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DaimlerChrysler LH New Yorker 1994, Electronic Service Manual


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The number 7 needle bearing has antireversal tabs

and is common with the number 5 and number 2
position. The orientation should allow the bearing to
seat flat against the rear sun gear (Fig. 26). A small
amount of petrolatum can be used to hold the bearing
to the rear sun gear.

Fig. 26 Number 7 Bearing

Fig. 27 Remove 2/4 Clutch Retainer Snap Ring

Fig. 28 Remove 2/4 Clutch Retainer

Fig. 29 Remove 2/4 Clutch Retainer

Fig. 30 Remove 2/4 Clutch Return Spring

21 - 40

TRANSAXLE

Summary of Contents for LH New Yorker 1994

Page 1: ...HOFRPH WR WKH 1HZ RUNHU 6 RQFRUGH QWUHSLG 9LVLRQ DQG 6XSSOHPHQWV OHFWURQLF 6HUYLFH 0DQXDO Click on logo to begin CLICK HERE FOR INSTRUCTIONS...

Page 2: ...erican Petroleum Institute API National Lubricating Grease Institute NLGI ENGINE OIL SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY SAE 30 single grade engine oil SAE 5W 30 multiple grade engine oil...

Page 3: ...re bottle brake master cylinder power steering and transmission Add fluid as needed Check all lights and all other electrical items for correct operation 7 500 MILES 12 000 KM OR AT 6 MONTHS Check eng...

Page 4: ...since last change Check engine coolant hoses and clamps Change engine oil Replace engine oil filter Adjust the belt tension of non automatic tensioning drive belts Check and replace as needed all aut...

Page 5: ...joints and front suspension ball joints 24 000 MILES 38 000KM Change engine oil Replace engine oil filter Inspect CV joints and front suspension ball joints 27 000 MILES 43 000KM Change engine oil Ins...

Page 6: ...n park or neutral and set park brake or equivalent Turn OFF all accessories Keyless Entry system must be turned OFF manually 4 Connect jumper cables to booster battery RED clamp to positive terminal B...

Page 7: ...transaxle can be damaged Secure loose and protruding parts from a disabled vehicle Always use a safety chain system that is indepen dent of the lifting and towing equipment Do not allow any of the tow...

Page 8: ...ny of these apply to you then change your engine oil every 4 800 kilometers 3 000 miles or 3 months whichever comes first If none of these apply to you then change your oil every 12 000 kilometers 7 5...

Page 9: ...atures above 18 C 0 F FLEXIBLE FUEL VEHICLES CAUTION If motor oils that DO NOT meet or exceed MS 9214 are used in engines operated on M85 fuel premature engine failure can result Vehicles operated usi...

Page 10: ...ngine oil or chassis grease 2 Thread filter onto adapter nipple When gasket makes contact with sealing surface tighten filter one full turn If necessary use a filter wrench do not over tighten 3 Add o...

Page 11: ...art in General Information section of this group SELECTING ANTIFREEZE Chrysler Corporation recommends Mopar Antifreeze Summer Coolant or equivalent be used to winterize and protect cooling system PRES...

Page 12: ...cuum circuit PCV system should be inspected at every oil change Service PCV system if engine oil is dis charged into air cleaner PCV SYSTEM TEST Refer to group 25 Emission Control System for proper pr...

Page 13: ...hat blended fuels be used when available METHANOL BLENDS Using gasoline blended with methanol in non flexible fuel engines can result in starting and drive ability problems Deterioration of fuel syste...

Page 14: ...The warmer the transaxle fluid the more accurate the reading 3 While sitting in driver seat apply brakes and place gear selector in each position Return gear se lector to park 4 Raise hood and remove...

Page 15: ...d when other under vehicle service is performed Inspect boots for cracking tears leaks or other defects If service re pair is required refer to Group 2 Suspension WHEEL BEARINGS The wheel bearings are...

Page 16: ...procedures refer to Group 2 Suspension SUSPENSION BALL JOINTS The ball joints are permanently sealed requiring no lubrication For proper diagnostic and service proce dures refer to Group 2 Suspension...

Page 17: ...Refer to General Infor mation section of this group A hose must be replaced if it has signs of cracking chafing fatigue or bulging For proper service procedures refer to Group 5 Brakes BRAKE LINE INSP...

Page 18: ...d oil grease and dirt should be wiped off If necessary use solvent to clean component to be lubricated After lubrication is complete wipe off excess grease or oil During winter season external lock cy...

Page 19: ......

Page 20: ...e part of the isolated top mount The lower end of the MacPherson strut assembly is at tached to the upper leg of the steering knuckle At tachment of the MacPherson strut assembly to the steering knuck...

Page 21: ...Fig 1 L H Platform Front Suspension 2 2 SUSPENSION AND DRIVESHAFTS...

Page 22: ...SUSPENSION STEERING DIAGNOSIS FRONT WHEEL DRIVE SUSPENSION AND DRIVESHAFTS 2 3...

Page 23: ...tegral part of the control arm and has a non tapered stud with a notch for clamp bolt clearance The stud is clamped and locked into the steering knuckle leg with a clamp bolt The ball joint used on th...

Page 24: ...Fig 2 L H Platform Front Suspension SUSPENSION AND DRIVESHAFTS 2 5...

Page 25: ...n internal driveshaft component will require the replacement of the driveshaft assembly FRONT WHEEL ALIGNMENT Front wheel alignment is the proper settings of all the interrelated suspension angles aff...

Page 26: ...are torqued to required specification when Toe setting procedure is completed 4 Tighten tie rod adjustment sleeve locknuts to 75 Nzm 55 ft lbs torque 5 Remove steering wheel clamp STRUT DAMPER ASSEMB...

Page 27: ...re they go through strut as sembly and steering knuckle When removing bolts turn nuts off bolts DO NOT TURN BOLTS IN STEER ING KNUCKLE If bolts are turned damage to steer ing knuckle will result 7 Rem...

Page 28: ...nuts on attaching bolts Fig 5 Torque the strut assembly to steering knuckle attaching bolt nuts to 169 Nzm 125 ft lbs TURN NUTS ON BOLTS DO NOT TURN BOLTS 4 Install braking disc back on front hub and...

Page 29: ...ts in this section of the service manual 2 Position strut assembly in a vise by clamping strut assembly by the steering arm Fig 1 Using paint or equivalent mark the strut unit lower spring isolator sp...

Page 30: ...strut and release strut shaft should return to its fully extended position If strut shaft does not return to its fully extended position replace strut unit STRUT REASSEMBLY 1 Install original or new...

Page 31: ...rated separately for each side of vehicle depending on optional equipment and type of service During service procedures where both springs are removed mark springs Chalk Tape etc Fig 11 to ensure ins...

Page 32: ...on pry bar to separate ball joint stud from steering knuckle Fig 2 Note Use caution when separating ball joint stud from steering knuckle so ball joint seal does not get cut CAUTION Pulling steering...

Page 33: ...150 Nzm 110 ft lbs When torquing tension strut nut keep tension strut from turning by holding tension strut at flat using an open end wrench Fig 3 CAUTION Pulling steering knuckle out from vehicle aft...

Page 34: ...n strut from turning Torque NEW tension strut to lower control retaining nut to 150 Nzm 110 ft lbs 5 Install lower control arm and tension strut as an assembly back on the vehicle See Lower Control Ar...

Page 35: ...nsion strut as an assembly back on the vehicle See Lower Control Arm Installation in this section of the service manual for the required installation procedure 2 Install washer on end of tension strut...

Page 36: ...con trol arm assembly Fig 19 3 Replace tension strut to lower control arm isola tor bushing Refer to Lower Control Arm Bushing Service in this section of the service manual for ten sion strut isolato...

Page 37: ...press 1 Remove lower control arm and tension strut as an assembly from the vehicle See Lower Control Arm Removal in this section of the service manual for the required removal procedure 2 Separate th...

Page 38: ...e vehicle See Lower Control Arm Installation in this section of the service manual for the required installation procedure TENSION STRUT BUSHING REMOVE To perform removal and replacement of the lower...

Page 39: ...the control arm assembly from the arbor press and pull Special Tool 6644 3 off the ten sion strut bushing in the control arm Tension strut bushing is now installed BALL JOINTS The lower front suspensi...

Page 40: ...movements affecting one wheel are partially transmitted to the opposite wheel to stabilize body roll Attachment of stabilizer bar to cradle assembly is through rubber isolated bushings Fig 1 Stabiliz...

Page 41: ...Fig 1 Front Stabilizer Bar And Stabilizer Bar Mounting 2 22 SUSPENSION AND DRIVESHAFTS...

Page 42: ...lizer bar bushing retainers with the mounting holes in the cradle assembly Fig 2 Install but do not tighten the 4 bushing retainer to cradle assembly mounting bolts The 4 retain ing bolts will be torq...

Page 43: ...t Fig 7 Using nylon webbing material such as seat belt material or equivalent mount it to the following loca tions on the 3 5 ltr engine 2 Remove bolt attaching timing belt housing to front of engine...

Page 44: ...joint stud from steering knuckle Fig 11 Note Use caution when separating ball joint stud from steering knuckle so ball joint seal does not get cut CAUTION Pulling steering knuckle out from vehicle aft...

Page 45: ...ansaxle mount until tran saxle mount just lifts off cradle assembly 10 Cradle assembly is now ready to be removed from vehicle using the following procedure A helper will be required when removing cra...

Page 46: ...iners back in vehicle as an assembly Fig 18 Be sure stabilizer bar in installed through openings in splash shields Fig 18 Install the stabilizer bar link to stabilizer bar attaching nuts Torque stabil...

Page 47: ...nts 5 Untie the stabilizer bar from brackets and posi tion it on cradle assembly Align the stabilizer bar bushing retainers with the mounting holes in the cradle assembly Fig 15 Install but do not tig...

Page 48: ...uspension knuckle in any way Service repair or replacement of the front drive hub and bearing can be done with the front suspen sion knuckle remaining on the vehicle REMOVE 1 Raise vehicle on jackstan...

Page 49: ...d MUST be replaced with a new hub and bearing assembly Also if flinger disc Fig 7 becomes damaged bent or dented during removal hub and bearing assembly must be re placed with a new hub and bearing as...

Page 50: ...rate ball joint stud from steering knuckle Fig 11 Note Use caution when sepa rating ball joint stud from steering knuckle so ball joint seal does not get cut CAUTION The strut assembly to steering knu...

Page 51: ...oreign ma terial or nicks CAUTION When installing hub and bearing assem bly into steering knuckle be careful not to damage the flinger disc Fig 7 on hub and bearing assem bly If flinger disc becomes d...

Page 52: ...front brake caliper back over braking disc and align with caliper mounting holes on steer ing knuckle Fig 18 Refer to Front Disc Brake Ser vice in the Brake Section of this service manual for caliper...

Page 53: ...tion and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 2 Remove the front wheel and tire assembly from the vehicle 3 Remove the front caliper assemb...

Page 54: ...uckle Insert a pry bar between hub and bearing assembly and steering knuckle Fig 7 and gently pry hub and bearing from knuckle If stub shaft is frozen to hub and bearing assembly tap end of stub shaft...

Page 55: ...he hub and bearing assembly to stub shaft retaining nut Fig 10 is a prevailing torque nut and can not be re used A NEW retaining nut MUST be used when assembled 3 Install a NEW hub and bearing assembl...

Page 56: ...ns SERVICING WHEEL STUDS The L H platform vehicles use a one piece lubri cated for life hub and bearing assembly CAUTION If wheel attaching stud needs to be re placed in the hub and bearing assembly t...

Page 57: ...er of wheel stud is past flange remove special tool from hub and bearing assembly Remove lug nut from stud and remove wheel stud from flange INSTALL 1 Install replacement wheel stud into flange of hub...

Page 58: ...dure Install the caliper adapter to steering knuckle attaching bolts and torque to 19 Nzm 168 in lbs 5 Install wheel and tire assembly on vehicle Tighten the wheel mounting stud nuts in proper se quen...

Page 59: ...driveshaft has a Tripod Joint an Interconnect ing Shaft and a outer C V joint The Tripod Joint is splined onto the transaxle stub shaft and the outer C V joint has a stub shaft that is splined into t...

Page 60: ...SUSPENSION STEERING DIAGNOSIS FRONT WHEEL DRIVE SUSPENSION AND DRIVESHAFTS 2 41...

Page 61: ...e do not pull on the intercon necting shaft when attempting to remove drive shafts from vehicle SERVICING DRIVESHAFTS REMOVE 1 Raise vehicle on jackstands or centered on a frame contact type hoist See...

Page 62: ...and premature bearing failure 10 Hold outer C V joint assembly with one hand Grasp steering knuckle with other and rotate it out and to the rear of the vehicle until outer C V joint clears hub and be...

Page 63: ...pod joint tripod joint will not move on stub shaft CAUTION When installing outer C V joint into the hub and bearing assembly do not allow the flinger disk Fig 12 on hub and bearing assembly to be come...

Page 64: ...ecurely tighten routing bracket attaching screw Fig 3 10 Install the braking disk back on the hub and bearing assembly Fig 15 11 Install front brake caliper back over braking disc and align with calip...

Page 65: ...e location in the assembly INNER TRIPOD JOINT SEAL BOOT REMOVE To remove sealing boots from driveshafts for re placement the drive shaft assemblies must be re moved from the vehicle See Servicing Driv...

Page 66: ...Fig 1 L H Platform Driveshaft Components SUSPENSION AND DRIVESHAFTS 2 47...

Page 67: ...types of material High temperature ap plications use silicone rubber where as stan dard temperature applications use hytrel plastic The silicone sealing boots are soft and pliable The Hytrel sealing...

Page 68: ...al Tool C 4975 and the following procedure Place crimping tool C 4975 over bridge of clamp Fig 8 Tighten nut on crimping tool C 4975 until jaws on tool are closed completely together face to face Fig...

Page 69: ...placement from vehicle See Servicing Driveshaft in this section of the service manual for the required driveshaft removal procedure 2 Remove large boot clamp retaining C V joint sealing boot to C V j...

Page 70: ...intercon necting shaft Outer C V joint seal boot MUST be positioned on interconnecting shaft so only the thinnest sight groove on interconnecting shaft is visible Fig 4 5 Clamp sealing boot on interc...

Page 71: ...ing using Crimper Special Tool C 4975 and the following procedure Place crimping tool C 4975 over bridge of clamp Fig 8 Tighten nut on crimping tool C 4975 until jaws on tool are closed completely tog...

Page 72: ...n trolled laterally using lateral links going from the front and rear of the spindle to the rear cross mem ber Fore and aft movement of the spindle is con trolled by a trailing arm The lateral links a...

Page 73: ...Fig 1 L H Platform Fully Independent Rear Suspension 2 54 SUSPENSION AND DRIVESHAFTS...

Page 74: ...ink adjustment link locknuts to 65 Nzm 48 ft lbs torque SERVICING REAR STRUTS REMOVAL 1 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting in the Lubrica tion and Maint...

Page 75: ...so point of center punch does not puncture strut assembly 9 Insert a center punch into the hole on the spindle Fig 7 Center punch must be tapped into spindle until jammed into hole This will spread s...

Page 76: ...hing nuts onto mount studs Fig 10 Using a crow foot and 3 8 in torque wrench torque the 3 strut mount to strut tower attaching nuts to 28 Nzm 20 ft lbs 2 Install spindle onto bottom of the strut assem...

Page 77: ...vehicle is equipped with rear drum brakes install rear brake flex hose onto wheel cylinder and support plate Fig 15 First torque brake hose to wheel cylinder tube nut to 17 Nzm 145 in lbs Then torque...

Page 78: ...r spring isolator spring and upper strut mount for indexing of the parts at assembly 3 Position Spring Compressors Special Tool C 4838 on the strut assembly spring Fig 1 Com press coil spring until al...

Page 79: ...1 5 Install the upper strut mount assembly onto the strut shaft aligning paint marks Fig 3 Install the upper strut mount to strut shaft retaining nut on strut shaft 6 Using Strut Rod Socket Special T...

Page 80: ...ontact type hoist See Hoisting in the Lubrica tion and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 2 Remove the rear wheel and tire assembly from...

Page 81: ...spindle Fig 4 Then remove rear brake support plate with parking brake cable at tached from rear spindle 7 If vehicle is equipped with Anti Lock brakes Remove speed sensor head from the rear disc brake...

Page 82: ...enter punch does not puncture strut assembly 13 Insert a center punch into the hole on the spindle Fig 11 Center punch must be tapped into spindle until jammed into hole This will spread spindle casti...

Page 83: ...vehicles equipped with rear drum brakes Install the rear brake support plate onto the spindle Fig 17 Install the 4 bolts attaching the rear brake support plate to the rear spindle Fig 17 Torque the br...

Page 84: ...vehicle is equipped with rear drum brakes install rear brake flex hose onto wheel cylinder and support plate Fig 21 Torque the brake hose to wheel cylinder tube nut to 17 Nzm 145 in lbs Torque the bra...

Page 85: ...vehicle will be adversely af fected REMOVE 1 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting in the Lubrica tion and Maintenance section of this manual for the requi...

Page 86: ...e the crossmember to frame rail attaching bolts to 95 Nzm 70 ft lbs 3 Align lateral links with spindles and install the lateral link to spindle attaching bolts Fig 2 Torque the lateral link to spindle...

Page 87: ...i lizer bar so it is centered in the vehicle so it does not contact other suspension components or vehicle body 2 Install the stabilizer bar attaching link onto stabilizer bar Install the stabilizer l...

Page 88: ...ed for this vehicle 2 Remove left rear wheel and tire assembly from the vehicle 3 Remove the nut and bolt attaching left lateral links to the spindle Fig 2 4 Remove the nut and bolt attaching the left...

Page 89: ...e 2 Remove right rear wheel and tire assembly from the vehicle 3 Remove the nut and bolt attaching right lateral links to the spindle Fig 5 4 Position a transmission jack under the fuel tank just forw...

Page 90: ...e attaching bolt Fig 5 Torque the lateral link to spindle attaching bolt to 140 Nzm 105 ft lbs 6 Install wheel and tire assembly on vehicle Tighten the wheel mounting stud nuts in proper se quence Fig...

Page 91: ...IONS AT CURB HEIGHT FRONT SUSPENSION TORQUE SPECIFICATIONS REAR SUSPENSION TORQUE SPECIFICATIONS 2 72 SUSPENSION AND DRIVESHAFTS 1994 New Yorker LHS Concorde Intrepid and Vision Publication No 81 270...

Page 92: ...ot available without Anti Lock Standard brake equipment consists of Double pin floating caliper front disc brakes Rear automatic adjusting drum brakes Proportioning valve on non Anti Lock brakes Maste...

Page 93: ...ld damage the coil spring coating and lead to a corrosion fail ure of the spring If a plastic clip is missing or is lost or broken during servicing a vehicle replace only with the equivalent part list...

Page 94: ...Fig 4 Shock Tower To Spring Minimum Clearance Area Fig 3 Proper Nut Thread Size And Tube Routing ABS Equipped BRAKES 5 3...

Page 95: ...Fig 1 DO NOT use brake fluid with a lower boiling point then DOT 3 as brake failure could result during prolonged hard braking DO NOT use petroleum based fluid because seal damage in the brake system...

Page 96: ...ite rota tion of the adjuster star wheel can be observed if the automatic adjuster is working properly If one or more adjusters do not function properly the respective drum must be removed for adjuste...

Page 97: ...aining fresh brake fluid Fig 4 3 Pump the brake pedal three or four times and hold it down before the bleeder screw is opened 4 Then open the bleeder screw at least 1 full turn When the bleeder screw...

Page 98: ...ching the Banjo connector to the caliper assembly Then attach the remaining hose end bracket to the vehicle frame to minimize hose twisting Then hand start the steel brake tube fitting into the hose e...

Page 99: ...ensure better seating of flared end tub ing PLACE TUBE NUT ON TUBING BEFORE FLARING THE TUBING ISO TUBING FLARE CAUTION All ISO style tubing flares Fig 2 are of metric dimensions When performing any s...

Page 100: ...the surface of the bar assembly Fig 5 This process has created the metric ISO tubing flare STOP LAMP SWITCH ADJUSTMENT The stop lamp switch incorporates a self adjusting feature If adjustment or repla...

Page 101: ...OUT BRAKES 3 ALL BRAKES DRAG 5 O REAR BRAKES DRAG 2 NO NO GRABBY BRAKES O X SPONGY BRAKE PEDAL X NO PREMATURE REAR LOCKUP 4 NO NO O EXCESSIVE PEDAL EFFORT 1 O ROUGH ENGINE IDLE O BRAKE CHATTER ROUGH N...

Page 102: ...BRAKE SYSTEM DIAGNOSTICS BRAKES 5 11 1994 New Yorker LHS Concorde Intrepid and Vision Publication No 81 270 4140 TSB 05 12 93 August 13 1993...

Page 103: ...BRAKE SYSTEM DIAGNOSTICS 5 12 BRAKES...

Page 104: ...BRAKE SYSTEM DIAGNOSTICS BRAKES 5 13...

Page 105: ...BRAKE SYSTEM DIAGNOSTICS BRAKE SYSTEM DIAGNOSTICS 5 14 BRAKES...

Page 106: ...IN SEALED BAGS OR CONTAINERS TO MINIMIZE DUST EXPO SURE TO YOURSELF AND OTHERS FOLLOW ALL RECOMMENDED PRACTICES PRE SCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION AND THE ENVIRONMEN TAL...

Page 107: ...bly from spindle 3 Remove automatic adjuster spring from auto matic adjuster lever Fig 6 4 Rotate the automatic adjuster screw assembly so that each shoe assembly moves out far enough to be free from...

Page 108: ...ct park brake cables to equal izer or park brake lever 6 Remove both lower brake shoe assembly to an chor plate springs Fig 9 7 Remove the 2 brake shoe assembly to support plate hold down springs from...

Page 109: ...heel to toe otherwise replace Shoes with lack of contact at toe or heel maybe improperly ground Clean and inspect support and adjusting screws Apply a thin coat of Mopar Multi Purpose Lubricant or eq...

Page 110: ...djust brake shoes assemblies so as not to interfere with brake drum installation 12 Install the rear brake drums on the hubs Af ter brake drums are installed pump brake pedal several times to partiall...

Page 111: ...se or brake fluid 2 Remove brake hose bracket from rear brake support plate Fig 1 3 Disconnect brake hose tube from wheel cylinder Fig 1 4 Remove rear wheel cylinder attaching bolts Fig 1 Then pull wh...

Page 112: ...late Tighten the wheel cylinder to brake support plate attaching bolts to 8 Nzm 75 in lbs 3 Hand start hydraulic brake hose tube fitting to wheel cylinder Attach brake hose bracket to support plate Fi...

Page 113: ...g 8 Com press cable housing retaining fingers and start hous ing out of support plate Fig 8 Remove wrench when retainer is free from the park brake cable mounting hole in the rear brake support plate...

Page 114: ...washer and retaining nut Fig 6 Torque hub and bearing assem bly retaining nut to 168 Nzm 124 ft lbs Install the lock nut and a new cotter pin Fig 6 on rear spindle Install dust cap 7 Adjust brake sho...

Page 115: ...ight front and left rear are part of another Both systems are routed through but hydraulically separated by the proportioning valve However since the brake systems are split diago nally the vehicle wi...

Page 116: ...tion key turned ON The same light will also illuminate should one of the two service brake hydraulic systems fail PROPORTIONING VALVES TESTING PROPORTIONING VALVE UNIT If premature rear wheel skid occ...

Page 117: ...er primary port and brake valve assembly Fig 2 2 Install the second gauge of set C 4007 A to the left rear brake outlet port Fig 2 An adapter tube made up from a M12x1 tube nut a short piece of brake...

Page 118: ...replace the valve See Fig 4 for pro portioning valve identification Fig 4 ABS Proportioning Valve Identification PROPORTIONING VALVE PRESSURES ABS BRAKES PROPORTIONING VALVE PRESSURES NON ABS BRAKES...

Page 119: ...ad directly into bosses on the steering knuckle Fig 2 Two machined abutments on the steering knuckle Fig 2 position and align the caliper fore and aft The guide pin bolts sleeves and bushings control...

Page 120: ...n emitting a sound signals that brake lining may need inspection and or replacement SHOE AND LINING WEAR If a visual inspection does not adequately determine condition of brake shoe lining a physical...

Page 121: ...S UN LESS SUCH OPERATION IS DONE WHILE USING PROPERLY EXHAUST VENTILATED EQUIPMENT DISPOSE OF ALL DUST AND DIRT SUSPECTED TO CONTAIN ANY ASBESTOS FIBERS IN SEALED BAGS OR CONTAINERS TO MINIMIZE DUST E...

Page 122: ...ent on steer ing knuckle Fig 2 5 Support caliper firmly to prevent weight of cali per from damaging the flexible brake hose Fig 3 6 Remove front braking disk rotor from hub by pulling it straight off...

Page 123: ...emove the protective paper from the noise sup pression gasket on both the inner and outer brake shoe assemblies if equipped Note The inboard and outboard brake shoes are not common refer to Fig 7 for...

Page 124: ...e has a firm brake pedal to adequately stop vehicle 12 Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings DISC BRAKE CALIPER...

Page 125: ...ing a plastic trim stick work piston seal out of its groove in caliper piston bore Fig 2 Discard old seal Do not use a screwdriver or other metal tool for this operation because of the possibil ity of...

Page 126: ...it by flushing the caliper with brake fluid wipe dry with a clean lint free cloth and then clean a second time ASSEMBLY 1 Clamp caliper in vise with protective caps on vise jaws CAUTION Excessive vise...

Page 127: ...le damage to the bushing 3 Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper assembly Flanges should be seated evenly on both sides of the bush...

Page 128: ...rd and outboard brake shoe assemblies onto the caliper assembly 6 Before installing caliper assembly on vehicle inspect braking disc If any conditions as described in Checking Braking Disc for Runout...

Page 129: ...ushings using internal metal sleeves which are attached to the adapter using threaded guide pin bolts The adapter and disc shield are mounted to the rear suspension knuckles of vehicle The adapter is...

Page 130: ...aces of the braking disc and external surfaces of the hub during service pro cedures Handling the braking disc and caliper should be done in such a way as to avoid deformation of the disc and scratchi...

Page 131: ...tle Refer to Cleaning And Inspection Of Brake Caliper BRAKE SHOE INSTALLATION 1 Completely retract caliper piston back into pis ton bore of caliper assembly This is required for caliper installation w...

Page 132: ...ure Fig 10 Make sure that caliper guide pin bolts bushings and sleeves are clear of the adapter bosses 8 Install the caliper guide pin bolts and tighten to 22 Nzm 192 in lbs Extreme caution should be...

Page 133: ...bore Brake pedal will fall away when piston has passed bore opening Then prop up the brake pedal to any position below the first inch of pedal travel this will prevent loss of brake fluid from the ma...

Page 134: ...e the scratches or corrosion re moved using crocus cloth Bores that have deep scratches or scoring should be honed Use Caliper Hone Special Tool C 4095 or equivalent providing the diameter of the bore...

Page 135: ...and binding of the piston in the bore of the caliper 6 Position dust boot in counterbore of the caliper piston bore 7 Using a hammer and Installer Piston Caliper Boot Special Tool C 4383 7 and Handle...

Page 136: ...gh the bushing Fig 13 until the one end of the bushing is fully seated into the seal groove on the one end of the sleeve 3 Holding the sleeve in place work the other end of the bushing over the end of...

Page 137: ...kness are present the braking disc must be replaced or refaced If the braking disc does not require any servicing install caliper assembly 7 Install brake hose onto caliper using banjo bolt Torque the...

Page 138: ...lation of new brake shoe assem blies Some discoloration or wear of the disc surface is normal and does not require resurfacing when linings are replaced Excessive runout or wobble in a disc can increa...

Page 139: ...rotor Thickness variation measurements of disc should be made in conjunction with runout Measure thickness of disc at 12 equal points with a micrometer at a radius approximately 25 4 mm 1 inch from e...

Page 140: ...rotor MUST be clean and free from any chips or contamination When mounting the disc on the brake lathe strict attention to the brake lathe manufacturer s operating instructions is required If the disc...

Page 141: ...st on an un machined surface of the braking disc Fig 9 The thickness mark ings may be located on the disc as shown in Fig 9 or on an alternate surface This marking includes 0 76 mm 0 030 inch allow ab...

Page 142: ...l duo servo brake which is mounted to the adapter The hat cen ter section Fig 1 of the rear rotor serves as the braking surface drum for the parking brakes On the vehicles with rear disc brake applica...

Page 143: ...FIG 2 PARKING BRAKE CABLE ROUTING 5 52 BRAKES...

Page 144: ...et and extension rotating sector toward rear of vehicle until ratchet extension contacts back of park brake pedal This will fully wind sector spring Fig 3 3 Insert a pin or drill bit into park brake l...

Page 145: ...brake pedal mechanism 2 Align park brake cable slug with attaching hole on park brake assembly Fig 7 Install park brake cable into cable attaching hole in park brake assem bly and rotate cable into p...

Page 146: ...e 4 Remove drivers side door opening sill molding Remove drivers side cowl kick molding to expose park brake pedal mechanism Fig 11 5 Remove rear console mounting bracket Fig 12 from park brake cable...

Page 147: ...t off cable using a screwdriver Fig 15 4 Remove front park brake cable from reaction bracket Fig 16 Remove screw attaching park brake cable routing clip to left front floor pan Fig 16 Remove front par...

Page 148: ...slug with attaching hole on park brake assembly Fig 20 Install park brake cable into cable attaching hole in park brake assem bly and rotate cable into place Be sure cable is properly seated in the c...

Page 149: ...pan attaching screw Fig 24 Torque the routing clip to floor pan attaching screw to 4 Nzm 35 in lbs Install front park brake cable into routing clips on floor pan crossmember 8 Ensure that park brake...

Page 150: ...re complete adjust rear brakes before adjusting parking brake See parking brake adjustment procedure in this section of the service manual for complete park ing brake adjustment procedure On drum in h...

Page 151: ...rs 3 Remove the 4 routing clips attaching rear park brake cable to floor pan and frame of vehicle Fig 3 5 PASSENGER MODELS 4 Remove shift knob from floor shifter Shift knob is removed by removing 3 32...

Page 152: ...o connect park brake cables to equalizer or park brake lever 13 Remove rear park brake cable from vehicle floor pan using the following procedure Disconnect rear park brake cable requiring replacement...

Page 153: ...nt procedure 6 PASSENGER MODELS 9 Install equalizer cover back on reaction bracket Fig 10 Torque equalizer cover to reaction bracket mounting bolts to 10 Nzm 88 in lbs 10 Fold rear passenger compartme...

Page 154: ...until cable is removed from cable mounting hole in adapter 6 Remove the 4 routing clips attaching rear park brake cable to floor pan and frame of vehicle Fig 3 5 PASSENGER MODELS 7 Remove shift knob...

Page 155: ...connect park brake cables to equalizer or park brake lever 16 Remove rear park brake cable from vehicle floor pan using the following procedure Disconnect rear park brake cable requiring replacement...

Page 156: ...own shift shaft until fully bottomed Then install and tighten 3 32 in allen head set screw located on driv ers side of shift knob 10 Install brake drum and wheel and tire assem bly 11 When repairs are...

Page 157: ...caliper assembly from adapter and braking disc See Disc Brake Shoe Re moval 2 Remove rear braking disc from rear hub See Removing Braking Disk 3 Remove dust cap from rear hub Remove cotter pin and nu...

Page 158: ...ld down clip Then remove front parking brake shoe assembly Fig 5 INSTALLING PARKING BRAKE SHOES 1 Install front parking brake shoe and holddown clip Fig 6 2 Install rear park brake shoe and upper park...

Page 159: ...Install hub and bearing assembly thrust washer and retaining nut Torque the hub and bear ing assembly retaining nut to 168 Nzm 124 ft lbs 10 Install the nut lock and cotter pin on the rear spindle Th...

Page 160: ...to the proportioning valve or the Anti Lock Brake system HCU The front part of this block connects to the secondary outlet tube and supplies the right rear and left front brakes The rear portion of t...

Page 161: ...Install new housing to reservoir grommets in master cylinder housing Fig 6 8 Lubricate brake fluid reservoir mounting area with clean brake fluid Place reservoir in position over grommets Seat reserv...

Page 162: ...on power brake vacuum booster It is not necessary to bleed the entire hydrau lic system after replacing the master cylinder providing that the master cylinder has been bled and filled upon installatio...

Page 163: ...ifference in pressure forces the output rod of the power booster out against the primary piston of the master cylin der As the pistons in the master cylinder move forward this creates the hydraulic pr...

Page 164: ...on power brake booster onto dash panel 2 Install and tighten the 4 power brake booster to dash panel mounting nuts Fig 4 to 29 Nzm 250 in lbs torque 3 Carefully position master cylinder on power brake...

Page 165: ...aced Damaged bearing seals and resulting excessive grease loss may also require bearing replacement Moderate grease loss from bearing is considered nor mal and should not require replacement of the hu...

Page 166: ...l The hydraulic pres sure is used to prevent wheel lock up during braking and to maintain traction at the driven wheels by reducing wheel spin The Teves Mark IV system uses a diagonal split hydraulic...

Page 167: ...hich provide brake pedal position information to the CAB MASTER CYLINDER W CENTER VALVES AND FLUID LEVEL SWITCH FLS 1 The master cylinder Fig 3 is a standard tandem design except that central valves a...

Page 168: ...ing and closing the inlet and outlet valves the CAB can apply and re lease the drive wheel calipers as needed to control wheel spin Two pressure relief valves allow unused fluid volume pressure to ret...

Page 169: ...ave dark black tire marks since the wheel never reaches a locked condition Tire marks may however be noticeable as light patched marks VEHICLE PERFORMANCE Anti Lock Brakes provide the driver with some...

Page 170: ...p Motor Circuit Not Working Properly Pump Motor Running Without Command Pedal Travel Sensor Circuit Valve Fault 8 10 FLS 2 Not processable Pressure Switch Brake Switch Circuits Disables Traction Contr...

Page 171: ...NY WAY SHOULD BE MADE TO REMOVE OR SERVICE ANY OTHER PARTS OF THE HCU The HCU Fig 1 and 2 is located in the engine compartment on the left frame rail forward of the master cylinder and is covered by a...

Page 172: ...em one for each rear brake hydraulic circuit The Proportioning Valves function the same as in a standard brake system The Proportioning Valves are located on the bottom of the HCU Fig 1 The proportion...

Page 173: ...ed and a fault code will be stored The ABS controller will have a white part label The ABS and Traction Control controller will have a blue part label The part numbers are also different The CAB on th...

Page 174: ...nti Lock Brake and Traction Control Systems are constantly monitored by the CAB for proper operation If the CAB detects a fault it can disable the Anti Lock and Traction Control function and turn on t...

Page 175: ...the various modes BRAKES RELEASED When the brake pedal is released all pressures in the system are the same Fig 1 at atmospheric pressure BASELINE BRAKES The Baseline Brake System is a diagonal split...

Page 176: ...Fig 2 Baseline Brakes Hydraulic Control Fig 3 Pressure Hold Hydraulic Control ANTI LOCK BRAKE SYSTEM 5 85...

Page 177: ...he inlet valves Fig 6 to the brake channel it does not need to apply For example if a traction loss condi tion is detected at the right front wheel only the CAB will close the left front inlet valve t...

Page 178: ...Fig 6 Traction Control Pressure Build Hydraulic Control Fig 5 Pressure Build Hydraulic Control ANTI LOCK BRAKE SYSTEM 5 87...

Page 179: ...Fig 7 Traction Control Pressure Hold Hydraulic Control Fig 8 Traction Control Pressure Decay Hydraulic Control 5 88 ANTI LOCK BRAKE SYSTEM...

Page 180: ...re used in this manual They are presented here for reference HCU Hydraulic Control Unit CAB Controller Anti Lock Brake ABS Anti Lock Brake System PSI Pounds per Square Inch pressure WSS Wheel Speed Se...

Page 181: ...connections or wiring When an intermittent fault is encountered check suspect circuits for 1 Poor mating of connector halves or terminals not fully seated in the connector body 2 Improperly formed or...

Page 182: ...al diagnostics sys tems and components covered earlier in this section Are accomplished by the use of the DRB II scan tool See testing procedures outlined in the Teves Mark IV Anti Lock Brakes Diagnos...

Page 183: ...ar wheel left rear wheel right front wheel and left front wheel 3 Locate diagnostics connector under dash panel to the right of the steering column 4 Connect the DRBII scan tool to the vehicle diag no...

Page 184: ...output tubes from the valve block on the HCU Fig 6 Disconnect the brake fluid supply hose from the master cylinder reservoir to the HCU reservoir at the HCU reservoir Plug end of supply hose to keep...

Page 185: ...zm 14 ft lbs 4 Remove plug from end of brake fluid supply hose going to reservoir at HCU Connect supply hose on HCU reservoir nipple and install hose clamp on hose Be sure clamp is past bead on nipple...

Page 186: ...of HCU is completed Failure to install heat shield could result in a failure of the CAB due to high temperature 11 Install heat shield back on HCU mounting bracket HYDRAULIC CONTROL UNIT FLUID RESERVO...

Page 187: ...ck in the vehicle Re fer to Hydraulic Control Unit Installation in this section of the service manual for the required instal lation procedure 5 Bleed the air from brake hydraulic system Re fer to Ble...

Page 188: ...1 Install pedal travel sensor retaining ring on travel sensor mounting grommet in the vacuum booster Fig 4 Tab on retaining ring should be lo cated in top notch of mounting grommet 2 Sparingly lubrica...

Page 189: ...HCU assembly back in the vehicle Re fer to Hydraulic Control Unit Installation in this section of the service manual for the required instal lation procedure 3 Install brake tube on proportioning val...

Page 190: ...front tire and wheel assembly on vehicle Install the wheel and tire assembly Tighten the wheel mounting stud nuts in proper sequence Fig 3 until all nuts are torqued to half specification Then repeat...

Page 191: ...y pull sensor assembly grommet from fender shield 4 Unplug speed sensor connector from vehicle wiring harness connector Fig 6 5 Remove the speed sensor cable routing bracket from the front strut assem...

Page 192: ...e assembly Tighten the wheel mounting stud nuts in proper sequence Fig 9 until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 129 Nzm 95...

Page 193: ...ting tube to trail ing arm attaching screws Fig 14 Install speed sen sor cable routing brackets at rear fender well and rear knuckle Fig 14 3 Insert speed sensor cable and grommet back in hole in rear...

Page 194: ...SPECIFICATIONS SPECIFICATIONS METRIC BRAKE ACTUATION SYSTEM TIGHTENING REFERENCE ANTI LOCK BRAKE SYSTEM 5 103...

Page 195: ......

Page 196: ...The coolant flows through the engine heater core deaeration pres sure bottle and by pass When Engine is warm Thermostat is open coolant flows through the radiator heater core deaeration pressure bottl...

Page 197: ...COOLING SYSTEM DIAGNOSIS 7 2 COOLING SYSTEM...

Page 198: ...COOLING SYSTEM DIAGNOSIS COOLING SYSTEM 7 3...

Page 199: ...COOLING SYSTEM DIAGNOSIS 7 4 COOLING SYSTEM...

Page 200: ...COOLING SYSTEM DIAGNOSIS COOLING SYSTEM 7 5...

Page 201: ...COOLING SYSTEM DIAGNOSIS 7 6 COOLING SYSTEM...

Page 202: ...COOLING SYSTEM DIAGNOSIS COOLING SYSTEM 7 7...

Page 203: ...E SYSTEM HOT AND UNDER PRESSURE BE CAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR 1 Drain Cooling System Refer to Draining Cool ing System in this group 2 Remove Poly V Drive Belt 3 Remove right front low...

Page 204: ...Timing System in Engine Section Group 9 for timing belt installation procedure and reassemble engine 5 Fill cooling system Refer to Refilling Cooling System ENGINE THERMOSTATS The engine thermostat i...

Page 205: ...OWED DRINK TWO GLASSES OF WATER AND INDUCE VOMITING IF INHALED MOVE TO FRESH AIR AREA SEEK MEDI CAL ATTENTION IMMEDIATELY DO NOT STORE IN OPEN OR UNMARKED CONTAINERS WASH SKIN AND CLOTHING THOROUGHLY...

Page 206: ...ressure is released When no pressure is released press down on the cap and turn fully counter clockwise WARNING WHEN INSTALLING DRAIN HOSE TO AIR BLEED VALVE ON THERMOSTAT HOUSING ROUTE HOSE AWAY FROM...

Page 207: ...g Sys tem and refill with clean distilled water see Refilling Cooling System Run engine with radiator cap in stalled until upper radiator hose is warm Stop engine and drain water from system If water...

Page 208: ...aks All hoses radiator and heater should be moved while at 15 psi since some leaks occur while driving due to engine rock etc If there are no external leaks after the gauge dial shows a drop in pressu...

Page 209: ...NOT OPEN HOT ON THE DEAERATION PRESSURE BOTTLE CAP IS A SAFETY PRECAUTION WHEN HOT PRES SURE BUILDS UP IN COOLING SYSTEM TO PRE VENT SCALDING OR INJURY THE DEAERATION PRESSURE BOTTLE CAP SHOULD NOT B...

Page 210: ...p in hand upside down If any light can be seen between vent valve and rubber gasket replace cap RADIATORS The radiators are cross flow types horizontal tubes with design features that provide greater...

Page 211: ...move upper radiator crossmember Fig 10 5 Remove hose clamps and hoses from the radia tor 6 Disconnect automatic transmission hoses from cooler and plug off 7 Disconnect the fan wiring connector from t...

Page 212: ...len or restricted hose should be replaced Do not damage radiator inlet and outlet when loosening hoses Radiator hoses should be routed without any kinks and indexed as designed The use of molded hoses...

Page 213: ...ontrol Module PCM The PCM switches the fans on through the fan relays Refer to Wiring Diagrams Manual for circuit and diagnostics Switching through the Power Control Module PCM provides fan control fo...

Page 214: ...6 44 N 150 6 10 lbs 3 3 3 5L ENGINE ACCESSORY DRIVE BELT SERVICE GENERATOR POWER STEERING PUMP AIR CONDITIONING COMPRESSOR AND WATER PUMP DRIVE BELT SERVICE GENERATOR POWER STEERING PUMP AND WATER PUM...

Page 215: ...ng pump and water pump drive belt to gain access to the air condi tioning drive belt 2 To remove and install the air conditioning com pressor drive belt first loosen the tensioner pulley lock nut then...

Page 216: ...ot operate trouble can be in either the power cord or the heater element Test power cord for continuity with a 110 volt voltmeter or 110 volt test light test heater element continuity with an ohmme te...

Page 217: ...SPECIFICATIONS TORQUE COOLING SYSTEM CAPACITY 7 22 COOLING SYSTEM...

Page 218: ...ube Care should be taken not to damage radiator or condenser cooling fins or water tubes during re moval INSTALLATION 1 Slide cooling module down into position seat the radiator assembly lower rubber...

Page 219: ......

Page 220: ...roup 8B Battery Starter Generator Service Group 8A Battery Starting Charging Systems Diag nostics will cover diagnostics only The Battery Starting and Charging Systems oper ate in conjunction with one...

Page 221: ...show Diagnostic Trouble Codes However the Malfunction Indicator Check Engine Lamp cannot express diagnostic trouble codes for all failures Diagnostic trouble codes are easier to obtain and more compl...

Page 222: ...st in determining the batter ies state of charge The factory installed battery is also sealed Water cannot and should not be added The battery is vented to release gases that are created when the batt...

Page 223: ...BATTERY DISCHARGING It is normal to have a small 5 to 30 milliamperes continuous electrical draw from the battery This draw will take place with the ignition in the OFF position and the courtesy dome...

Page 224: ...Fig 7 Battery Diagnostics BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS 8A 5...

Page 225: ...n If green dot is not visible in indicator charge the battery Refer to Battery Charging Procedures 2 Use a suitable Volt Ammeter Load tester Fig 10 connected to the battery posts Fig 11 Check the open...

Page 226: ...D CALL PHYSICIAN IMMEDIATELY KEEP OUT OF REACH OF CHILDREN CAUTION Disconnect the battery NEGATIVE cable first Fig 15 before charging battery to avoid dam age to electrical systems Do not exceed 16 0...

Page 227: ...R SONAL INJURY MAY RESULT CHARGING COMPLETELY DISCHARGED BATTERY The following procedure should be used to recharge a completely discharged battery Unless procedure is properly followed a good battery...

Page 228: ...ain control fuse A 20 Amp 1 Remove both fuses A and J By removing these fuses all ignition off draw from the electronic control modules will be disconnected The test light should go out If test light...

Page 229: ...Install interior brake lamp fuse J After in stalling fuse the current can reach 90 mA After time out the reading should not exceed 20 mA If OK go to step 11 If not disconnect Radio Body control modul...

Page 230: ...ttery top posts and terminals are clean 2 The generator drive belt tension and condition is correct 3 The battery state of charge is correct 4 The battery will endure load test 5 The battery cable con...

Page 231: ...rter feed circuit resistance test If voltage reads 12 4 volts or greater and amperage reads 0 to 10 amps go to starter control circuit test CAUTION Do not overheat the starter motor or draw the batter...

Page 232: ...st and negative lead to the posi tive battery cable clamp Rotate and hold the igni tion switch key in the START position Observe the voltmeter If voltage is detected correct poor contact between the c...

Page 233: ...y starter tests the ignition system must be disabled Unplug the ignition coil electrical connector Figs 6 and 7 STARTER SOLENOID TEST WARNING CHECK TO ENSURE THAT THE TRANS MISSION IS IN THE PARK POSI...

Page 234: ...3 Locate and remove the starter relay Fig 13 4 After the starter relay has been located and removed refer to Starter Relay Tests Fig 14 NEUTRAL STARTING AND BACK UP SWITCH Refer to Starter Relay Tests...

Page 235: ...Fig 14 Starter Relay Tests 8A 16 BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS...

Page 236: ...ield Coil Wire Terminal Nippondenso Fig 17 Continuity Test Between Solenoid Terminal and Field Coil Terminal Melco Fig 18 Continuity Test Between Solenoid Terminal and Field Coil Terminal Nippondenso...

Page 237: ...positive post A voltage drop test may be performed at each connection to locate a connection with excessive voltage drop If voltage drop tests are satisfactory reduce engine speed turn OFF blower mot...

Page 238: ...Fig 1 Charging Diagnostics BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS 8A 19...

Page 239: ...Fig 2 Wiring Connections Fig 3 Voltage Drop Test Fig 4 Output Voltage Test 8A 20 BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS...

Page 240: ...RAIN CONTROL MODULE The power control module is equipped with On Board Diagnostic features and monitors all engine control circuits during a run drive period If a circuit or system does not perform pr...

Page 241: ...Fig 6 Generator Diagnostic Trouble Codes 8A 22 BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS...

Page 242: ...Fig 7 Check For Inadequate Low Charging BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS 8A 23...

Page 243: ...Fig 8 Check For Overcharging 8A 24 BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS...

Page 244: ...Fig 9 Powertrain Control Connector Fig 10 Electrical Resistance Test Fig 11 Diagnostic Connector Location BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS 8A 25...

Page 245: ...SPECIFICATIONS BATTERY STARTER TORQUE SPECIFICATIONS 8A 26 BATTERY STARTING CHARGING SYSTEMS DIAGNOSTICS...

Page 246: ...ery posts Remove negative battery cable first Fig 2 3 Remove battery heat shield WARNING TO PROTECT THE HANDS FROM BAT TERY ACID A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES NOT THE HOUSEHOLD TYPE SHOU...

Page 247: ...ll battery hold down clamp making sure that it is properly positioned on battery 13 Place battery heat shield over battery The top inside surface of heat shield must be flush with top of battery 14 Co...

Page 248: ...le on 3 5L engines A planetary gear train transmits power between starter motor and pinion shaft The fields have six permanent magnets NIPPONDENSO STARTERS A Nippondenso reduction gear field coil star...

Page 249: ...ove the wiring from starter at this time 4 Remove three starter attaching bolts from engine transaxle Fig 5 5 Remove starter starter solenoid assembly from engine Position the starter to gain access t...

Page 250: ...tor field circuit plug 3 Remove the B terminal nut and wire Fig 2 4 Loosen adjusting T bolt but do not remove Fig 3 5 Loosen pivot bolt but do not remove 6 Loosen adjusting bolt to allow removal of th...

Page 251: ...connect the generator field circuit plug 10 Remove the B terminal nut and wire Fig 2 11 For installation reverse above procedures Tighten all fasteners to the proper torque Refer to the Torque Specifi...

Page 252: ...ner and the other for eye glasses The mini console has Overhead Travel Information System OTIS Two map courtesy lamps The base unit has Two map courtesy lamps MAP READING LAMPS The map lamps are actua...

Page 253: ...hrysler Collision Detection CCD bus messages from the body control module for all displayed information except the compass display If a dash is displayed OTIS is not receiving a CCD message from the b...

Page 254: ...netic tipped screwdriver etc If the roof becomes mag netized use a demagnetizing Tool 6029 to demagne tize the roof In this demagnetizing procedure you will use the demagnetizing tool to demagnetize t...

Page 255: ...move two screws from the eye glasses com partment 3 Remove screw from garage door transmitter compartment and remove transmitter if necessary Pull gently down at the rear of the console to discon nect...

Page 256: ...of posi tion 5 For installation reverse above procedures OVERHEAD CONSOLE BASE REPLACEMENT 1 Remove overhead console refer to above proce dures 2 Remove head liner refer to Group 23 Body 3 Using an tr...

Page 257: ......

Page 258: ...oup 0 Lubrication and Maintenance contains general maintenance information for ignition related items The Owner s Manual also contains mainte nance information The 3 3L and 3 5L engines use a fixed ig...

Page 259: ...use resistor spark plugs They have resistance values of 6 000 to 20 000 ohms when checked with at least a 1000 volt tester For spark plug identification and specifications Refer to the Specifications...

Page 260: ...nductive deposits during short operating periods Carbon fouled spark plugs with low mileage can be cleaned and reused FUEL FOULING A spark plug that is coated with excessive wet fuel is called fuel fo...

Page 261: ...ber temperature can cause preignition damage First the center electrode dissolves Then the ground electrode dissolves some what later Fig 9 Insulators appear relatively de posit free Determine if the...

Page 262: ...3 camshaft pulses the PCM knows cylinder four crankshaft timing marks follow One camshaft pulse after the three pulses indicates cylinder five The two camshaft pulses after cylinder 5 signals cylinder...

Page 263: ...sition of the last slot in each group Once the powertrain con trol module PCM senses the last slot it determines crankshaft position which piston will next be at TDC from the camshaft position sensor...

Page 264: ...hed ules for cold and warm engine operation The sched ules reduce engine emission and improve driveability When the engine is cold the PCM will demand slightly richer air fuel mixtures and higher idle...

Page 265: ...ing on and off the ground path for the solenoid side of the relays Both relays turn on and off at the same time The ASD relay connects battery voltage to the fuel injectors and ignition coil The fuel...

Page 266: ...e DRB scan tool and the appropriate Powertrain Diagnostic Proce dures manual If one or more tests indicate irregular weak or no spark proceed to Check Coil Test CHECK COIL TEST Coils one fires cylinde...

Page 267: ...ture Sensor 2 Ignition Timing Procedure 5 Knock Sensors 3 5L Engine 6 Manifold Absolute Pressure MAP Sensor 7 Powertrain Control Module PCM 2 Spark Plug Cables 3 Spark Plug Service 4 Spark Plug Tubes...

Page 268: ...take manifold plenum CAUTION When routing cables under the fuel rail on the left side of the engine during the cable removal or installation process do not pry up on the fuel rail because permanent da...

Page 269: ...to route the cables properly can cause the radio to reproduce ignition noise cross igni tion of the spark plugs or short circuit the cables to ground Never wire brush spark plugs The spark plug insula...

Page 270: ...t sprocket While holding the sensor in this position install and tighten the retaining bolt to 12 Nzm 105 in lbs torque 2 Attach electrical connector to sensor CAMSHAFT POSITION SENSOR 3 5L ENGINE The...

Page 271: ...ck The coil pack towers are numbered with the cylinder iden tification Fig 14 5 Reverse procedure for installation ELECTRONIC IGNITION COIL PACK 3 5L ENGINE The ignition coil pack attaches to the righ...

Page 272: ...tall intake manifold plenum Refer to Intake Manifold Plenum in Group 11 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR On 3 3L engines the MAP sensor threads into the rear of the intake manifold plenum Fig 18...

Page 273: ...MOVAL 1 Disconnect the negative cable from the battery 2 Remove the tilt lever attaching screw Remove lever 3 Remove the upper and lower cover from steer ing column 4 Remove multi function switch 5 Di...

Page 274: ...rn the ignition key to the run position When ignition switch is in the run position the lock cylinder retaining tab will depress 5 Depress tab and slide lock cylinder out of hous ing Fig 7 INSTALLATIO...

Page 275: ...se replace and adjust the interlock cas sette or interlock cable FLOOR SHIFT 1 With the floor shifter in Park place the ignition key in the LOCK OFF position The operator should not be able to remove...

Page 276: ...handle 2 Remove the bezel from the shifter console 3 Remove the drivers side under panel silencer 4 Remove the tilt lever attaching screw Remove lever 5 Remove upper and lower covers from the steer i...

Page 277: ...move the ignition key from the lock cylinder If not inspect the system for binding and repeat the adjustment procedure 11 Install the bezel on the shifter console 12 Install shifter handle 13 Install...

Page 278: ...g 16 REMOVAL 1 Remove the tilt lever attaching screw Remove lever 2 Remove the upper and lower covers from the steering column 3 If the vehicle has floor shift remove the inter lock cable If the vehic...

Page 279: ...any thing differs from the specifications on the Vehicle Emission Control Information Label use the specifi cations on the label SPARK PLUG CABLE ROUTING 3 3L AND 3 5L ENGINES IGNITION COILS SPARK PL...

Page 280: ...nd opposite the lock cylinder Fig 3 For ignition switch terminal and circuit identifi cation refer to Group 8W Wiring Diagrams REMOVAL 1 Disconnect the negative cable from the battery 2 Remove the til...

Page 281: ...Refer to Floor Shift Interlock Adjustment in this section REMOVAL 1 Disconnect negative cable from the battery 2 Remove the tilt lever attaching screw Remove lever 3 Remove the upper and lower covers...

Page 282: ...in the park position the shifter will remain in park Should the interlock cable break when the shifter is in neutral the operator won t be able to shift to park In either case replace and adjust the...

Page 283: ...e shifter If the system requires adjustment and not replace ment refer to the Floor Shift Interlock Adjustment procedure in this section REMOVAL 1 Remove shifter handle 2 Remove the bezel from the shi...

Page 284: ...e move the key at this point inspect the system for binding and repeat the adjustment procedure Place the shifter in the PARK position Turn the ignition key to the OFF lock position You should be able...

Page 285: ...USING The lock cylinder housing attaches to the steering column with tamper proof screws and hardened washers Fig 16 REMOVAL 1 Remove the tilt lever attaching screw Remove lever 2 Remove the upper and...

Page 286: ...BLOCK REMOVAL 12 LEFT UNDER INSTRUMENT PANEL SILENCER DUCT REMOVAL 11 LOWER CENTER BEZEL REMOVAL 11 LOWER INSTRUMENT PANEL REMOVAL 12 MASK LENS REPLACEMENT TYPE A AND C 3 MASK LENS WITH TRANSMISSION...

Page 287: ...ic Procedures Manual If the diagnostic procedure determines that a re placement of an instrument cluster component is re quired refer to the Instrument Cluster Service Proce dure INSTRUMENT CLUSTER AN...

Page 288: ...procedures SPEEDOMETER TACHOMETER AND TRANSMISSION RANGE INDICATOR REPLACEMENT TYPE A AND C 1 Remove six cluster back cover retaining screws and remove cover Fig 8 2 Disconnect transmission range ind...

Page 289: ...ard 3 Remove four mask lens retaining screws and then remove mask lens 4 Remove trip odometer reset knob by gently pull ing rearward 5 Remove the screws attaching speedometer tachometer assembly and r...

Page 290: ...3 Disconnect transmission range indicator and odometer connectors from the printed circuit board 4 Remove four mask lens retaining screws then remove mask lens 5 Remove tachometer and or fuel tempera...

Page 291: ...along perforated lines and pull back dash liner 4 Remove screw through oblong access hole at right end of knee bolster Fig 21 5 Remove push in fastener at lower leg of module from underneath instrumen...

Page 292: ...trument panel and pull bezel rearward to disengage clip s 3 For installation reverse above procedures HEADLAMP SWITCH REMOVAL 1 Remove end cover and headlamp switch bezel Fig 24 and 25 2 Remove three...

Page 293: ...Fig 24 Instrument Panel Breakdown 8E 8 INSTRUMENT PANEL AND GAUGES...

Page 294: ...Fig 25 Instrument Panel Breakdown New Yorker INSTRUMENT PANEL AND GAUGES 8E 9...

Page 295: ...For installation reverse above procedures En sure spare fuses are seated to left end cover INSTRUMENT PANEL LOWER CENTER COVER REMOVAL Remove screw on each side of center cover and remove center cover...

Page 296: ...etal light housing and remove lamp from socket 5 For installation reverse above procedures CIGAR LIGHTER REMOVAL 1 Remove lower slide out ash tray Fig 22 2 Remove two outboard screws from housing as s...

Page 297: ...wing glove box door down to floor Remove four screws at top of the glove box opening The New Yorker has six screws 6 Remove two nuts from center support bracket at ash receiver area 7 Remove two screw...

Page 298: ...procedures UPPER INSTRUMENT PANEL REMOVAL WARNING DISCONNECT AND ISOLATE THE BAT TERY NEGATIVE GROUND CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE THIS WILL DIS...

Page 299: ...le connectors Three in line bracket connector including 40 way jack screw and remove hazard relay Four outboard connectors to junction block Headliner connector at top of panel 18 Remove the two panel...

Page 300: ...to the generator instrument cluster and wind shield wiper motor Ground straps or wires are mounted from radio chassis to instrument panel support structure engine to frame and engine cradle These grou...

Page 301: ...AM FM STEREO CASSETTE TAPE 8F 2 AUDIO SYSTEM...

Page 302: ...AM FM STEREO CONTINUED AUDIO SYSTEM 8F 3...

Page 303: ...AM FM STEREO CONTINUED AM FM STEREO CONTINUED 8F 4 AUDIO SYSTEM...

Page 304: ...INFINITY AUDIO SYSTEM 8F 5...

Page 305: ...INFINITY CONTINUED 8F 6 AUDIO SYSTEM...

Page 306: ...INFINITY CONTINUED AUDIO SYSTEM 8F 7...

Page 307: ...INFINITY CONTINUED 8F 8 AUDIO SYSTEM...

Page 308: ...INFINITY CONTINUED AUDIO SYSTEM 8F 9...

Page 309: ...INFINITY CONTINUED 8F 10 AUDIO SYSTEM...

Page 310: ...Fig 1 Radio Connector Circuits AUDIO SYSTEM 8F 11...

Page 311: ...2 2 Remove two radio mounting screws Fig 3 3 Pull radio from panel and disconnect wiring ground strap or wires and antenna lead from radio 4 Remove radio 5 For installation reverse above procedures Fi...

Page 312: ...unting hard ware in the trunk right rear quarter panel REMOVAL The rubber bezel grommets are not inter change able between vehicle models 1 Inside trunk pull trunk liner aside 2 Unplug antenna lead fr...

Page 313: ...terminal 3 If the motor will not operate replace the an tenna assembly 4 If the motor runs freely and the antenna does not extend or retract the mast or drive assembly is at fault Remove the mast and...

Page 314: ...ore installing antenna Tighten antenna bracket ground strap screws to 4 Nzm 40 in lbs torque POWER ANTENNA MAST REMOVAL 1 Remove cap nut 2 Turn ignition key to ACCESSORY position and turn on radio 3 W...

Page 315: ...cover using an trim stick along rear edge c While lifting rear edge slide top cover rearward to disengage front clips and remove the top cover 2 To remove right or left speaker remove two retaining s...

Page 316: ...side left side trunk liner 2 Loosen the three amplifier attaching bolts Fig 15 3 Raise up amplifier to remove and disconnect the three electrical connectors 4 For installation reverse above procedures...

Page 317: ...NDITION One Speaker Non operative Remove output signal connector from amplifier and check for two to five ohms resistance to the non operative speaker Refer to Fig 14 for the appropriate pin numbers I...

Page 318: ...unction block Refer to Horn Relay Test HORN RELAY TEST 1 Remove horn relay 2 Using ohmmeter test for continuity between ground and terminal 12 of junction block a When the horn switch is not depressed...

Page 319: ...Fig 2 Horn Diagnosis 8G 2 HORNS...

Page 320: ...nd isolate negative battery cable in engine compartment 2 Remove the two speed control switches or cover plates from the steering wheel 3 Remove the screws that attach the driver airbag module to the...

Page 321: ......

Page 322: ...de of the airbag module Fig 1 For identification and location of the major components Figs 2 and 3 The system is designed to operate at speeds above 35 mph 50 km h WARNING THE USE OF SPEED CONTROL IS...

Page 323: ...iag nosis and repair procedures Refer to System Diagnosis Chart or Speed Control Circuit Figs 4 5 and 6 A poor connection can cause a complete or intermittent malfunction and is also the only connecti...

Page 324: ...Fig 4 System Diagnosis VEHICLE SPEED CONTROL SYSTEM 8H 3...

Page 325: ...Fig 5 System Diagnosis Continued 8H 4 VEHICLE SPEED CONTROL SYSTEM...

Page 326: ...step 2 replace powertrain control module ELECTRICAL TEST Electronic speed control systems may be tested us ing two different methods One involves use of a DRB If this test method is desired please re...

Page 327: ...eaner Figs 8 and 9 2 Remove both steering wheel speed control switches and disconnect the two way connectors a Using an ohmmeter check for continuity be tween pin 23 of the powertrain control module a...

Page 328: ...e the SET RESUME speed control switch assembly and disconnect the two way connector 4 Using an ohmmeter touch one lead to pin one and the other to pin 2 The meter should read no continuity Press the S...

Page 329: ...WARNING IF REMOVAL OF AIRBAG MODULE IS NECESSARY REFER TO GROUP 8M RESTRAINT SYSTEMS 1 Turn off ignition 2 Remove two screws from side of the switch 3 Rock switch away from airbag and steering wheel 4...

Page 330: ...witch to the off position If only momentary signaling such as indication of a lane change is desired the switch is actuated to a left or right intermediate detent position In this position the signal...

Page 331: ...Fig 1 Turn Signal and Hazard Warning Flasher Diagnosis 8J 2 TURN SIGNALS AND HAZARD WARNING FLASHER...

Page 332: ...rews to 2 Nzm 17 in lbs torque TURN SIGNAL AND HAZARD WARNING FLASHER LOCATION The turn signal flasher and the hazard warning flasher are combined into one unit called a combina tion flasher combo fla...

Page 333: ......

Page 334: ...speeds The wiper system completes the wipe cycle when the switch is turned OFF The blades park in the lowest portion of the wipe pattern When using the DRB refer to the Body Chassis Diagnostic Manual...

Page 335: ...ents are not met check linkage and pivot assembly for worn parts During high speed wet glass operation the right hand blade tip may override the cowl screen slightly This is normal and should not affe...

Page 336: ...Fig 5 Wiper Motor Runs Diagnosis WINDSHIELD WIPER AND WASHER SYSTEMS 8K 3...

Page 337: ...Fig 6 Wiper Motor Will Not Run Diagnosis 8K 4 WINDSHIELD WIPER AND WASHER SYSTEMS...

Page 338: ...ation in all switch positions c If motor is still inoperative and the fuse does not blow go to step 2 d If replacement fuse blows go to step 11 2 Disconnect motor wire connector 3 Check motor low spee...

Page 339: ...ontinuity from terminal 1 of wiper switch connector to terminal 16 of the body control module J3 24 way connector If no continuity repair circuit If OK go to step c c Using a voltmeter connect positiv...

Page 340: ...orts between the low speed motor feed terminal 3 or high speed motor feed terminal 2 and battery or ignition 2 Check for faulty wiper intermittent or Hi Lo relay 3 Check circuit from intermittent rela...

Page 341: ...s and blades disconnect hoses from in line connectors Be sure that the in line connector is saved 2 Remove the rear hood seal with the cowl top plastic screen and disconnect the washer hose at in line...

Page 342: ...shed all the way in the washer circuit will be completed INTERMITTENT WIPER SWITCH REPLACEMENT 1 Tilt column up and remove six screws holding lower column shroud 2 Tilt column down and remove upper sh...

Page 343: ...dule turns off Whenever a windshield washer malfunction occurs first verify that the windshield washer wire harness is properly connected to all connectors before starting normal diagnosis and repair...

Page 344: ...124 in lbs torque 4 Install battery tray and battery Connect bat tery terminals WASHER RESERVOIR PUMP 1 Remove liquid from reservoir 2 Disconnect battery terminals Remove battery and tray 3 Disconnect...

Page 345: ...E All models are equipped with the washer nozzles attached to the wiper arms Each arm has two nozzles The washer system requires no adjustment If nozzle performance is unsatisfactory they should be re...

Page 346: ...ti purpose Grease or equivalent to avoid corrosion Begin electrical system failure diagnosis by testing related fuses and circuit breakers in the fuse block and engine compartment Verify that bulbs ar...

Page 347: ...t headlamp switch Test high beam headlamp dimmer switch Check for loose or corroded connector terminals or splices in headlamp circuits Refer to Group 8W Wir ing Diagrams for component and splice loca...

Page 348: ...ams If the low beams are used to align the headlamps the vision of oncoming drivers can be affected ALIGNMENT SCREEN PREPARATION FIG 2 1 Position vehicle on a level surface perpendicular to a flat wal...

Page 349: ...fter the high beams are aligned properly To adjust headlamp alignment rotate alignment screws to achieve the specified low beam hot spot pattern FOG LAMP ALIGNMENT FIG 5 Prepare an alignment screen Re...

Page 350: ...Fig 6 Headlamp Bubble Level Calibration Fig 5 Fog Lamp Alignment Screen LAMPS 8L 5...

Page 351: ...3 Engage wire connector to back of headlamp bulb 4 Place lamp in position on module 5 Install screws to hold headlamp to module as sembly 6 Verify headlamp operation and alignment SIDE MARKER PARK AN...

Page 352: ...GNAL LAMP BULB REMOVAL FIG 5 1 Remove tail lamp from vehicle 2 Remove socket from lamp 3 Pull bulb from socket INSTALLATION 1 Insert bulb into socket 2 Install socket in lamp 3 Install tail lamp in ve...

Page 353: ...g holding bulb to lamp 7 Pull bulb from lamp INSTALLATION CAUTION Do not touch the glass of halogen bulbs with fingers or other possibly oily surface reduced bulb life will result 1 Push bulb into lam...

Page 354: ...park and turn signal lamp 6 Pull bulb from socket INSTALLATION 1 Push bulb into socket 2 Install socket into park and turn signal lamp 3 Place park and turn signal lamp in position on vehicle 4 Instal...

Page 355: ...side marker lamp socket INSTALLATION 1 Push bulb into side marker lamp socket 2 Install socket in side marker lamp 3 Lower vehicle and verify lamp operation CENTER HIGH MOUNTED STOP LAMP CHMSL The CHM...

Page 356: ...ignment sec tion for proper procedure HEADLAMP Lens fogging is a normal condition and does not require service Moisture will vent from tubes located on the back of the lamp REMOVAL FIG 2 1 Release hoo...

Page 357: ...adlamp alignment and calibrate bubble level Refer to Headlamp Alignment procedures in this group FOG LAMP REMOVAL FIG 5 1 Remove screws holding fog lamp to fascia 2 Pull fog lamp forward from opening...

Page 358: ...rear deck panel 8 Verify lamp operation TRUNK LID APPLIQUE LAMP REMOVAL FIG 8 1 Release trunk latch and open trunk lid 2 Remove push in fasteners holding trunk lid lin ing to back of trunk lid 3 Posi...

Page 359: ...front of the level 4 Push level rearward until retaining tabs disen gage from the channels on the side of the level 5 Separate level from vehicle INSTALLATION 1 Place level in position on vehicle 2 P...

Page 360: ...signal lamp 6 Install headlamp module 7 Verify headlamp bubble level and arrow calibra tion and headlamp alignment PARK AND TURN SIGNAL LAMP REMOVAL FIG 4 1 Release hood latch and open hood 2 Remove r...

Page 361: ...amp bulb and socket 2 Remove nuts holding rear side marker lamp to rear bumper fascia 3 Separate rear side marker lamp from vehicle INSTALLATION 1 Place rear side marker lamp in position on ve hicle 2...

Page 362: ...hood latch and open hood 2 Disengage wire connector from DRLR 3 Remove bolts holding DRLR to radiator closure panel 4 Separate DRLR from closure panel INSTALLATION 1 Place DRLR in position on closure...

Page 363: ...te keyless entry system to switch ON the courtesy lamps Refer to Group 8W Wiring Diagrams for component location and circuit information Refer to Body Sys tems Diagnostic Procedures Manual for more in...

Page 364: ...ASC after the component is removed from the vehicle Contact local dealer for location of nearest ASC A C Heater Control All 330 Ash Receiver All 161 Headlamp Switch All 4437661 Instrument Cluster All...

Page 365: ...ion of nearest ASC Door Courtesy All 212 2 Engine Compartment All 105 Glove Compartment All 194 Ignition Lock All ASC Overhead Console All 192 Overhead Information Center All 4437661 Reading Lamp Fron...

Page 366: ...face perpendicular to a flat wall 7 62 meters 25 ft away from front of headlamp lens 2 If necessary tape a line on the floor 7 62 meters 25 ft away from and parallel to the wall 3 From the floor up 1...

Page 367: ...o the low beam headlamp and cannot be aligned separately If the low beam headlamps are aligned properly and the fog lamps are not the headlamp module would require replacement Prepare an alignment scr...

Page 368: ...Fig 4 Fog Lamp Alignment Screen LAMPS 8L 3...

Page 369: ...ector to back of headlamp bulb 4 Place lamp module in position on vehicle 5 Install screws to hold headlamp module to ve hicle 6 Install radiator closure panel sight shield 7 Verify headlamp operation...

Page 370: ...ALLATION 1 Push bulb into socket 2 Install socket in tail lamp 3 Place tail lamp in position on rear closure panel 4 Install nuts to hold tail lamp to rear closure panel 5 Install trunk lining 6 Verif...

Page 371: ...HMSL LICENSE PLATE LAMP BULB REMOVAL FIG 7 1 Remove screws holding license plate lamp to rear bumper fascia 2 Separate license plate lamp from rear bumper fascia 3 Remove socket from lamp 4 Pull bulb...

Page 372: ...move headlamp module 2 Remove park and turn signal lamp 3 From behind front bumper fascia remove bolts holding mount adapter to radiator closure panel 4 Remove radiator grille 5 Remove bolts holding t...

Page 373: ...Pull tail lamp wire harness through hole in rear closure panel 8 Separate tail lamp from vehicle INSTALLATION 1 Place tail lamp in position on vehicle 2 Push tail lamp wire harness through hole in re...

Page 374: ...ear deck up per panel 3 Install rear deck upper panel 4 Engage CHMSL wire connector from body har ness 5 Verify CHMSL operation LICENSE PLATE LAMP REMOVAL FIG 7 1 Remove screws holding license plate l...

Page 375: ...rker 3157NA Rear Side Marker 168 Tail Stop Turn Signal 3057 INTERIOR LAMPS DIMMER CONTROLLED LAMPS Some components have lamps that can only be ser viced by a Authorized Service Center ASC after the co...

Page 376: ...INTERCHANGEABLE BUT IN TERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION THE FASTENERS SCREWS AND BOLTS ORIGI NALLY USED FOR THE AIRBAG COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFI CA...

Page 377: ...he ACM will store sufficient en ergy to deploy the airbags for only two minutes after the battery is disconnected The ACM contains on board diagnostics and will illuminate the AIRBAG warning lamp in t...

Page 378: ...c Procedures Manual Repair as re quired b The airbag warning lamp lights but fails to go out after 10 seconds Test the system using the DRB and Passive Restraint System Diagnostic Pro cedures Manual R...

Page 379: ...ect clockspring horn and airbag wiring connectors to the module Make airbag connection by pressing straight in on the connector The connector should be fully seated to assure positive connection Check...

Page 380: ...ule at right end of instrument panel 17 Remove left outlet duct 18 Remove steering column shrouds and discon nect six electrical connectors Slide wiring trough re tainer off of trough and stow wiring...

Page 381: ...Fig 9 Instrument Panel Components 8M 6 RESTRAINT SYSTEMS...

Page 382: ...Fig 10 Instrument Panel Components New Yorker RESTRAINT SYSTEMS 8M 7...

Page 383: ...ners and remove headlamp carrier 4 Remove three screws holding sensor to head lamp carrier surface and remove sensor Fig 13 5 Disconnect impact sensor electrical connector INSTALLATION 1 Connect senso...

Page 384: ...to 11 to 14 Nzm 105 to 125 in lbs torque CAUTION USE SUPPLIED SCREWS ONLY 3 Connect ACM 4 way and 13 way connectors and ensure both connectors and all locking tabs are en gaged 4 Install shifter beze...

Page 385: ...the ignition cylinder lock Locate the clockspring on the steering shaft and push down on the rotor until the clockspring is fully seated on the steering column Fasten clockspring to steering column us...

Page 386: ...front road wheels in the straight ahead position then Rotate the steering wheel half turn 180 degrees to the right clockwise Lock column with the ignition cylinder lock 2 Disconnect and isolate the ba...

Page 387: ......

Page 388: ...care should be taken in clean ing glass or removing foreign materials decals or stickers Normal glass cleaning solvents or hot water used with rags or toweling is recommended A C HEATER ATC CONTROL S...

Page 389: ...nd fired on inside surface of rear window glass Fig 4 comprise an electrical parallel circuit The electrically conductive lines are composed of a silver ceramic material which when fired on glass beco...

Page 390: ...it for preparing damaged area 3 Remove package separator clamp and mix plas tic conductive epoxy thoroughly Fold in half and cut center corner to dispense epoxy 4 For grid line mark off area to be rep...

Page 391: ......

Page 392: ...transmit ters Each transmitter has its own code and the code has been stored in memory If the transmitter is replaced or a second transmitter is added the code on both units have to be placed in memo...

Page 393: ...k each individual door for electrical lock and unlock or dis connect the motor connectors one at a time while operating the door lock switch In the event that none of the motors work the problem maybe...

Page 394: ...releasing the button two times within five sec onds interval will unlock all doors Upon pressing the LOCK button the horn will sound a short CHIRP to notify that the all door lock signal was received...

Page 395: ...control connector Fig 5 This is the programming line for the Remote Keyless Entry Module The door locks will lock and unlock to indicate the receiver is ready to receive transmitter code The trunk so...

Page 396: ...ress the unlock button once 2 If no voltage pulse replace RKE module If voltage is measured repair the harness between the receiver and the driver door lock motor 3 Check Pin 1 of the RKE module black...

Page 397: ...e black connector for ground 6 If no ground repair as necessary The ground is located near the airbag control module bracket If OK go to step 7 7 Check Pin 5 of the RKE module black connector for grou...

Page 398: ...g that arming is in progress If no monitored systems are activated during this period the system will arm After 15 seconds the Set lamp will continue to flash at a slower rate This indicates that the...

Page 399: ...Activate the power door locks in both the lock and unlock positions Open then close each door one at a time Rotate the key in each of the door lock cylinder to the unlock position Cycle the ignition...

Page 400: ...oup 23 Body for trunk lock cylinder removal 2 Remove security switch from cylinder or bracket and disconnect connector Figs 4 and 5 3 For installation reverse above procedures Fig 4 Trunk Lock Switch...

Page 401: ......

Page 402: ...Find correct circuit breaker on fuse block Pull out slightly but be sure that circuit breaker terminals still contact terminals in fuse block Connect ground wire of voltmeter to a good ground With pr...

Page 403: ...s required for access 2 Disconnect battery negative cable 3 Disconnect wiring harness power lead at carpet 4 Remove assembly from vehicle 5 For installation reverse above procedure In stall and torque...

Page 404: ...Fig 4 Seat Track Removal POWER SEATS 8R 3...

Page 405: ......

Page 406: ...t to black or gray wire terminal and touch other test light lead to tan wire terminal If the test light comes on the wiring circuit between the battery and switch is func tional If light does not come...

Page 407: ...window travel inspection 6 If window does not move check to make sure that it is free It is necessary that the window be free to slide up and down in the glass channels If the window is not free to m...

Page 408: ...ELECTRICAL GROUP INDEX IGNITION SYSTEM 8D LAMPS 8L WIRING DIAGRAMS 8W ELECTRICAL 8A 1...

Page 409: ...the mirrors are inoperative MIRROR MOTOR TEST 1 Using a trim stick remove power mirror switch from mounting position 2 Disconnect wire connector 3 Using two jumper wires one connected to a 12 volt sou...

Page 410: ...n of mirror before installing door trim panel AUTOMATIC DAY NIGHT INSIDE MIRROR Operational test Turn ignition switch to the ON position with the vehicle in park Fig 4 Place mirror switch in the high...

Page 411: ...n the off posi tion before testing the fasten seat belts Turn the ignition switch to the ON position with the driver s seat belt unbuckled and fully retracted The seat belt warning lamp should light f...

Page 412: ...the mounting screw 7 Connect the body to instrument panel wiring connector at the HVAC unit 8 Place the silencer pad back into place 9 Place the carpet back into place 10 Replace the right side heat d...

Page 413: ...d driver s door is open PROCEDURE 1 Check left door jamb switch for good ground when drivers door is open 2 Use DRB to perform CCD diagnostics on body control module for battery ignition switch input...

Page 414: ......

Page 415: ...AGRAM SHEETS AND INDEXES The wiring diagram sheets are organized to show systems relating to the basic vehicle and all of its options Add on or non factory options are not cov ered Diagram pages are i...

Page 416: ...identify which circuit code applies to a system refer to the Circuit Identification Code Chart This chart shows the main circuits only and does not show the second ary codes that may apply to some mo...

Page 417: ...is done when the connector is to large to be shown on the diagram page A box placed next to the connector identifies the connector and the cavity the wire is in In certain instances there may be more...

Page 418: ...tubing 12 Secure the fusible link to the existing ones to prevent chafing or damage to the insulation 13 Connect battery and test all affected systems WIRING REPAIR When replacing or repairing a wire...

Page 419: ...r using rosin core type solder only Do not use acid core solder 13 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...

Page 420: ...spring If a plastic clip is missing or is lost or broken during servicing a vehicle replace only with the equivalent part listed in the parts cata log SYMBOLS AND FUSE IDENTIFICATION Various symbols...

Page 421: ...Fig 11 Symbol Identification WIRING DIAGRAMS 8W 7...

Page 422: ...Fig 12 Controller and Module Locations 8W 8 WIRING DIAGRAMS...

Page 423: ...Fig 13 Wiring Harness Routing WIRING DIAGRAMS 8W 9...

Page 424: ...Fig 14 Ground Identification Chart 8W 10 WIRING DIAGRAMS...

Page 425: ...Fig 15 Power Distribution Center Identification WIRING DIAGRAMS 8W 11...

Page 426: ...Fig 16 Junction Block Identification 8W 12 WIRING DIAGRAMS...

Page 427: ...Front 18 Engine Compartment Wiring Left Rear 19 Engine Compartment Wiring Right Front 16 Caption Fig Engine Compartment Wiring Right Rear 17 Engine Wiring 3 3L 23 Engine Wiring 3 5L 24 Generator Wirin...

Page 428: ...Fig 1 Deck Lid Wiring Fig 2 Trunk Area Wiring 8W 14 WIRING DIAGRAMS...

Page 429: ...Fig 3 Body Wiring Right Rear Fig 4 Body Wiring Left Rear WIRING DIAGRAMS 8W 15...

Page 430: ...Fig 5 Body Wiring Right Front Fig 6 Body Wiring Left Side 8W 16 WIRING DIAGRAMS...

Page 431: ...Fig 7 Body Wiring Left Side Fig 8 ABS System Wiring Rear WIRING DIAGRAMS 8W 17...

Page 432: ...Fig 9 Instrument Panel Wiring Top Fig 10 Instrument Panel Wiring Left Side 8W 18 WIRING DIAGRAMS...

Page 433: ...Fig 11 Instrument Panel Wiring Center Fig 12 Instrument Panel Wiring Right Side WIRING DIAGRAMS 8W 19...

Page 434: ...Fig 13 Steering Column Wiring Fig 14 Door Wiring Rear 8W 20 WIRING DIAGRAMS...

Page 435: ...Fig 15 Door Wiring Front Fig 16 Engine Compartment Wiring Right Front WIRING DIAGRAMS 8W 21...

Page 436: ...Fig 17 Engine Compartment Wiring Right Rear Fig 18 Engine Compartment Wiring Left Front 8W 22 WIRING DIAGRAMS...

Page 437: ...Fig 19 Engine Compartment Wiring Left Rear Fig 20 Generator Wiring WIRING DIAGRAMS 8W 23...

Page 438: ...Fig 21 Battery Wiring Fig 22 Starter and Transmission Wiring 8W 24 WIRING DIAGRAMS...

Page 439: ...Fig 23 Engine Wiring 3 3L WIRING DIAGRAMS 8W 25...

Page 440: ...Fig 24 Engine Wiring 3 5L 8W 26 WIRING DIAGRAMS...

Page 441: ...Fig 25 Underhood Lamp Wiring WIRING DIAGRAMS 8W 27...

Page 442: ...8W 28 WIRING DIAGRAMS...

Page 443: ...74 3 G78 3 K4 10 K4 1 3 3L 14 K4 1 3 5L 15 K4 2 3 3L 14 K4 2 3 5L 15 K6 10 K6 1 3 3L 14 K6 1 3 5L 15 K7 3 3L 14 K7 3 5L 15 K7 1 13 K22 12 K24 10 Splice Number Fig K51 13 L1 3 L1 1 1 L2 7 L7 8 L7 1 10...

Page 444: ...Fig 1 Deck Lid Splices Fig 2 Trunk Area Splices 8W 30 WIRING DIAGRAMS...

Page 445: ...Fig 3 Body Splices Left Side Fig 4 Headliner Splices WIRING DIAGRAMS 8W 31...

Page 446: ...Fig 5 Door Splices Fig 6 HEVAC Splices 8W 32 WIRING DIAGRAMS...

Page 447: ...Fig 7 Instrument Panel Splices Fig 8 Instrument Panel Splices WIRING DIAGRAMS 8W 33...

Page 448: ...Fig 9 Transmission Splices Fig 10 Engine Compartment Splices Right Front 8W 34 WIRING DIAGRAMS...

Page 449: ...Fig 11 Engine Compartment Splices Right Rear Fig 12 Engine Compartment Splices Left Front WIRING DIAGRAMS 8W 35...

Page 450: ...Fig 13 Engine Compartment Splices Left Rear Fig 14 Engine Splices 3 3L 8W 36 WIRING DIAGRAMS...

Page 451: ...Fig 15 Engine Splices 3 5L WIRING DIAGRAMS 8W 37...

Page 452: ...8W 38 WIRING DIAGRAMS...

Page 453: ...d Door 50 Wiring Diagram Name Sheet Number Body Computer Connector Bone 71 72 132 Body Computer Connector Gray 73 74 133 Body Computer Connector Black 75 76 134 Body Ground Systems 111 Cramshaft Posit...

Page 454: ...l Module 13 14 15 16 17 18 19 20 Right Heated Oxygen Sensor 16 Throttle Position Sensor 16 Fuel Injection Ignition System 3 5L Engine 21 22 23 24 25 26 27 28 A C Pressure Transducer 26 Automatic Shutd...

Page 455: ...yless Entry Connectors 138 Knock Sensors 25 Wiring Diagram Name Sheet Number Lamps Ash Receiver Lamp 88 Center High Mounted Stop Lamp 1 110 Center High Mounted Stop Lamp 2 110 Decklid Lamp 101 Glove B...

Page 456: ...n Control Shutdown 3 Relay 8 Engine Starter 3 Relay 9 Not used 3 Relay 10 High Low Wiper 3 Power Door Lock Switch Connectors 137 Power Door Lock System 89 90 Left Door Lock Switch 89 Left Front Door L...

Page 457: ...64 Sensors A C Ambient Temperature Sensor 47 ATC In Car Sensor 49 Camshaft Position Sensor 3 3L ENG 16 Camshaft Position Sensor 3 5L ENG 24 Wiring Diagram Name Sheet Number Charge Air Temperature Sens...

Page 458: ...er Splice P38 92 Splice Q1 97 Splice T13 32 Splice T16 32 Splice T41 20 28 31 Splice V10 56 72 Splice X2 44 Splice X3 44 76 92 Splice X53 80 81 Splice X54 80 81 Splice X55 79 81 Splice X56 79 81 Splic...

Page 459: ...Switch 37 VTA Trunk Knockout Switch 77 Wiper Stalk Switch 56 Throttle Position Sensor 16 24 Wiring Diagram Name Sheet Number Transmission Control System 29 30 31 32 MVLPS 31 Output Speed Sensor 32 Sp...

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Page 504: ...1994 New Yorker LHS Concorde Intrepid Vision Publication No 81 270 4140 TSB 26 10 95 December 1995...

Page 505: ...1994 New Yorker LHS Concorde Intrepid Vision Publication No 81 270 4140 TSB 26 10 95 December 1995...

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Page 622: ...1994 New Yorker LHS Concorde Intrepid Vision Publication No 81 270 4140 TSB 26 04 95 June 1995...

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Page 625: ...f system that is unique to this vehicle For additional information on power sunroof operation refer to Group 23 9Body9 For information not contained in this section refer to Group 8W Wiring Diagrams i...

Page 626: ......

Page 627: ...e MOPAR GASKET MAKER MOPAR Gasket Maker is an anaerobic type gas ket material normally red in color The material cures in the absence of air when squeezed between two metallic surfaces It will not cur...

Page 628: ...inder to cylinder j If one or more cylinders have abnormally low compression pressures repeat steps 4b through 4h k If the same cylinder or cylinders repeat an abnormally low reading on the second com...

Page 629: ...Shimming the bear ings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft This can be accomplished by placing a minimum of 0 254 mm...

Page 630: ...ral items Check the following items 1 Engine oil level too 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 cy...

Page 631: ...Valves etc 7 Repair engine or components as necessary to prevent this problem from occurring again CAUTION Squirt approximately 1 teaspoon of oil into cylinders rotate engine to lubricate the cylinde...

Page 632: ...ENGINE DIAGNOSIS PERFORMANCE 9 6 ENGINE...

Page 633: ...ENGINE DIAGNOSIS MECHANICAL ENGINE 9 7...

Page 634: ...e component To ensure continued safe operation these components must be serviced only with genuine MO PAR replacement parts or equivalent Methanol compatible parts for the FFV Flexible Fuel Vehicle en...

Page 635: ...re installed on a rocker arm shaft attached to the cylin der head with four bolts and retainers Viton valve stem seals provide valve sealing Conventional type pushrods retainers and valve stem locks a...

Page 636: ...compressor aside 11 Disconnect exhaust pipe at manifold 12 Remove transmission inspection cover and mark flex plate to torque converter position 13 Remove screws holding torque converter to flex plat...

Page 637: ...urface In spect cover for distortion and straighten if necessary 3 Clean head rail if necessary Install a new gas ket and tighten cylinder head cover fasteners to 12 Nzm 105 in lbs 4 Install closed cr...

Page 638: ...g the 4 step torque turn method tighten according to the following val ues First All to 61 Nzm 45 ft lbs Second All to 88 Nzm 65 ft lbs Third All again to 88 Nzm 65 ft lbs Fourth 1 4 Turn Do not use a...

Page 639: ...rque again to 22 Nzm 200 in lbs After intake manifold is in place inspect to make sure seals are in place Refer to Group 11 Exhaust System and Intake Manifold to complete Intake Manifold Assem bly 5 I...

Page 640: ...d set it at right angle of valve stem being measured Fig 16 c Move valve to and from the indicator Refer to specifications Fig 18 Ream the guides for valves with oversized stems if dial indicator read...

Page 641: ...ed to top edge of valve face lower valve seat with a 15 degree stone If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone Valve seats which are worn or...

Page 642: ...procedure 5 Remove cylinder head covers and spark plugs 6 Remove connector wire from ignition coils 7 Using suitable socket and flex handle at crank shaft damper retaining screw turn engine so the num...

Page 643: ...oil level and leaks have been cor rected engine should be operated at fast idle to allow all of the air inside of the tappets to be bled out VALVE TRAIN NOISE DIAGNOSIS To determine source of valve tr...

Page 644: ...nto 2 spark plug hole Using the indicator find TDC on the com pression stroke 5 Position the degree wheel to zero 6 Remove dial indicator from spark plug hole 7 Place a 5 08 mm 0 200 inch spacer betwe...

Page 645: ...ition 8 Rotate crankshaft so the timing arrow is to the 12 o clock position 9 Place timing chain around camshaft sprocket and place the timing arrow to the 6 o clock position 10 Align the dark colored...

Page 646: ...belt Refer to Cooling System Group 7 for procedure 3 Remove crankshaft damper Fig 1 4 Using Tool C 4991 to remove oil seal Fig 8 Be careful not to damage that crankshaft seal surface of cover INSTALLA...

Page 647: ...camshaft sprocket and place the timing arrow to the 6 o clock position 5 Align the dark colored links with the dot on the camshaft sprocket place timing chain around crank shaft sprocket with the dark...

Page 648: ...in exact alignment remove and reinstall them correctly Install a new core hole plug at the rear of camshaft Be sure this plug does not leak ENGINE CORE OIL AND CAM PLUGS REMOVAL Using a blunt tool suc...

Page 649: ...Install connecting rod bolt protectors on connecting rod bolts Fig 3 Push each piston and rod assembly out of cylinder bore Be careful not to nick crankshaft journals 4 After removal install bearing...

Page 650: ...easured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in Fig 4 Refer to Fig 5 for specifica tions Pistons and cylinder bores should be mea sured at normal ro...

Page 651: ...he expander Hold end firmly and press down the portion to be installed until side rail is in position Do not use a piston ring expander Fig 11 3 Install upper side rail first and then the lower side r...

Page 652: ...mpressor over the piston and tighten with the special wrench Be sure posi tion of rings does not change during this opera tion 4 Install connecting rod bolt protectors on rod bolts Fig 3 5 Rotate cran...

Page 653: ...ng caps 1 Follow procedure specified in the Standard Ser vice Procedure Section for Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance Fig 16 The rod bearing bolts should be examine...

Page 654: ...ng halves in the engine Fig 2 All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation Bearing shells are avail able in standard and the following unders...

Page 655: ...1 Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek using care not to damage any bearing surface Do not loosen main bearin...

Page 656: ...tainer bore Fig 8 INSTALLATION 1 Place Special Seal Pilot Tool C 4681 on crank shaft Fig 9 2 Lightly coat seal O D with Loctite Stud N Bearing Mount or equivalent 3 Place seal over Special Seal Pilot...

Page 657: ...d wipe dry with a clean cloth Clean all gasket material from mounting surfaces of pan and block 2 Inspect oil drain plug and plug hole for stripped or damaged threads and repair as necessary Install a...

Page 658: ...EPAIR 1 Clean all parts thoroughly Mating surface of the chain case cover CCC should be smooth Replace pump cover if scratched or grooved 2 Lay a straightedge across the pump cover sur face Fig 7 If a...

Page 659: ...hat fails to meet specifications Fig 5 10 If oil pressure is low and pump is within speci fications inspect for worn engine bearings or other reasons for oil pressure loss OIL PUMP ASSEMBLY AND INSTAL...

Page 660: ...deforming the filter can by installing the remove install tool band strap against the can to base lock seam The lockseam joining the can to the base is reinforced by the base plate 1 Using Tool C 406...

Page 661: ...ENGINE SPECIFICATIONS 3 3L ENGINE 9 35...

Page 662: ...ENGINE SPECIFICATIONS CONT 9 36 3 3L ENGINE...

Page 663: ...ENGINE SPECIFICATIONS CONT 3 3L ENGINE 9 37...

Page 664: ...ENGINE SPECIFICATIONS CONT 9 38 3 3L ENGINE...

Page 665: ...TORQUE 3 3L ENGINE 9 39...

Page 666: ...m and Seals Service 43 Valve Service 53 GENERAL INFORMATION ENGINE IDENTIFICATION NUMBER OR CODE The engine identification number is located on the rear of the cylinder block just below the cylinder h...

Page 667: ...ckets and the engine water pump are driven by a single notched timing belt ROCKER ARM SHAFTS The shafts are retained by the aluminum alloy pedestals Four shafts are used one for each intake and exhaus...

Page 668: ...om radiator and en gine 6 Remove radiator and fan assembly Refer to Cooling System Group 7 for procedure 7 See Fuel System Group 14 For procedures to release fuel pressure disconnect fuel lines and ac...

Page 669: ...ING BELT COVERS SERVICE REMOVAL 1 Drain cooling system and remove upper radia tor hose for access to timing belt covers Refer to Cooling System Group 7 for draining procedure 2 Remove the accessory dr...

Page 670: ...5 If none of the above conditions are seen on the belt the belt cover can be installed TIMING BELT SERVICE REMOVAL 1 Mark belt running direction for installation 2 Align the camshaft sprockets with m...

Page 671: ...haft sprocket 2 revolutions and check the timing marks on the camshafts and crank shaft The marks should line up within their respec tive locations Fig 8 If marks do not line up repeat procedure SERVI...

Page 672: ...MSHAFT AND TIMING BELT INSTALLATION AND TIMING PROCEDURE CAUTION The camshaft sprockets are not inter changeable from side to side Fig 14 1 Place crankshaft sprocket to the TDC mark on the oil pump ho...

Page 673: ...ocket hex with a 36 mm 1 7 16 in wrench and tighten the camshaft bolts to 102 Nzm 75 ft lbs plus a 90 degree turn for the Right side and 115 Nzm 85 ft lbs plus a 90 degree turn for the Left side 10 Re...

Page 674: ...k plug wires 4 Loosen the A C compressor mounting bracket and pull away from cylinder head 5 Remove spark plug tube nut and o ring Fig 3 6 Remove rocker cover screws and remove cover Fig 4 INSTALLATIO...

Page 675: ...as an oil passage hole from the cylinder head located at the second rocker shaft support Fig 11 REMOVAL 1 Remove valve covers Refer to procedure out lined in this section 2 Identify the rocker arm ass...

Page 676: ...Install the rocker arm shaft assembly making sure that the identification marks face toward the front of engine 3 Tighten bolts in sequence to 31 Nzm 23 ft lbs Fig 11 HYDRAULIC LASH ADJUSTER The hydr...

Page 677: ...all camshaft into cylinder head 2 Install the camshaft cover and o ring to the head and tighten to 28 Nzm 250 in lbs 3 Install the rocker arm assembly Refer to proce dure outlined in this section CAMS...

Page 678: ...t enter the oil feed hole or the oil return hole INSPECTION 1 Before cleaning check for leaks damage and cracks 2 Clean cylinder head and oil passages 3 Check cylinder head for flatness Fig 18 4 Cylin...

Page 679: ...on 7 Install timing belt covers Refer to procedure outlined in this section 8 Install intake and exhaust manifolds Refer to Intake and Exhaust Manifolds Group 11 for proce dure VALVE SERVICE VALVE AND...

Page 680: ...s to accommodate the oversize valve stem are as follows 6 Slowly turn reamer by hand and clean guide thoroughly before installing new valve Do not at tempt to ream the valve guides from standard direc...

Page 681: ...in different directions The valve springs are color coded intake spring is right hand coil direction with white dye on the top coils and the exhaust spring is left hand coil direction with a pink dye...

Page 682: ...e pulley retaining screw till the number 1 piston is at Top Dead Center on the compression stroke 9 With air hose attached to spark plug adapter installed in number 1 spark plug hole apply 90 to 100 p...

Page 683: ...ting rods and connecting rod caps for cylinder identification Identify them if necessary Fig 2 3 Remove connecting rod cap Install connecting rod bolt protectors on connecting rod bolts Fig 3 Push eac...

Page 684: ...For cylinder bores which have been honed new piston and connecting rod assem blies are available for service FITTING PISTONS Piston and cylinder wall must be clean and dry Piston diameter should be m...

Page 685: ...ail is in position Do not use a piston ring expander Fig 11 3 Install upper side rail first and then the lower side rail 4 Install No 2 piston ring and then No 1 piston ring Fig 12 5 Position piston r...

Page 686: ...ing rod journal 8 Install rod caps Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nzm 40 ft lb Plus 1 4 turn CONNECTING RODS INSTALLATION OF CONNECTING ROD BEARINGS Fit all rods on...

Page 687: ...contact the scale the bolt should be replaced 2 Before installing the nuts the threads should be oiled with engine oil 3 Install nuts on each bolt finger tight then alter nately torque each nut to ass...

Page 688: ...ing halves in the engine Fig 2 All bear ing cap bolts removed during service procedures are to be cleaned and oiled before installation Bearing shells are available in standard and the following under...

Page 689: ...the dial indicator Refer to Fig 6 for specifica tion CRANKSHAFT END PLAY CHECK OPTIONAL 1 Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a...

Page 690: ...ilot Tool C 4681 and tap in place with a plastic hammer REAR CRANKSHAFT SEAL RETAINER When retainer removal is required remove retainer clean engine block and retainer of old gasket Make sure surfaces...

Page 691: ...ds oil under pressure to the cylinder heads It then flows to each cylinder head through passages to camshaft journals the rocker shafts to the rocker arms hy draulic lash adjusters Fig 1 OIL PAN SERVI...

Page 692: ...ess to timing belt covers and vibration damper Refer to Cooling System Group 7 for proce dure 2 Remove the accessory drive belts Refer to Ac cessory Drive System in Group 7 for service proce dure Remo...

Page 693: ...rs and measure clearance between rotor and body Fig 10 If measurement is 0 39 mm 0 015 inch or more replace body only if outer rotor is in specifications 6 Install inner rotor into body If clearance b...

Page 694: ...shaft sprocket Refer to front oil seal service procedure outlined in this section 4 Install timing belt Refer to procedure outlined in this section 5 Install the timing belt covers and vibration dampe...

Page 695: ...ase is reinforced by the base plate 1 Using Tool C 4065 unscrew filter from base and discard Fig 14 2 Wipe base clean then inspect gasket contact surface 3 Lubricate gasket of new filter with clean en...

Page 696: ...ENGINE SPECIFICATIONS 9 70 3 5L ENGINE...

Page 697: ...ENGINE SPECIFICATIONS CONT 3 5L ENGINE 9 71...

Page 698: ...ENGINE SPECIFICATIONS CONT 9 72 3 5L ENGINE...

Page 699: ...TORQUE 3 5L ENGINE 9 73 1994 New Yorker LHS Concorde Intrepid and Vision Publication No 81 270 4140 TSB 26 06 95 August 1995...

Page 700: ......

Page 701: ...e MOPAR GASKET MAKER MOPAR Gasket Maker is an anaerobic type gas ket material normally red in color The material cures in the absence of air when squeezed between two metallic surfaces It will not cur...

Page 702: ...inder to cylinder j If one or more cylinders have abnormally low compression pressures repeat steps 4b through 4h k If the same cylinder or cylinders repeat an abnormally low reading on the second com...

Page 703: ...Shimming the bear ings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft This can be accomplished by placing a minimum of 0 254 mm...

Page 704: ...ral items Check the following items 1 Engine oil level too 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 cy...

Page 705: ...Valves etc 7 Repair engine or components as necessary to prevent this problem from occurring again CAUTION Squirt approximately 1 teaspoon of oil into cylinders rotate engine to lubricate the cylinde...

Page 706: ...ENGINE DIAGNOSIS PERFORMANCE 9 6 ENGINE...

Page 707: ...ENGINE DIAGNOSIS MECHANICAL ENGINE 9 7...

Page 708: ...e component To ensure continued safe operation these components must be serviced only with genuine MO PAR replacement parts or equivalent Methanol compatible parts for the FFV Flexible Fuel Vehicle en...

Page 709: ...re installed on a rocker arm shaft attached to the cylin der head with four bolts and retainers Viton valve stem seals provide valve sealing Conventional type pushrods retainers and valve stem locks a...

Page 710: ...compressor aside 11 Disconnect exhaust pipe at manifold 12 Remove transmission inspection cover and mark flex plate to torque converter position 13 Remove screws holding torque converter to flex plat...

Page 711: ...urface In spect cover for distortion and straighten if necessary 3 Clean head rail if necessary Install a new gas ket and tighten cylinder head cover fasteners to 12 Nzm 105 in lbs 4 Install closed cr...

Page 712: ...g the 4 step torque turn method tighten according to the following val ues First All to 61 Nzm 45 ft lbs Second All to 88 Nzm 65 ft lbs Third All again to 88 Nzm 65 ft lbs Fourth 1 4 Turn Do not use a...

Page 713: ...rque again to 22 Nzm 200 in lbs After intake manifold is in place inspect to make sure seals are in place Refer to Group 11 Exhaust System and Intake Manifold to complete Intake Manifold Assem bly 5 I...

Page 714: ...d set it at right angle of valve stem being measured Fig 16 c Move valve to and from the indicator Refer to specifications Fig 18 Ream the guides for valves with oversized stems if dial indicator read...

Page 715: ...ed to top edge of valve face lower valve seat with a 15 degree stone If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone Valve seats which are worn or...

Page 716: ...procedure 5 Remove cylinder head covers and spark plugs 6 Remove connector wire from ignition coils 7 Using suitable socket and flex handle at crank shaft damper retaining screw turn engine so the num...

Page 717: ...oil level and leaks have been cor rected engine should be operated at fast idle to allow all of the air inside of the tappets to be bled out VALVE TRAIN NOISE DIAGNOSIS To determine source of valve tr...

Page 718: ...nto 2 spark plug hole Using the indicator find TDC on the com pression stroke 5 Position the degree wheel to zero 6 Remove dial indicator from spark plug hole 7 Place a 5 08 mm 0 200 inch spacer betwe...

Page 719: ...ition 8 Rotate crankshaft so the timing arrow is to the 12 o clock position 9 Place timing chain around camshaft sprocket and place the timing arrow to the 6 o clock position 10 Align the dark colored...

Page 720: ...belt Refer to Cooling System Group 7 for procedure 3 Remove crankshaft damper Fig 1 4 Using Tool C 4991 to remove oil seal Fig 8 Be careful not to damage that crankshaft seal surface of cover INSTALLA...

Page 721: ...camshaft sprocket and place the timing arrow to the 6 o clock position 5 Align the dark colored links with the dot on the camshaft sprocket place timing chain around crank shaft sprocket with the dark...

Page 722: ...in exact alignment remove and reinstall them correctly Install a new core hole plug at the rear of camshaft Be sure this plug does not leak ENGINE CORE OIL AND CAM PLUGS REMOVAL Using a blunt tool suc...

Page 723: ...Install connecting rod bolt protectors on connecting rod bolts Fig 3 Push each piston and rod assembly out of cylinder bore Be careful not to nick crankshaft journals 4 After removal install bearing...

Page 724: ...easured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in Fig 4 Refer to Fig 5 for specifica tions Pistons and cylinder bores should be mea sured at normal ro...

Page 725: ...he expander Hold end firmly and press down the portion to be installed until side rail is in position Do not use a piston ring expander Fig 11 3 Install upper side rail first and then the lower side r...

Page 726: ...mpressor over the piston and tighten with the special wrench Be sure posi tion of rings does not change during this opera tion 4 Install connecting rod bolt protectors on rod bolts Fig 3 5 Rotate cran...

Page 727: ...ng caps 1 Follow procedure specified in the Standard Ser vice Procedure Section for Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance Fig 16 The rod bearing bolts should be examine...

Page 728: ...ng halves in the engine Fig 2 All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation Bearing shells are avail able in standard and the following unders...

Page 729: ...1 Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a crankshaft cheek using care not to damage any bearing surface Do not loosen main bearin...

Page 730: ...tainer bore Fig 8 INSTALLATION 1 Place Special Seal Pilot Tool C 4681 on crank shaft Fig 9 2 Lightly coat seal O D with Loctite Stud N Bearing Mount or equivalent 3 Place seal over Special Seal Pilot...

Page 731: ...d wipe dry with a clean cloth Clean all gasket material from mounting surfaces of pan and block 2 Inspect oil drain plug and plug hole for stripped or damaged threads and repair as necessary Install a...

Page 732: ...EPAIR 1 Clean all parts thoroughly Mating surface of the chain case cover CCC should be smooth Replace pump cover if scratched or grooved 2 Lay a straightedge across the pump cover sur face Fig 7 If a...

Page 733: ...hat fails to meet specifications Fig 5 10 If oil pressure is low and pump is within speci fications inspect for worn engine bearings or other reasons for oil pressure loss OIL PUMP ASSEMBLY AND INSTAL...

Page 734: ...deforming the filter can by installing the remove install tool band strap against the can to base lock seam The lockseam joining the can to the base is reinforced by the base plate 1 Using Tool C 406...

Page 735: ...ENGINE SPECIFICATIONS 3 3L ENGINE 9 35...

Page 736: ...ENGINE SPECIFICATIONS CONT 9 36 3 3L ENGINE...

Page 737: ...ENGINE SPECIFICATIONS CONT 3 3L ENGINE 9 37...

Page 738: ...ENGINE SPECIFICATIONS CONT 9 38 3 3L ENGINE...

Page 739: ...TORQUE 3 3L ENGINE 9 39...

Page 740: ...m and Seals Service 43 Valve Service 53 GENERAL INFORMATION ENGINE IDENTIFICATION NUMBER OR CODE The engine identification number is located on the rear of the cylinder block just below the cylinder h...

Page 741: ...ckets and the engine water pump are driven by a single notched timing belt ROCKER ARM SHAFTS The shafts are retained by the aluminum alloy pedestals Four shafts are used one for each intake and exhaus...

Page 742: ...om radiator and en gine 6 Remove radiator and fan assembly Refer to Cooling System Group 7 for procedure 7 See Fuel System Group 14 For procedures to release fuel pressure disconnect fuel lines and ac...

Page 743: ...ING BELT COVERS SERVICE REMOVAL 1 Drain cooling system and remove upper radia tor hose for access to timing belt covers Refer to Cooling System Group 7 for draining procedure 2 Remove the accessory dr...

Page 744: ...5 If none of the above conditions are seen on the belt the belt cover can be installed TIMING BELT SERVICE REMOVAL 1 Mark belt running direction for installation 2 Align the camshaft sprockets with m...

Page 745: ...haft sprocket 2 revolutions and check the timing marks on the camshafts and crank shaft The marks should line up within their respec tive locations Fig 8 If marks do not line up repeat procedure SERVI...

Page 746: ...MSHAFT AND TIMING BELT INSTALLATION AND TIMING PROCEDURE CAUTION The camshaft sprockets are not inter changeable from side to side Fig 14 1 Place crankshaft sprocket to the TDC mark on the oil pump ho...

Page 747: ...ocket hex with a 36 mm 1 7 16 in wrench and tighten the camshaft bolts to 102 Nzm 75 ft lbs plus a 90 degree turn for the Right side and 115 Nzm 85 ft lbs plus a 90 degree turn for the Left side 10 Re...

Page 748: ...k plug wires 4 Loosen the A C compressor mounting bracket and pull away from cylinder head 5 Remove spark plug tube nut and o ring Fig 3 6 Remove rocker cover screws and remove cover Fig 4 INSTALLATIO...

Page 749: ...as an oil passage hole from the cylinder head located at the second rocker shaft support Fig 11 REMOVAL 1 Remove valve covers Refer to procedure out lined in this section 2 Identify the rocker arm ass...

Page 750: ...Install the rocker arm shaft assembly making sure that the identification marks face toward the front of engine 3 Tighten bolts in sequence to 31 Nzm 23 ft lbs Fig 11 HYDRAULIC LASH ADJUSTER The hydr...

Page 751: ...all camshaft into cylinder head 2 Install the camshaft cover and o ring to the head and tighten to 28 Nzm 250 in lbs 3 Install the rocker arm assembly Refer to proce dure outlined in this section CAMS...

Page 752: ...t enter the oil feed hole or the oil return hole INSPECTION 1 Before cleaning check for leaks damage and cracks 2 Clean cylinder head and oil passages 3 Check cylinder head for flatness Fig 18 4 Cylin...

Page 753: ...on 7 Install timing belt covers Refer to procedure outlined in this section 8 Install intake and exhaust manifolds Refer to Intake and Exhaust Manifolds Group 11 for proce dure VALVE SERVICE VALVE AND...

Page 754: ...s to accommodate the oversize valve stem are as follows 6 Slowly turn reamer by hand and clean guide thoroughly before installing new valve Do not at tempt to ream the valve guides from standard direc...

Page 755: ...in different directions The valve springs are color coded intake spring is right hand coil direction with white dye on the top coils and the exhaust spring is left hand coil direction with a pink dye...

Page 756: ...e pulley retaining screw till the number 1 piston is at Top Dead Center on the compression stroke 9 With air hose attached to spark plug adapter installed in number 1 spark plug hole apply 90 to 100 p...

Page 757: ...ting rods and connecting rod caps for cylinder identification Identify them if necessary Fig 2 3 Remove connecting rod cap Install connecting rod bolt protectors on connecting rod bolts Fig 3 Push eac...

Page 758: ...For cylinder bores which have been honed new piston and connecting rod assem blies are available for service FITTING PISTONS Piston and cylinder wall must be clean and dry Piston diameter should be m...

Page 759: ...ail is in position Do not use a piston ring expander Fig 11 3 Install upper side rail first and then the lower side rail 4 Install No 2 piston ring and then No 1 piston ring Fig 12 5 Position piston r...

Page 760: ...ing rod journal 8 Install rod caps Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nzm 40 ft lb Plus 1 4 turn CONNECTING RODS INSTALLATION OF CONNECTING ROD BEARINGS Fit all rods on...

Page 761: ...contact the scale the bolt should be replaced 2 Before installing the nuts the threads should be oiled with engine oil 3 Install nuts on each bolt finger tight then alter nately torque each nut to ass...

Page 762: ...ing halves in the engine Fig 2 All bear ing cap bolts removed during service procedures are to be cleaned and oiled before installation Bearing shells are available in standard and the following under...

Page 763: ...the dial indicator Refer to Fig 6 for specifica tion CRANKSHAFT END PLAY CHECK OPTIONAL 1 Move crankshaft all the way to the rear of its travel using a lever inserted between a main bearing cap and a...

Page 764: ...ilot Tool C 4681 and tap in place with a plastic hammer REAR CRANKSHAFT SEAL RETAINER When retainer removal is required remove retainer clean engine block and retainer of old gasket Make sure surfaces...

Page 765: ...ds oil under pressure to the cylinder heads It then flows to each cylinder head through passages to camshaft journals the rocker shafts to the rocker arms hy draulic lash adjusters Fig 1 OIL PAN SERVI...

Page 766: ...ess to timing belt covers and vibration damper Refer to Cooling System Group 7 for proce dure 2 Remove the accessory drive belts Refer to Ac cessory Drive System in Group 7 for service proce dure Remo...

Page 767: ...rs and measure clearance between rotor and body Fig 10 If measurement is 0 39 mm 0 015 inch or more replace body only if outer rotor is in specifications 6 Install inner rotor into body If clearance b...

Page 768: ...shaft sprocket Refer to front oil seal service procedure outlined in this section 4 Install timing belt Refer to procedure outlined in this section 5 Install the timing belt covers and vibration dampe...

Page 769: ...ase is reinforced by the base plate 1 Using Tool C 4065 unscrew filter from base and discard Fig 14 2 Wipe base clean then inspect gasket contact surface 3 Lubricate gasket of new filter with clean en...

Page 770: ...ENGINE SPECIFICATIONS 9 70 3 5L ENGINE...

Page 771: ...ENGINE SPECIFICATIONS CONT 3 5L ENGINE 9 71...

Page 772: ...ENGINE SPECIFICATIONS CONT 9 72 3 5L ENGINE...

Page 773: ...TORQUE 3 5L ENGINE 9 73 1994 New Yorker LHS Concorde Intrepid and Vision Publication No 81 270 4140 TSB 26 06 95 August 1995...

Page 774: ......

Page 775: ...n damage and worn cracked or broken hangers Re place all components that are badly corroded or dam aged Do not attempt to repair CATALYTIC CONVERTERS There is no regularly scheduled maintenance on any...

Page 776: ...t shields on cars if equipped Light over spray near the edges is permitted Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan tempera tures...

Page 777: ...n pipes past the engine engine support cradle and transmission Lay the exhaust system on the ground When replacement is required on any compo nent of the exhaust system it is most important that origi...

Page 778: ...mbly 3 5l engine There are different muffler assemblies and resona tor assemblies dependent on the type of vehicle being serviced Be certain to select the proper assembly for the vehicle being service...

Page 779: ...he accompanying clamp 3 Remove the exhaust support bracket s from the vehicle Fig 8 4 Install new exhaust support bracket s found on the replacement tailpipe resonator assembly onto ve hicle in the sa...

Page 780: ...regulator 9 Disconnect purge hose from throttle body Dis connect electrical connector from throttle position sensor and idle air control motor Fig 6 10 Remove EGR tube mounting screws at intake manifo...

Page 781: ...passages INSTALLATION 1 Clean all surfaces of cylinder block and cylinder heads 2 Place a drop about 1 4 in diameter of Mopar Silicone Rubber Adhesive Sealant or equivalent onto each of the four mani...

Page 782: ...screws 11 Tighten Intake Manifold Plenum mounting bolts to 28 Nzm 250 in lbs in sequence as shown in Fig 12 12 Tighten EGR tube mounting screws 13 Connect hoses to PCV valve and brake booster nipple 1...

Page 783: ...nd speed control cable from throttle arm Fig 1 5 Disconnect electrical connector from idle air control motor Fig 2 6 Disconnect electrical connector from intake air temperature sensor Fig 2 7 Remove g...

Page 784: ...ermostat housing and heater hose from rear of intake manifold 19 Remove intake manifold attaching bolts Fig 9 Fig 3 MAP Sensor Fig 4 Throttle Position Sensor Fig 5 Air Inlet Plenum Fig 6 EGR Tube Top...

Page 785: ...ter hose to fitting on intake manifold plenum 15 Connect purge tubes to fittings on throttle bodies 16 Install cover on intake manifold plenum 17 Connect negative cable to battery 18 Fill cooling syst...

Page 786: ...TORQUE SPECIFICATION 11 12 EXHAUST SYSTEM AND INTAKE MANIFOLD...

Page 787: ...on bottom of front fend ers 3 Install push in fasteners to hold fascia to front fenders 4 Engage fog lamp wire connector to body wire harness if equipped 5 Install push in fasteners to hold bottom of...

Page 788: ...of quar ter panel 8 Install wheelhouse splash shields as necessary to gain access to fascia fasteners ENGINE CRADLE CROSSMEMBER REMOVAL FIG 4 WARNING VERIFY THAT VEHICLE IS PROPERLY SUPPORTED AND SEC...

Page 789: ...crossmember to cradle 10 Lower vehicle 11 Remove engine support device 12 Install nuts to hold engine mounts to cradle 13 Align front suspension if necessary FRAME DIMENSIONS Frame dimensions are lis...

Page 790: ...Fig 6 Engine Compartment Side View 13 4 FRAME AND BUMPERS...

Page 791: ...Fig 7 Forward Frame Section and Engine Cradle FRAME AND BUMPERS 13 5...

Page 792: ...Fig 8 Rear Frame Section 13 6 FRAME AND BUMPERS...

Page 793: ...ith the proper octane rating those that contain detergents corrosion and stability additives are recommended Using gasolines that have these additives will help improve fuel economy reduce emissions a...

Page 794: ...line In areas of the country where carbon monoxide levels are high gasolines are being treated with oxygen ated materials such as ETBE MTBE and ethanol The use of gasoline blended with these materials...

Page 795: ...e ground Service vehicles in well ven tilated areas and avoid ignition sources Never smoke while servicing the vehicle Do not allow methanol to contact skin Prolonged contact with methanol can cause d...

Page 796: ...th transmission jack 3 Lower fuel tank Refer to Fuel Tank Removal in the Fuel Tank section of this Group Quick connect fittings attach the fuel tubes to the methanol concentration sensor Fig 1 4 Disco...

Page 797: ...he motor to the out let The pump module contains three check valves One valve relieves internal fuel pump pressure and regulates maximum pump output Another valve in side the pump module assembly in t...

Page 798: ...n the inside of the tank while removing the module Tilt the module to one side when removing from tank 11 Remove fuel pump module and gasket from tank 12 Drain remainder of fuel from reservoir before...

Page 799: ...sen sor itself It does not test the level sensor circuit Refer to Group 8W Wiring Diagrams for circuit iden tification The level sensor is a variable resistor Its resistance changes with the amount o...

Page 800: ...dule and the top of the level sensor housing Fig 16 Push level sensor down slightly 5 Slide level sensor wires through standpipe in side fuel pump module Fig 17 6 Slide level sensor out of installatio...

Page 801: ...e Fig 20 The dual function valve relieves fuel tank pressure and prevents fuel flow through the fuel tank vent hoses in the event of vehicle rollover All vehicles pass a full 360 rollover without fuel...

Page 802: ...n the bottom of the dia phragm The combination of fuel pressure and intake manifold open the return port The more intake mani fold vacuum applied to the regulator the less fuel pressure required to op...

Page 803: ...ASD Fuel System Test to pressur ize the fuel system Check for leaks REMOVAL 3 5L ENGINE The intake manifold plenum must be removed to service the fuel pressure regulator Refer to 3 5L In take Manifold...

Page 804: ...Pa 55 PSI With the engine idling and manifold vacuum applied to the regu lator the system operates at approximately 317 kPa 46 PSI Fuel system pressure varies with different amounts of manifold vacuum...

Page 805: ...roceed to Fuel System Pressure Above Specifications Fuel System Pressure Below Specifications If the fuel pressure reading in step 4 was below specifications test the system according to the follow in...

Page 806: ...installation procedures The fuel pump module and fuel filter inlet use plastic two tab quick connect fittings The fuel filter outlet and fuel rail connections use metal quick connect fittings PLASTIC...

Page 807: ...sing the ASD Fuel System Test the Automatic Shut Down ASD Relay remains energized for either 7 minutes until the test is stopped or until the ignition switch is turned to the Off position 6 Use the DR...

Page 808: ...ntil the retainer in the fitting con tact the fuel tube nipple shoulder Once the re tainer contact the shoulder all movement should stop If the quick connect fitting comes off of the fuel rail attach...

Page 809: ...Fig 40 Connecting Quick Connect Fittings to Fuel Rail FUEL DELIVERY 14 17...

Page 810: ...filter and fuel return circuit to the fuel rail Quick Connect fittings attach the fuel tubes When servicing fuel tubes or components near the tube ensure the tubes do not contact or rub against other...

Page 811: ...Fig 43 Chassis Fuel Tubes FUEL DELIVERY 14 19...

Page 812: ...he fuel tank are collected in a charcoal filled canister The vapors are held in the canister until the engine operates Engine vacuum draws the vapors through the intake mani fold into the combustion c...

Page 813: ...uel system and emission system hoses and tubes PRESSURE VACUUM FILLER CAP The fuel filler cap incorporates a two way relief valve that is closed to atmosphere during normal operating conditions The re...

Page 814: ...m inlet side of fuel filter Disconnect fuel return tube and vent tube near fuel filter Refer to Quick Connect Fittings in the Fuel Delivery section of this group 9 Disconnect both ends of the sway bar...

Page 815: ...filler tube and vent tube to fuel filler neck Align marks made on hose and tube during removal 9 Connect sway bar ends to link arms Tighten sway bar mounting nuts to 100 Nzm 74 ft lbs torque 10 Instal...

Page 816: ...ld the throttle body lever in the wide open position and install the throttle cable THROTTLE CABLE SERVICE CAUTION When servicing the accelerator pedal throttle cable or speed control cable do not dam...

Page 817: ...Fig 2 5 From the engine compartment rotate the throttle lever to wide open and install the throttle cable On 3 5L engines ensure the power steer ing hose is routed through the hook on the throttle ca...

Page 818: ...ehicles can operate on a mixture of up to 85 percent methanol 15 percent unleaded gasoline These vehicles also operate on mixtures containing a lower percentage of methanol or just pure unleaded gasol...

Page 819: ...on and off The number of flashes represents the trouble code There is a slight pause between the flashes representing the first and second digits of the code Longer pauses separate individual trouble...

Page 820: ...ol Motor Ignition Coils Low Speed Fan Relay MTV Solenoid Speed Control Relay Speed Control Vent Relay Speed Control Vacuum Relay Based on inputs it receives the powertrain control module PCM adjusts f...

Page 821: ...the DRB scan tool to the data link connector The data link connector con tains 6 terminals Terminal 3 is the SCI Receive circuit Terminal 4 is the SCI Transmit circuit AIR CONDITIONING PRESSURE TRANS...

Page 822: ...ft position sensor is mounted in the front of the timing case cover Fig 7 or Fig 8 INTAKE AIR TEMPERATURE SENSOR PCM INPUT The 3 5L engine and 3 3L FFV engine use an intake air temperature sensor 3 3L...

Page 823: ...de of the transmission housing above the differen tial housing Fig 12 The bottom of the sensor is positioned next to the drive plate Fig 10 Intake Air Temperature Sensor 3 3L FFV Engine Fig 7 Camshaft...

Page 824: ...SENSE PCM INPUT The ignition sense input informs the powertrain control module PCM that the ignition switch is in the crank or run position MANIFOLD ABSOLUTE PRESSURE SENSOR PCM INPUT The powertrain...

Page 825: ...uel injection system uses two heated oxygen sensors one in the outlet of each exhaust manifold Fig 19 or Fig 20 Both sensors monitor the amount of oxygen in the exhaust gas stream The left sensor moni...

Page 826: ...e speed has been selected The speed control Resume voltage indicates the previous fixed speed is requested The speed control Off voltage tells the PCM that the speed control system has deactivated Ref...

Page 827: ...sor signals to deter mine engine speed and ignition timing coil dwell If the PCM does not receive a crankshaft position sen sor signal and camshaft position sensor signal when the ignition switch is i...

Page 828: ...start time delay the PCM does not energize the solenoid When de energized no vapors are purged The PCM de energizes the solenoid during open loop operation The engine enters Closed Loop operation aft...

Page 829: ...y operation IDLE AIR CONTROL MOTOR PCM OUTPUT 3 3L ENGINE The idle air control motor attaches to the throttle body Fig 30 The PCM operates the idle air control motor The PCM adjusts engine idle speed...

Page 830: ...to keep the system operational and leaves the lamp on In limp in mode the PCM compensates for the failure of certain components that send incorrect signals The PCM substitutes inputs from other senso...

Page 831: ...energizes the high speed fan when engine coolant temperature reaches approximately 110 C 230 F The PCM de energizes the high speed fan and energizes the low speed fan when coolant tem perature drops...

Page 832: ...ies fuel strategy based on this input When the key is in the ON position and the engine is not running zero rpm the automatic shut down ASD relay and fuel pump relay are not energized Therefore batter...

Page 833: ...CELERATION MODE This is a CLOSED LOOP mode During decelera tion the following inputs are received by the PCM A C pressure transducer A C switch position Coolant temperature Manifold absolute pressure...

Page 834: ...fer to Throttle Body Synchronization in the Multi Port Fuel Injection Service Procedures section of this group FUEL PRESSURE REGULATOR The powertrain control module PCM does not con trol the fuel pres...

Page 835: ...RB scan tool and the appropriate Power train Diagnostic Manual The On Board Diagnostics section of this group has a description of diagnostic trouble codes It also contains a list of the actuator test...

Page 836: ...re spark plug cables are firmly connected in the correct order to the coil pack and spark plugs 5 Ensure the electrical connector is completely at tached to the idle air contact motor Fig 5 or Fig 6 F...

Page 837: ...the vacuum hose is connected to the manifold tuning valve and the vacuum harness Fig 11 11 Ensure the vacuum hose is attached to the fuel pressure regulator Fig 12 or Fig 13 Check the hose for cracks...

Page 838: ...corroded connections at the generator Fig 16 18 Check fuel supply and return tube connections for leaks 19 Verify electrical connector is attached to the crankshaft position sensor Fig 17 Fig 13 Fuel...

Page 839: ...coil side of the relay through terminal number 85 Terminal number 86 supplies voltage to the coil side of the relay When PCM de energizes the ASD and fuel pump relays terminal number 87A connects to t...

Page 840: ...3 3L FUEL INJECTOR DIAGNOSIS 14 48 FUEL INJECTION GENERAL DIAGNOSIS...

Page 841: ...3 5L FUEL INJECTOR DIAGNOSIS FUEL INJECTION GENERAL DIAGNOSIS 14 49...

Page 842: ...he output voltage at idle and at wide open throttle WOT At idle TPS output voltage should be greater than 0 6 volts At wide open throttle TPS output voltage should be less than 4 5 volts The output vo...

Page 843: ...CONTACT WITH EYES OR SKIN AVOID INGESTING THE CLEANER WASH THOROUGHLY AFTER USING CLEANER b While holding the throttle open spray the entire throttle body bore and the manifold side of the throttle p...

Page 844: ...nd portions of the throttle bore that are closest to the throttle blade when is closed must be free of deposits 4 Use compressed air to dry the throttle bodies 5 Inspect throttle bodies for foreign ma...

Page 845: ...ions reset throttle body synchronization Also recheck idle air control motor operation using the DRB scan tool If idle RPM is still above specifications after setting throttle body synchronization che...

Page 846: ...ifferent methods The first is to cycle the ignition switch On Off On Off On within 5 seconds Then count the number of times the mal function indicator lamp check engine lamp on the instrument panel fl...

Page 847: ...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 in memory Othe...

Page 848: ...harge intake air temperature sensor tempera ture and voltage Charging System Goal Cool coolant temperature and sensor voltage Injector Width pulse width Knock Sensor 2 Knock Sensor 1 MAP vacuum MAP Vo...

Page 849: ...dule PCM 60 way connector for the following Spread terminals Stretched or pulled out wires Undertightened or overtightened 60 way connector Tighten the PCM connector to 4 Nzm 35 in lbs torque When che...

Page 850: ...POWERTRAIN CONTROL MODULE 60 WAY CONNECTOR 14 58 FUEL INJECTION ON BOARD DIAGNOSTICS...

Page 851: ...ected from the oxygen sensor input or Left O2S Shorted to Voltage Oxygen sensor input voltage maintained above the normal operating range or Right O2S Stays at Center Neither rich or lean condition de...

Page 852: ...d during diagnostic test 33 A C Clutch Relay Circuit An open or shorted condition detected in the A C clutch relay circuit or A C Pressure Sensor Volts Too Low A C pressure transducer input below the...

Page 853: ...ring engine operation or Right O2S Signal Stays Below Center Lean Right oxygen sensor signal input indicates lean air fuel ratio condition during engine operation or Lean Operation at Wide Open Thrott...

Page 854: ...Circuit An open or shorted condition detected in the manifold tuning valve solenoid circuit 66 No CCD Bus Messages PCM did not receive messages from the CCD Bus or No CCD Messages From TCM The PCM did...

Page 855: ...ies 3 5L Engine 64 Throttle Body Synchronization 3 5L Engine 66 Throttle Body 3 3L Engine 64 Throttle Position Sensor TPS 3 3L Engine 80 Throttle Position Sensor TPS 3 5L Engine 80 FUEL SYSTEM PRESSUR...

Page 856: ...ANING COKED THROTTLE BODIES Coked throttle bodies will cause low idle speed and poor idle quality When replacing one throttle body always remove and clean the other throttle body After installing the...

Page 857: ...on enters socket in end of synchroni zation shaft Fig 8 Ensure spring attaches to shaft and throttle body arm Also ensure the spring does not bind when opening and closing the throttle blade 3 Instal...

Page 858: ...tube 10 Connect negative cable to battery THROTTLE BODY SYNCHRONIZATION 3 5L ENGINE Synchronize the throttle bodies if there is a gap between the adjustment screw and the linkage lever Fig 12 and Fig...

Page 859: ...le at rear of intake manifold plenum Dis connect vacuum line from fuel pressure regulator 9 Disconnect purge hose from throttle body Dis connect electrical connector from throttle position sensor and...

Page 860: ...rol motor 12 Install throttle cable and speed control cable in bracket 13 Hold throttle body lever in wide open position Install throttle and speed control cables 14 Connect purge hose to throttle bod...

Page 861: ...nsor Fig 22 9 Disconnect purge hose from throttle bodies Fig 22 10 Disconnect PCV make up air hose and idle air control motor supply hose part of air inlet plenum Remove air inlet plenum from behind m...

Page 862: ...um 9 Install air cleaner to plenum hose 10 Connect brake booster hose to fitting on intake manifold plenum 11 Connect purge tubes to fittings on throttle bod ies 12 Install cover on intake manifold pl...

Page 863: ...ch electrical connectors to fuel injectors 5 Connect vacuum supply tube to fuel pressure regulator 6 Install intake manifold plenum Refer to Intake Manifold Plenum 3 5L Engine in this section 7 Instal...

Page 864: ...ed to service the injectors use a new gasket when installing the rail 1 Lightly lubricate the O rings with a couple drops of clean engine oil When installing the injector index the notch on the inject...

Page 865: ...r to sensor CAMSHAFT POSITION SENSOR 3 5L ENGINE The camshaft position sensor is installed in the timing case cover above the left camshaft sprocket Fig 37 REMOVAL 1 Disconnect electrical connector fr...

Page 866: ...bs torque 2 Attach electrical connector to sensor 3 Install engine cover CRANKSHAFT POSITION SENSOR The crankshaft sensor is located on the passengers side of the transmission housing above the differ...

Page 867: ...t and solenoid s Ensure solenoid does not contact other surfaces or components The solenoid could make a clicking sound if it contacts other surfaces or components 3 Attach electrical connector to sol...

Page 868: ...it must be retracted Use the DRB IAC Motor Open Close Test to retract the pintle battery must be connected 2 Carefully place idle air control motor into throttle body 3 Install mounting screws Tighte...

Page 869: ...coil pack mounting screws 4 Remove coil The spark plug cables are num bered for cylinder identification Fig 52 5 Transfer spark plug cables to new coil pack The coil pack towers are numbered with the...

Page 870: ...NSTALLATION 1 Thread sensor into intake manifold plenum Tighten sensor to 10 Nzm 90 in lbs torque and then rotate it to horizontal position 2 Attach electrical connector to sensor MANIFOLD TUNING VALV...

Page 871: ...ts 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 milage in new PCM Use the DRB scan tool to change the mila...

Page 872: ...lockwise a few degrees to line up the mount ing screw holes with the screw holes in the throttle body The TPS has slight tension when rotated into position If it is difficult to rotate the TPS into po...

Page 873: ...throttle body Fig 66 The TPS has slight tension when rotated into position If it is difficult to rotate the TPS into posi tion install the sensor with the throttle shaft on the other side of the tabs...

Page 874: ...SPECIFICATIONS TORQUE 14 82 FUEL INJECTION SERVICE PROCEDURES...

Page 875: ...turns off If during the next time the vehicle operates the compo nent again triggers the diagnostic trouble code the light turns back on The malfunction indicator lamp signals the need for immediate s...

Page 876: ...DIAGNOSTIC TROUBLE CODE DESCRIPTION 14 2 FUEL SYSTEMS...

Page 877: ...DIAGNOSTIC TROUBLE CODE DESCRIPTION CONTINUED FUEL SYSTEMS 14 3...

Page 878: ...DIAGNOSTIC TROUBLE CODE DESCRIPTION CONTINUED 14 4 FUEL SYSTEMS...

Page 879: ...ect oil from the pump to either side of the integral steering rack piston Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle As required steering effort increa...

Page 880: ...pump All L H platform vehicles with all available engine options use the Sagi naw T C style power steering pump Fig 1 All L H platform vehicles use a remote mounted reservoir for the power steering f...

Page 881: ...STEERING COMPONENTS SERVICE DIAGNOSIS POWER STEERING SERVICE DIAGNOSIS STEERING 19 3...

Page 882: ...POWER STEERING SERVICE DIAGNOSIS 19 4 STEERING...

Page 883: ...POWER STEERING SERVICE DIAGNOSIS STEERING 19 5...

Page 884: ...POWER STEERING SERVICE DIAGNOSIS 19 6 STEERING...

Page 885: ...POWER STEERING SERVICE DIAGNOSIS STEERING 19 7...

Page 886: ...POWER STEERING SERVICE DIAGNOSIS 19 8 STEERING...

Page 887: ...m ring As the vanes reach the restricted area of the cam ring oil is forced out from between the vanes When excess oil flow is gener ated during high speed operation A regulated amount of oil returns...

Page 888: ...nst the stops Record the highest indicated pressure at each posi tion Compare readings to specifications If highest output pressures are not the same against either stop the steering gear is leaking i...

Page 889: ...me 4 Route power steering pressure hose through routing bracket on engine assembly See Fig 3 and 4 for hose routing and bracket location for 3 3 and 3 5 ltr engine applications 5 Install power steerin...

Page 890: ...e the power steering return hose fitting Fig 7 from the power steering gear Let power steering fluid drain from hose 2 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoistin...

Page 891: ...ble from the battery negative terminal and isolate cable 2 Loosen power steering pump serpentine drive belt on 3 3 ltr engine by loosening generator mount ing bolt A and adjusting bolt locknut B Fig 1...

Page 892: ...steering pressure hose at power steering pump must be maintained Be sure power steering hose is installed in routing clip Fig 7 at generator prior to tightening tube fitting This will maintain requir...

Page 893: ...m for leaks See Checking Fluid Level POWER STEERING PUMP PULLEY SERVICE REMOVE 1 Mount power steering pump assembly in a vise using one of the pump mounting bosses Fig 1 Do not clamp the body of the p...

Page 894: ...installer pushing the pulley onto the shaft of the power steering pump Fig 4 Ensure that the tool and the pulley remain aligned with the pump shaft so pulley does not become cocked on shaft 5 Continue...

Page 895: ...7 Nzm 60 in lbs 2 Install battery tray back in vehicle Then install and securely tighten the 4 fasteners attaching battery tray to frame rail and body 3 Raise vehicle 4 Install power steering return h...

Page 896: ...eering Fluid Do not use automatic transmission fluid Do not overfill Wipe filler cap clean then check the fluid level The dipstick should indicate FULL COLD when the fluid is at normal temperature of...

Page 897: ...in a turn The torsion bar twists causing relative rotary motion between the rotary valve body and the valve spool This movement directs oil behind the integral rack piston which in turn builds up hydr...

Page 898: ...motor Remove plenum from the right side of the vehicle Fig 4 9 Disconnect wiper module wiring harness con nector from vehicle wiring harness Fig 5 10 Remove the 5 screws attaching wiper module assemb...

Page 899: ...ctor from travel sen sor Using a small screwdriver lift retaining ring from notch Fig 9 Then remove retaining ring from grom met Remove pedal travel sensor from brake booster by carefully pulling it s...

Page 900: ...inal steering gear assembly is being in stalled back in vehicle Align paint mark on steering coupler with paint mark on steering gear shaft and install steering gear shaft into steering coupler If a r...

Page 901: ...proper ports of the steering gear Fig 16 Torque both power steering line fittings at steer ing gear to 31 Nzm 23 ft lbs 6 Align center take off on steering gear with the tie rod assemblies Install ti...

Page 902: ...brake booster back on intake manifold vacuum port Install hose clamp on vacuum hose 12 Install windshield wiper module assembly into cowl of vehicle Install and securely tighten the 5 screws attaching...

Page 903: ...mounting stud nuts in proper sequence Fig 27 until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 129 Nzm 95 ft lbs 24 Connect battery c...

Page 904: ...are torqued to half specification Then repeat the tightening sequence to the full specified torque of 129 Nzm 95 ft lbs 5 Check the front wheel TOE setting on vehicle and make required changes When m...

Page 905: ...mately 25 to 60 mph with the minimum power steering assist available reached at approxi mately 60 mph Variable assist power steering is provided by con trolling power steering fluid pressure at the po...

Page 906: ...control module Fig 2 is mounted on the steering gear assembly end cap Fig 2 The solenoid control module is removable from the steer ing gear for servicing without removing steering gear from vehicle...

Page 907: ...ehicle Fig 6 SOLENOID REMOVAL FROM STEERING GEAR 1 Remove electrical connector to the solenoid con trol valve at solenoid control module Fig 7 2 Remove power steering pressure hose Fig 8 from power st...

Page 908: ...e wiring harness connector seal are on connector is in good condition before installing connector on control module 6 Road test vehicle or refer to the test using the DRB scan tool to confirm correct...

Page 909: ...IDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGI NALLY USED FOR THE AIR BAG COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AI...

Page 910: ...Fig 1 L H Platform Saginaw Tilt Steering Column 19 32 STEERING...

Page 911: ...steering column must be positioned and locked to prevent uncontrolled rotation of the steering column shaft after steering column re moval from vehicle Use procedure below to cor rectly position and l...

Page 912: ...end covers Fig 8 Refer to Group 8 Electrical in this service manual for the required removal procedure 9 Remove the 2 air bag fuses from fuse panel Fig 9 Fig 4 Air Bag Module Attaching Bolts Fig 5 Wir...

Page 913: ...ter A C control assemblies 14 Remove the center upper outlet bezel Fig 14 from upper instrument panel Bezel is removed by carefully prying right side of bezel out from upper instrument panel until bez...

Page 914: ...aching lower knee bolster panel to cowl panel Fig 18 20 Carefully remove lower knee bolster panel from upper instrument panel lowering panel until wiring connectors for glove box light and trunk re le...

Page 915: ...echanism on steer ing column Fig 23 Then remove shift cable retain ing clip at shift cable support bracket Fig 24 being careful not to bend cable bracket CAUTION When ignition key is turned to the run...

Page 916: ...nting bracket by depressing tab 35 Remove steering column assembly from the passenger compartment of the vehicle Use care when removing steering column to avoid damaging the paint or interior trim STE...

Page 917: ...steering column mounting bracket Fig 32 Install but do not tighten the 2 nuts attaching steering column assem bly to mounting bracket 5 Position steering column so lower steering col umn mounting brac...

Page 918: ...to the Ignition Switch And Interlock Section of Group 8 for the required interlock cassette installation and ad justment procedures 10 If vehicle is equipped with a column shifter Correctly route shi...

Page 919: ...e glove box Fig 40 attaching lower knee bolster panel to cowl of vehicle 20 Install and securely tighten the 2 nuts at rear of ash receiver attaching lower knee bolster panel to floor pan support brac...

Page 920: ...nut tighten nut to draw steering wheel onto steering column shaft Torque steering wheel to steering column retaining nut to 61 Nzm 45 ft lbs 30 Connect vehicle wiring harness connectors to connection...

Page 921: ...roup 8 for the required opera tion check and adjustment of the interlock system GEAR SHIFT LEVER The gear shift lever assembly if equipped is a serviceable component of the Saginaw tilt steering colum...

Page 922: ...the gear shift cable adjuster 7 Install upper and lower shroud on steering col umn assembly and tilt lever Fig 1 STEERING COUPLER If diagnosed to be defective the steering column coupler assembly Fig...

Page 923: ...ler on steering shaft until correctly positioned to allow spring pin to be installed in coupler Then install spring pin into coupler until flush with surface of steering coupler Fig 3 SPECIFICATIONS A...

Page 924: ......

Page 925: ...Oil Pump Seal Replacement 33 Output Shaft Bearing Preload Shim Selection 49 Road Test 16 Selection of Lubricants 9 Short Stub Shaft Seal Replacement 22 Snubber Gap Measurement 65 Solenoid Assembly 24...

Page 926: ...ltiple disc grounded clutches Four hydraulic accumulators Two planetary gear sets This provides four forward ratios and a reverse ratio The clutch apply pistons have a centrifugally balanced oil cavit...

Page 927: ...arns the characteris tics of the particular transaxle that it is controlling It learns The release rate of the releasing element The apply time of the applying element The rate the apply element build...

Page 928: ...Diagnostic trouble code inspection Then perform a road test to determine if the prob lem has been corrected or that more diagnosis is necessary If the problem exists after the preliminary tests and c...

Page 929: ...DIAGNOSIS GUIDE VEHICLE WILL NOT MOVE TRANSAXLE 21 5...

Page 930: ...DIAGNOSIS GUIDE FLUID LEAKS 21 6 TRANSAXLE...

Page 931: ...DIAGNOSTIC TROUBLE CODE CHART A TRANSAXLE 21 7...

Page 932: ...DIAGNOSIS CHART B 21 8 TRANSAXLE...

Page 933: ...tal or friction material particles a complete transaxle recondition is needed Be sure to examine the fluid on the dipstick closely If there is any doubt about its condition drain out a sample for a do...

Page 934: ...d and filled with out having to remove the transaxle from the vehicle Use only Mopar 80W 90 petroleum based hypoid gear lubricant when replacing fluid REMOVAL 1 Raise vehicle on hoist 2 Remove differe...

Page 935: ...Remove cable from shift pin Fig 6 7 Remove cable retainer clip from shift cable con duit bracket Fig 7 CAUTION Column must be tilted fully upward to remove cable retainer clip Fig 2 Lower Column Cove...

Page 936: ...be engaged when ad justing linkage Rock vehicle back and forth to en sure that park sprag is fully engaged 4 Place conduit end fitting in clamp and tighten mounting bolt 5 Rotate fill tube to origina...

Page 937: ...k shifter for proper operation It should operate smoothly without binding The vehicle should crank in Park or Neutral only GEARSHIFT LINKAGE FLOOR SHIFT The gear shift linkage should be adjusted if an...

Page 938: ...Rock vehicle back and forth to en sure that park sprag is fully engaged 4 Place conduit end fitting in clamp and tighten mounting bolt 5 Rotate fill tube to original location Install and tighten fill...

Page 939: ...d pin 4 Disconnect interlock cable from shifter base slot Be careful not to break tab on interlock cable conduit end fitting Fig 8 5 Remove the three floor pan attaching nuts from the interior of the...

Page 940: ...n compar ing which internal units are applied in those posi tions The Elements in Use Chart provides a basis for road test analysis The process of elimination can be used to detect any unit which slip...

Page 941: ...tap 2 Move selector lever to the OD position 3 Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 50 mph CAUTION Both wheels must turn at the same spee...

Page 942: ...locks the output shaft Use a piece of rubber hose wrapped around the input shaft and a pair of clamp on pliers to turn the input shaft Next apply air pressure to the underdrive clutch Fig 3 The input...

Page 943: ...rder to correctly re pair this type of leak the transaxle must be removed from the vehicle and both transfer shaft seals re placed Refer to Transfer Shaft Seal Replacement pro cedure in this section F...

Page 944: ...ub weld Hub weld is inside and not visible Do not attempt to repair Replace torque converter FLUID LEAKAGE DIFFERENTIAL HOUSING AREA The differential uses 80w 90 petroleum based hy poid gear lube It c...

Page 945: ...transaxle can be covered with a soapy solution of water Be sure to cover the case with solution to check for case porosity 5 Look for bubbles to appear in the soapy solution that was applied to the t...

Page 946: ...ing to remove the transaxle from the vehicle If the adjuster or bearing located behind the adjuster require replacement do not use this procedure Refer to Differential Recondi tion section of this man...

Page 947: ...oler 1 Disconnect the cooler lines at the transaxle 2 Using a hand suction gun filled with mineral spirits reverse flush the cooler This is done by forc ing mineral spirits into the From Cooler line o...

Page 948: ...the solenoid pack The solenoid pack contains four solenoids If any one of the solenoids fail all of the solenoids must be replaced There are no serviceable parts for the sole noid pack TEST Refer to...

Page 949: ...p and slide the battery to the right 2 Loosen 60 way retaining screw located in the center of the 60 way connector Then disconnect the 60 way connector on transmission control module 3 Remove transmis...

Page 950: ...BACK UP LAMP DIAGNOSTIC CHART 21 26 TRANSAXLE...

Page 951: ...bs VALVE BODY The valve body can be removed with the transaxle remaining in the vehicle or with the transaxle re moved The illustrations in this procedure shows the transaxle removed from the vehicle...

Page 952: ...Remove valve body bolts Fig 4 8 Carefully remove valve body assembly from transaxle Fig 5 CAUTION The overdrive and underdrive accumula tors and springs may fall out when removing the valve body To re...

Page 953: ...body stiffener plate Fig 11 5 Remove 2 4 accumulator retaining plate screws 6 Remove thermal valve Fig 12 7 Remove valve body check balls Note the loca tion of valve body check balls Fig 13 Fig 8 Acc...

Page 954: ...transaxle Fig 17 5 Index the inner differential adjuster with a cross hair as shown in figure 18 CAUTION If short stub shaft has corrosion use caution when removing differential cover Inspect seal an...

Page 955: ...ish tightening the ad juster 1 4 turn to its index mark original location 16 Reinstall the outer adjuster locking bracket Fig 16 Valve Body Components Fig 17 Long Stub Shaft Removal Fig 18 Indexing In...

Page 956: ...stub shafts must be replaced before reinstalling drive shafts 9 Using a pry bar disconnect the inner CV joint from the transaxle Fig 4 10 Pull top of knuckle and drive shaft outward to allow clearance...

Page 957: ...ne application If the torque converter is being replaced apply a light coating of grease to the crankshaft pilot hole Inspect the driveplate for cracks before reinstalling transaxle If any cracks are...

Page 958: ...use a DRB scan tool to read or reset the break in status Perform the following steps with the DRB scan tool to reset the break in status 1 Plug the DRB scan tool into the blue CCD Bus connector The c...

Page 959: ...The red and green lights on the DRB scan tool will light up and then begin flashing Wait until the lights stop flashing before continuing with this proce dure 4 Press the number 4 key on the DRB scan...

Page 960: ...n this section Fig 3 Remove Transaxle Oil Pan Fig 4 Remove Transaxle Oil Filter Fig 5 Remove Valve Body Bolts Fig 6 Remove Valve Body From Transaxle Fig 7 Remove Underdrive Accumulator and Spring Fig...

Page 961: ...d with the springs in the Low Reverse Accumulator Fig 11 Low Reverse Accumulator Plug Cover Fig 9 Accumulator Locations Fig 10 Remove Low Reverse Accumulator Fig 12 Low Reverse Accumulator Piston Fig...

Page 962: ...installing drive shafts CAUTION By pass valve must be replaced trans mission failure occurs Fig 15 Remove Long Stub Shaft From Bell housing Fig 16 Remove Oil Pump Attaching Bolts Fig 17 Oil Pump Pulle...

Page 963: ...Remove No 1 Caged Needle Bearing Fig 22 Remove Input Clutch Assembly Fig 23 Remove Front Sun Gear Assembly Fig 24 Remove Front Carrier and Rear Annulus Assembly Fig 25 Remove Rear Sun Gear TRANSAXLE...

Page 964: ...the bearing to seat flat against the rear sun gear Fig 26 A small amount of petrolatum can be used to hold the bearing to the rear sun gear Fig 26 Number 7 Bearing Fig 27 Remove 2 4 Clutch Retainer S...

Page 965: ...Fig 31 2 4 Retainer and Spring Indexed Fig 32 Remove 2 4 Clutch Pack Fig 33 Remove Tapered Snap Ring Fig 34 Tapered Snap Ring Instructions Fig 35 Snap Ring Installed TRANSAXLE 21 41...

Page 966: ...fore applying new sealant Apply a 1 8 inch bead of sealant to flange of cover Fig 36 Low Reverse Reaction Plate Fig 37 Remove One Disc Fig 38 Remove Low Reverse Reaction Plate Snap Ring Fig 39 Remove...

Page 967: ...ressure If chain sprockets are not spread slightly removal or installation will be difficult Overspreading of the chain sprocket will also make sprocket removal dif ficult Fig 42 Remove Chain Snubber...

Page 968: ...ilure to grind and open stakes of the output shaft nut and transfer shaft nut will result in thread damage to the shafts during nut removal WARNING WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS Using...

Page 969: ...Do not reuse old transfer shaft nut or output shaft nut because the removed stake weak ens the nut flange When installing new nuts use special tool 6639 to stake output shaft nut and special tool 6589...

Page 970: ...ing cup rear ward Fig 56 Use special tool 5050A to install both front and rear bearing cups Fig 57 Fig 56 Remove Rear Bearing Cup Fig 57 Bearing Cup Installation Special Tool 5050A Fig 58 Remove Rear...

Page 971: ...ve touch the rear of the transaxle case Fig 61 Remove Snap Ring Fig 62 Low Reverse Piston Return Spring Fig 60 Compressor Tool in Use Fig 63 Remove Parking Sprag Pivot Retaining Screw Fig 64 Anchor Sh...

Page 972: ...the transfer shaft seal Refer to the Transfer Shaft Seal Removal Sec tion and the Differential Disassembly Assembly section To assemble transaxle reverse the above procedure Be sure to check both gro...

Page 973: ...do not snug screws 3 Turn case over on arbor press so that the plate is resting on the press base CAUTION The output shaft will extend through the hole of tool 6618A Ensure your press table has clear...

Page 974: ...shaft should have 1 to 8 in lbs of turning torque If the turning torque is higher than 8 in lbs install a thicker shim If the turning torque is less than 1 in lb install a thinner shim Make sure there...

Page 975: ...pack with finger and zero dial indicator The 2 4 clutch pack clearance is 0 76 to 2 64 mm 030 to 104 inch If not within specifica tions the clutch is not assembled properly There is no adjustment for...

Page 976: ...identi fication Fig 2 Reverse Clutch Snap Ring Fig 3 Pry Reverse Clutch Reaction Plate Fig 4 Reverse Clutch Reaction Plate Fig 5 Reverse Clutch Pack Fig 6 OD Reverse Pressure Plate Snap Ring Fig 7 OD...

Page 977: ...pack for reassembly identification Fig 8 Waved Snap Ring Fig 9 Remove OD Clutch Pack Fig 10 Overdrive Clutch Pack Fig 11 Overdrive Shaft Assembly Fig 12 Underdrive Shaft Assembly Fig 13 No 2 Needle Be...

Page 978: ...turn spring just enough to remove or install snap ring Fig 14 OD UD Reaction Plate Tapered Snap Ring Fig 15 OD UD Reaction Plate Fig 16 Remove One UD Clutch Disc Fig 17 UD Clutch Flat Snap Ring Fig 18...

Page 979: ...ig 23 Tap on Input Hub Fig 20 UD Return Spring and Retainer Fig 21 Underdrive Clutch Piston Fig 22 Input Hub Tapered Snap Ring Fig 24 Input Hub Removed Fig 25 Pull Retainer from Piston TRANSAXLE 21 55...

Page 980: ...ls to ease assembly of components Fig 29 Remove Input Shaft Fig 26 Install Snap Ring Fig 27 Snap Ring and Return Spring Fig 28 Remove Input Shaft Snap Ring Fig 1 Install Input Shaft Fig 2 Install Inpu...

Page 981: ...Return Spring and Snap Ring Fig 4 Install Snap Ring Fig 5 Install OD Reverse Piston Fig 6 Install Input Shaft Hub Assembly Fig 7 Input Hub Tapered Snap Ring Fig 8 Underdrive Clutch Piston TRANSAXLE 2...

Page 982: ...install snap ring Fig 9 Seal Compressor Special Tool 5067 Fig 10 UD Return Spring and Retainer Fig 11 Install UD Spring Retainer and Snap Ring Fig 12 Underdrive Clutch Pack Fig 13 UD Clutch Flat Snap...

Page 983: ...ay around Underdrive clutch pack clearance must be 0 91 to 1 47 mm 036 to 058 inch Select the proper reaction plate to achieve specifications Fig 17 Seating Tapered Snap Ring Fig 18 Set Up Dial Indica...

Page 984: ...0 Install OD Clutch Pack Fig 21 Install Waved Snap Ring Fig 22 OD Reverse Pressure Plate Fig 23 Pressure Plate Installed Fig 24 Install Flat Snap Ring Fig 25 Check OD Clutch Pack Clearance 21 60 TRANS...

Page 985: ...to achieve specifications All clutch clearances in the input clutch retainer have now been checked and approved To complete the assembly of the input clutch re tainer the reverse clutch and the overdr...

Page 986: ...as shown in Figures 20 through 28 Rechecking these clutch clearances is not necessary as they were set and approved previously Fig 31 Install No 2 Needle Bearing Fig 32 Install Underdrive Shaft Assem...

Page 987: ...to 025 inch For example if end play reading is 055 inch select No 4 Thrust Plate which is 071 to 074 thick This should provide an input shaft end play reading of 020 inch which is within specificatio...

Page 988: ...he distance between the two marks placed on the scale Fig 5 If the two marks on the scale are more than one inch apart replace the drive chain NO 4 THRUST PLATE CHART Fig 1 Screwdriver Placement Fig 2...

Page 989: ...6 3 If the measurement is not within specifications install the correct snubber as required DRIVE SPROCKET HEIGHT ADJUSTMENT PROCEDURE A spacer beneath the output sprocket is used to position the out...

Page 990: ...ocedure If any bearings in the differential require replace ment all the bearings on the differential carrier and transfer shaft must also be replaced The differential adjusters must also be replaced...

Page 991: ...chain sprocket will also make sprocket removal dif ficult CAUTION When reinstalling drive chain the blue link must face outward CAUTION Drive shaft retainer clips and seals lo cated on the stub shafts...

Page 992: ...ransfer shaft nut will result in thread damage to transfer shaft during nut removal WARNING WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS Fig 11 Remove Outer Adjuster Fig 12 Loosen Outer Adjuster Fig...

Page 993: ...carefully open stakes on nut Fig 18 Remove the transfer shaft nut CAUTION Do not reuse old transfer shaft nut be cause the removed stake weakens the nut flange CAUTION The transfer shaft cannot be re...

Page 994: ...d Remove transfer shaft seals Fig 23 using special tool 6310 and foot 6310 9 Tar 960 Do not reuse old seals The seals will be pulled out the rear of the case Remove the front transfer shaft bearing cu...

Page 995: ...cup and case If a 0 001 or 0 002 feeler gauge does not fit the bearing cup is com pletely seated into transaxle case 2 Install centering block special tool 6549 2 into the transaxle case Fig 2 Screw...

Page 996: ...cator must be zeroed This is done by placing the dial indicator in the zeroing fixture special tool 6549 6 Then place the zeroing fixture on a flat sur face Adjust the dial face so that the pointer on...

Page 997: ...on depth measurement obtained in step 11 add or subtract the adjustment factor to calculate the required shim thickness Refer to pinion head shim chart for shim selections This is the shim that will b...

Page 998: ...the pinion is installed The following steps will determine how many foot pounds are required on the outer differential adjuster to obtain the correct turning torque CAUTION Failure to set differential...

Page 999: ...tool 6502B Fig 16 The inner adjuster should be screwed in until under flush with inside of the case viewed from differential side 21 Install differential assembly into the transaxle case Fig 17 22 Ins...

Page 1000: ...the differential three or four turns in both directions CAUTION Turning torque of 19 to 23 in lbs can only be obtain when using new bearings Do not attempt to obtain this turning torque with used bea...

Page 1001: ...ply thin film of gear oil to protector 31 Apply a small amount of lube to seal lips and install front transfer shaft seal The serrated edges must face toward the rear of the transaxle Fig 26 32 Instal...

Page 1002: ...e original shim that was taken out of transaxle if possible If original shim is not available use the thickest shim as a starting point Refer to Transfer Shaft Rear Shim Chart for available sizes FIg...

Page 1003: ...ld be 0 5 to 1 3 Nzm 5 to 12 in lbs If the turning torque is too high install a thicker transfer shaft preload shim If the turning torque is too low install a thinner transfer shaft preload shim CAUTI...

Page 1004: ...rential assembly with ring gear attached into transaxle case Fig 38 45 Transfer shaft to ring gear backlash should be 0 0069 to 0 0099 thousands of an inch To get the backlash close enough to measure...

Page 1005: ...ions Tighten adjuster a second time to same torque recorded in step 25 Again reseat bearings Repeat this sequence until correct adjuster torque is maintained 49 To check and or adjust backlash remove...

Page 1006: ...ng brack ets 52 Install new inspection plug Use a wooden block to tap inspection plug into place It is easier to fill the differential prior to installing the transaxle back into the vehicle The diffe...

Page 1007: ...to 50 percent of the original drag torque after break in All bearing adjustments must be made with no other component interference or gear inter mesh except the transfer gear bearing Oil all bearings...

Page 1008: ...ses for a bus problem Open or short to ground battery in either or both CCD bus wires pins 4 and 43 Open or short to ground battery in either or both 42LE transaxle s bias wires pin 5 and 44 Open or s...

Page 1009: ...communicate with the transmission control module the DRB scan tool must be connected to the blue CCD bus connector The connector is located under the instrument panel Refer to the Using the DRB scan t...

Page 1010: ...DIAGNOSTIC TROUBLE CODE 12 DIAGNOSTIC TROUBLE CODE 13 21 86 TRANSAXLE...

Page 1011: ...DIAGNOSTIC TROUBLE CODE 14 DIAGNOSTIC TROUBLE CODE 15 TRANSAXLE 21 87...

Page 1012: ...DIAGNOSTIC TROUBLE CODE 16 DIAGNOSTIC TROUBLE CODE 17 21 88 TRANSAXLE...

Page 1013: ...DIAGNOSTIC TROUBLE CODE 18 DIAGNOSTIC TROUBLE CODE 19 TRANSAXLE 21 89...

Page 1014: ...DIAGNOSTIC TROUBLE CODE 20 21 90 TRANSAXLE...

Page 1015: ...DIAGNOSTIC TROUBLE CODE 21 27 TRANSAXLE 21 91...

Page 1016: ...DIAGNOSTIC TROUBLE CODE 28 21 92 TRANSAXLE...

Page 1017: ...DIAGNOSTIC TROUBLE CODE 29 DIAGNOSTIC TROUBLE CODE 31 32 TRANSAXLE 21 93...

Page 1018: ...DIAGNOSTIC TROUBLE CODE 36 DIAGNOSTIC TROUBLE CODE 35 21 94 TRANSAXLE...

Page 1019: ...DIAGNOSTIC TROUBLE CODE 37 DIAGNOSTIC TROUBLE CODE 38 TRANSAXLE 21 95...

Page 1020: ...DIAGNOSTIC TROUBLE CODE 41 44 21 96 TRANSAXLE...

Page 1021: ...DIAGNOSTIC TROUBLE CODE 45 DIAGNOSTIC TROUBLE CODE 46 TRANSAXLE 21 97...

Page 1022: ...hin 1 0 seconds via the CCD confirmation that the torque management request signal was read by the engine control module CONDITIONS When the torque fault management fault counter matures to a value ex...

Page 1023: ...DIAGNOSTIC TROUBLE CODE 50 58 TRANSAXLE 21 99...

Page 1024: ...DIAGNOSTIC TROUBLE CODE 60 62 21 100 TRANSAXLE...

Page 1025: ...42LE HYDRAULIC SCHEMATICS TRANSAXLE 21 101...

Page 1026: ...21 102 TRANSAXLE...

Page 1027: ...TRANSAXLE 21 103...

Page 1028: ...21 104 TRANSAXLE...

Page 1029: ...TRANSAXLE 21 105...

Page 1030: ...21 106 TRANSAXLE...

Page 1031: ...TRANSAXLE 21 107...

Page 1032: ...21 108 TRANSAXLE...

Page 1033: ...TRANSAXLE 21 109...

Page 1034: ...21 110 TRANSAXLE...

Page 1035: ...TRANSAXLE 21 111...

Page 1036: ...21 112 TRANSAXLE...

Page 1037: ...TRANSAXLE 21 113...

Page 1038: ...42LE SPECIFICATIONS 42LE FOUR SPEED AUTOMATIC TRANSAXLE 21 114 TRANSAXLE...

Page 1039: ...42LE TORQUE SPECIFICATIONS TRANSAXLE 21 115...

Page 1040: ...MASTER SHIM CHART 21 116 TRANSAXLE...

Page 1041: ...shown in the section on Tire Rotation This will achieve a greater tread life potential RADIAL PLY TIRES Radial ply tires improve handling tread life and ride quality and decrease rolling resistance Ra...

Page 1042: ...osted speed limits Where speed limits or conditions are such that the vehicle can be driven at high speeds correct tire inflation pressure is very important For speeds up to and including 120 km h 75...

Page 1043: ...will appear as a 13 mm 1 2 in band Tire replacement is necessary when indicators ap pear in two or more grooves or if localized balding occurs REPAIRING LEAKS For proper repairing a radial tire must b...

Page 1044: ...Fig 4 Tire Wear Patterns 22 4 WHEELS TIRES...

Page 1045: ...LEAD CORRECTION CHART LEAD CORRECTION CHART WHEELS TIRES 22 5...

Page 1046: ...e loosening of wheel nuts This could adversely affect the safety and handling of your ve hicle To install the wheel position it properly on the mounting surface using the hub pilot as a guide All whee...

Page 1047: ...the tire can be rotated on the wheel See Method 2 METHOD 1 RELOCATE WHEEL ON HUB Check accuracy of the wheel mounting surface ad just wheel bearings Drive vehicle a short distance to eliminate tire f...

Page 1048: ...SPECIFICATIONS Fig 6 Checking Wheel Run out TIRE SPECIFICATIONS TORQUE SPECIFICATIONS 22 8 WHEELS TIRES...

Page 1049: ...e can result Do not use abrasive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning solvents on painted or upholstered surfaces Damage to f...

Page 1050: ...ist the left side of the vehicle If the leak occurs on right turns hoist the right side of the vehicle For hoisting recommendations refer to Group 0 Lubrication and Maintenance General Information sec...

Page 1051: ...by improperly fitted exterior moldings or body ornamentation Loose mold ings can flutter creating a buzzing or chattering noise An open cavity or protruding edge can create whistling or howling noise...

Page 1052: ...d Clear Top Coat Refer to Introduction group of this manual for Body Code Plate information TOUCH UP PROCEDURE 1 Scrape loose paint and corrosion from inside scratch or chip 2 Clean affected area with...

Page 1053: ...AFTERMARKET PAINT REPAIR PRODUCTS BODY 23 5...

Page 1054: ...the parts supplier WINDSHIELD REPLACEMENT WINDSHIELD REMOVAL 1 Remove inside rear view mirror 2 Remove cowl cover Refer to Cowl Cover Re moval paragraph in this group 3 Remove windshield moldings Fig...

Page 1055: ...arks at the bottom of the windshield to the support spacers 9 Slowly lower windshield glass to windshield opening fence Guide the top molding into proper position if necessary Push windshield inward t...

Page 1056: ...44 between controller switch and A pillar connector Faulty circuit Q41 42 43 between controller switch and A pillar connector Faulty sunroof drive motor Faulty sunroof controller SYMPTOM B Audible whi...

Page 1057: ...Engage wire connector into sunroof control switch 3 Install overhead console SUNROOF MODULE REMOVAL FIG 1 1 Operate glass panel to open position 2 Disconnect battery negative cable 3 Remove left A pi...

Page 1058: ...ding drive motor 48 to sun roof module 4 Separate drive motor from sunroof module INSTALLATION 1 Place drive motor in position on sunroof module 2 Install bolts to hold drive motor to sunroof mod ule...

Page 1059: ...Remove screws holding guide link 2 to guide 1 11 Separate front guide 1 from sunroof module 12 Intermittently actuate the sunroof switch vent until the cam slide 15 is 12 mm 0 5 in past the front of...

Page 1060: ...therstrip together using Mopar Bond all Gel adhesive or equivalent GLASS PANEL ALIGNMENT The sunroof glass panel should be aligned parallel to the sides of the roof opening with slight weather strip c...

Page 1061: ...Fig 2 Sunroof Components BODY 23 13...

Page 1062: ...SUNROOF COMPONENT LEGEND 23 14 BODY...

Page 1063: ...Rear Door Glass 29 Rear Door Glass Alignment 30 Rear Door Glass Frame Trim 28 Rear Door Glass Regulator 30 Rear Door Glass Run Weatherstrip 30 Rear Door Hinge 32 Rear Door Inner Belt Weatherstrip 29...

Page 1064: ...closing hood HOOD RELEASE CABLE REMOVAL FIG 4 1 Release hood latch and open hood 2 Disconnect hood release cable casing and cable end from hood latch assembly Fig 4 Refer to Hood Latch Removal procedu...

Page 1065: ...elper at the opposite side of the vehicle to support the hood remove bottom bolts holding hood to hinge Separate the hood from the vehicle INSTALLATION 1 Place hood in position on vehicle With assis t...

Page 1066: ...ld cowl cover to lower windshield fence tabs 3 Engage clips to hold front edge of cowl cover to cowl opening edge 4 Engage push in fasteners to hold weatherstrip to cowl opening edge 5 Install wiper a...

Page 1067: ...ocker panel 6 Install front bumper fascia 7 Install headlamp assembly DOOR COMPONENTS The front and rear door on all LH models require the same service procedures regardless of door trim configu ratio...

Page 1068: ...ehind door silencer pad disengage push in retainers holding wire harness to trim panel 16 Remove wire harness from behind silencer pad and separate trim panel from door INSTALLATION 1 Install wire har...

Page 1069: ...n position on door 2 Push inner belt weatherstrip downward to en gage channel to top of inner door panel 3 Install door trim panel FRONT DOOR GLASS REMOVAL FIG 18 1 Remove door trim panel and upper tr...

Page 1070: ...p to window frame 8 Pull run weatherstrip from window frame chan nel INSTALLATION 1 Push run weatherstrip into window frame chan nel 2 Engage push in fastener to hold run weather strip to window frame...

Page 1071: ...channel to door panel 7 Engage power window motor wire connector if equipped 8 Install door glass 9 Align glass and verify operation 10 Install door trim panel FRONT DOOR LATCH REMOVAL FIG 23 1 Close...

Page 1072: ...rap to door hinge 5 Disengage check strap from pin on upper door hinge 6 Separate check strap from vehicle INSTALLATION 1 Place check strap in position on vehicle 2 Engage check strap onto pin on uppe...

Page 1073: ...d remove bolts holding upper hinge to door end frame 9 Disengage door check stop from pin on upper door hinge 10 Separate door from vehicle INSTALLATION 1 Place door in position on vehicle 2 Engage do...

Page 1074: ...pillar 3 Verify alignment and operation of door adjust as necessary FRONT DOOR PRIMARY WEATHERSTRIP REMOVAL FIG 33 1 Open front door 2 Pull primary weatherstrip from channel around upper window frame...

Page 1075: ...trim panel disconnect door jamb connector Remove fas teners holding wire harness close out cover to door end frame Disengage push in retainers holding door opening weatherstrip to door end frame Pull...

Page 1076: ...nel 7 Separate applique from door INSTALLATION 1 Place applique in position on door 2 Install screws to hold applique to door inside glass run channel 3 Install screw to hold bottom of applique to doo...

Page 1077: ...door glass to gain access to roller channel to glass fasteners through holes in inner door panel 4 Loosen screws holding regulator roller channel to glass 5 Slide roller channel rearward to allow scr...

Page 1078: ...p into window frame channel 2 Engage push in fastener to hold run weather strip to window frame 3 Insert weatherstrip into lower rear channel above door latch 4 Install door glass 5 Install upper reta...

Page 1079: ...arate latch from door INSTALLATION 1 Place latch in position in door 2 Install screws to hold door latch to door end frame 3 Connect outside door handle link to door latch 4 Connect lock cylinder link...

Page 1080: ...FIG 50 1 Close door glass 2 Remove door trim panel 3 Remove bolts holding check strap to door end frame 4 Remove retainer holding check strap to door hinge 5 Disengage check strap from pin on upper do...

Page 1081: ...Open rear door 2 Loosen door opening sill plate 3 Pull secondary weatherstrip from fence around door opening INSTALLATION 1 Position splice in weatherstrip at center of door opening sill 2 Push secon...

Page 1082: ...Tighten set screw to hold gear shift knob to gear shift CENTER CONSOLE REMOVAL FIG 56 1 Remove center console bezel 2 Remove screw holding forward crossmember to floor mounting bracket 3 Remove screw...

Page 1083: ...arate turning loop from adjuster 4 Disengage clips holding upper trim to B pillar 5 Separate B pillar trim from vehicle INSTALLATION 1 Place B pillar trim in position on vehicle 2 Engage clips to hold...

Page 1084: ...uarter panel 3 Install sill trim 4 Install bolt to hold rear seat shoulder harness to floor at bottom of quarter trim 5 Install rear seat cushion and back 6 Install upper quarter trim PARCEL SHELF TRI...

Page 1085: ...lding rear seat back and belts to floor 3 Push rear seat back upward to disengage hooks at top of seat back 4 Separate rear seat from vehicle INSTALLATION 1 Place rear seat in position in vehicle 2 En...

Page 1086: ...1 Place seat track in position on seat cushion 2 Install bolts to hold seat track to cushion frame 3 Place seat back in position on cushion 4 Install bolts to hold seat back to cushion 5 Install bolts...

Page 1087: ...ce adjuster in position on B pillar 2 Install bolts to hold shoulder belt adjuster to B pillar 3 Install upper B pillar trim FRONT SEAT BELT RETRACTOR REMOVAL FIG 72 1 Remove shoulder belt turning loo...

Page 1088: ...uarter trim 4 Install parcel shelf trim cover 5 Install lower quarter trim panel 6 Install upper quarter trim panels FLOOR CARPET REMOVAL FIG 75 1 Remove door sill trim covers 2 Remove cowl side trim...

Page 1089: ...roof REAR ASSIST HANDLE AND READING LAMP REMOVAL FIG 78 1 Pull down coat hook 2 Remove screw holding assist handle to roof from behind coat hook 3 Pull and hold assist handle down 4 Remove screws hold...

Page 1090: ...r panel 5 Remove screws holding splash shield to rear bumper fascia 6 Separate splash shield from vehicle INSTALLATION 1 Place splash shield in position on vehicle 2 Install screws to hold splash shie...

Page 1091: ...vehicle 5 Separate torsion bar from vehicle INSTALLATION 1 Place torsion bar in position on vehicle 2 Engage torsion bar into hinge 3 Using a vise grip plier locked on the end of the torsion bar posi...

Page 1092: ...ear of trunk lid 3 Remove bolts holding trunk latch to trunk lid 4 Separate trunk latch from trunk lid 5 Disengage power lock connector from latch sole noid 6 Disengage trunk ajar switch connector fro...

Page 1093: ...g trunk lid TRUNK LID SLAM BUMPER REMOVAL 1 Release trunk lid latch and open trunk lid 2 Unscrew slam bumper from trunk lid 3 Separate slam bumper from trunk lid INSTALLATION 1 Place slam bumper in po...

Page 1094: ...he same way as described in the Windshield section of this group 2 Place fence spacers at the locations shown 3 Install the rear window molding on glass 4 Apply a 10 mm 0 4 in bead of urethane around...

Page 1095: ...rille from vehicle INSTALLATION Reverse the preceding operation RADIATOR CLOSURE PANEL SIGHT SHIELD REMOVAL FIG 2 1 Release hood latch and open hood 2 Remove screws holding sight shield to radiator cl...

Page 1096: ...nner door panel 6 Install nut to hold rear of stationary glass to door frame 7 Install screws to hold top of stationary glass to door frame 8 Push glass run weatherstrip into rear channel 9 Close door...

Page 1097: ...ck frame from behind shoulder belts 4 Engage push in fasteners to hold upper bolster to child seat module above shoulder belts 5 Install liner in child seat module 6 Place lower bolster in position on...

Page 1098: ...holding lock cylinder to trunk lock bracket 3 Separate lock cylinder from bracket INSTALLATION 1 Insert lock cylinder into bracket 2 Install clip to hold lock cylinder to trunk lock bracket 3 Install...

Page 1099: ...l 3 Disengage CHMSL wire connector from rear body harness 4 Push wiring grommet through hole in deck panel 5 Disengage clips holding upper deck panel to rear deck below rear window 6 Separate rear dec...

Page 1100: ......

Page 1101: ...ration RADIATOR CLOSURE PANEL SIGHT SHIELD REMOVAL FIG 2 1 Release hood latch and open hood 2 Remove screws holding sight shield to radiator closure panel 3 Remove screws holding sight shield to head...

Page 1102: ...o inner door panel 6 Install nut to hold rear of stationary glass to door frame 7 Install screws to hold top of stationary glass to door frame 8 Push glass run weatherstrip into rear channel 9 Close d...

Page 1103: ...lder belts 5 Install liner in child seat module 6 Place lower bolster in position on seat child seat 7 Slide lower bolster cushion retainer into chan nel on child seat cushion 8 Install rear seat back...

Page 1104: ...lid 3 Separate applique from trunk lid INSTALLATION 1 Place applique in position on trunk lid 2 Install nuts to hold applique to trunk lid TRUNK LID APPLIQUE MOLDING REMOVAL FIG 11 1 Release trunk lat...

Page 1105: ...hold upper deck panel to rear deck below rear window 3 Install wiring grommet in hole in deck panel 4 Engage CHMSL wire connector into rear body harness 5 Install fasteners to hold rear deck upper pa...

Page 1106: ...s and channels Binding cable or linkage Faulty circuit ground Q44 between controller and switch Faulty circuit Q41 42 43 between controller and switch Faulty circuit ground Z1 to controller Faulty sun...

Page 1107: ...nector from electronic con troller 4 Disengage hose clamps and separate drain tubes from sunroof module 5 Using a suitable marking device mark outline of sunroof module on inside of roof panel to aid...

Page 1108: ...housing on each side of wind deflector 3 Verify sunroof operation TROUGH GUIDE LINK COVER REMOVAL FIG 2 1 Open sunroof to the vent position 2 Disengage push in fasteners holding cover to water trough...

Page 1109: ...side of cam Slide cam rearward into end of track 4 Insert guide and link rearward into end of track 5 Install screws 26 to hold trough links to drain trough 6 Slide cams 15 and guides 1 rearward Guid...

Page 1110: ...SUNROOF COMPONENT CALL OUTS 23 10 BODY...

Page 1111: ...Fig 2 Sunroof Components BODY 23 11...

Page 1112: ...panel The rear edge of the glass panel should be 1 mm 0 040 in lower than the rearward roof panel ADJUSTING GLASS PANEL SIDE CLEARANCE 1 Open sunroof to the vent position 2 Remove trough guide link c...

Page 1113: ...em the evaporator expansion valve and re circulating air door are omitted SYSTEM AIRFLOW The system draws outside air from the cowl open ing at the base of the windshield Then it goes into plenum cham...

Page 1114: ...corners of the doors ENGINE COOLING SYSTEM REQUIREMENTS To maintain the performance level of the heating air conditioning system the engine cooling system must be prepared as shown in this manual The...

Page 1115: ...URE MAY IRRITATE EYES NOSE AND THROAT USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R 134A SYSTEMS IF ACCIDENTAL SYSTEM DISCHARGE OCCURS VENTILATE WORK AREA BEFORE RE SUMIN...

Page 1116: ...RANT LEVEL LEAK TEST 1 Determine if there is any R 134a refrigerant in the system Use the DRB scan tool partial charge test or pressure gauge liquid line temperature partial charge check See system ch...

Page 1117: ...rature Using the Charge Determination Graph determine where the system is currently operating Fig 5 If the system is in the undercharged re gion ADD 0 057 Kg 2 oz to the system and recheck readings If...

Page 1118: ...icle 4 Set A C controls MANUAL A C A C on Panel Recirculation Temperature to full cold High blower ATC Automatic Temperature Control System Rotate blower knob to high full clockwise position Rotate te...

Page 1119: ...A C PERFORMANCE TEMPERATURES HEATING AND AIR CONDITIONING 24 7...

Page 1120: ...obing tools during system diagnosis and repair Failure to use their respective mating terminals or pin gauge to check for tightness will cause contact beam spreads This will result in loss of continui...

Page 1121: ...on 7 Remove electrical connection on actuator To install reverse removal procedure TEMPERATURE DOOR ACTUATOR The blend air temperature door actuator is an electric motor which mechanically positions t...

Page 1122: ...assenger compartment comfort The In Car sensor will automatically turn on when a vehicle door is opened If the door is left open the In Car Sensor will automatically turn off within ap proximately 5 m...

Page 1123: ...ly used in vehicles equipped with Automatic Temperature Con trol ATC It is located on the lower right side of the heater housing The power module receives pulse width modulated signals from the Body C...

Page 1124: ...lower motor retaining screws 7 Lower blower motor from housing Fig 16 To install reverse removal procedure Some vehicles may exhibit a whistling noise from the heater housing unit This noise is most n...

Page 1125: ...ANT LEVEL CHECK When the A C system is originally assembled all of the components except the compressor are lubricant free After the system has been charged with R 134a refrigerant and operated the lu...

Page 1126: ...in bolt removal 2 Tap the clutch plate with a plastic hammer and remove clutch plate and shim s Fig 2 CAUTION Do not use screwdrivers between the clutch plate assembly and pulley to remove front plat...

Page 1127: ...front plate assembly onto shaft 7 If installing a new front plate and or pulley assembly the gap between front plate and pulley face must be checked Use the following procedure a Attach a dial indica...

Page 1128: ...m A C system using a refrigerant recovery ma chine 2 Using a standard valve core tool remove the valve core Be careful to prevent any dirt debris from entering the valve core opening or getting on the...

Page 1129: ...uired whenever lines are removed and installed Use only O rings specified for this vehicle Failure to use the correct type of O ring will cause the connection to leak within a short period of time Whe...

Page 1130: ...nsion valve tubes 3 Disconnect line at compressor end using a 6 mm alan wrench 4 Remove line by pulling rear end of line up out of vehicle with compressor end following through the tie rod area To ins...

Page 1131: ...r housing REMOVAL 1 Disconnect battery 2 Remove right under panel silencer 3 Disconnect wiring connector for evaporator probe 4 At center of heater housing locate evaporator probe access plate Using a...

Page 1132: ...SION CAUSING INJURY OR PROPERTY DAMAGE REMOVAL AND INSTALLATION 1 Remove refrigerant from the A C system using a refrigerant recovery machine 2 Remove engine air inlet tube and the air distri bution d...

Page 1133: ...a safe area 13 Remove the center instrument panel bezel Fig 2 This bezel is held in place by four clips It can be removed by carefully prying it from the instrument panel 14 Remove center console fro...

Page 1134: ...r the rear of the duct 39 Remove the air bag module and brace from the vehicle 40 Remove three attaching bolts which holds the heater housing to the dash panel 41 Carefully roll the heater housing out...

Page 1135: ...ove mode door actuator Fig 4 5 Remove blend air door actuator Fig 5 6 Remove recirculation housing screws and clip Fig 6 Fig 1 Recirculation Door Actuator Wiring Fig 2 Recirculation Door Actuator Fig...

Page 1136: ...Fig 12 Twist probe counterclockwise and push tab into the housing 14 Pull the evaporator probe needle out of the evaporator fins Fig 13 Remove the evaporator probe through the opening at the blower m...

Page 1137: ...Fig 12 Evaporator Probe Fig 13 Evaporator Probe Needle Fig 14 Vent Door Seal Fig 15 Evaporator Seal Fig 16 A C Housing Screws Fig 17 Lower Housing HEATING AND AIR CONDITIONING 24 25...

Page 1138: ...e retaining tab at the base of the vent door Fig 20 Pull up on door and remove from housing Fig 21 22 Remove mode door actuating cam Fig 22 23 Fig 20 Vent Door Retaining Tab Fig 18 Evaporator Removal...

Page 1139: ...Remove link and defrost door from housing Fig 26 26 Remove defrost door link from door Fig 27 27 Remove vent door actuating arm from lower housing Fig 28 Fig 25 Defrost Door Arm Fig 26 Defrost Door A...

Page 1140: ...4 9 Install evaporator into the lower housing 10 Install upper housing onto lower housing 11 Install screws to retain the upper housing to the lower housing Fig 5 12 Install evaporator and vent door...

Page 1141: ...tor cover Fig 8 19 Seat blower motor wiring grommet at blower motor cover Fig 9 20 Install blower motor wiring to the blower mo tor resistor 21 Position recirculation housing to A C housing Fig 10 Ins...

Page 1142: ...circulation door actuator and wiring Fig 14 26 Install heater core into A C housing Fig 15 Retain core with screws Fig 16 Fig 11 Blend Air Door Actuator Fig 12 Mode Door Actuator Fig 13 Lower Distribu...

Page 1143: ...e door position and blower speed The sun sensor is not serviceable and must be replaced if found to be defective TEST The sun sensor is located so that the sun hits the sensor in the same way that it...

Page 1144: ...gger switch light will begin to flash Release the button when the light begins to flash The system is now in the diagnostic mode The following steps must be used to diagnose the system To abort the di...

Page 1145: ...e This indicates that the Panel mode has no problems Place the mode actuator knob in the Recirculate Panel mode The rear window defogger switch light should flash six times and then pause It should co...

Page 1146: ...resent in the body controller If there are no diagnostic trouble codes the system will return to its normal operation as indicated by temperature display Diagnostic trouble codes related to the ATC sy...

Page 1147: ...DRB SCAN TOOL FLOW CHART MANUAL ATC HEATING AND AIR CONDITIONING 24 35...

Page 1148: ...DRB SCAN TOOL MENU BODY SECTION CLIMATE CONTROL ITEMS 24 36 HEATING AND AIR CONDITIONING...

Page 1149: ...DRB SCAN TOOL FLOW CHART SYSTEM TESTS HEATING AND AIR CONDITIONING 24 37...

Page 1150: ......

Page 1151: ...tor crossmember Fig 2 8 Remove hose clamps and hoses from radiator 9 Disconnect automatic transaxle cooler line hoses from cooler Temporarily plug cooler lines after removal 10 Disconnect fan wiring c...

Page 1152: ...F button to stop the ATC system airflow This will make it easier to observe paper in the next step b Place a small piece of tissue paper in front of the sensor opening If the tissue sticks to the open...

Page 1153: ...VECI Label Chrysler permanently attaches the la bel to lower right corner of the hood Fig 1 It cannot be removed without defacing information and destroy ing the label The label contains the vehicle s...

Page 1154: ...CANADA VEHICLE EMISSION CONTROL INFORMATION LABEL TYPICAL CALIFORNIA VEHICLE EMISSION CONTROL INFORMATION LABEL TYPICAL 25 2 EMISSION CONTROL SYSTEMS...

Page 1155: ...ENGINE VACUUM SCHEMATIC 3 3L ENGINE EMISSION CONTROL SYSTEMS 25 3...

Page 1156: ...ENGINE VACUUM SCHEMATIC 3 5L ENGINE 25 4 EMISSION CONTROL SYSTEMS...

Page 1157: ...ves fuel tank pressure The valve also prevents fuel flow through the fuel tank vent valve hoses should the vehicle rollover The pressure relief valve opens at a certain cali brated pressure When fuel...

Page 1158: ...inner fender well next to the dash panel Fig 7 The top of the solenoid has the word TOP on it The solenoid will not operate unless it is installed correctly If the vehicle has a 3 5L engine the EVAP...

Page 1159: ...compress the spring and pull the plunger to the top of the valve Fig 12 In this position there is minimal vapor flow through the valve During periods of moderate intake manifold vacuum the plunger is...

Page 1160: ...the PCV valve from intake manifold The valve should rattle when shaken Replace the PCV valve and retest the system if it does not operate as described in the preceding tests Do not attempt to clean t...

Page 1161: ...ts to spread The 3 3L air induction system uses a resonator between the air cleaner and throttle body Fig 2 The make up air hose for the PCV system attaches to the resonator The 3 5L air induction sys...

Page 1162: ...the inputs from the heated oxygen sensors along with other inputs and adjusts the injector pulse width accordingly During Open Loop operation the PCM ignores the inputs from the heated oxygen sensors...

Page 1163: ...e intake mani fold to the exhaust manifold EGR valve Electronic EGR Transducer EET Connecting hoses The electronic EGR transducer EET contains an electrically operated solenoid and a back pressure tra...

Page 1164: ...ssion in neutral and the throttle closed allow the engine to idle for 70 seconds Abruptly accelerate the engine to approximately 2000 rpm but not over 3000 rpm The EGR valve stem should move when acce...

Page 1165: ...EGR DIAGNOSIS CHART 3 3L ENGINE EMISSION CONTROL SYSTEMS 25 13...

Page 1166: ...stem moves approximately 3 mm 1 8 inch maintain vacuum supply to diaphragm The valve should remain open for approximately 30 seconds or more If the valve leaks replace the EGR valve and transducer so...

Page 1167: ...m fitting on manifold 5 Slide transducer into bracket 6 Attach electrical connector to solenoid EGR TUBE 3 3L ENGINE The EGR tube attaches to the intake manifold ple num below the throttle body and th...

Page 1168: ...aces INSTALLATION 1 Loosely install EGR tube with new gaskets Fin ger tighten EGR tube mounting screws 2 Tighten EGR tube to EGR valve screws to 11 Nzm 95 in lbs torque 3 Tighten EGR tube to intake ma...

Page 1169: ...stroying the label The label contains the vehicle s emission specifica tions and vacuum hose routings All hoses must be connected and routed according to the label If any difference exists between the...

Page 1170: ...ENGINE VACUUM SCHEMATIC 3 5L ENGINE 25 2 EMISSION CONTROL SYSTEMS...

Page 1171: ...attempts to enrichen the mixture The PCM registers a fault if the EGR system has failed or degraded After registering a fault the PCM turns on the Malfunction Indicator Lamp instrument Check Engine li...

Page 1172: ......

Page 1173: ...TRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS ELECTRONIC ME CHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION Chrysler Corporation r...

Page 1174: ...ch 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 manua...

Page 1175: ...em 7 S Cooling System 8 Electrical 8 S Electrical 9 Engines 11 Exhaust System and Intake Manifold 13 Frame and Bumpers 14 Fuel System 14 S Fuel System 19 Steering 21 Transaxle 22 Wheels and Tires 23 B...

Page 1176: ......

Page 1177: ...rd this preliminary publica tion To order the special service tools used and illustrated please refer to the instructions on inside back cover NO PART OF THIS PUBLICATION MAY BE REPRODUCED STORED IN A...

Page 1178: ...aligned to a solid tab on the first page of each group The first page of the group has a contents section that lists major topics within the group Throughout this manual the vehicle family code LH is...

Page 1179: ...ction 7 Cooling System 8D Ignition Systems 8L Lamps 8W Wiring Diagrams 14 Fuel System 23 Body 24 Heating and Air Conditioning 25 Emission Control Systems Component and System Index Service Manual Comm...

Page 1180: ......

Page 1181: ...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 Hour of manufacture is also inc...

Page 1182: ...14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20 21 AND 22 Engine Code EGB 3 3L Six Cylinder Gasoline EGE 3 5L Six Cylinder Gasoline 24 Valve BODY CODE PLATE LINE 1...

Page 1183: ...CT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER SONAL INJURY STANDARD BODY DIMENSIONS INTERIOR DIMENSIONS VEHICLE BODY HEAD ROOM LEG ROOM SHOULDER ROOM HIP ROOM FAMILY STYLE FRONT REAR FRONT REAR FR...

Page 1184: ...ify controls and displays in this vehicle These symbols are applicable to those controls which are displayed on the instrument panel or in the immediate vicinity of the driver Fig 2 Grade 5 and 8 Stan...

Page 1185: ...CONVERSION TABLES INTRODUCTION 5...

Page 1186: ...CONVERSION TABLES INTERNATIONAL CONTROL AND DISPLAY SYMBOLS 6 INTRODUCTION...

Page 1187: ...he vehicle Fig 1 Refer to VIN Code Breakdown Chart To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden...

Page 1188: ......

Page 1189: ...TROL SYSTEMS 25 1 EVAPORATIVE EMISSION CONTROLS 25 1 FUEL SYSTEMS 14 1 HEATING AND AIR CONDITIONING 24 1 IGNITION SYSTEMS 8D 1 IGNITION SWITCH AND INTERLOCK 8D 1 INTRODUCTION Intro LAMPS 8L 1 BULB APP...

Page 1190: ......

Page 1191: ...tain service operations These special service tools or their equivalent if not obtainable through a local source are available through the following outlet C D Riley Enterprises Ltd P O Box 243 Amhers...

Page 1192: ...ever working on vehicles or vehicle components It is important to note that this publication contains various Cautions and Warnings These should be carefully read in order to minimize the risk of pers...

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Page 1195: ...obat Reader runs off the hard drive and uses the CD ROM drive to access the document content 1 Click the START button point to the Programs Group then point to the desired DaimlerChrysler manual group...

Page 1196: ...CD ROM in the CD ROM drive The Acrobat Reader runs off the hard drive and uses the CD ROM drive to access the document content 1 Double click on the Program Group icon for the DaimlerChrysler Manual...

Page 1197: ...Page is the first page that is displayed to a user after launching the Acrobat Reader application Refer to Sections 1 0 and 2 0 of this CD ROM Instruction Booklet Double click on the logo to enter th...

Page 1198: ...Tab Page Of A Manual The tab page contains a listing of all the groups within a manual Point the cursor the desired group and click to display the content for a group Figure 4 2 1 is a sample tab page...

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Page 1200: ...in A Manual Point the cursor over a desired content section and click to display the contents within a group Figure 3 4 1 shows the electronic outline within the left hand window and the document with...

Page 1201: ...in the electronic outline window which is located in the left window of the Acrobat Reader Click on an outline item to display the contents within a group Figure 3 5 1 is a sample document with electr...

Page 1202: ...k Summary of The basic Acrobat Reader features is contained in Table 4 2 1 Description Icon Usage Display The Previous View Click on the icon to use the previous view function Display The Next View Cl...

Page 1203: ...w function Set Image Size To 100 Click on the icon to set the document view image to 100 Make The Current Page Fit Inside The Window Click on the icon to scale a large page format to fit within the vi...

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