHEELS DIAGNOSIS AND TESTING STANDARD PROCEDURE TIRE AND WHEEL ROTATION 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 ...

Page 1768: ...ssembly first position it properly on the studs and hub mounting surface using the hub pilot as a guide CAUTION Never apply oil or grease to the wheel mounting studs or nuts 2 Install and progressively tighten the five wheel mounting lug nuts in the proper sequence Fig 12 until half the specified torque is reached Repeat the sequence tightening the wheel mounting lug nuts to a final torque of 135 ...

Page 1769: ...LOAD INDEX T SPEED RATING NOTE Consult the tire manufacturer regarding any questions on tire specifications or capabilities TIRE CHAINS Refer to the owners manual supplied with the vehi cle to determine whether the use of tire chains is per mitted on this vehicle DESCRIPTION RADIAL PLY TIRES Radial ply tires improve handling tread life and ride quality and decrease rolling resistance Radial ply ti...

Page 1770: ...using the temporary spare tire Refer to Owner s Manual for complete details DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING TIRE NOISE Unusual 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 ...

Page 1771: ...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 shoulder wear tire flexing and can result in tire failure Fig 16 Over inflation causes rapid center wear and loss of the...

Page 1772: ...ANING TIRES Before delivery of a vehicle remove the protective coating on the tires with white sidewalls or raised white letters To remove the protective coating apply warm water and let it soak for a few minutes After wards scrub the coating away 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 brus...

Page 1773: ...CE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREAT MENT OR VERY HIGH MILEAGE THE RIM COULD FAIL WITHOUT WARNING CLEANING ALUMINUM WHEEL CARE Chrome plated and painted aluminum wheels should be cleaned regularly using mild soap and water to maintain their luster and to prevent corro sion Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to ...

Page 1774: ...eel stud out of the hub and bearing flange INSTALLATION CAUTION If a wheel mounting stud needs to be replaced in the hub and bearing assembly DO NOT hammer the 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 Install replacement wheel stud into flange of hub and bearin...

Page 1775: ...ng assembly from the press 5 Remove the stud from the socket INSTALLATION CAUTION DO NOT hammer studs into the hub flange If a stud is installed in such a manner dam age to the hub and bearing assembly may occur leading to premature bearing failure 1 Install wheel stud into stud hole in hub and bearing assembly 2 Position the hub and bearing assembly face down with stud pointing down into the well...

Page 1776: ...ALCOHOL BASED CLEANING SOL VENTS PERSONAL INJURY CAN 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 combustibl...

Page 1777: ...itioned without being held have someone 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 ...

Page 1778: ...epair 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 Procedure The repair proc...

Page 1779: ...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 M 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 PANELS PPO POLYPHENYLENE OXIDE...

Page 1780: ...R PANELS B PILLARS QUARTER PANELS SPORT BAR TRIM LIFTGATE TRIM DECKLID TRIM SCUFF PLATES KICK PANELS CONSOLES 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 MODU...

Page 1781: ...to dry before moving on with the repair PANEL REINFORCEMENT Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement backing Reinforcements can be made with several applications of glass cloth saturated with structural adhesive Semi rigid or flexible repair materials should be used for semi rigid or flexible backing rein forcement Fig 2 and Fig 3 Open ...

Page 1782: ...he damaged area must be removed from the panel to achieve a successful repair All spider web 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 surfaces around the damaged area should be s...

Page 1783: ...scrap pieces of patch material into 50 mm 2 in squares to use as patch supports to sustain the patch in the cutout 5 Drill 4 mm 0 160 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...

Page 1784: ...ked nylon mesh dry wall tape over gaps around patch Fig 14 19 Mix enough adhesive to cover the entire patch area 20 Apply adhesive over the mesh around patch and smooth epoxy with a wide spreader to reduce fin ish grinding Use two to three layers of mesh and adhesive to create a stronger repair Fig 15 PATCHED PANEL SURFACING After patch panel is installed the patch area can be finished using the s...

Page 1785: ... 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 cleaned and lubri cated During the winter season external door lock cylinders should be lubricated to assure proper oper ation when exposed to water and ice Prior to the application of any lubricant the parts concerned should be ...

Page 1786: ...61 45 Front seat inboard pivot bolt 40 30 Front seat recliner to seat cushion frame 12 9 Front seat track to cushion frame bolts 12 9 Front seat back 45 34 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 bolts 28 20 Front door hinge to door nuts 28 20 Fr...

Page 1787: ...INDEX DESCRIPTION FIGURE STICK TRIM C 4755 16 REMOVER MOLDINGS C 4829 17 PLIERS HEADLINER CLIP 6967 18 Fig 16 STICK TRIM C 4755 Fig 17 REMOVER MOLDINGS C 4829 Fig 18 PLIERS HEADLINER CLIP 6967 23 12 BODY JR BODY Continued ...

Page 1788: ...cushion and back 2 With the top down remove motor assembly from the floor panel 3 Remove the reservoir fill plug 4 Visually inspect fluid level The fluid level should be at least at the bottom edge of fill hole when motor bracket is held on a level flat surface If low inspect for leak in hydraulic system 5 Motor Pump a Put reservoir fill plug back in place Apply power to the motor and listen for o...

Page 1789: ...nkage Cylinders will be extended 4 Remove motor from floor panel Keep motor connected to wire harness 5 Hold cylinders upside down cylinder rod point ing down 6 Hold motor pump assembly with reservoir up The rubber fill plug will be at the top 7 Raise motor pump assembly to at least 2 inches above the horizontal rear seat back reinforcement 8 Cycle system at least once making sure cylin ders can e...

Page 1790: ...he lines 22 Verify system operation ADJUSTMENT TOP FRAME CAM The top frame cam changes forward or rearward position of the top header in relation to the wind shield header The cam turns inside the rear side rail and thrust link Fig 2 It may be necessary to lengthen the balance links 1 or 2 serrations after a cam adjustment The position of the cam high side determines the angle between the center a...

Page 1791: ...TO 12 2 70 TO 110 DOWEL PIN 11 7 TO 17 7 104 TO 156 SET SCREW LATCH HOOK 2 4 TO 4 4 21 TO 39 BALANCE LINK TOP 11 7 TO 17 7 105 TO 155 BALANCE LINK BOTTOM 22 TO 32 192 TO 288 CAM ASSEMBLY TORX SCREW 5 2 TO 7 2 43 TO 67 LATCH ASSEMBLY 10 TO 14 85 TO 125 CASTING DOWEL PIN RECEIVER 22 TO 28 195 TO 147 CYLINDER ROD END 22 TO 28 195 TO 147 CYLINDER LOWER PIVOT 22 TO 28 195 TO 147 PIVOT BRACKET TOP ASSEM...

Page 1792: ...p mechanism 14 Separate rear weatherstrip retainer channels from vehicle 15 Remove top cover listing from adhesive on roof rail 16 Raise folding top to the mid point 17 Remove screws holding convertible top header feature strip to header panel 18 Mark location of top cover on top header 19 Remove staples holding top cover to header 20 Remove screws in end of roof bow 21 Slide convertible top plast...

Page 1793: ... adhesive on rear side rail 24 Install side rail rear weatherstrip retainer channels 25 Install side rail rear weatherstrips 26 Verify fit and operation Adjust as necessary TOP HEADLINER REMOVAL CAUTION To avoid damage to the sunvisors rotate the driver s and passenger s sunvisor down before lowering or raising the convertible top 1 Lower all windows 2 Unlatch top and raise top to midway position ...

Page 1794: ...pressure from the system Lower top all the way down and release air pressure again by squeeze fill plug 8 Bleed system Refer to 23 BODY CONVERT IBLE TOP ADJUSTMENTS HYDRAULIC MOTOR PUMP BLEEDING PROCEDURES 9 Secure motor pump assembly into floor panel mounts 10 Verify system operation 11 Install quarter trim panel 12 Install rear seat cushion and rear seat back making sure these components do not ...

Page 1795: ...tain and remove push in nuts holding curtain to the studs CAUTION Take precautions not to tear curtain on the boot shelf during removal 3 Disengage the headliner at the rear sail panels 4 Disconnect wire connectors from terminals on heated rear window 5 Pull wire harness from sleeves at each side of the rear window 6 Remove nuts attaching belt line tack strips to vehicle NOTE Support top 12 inches...

Page 1796: ...o sail springs from the old rear window assembly and install onto the new rear window assembly 2 Place rear window locking strip on third bow 3 Insert the locking strip into the channel of the number three roof bow A rubber mallet may be required to set locking strip into channel Fig 14 Fig 11 SAIL PANEL REFERENCE MARKS 1 SEAM REFERENCE MARK 2 COVER ASSEMBLY 3 REFERENCE MARK 4 STAPLES 5 OUTER TACK...

Page 1797: ... bow 12 Using the nuts install the belt line tacking strips starting with the center tack strip and work ing outboard 13 Feed rear window defogger wire harness through the sleeves at each side of the rear window 14 Connect rear window defogger wire connectors to terminals 15 Engage the headliner at the rear sail panel 16 Install shower curtain with push on nuts CAUTION Make sure top well is not tr...

Page 1798: ...he convertible top 1 Lower all windows 2 Unlatch top and raise top midway 3 Remove headliner Refer to 23 BODY CON VERTIBLE TOP HEADLINER REMOVAL 4 Disconnect the outer straps from the top cover 5 To replace bow number 1 and or 2 drill out the three screws attaching top cover to bow Fig 16 The screws have thread lock on the screws threads and are difficult to remove Fig 17 6 Disconnect both stay pa...

Page 1799: ... 23 BODY CON VERTIBLE TOP HEADLINER INSTALLATION 7 Lower top and latch top 8 Raise all windows SIDE CENTER RAIL REMOVAL 1 Lower all windows 2 Unlatch top and raise top half way 3 Remove rear seat cushion Refer to 23 BODY SEATS SEAT CUSHION REMOVAL 4 Remove rear seat back Refer to 23 BODY SEATS REAR SEAT BACK REMOVAL 5 Remove sill plate as necessary Refer to 23 BODY INTERIOR DOOR SILL TRIM INSTALLA...

Page 1800: ... WEATHERSTRIP Fig 22 WEATHERSTRIP ATTACHING SCREWS 1 ATTACHING SCREWS Fig 23 SIDE CENTER RAIL REAR ATTACH SCREW 1 REAR BOLT Fig 24 SIDE CENTER RAIL FRONT ATTACHING SCREWS 1 ATTACHING BOLTS JR CONVERTIBLE TOP 23 25 SIDE CENTER RAIL Continued ...

Page 1801: ... QUARTER PANEL TRIM INSTALLATION 10 Install speaker grille Refer to 23 BODY IN TERIOR QUARTER PANEL TRIM INSTALLA TION 11 Install sill plate Refer to 23 BODY INTE RIOR DOOR SILL TRIM INSTALLATION 12 Install rear seat back Refer to 23 BODY SEATS REAR SEAT BACK INSTALLATION 13 Install rear seat cushion Refer to 23 BODY SEATS SEAT CUSHION INSTALLATION 14 Lower top and latch top 15 Raise all windows F...

Page 1802: ... from decklid 4 Place suitable padding between decklid and deck panel to protect paint finish 5 With aid of a helper remove bolts attaching decklid to decklid hinge 6 Remove decklid from vehicle INSTALLATION 1 Position decklid on vehicle 2 With aid of a helper loosely install bolts attaching decklid to decklid hinge 3 Align marks made on decklid previously to decklid hinge 4 Tighten bolts attachin...

Page 1803: ...ide of decklid to aid in positioning hinge 2 Install hinge to vehicle 3 Install bolts attaching hinge to quarter panel trough 4 Tighten bolts to 22 5 N m 200 in lbs torque 5 Place decklid against padded block and hold it steady 6 Install bolts attaching hinge to decklid 7 Tighten bolts to 22 5 N m 200 in lbs torque 8 Install prop rod to mounting studs 9 Install the gas prop rod lock caps 10 Remove...

Page 1804: ...o marks made pre viously on rear closure panel 4 Tighten bolts to 12 N m 106 in lbs torque 5 Verify fit of decklid to deck panel and operation of decklid latch Adjust as necessary DECKLID LOCK CYLINDER REMOVAL 1 Release decklid latch and open decklid 2 Remove decklid latch 3 Remove clip attaching decklid lock cylinder to security alarm switch if so equipped Fig 5 4 Remove security alarm switch if ...

Page 1805: ... and handle assembly Fig 7 INSTALLATION 1 Clip emergency release cable onto the latch 2 Install the decklid latch cover Fig 6 DECKLID LATCH COVER 1 Push pin 2 Decklid latch cover Fig 7 EMERGENCY RELEASE CABLE 1 Release Cable Clip 2 Decklid Latch 23 30 DECKLID HATCH LIFTGATE TAILGATE JR ...

Page 1806: ...INSTALLATION 40 ADJUSTMENTS ADJUSTMENT 41 LATCH STRIKER REMOVAL 42 INSTALLATION 42 LOCK BUTTON BELL CRANK REMOVAL 42 INSTALLATION 42 LOCK CYLINDER DESCRIPTION 43 REMOVAL 43 INSTALLATION 43 SIDE VIEW MIRROR FLAG DOOR GLASS CHANNEL REMOVAL 43 INSTALLATION 43 TRIM PANEL REMOVAL 44 INSTALLATION 44 REAR VERTICAL GUIDE BAR REMOVAL JR 27 45 INSTALLATION JR 27 45 WINDOW REGULATOR REMOVAL REMOVAL 46 REMOVA...

Page 1807: ...port door on a suitable lifting device 2 Mark hinges attachment locations with a grease pencil or other suitable device to aid installa tion 3 Disengage wire connector at hinge A pillar 4 Remove bolts attaching door check strap to hinge A pillar Fig 2 5 Remove the nuts attaching the door to the door hinges and remove the door from the vehicle INSTALLATION 1 Position door onto the door hinges and i...

Page 1808: ... alignment 7 Remove door and hinge as necessary DOOR GLASS REMOVAL REMOVAL 1 Remove door trim panel and inner belt weath erstrip 2 Connect power window switch and lower win dow to approximately mid position The lift plate nuts will align with holes in the inner door panel 3 Loosen screws attaching regulator roller chan nel to glass 4 Slide roller channel rearward to allow screw heads to pass throu...

Page 1809: ... Remove rear guide plate from door glass 9 Lift door glass upward and out of opening at top of door Fig 6 INSTALLATION INSTALLATION 1 Lower glass down and in the opening at top of door 2 Position glass on roller channel 3 Slide roller channel forward to allow screw heads to engage key hole slots in channel 4 Tighten screws attaching regulator roller chan nel to glass Fig 5 INNER BELT STABILIZER Fi...

Page 1810: ...prior to adjusting the door glass NOTE Lower quarter glass to the full down position while making door glass adjustments unless other wise instructed TOP OF GLASS INBOARD OUTBOARD ADJUSTMENTS 1 Remove the access covers Disengage front cover by prying at its rear edge Disengage rear cover by prying at notch at bottom of reflector Fig 8 and Fig 9 2 Remove the convertible top side rail weather strip ...

Page 1811: ... inboard outboard adjustments 1 Remove door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 2 Remove window switch from door trim panel to operate glass 3 Remove watershield as necessary to gain access to the rear adjuster Lifting up the flap in the water shield can access the front adjuster Fig 10 4 With glass in the slightly lowered position to relieve pressure on up stops prior to adj...

Page 1812: ...lush with the mirror flag edge Adjust the mirror flag as necessary to achieve a flush condition Fig 13 10 Verify that the forward up stop fully contacts hook on glass Adjust contact bolt on the forward up stop as necessary GLASS FRONT REAR ADJUSTMENT 1 Remove the rear upper corner of watershield Refer to 23 BODY DOOR FRONT WATER SHIELD REMOVAL 2 Lower door glass slightly 2 mm or 5 64 inch to gain ...

Page 1813: ...adjustments are made 1 Raise quarter glass to full up position 2 Close door and cycle door glass between full up and full down positions 3 Verify that door glass operates smoothly and maintains correct alignment to convertible top and quarter glass 4 Verify that quarter glass weatherstrip fully contacts door glass 5 Verify that no scissoring of the door glass and weatherstrip occurs 6 If any of th...

Page 1814: ...anel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 2 Raise door glass 3 Remove water dam as necessary to gain access Refer to 23 BODY DOOR FRONT WATERDAM REMOVAL 4 Disconnect latch rod at door latch 5 Remove nuts attaching door handle to outer door panel Fig 18 6 Remove outside door handle from door INSTALLATION 1 Position outside door handle on door Fig 18 2 Install nuts attaching door handle to...

Page 1815: ...llar 7 Verify door fit and operation Adjust door hinge for proper door alignment if necessary Refer to 23 BODY DOOR FRONT DOOR ADJUSTMENTS LATCH REMOVAL 1 Remove door trim panel and watershield 2 Raise door glass 3 Remove the bolt and nut for the rear glass run channel and position aside 4 Disconnect lock rod from lock button bellcrank 5 Disengage lock and latch rods from clips on inner door panel...

Page 1816: ...OR FRONT TRIM PANEL INSTALLATION and water dam Refer to 23 BODY DOOR FRONT WATERDAM INSTALLATION ADJUSTMENTS ADJUSTMENT 1 Insert a suitable allen wrench through elon gated slot in door end frame and loosen bolt 1 2 to one full turn Fig 24 2 Cycle outside door handle twice 3 Tighten adjusting screw to 3 4 N m 30 in lbs torque 4 Verify latch operation Fig 21 Latch and Lock Rod Clips 1 INSIDE LOCK BU...

Page 1817: ...riker to marks on B pillar made previously 4 Tighten all fasteners 5 Verify door fit and operation Adjust door latch striker as necessary LOCK BUTTON BELL CRANK REMOVAL 1 Remove door trim panel 2 Disengage clip holding lock linkage to bell crank 3 Rotate bell crank until retaining ears align with slots in door panel 4 Remove bell crank from door Fig 26 INSTALLATION 1 Place bell crank into position...

Page 1818: ...OR GLASS CHANNEL REMOVAL 1 Remove side view mirror Refer to 23 BODY EXTERIOR SIDE VIEW MIRROR REMOVAL 2 Partially lower the door glass 3 Remove inner belt line glass seal 4 Remove attaching fasteners Fig 28 5 Remove the adjustment stud Count the num ber of turns to aid installation 6 Remove mirror flag INSTALLATION 1 Align glass into the guide and position the mir ror flag on door Fig 28 2 Install...

Page 1819: ...ion door trim panel near to door 2 Connect electrical connectors as necessary including foot light if so equipped 3 Engage clip attaching latch linkage to inside door handle 4 Lift the door trim slightly to get the lock knob into its bezel opening on the panel 5 Place front portion of upper trim strip flange into retainer channel while seating white forward locator pin into mating hole in sheet me...

Page 1820: ...screws Fig 31 3 Remove nut attaching top of guide bar to inner door panel 4 Using a suitable allen wrench hold jack screw stationary while removing nut attaching bottom of guide bar to inner door panel 5 Remove guide bar from vehicle and remove through access hole in inner door panel Fig 32 INSTALLATION JR 27 1 If a new guide bar is being installed preset bottom jack screw using old guide bar as a...

Page 1821: ... panel REMOVAL JR 27 ONLY NOTE For power window motor removal proce dures Refer to 8 ELECTRICAL POWER WIN DOWS WINDOW MOTOR REMOVAL 1 Remove door trim panel and water shield 2 Disconnect wire connector to power window motor 3 Remove nuts attaching regulator lift channel to door glass Refer to 23 BODY DOOR FRONT DOOR GLASS REMOVAL 4 Secure door glass in upward position 5 Mark position of rear bolt ...

Page 1822: ...gage bolt heads into key hole slots in inner door panel reinforcement and tighten bolts 3 Install roller channel to door panel 4 Install bolt at rear of roller channel Make sure that bolt is aligned to mark on inner door panel made previously 5 Tighten front and rear bolts of roller channel 6 Install nuts attaching regulator lift channel to door glass 7 Verify glass fit and operation Adjust door g...

Page 1823: ...iver 3 Lightly close the door to indent the clay with the door pin Fig 38 NOTE The alignment of the pin indentation to the receiver cup should be centered 4 If the door pin receiver needs to go for aft in the car remove the door pin receiver and add remove the pin receiver shims if necessary Refer to 23 BODY DOOR FRONT DOOR PIN ASSEMBLY REMOVAL NOTE 3 mm total of shims are standard but this can va...

Page 1824: ... bead INSTALLATION 1 Insure that the adhesive bead is not broken so the complete perimeter of the door seal will be main tained Replace any loose damaged adhesive with butyl sealer or similar If repair is not possible replace with a new watershield 2 Place the watershield into position using the two depressions that locate into the corresponding holes in the door inner panel Fig 39 3 Firmly press ...

Page 1825: ...N 57 APPLIQUE REMOVAL 1 Pull the glass run weatherstrip away from the window opening to access the applique screws Refer to 23 BODY WEATHERSTRIP SEALS REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 2 Remove the screws under the glass run weath erstrip Fig 1 3 Remove the upper push pin fastener 4 Remove the lower inner screw and remove the applique INSTALLATION 1 Install the applique and the screws 2 Ins...

Page 1826: ...to inner door panel 4 Install bolt attaching check strap to hinge pil lar 5 Position the watershield back Refer to 23 BODY DOORS REAR WATERSHIELD INSTAL LATION 6 Install rear door trim panel DOOR REMOVAL 1 Open and support door on a suitable lifting device 2 Mark hinges attachment locations with a grease pencil or other suitable device to aid installa tion 3 Disengage wire connector at hinge B pil...

Page 1827: ...41 GAP AND FLUSH SPECIFICATIONS 3 If door needs to be adjusted Fore Aft loosen B pillar to hinge bolts Fig 5 4 If door needs to be adjusted In Out loosen door to hinge nuts 5 If door alignment can not be achieved it maybe necessary to enlarge drill the hinge flange holes to 12 5 mm 1 2 inch 6 This may allow extra movement to achieve the proper alignment 7 Remove door and hinge as necessary Fig 4 R...

Page 1828: ...ding regulator roller channel to glass 5 Position rear run channel on door 6 Tighten bolts holding rear lower run channel to inner door panel 7 Install door trim panel and inner belt weather strip EXTERIOR HANDLE REMOVAL 1 Remove rear door trim panel 2 Close door glass 3 Disengage clip holding linkage to outside han dle 4 Remove linkage from outside handle Fig 7 5 Remove nuts holding outside handl...

Page 1829: ... hinge on vehicle 4 Loosely install nuts attaching hinge to door end frame Fig 9 5 Align hinge to marks made previously and tighten bolts and nuts to 28 N m 20 ft lbs torque 6 Install bolts attaching door check strap to lower A pillar 7 Verify door fit and operation Adjust door hinge for proper door alignment as necessary Refer to 23 BODY DOORS REAR DOOR ADJUSTMENTS Fig 8 REAR DOOR HINGES 1 UPPER ...

Page 1830: ...VAL 1 Mark outline of door latch striker on C pillar to aid installation 2 Remove screws attaching door latch striker to C pillar Fig 11 3 Remove door latch striker from vehicle NOTE Be sure to check for any shims between door latch striker and C pillar If any shims are found they must be reinstalled with the new door latch striker to maintain proper door operation INSTALLATION 1 Position door lat...

Page 1831: ... button 13 Remove rear door trim panel from vehicle INSTALLATION 1 Position rear door trim panel on vehicle 2 Connect linkage to latch handle 3 Engage clip holding linkage to latch handle 4 Connect wiring harness at door opening 5 Position the lock knob through the trim panel and engage trim panel from inner belt weatherstrip at top of door 6 Align the clips attaching perimeter of trim panel to re...

Page 1832: ...fer to 23 BODY DOORS REAR TRIM PANEL REMOVAL 2 Remove door speaker if equipped Refer to 8 ELECTRICAL AUDIO SPEAKER REMOVAL CAUTION Do not use dirty hands or lint type gloves when removing the watershield adhesive bead will be ruined 3 Peel watershield and adhesive away from the door inner panel Start in one corner carefully work ing towards the opposite corner 4 Store watershield flat adhesive sid...

Page 1833: ...E VIEW MIRROR REMOVAL 65 INSTALLATION 65 SIDE VIEW MIRROR GLASS REMOVAL 66 INSTALLATION 66 SPOILER REMOVAL REMOVAL JR 41 66 REMOVAL JR 27 67 INSTALLATION INSTALLATION JR 41 67 INSTALLATION JR 27 67 TAPE STRIPE REMOVAL ADHESIVES 67 INSTALLATION ADHESIVES 67 ACCESSORY DRIVE BELT SPLASH SHIELD REMOVAL 1 Remove the right front wheelhouse splash shield Refer to 23 BODY EXTERIOR RIGHT FRONT WHEELHOUSE S...

Page 1834: ...lding dry with lint free cloth Apply new body side molding two sided adhesive tape to back of molding 2 Clean body surface with Mopar Super Kleen solvent or equivalent Wipe surface dry with a lint free cloth 3 Apply a length of masking tape on the body parallel to the top edge of the molding to use as a guide if necessary 4 Remove protective cover from tape on back of molding Apply molding to body...

Page 1835: ...aching cowl cover to cowl 5 Install windshield wiper arms Refer to 8 ELECTRICAL WIPERS WASHERS WIPER ARMS INSTALLATION EXTERIOR NAME PLATES REMOVAL FOAM TAPE 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 Using a trim stick C 4755 or equivalent gently pry up at corners and remove 4 Clean off all traces of adhesive or...

Page 1836: ...ve fender from vehicle INSTALLATION 1 Place fender in position on vehicle 2 Start the center upper rail bolt Fig 5 or Fig 6 3 From inside engine compartment start the center upper rail bolt Install all the bolts attaching fender to upper rail and tighten 4 Install fender to lower cowl panel bolt 5 Install fender to rocker panel bolt 6 Place fascia into position 7 Install fender to fascia bolt 8 In...

Page 1837: ... operates properly GRILLE REMOVAL REMOVAL JR 41 1 Remove front bumper fascia from the vehicle Refer to 13 FRAMES BUMPERS BUMPERS FRONT FASCIA REMOVAL 2 Unsnap upper and lower grille surround s Using a trim stick if necessary Fig 8 3 Remove screws attaching grille 4 Remove grille from fascia Fig 8 FRONT GRILLE JR 41 1 GRILLE 4 2 ATTACHING SCREW S 3 FRONT FASCIA 4 UPPER GRILLE SURROUND 5 LOWER GRILL...

Page 1838: ...7 1 Position grille on fascia 2 Install screws attaching grille to fascia Fig 9 3 Install foam impact bar to fascia 4 Place fascia into position 5 Install front bumper fascia Refer to 13 FRAMES BUMPERS BUMPERS FRONT FASCIA INSTALLATION LEFT FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1 Remove left front wheel Refer to 22 TIRES WHEELS REMOVAL 2 Remove the seven push pin fasteners the three screws and re...

Page 1839: ...LATION 1 Install radiator support crossmember to vehi cle 2 Install nuts attaching hood latch to radiator support crossmember 3 Install bolts attaching crossmember to radiator closure panel 4 Install bolts attaching support braces to bottom of radiator support crossmember 5 Install push in fasteners attaching fascia grille to radiator support crossmember 6 Close hood REAR WHEELHOUSE SPLASH SHIELD ...

Page 1840: ... Disengage wire harness grommet from mirror flag if so equipped 5 Disconnect manual mirror adjuster from side mirror cover if so equipped 6 Remove nuts attaching side view mirror to mir ror flag Fig 16 7 Remove side view mirror from vehicle INSTALLATION 1 Feed power mirror wire harness through hole in mirror flag and seat grommet Do not pull on wire harness to seat grommet if so equipped 2 Route a...

Page 1841: ...der to the mirror assembly NOTE Position the mirror glass holder so that the moisture drain hole on the mirror glass holder assembly is facing downward 2 Align the mirror glass holder s attaching fin gers to the mirror motor housing NOTE Ensure that the protective rubber cover of the mirror motor housing is positioned correctly around the bottom of the fingers area 3 Using one hand firmly press th...

Page 1842: ...g 19 4 Position spoiler on the decklid aligning studs to holes and spoiler into position 5 Press firmly on the leading edge of spoiler to assure adhesion 6 Raise decklid and install nuts attaching spoiler to the decklid Tighten nuts to 5 N m 45 in lbs torque Fig 18 7 Close decklid TAPE STRIPE REMOVAL ADHESIVES 1 Mark reference points before removing 2 Using a heat gun gently apply heat in a circu ...

Page 1843: ... Rotate hood adjuster bumper clockwise Adjust hood adjuster bumper to achieve a hood height that is flush across the top surfaces along fenders 4 Close hood HINGE REMOVAL 1 Support hood on the side that requires hinge replacement 2 Mark hinge attachment locations with a grease pencil or other suitable device to aid installation 3 Remove cowl cover Refer to 23 BODY EXTE RIOR COWL GRILLE REMOVAL 4 R...

Page 1844: ...hood to hinge fin ger tight 4 Position bolts at outline marks and tighten 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 fenders 5 Connect under hood lamp wire connector to engine compartment wire harness if equipped 6 Verify hood latch operation and alignment Adjust as necessary LATCH REMOVAL 1 Release hood latch and open hood 2...

Page 1845: ...tch Refer to 23 BODY HOOD LATCH INSTALLATION PROP ROD REMOVAL 1 Release hood latch and open hood CAUTION Do not place prop rod or substitute against outer hood panel damage to exterior finish will result 2 Prop hood open using a length of wooden dowel rod ex Broomstick 3 Disengage prop rod from retainer attaching prop rod to radiator closure panel Fig 7 4 Remove prop rod from vehicle INSTALLATION ...

Page 1846: ...STRUMENT SILENCER PANEL REMOVAL 79 INSTALLATION 79 RIGHT LOWER SILENCER PANEL REMOVAL 79 INSTALLATION 79 RIGHT INSTRUMENT PANEL TRIM BEZEL REMOVAL 80 INSTALLATION 80 RIGHT LOWER INSTRUMENT PANEL TRIM REMOVAL 80 INSTALLATION 80 KICK SHIELD REMOVAL 81 INSTALLATION 81 DASH PANEL REMOVAL 81 INSTALLATION 81 CD CHANGER TRIM BEZEL REMOVAL 1 Using a trim stick special tool C 4755 or equivalent gently pry ...

Page 1847: ... be required 1 Recover the A C refrigerant Refer to 24 HEATING AIR CONDITIONING STANDARD PROCEDURE 2 Partially drain the coolant Refer to 7 COOL ING ENGINE STANDARD PROCEDURE 3 Remove one bolt retaining the A C lines to the right strut tower 4 Remove the two top HVAC housing retaining nuts in engine compartment Fig 2 5 Hoist vehicle and remove the lower HVAC housing retaining nut 6 Lower vehicle f...

Page 1848: ... 34 Remove two screws to the steering column shrouds and remove 35 Disconnect all the column wiring and unclip the harness from the steering column 36 Disconnect the transmission shift interlock and wire connector 37 Remove the four steering column retaining bolts and drop column to floor 38 Using a trim stick or equivalent pry up on the rear of the top cover and pull rearward as you lift off of i...

Page 1849: ...o the left cowl trim panel Refer to 23 BODY INTERIOR COWL TRIM INSTALLATION 19 Install the left door sill plate Refer to 23 BODY INTERIOR DOOR SILL TRIM INSTALLA TION 20 Install the one right side center instrument panel support bolt 21 Install the right silencer 22 Install the four right A pillar instrument panel retainers 23 Connect the right door harness connectors located within the A pillar 2...

Page 1850: ...rol 4 Remove the instrument panel center bezel from the vehicle INSTALLATION The HVAC control is mounted to the instrument panel center bezel If replacing the center bezel or the HVAC control it must be removed from the cen ter bezel Remove the six retaining screws to the HVAC control 1 Connect the wire connectors to the HVAC con trol 2 Position the center bezel over the retaining slots and firmly...

Page 1851: ...VAC control connectors 8 Position the center bezel over the retaining slots and firmly snap instrument panel center bezel into place 9 Install the left end cover 10 Connect the battery negative cable INSTRUMENT PANEL END COVER REMOVAL 1 Open front door 2 Using a trim stick special tool C 4755 or equivalent disengage clips holding end cover to instrument panel Fig 7 INSTALLATION 1 Position end cove...

Page 1852: ...el Instrument Panel Center Bezel Installation INSTRUMENT PANEL OUTBOARD BEZEL REMOVAL 1 Disconnect and isolate the battery negative remote cable 2 Using a trim stick special tool C 4755 or equivalent gently pry out on the instrument panel outboard switch bezel Fig 9 3 Disconnect the wire connector 4 Remove bezel from vehicle 5 Push in the sides of the power mirror switch to release it from the bez...

Page 1853: ... 4755 or equivalent gently pry out on the left instrument panel end cover and remove from vehicle Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL END CAP REMOVAL 2 Using a trim stick or equivalent gently pry out on the power mirror switch bezel disconnect the switch connector and remove 3 Remove the five screws to the left lower instru ment panel trim Disengage one wiring connector to deck lid ...

Page 1854: ...ning slots and firmly push into place 5 Install five screws attaching left lower instru ment panel trim 6 Connect power mirror switch wire connector 7 Install instrument panel bezel 8 Install end cap RIGHT LOWER SILENCER PANEL REMOVAL 1 Remove the attaching stamp nut Fig 12 2 Using a trim stick gently pry out silencer panel from lower right trim bezel 3 Remove panel from the instrument panel INSTA...

Page 1855: ...lower instrument panel trim Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL TRIM REMOVAL 7 Remove instrument panel center bezel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL REMOVAL 8 Remove instrument panel inboard bezel and outboard bezel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL TRIM REMOVAL Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL TRIM REMOVAL 9 Remove ...

Page 1856: ...d to insure engagement DASH PANEL REMOVAL NOTE The instrument panel dash panel vinyl skin and substrate can be removed without removing the entire instrument panel and HVAC assemblies 1 Follow all of the right lower instrument panel removal procedures Refer to 23 BODY INSTRU MENT PANEL INSTRUMENT PANEL TRIM REMOVAL 2 Disconnect and remove passenger air bag Refer to 8 ELECTRICAL RESTRAINTS PASSEN G...

Page 1857: ...top cover rearward edge 9 Assemble defroster duct and attach two screws 10 Attach five instrument panel to plenum screws 11 Attach two instrument panel steering column to plenum screws 12 Assemble instrument panel cluster 13 If vehicle is equipped with front speakers install four push nuts P N 06034833 connect speaker and attach to panel 14 If vehicle is equipped without front speakers install two...

Page 1858: ...STALLATION 92 QUARTER TRIM PANEL REMOVAL 93 INSTALLATION 93 REAR SHELF TRIM PANEL REMOVAL 93 INSTALLATION 94 REAR VIEW MIRROR REMOVAL REMOVAL 94 REMOVAL JR 27 ONLY 94 INSTALLATION INSTALLATION 94 INSTALLATION JR 27 ONLY 95 SHIFT BOOT REMOVAL 95 INSTALLATION 96 SUN VISOR REMOVAL 96 INSTALLATION 96 SUN VISOR SUPPORT REMOVAL 96 INSTALLATION 96 UPPER B PILLAR TRIM REMOVAL 97 INSTALLATION 97 UPPER DECK...

Page 1859: ...P INSTALLATION INSTALLATION JR 27 ONLY 1 Position trim panel near A pillar 2 Align locating pins on back side of trim panel to holes in A pillar 3 Press clips on A pillar trim panel into slots in A pillar Fig 1 INTERIOR TRIM PANELS 1 A PILLAR TRIM 2 BEZEL B PILLAR LOWER 3 UPPER B PILLAR TRIM 4 UPPER QUARTER TRIM 5 LOWER QUARTER TRIM 6 SEAT BELT 7 SCUFF PLATE 8 LOWER B PILLAR TRIM 9 SCUFF PLATE 10 ...

Page 1860: ...rear seat cushion Refer to 23 BODY SEATS SEAT CUSHION REMOVAL 3 Remove front seats Refer to 23 BODY SEATS SEAT REMOVAL 4 Remove amplifier on passenger side of floor pan if equipped 5 Remove bolts attaching front seat belts to floor 6 Remove lower B pillar trim panels as necessary to clear carpet 7 Remove cowl trim panels Refer to 23 BODY INTERIOR COWL TRIM REMOVAL 8 Remove floor console Refer to 2...

Page 1861: ...MOVAL 14 Install rear seat cushion Refer to 23 BODY SEATS SEAT CUSHION INSTALLATION 15 Install the eight push pin fasteners into the door opening sills 16 Install door opening sill plates INSTALLATION JR 27 ONLY 1 Position carpet in vehicle Fig 4 2 Install push in fasteners from rear of carpet attaching carpet to rear seat crossmember 3 Install front seat push pin fasteners 4 Feed wiring connector...

Page 1862: ...le Fig 6 INSTALLATION 1 Position cowl trim panel to vehicle 2 Install screws attaching cowl trim panel to inner cowl panel 3 Install door sill trim panel DOOR SILL TRIM PANEL REMOVAL 1 Using a fork type prying tool disengage clips holding door sill trim panel to door sill Fig 7 2 Starting at one end of sill trim panel pull upward on sill trim panel in order to disengage clips attaching sill trim p...

Page 1863: ...tly and lifting up until the locking tabs are free of the floor console Refer to Fig 8 for pressure points 5 Disconnect transmission range indicator bezel wire connector on the underside of bezel 6 Remove screws next to floor shifter and in con sole storage compartment attaching floor console to brackets on floor pan Fig 9 7 Disconnect wire connector for floor console accessories at floor pan 8 Re...

Page 1864: ...ee bolster 5 Release glove box door catches and allow to hang downward 6 Remove screws holding storage bin to forward instrument panel console Fig 12 7 Remove storage bin from forward instrument panel console 8 Remove screws holding forward instrument console to shifter mounting bracket 9 Remove screws attaching forward instrument panel console to instrument panel at sides of storage bin area 10 R...

Page 1865: ...OVAL 8 Remove upper quarter trim as necessary Refer to 23 BODY INTERIOR UPPER QUARTER TRIM REMOVAL 9 Disconnect headliner electrical connector along instrument panel bracket 10 Disconnect headliner electrical connector from fuse panel Fig 13 11 Pull down on the rear of the map lamp and sun roof switch to disengage clips from roof panel if equipped 12 Using Special Tool 6967 disengage headline rear...

Page 1866: ...OR SUN VISOR INSTALLATION 14 Connect electrical connector to sunroof switch if equipped 15 Push upward on sunroof switch to engage into switch retainer if equipped 16 Push upward on headlining around sunroof opening to engage hook and loop fasteners if equipped 17 Connect map lamp electrical connector if equipped 18 Confirm the headliner is not hung up on the side air bag deployment ramp 19 Push u...

Page 1867: ...3 Disengage clip attaching header trim panel to header panel 4 Remove header trim panel from vehicle Fig 15 INSTALLATION JR 27 ONLY 1 Position header trim panel on vehicle 2 Align locating pins on back side of trim panel to holes in header panel 3 Engage clip on trim panel to slots in header panel 4 Install center header trim panel Refer to 23 BODY INTERIOR INTERIOR TRIM PANELS INSTALLATION 5 Inst...

Page 1868: ...aching quarter trim panel to inner quarter panel through the speaker opening 5 Install vertical screws and inboard screw attaching quarter trim panel to inner quarter panel 6 Place toe blade into slotted sill clip 7 Install door sill trim panel 8 Install speaker grille 9 Install rear seat cushion and rear seat back REAR SHELF TRIM PANEL REMOVAL 1 Remove upper quarter trim panels as neces sary Refe...

Page 1869: ... Connect the center shoulder seat belt Refer to 8 ELECTRICAL RESTRAINTS SEAT BELT RETRACTOR INSTALLATION 9 Fold seat backs up REAR VIEW MIRROR REMOVAL REMOVAL 1 Remove screws attaching inside rear view mir ror to header panel 2 Disconnect wire connector to rear view mirror if so equipped 3 Remove rear view mirror from vehicle Fig 20 REMOVAL JR 27 ONLY All vehicles with driver and passenger side ai...

Page 1870: ... REMOVAL 1 Remove the shifter nob set screw and pull knob off of the shifter Fig 22 NOTE Do not use a trim stick or tool to remove transmission range indicator 2 Remove transmission range indicator bezel by squeezing the sides slightly and lifting up until the locking tabs are free of the floor console Refer to Fig 22 for pressure points 3 Disconnect the electrical connector if equipped and remove...

Page 1871: ... 5 Remove sun visor from vehicle INSTALLATION 1 Place sun visor into position 2 If equipped connect wire connector to body harness 3 Install screw attaching sun visor to header 4 Install screws attaching sun visor to roof header 5 Connect sun visor to center support SUN VISOR SUPPORT REMOVAL 1 Disengage sun visor from center support 2 Remove screw attaching support to roof header 3 Remove support ...

Page 1872: ...ect wire connector for CHMSL 3 Install screws attaching upper deck molding to rear deck panel inside decklid water trough 4 Install screws attaching upper deck molding to rear deck panel above convertible top rear attach ment 5 Raise and secure convertible top UPPER QUARTER TRIM REMOVAL 1 Remove the door opening weatherstrips as nec essary Refer to 23 BODY WEATHERSTRIP SEALS DOOR OPENING WEATHERST...

Page 1873: ...mper Fig 29 3 Remove damper from vehicle INSTALLATION 1 Place windshield header damper in position 2 Install nuts attaching damper 3 Install center header trim panel into position Refer to 23 BODY INTERIOR INTERIOR TRIM PANELS INSTALLATION Fig 28 UPPER QUARTER TRIM W O CURTAIN AIR BAG 1 C PILLAR LOWER 2 UPPER QUARTER TRIM PANEL 3 SHOLDER BELT Fig 29 Windshield Header Damper 1 STUDS 2 HEADER PANEL ...

Page 1874: ...AP4 INFERNO RED TINTED PEARL COAT WEL STONE WHITE CLEAR COAT SW1 LINEN GOLD PEARL COAT CYG INTERIOR COLORS INTERIOR COLOR DAIMLERCHRYSLER CODE INTERIOR COLOR DAIMLERCHRYSLER CODE G DEEP JADE LIGHT TAUPE P2 T TAUPE L5 L LIGHT TAUPE L2 S DARK SLATE GRAY DV BASECOAT CLEARCOAT FINISH DESCRIPTION On most vehicles a two part paint application basecoat clearcoat is used Color paint that is applied to pri...

Page 1875: ...o 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 st...

Page 1876: ... top of quarter panel 2 Install fasteners holding quarter window mod ule to inner quarter panel 3 Connect wire connector to power window motor 4 Raise glass lift channel to full up position 5 Position quarter glass on quarter window mod ule 6 Loosely install fasteners holding quarter glass to quarter window module 7 Lower and secure convertible top 8 Adjust quarter glass as necessary Refer to 23 B...

Page 1877: ...trip retainer gap Fig 4 6 Tighten all fasteners 7 Install center and rear side rail weatherstrips to side rail weatherstrip retainer channels 8 Cycle quarter glass between full up and full down positions Verify operation and adjust as neces sary 9 Verify that the top edge of the door glass is beneath the lip of the weatherstrip 10 Re apply the sealing patch Install the speaker cup speaker and spea...

Page 1878: ...Install center and rear side rail weatherstrips to side rail weatherstrip retainer channels 8 Cycle quarter glass between full up and full down positions Verify operation and adjust as neces sary 9 Tighten all fasteners 10 Verify that the top edge of the door glass is beneath the lip of the weatherstrip with glass in the full up position 11 Install quarter trim panel Refer to 23 BODY INTERIOR QUAR...

Page 1879: ...paper along the length of the seal there should be some resistance to pulling the paper out Fig 7 4 Verify that quarter glass weatherstrip fully contacts door glass 5 Verify that no scissoring of the door glass and weatherstrip occurs 6 If any of the above conditions are found a Adjust quarter glass b Adjust the door glass as necessary to cure the condition Fig 7 QUARTER GLASS ADJUSTMENT VERIFICAT...

Page 1880: ...N COVER 116 INSTALLATION FRONT SEAT CUSHION COVER 116 REAR SEAT DESCRIPTION 117 REAR SEAT CUSHION REMOVAL REMOVAL REAR 118 REMOVAL JR 27 ONLY 118 INSTALLATION INSTALLATION REAR 118 INSTALLATION JR 27 ONLY 118 REAR SEAT CUSHION COVER REMOVAL REMOVAL REAR SEAT CUSHION COVER 119 REMOVAL JR 27 ONLY 119 INSTALLATION INSTALLATION REAR SEAT CUSHION COVER 119 INSTALLATION JR 27 ONLY 119 REAR SEAT BACK REM...

Page 1881: ...ress the button on the head restraint sleeve guide left hand side and pull upward to release the head restraint 4 Remove head restraint from seat back INSTALLATION 1 Place head restraint in position 2 Push head restraint down into the lock posi tion 3 Raise head restraint to ensure it locks at the last stop Fig 1 Head Restraint Removal 1 SLEEVE GUIDE 2 BUTTON 3 STIFF WIRE 23 106 SEATS JR ...

Page 1882: ...EVE 4 SEAT BACK FRAME ASSEMBLY 5 LUMBAR CAM ASSEMBLY 6 LUMBAR HANDLE 7 LUMBAR ROD ASSEMBLY 8 LUMBAR BACKREST 9 SEAT SUSPENSION 10 POWER SEAT WIRING HARNESS 11 POWER SEAT ADJUSTER ASSEMBLY 12 POWER SEAT SWITCH 13 SEAT SIDE SHIELD 14 MANUAL SEAT ADJUSTER ASSEMBLY 15 CUSHION FRAME ASSEMBLY 16 MEMORY DUMP CAM 17 LOWER RECLINER HANDLE 18 RECLINER ASSEMBLY 19 UPPER RECLINER HANDLE JR SEATS 23 107 ...

Page 1883: ...olts attaching seat to side sill pylon 4 Position seat in full rearward position 5 Remove front inboard and outboard bolts hold ing seat to floor pan crossmember Fig 4 6 Tilt seat rearward and disconnect seat belt pre tensioner wire connector 7 Remove seat from vehicle REMOVAL POWER JR 27 1 Move seat to full forward position 2 Remove rear inboard bolt attaching seat to floor pan 3 Remove rear outb...

Page 1884: ...Install and tighten rear outboard bolt seat to side sill pylon 10 Install and tighten forward outboard bolt attaching seat to crossmember 11 Install and tighten forward inboard bolt attaching seat to crossmember 12 Move seat to full forward position Push rear ward slightly on seat to ensure that the adjuster latches are engaged on both seat tracks 13 Install and tighten rear inboard bolt attaching...

Page 1885: ...cure the lower seat belt anchor and seat belt buckle are not reusable Verify availability prior to proceeding 6 Remove seat cushion Refer to 23 BODY SEATS SEAT CUSHION REMOVAL 7 Remove nut attaching lower seat belt anchor to seat frame Fig 8 8 Back off nut attaching seat belt buckle to seat frame 9 Remove seat belt buckle pretensioner from seat frame 10 Remove E clip and washer from easy entry rod...

Page 1886: ...ner cable in front of metal strap at bottom of the seat back frame Fig 11 3 Position seat back to seat frame Refer to 23 BODY SEATS SEAT BACK INSTALLATION 4 Install bolt attaching recliner lead screw to seat frame Tighten bolt to 45 N m 33 ft lbs torque 5 Install pivot bolts attaching seat back to seat frame Tighten bolts to 51 N m 38 ft lbs torque 6 Attach easy entry rod to seat back passenger si...

Page 1887: ... lumbar support handle if equipped 5 Disengage the J strap retainer Fig 7 6 Remove hog rings attaching foam pad to back frame Fig 12 7 Roll seat back cover up to the next hog rings and remove hog rings 8 For bonded seat back cover separate frame from bonded cover and pad 9 Roll cover to top of cushion and remove head restraint sleeve guides Do not reuse head restraint sleeve guides 10 Remove cover...

Page 1888: ...me INSTALLATION INSTALLATION NOTE Do not reuse the recliner assembly attaching bolts 1 Position cover on the top of seat back 2 Install new head restraint sleeve guides 3 Carefully roll cover down to the area that hog rings are to be installed 4 Install hog rings 5 Install hog rings attaching back frame to foam pad 6 Roll cover downward Fig 14 Seat Cover Retainer Strip 1 SEAT BACK 2 PLASTIC RETAIN...

Page 1889: ...es 12 Slide long snaps on outboard portion of seat belt bezel inside seat back cover and seat belt retrac tor cover 13 Install upper recliner handle and lumbar adjustment handle if so equipped 14 Attach lower seat belt anchor to bolt on seat adjuster 15 Verify that seat belt is routed such that it will not be twisted when engaged to the seat belt buckle 16 Install new nut attaching lower seat belt...

Page 1890: ...d to seat frame 4 Install lower recliner handle FRONT SEAT CUSHION REMOVAL FRONT 1 Remove seat from vehicle 2 Remove front seat cushion side shields and dis connect wire connectors if equipped 3 Remove seat back 4 Remove seat cushion bolts 5 Disconnect wire harness fasteners from cushion frame Fig 21 6 Remove seat cushion Fig 22 INSTALLATION FRONT 1 Install wire harness fasteners to cushion frame ...

Page 1891: ...CUSHION COVER NOTE Fabric covered cushions are serviced as an assembly 1 Position seat cover on cushion 2 Align seat cover with cushion alignment inden tations Fig 25 3 Install hog rings 4 Engage J strap attaching seat cover to front of seat cushion frame 5 Install wire harness fasteners to cushion pan 6 Install seat cushion bolts 7 Install seat back Tighten recliner bolts to 12 N m 9 ft lbs torqu...

Page 1892: ...IPTION Refer to Fig 26 for more information while ser vicing the rear seat Fig 26 Rear Seat Exploded View 1 SEAT BACK FOAM AND FRAME 2 SEAT BACK COVER 3 SEAT CUSHION COVER 4 SEAT CUSHION FOAM AND FRAME JR SEATS 23 117 ...

Page 1893: ... cushions are serviced as an assembly NOTE Verify visibility of Latch bars in the seat bite area 1 Place rear seat cushion in position 2 Guild seat belts through loops 3 Engage retainer loops into cup on floor kick up 4 Push downward at forward edge at each retainer loop of the rear seat cushion to engage retainers INSTALLATION JR 27 ONLY NOTE Special care should be taken when removing rear seat c...

Page 1894: ...seat cushion foam 2 Install a hog ring at each hog ring location to attach seat cushion cover seam wires to wires in seat cushion foam Begin at center location and work out ward 3 Repeat above steps for opposite inboard vertical seam both outboard vertical seams and for the hor izontal seams 4 Pull seat cover over seat cushion frame and seat cushion foam 5 Install hog rings at hog ring locators ar...

Page 1895: ... fully engaged into retaining brackets 6 Install rear seat cushion REAR SEAT BACK COVER REMOVAL JR 27 ONLY 1 Remove rear seat back from vehicle Refer to 23 BODY SEATS REAR SEAT BACK REMOVAL 2 Place seat back on a suitable work surface in inverted position 3 Remove hog rings around perimeter of seat back holding seat back cover to seat back frame 4 Pull seat cover from seat back frame and seat back...

Page 1896: ...cliner 6 Remove towel bar spring 7 Remove push nuts attaching towel bar to seat adjuster 8 Remove towel bar from seat adjuster 9 Remove seat adjuster INSTALLATION INSTALLATION FRONT SEAT ADJUSTER POWER 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 to...

Page 1897: ...chanism to the seat back frame can be accessed 5 Remove rubber bellows covering lower part of seat back frame 6 Remove screws attaching upper recliner mech anism to seat frame 7 Remove bolts attaching recliner housing to seat frame 8 Push upper recliner mechanism into seat frame with handle shaft facing the front of the seat frame NOTE Do not reuse bolts holding recliner housing to seat frame Veri...

Page 1898: ...liner mechanism through hole in seat frame 4 Install screws attaching upper recliner mecha nism to seat frame 5 Install rubber bellows covering lower part of seat back frame 6 Install seat back cover 7 Install recliner spring bracket spring and lead screw 8 Install seat back to lower seat frame Refer to 23 BODY SEATS SEAT BACK INSTALLATION 9 Install recliner handle 10 Install seat into vehicle Ref...

Page 1899: ... GLASS PRIMER PVC VINYL PRIMER AND PINCH WELD FENCE PRIMER PROVIDED BY THE ADHESIVE MANUFACTURER IF NOT STRUCTURAL INTEGRITY COULD BE COMPROMISED DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNI CAL DATA SHEETS AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212 TECHNICIANS SHOU...

Page 1900: ...used 13 Remove windshield from vehicle REMOVAL The urethane adhesive holding the windshield to the opening pinch weld fence can be cut using a sharp cold knife from the exterior of the vehicle Using the cold knife method is effective if the wind shield is already broken If the glass must be sal vaged cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscil lati...

Page 1901: ... 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 9 Clean inside of windshield with ammonia based glass cleaner and lint free cloth 10 Apply Glass Prep adhesion promoter 25 mm 1 in wide around perimeter of windshield an...

Page 1902: ...ening 5 Position the windshield inside up on a suitable work surface with two padded wood 10 cm by 10 cm by 50 cm 4 in by 4 in by 20 in blocks placed par allel 75 cm 2 5 ft apart Fig 9 WARNING DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER POOR ADHESION CAN RESULT 6 Clean inside of windshield with ammonia based glass cleaner and lint free cloth 7 A...

Page 1903: ... windshield to verify repair BACKLITE REMOVAL For a description of tools and adhesive systems that are recommended for use in this procedure Refer to 23 BODY STATIONARY GLASS WIND SHIELD REMOVAL WARNING DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE IF IT IS NOT CURED THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCID...

Page 1904: ...R S DIRECTIONS FOR CUR ING TIME SPECIFICATIONS AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE CAUTION Open the left front door glass before installing the rear window to avoid pressurizing the passenger compartment if a door is slammed before the urethane bonding is fully cured Water leaks can result 1 Prepare the work area window fence and glass the same way as described in the Windshield sect...

Page 1905: ...e the sunroof will express open and the wind deflector will raise If the button is pressed a second time the sunroof will stop in that position Pressing and holding the close button will close the sunroof If the close button is released the sunroof will stop in that position DIAGNOSIS AND TESTING SUNROOF Before beginning sunroof diagnostics verify that all other power accessories are in proper ope...

Page 1906: ...ut does not close Binding cable Faulty circuit Faulty control switch Faulty sunroof electronic module Faulty drive motor Sunroof vents but does not open Binding cable or mechanism Faulty circuit Faulty switch Faulty sunroof electronic module Sunroof does not vent Binding cable or mechanism Faulty circuit Faulty control switch Faulty sunroof electronic module Sunroof water leak Drain tubes clogged ...

Page 1907: ...N TERIOR HEADLINER REMOVAL 4 Repair as necessary SUNROOF CONTROL SWITCH REMOVAL 1 Using a flat blade tool release switch from the headliner Fig 1 2 Disconnect the wire connector from the switch INSTALLATION 1 Connect the wire connector to the control switch 2 Install control switch into headliner 3 Test sunroof operation SUNROOF DRIVE MOTOR REMOVAL NOTE The sunroof system is timed from the fac tor...

Page 1908: ...es in the proper function of the sunroof The sunroof assembly come in the proper position As long as the motor is not has not been removed If the drive motor is removed and cycled the motor will have to be Timed If the sunroof glass panel has been moved from the park position with the drive motor removed Refer to 23 BODY SUNROOF GLASS PANEL ADJUSTMENTS 1 With drive motor removed from the sunroof a...

Page 1909: ... 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 If OK tighten the center two screws SUNROOF GLASS PANEL SEAL REMOVAL 1 Remove sunroof glass panel Refer to 23 BODY SUNROOF GLASS PANEL REMOVAL 2 Grasp the seal and pull seal away from the glass panel The seal is a one piece seal INSTALLATION NOTE Always...

Page 1910: ...gh INSTALLATION FRONT HOSES 1 Connect the drain hose to the sunroof housing and test drainage Fig 4 2 Set headliner into position 3 Connect express module drive motor and con trol switch wire connectors 4 Test sunroof operation adjust as necessary 5 Finish installing headliner Refer to 23 BODY INTERIOR HEADLINER INSTALLATION 6 Install sunroof opening trim lace Refer to 23 BODY SUNROOF OPENING TRIM...

Page 1911: ...TE There are locating pins on the roof panel near the front corners of the sunroof opening that will help position the sunroof module correctly 1 With the Glass panel in the fully closed posi tion 2 Raise rear end of sunroof module assembly and guide into position and start fasteners 3 Tighten the fasteners holding the sunroof mod ule to roof panel Tighten the fasteners to 11 N m 97 in lbs torque ...

Page 1912: ... and pull the handle out INSTALLATION 1 Install sunshade handle into the sunshade by pressing the handle into place until the tabs lock behind the sunshade 2 Install the sunshade into the vehicle between the roof and the glass panel in the vent position Fig 9 3 Move the sunshade to the closed position Through the opening using a flat tool engage the rear guides into the guide rails Fig 8 4 Slide s...

Page 1913: ...ease the wind deflector from sunroof housing Fig 11 3 Remove wind deflector Fig 12 INSTALLATION 1 Place wind deflector on wind deflector brackets 2 Install wind deflector hinge pins 3 Test sunroof operation Fig 11 Wind Deflector Hinge Pin 1 PUSH Fig 12 Wind Deflector 1 WIND DEFLECTOR 23 138 SUNROOF JR ...

Page 1914: ...TAINER MOLDING REMOVAL 145 INSTALLATION 145 OUTER DOOR BELT WEATHERSTRIP REMOVAL 145 INSTALLATION 145 QUARTER PANEL WEATHERSTRIP REMOVAL 145 INSTALLATION 146 QUARTER PANEL OUTER BELT WEATHERSTRIP MOLDING REMOVAL 146 INSTALLATION 146 REAR DOOR B PILLAR DOOR SEAL REMOVAL 146 INSTALLATION 146 REAR DOOR GLASS RUN WEATHERSTRIP REMOVAL 146 INSTALLATION 146 REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 147 I...

Page 1915: ...sh pins and remove the latch cover 4 Disconnect the three harness electrical connec tors and remove the ground strap screw 5 Tape the wires together and tape in one chase wire 6 Route the wires through the decklid 7 Pull decklid opening weatherstrip from decklid opening flange Fig 2 8 Remove decklid opening weatherstrip from vehicle INSTALLATION 1 Position decklid opening weatherstrip on vehi cle ...

Page 1916: ...on vehicle 2 Butt end of welt to edge of header A pillar weatherstrip 3 Push door opening welt onto door opening flange DRIP RAIL WEATHERSTRIP REMOVAL 1 Open front and rear doors 2 Remove two screws Fig 5 3 Position splash shield out of way 4 Starting at the bottom of the A pillar pull the drip rail weatherstrip from the windshield side molding 5 Pull the drip rail weatherstrip from the roof rail ...

Page 1917: ...ll door sill plate 3 Close door FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1 Remove door glass Refer to 23 BODY DOOR FRONT DOOR GLASS REMOVAL 2 Remove bolt attaching bottom of front lower run channel to inner door panel 3 Pull glass run weatherstrip from door glass opening frame 4 Remove lower run channel through opening at top of door Fig 8 INSTALLATION 1 Install lower run channel through opening ...

Page 1918: ... to front door Fig 10 2 Using a rubber mallet and block of wood tap upward at each clip attaching belt molding to door Fig 11 3 Lift up on the rear of the belt molding and pull rearward to remove INSTALLATION 1 Place belt molding in position 2 Using your hand press downward at each clip attaching belt molding to door till in position 3 Install screw attaching rearward end of mold ing to front door...

Page 1919: ...all new L foam starting at upper screw on A pillar retainer Fig 14 3 Position header and A pillar weatherstrip on vehicle 4 Secure weatherstrip into retainers at header and A pillar 5 Install nuts at upper corners of windshield 6 Install push in fasteners at lower corners of windshield 7 Install door sill trim panels 8 Install header trim panel 9 Install sun visors 10 Install inside rear view mirr...

Page 1920: ...arting at upper screw on A pillar 7 Install header and A pillar weatherstrip 8 Lower and secure convertible top OUTER DOOR BELT WEATHERSTRIP REMOVAL 1 Remove door glass 2 Remove screws attaching outer belt weather strip to outer door panel Fig 16 3 Remove outer belt weatherstrip from the vehicle INSTALLATION 1 Position outer belt weatherstrip on vehicle 2 Install screws to hold outer weatherstrip ...

Page 1921: ...olding 5 Install quarter trim panel 6 Raise and secure convertible top REAR DOOR B PILLAR DOOR SEAL REMOVAL 1 Using a suitable heat gun warm seal to approximately 100 F to ease adhesive separation 2 Peel B pillar seal from upper door frame top to bottom Fig 18 3 Clean adhesive residue from door frame INSTALLATION 1 If original seal is reused clean adhesive resi due from back of seal 2 Apply body s...

Page 1922: ... door Fig 21 2 Disengage clips attaching rearward end of belt molding to rear door 3 Using a rubber mallet and block of wood tap upward at each clip attaching belt molding to door Fig 22 4 Remove belt molding from door INSTALLATION 1 Place belt molding into position 2 Push or tap downward at each clip attaching belt molding to door 3 Engage clips attaching rearward end of belt molding to rear door...

Page 1923: ...MOVAL FRONT 1 Partially raise convertible top 2 Remove push in fasteners attaching weather strip to retainer 3 Remove weatherstrip from vehicle Fig 24 CENTER 1 Partially raise convertible top 2 Remove push in fasteners attaching weather strip to retainer 3 Remove weatherstrip from vehicle Fig 25 Fig 23 Secondary Sill Weatherstrip Typical 1 DOOR 2 SECONDARY SILL WEATHERSTRIP Fig 24 Front Side Rail ...

Page 1924: ... in fasteners into retainer channel aligning embossment on back side of weatherstrip to corner of retainer 3 Lower convertible top 4 Secure convertible top REAR 1 Position weatherstrip on vehicle 2 Install push in fasteners into retainer channel aligning embossment on back side of weatherstrip to corner of retainer 3 Push weatherstrip into retainer channel align ing embossment on backside of weath...

Page 1925: ...7 AND JR 41 160 SPECIFICATIONS SEALER LOCATIONS JR 27 ONLY 164 SPECIFICATIONS SEALER LOCATIONS JR 41 ONLY 180 STRUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS JR 27 196 SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS JR 41 207 WELD LOCATIONS SPECIFICATIONS SPECIFICATIONS WELD LOCATIONS JR 27 AND JR 41 214 SPECIFICATIONS WELD LOCATIONS JR 27 ONLY 248 SPECIFICAT...

Page 1926: ...Fig 1 BODY GAP AND FLUSH JR BODY STRUCTURE 23 151 GAP AND FLUSH Continued ...

Page 1927: ...4 0 1 0 Parallel within 1 5 Flush 1 5 Consistent within 2 0 7 Fuel Filter Door to Quarter Panel 3 0 0 75 Uniform within 1 0 Flush 1 0 8 Deck Lid Molding to Deck Lid 4 5 2 0 Parallel within 2 5 9 Deck Lid to Quarter Panel 4 0 1 0 Parallel within 1 0 Flush 1 5 Consistent within 1 5 10 Tail Lamp to Deck Lid 5 0 Blending to 5 5 1 5 LH RH to be within 2 0 11 Fascia to Deck Lid 7 0 2 0 Parallel Within 1...

Page 1928: ...Fig 2 BODY GAP AND FLUSH MEASUREMENTS JR BODY STRUCTURE 23 153 GAP AND FLUSH Continued ...

Page 1929: ...5 1 0 Parallel within 1 5 Flush 1 5 Consistent within 2 0 8 Fuel Filter Door to Quarter Panel 3 0 0 75 Uniform within 1 0 0 5 Under Flush 1 0 9 Front and Rear Doors at Sill 6 0 1 5 Parallel within 2 0 Front Door 5 5 Under Flush Rear Door 6 5 Under Flush 1 5 Consistent within 2 5 10 Deck Lid to Quarter Panel 4 5 1 0 Parallel within 1 0 Flush 1 5 Consistent within 1 5 11 Tail Lamp to Deck Lid 4 9 1 ...

Page 1930: ...Fig 3 WINDSHIELD OPENING JR BODY STRUCTURE 23 155 OPENING DIMENSIONS Continued ...

Page 1931: ...Fig 4 TRUNK OPENING Fig 5 DOOR OPENING 23 156 BODY STRUCTURE JR OPENING DIMENSIONS Continued ...

Page 1932: ...ATIONS BODY OPENING DIMENSIONS JR 41 INDEX DESCRIPTION FIGURE WINDSHIELD OPENING 6 REAR WINDOW AND TRUNK OPENING 7 DOOR OPENINGS 8 Fig 6 WINDSHIELD OPENING JR BODY STRUCTURE 23 157 OPENING DIMENSIONS Continued ...

Page 1933: ...Fig 7 REAR WINDOW AND TRUNK OPENING 23 158 BODY STRUCTURE JR OPENING DIMENSIONS Continued ...

Page 1934: ...Fig 8 DOOR OPENINGS JR BODY STRUCTURE 23 159 OPENING DIMENSIONS Continued ...

Page 1935: ... FIGURE HOOD HEM FLANGE 9 DASH PANEL TO LOWER COWL PLENUM PANEL 10 DASH PANEL TO FRONT FLOOR PAN 11 FRONT SUSPENSION UPPER MOUNTING 12 A PILLAR TO UPPER COWL 13 DASH PANEL LOWER COWL PLENUM 14 COWL PLENUM CLOSURE LOWER COWL PLENUM UPPER COWL PLENUM 15 Fig 9 HOOD HEM FLANGE 23 160 BODY STRUCTURE JR ...

Page 1936: ...Fig 10 DASH PANEL TO LOWER COWL PLENUM PANEL Fig 11 DASH PANEL TO FRONT FLOOR PAN JR BODY STRUCTURE 23 161 SEALER LOCATIONS Continued ...

Page 1937: ...Fig 12 FRONT SUSPENSION UPPER MOUNTING Fig 13 A PILLAR TO UPPER COWL 23 162 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1938: ...Fig 14 DASH PANEL LOWER COWL PLENUM Fig 15 COWL PLENUM CLOSURE LOWER COWL PLENUM UPPER COWL PLENUM JR BODY STRUCTURE 23 163 SEALER LOCATIONS Continued ...

Page 1939: ...ER DECK OPENING TO REAR FLOOR PAN 28 LOWER INNER DECK OPENING TO TAIL LAMP EXTENSION 29 INNER BODY SILL TO FRONT FLOOR PAN 30 INNER SILL EXTENSION TO SHOULDER BELT SUPPORT REINFORCEMENT 31 INNER REAR WHEEL HOUSING TO EXTENSION 32 REAR FLOOR PAN DECKLID INNER AREA RIGHT SIDE 33 REAR FLOOR PAN DECKLID INNER AREA LEFT SIDE 34 REAR WHEEL HOUSE LEFT SIDE 35 REAR WHEEL HOUSE RIGHT SIDE 36 REAR SHOCK TOW...

Page 1940: ...Fig 16 WINDSHIELD HEADER FRAME TO A PILLAR Fig 17 TAIL LAMP EXTENSION TO QUARTER PANEL AND DRAIN TROUGH JR BODY STRUCTURE 23 165 SEALER LOCATIONS Continued ...

Page 1941: ...Fig 18 TAIL LAMP EXTENSION TO LOWER DECKLID PANEL Fig 19 QUARTER PANEL TO DRAIN TROUGH 23 166 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1942: ...Fig 20 REAR SHELF PANEL REINFORCEMENT TO DRAIN TROUGH Fig 21 A PILLAR TO BODY SIDE OUTER PANEL JR BODY STRUCTURE 23 167 SEALER LOCATIONS Continued ...

Page 1943: ...Fig 22 OUTER QUARTER TO BODY SIDE OUTER DOG LEG Fig 23 LOWER DECK TO DRAIN TROUGH EXTENSION 23 168 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1944: ...Fig 24 FRONT DOOR LOWER HEM FLANGE Fig 25 DECKLID HEM FLANGE JR BODY STRUCTURE 23 169 SEALER LOCATIONS Continued ...

Page 1945: ...Fig 26 FRONT FLOOR PAN TO REAR FLOOR PAN Fig 27 A PILLAR TO COWL PLENUM PANEL 23 170 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1946: ...Fig 28 LOWER DECK OPENING TO REAR FLOOR PAN Fig 29 LOWER INNER DECK OPENING TO TAIL LAMP EXTENSION JR BODY STRUCTURE 23 171 SEALER LOCATIONS Continued ...

Page 1947: ...Fig 30 INNER BODY SILL TO FRONT FLOOR PAN Fig 31 INNER SILL EXTENSION TO SHOULDER BELT SUPPORT REINFORCEMENT 23 172 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1948: ...Fig 32 INNER REAR WHEEL HOUSING TO EXTENSION Fig 33 REAR FLOOR PAN DECKLID INNER AREA RIGHT SIDE JR BODY STRUCTURE 23 173 SEALER LOCATIONS Continued ...

Page 1949: ...Fig 34 REAR FLOOR PAN DECKLID INNER AREA LEFT SIDE Fig 35 REAR WHEEL HOUSE LEFT SIDE 23 174 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1950: ...Fig 36 REAR WHEEL HOUSE RIGHT SIDE Fig 37 REAR SHOCK TOWER BRACKET JR BODY STRUCTURE 23 175 SEALER LOCATIONS Continued ...

Page 1951: ...Fig 38 OUTER DECKLID TO OUTER DECKLID EXTENSION Fig 39 UPPER LOWER COWL PLENUM COWL SIDE PANEL 23 176 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1952: ...Fig 40 INNER OUTER UPPER LOAD PATH BEAM COWL SIDE PANEL Fig 41 OUTER QUARTER PANEL JR BODY STRUCTURE 23 177 SEALER LOCATIONS Continued ...

Page 1953: ...Fig 42 OUTER QUARTER PANEL SHELF ASSEMBLY Fig 43 BODY SIDE APERTURE INNER 23 178 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1954: ...Fig 44 INNER BODY SIDE APERTURE Fig 45 BAFFLES SEAL TAPE JR BODY STRUCTURE 23 179 SEALER LOCATIONS Continued ...

Page 1955: ...NEL DRAIN THROUGH 58 TAIL LAMP EXTENSION TO LOWER DECKLID PANEL 59 QUARTER PANEL TO DRAIN TROUGH 60 REAR SHELF PANEL REINFORCEMENT TO DRAIN TROUGH 61 ROOF DRIP RAIL SEAL SUPPORT 62 QUARTER DRIP RAIL SEAL SUPPORT 63 QUARTER PANEL TO BODY SIDE APERTURE DOOR FRAME JOINT 64 QUARTER PANEL TO BODY SIDE APERTURE DOG LEG 65 ROOF FLANGE TO QUARTER PANEL FLANGE 66 FRONT DOOR LOWER HEM FLANGE 67 REAR DOOR LO...

Page 1956: ...Fig 46 SILL INNER EXTENSION TO REAR FLOOR PAN Fig 47 INNER BODY SILL TO FRONT FLOOR PAN JR BODY STRUCTURE 23 181 SEALER LOCATIONS Continued ...

Page 1957: ...Fig 48 INNER LOWER DECK OPENING TO TAIL LAMP EXTENSION Fig 49 LOWER DECK OPENING TO REAR FLOOR PAN 23 182 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1958: ...Fig 50 DASH PANEL TO COWL INNER PANEL Fig 51 SILL INNER EXTENSION TO INNER REAR WHEELHOUSE JR BODY STRUCTURE 23 183 SEALER LOCATIONS Continued ...

Page 1959: ...Fig 52 SHELF PANEL TO INNER BODY SIDE APERTURE Fig 53 INNER REAR WHEELHOUSE TO REAR FLOOR PAN 23 184 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1960: ...Fig 54 REAR WHEELHOUSE Fig 55 REAR SHOCK TOWER BRACKET JR BODY STRUCTURE 23 185 SEALER LOCATIONS Continued ...

Page 1961: ...Fig 56 LOWER REAR FLOOR PAN TO LOWER DECK OPENING Fig 57 ROOF TO A PILLAR 23 186 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1962: ...Fig 58 TAIL LAMP EXTENSION TO QUARTER PANEL DRAIN THROUGH Fig 59 TAIL LAMP EXTENSION TO LOWER DECKLID PANEL JR BODY STRUCTURE 23 187 SEALER LOCATIONS Continued ...

Page 1963: ...Fig 60 QUARTER PANEL TO DRAIN TROUGH Fig 61 REAR SHELF PANEL REINFORCEMENT TO DRAIN TROUGH 23 188 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1964: ...Fig 62 ROOF DRIP RAIL SEAL SUPPORT Fig 63 QUARTER DRIP RAIL SEAL SUPPORT JR BODY STRUCTURE 23 189 SEALER LOCATIONS Continued ...

Page 1965: ...Fig 64 QUARTER PANEL TO BODY SIDE APERTURE DOOR FRAME JOINT Fig 65 QUARTER PANEL TO BODY SIDE APERTURE DOG LEG 23 190 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1966: ...Fig 66 ROOF FLANGE TO QUARTER PANEL FLANGE Fig 67 FRONT DOOR LOWER HEM FLANGE JR BODY STRUCTURE 23 191 SEALER LOCATIONS Continued ...

Page 1967: ...Fig 68 REAR DOOR LOWER HEM FLANGE Fig 69 DECKLID HEM FLANGE 23 192 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1968: ...Fig 70 FRONT FLOOR PAN TO REAR FLOOR PAN Fig 71 INNER UPPER LOAD BEAM COWL SIDE PANEL JR BODY STRUCTURE 23 193 SEALER LOCATIONS Continued ...

Page 1969: ...Fig 72 WINDSHIELD OPENING SIDE FRAME BODY SIDE APERTURE Fig 73 OUTER UPPER LOAD BEAM BODY SIDE APERTURE 23 194 BODY STRUCTURE JR SEALER LOCATIONS Continued ...

Page 1970: ...Fig 74 COWL SIDE PANEL BODY SIDE APERTURE INNER SIDE SILL Fig 75 ROOF SUPPORT DRIP RAIL ROOF PANEL JR BODY STRUCTURE 23 195 SEALER LOCATIONS Continued ...

Page 1971: ...AND INNER REAR WHEELHOUSE 80 LOWER DECK PANEL REAR FLOOR PAN AND REAR SHOULDER BELT CROSSMEMBER 81 WHEELHOUSE LEFT OUTER PANEL 82 WHEELHOUSE RIGHT OUTER PANEL 83 OPENING INNER FRAME RIGHT LEFT 84 PUSH PINS MELT SEAL 85 QUARTER OUTER PANEL TROUGH 86 QUARTER OUTER PANEL SUB 87 INNER BODY SIDE APERTURE 88 BODY SIDE APERTURE INNER QUARTER PANEL WINDSHIELD FRAME 89 REAR HEADER 90 OUTER WHEELHOUSE 91 LO...

Page 1972: ...Fig 76 FRONT AND REAR FLOOR PANS Fig 77 FRONT FLOOR PAN AND DASH PANEL JR BODY STRUCTURE 23 197 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1973: ...Fig 78 FRONT FLOOR PAN COWL SIDE PANEL AND INNER BODY SIDE SILL 23 198 BODY STRUCTURE JR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1974: ...Fig 79 REAR FLOOR PAN JR BODY STRUCTURE 23 199 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1975: ...Fig 80 INNER QUARTER PANEL AND INNER REAR WHEELHOUSE 23 200 BODY STRUCTURE JR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1976: ...Fig 81 LOWER DECK PANEL REAR FLOOR PAN AND REAR SHOULDER BELT CROSSMEMBER Fig 82 WHEELHOUSE LEFT OUTER PANEL JR BODY STRUCTURE 23 201 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1977: ...Fig 83 WHEELHOUSE RIGHT OUTER PANEL Fig 84 OPENING INNER FRAME RIGHT LEFT 23 202 BODY STRUCTURE JR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1978: ...Fig 85 PUSH PINS MELT SEAL Fig 86 QUARTER OUTER PANEL TROUGH JR BODY STRUCTURE 23 203 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1979: ...Fig 87 QUARTER OUTER PANEL SUB Fig 88 INNER BODY SIDE APERTURE 23 204 BODY STRUCTURE JR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1980: ...Fig 89 BODY SIDE APERTURE INNER QUARTER PANEL WINDSHIELD FRAME Fig 90 REAR HEADER JR BODY STRUCTURE 23 205 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1981: ...Fig 91 OUTER WHEELHOUSE Fig 92 LOWER QUARTER EXTENSION TAIL LAMP CAN OUTER QUARTER FILLER 23 206 BODY STRUCTURE JR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1982: ...INNER OUTER UPPER LOAD PATH BEAMS HINGE PILLAR REINFORCEMENT 96 INNER WINDSHIELD FRAME 97 ROOF BOW CENTER PILLAR 98 SIDE SILL REINFORCEMENT TO CENTER PILLAR 99 BAFFLE PLUG COWL PLENUM 100 ROOF PANEL INNER QUARTER UPPER BODY SIDE APERTURE UPPER WINDSHIELD FRAME BACKLITE FRAME REINFORCEMENT 101 Fig 93 FRONT AND REAR FLOOR PANS JR BODY STRUCTURE 23 207 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1983: ...Fig 94 FRONT REAR FLOOR PAN CROSSMEMBER REINFORCEMENT 23 208 BODY STRUCTURE JR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1984: ...Fig 95 FRONT FLOOR PAN AND DASH PANEL JR BODY STRUCTURE 23 209 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1985: ...Fig 96 INNER OUTER UPPER LOAD PATH BEAMS HINGE PILLAR REINFORCEMENT Fig 97 INNER WINDSHIELD FRAME 23 210 BODY STRUCTURE JR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1986: ...Fig 98 ROOF BOW CENTER PILLAR JR BODY STRUCTURE 23 211 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1987: ...Fig 99 SIDE SILL REINFORCEMENT TO CENTER PILLAR Fig 100 BAFFLE PLUG COWL PLENUM 23 212 BODY STRUCTURE JR STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1988: ...Fig 101 ROOF PANEL INNER QUARTER UPPER BODY SIDE APERTURE UPPER WINDSHIELD FRAME BACKLITE FRAME REINFORCEMENT JR BODY STRUCTURE 23 213 STRUCTURAL ADHESIVE LOCATIONS Continued ...

Page 1989: ...ER BRACKET TO FRONT SIDE RAIL REINFORCEMENT TO FRONT SIDE RAIL 112 REAR FRONT SIDE RAIL TO REAR FRONT RAIL CAP 113 FRONT SUSPENSION CROSSMEMBER BRACKET TO LOWER RADIATOR SUPPORT REAR FRONT SIDE RAIL TO FRONT SIDE RAIL 114 FRONT SUSPENSION UPPER MOUNTING CAP TO MOUNTING PANEL TO UPPER LOAD BEAM 115 FRONT WHEELHOUSE TO FRONT SIDE RAIL AND HEADLAMP 116 BRAKE BOOSTER REINFORCEMENT TO DASH PANEL LOWER ...

Page 1990: ...TENSION TO REAR FLOOR PAN 139 REAR SIDE RAIL EXTENSION TO CENTER FLOOR PAN SIDE RAIL REAR SUSPENSION CROSSMEMBER TO REAR FLOOR PAN 140 REAR SIDE RAIL REAR SUSPENSION CROSSMEMBER TO REAR FLOOR PAN 141 INNER SILL EXTENSION TO BODY SIDE APERTURE BRACKET TO REAR FLOOR PAN 142 INNER WINDSHIELD FRAME TO OUTER WINDSHIELD FRAME HINGE PILLAR REINFORCEMENT TO SILL BEAM 143 FRONT RAIL REAR CAP TO DASH PANEL ...

Page 1991: ... TO DASH PANEL 156 PLENUM LOWER SUPPORT PLENUM CLOSURE WINDSHIELD WIPER SUPPORT TO LOWER COWL PLENUM 157 HEADLAMP MOUNTING REINFORCEMENT TO HEADLAMP MOUNTING PANEL 158 FRONT FLOOR PAN RAIL EXTENSION REINFORCEMENT TO FRONT FLOOR PAN RAIL 159 Fig 102 LOWER RADIATOR CROSSMEMBER UPPER SUPPORT TO LOWER RADIATOR CROSSMEMBER LOWER SUPPORT 23 216 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 1992: ...03 UPPER RADIATOR MOUNTING CROSSMEMBER TO HOOD LATCH REINFORCEMENT Fig 104 FRONT ENGINE MOUNT SUPPORTS RADIATOR BRACKET SUPPORT TO LOWER RADIATOR CROSSMEMBER JR BODY STRUCTURE 23 217 WELD LOCATIONS Continued ...

Page 1993: ...Fig 105 REAR FRONT SIDE RAIL TO REAR FRONT RAIL CAP TO SILL REINFORCEMENT Fig 106 BUMPER EXTENSION HEADLAMP SUPPORT RAIL TO REAR FRONT SIDE RAIL 23 218 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 1994: ... 107 REAR FRONT SIDE RAIL TO REAR FRONT RAIL CAP TO REAR FRONT SIDE RAIL PLATE Fig 108 UPPER FRONT SUSPENSION MOUNTING CAP REINFORCEMENT TO UPPER LOAD BEAM JR BODY STRUCTURE 23 219 WELD LOCATIONS Continued ...

Page 1995: ...Fig 109 FRONT SUSPENSION UPPER MOUNTING PANEL TO FRONT FENDER SHIELD Fig 110 FRONT WHEELHOUSE TO FRONT SIDE RAIL AND HEADLAMP 23 220 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 1996: ...ig 111 FRONT SIDE RAIL REINFORCEMENT TO FRONT SIDE RAIL Fig 112 FRONT SUSPENSION CROSSMEMBER BRACKET TO FRONT SIDE RAIL REINFORCEMENT TO FRONT SIDE RAIL JR BODY STRUCTURE 23 221 WELD LOCATIONS Continued ...

Page 1997: ...13 REAR FRONT SIDE RAIL TO REAR FRONT RAIL CAP Fig 114 FRONT SUSPENSION CROSSMEMBER BRACKET TO LOWER RADIATOR SUPPORT REAR FRONT SIDE RAIL TO FRONT SIDE RAIL 23 222 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 1998: ...Fig 115 FRONT SUSPENSION UPPER MOUNTING CAP TO MOUNTING PANEL TO UPPER LOAD BEAM Fig 116 FRONT WHEELHOUSE TO FRONT SIDE RAIL AND HEADLAMP JR BODY STRUCTURE 23 223 WELD LOCATIONS Continued ...

Page 1999: ...Fig 117 BRAKE BOOSTER REINFORCEMENT TO DASH PANEL LOWER CONTROL PLENUM Fig 118 DASH PANEL TO LOWER COWL PLENUM UPPER COWL PLENUM TO COWL PLENUM CLOSURE 23 224 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2000: ...Fig 119 UPPER COWL PLENUM AND DASH PANEL TO LOWER COWL PLENUM Fig 120 COWL SIDE PANEL TO DASH PANEL TO LOWER COWL PLENUM JR BODY STRUCTURE 23 225 WELD LOCATIONS Continued ...

Page 2001: ...Fig 121 FRONT FLOOR PAN TO DASH PANEL 23 226 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2002: ...Fig 122 LOWER COWL PLENUM TO INNER LOAD BEAM BUMPER ATTACHING REINFORCEMENT JR BODY STRUCTURE 23 227 WELD LOCATIONS Continued ...

Page 2003: ...Fig 123 SHOCK TOWER EXTENSION TO DASH PANEL Fig 124 FRONT CONSOLE MOUNTING BRACKET TO FRONT FLOOR PAN 23 228 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2004: ...Fig 125 SEAT TRACK CROSSMEMBER FRONT FLOOR PAN TO INNER BODY SIDE SILL Fig 126 FRONT SEAT TRACK CROSSMEMBER TO FRONT FLOOR PAN JR BODY STRUCTURE 23 229 WELD LOCATIONS Continued ...

Page 2005: ... BRAKE BRACKET SHIFTER MOUNTING STUDS TO FRONT CONSOLE MOUNTING BRACKET Fig 128 SEAT MOUNTING CROSSMEMBER TO TUNNEL REINFORCEMENT TO FRONT CONSOLE MOUNTING BRACKET 23 230 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2006: ...Fig 129 WIRING HARNESS WELD STUDS FUEL TANK STRAP BRACKET TO REAR FLOOR PAN Fig 130 CENTER SEAT BELT REINFORCEMENT TO SEAT BELT ANCHOR TO REAR FLOOR PAN JR BODY STRUCTURE 23 231 WELD LOCATIONS Continued ...

Page 2007: ...g 131 SPARE WHEEL ANCHOR REINFORCEMENT FUEL TANK SUPPORT BRACKET TO REAR FLOOR PAN Fig 132 WELD STUD TO SEAT BELT ANCHOR REINFORCEMENT SPARE WHEEL BRACKET 23 232 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2008: ...SMEMBER REINFORCEMENT TO REAR FLOOR PAN FRONT CROSSMEMBER Fig 134 REAR RAIL EXTENSION BODY SIDE APERTURE BRACKET REAR FLOOR PAN CROSSMEMBER TO INNER BODY SIDE SILL EXTENSION JR BODY STRUCTURE 23 233 WELD LOCATIONS Continued ...

Page 2009: ...N CROSSMEMBER TO REAR FLOOR PAN SIDE RAIL REAR EXTENSION TO CENTER FLOOR SIDE RAIL Fig 136 CENTER FLOOR PAN SIDE RAIL TO CENTER SIDE RAIL EXTENSION TO REAR FLOOR PAN SIDE RAIL 23 234 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2010: ...TER FLOOR REAR SUSPENSION CROSSMEMBER TO CENTER SIDE RAIL EXTENSION TO REAR SIDE RAIL Fig 138 REAR FLOOR PAN FRONT CROSSMEMBER TO REAR FLOOR PAN TO FRONT FLOOR PAN JR BODY STRUCTURE 23 235 WELD LOCATIONS Continued ...

Page 2011: ...TO REAR SUSPENSION CROSSMEMBER SIDE RAIL EXTENSION TO REAR FLOOR PAN Fig 140 REAR SIDE RAIL EXTENSION TO CENTER FLOOR PAN SIDE RAIL REAR SUSPENSION CROSSMEMBER TO REAR FLOOR PAN 23 236 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2012: ...Fig 141 REAR SIDE RAIL REAR SUSPENSION CROSSMEMBER TO REAR FLOOR PAN JR BODY STRUCTURE 23 237 WELD LOCATIONS Continued ...

Page 2013: ...Fig 142 INNER SILL EXTENSION TO BODY SIDE APERTURE BRACKET TO REAR FLOOR PAN 23 238 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2014: ...Fig 143 INNER WINDSHIELD FRAME TO OUTER WINDSHIELD FRAME HINGE PILLAR REINFORCEMENT TO SILL BEAM JR BODY STRUCTURE 23 239 WELD LOCATIONS Continued ...

Page 2015: ...Fig 144 FRONT RAIL REAR CAP TO DASH PANEL TO FLOOR PAN Fig 145 FRONT SIDE RAIL REAR CAP TO FRONT FLOOR PAN 23 240 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2016: ...Fig 146 FRONT SEAT BELT ANCHORAGE TO INNER BODY SILL Fig 147 FRONT FLOOR PAN RAIL JR BODY STRUCTURE 23 241 WELD LOCATIONS Continued ...

Page 2017: ...Fig 148 ENGINE MOUNT TAPPING PLATE BUMPER EXTENSION TO FRONT SIDE RAIL Fig 149 BUMPER EXTENSION FRONT RAIL REINFORCEMENT SPACERS TO FRONT SIDE RAIL 23 242 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2018: ...PPER FRONT SUSPENSION MOUNT UPPER FRONT SUSPENSION MOUNT Fig 151 UPPER FRONT SUSPENSION REINFORCEMENT UPPER FRONT SUSPENSION MOUNT TO UPPER FRONT SUSPENSION MOUNT CAP JR BODY STRUCTURE 23 243 WELD LOCATIONS Continued ...

Page 2019: ...AIL PLATE FRONT SIDE RAIL REINFORCEMENT TO FRONT SIDE RAIL REAR Fig 153 FRONT SIDE RAIL REINFORCEMENT SWAY BAR BRACKET TO TOPPING PLATE FRONT SUSPENSION RETAINER TO FRONT SIDE RAIL PLATE 23 244 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2020: ...O FRONT BUMPER MOUNTING BRACKET FRONT SIDE RAIL PLATE TO FRONT Fig 155 WINDSHIELD WIPER TAPPING PLATE TO WINDSHIELD WIPER CENTER ATTACHING PLATE LOWER WIPER MODULE PLENUM BRACKET JR BODY STRUCTURE 23 245 WELD LOCATIONS Continued ...

Page 2021: ...6 WHEELHOUSE DEADENER PANEL DASH PANEL DEADENER PANEL TO DASH PANEL Fig 157 PLENUM LOWER SUPPORT PLENUM CLOSURE WINDSHIELD WIPER SUPPORT TO LOWER COWL PLENUM 23 246 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2022: ...Fig 158 HEADLAMP MOUNTING REINFORCEMENT TO HEADLAMP MOUNTING PANEL Fig 159 FRONT FLOOR PAN RAIL EXTENSION REINFORCEMENT TO FRONT FLOOR PAN RAIL JR BODY STRUCTURE 23 247 WELD LOCATIONS Continued ...

Page 2023: ...TO UPPER LOAD PATH BEAM 169 OUTER QUARTER PANEL REINFORCEMENT TO OUTER BELT REINFORCEMENT TO OUTER QUARTER PANEL 170 OUTER QUARTER PANEL TO QUARTER PANEL REINFORCEMENT TO INNER QUARTER PANEL 171 OUTER BODY SIDE PANEL TO FRONT OUTER QUARTER PANEL REINFORCEMENT 172 OUTER REAR WHEELHOUSE TO OUTER QUARTER PANEL REINFORCEMENT 173 OUTER REAR WHEELHOUSE TO OUTER QUARTER PANEL 174 INNER QUARTER WHEELHOUSE...

Page 2024: ...HOUSE UPPER DECK REINFORCEMENT TO UPPER DECK REAR REINFORCEMENT AND UPPER FRONT REINFORCEMENT 189 UPPER DECK PANEL FRONT REINFORCEMENT TO WHEELHOUSE UPPER DECK REINFORCEMENT EXTENSION 190 FRONT CONSOLE BRACKET TO FRONT FLOOR PAN 191 INNER SIDE SILL CROSSMEMBER REINFORCEMENT CROSSMEMBER TO REAR FLOOR PAN 192 SIDE RAILS CENTER SIDE RAIL EXTENSIONS TO REAR FLOOR PAN 193 REAR SUSPENSION CROSSMEMBER SE...

Page 2025: ...Fig 160 PARK BRAKE BRACKET AND SHIFTER MOUNTING STUDS TO FRONT CONSOLE MOUNTING BRACKET 23 250 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2026: ...Fig 161 REAR SEAT REINFORCEMENT REAR FLOOR PAN BRACKET AND INNER REAR WHEELHOUSE CROSSMEMBER SUPPORTS TO REAR FLOOR PAN JR BODY STRUCTURE 23 251 WELD LOCATIONS Continued ...

Page 2027: ...Fig 162 REAR SEAT REINFORCEMENT REAR FLOOR PAN BRACKET AND SHOULDER BELT SUPPORT GUSSET TO REAR FLOOR PAN 23 252 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2028: ...EMBER SUPPORT AND REAR FLOOR PAN BRACKET TO SHOULDER BELT SUPPORT GUSSET Fig 164 SHOULDER BELT SUPPORT GUSSET AND INNER REAR WHEELHOUSE CROSSMEMBER SUPPORT TO REAR FLOOR PAN BRACKET JR BODY STRUCTURE 23 253 WELD LOCATIONS Continued ...

Page 2029: ...Fig 165 DECK OPENING REINFORCEMENT AND STRIKER PLATE REINFORCEMENT TO LOWER DECK OPENING Fig 166 INNER BODY SIDE SILL TO COWL SIDE PANEL 23 254 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2030: ...LL EXTERIOR PANEL AND REAR RAIL EXTENSION TO INNER SILL EXTENSION Fig 168 REAR FLOOR PAN SIDE RAIL AND REAR BUMPER ATTACHING REINFORCEMENT TO REAR RAIL EXTENSION JR BODY STRUCTURE 23 255 WELD LOCATIONS Continued ...

Page 2031: ...LD FRAME TO INNER REINFORCEMENT TO INNER WINDSHIELD FRAME TO UPPER LOAD PATH BEAM Fig 170 OUTER QUARTER PANEL REINFORCEMENT TO OUTER BELT REINFORCEMENT TO OUTER QUARTER PANEL 23 256 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2032: ...ig 171 OUTER QUARTER PANEL TO QUARTER PANEL REINFORCEMENT TO INNER QUARTER PANEL Fig 172 OUTER BODY SIDE PANEL TO FRONT OUTER QUARTER PANEL REINFORCEMENT JR BODY STRUCTURE 23 257 WELD LOCATIONS Continued ...

Page 2033: ...Fig 173 OUTER REAR WHEELHOUSE TO OUTER QUARTER PANEL REINFORCEMENT Fig 174 OUTER REAR WHEELHOUSE TO OUTER QUARTER PANEL 23 258 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2034: ...Fig 175 INNER QUARTER WHEELHOUSE EXTENSION TO OUTER QUARTER WHEELHOUSE Fig 176 INNER REAR QUARTER PANEL TO REAR LOWER QUARTER PANEL EXTENSION JR BODY STRUCTURE 23 259 WELD LOCATIONS Continued ...

Page 2035: ... 177 REAR REINFORCEMENT BRACKET TO REAR SEAT FLOOR PAN REINFORCEMENT TO REAR INNER QUARTER PANEL Fig 178 LOWER WINDSHIELD HEADER TO UPPER WINDSHIELD HEADER 23 260 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2036: ...Fig 179 OUTER WINDSHIELD SIDE FRAME TO INNER WINDSHIELD SIDE FRAME Fig 180 INNER AND OUTER WINDSHIELD FRAME TO OUTER BODY SIDE PANEL TO INNER UPPER JR BODY STRUCTURE 23 261 WELD LOCATIONS Continued ...

Page 2037: ...Fig 181 INNER AND OUTER BODY SIDE SILL TO COWL SIDE PANEL Fig 182 INNER BODY SIDE SILL TO OUTER BODY SIDE PANEL TO INNER SIDE SILL EXTENSION 23 262 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2038: ...HEELHOUSE TO INNER QUARTER PANEL TO REAR INNER WHEELHOUSE QUARTER EXTENSION Fig 184 LOWER OUTER QUARTER PANEL EXTENSION TO REAR INNER QUARTER PANEL TO REAR INNER WHEELHOUSE JR BODY STRUCTURE 23 263 WELD LOCATIONS Continued ...

Page 2039: ...R INNER QUARTER PANEL TO INNER WHEELHOUSE EXTENSION TO FRONT INNER QUARTER PANEL Fig 186 LOWER REAR QUARTER PANEL EXTENSION TO REAR FLOOR PAN AND LOWER DECK PANEL 23 264 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2040: ...RONT UPPER DECK PANEL TROUGH TO UPPER DECK PANEL TROUGH Fig 188 UPPER DECK TROUGH PANEL TO UPPER DECK PANEL FRONT REINFORCEMENT TO DECK PANEL REAR REINFORCEMENT JR BODY STRUCTURE 23 265 WELD LOCATIONS Continued ...

Page 2041: ... DECK REINFORCEMENT TO UPPER DECK REAR REINFORCEMENT AND UPPER FRONT REINFORCEMENT Fig 190 UPPER DECK PANEL FRONT REINFORCEMENT TO WHEELHOUSE UPPER DECK REINFORCEMENT EXTENSION 23 266 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2042: ...Fig 191 FRONT CONSOLE BRACKET TO FRONT FLOOR PAN JR BODY STRUCTURE 23 267 WELD LOCATIONS Continued ...

Page 2043: ...Fig 192 INNER SIDE SILL CROSSMEMBER REINFORCEMENT CROSSMEMBER TO REAR FLOOR PAN 23 268 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2044: ...Fig 193 SIDE RAILS CENTER SIDE RAIL EXTENSIONS TO REAR FLOOR PAN Fig 194 REAR SUSPENSION CROSSMEMBER SEAT BACK SUPPORT TO REAR FLOOR PAN JR BODY STRUCTURE 23 269 WELD LOCATIONS Continued ...

Page 2045: ...Fig 195 PARK BRAKE BRACKET AND SHIFTER MOUNTING STUDS TO FRONT CONSOLE 23 270 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2046: ...FRAME OUTER LOAD BEAM HINGE PILLAR REINFORCEMENT TO BODY SIDE APERTURE 207 CENTER PILLAR REINFORCEMENT TO INNER CENTER PILLAR TO BODY SIDE APERTURE 208 INNER CENTER PILLAR WINDSHIELD FRAME INNER ROOF RAIL TO BODY SIDE APERTURE 209 HINGE PILLAR REINFORCEMENT TO SILL BEAM TO SIDE SILL REINFORCEMENT 210 OUTER REAR WHEELHOUSE SEAT BELT ANCHOR REINFORCEMENT TO BODY SIDE APERTURE 211 INNER QUARTER PANEL...

Page 2047: ... 225 REAR BUMPER ATTACHING REINFORCEMENT TO REAR RAIL BUMPER ATTACHING BRACKET 226 REAR SHELF PANEL SUPPORT TO REINFORCEMENT TO INNER REAR WHEELHOUSE TO REAR SHOCK MOUNTING BRACKET 227 INNER UPPER QUARTER PANEL TO REINFORCEMENT TO OUTER REAR WHEELHOUSE TO BODY SIDE APERTURE 228 INNER UPPER QUARTER PANEL REINFORCEMENT TO BODY SIDE APERTURE TO OUTER QUARTER PANEL 229 FRONT CONSOLE BRACKET TO FRONT F...

Page 2048: ...IL BUMPER REINFORCEMENT ATTACHING REINFORCEMENT TO CENTER FLOOR PAN SIDE RAIL Fig 197 CENTER PILLAR REINFORCEMENT TO INNER CENTER PILLAR TO INNER SIDE ROOF RAIL TO IN JR BODY STRUCTURE 23 273 WELD LOCATIONS Continued ...

Page 2049: ...Fig 198 TAPPING PLATES RETAINER REINFORCEMENT TO CENTER PILLAR REINFORCEMENT Fig 199 OUTER WHEELHOUSE TO UPPER INNER QUARTER PANEL REINFORCEMENT 23 274 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2050: ...INNER WINDSHIELD FRAME TO OUTER WINDSHIELD FRAME TO HINGE PILLAR REINFORCEMENT Fig 201 CENTER PILLAR REINFORCEMENT SILL BEAM REINFORCEMENT TO BODY SIDE APERTURE JR BODY STRUCTURE 23 275 WELD LOCATIONS Continued ...

Page 2051: ...Fig 202 CENTER PILLAR REINFORCEMENT TO BODY SIDE APERTURE Fig 203 CENTER PILLAR REINFORCEMENT TO CENTER ROOF SUPPORT TO BODY SIDE APERTURE 23 276 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2052: ...Fig 204 LOWER DECK OPENING REINFORCEMENT TO LOWER DECK OPENING PANEL Fig 205 CHILD SEAT TETHERS ANCHOR SHOULDER BELT REINFORCEMENT TO SHELF PANEL JR BODY STRUCTURE 23 277 WELD LOCATIONS Continued ...

Page 2053: ... INNER BODY SIDE SILL TO DASH PANEL TO COWL SIDE PANEL Fig 207 INNER TO OUTER WINDSHIELD FRAME OUTER LOAD BEAM HINGE PILLAR REINFORCEMENT TO BODY SIDE APERTURE 23 278 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2054: ...8 CENTER PILLAR REINFORCEMENT TO INNER CENTER PILLAR TO BODY SIDE APERTURE Fig 209 INNER CENTER PILLAR WINDSHIELD FRAME INNER ROOF RAIL TO BODY SIDE APERTURE JR BODY STRUCTURE 23 279 WELD LOCATIONS Continued ...

Page 2055: ... 210 HINGE PILLAR REINFORCEMENT TO SILL BEAM TO SIDE SILL REINFORCEMENT Fig 211 OUTER REAR WHEELHOUSE SEAT BELT ANCHOR REINFORCEMENT TO BODY SIDE APERTURE 23 280 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2056: ...Fig 212 INNER QUARTER PANEL REINFORCEMENT TO INNER QUARTER PANEL TO BODY SIDE APERTURE Fig 213 DRIP RAIL ROOF SUPPORT TO BODY SIDE APERTURE JR BODY STRUCTURE 23 281 WELD LOCATIONS Continued ...

Page 2057: ...Fig 214 OUTER WINDSHIELD FRAME TO INNER WINDSHIELD FRAME TO COWL SIDE PANEL 23 282 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2058: ...Fig 215 OUTER REAR WHEELHOUSE REAR SILL TO BODY SIDE APERTURE ROOF BOWS TO CENTER PILLAR REINFORCEMENT JR BODY STRUCTURE 23 283 WELD LOCATIONS Continued ...

Page 2059: ...Fig 216 REAR INNER WHEELHOUSE TO REAR OUTER WHEELHOUSE 23 284 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2060: ...Fig 217 INNER BODY SILL TO HINGE PILLAR REINFORCEMENT TO SILL BEAM TO BODY SIDE APERTURE JR BODY STRUCTURE 23 285 WELD LOCATIONS Continued ...

Page 2061: ...Fig 218 INNER SILL EXTENSION TO SIDE SILL REINFORCEMENT TO BODY SIDE APERTURE INNER REAR WHEELHOUSE 23 286 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2062: ...Fig 219 REAR SHELF SUPPORT TO WHEELHOUSE TO REAR OUTER WHEELHOUSE Fig 220 UPPER OUTER LOAD BEAM TO UPPER INNER LOAD BEAM TO BODY SIDE APERTURE JR BODY STRUCTURE 23 287 WELD LOCATIONS Continued ...

Page 2063: ...Fig 221 INNER BODY SIDE SILL TO COWL SIDE PANEL TO BODY SIDE APERTURE TO DASH PANEL 23 288 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2064: ...Fig 222 REAR SHELF PANEL SUPPORTS TO WHEELHOUSE TO SHELF PANEL REINFORCEMENT JR BODY STRUCTURE 23 289 WELD LOCATIONS Continued ...

Page 2065: ... OPENING PANEL TO QUARTER EXTENSION TO REAR FLOOR PAN Fig 224 REAR FLOOR PAN SIDE RAIL TO LOWER DECK OPENING PANEL REAR WHEELHOUSE TO QUARTER EXTENSION TO REAR FLOOR PAN 23 290 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2066: ...Fig 225 INNER WINDSHIELD FRAME TO WINDSHIELD FRAME REAR WINDOW FRAME TO UPPER INNER QUARTER PANEL TO OUTER ROOF PANEL JR BODY STRUCTURE 23 291 WELD LOCATIONS Continued ...

Page 2067: ...R ATTACHING REINFORCEMENT TO REAR RAIL BUMPER ATTACHING BRACKET Fig 227 REAR SHELF PANEL SUPPORT TO REINFORCEMENT TO INNER REAR WHEELHOUSE TO REAR SHOCK MOUNTING BRACKET 23 292 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2068: ...Fig 228 INNER UPPER QUARTER PANEL TO REINFORCEMENT TO OUTER REAR WHEELHOUSE TO BODY SIDE APERTURE JR BODY STRUCTURE 23 293 WELD LOCATIONS Continued ...

Page 2069: ...Fig 229 INNER UPPER QUARTER PANEL REINFORCEMENT TO BODY SIDE APERTURE TO OUTER QUARTER PANEL 23 294 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2070: ...Fig 230 FRONT CONSOLE BRACKET TO FRONT FLOOR PAN Fig 231 CROSSMEMBER REINFORCEMENT CROSSMEMBER TO REAR FLOOR PAN JR BODY STRUCTURE 23 295 WELD LOCATIONS Continued ...

Page 2071: ...Fig 232 INNER REAR WHEELHOUSE TO REAR FLOOR PAN Fig 233 SILL EXTENSION INNER REAR WHEELHOUSE TO REAR FLOOR PAN 23 296 BODY STRUCTURE JR WELD LOCATIONS Continued ...

Page 2072: ...Fig 234 INNER BODY SIDE SILL TO COWL SIDE PANEL JR BODY STRUCTURE 23 297 WELD LOCATIONS Continued ...

Page 2073: ......

Page 2074: ...tor Evaporator temperature sensor Blend air door and actuator Mode air door and actuator Recirculation air door and actuator Based upon the mode selected conditioned air can exit the HVAC housing through one or a combination of the three main housing outlets defrost panel or floor The defrost and panel outlets are located on the top of the HVAC housing and the floor outlet is located on the bottom...

Page 2075: ...flake A C on off button It can also be engaged by placing the mode control in the mix to defrost positions This will remove heat and humidity from the air before it is directed through or around the heater core The mode control on the A C heater control is used to direct the conditioned air to the selected system outlets The A C heater control sends a request signal to the BCM to operate the elect...

Page 2076: ...URE 33 MODE DOOR ACTUATOR STALL FAILURE 35 EVAPORATOR TEMPERATURE SENSOR FAILURE 37 BLEND DOOR ACTUATOR OUTPUT SHORTED TO BATTERY 38 BLEND DOOR ACTUATOR OUTPUT SHORTED TO GROUND 39 MODE DOOR ACTUATOR OUTPUT SHORTED TO BATTERY 40 MODE DOOR ACTUATOR OUTPUT SHORTED TO GROUND 41 RECIRCULATION DOOR ACTUATOR OUPUT SHORTED TO BATTERY 42 RECIRCULATION DOOR ACTUATOR OUTPUT SHORTED TO GROUND CODE DESCRIPTIO...

Page 2077: ...he display on the A C heater control will con tinue to blink until it completes an error check and a climate control door calibration Then it will display any DTC s that are present in the BCM related to the climate control system If there are no climate control related DTC s the ATC system will return to its normal operation as indicated by the temperature symbol C or F DTC s related to the ATC s...

Page 2078: ...nt to understand the effect that humidity has on the performance of the A C system When humidity is high the A C evaporator has to perform a double duty It must lower the air temper ature and it must lower the temperature of the moisture in the air that condenses on the evaporator fins Condensing the moisture in the air transfers heat energy into the evaporator fins and coils This reduces the amou...

Page 2079: ...g nosis chart 4 The engine should be warmed to operating temperature with the doors closed and windows open 5 Insert a thermometer in the driver side center panel outlet and operate the A C system until it sta bilizes 6 Start the engine and hold the idle at 1 000 rpm with the compressor clutch engaged If the A C com pressor does not engage see the A C Diagnosis chart 7 With the A C compressor clut...

Page 2080: ...lay 4 See A C Compressor Clutch Relay in this group Test the compressor clutch relay and relay circuits Repair the circuits or replace the relay if required 5 Improperly installed or faulty evaporator temperature sensor 5 See Evaporator Temperature Sensor in this group Test the sensor and replace if required 6 Faulty A C pressure transducer 6 See A C Pressure Transducer in this group Test the sens...

Page 2081: ...ant system Charge the refrigerant system to the proper level if required 5 Air in the refrigerant system 5 See Refrigerant System Leaks in this group Test the refrigerant system for leaks Repair evacuate and charge the refrigerant system if required 6 Engine overheating 6 Test the engine cooling system and repair if required Refer to Group 7 The low side pressure is too high and the high side pres...

Page 2082: ...et Temperature Celsius Fahrenheit Celsius Fahrenheit 15 5 60 62 2 144 21 1 70 63 8 147 26 6 80 65 5 150 32 2 90 67 2 153 If the heater outlet air temperature is below the minimum specification refer to Group 7 Cooling System Both of the heater hoses should be hot to the touch The coolant return heater hose should be slightly cooler than the coolant supply heater hose If the return hose is much coo...

Page 2083: ...psi Control Refrigerant Charge Capacity Refer to A C Underhood Specification Label locared in the engine compartment R 134a refrigerant A C Clutch Current Draw 2 4 15 amps 12 V 0 5V 21 C 70 F A C Clutch Air Gap 0 33 0 63 mm 0 013 0 025 in FASTENER TORQUE Description N m Ft Lbs In Lbs All Screws NOT Listed Below 2 17 A C Compressor Shaft Bolt 2 4L NA 2 7L 13 115 A C Compressor Shaft Nut 2 0L 2 4L T...

Page 2084: ...ON 25 BLEND DOOR ACTUATOR DESCRIPTION 25 OPERATION 25 REMOVAL 25 INSTALLATION 26 BLOWER MOTOR RESISTOR DESCRIPTION 26 OPERATION 27 DIAGNOSIS AND TESTING BLOWER MOTOR RESISTOR 27 REMOVAL 27 INSTALLATION 28 EVAPORATOR TEMPERATURE SENSOR DESCRIPTION 28 OPERATION 28 REMOVAL 29 INSTALLATION 29 IN CAR TEMPERATURE SENSOR DESCRIPTION 29 OPERATION 30 DIAGNOSIS AND TESTING IN CAR TEMPERATURE SENSOR ASPIRATO...

Page 2085: ...t might occur if the voltage induced in the clutch coil windings could not be dissipated A C heater control in the passenger compart ment A C pressure transducer on the A C discharge line Powertrain control module PCM in the engine compartment A C clutch relay in the power distribution center PDC Models equipped the 2 0L and 2 4L Turbo engine also use a thermal limiter switch mounted to the A C co...

Page 2086: ... 15 2 0 4 0 amps 11 5 12 5 volts STANDARD PROCEDURE A C CLUTCH BREAK IN After a new A C compressor clutch has been installed cycle the compressor clutch approximately twenty times five seconds on then five seconds off During this procedure set the A C heater controls to the A C Recirculation Mode the blower motor in the highest speed position and the engine speed at 1500 to 2000 rpm This procedure...

Page 2087: ...y is completely removed from the front housing hub Fig 4 12 Remove the screw that secures the clutch coil wire harness connector bracket to the compressor Fig 5 13 Remove the clutch field coil from the compres sor with the compressor field coil remover Special Tool 9354 in Kit 9349 and a two jaw puller 2 0L AND 2 4L TURBO ENGINE NOTE The A C compressor clutch can be serviced in the vehicle The ref...

Page 2088: ...tch plate stationary with the span ner wrench and remove the clutch nut Fig 6 8 Remove the clutch plate with puller Special Tool 6461 in Kit 6460 9 Remove the clutch shims from the compressor shaft 10 Remove the snap ring that secures the pulley and bearing assembly to the compressor with snap ring pliers Fig 7 11 Install the lip of the puller jaws Special Tool 6141 1 in Kit 6125 into the front ho...

Page 2089: ...ystem can remain fully charged during compressor clutch pulley and bearing assembly or coil replacement Examine the friction surfaces of the clutch pulley and the clutch plate for wear Fig 12 The pulley and 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 A C compressor for refrigerant oil If refrigerant oil is ...

Page 2090: ...d bearing assembly squarely onto the compressor front housing hub NOTE A distinct change of sound during the clutch pulley tapping process indicates that the pulley and bearing assembly has bottomed out against the compressor housing 5 Install the pulley and bearing assembly onto the compressor housing front hub with the clutch pulley installer Special Tool 9355 in Kit 9349 Fig 14 Tap the installe...

Page 2091: ...y with the holding fixture and install the clutch bolt Tighten the bolt to 13 N m 115 in lbs 10 Check the clutch air gap with a feeler gauge Fig 16 If the air gap does not meet the specifica tion add or subtract shims as required The air gap specification is 0 35 to 0 75 millimeter 0 014 to 0 030 inch 11 Position the A C compressor onto the mount ing bracket 12 Install the bolts that secure the A ...

Page 2092: ...ry the original shims first When install ing a clutch onto a compressor that previously did not have a clutch use 1 0 0 50 and 0 13 millimeter 0 040 0 020 and 0 005 inch shims from the clutch hardware package that is provided with the new clutch 8 Install the clutch shims onto the compressor shaft NOTE A distinct change of sound during the clutch plate tapping process indicates that the clutch pla...

Page 2093: ...tic field draws the movable relay contact point away from the fixed normally closed contact point and holds it against the fixed normally open contact point When the relay coil is de energized spring pressure returns the movable contact point back against the fixed normally closed contact point The resistor or diode is connected in parallel with the relay coil in the relay and helps to dissipate v...

Page 2094: ...C clutch relay into the receptacle of the PDC 2 Align the A C clutch relay terminals with the terminal cavities in the PDC receptacle and push down firmly on the relay until the terminals are fully seated 3 Close the cover of the PDC 4 Reconnect the negative battery cable A C HEATER CONTROL DESCRIPTION Both the manual temperature control MTC and the automatic temperature control ATC heating A C sy...

Page 2095: ...r bag system Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death 1 Disconnect and isolate the battery negative cable 2 Remove the center bezel from the instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL CENTER BEZEL REMOVAL 3 Place the center bezel on a workbench and remove the six screws that secure the A C ...

Page 2096: ...ses above 2971 kPa 431 psi or falls below 206 kPa 30 psi The A C pressure transducer input will also disengage the A C compressor clutch when ambient temperatures are below about 10 C 50 F due to the pressure temperature relationship of the refrigerant The A C pressure transducer is diagnosed using a DRBIII scan tool Refer to the appropriate diagnos tic information The A C pressure transducer cann...

Page 2097: ...ehicle The ambient air temperature sensor is mounted on the inside of front bumper beam and its data is used by the heating A C system to maintain optimum cabin temperature levels OPERATION The ambient air temperature sensor is a variable resistor that operates on a ground circuit and a 5 volt reference signal circuit sent by the powertrain control module PCM through a two wire lead and connector ...

Page 2098: ... the blend door linkage OPERATION The blend door actuator is connected to the body control module BCM through the vehicle electrical system by a dedicated five wire lead and connector of the HVAC wire harness The blend door actuator can move the blend air door in two directions A potenti ometer within the actuator allows the BCM to know the exact position of the blend air door at all times The ble...

Page 2099: ...NT PANEL INSTRUMENT PANEL ASSEMBLY INSTALLATION 5 Reconnect the negative battery cable BLOWER MOTOR RESISTOR DESCRIPTION A blower motor resistor Fig 32 is used on this model when it is equipped with the manual temper ature control MTC heater A C system Models equipped with the automatic temperature control ATC system use a blower power module instead of the blower motor resistor Refer to 24 HEATIN...

Page 2100: ...tion The wiring information includes wiring diagrams proper wire and connector repair procedures further details on wire harness routing and retention as well as pin out and location views for the various wire harness connectors splices and grounds 1 Disconnect and isolate the negative battery cable 2 Disconnect the wire harness connector from the blower motor resistor Refer to 24 HEATING AIR COND...

Page 2101: ...r probe is filled with a special silicone based thermal grease Two terminals within a molded plastic con nector receptacle on the sensor connect it to the vehi cle electrical system through a wire lead and connector of the HVAC wire harness OPERATION The evaporator temperature sensor is a thermistor that operates on a 5 volt reference signal sent out by the body control module BCM The evaporator t...

Page 2102: ...ing and reach up through the blower motor opening 7 Remove the evaporator temperature sensor probe from the A C evaporator Fig 36 INSTALLATION NOTE The A C evaporator is manufactured with three holes for evaporator temperature sensor probe insertion Always insert the probe into the uppermost hole 1 Install the evaporator temperature sensor probe into the A C evaporator 2 Install the access plate t...

Page 2103: ...rn on and then turn off approximately 2 minutes from the time the door was opened VEHICLE DOOR IS OPENED AND THEN CLOSED WITHOUT TURNING ON THE IGNITION SWITCH Motor will turn on and then turn off approximately 2 minutes after the door was closed The in car temperature sensor thermistor and aspi rator motor are part of the A C heater control and cannot serviced separately If faulty or damaged the ...

Page 2104: ...e information The mode door actuator cannot be adjusted or repaired and if faulty or damaged it must be replaced REMOVAL WARNING On vehicles equipped with airbags disable the airbag system before attempting any steering wheel steering column or instrument panel component diagnosis or service Disconnect and isolate the nega tive battery ground cable then wait two minutes for the airbag system capac...

Page 2105: ... glove box The blower motor power module consists of a molded plastic mounting plate with two integral connector receptacles Concealed behind the mount ing plate is the power module electronic circuitry and a large finned heat sink The blower motor power module is accessed for service by removing the pas senger side silencer panel OPERATION The blower motor power module is connected to the vehicle...

Page 2106: ...IGHT IP SILENCER PANEL INSTALLATION 5 Reconnect the negative battery cable RECIRCULATION DOOR ACTUATOR DESCRIPTION The recirculation door actuator Fig 44 is a reversible 12 volt direct current DC servo motor The single recirculation door actuator is located on the passenger side end of the HVAC housing on the air inlet housing The recirculation door actuator is mechanically connected to the recirc...

Page 2107: ...in accidental airbag deployment and possible personal injury or death 1 Disconnect and isolate the negative battery cable 2 Remove the instrument panel from the vehicle Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL ASSEMBLY REMOVAL 3 Disconnect the HVAC wire harness connector from the recirculation door actuator Fig 45 4 Remove the three screws that secure the recir culation door actuator to...

Page 2108: ...nsor is diagnosed using the DRBIII scan tool Refer to Body Diagnostic Procedures The sun sensor cannot be adjusted or repaired and if faulty or damaged it must be replaced DIAGNOSIS AND TESTING SUN SENSOR WARNING On vehicles equipped with airbags dis able the airbag system before attempting any steer ing wheel steering column or instrument panel component diagnosis or service Disconnect and isolat...

Page 2109: ...vice This is the only sure way to disable the air bag system Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death 1 Disconnect and isolate the negative battery cable 2 Remove the instrument panel top cover Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL TOP COVER REMOVAL 3 Remove the two screws that secure the sun sensor to...

Page 2110: ...eld coil to prevent damage to the A C compressor The thermal limiter switch will reset once the compressor temperature returns to safe operating temperatures OPERATION The thermal limiter switch interrupts battery feed to the A C clutch field coil when temperatures reach above 122 128 C 250 260 F The switch restores clutch field coil battery feed when the tem perature drops to below 104 116 C 220 ...

Page 2111: ...l top cover The airflow from the side window demister air outlets is directed by fixed vanes in the outlets and cannot be adjusted The side window demister air outlets are only serviced with the instrument panel top cover Refer to 23 BODY INSTRUMENT PAN EL INSTRUMENT PANEL END CAP REMOVAL There are four instrument panel air outlets One air outlet is located near each outboard end of the instrument...

Page 2112: ... instru ment panel air outlet s as required If needed use a trim stick to help remove the barrels INSTALLATION INSTALLATION AIR OUTLET NOTE Only the right outboard air outlet can be removed individually for service replacement The other instrument panel air outlets are part of the instrument cluster bezel and cannot be serviced separately 1 Position the air outlet onto the right outboard end of th...

Page 2113: ...anual mode or by sensor data auto matic mode The blower motor will operate when ever the ignition switch is in the Run position and the A C heater control power is turned on The blower motor and blower motor wheel are fac tory balanced and cannot be adjusted or repaired If faulty or damaged the blower motor and blower wheel must be replaced as an assembly DIAGNOSIS AND TESTING BLOWER MOTOR WARNING...

Page 2114: ... service This is the only sure way to disable the air bag system Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death 1 Disconnect and isolate the negative battery cable 2 Remove the instrument panel silencer from the passenger side of the instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL SILENCER REMOVAL 3 Disc...

Page 2115: ...g system Failure to take the proper precautions could result in an accidental airbag deployment and possible personal injury or death 1 Remove the HVAC housing from the vehicle Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION HVAC HOUSING REMOVAL 2 Remove the screws that secure the floor distri bution duct to the bottom of the HVAC housing Fig 7 3 Remove the floor distribution duct from the HVAC ...

Page 2116: ...tem Refer to 7 COOLING STANDARD PROCEDURE COOLING SYSTEM DRAIN 3 Disconnect and isolate the negative battery cable 4 Remove the instrument panel and HVAC hous ing from the vehicle as an assembly Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 5 Disconnect HVAC wire harness from the instrument panel wire harness connector at the left side of the HVAC housing 6 Remove the two nut...

Page 2117: ...inlet housing to the HVAC housing and remove the air inlet housing 7 Remove the three screws that secure the recir culation door actuator to the air inlet housing and remove the actuator Fig 10 8 Remove the screw that secures the recircula tion door actuator gear to the air inlet housing and remove the gear Fig 11 Fig 9 HVAC Wire Harness Connector 1 WIRE HARNESS CONNECTOR 2 SCREW 2 Fig 10 Recircul...

Page 2118: ...ly remove the foam seals from the heater core and the evaporator tube mounting flange of the HVAC housing Fig 13 12 Remove the screws that secure the upper and lower HVAC housing halves together and separate the housing halves Fig 14 Fig 12 Recirculation Door Release 1 RECIRCULATION DOOR 2 SCREWDRIVER 3 DOOR GEAR RELEASE Fig 13 HVAC Housing Seals 1 EVAPORATOR SEAL 2 A C EXPANSION VALVE 3 HVAC HOUS...

Page 2119: ... evaporator temperature sensor probe from the A C evaporator and remove the sensor Fig 16 15 Lift the A C evaporator out of the bottom half of the HVAC housing Fig 17 16 Lift the heater core out of the bottom half of the HVAC housing Fig 18 Fig 15 Evaporator Temperature Sensor 1 ACCESS PLATE Fig 16 Remove Probe 1 EVAPORATOR TEMPERATURE SENSOR PROBE Fig 17 A C Evaporator 1 A C EVAPORATOR 2 HVAC HOU...

Page 2120: ...loor de frost door cam to the HVAC housing Fig 21 21 Remove the floor defrost door cam link and door as an assembly Fig 22 Fig 19 Floor Distribution Duct and Actuators 1 FLOOR DISTRIBUTION DUCT 2 MODE DOOR ACTUATOR 3 BLEND DOOR ACTUATOR 4 HVAC HOUSING Fig 20 Mode Door Cam 1 MODE DOOR CAM 2 CAM SPLINE Fig 21 Floor Defrost Door Cam 1 FLOOR DEFROST AIR DOOR 2 LINK 3 PANEL DOOR LEVER 4 FLOOR DEFROST D...

Page 2121: ... Install the two blend air doors and levers into the HVAC housing NOTE Rotate the blend door cam until it fully seats into the HVAC housing The cam followers must be in the correct position to properly install the cam 2 Align the blend door cam followers to the blend door cam and install the cam into the HVAC housing Fig 27 3 Align the blend door actuator spline with the spline in the blend door c...

Page 2122: ...housing Fig 29 Fig 26 Blend Door Lever Release 1 BLEND AIR DOOR 2 DOOR LEVER RELEASE 3 SCREWDRIVER Fig 27 Blend Door Cam 1 CAM FOLLOWER GUIDE 2 2 CAM FOLLOWER 2 3 BLEND DOOR CAM Fig 28 Blend Door Actuator 1 BLEND DOOR ACTUATOR 2 DOOR CAM SPLINE 3 ACTUATOR SPLINE Fig 29 Air Deflector Vanes 1 PANEL DOOR 2 AIR DELFECTOR VANES 3 LOCATING TABS JR DISTRIBUTION 24 49 HVAC HOUSING Continued ...

Page 2123: ...followers to the mode door cam and install the cam onto the HVAC housing Fig 31 10 Align the mode door actuator spline with the spline in the mode door cam and install the mode door actuator Fig 32 11 Install the three screws that secure the mode door actuator to the HVAC housing Tighten the screws to 2 N m 17 in lbs Fig 30 Mode Door Levers 1 FLOOR DEFROST LEVER 2 PANEL LEVER Fig 31 Mode Door Cam ...

Page 2124: ...evaporator is manufactured with three holes for evaporator temperature sensor probe insertion Always insert the probe into the uppermost hole 15 Install the evaporator temperature sensor probe into the A C evaporator 16 Install the access plate to the HVAC housing 17 Install the heater core into the bottom half of the HVAC housing Fig 35 Fig 33 Floor Distribution Duct 1 FLOOR DISTRIBUTION DUCT 2 M...

Page 2125: ...38 NOTE The recirculation door actuator gear and door gear must be properly aligned to operate cor rectly 23 Align and install the recirculation door actua tor gear with the door gear 24 Install the screw that secure the recirculation door actuator gear to the air inlet housing Tighten the screw to 2 N m 17 in lbs Fig 36 Blend And Mode Door Shafts 1 PANEL DOOR SHAFT 2 BLEND DOOR SHAFT 3 BLEND DOOR...

Page 2126: ...N NOTE The HVAC housing must be removed from the vehicle and disassembled for service of the A C evaporator heater core and the mode air and blend air doors 1 Position the HVAC housing to the instrument panel Make sure that all air ducts are properly aligned or connected 2 Install the two nuts and bolts that secure the HVAC housing to the instrument panel Tighten the nuts and bolts securely 3 Conn...

Page 2127: ... the center dis tribution duct to the instrument panel support Fig 40 9 Remove the center distribution duct from the instrument panel support and disconnect it from the panel and demister duct assembly 10 Remove the center instrument panel duct from the instrument panel 11 Remove the screws that secure the panel and demister duct assembly to the instrument panel sup port and remove the duct assemb...

Page 2128: ... console floor bracket 6 Disconnect the left and right side rear floor heat ducts from the rear floor distribution duct and remove them from the vehicle 7 If required remove the rear floor distribution duct from the bottom of the HVAC housing INSTALLATION 1 Install the rear floor distribution duct to the bottom of the HVAC housing 2 Install the left and right side rear floor heat ducts to the rear...

Page 2129: ... DESCRIPTION 65 OPERATION 65 REMOVAL 65 INSTALLATION 66 A C DISCHARGE LINE DESCRIPTION 67 REMOVAL 67 INSTALLATION 68 A C EVAPORATOR DESCRIPTION 69 OPERATION 69 REMOVAL 69 INSTALLATION 69 A C EXPANSION VALVE DESCRIPTION 70 OPERATION 70 DIAGNOSIS AND TESTING A C EXPANSION VALVE 70 REMOVAL 71 INSTALLATION 71 HEATER CORE DESCRIPTION 72 OPERATION 72 REMOVAL 73 INSTALLATION 73 LIQUID LINE DESCRIPTION 73...

Page 2130: ...e eyes nose and or throat Wear eye protection when servicing the A C refrigerant system Serious eye injury can result from direct contact with the refrigerant If eye contact occurs seek medical attention immediately WARNING Do not expose the refrigerant to open flame Poisonous gas is created when refrigerant is burned An electronic leak detector is recom mended Severe personal injury or death may ...

Page 2131: ... a container of refrigerant oil until you are ready to use it Replace the cap on the oil container immedi ately after using Store refrigerant oil only in a clean airtight and moisture free container CAUTION Do not overcharge the refrigerant sys tem Overcharging will cause excessive compressor head pressure and can cause compressor noise and A C system failure DIAGNOSIS AND TESTING REFRIGERANT SYST...

Page 2132: ...ing service equip ment from the refrigerant system Failure to observe these warnings may result in personal injury or death WARNING Refer to the applicable warnings and cau tions for this system before performing the following operation Refer to 24 HEATING AIR CONDITION ING PLUMBING WARNINGS and Refer to 24 HEAT ING AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cautions cou...

Page 2133: ...se a reliability problem with the A C compressor If an A C compressor designed to use R 134a refrig erant is left open to the atmosphere for an extended period of time It is recommended that the refriger ant oil be drained and replaced with new oil or a new A C compressor be used This will eliminate the pos sibility of contaminating the refrigerant system If the refrigerant system has been open to...

Page 2134: ...TIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 2 A manifold gauge set and an R 134a refriger ant recovery recycling charging station that meets SAE standard J2210 should be connected to the refrigerant system 3 Measure the proper amount of refrigerant and heat it to 52 C 125 F with the charging station See the operating instructions supplied by the equip ment manufacturer for pro...

Page 2135: ... If the relief valve vents refrigerant it does not necessarly mean that the valve is faulty The high pressure relief valve is a factory cali brated unit The relief valve cannot be adjusted or repaired and must not be removed or otherwise dis turbed On the TRS 090 A C compressor the relief valve is serviced only as a part of the compressor assembly On the HS 15 A C compressor the relief valve is se...

Page 2136: ...fer to 24 HEATING AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result in possible personal injury or death NOTE The A C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system Dis charging is not necessary if servicing the A C clut...

Page 2137: ... plugs from the opened fit tings on the A C suction line and the A C discharge line and the compressor ports 5 Lubricate the new O ring seals with clean refrigerant oil and install them onto the suction and the discharge line fittings Use only the specified seals as they are made of a special material for the R 134a system Use only refrigerant oil of the type recommended for the A C compressor in ...

Page 2138: ...ves up its heat The refrigerant then condenses as it leaves the A C condenser and becomes a high pressure liquid The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A C system There fore it is important that there are no objects placed in front of the radiator grille openings at the front of the vehicle or foreign material on the condenser fins th...

Page 2139: ...nser Refer to 24 HEAT ING AIR CONDITIONING PLUMBING LINE A C DISCHARGE INSTALLATION and Refer to 24 HEATING AIR CONDITIONING PLUMBING LINE A C LIQUID INSTALLATION 4 If equipped remove the tape or plugs from the automatic transmission cooler lines and the cooler ports located on the left end of the A C condenser and connect the lines to the ports Refer to 7 COOLING TRANSMISSION STANDARD PROCEDURE T...

Page 2140: ...ble warnings and cau tions for this system before performing the following operation Refer to 24 HEATING AIR CONDITION ING PLUMBING WARNINGS and Refer to 24 HEAT ING AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cautions could result in possible personal injury or death 1 Recover the refrigerant from the refrigerant system Refer to 24 HEATING AIR CONDITION ING PLUMBING STAN...

Page 2141: ...to the A C compressor Tighten the bolt to 22 N m 16 ft lbs 7 Remove the tape or plugs from the opened dis charge line fitting and the inlet port on the A C con denser 8 Lubricate a new O ring seal with clean refrig erant oil and install it onto the discharge line fitting Use only the specified seal as it is made of a special material for the R 134a system Use only refrigerant oil of the type recom...

Page 2142: ...ot be repaired and if faulty or damaged it must be replaced REMOVAL 1 Remove the HVAC housing Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION HOUSING HVAC REMOVAL 2 Disassemble the HVAC housing as necessary to access the A C evaporator Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION HOUSING HVAC DISASSEMBLY 3 Remove the evaporator temperature sensor probe from the A C evaporator Fig 13 4 Caref...

Page 2143: ...tor to meet the vehicle A C cooling requirements Controlling the refrigerant flow through the A C evaporator ensures that none of the refrigerant leaving the A C evapora tor is still in a liquid state which could damage the A C compressor The A C expansion valve is factory calibrated and cannot be adjusted or repaired and if faulty or dam aged it must be replaced DIAGNOSIS AND TESTING A C EXPANSIO...

Page 2144: ...ll A C system performance Refer to 24 HEATING AIR CONDITIONING DIAGNOSIS AND TESTING A C PERFORMANCE TEST REMOVAL WARNING Refer to the applicable warnings and cautions for this system before performing the fol lowing operation Refer to 24 HEATING AIR CONDITIONING PLUMBING WARNINGS and Refer to 24 HEATING AIR CONDITIONING PLUMBING CAUTIONS Failure to follow the warnings and cau tions could result i...

Page 2145: ...ROCEDURE REFRIGERANT SYS TEM EVACUATE 11 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM CHARGE HEATER CORE DESCRIPTION The heater core Fig 18 is located in the HVAC housing behind the instrument panel The heater core is a heat exchanger made of rows of tubes and fins The heater core tubes are attached to the side of the heater cor...

Page 2146: ...the heater core and insulator out of the lower half of the HVAC housing Fig 19 INSTALLATION 1 Install the heater core into the bottom half of the HVAC housing Make sure that the evaporator insulator is properly installed 2 Assemble the HVAC housing Refer to 24 HEATING AIR CONDITIONING DISTRIBUTION HVAC HOUSING ASSEMBLY NOTE If the heater core is being replaced flush the cooling system Refer to 7 C...

Page 2147: ...onnect and isolate the negative battery cable 2 Recover the refrigerant from the refrigerant system Refer to 24 HEATING AIR CONDITION ING PLUMBING STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY 3 If equipped with the 2 4L Turbo engine remove the secondary retaining clip from the spring lock cou pler that secures the liquid line Fig 22 to the A C condenser and disconnect the liquid line fitting usi...

Page 2148: ...3 Lubricate new rubber O ring seals with clean refrigerant oil and install them on the liquid and suc tion line fittings Use only the specified O rings as they are made of a special material for the R 134a system Use only refrigerant oil of the type recom mended for the A C compressor in the vehicle 4 Connect the liquid line and suction line fittings to the A C expansion valve 5 Install the nut th...

Page 2149: ...nt inside the receiver drier absorbs any moisture which may have entered and become trapped within the refrigerant system In addition during periods of high demand operation of the A C system the receiver drier acts as a reservoir to store surplus refrigerant The receiver drier cannot be repaired If the receiv er drier is faulty or damaged or if the refrigerant system has been contaminated or left...

Page 2150: ...d cage prevent the flared end of the female fitting from pulling out of the cage Two O rings on the male half of the fitting are used to seal the connection These O rings are com patible with R 134a refrigerant and must be replaced with O rings made of the same material Secondary clips are installed over the two con nected coupler halves at the factory for added blowoff protection In addition some...

Page 2151: ... 2 Clean any dirt or foreign material from both halves of the coupler fitting 3 Install new O rings on the male half of the cou pler fitting CAUTION Use only the specified O rings as they are made of a special material for the R 134a sys tem The use of any other O rings may allow the connection to leak intermittently during vehicle operation 4 Lubricate the male fitting and O rings and the inside ...

Page 2152: ...ion The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture Refrigerant oil will quickly absorb any moisture it comes in contact with therefore special effort must be used to keep all R 134a sys tem components moisture free Moisture in the refrigerant oil is very difficult to remove and will cause a...

Page 2153: ...ug in or tape over the opened ser vice port s INSTALLATION 1 Lubricate the valve core with clean refrigerant oil prior to installation Use only refrigerant oil of the type recommended for the A C compressor in the vehicle 2 Remove the tape or plug from the service port CAUTION A valve core that is not fully seated in the A C service port can result in damage to the valve during refrigerant system ...

Page 2154: ... system Refer to 24 HEATING AIR CONDITION ING PLUMBING STANDARD PROCEDURE REFRIGERANT SYSTEM RECOVERY 3 Remove the bolt that secures the suction line to the A C compressor Fig 32 4 Disconnect the suction line from the A C com pressor and remove and discard the O ring seal 5 Install plugs in or tape over the suction line fitting and the compressor port 6 Remove the bolt that secures the refrigerant...

Page 2155: ...pe recommended for the A C compressor in the vehicle 9 Install the suction line onto the A C compres sor 10 Install the bolt that secures the suction line to the A C compressor Tighten the bolt to 22 N m 16 ft lbs 11 Reconnect the negative battery cable 12 Evacuate the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING STANDARD PROCEDURE REFRIGERANT SYS TEM EVACUATE 13 Charge the ref...

Page 2156: ...cycles for the Fuel System Monitor and the Misfire Monitor A warm up cycle can best be described by the following The engine must be running A rise of 40 F in engine temperature must occur from the time when the engine was started Engine coolant temperature must crossover 160 F A driving cycle that consists of engine start up and engine shut off Once the above conditions occur the PCM is con sider...

Page 2157: ... Detection NVLD P N Switch Trans Controls Output Functionality PCM outputs are tested for functionality in addition to testing for opens and shorts When the PCM provides a voltage to an out put component it can verify that the command was carried out by monitoring specific input signals for expected changes For example when the PCM com mands the Idle Air Control IAC Motor to a specific position un...

Page 2158: ...d throttle opening Transmission in gear automatic only Fuel system in Closed Loop Long Term Adaptive within parameters Power Steering Switch in low PSI no load Engine at idle Fuel level above 15 Ambient air temperature Barometric pressure Engine RPM within acceptable range of desired idle Closed throttle speed Pending Conditions The Task Manager typi cally does not run the Oxygen Sensor Signal Mon...

Page 2159: ...ests fail a DTC is stored Because the ignition is OFF the MIL is illuminated at the begin ning of the next key cycle after the 2nd failure Enabling Conditions The following conditions must be met for the PCM to run the oxygen sensor heater test Engine run time of at least 5 1 minutes Key OFF power down Battery voltage of at least 10 volts Sufficient Oxygen Sensor cool down Pending Conditions There...

Page 2160: ...tream sensor switch rate must be less than 80 of the upstream rate 60 for manual transmis sions The failure percentages are 90 and 70 respectively Enabling Conditions The following conditions must typically be met before the PCM runs the cat alyst monitor Specific times for each parameter may be different from engine to engine Accumulated drive time Enable time Ambient air temperature Barometric p...

Page 2161: ...ts of vacuum assisted engine control system 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 diagnostic...

Page 2162: ...or 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 specifi...

Page 2163: ...S 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 monitor the system the number of lean to rich switches of upstream and downstream O2S s is counted The ratio of downstream switches to upstream switches is used to determine whether the catalyst is operating properly An effective catalyst will have fewer downstream sw...

Page 2164: ...s a resistor to protect the switch from a short to battery or a short to ground The NGC utilizes a high side driver to energize and duty cycle the solenoid HIGH AND LOW LIMITS The PCM compares input signal voltages from each input device with established high and low limits for the device If the input voltage is not within limits and other criteria are met the PCM stores a diagnos tic trouble code...

Page 2165: ...III STATE DISPLAY TEST MODE OPERATION The switch inputs to the Powertrain Control Mod ule PCM have two recognized states HIGH and LOW For this reason the PCM cannot recognize the difference 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 t...

Page 2166: ...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 soleno...

Page 2167: ...ESS TO NVLD 4 FILL TUBE TO FUEL TANK CONNECTOR ELASTOMERIC 14 VAPOR CANISTER 5 TANK VENT ROLLOVER VALVE S 15 PURGE LINE 6 VAPOR RECIRCULATION LINE 16 PURGE DEVICE 7 TANK VAPOR LINE 17 WITHOUT NVLD 8 VAPOR LINE TO CANISTER 18 BREATHER ELEMENT 9 CHECK VALVE N C 19 FLOW CONTROL ORIFICE 10 CONTROL VALVE 20 SERVICE PORT 21 WITH NVLD 25 12 EVAPORATIVE EMISSIONS JR EVAPORATIVE EMISSIONS Continued ...

Page 2168: ...ery cable FUEL FILLER CAP DESCRIPTION The plastic fuel fill cap is threaded quarter turn onto the end of the fuel filler tube It s purpose is to retain vapors and fuel in the fuel tank OPERATION The fuel filler cap incorporates a two way relief valve that is closed to atmosphere during normal operating conditions The relief valve is calibrated to open when a pressure of 17 kPa 2 5 psi or vacuum of...

Page 2169: ...st have recirculation lines that do not have the in line normally closed check valve that pro tects the system from failed nozzle liquid ingestion in order to detect cap off conditions The normally closed valve in the NVLD is intended to maintain the seal on the evaporative system dur ing the engine off condition If vacuum in the evapo rative system exceeds 3 to 6 H2O 0 75 to 1 5 KPA the valve wil...

Page 2170: ...either following shut off or by having the fuel level in the tank rise high enough to close the control valve The control valve Refer to 14 FUEL SYS TEM FUEL DELIVERY FUEL TANK OPERATION contains a float that rises to seal the large diameter vent path to the canister At this point in the fueling of the vehicle the tank pressure increases the check valve closes preventing tank fuel from spitting ba...

Page 2171: ...G HARNESS TO NVLD 4 FILL TUBE TO FUEL TANK CONNECTOR ELASTOMERIC 14 VAPOR CANISTER 5 TANK VENT ROLLOVER VALVE S 15 PURGE LINE 6 VAPOR RECIRCULATION LINE 16 PURGE DEVICE 7 TANK VAPOR LINE 17 WITHOUT NVLD 8 VAPOR LINE TO CANISTER 18 BREATHER ELEMENT 9 CHECK VALVE N C 19 FLOW CONTROL ORIFICE 10 CONTROL VALVE 20 SERVICE PORT 21 WITH NVLD 25 16 EVAPORATIVE EMISSIONS JR ORVR Continued ...

Page 2172: ...lure requires double failure plugged to NVLD and atmosphere Leak detection pump failed closed Leak detection pump filter plugged On Board diagnostics evaporative system leak test just conducted Canister vent valve vent plugged to atmosphere Engine still running when attempting to fill System designed not to fill Defective fill nozzle Try another nozzle Fuel Spits Out Of Filler Tube During fill See...

Page 2173: ...ERATING 1 With engine idling remove the hose from the PCV valve If the valve is not plugged a hissing noise will be heard as air passes through the valve A strong vacuum should also be felt when a finger is placed over the valve inlet 2 Install hose on PCV valve Remove the make up air hose from the air plenum at the rear of the engine Hold a piece of stiff paper parts tag loosely over the end of t...

Page 2174: ...evaporative canister is not purged 100 of the time the PCM stores information about the evapora tive canister s vapor content in a memory cell The purge free cells are constructed similar to cer tain purge normal cells The purge free cells can be monitored by the DRB III Scan Tool The only dif ference between the purge free cells and normal adaptive cells is that in purge free the purge is com ple...

Page 2175: ...g 15 and Fig 16 2 Swing EVAP canister into the lower mounting and snap into place Fig 14 3 Install the hoses to the top of the EVAP canis ter Fig 13 4 Connect the electrical connector 5 Install the fuel tank refer to the fuel tank installation section 6 Connect the negative battery cable Fig 15 EVAP CANISTER TOP TAB Fig 16 EVAP CANISTER TOP MOUNTING 25 20 EVAPORATIVE EMISSIONS JR VAPOR CANISTER Co...

Page 2176: ...l head 2 4L 30 22 1 265 EGR tube to EGR valve 2 4L 11 3 8 5 99 9 EGR tube to intake manifold 2 4L 11 3 8 5 99 9 TUBE REMOVAL 4 CYLINDER 1 Disconnect the negative battery cable 2 Remove the air cleaner box 3 Remove the EGR tube clamp bolt at intake manifold 4 Slide clamp out of the intake manifold slot Fig 1 5 Remove the 2 bolts from EGR valve 6 Remove the tube and gasket Fig 2 7 Remove the rubber ...

Page 2177: ...te 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 trical connector OPERATION The exhaust gas recirculation flow is determined by the engine controller For a given set of conditions t...

Page 2178: ... cylinder head and EGR tube where EGR valve interfaces 2 Install new gasket between the EGR valve and the transducer to cylinder head and loose install bolts 3 Install the 2 bolts from EGR tube to EGR valve 4 Tighten the EGR valve to cylinder head bolts to 22 9 N m 202 in lbs 5 Tighten the EGR tube to EGR valve bolts to 11 3 N m 100 in lbs 6 Connect the electrical connector to EGR trans ducer 7 Co...

Page 2179: ...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 Task Manager does not run the Catalyst Monitor until the Oxygen Sensor fault is remedied Sinc...

Page 2180: ... compo nent must pass the test under a Similar Conditions Window in order to record a good trip A Similar Con ditions Window is when engine RPM is within 375 RPM and load is within 20 of when the fault occurred NOTE It is important to understand that a compo nent does not have to fail under a similar window of operation to mature It must pass the test under a Similar Conditions Window when it fail...

Page 2181: ... range when the failure occurred Indicated by switch ing from NO to YES Absolute MAP When Fuel Sys Fail The stored MAP reading at the time of failure Informs the user at what engine load the failure occurred Absolute MAP A live reading of engine load to aid the user in accessing the Similar Conditions Window RPM When Fuel Sys Fail The stored RPM reading at the time of failure Informs the user at w...

Page 2182: ...d Long Term Adap tive to calculate the Adaptive Memory Factor for total fuel correction 200 Rev Counter Counts 0 100 720 degree cycles SCW Cat 200 Rev Counter Counts when in similar conditions SCW FTP 1000 Rev Counter Counts 0 4 when in similar conditions Misfire Good Trip Counter Counts up to three to turn OFF the MIL JR ON BOARD DIAGNOSTICS 25 27 TASK MANAGER Continued ...

Page 2183: ... MAF sensor A voltage will be produced via the MAF sen sor when air is passed through This voltage corre lates to airflow The amount of voltage airflow will determine the amount of fuel that will be added to achieve the goal air fuel ratio Air is then compressed by the air injector pump It is expelled from the pump and routed into a rubber tube where it reaches the air pressure relief valve Pressu...

Page 2184: ... vehicle and support 5 Remove 3 mounting nuts Fig 2 6 Unlock electrical connector Fig 3 7 Unclip electrical connector from mounting bracket Fig 4 8 Press tab and disconnect electrical connector Fig 5 Fig 2 AIR PUMP MOUNTING Fig 3 ELECTRICAL CONNECTOR LOCKING TAB Fig 4 CONNECTOR RETAINING CLIP Fig 5 DEPRESS TAB ON CONNECTOR JR AIR INJECTION 25 29 PUMP Continued ...

Page 2185: ...PTION The check valve is located on the exhaust manifold OPERATION The one way check valve has a one way diaphragm which prevents hot exhaust gases from backing up into the air injection hose and air injection pump The check valve will protect the system if the air injection pump an air hose ruptures or exhaust sys tem pressure becomes abnormally high REMOVAL Location of One Way Check Valve and co...

Page 2186: ... air cleaner box Fig 9 2 Squeeze the quick connect on the tube to release it Fig 10 3 Disconnect connector tube at air pump Fig 11 and one way check valve Fig 12 4 Remove connector tube note routing of tube Fig 9 AIR CLEANER INLET TUBE Fig 10 CONNECTOR TUBE QUICK CONNECT Fig 11 AIR PUMP TUBE CONNECTION Fig 12 VALVE AND CONNECTOR HOSE JR AIR INJECTION 25 31 ONE WAY CHECK VALVE Continued ...

Page 2187: ...e way check valve Fig 12 and tube to air pump Fig 11 3 Install air inlet duct to air cleaner box Fig 9 CONNECTOR TUBE ROUTING CONNECTOR TUBE ROUTING CONNECTOR TUBE ROUTING CONNECTOR TUBE ROUTING 25 32 AIR INJECTION JR CONNECTING TUBE Continued ...

Page 2188: ...xuate The ceramic element changes resistance respectively to changes in temperature This voltage correlates to airflow The change in resistance varies the signal voltage output to the PCM REMOVAL 1 Disconnect negative battery cable 2 Remove the air pump assembly Refer to 25 EMISSIONS CONTROL AIR INJECTION PUMP REMOVAL 3 Remove 2 bracket mounting bolts Fig 13 4 Remove the bracket assembly Fig 14 CO...

Page 2189: ...NSTALLATION 1 Install the rubber mounting to MAF sensor 2 Twist the MAF sideways and install to bracket Fig 17 3 Connect the electrical connector to MAF Fig 15 MASS AIR FLOW SENSOR 1 Mass Air flow Sensor MAF 2 Relay 2 Inlet Filter Fig 16 REMOVING SENSOR FROM BRACKET Fig 17 Fig 18 25 34 AIR INJECTION JR MASS AIR FLOW SENSOR Continued ...

Page 2190: ...9 5 Install 2 bracket mounting bolts Fig 20 6 Install the air pump assembly Refer to 25 EMISSIONS CONTROL AIR INJECTION PUMP INSTALLATION 7 Connect negative battery cable Fig 19 Fig 20 JR AIR INJECTION 25 35 MASS AIR FLOW SENSOR Continued ...

Page 2191: ......

Page 2192: ...D 23 27 DEFROSTER DUCT 24 42 DIFFERENTIAL BEARING CUPS 21 28 DIFFERENTIAL 21 20 DIODE 8W 01 14 DISC BRAKE CALIPER FRONT 5 15 DISC BRAKE CALIPER REAR 5 20 DOOR CYLINDER LOCK SWITCH 8N 3 DOOR GLASS INNER BELT STABILIZER 23 39 DOOR GLASS 23 33 23 53 DOOR INNER BELT WEATHERSTRIP 23 141 DOOR LOCK UNLOCK SWITCH 8N 4 DOOR LOCK MOTOR 8N 4 DOOR OPENING TRIM WELT 23 141 DOOR PIN ASSEMBLY 23 48 DOOR SILL TRI...

Page 2193: ...WEATHERSTRIP 23 145 QUARTER TRIM PANEL 23 93 QUICK CONNECT FITTING 14 11 RADIATOR DRAINCOCK 7 36 RADIATOR F AN S 7 39 RADIATOR SUPPORT CROSSMEMBER 23 64 RADIATOR 7 35 RADIO 8A 10 REAR BEARING OIL FEED TROUGH 21 39 REAR CHECK STRAP 23 51 REAR DOOR B PILLAR DOOR SEAL 23 146 REAR DOOR GLASS RUN WEATHERSTRIP 23 146 REAR DOOR INNER BELT WEATHERSTRIP 23 147 REAR DOOR OUTER BELT MOLDING 23 147 REAR F ASC...

Page 2194: ... 3 VACUUM RESERVOIR 8P 5 VALVE BODY 21 181 21 335 VALVE SPRINGS SEALS 9 106 VALVE SPRINGS AND SEALS 9 35 VALVE SPRINGS 9 187 VALVE STEM SEALS 9 189 VALVE TIMING 9 66 9 228 VALVE 25 22 VAPOR CANISTER 25 19 VECI LABEL Intro 11 VEHICLE CERTIFICATION LABEL Intro 10 VEHICLE IDENTIFICATION NUMBER Intro 9 VEHICLE SPEED SENSOR 21 42 VEHICLE THEFT SECURITY 8Q 1 VIBRATION DAMPER 9 51 9 121 9 207 VOLTAGE REG...

Page 2195: ...______________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Dealership Technician Dealer Code Retail Customer Manual Title Year Number and Page _________________________________________________ _____________________________________________...

Page 2196: ...DaimlerChrysler Corporation Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills MI 48326 2757 ...

Page 2197: ...TRY KEY IMMOBILIZER MODULE 12 3 3 DIAGNOSTIC TROUBLE CODES 12 3 3 1 HARD CODE 12 3 3 2 INTERMITTENT CODE 13 3 3 3 STARTS SINCE SET COUNTER 13 3 3 4 DISTANCE SINCE MI SET 13 3 4 USING THE DRBIII 13 3 5 DRBIII ERROR MESSAGES AND BLANK SCREEN 13 3 5 1 DRBIII DOES NOT POWER UP 14 3 5 2 DISPLAY IS NOT VISIBLE 14 4 0 DISCLAIMERS SAFETY WARNINGS 14 4 1 DISCLAIMERS 14 4 2 SAFETY 14 4 2 1 TECHNICIAN SAFETY...

Page 2198: ...OR HIGH 66 P0116 ENGINE COOLANT TEMPERATURE PERFORMANCE 68 P0117 ENGINE COOLANT TEMPERATURE SENSOR LOW 71 P0118 ENGINE COOLANT TEMPERATURE SENSOR HIGH 73 P0122 THROTTLE POSITION SENSOR 1 LOW 75 P0123 THROTTLE POSITION SENSOR 1 HIGH 78 P0125 INSUFFICIENT COOLANT TEMP FOR CLOSED LOOP FUEL CONTROL 81 P0128 THERMOSTAT RATIONALITY 83 P0129 BAROMETRIC PRESSURE OUT OF RANGE LOW 88 P0131 O2 SENSOR 1 1 VOL...

Page 2199: ...168 P0440 GENERAL EVAP SYSTEM FAILURE 170 P0441 EVAP PURGE SYSTEM PERFORMANCE 175 P0442 EVAP SYSTEM MEDIUM LEAK 177 P0455 EVAP SYSTEM LARGE LEAK 177 P0443 EVAP PURGE SOLENOID CIRCUIT 182 P0452 NVLD PRESSURE SWITCH SENSE CIRCUIT LOW 185 P0453 NVLD PRESSURE SWITCH SENSE CIRCUIT HIGH 188 P0456 EVAP SYSTEM SMALL LEAK 190 P0457 LOOSE FUEL CAP 192 P0461 FUEL LEVEL SENSOR 1 PERFORMANCE 196 P0462 FUEL LEV...

Page 2200: ...P1593 SPEED CONTROL SWITCH STUCK 273 P1602 PCM NOT PROGRAMMED 276 P1603 PCM INTERNAL DUAL PORT RAM COMMUNICATION 277 P1604 PCM INTERNAL DUAL PORT RAM READ WRITE INTEGRITY FAILURE 277 P1607 PCM INTERNAL SHUTDOWN TIMER RATIONALITY 277 P1696 EEPROM MEMORY WRITE DENIED INVALID 278 P1697 EMR SRI MILEAGE NOT STORED 278 P2074 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION HIGH FLOW VACUUM LEAK 280 P2096...

Page 2201: ...LINK EXTERNAL FAULT 323 ROLLING CODE FAILURE 325 VIN MISMATCH 325 TRANSPONDER COMMUNICATION FAILURE 327 TRANSPONDER CYCLIC REDUNDANCY CHECK CRC FAILURE 327 TRANSPONDER ID MISMATCH 327 TRANSPONDER RESPONSE MISMATCH 327 STARTING CHECKING FUEL DELIVERY 330 CHECKING FUEL PRESSURE LEAK DOWN 333 CHECKING HARD START FUEL DELIVERY SYSTEM 334 ENGINE CRANKS DOES NOT START 336 NO CRANK CONDITION 340 NO RESPO...

Page 2202: ...ACK 2 WAY 365 FUEL INJECTOR NO 6 2 7L BLACK 2 WAY 365 FUEL PUMP MODULE 4 WAY 365 GENERATOR BLACK 2 WAY 366 IDLE AIR CONTROL MOTOR BLACK 2 WAY 366 IGNITION COIL PACK 2 0L 2 4L BLACK 3 WAY 366 INLET AIR TEMP SENSOR BLACK 2 WAY 366 KNOCK SENSOR 2 0L 2 4L BLACK 2 WAY 366 KNOCK SENSOR 2 7L BLACK 2 WAY 367 LEFT SPEED CONTROL SWITCH LT GREEN 2 WAY 367 MANIFOLD ABSOLUTE PRESSURE SENSOR GRAY 3 WAY 367 MASS...

Page 2203: ...MMOBILIZER MODULE BLACK 6 WAY 376 THROTTLE POSITION SENSOR 2 0L 2 4L GRAY 3 WAY 376 THROTTLE POSITION SENSOR 2 7L BLACK 3 WAY 376 VEHICLE SPEED CONTROL SERVO BLACK 4 WAY 377 VEHICLE SPEED SENSOR 2 0L MTX BLACK 3 WAY 377 10 0 SCHEMATIC DIAGRAMS 379 10 1 JR 2 0L 2 4L 379 10 2 JR 2 7L 381 11 0 CHARTS AND GRAPHS 383 vii ...

Page 2204: ...NOTES viii ...

Page 2205: ...ection 8 0 All connector pinouts are in Section 9 0 All system schematics are in Section 10 0 An placed before the symptom description indi cates a customer complaint When repairs are required refer to the appropri ate service information for the proper removal and repair procedure Diagnostic procedures change every year New diagnostic systems may be added carryover sys tems may be enhanced READ T...

Page 2206: ...t then a trouble code will be stored in the PCM It is possible that a trouble code for a monitored circuit may not be entered into the PCM memory even though a malfunction has occurred This may happen because one of the trouble code criteria has not been met The PCM compares input signal voltages from each input device with specifications the estab lished high and low limits of the range that are ...

Page 2207: ...ntrol Short To Ground Oxygen Sensor Heater System For Short To Voltage Oxygen Sensor Response Fuel System Lean Fuel System Rich Inputs Checked For Requires 3 Consecutive Rationality Catalytic Converter Fuel System Good Trips To Efficiency Except EWMA Extinguish The MIL Outputs Checked For up to 6 tests per trip Functionality and a one trip fault EGR System Misfire Monitor Evaporative Emission Moni...

Page 2208: ...or For additional information refer to the Chrysler Corporation Technical Training Workbook titled On Board Diagnostics OBDII EOBD part num ber 81 699 01050 The most efficient order to run the monitors has been outlined below including suggestions to aid the process A NA TURAL VACUUM LEAK DETECTION WITH PURGE MONITOR This monitor requires a cool down cycle usually an overnight soak for at least 8 ...

Page 2209: ...ing the 12 volt high side drive and shortens duty cycle or none at all when less voltage is needed O2 SENSOR The O2 system with ignition on and engine off has a normalized O2 voltage of around 5 volts as displayed on the DRBIII or measured with a high impedance voltmeter As the O2 sensor starts gen erating a signal the voltage will move towards 2 5 volts The voltage will typically vary between 2 5...

Page 2210: ...sed to close the vent during the medium and large leak tests and during the purge flow check This solenoid requires initial 1 5 amps of current to pull the valve open but after 100 ms will be duty cycled down to an average of about 150 mA for the remainder of the drive cycle Another feature in the NVLD Assembly is a diaphragm that will open the seal with pressure in the evaporative system The seal...

Page 2211: ...suffi cient to confirm purge solenoid function and con formance with the purge flow test requirement The Purge Flow Monitor is passed based on switch activity when purge is turned on or based on a rich fuel control shift when purge is turned on Medium and Large Leak Test Intrusive NOTE This intrusive test will only be run if the Small Leak passive test fails or is inconclusive the switch does not ...

Page 2212: ...FIGURE 1 8 GENERAL INFORMATION ...

Page 2213: ...FIGURE 2 9 GENERAL INFORMATION ...

Page 2214: ... a fuel injector is clogged the pintle is sticking or the wrong injectors are installed Fuel Requirements Poor quality gasoline can cause problems such as hard starting stalling and stumble Use of methanol gasoline blends may re sult in starting and driveability problems See indi vidual symptoms and their definitions in Section 6 0 Glossary of Terms PCM Grounds The PCM cannot detect a poor system ...

Page 2215: ...d The SKIS incorporates a VTSS LED located on the instrument panel upper cover The LED re ceives switched ignition voltage and is hardwired to the body control module The LED is actuated when the SKIM sends a PCI Bus message to the body controller requesting the LED on The body control ler then provides the ground for the LED The SKIM will request VTSS LED operation for the following bulb checks a...

Page 2216: ...d to each SKIM AT ONE TIME Once a key is learned to a SKIM it the key cannot be transferred to another vehicle If ignition key programming is unsuccessful the DRBIII will display one of the following messages Programming Not Attempted The DRBIII attempts to read the programmed key status and there are no keys programmed in the SKIM mem ory Programming Key Failed Possible Used Key From Wrong Vehicl...

Page 2217: ...veled by the vehicle while the MI is activated must be available at any instant through the serial port on the standard data link connector This feature works as follows 1 If the MI is illuminated due to a fault the distance count is updated i e it is counting 2 If there is a stale MI fault i e the fault is still frozen in memory but the MI has been extin guished due to 3 good trips the distance c...

Page 2218: ... the vehicle It is especially important to block the wheels on front wheel drive vehicles the parking brake does not hold the drive wheels When servicing a vehicle always wear eye pro tection and remove any metal jewelry such as watchbands or bracelets that might make an inad vertent electrical contact When diagnosing a powertrain system problem it is important to follow approved procedures where ...

Page 2219: ... duplicate the diagnostic code or symptom condition CAUTION Before road testing a vehicle be sure that all components are reassembled During the test drive do not try to read the DRBIII screen while in motion Do not hang the DRBIII from the rear view mirror or operate it yourself Have an assistant available to operate the DRBIII 4 3 2 VEHICLE DAMAGE CAUTIONS CAUTION For vehicles equipped with NGC ...

Page 2220: ...transmission control module lack of pow er sluggish The engine has less than expected power with little or no increase in vehicle speed when the throttle is opened LDP leak detection pump MAP manifold absolute pressure sensor MIL malfunction indicator lamp MTV manifold tuning valve NGC next generation controller O2S oxygen sensor PCI programmable communication inter face PCM powertrain control mod...

Page 2221: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 17 ...

Page 2222: ...h the DRB answ er the question With the DRB enter Body then Body Computer With the DRB enter Anti Lock Brakes With the DRB enter Body then Electro Mechanical Cluster MIC With the DRB enter Passive Restraints then Airbag Were you able to establish communications with any of the modules All Yes Go To 2 No Refer to symptom PCI Bus Communication Failure in the Com munications category Perform POWERTRA...

Page 2223: ... Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the appropriate terminal of special tool 8815 Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION ...

Page 2224: ...essary to perform this step Did the vehicle pass this test All Yes Go To 2 No Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the DRBIII from the DLC Disconnect the PCM harness connectors Turn the ignition on Measure the voltage of the PCM SCI Transmit circuit at the Data Link harness connector cav 7 Is the voltage above 1 0 volt All Yes Repair the...

Page 2225: ...he ignition off Disconnect the PCM harness connector Disconnect the DRBIII from the DLC Measure the resistance between ground and the PCM SCI Receive circuit in the Data Link harness connector cav 12 Is the resistance below 5 0 ohms All Yes Repair the PCM SCI Receive circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Disconnect the PCM harne...

Page 2226: ...he resistance of the PCM SCI Transmit circuit from the Data Link harness connector cav 7 to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the PCM SCI Transmit circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 9 If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in...

Page 2227: ...mmunica tion with the BCM Perform SKIS VERIFICATION 2 Turn the ignition off Disconnect the SKIM harness connector Using a 12 volt test light connected to 12 volts probe the ground circuit Is the test light illuminated All Yes Go To 3 No Repair the Ground circuit for an open Perform SKIS VERIFICATION 3 Turn the ignition off Disconnect the SKIM harness connector Turn the ignition on Using a 12 volt ...

Page 2228: ...elect lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the SKIM connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately...

Page 2229: ...mptom Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Turn the ignition on Using a 12 volt test light connected to g...

Page 2230: ...RANSMISSION VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Using a 12 volt test light connected to 12 volts probe each ground circuit in the appropr...

Page 2231: ... in the appropriate terminal of special tool 8815 Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Replace and program the Powertrain Control Module in accor dance with the service information WITH THE DRBIII PER FORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1...

Page 2232: ...rs a NO RESPONSE message or a BUS SIGNALS OPEN message Turn the ignition on Using the DRB attempt to communicate with the following control modules Body Control Module BCM Instrument Cluster MIC Airbag Control Module Controller Antilock Brake CAB Was the DRB able to communicate with one or more Module s All Yes Go To 2 No Go To 3 2 Turn the ignition off Note Visually inspect the related w iring ha...

Page 2233: ...lts for any measurement All Yes Go To 6 No Replace the Body Control Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the module that corresponds to the PCI Bus circuit that measured steadily above 7 0 volts Turn the ignition on NOTE If the PCI Bus circuit for the Radio w as above 7 0 volts and is equipped w ith a CD Changer d...

Page 2234: ... that resistance measured below 1000 0 ohms NOTE If the PCI Bus circuit for the Radio w as below 1000 0 ohms and is equipped w ith a CD Changer disconnect the CD Changer before the Radio NOTE If the PCI Bus circuit for the Instrument Cluster MIC w as below 1000 0 ohms and is equipped w ith a Compass Mini Trip Computer CMTC disconnect the CMTC before the MIC Measure the resistance between ground an...

Page 2235: ...ced pinched partially broken wires and broken bent pushed out or corroded terminals CAUTION NEVER PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Inspect and clean all PCM engine and chassis grounds If numerous trouble codes were set use a wire schem...

Page 2236: ...NSPECTION INTERMITTENT CKP SIGNAL CAMSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR TEST ACTION APPLICABILITY 1 WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data With the DRBIII erase DTCs St...

Page 2237: ...the ignition off Remove the Camshaft Position Sensor Inspect the Tone Wheel Pulse Ring for damage foreign material or excessive movement Were any problems found All Yes Repair or replace the Tone Wheel Pulse Ring as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 If there are no possible causes remaining view repair All Repair Replace the Camshaft Position Sensor Perform POWERTRA...

Page 2238: ...t pushed out or corroded terminals Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor are properly installed and the mounting bolt s tight Refer to any TSBs that may apply Were any of the above conditions present All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 9 9 Turn the ignition off Remove the Crankshaft Position Sensor Inspect the Tone Wheel ...

Page 2239: ... on the Crank Position Sensor and wiggle the CKP Sensor Turn the ignition off Inspect the Sensor harness connector PCM harness connector Sensor connector and PCM connector for loose bent corroded or pushed out pins terminals Inspect the related wire harness and the splices in the K24 CKP circuits Were any problems found All Yes Repair the wiring connector concerns as needed or replace the Cranksha...

Page 2240: ...n Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is on Set Condition Desired state does not match Actual state P0051 O2 SENSOR 2 1 HEATER CIRCUIT LOW When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is on Set Condition The PCM detects the O2 Heater voltage is out of acceptable range Below 0 0926 of a volt One Trip Fault P0057 O2 SENSOR 2 2...

Page 2241: ...CATION TEST VER 5 3 Turn the ignition off NOTE Allow the O2 sensor to cool dow n to room temperature Disconnect the O2 Sensor harness connector Measure the resistance across the O2 Sensor Heater element component side NOTE Heater Resistance Specification 1 1 and 2 1 3 0 to 4 0 ohms or 1 2 and 2 2 4 0 to 5 0 ohms Is the O2 Sensor Heater element within specification All Yes Go To 4 No Replace the O2...

Page 2242: ... 5 0 ohms All Yes Repair the short to ground in the O2 Sensor Heater Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 38 DRI...

Page 2243: ...8 O2 SENSOR 1 2 HEATER CIRCUIT HIGH When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is off Set Condition Desired state does not equal Actual state One trip fault P0052 O2 SENSOR 2 1 HEATER CIRCUIT HIGH When Monitored Battery voltage above 10 6 volts ASD is powered up and O2 heater is off Set Condition The O2 heater voltage is out of range high P0058 O2 SENSOR 2 2 HE...

Page 2244: ...ance across the O2 Sensor Heater element component side NOTE Heater Resistance Specification 1 1 and 2 1 3 0 to 4 0 ohms or 1 2 and 2 2 4 0 to 5 0 ohms Is the O2 Sensor Heater element within specification All Yes Go To 4 No Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 4 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running With the DRBI...

Page 2245: ...ROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the O2 Heater Control circuit from the O2 Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes NOTE Before continuing check the PCM harness connecto...

Page 2246: ...thin a predetermined time an error will be detected Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO HIGH RESISTANCE IN MAP K6 5 VOLT SUPPLY CIRCUIT RESISTANCE TO GROUND IN MAP K6 5 VOLT SUPPLY CIRCUIT MAP SENSOR HIGH RESISTANCE IN K1 MAP SIGNAL CIRCUIT RESISTANCE TO GROUND IN K1 MAP SIGNAL CIRCUIT HIGH RESISTANCE IN K4 MAP GROUND CIRCUIT PCM TP SENSOR OPERATION HIGH RESISTANCE IN TP SENSOR ...

Page 2247: ...lowly depressing the throttle pedal from the idle position to the wide open throttle position Does the voltage start approximately at 0 8 volts and go above 3 5 volts with a smooth transition All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 4 4 Turn the ignition off Disconnect the TP Sensor harness connector Discon...

Page 2248: ...ignition off Disconnect the TP Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K22 TP Signal circuit from the TP Sensor harness connector to th...

Page 2249: ...mation Perform POWERTRAIN VERIFICATION TEST VER 5 11 Turn the ignition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K...

Page 2250: ...f special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 15 No Repair the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 15 Turn the ignition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K1 MAP Signal circuit at the MAP Sensor harness connector Is the resistance above 100k ohms All Yes...

Page 2251: ...rminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 47 DRIVEABILITY NGC P0068 MANIFOLD PRESSURE THROTTLE POSITION CORRELATION Continued ...

Page 2252: ...error is detected Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO K25 AAT SIGNAL CIRCUIT SHORTED TO BATTERY VOLTAGE AMBIENT AIR TEMPERATURE SENSOR VOLTAGE BELOW 1 0 VOLT K25 AAT SIGNAL CIRCUIT OPEN K4 SENSOR GROUND CIRCUIT OPEN K25 AAT SIGNAL CIRCUIT SHORTED TO GROUND K25 AAT SIGNAL CIRCUIT SHORTED TO K4 SENSOR GROUND PCM LOW PCM HIGH TEST ACTION APPLICABILITY 1 Ignition on engine not runni...

Page 2253: ...ure Sensor harness connector Using a jumper wire jumper across the Ambient Air Temperature Sensor harness connector Ignition on engine not running With the DRBIII read the Ambient Air Temperature voltage Is the voltage below 1 0 volt All Yes Replace the Ambient Air Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 Turn the ignition off Disconnect the Ambient Air Temperatur...

Page 2254: ...ION TEST VER 5 7 Turn the ignition off Disconnect the Ambient Air Temperature Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K25 AAT Signal circuit Is the resistance below 100 ohms All Yes Repair the short to ground in the K25 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 8 8 Turn the ignition off Disconnect the ...

Page 2255: ...he INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the Ambient Air Temperature Sensor harness connector Ignition on engine not running With the DRBIII read Ambient Air Temperature Sensor voltage Is the voltage above 1 0 volt All Yes Replace the Ambient Air Temperature Sensor Perform POWERTRAIN VERIFICATION TE...

Page 2256: ...0 ohms All Yes Repair the K4 Sensor ground shorted to the K25 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with t...

Page 2257: ...PPLICABILITY 1 Ignition on engine not running With the DRBIII read the Ambient Air Temperature Sensor voltage Is the voltage above 4 8 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the Ambient Air Temperature Sensor harness connector Ignition on engine not running Measu...

Page 2258: ...l 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the K25 AAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Disconnect the Ambient Air Temperature Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN ...

Page 2259: ...IRCUIT SHORTED TO GROUND K1 MAP SIGNAL CIRCUIT SHORTED TO K4 SENSOR GROUND CIRCUIT PCM K6 5 VOLT SUPPLY CIRCUIT PCM K1 MAP SENSOR SIGNAL CIRCUIT TEST ACTION APPLICABILITY 1 Start the engine With the DRBIII read the MAP Sensor voltage Is the voltage below 078 of a volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VE...

Page 2260: ...1 MAP Signal circuit and the K4 Sensor ground circuit in the MAP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the K4 Sensor ground shorted to the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 6 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possi...

Page 2261: ...the MAP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the open in the K6 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 9 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view...

Page 2262: ...AL CIRCUIT OPEN K4 SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Start the engine With the DRBIII read the MAP Sensor voltage Is the voltage above 4 9 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness ...

Page 2263: ...HE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K1 MAP Signal circuit from the MAP Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the K1 MAP Signal circuit Perform ...

Page 2264: ...ion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 60 DRIVEABILITY NGC P0108 MAP SENSOR HIGH Continued ...

Page 2265: ... IAT SIGNAL SHORTED TO GROUND K21 IAT SIGNAL CIRCUIT SHORTED TO K4 SENSOR GROUND PCM HIGH PCM LOW TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION...

Page 2266: ... harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 6 Turn the ignition off Disconnect the IAT Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WIL...

Page 2267: ...ect the PCM harness connector Measure the resistance between the K4 Sensor ground circuit and the K21 IAT Sensor Signal circuit at the IAT Sensor harness connector Is the resistance below 5 0 ohms All Yes Repair the K4 Sensor ground circuit shorted to the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No NOTE Before continuing check the PCM harness connector terminals for corros...

Page 2268: ...age below 1 0 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the IAT harness connector Ignition on engine not running With the DRBIII read IAT Sensor voltage Is the voltage above 1 0 volt All Yes Replace the IAT Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 3...

Page 2269: ... the K4 Sensor ground shorted to the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Informatio...

Page 2270: ... K4 SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read the IAT Sensor voltage Is the voltage above 4 6 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the IAT Sensor harness connector Ignition on engine not runni...

Page 2271: ...o Repair the open in the K21 IAT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Disconnect the IAT Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM D...

Page 2272: ...TO BATTERY VOLTAGE ECT SENSOR VOLTAGE BELOW 1 0 VOLT K2 ECT SIGNAL CIRCUIT OPEN K4 SENSOR GROUND CIRCUIT OPEN K2 ECT SIGNAL CIRCUIT SHORTED TO GROUND K2 ECT SIGNAL SHORTED TO K4 SENSOR GROUND PCM HIGH PCM LOW TEST ACTION APPLICABILITY 1 NOTE Due to the fact that the PCM compares the IAT AAT and ECT sensor to see if they are w ithin a calibrated temp of one another the use of a block heater can cau...

Page 2273: ... Sensor harness connector Using a jumper wire jumper across the ECT Sensor harness connector Ignition on engine not running With the DRBIII read the ECT Sensor voltage Is the voltage below 1 0 volt All Yes Replace the ECT Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 Turn the ignition off Disconnect the ECT Sensor harness connector Disconnect the PCM harness connector CAUTION DO N...

Page 2274: ...nect the ECT Sensor harness connector Turn the ignition off Disconnect the PCM harness connector Measure the resistance between ground and the K2 ECT Signal circuit in the ECT Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 8 8 Turn the ignition off Disconnect the ECT Senso...

Page 2275: ...Is the voltage below 1 0 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the ECT harness connector Ignition on engine not running With the DRBIII read ECT Sensor voltage Is the voltage between 4 8 and 5 2 volts All Yes Replace the ECT Sensor Perform POWERTRAIN VERIFICATION...

Page 2276: ...4 Sensor ground shorted to the K2 ECT Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Informatio...

Page 2277: ...T OPEN K4 SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read the ECT Sensor voltage Is the voltage above 4 9 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the ECT Sensor harness connector Ignition on engine not...

Page 2278: ...No Repair the open in the K2 ECT Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Disconnect the ECT Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM D...

Page 2279: ...EN TP SENSOR INTERNAL FAILURE K22 TP SIGNAL CIRCUIT SHORTED TO GROUND K22 TP SIGNAL CIRCUIT SHORTED TO K4 SENSOR GROUND CIRCUIT PCM K6 5 VOLT SUPPLY CIRCUIT PCM K22 TP SENSOR SIGNAL TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read the Throttle Position Sensor voltage Is the voltage below 0 2 of a volt All Yes Go To 2 No Go To 10 2 Turn the ignition off Disconnect the...

Page 2280: ...Signal circuit and the K4 Sensor ground circuit in the TPS harness connector Is the resistance below 100 ohms All Yes Repair the short to K4 Sensor ground in the K22 TP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 6 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes r...

Page 2281: ...heck the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 10 Ignition on engine not running With the DRBIII monitor the Throttle Position Sensor voltage ...

Page 2282: ...SIGNAL CIRCUIT OPEN K4 SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 NOTE Ensure the throttle is fully closed and free from binding or carbon build up Start the engine With the DRBIII read the TP Sensor voltage Is the voltage above 4 5 volts All Yes Go To 2 No Go To 8 2 Turn the ignition off Disconnect the TP Sensor harness connector Disconnect the PCM harness connector Measure the re...

Page 2283: ...PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K22 TP Signal circuit from the TP harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the K22 TP Signal circuit Perform POWERTRAIN ...

Page 2284: ... TEST VER 5 8 Ignition on engine not running With the DRBIII monitor the TP Sensor voltage Slowly open the throttle from the idle position to the wide open throttle position Does voltage start at approximately 0 7 of a volt and go above 3 5 volts with a smooth transition All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 No R...

Page 2285: ... DTC is set along w ith this code diagnose the ECT DTC first NOTE Inspect the ECT terminals and related PCM terminals Ensure the terminals are free from corrosion and damage NOTE The best w ay to diagnose this DTC is to allow the vehicle to sit overnight outside in order to have a totally cold soaked engine Note Extremely cold outside ambient temperatures may have caused this DTC to set WARNING Ne...

Page 2286: ...the proper temperature All Yes Go To 3 No Replace the thermostat Perform POWERTRAIN VERIFICATION TEST VER 5 3 Ignition on engine not running With the DRBIII read the ECT Sensor temperature value If the engine was allowed to sit overnight cold soak the temperature value should be a sensible value that is somewhere close to the ambient temperature Note If engine coolant temperature is above 82 C 180...

Page 2287: ...GINE COOLANT TEMPERATURE TEMPERATURE SENSOR VOLTAGE BELOW 1 0 VOLT SIGNAL CIRCUIT OPEN SENSOR GROUND CIRCUIT OPEN SIGNAL CIRCUIT SHORTED TO GROUND SIGNAL CIRCUIT SHORTED TO SENSOR GROUND PCM LOW PCM HIGH TEST ACTION APPLICABILITY 1 NOTE If any ECT AAT CMP or CKP sensor DTCs have set along w ith P0128 diagnose them first before continuing NOTE Ensure that Pinion Factor has been programmed correctly...

Page 2288: ...g With the DRBIII monitor the Engine Coolant temperature If the engine was allowed to sit overnight cold soak the temperature value should be a sensible value that is somewhere close to the ambient temperature NOTE If engine coolant temperature is above 82 C 180 F allow the engine to cool until 65 C 150 F is reached Start the Engine During engine warm up monitor the ECT Deg value on the DRBIII The...

Page 2289: ...ormal operating temperature monitor the Temperature sensor parameters while wiggling the wire harness Look for parameter values to change Visually inspect the related wire harness Look for any chafed pierced pinched partially broken wires and broken bent pushed out or corroded terminals CAUTION NEVER PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS...

Page 2290: ... Signal circuit from the Temperature Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 11 No Repair the open in the Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 11 Turn the ignition off Disconnect the applicable Temperature Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM H...

Page 2291: ...ture Sensor harness connector Disconnect the PCM harness connector Measure the resistance between the Signal circuit and the Sensor ground circuit in the Temperature Sensor harness connector Is the resistance below 100 ohms All Yes Repair the Sensor ground shorted to the Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No NOTE Before continuing check the PCM harness connector terminals fo...

Page 2292: ...6 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K6 5 VOLT SUPPLY CIRCUIT OPEN MAP SENSOR INTERNAL FAILURE K1 MAP SIGNAL CIRCUIT OPEN K1 MAP SIGNAL CIRCUIT SHORTED TO GROUND PCM K6 5 VOLT SUPPLY CIRCUIT PCM K1 MAP SIG CIRCUIT TEST ACTION APPLICABILITY 1 NOTE Refer to any TSBs that may apply to this DTC before proceeding Ignition on engine not running With the DRBIII read the MAP Sensor voltage Is the vol...

Page 2293: ...gnition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K1 MAP Signal circuit at the MAP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the K1 MAP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 6 NOTE Before continuing check the PCM harness conne...

Page 2294: ...form POWERTRAIN VERIFICATION TEST VER 5 10 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 11 Start the engine NOTE If ...

Page 2295: ...seconds Two trip Fault P0151 O2 SENSOR 2 1 VOLTAGE LOW When Monitored Engine Running for less than 30 seconds O2 Sensor Heater Temper ature less than 376 C 705 F Battery voltage greater than 10 99 volts Set Condition The oxygen sensor signal voltage is below 1 5 volts for 3 seconds One trip Fault P0157 O2 SENSOR 2 2 VOLTAGE LOW When Monitored Engine Running for less than 30 seconds O2 Sensor Heate...

Page 2296: ... engine to reach normal operating temperature With the DRBIII read the O2 Sensor voltage Is the voltage below 2 52 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running With the DRBIII monitor the O2 Sensor voltage ...

Page 2297: ...ER 5 No Go To 6 6 Turn the ignition off Disconnect the O2 Sensor harness connector Disconnect the PCM harness connector Measure the resistance between the O2 Signal circuit and the O2 Return circuit in the O2 Sensor harness connector Is the resistance below 100 ohms All Yes Repair the O2 Return circuit shorted to the O2 Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 7 7 Turn th...

Page 2298: ...ter Temperature is greater than 350 C 662 F Battery voltage greater than 10 99 volts Set Condition The Oxygen Sensor voltage is above 3 9902 volts for 30 seconds Two trip fault P0152 O2 SENSOR 2 1 VOLTAGE HIGH When Monitored The engine running for 119 seconds O2 Sensor Heater Temperature is greater than 585 C 1085 F Battery voltage greater than 10 99 volts Set Condition The Oxygen Sensor voltage i...

Page 2299: ...rn the ignition off Disconnect the O2 Sensor harness connector WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Start the engine and allow the engine to idle Measure the voltage on the O2 Sensor Signal circuit in the O2 Sensor harness connector NOTE Measure the voltage in reference to grou...

Page 2300: ...te terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open O2 Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 6 Turn the ignition off Disconnect the O2 Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN ...

Page 2301: ... for a minimum 120 seconds Coolant Temp greater than 70 C 158 F Catalytic Converter Temperature greater than 600 C 1112 F Set Condition The PCM monitors the state of change of the front O2 sensor and the rear 02 sensor The PCM will then compare the differences between both readings if the differences are greater than a calibrated amount the PCM will record a fault Two trip failure P0153 O2 SENSOR ...

Page 2302: ...Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Start the engine Inspect the exhaust system for leaks between the engine and the O2 Sensors Are there any exhaust leaks All Yes Repair or replace the leaking exhaust parts as necessary Perform POWERT...

Page 2303: ...ll Yes Check the O2 Return circuit for damage short to ground open or short to voltage If OK replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 If there are no possible causes remaining view repair All Repair Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 99 DRIVEABILITY NGC P0133 O2...

Page 2304: ...FROMANCE When Monitored Engine Running and Heater duty cycle greater than 0 Set Condition O2 Heater Temperature does not reach 575 C 959 F within 45 second during monitoring conditions Two Trip Fault P0155 O2 SENSOR 2 1 HEATER PERFORMANCE When Monitored Engine Running and Heater duty cycle greater than 0 Set Condition O2 Heater Temperature does not reach 575 C 959 F within 90 second during monitor...

Page 2305: ...nd 2 2 4 0 to 5 0 ohms Is the resistance within the specifications All Yes Go To 4 No Replace the O2 Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 4 Turn the ignition off Disconnect the O2 Sensor harness connector Measure the resistance between an engine ground and the O2 Heater Ground circuit in the O2 Sensor harness connector Is the resistance below 0 5 of an ohm All Yes Go To 5 No Repair th...

Page 2306: ...ge terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 102 DRIVEABILITY NGC P0135 O2 SENSOR 1 1 HEATER PERFORMANCE Continued ...

Page 2307: ...s and a trouble code is stored P0174 FUEL SYSTEM 2 1 LEAN When Monitored With the engine running in closed loop mode the ambient battery temperature above 7 C 20 F altitude below 8500 ft and fuel level greater than 15 Set Condition If the PCM multiplies short term compensation by long term adaptive and a certain percentage is exceeded for two trips a freeze frame is stored the MIL illuminates and ...

Page 2308: ... your fuel pressure reading All Within Specification Go To 3 Below Specification Go To 12 Caution Stop All Actuations 3 NOTE If one of the O2 Sensors Signal or Return circuits are shorted to ground or voltage all the other O2 Sensor voltage readings w ill be affected NOTE After the repairs have been made verify proper O2 Sensor operation If all the O2 Sensor voltage readings have not returned to n...

Page 2309: ... If engine coolant temperature is above 82 C 180 F allow the engine to cool until 65 C 150 F is reached Start the Engine During engine warm up monitor the ECT Sensor value The temperature value change should be a smooth transition from start up to normal operating temperature 82 C 180 F The value should reach at least 82 C 180 F Did the ECT value increase with a smooth transition and did it reach ...

Page 2310: ...o 11 No Check the O2 Signal circuit for a short to ground open or short to voltage Inspect the O2 Sensor connector and the PCM harness connector If OK replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 11 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running Measure the vo...

Page 2311: ...ification is 400 KPa 34 KPa 58 psi 5 psi Is the fuel pressure within specification All Yes Repair or replace fuel supply line as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 13 Caution Stop All Actuations 13 Turn the ignition off Warning The fuel system is under a constant pressure even w ith the engine off Before testing or servicing any fuel system hose fitting or line the fuel ...

Page 2312: ...rips a freeze frame is stored the MIL illuminates and a trouble code is stored P0175 FUEL SYSTEM 2 1 RICH When Monitored With the engine running in closed loop mode the ambient battery temperature above 7 C 20 and altitude below 8500 ft Set Condition If the PCM multiplies short term compensation by long term adaptive as well as a purge fuel multiplier and the result is below a certain value for 30...

Page 2313: ...ion Replace the fuel filter pressure regulator Perform POWERTRAIN VERIFICATION TEST VER 5 Caution Stop All Actuations 3 NOTE If one of the O2 Sensors Signal or Return circuits are shorted to ground or voltage all the other O2 Sensor voltage readings w ill be affected NOTE After the repairs have been made verify proper O2 Sensor operation If all the O2 Sensor voltage readings have not returned to n...

Page 2314: ...id the thermostat must be operating correctly Note This test w orks best if performed on a cold engine cold soak Ignition on engine not running With the DRBIII read the Engine Coolant Temperature Sensor value If the engine was allowed to sit overnight cold soak the temperature value should be a sensible value that is somewhere close to the ambient temperature Note If engine coolant temperature is ...

Page 2315: ...th the DRBIII monitor the O2 Sensor voltage The O2 Sensor voltage should read 5 0 volts on the DRBIII with the connector disconnected Using a jumper wire jump from the O2 Signal circuit to the O2 Return circuit in the O2 Sensor harness connector NOTE The voltage should drop from 5 0 volts dow n to 2 5 volts w ith the jumper w ire connected Did the O2 Sensor voltage drop from 5 volts to 2 5 volts A...

Page 2316: ...mage or terminal push out Repair as necessary Replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 No Check the O2 Return circuit for damage short to ground open or short to voltage Inspect the O2 Sensor connector and the PCM harness connector If OK replace the Powertrain Control Module in accordance with the Servic...

Page 2317: ...f One Trip Fault P0203 FUEL INJECTOR 3 When Monitored With battery voltage greater than 10 volts Auto Shutdown Relay energized Engine speed less than 3000 rpm Set Condition No inductive spike is detected after injector turn off One Trip Fault P0204 FUEL INJECTOR 4 When Monitored With battery voltage greater than 10 volts Auto Shutdown Relay energized Engine speed less than 3000 rpm Set Condition N...

Page 2318: ...gine not running With the DRBIII actuate the ASD Relay Using a 12 volt test light connected to ground backprobe the F42 ASD Relay Output circuit at the Fuel Injector harness connector Does the test light illuminate brightly All Yes Go To 3 No Repair the open or high resistance in the F42 ASD Relay Output circuit Perform POWERTRAIN VERIFICATION TEST VER 5 3 Turn the ignition off Disconnect the Fuel...

Page 2319: ...rform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Disconnect the Fuel Injector harness connector Disconnect the PCM harness connectors Measure the resistance between ground and the Injector Control circuit at the Fuel Injector harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the Injector Control circuit Perform POWERTRAIN VERIFICATION TEST VER...

Page 2320: ...uccessfully updated Set Condition When more than a 1 8 misfire rate is measured during two trips or with a 10 to 30 misfire rate during one trip P0302 CYLINDER 2 MISFIRE When Monitored Any time the engine is running and the Target Learning Coefficient has been successfully updated Set Condition When more than a 1 8 misfire rate is measured during two trips or with a 10 to 30 misfire rate during on...

Page 2321: ...ion When more than a 1 8 misfire rate is measured during two trips or with a 10 to 30 misfire rate during one trip POSSIBLE CAUSES INTERMITTENT MISFIRE VISUAL AND PHYSICAL INSPECTION IGNITION WIRE ASD RELAY OUPUT CIRCUIT COIL ENGINE MECHANICAL PROBLEM IGNITION COIL COIL CONTROL CIRCUIT SPARK PLUG CHECKING FUEL PRESSURE FUEL PUMP INLET STRAINER PLUGGED RESTRICTED FUEL SUPPLY LINE FUEL PUMP MODULE C...

Page 2322: ...nal to component connection i e CKP sensor Fuel Injector Ign coil etc Vacuum leaks Restricted Air Induction system NOTE Verify the integrity of the pow ers and grounds for the PCM Were any of the above conditions present All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 3 3 NOTE On the 3 5L engines it may necessary to remove the upper intake to access some ignition co...

Page 2323: ...pressure regulator Perform POWERTRAIN VERIFICATION TEST VER 5 6 NOTE Before continuing visually and physically inspect the fuel delivery system for external leaks or damage Repair replace as necessary Turn the ignition off WARNING The fuel system is under a constant pressure even w ith the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be ...

Page 2324: ...TEM must be free of any restrictions or leaks ENGINE PCV SYSTEM must flow freely TORQUE CONVERTER STALL SPEED must be within specifications POWER BRAKE BOOSTER no internal vacuum leaks FUEL must be free of contamination Are there any engine mechanical problems All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 18 9 Turn the ignition off Disconnect the Fuel Injector har...

Page 2325: ...ne at the fuel pump module Install special 5 16 fuel line adapter tool 6539 between the disconnected fuel line and the fuel pump module Attach a fuel pressure test gauge to the T fitting on the tool 6539 Ignition on engine not running With the DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 400 KPa 34 KPa 58 psi 5 psi Is the fuel pres...

Page 2326: ...uit Crank the engine for 5 second while observing the test light Does the test light blink flicker All Yes Replace the Ignition Coil Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 17 17 Turn the ignition off Disconnect the Ignition Coil harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM ...

Page 2327: ...shed out or corroded terminals CAUTION NEVER PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Inspect and clean all PCM engine and chassis grounds NOTE Review ing the vehicle repair history may aid in the repair of the misfire condition Visually and p...

Page 2328: ... PCM battery disconnect to reset the PCM Start the engine If the MIL has not yet illuminated test drive the vehicle to try to get the code to reset Does the code reset while cranking or during the test drive All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Visually inspect the CKP wire harness Look for any chaf...

Page 2329: ...sive movement Were any problems found All Yes Repair or replace the Tone Wheel Flex Plate as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 4 4 If there are no possible causes remaining view repair All Repair Replace the Crankshaft Position Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 125 DRIVEABILITY NGC P0315 NO CRANK SENSOR LEARNED Continued ...

Page 2330: ...NAL CIRCUIT OPEN K42 KS SIGNAL CIRCUIT SHORTED TO K45 KS RETURN CIRCUIT K45 KS RETURN CIRCUIT OPEN KNOCK SENSOR TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFI...

Page 2331: ...pair the open in the K42 KS Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Disconnect the Knock Sensor harness connector Measure the resistance between the K42 KS Signal circuit and the K45 KS Return circuit in the Knock Sensor harness connector Is the resistance below 100 ohms All Yes Repair the K42 KS Signal circuit for a short to K45 KS Return circuit Perform ...

Page 2332: ...RBIII read DTC s Does the DRBIII display the DTC that was previously erased All Yes NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 No Test Complete 128 DRIVEABILITY NGC P0325 KNOCK SEN...

Page 2333: ... CKP SIGNAL K6 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K6 5 VOLT SUPPLY CIRCUIT OPEN K6 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE K24 CKP SIGNAL CIRCUIT SHORTED GROUND K24 CKP SIGNAL CIRCUIT OPEN K24 CKP SIGNAL CIRCUIT SHORTED TO VOLTAGE K24 CKP SIGNAL SHORTED TO K6 5 VOLT SUPPLY CIRCUIT K4 SENSOR GROUND CIRCUIT OPEN PCM K6 5 VOLT SUPPLY PCM K24 CKP SIGNAL CRANKSHAFT POSITION SENSOR TEST ACTION APP...

Page 2334: ...WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Ignition on engine not running Wiggle the related wire harness and lightly tap on the Crank Position Sensor Observe the lab scope screen Look for any pulses generated by the CKP Sensor Start the engine Allow the engine to idle Observe the lab scope ...

Page 2335: ...FICATION TEST VER 5 8 Turn the ignition off Disconnect the CKP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K24 CKP Signal circuit in the CKP Sensor harness connector Is the resistance below 5 0 ohms All Yes Repair the short to ground in the K24 CKP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 9 9 Turn the ignitio...

Page 2336: ...ce and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 13 Turn the ignition off Disconnect the CKP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K6 5 Volt Supply circuit in the CKP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the sho...

Page 2337: ...in the K6 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 16 16 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIF...

Page 2338: ...NSPECTION CHECKING CAMSHAFT POSITION SENSOR SIGNAL WITH THE DRBIII LAB CRANKSHAFT POSITION SENSOR K24 CKP SIGNAL CIRCUIT OPEN K24 CKP SIGNAL CIRCUIT SHORT TO GROUND K24 CKP SIGNAL CIRCUIT SHORTED TO B K24 CKP SIGNAL CIRCUIT SHORT TO K6 5 VOLTS PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter d...

Page 2339: ...rminals Ensure the Crankshaft Position Sensor and the Camshaft Position Sensor are properly installed and the mounting bolt s are tight Refer to any TSBs that may apply Were any of the above conditions present All Yes Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 4 4 Turn the ignition off Disconnect the CKP Sensor connector Ignition on engine not running Measure the volta...

Page 2340: ...isconnect the CKP Sensor connector Disconnect the PCM connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance in the K24 CKP Signal circuit between the CKP harness connector and the appropriate terminal of spec...

Page 2341: ...e K6 5 Volt Supply circuit and the K24 CKP signal circuit at the CKP Sensor harness connector Wiggle the related wire harness while taking this measurement Is the resistance below 5 0 ohms All Yes Repair the short to the K6 5 Volt Supply circuit in the K24 CKP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 12 12 NOTE Before continuing check the PCM harness connector terminals f...

Page 2342: ...ION SENSOR SIGNAL INTERMITTENT CAMSHAFT POSITION SENSOR SIGNAL K6 5 VOLT SUPPLY CIRCUIT SHORTED TO GROUND K6 5 VOLT SUPPLY CIRCUIT OPEN K6 5 VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE K44 CMP SIGNAL CIRCUIT SHORTED GROUND K44 CMP SIGNAL CIRCUIT OPEN K44 CMP SIGNAL CIRCUIT SHORTED TO VOLTAGE K44 CMP SIGNAL SHORTED TO K6 5 VOLT SUPPLY CIRCUIT K4 SENSOR GROUND CIRCUIT OPEN PCM K6 5 VOLT SUPPLY PCM K44 CM...

Page 2343: ... IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Ignition on engine not running Wiggle the related wire harness and lightly tap on the Camshaft Position Sensor Observe the lab scope screen Start the engine Allow the engine to idle Observe the lab scope screen Did the CMP Sensor generate any erratic pulses All Ye...

Page 2344: ...ERTRAIN VERIFICATION TEST VER 5 8 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K44 CMP Signal circuit in the CMP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the K44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 9 9 Turn...

Page 2345: ...am the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 13 Turn the ignition off Disconnect the CMP Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K6 5 Volt Supply circuit in the CMP Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to ground...

Page 2346: ... in the K6 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 16 16 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERI...

Page 2347: ... APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off With the DRBIII lab scope probe and the Miller special tool 6801 backprob...

Page 2348: ...IN VERIFICATION TEST VER 5 5 Turn the ignition off Carefully disconnect the Battery Ground cable Remove the Camshaft Position Sensor Inspect the Tone Wheel Pulse Ring for damage foreign material or excessive movement Were any problems found All Yes Repair or replace the Tone Wheel Pulse Ring as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 6 NOTE An intermittent glitch in the Cra...

Page 2349: ...nal circuit in the CMP Sensor harness connector Wiggle the related wire harness while monitoring the resistance value Does the resistance stay below 100 ohms All Yes Repair the short to ground in the K44 CMP Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 10 10 Turn the ignition off Disconnect the CMP Sensor connector Ignition on engine not running Measure the voltage on the K44...

Page 2350: ...or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 146 DRIVEABILITY NGC P0344 CAMSHAFT POSITION SENSOR INTERMITTENT Continued ...

Page 2351: ...ignal reading fueling samples If a larger than expected variation is detected a soft failure is recorded Three soft failures set a one trip failure After two failed trips a DTC is set and the MIL is illuminated POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO EGR VALVE OPEN AT IDLE EGR VALVE ASSEMBLY INSPECTION EGR SOLENOID ASSEMBLY EGR SOLENOID GROUND CIRCUIT OPEN EGR SOLENOID CONTROL CKT SHORT TO GND EGR...

Page 2352: ... TEST VER 5 No Go To 4 4 Inspect the EGR Assembly for the following Gasket s for leaking Damage and or holes in the EGR tube s Carbon build up on or near the EGR pintle and passage ways Obstruction in the EGR tubes Were any problem found All Yes Repair or replace the EGR Assembly as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 Turn the ignition off Disconnect the EGR Solenoid ...

Page 2353: ...e EGR Solenoid harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the EGR Solenoid Control circuirt Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 10 10 Turn the ignition off Disconnect the PCM harness connector Disconnect the EGR Solenoid harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE ...

Page 2354: ...ION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on Turn all ac...

Page 2355: ...he EGR Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 Turn the ignition off Disconnect the PCM harness connector Disconnect the EGR Solenoid harness connector Measure the resistance between ground and the EGR Solenoid Control circuit at the EGR Solenoid harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the EGR Solenoid Contro...

Page 2356: ... EGR Solenoid harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 8 No Repair the open in the EGR Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 8 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining v...

Page 2357: ...ASSEMBLY GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 NOTE Diagnose all other EGR DTC s first before continuing Start the engi...

Page 2358: ...RTRAIN VERIFICATION TEST VER 5 5 NOTE The conditions that set the DTC are not present at this time The follow ing list may help in identifying the intermittent condition NOTE Closely inspect the EGR tube s for obstructions damage and holes Also inspect the gasket s for leaks WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS...

Page 2359: ...form POWERTRAIN VERIFICATION TEST VER 5 8 Turn the ignition off Disconnect the EGR Solenoid harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the EGR Sensor...

Page 2360: ...ge or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 156 DRIVEABILITY NGC P0404 EGR POSITION SENSOR PERFORMANCE Continued ...

Page 2361: ... SUPPLY CIRCUIT PCM EGR POSITION SENSOR SIGNAL TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read the EGR Position Sensor voltage Is the voltage below 0 2 of a volt All Yes Go To 2 No Go To 10 2 Turn the ignition off Disconnect the EGR Solenoid harness connector Turn the ignition on Measure the voltage of the 5 Volt Supply circuit in the EGR Solenoid harness connector Is the vol...

Page 2362: ...ses remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 7 Turn the ignition off Disconnect the EGR Solenoid harness connector Disconnect the PCM harness connector Measure the resistance between ground and the 5 Volt Supply circuit at the EGR Solenoid harness connector Is the resist...

Page 2363: ...RAIN VERIFICATION TEST VER 5 10 NOTE The engine w ill run rough and possibly stall in the follow ing test Feather the accelerator pedal to keep the engine from stalling Start the engine With the DRBIII enter Engine System Test and then EGR System Test Push the 4 VARIABLE function Monitor the EGR voltage while slowly pushing the up arrow Is the voltage change smooth All Yes Test Complete No Replace...

Page 2364: ... VOLTAGE EGR SOLENOID ASSEMBLY INTERNAL FAILURE SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Start the engine With the DRBIII read the EGR Position Sensor voltage Is the voltage above 4 5 volts All Yes Go To 2 No Go To 8 2 Turn the ignition off Disconnect the EGR Solenoid harness connector Disconnect the PCM harness connector Measure the resistance between the EGR Position Sensor Sig...

Page 2365: ...GR Position Sensor Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 Turn the ignition off Disconnect the EGR Solenoid harness connector Connect a jumper wire between the EGR Position Sensor Signal circuit and the Sensor ground circuit With the DRBIII monitor the EGR Position Sensor voltage Turn the ignition on Is the voltage below 0 5 of a volt All Yes Replace the EGR Solenoi...

Page 2366: ...l run rough and possibly stall in the follow ing test Feather the accelerator pedal to keep the engine from stalling Start the engine With the DRBIII enter Engine System Test and then EGR System Test Push the 4 VARIABLE function Monitor the EGR voltage while slowly pushing the up arrow Is the voltage change smooth All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Per...

Page 2367: ...IR INJ ECTION PUMP RELAY AIR INJ ECTION PUMP GROUND CIRCUIT AIR INJ ECTION PUMP MOTOR AIR INJ ECTION PASSAGES O2 SENSOR TEST ACTION APPLICABILITY 1 NOTE Before performing the follow ing test alw ays check the Air Pump Assembly in line connectors Ensure that there is no terminal damage corrosion or backed out terminals Verify that there is good w ire to terminal connection in the connector Ignition...

Page 2368: ...e w ay valve Does forced air come out of the Exhaust one way valve All Yes Go To 4 No Go To 5 4 WARNING Before performing this test to avoid personal injury allow the exhaust manifold and related components to cool dow n to a safe tempera ture NOTE The exhaust system must be free of leaks in order for this test to w ork properly Turn the ignition off Remove the Exhaust one way valve Remove the O2 ...

Page 2369: ...onnector Does the test light illuminate brightly All Yes Go To 7 No Go To 8 7 Turn the ignition off Disconnect the Air Injection Pump Motor harness connector Using a 12 volt test light connected to battery voltage probe the Air Injection Pump Motor ground circuit Does the test light illuminate brightly All Yes Replace the Air Injection Pump Motor Perform POWERTRAIN VERIFICATION TEST VER 5 No Repai...

Page 2370: ... connectors Ensure that there is no terminal damage corrosion or backed out terminals Verify that there is good w ire to terminal connection in the connector Ignition on engine not running With the DRBIII actuate the Air Pump Relay Is the Air Pump Relay operating All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 2 2...

Page 2371: ... from the Air Pump Relay harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the Air Pump Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Disconnect the Air Pump harness connector Measure the resistance between ground and the Air Pump Relay Control circuit in the Air Pump ...

Page 2372: ...AK ENGINE MECHANICAL CONDITION AGING O2 SENSOR CATALYTIC CONVERTER TEST ACTION APPLICABILITY 1 NOTE A new rear O2 Sensor along w ith an aging front O2 Sensor may cause the DTC to set Review the repair history of the vehicle before continuing NOTE If an O2 Sensor or Fuel System Lean DTC s is set along w ith the Catalytic Converter Efficiency DTC diagnose the O2 Sensor DTC s before continuing NOTE C...

Page 2373: ...r or replace the leaking exhaust parts as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 4 4 Check the exhaust for excessive smoke caused by an internal problem in the engine Is a engine mechanical condition present All Yes Repair the engine mechanical condition as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 A new rear O2 Sensor along with an aging front O2 Sen...

Page 2374: ...GOOD TRIP EQUAL TO ZERO VISUAL AND PHYSICAL INSPECTION EVAP PURGE SOLENOID VACUUM SUPPLY INSPECTION EVAP PURGE SOLENOID STUCK CLOSED NVLD SWITCH OPERATION Z1 GROUND CIRCUIT OPEN NVLD ASSEMBLY K107 NVLD SWITCH SIGNAL CIRCUIT OPEN EVAPORATIVE EMISSION LEAK DETECTION PCM PCM TEST ACTION APPLICABILITY 1 NOTE If any of the follow ing DTCs are set P0443 P0452 P0453 P0498 or P0499 diagnose them first bef...

Page 2375: ...RIFICATION TEST VER 5 No Go To 4 4 Disconnect the vacuum supply hoses form the EVAP Purge Solenoid Using a hand vacuum pump apply 10 in Hg to the CAN side of the EVAP Purge Solenoid Ignition on engine not running Observe the vacuum gauge With the DRBIII actuate the EVAP Purge Solenoid Does the vacuum drop when the solenoid is actuated All Yes Go To 5 No Replace the Evap Purge Solenoid Perform POWE...

Page 2376: ... tester s control panel Press the remote smoke air start button Position the red flag on the air flow meter so it is aligned with the indicator ball When the calibration is complete release the remote button The EELD is now calibrated the flow meter in liters per minute Install the service port adapter 8404 14 on the vehicle s service port if equipped or install the 8404 ADP service adapter in the...

Page 2377: ...e remote smoke air start button and use the ultraviolet UV black light 8404 UVL and the yellow goggles 8404 20 to look for residual traces of dye that are left behind by the smoke The exiting smoke deposits a residual fluid that is either bright green or bright yellow in color when viewed with a UV light NOTE Carefully inspect the vent side of the EVAP Canister Due to the filtering system in the c...

Page 2378: ...RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K107 NVLD Switch Signal circuit from the NVLD electrical harness connector to the appropriate terminal of the special tool 8815 Is the resistance below 5 0 ohms All Yes NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push...

Page 2379: ...52 P0453 P0498 or P0499 diagnose them first before continuing w ith P0441 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 NOTE After disconnecting the Evap Purg...

Page 2380: ... Purge Solenoid Inspect the vacuum port at the throttle body for any damage or plugging Were any problems found All Yes Repair the vacuum supply hose tube as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 176 DRIVEABILITY NGC P0441 EVAP PURGE SYSTEM PERFORMANCE Continued ...

Page 2381: ...e EVAP system If the NVLD switch reopens before the calibrated amount of time for a Medium leak an error is detected Two Trip Fault P0455 EVAP SYSTEM LARGE LEAK When Monitored Engine Running Cold start test Fuel Level greater than 12 Ambient Temperature between 4 C and 32 C 39 F and 89 F Close Loop fuel system Test runs when small leak test is maturing Set Condition The PCM activates the EVAP Purg...

Page 2382: ...cord the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Go To 7 2 Perform a visual and physical inspection of the entire Evaporative Emission system Check for the follow conditions Holes or cracks Loose seal points Evidence of damaged components Incorrect routing of hoses and tubes Fuel Cap gasket seal Were any of the above conditions found All Ye...

Page 2383: ...nel based on DTC leak size Press the remote smoke air start button Position the red flag on the air flow meter so it is aligned with the indicator ball When the calibration is complete release the remote button The EELD is now calibrated the flow meter in liters per minute to the size leak indicated by the DTC set in the PCM Install the service port adapter 8404 14 on the vehicle s service port if...

Page 2384: ...moke If a leak is concealed from view i e top of fuel tank release the remote smoke air start button and use the ultraviolet UV black light 8404 UVL and the yellow goggles 8404 20 to look for residual traces of dye that is left behind by the smoke The exiting smoke deposits a residual fluid that is either bright green or bright yellow in color when viewed with a UV light NOTE Carefully inspect the...

Page 2385: ...S BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Review the DRBIII Freeze Frame information If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply NOTE A loose gas cap could have caused this DTC to set Make sure gas cap is tight and in good condition Ensure the gas cap meets OEM specifications Perform a visual and physical inspe...

Page 2386: ...UIT SHORTED TO GROUND POWERTRAIN CONTROL MODULE TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the...

Page 2387: ...urge Solenoid Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 Turn the ignition off Disconnect the Evap Purge Solenoid harness connector Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFOR...

Page 2388: ...age or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 184 DRIVEABILITY NGC P0443 EVAP PURGE SOLENOID CIRCUIT Continued ...

Page 2389: ...ND EVAP PURGE SOLENOID LEAKS STUCK OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the EVA...

Page 2390: ...m POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 Turn the ignition on Using the DRBIII monitor the NVLD Switch State Disconnect the NVLD electrical connector Does the Switch change from CLOSED to OPEN All Yes Replace the NVLD Assembly Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 6 Turn the ignition off Disconnect the NVLD electrical harness connector Disconnect the PCM harness connector ...

Page 2391: ... the resistance below 5 0 ohms All Yes Repair the short to ground in the K52 EVAP Purge Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFIC...

Page 2392: ...Using the DRBIII perform the NVLD FORCED MONITOR TEST Monitor the NVLD Switch state NOTE As the test runs the NVLD Sw itch should go from an OPEN state to a CLOSED state and then return to OPEN w hen the test is complete Did the NVLD Switch operate as described above All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To...

Page 2393: ...d Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the Z1 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 6 Turn the ignition off Disconnect the NVLD electrical harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONN...

Page 2394: ...ON APPLICABILITY 1 NOTE The difference in ambient temperature outside temp VS shop temp may conceal a leak it is best to perform this test after the vehicle s temperature has stabilized in the w ork area Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Go To 4 2 Perform a visual...

Page 2395: ...ack light 8404 UVL and the yellow goggles 8404 20 to look for residual traces of dye that are left behind by the smoke The exiting smoke deposits a residual fluid that is either bright green or bright yellow in color when viewed with a UV light NOTE Carefully inspect the vent side of the EVAP Canister Due to the filtering system in the canister the smoke or dye may or may not be visual Introducing...

Page 2396: ...he customer that the gas fill cap is loose or off Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 6 2 Perform a visual and physical inspection of the Fuel Fill Cap ...

Page 2397: ...tip clear hose into the appropriate calibration orifice on the tester s control panel based on DTC leak size Press the remote smoke air start button Position the red flag on the air flow meter so it is aligned with the indicator ball When the calibration is complete release the remote button The EELD is now calibrated the flow meter in liters per minute to the size leak indicated by the DTC set in...

Page 2398: ...ting smoke If a leak is concealed from view i e top of fuel tank release the remote smoke air start button and use the ultraviolet UV black light 8404 UVL and the yellow goggles 8404 20 to look for residual traces of dye that is left behind by the smoke The exiting smoke deposits a residual fluid that is either bright green or bright yellow in color when viewed with a UV light NOTE Carefully inspe...

Page 2399: ... WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING Review the DRBIII Freeze Frame information If possible try to duplicate the conditions under which the DTC was set Refer to any Technical Service Bulletins TSB that may apply NOTE Make Ensure the gas cap meets OEM specifications Perform a visual and physical inspection of the entire Evaporative Emission sy...

Page 2400: ...UIT SHORTED TO GROUND G4 FUEL LEVEL SIGNAL CIRCUIT OPEN Z2 GROUND CIRCUIT OPEN INTERNAL INSPECTION OF THE FUEL TANK FUEL LEVEL SENSOR TEST ACTION APPLICABILITY 1 NOTE Diagnose P0462 or P0463 first if set along w ith P0461 NOTE Inspect the Fuel Pump Module harness connector for any corrosion or damage Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data ...

Page 2401: ...p Module harness connector Measure the resistance of the Z2 Ground circuit from the Fuel Pump Module harness connector to ground Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the Z2 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 6 WARNING The fuel system is under a constant pressure even w ith the engine off Before opening the fuel system the fuel pressure must ...

Page 2402: ... LEVEL SENSOR 1 HIGH When Monitored Ignition on and battery voltage above 10 4 volts Set Condition The fuel level sensor signal voltage at the PCM goes above 4 7 volts for more than 5 seconds One Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO INTERMITTENT CONDITION TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read DTC s Is the Good Trip displayed and equal to zero All Yes R...

Page 2403: ... RELAY CONTROL CIRCUIT SHORT TO GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII actuate the Radiator Fan Relay Is the Low Speed Radiator Fan Relay operating All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 2 2 Turn the ignition off Remove the Low Speed Radiator Fan Relay from t...

Page 2404: ...rom the PDC to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the C24 Low Speed Rad Fan Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Remove the Low Speed Radiator Fan Relay from the PDC Disconnect the PCM harness connector Measure the resistance between ground and the C24 Low Speed Rad...

Page 2405: ...RAD FAN RELAY CONTROL CIRCUIT SHORT TO GROUND PCM TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII actuate the High Speed Radiator Fan Relay Is the High Speed Radiator Fan Relay operating All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 2 2 Turn the ignition off Remove the High Speed Radiator Fan Re...

Page 2406: ...e resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the C27 High Speed Rad Fan Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Remove the High Speed Radiator Fan Relay from the PDC Disconnect the PCM harness connector Measure the resistance between ground and the C27 High Speed Rad Fan Relay Control circuit in the PDC Is the resistance below 5...

Page 2407: ... flow though the Air Injection system a fault is recorded Two Trip Fault P2431 MAF SENSOR PERFORMANCE When Monitored Engine Running No other MAF sensor faults are present Air Injection System is active Set Condition The PCM detects the MAF sensor has an excessive amount of air flow or not enough air flow though it Two Trip Fault POSSIBLE CAUSES GOOD TRIP EQUAL TO ZERO VISUAL AND PHYSICAL INSPECTIO...

Page 2408: ...s and kinks Exhaust one way check valve blockage plugged or damage Were any of the above conditions found All Yes Repair or replace as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 3 3 Turn the ignition off Disconnect the MAF Sensor harness connector Ignition on engine not running Using the DRBIII actuate the ASD Relay With a 12 volt test light connected to ground probe the ASD Rel...

Page 2409: ...gnition off Disconnect the MAF Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the MAF Signal circuit from the MAF Sensor harness connector to the ...

Page 2410: ...MAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the Sensor ground circuit from the MAF Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 11 No Repair the open in the Sensor ground circuit Perform POWERTRAIN VERIFICATION TEST VER...

Page 2411: ...ignition off Disconnect the NVLD electrical harness connector Measure the resistance of the NVLD Solenoid coil Is the resistance between 7 5 to 8 5 ohms All Yes Go To 3 No Replace the NVLD Assembly Perform POWERTRAIN VERIFICATION TEST VER 5 3 Turn the ignition off Disconnect the NVLD electrical harness connector Disconnect the PCM harness connector Measure the resistance between ground and the K10...

Page 2412: ...PEN Z1 GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the NVLD Assembly ha...

Page 2413: ... of the K106 NVLD Sol Control circuit from the NVLD Assembly harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the K106 NVLD Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Disconnect the NVLD Assembly harness connector Measure the resistance between the Z1 Ground circuit ...

Page 2414: ...nuing Ignition on engine not running With the DRBIII read PCM DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition on With the DRBIII check the Transmission DTCs Are there any Transmission DTCs present All Y...

Page 2415: ...ICABILITY 1 Raise the drive wheels off the ground WARNING BE SURE TO KEEP HANDS AND FEET CLEAR OF ROTATING WHEELS Start the engine With the DRBIII monitor the Vehicle Speed Sensor Place the transmission in any forward gear Allow the wheels to rotate Does the DRBIII display vehicle speed above 0 MPH KMH All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTR...

Page 2416: ... 100 ohms All Yes Repair the G7 VSS Signal circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 6 Turn the ignition off Disconnect the Vehicle Speed Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION...

Page 2417: ...SPEED HIGH PERFORMANCE When Monitored Engine Running During an idle condition Set Condition If the engine RPM does not come within a calibratable high limit of the target idle speed a failure timer will increment When the appropriate failure timer reaches its maximum threshold without sign of RPM trending towards control a soft fail is generated When a calibratable number of the soft fails is reac...

Page 2418: ...nternal vacuum leaks Were any vacuum leaks found All Yes Repair the vacuum leak as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 Inspect the Air Induction System for the following problems Restrictions Dirty Air Cleaner Foreign material trapped in the air intake tube etc Leaks Air Intake tube connection Air Cleaner housing etc Were any problems found All Yes Repair or replace a...

Page 2419: ...e engine w ill not idle maintain an engine speed betw een 800 and 1500 RPM Start the engine Allow the engine to idle With the DRBIII read the IAC Current Is the IAC Current below 146 mA All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the IAC Motor harness connector Remove the I...

Page 2420: ...nal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 Turn the ignition off Disconnect the IAC Motor harness connector Disconnect the PCM harness connectors Measure the resistance between ground and the K39 IAC Motor Control circuit in the IAC Motor harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the K39 IAC Motor Control circuit Perform POWER...

Page 2421: ...age or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 217 DRIVEABILITY NGC P0508 IAC VALVE SENSE CIRCUIT LOW Continued ...

Page 2422: ... CIRCUIT PCM TEST ACTION APPLICABILITY 1 NOTE If the engine w ill not idle maintain an engine speed betw een 800 and 1500 RPM Start the engine Allow the engine to idle With the DRBIII read the IAC Current Is the IAC Current above 999 mA All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disc...

Page 2423: ... a volt All Yes Repair the short to voltage in the K39 IAC Motor Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 5 5 Turn the ignition off Disconnect the IAC Motor harness connector Measure the resistance across the IAC Motor harness connector Is the resistance below 5 0 ohms All Yes Repair the K60 IAC Motor Signal circuit short to the K39 IAC Motor Control circuit Perform POWE...

Page 2424: ...All Yes Go To 2 No Go To 7 2 With the DRBIII attempt to communicate with the SKIM Turn the ignition on Can the DRBIII communicate with the SKIM All Yes Go To 3 No Refer to the No Communication category Perform SKIS VERIFICATION 3 Turn the ignition on With the DRBIII check for SKIM DTCs Are any DTCs present in the SKIM All Yes Refer to SKIM category for the related symptom s Perform SKIS VERIFICATI...

Page 2425: ...ssary Replace and program the Powertrain Control Module in accordance with the Service Information Perform SKIS VERIFICATION No Test Complete 7 NOTE You must obtain the SKIM pin number NOTE This DTC could have been set if the SKIM harness connector w as disconnected or if the SKIM w as replaced recently NOTE All keys that the customer uses for this vehicle must be tested to verify they are operati...

Page 2426: ...TED TO K4 SENSOR GROUND CIRCUIT PCM K7 5 VOLT SUPPLY CIRCUIT PCM A C PRESSURE SENSOR SIGNAL TEST ACTION APPLICABILITY 1 NOTE Ensure the A C refrigerant System is properly charged per the Service Information Start the engine With the DRBIII read the A C Pressure Sensor voltage Is the voltage below 0 6 of a volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability categ...

Page 2427: ...ssure Sensor Signal circuit and the K4 Sensor ground circuit in the A C Pressure Sensor harness connector Is the resistance below 100 ohms All Yes Repair the short to the K4 Sensor ground circuit in the C18 A C Pressure Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 NGC No Go To 6 6 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push ou...

Page 2428: ...ressure Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the open in the K7 5 Volt Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 9 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining ...

Page 2429: ...sure the A C refrigerant System is properly charged per the Service Information Start the engine With the DRBIII read the A C Pressure Sensor voltage Is the voltage above 4 6 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 2 Turn the ignition off Disconnect the A C Pressure Sensor harness connector Dis...

Page 2430: ...E PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the C18 A C Pressure Sensor Signal circuit from the A C Pressure Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the C18 A C Pressure ...

Page 2431: ...age or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 227 DRIVEABILITY NGC P0533 A C PRESSURE SENSOR HIGH Continued ...

Page 2432: ...ND K10 PSP SWITCH SIGNAL CIRCUIT OPEN POWER STEERING PRESSURE SWITCH PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 2 Turn th...

Page 2433: ...8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the K10 PSP Switch Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 5 Turn the ignition off Disconnect the Power Steering Pressure Switch harness connector Ignition on engine not running Connect a J umper Wire to the K10 PSP Switch Signal circuit at harness connector Using the DRBIII while monitoring the Power...

Page 2434: ...EN FIELD CONTROL CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 NOTE Ensure the Battery is in good condition Using the Midtronics Battery Tester test the Battery before continuing NOTE Inspect the vehicle for aftermarket accessories that may exceed the Generator System output Turn the ignition off NOTE Ensure the generator drive belt is in good operating condition NOTE Inspect the fuses in the PDC I...

Page 2435: ...oltage between the Generator case and Battery ground post Is the voltage above 0 1 of a volt All Yes Repair Generator Ground for high resistance Generator Case to Battery ground side Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 4 4 Turn the ignition off Disconnect the Generator Field harness connector Using a 12 volt test light jumper it across the Generator Field harness connector Igni...

Page 2436: ...DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K20 Gen Field Control circuit from the Generator Field harness connector to the appropriate terminal of the special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 8 No Repair the open in the K20 Gen Field Control circuit Perform POWERT...

Page 2437: ...he generator drive belt is in good operating condition NOTE Inspect the fuses in the PDC If a fuse is found to be open use the w iring diagram schematic as a guide inspect the w iring and connectors for damage Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMI...

Page 2438: ...oltage in the K20 Gen Field Control circuit Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 4 4 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform PO...

Page 2439: ...TERMITTENT CONDITION symptom in the Diagnostic category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Remove the Brake Lamp Switch and disconnect the harness connector Measure the resistance between the Z1 Ground circuit terminal and the K29 Brake Switch Signal terminal at the Brake Lamp Switch Apply and release the brake pedal plunger while monitoring the ohmmeter Does the re...

Page 2440: ...s as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 236 DRIVEABILITY NGC P0572 BRAKE SWITCH 1 CIRCUIT LOW Continued ...

Page 2441: ... DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION in the symptom Diagnostic category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition off Disconnect the Brake Lamp Switch harness connector Measure the resistance between the Z1 Ground circuit terminal and the K29 Brake Switch Signa...

Page 2442: ...VERIFICATION TEST VER 5 4 Measure the resistance between the Z2 Ground circuit and ground at the Brake Lamp Switch harness connector Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the Z1 Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary Us...

Page 2443: ...I read the Speed Control voltage Is the Speed Control voltage below 1 0 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 4 NGC 2 Ignition on engine not running With the DRBIII monitor the Speed Control Switch voltage Disconnect the Speed Control On Off Switch harness connector Did the voltage change to above 4...

Page 2444: ...he Speed Control Resume Accel Switch harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance between ground and the V37 S C Switch Signal circuit to the appropriate ...

Page 2445: ...ith the DRBIII read the Speed Control voltage Is the Speed Control voltage above 4 8 volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 4 NGC 2 Turn the ignition off Remove the Speed Control Switches from the steering wheel Measure the resistance across each Speed Control Switch Monitor the ohmmeter while pressi...

Page 2446: ...h harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K4 Sensor Ground circuit from the Speed Control harness connector to the appropriate terminal of spe...

Page 2447: ... OPEN PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data With the DRBIII actuate the Speed Control Vacuum Solenoid and note operation Does the Speed Control Vacuum Solenoid actuate properly All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 4 NGC No ...

Page 2448: ...ontrol Vacuum Solenoid Using a 12 volt test light connected to battery voltage probe the S C Vacuum Control circuit Does the test light illuminate brightly and flash on and off All Yes Replace the Speed Control Servo Perform POWERTRAIN VERIFICATION TEST VER 4 NGC No Go To 6 6 Turn the ignition off Disconnect the S C Servo harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE ...

Page 2449: ... Switch harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the open high resistance in the V32 S C Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 4 NGC 9 Turn the ignition off Disconnect the Brake Switch harness connector Disconnect the PCM harness connector Measure the resistance between ground and the V32 S C Sup...

Page 2450: ...VENT SOLENOID TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data With the DRBIII actuate the Speed Control Vent Solenoid and note operation Does the Speed Control Vent Solenoid acutate properly All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 4 NGC No ...

Page 2451: ...olenoid Using a 12 volt test light connected to battery voltage probe the V35 Speed Control Vent Solenoid Control circuit in the Speed Control Servo harness connector Does the test light illuminate brightly and flash on and off All Yes Replace the Speed Control Servo Perform POWERTRAIN VERIFICATION TEST VER 4 NGC No Go To 8 6 Turn the ignition off Disconnect the Brake Lamp Switch harness connector...

Page 2452: ...e appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the open high resistance in the V35 S C Vent Sol Control circuit Perform POWERTRAIN VERIFICATION TEST VER 4 NGC 9 Turn the ignition off Disconnect the S C Servo harness connector Disconnect the PCM harness connector Measure the resistance between ground and the V35 S C Vent Sol Control circuit at...

Page 2453: ...TED TO GROUND V30 S C BRAKE SWITCH OUTPUT CIRCUIT OPEN BRAKE LAMP SWITCH PCM S C SOURCE CIRCUIT TEST ACTION APPLICABILITY 1 Turn the ignition off Disconnect the Speed Control Servo harness connector Ignition on engine not running NOTE It is necessary to PRESS and HOLD the Speed Control Sw itch in the ON position w hile checking for voltage Using a 12 volt test light connected to ground probe the V...

Page 2454: ...e Switch harness connector Is the resistance below 100 ohms All Yes Go To 4 No Repair the short to ground in the V32 S C Power Supply circuit Perform POWERTRAIN VERIFICATION TEST VER 5 4 Turn the ignition off Disconnect the Speed Control Servo harness connector Disconnect the Brake Switch harness connector Measure the resistance between ground and the V30 S C Brake Switch Output circuit at the Spe...

Page 2455: ...e reading Does the test light illuminate brightly All Yes Replace the Brake Lamp Switch Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 7 7 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance...

Page 2456: ...tion Internal Bus communication failure between processors P0601 INTERNAL MEMORY CHECKSUM INVALID When Monitored With the ignition on Set Condition Internal checksum for software failed does not match calculated value POSSIBLE CAUSES PCM INTERNAL OR SPI TEST ACTION APPLICABILITY 1 The Powertrain Control Module is reporting internal errors view repair to continue All Repair Replace and program the ...

Page 2457: ...CTION APPLICABILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 2 2 Turn the ignition off Disconnect the Generator Field harness connector Using a 12 volt...

Page 2458: ... resistance below 100 ohms All Yes Repair the K20 Gen Field Control circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 6 6 Turn the ignition off Disconnect the Generator Field harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TE...

Page 2459: ...Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 2 2 Turn the ignition off Remove the Fuel Pump Relay from the PDC Ignition on engine not running Measure the voltage of the A14 Fused Ignition Switch Output circuit in the PDC Is the voltage above 11 0 volts All Yes Go To 3 No Repair the A14 Fused Ignition Switch Output ...

Page 2460: ...rol circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Remove the Fuel Pump Relay from the PDC Measure the resistance between ground and the K31 Fuel Pump Relay Control circuit in the PDC Is the resistance below 5 0 ohms All Yes Repair the short to ground in the K31 Fuel Pump Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 6 NOTE Before continuin...

Page 2461: ...ing temperature With the DRBIII read DTCs Does the DTC reset All Yes Go To 2 No The VIN has been successfully programmed into the PCM Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 2 NOTE The ignition sw itch must be left in the off position for a minimum of 10 seconds Cycle the ignition switch to the off position and then back to run Attempt to program the PCM with the applicable inf...

Page 2462: ...To 2 No The mileage has been succcessfully programmed into the PCM Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 2 NOTE The ignition sw itch must be left in the off position for a minimum of 10 seconds Cycle the ignition switch to the off position and then back to run Attempt to program the PCM with the applicable information Start the vehicle and allow it to reach normal operating t...

Page 2463: ...w the engine to reach normal operating temperature With the DRBIII read DTCs Does the DTC reset All Yes Go To 2 No The SKIM KEY information has been succcessfully programmed into the PCM Test is complete Perform SKIS VERIFICATION 2 NOTE The ignition sw itch must be left in the off position for a minimum of 10 seconds Cycle the ignition switch to the off position and then back to run Attempt to pro...

Page 2464: ...TO GROUND PCM TEST ACTION APPLICABILITY 1 Ignition on engine not running With the DRBIII actuate the A C Clutch Relay Is the A C Clutch Relay operating All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 2 NGC No Go To 2 2 Turn the ignition off Remove the A C Clutch Relay from the PDC Ignition on engine not running Measure the v...

Page 2465: ... from the PDC to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the open in the C28 A C Clutch Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 5 Turn the ignition off Remove the A C Clutch Relay from the PDC Measure the resistance between ground and the C28 A C Clutch Control circuit in the PDC Is the resistance below 5...

Page 2466: ...ng All Yes Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 2 2 Turn the ignition off Remove the ASD Relay from the PDC Ignition on engine not running Measure the voltage of the A14 Fused B circuits in the PDC Is the voltage above 11 0 volts All Yes Go To 3 No Repair the A14 Fused B circuit Check and replace any open fuses...

Page 2467: ...circuit Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Remove the ASD Relay from the PDC Measure the resistance between ground and the K51 ASD Relay Control circuit in the PDC Is the resistance below 5 0 ohms All Yes Repair the short to ground in the K51 ASD Relay Control circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 6 6 NOTE Before continuing check the PCM harnes...

Page 2468: ...UT CIRCUIT OPEN PCM NO START PCM START TEST ACTION APPLICABILITY 1 NOTE Diagnose P0685 Auto Shutdow n Relay Control Circuit first if set along w ith this DTC With the DRBIII erase the DTC Attempt to start the engine If the engine will not start crank the engine for at least 15 seconds It may be necessary to repeat several times Does the DTC reset All Yes Go To 2 No Refer to the INTERMITTENT CONDIT...

Page 2469: ... terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 5 Turn the ignition off Install a substitute relay in place of the ASD Relay Ignition on engine not running With the DRBIII erase DTCs Attempt to start the eng...

Page 2470: ... ASD Relay Output circuits at the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 8 No Repair the open in the ASD Relay Output circuit s Perform POWERTRAIN VERIFICATION TEST VER 5 8 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view rep...

Page 2471: ...now that a DTC s is stored in the Transmission Control Module Erase this DTC from the PCM after all Transmission DTC s have been repaired Using the DRBIII read the Transmission Controller DTC and refer to the Transmission Category and perform the appropriate symptom PCM Diagnostic Information complete All Continue Test Complete 267 DRIVEABILITY NGC ...

Page 2472: ... communicate w ith the TCM refer to the Communication Category and preform the appropriate symptom With the DRBIII read PCM DTCs and record the related Freeze Frame data Is the Good Trip displayed and equal to zero All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 Turn the ignition on With the DRBIII check the T...

Page 2473: ...PEN SIGNAL CIRCUIT SHORTED TO GROUND SIGNAL CIRCUIT SHORTED TO SENSOR GROUND PCM LOW PCM HIGH TEST ACTION APPLICABILITY 1 NOTE NOTE Due to the fact that the PCM compares the IAT AAT and ECT sensors to see if they are w ithin a calibrated temp of one another the use of a block heater can cause false readings for the PCM Check w ith the customer to see if they use a block h Ignition on engine not ru...

Page 2474: ... Yes Go To 5 No Go To 6 5 Inspect the Temperature sensors for any physical damage Inspect the engine coolant Ensure the coolant is at the proper level Refer to the Service Information COOLING Ensure the Temperature sensors are properly mounted WARNING WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHI...

Page 2475: ...cable Temperature Sensor harness connector Using a jumper wire jumper across the Temperature Sensor harness connector Ignition on engine not running With the DRBIII read the Temperature voltage Is the voltage below 1 0 volt All Yes Replace the applicable Temperature Sensor Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 9 9 Turn the ignition off Disconnect the applicable Temperature Sensor har...

Page 2476: ...ION TEST VER 5 11 Turn the ignition off Disconnect the applicable Temperature Sensor harness connector Disconnect the PCM harness connector Measure the resistance between ground and the Signal circuit in the Temperature harness connector Is the resistance below 100 ohms All Yes Repair the short to ground in the Signal circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 12 12 Turn the ignit...

Page 2477: ...RCUIT SHORTED TO BATTERY VOLTAGE V37 S C SIGNAL CIRCUIT OPEN K4 SENSOR GROUND OPEN PCM TEST ACTION APPLICABILITY 1 Start the engine With the DRBIII monitor each switch function for the Speed Control Switches Press and release each Speed Control Button Resume Accel Cancel Decel Coast On Off Set Does each switch function change status when pressing and then depressing each switch All Yes Refer to th...

Page 2478: ...S PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the V37 S C Signal circuit from the Speed Control harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms for both measurement All Yes Go To 5 No Repair the open i...

Page 2479: ...chematics as a guide inspect the wire harness and connectors Pay particular attention to all Power and Ground circuits If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module per Service Information Perform POWERTRAIN VERIFICATION TEST VER 4 NGC 275 DRIVEABILITY NGC P1593 SPEED CONTROL SWITCH STUCK Continued ...

Page 2480: ...The PCM has been successfully programmed Test is complete Perform POWERTRAIN VERIFICATION TEST VER 1 2 NOTE The ignition sw itch must be left in the off position for a minimum of 10 seconds Cycle the ignition switch to the off position and then back to run Attempt to program the PCM Start the vehicle and allow it to reach normal operating temperatures With the DRBIII read DTCs Does the DTC reset A...

Page 2481: ...ctor CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Turn the ignition to run Using a 12 volt test light connected to ground probe the Fused Ignition Switch Output Off Run Start cavity C1 12 circuit at the appropriate terminal of the s...

Page 2482: ...hen Monitored Ignition key on continuous Set Condition An attempt to program write to the internal EEPROM failed Also checks at powerdown POSSIBLE CAUSES DRB DISPLAYS WRITE FAILURE DRB DISPLAYS WRITE REFUSED 2ND TIME DRB DISPLAYS SRI MILEAGE INVALID COMPARE SRI MILEAGE WITH ODOMETER TEST ACTION APPLICABILITY 1 With the DRBIII perform the SRI Memory Test Does the DRBIII display Write Failure All Ye...

Page 2483: ...t Complete 4 With the DRBIII perform the SRI Memory Test Does the DRBIII display SRI Mileage Invalid All Yes Update the mileage and retest the SRI Memory Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 5 5 Compare the SRI Mileage stored with the Instrument Panel Odometer Is the mileage within the specified range displayed on the DRBIII All Yes Test Complete No Update the mileage and retest the...

Page 2484: ...UAL TO ZERO VACUUM LEAK HIGH RESISTANCE IN MAP K6 5 VOLT SUPPLY CIRCUIT RESISTANCE TO GROUND IN MAP K6 5 VOLT SUPPLY CIRCUIT MAP SENSOR HIGH RESISTANCE IN K1 MAP SIGNAL CIRCUIT RESISTANCE TO GROUND IN K1 MAP SIGNAL CIRCUIT HIGH RESISTANCE IN K4 MAP GROUND CIRCUIT PCM TP SENSOR OPERATION HIGH RESISTANCE IN TP SENSOR K6 5 VOLT SUPPLY CIRCUIT RESISTANCE TO GROUND IN TP SENSOR K6 5 VOLT SUPPLY CIRCUIT...

Page 2485: ...arge vacuum leak is most likely the cause of this DTC Inspect the Intake Manifold for leaks and cracks Inspect the Power Brake Booster for any vacuum leaks Inspect the PCV system for proper operation or any vacuum leaks Were any vacuum leaks found All Yes Repair the vacuum leak as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 3 3 Start the engine With the DRBIII monitor the MAP Sen...

Page 2486: ...RTRAIN VERIFICATION TEST VER 5 7 Turn the ignition off Disconnect the TP Sensor harness connector With the DRBIII monitor the TP Sensor voltage Ignition on engine not running Connect a jumper wire between the K22 TP Signal circuit and the K4 Sensor ground circuit Does the TP Sensor voltage change from approximately 4 9 volts to below 0 5 of a volt All Yes Replace the Throttle Position Sensor Perfo...

Page 2487: ...ensor Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 11 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 12 T...

Page 2488: ...FICATION TEST VER 5 No Go To 15 15 Turn the ignition off Disconnect the MAP Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K1 MAP Signal circu...

Page 2489: ...connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 18 No Repair the K4 Sensor Ground circuit Perform POWERTRAIN VERIFICATION TEST VER 5 18 NOTE Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and pr...

Page 2490: ...0 F and altitude below 8500 ft Set Condition If the PCM adds downstream short term compensation to long term adaptive and a certain percentage is exceeded for two trips a freeze frame is stored the MIL illuminates and a trouble code is stored P2098 DOWN STREAM FUEL SYSTEM 1 2 LEAN When Monitored With the engine running in closed loop mode the ambient battery temperature above 7 C 20 F altitude bel...

Page 2491: ... before performing a physical inspection Visually and Physically inspect the exhaust system for holes cracks and or blockage Is the exhaust system is good condition All Yes Go To 3 No Repair or Replace as necessary Perform POWERTRAIN VERIFICATION TEST VER 5 3 Check for any of the following conditions mechanical problems AIR INDUCTION SYSTEM must be free from leaks ENGINE VACUUM must be at least 13...

Page 2492: ...lts All Yes Go To 6 No Check the O2 Signal circuit for a short to ground open or short to voltage Inspect the O2 Sensor connector and the PCM harness connector If OK replace and program the Powertrain Control Module in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 6 Turn the ignition off Disconnect the O2 Sensor harness connector Ignition on engine not running ...

Page 2493: ... 0L 2 4L When Monitored Engine Running Set Condition If PCM detects that the secondary ignition burn time is incorrect or not present an error is detected One Trip Fault P2305 IGNITION COIL 2 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 2 0L 2 4L When Monitored Engine Running Set Condition If PCM detects that the secondary ignition burn time is incorrect or not present an error is detected One Trip F...

Page 2494: ...repeated for the adjacent ignition w ire Turn the ignition off Remove the ignition wire Measure the resistance of the ignition wire Is the resistance below 10K ohms All Yes Go To 4 No Replace the Ignition Wire Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 4 Turn the ignition off Disconnect the Ignition Coil harness connector Turn the ignition on With the DRBIII actuate the ASD Relay Using a 12 vo...

Page 2495: ... Before continuing check the PCM harness connector terminals for corrosion damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 9 Turn the ignition off Remove the Spark Plug Inspect the Spark Plug fo...

Page 2496: ... IONIZATION 2 7L When Monitored Engine Running Set Condition If PCM detects that the secondary ignition burn time is incorrect or not present an error is detected One Trip Fault P2305 IGNITION COIL 2 SECONDARY CIRCUIT INSUFFICIENT IONIZATION 2 7L When Monitored Engine Running Set Condition If PCM detects that the secondary ignition burn time is incorrect or not present an error is detected One Tri...

Page 2497: ...ILITY 1 Ignition on engine not running With the DRBIII read DTCs and record the related Freeze Frame data Is the Good Trip Counter displayed and equal to zero All Yes Go To 2 No Go To 8 2 Turn the ignition off Remove the ignition coil NOTE Before continuing inspect the ignition coil for damage or carbon tracking coil or the spark plug insulator boot If a problem is found replace the ignition coil ...

Page 2498: ...tor Measure the resistance of the Coil Control circuit between the Ignition Coil harness connector and the special tool 8815 terminal Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the Coil Control circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 6 Turn the ignition off Disconnect the Ignition Coil harness connector Disconnect the PCM harness connector Measure the res...

Page 2499: ... the bottom of the spark plug on a solid surface The electrode in the spark plug should not move Were any of the above condition present All Yes Replace the Spark Plug Perform POWERTRAIN VERIFICATION TEST VER 2 NGC No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 295 DRIVEABILITY NGC P2302 IGNITION COIL 1 SECONDARY CIRCUIT I...

Page 2500: ...ays check the Air Pump Assembly in line connectors Ensure that there is no terminal damage corrosion or backed out terminals Verify that there is good w ire to terminal connection in the connector Start the engine With the DRBIII read the MAF Sensor voltage Is the voltage above 4 9267 volts All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRA...

Page 2501: ...NECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the MAF Signal circuit from the MAF Sensor harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the open in the MAF Signal circu...

Page 2502: ...on damage or terminal push out Repair as necessary If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 5 298 DRIVEABILITY NGC P2432 MAF SENSOR HIGH Continued ...

Page 2503: ...in line connectors Ensure that there is no terminal damage corrosion or backed out terminals Verify that there is good w ire to terminal connection in the connector Start the engine With the DRBIII read the MAF Sensor voltage Is the voltage below 07829 of a volt All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 5 2 ...

Page 2504: ... VERIFICATION TEST VER 5 No Go To 5 5 Turn the ignition off Disconnect the MAF Sensor harness connector Disconnect the PCM harness connector Measure the resistance between the MAF Signal circuit and the Sensor ground circuit in the MAF Sensor harness connector Is the resistance below 100 ohms All Yes Repair the Sensor ground shorted to the MAF Signal circuit Perform POWERTRAIN VERIFICATION TEST VE...

Page 2505: ...AL CIRCUIT OPEN MAF SIGNAL CIRCUIT SHORTED TO GROUND MAF SIGNAL CIRCUIT SHORTED TO K4 SENSOR GROUND CIRCUIT SENSOR GROUND CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 NOTE Before performing the follow ing test alw ays check the Air Pump Assembly in line connectors Ensure that there is no terminal damage corrosion or backed out terminals Verify that there is good w ire to terminal connection in the...

Page 2506: ...Air Injection Pump is actuated forced air should come out of the opening of the Exhaust one w ay valve Does forced air come out of the Exhaust one way valve All Yes Go To 4 No Go To 13 4 WARNING Before performing this test to avoid personal injury allow the exhaust manifold and related components to cool dow n to a safe tempera ture NOTE The exhaust system must be free of leaks in order for this t...

Page 2507: ...t circuit Perform POWERTRAIN VERIFICATION TEST VER 5 No Go To 7 7 Turn the ignition off Disconnect the MAF Sensor harness connector Disconnect the PCM harness connector Ignition on engine not running Measure the voltage of the MAF Signal circuit in the MAP Sensor harness connector Is any voltage present All Yes Repair the short to battery voltage in the MAF Signal circuit Perform POWERTRAIN VERIFI...

Page 2508: ...ion off Disconnect the MAF Sensor harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the Sensor ground circuit from the MAF Sensor harness connector to the a...

Page 2509: ... test light illuminate brightly All Yes Go To 15 No Go To 16 15 Turn the ignition off Disconnect the Air Injection Pump Motor harness connector Using a 12 volt test light connected to battery voltage probe the Air Injection Pump Motor ground circuit Does the test light illuminate brightly All Yes Replace the Air Injection Pump Motor Perform POWERTRAIN VERIFICATION TEST VER 5 No Repair the open in ...

Page 2510: ...TION Z1 GEN FIELD GROUND CIRCUIT OPEN K20 GEN FIELD CONTROL CIRCUIT SHORTED TO BATTERY VOLTAGE K20 GEN FIELD CONTROL CIRCUIT SHORTED TO GROUND K20 GEN FIELD CONTROL CIRCUIT OPEN PCM TEST ACTION APPLICABILITY 1 NOTE Inspect the vehicle for aftermarket accessories that may exceed the Generator System output Turn the ignition off NOTE The battery must be fully charged NOTE The Generator belt tension ...

Page 2511: ...ltage between the Generator case and Battery ground post Is the voltage above 0 1 of a volt All Yes Repair Generator Ground for high resistance Generator Case to Battery ground side Perform POWERTRAIN VERIFICATION TEST VER 3 NGC No Go To 4 4 Turn the ignition off Disconnect the Generator Field harness connector Using a 12 volt test light jumper it across the Generator Field harness connector Ignit...

Page 2512: ...ERIFICATION TEST VER 3 NGC No Go To 8 8 Turn the ignition off Disconnect the Generator Field harness connector Disconnect the PCM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the K20 Gen F...

Page 2513: ...BILITY 1 NOTE If P1603 or P1604 are set along w ith this DTC diagnose them first before continuing w ith P1698 NOTE Before continuing inspect all fuses and ensure that all pow er and ground circuits are operating properly NOTE Check all pow ers and grounds to the PCM before continuing Turn the ignition on With the DRBIII erase DTCs Start the engine allow the engine to run for at least 20 seconds w...

Page 2514: ...sed Ignition Switch Output circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 3 Note Determine w hich modules this vehicle is equipped w ith before begin ning Note When attempting to communicate w ith any of the modules on this vehicle the DRB w ill display 1 of 2 different communication errors a NO RESPONSE message or a BUS SIGNALS OPEN message Turn the ignition on Using the DRB attem...

Page 2515: ...the engine on and off several times Leave the engine running for at least 20 second each time With the DRBIII read DTC s Does the DTC reset All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition on With the DRBIII attempt to communicate with the BCM Can communication be established with the BCM All ...

Page 2516: ...AGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the PCI BUS circuit between the Special Tool 8815 and the BCM harness connector Is the resistance below 5 0 ohms All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION TEST ...

Page 2517: ...eability category Perform POWERTRAIN VERIFICATION TEST VER 1 2 Ignition on engine not running With the DRBIII attempt to communicate with the Instrument cluster Can communication be established with the Instrument Cluster All Yes Go To 3 No Refer to the Communication Category and perform the appropri ate symptom related to no communication with cluster Perform POWERTRAIN VERIFICATION TEST VER 1 3 ...

Page 2518: ...ate if the Bus is operational from the DLC to the SKIM Was the DRB III able to communicate with the SKIM All Yes Go To 3 No Refer to symptom BUS SIGNAL OPEN FROM SKIM in the COMMUNICATION category Perform SKIS VERIFICATION 3 Turn the ignition off Disconnect the PCM harness connectors Disconnect the SKIM harness connector CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNE...

Page 2519: ... DTC are not present at this time The follow ing list may help in identifying the intermittent condition With the engine running and at normal operating temperature monitor the DRB parameters related to the DTC while wiggling the wire harness Look for parameter values to change and or a DTC to set Review the DTC When Monitored and Set Conditions If possible try to duplicate the conditions under wh...

Page 2520: ... 20 second each time With the DRBIII read DTCs Does the DTC reset All Yes Go To 2 No Refer to the INTERMITTENT CONDITION symptom in the Driveability category Perform POWERTRAIN VERIFICATION TEST VER 1 2 Ignition on engine not running With the DRBIII attempt to communicate with the BCM Can communication be established with the BCM All Yes Go To 3 No Refer to the Communication Category and perform t...

Page 2521: ...ALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the PCI Bus circuit from the BCM harness connector to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Replace BCM in accordance with the Service Information Perform POWERTRAIN VERIFICATION TEST VER 1 No Repair the PCI Bus circuit between the PCM and the BCM for an open Perform POWERTR...

Page 2522: ... THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Turn the ignition on Using a 12 volt test light connected to ground probe the A41 PCM Fused Ignition Switch Output circuit in the Pinout Box Does the test light illuminate brightly All Yes Go To 3 No Repair ...

Page 2523: ...arness connector to ground Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the Ground circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 3 Disconnect the A C Clutch harness connector Turn the ignition on With the DRBIII actuate the A C Clutch Relay Measure the voltage of the A C Clutch Relay Output circuit in the A C Clutch harness connector Is the voltage above 11 0 vol...

Page 2524: ...3 A C Clutch Relay Output circuit between the PDC and the A C Clutch harness connector Is the resistance below 5 0 ohms All Yes Replace the A C Clutch Relay Perform POWERTRAIN VERIFICATION TEST VER 2 NGC No Repair the C3 A C Clutch Relay Output circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 2 NGC 320 DRIVEABILITY NGC CHECKING THE A C RELAY OUTPUT Continued ...

Page 2525: ...t reset by the micro controller every 65 5 milliseconds EEPROM FAILURE When Monitored With the ignition on Set Condition When the value written to EEPROM memory does not equal the value read back after the write operation INTERNAL FAULT When Monitored With the ignition on Set Condition The SKIM has detected a fault during an internal self test RAM FAILURE When Monitored With the ignition on Set Co...

Page 2526: ... erase the SKIM DTCs Perform 5 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIII read the SKIM DTCs Did the same SKIM DTC return All Yes Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Perform SKIS VERIFICATION No Test Complete 322 SENTRY KEY IMMOBILIZER ANTENNA FAILURE Continued ...

Page 2527: ...ke that occurs with the PCM due to a SKIM reset or during SECRET KEY transfers to the PCM Set Condition When the SKIM does not receive an expected PCI BUS message trans mission acknowledgement from the PCM after 3 transmit attempts POSSIBLE CAUSES INTERMITTENT WIRING HARNESS PROBLEM WIRING HARNESS INSPECTION SKIM PCM TEST ACTION APPLICABILITY 1 NOTE Ensure the PCM has proper pow er and ground conn...

Page 2528: ...PCM and SKIM DTC s Perform 5 ignition key cycles leaving the ignition key on for a minimum of 90 seconds per cycle With the DRBIII read the SKIM DTCs Does the code appear All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform SKIS VERIFICATION No Test Complete 4 Turn the ignition off Note Visually inspect the related w iring harness Look for a...

Page 2529: ...ived by the SKIM within 3 5 seconds of transmitting the last Valid Key Code message to the PCM VIN MISMATCH When Monitored With the ignition on Set Condition When the VIN received from the PCM does not match the VIN stored in the SKIM s EEPROM POSSIBLE CAUSES VERIFYING PCM VIN REPLACE SKIM AND CHECK DTC S INTERMITTENT WIRING HARNESS PROBLEM PCM TEST ACTION APPLICABILITY 1 With the DRBIII erase the...

Page 2530: ... all PCM and SKIM DTC s Perform 5 ignition key cycles leaving the ignition key on for 90 seconds per cycle With the DRBIII check for SKIM DTCs Does the DRBIII display the same DTC All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform SKIS VERIFICATION No The repair is complete Perform SKIS VERIFICATION 4 Turn the ignition off Note Visually in...

Page 2531: ...IC REDUNDANCY CHECK CRC FAILURE When Monitored At ignition on and during Key Programming Mode Set Condition When 5 consecutive transponder signal transmissions are sent to the SKIM with the correct message format but with invalid data TRANSPONDER ID MISMATCH When Monitored At ignition on and during Key Programming Mode Set Condition When the transponder ID read by the SKIM does not match any of th...

Page 2532: ...e ignition on With the DRBIII read the SKIM DTCs Is the DTC present for all ignition keys All Yes Replace and program the Sentry Key Immobilizer Module in accordance with the Service Information Perform SKIS VERIFICATION No Replace the ignition key s that cause the SKIM DTC Perform SKIS VERIFICATION 4 With the DRBIII attempt to reprogram the ignition keys to the SKIM With the DRBIII erase the SKIM...

Page 2533: ... the related w iring harness Look for any chafed pierced pinched or partially broken w ires NOTE Visually inspect the related w iring harness connectors Look for broken bent pushed out or corroded terminals Note Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair wiring harness connectors as necessary Perform SKIS VERIFICATION No Test Complete 329 SEN...

Page 2534: ... No Go To 5 Caution Stop All Actuations 2 Turn the ignition off WARNING The fuel system is under a constant pressure even w ith the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Install a fuel gauge Turn the ignition on With the DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure spec...

Page 2535: ...fuel system pressure must be released Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer Is the Fuel Inlet Strainer plugged All Yes Replace the Fuel Pump Inlet Strainer Perform POWERTRAIN VERIFICATION TEST VER 1 No Replace the Fuel Pump Module Perform POWERTRAIN VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the fuel pump module harness connector Turn the ignition on With ...

Page 2536: ... Perform POWERTRAIN VERIFICATION TEST VER 1 9 Turn the ignition off Remove the Fuel Pump Relay from the PDC Disconnect the Fuel Pump Module harness connector NOTE Check connectors It is critical that the connector is free from any signs of corrosion or deformities Measure the resistance of the A141 Fuel Pump Relay Output circuit from the relay connector to the fuel pump module connector Is the res...

Page 2537: ...testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Install special 5 16 fuel line adapter tool 6539 Attach a fuel pressure test gauge to the T fitting on the tool 6539 Start the engine and allow the fuel system to reach maximum pressure Turn the ignition off NOTE Fuel specification is 400 KPa 34 KPa 58 psi 5 psi Using special tool C4390 Hose Clamp P...

Page 2538: ...on Go To 4 2 Turn the ignition off WARNING The fuel system is under a constant pressure even w ith the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Raise vehicle on hoist and disconnect the fuel supply line at the fuel pump module Install special 5 16 fuel line adapter tool 6539 between the disconnected fuel line and the fuel...

Page 2539: ...ant pressure even w ith the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Install special 5 16 fuel line adapter tool 6539 Attach a fuel pressure test gauge to the T fitting on the tool 6539 Start the engine and allow the fuel system to reach maximum pressure Turn the ignition off NOTE Fuel specification is 400 KPa 34 KPa 58 p...

Page 2540: ...h the DRB and that there are no DTC s stored in the PCM memory If the PCM reports a No Response condition refer to the Communication category for the proper tests Read the PCM DTC s with the DRB If any DTC s are present they must be repaired before continuing with any other No Start diagnostic tests Refer to the Symptom list for the related P code that is reported by the PCM Ensure that the PCI bu...

Page 2541: ... No Go To 8 Caution Stop All Actuations 4 Turn the ignition off WARNING The fuel system is under a constant pressure even w ith the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Install a fuel pressure gauge Turn the ignition on With the DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pres...

Page 2542: ... system is under a constant pressure even w ith the engine off Before testing or servicing any fuel system hose fitting or line the fuel system pressure must be released Remove the Fuel Pump Module and inspect the Fuel Inlet Strainer Is the Fuel Inlet Strainer plugged All Yes Replace the Fuel Pump Inlet Strainer Perform POWERTRAIN VERIFICATION TEST VER 1 No Replace the Fuel Pump Module Perform POW...

Page 2543: ...N TEST VER 1 10 If there are no possible causes remaining view repair All Repair Replace the Fuel Pump Module Perform POWERTRAIN VERIFICATION TEST VER 1 11 Turn the ignition off Remove the Fuel Pump Relay from the PDC With a 12 volt test light connected to ground probe the Fuel Pump Relay Fused B circuit at the PDC Does the test light illuminate All Yes Go To 12 No Repair the Fuel Pump Relay Fused...

Page 2544: ...t seized Is the engine able to turn over All Yes Go To 2 No Repair the mechanical condition preventing the starter motor from cranking Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM harness connectors Move the Gear selector through all gear positions from Park to 1st and back While moving the gear selector through each gear measure the resistance between grou...

Page 2545: ...n neutral Warning The engine may be cranked in the next step Keep aw ay from moving engine parts Briefly connect a jumper wire between Starter Relay B circuit and the Starter Relay Output Circuits Did the Starter Motor crank the engine All Yes Go To 6 No Go To 9 6 Turn the ignition off Remove the Starter Relay from the PDC Turn the ignition on Using a 12 volt test light probe the Ignition Switch O...

Page 2546: ...ce of the Starter Relay Output circuit between the Relay and the Solenoid harness connector Is the resistance below 5 0 ohms All Yes Go To 10 No Repair Starter Relay Output circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 10 Turn the ignition off Remove the Starter Relay from the PDC Using a 12 volt test light connected to ground probe the Fused B circuit at the Starter Relay termina...

Page 2547: ...gnition off Disconnect the PCM harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the PCM Fused Ignition Switch Output circuit in the PCM harness connector Does the test light illuminate brightly All Yes Go To 3 No Repair the Ignition Switch Output circuit Perform POWERTRAIN VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the PCM harness connecto...

Page 2548: ...Turn the ignition on With the DRBIII read DTC s Are any DTCs present All Yes Refer to the Driveability Category and perform the appropriate symptom Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on NOTE If you are unable to communicate w ith the SKIM refer to the Communication Category and perform the appropriate symptom With the DRBIII read the SKIM codes Are there any ...

Page 2549: ...hicle on hoist and disconnect the fuel pressure line at the fuel pump module Install special 5 16 fuel line adapter tool 6539 between the disconnected fuel line and the fuel pump module Attach a fuel pressure test gauge to the T fitting on tool 6539 Turn the ignition on With the DRBIII actuate the ASD Fuel System test and observe the fuel pressure gauge NOTE Fuel pressure specification is 400 KPa ...

Page 2550: ...e is above 82 C 180 F allow the engine to cool until 65 C 150 F is reached Start the engine During engine warm up monitor the Engine Coolant Temperature value The temperature value change should be a smooth transition from start up to normal operating temp 82 C 180 F The value should reach at least 82 C 180 F Did the Engine Temperature value increase smoothly and did it reach at least 82 C 180 F A...

Page 2551: ... to run Good Trip time in each gear this w ill confirm the repair and to ensure that the DTC has not re matured 14 Check for Diagnostic Trouble Codes DTC s during the road test If a DTC sets during the road test return to the Symptom list and perform the appropriate symptom 15 NOTE Erase P0700 DTC in the PCM to turn the MIL light off after making transmission repairs Were there any Diagnostic Trou...

Page 2552: ...ERIFICATION TEST VER 2 NGC APPLICABILITY 1 NOTE After completing the Pow ertrain Verification Test the Transmission Verifi cation Test must be performed 2 NOTE If the PCM has been replaced and the correct VIN and mileage have not been programmed a DTC w ill be set in the ABS Module Airbag Module and the SKIM 3 NOTE If the vehicle is equipped w ith a Sentry Key Immobilizer System Secret Key data mu...

Page 2553: ...spect the vehicle to ensure that all components related to the repair are connected properly 5 With the DRBIII clear DTCs 6 Perform generator output test Refer to the appropriate service information as necessary 7 Start the engine and set engine speed to 2000 RPM for at least thirty seconds 8 Cycle the ignition key off and on 9 With the DRBIII read the DTCs If the DTC returns or any other symptom ...

Page 2554: ...rol did not disengage the repair is not complete Check for TSBs that pertain to speed control problem and then if necessary return to Symptom List 11 Bring the vehicle speed back up to 35 MPH 12 Press the RESUME ACCEL switch If the speed control did not resume the previously set speed the repair is not complete Check for TSBs that pertain to speed control problem and then if necessary return to Sy...

Page 2555: ...erform steps 5 8 If a Major OBDII Monitor DTC was repaired skip those steps and continue verification 10 After the ignition has been off for at least 10 seconds restart the vehicle and run 2 minutes 11 If the Good Trip counter changed to one or more and there are no new DTC s the repair was successful and is now complete Erase DTC s and disconnect the DRBIII 12 If the repaired DTC has reset the re...

Page 2556: ... test when the repair is complete Did the indicator ball indicate the a leak is present All Yes Repeat the DTC test to identify the leak and repair No Repair is complete SKIS VERIFICATION APPLICABILITY 1 Reconnect all previously disconnected components and connectors 2 Obtain the vehicle s unique Personal Identification Number PIN assigned to it s original SKIM This number can be obtained from the...

Page 2557: ...8 0 COMPONENT LOCATIONS 8 1 CONTROL MODULES AND PDC 8 2 CONTROL AND SOLENOIDS 2 0L 2 4L 2 7L 2 0L 2 4L 2 7L C O M P O N E N T L O C A T I O N S 353 COMPONENT LOCATIONS ...

Page 2558: ...2 0L 2 4L 2 7L 8 3 DA TA LINK CONNECTOR 8 4 SENSORS 2 0L 2 4L 2 7L C O M P O N E N T L O C A T I O N S 354 COMPONENT LOCATIONS 8 2 CONTROL AND SOLENOIDS Continued ...

Page 2559: ...2 0L 2 4L 2 7L 2 0L 2 4L 2 7L 2 0L 2 4L 2 7L C O M P O N E N T L O C A T I O N S 355 COMPONENT LOCATIONS ...

Page 2560: ...2 0L 2 4L 2 0L 2 4L 2 7L 2 0L 2 4L 2 7L C O M P O N E N T L O C A T I O N S 356 COMPONENT LOCATIONS 8 4 SENSORS Continued ...

Page 2561: ...8 5 FUEL SYSTEM 2 0L 2 4L 2 0L 2 4L 2 7L C O M P O N E N T L O C A T I O N S 357 COMPONENT LOCATIONS ...

Page 2562: ...8 6 SWITCHES C O M P O N E N T L O C A T I O N S 358 COMPONENT LOCATIONS ...

Page 2563: ...Y CAV CIRCUIT FUNCTION 1 C3 14DB BK A C COMPRESSOR CLUTCH RELAY OUTPUT 2 A C PRESSURE TRANSDUCER GRA Y 4 WA Y CAV CIRCUIT FUNCTION 1 K4 20BK LB SENSOR GROUND 1 2 K6 20VT WT 5 VOLT SUPPLY 3 C18 20DB A C PRESSURE SIGNAL 4 AMBIENT TEMP SENSOR BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 K25 18VT LG AAT SIGNAL 2 K4 18BK LB SENSOR GROUND 1 C O N N E C T O R P I N O U T S 359 CONNECTOR PINOUTS ...

Page 2564: ...ED B CAMSHAFT POSITION SENSOR BLACK 3 WA Y CAV CIRCUIT FUNCTION 1 K6 20VT WT 5 VOLT SUPPLY 2 K4 20BK LB SENSOR GROUND 1 3 K44 20TN YL CMP SIGNAL COIL ON PLUG NO 1 2 7L BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K91 18TN RD COIL CONTROL NO 1 COIL ON PLUG NO 2 2 7L BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K...

Page 2565: ...LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K94 18TN LG COIL CONTROL NO 4 COIL ON PLUG NO 5 2 7L BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K95 18TN DG COIL CONTROL NO 5 COIL ON PLUG NO 6 2 7L BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 F42 18DG LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K96 18TN LB COIL CONTROL NO 6 C O N N E C T O R P I N O U T S 361 CONNEC...

Page 2566: ...OFF RUN START 9 D6 20PK LB SCI RECEIVE TCM 10 11 12 D20 20LG SCI RECEIVE 13 14 15 D15 20WT DG SCI TRANSMIT TCM 16 M1 20PK FUSED B EGR SOLENOID 2 4L PZEV 2 7L BLACK 6 WA Y CAV CIRCUIT FUNCTION 1 K235 20LG PK EGR SENSOR SIGNAL 2 K6 20VT WT 5 VOLT SUPPLY 3 K4 20BK LB SENSOR GROUND 1 4 Z12 20BK TN 2 4L PZEV GROUND 4 Z12 16BK TN 2 7L GROUND 5 6 K35 20GY YL EGR SOLENOID CONTROL ENGINE COOLANT TEMP SENSO...

Page 2567: ...IC SHUT DOWN RELAY OUTPUT 2 K11 18WT DB INJECTOR CONTROL NO 1 FUEL INJECTOR NO 1 2 7L BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K11 18WT DB INJECTOR CONTROL NO 1 FUEL INJECTOR NO 2 2 0L 2 4L BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K12 18TN INJECTOR CONTROL NO 2 C O N N E C T O R P I N O U T S 363 CONNECTOR PINOUTS ...

Page 2568: ... LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K13 18YL WT INJECTOR CONTROL NO 3 FUEL INJECTOR NO 3 2 7L BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K13 18YL WT INJECTOR CONTROL NO 3 FUEL INJECTOR NO 4 2 0L 2 4L BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K14 18LB BR INJECTOR CONTROL NO 4 C O N N E C T O R P I N O U T S 364 CONN...

Page 2569: ... AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K38 18GY INJECTOR CONTROL NO 5 FUEL INJECTOR NO 6 2 7L BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K58 18BR DB INJECTOR CONTROL NO 6 FUEL PUMP MODULE 4 WA Y CAV CIRCUIT FUNCTION 1 Z211 12BK GROUND 2 Z211 18BK GROUND 3 G4 18DB FUEL LEVEL SENSOR SIGNAL 4 A141 14RD FUEL PUMP RELAY OUTPUT C O N N E C T O R P I N O U T S 365 CON...

Page 2570: ... PACK 2 0L 2 4L BLACK 3 WA Y CAV CIRCUIT FUNCTION 1 K17 18DB TN COIL CONTROL NO 2 2 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 3 K19 18BK GY COIL CONTROL NO 1 INLET AIR TEMP SENSOR BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 K21 20BK RD IAT SIGNAL 2 K4 20BK LB SENSOR GROUND 1 KNOCK SENSOR 2 0L 2 4L BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 K42 20DB LG KS SIGNAL 2 K45 20BK VT KS RETURN C O N N E C T O R P I N ...

Page 2571: ... B Z123 22BK LB GROUND MANIFOLD ABSOLUTE PRESSURE SENSOR GRA Y 3 WA Y CAV CIRCUIT FUNCTION 1 K1 20DG RD MAP SIGNAL 2 K4 20BK LB SENSOR GROUND 1 3 K6 20VT WT 5 VOLT SUPPLY MASS AIR FLOW SENSOR 2 4L PZEV BLACK 6 WA Y CAV CIRCUIT FUNCTION 1 2 K4 16BL SENSOR GROUND 1 3 4 A142 16YL AUTOMATIC SHUT DOWN RELAY OUTPUT 5 K57 16WT MAF SENSOR SIGNAL 6 C O N N E C T O R P I N O U T S 367 CONNECTOR PINOUTS ...

Page 2572: ...INE OIL PRESSURE SWITCH SENSE 2 OXYGEN SENSOR 1 1 RIGHT BANK UP 2 7L 4 WA Y CAV CIRCUIT FUNCTION 1 Z192 20BK GROUND 2 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 1 UPSTREAM 2 0L 2 4L 4 WA Y CAV CIRCUIT FUNCTION 1 Z228 20BK GROUND 2 K99 18BR OR O2 1 1 HEATER CONTROL 3 K902 18BR DG O2 RETURN UP 4 K41 20BK DG O2 1 1 SIGNAL C O N N E C T O ...

Page 2573: ... 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 2 7L 4 WA Y CAV CIRCUIT FUNCTION 1 Z193 20BK GROUND 2 K299 18BR WT O2 2 1 HEATER CONTROL 3 K902 18BR DG O2 RETURN UP 4 K241 20LG RD O2 2 1 SIGNAL OXYGEN SENSOR 2 2 LEFT BANK DOWN 2 7L 4 WA Y CAV CIRCUIT FUNCTION 1 Z186 20BK GROUND 2 K399 18BR GY O2 2 2 HEATER CONTROL 3 K904 18DB DG O2 RETURN...

Page 2574: ...C O N N E C T O R P I N O U T S 370 CONNECTOR PINOUTS ...

Page 2575: ...FUEL PUMP RELAY CONTROL 13 14 F12 18DB WT FUSED IGNITION SWITCH OUTPUT RUN START 15 A141 14DG WT FUEL PUMP RELAY OUTPUT 16 A1 18RD FUSED B LOW SPEED RADIA TOR FAN RELA Y CAV CIRCUIT FUNCTION 70 C24 20DB TN LOW RAD F AN RELAY CONTROL 71 F12 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 72 C23 12DG LOW RAD F AN RELAY OUTPUT 73 74 A16 12RD LG FUSED B STARTER MOTOR RELA Y CAV CIRCUIT FUNCTION 7 K90 2...

Page 2576: ... 22 23 24 25 D20 20LG SCI RECEIVE PCM 26 D6 20PK LB EATX SCI RECEIVE TCM 27 K7 18OR MTX EXPORT 5 VOLT SUPPLY 28 K62 18BK OR 2 4L PZEV AIR PUMP MOTOR RELAY CONTROL 29 A14 16RD TN FUSED B 30 A41 16YL FUSED IGNITION SWITCH OUTPUT START 31 K141 20TN WT 2 7L O2 SENSOR 1 2 SIGNAL 32 K904 18DB DG O2 RETURN DOWN 33 K341 20PK WT 2 7L O2 SENSOR 2 2 SIGNAL 34 35 36 D21 20PK SCI TRANSMIT PCM 37 D15 20WT DG EA...

Page 2577: ...ROL NO 2 14 K11 18WT DB INJECTOR CONTROL NO 1 15 16 17 K199 18BR VT 2 0L 2 4L O2 1 2 HEATER CONTROL 17 K299 18BR WT 2 7L 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 K235 20LG PK 2 4L PZEV 2 7L EGR SENSOR SIGNAL 23 K1 20DG RD MAP SIGNAL 24 K45 20BK VT KS RETURN 25 K42 20DB LG KS SIGNAL 26 K57 20DB 2 4L...

Page 2578: ...13 14 15 16 17 K4 18BK LB SENSOR GROUND 1 18 19 F142 16OR DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 20 K52 20PK BK EVAP PURGE CONTROL 21 T26 20DG OR CLUTCH INTERLOCK UPSTOP SWITCH OUTPUT 22 23 K29 20WT PK BRAKE SWITCH SIGNAL 24 25 26 T44 20YL AUTOSTICK DOWNSHIFT SWITCH SIGNAL 27 T5 20LG AUTOSTICK UPSHIFT SWITCH SIGNAL 28 F142 16OR DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 29 K108 20WT TN EVAP PURG...

Page 2579: ...SSURE SWITCH SENSE 23 24 25 26 27 T41 20BK WT TRS T41 SENSE 28 T16 20RD TRANSMISSION CONTROL RELAY OUTPUT 29 T50 20DG L R PRESSURE SWITCH SENSE 30 T47 20YL 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 SENSOR GROUND 35 T54 20VT YL TRANSMISSION TEMPERATURE SENSOR SIGNAL 36 37 T42 20VT WT TRS T42 SENSE 38 T16 2...

Page 2580: ... FUSED IGNITION SWITCH OUTPUT RUN START 5 Z110 20BK GROUND 6 A51 20RD WT FUSED B THROTTLE POSITION SENSOR 2 0L 2 4L GRA Y 3 WA Y CAV CIRCUIT FUNCTION 1 K6 20VT WT 5 VOLT SUPPLY 2 K22 20OR DB TP SIGNAL 3 K4 20BK LB SENSOR GROUND 1 THROTTLE POSITION SENSOR 2 7L BLACK 3 WA Y CAV CIRCUIT FUNCTION 1 K6 20VT WT 5 VOLT SUPPLY 2 K22 20OR DB TP SIGNAL 3 K4 20BK LB SENSOR GROUND 1 C O N N E C T O R P I N O ...

Page 2581: ...5 20LG RD S C VENT CONTROL 3 V30 20DB RD SPEED CONTROL BRAKE SWITCH OUTPUT 4 Z190 20BK GROUND VEHICLE SPEED SENSOR 2 0L MTX BLACK 3 WA Y CAV CIRCUIT FUNCTION 1 K7 18OR WT 5 VOLT SUPPLY 2 K4 20BK LB SENSOR GROUND 1 3 G7 18WT OR VEHICLE SPEED SIGNAL C O N N E C T O R P I N O U T S 377 CONNECTOR PINOUTS ...

Page 2582: ...NOTES 378 ...

Page 2583: ...10 0 SCHEMATIC DIAGRAMS 10 1 JR 2 0L 2 4L S C H E M A T I C D I A G R A M S 379 SCHEMATIC DIAGRAMS ...

Page 2584: ...S C H E M A T I C D I A G R A M S 380 SCHEMATIC DIAGRAMS 10 1 JR 2 0L 2 4L Continued ...

Page 2585: ...10 2 JR 2 7L S C H E M A T I C D I A G R A M S 381 SCHEMATIC DIAGRAMS ...

Page 2586: ...S C H E M A T I C D I A G R A M S 382 SCHEMATIC DIAGRAMS 10 2 JR 2 7L Continued ...

Page 2587: ...11 0 CHARTS AND GRAPHS C H A R T S A N D G R A P H S 383 CHARTS AND GRAPHS ...

Page 2588: ...C H A R T S A N D G R A P H S 384 CHARTS AND GRAPHS ...

Page 2589: ...NOTES 385 ...

Page 2590: ...NOTES 386 ...

Page 2591: ... BLANK SCREEN 4 3 7 1 DRBIII DOES NOT POWER UP 4 3 7 2 DISPLAY IS NOT VISIBLE 4 4 0 DISCLAIMERS SAFETY WARNINGS 5 4 1 DISCLAIMERS 5 4 2 SAFETY 5 4 2 1 TECHNICIAN SAFETY INFORMATION 5 4 2 2 VEHICLE PREPARATION FOR TESTING 5 4 2 3 SERVICING SUB ASSEMBLIES 5 4 2 4 DRBIII SAFETY INFORMATION 5 4 3 WARNINGS 6 4 3 1 VEHICLE DAMAGE WARNINGS 6 4 3 2 ROAD TESTING A COMPLAINT VEHICLE 6 4 4 DIAGNOSIS 6 5 0 RE...

Page 2592: ...5 8 0 COMPONENT LOCATIONS 47 8 1 DATA LINK CONNECTOR 47 8 2 FUSES 47 8 3 WHEEL SPEED SENSORS 48 8 3 1 FRONT 48 8 3 2 REAR 48 8 4 WHEEL SPEED SENSOR CONNECTORS 49 8 4 1 FRONT 49 8 4 2 REAR 49 8 5 BRAKE SWITCH 49 9 0 CONNECTOR PINOUTS 51 ANTI LOCK BRAKE MODULE 47 WAY 51 BRAKE LAMP SWITCH GRAY 6 WAY 52 DATA LINK CONNECTOR BLACK 16 WAY 52 FUSES JB 54 LEFT FRONT WHEEL SPEED SENSOR BLACK 2 WAY 54 LEFT R...

Page 2593: ...ers the Teves Mark 25e Antilock Braking System ABS found on the 2005 J R Sebring Stratus 1 2 SIX STEP TROUBLESHOOTING PROCEDURE Diagnosis of the ABM is done in six basic steps verification of complaint verification of any related symptoms symptom analysis problem isolation repair of isolated problem verification of proper operation 2 0 IDENTIFICATION OF SYSTEM Vehicles equipped with the Teves Mark...

Page 2594: ...I while in diagnostic mode store diagnostic information in non volatile mem ory The ABM continuously monitors the speed of each wheel When a wheel locking tendency is detected the ABM will command the appropriate valve to modulate brake fluid pressure in its hy draulic unit Brake pedal position is maintained during an antilock stop by being a closed system The ABM continues to control pressure in ...

Page 2595: ...tage signal with changing voltage and current levels The ABM monitors the changing amperage digital signal from each wheel speed sensor The resulting signal is interpreted by the ABM as the wheel speed Because of internal circuitry correct w heel speed sensor function cannot be determined by a continuity or resistance check through the sensor Correct antilock system operation is dependent on tone ...

Page 2596: ...s elapsed When in this thermal protection mode the traction control indicator will illuminate however a fault will not be registered 3 5 DIAGNOSTIC TROUBLE CODES The Anti lock Brake Module may report any of several Diagnostic Trouble Codes DTC s For a list of the DTC s diagnosed in this manual refer to the Table of Contents 3 6 FREEZE FRAME Freeze Frame takes a snapshot of specific vehi cle inform...

Page 2597: ...tion Only those components with approved repair and installation procedures in the service manual should be serviced 4 2 4 DRBIII SAFETY INFORMA TION WARNING EXCEEDING THE LIMITS OF THE DRBIII MULTIMETER IS DANGEROUS IT CAN EXPOSE YOU TO SERIOUS OR POSSIBLY FATAL INJURY CAREFULLY READ AND UNDERSTAND THE CAUTIONS AND THE SPECIFICATION LIMITS Follow the vehicle manufacturer s service speci fications...

Page 2598: ... Battery Voltage Out of Range diag nostic trouble code is present it must be re paired prior to addressing any other DTC s If any additional DTC s are present proceed to the appropriate test by locating the matching test in the Table of Contents and begin to diagnose the symptom 5 For ABS if there are no diagnostic trouble codes present identify the customer complaint Select Inputs Outputs and rea...

Page 2599: ...ox DTC diagnostic test code EVBP electronic variable brake proportion ing HCU hydraulic control unit I C integrated circuit ICU integrated control unit IPM integrated power module JBLK junction block mA milli Amp PCI programmable communication inter face P M pump motor TCS traction control system VSS vehicle speed signal WSS wheel speed sensor 7 GENERAL INFORMATION ...

Page 2600: ...NOTES 8 ...

Page 2601: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 9 ...

Page 2602: ...RCUIT OPEN ABM GROUND CIRCUIT OPEN ABM INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the DRBIII display ABM INTERNAL All Yes Go To 2 No Go To 7 2 Turn the ignition off Disconnect the ABM harness connector Inspect the ABM ABM harness connector for damage I...

Page 2603: ...All Yes Go To 6 No Repair the ABS Pump Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the ABM harness connector Measure the resistance of the ground circuits Is the resistance below 5 0 ohms All Yes Replace the Anti Lock Brake Module in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the ground circuit s for ...

Page 2604: ... on With the DRBIII read DTC s With the DRBIII erase DTC s Turn the ignition off Start the engine With the DRBIII read DTC s Does the DRBIII display BATTERY VOLTAGE OUT OF RANGE All Yes Go To 2 No Go To 6 2 Turn the ignition off Perform a battery test and charging system test NOTE Refer to service information for the related test s symptom s Does the battery and charging system pass All Yes Go To ...

Page 2605: ...ms All Yes Replace the Anti Lock Brake Module in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for brok...

Page 2606: ...nition on With the DRBIII attempt to communicate with the Body Control Module Was the DRBIII able to I D or communicate with the BCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRBIII erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRBIII read DTC s Did this DTC reset ...

Page 2607: ...NSTRUMENT CLUSTER SELF TEST INSTRUMENT CLUSTER INTERNAL FAULT ABM INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read DTCs Are there any Instrument Cluster or ABM DTCs present All Yes Refer to the appropriate category for the related symptom s Perform ABS VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Perform the Key on Bulb Check Does the ABS Brake or ...

Page 2608: ...Instrument Cluster self test NOTE Refer to Body information for the related test s Did the indicators illuminate during the Instrument Cluster self test All Yes Replace the Anti Lock Brake module in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Turn the ignition to RUN Perform the Instrument Cluster self test NOTE Refer to Body infor...

Page 2609: ...on On Continuously Set Condition When the ABM detects a wheel speed sensor circuit current is out of range RIGHT FRONT WHEEL SPEED SENSOR CIRCUIT When Monitored Ignition On Continuously Set Condition When the ABM detects a wheel speed sensor circuit current is out of range RIGHT REAR WHEEL SPEED SENSOR CIRCUIT When Monitored Ignition On Continuously Set Condition When the ABM detects a wheel speed...

Page 2610: ...ector Is the affected Wheel Speed Sensor or any of the connector s damaged All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the affected Wheel Speed Sensor connector Note Check connector Clean repair as necessary Turn the ignition on Measure the voltage between affected Wheel Speed Sensor 12 Volt Supply circuit and ground Is the voltage ...

Page 2611: ...l Speed Sensor Signal circuit for a short to voltage Perform ABS VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Disconnect the ABM harness connector Disconnect the affected Wheel Speed Sensor connector Using a 12 volt test light connected to 12 volts probe the affected Wheel Speed Sensor Signal circuit Does the test light illuminate All Yes Repair the affected Wheel Speed Sensor Signal...

Page 2612: ... Turn the ignition off Reconnect ALL affected Wheel Speed Sensor circuit connectors Disconnect the affected Wheel Speed Sensor connector Turn the ignition on Measure the voltage of the affected Wheel Speed Sensor 12 Volt Supply circuit in the affected Wheel Speed Sensor connector while reconnecting the sensor connector Did the affected Wheel Speed Sensor 12 Volt Supply circuit drop voltage to 0 DC...

Page 2613: ...ires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Were any problems found All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Test Complete 21 BRAKES 25E LEFT FRONT WHEEL SPEED SENSOR CIRCUIT Continued ...

Page 2614: ...l circuit missing signal continuously low wheel speed changes erratically periodic drop out of a wheel speed and too long of pressure reduction during an ABS event RIGHT FRONT WHEEL SPEED SENSOR SIGNAL When Monitored Ignition On Continuously Set Condition When the ABM detects the following on the wheel speed sensor signal circuit missing signal continuously low wheel speed changes erratically peri...

Page 2615: ...ph Is the affected Wheel Speed Signal showing 0 km h 0 mph All Yes Go To 3 No The condition is not present at this time Monitor DRBIII parameters while wiggling the related wiring harness Refer to any Technical Service Bulletins TSB that may apply Visually inspect the related wiring harness and connector terminals Perform ABS VERIFICATION TEST VER 1 3 Turn the ignition off Inspect the ABM connecto...

Page 2616: ...rvice information if necessary for procedures or specifications Is the wheel bearing clearance within specifications All Yes Go To 7 No Repair as necessary Perform ABS VERIFICATION TEST VER 1 7 Turn the ignition off Visually inspect brakes for locking up due to lining contamination or overheating Inspect all components for defects which may cause a WHEEL SPEED SENSOR SIGNAL DTC to set Is any compo...

Page 2617: ...he cluster wakeup circuit Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIII erase DTC s With the DRBIII read DTC s Did this DTC reset All Yes Go To 3 No The condition that caused this DTC is currently not present Use the wiring diagrams schematic as a guide and inspect the related wiring harness for a possible intermittent Perform BODY VERIFICATION TEST VER 1 3...

Page 2618: ...from off to on and wait approximately 1 minute With the DRBIII read DTC s Did this DTC reset All Yes Replace the module which set the DTC in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 26 BRAKES 25E MIC MESSAGES NOT RECEIVED Continued ...

Page 2619: ...EN ABM INTERNAL FAULT PCI BUS CIRCUIT SHORT TO VOLTAGE PCI BUS CIRCUIT SHORT TO GROUND TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the DRBIII display PCI BUS COMMUNICATION All Yes Go To 2 No Go To 9 2 Turn the ignition off Disconnect the ABM harness connector Inspect ...

Page 2620: ...f Disconnect the ABM harness connector Measure the resistance of the ground circuits Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the ABM harness connector Turn the ignition on Measure the voltage of the PCI Bus circuit Is there any voltage present All Yes Repair the PCI Bus circui...

Page 2621: ...ule in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 9 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Were ...

Page 2622: ...III erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the DRBIII display PCI BUS LOOPBACK All Yes Go To 2 No Go To 6 2 Turn the ignition off Disconnect the ABM harness connector Inspect the ABM ABM harness connector for damage Is there any broken bent pushed out corroded or spread terminals All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To ...

Page 2623: ...nti Lock Brake Module in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for broken bent pushed out or co...

Page 2624: ...PEN ABM INTERNAL FAULT PCI BUS CIRCUIT SHORT TO VOLTAGE PCI BUS CIRCUIT SHORT TO GROUND TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the DRBIII display PCI BUS SHORTED TO GROUND All Yes Go To 2 No Go To 9 2 Turn the ignition off Disconnect the ABM harness connector Ins...

Page 2625: ...Disconnect the ABM harness connector Measure the resistance of the ground circuits Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the ABM harness connector Turn the ignition on Measure the voltage of the PCI Bus circuit Is there any voltage present All Yes Repair the PCI Bus circuit ...

Page 2626: ...e in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 9 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Were an...

Page 2627: ...OPEN ABM INTERNAL FAULT PCI BUS CIRCUIT SHORT TO VOLTAGE PCI BUS CIRCUIT SHORT TO GROUND TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the DRBIII display PCI BUS SHORTED TO VOLTAGE All Yes Go To 2 No Go To 9 2 Turn the ignition off Disconnect the ABM harness connector I...

Page 2628: ...isconnect the ABM harness connector Measure the resistance of the ground circuits Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the ABM harness connector Turn the ignition on Measure the voltage of the PCI Bus circuit Is there any voltage present All Yes Repair the PCI Bus circuit f...

Page 2629: ...e in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 9 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for broken bent pushed out or corroded terminals Refer to any Hotline letters or Technical Service Bulletins that may apply Were an...

Page 2630: ...RBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the DRBIII display PCI HARDWARE All Yes Go To 2 No Go To 6 2 Turn the ignition off Disconnect the ABM harness connector Inspect the ABM ABM harness connector for damage Is there any broken bent pushed out corroded or spread terminals All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 3 ...

Page 2631: ... Anti Lock Brake Module in accordance with the Service Information Perform ABS VERIFICATION TEST VER 1 No Repair the ground circuit s for an open Perform ABS VERIFICATION TEST VER 1 6 Turn the ignition off Visually inspect the related wiring harness Look for any chafed pierced pinched or partially broken wires Visually inspect the related wire harness connectors Look for broken bent pushed out or ...

Page 2632: ... ignition on With the DRBIII enter Instrument Cluster System Tests then PCM Monitor Does the DRBIII display PCM is active on BUS All Yes Erase the DTC if DTC resets measure the resistance of the PCI Bus circuit between the PCM connector and the ABM connector If open repair as necessary Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIII attempt to communicate wit...

Page 2633: ...TION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Measure the resistance of the PCI Bus circuit between the DLC and the PCM connector Is the resistance below 5 0 ohms All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the PCI Bus circuit for an open Perform BODY VERIFICATION TEST VER 1 41 BRA...

Page 2634: ...ERMITTENT DTC DAMAGED ABM ABM HARNESS CONNECTOR ABS PUMP FUSED B CIRCUIT OPEN PUMP MOTOR GROUND CIRCUITS OPEN ABM INTERNAL FAULT TEST ACTION APPLICABILITY 1 Turn the ignition off Turn the ignition on With the DRBIII read DTCs With the DRBIII erase DTCs Turn the ignition off Turn the ignition on With the DRBIII read DTCs Does the DRBIII display PUMP MOTOR CIRCUIT All Yes Go To 4 No Go To 2 2 Turn t...

Page 2635: ... out corroded or spread terminals All Yes Repair as necessary Perform ABS VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the ABM harness connector Check connectors Clean repair as necessary Measure the voltage of the ABS Pump Fused B circuit Is the voltage above 10 volts All Yes Go To 6 No Repair the ABS Pump Fused B circuit for an open Perform ABS VERIFICATION TEST VER 1 6 ...

Page 2636: ...TION APPLICABILITY 1 Turn the ignition on With the DRB enter Transmission Was the DRB able to I D or communicate with the TCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Yes Replace the Transmission ...

Page 2637: ...complete Are any DTC s present or is the original concern still present All Yes Repair is not complete refer to appropriate symptom No Repair is complete BODY VERIFICATION TEST VER 1 APPLICABILITY 1 Disconnect all jumper wires and reconnect all previously disconnected components and connectors 2 NOTE If the SKIM or PCM w as replaced refer to the service information for proper programming procedure...

Page 2638: ...NOTES 46 ...

Page 2639: ...8 0 COMPONENT LOCATIONS 8 1 DA TA LINK CONNECTOR 8 2 FUSES C O M P O N E N T L O C A T I O N S 47 COMPONENT LOCATIONS ...

Page 2640: ...8 3 WHEEL SPEED SENSORS 8 3 1 FRONT LEFT FRONT RIGHT FRONT 8 3 2 REAR LEFT REAR RIGHT REAR C O M P O N E N T L O C A T I O N S 48 COMPONENT LOCATIONS ...

Page 2641: ...8 4 WHEEL SPEED SENSOR CONNECTORS 8 4 1 FRONT LEFT FRONT RIGHT FRONT 8 4 2 REAR LEFT REAR RIGHT REAR 8 5 BRAKE SWITCH C O M P O N E N T L O C A T I O N S 49 COMPONENT LOCATIONS ...

Page 2642: ...NOTES 50 ...

Page 2643: ...D B VALVE 33 B6 20WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 34 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 35 36 B4 20LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 37 B3 20LG DB LEFT REAR WHEEL SPEED SENSOR SIGNAL 38 39 40 41 42 B1 20YL DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL 43 B2 20YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 44 45 B9 20RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SU...

Page 2644: ...6WT TN BRAKE LAMP SWITCH OUTPUT 6 A7 18RD BK FUSED B DA TA LINK CONNECTOR BLACK 16 WA Y CAV CIRCUIT FUNCTION 1 2 D25 20VT YL PCI BUS DLC 3 4 Z305 20BK YL GROUND 5 Z306 20BK VT GROUND 6 7 D21 20PK SCI TRANSMIT 8 F11 20RD WT FUSED IGNITION SWITCH OUTPUT OFF RUN START 9 D6 20PK LB SCI RECEIVE TCM 10 11 12 D20 20LG SCI RECEIVE 13 14 15 D15 20WT DG SCI TRANSMIT TCM 16 M1 20PK FUSED B C O N N E C T O R ...

Page 2645: ...C O N N E C T O R P I N O U T S 53 CONNECTOR PINOUTS ...

Page 2646: ... OUTPUT OFF RUN START 12 10A INTERNAL FUSED LEFT LOW BEAM OUTPUT 13 20A INTERNAL FUSED RIGHT LOW BEAM OUTPUT 14 10A X12 18RD WT FUSED IGNITION SWITCH OUTPUT RUN ACC 15 10A INTERNAL FUSED IGNITION SWITCH OUTPUT RUN ACC 16 10A F23 20DB YL FUSED IGNITION SWITCH OUTPUT RUN 17 10A F14 18LG YL FUSED IGNITION SWITCH OUTPUT RUN 17 10A F14 20LG YL FUSED IGNITION SWITCH OUTPUT RUN LEFT FRONT WHEEL SPEED SEN...

Page 2647: ...C O N N E C T O R P I N O U T S 55 CONNECTOR PINOUTS ...

Page 2648: ...8BR JR27 FUSED B 20 20A A15 16PK FUSED B 21 SPARE 22 20A A20 12RD DB ABS FUSED B 23 20A F12 18DB WT FUSED IGNITION SWITCH OUTPUT RUN START 23 20A F12 18DB WT HEATED SEATS FUSED IGNITION SWITCH OUTPUT RUN START 24 20A F42 16DG LG 2 7L FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 25 20A F142 16OR DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT RIGHT FRONT WHEEL SPEED SENSOR BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 B...

Page 2649: ...10 0 SCHEMATIC DIAGRAMS 10 1 TEVES MARK 25e ANTI LOCK BRAKE MODULE S C H E M A T I C D I A G R A M S 57 SCHEMATIC DIAGRAMS ...

Page 2650: ...NOTES 58 ...

Page 2651: ...YSTEM 12 3 7 ELECTRICALLY HEATED SYSTEMS 12 3 7 1 HEATED SEAT RELAY 12 3 7 2 REAR WINDOW DEFOGGER 12 3 8 EXTERIOR LIGHTING SYSTEM 12 3 8 1 HEADLAMP DELAY 12 3 9 HEATING AND A C SYSTEM 13 3 9 1 SYSTEM AVAILABILITY 13 3 9 2 SYSTEM CONTROLS 13 3 9 2 1 MANUAL TEMPERATURE CONTROL MTC 13 3 9 2 2 AUTOMATIC TEMPERATURE CONTROL ATC 13 3 9 3 SYSTEM REVISIONS ATC MTC 13 3 9 4 SYSTEM DIAGNOSTICS ATC MTC 14 3 ...

Page 2652: ...NTERNAL 2 24 INTERNAL 3 24 INTERNAL 4 24 OUTPUT DRIVER 1 24 OUTPUT DRIVER 2 24 STORED ENERGY FIRING 1 24 AIRBAG WARNING INDICATOR DRIVER 26 AIRBAG WARNING INDICATOR OPEN 26 AIRBAG WARNING INDICATOR SHORT 26 CALIBRATION MISMATCH 29 CLUSTER MESSAGE MISMATCH 31 DRIVER CURTAIN SQUIB CIRCUIT OPEN 33 DRIVER CURTAIN SQUIB CIRCUIT SHORT 36 DRIVER CURTAIN SQUIB SHORT TO BATTERY 39 DRIVER CURTAIN SQUIB SHOR...

Page 2653: ... SQUIB 1 SHORT TO GROUND 137 PASSENGER SQUIB 2 CIRCUIT OPEN 140 PASSENGER SQUIB 2 CIRCUIT SHORT 143 PASSENGER SQUIB 2 SHORT TO BATTERY 146 PASSENGER SQUIB 2 SHORT TO GROUND 149 POWER SUPPLY VOLTAGE LOW 152 RIGHT SIDE IMPACT SENSOR INTERNAL 1 155 VEHICLE BODY STYLE MISMATCH 157 AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES 160 AUDIO ALL OUTPUTS SHORT PREMIUM AUDIO SYSTEM 161 ALL OUTPUTS SHORT BA...

Page 2654: ...CONNECTED 190 BOOTLOADER CHECKSUM FAILURE 191 EEPROM CHECKSUM FAILURE 192 MIC MESSAGES NOT RECEIVED 193 ORC MESSAGES NOT RECEIVED 194 PCM MESSAGES NOT RECEIVED 195 POST FAILURE 197 SKIM MESSAGES NOT RECEIVED 198 TCM MESSAGES NOT RECEIVED 199 TRAVELER MESSAGES NOT RECEIVED CMTC 200 NO RESPONSE FROM ACM 201 NO RESPONSE FROM AUTOMATIC TEMPERATURE CONTROL MODULE 203 NO RESPONSE FROM BODY CONTROL MODUL...

Page 2655: ... INOPERATIVE EQUIPPED WITH MANUAL TEMP CONTROL 249 EXTERIOR LIGHTING HEADLAMP DELAY RELAY INOPERATIVE 252 HI BEAM HEADLAMPS WILL NOT TURN OFF 253 HIGH BEAM HEADLAMPS WILL NOT TURN ON 254 LOW BEAM HEADLAMPS WILL NO TURN OFF 256 LOW BEAM HEADLAMPS WILL NOT TURN ON 257 HEATING A C A C BLEND DOOR INPUT SHORTED TO BATTERY MTC 259 A C BLEND DR INPUT OPEN SHORT TO GROUND MTC 260 A C HEAD A C SWITCH FAILU...

Page 2656: ... MOTOR INOPERATIVE ATC 328 BLOWER MOTOR INOPERATIVE MTC 333 BLOWER MOTOR SPEEDS INCORRECT MTC 336 BLOWER RUNS AT ONLY ONE SPEED ATC 338 VF SEGMENTS STUCK ON ONE SETTING OR DISPLAYS F OR SOME OR ALL INOPERATIVE 340 IGNITION POWER ACCESSORY HORN INOPERATIVE 343 INSTRUMENT CLUSTER ABS LAMP CIRCUIT OPEN 347 ABS LAMP CIRCUIT SHORT 347 AIRBAG LAMP CIRCUIT OPEN 347 AIRBAG LAMP CIRCUIT SHORT 347 FUEL LEVE...

Page 2657: ...ENTER PROGRAM MODE 401 ALL DOORS EXCEPT DRIVER FAILING TO UNLOCK FROM ANY SWITCH 402 ALL DOORS FAILING TO LOCK AND UNLOCK FROM ANY SWITCH 403 ALL DOORS FAILING TO LOCK AND UNLOCK FROM ONE SWITCH 406 ALL DOORS FAILING TO LOCK FROM ANY SWITCH 409 ALL DOORS FAILING TO LOCK FROM ONE SWITCH 410 ALL DOORS FAILING TO UNLOCK FROM ONE SWITCH 411 AUTOMATIC ROLLING DOOR LOCKS INOPERATIVE 412 DECKLID RELEASE ...

Page 2658: ...EYLESS ENTRY MODULE 463 8 4 POWER TOP 464 8 4 1 POWER TOP RELAY 464 8 4 2 WINDOW DROP RELAY ASSEMBLY 464 8 5 VEHICLE THEFT SECURITY SYSTEM 465 8 5 1 DECKLID CYLINDER LOCK SWITCH 465 9 0 CONNECTOR PINOUTS 467 A C EVAPORATOR TEMPERATURE SENSOR BLACK 2 WAY 467 A C HEATER CONTROL C1 MTC NATURAL 8 WAY 467 A C HEATER CONTROL C2 MTC BLACK 10 WAY 467 AIRBAG CONTROL MODULE ORC BASE YELLOW 23 WAY 468 AIRBAG...

Page 2659: ...AY 482 DRIVER POWER WINDOW MOTOR JR41 LT GRAY 2 WAY 482 DRIVER SEAT BELT SOLENOID JR27 EXPORT NATURAL 2 WAY 482 DRIVER SEAT BELT SWITCH JR41 EXCEPT EXPORT GRAY 2 WAY 482 DRIVER SEAT BELT TENSIONER JR27 YELLOW 4 WAY 483 DRIVER SEAT BELT TENSIONER JR41 YELLOW BLACK 2 WAY 483 FRONT WASHER PUMP MOTOR BLACK 2 WAY 483 FRONT WIPER MOTOR BLACK 4 WAY 483 FUEL PUMP MODULE 4 WAY 484 HEADLAMP LEVELING SWITCH ...

Page 2660: ...ER POWER WINDOW SWITCH BLUE 12 WAY 496 MODE DOOR ACTUATOR BLACK 5 WAY 497 MULTI FUNCTION SWITCH C1 NATURAL 10 WAY 497 MULTI FUNCTION SWITCH C2 BLUE 12 WAY 497 OIL PRESSURE SWITCH 2 WAY 498 OVERHEAD MAP COURTESY LAMPS JR41 BLACK 3 WAY 498 PASSENGER AIRBAG YELLOW 4 WAY 498 PASSENGER DOOR LOCK MOTOR AJAR SWITCH BLACK 4 WAY 498 PASSENGER DOOR LOCK SWITCH NATURAL 4 WAY 498 PASSENGER POWER WINDOW MOTOR ...

Page 2661: ...Y 513 RIGHT REAR POWER WINDOW SWITCH JR41 BLUE 6 WAY 513 RIGHT REAR SPEAKER 3 WAY 514 RIGHT REMOTE RADIO SWITCH 2 7L 2 WAY 514 RIGHT SIDE IMPACT SENSOR 1 GRAY 2 WAY 514 RIGHT TAIL SIDE MARKER LAMP 2 WAY 514 RIGHT TAIL STOP LAMP GRAY 3 WAY 514 RIGHT TAIL TURN SIGNAL LAMP JR41 DODGE GRAY 3 WAY 515 RIGHT TURN LAMP CHRYSLER EXCEPT JR41 DODGE TAN 2 WAY 515 SENTRY KEY IMMOBILIZER MODULE BLACK 6 WAY 515 ...

Page 2662: ...GHTING 532 10 10 1 COURTESY LAMPS 532 10 10 2 PANEL LAMPS 532 10 11 MECHANICAL INSTRUMENT CLUSTER 533 10 12 POWER DOOR LOCKS RKE 534 10 13 POWER TOP 535 10 13 1 CONVERTIBLE TOP 535 10 13 2 POWER TOP 4 WINDOW DROP 536 10 14 VEHICLE COMMUNICATION 537 10 14 1 PCI BUS COMMUNICATION 537 10 14 3 PCM COMMUNICATION 538 10 15 VEHICLE THEFT SECURITY SYSTEM 539 10 16 WIPER SYSTEM 540 10 16 1 WIPER SWITCH 540...

Page 2663: ...This diagnostic procedures manual covers all 2005 Chrysler Sebring convertible and four door models and Dodge Stratus four door models 1 2 SIX STEP TROUBLESHOOTING PROCEDURE Diagnosis of the body system is done in six basic steps verification of complaint verification of any related symptoms symptom analysis problem isolation repair of isolated problem verification of proper operation 1 3 FUSES AN...

Page 2664: ...s with the Instru ment Cluster MIC Body Control Module BCM and Powertrain Control Module PCM Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid informa tion If the ACM detects a monitored system fault it sends a message to the instrument cluster via PCI bus to turn on the Airbag Warning Indicator The ACM can set both active and stored diagnosti...

Page 2665: ...ed directly to the steering wheel Located under the trim cover are the horn switch the airbag cushion and the airbag cushion supporting compo nents The airbag module includes a housing to which the cushion and hybrid inflator are attached and sealed The driver airbag has dual stage squib inflators that include a small canister of highly compressed argon gas The ACM uses vehicle crash severity to d...

Page 2666: ...hen it is reinstalled on the steering column following any service procedure or it could be damaged The clockspring cannot be repaired and it must be replaced 3 1 3 PASSENGER AIRBAG The airbag door in the instrument panel top cover above the glove box is the most visible part of the passenger side airbag system The airbag door has a living hinge at the top which is secured to the instrument panel ...

Page 2667: ...des is an active code DTC SQUIB STATUS Passenger squib 1 open Passenger squib 2 open Status of Airbag is Unknown 3 1 4 SEA T BELT TENSIONER SBT The J R41 4 door driver and front passenger seat belt retractor tensioners are mounted to the in board side of the B pillar at the floor The ten sioner is an integral part of the seat belt retractor The J R27 convertible driver and front passenger seat bel...

Page 2668: ...n deployment the curtain will tear open the head liner allowing the curtain airbag to fully deploy between the headliner and seat The curtain airbag module cannot be repaired and must be replaced if deployed or in any way damaged WARNING THE PASSENGER AIRBAG MODULE CONTAINS ARGON GAS PRESSUR IZED TO 17236 89 Kpa 2500 PSI DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR DO N...

Page 2669: ...12 seconds minimum even if the problem existed for less than 12 seconds The code is stored along with the time in minutes it was active and the number of times the ignition has been cycled since the problem was last detected The minimum time shown for any code will be one minute even if the code was actually present for less than one minute Thus the time shown for a code that was present for two m...

Page 2670: ...uit The radio then responses to the message This circuit is fairly simple to troubleshoot The circuit must be complete from the switches in the steering wheel to the BCM The ground must be complete so that the switches can cause the voltage drop for the BCM to see The circuit passes through the clockspring so continuity through this device must be verified 3 3 BODY CONTROL MODULE The body control ...

Page 2671: ...on while continuing to press the unlock buttons Release both buttons RKE will toggle state of one press two press rear release RKE Program New FOB Us ing an already programmed FOB Not Applica ble Turn vehicle ignition switch on With pro grammed FOB continually press the unlock button for a minimum of 4 seconds to a maximum of 10 seconds Within the 4 10 second range press the panic button while con...

Page 2672: ...time These causes for inaccuracy will be filtered out by the BCM The CMTC receives dedicated PCI Bus messages with the calculated information from the BCM for the trip computer displays The CMTC cannot be repaired and if faulty or damaged it must be replaced The incandescent lamp for the STEP and US M button illumination is serviceable OPERA TION Actuation of the STEP button will cause the CMTC to...

Page 2673: ...perature display Press and hold the STEP and US M buttons simultaneously until CAL begins flashing and then release the buttons CAL is displayed without flashing Drive slowly less than 4 MPH 8KPH in 3 complete 360 degree circles CAL will remain illuminated to alert the driver that the compass is in the calibration mode After calibration is complete CAL will turn off If the compass appears unable t...

Page 2674: ...e no OK replace the Sensor 3 6 DOOR AJAR SYSTEM The door ajar and decklid ajar states are used as inputs for the Body Control Module BCM The BCM uses these inputs to determine exactly what position the doors and decklid are in The DRBIII will display the state of the door ajar and the decklid ajar switches in Inputs Outputs It s impor tant to note that when any door or the decklid is closed the sw...

Page 2675: ...ator blend mode recirculation operation is desired provides a request over the PCI Bus to the BCM when A C operation is desired provides a request over the PCI Bus to the BCM when EBL operation is desired provides desired blower motor operating speed data over the PCI Bus to the BCM The Body Control Module BCM drives the ATC status indicators EBL A C and Recirc over the PCI Bus remembers the last ...

Page 2676: ...le if the lock button is pressed with a door open illuminated entry will cancel when the door closes If the doors are closed and the ignition switch is turned on the illuminated entry also cancels 3 11 MECHANICAL INSTRUMENT CLUSTER The Mechanical Instrument Cluster MIC is di vided into 4 sections Primary gauges Speedometer and Tachometer secondary gauges Fuel Level Engine Coolant Temperature PCI b...

Page 2677: ...bled by using either the DRBIII or the customer programmable method When en abled all doors will lock when the vehicle reaches a speed of 15 mph 24 kmh and all doors are closed If a door is opened and the vehicle slows to below 15 mph 24 kmh the locks will operate again once all doors are closed and the speed is above 15 mph 24 kmh This feature is not available in European markets Decklid Release ...

Page 2678: ... identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII If any modules are responding the failure is not related to the total bus but can be caused by one or more modules PCI circuit or power supply and ground circuits The DRBIII may display BUS SIG NALS OPEN OR NO RESPONSE to indicate a communication problem These same messages w...

Page 2679: ...r about 3 minutes then headlamps for an additional 15 minutes if the offending input is still present For complaints about the Theft Alarm going off on its own use the DRBIII and select Body Com puter then Input Output Display and read the Last VTSS Cause status Tamper Alert The VTSS indicator lamp will flash twice quickly and the horn will chirp three times when the system is disarmed to indicate...

Page 2680: ...will continue to run for 2 additional wipe cycles The wiper system utilizes the BCM to control the on off and hi low relays from low and hi speed wiper functions intermittent wiper delay as the switch position changes pulse wipe wipe after wash mode and wiper motor park functions The BCM uses the vehicle speed input to double the usual delay time below 10 MPH 16 KMH 3 17 USING THE DRBIII Refer to ...

Page 2681: ...tem sub components may result in personal injury and or improper sys tem operation Only those components with ap proved repair and installation procedures in the service manual should be serviced 4 2 4 DRBIII SAFETY INFORMA TION WARNING EXCEEDING THE LIMITS OF THE DRBIII MULTIMETER IS DANGEROUS READ ALL DRBIII INSTRUCTIONS BEFORE USING THE MULTIMETER FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT...

Page 2682: ...MENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII OR OTHER TEST EQUIPMENT FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH 5 0 REQUIRED TOOLS AND EQUIPMENT DRBIII diagnostic read out box J umper wires Ohmmeter Voltmeter Test Light 8310 Airbag System Load Tool 8443 SRS Airbag System Load Tool 6 0 GLOSSARY OF TERMS 6 1 ACRO...

Page 2683: ...QUIB also called initiator located inside airbag SRS supplemental restraint system TCM transmission control module VFD vacuum fluorescent display VTSS vehicle theft security system 21 GENERAL INFORMATION ...

Page 2684: ...NOTES 22 ...

Page 2685: ...7 0 DIAGNOSTIC INFORMATION AND PROCEDURES 23 ...

Page 2686: ...tinuously performs internal circuit tests Set Condition This DTC will set if the module identifies an out of range internal circuit INTERNAL 2 When Monitored With the ignition on the module on board diagnostics continuously performs internal circuit tests Set Condition This DTC will set if the module identifies an out of range internal circuit INTERNAL 3 When Monitored With the ignition on the mod...

Page 2687: ...CABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM Select the appropriate module and DTC type combination All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 2 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TO AV...

Page 2688: ...rbag lamp driver has failed AIRBAG WARNING INDICATOR OPEN When Monitored With ignition on the ACM monitors the PCI Bus for a message from the MIC containing the airbag warning indicator status The ACM request the warning lamp status from the MIC once every second Set Condition This DTC will set immediately if the indicator status is OPEN AIRBAG WARNING INDICATOR SHORT When Monitored With ignition ...

Page 2689: ...lect PASSIVE RESTRAINTS AIRBAG and MONITOR DIS PLAY Using the DRBIII read the WARNING LAMP MONITOR screen Select the LAMP STATUS displayed on the DRB monitors screen Observe the Lamp Driver State and Actual Lamp State Is the LAMP DRIVER and ACTUAL LAMP STATE OK All YES Go To 4 NO Replace Instrument Cluster Perform __AIRBAG VERIFICATION TEST VER 1 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN TH...

Page 2690: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or ...

Page 2691: ...NDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnect...

Page 2692: ...any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you ...

Page 2693: ... MISMATCH STORED CODE OR INTERMITTENT CONDITION ACM CLUSTER MESSAGE MISMATCH ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components th...

Page 2694: ...L INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent pr...

Page 2695: ...G CIRCUIT OPEN DRIVER CURTAIN SQUIB LINE 1 OR LINE 2 CIRCUIT OPEN ACM DRIVER CURTAIN SQUIB CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To ...

Page 2696: ...G VERIFICATION TEST VER 1 3 WARNING TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Airbag Load Tool from the Driver Curtain Airbag connector s Disconnect the Airbag Control Module Connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool ACM Adapter to the Airbag Control Module connector s Measure the resistanc...

Page 2697: ...ed components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or c...

Page 2698: ...RBAG CIRCUIT SHORT DRIVER CURTAIN SQUIB LINE 1 SHORT TO LINE 2 ACM DRIVER CURTAIN SQUIB CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ...

Page 2699: ...e Service Information Perform __AIRBAG VERIFICATION TEST VER 1 3 WARNING TURN THE IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Airbag Load Tool from the Driver Curtain Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool ACM Adapter to the ACM connector ...

Page 2700: ...ed components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or c...

Page 2701: ...CTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TURN THE IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Driver Curtain Airbag connector s NOTE Check connectors Clean repair as necessary WARNING DO NOT PLACE AN INTACT UNDEPLOYED CURTAIN A...

Page 2702: ...efore diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional check...

Page 2703: ...T TO GROUND DRIVER CURTAIN SQUIB LINE 1 OR LINE 2 SHORTED TO GROUND ACM DRIVER CURTAIN SQUIB SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC G...

Page 2704: ...HE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING WARNING DO NOT PLACE AN INTACT UNDEPLOYED CURTAIN AIRBAG FACE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED AND COULD RESULT IN SERI OUS OR FATAL INJURY Disconnect the Load Tool from the Driver Curtain Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as ...

Page 2705: ...d components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or co...

Page 2706: ... w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 NOTE Ensure the battery is fully charged WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconne...

Page 2707: ...sistance below 1 0 ohms on both circuit All Yes Go To 4 No Repair open or high resistance in Driver Seat Belt Tensioner Line 1 Line 2 circuits Perform __AIRBAG VERIFICATION TEST VER 1 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILUR...

Page 2708: ...components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or comp...

Page 2709: ...ll be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Driver Seat Belt Tensioner connector N...

Page 2710: ...0K Ohms All Yes Repair Driver Seat Belt Tensioner Line 1 circuit short to Driver Seat Belt Tensioner Line 2 circuit Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE PR...

Page 2711: ...components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or comp...

Page 2712: ...ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Driver Seat Belt Tensioner connector ...

Page 2713: ...he Driver SBT connector and ground Is there any voltage present All Yes Repair Driver Seat Belt Tensioner Line 1 or Line 2 circuit short to battery Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE...

Page 2714: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compon...

Page 2715: ... w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Driver Seat Belt Tensioner connect...

Page 2716: ... below 10K ohms on either circuit All Yes Repair Driver Seat Belt Tensioner Line 1 or Line 2 circuits short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE ...

Page 2717: ...omponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 2718: ...KSPRING SQUIB 1 CIRCUIT OPEN DRIVER SQUIB 1 LINE 1 OR LINE 2 CIRCUITS OPEN ACM DRIVER SQUIB 1 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ...

Page 2719: ...ol from the Driver Airbag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII read the active Airbag Control Module DTC s Does the DRBIII show DRIVER SQUIB 1 CIRCUIT OPEN All Ye...

Page 2720: ...nnectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII mo...

Page 2721: ... SQUIB 1 CIRCUITS SHORT DRIVER AIRBAG SQUIB 1 LINE 1 SHORT TO LINE 2 ACM DRIVER SQUIB LINE 1 SHORT TO LINE 2 STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To ...

Page 2722: ...onnect the Load Tool from the Driver Airbag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII read the active Airbag Control Module DTC s Does the DRBIII show DRIVER SQUIB 1 C...

Page 2723: ...nectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII mon...

Page 2724: ...SQUIB 1 SHORT TO BATTERY DRIVER SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM DRIVER SQUIB 1 SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED ACM DTC All ACM ACTIVE DTC G...

Page 2725: ... DTC s Does the DRBIII show DRIVER SQUIB 1 SHORT TO BATTERY All Yes Go To 3 No Replace the Driver Airbag in accordance with the Service Infor mation Perform __AIRBAG VERIFICATION TEST VER 1 3 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Driver Airbag connector s Disconnect the Clock...

Page 2726: ... present they must be resolved before diagnosing any stored codes WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminal...

Page 2727: ...RIVER SQUIB 1 SHORT TO GROUND DRIVER SQUIB 1 LINE 1 OR LINE 2 SHORTED TO GROUND ACM DRIVER SQUIB 1 SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC ...

Page 2728: ...nect the Load Tool from the Driver Airbag connector s Disconnect the Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII read the active Airbag Control Module DTC s Does the DRBIII show DRIVER SQUIB 1 SHORT T...

Page 2729: ...tors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monito...

Page 2730: ...ING DRIVER SQUIB 2 CIRCUIT OPEN DRIVER SQUIB 2 LINE 1 OR LINE 2 CIRCUITS OPEN ACM DRIVER SQUIB 2 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To...

Page 2731: ...tor Disconnect the Clockspring connector NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII read the active Airbag Control Module DTC s Does the DRBIII show DRIVER SQUIB 2 CIRCUIT OPEN All Yes Go To 4 No Replace the Clockspring i...

Page 2732: ...connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII ...

Page 2733: ...RIVER SQUIB 2 CIRCUIT SHORT DRIVER SQUIB 2 LINE 1 SHORT TO LINE 2 ACM DRIVER SQUIB 2 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STOR...

Page 2734: ...ct the Load Tool from the Driver Airbag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII read the active Airbag Control Module DTC s Does the DRB show DRIVER SQUIB 2 CIRCUIT ...

Page 2735: ...nectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII mon...

Page 2736: ...QUIB 2 SHORT TO BATTERY DRIVER SQUIB 2 LINE 1 OR LINE 2 SHORT TO BATTERY ACM DRIVER SQUIB 2 SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To ...

Page 2737: ...bag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII read the active Airbag Control Module DTC s Does the DRB show DRIVER SQUIB 2 SHORT TO BATTERY All Yes Go To 4 No Replace ...

Page 2738: ...ectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII moni...

Page 2739: ...IVER SQUIB 2 SHORT TO GROUND DRIVER SQUIB 2 LINE 1 OR LINE 2 SHORT TO GROUND ACM DRIVER SQUIB 2 SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go ...

Page 2740: ... the Load Tool from the Driver Airbag connector s Disconnect the Clockspring connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool to the Clockspring connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII read the active Airbag Control Module DTC s Does the DRB show DRIVER SQUIB 2 SHORT TO G...

Page 2741: ...ectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII moni...

Page 2742: ...ed to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Replace the Left Side Impact Sensor 1 Reconnect the vehicle wire harness to the impact sensor Remove any special tools or jumper wires and reconnect all previously disconnected components...

Page 2743: ...tors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monito...

Page 2744: ...ACM FUSED IGNITION OUTPUT RUN START CIRCUIT OPEN ACM RUN START SHORTED TO GROUND FUSED IGNITION SWITCH OUTPUT RUN START CIRCUIT SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Ensure the battery is fully charged Turn the ignition on NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM DETERMINE ACTIVE OR STO...

Page 2745: ...ean and repair as necessary Connect the appropriate Load Tool ACM Adaptor to the Airbag Control Module connector s Measure the resistance of the Fused Ignition Switch Output Run Start circuit between the ACM Adaptor and ground Is the resistance below 10K ohms All Yes Repair the Fused Ignition Switch Output Run Start circuit short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Replace the Ai...

Page 2746: ...NI TION ON THEN RECONNECT THE BATTERY Measure the voltage of the Fused Ignition Switch Output Run Start Circuit at the ACM Adaptor Is the voltage above approximately 6 0 volts All Yes Go To 7 No Repair open Fused Ignition Switch Output Run Start circuit Perform __AIRBAG VERIFICATION TEST VER 1 7 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MI...

Page 2747: ...nected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit ...

Page 2748: ...D RUN CIRCUIT FUSED IGNITION SWITCH OUTPUT RUN CIRCUIT SHORT TO GROUND ACM FUSED IGNITION RUN CIRCUIT SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM DETERMINE ACTIVE OR STORED DTC All ACM ACTIVE DTC...

Page 2749: ...t Run circuit for a short to ground and replace Airbag Run Fuse Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG ...

Page 2750: ...ATTERY Measure the voltage of the Fused Ignition Switch Output Run circuit at the Airbag Control Module connector Is the voltage above approximately 6 0 volts All Yes Go To 8 No Repair the open or high resistance in the Fused Ignition Switch Output Run circuit Perform __AIRBAG VERIFICATION TEST VER 1 8 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT...

Page 2751: ...nected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit ...

Page 2752: ...DE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Turn the ign...

Page 2753: ...OCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJ...

Page 2754: ...OSSIBLE CAUSES SIGNAL CIRCUIT SHORTED TO BATTERY SIGNAL CIRCUIT SHORT TO GROUND LEFT SIDE SENSOR CIRCUITS SHORTED TOGETHER GROUND CIRCUIT OPEN SIGNAL CIRCUIT OPEN ACM LEFT SIDE IMPACT SENSOR REPAIR IS COMPLETE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM...

Page 2755: ...orted for a short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 Measure the resistance between the Left Side Impact Sensor Signal and Sensor Ground circuits at the Left Side Impact Sensor connector Is the resistance below 100K ohms All Yes Repair the Left Side Impact Sensor circuits shorted together Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 Connect the appropriate Loa...

Page 2756: ...and read active codes and if there are none present read the stored codes DID the active Left Side Impact Sensor DTC return All Yes Go To 8 No Repair is complete Perform __AIRBAG VERIFICATION TEST VER 1 8 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST...

Page 2757: ...omponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 2758: ...T ACTION APPLICABILITY 1 NOTE Ensure that the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM Turn the ignition on SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Connect the DRBIII to...

Page 2759: ...ARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH If there are no possible causes remaining view repair All Repair Replace the Ai...

Page 2760: ...connected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circu...

Page 2761: ...ill be referred to as an ACM From the list below select the appropriate module and DTC type for the this diagnostic trouble code DETERMINE ACTIVE OR STORED DTC All ACM ACTIVE Go To 2 ACM STORED Go To 3 NOTE When reconnecting airbag system components the Ignition must be turned off and the Battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH DISCONNECT THE BATTERY AND WAIT TWO M...

Page 2762: ...connected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circu...

Page 2763: ...SSIBLE CAUSES SIGNAL CIRCUIT SHORTED TO BATTERY SIGNAL CIRCUIT SHORT TO GROUND RIGHT SIDE SENSOR CIRCUITS SHORTED TOGETHER GROUND CIRCUIT OPEN SIGNAL CIRCUIT OPEN ACM PASSENGER SIDE IMPACT SENSOR REPAIR IS COMPLETE STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the...

Page 2764: ...or a short to ground Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 Measure the resistance between the Right Side Impact Sensor Signal and Sensor Ground circuits at the Right Side Impact Sensor connector Is the resistance below 100K ohms All Yes Repair the Right Side Impact Sensor circuits shorted together Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 5 5 Connect the appropriate Load To...

Page 2765: ...nd read active codes and if there are none present read the stored codes DID the active Right Side Impact Sensor DTC return All Yes Go To 8 No Repair is complete Perform __AIRBAG VERIFICATION TEST VER 1 8 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST...

Page 2766: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compon...

Page 2767: ...AIRBAG CIRCUIT OPEN PASSENGER CURTAIN SQUIB LINE 1 OR LINE 2 CIRCUIT OPEN ACM PASSENGER CURTAIN SQUIB CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC ...

Page 2768: ...THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Airbag Load Tool from the Passenger Curtain Airbag connector s Disconnect the Airbag Control Module Connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool ACM Adaptor to the Airbag Control Module connector s Measure the resistance of the Passenger Curtain Squib Line 1 and Line 2 circuits be...

Page 2769: ... components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or com...

Page 2770: ...TAIN SQUIB CIRCUIT SHORT PASSENGER CURTAIN SQUIB LINE 1 SHORT TO LINE 2 ACM PASSENGER CURTAIN SQUIB CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC G...

Page 2771: ... PROCEEDING Disconnect the Load Tool from the Passenger Curtain Airbag connector s Disconnect the Airbag Control Module connector NOTE Check connectors Clean and repair as necessary WARNING TO AVOID PERSONAL INJURY OR DEATH DO NOT PLACE AN INTACT UNDEPLOYED CURTAIN AIRBAG FACE DOWN ON A HARD SUR FACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED Connect the appropriate Load Tool ACM...

Page 2772: ... components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or com...

Page 2773: ...HORT TO BATTERY CURTAIN SQUIB LINE 1 OR LINE 2 SHORTED TO BATTERY ACM PASSENGER CURTAIN SQUIB SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go T...

Page 2774: ...E BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Airbag Load Tool from the Passenger Curtain Squib connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool ACM Adaptor to the ACM connector s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION ON THEN RECONNECT THE BATTERY Measure the voltag...

Page 2775: ...omponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compo...

Page 2776: ...IB SHORT TO GROUND PASSENGER CURTAIN SQUIB LINE 1 OR LINE 2 SHORT TO GROUND ACM PASSENGER CURTAIN SQUIB SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE...

Page 2777: ... Disconnect the Airbag Control Module connector s Disconnect the Load Tool from the Passenger Curtain Airbag connector s NOTE Check connectors Clean and repair as necessary WARNING TO AVOID PERSONAL INJURY OR DEATH DO NOT PLACE AN INTACT UNDEPLOYED CURTAIN AIRBAG FACE DOWN ON A HARD SUR FACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED Connect the appropriate Load Tool ACM Adaptor ...

Page 2778: ...components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or comp...

Page 2779: ...AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Passenger Seat...

Page 2780: ...ance below 1 0 ohms on either circuit All Yes Go To 4 No Repair open or high resistance in Passenger Seat Belt Tensioner Line 1 or Line 2 circuits Perform __AIRBAG VERIFICATION TEST VER 1 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FA...

Page 2781: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compon...

Page 2782: ...ules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Passenger Seat Belt Tensioner ...

Page 2783: ...Is the resistance below 10K ohms All Yes Repair the Passenger Seat Belt Tensioner Line 1 short to Line 2 circuit Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE PROPE...

Page 2784: ...mponents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or compon...

Page 2785: ...odules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Passenger Seat Belt Tensione...

Page 2786: ...Seat Belt Tensioner connector and ground Is there any voltage on either circuit All Yes Repair the Passenger Seat Belt Tensioner Line 1 or Line 2 short to battery Perform __AIRBAG VERIFICATION TEST VER 1 No Go To 4 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY ...

Page 2787: ...onents and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or componen...

Page 2788: ... ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN IGNITION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING Disconnect the Passenger Seat Belt Te...

Page 2789: ...NI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Using the wiring diagram schematic as a guide inspect the wiring and connectors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnec...

Page 2790: ...UIB 1 CIRCUIT OPEN PAB SQUIB 1 LINE 1 OR LINE 2 CIRCUIT OPEN ACM PAB SQUIB 1 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go...

Page 2791: ...T THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control module connector s NOTE Check connectors Clean and repair as necessary Connect the Load Tool ACM Adaptor to the Airbag Control Module connector s Measure the resistance of the Passenger Squib 1 Line 1 and Line 2 circuit between the ACM Adaptor and the P...

Page 2792: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or ...

Page 2793: ...1 CIRCUIT SHORT PAB SQUIB 1 LINE 1 SHORT TO LINE 2 ACM PAB SQUIB 1 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOT...

Page 2794: ...IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool Adapter to the Airbag Control Module connec tor s Measure the resistance between Passenger Squib 1 Line 1 and Line 2 circuits...

Page 2795: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or ...

Page 2796: ...TTERY PAB SQUIB 1 LINE 1 OR LINE 2 SHORT TO BATTERY ACM PAB SQUIB 1 CIRCUIT SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC...

Page 2797: ...INUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connec tor s WARNING AVOID PERSONAL INJURY OR DEATH TURN IGNITION ON THEN RECONNECT THE BATTERY Measure the voltage on the Passenger Squib ...

Page 2798: ...d components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or co...

Page 2799: ...S SHORT TO GROUND PAB SQUIB 1 LINE 1 OR LINE 2 SHORT TO GROUND ACM PAB SQUIB 1 SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED D...

Page 2800: ...F DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connector Measure the resistance of the Passenger Squib 1 Line 1 or Line 2 circuit between the Passenger...

Page 2801: ...ed components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or c...

Page 2802: ...UIB 2 CIRCUIT OPEN PASSENGER SQUIB 2 LINE 1 OR LINE 2 CIRCUIT OPEN ACM PASSENGER SQUIB 2 CIRCUIT OPEN STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM S...

Page 2803: ...NNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool adaptor to the Airbag Control Module connec tor s Measure the resistance of the Passenger Squib 2 Line 1 and Line 2 circuits between the ACM Ada...

Page 2804: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or ...

Page 2805: ...2 CIRCUIT SHORT PASSENGER SQUIB 2 LINE 1 SHORT TO LINE 2 ACM PASSENGER SQUIB 2 CIRCUIT SHORT STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC...

Page 2806: ...TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connec tor s Measure the resistance between the Passenger Squib 2 Line 1 and line 2 circuits ...

Page 2807: ...ted components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or ...

Page 2808: ...TTERY PASSENGER SQUIB 2 LINE 1 OR LINE 2 SHORT TO BATTERY ACM PASSENGER SQUIB 2 CIRCUIT SHORT TO BATTERY STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 AC...

Page 2809: ... TWO MINUTES BE FORE PROCEEDING Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean and repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connec tor s WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY Measure the voltage on the Pa...

Page 2810: ...d components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or co...

Page 2811: ...ORT TO GROUND PASSENGER SQUIB 2 LINE 1 OR LINE 2 SHORT TO GROUND ACM PASSENGER SQUIB 2 CIRCUIT SHORT TO GROUND STORED CODE OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on NOTE Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go T...

Page 2812: ...ERSONAL INJURY OR DEATH DO NOT PLACE AN INTACT UNDEPLOYED AIRBAG FACE DOWN ON A HARD SURFACE THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTALLY DEPLOYED Disconnect the Load Tool from the Passenger Airbag connector s Disconnect the Airbag Control Module connector s NOTE Check connectors Clean repair as necessary Connect the appropriate Load Tool Adaptor to the Airbag Control Module connec tor s Me...

Page 2813: ...ed components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit or c...

Page 2814: ...Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM Repair all Ignition Run and Run Start circuit DTCs before performing this test SELECT ACTIVE OR STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected ...

Page 2815: ...tart circuits at the ACM adaptor The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly on both circuits All Yes Go To 4 No Repair the high resistance in the Fused Ignition Switch Output Run and Run Start circuits Perform __AIRBAG VERIFICATION TEST VER 1 4 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN TH...

Page 2816: ...nected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit ...

Page 2817: ...as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 4 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery must be disconnected 2 Replace the Right Side Impact Sensor 1 Reconnect the vehicle body harness to the impact sensor Remove any special tools or jumper wires and reconnect all previously disconnected components exce...

Page 2818: ...tors Look for chaffed pierced pinched or partially broken wires and broken bent pushed out spread corroded or contaminated terminals The following additional checks may assist you in identifying a possible intermittent problem Reconnect any disconnected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monito...

Page 2819: ...E OR INTERMITTENT CONDITION ACTIVE CODE PRESENT TEST ACTION APPLICABILITY 1 Turn the ignition on Ensure the battery is fully charged NOTE For the purpose of this test the AECM and ORC modules w ill be referred to as an ACM SELECT ACTIVE or STORED DTC All ACM ACTIVE DTC Go To 2 ACM STORED DTC Go To 5 NOTE When reconnecting Airbag system components the ignition must be turned off and the battery mus...

Page 2820: ...G TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION OFF DISCONNECT THE BATTERY AND WAIT TWO MINUTES BE FORE PROCEEDING WARNING IF THE AIRBAG CONTROL MODULE IS DROPPED AT ANY TIME IT MUST BE REPLACED FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH If there are no possible causes remaining view repair All Repair Replace the Airbag ...

Page 2821: ...ected components and harness connector WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNI TION ON THEN RECONNECT THE BATTERY With the DRBIII monitor active codes as you work through the following steps WARNING TO AVOID PERSONAL INJURY OR DEATH MAINTAIN A SAFE DISTANCE FROM ALL AIRBAGS WHILE PERFORMING THE FOLLOWING STEPS Wiggle the wiring harness and connectors of the related airbag circuit o...

Page 2822: ...DRBIII select the PASSIVE RESTRAINTS AIRBAG MONITOR DIS PLAY and read the WARNING LAMP STATES With no active DTCs Does the LAMP REQ by ACM monitor show ON All Yes Replace the Airbag Control Module in accordance with Service Instructions Perform __AIRBAG VERIFICATION TEST VER 1 No Refer to INSTRUMENT CLUSTER CATEGORY symptom list for problems related to Instrument Cluster Perform __AIRBAG VERIFICAT...

Page 2823: ...io DTC s Cycle the ignition switch from off to on and wait 10 seconds With the DRBIII read the audio DTC s Does the DRBIII display ALL OUTPUTS SHORT All Yes Go To 2 No Refer to the wiring diagrams located in the service information to help isolate a possible intermittent short Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Power Amplifier harness connector Turn the ign...

Page 2824: ... any speaker circuit Is the resistance below 1000 0 1K ohms All Yes Repair the speaker circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Power Amplifier harness connector Disconnect the Radio C1 harness connector Measure the resistance between each speaker circuit and each speaker circuit Is the resistance below 1000 0 1K ohms for ...

Page 2825: ...he audio DTC s Does the DRBIII display ALL OUTPUTS SHORT All Yes Go To 2 No Refer to the wiring diagrams located in the service information to help isolate a possible intermittent short Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off NOTE Perform this procedure after disconnecting each front speaker and each I P speaker if equipped connector Disconnect each front speaker and each I P ...

Page 2826: ...All Yes Repair the speaker circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect each front and rear speaker harness connector Disconnect the Radio C1 harness connector Measure the resistance between ground and each speaker circuit Is the resistance below 1000 0 1K ohms All Yes Repair the speaker circuit for a short to ground Perform BODY ...

Page 2827: ...WITCH INOPERATIVE TIME SWITCH INOPERATIVE TUNE SWITCH INOPERATIVE Test Note All symptoms listed above are diagnosed using the same tests The title for the tests w ill be CASSETTE PLAYER INOP When Monitored and Set Condition CASSETTE PLAYER INOP When Monitored Continuously with the ignition and radio turned on Set Condition The code will set if the radio detects a internal cassette failure CD MECHA...

Page 2828: ... DTC is set erase the DTC and attempt to reset the DTC If DTC resets follow this test This is an internal radio failure View repair All Repair Replace the Radio Perform BODY VERIFICATION TEST VER 1 166 AUDIO CASSETTE PLAYER INOP Continued ...

Page 2829: ...Changer turned on Set Condition The code will set if the CD Changer detects a mechanical failure POSSIBLE CAUSES INTERNAL FAILURE TEST ACTION APPLICABILITY 1 NOTE Erase DTC and attempt to reset If DTC resets follow this test This is an internal CD Changer failure View repair All Repair Replace the CD Changer Perform BODY VERIFICATION TEST VER 1 167 AUDIO ...

Page 2830: ...t is not formatted as a music CD is installed in the CD Changer POSSIBLE CAUSES CD CHANGER READ FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched music CD Turn the radio on and select the good CD With the DRBIII read DTC s Does the DRBIII display CD CHANGER READ FAILURE All Yes Replace the CD Changer Perform BODY VERIFICATION TEST VER 1 No Test Complete 168 A...

Page 2831: ...PPLICABILITY 1 With the DRBIII erase the audio DTC s Start the engine and allow the engine to reach normal operating temperature If the vehicle has been in the hot sunlight or extreme cold move the vehicle indoors and open the doors to allow the inside temperature to stabilize The CD Changer will operate between 23 C and 65 C 10 F and 145 F With the DRBIII read DTC s Does the DRBIII display CD CHA...

Page 2832: ...hat is not formatted as a music CD or is scratched dirty so the radio can not play the CD POSSIBLE CAUSES CD PLAY FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched music CD Turn the radio CD player on With the DRBIII read DTC s Does the DRBIII display CD PLAY FAILURE All Yes Replace the Radio Perform BODY VERIFICATION TEST VER 1 No Test Complete 170 AUDIO ...

Page 2833: ...if a CD that is not formatted as a music CD is installed in the radio CD player POSSIBLE CAUSES CD READ FAILURE TEST ACTION APPLICABILITY 1 Replace the problem CD with a good clean unscratched music CD Turn the radio CD player on With the DRBIII read DTC s Does the DRBIII display CD READ FAILURE All Yes Replace the Radio Perform BODY VERIFICATION TEST VER 1 No Test Complete 171 AUDIO ...

Page 2834: ...N APPLICABILITY 1 With the DRBIII erase the audio DTC s Start the engine and allow the engine to reach normal operating temperature If the vehicle has been in the hot sunlight or extreme cold move the vehicle indoors and open the doors to allow the inside temperature to stabilize The radio CD player will operate between 30 C and 85 C 22 F and 185 F With the DRBIII read DTC s Does the DRBIII displa...

Page 2835: ...rform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Radio harness connector Start the engine Measure the voltage of each Fused B circuit and the Fused Ignition Switch Output circuit Is the voltage above or approximately 14 volts for each measurement All Yes Go To 3 No Repair the circuit for high resistance Perform BODY VERIFICATION TEST VER 1 3 Note Reconnect all previously d...

Page 2836: ... Go To 2 No Repair Antenna connection as needed Perform BODY VERIFICATION TEST VER 1 2 Refer to the Audio System in the service information and test the Antenna in accordance with the service procedure Is the Antenna ok All Yes Go To 3 No Repair or replace the Antenna assembly as necessary Perform BODY VERIFICATION TEST VER 1 3 NOTE Reconnect all previously disconnected components Turn the ignitio...

Page 2837: ...the audio DTC s Does the DRBIII display POWER AMP SHUTDOWN All Yes Go To 2 No Refer to the wiring diagrams located in the service information to help isolate a possible intermittent short Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off NOTE Perform this procedure after disconnecting each front speaker and each I P speaker if equipped connector Disconnect each front speaker and each I ...

Page 2838: ...All Yes Repair the speaker circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect each front and rear speaker harness connector Disconnect the Radio C1 harness connector Measure the resistance between ground and each speaker circuit Is the resistance below 1000 0 1K ohms All Yes Repair the speaker circuit for a short to ground Perform BODY ...

Page 2839: ...e DRBIII erase the audio DTC s Cycle the ignition switch from off to on and wait 10 seconds With the DRBIII read the audio DTC s Does the DRBIII display POWER AMP SHUTDOWN All Yes Go To 2 No Refer to the wiring diagrams located in the service information to help isolate a possible intermittent short Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Power Amplifier harness...

Page 2840: ...any speaker circuit Is the resistance below 1000 0 1K ohms All Yes Repair the speaker circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the Power Amplifier harness connector Disconnect the Radio C1 harness connector Measure the resistance between each speaker circuit and each speaker circuit Is the resistance below 1000 0 1K ohms for a...

Page 2841: ...ymptom Perform BODY VERIFICATION TEST VER 1 2 Operate the horn from the horn button NOTE This is to ensure the Horn Radio Control MUX circuit is NOT open or shorted betw een the clockspring and the BCM Does the horn operate properly from the horn button All Yes Repair the Horn Radio Control MUX circuit or the Ground circuit for an open between the inoperative switch and the clockspring If OK repla...

Page 2842: ...e ignition on Close both doors With the DRBIII actuate the Chime Does the chime sound when actuated by the DRB All Yes The chime operates as it should Check other reasons for the chime being inoperative and select from the symptom list Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 180 CHIME ...

Page 2843: ...h the DRBIII select Electro Mech Cluster Input Output Turn the ignition on Read the seat Belt Sw status Does the DRBIII display Seat Belt Sw Closed All Yes Go To 3 No Repair the Seat Belt switch pigtail wiring or replace the Buckle assembly Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Removed the Instrument Cluster from the instrument panel Disconnect the Seat Belt Switch connector...

Page 2844: ...t be operational for the result of this test to be valid Turn the ignition off Remove the Body Control Module from the J unction Block Turn the headlamps on Measure the voltage of the Headlamp Switch Output circuit in the J unction Block internal 12 way connector Is the voltage above 10 0 volts All Yes Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Repair the Head Lamp Swi...

Page 2845: ...Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on Disconnect the Ignition Switch C3 harness connector Connect a jumper between the Key In Ignition Switch Sense circuit and the Ground circuit With the DRBIII enter Body Computer then Input Output and observe the Key In Ignition Switch status Does the DRBIII display Key In Ign Closed All Yes Replac...

Page 2846: ...een the ignition switch connector and the BCM harness C1 connector Is the resistance below 5 0 ohms All Yes Go To 5 No Repair the Key In Ignition Switch Sense circuit for an open Perform BODY VERIFICATION TEST VER 1 5 If there are no possible causes remaining view repair All Repair Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 184 CHIME CHIME INOPERATIVE WITH KEY IN IGNITION...

Page 2847: ... 5 0 ohms All Yes Go To 3 No Repair the open ground wire Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Seat Belt Switch connector Connect a jumper wire between Seat Belt Switch Sense CKT and the Ground CKT in the Seat Belt Switch connector With the DRB III select Electro Mech Cluster Input Outputs Turn the ignition on Read the Seat Belt SW status Does the DRB III show Seat Belt SW CLOSED A...

Page 2848: ... APPLICABILITY 5 If there are no possible causes remaining view repair All Repair Replace the Instrument Cluster Perform BODY VERIFICATION TEST VER 1 186 CHIME CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED Continued ...

Page 2849: ... 1 2 Turn the ignition off Disconnect the Ignition Switch C3 harness connector Disconnect the Body Control Module C1 harness connector Measure the resistance of the Key in Ignition Switch Sense circuit to ground Is the resistance below 100 0 ohms All Yes Repair the Key in Ignition Switch Sense circuit to ground Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Disconnect the Ignition Switch C3 con...

Page 2850: ...eed warning chime is for Gulf Coast Countries only With the DRBIII check the Body Control Module country code setting Is the country code incorrect All Yes Program the correct country code setting Perform BODY VERIFICATION TEST VER 1 No Replace and program the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 188 CHIME ...

Page 2851: ...TROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB enter Body then Automatic Temp Control Was the DRB able to I D or communicate with the ATC All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Cycle the ignition switch from off to on and wait approximately 1 minute With the DRB read...

Page 2852: ...d this DTC reset All Yes Go To 2 No No problem found at this time Use the wiring diagrams located in the service information to help isolate a possible intermittent wiring problem Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove the BCM from the J unction Block Turn the ignition on Using a 12 volt test light connected to ground probe the Fused B circuit in the J unction Block Bo...

Page 2853: ...SES BOOTLOADER CHECKSUM FAILURE TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase BCM DTC s Turn the ignition off then turn the ignition on With the DRB read BCM DTC s Did this DTC reset All Yes Replace the Body Control Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 191 COMMUNICATI...

Page 2854: ...M CHECKSUM FAILURE TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase BCM DTC s Turn the ignition off then turn the ignition on With the DRB read BCM DTC s Did this DTC reset All Yes Replace the Body Control Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 192 COMMUNICATION ...

Page 2855: ...ABILITY 1 Turn the ignition on With the DRB enter Body then Electro Mech Cluster Was the DRB able to I D or communicate with the Instrument Cluster MIC All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Yes...

Page 2856: ... Turn the ignition on With the DRB attempt to communicate with the Airbag Control Module ORC Was the DRB able to I D or communicate with the Airbag Control Module ORC All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DT...

Page 2857: ...C s Did this DTC reset All Yes Go To 2 No Refer to the wiring diagrams located in the service information to help isolate a possible intermittent open or shorted wiring condi tion Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition on With the DRB enter Body Computer System Tests then PCM Monitor Does the DRB display PCM is active on BUS All Yes Replace the Body Control Module in accordance w...

Page 2858: ... circuit in the PCM connector special tool 8815 if NGC Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Replace the Powertrain Control Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the PCM harness connector NOTE IF NGC DO NOT P...

Page 2859: ...URE TEST ACTION APPLICABILITY 1 Connect the DRB to the Data Link Connector Turn the ignition on With the DRB erase BCM DTC s Turn the ignition off then turn the ignition on With the DRB read BCM DTC s Did this DTC reset All Yes Replace the Body Control Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Test Complete 197 COMMUNICATION ...

Page 2860: ...E TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB attempt to communicate with the SKIM Was the DRB able to I D or communicate with the SKIM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Y...

Page 2861: ...Y CONTROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB enter Transmission Was the DRB able to I D or communicate with the TCM All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset All Yes R...

Page 2862: ... TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRB enter Body then Overhead Console Was the DRB able to I D or communicate with the Traveler CMTC All Yes Go To 2 No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 2 With the DRB erase DTC s Turn the ignition on and wait approximately 1 minute With the DRB read DTC s Did this DTC reset A...

Page 2863: ...o 2 No Repair the Fused Ignition Switch Output Run and Fused Ignition Switch Output Run Start circuits for an open Replace the fuse s if necessary Perform __AIRBAG VERIFICATION TEST VER 1 NOTE When reconnecting airbag system components the ignition must be turned off and the battery must be disconnected 2 Ensure that the battery is fully charged WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE I...

Page 2864: ...ts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the ACM connector Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Replace the Airbag Control Module in accordance with the service information WARNING Make sure the battery is disconnected and wait 2 minutes be...

Page 2865: ...tion off Disconnect the Automatic Temperature Control Head harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Fused Ignition Switch Output circuit Is the test light illuminated All Yes Go To 3 No Repair the Fused Ignition Switch Output circuit for an open or short Refer to the wiring diagrams in the service information Perform BODY VERIFICATION TEST VER...

Page 2866: ...complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the ATC Head connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Replace the Automatic Temperature Control Head in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 T...

Page 2867: ...symptom Turn the ignition off Disconnect the BCM C1 C2 and C3 harness connectors NOTE Ensure all lights are turned off Using a 12 volt test light connected to 12 volts probe each ground circuit Is the test light illuminated for each circuit All Yes Replace the Body Control Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 No Repair the Ground circuit s for an o...

Page 2868: ...ations with either of the modules All Yes Go To 2 No Refer to the Communications category and perform the symptom PCI Bus Communication Failure Perform ABS VERIFICATION TEST VER 1 2 Turn the ignition off Inspect all junction block fuses Are any of the fuses open All Yes Check the Fused Ignition Switch Output circuit for a short to ground refer to the wiring diagrams located in the service informat...

Page 2869: ...lect lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the CAB connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7...

Page 2870: ...n off Disconnect the Instrument Cluster harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Fused Ignition Switch Output circuit Is the test light illuminated All Yes Go To 3 No Repair the Fused Ignition Switch Output circuit for an open or short Refer to the wiring diagrams in the service information Perform BODY VERIFICATION TEST VER 1 3 Turn the ignit...

Page 2871: ...elect Pep Module Tools Select lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus MIC circuit in the Instrument Cluster connector cav 2 Turn the ignition on Observe the voltage display on the DRB Lab Scop...

Page 2872: ... the DRB answ er the question With the DRB enter Body then Body Computer With the DRB enter Anti Lock Brakes With the DRB enter Body then Electro Mechanical Cluster MIC With the DRB enter Passive Restraints then Airbag Were you able to establish communications with any of the modules All Yes Go To 2 No Refer to symptom PCI Bus Communication Failure in the Com munications category Perform POWERTRAI...

Page 2873: ...Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the appropriate terminal of special tool 8815 Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform POWERTRAIN VERIFICATION T...

Page 2874: ...essary to perform this step Did the vehicle pass this test All Yes Go To 2 No Repair as necessary Perform POWERTRAIN VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the DRBIII from the DLC Disconnect the PCM harness connectors Turn the ignition on Measure the voltage of the PCM SCI Transmit circuit at the Data Link harness connector cav 7 Is the voltage above 1 0 volt All Yes Repair the...

Page 2875: ...e ignition off Disconnect the PCM harness connector Disconnect the DRBIII from the DLC Measure the resistance between ground and the PCM SCI Receive circuit in the Data Link harness connector cav 12 Is the resistance below 5 0 ohms All Yes Repair the PCM SCI Receive circuit for a short to ground Perform POWERTRAIN VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Disconnect the PCM harnes...

Page 2876: ...he resistance of the PCM SCI Transmit circuit from the Data Link harness connector cav 7 to the appropriate terminal of special tool 8815 Is the resistance below 5 0 ohms All Yes Go To 9 No Repair the PCM SCI Transmit circuit for an open Perform POWERTRAIN VERIFICATION TEST VER 1 9 If there are no possible causes remaining view repair All Repair Replace and program the Powertrain Control Module in...

Page 2877: ... to communicate with the Body Control Module BCM Was the DRB able to I D or establish communications with either of the modules All Yes Go To 2 No Refer to the Communications category and perform the symptom PCI Bus Communication Failure Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Remove and inspect fuse 14 in the junction block Is the fuse open All Yes Go To 3 No Go To 6 3 Turn t...

Page 2878: ... fuse 14 is installed in the junction block Disconnect the Radio C1 harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Fused Ignition Switch Output circuit Is the test light illuminated All Yes Go To 7 No Repair the Fused Ignition Switch Output circuit for an open Perform BODY VERIFICATION TEST VER 1 7 Turn the ignition off Disconnect the Radio C1 harne...

Page 2879: ...o set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the Radio connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Replace the Radio Perform BODY VERIFICATION TEST VER 1 No Go To 10 10 Disconnect the Radio C...

Page 2880: ...mmunica tion with the BCM Perform SKIS VERIFICATION 2 Turn the ignition off Disconnect the SKIM harness connector Using a 12 volt test light connected to 12 volts probe the ground circuit Is the test light illuminated All Yes Go To 3 No Repair the Ground circuit for an open Perform SKIS VERIFICATION 3 Turn the ignition off Disconnect the SKIM harness connector Turn the ignition on Using a 12 volt ...

Page 2881: ...elect lab scope Select Live Data Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the SKIM connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately...

Page 2882: ...mptom Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Turn the ignition on Using a 12 volt test light connected to g...

Page 2883: ...ANSMISSION VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the PCM harness connectors CAUTION DO NOT PROBE THE PCM HARNESS CONNECTORS PROBING THE PCM HARNESS CONNECTORS WILL DAMAGE THE PCM TERMI NALS RESULTING IN POOR TERMINAL TO PIN CONNECTION INSTALL MILLER SPECIAL TOOL 8815 TO PERFORM DIAGNOSIS Using a 12 volt test light connected to 12 volts probe each ground circuit in the appropri...

Page 2884: ... in the appropriate terminal of special tool 8815 Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Replace and program the Powertrain Control Module in accor dance with the service information WITH THE DRBIII PER FORM QUICK LEARN AND REPROGRAM PINION FACTOR Perform 40 41TE NGC TRANSMISSION VERIFICATION TEST VER 1...

Page 2885: ...FICATION TEST VER 1 2 Turn the ignition off Disconnect the Compass Mini Trip Computer harness connector Turn the ignition on Using a 12 volt test light connected to ground probe the Fused Ignition Switch Output circuit Is the test light illuminated All Yes Go To 3 No Repair the Fused Ignition Switch Output circuit for an open or short Refer to the wiring diagrams in the service information Perform...

Page 2886: ...ta Select 12 volt square wave Press F2 for Scope Press F2 and use the down arrow to set voltage range to 20 volts Press F2 again when complete Connect the Black lead to the chassis ground Connect the Red lead to the PCI Bus circuit in the CMTC connector Turn the ignition on Observe the voltage display on the DRB Lab Scope Does the voltage pulse from 0 to approximately 7 5 volts All Yes Replace the...

Page 2887: ...s a NO RESPONSE message or a BUS SIGNALS OPEN message Turn the ignition on Using the DRB attempt to communicate with the following control modules Body Control Module BCM Instrument Cluster MIC Airbag Control Module Controller Antilock Brake CAB Was the DRB able to communicate with one or more Module s All Yes Go To 2 No Go To 3 2 Turn the ignition off Note Visually inspect the related w iring har...

Page 2888: ...ts for any measurement All Yes Go To 6 No Replace the Body Control Module in accordance with the service information Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the module that corresponds to the PCI Bus circuit that measured steadily above 7 0 volts Turn the ignition on NOTE If the PCI Bus circuit for the Radio w as above 7 0 volts and is equipped w ith a CD Changer di...

Page 2889: ... that resistance measured below 1000 0 ohms NOTE If the PCI Bus circuit for the Radio w as below 1000 0 ohms and is equipped w ith a CD Changer disconnect the CD Changer before the Radio NOTE If the PCI Bus circuit for the Instrument Cluster MIC w as below 1000 0 ohms and is equipped w ith a Compass Mini Trip Computer CMTC disconnect the CMTC before the MIC Measure the resistance between ground an...

Page 2890: ...able to I D or communicate with the BCM All Yes Go To 2 No Refer to the Communication category and perform the appropri ate symptom Perform BODY VERIFICATION TEST VER 1 2 With the DRBIII erase DTC s Turn the ignition on and wait approximately 1 minute With the DRBIII read DTC s Did this DTC reset All Yes Replace the Compass Mini Trip Computer in accordance with the Service Information Perform BODY...

Page 2891: ...Check the CMTC memory Communications and Compass internal Check the CMTC UGDO communications if equipped Display Pass Fail Bus Bus 1 or Bus 2 when complete Did the Compass Mini Trip Computer display Fail All Yes Replace the Compass Mini Trip Computer in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Move the vehicle to an area away from any large metal ob...

Page 2892: ...on With the DRBIII erase the DTC With the DRBIII perform the Compass Mini Trip Computer Self Test With the DRBIII read DTCs Did the DTC reset All Yes Replace the Compass Mini Trip Computer in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Test Complete 230 COMPASS MINI TRIP COMPUTER ...

Page 2893: ...he DRB read DTC s Did this DTC reset All Yes Go To 2 No Refer to the wiring diagrams located in the service information to help isolate a possible intermittent open or shorted wiring condi tion Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition on With the DRB enter Body Computer System Tests then PCM Monitor Does the DRB display PCM is active on BUS All Yes Replace the Compass Mini Trip Com...

Page 2894: ...tle for the tests w ill be AVERAGE FUEL ECONOMY INOPERATIVE OR WRONG POSSIBLE CAUSES COMPASS MINI TRIP COMPUTER TEST ACTION APPLICABILITY 1 NOTE Diagnose and repair any BCM or COMMUNICATION DTCs before proceeding If all the possible causes above are operating correctly view repair All Repair Replace the Compass Mini Trip Computer in accordance with the Service Information Perform BODY VERIFICATION...

Page 2895: ...Turn the ignition off Disconnect the Compass Mini Trip Computer harness connector Turn the ignition on Measure the voltage between the Fused Ignition Switch Output circuit and ground Is the voltage below 10 5 volts All Yes Repair the Fused Ignition Switch Output circuit for an open Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the Compass Mini Trip Computer har...

Page 2896: ...ure Sensor using the following temperature resistance values 10 C 50 F Sensor Resistance 17 99 21 81 Kilohms 20 C 68 F Sensor Resistance 11 37 13 61 Kilohms 25 C 77 F Sensor Resistance 9 12 10 88 Kilohms 30 C 86 F Sensor Resistance 7 37 8 75 Kilohms 40 C 104 F Sensor Resistance 4 90 5 75 Kilohms 50 C 122 F Sensor Resistance 3 33 3 88 Kilohms Is the Ambient Temperature Sensor resistance measurement...

Page 2897: ... a 12 volt Test Light connected to 12 volts test the Case Ground for continuity Does the light illuminate All Yes Go To 3 No Repair the Case Ground for an open Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Decklid Ajar Switch connector With the DRBIII in Inputs Outputs read the DECKLID AJ AR SW state Connect a jumper wire between Sense circuit and body ground Does the DRBIII display DECKLI...

Page 2898: ...d the DECKLID AJ AR SW state Did the Switch State change from CLOSED to OPEN All Yes Replace the Decklid Release Solenoid Ajar Switch Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the Body Control Module C4 harness connector Disconnect the Decklid Ajar Switch harness connector Using a 12 volt Test Light connected to 12 volts test the Sense circuit for a short to ground Does the Test...

Page 2899: ... Light connected to 12 volts test the Ground circuit for continuity Does the light illuminate All Yes Go To 3 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Driver Door Lock Motor Ajar Switch connector With the DRBIII in Inputs Outputs read the DRV DR AJ AR SW state Connect a jumper wire between Sense circuit and the Ground circuit Does the DRBIII di...

Page 2900: ...RV DR AJ AR SW state Does the Switch State change from CLOSED to OPEN All Yes Replace the Driver Door Lock Motor Ajar Switch Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the Body Control Module C4 harness connector Disconnect the Driver Door Lock Motor Ajar Switch harness connector Using a 12 volt Test Light connected to 12 volts test the Sense circuit for a short to ground Does th...

Page 2901: ...st Light connected to 12 volts test the Ground circuit for continuity Does the light illuminate All Yes Go To 3 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Left Rear Door Lock Motor Ajar Switch connector With the DRBIII in Inputs Outputs read the LR DR AJ AR SW state Connect a jumper wire between the Sense circuit and the Ground circuit Does the D...

Page 2902: ...ch harness connector With the DRBIII in Inputs Outputs read the LR DR AJ AR SW state Does the Switch State change from CLOSED to OPEN All Yes Replace the Left Rear Door Lock Motor Ajar Switch Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the Body Control Module C4 harness connector Disconnect the Left Rear Door Lock Motor Ajar Switch harness connector Using a 12 volt Test Light conn...

Page 2903: ...t Light connected to 12 volts test the Ground circuit for continuity Does the light illuminate All Yes Go To 3 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Passenger Door Lock Motor Ajar Switch connector With the DRBIII in Inputs Outputs read the PAS DR AJ AR SW state Connect a jumper wire between the Sense circuit and the Ground circuit Does the D...

Page 2904: ...witch harness connector With the DRBIII in Inputs Outputs read the PAS DR AJ AR SW state Does the Switch State change from CLOSED to OPEN All Yes Replace the Passenger Door Lock Motor Ajar Switch Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the Body Control Module C4 harness connector Disconnect the Passenger Door Lock Motor Ajar Switch harness connector Using a 12 volt Test Light ...

Page 2905: ...he Ground circuit for continuity Does the light illuminate All Yes Go To 3 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Right Rear Door Lock Motor Ajar Switch connector With the DRBIII in Inputs Outputs read the RR DR AJ AR SW state Connect a jumper wire between the Sense circuit and the Ground circuit Does the DRBIII display RR DR AJ AR SW CLOSED ...

Page 2906: ...ch harness connector With the DRBIII in Inputs Outputs read the RR DR AJ AR SW state Does the Switch State change from CLOSED to OPEN All Yes Replace the Right Rear Door Lock Motor Ajar Switch Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Disconnect the Body Control Module C4 harness connector Disconnect the Right Rear Door Lock Motor Ajar Switch harness connector Using a 12 volt Test Light co...

Page 2907: ...oes the test light illuminate brightly All Yes Go To 3 No Repair the Fused Ignition Switch Output circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Install a known good relay in place of the Heated Seat Relay Does the system now operate correctly All Yes Replace the Heated Seat Relay Perform BODY VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off Remove the Heated Seat Relay from ...

Page 2908: ...lated HVAC DTC s present All Yes Refer to the symptom list for related DTC s Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 With the DRBIII in ATC Inputs Outputs read the EBL sw state while toggling the Rear Defogger button Does the EBL Switch state change when the switch is depressed All Yes Go To 3 No Replace the Automatic Temperature Control Head Perform BODY VERIFICATION TEST VER 1 3 Turn t...

Page 2909: ...tion on Turn the Rear Window Defogger on Using a 12 volt test light check for voltage at the Rear Window Defogger Relay Output circuit at the defogger grid Did the test light illuminate All Yes Replace the original Rear Window Defogger Relay Perform BODY VERIFICATION TEST VER 1 No Repair the Rear Window Defogger Relay Output circuit for an open Perform BODY VERIFICATION TEST VER 1 8 Check J unctio...

Page 2910: ...ow Defogger Relay Perform BODY VERIFICATION TEST VER 1 No Go To 11 11 Remove the BCM from the junction block Reinstall the Rear Window Defogger Relay if removed Turn the ignition on Momentarily jumper the Rear Window Defogger Relay Control circuit cavity 3 in the BCM internal connector to ground Does the relay click All Yes Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Re...

Page 2911: ...rol Module DTC s Are there any related HVAC DTC s present All Yes Refer to the symptom list for related DTC s Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Toggle the Rear Defogger switch and observe the indicator Does the indicator toggle on and off when the switch is pressed All Yes Go To 3 No Go To 4 3 Turn the ignition on Turn the Rear Window Defogger on Using a 12 volt test light check fo...

Page 2912: ...PDC fuse 6 Perform BODY VERIFICATION TEST VER 1 8 Remove the Rear Window Defogger Relay from the J unction Block Install a known good relay in the Rear Window Defogger Relay connector Turn the ignition on Toggle the Rear Window Defogger switch and observe the indicator Does the Rear Window Defogger indicator illuminate All Yes Replace the original Rear Window Defogger Relay Perform BODY VERIFICATI...

Page 2913: ...Install a known good relay in the Rear Window Defogger Relay connector Turn the ignition on Toggle the Rear Window Defogger switch and observe the indicator Does the Rear Window Defogger indicator illuminate All Yes Replace the original Rear Window Defogger Relay Perform BODY VERIFICATION TEST VER 1 No Go To 13 13 Remove the BCM from the junction block Reinstall the Rear Window Defogger Relay if r...

Page 2914: ... BODY VERIFICATION TEST VER 1 3 Turn the ignition off Install a known good relay in place of the Headlamp Delay Relay Actuate the Headlamp Delay system Does the Headlamp Delay system operate normally All Yes Replace the Headlamp Delay Relay Perform BODY VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition on With the DRBIII read the Ignition Voltage Does the DRBIII display voltage above 10 0 vol...

Page 2915: ...ve the Headlamp Delay Relay Measure the voltage of the Headlamp Delay Relay Control circuit in the relay connector Is the voltage above 1 0 volts All Yes Go To 3 No Replace the Headlamp Delay Relay Perform BODY VERIFICATION TEST VER 1 3 Remove the Headlamp Delay Relay from the junction block Disconnect the Multifunction Switch connector Measure the voltage of the Switched Headlamp Delay Relay Cont...

Page 2916: ...he Headlamp Delay Relay connector Is the voltage above 10 0 volts All Yes Go To 3 No Repair the open fused B circuit from PDC fuse 4 Perform BODY VERIFICATION TEST VER 1 3 Remove fuse 4 from the PDC Disconnect the Multifunction Switch connector Measure the resistance of the Fused Low Beam Output Circuit to ground Is the resistance below 5 0 ohms All Yes Repair the Fused Low Beam output circuit for...

Page 2917: ... Is the voltage above 5 0 volts All Yes Go To 7 No Repair the open Fused Low Beam Output circuit Perform BODY VERIFICATION TEST VER 1 7 Disconnect the Multifunction Switch connector Turn the headlamps on Ensure the Headlamp Delay Relay is installed Connect a jumper wire between the Fused Low Beam Relay Output and the Switched High Beam Relay Control circuits in the multifunction switch connector D...

Page 2918: ...the Low Beams turn off All Yes Go To 3 No Repair the Headlamp Delay Relay Output Circuit for a short to voltage condition Perform BODY VERIFICATION TEST VER 1 3 Substitute a known good relay in place of the Headlamp Delay Relay Does the system operate normally All Yes Replace the Headlamp Delay Relay Perform BODY VERIFICATION TEST VER 1 No Go To 4 4 Turn the ignition off Remove the Headlamp Delay ...

Page 2919: ... Listen to or touch the Headlamp Delay Relay Does the relay click during actuation All Yes Go To 3 No Go To 5 3 Remove the Headlamp Delay Relay Measure the voltage of the Fused B circuit in the Headlamp Delay Relay Is the voltage above 10 0 volts All Yes Go To 4 No Replace the J unction Block Perform BODY VERIFICATION TEST VER 1 4 Remove the Headlamp Delay Relay from the junction block Ensure fuse...

Page 2920: ...junction block Measure resistance of the Headlamp Delay Relay control circuit Is the resistance below 5 0 ohms All Yes Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Replace the J unction Block Perform BODY VERIFICATION TEST VER 1 8 Remove and test the PDC Fuse 4 Is the Fuse open All Yes Go To 9 No Repair the open Fused B circuit between the Headlamp Delay Relay connector ...

Page 2921: ...ss connector Turn the ignition on Measure the voltage of the Temperature Select Signal circuit Is the voltage above 0 3 volts All Yes Go To 2 No Replace the A C Heater Control in accordance with the Service Information Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the A C Heater Control C1 harness connec...

Page 2922: ...T ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read the Body Computer DTCs Are Mode Door Input Open STG and Blend Door Input Open STG DTCs present May set TCM Msg Not Recd All Yes If J B Fuse 11 is open check for short to ground in J unction Block BCM and Fused Ign Sw Output Ckt If J B Fuse 11 is not open check for an open between J B Fuse 11 Pin 19 and J B C7 10 harness connector a...

Page 2923: ...elect Signal circuit at the A C Heater Control C1 harness connector Is the resistance below 10K ohms All Yes Repair the Temperature Select Signal circuit for a short to the Sensor Ground circuit Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the A C Heater Control C1 harness connector Disconnec...

Page 2924: ...ving the voltmeter Does the voltage change fluidly from approximately 9 0 volts full cold to 11 89 volts full hot All Yes Replace and program the Body Control Module in accordance with the Service Information Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Replace the A C Heater Control in accordance with the Service Information Calibrat...

Page 2925: ...ngs Recirc A C position A C EBL Switch 4 42 volts Mode Switch 1 32 volts Panel A C position A C EBL Switch 4 42 volts Mode Switch 3 20 volts Mix A C position A C EBL Switch 4 42 volts Mode Switch 5 07 volts Panel Heater position A C EBL Switch 10 79 volts Mode Switch 3 20 volts Mix Heater position A C EBL Switch 10 79 volts Mode Switch 5 07 volts Floor Heater position A C EBL Switch 10 79 volts Mo...

Page 2926: ...ol C1 harness connector Turn the ignition on Measure the voltage of the A C Switch Sense circuit Is the voltage above 10 0 volts All Yes Go To 2 No Go To 3 2 Turn the ignition off Disconnect the A C Heater Control C1 harness connector Disconnect the Body Control Module C2 harness connector Turn the ignition on Measure the voltage of the A C Switch Sense circuit Is there any voltage present All Yes...

Page 2927: ...To Batt All Yes Replace the A C Heater Control in accordance with the Service Information Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for conditions causing an intermittent short Calibration must be performed after repair replacement is com pleted Perform...

Page 2928: ...CORRECT INTERMITTENT WIRING PROBLEM TEST ACTION APPLICABILITY 1 Turn the ignition on Put the Mode Control switch in the Recirc Bi Level full left position With the DRBIII record and erase Body Computer DTC s With the DRBIII in Sensor Display read the A C EBL voltage Is the voltage below 0 5 volts All Yes Go To 2 No Go To 6 2 Turn the ignition off Disconnect the A C Heater Control C1 harness connec...

Page 2929: ...ccordance with the Service Information Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition on With the DRBIII record and erase DTCs Ensure that the Rear Window Defogger is off Put the Mode Control switch in the Recirc Bi Level full left position Start the engine With the DRBIII in Sensor Display read the A C ABLE Switch volt...

Page 2930: ...d All Yes Replace and program the Body Control Module in accordance with the Service Information Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for conditions causing an intermittent short Calibration must be performed after repair replacement is com pleted ...

Page 2931: ...e s Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition on With the DRBIII in Sensor Display read the A C EBL voltage while pressing and releasing the Rear Defogger switch several times Does the voltage decrease when pressing the switch and increase when the switch is released All Yes Go To 3 No Replace the A C Heater Control in accordance with the Service Information Perform BODY ...

Page 2932: ...TO GROUND TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII read the Body Computer DTCs Are Mode Door Input Open STG and Blend Door Input Open STG DTCs present May set TCM Msg Not Recd All Yes If J B Fuse 11 is open check for short to ground in J unction Block BCM and Fused Ign Sw Output Ckt If J B Fuse 11 is not open check for an open between J B Fuse 11 Pin 19 and J B C7 10 harnes...

Page 2933: ...de Switch MUX circuit at the A C Heater Control C harness connector Is the resistance below 10K ohms All Yes Repair the A C Mode Switch MUX circuit for a short to the Sensor Ground circuit Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Reconnect the A C Heater Control C1 harness connector Disconnect the B...

Page 2934: ...bserving the voltmeter Does the voltage change fluidly from approximately 8 8 volts Recirc to 11 7 volts Defrost All Yes Replace and program the Body Control Module in accordance with the Service Information Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Replace the A C Heater Control in accordance with the Service Information Calibrati...

Page 2935: ...connector Turn the ignition on Measure the voltage of the A C Mode Switch MUX circuit Is the voltage above 0 3 volts All Yes Go To 2 No Replace the A C Heater Control in accordance with the Service Information Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the A C Heater Control C1 harness connector Disco...

Page 2936: ... DTC in either BCM or Automatic Temperature Control AUTO SWITCH FAILURE ATC When Monitored With the ignition on Set Condition This DTC will set if the Auto switch is held in the closed position for 10 minutes The BCM will store this DTC The DRBIII will display this DTC in either BCM or Automatic Temperature Control BILEVEL SWITCH FAILURE ATC When Monitored With the ignition on Set Condition This D...

Page 2937: ...ition This DTC will set if the Off switch is held in the closed position for 10 minutes The BCM will store this DTC The DRBIII will display this DTC in either BCM or Automatic Temperature Control PANEL SWITCH FAILURE ATC When Monitored With the ignition on Set Condition This DTC will set if the Panel switch is held in the closed position for 10 minutes The BCM will store this DTC The DRBIII will d...

Page 2938: ...ailure Go To 4 2 Turn the ignition on With the DRBIII in Automatic Temperature Control Inputs Outputs read the switch states Do any of the switch states read Closed All Yes Replace the Automatic Temperature Control in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition on With the DRBIII in Automatic Temperature Control Inputs Outputs read th...

Page 2939: ... Automatic Temperature Control in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition on With the DRBIII record and erase Body Computer DTC s Cycle the ignition switch With the DRBIII read the Body Computer DTCs Did the DTC reset All Yes Replace the Automatic Temperature Control in accordance with the Service Information Perform BODY VERIFICATION TEST V...

Page 2940: ... to detect the end of travel for the blend door POSSIBLE CAUSES SUN OR IN CAR TEMPERATURE SENSOR FAILURE SUN SENSOR SHORTED SUN SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE BODY CONTROL MODULE CHECK CODE S PRESENT MODE DOOR FEEDBACK STALLTEST FAILURE DTC PRESENT ADDITIONAL FEEDBACK STALL TEST FAILURE DTCS PRESENT BLEND DOOR FEEDBACK SIGNAL CIRCUIT SHORTED TO THE DOOR DRIVER CIRCUIT S BLEND DOOR LINKAG...

Page 2941: ...No Vehicles With MTC Go To 5 2 Turn the ignition on NOTE Voltages specified are from shining a 25 w att incandescent bulb on the sensor through the w indshield of a vehicle parked indoors Performing this test w ith a higher w att bulb w ith a vehicle parked in the sun w ill result in low er voltage readings With the DRBIII in Sensor Display monitor Sun Sensor voltage while shining an incandescent ...

Page 2942: ... the engine With the DRBIII in Miscellaneous actuate Calibrate HVAC Door Motors With the DRBIII read the Body Computer DTCs What code s does the DRBIII display All Other than Feedback or Stall Test Fail Refer to the appropriate category for the related symptom s Diag nose all other DTCs before diagnosing Stall Test or Feedback Failures Calibration must be performed after repair replacement is comp...

Page 2943: ...form BODY VERIFICATION TEST VER 1 No Go To 9 9 Turn the ignition off Reconnect the BCM C2 harness connector Disconnect the Blend Door Actuator harness connector While back probing connect a test light between the Blend Door Driver circuit and the Common Door Driver circuit in the Blend Door Actuator harness connector Start the engine With the DRBIII select Body Body Computer System Tests Actuate M...

Page 2944: ...DY VERIFICATION TEST VER 1 No Repair the Common Door Driver circuit for an open Calibration must be performed after repair replacement is completed Perform BODY VERIFICATION TEST VER 1 12 Turn the ignition off Disconnect the Blend Door Actuator harness connector Disconnect the Body Control Module C2 harness connector Measure the resistance of the Sensor Ground circuit between the Blend Door Actuat...

Page 2945: ...nce between the 5 Volt Supply circuit and the Sensor Ground circuit in the BCM C2 harness connector Is the resistance below 10K ohms All Yes Repair the 5 Volt Supply circuit for a short to the Sensor Ground circuit Calibration must be performed after repair replacement is completed Perform BODY VERIFICATION TEST VER 1 No Replace and program the Body Control Module in accordance with the Service In...

Page 2946: ...N TEST VER 1 20 Turn the ignition off Disconnect the Blend Door Actuator harness connector Disconnect the Body Control Module C2 harness connector Measure the resistance between the Blend Door Feedback Signal circuit and the Sensor Ground circuit in the BCM C2 harness connector Is the resistance below 10K ohms All Yes Repair the Blend Door Feedback Signal circuit for a short to the Sensor Ground c...

Page 2947: ... be performed after repair replacement is completed Perform BODY VERIFICATION TEST VER 1 23 Turn the ignition off NOTE Visually inspect the related w iring harness and circuits Look for any chafed pierced pinched or partially broken w ires NOTE Visually inspect the related w iring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins...

Page 2948: ... set if the BCM detects a short to voltage on the Common Door Driver circuit All Door Output Shorted To Batt DTCs may set if at least one door output is shorted MODE DOOR OUTPUT SHORT TO BATTERY ATC MTC When Monitored Whenever the BCM attempts to drive the Mode Door Actuator Set Condition This DTC will set if the BCM detects a short to voltage on the Mode Door Driver circuit All Door Output Shorte...

Page 2949: ... each of the Door Driver circuits Blend Mode Recirc Common Is the voltage above 0 2 volts All Yes Repair all Door Driver circuits with voltage above 0 2 volts for a short to battery Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the Body Control Module C2 harness connector Measure the resistanc...

Page 2950: ...CM C2 harness connector Is the resistance below 10K ohms on any of the circuits All Yes Repair all door driver circuits with a resistance below 10K ohms for short to the Common Door Driver circuit Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Replace and program the Body Control Module in accordance with the Service Information Calibra...

Page 2951: ...nector Measure the resistance between the Common Door Driver circuit and the Blend Door Driver circuit Is the resistance below 10K ohms All Yes Repair the Blend Door Driver circuit for a short to the Common Door Driver circuit Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Go To 9 9 Turn the ignition off Ensure the Body Control Module C...

Page 2952: ...ce the Recirculation Door Actuator in accordance with the Service Information Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 11 Turn the ignition off NOTE Visually inspect the related w iring harness and circuits Look for any chafed pierced pinched or partially broken w ires NOTE Visually inspect the related w iring harness connectors Look...

Page 2953: ... detects one or more of the following outputs shorted to ground mode door driver blend door driver recirculation door driver or the common door driver MODE DOOR OUTPUT SHORT TO GROUND ATC MTC When Monitored Whenever the BCM attempts to drive one of the HVAC actuators Set Condition This DTC will set if the BCM detects one or more of the following outputs shorted to ground mode door driver blend doo...

Page 2954: ...trol Module C2 harness connector Measure the resistance between ground and each of the Door Driver circuits Blend Mode Recirc Common Is the resistance below 10K ohms on any of the circuits All Yes Repair all Door Driver circuits with a resistance below 10K ohms for a short to ground Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Go To 3...

Page 2955: ...dal Start the engine With the DRBIII in Miscellaneous actuate Calibrate HVAC Door Motors With the DRBIII read the Body Computer DTCs Does the DRBIII display XXXX Door Output Short To Ground All Yes Go To 6 No Go To 7 6 Turn the ignition off Disconnect the C200 in line connector HVAC located in the center of the instrument panel above the accelerator pedal Disconnect the Body Control Module C2 harn...

Page 2956: ... record and erase Body Computer DTC s Cycle the ignition switch Start the engine With the DRBIII in Miscellaneous actuate Calibrate HVAC Door Motors With the DRBIII read the Body Computer DTCs Does the DRBIII display XXXX Door Output Short To Ground All Yes Go To 9 No Replace the Mode Door Actuator in accordance with the Service Information Calibration must be performed after repair replacement is...

Page 2957: ...uator harness connector Measure the resistance between the Recirculation Door Driver circuit and the Common Door Driver circuit Is the resistance below 10K ohms All Yes Repair the Recirculation Door Driver circuit for a short to the Common Door Driver circuit Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Replace the Recirculation Door ...

Page 2958: ...n With the DRBIII record and erase Body Computer DTC s Cycle the ignition switch With the DRBIII read the Body Computer DTCs What code s does the DRBIII display All DTC s other than Dimming Code RX Fail Refer to the appropriate category for the related symptom s Diagnose all other DTCs before diagnosing Dimming Code RX Failure Perform BODY VERIFICATION TEST VER 1 Dimming Code RX Failure only Go To...

Page 2959: ...in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 4 Turn the ignition off NOTE Visually inspect the related w iring harness and circuits Look for any chafed pierced pinched or partially broken w ires NOTE Visually inspect the related w iring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that ...

Page 2960: ...ENSOR INTERMITTENT WIRING PROBLEM EVAPORATOR TEMP SENSOR SIGNAL CIRCUIT SHORT TO GROUND EVAPORATOR TEMP SENSOR SIGNAL CKT SHORT TO SENSOR GROUND BODY CONTROL MODULE EVAPORATOR TEMP SENSOR STAYS LOW TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII in Sensors read the Evaporator Temperature Sensor voltage Is the voltage above 5 5 volts All Yes Go To 2 No Go To 7 2 Turn the ignition o...

Page 2961: ...ll Yes Go To 5 No Repair the Evaporator Temperature Sensor Signal circuit for an open Perform BODY VERIFICATION TEST VER 1 5 Turn the ignition off Disconnect the Evaporator Temperature Sensor harness connector Disconnect the Body Control Module C2 harness connector Measure the resistance of the Sensor Ground circuit between the BCM C2 connector and the Evaporator Temp Sensor connector Is the resis...

Page 2962: ...ll Yes Using the wiring diagram schematic as a guide inspect the wiring and connectors for conditions causing an intermittent short or open Perform BODY VERIFICATION TEST VER 1 No Replace the Evaporator Temperature Sensor in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 9 Turn the ignition off Disconnect the Evaporator Temperature Sensor harness connector Disconnect ...

Page 2963: ...are no possible causes remaining view repair All Repair Replace and program the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 301 HEATING A C EVAPORATOR SENSOR FAILURE ATC MTC Continued ...

Page 2964: ...Go To 3 2 Turn the ignition on With the DRBIII in Automatic Temperature Control Monitor Display PCI Bus Info ATC look for ATC Status Msg Pres Does the DRBIII display ATC Status Msg Pres Yes All Yes Replace the Automatic Temperature Control in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Replace and program the Body Control Module in accordance with the Service In...

Page 2965: ...TOR MOTOR BODY CONTROL MODULE ASPIRATOR DRIVER OPEN BODY CONTROL MODULE ASPIRATOR STAYS RUNNING ASPIRATOR MOTOR DRIVER CIRCUIT SHORTED TO GROUND IN CAR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE AUTOMATIC TEMPERATURE CONTROL ASPIRATOR STAYS RUNNING BODY CONTROL MODULE SHORTED IN CAR TEMP SENSOR SIGNAL IN CAR TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND IN CAR TEMPERATURE SENSOR SI...

Page 2966: ... All Aspirator motor inoperative Go To 2 Aspirator timer inoperative Go To 6 In Car Temp Sense above 5 3 volts Go To 8 In Car Temp Sense below 4 5 volts Go To 9 None of the above Go To 12 2 Turn the ignition off Disconnect the Automatic Temperature Control harness connector Turn the ignition on Measure the voltage between the Fused B circuit and ground Is the voltage above 10 0 volts All Yes Go To...

Page 2967: ...rvice Information Perform BODY VERIFICATION TEST VER 1 6 NOTE Ensure that the courtesy lamps operate properly from the drivers door before proceeding If not refer to the Interior Lighting category for the related symptom s NOTE This path is for the aspirator continuing to run w ith the key off and the doors closed Turn the ignition off Disconnect the Body Control Module C1 harness connector Turn t...

Page 2968: ...n off Disconnect the Body Control Module C1 C2 harness connectors Disconnect the Automatic Temperature Control harness connector Measure the resistance between the Sensor Ground circuit and the In Car Temper ature Sensor Signal circuit in the ATC harness connector Is the resistance below 10K ohms All Yes Repair the In Car Temperature Sensor Signal circuit for a short to the Sensor Ground circuit P...

Page 2969: ... time The aspirator and in car temp sensor should be fully operational Refer to the wiring diagrams located in the service information to help isolate a possible intermittent wiring problem Perform BODY VERIFICATION TEST VER 1 14 Turn the ignition off Disconnect the Body Control Module C2 harness connector Back probe one ohmmeter lead to the Sensor Ground ckt in the BCM C2 harness connector and th...

Page 2970: ...of travel for the mode door POSSIBLE CAUSES SUN OR IN CAR TEMPERATURE SENSOR FAILURE SUN SENSOR SHORTED SUN SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE BODY CONTROL MODULE CHECK CODE S PRESENT BLEND DOOR FEEDBACK STALLTEST FAILURE DTC PRESENT ADDITIONAL FEEDBACK STALL TEST FAILURE DTCS PRESENT MODE DOOR FEEDBACK SIGNAL CIRCUIT SHORTED TO THE DOOR DRIVER CIRCUIT S MODE DOOR LINKAGE ACTUATOR MODE DOOR ...

Page 2971: ...Go To 5 2 Turn the ignition on NOTE Voltages specified are from shining a 25 w att incandescent bulb on the sensor through the w indshield of a vehicle parked indoors Performing this test w ith a higher w att bulb w ith a vehicle parked in the sun w ill result in low er voltage readings With the DRBIII in Sensor Display monitor Sun Sensor voltage while shining an incandescent lamp min 25 watt dire...

Page 2972: ...he engine With the DRBIII in Miscellaneous actuate Calibrate HVAC Door Motors With the DRBIII read the Body Computer DTCs What code s does the DRBIII display All Other than Feedback or Stall Test Fail Refer to the appropriate category for the related symptom s Diag nose all other DTCs before diagnosing Stall Test or Feedback Failures Calibration must be performed after repair replacement is comple...

Page 2973: ...rform BODY VERIFICATION TEST VER 1 No Go To 9 9 Turn the ignition off Reconnect the BCM C2 harness connector Disconnect the Mode Door Actuator harness connector While back probing connect a test light between the Mode Door Driver circuit and the Common Door Driver circuit in the Mode Door Actuator harness connector Start the engine With the DRBIII select Body Body Computer System Tests Actuate Mod...

Page 2974: ...Y VERIFICATION TEST VER 1 No Repair the Common Door Driver circuit for an open Calibration must be performed after repair replacement is completed Perform BODY VERIFICATION TEST VER 1 12 Turn the ignition off Disconnect the Mode Door Actuator harness connector Disconnect the Body Control Module C2 harness connector Measure the resistance of the Sensor Ground circuit between the Mode Door Actuator ...

Page 2975: ...ance between the 5 Volt Supply circuit and the Sensor Ground circuit in the BCM C2 harness connector Is the resistance below 10K ohms All Yes Repair the 5 Volt Supply circuit for a short to the Sensor Ground circuit Calibration must be performed after repair replacement is completed Perform BODY VERIFICATION TEST VER 1 No Replace and program the Body Control Module in accordance with the Service I...

Page 2976: ...TEST VER 1 20 Turn the ignition off Disconnect the Mode Door Actuator harness connector Disconnect the Body Control Module C2 harness connector Measure the resistance between the Mode Door Feedback Signal circuit and the Sensor Ground circuit in the BCM C2 harness connector Is the resistance below 10K ohms All Yes Repair the Mode Door Feedback Signal circuit for a short to the Sensor Ground circui...

Page 2977: ... be performed after repair replacement is completed Perform BODY VERIFICATION TEST VER 1 23 Turn the ignition off NOTE Visually inspect the related w iring harness and circuits Look for any chafed pierced pinched or partially broken w ires NOTE Visually inspect the related w iring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins...

Page 2978: ... CONTROL MODULE RECIRCULATION DOOR DRIVER CIRCUIT OPEN COMMON DOOR DRIVER CIRCUIT OPEN RECIRCULATION DOOR LINKAGE ACTUATOR WIRING CAUSING INTERMITTENT CONDITION TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII record and erase Body Computer DTC s Cycle the ignition switch Start the engine With the DRBIII in Miscellaneous actuate Calibrate HVAC Door Motors With the DRBIII read the B...

Page 2979: ...e of the Recirculation Door Driver circuit between the BCM C2 harness connector and the Recirculation Door Actuator harness connector Is the resistance below 5 0 ohms All Yes Go To 4 No Repair the Recirculation Door Driver circuit for an open Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 4 Turn the ignition off Disconnect the Body Control...

Page 2980: ...e related w iring harness connectors Look for broken bent pushed out or corroded terminals NOTE Refer to any Technical Service Bulletins TSB that may apply Were any problems found All Yes Repair as necessary Calibration must be performed after repair replacement is com pleted Perform BODY VERIFICATION TEST VER 1 No Test Complete 318 HEATING A C RECIRCULATION DOOR STALL TEST FAILURE ATC MTC Continu...

Page 2981: ...Replace the Sun Sensor in accordance with the Service Informa tion Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Sun Sensor VTSS LED harness connector Disconnect the Body Control Module C1 C2 harness connectors Measure the resistance between ground and the Sun Sensor Signal circuit Is the resistance below 100 0 ohms All Yes Repair the Sun Sensor Signal circuit for a s...

Page 2982: ...re are no possible causes remaining view repair All Repair Replace and program the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 320 HEATING A C SUN LOAD SENSOR FAILURE ATC Continued ...

Page 2983: ...ld position Turn the Mode Control switch to the Panel Heater position Turn the Blower switch off With the DRBIII record and erase Powertrain Computer DTC s With the DRBIII record and erase Body Computer DTCs Start the engine NOTE Proceed directly to the conclusion of this test and answ er Yes to the question if the DRBIII displays any HVAC related DTC s w hile performing anyone of the follow ing s...

Page 2984: ...t All Yes Refer to the appropriate catagory for the related symptom Perform BODY VERIFICATION TEST VER 1 No Recheck the climate control system performance Refer to Service Information for additional information Perform BODY VERIFICATION TEST VER 1 322 HEATING A C A C SYSTEM TEST MTC Continued ...

Page 2985: ...he ignition on With the DRBIII record and erase the Body Computer DTC s Start the engine NOTE Monitor the DRBIII for active Body Computer DTCs w hile perform ing the follow ing test steps If a DTC appears during any test step proceed to the conclusion question NOTE NOTE If multiple DTCs appear repair any that relate to a short circuit first Slowly turn the blower control to each blower speed and l...

Page 2986: ...nt All Yes Refer to the appropriate catagory for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Recheck the climate control system performance Refer to Service Information for additional information Perform BODY VERIFICATION TEST VER 1 324 HEATING A C ATC SYSTEM TEST Continued ...

Page 2987: ...rature Control Incorrect In Sun Shade is still present Is the symptom still present All Yes Go To 2 No Test Complete 2 Turn the ignition off Disconnect the Sun Sensor VTSS LED harness connector Turn the ignition on With the DRBIII in Sensor Display read the Sun Sensor voltage Is the voltage below 4 8 volts All Yes Replace and program the Body Control Module in accordance with the Service Informati...

Page 2988: ...a tion Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off Disconnect the Sun Sensor VTSS LED harness connector Connect a jumper wire between the Sun Sensor Signal circuit and ground Turn the ignition on With the DRBIII in Sensor Display read the Sun Sensor voltage Is the Sun Sensor voltage below 0 2 volts All Yes Repair the Sensor Ground circuit for an open Perform BODY VERIFI...

Page 2989: ...CAUSES BACK LIGHTING INOPERATIVE TEST ACTION APPLICABILITY 1 View Repair All Repair Refer to I P Illumination Lamps Not Working Properly in the Interior Lighting category for the diagnostic procedure Perform BODY VERIFICATION TEST VER 1 327 HEATING A C ...

Page 2990: ...PPLY CIRCUIT OPEN BLOWER MOTOR GROUND CIRCUIT OPEN BLOWER POWER MODULE BODY CONTROL MODULE BLOWER MOTOR BLOWER POWER MODULE TEST ACTION APPLICABILITY 1 Turn the ignition off Remove and inspect J B Fuse 1 Is the fuse open All Yes Go To 2 No Go To 7 2 Replace J B Fuse 1 Turn the ignition on Operate the blower motor in all speeds Start the engine and operate the ATC system in all modes and speeds Doe...

Page 2991: ... Motor Supply circuit Is the resistance below 10K ohms All Yes Repair the Blower Motor Supply circuit for a short to ground Replace J B Fuse 1 Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off Replace J B Fuse 1 Reconnect the Blower Motor harness connector Disconnect the Blower Power Module C1 harness connector Disconnect the Blower Power Module C2 harness connector Connect a...

Page 2992: ... Turn the ignition on Measure the voltage between the Blower Motor Control circuit and ground Is the voltage above 0 2 volts All Yes Repair the Blower Motor Control circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Go To 10 10 Turn the ignition off Disconnect the Blower Power Module C1 harness connector Disconnect the Body Control Module C1 harness connector Measure the resist...

Page 2993: ...ST VER 1 13 Turn the ignition off Reconnect the Blower Motor harness connector Reconnect the Blower Power Module C1 and C2 harness connectors Back probe one voltmeter lead to the Blower Motor Control ckt in the Body Control Module C1 harness connector and the other lead to ground Reconnect the Body Control Module C1 harness connector Start the engine Turn the Automatic Temperature Control off Obse...

Page 2994: ...s to w here the signal pattern is a flat line on ground Set the blower control to LO speed and then slowly turn it to HI speed while observing the DRBIII display The duty cycle pattern should change smoothly as the blower switch is turned from Lo to High The high part of the cycle will decrease as the blower speed increases Does the DRBIII display the signal as described above All Yes Go To 15 No ...

Page 2995: ...n the ignition on Turn the blower on and operate it in all speeds and modes Does the blower motor operate properly without blowing the fuse All Yes Check the Fused Ignition Switch Output RUN circuit for an intermittent short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Turn the Blower switch off Disconnect the Blower Motor harness connector Measure the resistan...

Page 2996: ...o 7 6 Turn the ignition off Disconnect the A C Heater Control C2 harness connector Measure the resistance between ground and the Ground circuit Is the resistance below 5 0 ohms All Yes Replace the A C Heater Control in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 7 Turn the ignition off Di...

Page 2997: ...ON TEST VER 1 No Go To 9 9 Turn the Blower switch off Turn the ignition on NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Using a 12 volt test light connected to ground back probe the Fused Ignition Switch Output RUN circuit in the Blower Motor harness connector Does the test light illuminate brightly All Yes Replace the Blower Mot...

Page 2998: ...or Resistor Block harness connector Measure the resistance between ground and each of the Blower Motor Driver circuits Is the resistance below 10K ohms on any of the circuits All Yes Repair the Blower Motor Driver circuit s for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the Blower Motor harness connector Disconnect the Blower Motor Resistor...

Page 2999: ...er Motor Driver circuit and the M1 M2 and High Blower Motor Driver circuits Measure the resistance between the M1 Blower Motor Driver circuit and the M2 and High Blower Motor Driver circuits Measure the resistance between the M2 Blower Motor Driver circuit and the High Blower Motor Driver circuit Is the resistance below 10K ohms between any of the circuits All Yes Repair the shorted Blower Motor D...

Page 3000: ...ER 1 No Go To 2 2 Turn the ignition on With the DRBIII in Automatic Temperature Control Monitor Display PCI Bus Info ATC look for Fan Req To BCM Does the DRB display Fan Req To BCM Yes All Yes Go To 3 No Replace the Automatic Temperature Control in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Blower Power Module C1 harness conn...

Page 3001: ...d on input from the blow er control sw itch NOTE When the blow er control sw itch is set to Lo speed the BCM provides a short duty cycle less time grounding the signal As higher blow er speeds are requested the BCM increases the duty cycle more time grounding the signal NOTE When the blow er control sw itch is set to High speed the duty cycle increases to w here the signal pattern is a flat line o...

Page 3002: ...GROUND CIRCUIT S OPEN AUTOMATIC TEMPERATURE CONTROL TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII record and erase Body Computer DTC s Cycle the ignition switch With the DRBIII read the Body Computer DTCs Does the DRBIII display any DTCs All Yes Refer to the appropriate category for the related symptom s Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Which symptom is present ...

Page 3003: ... Outputs read the switch states while pressing the Auto Off A C Recirc Panel Floor Mix Bilevel EBL and Defrost buttons on the ATC one at a time Does each switch state change from Open to Closed accordingly All Yes Go To 6 No Replace the Automatic Temperature Control in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition on While observing the ATC temper...

Page 3004: ...put circuit and ground Is the voltage above 10 0 volts All Yes Go To 10 No Repair the Fused Ignition Switch Output circuit for an open Perform BODY VERIFICATION TEST VER 1 10 Turn the ignition off Disconnect the Automatic Temperature Control harness connector Close all doors and ensure all lights are off Wait one minute for the Body Control Module to go to sleep Measure the resistance between grou...

Page 3005: ... CONTROL MODULE INTERNAL MALFUNCTION HORN RELAY J UNCTION BLOCK OPEN HORN RELAY OUTPUT CIRCUIT OPEN HORN RELAY OUTPUT CIRCUIT OPEN GROUND CIRCUIT OPEN HORN TEST ACTION APPLICABILITY 1 With the DRBIII actuate the HORN RELAY Does the Horn sound while actuating the Horn Relay All Yes Go To 2 No Go To 7 2 Press and hold the Horn button With the DRBIII in Inputs Outputs read the HORN SW state Does the ...

Page 3006: ...ckspring C3 harness connector Measure the resistance of the Horn Radio Control MUX circuit between the Horn Switch and Clockspring Is the resistance below 5 0 ohms All Yes Replace the Clockspring Perform BODY VERIFICATION TEST VER 1 No Repair the Horn Radio Control MUX circuit for an open between the Clockspring and the Horn switch Perform BODY VERIFICATION TEST VER 1 6 Disconnect the Body Control...

Page 3007: ...EST VER 1 No Go To 10 10 Connect a jumper wire between the Horn Relay Output circuit at the J unction Block C2 connector and B Disconnect the Horn connector Measure the voltage of the Horn Relay Output circuit at the horn connector Is the voltage above 10 0 volts All Yes Go To 11 No Repair the Horn Relay Output circuit for an open Perform BODY VERIFICATION TEST VER 1 11 Disconnect the jumper wire ...

Page 3008: ...original location Measure the voltage of the Fused B circuits at the Horn Relay connector Is the voltage above 10 0 volts at each cavity All Yes Go To 15 No Replace the J unction Block Perform BODY VERIFICATION TEST VER 1 15 Remove the Horn Relay from the junction block Remove the BCM from the junction block Connect a jumper wire between the Fused B circuit and the Horn Relay Control circuit at th...

Page 3009: ... When Monitored The Instrument Cluster performs an internal diagnostic at power up and when the bulb is requested Set Condition When the Instrument Clusteris detects a fault in the ABS bulb circuit AIRBAG LAMP CIRCUIT OPEN When Monitored The Instrument Cluster performs an internal diagnostic of the circuit at power up and when the bulb is requested Set Condition When the Instrument Cluster is dete...

Page 3010: ...d DTCs Did the Indicator Lamp Open or Short DTC reset All Yes Go To 2 No Test Complete 2 Turn the ignition off Remove and inspect the Indicator Bulb in question Is the Indicator Bulb in question defective All Yes Replace the Indicator Bulb in accordance with the Service Infor mation Perform BODY VERIFICATION TEST VER 1 No Replace the Instrument Cluster in accordance with the Service Information Pe...

Page 3011: ...O SENSOR GROUND CIRCUIT FUEL LEVEL SENSOR SIGNAL CIRCUIT SHORT TO GROUND FUEL LEVEL SENSOR INTERMITTENT CONDITION BODY CONTROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII erase DTCs Cycle the ignition Wait approximately 1 minute With the DRBIII in Body Computer read DTCs Does the DTC reset All Yes Go To 2 No The condition is not present at this time Monitor DRBIII param...

Page 3012: ...isconnect the Fuel Tank Module harness connector Measure the resistance between the Fuel Level Sensor Signal circuit and the Sensor Ground circuit in the BCM connector Is the resistance below 5 0 ohms All Yes Repair the Fuel Level Sensor Signal circuit for a short to the Sensor Ground circuit Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the BCM harness connect...

Page 3013: ...ely 340 Ohms 1 2 Approximately 550 Ohms 1 4 Approximately 760 Ohms Empty Approximately 940 Ohms Does the Fuel Level Sensor resistance measure within specifications All Yes Replace the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Replace the Fuel Level Sensor in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 351...

Page 3014: ...tored With the ignition on Set Condition The Instrument Cluster detects no PCI Bus communiaction with the BCM for 5 seconds The cluster will position the Fuel Gauge needle to E illuminate the Low Fuel indicator and illuminate the VF display at full brightness NO ORC BUS MESSAGES RECEIVED When Monitored With the ignition on Set Condition The Instrument Cluster detects no PCI Bus communication with ...

Page 3015: ...with the ABS BCM ORC or TCM module Was the DRB able to I D or communicate with the module in question All Yes Test Complete No Refer to the Communication category for the related symptom s Perform BODY VERIFICATION TEST VER 1 353 INSTRUMENT CLUSTER NO ABS BUS MESSAGES RECEIVED Continued ...

Page 3016: ...ing Diagrams as a guide disconnect each dimmed component one at a time while checking for the DTC to reset Turn the ignition on Turn the Headlamps on With the DRBIII read DTCs Does the DRBIII display PANEL DIMMING OUTPUT SHORT All Yes Go To 3 No Replace the shorted component as necessary Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Using the Wiring Diagrams as a guide disconnect ea...

Page 3017: ...BLE CAUSES PCM MESSAGE NOT RECEIVED NO COMMUNICATION WITH THE PCM PCI BUS CIRCUIT OPEN POWERTRAIN CONTROL MODULE TEST ACTION APPLICABILITY 1 Turn the ignition on With the DRBIII enter Instrument Cluster System Tests then PCM Monitor Does the DRBIII display PCM is active on the BUS All Yes Erase the DTC if DTC resets replace the Instrument Cluster in accordance with the Service Information Perform ...

Page 3018: ...sure the resistance of the PCI Bus circuit between the diagnostic junction port tester and the PCM C2 connector Is the resistance below 5 0 ohms All Yes Replace and program the Powertrain Control Module in accor dance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the PCI Bus circuit for an open Perform BODY VERIFICATION TEST VER 1 356 INSTRUMENT CLUSTER PCM MESSAGE NO...

Page 3019: ...lace the Brake Fluid Level Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Park Brake Switch harness connector Turn the ignition on Observe the Brake Warning Indicator Is the Brake Warning Indicator illuminated All Yes Go To 3 No Replace the Park Brake Switch in accordance with the Service Information Perform BODY VERIFI...

Page 3020: ...ing Indicator illuminate for approximately 4 seconds and turn off All Yes Go To 2 No Remove and inspect the Brake Warning Indicator bulb and socket if found to be defective replace as necessary If the bulb and socket check OK replace the Instrument Cluster in accor dance with the Service Information Perform BODY VERIFICATION TEST VER 1 2 Is the fault condition related to the Park Brake All Yes Go ...

Page 3021: ...in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off Disconnect the Brake Fluid Level Switch harness connector Measure the resistance between ground and the Brake Fluid Level Switch Ground circuit Is the resistance below 5 0 ohms All Yes Go To 7 No Repair the Brake Fluid Level Switch Ground circuit for an open Perform BODY VERIFICATION ...

Page 3022: ...dicator illuminate for approximately 4 seconds and then turn off All Yes Go To 2 No Go To 3 2 Using the DRBIII read DTC s Are there any DTC s present All Yes Refer to symptom list for problems related to the DTC Perform BODY VERIFICATION TEST VER 1 No The condition is not present at this time Monitor DRBIII parameters while wiggling the related wire harness Refer to any Technical Service Bulletins...

Page 3023: ...t begins Observe the Cruise Indicator during the Self Test Did the Cruise indicator illuminate for approximately 4 seconds and then turn off All Yes Go To 2 No Go To 3 2 Start the engine Drive the vehicle Activate the Cruise system Does the Cruise system operate properly All Yes Test Complete No Refer to Cruise diagnostics for the related symptom s Perform BODY VERIFICATION TEST VER 1 3 Remove and...

Page 3024: ...st The gauge will position the indicator needle at the following calibration points C H 1 2 C Did the Engine Coolant Temperature Gauge position the needle correctly All Yes Go To 3 No Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition on With the DRBIII read the Engine Coolant Temperature in the PCM EMIC and the BCM Do...

Page 3025: ...icator during the Self Test Did the Engine Coolant Temperature indicator illuminate for approximately 4 seconds and then turn of All Yes Go To 2 No Go To 3 2 Turn the ignition on Using the DRBIII read DTC s Are there any DTC s present All Yes Refer to symptom list for problems related to DRIVEABILITY Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Remove the Engine Coolant ...

Page 3026: ...e Service Information Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Fuel Pump Module harness connector Measure the resistance of the Fuel Level Sensor The Fuel Level Sensor resistance must be within the following values Full Approximately 130 Ohms 3 4 Approximately 340 Ohms 1 2 Approximately 550 Ohms 1 4 Approximately 760 Ohms Empty Approximately 940 Ohms Does the Fue...

Page 3027: ... Switch harness connector Turn the ignition on With the DRBIII in Body Control Inputs Outputs read the Hi Beams state Does the DRBIII display On All Yes Go To 3 No Replace the Multi Function Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Multi Function Switch harness connector Disconnect the J unction Block C6 harness c...

Page 3028: ...se in the J unction Block and ground Is there any voltage present All Yes Replace the J unction Block in accordance with the Service Infor mation Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 366 INSTRUMENT CLUSTER HIGH BEAM INDICATOR ALWAYS ON Continued ...

Page 3029: ... the Hi Beam Lamp Did the High Beam Indicator illuminate All Yes Go To 2 No Go To 6 2 Turn the ignition on With the DRBIII in Body Control Inputs Outputs read the Hi Beams state while actuating the High Beam Headlamps Does the DRBIII Inputs Outputs display On All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the...

Page 3030: ...r Disconnect the Multi Function Switch harness connector Measure the resistance of the Dimmer Switch High Beam Output circuit Is the resistance above 5 0 ohms All Yes Repair the Dimmer Switch High Beam Output circuit between the Multi Function Switch and the J unction Block for an open Perform BODY VERIFICATION TEST VER 1 No Replace the Multi Function Switch in accordance with the Service Informat...

Page 3031: ...off All Yes Go To 2 No Go To 3 2 Using the DRBIII read DTC s Is the DTC FUEL LEVEL SENDING UNIT INOP present All Yes Refer to symptom list for diagnosis of the DTC Perform BODY VERIFICATION TEST VER 1 No The condition is not present at this time Monitor DRBIII parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply Visually in spect the relate...

Page 3032: ...conds then turn off All Yes Go To 2 No Go To 3 2 Using the DRBIII read DTC s Are there any DTC s present All Yes Refer to symptom list for problems related to the DTC Perform BODY VERIFICATION TEST VER 1 No The condition is not present at this time Monitor DRBIII parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply Visually in spect the rel...

Page 3033: ...All Yes Go To 2 No Go To 4 2 Start the engine Does the Oil Pressure Indicator turn off All Yes The condition is not present at this time Monitor DRBIII parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply Visually in spect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition ...

Page 3034: ...on Switch Output circuit for an open or high resistance circuit If the fuse is open make sure to check for a short to ground and repair as necessary Perform BODY VERIFICATION TEST VER 1 7 Turn the ignition off Disconnect the Oil Pressure Switch harness connector Turn the ignition on Using a 12 volt test light connected to ground check the Oil Pressure Indicator circuit Does the test light illumina...

Page 3035: ...he DRBIII display any MIC PCM or TCM DTCs All Yes Refer to symptom list for problems related to DTC s Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Perform the Instrument Cluster Self Test Turn the ignition off Press and hold the Trip Reset button Turn the ignition on Observe the PRND AutoStick VF display during the Self Test Did any part of the VF display fail to illuminate All Yes Replace th...

Page 3036: ...ODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the Seat Belt Switch harness connector Measure the resistance between ground and the Seat Belt Switch Ground circuit Is the resistance above 5 0 ohms All Yes Repair the Seat Belt Switch Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the Seat Belt Switch harness c...

Page 3037: ... ignition off Disconnect the Seat Belt Switch harness connector NOTE Performing this test on vehicles equipped w ith Pre Tensioners w ill set a DTC in the ACM Clear codes after repairs are complete Turn the ignition on Observe the Seat Belt Indicator Did the Seat Belt indicator illuminate All Yes Replace the Seat Belt Buckle in accordance with the Service Information Perform BODY VERIFICATION TEST...

Page 3038: ...at the RED lead is on the of the LED Did the Seat Belt Indicator illuminate All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Replace the Seat Belt Indicator LED in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 376 INSTRUMENT CLUSTER SEAT BELT INDICATOR INOPERATIVE Continued ...

Page 3039: ...utton Turn the ignition to the Unlock position Observe the Speedometer during the Self Test The Speedometer should position the indicator needle at the following calibration points 0 100 75 55 20 0 MPH Did the Speedometer needle position correctly All Yes Go To 3 No Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 3 With the DRBIII veri...

Page 3040: ...om list for problems related to inaccurate Vehicle Speed and communications Perform BODY VERIFICATION TEST VER 1 No The condition is not present at this time Monitor DRBIII parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply Visually in spect the related wiring harness and connector terminals Perform BODY VERIFICATION TEST VER 1 378 INSTRU...

Page 3041: ...ion to the Unlock position Observe the Tachometer during the Self Test The Tachometer should position the indicator needle at the following calibration points 0 6000 3000 1000 0 Did the Tachometer needle position correctly All Yes The condition is not present at this time Monitor DRBIII parameters while wiggling the related wire harness Refer to any Technical Service Bulletins TSB that may apply V...

Page 3042: ...rol Indicator Is the Traction Control Indicator illuminated All Yes Go To 2 No Replace the Traction Control Switch in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Traction Control Switch harness connector Disconnect the Instrument Cluster harness connector Measure the resistance between ground and the Traction Control Switch Se...

Page 3043: ...b and socket repair or replace as necessary If the bulb and socket check OK replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the Traction Control Switch harness connector Connect a jumper wire between the Traction Control Switch Sense circuit and the Traction Control Switch ground circuit Did the Tract...

Page 3044: ...se circuit between the Traction Control Switch connector and the Instrument Cluster connector Is the resistance below 5 0 ohms All Yes Replace the Instrument Cluster in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Repair the Traction Control Switch Sense circuit for an open Perform BODY VERIFICATION TEST VER 1 382 INSTRUMENT CLUSTER TRACTION CONTROL INDICATOR INO...

Page 3045: ...symptom Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 Turn the ignition off Disconnect the BCM C1 harness connector Measure the voltage between the VTSS Indicator Driver circuit and ground Is the voltage above 10 5 volts All Yes Replace and program the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconne...

Page 3046: ...mittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Disconnect the J unction Block harness connector Turn on all overhead map and rear rearing lamps by their own individual switches This will disconnect each lamp from the Courtesy Lamp Driver Circuit Did any lamp fail to light when it was turned on by it s own switch All Yes Repair...

Page 3047: ...Actuate the Dimming Level Switch With the DRBIII read the DTC information Does the DRBIII read Dimming Level Switch Input Failure All Yes Go To 2 No The condition that caused the symptom is currently not present Inspect the related wiring for a possible intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Disconnect the J uncti...

Page 3048: ...ad map and rear rearing lamps by their own individual switches This will disconnect each lamp from the Courtesy Lamp Driver Circuit Did any lamp fail to light when it was turned on by it s own switch All Yes Repair the short to battery condition Perform BODY VERIFICATION TEST VER 1 No Go To 5 5 Turn the ignition off Disconnect the J unction Block Harness Connector from the front of the junction bl...

Page 3049: ...lts All Yes Go To 2 No Replace the J unction Block Perform BODY VERIFICATION TEST VER 1 2 Check J unction Block Fuse 5 Is Fuse 5 open All Yes Replace the open fuse Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Back probe a jumper wire from the Courtesy Lamps Driver circuit to the J unction Block C10 connector and ground Do the courtesy lamps come on All Yes Replace the Body Control Module Perf...

Page 3050: ... affected component Is there a problem with any bulb or socket All Yes Replace the defective bulb or socket as needed in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off to the lock position Disconnect the Body Control Module harness connector Disconnect the affected component harness connector Note Check connectors Clean repair as nec...

Page 3051: ...ICATION TEST VER 1 No Go To 5 5 Ignition on engine not running Using a 12 volt test light connected to ground back probe the affected component Dimming circuit at the BCM harness connector NOTE The test light must illuminate brightly Compare the brightness to that of a direct connection to the battery Does the test light illuminate brightly All Yes Go To 6 No Go To 7 6 If there are no possible cau...

Page 3052: ...ER CIRCUIT SHORTED TO GROUND DECKLID RELEASE SOLENOID DRIVER CIRCUIT OPEN BODY CONTROL MODULE DECKLID RELEASE SOLENOID DRIVER CIRCUIT SHORT TO VOLTAGE BODY CONTROL MODULE DECKLID RELEASE SOLENOID DRIVER INOPERATIVE TEST ACTION APPLICABILITY 1 With the DRBIII erase DTC s Press the decklid release switch several times With the DRBIII read DTC s Did this DTC reset All Yes Go To 2 No Go To 10 2 Discon...

Page 3053: ...Yes Go To 6 No Repair the ground circuit for an open Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition off Disconnect the Decklid Release Solenoid Ajar Switch harness connector Connect a 12 volt Test Light between the Decklid Release Solenoid Driver ckt and the ground circuit cavs 1 and 3 Press the decklid release switch several times and observe the test light Did the test light illuminate...

Page 3054: ...pen Perform BODY VERIFICATION TEST VER 1 9 If there are no possible causes remaining view repair All Repair Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 10 Turn the ignition off Note Visually inspect the related w iring harness Look for any chafed pierced pinched or partially broken w ires Note Visually inspect the related w ire harness connectors Look for broken bent pushe...

Page 3055: ...C s Did this DTC reset All Yes Go To 2 No Go To 5 2 Disconnect the Decklid Release Switch harness connector With the DRBIII erase DTC s Cycle the ignition switch from off to on and wait at least 30 seconds With the DRBIII read DTC s Did this DTC reset All Yes Go To 3 No Replace the Decklid Release Switch Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Decklid Release Sw...

Page 3056: ...inspect the related w iring harness Look for any chafed pierced pinched or partially broken w ires Note Visually inspect the related w ire harness connectors Look for broken bent pushed out or corroded terminals Were any problems found All Yes Repair wiring harness connectors as necessary Perform BODY VERIFICATION TEST VER 1 No Test Complete 394 POWER DOOR LOCKS RKE DECKLID RELEASE SWITCH FAILURE ...

Page 3057: ...ODULE DOOR LOCK SWITCH SHORTED TEST ACTION APPLICABILITY 1 With the DRBIII erase DTC s Operate both door lock switches to the lock and unlock positions several times With the DRBIII read DTC s Did this DTC reset All Yes Go To 2 No Go To 7 2 Disconnect the Driver Door Lock Switch harness connector Turn the ignition on With the DRBIII enter BODY COMPUTER then SENSORS and observe the Dr Lock SW volta...

Page 3058: ... the ignition on Measure the voltage of the Passenger Door Lock Switch Mux circuit Is there any voltage present All Yes Repair the Passenger Door Lock Switch Mux circuit for a short to voltage Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 If there are no possible causes remaining view repair All Repair Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 7 Turn the ignition off...

Page 3059: ...T ACTION APPLICABILITY 1 With the DRBIII erase DTC s Insert the key in the Driver Cylinder Lock Switch and rotate the key to the lock and unlock positions several times With the DRBIII read DTC s Did this DTC reset All Yes Go To 2 No Go To 6 2 Insert the key in the Driver Cylinder Lock Switch and rotate the key to the lock and unlock positions Does the key bind in any position All Yes Repair or re...

Page 3060: ... BODY VERIFICATION TEST VER 1 No Go To 5 5 If there are no possible causes remaining view repair All Repair Replace the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 6 Turn the ignition off NOTE Using the w iring diagram schematic as a guide inspect the w iring and connectors Were any problems found All Yes Repair wiring harness or connectors a...

Page 3061: ...OW TRANSMITTER LOW VOLTAGE OUTPUT TEST ACTION APPLICABILITY 1 To determine which transmitter set the code press any button on each transmitter If a chime in the BCM is heard when a button is pressed that is the problem transmitter Test the voltage of each battery in the problem transmitter Is the voltage at or above 3 0 in each battery All Yes Replace the RKE Transmitter Perform BODY VERIFICATION ...

Page 3062: ... ill only set if the BCM receives an indication from the RKE module that it has entered program mode w ithout the BCM requesting so Replace the Remote Keyless Entry Module and program a transmitter With the DRBIII clear DTCs Operate the Door Locks several times with the RKE transmitter With the DRBIII read DTC s Did this DTC reset All Yes Replace the Body Control Module in accordance with the Serv...

Page 3063: ...ABILITY 1 Note This DTC w ill only set w hen attempting to enter the program RKE mode Replace the Remote Keyless Entry Module With the DRB Clear DTC s With the DRB attempt to enter the RKE program mode With the DRB check DTC s Did this DTC reset All Yes Replace the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 No If the replaced module was a te...

Page 3064: ...ctor Measure the resistance between ground and the any Unlock Relay Output circuits in the BCM C4 connector Is the resistance below 1000 0 ohms should be infinite All Yes Repair the Door Unlock Relay Output circuits as necessary Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 If there are no possible causes remaining view repair All Repair Replace the Body Control Module Perform BODY VERIFICATIO...

Page 3065: ...TED TEST ACTION APPLICABILITY 1 Lower the drivers window Remove the ignition key Unlock all doors With the DRBIII actuate the Door Lock Relay Do the doors lock during the actuation test All Yes Go To 2 No Go To 10 2 With the DRBIII observe the Door Lock Switch Voltage Is the voltage above 0 2 volts All Yes Refer to symptom DOOR LOCK SWITCH FAILURE in the POWER DOOR LOCK RKE category Perform BODY V...

Page 3066: ... below 1000 0 ohms All Yes Replace the Driver Door Lock Switch Perform BODY VERIFICATION TEST VER 1 No Go To 7 7 Turn the ignition off Ensure the Passenger Door Lock Switch is connected before proceeding Disconnect the BCM C4 harness connector Measure the resistance of the Passenger Door Switch MUX circuit in the BCM C4 connector to ground Is the resistance below 1000 0 ohms All Yes Replace the Pa...

Page 3067: ...or Unlock Relay Output circuits as necessary Perform BODY VERIFICATION TEST VER 1 No Go To 12 12 Turn the ignition off Remove the Body Control Module from the J unction Block Using a 12 volt test light connected to 12 volts check the Ground circuit Does the test light illuminate brightly All Yes Go To 13 No Repair the open Ground circuit through the junction block Perform BODY VERIFICATION TEST VE...

Page 3068: ...e door cylinder lock switches if equipped Is the problem with a Door Cylinder Lock Switch VTSS All Yes Go To 2 No Go To 7 2 Disconnect the inoperative Door Cylinder Lock Switch connector Measure the voltage between the Fused B circuit and ground Is the voltage above 10 0 volts All Yes Go To 3 No Repair the Fused B circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Disconnect the inoperativ...

Page 3069: ...ordance with the Service Information Perform BODY VERIFICATION TEST VER 1 7 Disconnect the inoperative Door Lock Switch connector Measure the voltage between the Fused B circuit and ground Is the voltage above 10 0 volts All Yes Go To 8 No Repair the Fused B circuit for an open Perform BODY VERIFICATION TEST VER 1 8 Disconnect the inoperative Door Lock Switch connector Disconnect the BCM C4 connec...

Page 3070: ...he Door Lock Sw Volts status Is the voltage above 9 0 volts All Yes Replace the Power Door Lock Switch Perform BODY VERIFICATION TEST VER 1 No Go To 11 11 If there are no possible causes remaining view repair All Repair Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 408 POWER DOOR LOCKS RKE ALL DOORS FAILING TO LOCK AND UNLOCK FROM ONE SWITCH Continued ...

Page 3071: ... Measure the resistance between ground and any Lock Relay Output circuits in the BCM C4 connector Is the resistance below 1000 0 ohms should be infinite All Yes Repair the Lock Relay Output circuits as necessary Perform BODY VERIFICATION TEST VER 1 No Go To 2 2 If there are no possible causes remaining view repair All Repair Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 409 ...

Page 3072: ...r the driver door window Operate the power door lock switch or the door cylinder lock switch in the lock position Is a Power Door Lock Switch or a Door Cylinder Lock Switch inoperative in the lock position All Yes Replace the Power Door Lock Switch or Door Cylinder Lock Switch Perform BODY VERIFICATION TEST VER 1 No Test Complete 410 POWER DOOR LOCKS RKE ...

Page 3073: ...BILITY 1 Operate the power door lock switch or the door cylinder lock switch in the unlock position Is a Power Door Lock Switch or a Door Cylinder Lock Switch inoperative in the unlock position All Yes Replace the Power Door Lock Switch or Door Cylinder Lock Switch Perform BODY VERIFICATION TEST VER 1 No Test Complete 411 POWER DOOR LOCKS RKE ...

Page 3074: ...ERIFICATION TEST VER 1 No Go To 2 2 With the DRBIII read Engine DTC s Does the DRBIII display any TPS or VSS related DTC s All Yes Refer to symptom list for problems related to DRIVEABILITY Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 With the DRBIII enter Body Computer then Miscellaneous and observe the Rolling Door Lock status Does the DRBIII display ROLLING DOOR LOCKS ENABLED All Yes Go To...

Page 3075: ...h harness connector Measure the resistance between ground and the ground circuit Is the resistance below 5 0 ohms All Yes Go To 3 No Repair the ground circuit for an open Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition on Disconnect the Decklid Release Solenoid Ajar Switch harness connector Connect a 12 volt Test Light between the Decklid Release Solenoid Driver circuit and the Ground cir...

Page 3076: ...ess connector Disconnect the Body Control Module C4 connector Measure the resistance of the Decklid Release Solenoid Driver wire between the Decklid Release Solenoid Ajar Switch connector and the Body Control Module C4 connector Is the resistance below 5 0 ohms All Yes Go To 8 No Repair the Decklid Release Solenoid Driver wire for an open Perform BODY VERIFICATION TEST VER 1 8 If there are no poss...

Page 3077: ...n the DOOR AJ AR category Perform BODY VERIFICATION TEST VER 1 2 NOTE Ensure that the Key is still in the Ignition Sw itch With the DRBIII enter Body Computer then Input Output and read the Key In Ignition Switch status Does the DRBIII display KEY IN IGN SW CLOSED All Yes Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Go To 3 3 Turn the ignition off Disconnect the Ignition...

Page 3078: ...ct the Ignition Switch C3 connector Disconnect the Body Control Module C1 harness connector Measure the resistance of the Key In Ignition Switch Sense circuit between the ignition switch connector and the BCM C2 connector Is the resistance below 5 0 ohms All Yes Go To 6 No Repair the Key In Ignition Switch Sense circuit for an open Perform BODY VERIFICATION TEST VER 1 6 If there are no possible ca...

Page 3079: ...nect the Body Control Module C4 connector Measure the resistance between ground and the Driver Lock Relay Output circuit Is the resistance below 100 0 ohms All Yes Repair the Driver Lock Relay Output circuit for a short to ground Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Driver Unlock Relay Ground open Perform BODY VERIFICATION TEST VER 1 417 POWER DOOR LOCKS RKE ...

Page 3080: ...e Body Control Module C4 connector Measure the resistance between ground and the Driver Unlock Relay Output circuit in the Body Control Module C4 connector Is the resistance below 100 0 ohm All No Replace the Body Control Module in accordance with the Service Information Perform BODY VERIFICATION TEST VER 1 Yes Repair the Driver Unlock Relay Output circuit for a short to ground Perform BODY VERIFI...

Page 3081: ...LING TO Disconnect the Driver Door Lock Motor Ajar Switch connector Connect a 12 volt Test Light between the Driver Unlock Relay Output and the Driver Lock Relay Output circuits in the door lock motor connector Press the Door Lock Switch in the Lock and Unlock positions and observe the test light Does the Test Light flash on and off as the switch is pressed All Yes Replace the Driver Door Lock Mot...

Page 3082: ...ns and observe the test light Does the Test Light flash on and off as the switch is pressed All Yes Replace the Door Lock Motor Perform BODY VERIFICATION TEST VER 1 No Go To 7 7 Disconnect the appropriate Door Lock Motor Ajar Switch connector Using a 12 volt test light connected to ground check the Lock Relay Output circuit With the DRBIII actuate the Door Lock Relay and observe the Test Light Did...

Page 3083: ...ctor follow the instructions on the back of the tester and test the transmitter several times Does the signal strength display STRONG All Yes Go To 4 No Replace the transmitter Perform BODY VERIFICATION TEST VER 1 4 With the DRBIII select BODY BODY COMPUTER MISCELLANEOUS then PROGRAM RKE Follow instructions on the screen Exit PROGRAM RKE Try the Door Locks using the Transmitter Did the Door Locks ...

Page 3084: ...e testing With the DRBIII enter BODY BODY COMPUTER MISCELLANEOUS then RKE FOB TEST and follow the instructions on the DRB Did the substitute RKE Transmitter respond correctly All No Replace the Remote Keyless Entry RKE Module and reprogram all vehicle transmitters following the instructions on the DRBIII Perform BODY VERIFICATION TEST VER 1 Yes Replace the RKE transmitter and reprogram all others ...

Page 3085: ...To 2 No Refer to symptom HORNS FAIL TO SOUND in the VEHICLE THEFT SECURITY SYSTEM category Perform BODY VERIFICATION TEST VER 1 2 With the DRBIII enter Body Computer Miscellaneous then RKE Horn Chirp and observe the horn chirp status Does the DRBIII display HORN CHIRP DISABLED All Yes With the DRBIII enable the Horn Chirp Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perf...

Page 3086: ... CONVERTIBLE TOP SWITCH SHORT TO BATTERY BODY CONTROL MODULE CONVERTIBLE TOP SWITCH MUX OPEN TEST ACTION APPLICABILITY 1 With the DRBIII erase DTCs Turn the ignition on Operate the power top in all positions including the 4 window drop position With the DRBIII read DTCs Does the DRBIII display POWER TOP SWITCH OPEN OR SHORTED TO BATTERY All Yes Go To 2 No Using the wiring diagram schematic as a gu...

Page 3087: ... Go To 5 5 Disconnect the Power Top Switch connector Using a 12 volt test light connected to 12 volts check the Ground circuit in the Power Top Switch connector Does the test light illuminate brightly All Yes Go To 6 No Repair the Ground circuit for an open Perform BODY VERIFICATION TEST VER 1 6 Disconnect the Body Control Module C4 connector Disconnect the Power Top Switch connector Measure the r...

Page 3088: ...TCs Does the DRBIII display POWER TOP SWITCH SHORTED TO GROUND All Yes Go To 2 No Using the wiring diagram schematic as a guide inspect the wiring and connectors for a possible intermittent short to ground Perform BODY VERIFICATION TEST VER 1 2 Disconnect the Power Top Switch connector With the DRBIII erase DTCs Cycle the ignition switch from OFF to ON With the DRBIII read DTCs Does the DRBIII dis...

Page 3089: ...ON APPLICABILITY 4 If there are no possible causes remaining view repair All Repair Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 427 POWER TOP POWER TOP SWITCH SHORTED TO GROUND Continued ...

Page 3090: ...CTION APPLICABILITY 1 With the DRBIII erase DTCs Turn the ignition on Operate the power top in all positions including the 4 window drop position With the DRBIII read DTCs Does the DRBIII display POWER TOP SWITCH STUCK All Yes Go To 2 No Check the switch for a possible sticking condition Using the wiring diagram schematic as a guide inspect the wiring and connectors for a possible intermittent sho...

Page 3091: ...ertible Top Switch Mux circuit Is the resistance below 100 0 ohms All Yes Repair the Convertible Top Switch Mux wire for a short to ground Perform BODY VERIFICATION TEST VER 1 No Go To 4 4 If there are no possible causes remaining view repair All Repair Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 429 POWER TOP POWER TOP SWITCH STUCK Continued ...

Page 3092: ...y Perform BODY VERIFICATION TEST VER 1 2 Prepare the vehicle for the top to operate With the DRBIII read the CONVERT TOP SW voltage Press the Top Switch to the second detent and observe the voltage Is the voltage between 1 6 and 2 2 volts when the switch is pressed All Yes Go To 3 No Replace the Power Top Switch Perform BODY VERIFICATION TEST VER 1 3 Disconnect the Window Drop Relay Assembly conne...

Page 3093: ...rcuit for an open Perform BODY VERIFICATION TEST VER 1 5 Disconnect the Body Control Module C4 connector Turn the ignition on Momentarily connect a jumper wire between ground and the Window Down Relay Control circuit in the BCM C4 connector Did all four windows go down when the wire was grounded All Yes Go To 6 No Replace the Window Drop Relay Assembly Perform BODY VERIFICATION TEST VER 1 6 If the...

Page 3094: ...h the DRBIII record and erase DTC s Cycle the ignition switch from ON to OFF With the DRBIII read DTC s Operate the Decklid Cylinder Lock Switch several times while monitoring the DRBIII Does the DRBIII display DECKLID SWITCH DISARM FAILURE All Yes Go To 2 No The condition that caused this symptom is currently not present Using the wiring diagram schematic as a guide inspect the related wiring har...

Page 3095: ... Cylinder Lock Switch Perform VTSS VERIFICATION TEST 1A No Go To 4 4 Disconnect the Body Control Module C4 harness connector Disconnect the Decklid Cylinder Lock Switch harness connector Measure the resistance of the Sense circuit Is the resistance below 5 0 ohms All Yes Replace the Body Control Module Perform VTSS VERIFICATION TEST 1A No Repair the Decklid Security Switch Sense circuit for an ope...

Page 3096: ...SS Cause state Were there any causes displayed All Yes Check for a possible intermittent condition with the circuit indicated by the DRBIII No The condition that caused this symptom is currently not present Inspect the related wiring harness for a possible intermittent condition Look for any chafed pierced pinched or partially broken wires 434 VEHICLE THEFT SECURITY ...

Page 3097: ...ODULE INTERNAL MALFUNCTION TEST ACTION APPLICABILITY 1 Turn the Courtesy Lamps on Do the Courtesy Lamps operate properly All Yes Replace the Body Control Module Perform VTSS VERIFICATION TEST 1A No Refer to symptom COURTESY LAMPS INOPERATIVE ALL LAMPS in the INTERIOR LIGHTING category 435 VEHICLE THEFT SECURITY ...

Page 3098: ...SS POSSIBLE CAUSES DOOR SWITCH FAILURE TEST ACTION APPLICABILITY 1 For this failure proceed with diagnosis All For this condition Refer to symptom DOOR CENTRAL LOCK UNLOCK SWITCH FAILURE in the POWER DOOR LOCKS RKE CATAGORY 436 VEHICLE THEFT SECURITY ...

Page 3099: ...h while actuating the Headlamp Delay Relay All Yes Replace the Body Control Module No Go To 3 3 Remove the Headlamp Delay Relay from the J unction Block Temporarily remove the Horn Relay from the J unction Block Reinstall the Horn Relay in place of the Headlamp Delay Relay With the DRBIII actuate the Headlamp Delay Relay Do the Headlamps flash while actuating the Headlamp Delay Relay All Yes Repla...

Page 3100: ... 0 volts All Yes Go To 6 No Replace the J unction Block Perform VTSS VERIFICATION TEST 1A 6 Disconnect the jumper wire Reinstall the Headlamp Delay Relay in the J unction Block Remove the BCM from the junction block Measure the voltage of the Headlamp Delay Relay Control circuit cavity 5 in the BCM internal connector Is the voltage above 10 0 volts All Yes Replace the Body Control Module Perform V...

Page 3101: ... diagnosis All Horn Functional Test Go To 2 2 With the DRBIII actuate the HORN RELAY Do the Horns sound while actuating the Horn Relay All Yes Go To 3 No Refer to HORNS FAIL TO SOUND symptom in the VTSS cat agory 3 With the DRBIII in Inputs Outputs read the following Door Decklid Ajar Switch states DRV DR AJ AR SW PAS DR AJ AR SW LR DR AJ AR SW 4 Door RR DR AJ AR SW 4 Door DECKLID AJ AR SW Do the ...

Page 3102: ... TEST ACTION APPLICABILITY 1 With the DRBIII read the DRV DR AJ AR SW status Open the driver door Does the DRBIII display CLOSED All Yes Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 No Refer to symptom DRIVER DOOR AJ AR CKT OPEN in the DOOR AJ AR category 440 VEHICLE THEFT SECURITY ...

Page 3103: ... TEST ACTION APPLICABILITY 1 With the DRBIII read the LR DR AJ AR SW status Open the left rear door Does the DRBIII display CLOSED All Yes Replace the Body Control Module Perform VTSS VERIFICATION TEST 1A No Refer to symptom LEFT REAR DOOR AJ AR CKT OPEN in the DOOR AJ AR category 441 VEHICLE THEFT SECURITY ...

Page 3104: ... TEST ACTION APPLICABILITY 1 With the DRBIII read the PAS DR AJ AR SW status Open the passenger door Does the DRBIII display CLOSED All Yes Replace the Body Control Module Perform VTSS VERIFICATION TEST 1A No Refer to symptom PASSENGER DOOR AJ AR CKT OPEN in the DOOR AJ AR category 442 VEHICLE THEFT SECURITY ...

Page 3105: ... TEST ACTION APPLICABILITY 1 With the DRBIII read the RR DR AJ AR SW status Open the right rear door Does the DRBIII display CLOSED All Yes Replace the Body Control Module Perform VTSS VERIFICATION TEST 1A No Refer to symptom RIGHT REAR DOOR AJ AR CKT OPEN in the DOOR AJ AR category 443 VEHICLE THEFT SECURITY ...

Page 3106: ... fuse open All Yes Inspect repair the Fused B circuit for a short to ground Replace the Fuse Perform VTSS VERIFICATION TEST 1A No Go To 3 3 Reinstall Fuse 7 in the J unction Block Gain access to the J unction Block connector C7 While back probing measure the voltage of the Fused B circuit at the J unction Block connector C7 Is the voltage above 10 0 volts All Yes Go To 4 No Replace the J unction B...

Page 3107: ...tion on With the DRB in Vehicle Theft actuate the VTSS Indicator lamp Is the voltage above 10 0 volts when the VTSS Indicator lamp is actuated All Yes Replace the Instrument Cluster assembly Perform VTSS VERIFICATION TEST 1A No Go To 7 7 Disconnect the Instrument Cluster harness connector Disconnect the BCM C1 harness connector Measure the resistance of the VTSS Indicator Driver circuit between th...

Page 3108: ...TEST ACTION APPLICABILITY 1 With the DRBIII read the DECKLID AJ AR SW status Open the decklid Does the DRBIII display CLOSED All Yes Replace the Body Control Module Perform VTSS VERIFICATION TEST 1A No Refer to symptom DECKLID DOOR AJ AR CKT OPEN in the DOOR AJ AR category 446 VEHICLE THEFT SECURITY ...

Page 3109: ...m is enabled Was the Theft Alarm enabled All Yes Go To 2 No With the DRBIII enable the Vehicle Theft Security System VTSS Perform VTSS VERIFICATION TEST 1A 2 With the DRBIII read the active DTC s Are any VTSS related DTC s present All Yes Refer to the Symptom List and diagnose the appropriate symp tom No Replace the Body Control Module Perform VTSS VERIFICATION TEST 1A 447 VEHICLE THEFT SECURITY ...

Page 3110: ...om is currently not present Inspect the related wiring for a possible intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the HI LO Wiper Relay Disconnect the BCM from the junction block Measure the voltage of the HI LO Wiper Relay Control Circuit Is the voltage below 5 0 volts All Yes Repair t...

Page 3111: ...he related wiring for a possible intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Disconnect the BCM from the junction block Connect a jumper wire between the HI LO Wiper Relay Control Circuit and ground With the DRBIII monitor the wiper relay Does the Wiper Relay show CLOSED All Yes Repair the HI LO Wiper Relay Control Cir...

Page 3112: ...e HI LO Wiper Relay Turn the wipers on Do the Wipers operate normally All Yes Replace the Wiper HI LO Relay Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 450 WINDSHIELD WIPER WASHER WIPER ON OFF RELAY OUTPUT SHORTED LOW Continued ...

Page 3113: ...DRBIII read the DTC information Does the DRBIII read Wiper Park Switch Open Circuit All Yes Go To 2 No The condition that caused the symptom is currently not present Inspect the related wiring for a possible intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Disconnect the BCM C3 harness connector Connect a jumper wire betwee...

Page 3114: ...short to voltage Perform BODY VERIFICATION TEST VER 1 4 Turn the Wipers off Disconnect the Wiper Motor Connector With the DRBIII monitor the Wiper Park Switch Connect a jumper wire between the Wiper Park Switch Sense Circuit and ground Does the Wiper Park Switch show CLOSED All Yes Replace the Wiper Motor Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICA...

Page 3115: ...No The condition that caused the symptom is currently not present Inspect the related wiring for a possible intermittent condition Look for any chafed pierced pinched or partially broken wires Perform BODY VERIFICATION TEST VER 1 2 Turn the ignition off Disconnect the J unction Block Harness Connector from the front of the junction block Disconnect the Wiper Park Switch harness connector Remove th...

Page 3116: ...nector Measure the resistance of the Wiper Switch MUX Circuit Is the resistance below 5 0 ohms All Yes Replace the Wiper Switch Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 454 WINDSHIELD WIPER WASHER WIPER PARK SWITCH SHORTED TO GROUND Continued ...

Page 3117: ...e of the Fused B Circuit Is the voltage above 10 0 volts All Yes Go To 3 No Repair the Fused B Circuit for an open condition Perform BODY VERIFICATION TEST VER 1 3 Turn the ignition off Disconnect the Headlamp Washer Relay Disconnect the BCM C3 harness connector Measure the resistance of the Headlamp Washer Relay Control Circuit Is the resistance below 5 0 ohms All Yes Go To 4 No Repair the Headla...

Page 3118: ...mp Washer Pump Motor Perform BODY VERIFICATION TEST VER 1 No Go To 6 6 Turn the ignition off Install a known good relay in place of the Headlamp Washer Relay Turn the Washers on Do the Headlamp Washers operate normally All Yes Replace the Headlamp Washer Relay Perform BODY VERIFICATION TEST VER 1 No Replace the Body Control Module Perform BODY VERIFICATION TEST VER 1 456 WINDSHIELD WIPER WASHER HE...

Page 3119: ...tor 9 Road test the vehicle With the DRBIII monitor the engine RPM Make 15 to 20 1 2 2 3 3 4 upshifts Perform these shifts from a standing start to 45 MPH with a constant throttle opening of 20 to 25 degrees 10 Below 25 MPH make 5 to 8 wide open throttle kickdowns to 1st gear Allow at least 5 seconds each in 2nd and 3rd gear between each kickdown 11 For a specific DTC drive the vehicle to the Symp...

Page 3120: ...esent or is the original concern still present All Yes Repair is not complete refer to appropriate symptom No Repair is complete BODY VERIFICATION TEST VER 1 APPLICABILITY 1 Disconnect all jumper wires and reconnect all previously disconnected components and connectors 2 NOTE If the SKIM or PCM w as replaced refer to the service information for proper programming procedures 3 If the Body Control M...

Page 3121: ... not complete refer to appropriate symptom No Repair is complete SKIS VERIFICATION APPLICABILITY 1 Reconnect all previously disconnected components and connectors 2 Obtain the vehicle s unique Personal Identification Number PIN assigned to it s original SKIM This number can be obtained from the vehicle s invoice or Chrysler s Customer Center 1 800 992 1997 3 NOTE When entering the PIN care should ...

Page 3122: ...nts except the Battery 2 WARNING TO AVOID PERSONAL INJURY OR DEATH TURN THE IGNITION ON THEN RECONNECT THE BATTERY 3 Connect the DRBIII to the Data Link Connector use the most current software available 4 Use the DRBIII and erase the stored codes in all airbag system modules 5 Turn the ignition off and wait 15 seconds then turn the ignition on 6 Wait one minute and read active codes and if there a...

Page 3123: ...8 0 COMPONENT LOCATIONS 8 1 AIRBAG SYSTEM 8 1 1 BASE SYSTEM 8 1 2 PREMIUM SYSTEM C O M P O N E N T L O C A T I O N S 461 COMPONENT LOCATIONS ...

Page 3124: ...4 Door Models Convertible Models 8 2 HVAC UNIT C O M P O N E N T L O C A T I O N S 462 COMPONENT LOCATIONS 8 1 AIRBAG SYSTEM Continued ...

Page 3125: ...8 3 POWER DOOR LOCKS RKE 8 3 1 DRIVER CYLINDER LOCK SWITCH 8 3 2 DECKLID RELEASE SOLENOID 8 3 3 REMOTE KEYLESS ENTRY MODULE C O M P O N E N T L O C A T I O N S 463 COMPONENT LOCATIONS ...

Page 3126: ...8 4 POWER TOP 8 4 1 POWER TOP RELA Y 8 4 2 WINDOW DROP RELA Y ASSEMBL Y C O M P O N E N T L O C A T I O N S 464 COMPONENT LOCATIONS ...

Page 3127: ...8 5 VEHICLE THEFT SECURITY SYSTEM 8 5 1 DECKLID CYLINDER LOCK SWITCH C O M P O N E N T L O C A T I O N S 465 COMPONENT LOCATIONS ...

Page 3128: ...NOTES 466 ...

Page 3129: ...UTPUT 3 E17 18YL BK DAY BRIGHTNESS SENSE 4 E2 20OR PANEL LAMPS DRIVER 5 C21 20DB OR A C SWITCH SENSE 6 C58 20RD TN A C MODE SWITCH MUX 7 F11 20RD WT FUSED IGNITION SWITCH OUTPUT OFF RUN START 8 C82 20YL OR TEMPERATURE SELECT SIGNAL A C HEA TER CONTROL C2 MTC BLACK 10 WA Y CAV CIRCUIT FUNCTION 1 2 C4 16TN LOW BLOWER MOTOR DRIVER 3 C6 14LB M2 BLOWER MOTOR DRIVER 4 5 Z119 14BK GY GROUND 6 7 C5 16LG M...

Page 3130: ...R SQUIB 1 LINE 2 7 R55 20LG DG DRIVER SEAT BELT TENSIONER LINE 1 8 R53 20LG YL DRIVER SEAT BELT TENSIONER LINE 2 9 R61 20OR LB DRIVER SQUIB 2 LINE 1 10 R63 20TN LB DRIVER SQUIB 2 LINE 2 11 R43 20BK LB DRIVER SQUIB 1 LINE 1 12 R45 20DG LB DRIVER SQUIB 1 LINE 2 13 14 F14 20LG YL FUSED IGNITION SWITCH OUTPUT RUN START 15 F23 20DB YL FUSED IGNITION SWITCH OUTPUT RUN 16 Z100 18BK GROUND 17 18 19 20 21 ...

Page 3131: ... PASSENGER SEAT BELT TENSIONER LINE 1 4 R54 20LB YL PASSENGER SEAT BELT TENSIONER LINE 2 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 R77 20LB BR LEFT CURTAIN SQUIB 1 LINE 2 26 R75 20LB OR LEFT CURTAIN SQUIB 1 LINE 1 27 R74 20LB YL RIGHT CURTAIN SQUIB 1 LINE 1 28 R76 20LB WT RIGHT CURTAIN SQUIB 1 LINE 2 29 30 31 32 C O N N E C T O R P I N O U T S 469 CONNECTOR PINOUTS ...

Page 3132: ...QUIB 2 LINE 1 8 R64 20TN YL PASSENGER SQUIB 2 LINE 2 9 10 11 12 R16 20BR LG RIGHT SIDE IMPACT SENSOR 1 GROUND 13 14 15 D25 20VT YL JR27 PCI BUS 15 D25 20VT JR41 PCI BUS 16 F14 20LG YL FUSED IGNITION SWITCH OUTPUT RUN START 17 18 19 20 R15 20LG BR LEFT SIDE IMPACT SENSOR 1 GROUND 21 22 Z100 20BK GROUND 23 24 F23 20DB YL FUSED IGNITION SWITCH OUTPUT RUN 25 R13 20LG TN LEFT SIDE IMPACT SENSOR 1 SIGNA...

Page 3133: ...3 B6 20WT DB RIGHT FRONT WHEEL SPEED SENSOR SIGNAL 34 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 35 36 B4 20LG LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 37 B3 20LG DB LEFT REAR WHEEL SPEED SENSOR SIGNAL 38 39 40 41 42 B1 20YL DB RIGHT REAR WHEEL SPEED SENSOR SIGNAL 43 B2 20YL RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 44 45 B9 20RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUPPLY 46 B8 ...

Page 3134: ...TURAL 5 WA Y CAV CIRCUIT FUNCTION 1 C33 20DB RD BLEND AIR DOOR DRIVER 2 C57 20DB GY SENSOR GROUND 3 C36 20RD WT BLEND DOOR FEEDBACK SIGNAL 4 C26 20PK DB 5 VOLT SUPPLY 5 C34 20DB WT COMMON DOOR DRIVER BLOWER MOTOR BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 C72 12GY ATC BLOWER MOTOR SUPPLY 1 C7 12BK MTC BLOWER MOTOR DRIVER 2 C71 12DB ATC BLOWER MOTOR GROUND 2 C1 12DG MTC FUSED IGNITION SWITCH OUTPUT RUN BL...

Page 3135: ...20BK OR VTSS INDICATOR DRIVER 4 G26 20LB KEY IN IGNITION SWITCH SENSE 5 L177 20WT OR PRE MIUM PARK LAMP RELAY CONTROL 6 P58 20WT EXPORT RKE EXTERNAL ANTENNA 7 P158 20BK EXPORT RKE EXTERNAL ANTENNA 8 C10 20RD TN ATC IN CAR TEMPERATURE SENSOR SIGNAL 9 C38 20DB ATC SUN SENSOR SIGNAL 10 D6 20PK LB EATX SCI RECEIVE TCM 11 C56 20RD LG ATC BLOWER MOTOR CONTROL 12 A31 18BK LB FUSED IGNITION SWITCH OUTPUT ...

Page 3136: ... EXCEPT JR41 BASE PCI BUS SKIM 19 D25 20VT OR PCI BUS MIC 20 D25 20VT YL PCI BUS DLC 21 D25 20VT LG PCI BUS ATC 22 E2 20OR PANEL LAMPS DRIVER 23 C58 20RD TN BASE EXPORT A C MODE SWITCH MUX 23 L109 20WT PREMIUM FUSED IGNITION SWITCH OUTPUT 24 C32 20GY DB RECIRCULATION DOOR DRIVER 25 C33 20DB RD BLEND AIR DOOR DRIVER 26 C35 20DG YL MODE DOOR DRIVER BODY CONTROL MODULE C3 GRA Y 16 WA Y CAV CIRCUIT FU...

Page 3137: ...ER UNLOCK RELAY OUTPUT 14 G38 18GY JR27 GARAGE DOOR OPENER ENABLE 15 P97 20WT DG DRIVER DOOR SWITCH MUX 16 P96 20WT LG PASSENGER DOOR SWITCH MUX 17 Q31 20WT BK JR27 CONVERTIBLE TOP SWITCH MUX 18 G78 18TN BK DECKLID AJAR SWITCH SENSE 19 E2 20OR PANEL LAMPS DRIVER 20 P6 20RD WT JR27 TOP UP RELAY CONTROL 21 G71 20VT YL VTSS DECKLID SECURITY SWITCH SENSE 22 G4 20DB FUEL LEVEL SENSOR SIGNAL 23 P5 20YL ...

Page 3138: ...4 20DB WT 2 C35 20DG YL 3 C33 20DB RD 4 C4 14TN 5 C57 20DB GY 6 C26 20PK DB 7 C7 12BK TN 8 C1 12DG 9 C12 20LG BK 10 C36 20RD WT 11 C37 20YL 12 C5 16LG 13 14 15 C6 16LB 16 C32 20GY DB C200 MTC NA TURAL INSTRUMENT PANEL SIDE CAV CIRCUIT 1 C34 20DB WT 2 C35 20DG YL 3 C33 20DB RD 4 C4 16TN 5 C57 20DB YL 6 C26 20PK DB 7 C7 14BK TN 8 C1 14DG 9 C12 20LG BK 10 C36 18RD WT 11 C37 20YL 12 C5 16LG 13 14 15 C...

Page 3139: ...BK 11 P177 20DB WT 12 P93 22YL BK 13 G75 20TN RD JR27 13 G75 20TN JR41 14 15 16 C310 BROWN LEFT FRONT DOOR SIDE CAV CIRCUIT 1 2 M1 20PK 3 P97 20WT DG 4 P91 22WT BK 4 P91 22WT BK 5 P95 22DB 6 7 Q16 14BR WT 8 Q14 14GY JR27 8 Q18 14GY BK JR41 9 Q37 20OR WT JR27 10 P175 20OR BK 11 P177 20DB WT 12 P93 22YL BK 13 G75 20TN 14 15 16 C O N N E C T O R P I N O U T S 477 CONNECTOR PINOUTS ...

Page 3140: ... 20WT YL JR27 12 C16 20LB YL POWER MIR RORS C311 BLUE LEFT FRONT DOOR SIDE CAV CIRCUIT 1 Q1 14YL JR41 2 Q23 14RD WT JR27 3 Q13 14DB JR27 3 Q17 14DB WT JR41 4 F21 14TN 5 Q26 14VT WT 6 Z314 14BK JR27 6 Z243 14BK JR41 7 Q28 14DG WT EXCEPT JR27 7 Q24 14DG JR27 8 X85 18LG DG 9 X87 18LG VT 10 G73 20LG OR VTSS 11 F20 20WT YL JR27 12 C16 20LB YL POWER MIR RORS CD CHANGER BLACK 8 WA Y CAV CIRCUIT FUNCTION ...

Page 3141: ...K LB GROUND 3 Z123 22BK OR GROUND 4 X3 22BK RD HORN RADIO CONTROL MUX COMPASS MINI TRIP COMPUTER BLACK 6 WA Y CAV CIRCUIT FUNCTION 1 2 D25 20VT RD PCI BUS 3 M1 20PK FUSED B 4 Z104 20BK GROUND 5 F20 20WT FUSED IGNITION SWITCH OUTPUT RUN 6 DA TA LINK CONNECTOR BLACK 16 WA Y CAV CIRCUIT FUNCTION 1 2 D25 20VT YL PCI BUS DLC 3 4 Z305 20BK YL GROUND 5 Z306 20BK VT GROUND 6 7 D21 20PK SCI TRANSMIT 8 F11 ...

Page 3142: ...D AJAR SWITCH SENSE 3 P2 20BK WT DECKLID RELEASE SOLENOID DRIVER DECKLID RELEASE SWITCH BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 P1 20BK WT DECKLID RELEASE SWITCH SENSE 2 Z223 20BK DB GROUND DOME LAMP JR41 BLACK 3 WA Y CAV CIRCUIT FUNCTION 1 2 M1 20PK FUSED B 3 M2 20YL COURTESY LAMPS DRIVER 3 M2 20YL PREMIUM COURTESY LAMPS DRIVER DRIVER AIRBAG SQUIB 1 GRA Y 2 WA Y CAV CIRCUIT FUNCTION 1 R45 20DG LB DRI...

Page 3143: ... DRIVER DOOR LOCK MOTOR AJAR SWITCH BLACK 4 WA Y CAV CIRCUIT FUNCTION 1 G75 20TN DRIVER DOOR AJAR SWITCH SENSE 2 Z314 20BK JR27 GROUND 2 Z243 20BK JR41 GROUND 3 P177 20DB WT DRIVER UNLOCK RELAY OUTPUT 4 P175 20OR BK DRIVER LOCK RELAY OUTPUT DRIVER DOOR LOCK SWITCH NA TURAL 4 WA Y CAV CIRCUIT FUNCTION 1 M1 20PK FUSED B 2 3 Z314 20BK JR27 GROUND 3 Z243 20BK JR41 GROUND 4 P97 20WT DG DRIVER DOOR SWIT...

Page 3144: ...UNCTION 1 Q21 16WT LEFT FRONT WINDOW DRIVER DOWN 2 Q11 16LB DRIVER POWER WINDOW DRIVER UP DRIVER SEA T BELT SOLENOID JR27 EXPORT NA TURAL 2 WA Y CAV CIRCUIT FUNCTION 1 R7 18OR BK DRIVER SEAT BELT SOLENOID CONTROL 2 Z220 18BK GROUND DRIVER SEA T BELT SWITCH JR41 EXCEPT EXPORT GRA Y 2 WA Y CAV CIRCUIT FUNCTION 1 Z237 20BK GROUND 2 G10 20LG RD SEAT BELT SWITCH SENSE C O N N E C T O R P I N O U T S 48...

Page 3145: ...2 WA Y CAV CIRCUIT FUNCTION 1 R53 20LG YL DRIVER SEAT BELT TENSIONER LINE 2 2 R55 20LG DG DRIVER SEAT BELT TENSIONER LINE 1 FRONT WASHER PUMP MOTOR BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 Z216 18BK GROUND 2 V10 18BR FRONT WASHER PUMP MOTOR CONTROL FRONT WIPER MOTOR BLACK 4 WA Y CAV CIRCUIT FUNCTION 1 V55 20TN RD FRONT WIPER PARK SWITCH SENSE 2 Z114 20BK GROUND 3 V3 16BR WT FRONT WIPER LOW SPEED OUTPUT...

Page 3146: ...R JR27 GROUND 2 Z3 16BK JR41 GROUND 3 L101 18RD HEADLAMP ADJUST SIGNAL HEADLAMP WASHER PUMP MOTOR JR41 EXPORT 2 WA Y CAV CIRCUIT FUNCTION 1 V53 14RD YL HEADLAMP WASHER RELAY OUTPUT 2 Z216 14BK GROUND HORN BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 Z307 20BK GROUND 2 X2 20DG RD HORN RELAY OUTPUT IGNITION SWITCH C1 BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 A51 20RD WT FUSED B 2 A81 20DG RD FUSED IGNITION SWITCH ...

Page 3147: ...IRCUIT FUNCTION 1 2 D25 20VT OR PCI BUS MIC 3 D25 20VT RD PCI BUS TRAVELER 4 5 G69 20BK OR VTSS INDICATOR DRIVER 6 7 8 B27 20RD YL TRACTION CONTROL SWITCH SENSE 9 10 Z105 20BK LB GROUND 11 Z106 18BK OR GROUND 12 E2 20OR PANEL LAMPS DRIVER 13 L36 18LG REAR FOG LAMPS REAR FOG LAMP INDICATOR 14 G6 20GY ENGINE OIL PRESSURE SWITCH SENSE 15 F11 20RD WT FUSED IGNITION SWITCH OUTPUT OFF RUN START 16 17 18...

Page 3148: ...C O N N E C T O R P I N O U T S 486 CONNECTOR PINOUTS ...

Page 3149: ...RIGHT LOW BEAM OUTPUT 14 10A X12 18RD WT FUSED IGNITION SWITCH OUTPUT RUN ACC 15 10A INTERNAL FUSED IGNITION SWITCH OUTPUT RUN ACC 16 10A F23 20DB YL FUSED IGNITION SWITCH OUTPUT RUN 17 10A F14 18LG YL FUSED IGNITION SWITCH OUTPUT RUN 17 10A F14 20LG YL FUSED IGNITION SWITCH OUTPUT RUN HEADLAMP DELA Y RELA Y CAV CIRCUIT FUNCTION 1 INTERNAL FUSED B 2 INTERNAL HEADLAMP DELAY RELAY CONTROL 3 INTERNAL...

Page 3150: ...N SIGNAL 6 L33 20LG BR FUSED LEFT HIGH BEAM OUTPUT 7 8 L7 20BK YL HEADLAMP SWITCH OUTPUT 9 L7 20BK BR HEADLAMP SWITCH OUTPUT 10 L39 20LB OR FRONT FOG LAMPS FOG LAMP SWITCH OUTPUT 11 L39 20LB FRONT FOG LAMPS FOG LAMP SWITCH OUTPUT 12 L43 18VT FUSED LEFT LOW BEAM OUTPUT JUNCTION BLOCK C2 10 WA Y CAV CIRCUIT FUNCTION 1 L50 20WT TN ABS BRAKE LAMP SWITCH OUTPUT 2 A7 18RD BK FUSED B 3 L50 16WT TN BRAKE ...

Page 3151: ... 9 A21 16DB FUSED IGNITION SWITCH OUTPUT RUN START 10 L39 18LB FOG LAMP SWITCH OUTPUT 11 12 M1 18PK FUSED B 13 M1 20PK DB FUSED B 14 A31 16BK WT FUSED IGNITION SWITCH OUTPUT RUN ACC 15 Z110 20BK GROUND 16 F14 20LG YL FUSED IGNITION SWITCH OUTPUT RUN START 16 F14 18LG YL JR41 FUSED IGNITION SWITCH OUTPUT RUN START JUNCTION BLOCK C6 WHITE 6 WA Y CAV CIRCUIT FUNCTION 1 A22 12BK OR FUSED IGNITION SWIT...

Page 3152: ...0LB YL HEATED MIRRORS FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 4 C16 20LB OR HEATED MIRRORS FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 5 F21 14TN FUSED IGNITION SWITCH OUTPUT RUN 6 Q1 14YL VT JR41 POWER WINDOW SWITCH FEED 7 Q1 14YL WT JR41 POWER WINDOW SWITCH FEED 8 Q1 14YL TN JR41 POWER WINDOW SWITCH FEED JUNCTION BLOCK C9 WHITE 12 WA Y CAV CIRCUIT FUNCTION 1 F35 16RD POWER SEATS FUSED B 2 F20 20WT F...

Page 3153: ...20BK JR27 GROUND 4 Z312 18BK JR41 PRE MIUM GROUND 5 6 M1 20PK FUSED B JUNCTION BLOCK C11 EXPORT BLACK 8 WA Y CAV CIRCUIT FUNCTION 1 2 L25 20BR FUSED FOG LAMP SWITCH FEED 3 4 5 6 7 8 LEFT CURTAIN AIRBAG SQUIB JR41 YELLOW 2 WA Y CAV CIRCUIT FUNCTION 1 R77 20LB BR LEFT CURTAIN SQUIB 1 LINE 2 2 R75 20LB OR LEFT CURTAIN SQUIB 1 LINE 1 LEFT FOG LAMP EXCEPT JR27 BLACK 2 WA Y CAV CIRCUIT FUNCTION A L39 20...

Page 3154: ...1 X87 20LG VT LEFT INSTRUMENT PANEL SPEAKER 2 X85 20LG DG LEFT INSTRUMENT PANEL SPEAKER LEFT FRONT INSTRUMENT PANEL SPEAKER JR27 PREMIUM BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 X81 18YL BK AMPLIFIED LEFT INSTRUMENT PANEL SPEAKER 2 X83 18YL RD AMPLIFIED LEFT INSTRUMENT PANEL SPEAKER LEFT FRONT INSTRUMENT PANEL SPEAKER JR41 PREMIUM 3 WA Y CAV CIRCUIT FUNCTION 1 X81 18YL BK AMPLIFIED LEFT INSTRUMENT PANE...

Page 3155: ... CIRCUIT FUNCTION 1 L7 18BK YL FUSED PARK LAMP RELAY OUTPUT 2 Z149 18BK GROUND LEFT LICENSE LAMP JR41 EXPORT NA TURAL 2 WA Y CAV CIRCUIT FUNCTION 1 L7 18BK YL FUSED PARK LAMP RELAY OUTPUT 2 Z150 18BK GROUND LEFT PARK TURN SIGNAL LAMP BLACK 3 WA Y CAV CIRCUIT FUNCTION 1 L61 16LG LEFT TURN SIGNAL 2 L7 20BK BR HEADLAMP SWITCH OUTPUT 3 Z148 20BK GROUND C O N N E C T O R P I N O U T S 493 CONNECTOR PIN...

Page 3156: ...INDOW DRIVER UP 2 Q13 14GY JR41 LEFT REAR WINDOW DRIVER UP LEFT REAR POWER WINDOW SWITCH JR41 BLUE 6 WA Y CAV CIRCUIT FUNCTION 1 Q23 14DG LEFT REAR WINDOW DRIVER DOWN 2 Q17 14DB WT MASTER WINDOW SWITCH LEFT REAR UP 3 4 Q27 14RD BK MASTER WINDOW SWITCH LEFT REAR DOWN 5 Q13 14GY LEFT REAR WINDOW DRIVER UP 6 Q1 14YL POWER WINDOW SWITCH FEED LEFT REAR SPEAKER 3 WA Y CAV CIRCUIT FUNCTION 1 X91 18WT BK ...

Page 3157: ...AV CIRCUIT FUNCTION 1 Z149 18BK JR27 GROUND 1 Z150 18BK JR41 GROUND 2 L7 18BK YL FUSED PARK LAMP RELAY OUTPUT LEFT TAIL STOP LAMP GRA Y 3 WA Y CAV CIRCUIT FUNCTION 1 Z149 18BK JR27 GROUND 1 Z150 18BK JR41 GROUND 2 L7 18BK YL FUSED PARK LAMP RELAY OUTPUT 3 L50 18WT TN BRAKE LAMP SWITCH OUTPUT LEFT TAIL TURN SIGNAL LAMP JR41 DODGE GRA Y 3 WA Y CAV CIRCUIT FUNCTION 1 Z150 18BK GROUND 2 L7 18BK YL FUS...

Page 3158: ...JR41 MASTER WINDOW SWITCH LEFT REAR DOWN 4 Q18 14GY BK EXCEPT JR27 MASTER WINDOW SWITCH RIGHT REAR UP 4 Q14 14GY JR27 RIGHT REAR WINDOW DRIVER UP 5 Q1 14YL JR41 POWER WINDOW SWITCH FEED 6 7 Q11 14LB JR27 LEFT FRONT WINDOW DRIVER UP 7 Q11 16LB JR41 LEFT FRONT WINDOW DRIVER UP 8 Q19 14OR YL JR27 MASTER WINDOW SWITCH LEFT FRONT DOWN 8 Q21 16WT JR41 LEFT FRONT WINDOW DRIVER DOWN 9 Q32 14LB OR JR27 MAS...

Page 3159: ...CH C2 BLUE 12 WA Y CAV CIRCUIT FUNCTION 1 L4 16VT WT EXCEPT PREMIUM DIMMER SWITCH LOW BEAM OUTPUT 1 L309 20WT OR PRE MIUM AUTO HEADLAMP RELAY OUTPUT 2 L4 16VT WT DIMMER SWITCH LOW BEAM OUTPUT 3 L3 14RD OR DIMMER SWITCH HIGH BEAM OUTPUT 4 A3 16RD WT FUSED B 5 A3 16RD WT FUSED B 6 L7 16BK YL HEADLAMP SWITCH OUTPUT 7 F33 16PK RD FUSED B 8 E19 20RD PANEL LAMPS DRIVER 9 C57 20DB GY SENSOR GROUND 10 L10...

Page 3160: ... 3 R62 20OR YL PASSENGER SQUIB 2 LINE 1 4 R64 20TN YL PASSENGER SQUIB 2 LINE 2 PASSENGER DOOR LOCK MOTOR AJAR SWITCH BLACK 4 WA Y CAV CIRCUIT FUNCTION 1 G74 20TN RD PASSENGER DOOR AJAR SWITCH SENSE 2 Z315 20BK JR27 GROUND 2 Z242 20BK JR41 GROUND 3 P178 20PK LB PASSENGER UNLOCK RELAY OUTPUT 4 P176 20PK BK PASSENGER LOCK RELAY OUTPUT PASSENGER DOOR LOCK SWITCH NA TURAL 4 WA Y CAV CIRCUIT FUNCTION 1 ...

Page 3161: ...1 Q22 14VT JR27 RIGHT FRONT WINDOW DRIVER DOWN 1 Q22 16VT JR41 RIGHT FRONT WINDOW DRIVER DOWN 2 Q16 14BR WT MASTER WINDOW SWITCH RIGHT FRONT UP 3 4 Q26 14VT WT MASTER WINDOW SWITCH RIGHT FRONT DOWN 5 Q12 14BR JR27 RIGHT FRONT WINDOW DRIVER UP 5 Q12 16BR JR41 RIGHT FRONT WINDOW DRIVER UP 6 F21 14TN JR27 FUSED IGNITION SWITCH OUTPUT RUN 6 Q1 14YL JR41 POWER WINDOW SWITCH FEED PASSENGER SEA T BELT SO...

Page 3162: ...ON 1 X82 18LB VT AMPLIFIED RIGHT FRONT SPEAKER 2 X87 18LG VT AMPLIFIED LEFT FRONT SPEAKER 3 X92 20TN BK AMPLIFIED RIGHT REAR SPEAKER 4 X86 18OR RD AMPLIFIED RIGHT INSTRUMENT PANEL SPEAKER 5 X83 18YL RD AMPLIFIED LEFT INSTRUMENT PANEL SPEAKER 6 X80 18LB BK AMPLIFIED RIGHT FRONT SPEAKER 7 X85 18LG DG AMPLIFIED LEFT FRONT SPEAKER 8 X94 20TN VT AMPLIFIED RIGHT REAR SPEAKER 9 X93 20WT RD AMPLIFIED LEFT...

Page 3163: ... LEFT FRONT SPEAKER 17 X58 20DB OR RIGHT REAR SPEAKER 18 X57 20BR LB LEFT REAR SPEAKER 19 20 21 X91 20WT BK AMPLIFIED LEFT REAR SPEAKER 22 X92 20TN BK AMPLIFIED RIGHT REAR SPEAKER POWER AMPLIFIER C2 JR27 PREMIUM WHITE 18 WA Y CAV CIRCUIT FUNCTION 1 F75 16VT FUSED B 2 3 4 5 X52 20DB WT RIGHT REAR SPEAKER 6 X51 20BR YL LEFT REAR SPEAKER 7 X54 20VT RIGHT FRONT SPEAKER 8 X53 20DG LEFT FRONT SPEAKER 9 ...

Page 3164: ...8YL RD AMPLIFIED LEFT INSTRUMENT PANEL SPEAKER 4 X86 18OR RD AMPLIFIED RIGHT INSTRUMENT PANEL SPEAKER 5 6 7 X85 18LG DG AMPLIFIED LEFT FRONT SPEAKER 8 X80 18LB BK AMPLIFIED RIGHT FRONT SPEAKER 9 X81 18YL BK AMPLIFIED LEFT INSTRUMENT PANEL SPEAKER 10 X84 18OR BK AMPLIFIED RIGHT INSTRUMENT PANEL SPEAKER 11 12 C O N N E C T O R P I N O U T S 502 CONNECTOR PINOUTS ...

Page 3165: ...C O N N E C T O R P I N O U T S 503 CONNECTOR PINOUTS ...

Page 3166: ...D SEATS FUSED IGNITION SWITCH OUTPUT RUN START 24 20A F42 16DG LG 2 7L FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 25 20A F142 16OR DG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT FRONT WIPER HIGH LOW RELA Y CAV CIRCUIT FUNCTION 45 V16 20VT PK FRONT WIPER HIGH LOW RELAY CONTROL 46 V3 16BR WT FRONT WIPER LOW SPEED OUTPUT 47 F13 20DB FUSED IGNITION SWITCH OUTPUT RUN ACC 48 V4 16RD YL FRONT WIPER HIGH SPEED OUT...

Page 3167: ...ON SWITCH OUTPUT RUN START 68 P86 16PK BK HEATED SEAT RELAY OUTPUT 69 F235 16RD FUSED B REAR FOG LAMP RELA Y JR27 EXPORT CAV CIRCUIT FUNCTION 55 L36 18LG REAR FOG LAMP CONTROL 56 57 Z247 18BK GROUND 58 L95 18DG YL REAR FOG LAMP RELAY OUTPUT 59 A7 16RD BK FUSED B C O N N E C T O R P I N O U T S 505 CONNECTOR PINOUTS ...

Page 3168: ...L BK FUSED IGNITION SWITCH OUTPUT RUN 2 Z249 20BK GROUND 3 Q31 20OR DB CONVERTIBLE TOP SWITCH MUX POWER TOP UP DOWN RELA YS JR27 6 WA Y CAV CIRCUIT FUNCTION A P6 20RD WT TOP UP RELAY CONTROL B P3 12YL TOP UP RELAY OUTPUT C A25 12DB FUSED B D Z253 12BK GROUND E P4 12RD TOP DOWN RELAY OUTPUT F P5 20YL BK TOP DOWN RELAY CONTROL C O N N E C T O R P I N O U T S 506 CONNECTOR PINOUTS ...

Page 3169: ... 22 23 24 25 D20 20LG SCI RECEIVE PCM 26 D6 20PK LB EATX SCI RECEIVE TCM 27 K7 18OR MTX EXPORT 5 VOLT SUPPLY 28 K62 18BK OR 2 4L PZEV AIR PUMP MOTOR RELAY CONTROL 29 A14 16RD TN FUSED B 30 A41 16YL FUSED IGNITION SWITCH OUTPUT START 31 K141 20TN WT 2 7L O2 SENSOR 1 2 SIGNAL 32 K904 18DB DG O2 RETURN DOWN 33 K341 20PK WT 2 7L O2 SENSOR 2 2 SIGNAL 34 35 36 D21 20PK SCI TRANSMIT PCM 37 D15 20WT DG EA...

Page 3170: ... CONTROL 19 T16 20RD TRANSMISSION CONTROL RELAY OUTPUT 20 21 22 T9 20OR BK OD PRESSURE SWITCH SENSE 23 24 25 26 27 T41 20BK WT TRS T41 SENSE 28 T16 20RD TRANSMISSION CONTROL RELAY OUTPUT 29 T50 20DG L R PRESSURE SWITCH SENSE 30 T47 20YL 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 SENSOR GROUND 35 T54 20VT Y...

Page 3171: ... PANEL SPEAKER 11 Z1 18BK GROUND 12 M1 20PK FUSED B 13 X60 20DG RD EXCEPT JR27 BASE RADIO 12V OUTPUT 14 D25 20VT YL PCI BUS RADIO 15 16 17 18 X51 20BR YL LEFT REAR SPEAKER 19 X57 20BR LB LEFT REAR SPEAKER 20 X58 20DB OR RIGHT REAR SPEAKER 21 X52 20DB WT RIGHT REAR SPEAKER 22 RADIO C2 BLACK 10 WA Y CAV CIRCUIT FUNCTION 1 X40 22GY WT AUDIO OUT RIGHT 2 Z4 22BK OR GROUND 3 C235 WT LB CD GROUND SHIELD ...

Page 3172: ...1 LINE 1 RIGHT FRONT DOOR SPEAKER BLACK 3 WA Y CAV CIRCUIT FUNCTION 1 X80 18LB BK BASE RIGHT FRONT SPEAKER 1 X80 18LB BK PREMIUM AMPLIFIED RIGHT FRONT SPEAKER 2 3 X82 18LB VT BASE RIGHT FRONT SPEAKER 3 X82 18LB VT PREMIUM AMPLIFIED RIGHT FRONT SPEAKER RIGHT FRONT INSTRUMENT PANEL SPEAKER JR27 BASE WHITE 2 WA Y CAV CIRCUIT FUNCTION 1 X82 20LB VT RIGHT INSTRUMENT PANEL SPEAKER 2 X80 20LB BK RIGHT IN...

Page 3173: ...18OR RD AMPLIFIED RIGHT INSTRUMENT PANEL SPEAKER RIGHT HEADLAMP EXCEPT EXPORT BLACK 3 WA Y CAV CIRCUIT FUNCTION 1 L44 20VT RD FUSED RIGHT LOW BEAM OUTPUT 2 Z142 20BK GROUND 3 L34 18RD OR FUSED RIGHT HIGH BEAM OUTPUT RIGHT LA VALIER MODULE EXPORT BLACK 6 WA Y CAV CIRCUIT FUNCTION 1 Z162 16BK GROUND 2 L101 18RD HEADLAMP ADJUST SIGNAL 3 L34 18RD OR FUSED RIGHT HIGH BEAM OUTPUT 4 L60 20TN RIGHT TURN S...

Page 3174: ...K GROUND RIGHT PARK TURN SIGNAL LAMP BLACK 3 WA Y CAV CIRCUIT FUNCTION 1 L60 20TN RIGHT TURN SIGNAL 2 L7 20BK YL HEADLAMP SWITCH OUTPUT 3 Z147 20BK GROUND RIGHT REAR DOOR LOCK MOTOR AJAR SWITCH JR41 BLACK 4 WA Y CAV CIRCUIT FUNCTION 1 G76 20TN YL RIGHT REAR DOOR AJAR SWITCH SENSE 2 Z318 18BK GROUND 3 P182 18PK DB RIGHT REAR UNLOCK RELAY OUTPUT 4 P180 18OR TN RIGHT REAR LOCK RELAY OUTPUT C O N N E ...

Page 3175: ...NDOW MOTOR BLACK 2 WA Y CAV CIRCUIT FUNCTION 1 Q24 14DG RIGHT REAR WINDOW DRIVER DOWN 2 Q14 14GY RIGHT REAR WINDOW DRIVER UP RIGHT REAR POWER WINDOW SWITCH JR41 BLUE 6 WA Y CAV CIRCUIT FUNCTION 1 Q24 14DG RIGHT REAR WINDOW DRIVER DOWN 2 Q18 14GY BK MASTER WINDOW SWITCH RIGHT REAR UP 3 4 Q28 14DG WT MASTER WINDOW SWITCH RIGHT REAR DOWN 5 Q14 14GY RIGHT REAR WINDOW DRIVER UP 6 Q1 14YL POWER WINDOW S...

Page 3176: ...NTROL MUX 2 Z123 22BK OR GROUND RIGHT SIDE IMPACT SENSOR 1 GRA Y 2 WA Y CAV CIRCUIT FUNCTION 1 R16 20BK LG RIGHT SIDE IMPACT SENSOR 1 GROUND 2 R14 20TN LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL RIGHT TAIL SIDE MARKER LAMP 2 WA Y CAV CIRCUIT FUNCTION 1 Z151 18BK GROUND 2 L7 18BK YL FUSED PARK LAMP RELAY OUTPUT RIGHT TAIL STOP LAMP GRA Y 3 WA Y CAV CIRCUIT FUNCTION 1 Z151 18BK GROUND 2 L7 18BK YL FUSED P...

Page 3177: ...K GROUND SENTRY KEY IMMOBILIZER MODULE BLACK 6 WA Y CAV CIRCUIT FUNCTION 1 2 D25 20VT PK PCI BUS SKIM 3 4 F12 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 5 Z110 20BK GROUND 6 A51 20RD WT FUSED B SUN SENSOR A TC BLACK 4 WA Y CAV CIRCUIT FUNCTION 1 2 3 C57 20DB GY SENSOR GROUND 4 C38 20DB SUN SENSOR SIGNAL TRACTION CONTROL SWITCH 2 WA Y CAV CIRCUIT FUNCTION 1 Z2 20BK LG GROUND 2 B27 20RD YL TRACT...

Page 3178: ...TER WINDOW SWITCH RIGHT REAR DOWN 5 F20 20WT FUSED IGNITION SWITCH OUTPUT RUN 6 Q37 20OR WT WINDOW DROP RELAY CONTROL 7 Q21 14WT LEFT FRONT WINDOW DRIVER DOWN 8 Q23 14RD WT LEFT REAR WINDOW DRIVER DOWN 9 Q26 14VT WT WINDOW DROP RELAY RIGHT FRONT DOWN 10 Q24 14DG RIGHT REAR WINDOW DRIVER DOWN 11 F21 14TN FUSED IGNITION SWITCH OUTPUT RUN 12 F21 14TN FUSED IGNITION SWITCH OUTPUT RUN C O N N E C T O R...

Page 3179: ...10 0 SCHEMATIC DIAGRAMS 10 1 AIRBAG SYSTEMS 10 1 1 BASE S C H E M A T I C D I A G R A M S 517 SCHEMATIC DIAGRAMS ...

Page 3180: ...10 1 2 PREMIUM S C H E M A T I C D I A G R A M S 518 SCHEMATIC DIAGRAMS 10 1 AIRBAG SYSTEMS Continued ...

Page 3181: ...10 2 AUDIO SYSTEM 10 2 1 BASE RADIO JR41 S C H E M A T I C D I A G R A M S 519 SCHEMATIC DIAGRAMS ...

Page 3182: ...10 2 2 BASE RADIO JR27 S C H E M A T I C D I A G R A M S 520 SCHEMATIC DIAGRAMS 10 2 AUDIO SYSTEM Continued ...

Page 3183: ...10 2 3 PREMIUM SYSTEM JR41 S C H E M A T I C D I A G R A M S 521 SCHEMATIC DIAGRAMS ...

Page 3184: ...10 2 4 PREMIUM SYSTEM JR27 S C H E M A T I C D I A G R A M S 522 SCHEMATIC DIAGRAMS 10 2 AUDIO SYSTEM Continued ...

Page 3185: ...10 2 5 CD CHANGER 10 2 6 REMOTE RADIO CONTROLS S C H E M A T I C D I A G R A M S 523 SCHEMATIC DIAGRAMS ...

Page 3186: ...10 3 CHIME SYSTEM 10 4 COMPASS MINI TRIP COMPUTER CMTC S C H E M A T I C D I A G R A M S 524 SCHEMATIC DIAGRAMS ...

Page 3187: ...10 5 DOOR AJAR S C H E M A T I C D I A G R A M S 525 SCHEMATIC DIAGRAMS ...

Page 3188: ...10 6 ELECTRICALL Y HEA TED SYSTEMS 10 6 1 HEA TED SEA T RELA Y 10 6 2 REAR WINDOW DEFOGGER AUTOMA TIC TEMPERA TURE CONTROL S C H E M A T I C D I A G R A M S 526 SCHEMATIC DIAGRAMS ...

Page 3189: ...10 6 3 REAR WINDOW DEFOGGER MANUAL TEMPERA TURE CONTROL S C H E M A T I C D I A G R A M S 527 SCHEMATIC DIAGRAMS ...

Page 3190: ...10 7 EXTERIOR LIGHTING HEADLAMPS S C H E M A T I C D I A G R A M S 528 SCHEMATIC DIAGRAMS ...

Page 3191: ...10 8 HEA TING AND A C 10 8 1 AUTOMA TIC TEMPERA TURE CONTROL A TC S C H E M A T I C D I A G R A M S 529 SCHEMATIC DIAGRAMS ...

Page 3192: ...10 8 2 MANUAL TEMPERA TURE CONTROL MTC S C H E M A T I C D I A G R A M S 530 SCHEMATIC DIAGRAMS 10 8 HEA TING AND A C Continued ...

Page 3193: ...10 9 IGNITION POWER ACCESSORY HORN SYSTEM S C H E M A T I C D I A G R A M S 531 SCHEMATIC DIAGRAMS ...

Page 3194: ...10 10 INTERIOR LIGHTING 10 10 1 COURTESY LAMPS 10 10 2 PANEL LAMPS S C H E M A T I C D I A G R A M S 532 SCHEMATIC DIAGRAMS ...

Page 3195: ...10 11 MECHANICAL INSTRUMENT CLUSTER S C H E M A T I C D I A G R A M S 533 SCHEMATIC DIAGRAMS ...

Page 3196: ...10 12 POWER DOOR LOCKS RKE S C H E M A T I C D I A G R A M S 534 SCHEMATIC DIAGRAMS ...

Page 3197: ...10 13 POWER TOP 10 13 1 CONVERTIBLE TOP S C H E M A T I C D I A G R A M S 535 SCHEMATIC DIAGRAMS ...

Page 3198: ...10 13 2 POWER TOP 4 WINDOW DROP S C H E M A T I C D I A G R A M S 536 SCHEMATIC DIAGRAMS 10 13 POWER TOP Continued ...

Page 3199: ...10 14 VEHICLE COMMUNICA TION 10 14 1 PCI BUS COMMUNICA TION S C H E M A T I C D I A G R A M S 537 SCHEMATIC DIAGRAMS ...

Page 3200: ...10 14 3 PCM COMMUNICA TION S C H E M A T I C D I A G R A M S 538 SCHEMATIC DIAGRAMS 10 14 VEHICLE COMMUNICA TION Continued ...

Page 3201: ...10 15 VEHICLE THEFT SECURITY SYSTEM S C H E M A T I C D I A G R A M S 539 SCHEMATIC DIAGRAMS ...

Page 3202: ...10 16 WIPER SYSTEM 10 16 1 WIPER SWITCH 10 16 2 FRONT WIPERS S C H E M A T I C D I A G R A M S 540 SCHEMATIC DIAGRAMS ...

Page 3203: ...TRANSMITTED IN ANY FORM OR BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION DaimlerChrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products previously manufac tured Cop...

Page 3204: ...nts section that lists major topics within the group If you are not sure which Group contains the information you need look up the Component System in the alphabetical index located in the rear of this manual A Service Manual Comment form is included at the rear of this manual Use the form to provide DaimlerChrysler Corporation with your comments and suggestions Tightening torques are provided as ...

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