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Dodge R1500 1999, Service Manual

The Dodge R1500 1999 Service Manual is essential for maintaining and repairing your vehicle. Download this manual for free from manualshive.com to access detailed instructions and diagrams to help you tackle any issue that may arise. Make sure to have this manual on hand to keep your Dodge running smoothly.

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SERVICE PORT INSPECTION

Condition                 Code                          Procedure

Application

 does not match

 refrigerant type  .......  B  ............  Require replacement.

Leaking  .................  A  ..  Require repair or replacement.

Threads damaged  .........  A  ..  Require repair or replacement.

Threads stripped (threads

 missing)  ...............  A  ............  Require replacement.

Valve cap leaking  .......  A  ...  Require repair or replacement

                                                          of cap.

Valve cap missing  .......  C  ....  Require replacement of valve

                                                             cap.

Valve core sticking  .....  B  ..  Require repair or replacement.

         SPRING LOCK COUPLINGS

SPRING LOCK COUPLING INSPECTION

Condition                 Code                          Procedure

Leaking  .................  A  ...........  ( 1) Require repair or

                                                     replacement.

(1) - Require inspection of mating and sealing surface and

      repair or replace as necessary.

         SUCTION THROTTLING VALVES (STVS)

SUCTION THROTTLING VALVE (STV) INSPECTION

Condition                 Code                          Procedure

Connection damaged  ......  B  ..  Require repair or replacement.

Fitting damaged  .........  B  ..  Require repair or replacement.

Inoperative  .............  A  ...........  ( 1) Require repair or

                                                     replacement.

Leaking  .................  A  ..  Require repair or replacement.

Threads damaged  .........  A  ..  Require repair or replacement.

Threads stripped (threads

 missing)  ...............  A  ............  Require replacement.

(1) - Inoperative includes intermittent operation or out of

      OEM specification.

         SWITCHES (ELECTRICAL)

SWITCH (ELECTRICAL) INSPECTION

Condition                 Code                          Procedure

Attaching hardware

 broken  .................  A  ...  Require repair or replacement

                                                     of hardware.

Attaching hardware

 missing  ................  C  ..........  Require replacement of

                                                        hardware.

Summary of Contents for R1500 1999

Page 1: ...Air Charge Temperature Sensor ACV Thermactor Air Control Valve ADJ Adjust or Adjustable ADV Advance AFS Airflow Sensor AI Air Injection AIR or A I R Air Injection Reactor AIS Air Injection System ALCL...

Page 2: ...Blst Ballast Blwr Blower Brkr Breaker C ABBREVIATION TABLE C ABBREVIATION TABLE ABBREVIATION DEFINITION C Celsius Degrees C 3 Computer Controlled Coil Ignition C 4 Computer Controlled Catalytic Conver...

Page 3: ...ter Cu In Cubic Inch Cyl Cylinder D ABBREVIATION TABLE D ABBREVIATION TABLE ABBREVIATION DEFINITION D Drive DBC Dual Bed Catalyst DC Direct Current or Discharge DDD Dual Diaphragm Distributor DERM Dia...

Page 4: ...on system _ EGRC EGR Control solenoid or system _ EGRV EGR Vent solenoid or system _ EMR Emission Maintenance Reminder Module ESA Electronic Spark Advance _ ESC Electronic Spark Control _ EST Electron...

Page 5: ...HLDT Headlight HO High Output HP High Performance HSC High Swirl Combustion HSO High Specific Output HTR Heater HVAC Heating Headlt Headlight Hg Mercury Hgt Height Htr Heater Hz Hertz Cycles Per Seco...

Page 6: ...BLE ABBREVIATION DEFINITION k ohms 1000 ohms kilo as in k ohms kg Kilograms weight kg cm Kilograms Per Square Centimeter KAM Keep Alive Memory KAPWR Keep Alive Power KM H Kilometers Per Hour KOEO Key...

Page 7: ...Fuel Injection MIL Malfunction Incicator Light MLP Manual Lever Position MPFI Multi Point Fuel Injection MPH Miles Per Hour MPI Multi Point Fuel Injection Man Manual Mech Mechanical Mem Memory Mtr Mo...

Page 8: ...Diagnostic Module PCV Positive Crankcase Ventilation PFE Pressure Feedback EGR sensor or circuit PFI Port Fuel Injection see MA SEFI PGM CARB Programmed Carburetor PGM FI Programmed Fuel Injection PI...

Page 9: ...r _ SCS Air Suction Control Solenoid _ SDM Supplemental Restraint System Diagnostic Module _ SDU SRS Diagnostic Unit _ SEN Sensor _ SES Service Engine Soon _ SFI Sequential Port Fuel Injection _ SIG R...

Page 10: ...nical Service Bulletin _ TTS Transmission Temperature Switch TV Thermovalve _ TWC Three Way Catalyst _ Temp Temperature _ Trans Transaxle Transmission _ V ABBREVIATION TABLE V ABBREVIATION TABLE ABBRE...

Page 11: ...W ABBREVIATION TABLE W ABBREVIATION TABLE ABBREVIATION DEFINITION W With _ W O Without _ WAC WOT WOT A C Cut off switch WAC Wide Open Throttle A C WHT White _ WOT Wide Open Throttle _ YEL Yellow _...

Page 12: ...Sebring Convertible JX Body 1 Body codes are determined by fifth character of VIN code BODY DESIGNATIONS CHRYSLER CORP LIGHT TRUCKS VANS Model Body Designation Caravan Town Country Voyager NS Series...

Page 13: ...nture U Series 1 Series codes are determined by fifth character of VIN code BODY DESIGNATIONS JEEP LIGHT TRUCKS Model 1 Body Designation Cherokee XJ Series Grand Cherokee WJ Series Wrangler TJ Series...

Page 14: ...l Ram Van Wagon Sanden TR 105 Scroll Ford Motor Co E Series Van Ford FS 10 10 Cyl Expedition Navigator Ford FS 10 10 Cyl Explorer Mountaineer Ford FS 10 10 Cyl F Series Pickup Except Super Duty Ford F...

Page 15: ...Body 9 0 24 0 G Body With HD6 HT6 Compressor 8 0 32 0 With V5 Compressor 9 0 32 0 H Body 9 0 32 0 J Body 9 0 24 0 M Body 3 4 19 0 21 0 N Body 9 0 2 S Body 3 4 1 22 9 26 5 V Body 9 0 33 5 W Body 9 0 30...

Page 16: ...T Series 2 2L 9 0 30 0 32 0 4 3L 8 0 30 0 32 0 U Series With Rear Unit 11 0 46 0 Without Rear Unit 8 0 32 0 Jeep Cherokee 8 1 20 0 Grand Cherokee 5 8 24 0 Wrangler 8 1 20 0 1 Total system capacity un...

Page 17: ...ND 8 PAG oil SUN PAG 56 oil SP 10 PAG oil or SP 20 PAG oil FORD MOTOR CO Use YN 12B or YN 12C PAG Refrigerant Oil specification WSH M1C231 B or SP 20 PAG Oil specification WST M1C231 B2 GENERAL MOTORS...

Page 18: ...possible Rotate compressor shaft 6 8 revolutions by hand while pouring oil from ports Collect oil in a clean container and measure amount drained DO NOT reuse old refrigerant oil 2 If amount drained...

Page 19: ...drain plug 2 If no compressor oil leaks exist and more than one ounce is drained add amount drained from old compressor If less than one ounce is drained from old compressor add 2 ounces of refrigeran...

Page 20: ...REFRIGERANT OIL CAPACITIES Component Ounces Compressor 3 0 Condenser 0 7 1 0 Receiver Drier 0 3 System Total 3 4 NIPPONDENSO 10PA17 10PA17C 10 CYL Chrysler Corp Avenger Sebring Coupe 1 Remove A C com...

Page 21: ...or 2 0 Receiver Drier 1 0 A C System Total 5 0 Grand Cherokee Accumulator 4 0 Compressor 2 Condenser 1 0 Evaporator 2 0 Refrigerant Line 1 0 System Total 7 4 Neon Compressor 3 Condenser 1 0 Evaporator...

Page 22: ...nt oil to replacement accumulator 2 Add specified amount of refrigerant oil following replacement of other system components such as hoses fixed orifice tube A C clutch cycling switch compressor press...

Page 23: ...at was drained from compressor If amount drained is less than 3 ounces add 3 ounces to compressor See SD 7H15 COMPONENT REFRIGERANT OIL CAPACITIES table Add refrigerant oil through suction port 3 Use...

Page 24: ...Front 2 0 Rear 2 0 Receiver Drier 1 0 System Total With Rear Unit 10 0 Without Rear Unit 8 0 1 Ensure replacement compressor contains the same amount of refrigerant oil as was drained from old compres...

Page 25: ...s JA Body Concorde Intrepid LHS 300M LH Body Neon PL Body Sebring Convertible JX Body 1 Body codes are determined by fifth character of VIN code BODY DESIGNATIONS CHRYSLER CORP LIGHT TRUCKS VANS Model...

Page 26: ...ana G Series Tracker J Series Montana Silhouette Venture U Series 1 Series codes are determined by fifth character of VIN code BODY DESIGNATIONS JEEP LIGHT TRUCKS Model 1 Body Designation Cherokee XJ...

Page 27: ...Sanden SD 7H15 7 Cyl Caravan Town Country Voyager Nippondenso 10PA17 10 Cyl Ram Van Wagon Sanden TR 105 Scroll Ford Motor Co E Series Van Ford FS 10 10 Cyl Expedition Navigator Ford FS 10 10 Cyl Expl...

Page 28: ...Coil Replacer T91L 19623 CH onto coil and Coil Pressing Adapter T89P 19623 EH onto coil replacer 2 Install 2 jaw puller on compressor and coil replacer Engage jaws on puller with compressor front moun...

Page 29: ...aft about 10 revolutions and leak test shaft seal installation 4 Install new shaft seal felt Install clutch plate Install new clutch plate bolt and tighten it to 98 123 INCH lbs 11 14 N m 5 Using a fe...

Page 30: ...2 A DO NOT support pulley rim on flat surface or pulley will be damaged Install bearing in pulley using hammer Bearing Installer J 9481 A and Handle J 29886 3 With pulley on support use Bearing Stakin...

Page 31: ...Fig 2 Compressor Components Harrison HD6 HT6 HD6 HR 6HE 6 Cylinder Courtesy of general motors corp...

Page 32: ...Fig 3 Compressor Components Harrison V5 5 Cylinder Shown V7 7 Cylinder Is Similar Courtesy of general motors corp SHAFT SEAL...

Page 33: ...J 23128 A Install shaft seal so flared side of lip seal is installed toward compressor Expand seal using shaft seal remover installer Install shaft seal on Seal Protector J 34614 Place seal protector...

Page 34: ...ove shaft seal Installation 1 Install Compressor Shaft Seal Protector J 34614 onto compressor shaft Lubricate NEW shaft seal with refrigerant oil DO NOT touch sealing surfaces Engage seal remover inst...

Page 35: ...emove clutch plate shaft key and shims See Fig 5 Remove snap ring and remove pulley assembly Remove snap ring and disconnect clutch coil lead Remove clutch coil Installation 1 Install clutch coil so p...

Page 36: ...with refrigerant oil Install shaft seal protector on compressor shaft Install new front housing O ring on compressor assembly 3 Install front housing on compressor assembly Ensure dowel pins are alig...

Page 37: ...gap at 3 locations again Air gap should be 0 016 0 027 0 41 0 69 mm If air gap is not within specification add or remove shims to obtain correct air gap 4 Add correct amount of refrigerant oil to comp...

Page 38: ...ting bracket Support compressor in engine compartment 2 Using spanner wrench hold clutch plate and remove compressor shaft nut See Fig 1 Using a steering wheel puller remove clutch plate compressor sh...

Page 39: ...haft key Use a hammer and Shaft Protector 6141 2 to install clutch plate on compressor shaft Ensure clutch plate bottoms out on clutch shims Replace compressor shaft nut and tighten compressor shaft n...

Page 40: ...tem SANDEN TRS 90 TR 105 SCROLL CLUTCH ASSEMBLY Removal 1 Without discharging A C system remove compressor from mount Install two 6 mm bolts in holes of clutch plate Use 6 mm bolts and 2 box end wrenc...

Page 41: ...sleeve tighten remover bolt and remove drive plate and shims 3 Remove pulley external snap ring Position Puller Center Adapter SA9149AC 2 over end of compressor shaft Attach 3 jaw puller to back of pu...

Page 42: ...utch relay Faulty electronic cycling clutch switch Improperly installed or faulty low pressure cycling clutch switch Faulty low pressure cut off switch Faulty high pressure cut off switch Faulty PCM F...

Page 43: ...Restricted refrigerant flow through refrigerant lines Restricted refrigerant flow through expansion valve Restricted refrigerant flow through fixed orifice tube Restricted refrigerant flow through re...

Page 44: ...on vacuum gauge several times to ensure exact vacuum reading Connect vacuum gauge hose probe to control panel side of check valve Vacuum gauge reading should be 8 in Hg Replace check valve if vacuum...

Page 45: ...heater control panel vacuum switch assembly If proper vacuum readings are not obtained check appropriate vacuum circuit 8 Start vacuum check by plugging vacuum hose at vacuum actuator in suspect circu...

Page 46: ...Fig 2 Blower Motor System Diagnosis Except RWD Van Courtesy of Chrysler Corp...

Page 47: ...Fig 3 Blower Motor Control System Diagnosis RWD Van Courtesy of Chrysler Corp...

Page 48: ...Fig 4 Blower Motor Noise Vibration Diagnosis Courtesy of Chrysler Corp...

Page 49: ...Fig 5 A C Compressor Compressor Clutch Diagnosis 1 Of 2 Courtesy of Chrysler Corp...

Page 50: ...Fig 6 A C Compressor Compressor Clutch Diagnosis 2 Of 2 Courtesy of Chrysler Corp...

Page 51: ...Fig 7 A C Diagnosis Fixed Displacement Compressors Courtesy of Chrysler Corp...

Page 52: ...HOSES AND FITTING ASSEMBLIES AIR CONTROL DOORS AIR DAMS EXTERNAL AIR DISTRIBUTION SYSTEM BELTS BLEND DOORS BLOWER FANS BLOWER WHEEL OR SQUIRREL CAGE BLOWER MOTORS BLOWER RESISTORS BLOWER SWITCHES CAB...

Page 53: ...lationship between the consumer and the auto repair industry We produce materials that give motorists the information and encouragement to take greater responsibility for their vehicles through proper...

Page 54: ...e requirements are stringent and a self policing method has been incorporated which includes the mystery shopping of outlets We welcome you to join us as we continue our outreach with your support bot...

Page 55: ...s convenience in avoiding a future problem Example The customer desires improved ride and or handling but the vehicle s shocks or struts have not failed In this case replacement may be suggested to sa...

Page 56: ...R CONDITIONING SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE OPERATION CAUTION Before working on any air conditioning system be sure to review current local state federal and EPA regula...

Page 57: ...ire replacement Inoperative A 2 Require replacement Missing C Require replacement Noisy 2 Suggest repair or replacement Out of adjustment B Require repair or replacement Terminal broken A Require repa...

Page 58: ...ing performance 1 Suggest repair or replacement of linkage Linkage broken A Require repair or replacement of linkage Linkage loose affecting performance A Require repair or replacement of linkage Link...

Page 59: ...pe incorrect such as compression fitting B Require replacement Flange leaking A Require repair or replacement Insufficient clamping force allowing hose to leak A Require repair or replacement Leaking...

Page 60: ...ked affecting air conditioning system performance A Require repair or replacement Loose affecting air conditioning system performance A Require repair Loose not affecting air conditioning system perfo...

Page 61: ...cement Distorted A Require replacement Fins missing C Require replacement Hub separated A Require replacement Inoperative A 1 Require replacement Mounting loose A Require repair or replacement Noisy 2...

Page 62: ...inal loose not affecting performance 1 Suggest repair or replacement Vibration 1 Suggest replacement Wire lead conductors exposed B Require repair or replacement Wire lead corroded A Require repair or...

Page 63: ...acement of part 2 Inoperative includes intermittent operation or out of OEM specification BLOWER SWITCHES See SWITCHES CABIN AIR FILTERS CABIN AIR FILTER INSPECTION Condition Code Procedure Air flow o...

Page 64: ...ggest repair or replacement Terminal loose affecting performance B Require repair or replacement Terminal loose not affecting performance 1 Suggest repair or replacement Will not disengage A Require r...

Page 65: ...quire replacement Housing broken affecting performance A Require repair or replacement Housing broken not affecting performance No service suggested or required Housing cracked affecting performance A...

Page 66: ...ing performance No service suggested or required Bracket broken affecting performance A Require replacement Bracket broken not affecting performance No service suggested or required Bracket corroded a...

Page 67: ...epair or replacement Bracket bent not affecting performance No service suggested or required Bracket broken affecting performance A Require replacement Bracket broken not affecting performance No serv...

Page 68: ...r broken A Require repair or replacement Connector Weatherpack type leaking A Require repair or replacement Connector melted affecting performance A 1 Require repair or replacement Connector melted no...

Page 69: ...ffecting performance A Require repair or replacement Bracket bent not affecting performance No service suggested or required Bracket broken affecting performance A Require replacement Bracket broken n...

Page 70: ...if applicable A 1 Further inspection required Connector broken A Require repair or replacement Connector melted affecting performance A 2 Require repair or replacement Connector melted not affecting p...

Page 71: ...ANT INSPECTION Condition Code Procedure Acidity pH incorrect 1 Suggest correction or replacement Contaminated B 1 Require replacement or recycling Further inspection required Level incorrect B 2 Requi...

Page 72: ...lacement Fastener loose A Require repair or replacement of fastener Inoperative A 1 Require replacement Leaking 1 Suggest replacement Seized A Require replacement Slips insufficient fan speed A Requir...

Page 73: ...inal loose not affecting performance 1 Suggest repair or replacement Vibration 1 Suggest replacement Wire lead conductors exposed B Require repair or replacement Wire lead corroded A Require repair or...

Page 74: ...rformance No service suggested or required Bracket corroded affecting performance A Require repair or replacement Bracket corroded not affecting performance 2 Suggest repair or replacement Bracket cra...

Page 75: ...tive A 1 Require repair or replacement Leaking A Require replacement Restricted A Require repair or replacement Threads damaged A Require repair or replacement Threads stripped threads missing A Requi...

Page 76: ...rmance B Require repair or replacement Terminal loose not affecting performance 1 Suggest repair or replacement 1 Determine cause and correct prior to replacement of part 2 Inoperative includes interm...

Page 77: ...lacement of hardware Connection leaking A Require repair or replacement Corroded 1 Suggest repair or replacement Disconnected A Require repair or replacement Fins damaged affecting performance A Requi...

Page 78: ...quire replacement Threads damaged A Require repair or replacement Threads stripped threads missing A Require replacement Type incorrect 1 Suggest repair or replacement HIGH PRESSURE RELIEF VALVES HPRV...

Page 79: ...e replacement Bypassing internally A Require repair or replacement Filter screen torn A Require replacement Installation incorrect B Require repair Restricted A Require repair or replacement PILOT OPE...

Page 80: ...ct leaking A Require repair or replacement Duct missing C Require replacement Duct restricted A Require repair or replacement Leaking A Require repair or replacement Noisy 2 Suggest cleaning or repair...

Page 81: ...ction leaking A Require repair or replacement Corroded 1 Suggest repair or replacement Drain inoperative A Require repair or replacement Fins damaged affecting performance A Require repair or replacem...

Page 82: ...eads damaged A Require repair or replacement Threads stripped threads missing A Require replacement Tubing connection leaking A Require repair or replacement 1 Inspect system to determine effects of d...

Page 83: ...pair or replacement Terminal burned affecting performance A 2 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting perfor...

Page 84: ...quire inspection of mating and sealing surface and repair or replace as necessary SUCTION THROTTLING VALVES STVS SUCTION THROTTLING VALVE STV INSPECTION Condition Code Procedure Connection damaged B R...

Page 85: ...uire repair or replacement Terminal broken A Require repair or replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest r...

Page 86: ...RESSURE SENSOR INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or replacement of hardware Attaching hardware missing C Require replacement of hardware Attaching hardware...

Page 87: ...repair or replacement of hardware Attaching hardware missing C Require replacement of hardware Attaching hardware not functioning A Require repair or replacement of hardware Cracked A Require replace...

Page 88: ...VE IN RECEIVER VIR INSPECTION Condition Code Procedure Application incorrect B Require replacement Attaching hardware broken A Require repair or replacement of hardware Attaching hardware missing C Re...

Page 89: ...en Fitting damaged B Require repair or replacement Fusible plug leaking A Require replacement of plug Inoperative A 2 Require repair or replacement Leaking A Require repair or replacement Pressure rel...

Page 90: ...r or replacement Terminal loose not affecting performance 1 Suggest repair or replacement Vibration 1 Suggest replacement Wire lead conductors exposed B Require repair or replacement Wire lead corrode...

Page 91: ...acement Protective shield conduit missing C Require replacement Routed incorrectly B Require repair Secured incorrectly B Require repair Terminal broken A Require repair or replacement Terminal burned...

Page 92: ...s disconnected radio will go into anti theft protection mode Obtain radio anti theft protection code from owner prior to servicing vehicle DESCRIPTION These systems are a blend air type Outside air en...

Page 93: ...n and off regulating system pressure which controls temperature of evaporator Clutch cycling low pressure switch contacts are normally open when suction low side pressure drops below 25 psi 1 8 kg cm...

Page 94: ...ut out switch and control panel between ground and PCM PCM controls compressor clutch operation When discharge pressure reaches 10 psi 7 kg cm switch interrupts A C request signal to PCM PCM de energi...

Page 95: ...is as specified go to next step If gauge reading is not as specified check for vacuum leak in vacuum lines or A C heater control panel 3 Move temperature control knob quickly to full hot and full col...

Page 96: ...ERFORMANCE TEMPERATURE SPECIFICATIONS RAM PICKUP Ambient Temp F C Outlet Vent Temp F C 70 21 40 45 5 7 80 27 55 60 13 16 90 32 60 70 16 21 100 38 70 75 21 24 110 43 80 85 27 29 120 49 85 90 29 32 A C...

Page 97: ...battery cable Remove blower motor or compressor clutch relay Using an ohmmeter check for continuity between terminals No 87A and 30 of relay See Fig 1 or 2 If continuity does not exist replace relay...

Page 98: ...kay replace underhood power distribution center 2 Disconnect negative battery cable Remove A C heater control panel See A C HEATER CONTROL PANEL R I Disconnect A C heater control panel harness connect...

Page 99: ...Light Blue wire and Black Orange wire and Dark Green wire while rotating blower motor switch 3 If continuity does not exist at any terminal replace faulty blower motor switch If continuity exists as...

Page 100: ...nic cycling clutch switch and low pressure cut out switch If continuity exists in Dark Blue Yellow wire go to next step If continuity does not exist in Dark Blue Yellow wire repair wire as necessary 4...

Page 101: ...recovery recycling equipment Disconnect refrigerant lines from evaporator and plug or cover all openings in A C system Remove instrument panel See INSTRUMENT PANEL 2 In engine compartment disconnect h...

Page 102: ...Fig 4 A C Heater Housing Removal Installation Dakota Durango Front Courtesy of Chrysler Corp...

Page 103: ...r switch Remove upper liftgate opening trim Disengage A B C and D pillar trim as necessary to prevent trim panel interference 3 Move second and third row seats to cargo position Move front seats to fu...

Page 104: ...erse removal procedure A C HEATER CONTROL PANEL R I Removal Installation Dakota Durango 1 Disconnect negative battery cable On models equipped with A T unlock ignition switch Set parking brake and pla...

Page 105: ...C system Loosen support bracket screw Remove accumulator 4 To install reverse removal procedure Install new O rings Evacuate and charge A C system BLOWER MOTOR Removal Dakota Durango Front 1 Disconne...

Page 106: ...wer motor shaft Installation Align reference marks made during removal Press blower fan hub onto blower motor shaft Ensure retainer clip ears are indexed over flats of blower motor shaft and fan hub E...

Page 107: ...stem CONDENSER NOTE Before removing condenser note location of radiator and condenser air seals If air seals are not installed properly A C and engine cooling systems will not perform properly Removal...

Page 108: ...and charge A C system Fill cooling system On 5 9L diesel engine engine is equipped with a one way check valve DO NOT run engine while filling cooling system Fill engine with engine turned off INSTRUME...

Page 109: ...ht kick panel trim Remove 5 screws and knee bolster steering column cover Remove hood release and parking brake release handle screws from lower instrument panel support Remove 6 screws and instrument...

Page 110: ...le Installation 1 Before installing temperature control cable ensure that self adjuster clip is positioned as indicated See Fig 8 Measurements must be made with cable end bottomed against flag retaine...

Page 111: ...Compressor Fitting 1 35 47 INCH Lbs N m Compressor Oil Filler Plug 84 9 5 A C Heater Housing Mounting Nuts Front 60 7 A C Heater Housing Mounting Screws Rear 106 12 1 Wet torque fitting Lubricate ser...

Page 112: ...Fig 10 Manual A C Heater System Vacuum Diagram Ram Pickup Courtesy of Chrysler Corp WIRING DIAGRAMS...

Page 113: ...Fig 11 Manual A C Heater System Wiring Diagram Durango Rear Blower...

Page 114: ...Fig 12 Manual A C Heater System Wiring Diagram Durango...

Page 115: ...Fig 13 Manual A C Heater System Wiring Diagram Dakota 2 5L...

Page 116: ...Fig 14 Manual A C Heater System Wiring Diagram Dakota 3 9L 5 2L 5 9L...

Page 117: ...Fig 15 Manual A C Heater System Wiring Diagram Ram Pickup...

Page 118: ...utch relay Faulty electronic cycling clutch switch Improperly installed or faulty low pressure cycling clutch switch Faulty low pressure cut off switch Faulty high pressure cut off switch Faulty PCM F...

Page 119: ...Restricted refrigerant flow through refrigerant lines Restricted refrigerant flow through expansion valve Restricted refrigerant flow through fixed orifice tube Restricted refrigerant flow through re...

Page 120: ...on vacuum gauge several times to ensure exact vacuum reading Connect vacuum gauge hose probe to control panel side of check valve Vacuum gauge reading should be 8 in Hg Replace check valve if vacuum...

Page 121: ...heater control panel vacuum switch assembly If proper vacuum readings are not obtained check appropriate vacuum circuit 8 Start vacuum check by plugging vacuum hose at vacuum actuator in suspect circu...

Page 122: ...Fig 2 Blower Motor System Diagnosis Except RWD Van Courtesy of Chrysler Corp...

Page 123: ...Fig 3 Blower Motor Control System Diagnosis RWD Van Courtesy of Chrysler Corp...

Page 124: ...Fig 4 Blower Motor Noise Vibration Diagnosis Courtesy of Chrysler Corp...

Page 125: ...Fig 5 A C Compressor Compressor Clutch Diagnosis 1 Of 2 Courtesy of Chrysler Corp...

Page 126: ...Fig 6 A C Compressor Compressor Clutch Diagnosis 2 Of 2 Courtesy of Chrysler Corp...

Page 127: ...Fig 7 A C Diagnosis Fixed Displacement Compressors Courtesy of Chrysler Corp...

Page 128: ...r example as excessive heat will cause refrigerant system pressure to increase Never expose refrigerant directly to open flame If refrigerant needs to be warmed place bottom of refrigerant tank in war...

Page 129: ...Fittings O Rings All R 134a based A C systems use 1 2 16 ACME threaded fittings identifiable by square threads and quick connect service ports See Fig 1 Fig 1 Identifying R 134a Service Ports Courtesy...

Page 130: ...3 Most manufacturers will identify refrigerant type with labels affixed to compressor Before servicing an A C system always determine which refrigerant is being used Fig 2 Underhood Refrigerant Identi...

Page 131: ...te of 005 percent by weight NOTE Use ONLY the specified oil for the appropriate system or A C compressor Always check the underhood A C specification label or A C compressor label before adding refrig...

Page 132: ...ngs with sealing caps that thread into inside of service port instead of onto outside of service port The high side uses a large service port and the low side uses a small service port See Fig 1 The R...

Page 133: ...9 4 V Body 9 4 W Body 9 4 Y Body 3 12 Z Body 7 15 1 On high side liquid line between receiver drier and evaporator 2 On low side hose between evaporator and compressor 3 On high side liquid line 4 On...

Page 134: ...t 4 On compressor manifold 5 On low side line near accumulator 6 On high side line between compressor and condenser near front of engine compartment 7 On low side line extension near receiver drier at...

Page 135: ...Fig 7 Locating Service Valves Caravan Town Country Voyager Courtesy of chrysler corp...

Page 136: ...Fig 8 Locating Service Valves Windstar Courtesy of ford motor co SERVICE EQUIPMENT...

Page 137: ...12 manifold gauge sets MANIFOLD GAUGE SET A manifold gauge set is used to determine the system s high side and low side pressures correct refrigerant charge and operating efficiency High discharge an...

Page 138: ...ide gauge Close hand valve after 3 5 seconds Purging of test hoses is now complete and system is ready for testing NOTE If manifold gauge set is to be used in conjunction with refrigerant recovery rec...

Page 139: ...a Nippondenso 10 cylinder compressor See Figs 9 17 Gauge indications will vary depending on system configuration and compressor application Temperature and humidity as well as other factors affect pr...

Page 140: ...Fig 10 Some Moisture In R 134a System Fig 11 Low R 134a Charge...

Page 141: ...Fig 12 Poor R 134a Refrigerant Circulation Fig 13 No R 134a Refrigerant Circulation...

Page 142: ...Fig 14 Insufficient Cooling Of Condenser Or R 134a Refrigerant Overcharge...

Page 143: ...Fig 15 Air In R 134a System...

Page 144: ...Fig 16 Expansion Valve Improperly Mounted Or Heat Sensing Tube Defective Opening Too Wide Fig 17 Compressor Malfunction...

Page 145: ...and leak test A C system Ensure A C system operates properly FORD MOTOR CO NOTE Replace orifice tube whenever compressor is replaced Fixed orifice tube is located in the condenser to evaporator liqui...

Page 146: ...Fig 18 Removing Orifice Tube Typical Courtesy of ford motor co...

Page 147: ...ifice tube in metal portion of liquid line near bend indented notches or circular depression See Fig 20 2 Cut a 2 5 63 5 mm section from liquid line at least 1 25 4 mm from start of bend in line and d...

Page 148: ...63 5 mm section from liquid line with indentation in the middle at least 1 25 4 mm from start of closest bend Clean out liquid line to remove contaminants 3 Lubricate orifice tube replacement kit comp...

Page 149: ...id line retaining clips 2 Disconnect liquid line at orifice tube location between evaporator and condenser Use Dual O Ring Joint Separator J 38042 to hold pressure against liquid line female nut while...

Page 150: ...On N body raise and support vehicle On all models disconnect condenser to evaporator line at condenser outlet and discard O rings 2 Disconnect condenser to evaporator line clip on right side body rail...

Page 151: ...g between junction block and evaporator If necessary remove air cleaner assembly 3 On all models remove and discard fitting O ring Using Orifice Tube Remover Installer J 26549 E remove orifice tube fr...

Page 152: ...e Using a heat gun carefully apply heat 1 4 from dimples on liquid line Be careful not to overheat line 3 If A C pressure switch is located near orifice tube remove switch to protect it from heat Whil...

Page 153: ...and dirt 2 Using needle nose pliers remove fixed orifice tube from condenser outlet tube Note fixed orifice tube orientation for correct installation To install reverse removal procedure Ensure fixed...

Page 154: ...ow manufacturer s instructions provided with ACR4 equipment being used JEEP Manufacturer recommends using refrigerant recovery recycling equipment which meets SAE standard J1991 or J2210 Always follow...

Page 155: ...ith correct amount of refrigerant oil See COMPRESSOR REFRIGERANT OIL CHECKING article 7 Cut suction hose between compressor and accumulator closer to compressor Remove a length of suction hose to acco...

Page 156: ...Fig 22 Permanent A C System Filters Courtesy of ford motor co...

Page 157: ...ter to vacuum pump Connect manifold gauge set Yellow hose to vacuum pump adapter 2 Fully open manifold gauge set low pressure valve and adapter valve and start vacuum pump Operate vacuum pump for abou...

Page 158: ...m for 30 minutes open all valves start vacuum pump and operate for an additional 10 minutes Close all valves Turn vacuum pump off and disconnect pump If A C system cannot get to or maintain specified...

Page 159: ...f leak is detected retighten connections and repeat A C system evacuation See EVACUATING A C SYSTEM 4 If refrigerant is drawn in start engine Turn A C on and set temperature control to maximum cold an...

Page 160: ...n is made recheck readings to ensure proper charge For system refrigerant capacity see REFRIGERANT OIL REFRIGERANT SPECIFICATIONS article REFRIGERANT CHARGE LEVEL Liquid Line Temp 1 Discharge Pressure...

Page 161: ...ng ACR4 System J 39500 The ACR4 system has one filtering cycle during recovery plus an automatic multiple pass filtering during evacuation cycle Follow manufacturer s instructions provided with ACR4 e...

Page 162: ...erant leak detector check all refrigerant line connections for leaks Check condenser and compressor seal area Start engine and allow to idle Operate A C system for about 5 minutes Set A C controls to...

Page 163: ...be in a reference source where refrigerant is known to be present in small amounts Adjust controls and sensitivity knob until detector reacts properly Move probe away from refrigerant source and the r...

Page 164: ...r WILL NOT change ignition timing but will change fuel system synchronization Fuel system synchronization should be checked anytime distributor is removed or rotated Dakota 3 9L 5 2L 5 9L Durango Ram...

Page 165: ...wn bolt to 16 ft lbs 22 N m Shut engine off Remove scan tool Fig 1 Locating Data Link Connector DLC Dakota Durango Courtesy of Courtesy of Chrysler Corp Fig 2 Locating Data Link Connector DLC Ram Pick...

Page 166: ...W NOTE Throttle body minimum airflow procedure checks throttle body calibration for correct idle speed Procedure may be used for idle speed problems caused by the throttle body Throttle body minimum a...

Page 167: ...recheck minimum airflow idle RPM If correct minimum airflow idle RPM cannot be obtained replace throttle body Go to next step 7 Remove air metering fitting Reinstall vacuum hoses as necessary Reinstal...

Page 168: ...ve clearance must be adjusted with engine temperature less than 140 F 60 C 1 Disconnect negative battery cables Remove valve cover Remove fuel pump gear access cover located at front of engine Using E...

Page 169: ...xt step If any valve clearance is not within specification loosen rocker lever adjusting screw lock nut and adjust valve clearance by rotating rocker lever adjusting screw Tighten rocker lever adjusti...

Page 170: ...loosen rocker lever adjusting screw lock nut and adjust valve clearance by rotating rocker lever adjusting screw Tighten rocker lever adjusting screw lock nut to specification See TORQUE SPECIFICATION...

Page 171: ...erent calibrations available Repair as necessary Fig 3 Identifying Pump Keyway Pump Data Plate Courtesy of Chrysler Corp 3 Reinstall pump timing gear Ensure timing marks on crankshaft gear camshaft ge...

Page 172: ...Chrysler Corp IDLE SPEED Idle speed is controlled by Engine Control Module ECM Idle speed is not adjustable THROTTLE POSITION SENSOR THROTTLE POSITION SENSOR ADJUSTMENT Throttle position sensor may a...

Page 173: ...warning light and Data Link Connector DLC When a malfunction occurs a fault code is stored and AIR BAG warning light is activated for more than 12 seconds When impact sensor registers sufficient decel...

Page 174: ...ransmission tunnel Impact sensor energy reserve capacitor and On Board Diagnostics OBD are an integral part of ACM ACM monitors critical input and output circuits within air bag system ensuring they a...

Page 175: ...sconnecting battery cables to resume procedure After repairs ensure AIR BAG warning light works properly and no system faults are indicated See SYSTEM OPERATION CHECK Always wear safety glasses when s...

Page 176: ...eability problems may exist until computer systems have completed a relearn cycle See COMPUTER RELEARN PROCEDURES in GENERAL INFORMATION before disconnecting battery DISABLING ACTIVATING AIR BAG SYSTE...

Page 177: ...harness 3 Strip 1 25 mm of insulation from wire ends Make a harness consisting of 2 wires 20 feet or longer Connect 20 foot wires to clockspring harness Ensure there are no loose parts in passenger c...

Page 178: ...e Removal 1 Before proceeding see SERVICE PRECAUTIONS Disable air bag system See DISABLING ACTIVATING AIR BAG SYSTEM Remove bottom of center console ACM trim cover 2 On M T models remove center consol...

Page 179: ...N m DO NOT connect negative battery cable at this time Go to SYSTEM OPERATION CHECK Fig 2 Identifying ACM Trim Cover A T Models Courtesy of DaimlerChrysler Corp Fig 3 Removing Air Bag Control Module...

Page 180: ...enter of glove box bin towards front of vehicle Flex glove box bin far enough so glove box stops will clear sides of instrument panel opening Roll glove box down until stop bumpers are beyond sides of...

Page 181: ...on steering wheel hub fit formations on inside of clockspring Pull clockspring cruise control switch if equipped and horn wires through lower large holes and upper small holes in steering wheel 3 Ins...

Page 182: ...ch from bezel 6 To install reverse removal procedure Tighten PAD switch mounting screws to specification See TORQUE SPECIFICATIONS DO NOT connect negative battery cable at this time Go to SYSTEM OPERA...

Page 183: ...Depress 2 plastic auto locking tabs See Fig 5 Keeping auto locking tabs depressed rotate clockspring rotor clockwise to end of its travel DO NOT apply excessive force Rotate rotor counterclockwise 2...

Page 184: ...e designed for use with DRB SELF DIAGNOSTIC SYSTEM SRS is monitored by Air Bag Control Module ACM ACM contains safing sensor an integral sensor in circuitry of system which is used to deploy air bag m...

Page 185: ...Always follow air bag service precautions to avoid air bag deployment and possible personal injury Refer to procedure under See SERVICE PRECAUTIONS After component replacement ensure proper system op...

Page 186: ...ny DTCs fault messages exist perform appropriate test 3 If PAD switch OFF indicator fails to illuminate when in the OFF position go to PAD SWITCH INDICATOR PROBLEMS If PAD switch OFF indicator illumin...

Page 187: ...f the air bag restraint system require voltage or resistance checks at various system connector terminals See Figs 6 19 Fig 6 Identifying Powertrain Control Module PCM Connector Terminals Courtesy of...

Page 188: ...8 Locating Seat Belt Control Timer Module Main Seat Connector Courtesy of DaimlerChrysler Corp Fig 9 Identifying Seat Belt Control Timer Module SCTM Connector Terminals Courtesy of DaimlerChrysler Co...

Page 189: ...Fig 10 Identifying Air Bag Control Module ACM Connector Terminals Courtesy of DaimlerChrysler Corp Fig 11 Identifying Driver Squib Connector Terminals Courtesy of DaimlerChrysler Corp...

Page 190: ...Fig 12 Locating Clockspring 2 Pin Connector Courtesy of DaimlerChrysler Corp Fig 13 Identifying Passenger Air Bag Disable PAD Switch Connector Terminals Switch Side Courtesy of DaimlerChrysler Corp...

Page 191: ...Passenger Air Bag Disable PAD Switch Connector Terminals Harness Side Courtesy of DaimlerChrysler Corp Fig 15 Identifying Passenger Air Bag Disable PAD Switch 2 Pin Connector Terminals Courtesy of Da...

Page 192: ...Fig 16 Identifying Data Link Connector DLC Terminals Courtesy of DaimlerChrysler Corp...

Page 193: ...Fig 17 Identifying Fuses Junction Block Courtesy of DaimlerChrysler Corp...

Page 194: ...dentifying Clockspring 2 Pin Connector Terminals Courtesy of DaimlerChrysler Corp Fig 19 Identifying Passenger Air Bag 2 Pin Connector Terminals Courtesy of DaimlerChrysler Corp REPAIRING STORED TROUB...

Page 195: ...splays MIC LAMP STATUS ON go to next step 3 If DRB displays ACM LAMP REQUEST ON go to next step If DRB does not display ACM LAMP REQUEST ON replace instrument cluster 4 If there are no potential cause...

Page 196: ...ire If resistance is less than 5 ohms go to next step If resistance is more than 5 ohms repair open or high resistance in Black Light Blue wire 5 If there are no potential causes for this DTC remainin...

Page 197: ...Using a voltmeter check voltage between ground and clockspring connector terminals No 1 Black Light Blue wire and No 2 Dark Green Light Blue wire If voltage is more than 5 volts on either circuit rep...

Page 198: ...BAG CONTROL MODULE ACM under REMOVAL INSTALLATION 5 Turn ignition off Using an ohmmeter check resistance between ground and fused ignition switch output RUN circuit at fuse No 18 If resistance is mor...

Page 199: ...AIR BAG VERIFICATION TEST after all repairs Each time a connector is disconnected inspect it to ensure it is in good condition Always focus on circuit being tested Dirt water and corrosion are most c...

Page 200: ...ach time a connector is disconnected inspect it to ensure it is in good condition Always focus on circuit being tested Dirt water and corrosion are most common problems in connectors Due to manufactur...

Page 201: ...ff Disconnect battery and wait 2 minutes before proceeding Disconnect passenger side air bag module connector Disconnect clockspring connector Go to next step 3 Using an ohmmeter check resistance betw...

Page 202: ...r bag module 2 pin connector terminals A Black Yellow wire and B Dark Green Yellow wire If resistance is less than 5 ohms in either circuit repair short in Black Yellow wire or Dark Green Yellow wire...

Page 203: ...CM If voltage is less than one volt repair open in Light Green Black wire If voltage is between 9 10 volts perform Seat Belt Control Timer Module SCTM diagnostics Repair as required If voltage is not...

Page 204: ...NO RESPONSE FROM PCM and vehicle is a Club Cab BE go to next step If DRB does not display NO RESPONSE FROM PCM and vehicle is a Standard Cab BR go to step 3 2 Using DRB select PASSIVE RESTRAINTS AIRBA...

Page 205: ...indicator fails to illuminate in OFF position go to next step If PAD switch off indicator does not fail to illuminate in OFF position go to step 5 2 Using DRB read active DTCs If DRB displays LOSS OF...

Page 206: ...T VERIFICATION TEST under DIAGNOSTIC TESTS after all repairs Each time a connector is disconnected inspect it to ensure it is in good condition Always focus on circuit being tested Dirt water and corr...

Page 207: ...ait 2 minutes before proceeding Disconnect ACM Using an ohmmeter check resistance between ACM connector terminal No 14 Light Green Yellow wire and fused side Light Green Yellow wire of fuse No 19 loca...

Page 208: ...wire If voltage is more than 0 2 volt repair short in White Black wire If voltage is less than 0 2 volt replace DRB or DRB cable as necessary 8 Turn ignition off Using an ohmmeter check resistance be...

Page 209: ...WIRING DIAGRAMS Fig 20 Air Bag System Wiring Diagram...

Page 210: ...omponents sensor sensor rings Sensor rings must be pressed into hubs NOT hammered into hubs Striking these components can cause demagnetization or a loss of polarization affecting the accuracy of the...

Page 211: ...Theft Security System VTSS will not arm using key in lock cylinder or mechanical lock button While system is arming SECURITY light will flash rapidly for 15 seconds Opening any door or turning the ig...

Page 212: ...d in junction block under left side of instrument panel For circuit testing see WIRING DIAGRAMS Headlight Relay Horn Relay Remove relay to be tested Measure resistance between appropriate relay termin...

Page 213: ...ening far enough to gain access to connectors Disconnect harness connectors and remove CTM from underdash To install reverse removal procedure Reprogram new CTM See appropriate BODY CONTROL COMPUTER T...

Page 214: ...w door ajar switch from pillar On Ram Pickup using pliers pull back and forth to slide switch from pillar On all models pull door jamb switch away from pillar enough to disconnect 2 harness connectors...

Page 215: ...battery cable Remove inside door panel Disconnect door lock cylinder harness connector Disengage door lock cylinder switch from back of door lock cylinder Remove door lock cylinder switch pigtail reta...

Page 216: ...Fig 5 Anti Theft System Wiring Diagram Ram Pickup...

Page 217: ...Fig 6 Anti Theft System Wiring Diagram Ram Van Ram Wagon...

Page 218: ...ission Model Cab Chassis 5 9L Gasoline 46RE 5 9L Diesel 8 0L 47RE Dakota Durango 3 9L 42RE 5 2L 44RE 5 9L 46RE Grand Cherokee 4 0L 42RE Ram Pickup 3 9L 42RE 5 2L RWD 42RE 5 2L 4WD 46RE 5 9L Gasoline 4...

Page 219: ...nsor Crankshaft Position CKP sensor Vehicle Speed Sensor VSS Throttle Position TP sensor and battery temperature sensor There are 4 governor pressure curves programmed into the PCM Governor pressure c...

Page 220: ...the PCM indicating the output pressure of governor pressure solenoid The PCM uses this signal to control governor pressure Governor pressure solenoid is located on valve body See Fig 1 GOVERNOR PRESS...

Page 221: ...RE SENSOR NOTE Transmission fluid temperature sensor may also be referred to as transmission fluid temperature thermistor or transmission fluid temperature sender Transmission fluid temperature sensor...

Page 222: ...e DTCs See RETRIEVING DIAGNOSTIC TROUBLE CODES Repair DTCs in order displayed Always perform test verification test after any repair procedure is completed unless specified otherwise See appropriate v...

Page 223: ...DTC DRB III Scan Tool Message P0711 TRANS TEMP SENSOR NO TEMP RISE AFTER START P0712 TRANS TEMP SENSOR VOLTAGE TO LOW P0713 TRANS TEMP SENSOR VOLTAGE TO HIGH P0720 LOW OUTPUT SPEED SENSOR RPM ABOVE 1...

Page 224: ...es Check for Technical Service Bulletins TSBs relating to the problem NOTE For circuit description and wire color information see WIRING DIAGRAMS CONNECTOR IDENTIFICATION CONNECTOR IDENTIFICATION DIRE...

Page 225: ...Fig 2 Identifying Data Link Connector DLC Terminals Courtesy of DaimlerChrysler Corp...

Page 226: ...entifying Overdrive O D Off Switch Connector Terminals AN DN BR Bodies Courtesy of DaimlerChrysler Corp Fig 4 Identifying Overdrive O D Off Switch Connector Terminals WJ Body Courtesy of DaimlerChrysl...

Page 227: ...g 5 Identifying Park Neutral Position PNP Switch Connector Terminals Courtesy of DaimlerChrysler Corp Fig 6 Identifying Powertrain Control Module PCM Connector Terminals Courtesy of DaimlerChrysler Co...

Page 228: ...ifying Transmission Control Relay Connector Terminals AB Body Courtesy of DaimlerChrysler Corp Fig 8 Identifying Transmission Control Relay Connector Terminals AN BR DN WJ Bodies Courtesy of DaimlerCh...

Page 229: ...ig 9 Identifying Transmission Governor Pressure Sensor Connector Terminals Courtesy of DaimlerChrysler Corp Fig 10 Identifying Transmission Output Shaft Speed Sensor Connector Terminals AB BR WJ Bodie...

Page 230: ...ig 11 Identifying Transmission Output Shaft Speed Sensor Connector Terminals AN DN Bodies Courtesy of DaimlerChrysler Corp Fig 12 Identifying Transmission Solenoid Connector Terminals Courtesy of Daim...

Page 231: ...erature ECT sensor temperature and transmission temperature sensor temperature If transmission temperature is within 9 F 13 C of ECT temperature go to step 5 If transmission temperature is not within...

Page 232: ...o to next step 7 Inspect all related wiring and connectors Repair as necessary If wiring and connectors are okay see INACTIVE DTC CONDITION under SELF DIAGNOSTIC SYSTEM Testing is complete 8 Disconnec...

Page 233: ...t transmission solenoid harness connector Remove transmission oil pan Disconnect transmission pressure temperature sensor harness connector Measure voltage between ground and transmission temperature...

Page 234: ...hort to ground in output speed sensor signal circuit Park Neutral switch code present Malfunctioning sensor Short to ground in output speed sensor ground circuit Malfunctioning PCM OSS harness intermi...

Page 235: ...osition and record voltage at each position If voltage is greater than one volt in any gear position repair speed sensor ground circuit for a short to power If voltage is not as specified go to next s...

Page 236: ...age If vehicle does not stall testing is complete 7 Turn ignition off Remove oil pump and inspect reaction shaft input shaft and input seal Repair transmission as necessary See appropriate AUTOMATIC T...

Page 237: ...Turn ignition off Disconnect White PCM harness connector C2 Inspect connector and terminals for damage Repair as necessary If connector and terminals are okay turn ignition on Measure voltage between...

Page 238: ...STEM TEST If engine stalls testing complete If engine does not stall replace PCM 17 Reconnect transmission solenoid harness connector Measure resistance of TCC solenoid control circuit between ground...

Page 239: ...istance is less than 5 ohms repair TCC solenoid control circuit for short to ground If resistance is 5 ohms or greater go to next step 8 Reconnect transmission solenoid harness connector Measure resis...

Page 240: ...743 does not reset see INACTIVE DTC CONDITION under SELF DIAGNOSTIC SYSTEM Testing is complete DTC P0748 GOVERNOR PRESSURE SOL CONTROL TRANS RELAY CIRCUITS Circuit Description Circuit is monitored con...

Page 241: ...lay output circuit at transmission control relay connector and governor pressure solenoid control circuit at White PCM harness connector C2 If resistance is 2 5 5 0 ohms replace PCM If resistance is n...

Page 242: ...control relay output circuit at transmission control relay connector and TCC solenoid harness connector If resistance is greater than 5 ohms repair open transmission control relay output circuit If re...

Page 243: ...isconnect governor pressure solenoid harness connector Inspect connector and terminals for damage Repair as necessary If connector and terminals are okay measure resistance across governor pressure so...

Page 244: ...ss between governor pressure solenoid and PCM Note if DTC P0748 resets If DTC P0748 resets repair wiring harness as necessary If DTC P0748 does not reset go to next step 21 Inspect all related wiring...

Page 245: ...ach a speed of 50 MPH Depress Overdrive OD switch 4 times so vehicle attempts to shift from 4th gear to 3rd gear and back If vehicle does not shift between 3rd and 4th gear go to step 5 If vehicle shi...

Page 246: ...ohms or greater repair open 3 4 shift solenoid circuit If resistance is less than 5 ohms replace transmission solenoid and harness assembly 13 Disconnect transmission solenoid harness connector Inspec...

Page 247: ...t solenoid control circuit at transmission solenoid harness connector If voltage is greater than 10 volts go to next step If voltage is 10 volts or less go to step 7 6 Repair 3 4 shift solenoid contro...

Page 248: ...are okay go to next step 17 Wiggle wiring harness between TCC solenoid and PCM Note if DTC P0753 resets If DTC P0753 resets repair wiring harness as necessary If DTC P0753 does not reset replace PCM...

Page 249: ...pen transmission control relay output circuit If resistance is less than 5 ohms go to next step 11 Turn ignition on Measure voltage between ground and fused B circuit at transmission control relay con...

Page 250: ...TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT P1765 TRANS 3 4 SHIFT SOLENOID TRANS RELAY CIRCUITS P0753 1 See appropriate SELF DIAGNOSTICS article in ENGINE PERFORMANCE 3 Check transmission fluid for prop...

Page 251: ...sts TCC engagement in 3rd gear and overdrive Code will set if expected RPM drop is not achieved while attempting to engage TCC and or overdrive Code indicates malfunctioning torque converter or overdr...

Page 252: ...transmission governor pressure test port See appropriate AUTOMATIC TRANSMISSION OVERHAUL article Ensure engine and transmission are at normal operating temperature With an assistant test drive vehicle...

Page 253: ...on shaft input shaft and input seal If any parts are damaged repair as necessary and replace torque converter If all parts are okay go to next step 24 Record freeze frame data to determine conditions...

Page 254: ...7 Place gear selector in Park With engine still running remove transmission control relay Depress brake pedal and place gear selector in D position Read governor pressure sensor value If value is 40...

Page 255: ...dicator Light MIL illuminated Code sets if governor pressure sensor is greater than 3 psi 2 kg cm when requested pressure is zero with governor pressure solenoid duty cycle at 95 percent for 2 65 seco...

Page 256: ...is on and engine running Code sets if governor pressure is out of range for 1 3 seconds Test must fail 3 times to set code Possible Causes Solenoid pack connector 5 volt supply circuit open Governor...

Page 257: ...does not reset test is complete If DTC P1762 resets go to next step 10 Drain transmission fluid and remove oil pan Replace governor pressure sensor Inspect oil pan for burnt oil and debris Repair tra...

Page 258: ...nsmission solenoid and harness assembly If resistance is 5 ohms or less go to next step 8 Reconnect all harness connectors except governor pressure sensor harness connector Carefully connect a fused j...

Page 259: ...resistance of governor pressure sensor signal circuit between White PCM harness connector C2 and governor pressure sensor connector If resistance is greater than 5 ohms repair or replace transmission...

Page 260: ...If voltage is not as specified go to next step 4 Reconnect transmission solenoid harness connector Measure resistance of sensor ground circuit between Black PCM harness connector C1 and transmission...

Page 261: ...s and terminals for damage Repair as necessary If connector and terminals are okay measure resistance between sensor ground circuit at Black PCM harness connector C1 and governor pressure sensor signa...

Page 262: ...freeze frame data to determine conditions which set code Turn ignition off Disconnect PCM harness connectors Disconnect transmission solenoid harness connector Inspect connector and terminals for dama...

Page 263: ...mperature sensor If voltage is greater than 1 volt go to next step 13 Measure resistance of governor pressure sensor signal circuit between White PCM harness connector C2 and governor pressure sensor...

Page 264: ...ime Using wiring diagram as a guide inspect wiring and connectors Repair wiring harness as necessary If wiring and connectors are okay go to next step 24 Using scan tool clear DTCs While reading DTCs...

Page 265: ...ms or greater go to next step 8 Measure resistance of transmission relay control circuit between transmission control relay connector and White PCM harness connector C2 If resistance is 5 ohms or grea...

Page 266: ...f PCM detects an incorrect Park Neutral Position PNP switch state for a given mode of vehicle operation Possible causes are faulty connections faulty PNP switch mechanical transmission problem or PCM...

Page 267: ...e into PCM Using scan tool manufacturer s instructions clear DTCs from ABS and SRS modules Go to step 1 Procedure For Updating Secret Key Data Connect scan tool to Data Link Connector DLC Go to ENGINE...

Page 268: ...ng To update secret key data proceed to appropriate procedure listed below CAUTION DO NOT attempt to adjust screws or disassemble APPS Settings are preset at factory and are not intended to by changed...

Page 269: ...from ABS and SRS modules proceed to appropriate procedure listed below On models equipped with a Smart Key Immobilizer Module SKIM if replacing Powertrain Control Module PCM secret key data must also...

Page 270: ...TION DO NOT attempt to adjust screws or disassemble APPS Settings are preset at factory and are not intended to by changed Procedure For Programming APPS Reassemble all components Turn ignition switch...

Page 271: ...R will change to one or more If MISFIRE GOOD TRIP COUNTER changes to one or more test is complete Go to step 9 If MISFIRE GOOD TRIP COUNTER does not change to one or more go to next step 8 Using scan...

Page 272: ...ed sensor or shaft speed sensor Removal Installation 1 Disconnect electrical connector from output shaft speed sensor located on case of overdrive unit Remove output shaft speed sensor with O ring 2 T...

Page 273: ...Fig 13 Transmission Wiring Diagram Dakota...

Page 274: ...Fig 14 Transmission Wiring Diagram Durango...

Page 275: ...Fig 15 Transmission Wiring Diagram Pickup 3 9L 5 2L 5 9L 8 0L 1 Of 2...

Page 276: ...Fig 16 Transmission Wiring Diagram Pickup 3 9L 5 2L 5 9L 8 0L 2 Of 2...

Page 277: ...Fig 17 Transmission Wiring Diagram Pickup 5 9L Diesel 1 Of 2...

Page 278: ...Fig 18 Transmission Wiring Diagram Pickup 5 9L Diesel 2 Of 2...

Page 279: ...Fig 19 Transmission Wiring Diagram Ram Van Wagon 1 Of 2...

Page 280: ...Fig 20 Transmission Wiring Diagram Ram Van Wagon 2 Of 2...

Page 281: ...Fig 21 Transmission Wiring Diagram Jeep Grand Cherokee...

Page 282: ...s or poor electrical connections Before condemning the computerized system perform each test listed in this article Two different module systems are used for powertrain control of diesel engine The En...

Page 283: ...to next step 5 Verify fuel filter water separator has been serviced according to proper service schedule See SERVICE ADJUSTMENT SPECIFICATIONS TRUCKS article 6 Check color of Filter Minder Filter Min...

Page 284: ...r corner of engine compartment 9 Check for loose defective or corroded connections at intake manifold air temperature sensor See Fig 4 10 Ensure electrical connections on intake manifold air heater re...

Page 285: ...Fig 4 Locating Intake Manifold Air Temperature Sensor Courtesy of Chrysler Corp...

Page 286: ...Fig 5 Locating Intake Manifold Air Heater Relays Courtesy of Chrysler Corp...

Page 287: ...el injection pump to fuel injector may cause starting problems poor engine performance and excessive Black smoke 11 Check all fuel supply and returns lines for damage kinking or leakage Check throttle...

Page 288: ...EL HEATER 1 Fuel heater is located in fuel filter water separator See Fig 1 Fuel heater uses a fuel heater temperature sensor for controlling operation of the fuel heater 2 A defective fuel heater may...

Page 289: ...r leaking fuel supply line to fuel transfer pump or fuel return line located on driver s side of engine See Fig 1 Repair fuel supply line or fuel return line if restricted or leaking 2 Check for fuel...

Page 290: ...th a clamp to fitting Place other end of hose in a fuel container Turn ignition switch to START position then release to RUN position without starting engine Fuel transfer pump should run for 25 secon...

Page 291: ...icle If no leaks are found go to next step 3 Remove suspect injector See FUEL INJECTOR under FUEL SYSTEM in REMOVAL OVERHAUL INSTALLATION TRUCKS DIESEL article Test injector with a diesel fuel injecto...

Page 292: ...or damaged misrouted vacuum hoses Before condemning the computerized system perform each test listed in this article NOTE Perform all voltage tests with a Digital Volt Ohmmeter DVOM with a minimum 10...

Page 293: ...removed Clear DTCs from PCM after fuel pressure release procedure To clear DTCs from PCM see CLEARING DTCS under SELF DIAGNOSTIC SYSTEM in SELF DIAGNOSTICS JEEP TRUCKS RWD VANS article Vehicles Witho...

Page 294: ...923 into fuel rail Ensure adapter is fully seated in fuel rail Install latch clip into fuel rail with latch clip fingers pointing downward If latch clip will not fully seat so latch clip fingers exten...

Page 295: ...omes defective a Diagnostic Trouble Code FTC may be stored in the PCM For additional information on diagnosis for fuel pump relay and control circuit see TEST TC 101A in SELF DIAGNOSTICS JEEP TRUCKS R...

Page 296: ...with a distributor DO NOT attempt to adjust timing by rotating distributor If distributor is rotated fuel system synchronization will be changed If distributor is rotated or removed check fuel system...

Page 297: ...o to next step If scan tool displays any message except BUS OPERATIONAL see appropriate VEHICLE COMMUNICATIONS article 3 Using scan tool select READ DTCs If any Diagnostic Trouble Codes fault messages...

Page 298: ...EMS WINDSHIELD WIPER SYSTEM WIPER PARK SWITCH FAILURE INTERMITTENT WIPERS INOPERATIVE NO WIPER ACTUATION AFTER WASH BUTTON PUSHED WIPER SPEED SENSITIVE FEATURE INOPERATIVE CHIME SYSTEM CHIME INOPERATI...

Page 299: ...go to next step If chime sounds system is currently functioning correctly 2 Using scan tool read driver s door ajar switch status If scan tool displays LFDOOR AJAR SWITCH CLOSED go to next step If sca...

Page 300: ...o to OPEN LEFT DOOR AJAR CIRCUIT 3 Turn on headlights If chime does not sound repair open headlight sense circuit Light Blue wire between CTM and headlight switch See appropriate wiring diagram in BOD...

Page 301: ...t cluster 10 pin connector C2 terminal No 7 If resistance is less than 5 ohms replace CTM If resistance is 5 ohms or more repair open Dark Blue Red wire CHIME SOUNDS WITH DRIVER DOOR OPEN NOTE For con...

Page 302: ...jar switch and CTM If scan tool does not display DRDOOR AJAR SW CLOSED replace CTM OPEN RIGHT DOOR AJAR CIRCUIT NOTE For connector terminal identification and wiring diagrams see BODY CONTROL COMPUTER...

Page 303: ...e closed Open right front door and remove door panel Disconnect right front door ajar switch Using scan tool read right front door ajar switch status If scan tool displays PASSDOOR AJAR SW CLOSED go t...

Page 304: ...ing self test If inoperative light did not illuminate during self test go to next step If inoperative light illuminated during self test verify if light is controlled by an input to instrument cluster...

Page 305: ...circuit board 5 Turn ignition on If CHECK GAUGES light illuminated go to next step If CHECK GAUGES light did not illuminate go to step 11 6 Turn ignition off Inspect oil level If oil level is within...

Page 306: ...go to next step 17 Check charging system operation If charging system is operating properly replace instrument cluster If charging system is not operating properly repair engine charging problem 18 U...

Page 307: ...es not display SC go to next step 3 Connect a backprobe jumper wire between ground and CMTC harness connector terminal No 3 Violet Light Green wire If CMTC displays SC repair open Violet Light Green w...

Page 308: ...minal identification and wiring diagrams see BODY CONTROL COMPUTER INTRODUCTION article Perform VERIFICATION TEST VER 1A after each repair CAUTION Always turn ignition switch to OFF position prior to...

Page 309: ...rectly 4 Using scan tool read left door ajar status Open and close left door If door ajar state changed from OPEN to CLOSED go to next step If door ajar state did not change from OPEN to CLOSED go to...

Page 310: ...ct connector Using an external voltmeter measure voltage between ground and CTM 18 pin connector C2 terminal No 1 Orange Black wire If voltage is more than 9 5 volts while door lock switch is pressed...

Page 311: ...tage is 9 5 volts or less repair open Pink Dark Green wire between CTM and door lock switch REMOTE KEYLESS ENTRY PROBLEM NOTE For connector terminal identification and wiring diagrams see BODY CONTROL...

Page 312: ...wire If resistance is 1000 ohms or more replace CTM DOOR LOCK SWITCH FAILURE NOTE For connector terminal identification and wiring diagrams see BODY CONTROL COMPUTER INTRODUCTION article Perform VERI...

Page 313: ...MPUTER INTRODUCTION article Perform VERIFICATION TEST VER 1A after each repair CAUTION Always turn ignition switch to OFF position prior to disconnecting or connecting any module connector 1 Using sca...

Page 314: ...ext step 10 Measure voltage between ground and overhead console 12 pin connector terminal No 5 Pink wire Turn ignition on If voltage is more than 10 volts go to next step If voltage is 10 volts or les...

Page 315: ...If scan tool displays door disarm switch state CLOSED go to next step If scan tool does not display door disarm switch state CLOSED repair open left door disarm switch ground circuit Black Light Green...

Page 316: ...Green wire If voltage is more than 9 volts go to next step If voltage is 9 volts or less replace wiper motor 3 Locate Central Timer Module CTM CTM is located under left side of instrument panel Using...

Page 317: ...SPONSE go to appropriate VEHICLE COMMUNICATIONS article If scan tool displays any CCD bus failure message go to SYMPTOM IDENTIFICATION If scan tool does not display NO RESPONSE or any CCD bus failure...

Page 318: ...ll RKE transmitters and program other options as necessary 2 Ensure ignition is on Erase all DTCs using scan tool Turn ignition off and wait 5 seconds Turn ignition on and fully operate system that wa...

Page 319: ...E STOPLIGHT SWITCHES BULB SOCKETS BULBS AND LEDS CALIPER HARDWARE CALIPERS CONTROLLERS DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS DRAC AND DRAB DISABLE SWITCHES DRUMS ELECTRICAL PUMPS AND MOTORS ELECT...

Page 320: ...faction These Standards of Service require that an inspection of the vehicle s problem system be made and the results communicated to the customer according to industry standards Given that the indust...

Page 321: ...Before any service is performed on a vehicle an inspection of the appropriate system must be performed The results of this inspection must be explained to the customer and documented on an inspection...

Page 322: ...edure states that required or suggested repair or replacement is recommended the customer must be informed of the generally acceptable repair replacement options whether or not performed by the shop W...

Page 323: ...NSPECTION Condition Code Procedure Leaking B Require replacement Missing C Require replacement Pre charge incorrect B Require replacement ANCHOR PINS See BACKING PLATES ANTI LOCK BRAKE SYSTEMS NOTE An...

Page 324: ...fluids are clear or light amber in color DOT 5 brake fluid is violet in color Correct fluid required for the brake system is stamped on the master cylinder cover BRAKE FLUID INSPECTION Condition Code...

Page 325: ...orn 1 Suggest replacement Pivot bushings worn affecting performance A Require replacement of pivot bushings BRAKE SHOES See FRICTION MATERIAL BRAKE SHOE HARDWARE See also SELF ADJUSTING SYSTEMS BRAKE...

Page 326: ...eplacement of part 2 Determine cause and correct prior to repair or replacement of part BULB SOCKETS BULB SOCKET INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or repla...

Page 327: ...lication incorrect B 1 Require replacement Base burned affecting performance A 2 Require repair or replacement Base burned not affecting performance 2 2 Suggest repair or replacement Base corroded aff...

Page 328: ...er pin or bolt and lubricants Slider pin bolt rust pitted A Require replacement of slider pin or bolt and lubricants Slider pin bolt worn A Require replacement of slider pin or bolt and lubricants Thr...

Page 329: ...equire repair or replacement of caliper bracket Mounting pin threads stripped in steering knuckle threads missing A Require repair or replacement of steering knuckle Mounting pin threads stripped thre...

Page 330: ...g performance A 2 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair or replacement Termin...

Page 331: ...ment Measured diameter is greater than OEM discard specifications B Require replacement Out of round runout affecting performance A Require reconditioning or replacement Out of round runout exceeding...

Page 332: ...ce 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair or replacement Terminal corroded not affecting performance 2 Suggest repair or replacement Terminal loose af...

Page 333: ...A Require repair or replacement Terminal corroded not affecting performance 2 Suggest repair or replacement Terminal loose affecting performance B Require repair or replacement Terminal loose not affe...

Page 334: ...ermanently attached hardware missing C Require replacement Permanently attached hardware seized A Require repair or replacement Rivets loose B Require replacement Separating from backing B Require rep...

Page 335: ...r is to alert him or her to check for friction wear Wear indicators may be bent or broken Therefore the friction material must be measured The need for friction material replacement is determined base...

Page 336: ...r or replacement Housing cracked B Require repair or replacement Inoperative 2 A Require repair or replacement Internal leak A Require repair or replacement Missing C Require replacement Terminal burn...

Page 337: ...r replacement Leaks fluid at unit B Require repair or replacement Leaks fluid from pressure hose s B Require replacement of hose s Leaks fluid into passenger compartment B Require repair or replacemen...

Page 338: ...A Require repair or replacement Melted affecting performance A Require replacement Melted not affecting performance 2 Suggest replacement Missing C Require replacement MASTER CYLINDERS MASTER CYLINDER...

Page 339: ...M INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or replacement of hardware Attaching hardware missing C Require replacement of hardware Attaching hardware not function...

Page 340: ...TCHES PRESSURE SWITCHES See SWITCHES RELAYS NOTE Copied from Electrical UIGs RELAY INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or replacement of hardware Attaching h...

Page 341: ...you may suggest reconditioning of the other rotor on the same axle to eliminate uneven braking behavior Determine the need to replace based upon the individual rotor conditions that follow Reconditio...

Page 342: ...be worn to discard specifications 3 If OEM does not supply machine to specifications you may machine to discard specifications 4 Scoring is defined as grooves or ridges in the friction contact surface...

Page 343: ...uire rerouting according to vehicle manufacturer s specifications Leaking A Require repair or replacement Loose A Require repair or replacement Missing C Require replacement Resistance out of specific...

Page 344: ...C Require replacement of hardware Attaching hardware not functioning A Require repair or replacement of hardware Corroded affecting structural integrity A Require replacement Fitting incorrect for ex...

Page 345: ...ormance 2 1 Suggest repair or replacement Missing C Require replacement Out of adjustment B Require repair or replacement Terminal broken A Require repair or replacement Terminal burned affecting perf...

Page 346: ...mance A Require repair Identify and correct cause Cracked B Require replacement Loose A Require replacement of worn parts Missing C Require replacement Number of teeth incorrect B Require replacement...

Page 347: ...ormance 2 Suggest repair or replacement Terminal loose affecting performance B Require repair or replacement Terminal loose not affecting performance 1 Suggest repair or replacement Threads damaged A...

Page 348: ...r or replacement Terminal loose affecting performance B Require repair or replacement Terminal loose not affecting performance 1 Suggest repair or replacement Threads damaged A Require repair or repla...

Page 349: ...mine the need to replace based upon the individual component conditions that follow WHEEL BEARINGS RACES AND SEALS INSPECTION Condition Code Procedure Axle seal on drive axle leaking A Require replace...

Page 350: ...in wheel cylinder if non repairable A 1 Require replacement Bleeder screw plugged A 1 Require repair or replacement of bleeder screw Bleeder screw seized A 2 Require replacement Bore corroded pitted B...

Page 351: ...uggest replacement Open A Require repair or replacement Protective shield conduit melted 2 1 Suggest repair or replacement Protective shield conduit missing 2 Suggest repair or replacement Resistance...

Page 352: ...ck Brake Systems ABS see appropriate ANTI LOCK article BLEEDING BRAKE SYSTEM BLEEDING PROCEDURES Complete Brake System Before bleeding system exhaust all vacuum from power unit by depressing brake ped...

Page 353: ...o master cylinder using appropriate adapters Attach bleeder hose to first bleeder valve to be serviced See BLEEDING SEQUENCE table 2 Submerge other end of hose in clean glass jar partially filled with...

Page 354: ...off adjusting nut an additional 2 turns Apply and release parking brake several times checking for free rotation at rear wheels REAR BRAKE SHOES 1 Raise and support vehicle Ensure parking brake lever...

Page 355: ...e in Hg within 15 seconds booster diaphragm or check valve is faulty POWER BRAKE BOOSTER CHECK VALVE TEST Disconnect vacuum hose from check valve Remove check valve and valve seal from booster Use a h...

Page 356: ...cal Courtesy of Chrysler Corp Installation 1 Clean caliper and adapter slide surfaces using wire brush Lubricate with multipurpose grease Remove protective paper from noise suppression gasket on inner...

Page 357: ...om edge of rotor If thickness varies more than parallelism specification resurface or replace rotor See DISC BRAKE SPECIFICATIONS Removal Dakota 2WD Ram Pickup 2WD 5 Studs Ram Van Raise and support ve...

Page 358: ...knuckle so they extend through back of knuckle Install hub spacer ensuring flat on space is positioned to rear Use chassis grease to hold spacer in position if necessary NOTE If equipped with wheel sp...

Page 359: ...imary shoe Install secondary shoe on support plate with shoe pin spring and retainer Insert strut into slot in parking brake lever 3 Install anchor plate and eye of adjusting cable over anchor Install...

Page 360: ...am Pickup 1 Remove drum See AXLE BEARING SEAL FULL FLOATING AXLE Disconnect adjusting lever from cable Disconnect adjusting lever return spring from lever Remove lever and return spring from pivot pin...

Page 361: ...moval Installation 1 Remove wheel drum and brake shoes Inspect boots for damage and signs of leakage Disconnect and plug hydraulic brakeline from wheel cylinder Remove attaching bolts and remove cylin...

Page 362: ...by hand 4 To complete installation position master cylinder over studs of power brake booster Align power cylinder brake push rod with cylinder piston Install master cylinder nuts and tighten to spec...

Page 363: ...e BLEEDING PROCEDURES under BLEEDING BRAKE SYSTEM AXLE BEARING SEAL FULL FLOATING AXLE Removal Installation Ram Pickup With 12 13 Drums 1 Raise and support vehicle Remove wheel Remove axle shaft nuts...

Page 364: ...9 Drum Drum Width 2 50 63 5 Maximum Allowable Diameter 9 060 230 12 Wheel Cylinder Diameter 750 19 05 10 Drum Drum Width 2 50 63 5 Maximum Allowable Diameter 10 060 255 52 Wheel Cylinder Diameter 810...

Page 365: ...s Ram Van 1 2 Ton 130 176 3 4 1 Ton 210 285 Caliper Mounting Bolts Dakota Guide Pins 22 30 Ram Pickup 38 52 Ram Van 24 33 Combination Valve Mounting Bolt Ram Pickup 17 23 Diesel Hydraulic Booster Hose...

Page 366: ...85 115 115 156 Ram Pickup 5 Stud Wheel 95 129 8 Stud Wheel Single Wheel 135 183 Dual Wheel 145 197 Ram Van 15 Wheel 5 Stud 80 110 109 149 16 Wheel 8 Stud 120 150 163 203 INCH Lbs N m Locking Hub Allen...

Page 367: ...wear is not possible Clutch is actuated through hydraulic master cylinder and slave cylinder and is self adjusting SHIFT LINKAGE ADJUSTMENT NV231 Dakota 1 Shift transfer case into 4H position and sec...

Page 368: ...ift rod slides freely in adjusting swivel 2 Ensure transfer case shift lever is in 4FT position Slide adjusting swivel forward until shift lever contacts shifter gate crossover then slide adjusting sw...

Page 369: ...ing or removing fluid from reservoir This will cause clutch release problems TESTING CLUTCH PEDAL POSITION SWITCH NOTE The position switch is an integral part of clutch master cylinder push rod and ca...

Page 370: ...or reading This means housing bore is offset from crankshaft centerline by 0 006 1 2 of 0 012 4 On gas engines acceptable total indicator reading is 0 010 If measured total indicator reading is more t...

Page 371: ...ing Clutch Housing Bore Courtesy of Chrysler Corp Fig 5 Measurement Of Clutch Housing Bore Example Courtesy of Chrysler Corp Clutch Housing Face Runout NV4500 1 After performing a clutch housing bore...

Page 372: ...hest For example 0 009 minus 0 004 0 013 Total allowable face runout is 0 010 3 Correct housing face runout by installing shims between clutch housing and transmission Shims have to be made using shim...

Page 373: ...transfer case rearward until free of transmission Remove transfer case from under vehicle Removal NV231 NV242 Dakota 1 Shift transfer case into neutral Raise vehicle If transfer case will be repaired...

Page 374: ...table Removal NV 3500 1 Disconnect negative battery cable Shift transmission to Neutral Open console lid and remove bolts attaching console to floor pan Lift cup holder bin and remove bolt attaching c...

Page 375: ...t linkage at transfer case range lever and remove shift lever from transmission Remove bolts nuts attaching transmission to rear mount 4 Support transmission with a transmission jack Secure transmissi...

Page 376: ...der and move aside Remove starter Remove transmission splash shield Remove transmission harness wires from clips on transmission shift cover On some models it may be necessary to remove front axle str...

Page 377: ...rfaces for grease or oil contamination Check clutch disc for wear Clutch disc face to rivet head distance should be at least 008 20 mm Check splines of disc hub and transaxle input shaft 3 Using strai...

Page 378: ...nd bearing are properly secured Install transmission and clutch housing Fig 11 Exploded View Of RWD Clutch Release Bearing Assembly Courtesy of Chrysler Corp CLUTCH MASTER CYLINDER Removal 1 Disconnec...

Page 379: ...Ram Pickup 50 68 4WD NV3500 Ram Pickup 40 45 54 61 Flywheel Bolts Dakota 2 5L 70 95 Dakota V6 V8 55 75 Pressure Plate Bolts 5 16 17 23 3 8 30 41 Transfer Case To Transmission Nuts AX15 26 35 N m NV35...

Page 380: ...e why each procedure is to be performed before proceeding Vehicle Driveability Computer Relearn Procedure Manufacturer does not provide a specified computer relearn procedure for obtaining proper driv...

Page 381: ...aced Solenoid assembly was replaced Valve body was reconditioned or replaced 2 Transaxle shift quality quick learn procedure must be performed using Chrysler s Diagnostic Readout Box III DRB III scan...

Page 382: ...ng Chrysler s Diagnostic Readout Box DRB III scan tool 2 Connect scan tool to Data Link Connector DLC below driver s side of instrument panel For DLC location see appropriate SELF DIAGNOSTICS article...

Page 383: ...Press ON OFF button to turn speed control system on Accelerate to desired speed minimum of 35 MPH and press SET COAST button Vehicle speed will be maintained NOTE Speed control system will automatical...

Page 384: ...road test verifies an inoperative system and speedometer operates smoothly check for Diagnostic Trouble Codes DTCs See SELF DIAGNOSTIC SYSTEM Misadjusted brake switch See BRAKE SWITCH under REMOVAL IN...

Page 385: ...k brake switch adjustment See BRAKE SWITCH under REMOVAL INSTALLATION If brake switch adjustment is okay replace defective brake switch BRAKE SWITCH CONTINUITY Switch Plunger Check Between Continuity...

Page 386: ...of 25 in Hg A vacuum reservoir is not used on diesel vehicles 2 If vacuum is not as specified disconnect vacuum supply hose from vacuum pump Install vacuum gauge to vacuum pump Start engine and obser...

Page 387: ...Fig 2 Identifying Brake Switch Harness Connector Terminals Courtesy of Chrysler Corp Fig 3 Identifying Powertrain Control Module PCM Connector Terminals Courtesy of Chrysler Corp...

Page 388: ...e servicing speed control components on or around steering column See AIR BAG RESTRAINT SYSTEMS TRUCKS article SERVICE PRECAUTIONS Before proceeding with diagnosis the following precautions must be fo...

Page 389: ...AGNOSTIC TESTS Once all repairs are made clear DTCs See CLEARING DIAGNOSTIC TROUBLE CODES If no DTCs are retrieved and fault still exists go to CHECKING SPEED CONTROL OPERATION under SYSTEM TESTS CLEA...

Page 390: ...stance is 300 1200 ohms go to next step 10 Using an ohmmeter measure resistance of OSS signal circuit between PCM connector C2 terminal No 28 and OSS connector Light Green Black wire on Ram Pickup Lig...

Page 391: ...C vent solenoid Wiggle wiring harness between S C servo and brake switch to PCM while scan tool is still actuating speed control vacuum solenoid If wiggling did not cause interruption of S C servo act...

Page 392: ...tor Turn ignition on Turn S C on Using a 12 volt test light probe S C power supply circuit at brake switch connector terminal No 3 Yellow Red wire If test light is illuminated and bright go to next st...

Page 393: ...ight Green wire on all other models If resistance is less than 5 ohms go to next step If resistance is 5 ohms or more go to step 7 6 Using an ohmmeter measure resistance across ON OFF switch Resistanc...

Page 394: ...ms repair short to ground Perform TEST VER 4A under VERIFICATION TESTS If resistance is 5 ohms or more go to next step 6 Disconnect PCM Inspect connectors Clean or repair as necessary Using an ohmmete...

Page 395: ...C servo Perform TEST VER 4A under VERIFICATION TESTS 7 Turn ignition off Disconnect brake switch connector Inspect connectors Clean or repair as necessary Turn ignition on Using scan tool actuate S C...

Page 396: ...ct connectors Clean or repair as necessary Using an ohmmeter check resistance between ground and PNP switch sense circuit If resistance is less than 5 ohms repair short to ground Perform TEST VER 5A u...

Page 397: ...under VERIFICATION TESTS If resistance is less than 5 ohms go to next step 9 Reconnect S C servo connector Turn ignition and S C on While observing scan tool press SET switch several times If scan too...

Page 398: ...4 and brake switch White Pink wire If resistance is 5 ohms or more repair open brake switch sense circuit Perform TEST VER 4A under VERIFICATION TESTS If resistance is less than 5 ohms replace PCM Per...

Page 399: ...am Van Ram Wagon Red Light Green wire on all other models If resistance is less than 5 ohms repair short to ground Perform TEST VER 4A under VERIFICATION TESTS If resistance is 5 ohms or more go to ne...

Page 400: ...ary Using scan tool erase DTCs from PCM 3 Road test vehicle at a speed greater than 35 MPH Turn S C switch on Press and release SET button If S C does not engage repair is not complete Check for relat...

Page 401: ...e is equipped with ABS or air bag enter correct VIN and mileage in PCM Erase DTCs in ABS and air bag modules Inspect vehicle to ensure all engine and speed control system components are connected 3 If...

Page 402: ...clip Remove retaining clip Remove servo Removal Ram Van Ram Wagon 1 Disconnect negative battery cable Remove engine cover Remove air cleaner assembly Using finger pressure only push servo cable connec...

Page 403: ...Fig 5 Cruise Control System Wiring Diagram Dakota...

Page 404: ...Fig 6 Cruise Control System Wiring Diagram Durango...

Page 405: ...Fig 7 Cruise Control System Wiring Diagram Ram Pickup...

Page 406: ...Fig 8 Cruise Control System Wiring Diagram Ram Van Ram Wagon...

Page 407: ...of axle tube yoke Hub bearings are serviced as an assembly On vehicles equipped with Anti Lock ABS brakes a brake sensor is mounted on knuckle assemblies and tone rings are pressed onto axle shaft Dif...

Page 408: ...om axle housing and collar on intermediate axle shaft Installation 1 Install NEW oil seal on axle shaft with seal lip facing toward splines on differential end of axle shaft Coat seal lip with wheel b...

Page 409: ...m torque specification See TORQUE SPECIFICATIONS table 3 To install remaining components reverse removal procedure using NEW U joint straps and bolts Ensure all reference marks are aligned Tighten bol...

Page 410: ...11 N m Add 5 ounces 148 ml of GL 5 gear lubricant to shift motor housing through indicator switch mounting hole DIFFERENTIAL ASSEMBLY NOTE Differential assembly consists of differential case and comp...

Page 411: ...Remove oil seal from axle housing 10 Remove slinger if equipped pinion bearing and preload shim s Note thickness of preload shims for reassembly reference in case shims become misplaced 11 Remove pin...

Page 412: ...f preload shims in order to obtain zero end play of differential case Procedure must be performed before installing pinion in axle housing 3 Install ring gear on differential case Use NEW ring gear bo...

Page 413: ...h variance marking is etched on pinion face See Fig 3 2 Etched marking in thousandths of an inch indicates deviation from standard pinion depth setting Standard pinion depth setting is distance from c...

Page 414: ...00 Fig 3 Identifying Pinion Markings Pinion Depth Measurement Courtesy of Chrysler Corp 3 If original pinion ring gear and axle housing are being used and pinion depth shims are being replaced determ...

Page 415: ...ll be nominal standard pinion depth setting and no shims are required When using pinion depth shim adjustment chart thickness of original pinion depth shim pack must be accurately determined If origin...

Page 416: ...h shim pack to obtain correct shim thickness If etched marking is zero no change is required in pinion depth shim pack thickness 6 Measure pinion depth shims separately using micrometer If slinger is...

Page 417: ...Bearing D 345 for 216 FBI axle or D 343 for 248 FBI axle 2 Install differential case in axle housing Install bearing caps on axle housing Ensure bearing caps are installed in original location Install...

Page 418: ...eat differential bearings 18 Using dial indicator check ring gear backlash See Fig 6 Ensure ring gear backlash is as specified See AXLE ASSEMBLY SPECIFICATIONS 19 If ring gear backlash exceeds specifi...

Page 419: ...at minimum point ring gear backlash should not exceed 007 18 mm anywhere on ring gear TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Applications Ft Lbs N m ABS Sensor Bolt 1 Axle Nut 175 237 Ball Joint...

Page 420: ...al assembly is a limited slip type differential It is similar in operation to a conventional type differential except for 2 clutch packs located at the side gears in the differential case See Fig 1 Cl...

Page 421: ...riction Modifier Fill axle with gear lube Install oil filler plug Lower vehicle TROUBLE SHOOTING DIFFERENTIAL NOISE 1 Ensure differential lubricant is at normal operating temperature Road test vehicle...

Page 422: ...ar wheel drive axle is functioning properly REMOVAL INSTALLATION Servicing procedure is same as that used for a standard differential See appropriate RBI FULL FLOATING AXLES article for servicing proc...

Page 423: ...ned 5 Install remaining clutch components and side gear on differential case lower half Install differential case upper half on differential case lower half with reference marks aligned 6 Install diff...

Page 424: ...may be serviced without disturbing wheel bearings On vehicles equipped with Rear Wheel Anti Lock RWAL brakes a brake sensor is mounted on top of axle housing and an exciter ring is mounted on ring gea...

Page 425: ...heel bearing grease Install inner wheel bearing and oil seal in rear hub if removed Install rear hub and brake drum Install outer wheel bearing and adjusting nut Tighten adjusting nut to specification...

Page 426: ...of force required to rotate pinion This is pinion bearing preload Record pinion bearing preload for reassembly reference 3 Remove pinion nut and washer from pinion Scribe reference mark on pinion flan...

Page 427: ...g 4 On all axles support axle housing assembly with floor jack Remove rear spring U bolts Lower axle housing assembly and remove from vehicle Installation 1 To install reverse removal procedure Ensure...

Page 428: ...le housing If reusing bearing races for differential bearings mark bearing race location for reassembly reference Bearing races must be installed with same differential bearing 7 If removing ring gear...

Page 429: ...axle shaft splines Examine shaft of pinion shaft for scoring or excessive wear 3 On axles with Rear Wheel Anti Lock RWAL brakes if exciter ring is not removed from differential case ensure exciter rin...

Page 430: ...sible Zero dial indicator 4 Pry differential case to left as far as possible Note dial indicator reading This reading is referred to as differential case zero end play Record differential case zero en...

Page 431: ...Fig 4 Identifying Pinion Markings Pinion Depth Measurement Courtesy of Chrysler Corp Pinion Depth 1 Ring gear and pinion are a matched set A gear matching...

Page 432: ...of pinion depth shim pack to obtain thickness of correct shim If result is positive add this amount to thickness of pinion depth shim pack to obtain thickness of correct shim If result is zero this w...

Page 433: ...Pinion Bearing Preload 1 Install slinger on pinion if equipped Press rear inner pinion bearing onto pinion until bearing is fully seated Install preload shims on pinion Install pinion in axle housing...

Page 434: ...Fig 6 Checking Pinion Depth Courtesy of Chrysler Corp 6 Coat lip of oil seal with gear lube Using appropriate oil seal installer and handle install oil seal...

Page 435: ...lled on ring gear side of differential case These preload shims will be referred to as ring gear backlash preload shims 8 Remaining preload shims required to equal differential case zero end play will...

Page 436: ...very 90 degrees to check for variation Ring gear backlash variation should not exceed 002 05 mm For example if ring gear backlash is 005 15 mm at the minimum point ring gear backlash should not exceed...

Page 437: ...cklash is 005 15 mm at minimum point ring gear backlash should not exceed 007 18 mm anywhere on ring gear TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Applications Ft Lbs N m ABS Sensor Bolt 248 267 RB...

Page 438: ...e shaft splined into the side gear On semi floating axle shafts vehicle weight is supported on axle shaft and bearing Drive shaft rotates the pinion which drives the ring gear Power is transferred fro...

Page 439: ...able in TROUBLE SHOOTING article in GENERAL INFORMATION REMOVAL INSTALLATION AXLE SHAFT BEARING CAUTION When servicing differential DO NOT rotate one axle shaft unless both axles are installed into di...

Page 440: ...tighten lock bolt to specification See TORQUE SPECIFICATIONS Ensure axle housing and axle housing cover sealing surfaces are clean 5 Apply a 1 4 thick bead of silicone sealant on inside of bolt holes...

Page 441: ...t be installed on pinion with convex side of washer facing outward away from pinion 3 Install washer on pinion with convex side of washer facing outward away from pinion Install NEW pinion nut Tighten...

Page 442: ...sing INCH lb torque wrench measure amount of force required to rotate pinion This is pinion bearing preload Record pinion bearing preload for reassembly reference if front pinion bearing will be repla...

Page 443: ...ar bolts Using soft face hammer drive ring gear from differential carrier Tap exciter ring from differential carrier if equipped 10 If disassembling differential carrier rotate side gears and align pi...

Page 444: ...reassembly Reassembly Adjustments 1 Install side gear thrust washers on side gears Install side gears in differential carrier Install pinion gear thrust washers on pinion gears Install pinion gears in...

Page 445: ...85 SP 526 Sleeve A SP 5382 SP 1730 Sleeve B SP 3194 B SP 535 A Spacer A SP 6030 SP 6017 Spacer B SP 6022 SP 6022 Washer SP 534 SP 534 Pinion Depth 1 Using appropriate driver install bearing races for...

Page 446: ...is amount to feeler gauge thickness to obtain thickness of correct shim When etched marking is positive subtract this amount to obtain thickness of correct shim If etched marking is zero no change is...

Page 447: ...g preload CAUTION If original pinion bearings are installed tighten pinion nut until original pinion bearing preload is obtained DO NOT overtighten or loosen then retighten pinion nut when adjusting p...

Page 448: ...ntinue to tighten left adjuster until torque remains constant at 75 ft lbs 102 N m 11 Check ring gear backlash every 90 degrees to check ring gear backlash variation Ring gear backlash variation shoul...

Page 449: ...differential carrier Install axle shaft in side gear DO NOT install clip Recheck side gear clearance If side gear clearance is now less than 012 30 mm add this measurement to thickness of side gear th...

Page 450: ...8 Bolt Thread 110 149 U Joint Strap Bolt Diesel Models 25 34 Gasoline Models 14 19 Wheel Lug Nut Dakota 85 110 115 149 Ram Pickup 5 Lug 80 110 108 149 8 Lug Single Wheel 120 150 163 203 8 Lug Dual Whe...

Page 451: ...ferential assembly is optional equipment The Trac Lok differential assembly is a limited slip type differential It is similar in operation to a conventional type differential except for 2 clutch packs...

Page 452: ...se is facing downward Wipe out all accessible areas of axle housing Ensure sealing surfaces on axle housing and cover are clean Apply a 1 4 thick bead of silicone sealant on inside of bolt holes and a...

Page 453: ...essary See Fig 1 3 Install appropriate Step Plate on lower side gear Install appropriate threaded forcing screw into upper side gear See Fig 2 4 Thread Forcing Screw into threaded adapter disc until f...

Page 454: ...Fig 1 Exploded View Of Trac Lok Differential Courtesy of Chrysler Corp...

Page 455: ...Fig 2 Removing Differential Case Components Courtesy of Chrysler Corp NOTE If any clutch pack components are defective both clutch packs must be replaced...

Page 456: ...ss clutch packs Install pinion gears on side gears Using turning bar rotate differential case until hole in differential case is aligned with pinion gears Remove turning bar 5 Lubricate pinion gear th...

Page 457: ...steel or aluminum Number of drive shafts used by vehicle depends on vehicle length and 4WD capability Long wheel base vehicles use 2 rear drive shafts with a center bearing support assembly See Fig 1...

Page 458: ...en replace as needed DRIVE SHAFT S Check drive shaft s for missing weights broken welds or for dents affecting balance Check for undercoating mud snow ice on drive shaft s Clean shafts thoroughly and...

Page 459: ...nect center bearing support assembly to crossmember bracket Ensure front face of center bearing support assembly is perpendicular 90 to center line of drive shaft If center bearing support assembly is...

Page 460: ...test 4 Continue procedure until vibration is at lowest level If no difference is noted with clamp head moved to all 4 positions vibrations may not be due to drive shaft imbalance 5 If vibration decre...

Page 461: ...one degree If difference of angles is greater than specified adjustment is necessary See ADJUSTING VERTICAL ANGLE Fig 4 Measuring Drive Shaft Vertical Angle Courtesy of Chrysler Corp Fig 5 Identifyin...

Page 462: ...agnet to bearing cap and note angle Difference between 2 measured angles is drive shaft rear angle See Fig 5 Remove inclinometer 4 Rotate drive shaft until a slip joint yoke bearing cap faces downward...

Page 463: ...of vehicle NOTE If encountering difficulty in making drive shaft vertical adjustments on one piece drive shafts drive shaft may be out of horizontal alignment See CHECKING HORIZONTAL ALIGNMENT NOTE On...

Page 464: ...Misalignment Of Drive Shaft Courtesy of Chrysler Corp Fig 9 Checking Horizontal Alignment Courtesy of Chrysler Corp 3 To make horizontal alignment checks set up straightedges as shown See Fig 9 Set tr...

Page 465: ...than slight horizontal misalignment exists Minor adjustment of drive shaft horizontal alignment may be made by loosening axle housing U bolts and moving either side of axle housing forward or backwar...

Page 466: ...isassembled from yoke ALWAYS replace complete U joint whenever extreme external lubrication leakage or bearing cap damage exists Before disassembly mark flange yoke to drive shaft for reassembly refer...

Page 467: ...e U joint assembly items are not individually serviceable or repairable If needle bearings seals spider or bearing caps are found to be defective damaged or excessively worn complete U joint assembly...

Page 468: ...on 1 Before installing drive shaft clean mating flange and inspect machined surface for scratches nicks and burrs Support drive shaft during installation to prevent bending shaft at sharp angle to CV...

Page 469: ...Fig 12 Double Cardan Constant Velocity CV U Joint Dakota Ram Pickup Courtesy of Chrysler Corp...

Page 470: ...s ACTUATORS ELECTRICAL ACTUATORS VACUUM AXLES BEARINGS AND RACES BELL CRANKS BELL HOUSINGS BUSHINGS EXTERNAL CABLES SPEEDOMETER CABLES TV DETENT AND SHIFT CARRIER BEARINGS CLUTCH CABLES AND CABLE HOUS...

Page 471: ...LATES PRESSURE SWITCHES RACES RUBBER JOINTS METALASTIC SCREENS SEALS SEALS METAL CLAD SELECTOR INTERLOCK SYSTEMS SERVOS SHIFT INTERLOCK SYSTEMS SELECTOR AND KEY INTERLOCK SYSTEMS SENSORS SIDE COVERS S...

Page 472: ...Suspension Engine Maintenance and Performance HVAC and Electrical Systems Further revisions to all of these inspection were recently published Further revisions to all of these inspection communicati...

Page 473: ...decision to repair or replace must be made in the customer s best interest and at his or her choice given the options available This section lists the various parts and conditions that indicate a req...

Page 474: ...present the facts allowing the customer to draw their own conclusions and make an informed decision about how to proceed The following reasons may be used for required and suggested services These co...

Page 475: ...nts not requiring removal of the assembly refer to the component listing in this document DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES NOTE Does not include half shafts DIFFERENTIAL AND FINAL DRIVE ASSEMBL...

Page 476: ...cedure Attaching hardware broken A Require repair or replacement of hardware Attaching hardware missing C Require replacement of hardware Attaching hardware not functioning A Require repair or replace...

Page 477: ...ctor broken A Require repair or replacement Connector Weatherpack type leaking A Require repair or replacement Connector melted affecting performance A 1 Require repair or replacement Connector melted...

Page 478: ...tive includes intermittent operation or out of OEM specification AXLES AXLE INSPECTION Condition Code Procedure Bent A Require replacement Broken A Require replacement End play exceeds specifications...

Page 479: ...S BELL CASE TAIL EXTENSION AND AUXILIARY BUSHINGS EXTERNAL BUSHING EXTERNAL INSPECTION Condition Code Procedure Attaching hardware bent B Require repair or replacement of bent part if available otherw...

Page 480: ...repair or replacement Split A Require replacement Surface cracking weather checked No service suggested or required Worn affecting performance A Require repair or replacement Worn close to the end of...

Page 481: ...ed A 1 Require repair or replacement Missing C Require replacement Noisy 2 Suggest repair or replacement Routed incorrectly 2 Suggest repair Seized A Require repair or replacement 1 Determine cause an...

Page 482: ...f adjuster inoperative A Require repair or replacement of self adjuster Threads damaged A Require repair or replacement Threads stripped threads missing A Require replacement 1 Determine cause and cor...

Page 483: ...el is being resurfaced or replaced In this case replacement of clutch disc is required Ridged B No service suggested or required unless the pressure plate or flywheel is being resurfaced or replaced I...

Page 484: ...adjustment Housing damaged affecting performance A Require repair or replacement Master cylinder has residue in reservoir make parallel w brakes when they are done 2 1 Further inspection required Thr...

Page 485: ...s specifications B Require replacement Worn close to the end of its useful life 1 Suggest replacement Worn affecting performance A Require replacement CLUTCH SLAVE CYLINDERS CONCENTRIC CLUTCH SLAVE CY...

Page 486: ...lic system must be opened 2 Seized is defined as a bleeder screw that cannot be removed after a practical attempt at removing it has been made COMPANION FLANGES See YOKES AND SLIP YOKES CONNECTORS See...

Page 487: ...t Outer covering damaged to the extent that the inner fabric is visible A Require replacement Protective sleeves damaged 2 Suggest replacement of sleeves Protective sleeves missing C Require replaceme...

Page 488: ...l manufacturing process of heat treating the housing DIP STICK TUBES DIP STICK TUBE INSPECTION Condition Code Procedure Broken A Require repair or replacement Checkball missing C Suggest repair or rep...

Page 489: ...r or replacement Bushing or seal surface worn affecting performance A Require repair or replacement Leaking through soft yoke plug A Require repair or replacement of soft yoke plug Out of balance A Re...

Page 490: ...repair or replacement Torn A Require replacement Worn affecting performance metal or nylon screen type A Require repair or replacement 1 Further inspection may be required to determine the source of...

Page 491: ...Fluid that is burned indicates a serious problem Determine and correct the cause 3 If a fluid other than hydraulic fluid is present in the hydraulic system which DOES affect the rubber parts the requi...

Page 492: ...out exceeds specifications B Require repair or replacement Scored B Require repair or replacement Surface cracks after resurfacing to manufacturer s minimum specifications B Require replacement Wear e...

Page 493: ...tricted not affecting performance 2 Suggest repair or replacement Routed incorrectly 2 Suggest replacement Safety clip missing C Require replacement Spongy 1 Suggest repair or replacement Stripped A R...

Page 494: ...d or required Bracket corroded affecting performance A Require repair or replacement Bracket corroded not affecting performance 2 Suggest repair or replacement Bracket cracked affecting performance A...

Page 495: ...replacement of linkage Linkage loose affecting performance A Require repair or replacement of linkage Linkage loose not affecting performance 1 Suggest repair or replacement of linkage Linkage missing...

Page 496: ...equire replacement Contaminated water fuel etc A 1 Require replacement Housing cracked A Require replacement Inoperative A 2 Require replacement Leaking fluid externally A Require repair or replacemen...

Page 497: ...Rubber deteriorated not affecting performance No service suggested or required Threads damaged A Require repair or replacement Threads stripped threads missing A Require replacement ODOMETER DRIVES M...

Page 498: ...ER JOINT METALASTIC INSPECTION Condition Code Procedure Drive flange bent A Require repair or replacement Drive flange damaged affecting performance A Require replacement Rubber drive joint cracked 2...

Page 499: ...lacement of hardware Connector broken A Require repair or replacement Connector Weatherpack type leaking A Require repair or replacement Connector melted A 1 Require repair or replacement Connector mi...

Page 500: ...SENSOR ELECTRONIC WHEEL AND VEHICLE INSPECTION Condition Code Procedure Air gap incorrect B 1 Require adjustment or replacement Attaching hardware missing C Require replacement of hardware Attaching...

Page 501: ...d open A Require repair or replacement Wire lead shorted A Require repair or replacement 1 If a sensor is not adjustable further inspection is required to identify and correct cause 2 Determine cause...

Page 502: ...est repair or replacement Lens missing C 1 Require repair or replacement Malfunctioning A 2 Require repair or replacement Noisy 2 Suggest repair or replacement Threads damaged A Require repair or repl...

Page 503: ...erminal loose affecting performance B Require repair or replacement Terminal loose not affecting performance 1 Suggest repair or replacement 1 Determine cause and correct prior to repair or replacemen...

Page 504: ...mance 2 Suggest repair or replacement Terminal loose affecting performance B Require repair or replacement Terminal loose not affecting performance 1 Suggest repair or replacement Won t return A Requi...

Page 505: ...oken A Require replacement Pilot worn affecting performance A Require replacement Threads damaged A Require repair or replacement Threads stripped threads missing A Require replacement Weights missing...

Page 506: ...N Condition Code Procedure Bent interfering with filter or other internal components A Require repair or replacement Leaking A Require repair or replacement TRANSMISSION RANGE INDICATORS PRNDL TRANSMI...

Page 507: ...ap seal cracked 2 Suggest replacement End cap seal missing C Require replacement of seal Grease fitting broken A 1 Require replacement of grease fitting Grease fitting missing C 2 Require replacement...

Page 508: ...tightening sequence DO NOT lubricate threads unless specified by the vehicle manufacturer WHEEL ATTACHMENT HARDWARE INSPECTION Condition Code Procedure Bent A Require replacement Broken A 1 Require re...

Page 509: ...ent Protective shield conduit melted 2 1 Suggest repair or replacement Protective shield conduit missing 2 Suggest repair or replacement Resistance voltage drop out of specification A Require repair o...

Page 510: ...plug A Require repair or replacement of soft yoke plug Retainer strap bent A Require replacement of retainer strap Slip yoke broken A Require replacement Splines worn affecting performance A Require...

Page 511: ...of dash inboard of steering column opening Combination Flasher Left side of dash on junction block Engine Starter Motor Relay On power distribution center Fog Lamp Relay On power distribution center F...

Page 512: ...front inner fender Daytime Running Lamp DRL Module In engine compartment on left inner fender panel Engine Control Module Diesel On left side of engine behind fuel filter Fuel Pump Module Top of fuel...

Page 513: ...Idle Air Control Motor 3 9L On throttle body...

Page 514: ...Idle Air Control Motor 5 2L On throttle body...

Page 515: ...Idle Air Control Motor 5 9L On throttle body Idle Air Control Motor 8 0L On throttle body...

Page 516: ...or Pedal Position Sensor Diesel At left front of engine below cable lever linkage cover Ambient Temperature Sensor Underside of hood panel near latch striker Battery Temperature Sensor Below battery t...

Page 517: ...Crankshaft Position Sensor 3 9L Right rear of engine block...

Page 518: ...Crankshaft Position Sensor 5 2L Right rear of engine block...

Page 519: ...Crankshaft Position Sensor 5 9L Right rear of engine block Crankshaft Position Sensor 8 0L On right lower side of...

Page 520: ...nder block above oil pan rail Engine Coolant Temperature Sensor Diesel On front of cylinder head near thermostat housing Engine Coolant Temperature Sensor 3 9L In water jacket at front of intake manif...

Page 521: ...Engine Coolant Temperature Sensor 5 2L In water jacket at front of intake manifold Engine Coolant Temperature Sensor 5 9L In water jacket at front of intake manifold Engine Coolant Temperature...

Page 522: ...at housing Engine Oil Pressure Sensor Diesel On left side of engine near ECM Engine Oil Pressure Sensor 3 9L Near distributor Engine Oil Pressure Sensor 5 2L Near distributor Engine Oil Pressure Senso...

Page 523: ...2S Post Catalyst 5 9L Medium Duty Near outlet end of catalytic converter Heated Oxygen Sensor HO2S Post Catalyst 8 0L California In exhaust pipe rear of catalytic converter Heated Oxygen Sensor HO2S P...

Page 524: ...Intake Air Temperature Sensor Diesel In left rear side of intake manifold...

Page 525: ...Intake Air Temperature Sensor 3 9L In right front side of intake manifold...

Page 526: ...Intake Air Temperature Sensor 5 2L In right front side of intake manifold...

Page 527: ...Intake Air Temperature Sensor 5 9L In right front side of intake manifold...

Page 528: ...Intake Air Temperature Sensor 8 0L In left front side of intake manifold Manifold Absolute Pressure MAP Sensor 3 9L On throttle body...

Page 529: ...Manifold Absolute Pressure MAP Sensor 5 2L On throttle body...

Page 530: ...Manifold Absolute Pressure MAP Sensor 5 9L On throttle body...

Page 531: ...Manifold Absolute Pressure MAP Sensor 8 0L On right upper side of intake manifold...

Page 532: ...Manifold Air Pressure MAP Sensor Diesel In left rear side of intake manifold Rear Wheel Speed Sensor In differential housing...

Page 533: ...Throttle Position TP Sensor 3 9L On throttle body...

Page 534: ...Throttle Position TP Sensor 5 2L On throttle body...

Page 535: ...Throttle Position TP Sensor 5 9L On throttle body...

Page 536: ...Throttle Position TP Sensor 8 0L On throttle body Transmission Output Shaft Speed Sensor A T On left side of transmission...

Page 537: ...Water In Fuel Sensor Diesel At bottom of fuel filter water separator canister...

Page 538: ...d on right inner fender Transmission Solenoid Assembly A T On left side of transmission Vehicle Speed Control Servo In engine compartment below battery SWITCHES Component Component Location A C High P...

Page 539: ...ion valve Clutch Pedal Position Switch On clutch master cylinder pushrod Low Washer Fluid Level Switch On side of washer fluid reservoir Park Brake Switch On park brake mechanism Park Neutral Position...

Page 540: ...OUS Component Component Location Blower Motor Resistor Block Behind right side of dash on A C heater housing Data Link Connector DLC Left bottom of dash Fuel Heater Diesel In top of fuel filter housin...

Page 541: ...Intake Air Heater Diesel Attached to metal block on top of intake manifold...

Page 542: ...WIRES BELTS BULB SOCKETS BULBS SEALED BEAMS AND LEDS CD PLAYERS CIGARETTE LIGHTER ASSEMBLIES CIRCUIT BREAKERS CLUTCH SWITCHES CONNECTORS CONTROL MODULES CRUISE CONTROL BRAKE SWITCHES CRUISE CONTROL CA...

Page 543: ...CERS VACUUM ACCUMULATORS RESERVOIRS VACUUM RESERVOIRS VOLTAGE REGULATORS WASHER FLUID LEVEL SENDERS WASHER PUMPS WIPER ARMS AND BLADES WIPER BLADES WIPER HOSES AND NOZZLES WIPER LINKAGES WIPER NOZZLES...

Page 544: ...ver how we conduct our business and we must be viewed as part of the solution and not part of the problem Meetings with state and other government officials and their representatives concerned with au...

Page 545: ...failure Example A brake rotor has been worn to the point where it measures less than the vehicle manufacturer s discard specifications Replacement of the rotor is required because it does not meet de...

Page 546: ...rformance eliminate noise etc 3 To comply with maintenance recommended by the vehicle s Original Equipment Manufacturer OEM 4 Technician s recommendation based on substantial and informed experience N...

Page 547: ...equire replacement Terminal broken A Require repair or replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 1 1 Suggest repair...

Page 548: ...ing performance A Require repair or replacement of linkage Linkage loose not affecting performance 1 Suggest repair or replacement of linkage Linkage missing C Require replacement Linkage noisy 2 Sugg...

Page 549: ...t affecting performance 1 Suggest repair or replacement Inoperative A 2 Require repair or replacement Noisy 2 Suggest repair or replacement Pulley incorrect B Require replacement Terminal broken A Req...

Page 550: ...replacement Missing C Require replacement Motor runs continuously A Require or replacement Power antenna noisy 2 Suggest repair or replacement Sticking 2 Suggest repair or replacement Terminal broken...

Page 551: ...al vehicle manufacturer for a specific vehicle BATTERY INSPECTION Condition Code Procedure Battery frozen 1 Further inspection required Case leaking A Require replacement Casing swollen A 2 Further in...

Page 552: ...harging Guide of the BCI Service Manual battery charger operating manual or battery manufacturer s specifications 4 Determine cause of low fluid level Refill to proper level s with water distilled wat...

Page 553: ...ir or replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performa...

Page 554: ...e repair BATTERY WIRES See BATTERY CABLES WIRES AND CONNECTORS BELTS BELT INSPECTION Condition Code Procedure Alignment incorrect B 1 Further inspection required Cracked 1 Suggest replacement Frayed 1...

Page 555: ...repair or replacement Terminal burned affecting performance A 2 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting perf...

Page 556: ...t affecting performance 2 Suggest repair or replacement Bracket cracked affecting performance A Require repair or replacement Bracket cracked not affecting performance 1 Suggest repair or replacement...

Page 557: ...air or replacement of hardware Attaching hardware missing C Require replacement of hardware Attaching hardware not functioning A Require repair or replacement of hardware Inoperative A 1 Require repai...

Page 558: ...r replacement Connector missing A Require repair Contaminated A 3 Require repair or replacement Inoperative B 4 Require repair or replacement Further inspection required Leaking A Require repair or re...

Page 559: ...SE CONTROL CABLES See CRUISE CONTROL LINKAGES AND CABLES CRUISE CONTROL CLUTCH SWITCHES See SWITCHES CRUISE CONTROL LINKAGES AND CABLES CRUISE CONTROL LINKAGE AND CABLE INSPECTION Condition Code Proce...

Page 560: ...to repair or replacement of part 2 Follow OEM recommended adjustment procedures Require repair or replacement if out of specification CRUISE CONTROL RESERVOIRS See CRUISE CONTROL VACUUM HOSES TUBES A...

Page 561: ...en A Require replacement Housing cracked A Require replacement Internal resistance does not meet specifications B 2 Require replacement Lead routing incorrect B Require rerouting according to vehicle...

Page 562: ...2 Suggest repair or replacement Broken A Require repair or replacement Burned affecting performance A 1 Require repair or replacement Burned not affecting performance 2 1 Suggest repair or replacement...

Page 563: ...cement Broken A Require repair or replacement Burned affecting performance A 1 Require repair or replacement Burned not affecting performance 2 1 Suggest repair or replacement Cracked affecting perfor...

Page 564: ...C Require replacement of hardware Attaching hardware not functioning A Require repair or replacement of hardware Broken affecting performance A Require replacement Broken not affecting performance No...

Page 565: ...rroded not affecting performance 2 Suggest repair or replacement Cracked affecting performance A Require repair or replacement Cracked not affecting performance 1 Suggest repair or replacement Inopera...

Page 566: ...replacement Lens missing C 2 Require repair or replacement Malfunctioning A 3 Require repair or replacement Mechanical head noisy 2 Suggest repair or replacement Terminal broken A Require repair or re...

Page 567: ...Open A Require repair or replacement Resistance high A Require repair or replacement Terminal resistance voltage drop is out of specification B Require repair or replacement Voltage drop out of speci...

Page 568: ...ve A 2 Require repair or replacement Terminal broken A Require repair or replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2...

Page 569: ...repair or replacement Terminal corroded affecting performance A Require repair or replacement Terminal corroded not affecting performance 2 Suggest repair or replacement Terminal loose affecting perfo...

Page 570: ...t Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require re...

Page 571: ...elted not affecting performance 2 Suggest replacement Missing C Require replacement MICROPHONES See SPEAKERS AND MICROPHONES MIRRORS ELECTROCHROMATIC AND HEATED MIRROR ELECTROCHROMATIC AND HEATED INSP...

Page 572: ...repair or replacement Attaching hardware broken A Require repair or replacement of hardware Attaching hardware missing C Require replacement of hardware Attaching hardware not functioning A Require re...

Page 573: ...replacement Linkage noisy 2 Suggest repair or replacement Missing C Require replacement Noisy 2 Suggest repair or replacement Out of adjustment B 4 Further inspection required Resistance out of specif...

Page 574: ...Require replacement Drive cable noisy 2 Suggest repair or replacement Inoperative A 2 Further inspection required Leaking A Require replacement Lens broken A 3 Require repair or replacement Lens cloud...

Page 575: ...fe A Require replacement RECEIVERS AMPLIFIERS EQUALIZERS AND SUB WOOFER VOLUME CONTROLS RECEIVER AMPLIFIER EQUALIZER AND SUB WOOFER VOLUME CONTROL INSPECTION Condition Code Procedure Attaching hardwar...

Page 576: ...ence RELAY BOXES RELAY BOX INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or replacement of hardware Attaching hardware missing C Require replacement of hardware Attach...

Page 577: ...sing C Require replacement of hardware Attaching hardware not functioning A Require repair or replacement of hardware Housing broken A Require replacement Housing cracked 2 Suggest replacement Inopera...

Page 578: ...equire repair or replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecti...

Page 579: ...pair or replacement Further inspection required Membrane torn A Require replacement Missing C Require replacement Polarity reversed A Require repair Sound quality poor A 3 Require repair or replacemen...

Page 580: ...erformance A Require repair or replacement Bracket corroded not affecting performance 2 Suggest repair or replacement Bracket cracked affecting performance A Require repair or replacement Bracket crac...

Page 581: ...service suggested or required Bracket corroded affecting performance A Require repair or replacement Bracket corroded not affecting performance 2 Suggest repair or replacement Bracket cracked affectin...

Page 582: ...ded affecting performance A Require repair or replacement Terminal corroded not affecting performance 2 Suggest repair or replacement Terminal loose affecting performance B Require repair or replaceme...

Page 583: ...erminal broken A Require repair or replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Termina...

Page 584: ...Terminal corroded not affecting performance 2 Suggest repair or replacement Terminal loose affecting performance B Require repair or replacement Terminal loose not affecting performance 1 Suggest rep...

Page 585: ...r replacement Cracked affecting performance A Require repair or replacement Cracked not affecting performance 1 Suggest repair or replacement Inoperative A 2 Require repair or replacement Melted affec...

Page 586: ...broken A Require repair or replacement of hardware Attaching hardware missing C Require replacement of hardware Attaching hardware not functioning A Require repair or replacement of hardware Connecto...

Page 587: ...re missing C Require replacement of hardware Attaching hardware not functioning A Require repair or replacement of hardware Connector broken A Require repair or replacement Connector Weatherpack type...

Page 588: ...ing performance B Require repair or replacement Terminal loose not affecting performance 1 Suggest repair or replacement 1 Determine cause and correct prior to repair or replacement of part 2 Further...

Page 589: ...gest repair or replacement Terminal loose affecting performance B Require repair or replacement Terminal loose not affecting performance 1 Suggest repair or replacement 1 Determine cause and correct p...

Page 590: ...e Connector broken A Require repair or replacement Connector melted A 1 Require repair or replacement Connector missing C Require replacement Inoperative A 2 Require repair or replacement Leaking exte...

Page 591: ...t functioning A Require repair or replacement of hardware Attaching socket stripped A Require replacement Bent A Require repair or replacement Loose 2 Suggest repair or replacement Missing C Require r...

Page 592: ...perative A 1 Require replacement Loose 2 Suggest repair or replacement Missing C Require replacement Noisy 2 Suggest repair or replacement Tension insufficient B Require repair or replacement Worn aff...

Page 593: ...rotective shield conduit melted 2 1 Suggest repair or replacement Protective shield conduit missing 2 Suggest repair or replacement Resistance voltage drop out of specification A Require repair or rep...

Page 594: ...in solid state circuits transistors diodes semiconductors that may become damaged when contacted with an electrostatic charge The following information applies to all ESD sensitive devices The ESD sym...

Page 595: ...package of a new part until it is time to install the part 4 Before removing the part from its package ground the package to a known good ground source CHECKING STATIC SENSITIVE CIRCUITS DEVICES 1 Sol...

Page 596: ...3L V6 SFI PCV EVAP TWC FR 2 EVAP PSOL EVAP PRRV Caravan BP EGR SPK 2 3 EVAP LDP Town Country 1 HO2S CEC MIL 3 EVAP LDPF EVAP VC Voyager 2 BP EGR BPT SPK CC 3 8L V6 SFI PCV EVAP TWC FR 2 EVAP PSOL EVAP...

Page 597: ...DP 1 HO2S CEC 6 EVAP LDPF 9 SRI MIL 6 EVAP VV EVAP VC SPK CC 9 AP RV 1 9 AP CKV 5 9L V8 SFI PCV EVAP TWC FR 2 EVAP PSOL EVAP PRRV Ram Van SPK 1 HO2S CEC 2 3 EVAP LDP Ram Wagon MIL 3 EVAP LDPF 5 EVAP V...

Page 598: ...EGR System BP EGR BPT BP EGR Backpressure Transducer CCV Crankcase Ventilation CEC Computerized Engine Controls CNG Compressed Natural Gas EFI Electronic Fuel Injection EGR CKV EGR Check Valve EVAP Fu...

Page 599: ...SFI 2 Hall Effect 3 9L X SFI 2 Hall Effect 5 2L Y SFI 2 Hall Effect 5 9L Z SFI 2 Hall Effect Durango DN 3 9L X SFI 2 Hall Effect 5 2L Y SFI 2 Hall Effect 5 9L Z SFI 2 Hall Effect Ram Pickup 5 3 9L X S...

Page 600: ...tial Fuel Injection 3 Distributorless Ignition System 4 Engine code G indicates flex fuel 5 Body code for standard pickup is BR Body code for Quad Cab is BE 6 Light duty emissions 7 Heavy duty emissio...

Page 601: ...der Head Near Rear Of Exhaust Manifold 3 3L 3 8L V6 Rear Of Cylinder Block Below Cylinder Head Just Above Flywheel Dakota Durango Ram Pickup Ram Van Ram Wagon 2 5L 4 Cylinder Machined Pad On Right Sid...

Page 602: ...n California or is a Federal vehicle vacuum hose routing schematic etc can be found on this label See Fig 1 In addition to the VECI label some emission control inspection and maintenance programs may...

Page 603: ...arresters etc are present routed properly and in serviceable condition Fig 2 Typical Open Closed Type PCV System THERMOSTATIC AIR CLEANER TAC The TAC supplies warm air to air intake during cold engine...

Page 604: ...nted into the PCV system and stored inside the crankcase The main components of a fuel evaporation system are a sealed fuel tank a liquid vapor separator and vent lines to a vapor storing canister fil...

Page 605: ...lyst in this type of converter Visually check for presence of catalytic converter s Check for external damage such as severe dents removed or damaged heat shields etc Also check for pellets or pieces...

Page 606: ...device reducing all 3 emissions As exhaust gases leave the bed they pass through the air space and into the second OC converter catalyst bed Visually check for presence of catalytic converter s Check...

Page 607: ...y of General Motors Corp Dual Diaphragm EGR Valve This type uses 2 diaphragms with different effective areas and 2 vacuum sources Although similar to the single diaphragm type the second diaphragm is...

Page 608: ...he amount of EGR It provides more recirculation during heavy engine loads than the single diaphragm EGR valve A small diaphragm controlled valve inside EGR valve acts as a pressure regulator The contr...

Page 609: ...tom side of the diaphragm See Fig 10 When ported vacuum is applied to the main vacuum chamber partially opening the valve the vacuum signal from the manifold side reduced by exhaust backpressure is tr...

Page 610: ...ypical Negative Backpressure EGR Valve Courtesy of General Motors Corp Digital EGR Valve The digital EGR valve operates independently of engine manifold vacuum This valve controls EGR flow through 3 o...

Page 611: ...recise EGR flow control At idle the EGR valve allows a very small amount of exhaust gas to enter the intake manifold This EGR valve normally operates above idle speed during warm engine operation Veri...

Page 612: ...urrent to the solenoid The ECM controls EGR flow with a pulse width modulated signal based on airflow TPS and RPM This system also contains a pintle position sensor which works similarly to a TPS sens...

Page 613: ...p is a belt driven vane type pump mounted to engine in combination with other accessories The air pump itself consists of the pump housing an inner air cavity a rotor and a vane assembly As the vanes...

Page 614: ...gnal constantly fluctuates between high and low crossing a reference voltage supplied by the ECM on the O2 signal line This is referred to as cross counts A problem in the O2 sensor circuit should set...

Page 615: ...retor As the exhaust gas quickly warms the intake mixture distribution is improved This results in better cold engine driveability shorter choke periods and lower emissions Ensure EFE valve in exhaust...

Page 616: ...ith engine running fail vehicle and service or replace applicable emission related components To reset an EMR indicator refer to appropriate MAINTENANCE REMINDER LIGHTS in the MAINTENANCE section MALF...

Page 617: ...ly See Figs 5 through 14 4 CYLINDER BELT ADJUSTMENT SPECIFICATIONS CARS Application New Belt 1 Used Belt Lbs kg Lbs kg Avenger Sebring Coupe 2 0L Generator 110 160 50 73 90 110 41 50 Power Steering Wi...

Page 618: ...es of service BELT ADJUSTMENT SPECIFICATIONS TRUCKS Application New Belt 1 Used Belt Lbs kg Lbs kg Dakota Durango 2 5L 180 200 82 91 140 160 64 73 3 9L 5 2L 5 9L 2 2 FWD Vans Caravan Voyager 2 4L A C...

Page 619: ...Fig 2 Belt Routing 2 0L Neon Courtesy of Chrysler Corp Fig 3 Belt Routing 2 0L Talon With Turbo Courtesy of Chrysler Corp...

Page 620: ...Fig 4 Belt Routing 2 0L 2 4L 2 5L V6 Breeze Caravan Cirrus Sebring Convertible Stratus Voyager Courtesy of Chrysler Corp Fig 5 Belt Routing 2 5L Dakota With A C Courtesy of Chrysler Corp...

Page 621: ...Fig 6 Belt Routing 2 5L Dakota Without A C Courtesy of Chrysler Corp Fig 7 Belt Routing 2 5L Avenger Sebring Coupe Courtesy of Chrysler Corp...

Page 622: ...Fig 8 Belt Routing 3 0L Caravan Voyager Courtesy of Chrysler Corp Fig 9 Belt Routing 3 3L 3 8L Caravan Town Country Voyager Courtesy of Chrysler Corp...

Page 623: ...Fig 10 Belt Routing 2 7L Concorde Intrepid LHS 300M Courtesy of Chrysler Corp Fig 11 Belt Routing 3 2L 3 5L Concorde Intrepid LHS 300M Courtesy of Chrysler Corp...

Page 624: ...Fig 12 Belt Routing 3 9L 5 2L 5 9L Gasoline Dakota Durango Ram Pickup Ram Van Wagon Without Air Pump Courtesy of Chrysler Corp...

Page 625: ...Fig 13 Belt Routing 5 9L Diesel Ram Pickup Courtesy of Chrysler Corp...

Page 626: ...Fig 14 Belt Routing 5 9L 8 0L Gasoline Ram Pickup With Air Pump Courtesy of Chrysler Corp...

Page 627: ...CARS Application Specification Avenger Sebring Coupe Coolant Replacement Interval 30 000 Miles Or 24 Months Coolant Capacity 7 4 Qts 7 0L Pressure Cap 16 psi Thermostat DOHC Starts To Open 195 F 91 C...

Page 628: ...ts 12 5L Dakota 2 5L 9 8 Qts 9 3L 3 9L 14 0 Qts 13 2L 5 2L 14 3 Qts 13 5L 5 9L 14 6L 13 7L Durango 3 9L 14 0 Qts 13 2L 5 2L 5 9L 14 3 Qts 13 5L Ram Pickup 3 9L 5 2L 5 9L Gasoline 20 0 Qts 18 9L 5 9L D...

Page 629: ...ction pump SPECIAL ENGINE MARKS Information identifying undersize and oversize components is found at various engine locations and is decoded as follows Crankshaft Rod Journals The letter M main or R...

Page 630: ...icle is equipped with leak detection pump LDP Vehicle may be equipped with flap installed into fuel filler tube even if vehicle is NOT equipped with LDP and EVAP monitor system 2 Remove fuel pump rela...

Page 631: ...arates from quick connect fitting Discard old pull tab Disconnect quick connect fitting from fuel line CAUTION DO NOT install a quick connect fitting without retainer being either in fuel tube or alre...

Page 632: ...ct fitting pull on fuel line and disconnect fitting to ensure fuel line is locked in place 5 Pull on fuel line and disconnect fitting to ensure fuel line is locked in place If fuel line is not locked...

Page 633: ...equipped using approved refrigerant recovery recycling equipment Disconnect A C lines at condenser and plug openings Remove A C compressor Disconnect fan shroud 3 Remove front bumper grille and suppor...

Page 634: ...charge A C system if equipped using approved refrigerant recovery recycling equipment Disconnect A C lines and plug openings On Pickup remove upper core support transmission cooler and A C condenser O...

Page 635: ...FITTINGS Disconnect accelerator linkage Remove throttle body Remove starter and generator Disconnect power steering hoses Raise and support vehicle Drain oil Disconnect exhaust pipe at exhaust manifo...

Page 636: ...rp Installation To install reverse removal procedure Tighten bolts nuts to specification See TORQUE SPECIFICATIONS table On A T models ensure reference marks on torque converter and flexplate are alig...

Page 637: ...gon air cleaner and generator Disconnect necessary electrical wiring coolant hoses and vacuum hoses Remove distributor cap and spark plug wires Remove valve covers if necessary 3 Remove bolts intake m...

Page 638: ...ealant at 4 corner joints Install front and rear gaskets Ensure holes in front and rear gaskets engage with dowels in cylinder block 3 Install intake manifold and install all bolts finger tight Tighte...

Page 639: ...ld Lower vehicle Remove exhaust heat shields if equipped Remove bolts nuts washers and exhaust manifold Note location of conical washer on bolts studs Remove manifold Inspection Check exhaust manifold...

Page 640: ...attery and drain coolant Remove generator bracket support rod and generator Remove intake and exhaust manifold See INTAKE MANIFOLD and EXHAUST MANIFOLD 2 Remove rocker arms and push rods See ROCKER AR...

Page 641: ...EAL Tighten front cover oil pan and then vibration damper bolts to specification See TORQUE SPECIFICATIONS table To complete installation reverse removal procedure TIMING CHAIN Inspection 1 Remove fro...

Page 642: ...engine to allow valve lifters to bleed down after rocker arm installation Installation 1 On 3 9L engine locate V6 mark stamped on vibration damper 147 degrees ATDC Rotate engine by hand until V6 mark...

Page 643: ...ast idle until valve lifters have filled with oil and become quiet Installation 1 Lubricate valve lifters and push rods before installing in original locations Ensure valve lifter is installed so oil...

Page 644: ...r See Fig 10 This prevents camshaft from contacting plug located in rear of cylinder block Install distributor lock bolt to retain camshaft installer 3 Install camshaft thrust plate and oil tab Ensure...

Page 645: ...ishes it to correct size 3 Ensure No 1 cylinder is at TDC on compression stroke Install distributor drive shaft so slot is aligned toward left front intake manifold bolt as viewed from rear of engine...

Page 646: ...block joint See Fig 11 Fig 11 Installing Rear Crankshaft Oil Seal Courtesy of Chrysler Corp WATER PUMP...

Page 647: ...lutch assembly as a unit Locate accessory drive belt tensioner and rotate tensioner clockwise counterclockwise on heavy duty cycle engines to release tension on accessory drive belt 4 Note drive belt...

Page 648: ...o frame bracket holes to support engine 3 Lower engine and allow it to rest on bolts installed in side engine mounts Remove oil pan bolts oil pan and gaskets Installation 1 To install reverse removal...

Page 649: ...s meet end seals and end seals contact cylinder block See Fig 14 2 To facilitate oil pan installation fabricate 4 alignment dowels from 1 1 2 x 5 16 bolts See Fig 15 Tighten bolts to specification See...

Page 650: ...abricate 4 alignment dowels from 1 1 2 x 5 16 bolts See Fig 15 Tighten bolts to specification See TORQUE SPECIFICATIONS table To install remaining components reverse removal procedure Removal Grand Ch...

Page 651: ...Fig 15 Oil Pan Alignment Dowel Fabrication Installation Courtesy of Chrysler Corp OVERHAUL...

Page 652: ...tep Ream valve guides to oversize in gradual steps so guides are reamed true in relation to valve seat After reaming valve guides valve seat runout must be checked Valve Guides Check valve stem oil cl...

Page 653: ...ee PISTONS PINS RINGS table under ENGINE SPECIFICATIONS 2 Position piston ring gaps in proper location See Fig 16 Compression ring gaps must be staggered so they do not align with oil ring rail gap En...

Page 654: ...ylinder Block 1 Check cylinder bore out of round and taper Measure cylinder bore diameter below top surface of cylinder bore middle of bore and bottom of cylinder bore Bore cylinder block if bore diam...

Page 655: ...ow or no oil pressure 2 To check installation remove oil sending unit and insert wire down passage Oil line plug should be 7 50 7 68 in 190 0 195 2 mm from machined surface of block If plug is too hig...

Page 656: ...Mount Adhesive or equivalent Plug should be 2 12 2 31 in 54 0 57 7 mm from bottom of block Fig 18 Cross Sectional View Of Oil Line Plug Location Courtesy of Chrysler Corp OIL PUMP Removal Disassembly...

Page 657: ...specification See OIL PUMP SPECIFICATIONS table 2 Install outer rotor into pump body Press outer rotor to one side and measure clearance between outer rotor and pump body Replace oil pump assembly if...

Page 658: ...rotor cavity with engine oil before installing To install reverse removal procedure TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft Lbs N m Axle Bracket To Bellhousing Bolt Dakota 4WD Duran...

Page 659: ...Motor Bolt Dakota 4WD Durango 4WD 65 88 Spark Plug 30 41 Starter Bolts 50 68 Throttle Body Bolt 17 23 Transfer Case Yoke Bolt Dakota 4WD Durango 4WD 20 27 Vibration Damper Bolt 135 183 Water Pump Bolt...

Page 660: ...haft End Play Standard 002 007 05 18 Wear Limit 010 25 Main Bearings Journal Diameter 3 9L 5 2L 2 4995 2 5005 63 487 63 513 5 9L 2 8095 2 8105 71 361 71 387 Journal Out Of Round 001 03 Journal Taper 0...

Page 661: ...5 38 1 40 Side Clearance 2 0080 203 Max 1 Interference fit 2 Steel rail oil ring should be free in groove but clearance within maximum specification VALVES VALVE SPRINGS Application Specification Inta...

Page 662: ...L 313 314 7 95 7 98 mm 5 9L 374 375 9 50 9 53 mm Valve Stem To Guide Oil Clearance Standard 001 003 02 08 mm Wear Limit 1 017 43 mm 1 Specification applies to method obtained by rocking valve stem in...

Page 663: ...m Cylinder Bore Standard Diameter 3 9L 5 2L 3 910 3 912 99 31 99 36 5 9L 4 000 4 002 101 60 101 65 Maximum Taper 010 25 Maximum Out Of Round 005 13 Maximum Oversize 040 1 016 VALVE LIFTERS Application...

Page 664: ...ul procedures and specifications for the vehicle being repaired GENERAL Engine components must be inspected to meet manufacturer s specifications and tolerances during overhaul Proper dimensions and t...

Page 665: ...omponents X ray inspection maybe used to detect internal and external flaws in any material PRESSURE TESTING Cylinder heads can be tested for cracks using a pressure tester Pressure testing is perform...

Page 666: ...lift in the tank for several hours without damage After cleaning flush parts with hot water Steam cleaning with boiling hot water sprayed at high pressure is recommended as the final cleaning process...

Page 667: ...plications require cylinder head bolts be removed in proper sequence to prevent cylinder head damage See Fig 1 Remove cylinder head Fig 1 Typical Cylinder Head Tightening or Loosening Sequence This Gr...

Page 668: ...lifter to be bled down and clearance measured Different length push rods can be used to obtain proper clearance Clearance will be checked between tip of rocker arm and tip of valve stem in proper seq...

Page 669: ...approved cleaning methods Inspect cylinder head for cracks damage or warped gasket surface Place straightedge across gasket surface Determine clearance at center of straightedge Measure across both d...

Page 670: ...by machining intake manifold surface that contacts cylinder head Cylinder head may be machined on surface that contacts intake manifold Using oil stone remove burrs or scratches from all sealing surfa...

Page 671: ...eplace all valve springs when overhauling cylinder head Fig 5 Checking Valve Spring Pressure Typical This Graphic For General Information Only VALVE GUIDE Measuring Valve Guide Clearance Check valve s...

Page 672: ...cation If valve guide clearance exceeds specification valves with oversize stems may be used or valve guide must be replaced On some applications a false guide is installed then reamed to proper speci...

Page 673: ...Valve Guides Typical This Graphic For General Information Only Replacing Valve Guide Replace valve guide if clearance exceeds specification Valve guides are either pressed hammered or shrunk in place...

Page 674: ...lled guide insures a tight guide fit upon assembly The new guide must be reamed to specification Fig 8 Typical Valve Guide Remover Installer This Graphic For General Information Only VALVES VALVE SEAT...

Page 675: ...ith hand drill Lift valve upward off the seat and change position often This is done to prevent grooving of valve seat Lap valve until a smooth polished seat is obtained Thoroughly clean grinding comp...

Page 676: ...coat valve face lightly with Prussian Blue dye Install valve and rotate it on valve seat If pattern is even and entire seat is coated at valve contact point valve is concentric with the seat REASSEMB...

Page 677: ...uld hold valve closed If air pressure does not hold valve closed check for damaged or bent valve Cylinder head must be removed for service Using valve spring compressor compress valve springs Remove v...

Page 678: ...if required See VALVE ADJUSTMENT in this article Pushrods Remove rocker arms Mark push rods for location Remove push rods Push rods can be steel or aluminum solid or hollow Hollow pushrods must be int...

Page 679: ...l Hydraulic Valve Lifter Assemblies Typical This Graphic For General Information Only On sticking lifters disassemble and clean lifter DO NOT mix lifter components or positions Parts are select fitted...

Page 680: ...lifter in original location Install remaining components Valve lash adjustment is not required on most hydraulic lifters Preload of hydraulic lifter is automatic Some models may require adjustment Me...

Page 681: ...ning Remove all carbon and varnish from piston Pistons and connecting rods may be cleaned in cold type chemical tank Using ring groove cleaner clean all deposits from ring grooves Ensure all deposits...

Page 682: ...specification Mark piston for proper cylinder location ASSEMBLING PISTON CONNECTING ROD Install proper fitted piston on connecting rod for proper cylinder Ensure piston marking on top of piston marke...

Page 683: ...may be corrected by using a fine file while other manufacturers recommend using another ring set Mark rings for proper cylinder installation after checking end gap Fig 15 Checking Piston Ring End Gap...

Page 684: ...Install lower bearings in rod caps Ensure bearing tabs are properly seated Position piston ring gaps according to manufacturers recommendations See Fig 16 Lubricate pistons rings and cylinder walls Fi...

Page 685: ...emaining cylinders Check bearing clearance See MAIN CONNECTING ROD BEARING CLEARANCE in this article Once clearance is checked lubricate journals and bearings Install bearing caps Ensure marks are ali...

Page 686: ...e or during reassembly Plastigage material is oil soluble Ensure journals and bearings are free of oil or solvent Oil or solvent will dissolve material and false reading will be obtained Install small...

Page 687: ...ings and caps in original location on cylinder block Tighten bolts to specification On connecting rods install bearings and caps on connecting rods Install proper connecting rod cap on corresponding r...

Page 688: ...Inspect crankshaft for scoring and nicks Inspect crankshaft for cracks using Magnaflux procedure Inspect rear seal area for grooving or damage Inspect bolt hole threads for damage If pilot bearing or...

Page 689: ...is article Once clearance is checked lubricate lower main bearing and journals Install main bearing caps in original location Install rear seal in rear main bearing cap if removed Some rear main beari...

Page 690: ...end play can be checked using feeler gauge Pry crankshaft rearward Pry crankshaft forward Using feeler gauge measure clearance between crankshaft and thrust bearing surface See Fig 22 Fig 22 Checking...

Page 691: ...l bore gauge For determining out of round measure cylinder parallel and perpendicular to the block centerline Difference in the 2 readings is the bore out of round Cylinder bore must be checked at top...

Page 692: ...cation Tighten bolts to specification Using inside micrometer measure main bearing bore in 2 areas 90 degrees apart Determine bore size and out of round If diameter is not within specification block m...

Page 693: ...the camshaft rear plug The camshaft bearing remover is assembled with its shoulder resting on the bearing to be removed according to manufacturer s instructions Tighten puller nut until bearing is re...

Page 694: ...timing chain stretch rotate crankshaft to eliminate slack from one side of timing chain Mark reference point on cylinder block Rotate crankshaft in opposite direction to eliminate slack from remaining...

Page 695: ...or cracking Replace belt if cracked damaged missing teeth or oil soaked Used timing belt must be installed in original direction of rotation Inspect all sprocket teeth for wear Replace all worn sproc...

Page 696: ...e rails are used with spring loaded tensioners ensure at least half of original rail thickness remains Spring loaded tensioner should be inspected for damage Ensure all timing marks are aligned Adjust...

Page 697: ...Fig 26 Timing Belt Tension Adjustment Typical This Graphic For General Information Only TIMING GEARS...

Page 698: ...e of camshaft gear Adjust indicator to zero Rotate camshaft gear 360 degrees and note reading If backlash or runout exceed specifications replace camshaft and or crankshaft gear REAR MAIN OIL SEAL PLE...

Page 699: ...installation See Fig 28 Fig 28 Typical Rope Seal Installation This Graphic For General Information Only Split Rubber Type Seal Follow manufacturers procedures when installing split rubber type rear m...

Page 700: ...nd measure thickness and diameter Measure inner rotor thickness Inspect shaft for scoring or wear Inspect rotors for pitting or damage Inspect cover for grooving or wear Replace components if worn or...

Page 701: ...straightedge and feeler gauge Replace pump if clearance exceeds specification GEAR TYPE Oil pump gears must be marked for location prior to removal See Fig 32 Remove gears from pump body Inspect gears...

Page 702: ...s Graphic For General Information Only BREAK IN PROCEDURE PLEASE READ THIS FIRST NOTE Always refer to appropriate engine overhaul article in the ENGINES section for complete overhaul procedures and sp...

Page 703: ...when a new or reground camshaft has been installed Operate and maintain engine speed between 1500 2500 RPM for approximately 30 minutes Procedure may vary due to manufacturers recommendations PISTON...

Page 704: ...S AIR CONDITIONING PRESSURE SENSORS AIR DUCTS AND TUBES AIR FILTER ELEMENTS AIR FILTER GASKETS AIR FILTER HOUSINGS AND GASKETS AIR FUEL RATIO SENSORS AIR INJECTION CONTROL SOLENOIDS AIR PLENUMS AIR PU...

Page 705: ...SMISSION CONTROL DEVICES ELECTRONIC TRANSMISSION FEEDBACK DEVICES ENGINE COOLANT TEMPERATURE SENSORS ENGINE COOLING SYSTEMS ENGINE COVERS OIL PAN VALVE COVER TIMING COVER ENGINE OIL ENGINE OIL CANISTE...

Page 706: ...SENSORS LIQUID VAPOR SEPARATORS MANIFOLD ABSOLUTE PRESSURE MAP SENSORS MASS AIR FLOW MAF SENSORS METAL AIR MANIFOLDS AND PIPES METAL AIR PIPES MIX CONTROL SOLENOIDS MOTOR MOUNTS O RINGS GASKETS SEALS...

Page 707: ...pair industry We produce materials that give motorists the information and encouragement to take greater responsibility for their vehicles through proper manufacturer recommended maintenance We encour...

Page 708: ...outreach with your support both the automotive repair industry and your customers will reap the benefits Please visit MAP at our Internet site www motorist org or contact us at 1444 I Street NW Suite...

Page 709: ...e s shocks or struts have not failed In this case replacement may be suggested to satisfy the customer s wishes In this case replacement of the shocks or struts may not be sold as a requirement A cust...

Page 710: ...C camshaft camshaft bearings lash adjusters tappets and rockers CYLINDER HEAD ASSEMBLY INSPECTION Condition Code Procedure Adjustable valve lash is out of specification B Require repair Internal compo...

Page 711: ...e other head gasket on a V type engine SHORT BLOCK ASSEMBLIES NOTE A Short Block Assembly is a cylinder block and all those components contained within the limits of the block deck or decks the pan ra...

Page 712: ...replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A...

Page 713: ...INSPECTION Condition Code Procedure Alignment incorrect B Require repair or replacement Attaching hardware broken A Require repair or replacement of hardware Attaching hardware missing C Require repl...

Page 714: ...Require repair or replacement Terminal corroded not affecting performance 2 Suggest repair or replacement Terminal loose affecting performance B Require repair or replacement Terminal loose not affect...

Page 715: ...erformance 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair or replacement Terminal corroded not affecting performance 2 Suggest repair or replacement Terminal...

Page 716: ...t replacement to comply with vehicle s OEM recommended service intervals Melted A Required replacement Missing C Require replacement Restricted affecting performance A Require replacement Water contam...

Page 717: ...l burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair or r...

Page 718: ...inal broken A Require repair or replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal c...

Page 719: ...ement 1 Inoperative includes intermittent operation or out of OEM specification AIR PUMP BELTS AIR PUMP BELT INSPECTION Condition Code Procedure Alignment incorrect B 1 Further inspection required Cra...

Page 720: ...formance 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair or replacement Terminal corroded not affecting performance 2 Suggest repair or replacement Terminal lo...

Page 721: ...Require repair or replacement of hardware Attaching hardware missing C Require replacement of hardware Attaching hardware not functioning A Require repair or replacement of hardware Conductor exposed...

Page 722: ...ir or replacement Missing C Require replacement Resistance out of specification B Require repair or replacement Restricted affecting performance A Require repair or replacement Terminal broken A Requi...

Page 723: ...r for 30 seconds and maintain at least a voltage of 1 2 volts per cell 7 2 volts for a 12 volt battery Cranking Amps CA The number of amperes a new fully charged battery typically at 32 F 0 C can deli...

Page 724: ...ttery to warm thoroughly and then performance test If battery fails performance test require replacement 2 No service suggested or required unless the battery fails performance test in which case requ...

Page 725: ...oltage drop out of specification A Require repair or replacement Routed incorrectly B Require repair Secured incorrectly B Require repair Shorted A Require repair or replacement Terminal broken A Requ...

Page 726: ...equire repair or replacement Threads stripped threads missing A Require replacement Water drain clogged A Require repair BATTERY WIRES See BATTERY CABLES WIRES AND CONNECTORS BELT DRIVEN AIR PUMPS BEL...

Page 727: ...t Seized A Require repair or replacement BELT TENSIONERS ACCESSORY AND CAM BELTS BELT TENSIONER ACCESSORY AND CAM BELT INSPECTION Condition Code Procedure Alignment incorrect B Require repair or repla...

Page 728: ...ded affecting performance A Require repair or replacement Terminal corroded not affecting performance 2 Suggest repair or replacement Terminal loose affecting performance B Require repair or replaceme...

Page 729: ...ding A Require repair or replacement of linkage Leaking A Require repair or replacement Mechanical operation incorrect B Require repair or replacement Operating incorrectly B Require repair or replace...

Page 730: ...Require repair or replacement Connector melted A 1 Require repair or replacement Connector missing C Require replacement Inoperative B 2 Require repair or replacement Further inspection required Miss...

Page 731: ...ement or recycling Further inspection required Level low B 2 Require filling to proper level Maintenance intervals 3 3 Suggest replacement Mixture incorrect B Require correction or replacement Type in...

Page 732: ...quire replacement Terminal broken A Require repair or replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or...

Page 733: ...Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair or replacement Terminal corroded not affecting performance 2 Suggest...

Page 734: ...e lead conductors exposed B Require repair or replacement Wire lead corroded A Require repair or replacement Wire lead open A Require repair or replacement Wire lead shorted A Require repair or replac...

Page 735: ...exposed B Require repair or replacement Wire lead corroded A Require repair or replacement Wire lead open A Require repair or replacement Wire lead shorted A Require repair or replacement 1 Determine...

Page 736: ...n A Require repair or replacement Wire lead shorted A Require repair or replacement 1 Determine cause and correct prior to repair or replacement of part 2 Determine source of contamination such as eng...

Page 737: ...cification B Require repair or replacement 1 Inoperative includes intermittent operation DISTRIBUTOR BOOTS AND SHIELDS DISTRIBUTOR BOOT AND SHIELD INSPECTION Condition Code Procedure Attaching hardwar...

Page 738: ...ting performance 2 Suggest repair or replacement Terminal eroded affecting performance A Require repair or replacement Terminal eroded not affecting performance No service suggested or required Termin...

Page 739: ...A Require repair or replacement Gear worn affecting performance A Require replacement Gear worn not affecting performance No service suggested or required Integrated pickup triggering device loose A...

Page 740: ...2 Require replacement of spring s 1 Inoperative includes intermittent operation or out of OEM specification If the inoperative diaphragm is separate from the heat riser then require replacement of the...

Page 741: ...minal broken A Require repair or replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal...

Page 742: ...icted affecting performance A Require repair or replacement Terminal broken A Require repair or replacement Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not...

Page 743: ...nt Resistance out of specification B Require repair or replacement Restricted affecting performance A Require repair or replacement Terminal broken A Require repair or replacement Terminal burned affe...

Page 744: ...replacement Further inspection required Leaking A Require repair or replacement Missing C Require replacement Resistance out of specification B Require repair or replacement Restricted affecting perf...

Page 745: ...replacement Baffle loose 2 Suggest repair or replacement Baffle missing C Require replacement Bent affecting performance A Require repair or replacement Bent not affecting performance No service sugg...

Page 746: ...amaged not affecting performance 2 Suggest repair or replacement Fluid flow restrictions A Require repair or replacement Internal restrictions affecting performance A Require repair or replacement Lea...

Page 747: ...fuel metal particles or water when changing oil Require repair or replacement 4 Determine cause such as broken motor mount ENGINE OIL GASKETS See ENGINE OIL DRAIN PLUGS AND GASKETS ENGINE OIL PRESSUR...

Page 748: ...aching hardware threads stripped threads missing A Require repair or replacement of hardware Connector broken A Require repair or replacement Connector Weatherpack type leaking A Require repair or rep...

Page 749: ...r accepted cleaning procedure EVAPORATIVE EMISSION EVAP CANISTERS EVAPORATIVE EMISSION EVAP CANISTER INSPECTION Condition Code Procedure Inoperative A 1 Require repair or replacement Leaking A Require...

Page 750: ...ment Wire lead conductors exposed B Require repair or replacement Wire lead corroded A Require repair or replacement Wire lead open A Require repair or replacement Wire lead shorted A Require repair o...

Page 751: ...affecting performance 1 Suggest repair or replacement Threads damaged A Require repair or replacement Threads stripped threads missing A Require replacement Wire lead conductors exposed B Require rep...

Page 752: ...repair or replacement Terminal corroded not affecting performance 2 Suggest repair or replacement Terminal loose affecting performance B Require repair or replacement Terminal loose not affecting perf...

Page 753: ...or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair or replacement Terminal corroded not affecting perfor...

Page 754: ...repair or replacement Inoperative A 1 Require replacement Leaking A Require replacement 1 Inoperative includes intermittent operation or out of OEM specification FUEL AND COLD START INJECTORS NOTE You...

Page 755: ...ire repair or replacement Threads stripped threads missing A Require replacement 1 Determine cause and correct prior to repair or replacement of part 2 Inoperative includes intermittent operation out...

Page 756: ...t Missing C Require replacement Restricted 2 Suggest repair or replacement FUEL FILTERS FUEL FILTER INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or replacement of har...

Page 757: ...cting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair or replacement Te...

Page 758: ...ent Terminal loose not affecting performance 1 Suggest repair or replacement Wire lead conductors exposed B Require repair or replacement Wire lead corroded A Require repair or replacement Wire lead o...

Page 759: ...sy 2 Suggest repair or replacement Out of specification B Require repair or replacement Terminal broken A Require repair or replacement Terminal burned affecting performance A 1 Require repair or repl...

Page 760: ...CTORS See FUEL FILLER NECKS AND RESTRICTORS FUEL TANKS FUEL TANK INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or replacement of hardware Attaching hardware missing C...

Page 761: ...ALVE COVER INSPECTION Condition Code Procedure Leaking 2 1 Suggest repair or replacement 1 Require inspection of mating and sealing surface and repair or replace as necessary HARMONIC DAMPERS HARMONIC...

Page 762: ...pair or replacement Malfunctioning A 1 Require repair or replacement Missing C Require replacement Restricted A Require repair or replacement Vacuum leak A Require repair or replacement 1 Includes ino...

Page 763: ...replacement of safety clip Stripped A Require replacement HOSE CLAMPS See HOSE AND TUBE COUPLERS CONNECTORS AND CLAMPS HOSE CONNECTORS See HOSE AND TUBE COUPLERS CONNECTORS AND CLAMPS HOSE COUPLERS Se...

Page 764: ...incorrect 1 Suggest repair or replacement HOUSINGS See THERMOSTATS AND HOUSINGS IDLE AIR CONTROLS IDLE AIR CONTROL INSPECTION Condition Code Procedure Attaching hardware missing C Require replacement...

Page 765: ...f contamination such as engine coolant fuel metal particles or water Require repair or replacement 3 Inoperative includes intermittent operation or out of OEM specification Some components may be serv...

Page 766: ...repair or replacement 1 Determine cause and correct prior to repair or replacement of part 2 Determine source of contamination such as engine coolant fuel metal particles or water Require repair or re...

Page 767: ...lacement Wire lead conductors exposed B Require repair or replacement Wire lead corroded A Require repair or replacement Wire lead open A Require repair or replacement Wire lead shorted A Require repa...

Page 768: ...r or replacement Wire lead open A Require repair or replacement Wire lead shorted A Require repair or replacement 1 Refer to manufacturer s diagnostic trouble code procedure and require repair or repl...

Page 769: ...minal corroded not affecting performance 2 Suggest repair or replacement Terminal loose affecting performance B Require repair or replacement Terminal loose not affecting performance 1 Suggest repair...

Page 770: ...corroded A Require repair or replacement Wire lead open A Require repair or replacement Wire lead shorted A Require repair or replacement 1 Determine cause and correct prior to repair or replacement o...

Page 771: ...lead conductors exposed B Require repair or replacement Wire lead corroded A Require repair or replacement Wire lead open A Require repair or replacement Wire lead shorted A Require repair or replace...

Page 772: ...ment Connector Weatherpack type leaking A Require repair or replacement Connector melted A 1 Require repair or replacement Connector missing C Require replacement Inoperative B 2 Require repair or rep...

Page 773: ...ion MANIFOLD ABSOLUTE PRESSURE MAP SENSORS MANIFOLD ABSOLUTE PRESSURE MAP SENSOR INSPECTION Condition Code Procedure Attaching hardware missing C Require replacement of hardware Attaching hardware thr...

Page 774: ...e of contamination such as engine coolant fuel metal particles or water Require repair or replacement 3 Inoperative includes intermittent operation or out of OEM specification Some components may be s...

Page 775: ...orted A Require repair or replacement 1 Determine cause and correct prior to repair or replacement of part 2 Determine source of contamination such as engine coolant fuel metal particles or water Requ...

Page 776: ...spection required Leaking A Require repair or replacement Missing C Require replacement Resistance out of specification B Require repair or replacement Restricted affecting performance A Require repai...

Page 777: ...oning A Require repair or replacement of hardware Broken A Require replacement Leaking hydraulic mount A Require replacement Mounting hole worn affecting performance A Require replacement Mounting hol...

Page 778: ...repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair or replacement Terminal corroded not affecting...

Page 779: ...fecting performance B Require repair or replacement Terminal loose not affecting performance 1 Suggest repair or replacement Threads damaged A Require repair or replacement Threads stripped threads mi...

Page 780: ...aching hardware threads damaged A Require repair or replacement of hardware Attaching hardware threads stripped threads missing A Require repair or replacement of hardware Connector broken A Require r...

Page 781: ...ittent operation or out of OEM specification Some components may be serviceable check for accepted cleaning procedure PCV BREATHER ELEMENTS PCV BREATHER ELEMENT INSPECTION Condition Code Procedure Att...

Page 782: ...to comply with vehicle s OEM recommended service intervals Missing C Require replacement Restricted A Require replacement 1 Inoperative includes intermittent operation or out of OEM specification PICK...

Page 783: ...cification Refer to OEM recommended service procedures POWER STEERING PRESSURE SENSORS POWER STEERING PRESSURE SENSOR INSPECTION Condition Code Procedure Attaching hardware missing C Require replaceme...

Page 784: ...r Require repair or replacement 3 Inoperative includes intermittent operation or out of OEM specification Some components may be serviceable check for accepted cleaning procedure POWERTRAIN CONTROL MO...

Page 785: ...quire repair or replacement of affected component s 2 Determine cause and correct prior to repair or replacement of part 3 Determine source of contamination such as engine coolant fuel metal particles...

Page 786: ...TOR FAN CLUTCH INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or replacement of hardware Attaching hardware missing C Require replacement of hardware Attaching hardware...

Page 787: ...l restrictions not affecting performance 2 Suggest repair or replacement Leaking A Require repair or replacement Threads damaged A Require repair or replacement Threads stripped threads missing A Requ...

Page 788: ...ent Inoperative B 3 Require repair or replacement Further inspection required Leaking A Require repair or replacement Missing C Require replacement Resistance out of specification B Require repair or...

Page 789: ...or Barometric Pressure Sensor BARO Camshaft Position Sensor CMP Clutch Pedal Position Switch CPP Cooling Fan Motor Sensors and Switches Crankshaft Position Sensor CKP Electronic Transmission Feedback...

Page 790: ...ooling system performance A Require repair or replacement Cracked affecting cooling system performance A Require repair or replacement Loose affecting cooling system performance A Require repair Loose...

Page 791: ...ring noisy A Require replacement Bearing worn A Require replacement Boost pressure incorrect A 1 Require repair or replacement Clearance out of specification B Require repair or replacement Leaking A...

Page 792: ...t Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require re...

Page 793: ...Threads stripped threads missing A Require replacement Wire lead conductors exposed B Require repair or replacement Wire lead corroded A Require repair or replacement Wire lead open A Require repair...

Page 794: ...ement 1 Inoperative includes intermittent operation or out of OEM specification THROTTLE BODIES THROTTLE BODY INSPECTION Condition Code Procedure Connector broken A Require repair or replacement Conne...

Page 795: ...g procedure THROTTLE CABLES See THROTTLE LINKAGES AND CABLES THROTTLE LINKAGES AND CABLES THROTTLE LINKAGE AND CABLE INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or r...

Page 796: ...ing hardware threads damaged A Require repair or replacement of hardware Attaching hardware threads stripped threads missing A Require repair or replacement of hardware Connector broken A Require repa...

Page 797: ...re threads damaged A Require repair or replacement of hardware Attaching hardware threads stripped threads missing A Require repair or replacement of hardware Connector broken A Require repair or repl...

Page 798: ...re Attaching hardware not functioning A Require repair or replacement of hardware Bent A Require replacement Cracked A Require replacement Key damaged A Require replacement Loose A Require repair or r...

Page 799: ...g A Require replacement Body dented A 1 Further inspection required Body punctured A Require replacement Bushing deteriorated affecting performance A Require replacement Bushing deteriorated not affec...

Page 800: ...inal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair o...

Page 801: ...hing hardware not functioning A Require repair or replacement of hardware Boost pressure incorrect A 1 Require repair or replacement Leaking A Require repair or replacement Noisy 2 Suggest repair or r...

Page 802: ...placement Resistance out of specification B Require repair or replacement Restricted affecting performance A Require repair or replacement Terminal broken A Require repair or replacement Terminal burn...

Page 803: ...placement Connector missing C Require replacement Contaminated A 2 Require repair or replacement Inoperative B 3 Require repair or replacement Further inspection required Leaking A Require repair or r...

Page 804: ...ng A Require repair or replacement Connector melted A 1 Require repair or replacement Connector missing C Require replacement Contaminated A 2 Require repair or replacement Inoperative B 3 Require rep...

Page 805: ...air or replacement of hardware Connector broken A Require repair or replacement Connector Weatherpack type leaking A Require repair or replacement Connector melted A 1 Require repair or replacement Co...

Page 806: ...re Boost pressure incorrect A 1 Require repair or replacement Further inspection required Leaking A Require repair or replacement 1 Incorrect boost pressure includes intermittent operation or out of O...

Page 807: ...f part 2 Check fan motor controls Inoperative includes intermittent operation or out of OEM specification WATER PUMPS NON ELECTRIC WATER PUMP NON ELECTRIC INSPECTION Condition Code Procedure Attaching...

Page 808: ...conduit melted 2 1 Suggest repair or replacement Protective shield conduit missing 2 Suggest repair or replacement Resistance voltage drop out of specification A Require repair or replacement Routed...

Page 809: ...torists the information and encouragement to take greater responsibility for their vehicles through proper manufacturer recommended maintenance We encourage participating service and repair shops incl...

Page 810: ...outreach with your support both the automotive repair industry and your customers will reap the benefits Please visit MAP at our Internet site www motorist org or contact us at 1444 I Street NW Suite...

Page 811: ...have not failed In this case replacement may be suggested to satisfy the customer s wishes In this case replacement of the shocks or struts may not be sold as a requirement A customer of course has t...

Page 812: ...cle Be sure to review and adhere to EPA policy on removing and replacing catalytic converters Where state or local laws are stricter they take precedence over these guidelines NOTE Some exhaust system...

Page 813: ...s cracked B Require repair or replacement Internal rattle except pellet type 2 1 Further inspection required Mounting brackets that are part of converter broken A Require repair or replacement Obvious...

Page 814: ...replacement Clamp loose A Require repair or replacement Clamp missing C Require replacement Corroded affecting structural integrity 1 Suggest replacement Incorrect type i e flange ball socket etc B Re...

Page 815: ...t Missing C Require replacement MANIFOLDS CAST AND TUBE TYPE MANIFOLD CAST AND TUBE TYPE INSPECTION Condition Code Procedure Air injection tube in manifold broken A Require repair or replacement of in...

Page 816: ...stud Stud missing C Require replacement of stud Stud threads damaged A Require repair or replacement of stud Stud threads stripped threads missing A Require replacement of stud 1 Stove may not be avai...

Page 817: ...re replacement Sound quality unsatisfactory 2 Suggest replacement to address customer need and or request Split exhaust leaking A Require replacement Weak due to corrosion but no leaks present 1 Sugge...

Page 818: ...must be within specifications at all points If no defects are found check gear tooth contact pattern GEAR TOOTH CONTACT PATTERN NOTE Drive pattern should be well centered on ring gear teeth Coast patt...

Page 819: ...ith no change in backlash moving pinion further from ring gear moves drive pattern toward heel and top of tooth and moves coast pattern toward toe and top of tooth 2 With no change in backlash moving...

Page 820: ...rust and scale Follow manufacturer s instructions in the use of cleaner If considerable rust and scale has to be removed cooling system should be flushed Clean radiator air passages with compressed ai...

Page 821: ...n a 50 50 mixture of coolant and water See Fig 1 Do not allow thermostat or thermometer to touch bottom of container Heat water until thermostat just begins to open 2 Read temperature on thermometer T...

Page 822: ...f pressure drops inspect for external leaks If no leaks are apparent detach tester and run engine until normal operating temperature is reached Reattach tester and observe If pressure builds up immedi...

Page 823: ...r Switch Fan speed is controlled with a rotary blower motor switch There are 4 different fan speed settings one low speed 2 medium speeds and one high speed Mode Control Knob A rotary mode switch is u...

Page 824: ...em Check serpentine drive belt tension Check radiator and radiator fan operation Ensure that accessory vacuum supply line is connected at power brake booster Dakota or engine vacuum source except Dako...

Page 825: ...d Durango fuse No 12 40 amp on Ram Pickup If battery voltage exists go to next step If battery voltage does not exist check for open in Red wire between battery and underhood power distribution center...

Page 826: ...ep 2 If continuity exists go to next step If continuity does not exist repair open in Black wire between heater control panel and ground connector located at lower right of steering column 3 Place hea...

Page 827: ...ck for an open in circuit between heater control panel connector and blower motor relay Fig 3 Identifying Heater Control Panel C1 Connector Terminals Courtesy of Chrysler Corp Fig 4 Identifying Heater...

Page 828: ...T HEATER OUTPUT 1 Start engine Allow engine to reach normal operating temperature With engine at idle set controls to maximum heat floor and high blower positions Using a thermometer check air tempera...

Page 829: ...nect blower motor cooling tube Remove blower motor electrical connector from retainer Disconnect electrical connector 2 Remove blower motor and fan assembly mounting bolts Remove blower motor and fan...

Page 830: ...Fig 5 Identifying Heater Assembly Components Ram Pickup Courtesy of Chrysler Corp...

Page 831: ...stall reverse removal procedure Removal Installation Ram Pickup Blower motor resistor is located under glove box attached to blower motor housing See Fig 5 Disconnect negative battery cable Remove blo...

Page 832: ...gative battery cable Drain cooling system In engine compartment remove coolant hoses from heater core tubes Plug all openings Remove coolant overflow bottle Remove instrument panel See INSTRUMENT PANE...

Page 833: ...equipped set tilt steering column in lowest position 2 On all models carefully pry bezel away from instrument panel to disengage clips Unplug connectors from cigarette lighter and auxiliary power out...

Page 834: ...ster Bezel Ram Pickup Courtesy of Chrysler Corp CAUTION Use care when removing or installing instrument cluster bezel so as not to damage trip odometer reset button If trip odometer reset button is da...

Page 835: ...from parking brake linkage rod located at back of parking brake release handle Remove rod end from parking brake handle Remove instrument panel center support bracket Unplug vacuum harness connector...

Page 836: ...vehicle 6 From driver s side of instrument panel disengage parking brake release linkage rod from parking brake mechanism Disconnect instrument panel wiring harness from parking brake mechanism Disco...

Page 837: ...tioned as indicated See Fig 10 Measurements must be made with cable end bottomed against flag retainer on heater control panel end of cable housing 2 Measure distance between center of self adjusting...

Page 838: ...t to remove fastener from cowl side panel 3 Lift cowl plenum cover enough to access windshield washer nozzle and vacuum plumbing Disconnect vacuum supply hose from vacuum reservoir Remove cowl plenum...

Page 839: ...Fig 11 Heater System Vacuum Circuits Dakota Courtesy of Chrysler Corp...

Page 840: ...Fig 12 Heater System Vacuum Circuits Durango Courtesy of Chrysler Corp...

Page 841: ...Fig 13 Heater System Vacuum Circuits Ram Pickup Courtesy of Chrysler Corp...

Page 842: ...Fig 14 Heater System Vacuum Circuits Ram Van Wagon Courtesy of Chrysler Corp WIRING DIAGRAMS...

Page 843: ...Fig 15 Heater System Wiring Diagram Dakota...

Page 844: ...Fig 16 Heater System Wiring Diagram Durango...

Page 845: ...Fig 17 Heater System Wiring Diagram Ram Pickup...

Page 846: ...Fig 18 Heater System Wiring Diagram Ram Van Wagon...

Page 847: ...veral pages Today the majority of these diagrams follow a much improved format which permits space for internal switch details Wiring diagrams are drawn in a top down format The diagrams are drawn wit...

Page 848: ...wiring symbol are used in these diagrams The illustration below will help clarify any symbols that are not easily understood at a glance Most components are labeled Motor Switch or Relay in addition t...

Page 849: ...LOCATIONS TABLE Component Wiring Diagram ABS Electronic Control Unit Anti Lock Brakes Data Link Connectors ABS Hydraulic Unit Anti Lock Brakes Acceleration Sensor Anti Lock Brakes Accessory Delay Rela...

Page 850: ...Sensor Air Bag Air Bag Restraint System Distributor Engine Performance Door Lock Actuators Power Door Locks Remote Keyless Entry Door Lock Relay s Power Door Locks Electrochromic Mirror Power Mirrors...

Page 851: ...tia Fuel Shutoff Switch Engine Performance Inhibit Relay Starters Instrument Cluster Analog Instrument Panels Intake Air Temperature IAT Sensor Engine Performance Interior Lights Illumination Interior...

Page 852: ...an Motor s Electric Cooling Fans Radiator Fan Relay s Engine Performance Electric Cooling Fans Rainsense Module Wiper Washer Systems Raise Relay Power Convertible Top Remote Anti Theft Personality RAP...

Page 853: ...Twilight Sentinel Switch Headlight Systems Daytime Running Lights Vapor Canister Leak Detection Pump Engine Performance Vehicle Control Module VCM Engine Performance Vehicle Dynamic Module Electronic...

Page 854: ...e is not sufficient to open oil pressure sending unit switch Oil pressure warning light bulb test occurs with ignition switch in RUN position All instrument clusters include these analog gauges Coolan...

Page 855: ...age between ground and both sides of fuse No 17 10 amp in junction block If battery voltage exists on both sides go to next step If battery voltage exists on one side only repair short circuit and rep...

Page 856: ...go to next step If all gauges and CCD bus controlled indicator lights are inoperative go to step 5 2 Check fuse No 12 15 amp in junction block If fuse is okay go to next step If any fuse is blown repa...

Page 857: ...circuit between instrument cluster connector C2 terminal No 7 Black wire and ground See WIRING DIAGRAMS 9 Turn ignition off and disconnect negative battery cable Remove instrument cluster See INSTRUME...

Page 858: ...e needle should stop at 3 calibration points then return to relaxed position If any gauge does not perform as specified remove instrument cluster See INSTRUMENT CLUSTER under REMOVAL INSTALLATION Insp...

Page 859: ...block 3 Turn ignition off Disconnect negative battery cable Disconnect 4WD switch connector 4WD switch connector is located at right side of front axle Check continuity between 4WD switch connector B...

Page 860: ...NOPERATIVE RAM PICKUP DIESEL 1 Remove and inspect fuse No 17 10 amp in junction block Junction block is located at left end cover of instrument panel If fuse is okay go to next step If fuse is blown l...

Page 861: ...t 2 minutes before servicing instrument cluster See appropriate AIR BAG RESTRAINT SYSTEMS article CAUTION When battery is disconnected vehicle computer and memory systems may lose memory data Driveabi...

Page 862: ...r Remove shift indicator Remove instrument cluster To install reverse removal procedure Fig 3 Removing Instrument Cluster Bezel Ram Pickup Courtesy of Chrysler Corp Removal Installation Ram Van Ram Wa...

Page 863: ...ve left underdash cover and knee bolster reinforcement Remove 2 CTM retaining screws at right side of underdash opening See Fig 5 2 Slide CTM down into opening far enough to gain access to connectors...

Page 864: ...r Corp SHIFT INDICATOR Removal Installation Ram Pickup 1 Remove instrument cluster See INSTRUMENT CLUSTER Remove shift indicator from back of instrument cluster Place gear selector in PARK position Re...

Page 865: ...cover has 4 retaining clips on upper half and will require prying or lifting with flat bladed tool to remove Remove steering column opening cover 2 Remove park brake release handle and data Link Conn...

Page 866: ...rews and bezel To install switch reverse removal procedure Removal Installation Ram Van Ram Wagon 1 Disconnect negative battery cable Turn ignition switch to UNLOCK position and shift gear selector to...

Page 867: ...WIRING DIAGRAMS Fig 9 Analog Instrument Panel Wiring Diagram Ram Pickup 1 Of 2...

Page 868: ...Fig 10 Analog Instrument Panel Wiring Diagram Ram Pickup 2 Of 2...

Page 869: ...Fig 11 Analog Instrument Panel Wiring Diagram Ram Van Ram Wagon...

Page 870: ...ERVICE DIESEL SCHEDULED SERVICES NORMAL SERVICE DIESEL R2500 SCHEDULED SERVICES NORMAL SERVICE GAS SCHEDULED SERVICES SEVERE SERVICE GAS SCHEDULED SERVICES NORMAL SERVICE GAS MD SCHEDULED SERVICES SEV...

Page 871: ...icle Weight H 6001 7000 Lbs J 7001 8000 Lbs K 8001 9000 Lbs L 9001 10000 Lbs M 10001 14000 Lbs W Hydraulic Brakes 5 Truck Line C Ram Chassis Ram Pick Up 4x2 F Ram Chassis Ram Pick Up 4x4 6 Series 1 15...

Page 872: ...ice is recommended at mileage intervals based on vehicle operation Normal Service and Severe Service schedules are based on the following primary operating conditions Normal Service Driven More Than 1...

Page 873: ...Fig 1 Service Point Locations Typical V6 and V8 Engines Courtesy of Chrysler Corp Fig 2 Service Point Locations 8 0L V10 Engine Courtesy of Chrysler Corp...

Page 874: ...Fig 3 Service Point Locations 5 9L Turbo Diesel Courtesy of Chrysler Corp ADDITIONAL SERVICE INFORMATION DIESEL MODELS...

Page 875: ...Fig 4 Engine Service Locations 5 9L Engine Diesel Courtesy of Chrysler Corp NOTE For more information regarding 5 9L Diesel engine service refer to the E THEORY OPERATION 5 9L DIESEL article...

Page 876: ...to the F BASIC TESTING 5 9L DIESEL article in the ENGINE PERFORMANCE section NOTE DO NOT remove the air filter housing to inspect air filter element When disc in Filter Minder is in the RED zone the...

Page 877: ...more information regarding 5 9L Diesel engine service refer to the 5 9L V8 TURBO DIESEL VIN D article in the ENGINE MECHANICAL section When a diesel vehicle runs out of fuel air is pulled into the fue...

Page 878: ...30 times 3 Start engine using normal procedure 4 Engine may run rough until air is forced from lines CAUTION If this procedure fails to start vehicle more involved procedures may be required Fig 7 Val...

Page 879: ...the ENGINE MECHANICAL section Fig 8 Valve Adjustment Step 1 of 2 Diesel Courtesy of Chrysler Corp NOTE For more information regarding 5 9L Diesel engine service refer to the 5 9L V8 TURBO DIESEL VIN...

Page 880: ...y of Chrysler Corp NOTE For more information regarding 5 9L Diesel engine service refer to the 5 9L V8 TURBO DIESEL VIN D article in the ENGINE MECHANICAL section Fig 10 Water Separator Diesel Courtes...

Page 881: ...ilter until clear fuel is visible Drain fuel into a container and follow proper disposal procedures CAUTION DO NOT drain fuel water separator when engine is running or hot Allow engine to cool before...

Page 882: ...Fig 12 CNG Fuel Rail Service Points Courtesy of Chrysler Corp...

Page 883: ...Fig 13 CNG Fuel Tank Components Courtesy of Chrysler Corp...

Page 884: ...Fig 14 Manual Shutoff Valve Location Courtesy of Chrysler Corp...

Page 885: ...Fig 15 CNG Fuel Filter Courtesy of Chrysler Corp IDENTIFICATION LABEL LOCATIONS Fig 16 Identification Label Locations Courtesy of Chrysler Corp...

Page 886: ...Fig 17 CNG Identification Label Locations Courtesy of Chrysler Corp Fig 18 Tank Test Date Label Location Courtesy of Chrysler Corp LUBRICATION SPECIFICATIONS DIESEL...

Page 887: ...ansmission Fluid Transfer Case All ATF 2 Type 7176 Fluid Or DEXRON III ATF Manual All 75W 90 Synthc API GL4 Transmission Fluid Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Wheel Bearin...

Page 888: ...k 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant Automatic 46RE Dry Fill 17 Qts 16L Transmission Fluid 47RE Dry Fill 17 Qts 16L Manual NV4500 4 Qts 3 8L Transmission Fluid Rear Axle DANA 70 Model 267...

Page 889: ...Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Automatic All ATF 2 Type 7176 Transmission Fluid Transfer Case All ATF 2 Type 7176 Fluid Or DEXRON III ATF Manual NV 4500 75W 90 Synth...

Page 890: ...3 9L Drained W New Filter 4 Qts 3 8L 5 2L Drained W New Filter 5 Qts 4 7L 5 9L Drained W New Filter 5 Qts 4 7L 3 9L Drained 3 5 Qts 3 3L 5 2L Drained 4 5 Qts 4 2L 5 9L Drained 4 5 Qts 4 2L Engine 3 9L...

Page 891: ...culated levels Always use dipstick if available to measure level WHEEL TIRE SPECIFICATIONS TIRE REPLACEMENT The tires on your new vehicle provide a balance of many characteristics They should be inspe...

Page 892: ...ction of the system Use only plain water when cleaning the horn pad Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system WARNING To avoid injury fr...

Page 893: ...be caused by a restriction therefore adding refrigerant can cause a dangerous pressure rise ANTI LOCK BRAKE SYSTEM CAUTION The anti lock brake system contains electronic equipment that can be suscept...

Page 894: ...e use of an incorrect amperage rating fuse may result in a dangerous electrical system overload BRAKE PAD WEAR INDICATOR Indicator will cause a squealing or scraping noise warning that brake pads need...

Page 895: ...G Many solid state electrical components can be damaged by static electricity ESD Some will display a warning label but many will not Discharge personal static electricity by touching a metal ground p...

Page 896: ...15 These tires are too large for sufficient body clearance with chains or other traction devices Tire chains are not allowed on 4x2 vehicles equipped with P235 70R15 tires or 4x4 vehicles equipped wit...

Page 897: ...Fig 19 Interior Fuse Panel Courtesy of Chrysler Corp Fuse Circuit Breaker Identification...

Page 898: ...wertrain Control Module PCM Ignition Module High Pressure Fuel Shut Off Solenoid Relay CNG Models Only EGR Solenoid CNG Models Only 10 Not Used Vehicle Speed Control 11 10 Amp Red Buzzer Overhead Cons...

Page 899: ...uto Transmission Relay D Anti Lock Brake System Relay E Auto Shutdown Relay F Air Conditioning Clutch Relay G Horn Relay H Fuel System Relay J ABS Warning Light Relay K Fog Lamp 2 Relay L Fog Lamp 1 R...

Page 900: ...meter is slightly longer than a yard about 40 inches An aspirin tablet is about one centimeter across 4 inches A millimeter is about the thickness of a dime VOLUME Cubic meters and centimeters are us...

Page 901: ...ascals Thoroughly confused Try the examples below Atmospheric pressure at sea level is about 14 7 psi Atmospheric pressure at sea level is about 1 bar Atmospheric pressure at sea level is about 1 kg c...

Page 902: ...88 4 763 13 64 203 5 159 7 32 219 5 556 15 64 234 5 953 1 4 250 6 350 17 64 266 6 747 9 32 281 7 144 19 64 297 7 541 5 16 313 7 938 21 64 328 8 334 11 32 344 8 731 23 64 359 9 128 3 8 375 9 525 25 64...

Page 903: ...7 20 241 13 16 813 20 638 53 64 828 21 034 27 32 844 21 431 55 64 859 21 828 7 8 875 22 225 57 64 891 22 622 29 32 906 23 019 59 64 922 23 416 15 16 938 23 813 61 64 953 24 209 31 32 969 24 606 63 64...

Page 904: ...er turns off mirror heater after about 10 minutes COMPONENT TESTS AUTOMATIC DAY NIGHT INSIDE MIRROR 1 Turn ignition switch to ON position with transmission in Neutral or Park Place mirror switch in ON...

Page 905: ...yager Disconnect harness connector from mirror and headlight switch Using 2 jumper wires connect one jumper to a 12 volt source and the other jumper wire to a good ground Connect other end of jumper w...

Page 906: ...irror Operation Mirror Operation To Pin Pin Right Left Switch Connector 1 12 6 N A Up 7 6 N A Left 6 12 N A Down 6 7 N A Right 13 1 Up N A 8 1 Left N A 1 13 Down N A 1 8 Right N A 5 11 2 2 1 Use illus...

Page 907: ...ON table check for open or shorted circuit or replace mirror assembly as necessary See Fig 3 POWER MIRROR MOTOR TEST DAKOTA DURANGO RAM PICKUP RAM VAN RAM WAGON Apply 12 Volts Ground Mirror To Pin Pin...

Page 908: ...R Right Up 9 13 1 11 9 12 Down 9 1 13 11 12 11 Left 9 8 1 11 9 7 Right 9 1 8 11 7 11 Illumination N A 5 11 Dakota Durango Ram Pickup Ram Van Ram Wagon Remove switch and disconnect wiring connector Se...

Page 909: ...enever rear window defogger is on Caravan Town Country Voyager 1 Mirror should be warm to touch with rear window defogger activated If mirror is not warm to touch check fuse No 12 10 amp in junction b...

Page 910: ...CAUTION When battery is disconnected vehicle computer and memory systems may lose memory data Driveability problems may exist until computer systems have completed a relearn cycle See COMPUTER RELEAR...

Page 911: ...ob Remove power window lock switch assembly by inserting a screwdriver in notch at forward end of switch housing to release locking tabs Pull switch assembly forward and out from door panel Remove tri...

Page 912: ...WIRING DIAGRAMS Fig 5 Power Mirror System Wiring Diagram Caravan Town Country Voyager...

Page 913: ...Fig 6 Power Mirror System Wiring Diagram Dakota...

Page 914: ...Fig 7 Power Mirror System Wiring Diagram Durango...

Page 915: ...Fig 8 Power Mirror System Wiring Diagram Ram Pickup...

Page 916: ...Fig 9 Power Mirror System Wiring Diagram Ram Van Ram Wagon...

Page 917: ...N CAUTION Always turn ignition off when connecting or disconnecting battery cables battery chargers or jumper cables DO NOT turn test switch to OFF position which causes current to run through ammeter...

Page 918: ...ircuits powered up 5 Select low amp scale Switch lead to the correct meter position Turn test switch to OFF position and compare results to normal current draw See the GENERAL MOTORS PARASITIC LOAD TA...

Page 919: ...1 0 Voltage Regulator 1 4 2 0 INTERMITTENT PARASITIC LOAD PROBLEMS Intermittent parasitic lad can occur because of a memory device that does not power down with ignition off With an intermittent paras...

Page 920: ...Fig 2 Diode Check Solenoid Test General Motors Courtesy of General Motors Corp QUAD DRIVER TEST GENERAL MOTORS...

Page 921: ...Fig 3 Quad Driver Test General Motors Courtesy of General Motors Corp...

Page 922: ...ion procedures are covered in this article If component removal and installation is primarily an unbolt and bolt on procedure only a torque specification may be furnished COMPUTERIZED ENGINE CONTROLS...

Page 923: ...ntercooler if damaged CAUTION DO NOT use caustic cleaners to clean intercooler or intercooler may be damaged 2 If intercooler cleaning is required flush intercooler with a non caustic solvent in the o...

Page 924: ...ger with your finger as sharp edges may exist 3 Pour 3 ozs 60 cc of clean engine oil into turbocharger oil supply line fitting on turbocharger while using soft object to rotate turbine wheel in turboc...

Page 925: ...Tighten CKP bolt to specification See TORQUE SPECIFICATIONS INTAKE MANIFOLD AIR TEMPERATURE SENSOR Removal Installation 1 Disconnect electrical connector from intake manifold air temperature sensor S...

Page 926: ...NOTE APPS is replaced as assembly including lever brackets and sensor Removal 1 Disconnect negative battery cables Remove cable cover Using finger pressure only disconnect end of speed control servo...

Page 927: ...battery See Fig 5 Disconnect negative battery cables 2 Note location of wiring on intake manifold air heater relays for installation reference Disconnect electrical connectors at intake manifold air...

Page 928: ...ner ring disconnect fitting See Fig 6 Determine type of disconnect fitting used and use proper procedure for proper disconnect fitting Fig 6 Identifying Fuel Line Disconnect Fitting Courtesy of Chrysl...

Page 929: ...ent that may be replaced is the plastic retainer If plastic retainer must be removed from fuel system component carefully release the plastic retainer from the fuel system component using 2 screwdrive...

Page 930: ...fuel lines Allow 2 minute intervals between starter operations 3 To bleed air from fuel injection pump ensure parking brake is applied and transmission is in Neutral as engine may start when operating...

Page 931: ...sing NEW O ring install WIF sensor on canister if removed Tighten WIF sensor to specification See TORQUE SPECIFICATIONS 2 Install drain valve on canister if removed Tighten drain valve to canister bol...

Page 932: ...uel tank module lock nut from fuel tank Remove fuel tank module and gasket from fuel tank Inspect in tank fuel filter for damage Installation 1 Using NEW gasket install fuel tank module in fuel tank I...

Page 933: ...manifold air heater assembly If removing injector at cylinder No 5 remove engine lifting bracket Ensure area around fuel injector and high pressure fuel line is clean Disconnect high pressure fuel li...

Page 934: ...ion See TORQUE SPECIFICATIONS Bleed high pressure fuel lines See FUEL LINE BLEEDING under FUEL SYSTEM FUEL INJECTION PUMP CAUTION High pressure fuel lines must be clamped securely and routed so they d...

Page 935: ...ve them before engine start 4 Using gear puller separate injection pump gear from injection pump shaft See Fig 11 DO NOT pull fuel injection pump drive gear too far forward or timing gear cover may be...

Page 936: ...t Mounting Bolts Courtesy of Chrysler Corp Fig 11 Removing Fuel Injection Pump Drive Gear Courtesy of Chrysler Corp NOTE Before installing fuel injection pump ensure shaft on fuel injection pump is pr...

Page 937: ...e gear to shaft mating surfaces are clean and free of oil to provide proper seating of fuel injection pump drive gear on shaft of fuel injection pump 2 Pump gear keyway has an arrow and 3 digit number...

Page 938: ...from fuel system See FUEL LINE BLEEDING FUEL TANK ROLLOVER VALVE Removal 1 Fuel tank rollover valve is pressed into rubber grommet on top of fuel tank module See Fig 7 Manufacturer recommends removing...

Page 939: ...not contact each other or any other components DO NOT weld or substitute high pressure fuel lines High pressure lines are same length and proper high pressure fuel line must be installed in specified...

Page 940: ...Remove 4 air intake housing bolts Remove air intake housing from top of intake manifold air heater elements See Fig 13 2 Remove heater element assembly from intake manifold Clean old gasket from air i...

Page 941: ...4 Intake Manifold Air Heater Housing Bolt 18 24 Intake Manifold Air Temperature Sensor 20 27 Intake Manifold Cover Bolt 1 18 24 Oil Fill Plug 21 29 Overflow Valve To Fuel Injection Pump 24 33 Park Neu...

Page 942: ...Module PCM the correct vehicle mileage and Vehicle Identification Number VIN must be programmed into the PCM to prevent Diagnostic Trouble Codes DTCs from being set in the Anti Lock Brake System ABS...

Page 943: ...Fig 2 Locating PCM Ram Pickup Courtesy of Chrysler Corp Fig 3 Locating PCM Ram Van Ram Wagon Courtesy of Chrysler Corp PCM PROGRAMMING...

Page 944: ...ssary ENGINE SENSORS SWITCHES BATTERY TEMPERATURE SENSOR Removal Installation Battery temperature sensor is snapped into center of battery tray directly below the battery Remove battery Disconnect ele...

Page 945: ...er on brake switch must be pulled outward to fully extended position and then pushed inward 4 detent positions to ensure proper brake switch adjustment Installation 1 Pull plunger on brake switch outw...

Page 946: ...de of generator and contains a Tan Black wire and a Black Light Blue wire in the electrical connector 2 Remove air cleaner if necessary for access to engine coolant temperature sensor On models equipp...

Page 947: ...oling system FUEL LEVEL SENSOR Removal Installation See FUEL LEVEL SENSOR under FUEL SYSTEM INTAKE AIR TEMPERATURE IAT SENSOR NOTE Intake air temperature sensor may also be referred to as intake manif...

Page 948: ...AT Sensor Dakota 3 9L 5 2L 5 9L Durango Ram Pickup 3 9L 5 2L 5 9L Ram Van Ram Wagon Courtesy of Chrysler Corp Fig 6 Locating Intake Air Temperature IAT Sensor Ram Pickup 8 0L Courtesy of Chrysler Corp...

Page 949: ...ntake manifold Rubber seal gasket is part of the MAP sensor and is not serviceable Inspect rubber seal gasket for damage Replace MAP sensor with rubber seal gasket if gasket is defective 3 To install...

Page 950: ...ressure MAP Sensor Dakota 3 9L 5 2L 5 9L Durango Ram Pickup 3 9L 5 2L 5 9L Ram Van Ram Wagon Courtesy of Chrysler Corp Fig 9 Locating Manifold Absolute Pressure MAP Sensor Ram Pickup 8 0L Courtesy of...

Page 951: ...er s Side Rear Corner Of Cylinder Block Below Distributor 1 Contains a Gray Yellow wire and a Black Light Blue wire in the electrical connector 2 Contains a Gray Orange wire and a Black Light Blue wir...

Page 952: ...QUE SPECIFICATIONS Install electrical connector Add Mopar Plus 7176 ATF as necessary POWER STEERING PRESSURE SWITCH Removal Installation Dakota 2 5L 1 Power steering pressure switch is located in pres...

Page 953: ...retaining bolts for TP sensor to specification See TORQUE SPECIFICATIONS 4 Operate throttle lever on throttle body to ensure no binding exists in TP sensor Install electrical connector and air inlet d...

Page 954: ...TRANSMISSION OVERDRIVE SWITCH NOTE Transmission overdrive switch may also be referred to as overdrive override switch OD switch or overdrive off switch Removal Installation A T Models Transmission ove...

Page 955: ...ated on throttle body and contains a 4 pin electrical connector On Ram Van and Ram Wagon remove engine cover 2 On all models remove air inlet duct or air cleaner assembly for access to IAC motor Disco...

Page 956: ...ION GOVERNOR PRESSURE SOLENOID NOTE Transmission governor pressure solenoid may also be referred to as governor pressure solenoid Removal Installation A T Models Transmission governor pressure solenoi...

Page 957: ...nect camshaft position sensor electrical wiring harness Lift camshaft position sensor from distributor housing 4 To install reverse removal procedure Ensure tab on bottom of camshaft position sensor e...

Page 958: ...sensor is installed camshaft sprocket may have to be rotated to allow high machined area on camshaft sprocket to be aligned with camshaft position sensor mounting hole opening on timing chain cover D...

Page 959: ...any of the original rib material is still present See Fig 16 The rib material was used to position the camshaft position sensor at the correct installation depth when the sensor was originally install...

Page 960: ...reinstalling camshaft position sensor to obtain the correct camshaft position sensor installation depth 8 Remove camshaft position sensor from timing chain cover Remove paper spacer from camshaft end...

Page 961: ...ocating Rib Material On Camshaft Position Sensor Ram Pickup 8 0L Courtesy of Chrysler Corp Fig 17 Placing Scribe Line On Timing Chain Cover Ram Pickup 8 0L Courtesy of Chrysler Corp CRANKSHAFT POSITIO...

Page 962: ...al procedure Tighten crankshaft position sensor retaining bolts and wheel lug nuts to specification See TORQUE SPECIFICATIONS Removal Installation Ram Pickup 3 9L 5 2L 5 9L Ram Van Ram Wagon 1 Cranksh...

Page 963: ...l and tighten crankshaft position sensor retaining bolt to specification See TORQUE SPECIFICATIONS 3 To install remaining components reverse removal procedure Ensure NEW plastic tie is installed throu...

Page 964: ...rical connector for distributor 2 Remove spark plug from cylinder No 1 at timing chain end of engine Rotate crankshaft clockwise viewed from front of engine until cylinder No 1 is at Top Dead Center T...

Page 965: ...ment pin is used to temporarily lock distributor rotor in correct position for cylinder No 1 Plastic alignment pin must be removed after installing distributor Fig 21 Locating Plastic Alignment Pin Da...

Page 966: ...amshaft position sensor from distributor See Fig 13 Rotate distributor shaft and install a 3 16 4 76 mm diameter drift through proper alignment hole in plastic ring and into access hole in bottom of d...

Page 967: ...5 2L 5 9L Ram Van Ram Wagon 1 Disconnect negative battery cable On Ram Van and Ram Wagon remove engine cover On all models remove air cleaner assembly Remove distributor cap Disconnect electrical con...

Page 968: ...YNCHRONIZATION under FUEL SYSTEM in ON VEHICLE ADJUSTMENTS article IGNITION COIL Removal Installation Dakota 2 5L Ignition coil is located on side of engine near distributor Service procedure is prima...

Page 969: ...e or electrical components 1 Remove fuel cap from fuel tank Note location of spring loaded flapper valve inside fuel tank filler tube assembly Flapper valve is located just below the fuel cap area on...

Page 970: ...esidual fuel pressure may exist 9 Diagnostic Trouble Code DTCs may have been stored in Powertrain Control Module PCM due to the removal of fuel pump relay Using scan tool clear DTCs from PCM See appro...

Page 971: ...onnect fitting 3 Inspect components for damage If disconnect fitting is damaged entire assembly must be replaced The only component that may be replaced is the plastic retainer If plastic retainer mus...

Page 972: ...l line fitting Perform STEP 2 See Fig 25 Pull fuel line fitting with fuel line from fuel rail 4 Inspect fuel line fitting components for damage If fuel line fitting components are damaged entire fuel...

Page 973: ...all fuel line fitting on fuel rail 5 Rotate latch clip downward so it snaps into position Ensure latch clip is fully snapped into position If latch clip will not snap into position check for improper...

Page 974: ...ilter fuel pressure regulator Installation 1 Install plastic fuel line with NEW retaining clamp on fuel filter fuel pressure regulator Rotate fuel filter fuel pressure regulator in plastic fuel line u...

Page 975: ...Fig 27 Locating Fuel Pump Module Components Dakota Courtesy of Chrysler Corp Fig 28 Locating Fuel Pump Module Components Durango Courtesy of Chrysler Corp...

Page 976: ...Fig 29 Locating Fuel Pump Module Components Ram Pickup Courtesy of Chrysler Corp Fig 30 Locating Fuel Pump Module Components Ram Van Ram Wagon Courtesy of Chrysler Corp FUEL LEVEL SENSOR...

Page 977: ...erence Remove wires for fuel level sensor from electrical connector for fuel pump and fuel level sensor 5 Note location of notch and locking tab at end of fuel level sensor See Fig 31 Carefully push l...

Page 978: ...ure area around fuel pump module is clean Using Fuel Pump Module Lock Nut Spanner Wrench 6856 remove fuel pump module lock nut See Fig 32 Remove fuel pump module with rubber gasket from fuel tank CAUT...

Page 979: ...el Pump Module Lock Nut Dakota Ram Pickup Ram Van Ram Wagon Courtesy of Chrysler Corp Fig 33 Positioning Fuel Pump Module In Fuel Tank Dakota Courtesy of Chrysler Corp Removal Durango 1 Fuel pump modu...

Page 980: ...TION When fuel pump module is removed from fuel tank rubber gasket must be replaced DO NOT reuse rubber gasket Installation 1 Ensure sealing area on fuel tank is clean Using NEW rubber gasket install...

Page 981: ...ce while tightening fuel pump module lock nut to specification See TORQUE SPECIFICATIONS Reinstall fuel tank using proper procedure Removal Ram Van Ram Wagon 1 Fuel pump module is located on top of fu...

Page 982: ...2 Disconnect fuel line from fuel rail See FUEL LINE AT FUEL RAIL Connect Fuel Hose 6541 6539 6631 or 6923 for proper engine application at fuel line fitting on fuel rail Place remaining end of fuel h...

Page 983: ...l to body screw See Fig 36 Remove the 3 bezel to body screws at the outer circumference of the plastic bezel DO NOT remove fuel tank filler tube assembly to bezel screws Fig 36 Locating Plastic Bezel...

Page 984: ...fuel tank as far as possible See Fig 37 Ensure disconnect fitting is fully pressed onto fuel tank fitting before attempting to push release sleeve into disconnect fitting 11 Push release sleeve upwar...

Page 985: ...container 3 Connect scan tool to Data Link Connector DLC DLC is a 16 pin connector attached to bottom of driver s side of the instrument panel just to the right of the brake pedal Using scan tool manu...

Page 986: ...ghtly rotate fuel tank so vent hose and filler hose on fuel tank are above the fuel level in the fuel tank to prevent fuel leakage when hoses are disconnected Vent hose and filler hose attach to fitti...

Page 987: ...6 If fuel tank was previously drained go to next step If fuel tank was not previously drained siphon fuel from fuel tank into an approved gasoline container by installing siphon hose in small vent ho...

Page 988: ...es at throttle body Remove control cable mounting bracket from intake manifold for access to fuel rail 4 Remove fuel rail bolts Ensure area around injectors and intake manifold is clean Using rocking...

Page 989: ...Ensure all injectors are fully seated 4 Tighten fuel rail bolts and throttle body bolts to specification See TORQUE SPECIFICATIONS Install fuel line on fuel rail using proper procedure See FUEL LINE A...

Page 990: ...all injectors are fully seated 4 Tighten fuel rail bolts to specification See TORQUE SPECIFICATIONS Using NEW gasket install upper intake manifold with all bolts loosely installed Tighten upper intake...

Page 991: ...specification See TORQUE SPECIFICATIONS Removal Installation Ram Pickup 1 Two EVAP canisters are used EVAP canisters are located on mounting bracket attached to outside of passenger s side frame rail...

Page 992: ...n center Unsnap power distribution center from battery tray Carefully position power distribution center aside 5 Remove battery tray Disconnect electrical connector and vacuum hoses at EVAP leak detec...

Page 993: ...emoval Ram Van Ram Wagon 1 EVAP leak detection pump and EVAP leak detection pump filter must be replaced as an assembly EVAP leak detection pump and EVAP leak detection pump filter are located on moun...

Page 994: ...AP Leak Detection Pump Filter EVAP Purge Solenoid Ram Pickup Courtesy of chrusler corp Fig 42 Locating EVAP Leak Detection Pump EVAP Leak Detection Pump Filter EVAP Purge Solenoid Ram Van Ram Wagon Co...

Page 995: ...P purge solenoid is located at driver s side of engine compartment near brake booster See Fig 44 2 On all models disconnect electrical connector and vacuum hoses at EVAP purge solenoid Use care not to...

Page 996: ...41 2 On Ram Van and Ram Wagon EVAP purge solenoid is located at driver s side of engine compartment near the wheelwell See Fig 42 3 On all models disconnect electrical connector and vacuum hoses at E...

Page 997: ...9L 17 23 Throttle Body Nut 8 0L 16 22 Upper Intake Manifold Bolt 8 0L 6 16 22 Upstream Oxygen Sensor 22 30 Wheel Lug Nut Dakota Durango 100 136 INCH Lbs N m Air Cleaner Housing To Throttle Body Nut D...

Page 998: ...CH lbs 8 0 N m 4 Tighten bolts to 100 INCH lbs 11 3 N m 5 Tighten retaining nuts to 60 INCH lbs 6 8 N m 6 Tighten bolts to specification in sequence See 39 7 On ignition coil using only bolts tighten...

Page 999: ...ing Severe conditions are NOT taken into account Frequent short driving less than 5 Miles 8 Km Frequent driving in dusty conditions Frequent trailer towing Extensive idling More than 50 of your drivin...

Page 1000: ...ne oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity...

Page 1001: ...er Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACIT...

Page 1002: ...n With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Mult...

Page 1003: ...age Automatic Transmission Bands Clean Fuel Strainer Adjust Valve Lash Clearance REPLACE Engine Oil Engine Oil Filter Fuel Filter Automatic Transmission Fluid Filter LUBRICATION SPECIFICATIONS Materia...

Page 1004: ...cation 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant Automatic 46RE Dry Fill 17 Qts 16L Transmission Fluid 47RE Dry Fill 17...

Page 1005: ...Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition...

Page 1006: ...W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Et...

Page 1007: ...evel Hoses Clamps SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above...

Page 1008: ...ulated levels Always use dipstick if available to measure level 48 000 MILE 77 000 KM 48 MONTH NORMAL SERVICE 48 000 MILE 77 000 KM 48 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed INSP...

Page 1009: ...lti Mileage Linkage Lubricant Lubricant Automatic All ATF 2 Type 7176 Transmission Fluid Wheel Bearing All High Temperature Multi Grease Purporse EP Grease 1 SAE 10W 30 engine oil is preferred Use onl...

Page 1010: ...1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50...

Page 1011: ...ERVICE Rotate Tires Lubricate Steering Linkage Clean Fuel Strainer REPLACE Engine Oil Engine Oil Filter Engine Coolant Fuel Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oi...

Page 1012: ...ipstick if available to measure level 66 000 MILE 106 000 KM 66 MONTH NORMAL SERVICE 66 000 MILE 106 000 KM 66 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake...

Page 1013: ...fication 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick...

Page 1014: ...0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethyle...

Page 1015: ...NORMAL SERVICE 78 000 MILE 125 000 KM 78 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Rotate Tires Lubricat...

Page 1016: ...10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 84 000 MILE 134...

Page 1017: ...ar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Up...

Page 1018: ...Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API...

Page 1019: ...gine Oil Filter Automatic Transmission Fluid Filter Fuel Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C...

Page 1020: ...ned 26 Qts 24 5L Coolant Automatic 46RE Dry Fill 17 Qts 16L Transmission Fluid 47RE Dry Fill 17 Qts 16L 1 Capacities are recommended or calculated levels Always use dipstick if available to measure le...

Page 1021: ...10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9...

Page 1022: ...Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Milea...

Page 1023: ...RICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C...

Page 1024: ...SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Front Wheel Bearings 4x2 SERVICE Rotate Tires Lubricate Steering Linkage Automatic...

Page 1025: ...S Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant Automatic 46RE Dry Fill 17 Qts 16L Transmission...

Page 1026: ...Axle SAE 80W 90 Lubricant GL 5 Gear Lube Power All Mopar Power Steering Steering Fluid Or Equivalant Fluid 3 Petroleum Based Clutch All Multipurpose Grease Linkage NLGI Grade 2 E P Lubricant A C All...

Page 1027: ...xle Model 267 2WD 7 Pts 3 3L Limited Slip Differential Model 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Front Axle Model 248 7 6 Pts 3 6L Lubricant Transfer Case NV241...

Page 1028: ...ck fluid levels of coolant reservoir brake master cylinder power steering transmission Add fluids as required Once a month check all lights and all other electrical items for correct operation Once a...

Page 1029: ...re based on normal vehicle usage ONLY The following Severe conditions are NOT taken into account Frequent short driving less than 5 Miles 8 Km Frequent driving in dusty conditions Frequent trailer tow...

Page 1030: ...approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 3 9L Drained W New Filter 4 Qts 3 8L 5 2L Drained W New Filter 5 Qts 4 7L 5 9L Drained W New Filter 5 Qts...

Page 1031: ...eage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 3 9L Drained W New Filt...

Page 1032: ...ICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 5...

Page 1033: ...ure level 30 000 MILE 48 000 KM 24 MONTH NORMAL SERVICE 30 000 MILE 48 000 KM 24 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Ho...

Page 1034: ...Drained W New Filter 5 Qts 4 7L 3 9L Drained 3 5 Qts 3 3L 5 2L Drained 4 5 Qts 4 2L 5 9L Drained 4 5 Qts 4 2L Engine 3 9L Drained 20 Qts 19L Coolant 5 2L Drained 20 Qts 19L 5 9L Drained 20 Qts 19L 1 C...

Page 1035: ...er Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Automatic All ATF 2 Type 7176 Transmission Fluid Transfer Case All ATF 2 Type 7176 Fluid Or DEXRON...

Page 1036: ...jor Service Was Performed INSPECT Exhaust System Brake Hoses Front Wheel Bearing 4x2 Brake Linings SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter Engine Coolant L...

Page 1037: ...L 5 9L Drained 4 5 Qts 4 2L Engine 3 9L Drained 20 Qts 19L Coolant 5 2L Drained 20 Qts 19L 5 9L Drained 20 Qts 19L 1 Capacities are recommended or calculated levels Always use dipstick if available to...

Page 1038: ...il with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 3 9L Drained W New Filter 4 Qts 3 8L 5 2L Drained W New Filter 5 Qts 4 7L 5 9L Drained W New Filter 5 Qts 4 7L 3 9L...

Page 1039: ...perature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubri...

Page 1040: ...el Hoses Clamps Front Wheel Bearings 4x2 Brake Linings SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil 1 1 If mileage is less than 7 500 miles 12 000 KM yearly replace the oil filte...

Page 1041: ...rained 4 5 Qts 4 2L 5 9L Drained 4 5 Qts 4 2L Engine 3 9L Drained 20 Qts 19L Coolant 5 2L Drained 20 Qts 19L 5 9L Drained 20 Qts 19L 1 Capacities are recommended or calculated levels Always use dipsti...

Page 1042: ...smission Fluid Transfer Case All ATF 2 Type 7176 Fluid Or DEXRON III ATF 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specificat...

Page 1043: ...cate Steering Linkage REPLACE Engine Oil 1 1 If mileage is less than 7 500 miles 12 000 KM yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification...

Page 1044: ...ained 20 Qts 19L 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 90 000 MILE 144 000 KM 72 MONTH NORMAL SERVICE 90 000 MILE 144 000 KM 72 MONTH NORM...

Page 1045: ...only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 3 9L Drained W New Filter 4 Qts 3 8L 5 2L Drained W New Filter 5 Qts 4 7L 5 9L Drained W New Filt...

Page 1046: ...F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is...

Page 1047: ...LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0...

Page 1048: ...MONTH NORMAL SERVICE 112 500 MILE 180 000 KM 90 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Front Wheel Bearings...

Page 1049: ...C LB 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 3 9L Drained W New Filter 4 Qts 3 8L 5 2L Drained W...

Page 1050: ...r Spark Plugs Ignition Cables LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SA...

Page 1051: ...ial Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of C...

Page 1052: ...Modifier 3 Never add gear oil automatic transmission fluid or hydroboost power steering fluid FLUID CAPACITIES FLUID CAPACITIES TABLE Item Condition Specification 1 Engine Oil 3 9L Drained W New Filte...

Page 1053: ...er Power Drained 2 7 Pts 1 3L Steering Fluid A C Charge Capacity 32 Oz 9Kg Refrigerant Refrigerant A C System Capacity 7 75 Oz 230ML Oil Fuel Tank 119 139 Wheelbase Vehicles 26 Gal 98L All Others 35 G...

Page 1054: ...efined as any one of the following conditions Frequent short driving less than 5 Miles 8 16 Km Frequent driving in dusty conditions Frequent trailer towing Extensive idling More than 50 of your drivin...

Page 1055: ...Dodge trucks Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine...

Page 1056: ...All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specificati...

Page 1057: ...ke Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID C...

Page 1058: ...40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater...

Page 1059: ...Rear Axle DANA 70 Model 267 2WD 7 Pts 3 3L Lubricant DANA 70 Model 267 4WD 7 8 Pts 3 6L DANA 80 Model 286 2WD 6 8 Pts 3 2L DANA 80 Model 286 4WD 10 1 Pts 4 8L Rear Axle Model 267 2WD 7 Pts 3 3L Limit...

Page 1060: ...Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approve...

Page 1061: ...SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled W...

Page 1062: ...ial Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Tha...

Page 1063: ...0 MILE 38 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Front Wheel Bearings 4x2 Fan Hub Damper Water Pump Wee...

Page 1064: ...7176 Transmission Fluid Rear Axle All Mopar Hypoid Lubricant Lubricant SAE 80W 90 2 GL 5 Gear Lube 4x4 Front All Mopar Hypoid Lubricant Axle SAE 80W 90 Lubricant GL 5 Gear Lube Wheel Bearing All High...

Page 1065: ...ays use dipstick if available to measure level 27 000 MILE 43 000 KM SEVERE DUTY SERVICE 27 000 MILE 43 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake...

Page 1066: ...Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick if available to m...

Page 1067: ...eering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine O...

Page 1068: ...ater Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with...

Page 1069: ...Case Fluid Fuel Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30...

Page 1070: ...ty Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant Automatic 46RE Dry Fill 17 Qts 16L Transmission Fluid 47RE Dry Fill 17 Qts 16L Rear Axle DANA 70...

Page 1071: ...er 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine...

Page 1072: ...Tires Lubricate Steering Linkage Clean Fuel Strainer REPLACE Engine Oil Engine Oil Filter Fuel Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above...

Page 1073: ...easure level 45 000 MILE 72 000 KM SEVERE DUTY SERVICE 45 000 MILE 72 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses C...

Page 1074: ...Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 48 00...

Page 1075: ...0 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Automatic All ATF 2 Type 7176 Transmission Flui...

Page 1076: ...Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Rear Axle Model 248 2WD 6 3 Pts 3L Limited Slip Differential Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Mode...

Page 1077: ...0 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks...

Page 1078: ...Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture...

Page 1079: ...ine Oil Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18...

Page 1080: ...VICE 60 000 MILE 96 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Water Pump Weep Hole For Brockage Brake Lini...

Page 1081: ...80W 90 2 GL 5 Gear Lube 4x4 Front All Mopar Hypoid Lubricant Axle SAE 80W 90 Lubricant GL 5 Gear Lube 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol 2 Axles with...

Page 1082: ...Always use dipstick if available to measure level 63 000 MILE 101 000 KM SEVERE DUTY SERVICE 63 000 MILE 101 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System B...

Page 1083: ...tem Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels...

Page 1084: ...3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Eng...

Page 1085: ...lled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil...

Page 1086: ...Automatic Transmission Fluid Filter Rear Axle Fluid Front Axle Fluid 4x4 Transfer Case Fluid LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE...

Page 1087: ...n Modifier such as Mopar Gear Oil Additive Friction Modifier FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine...

Page 1088: ...VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter LUBRICATION SPECIFI...

Page 1089: ...Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 78 000 MILE 130 000 KM SEVERE DUTY SERVICE 78 000 MILE 130 000 KM SEVERE DUTY SERV...

Page 1090: ...ly API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5...

Page 1091: ...ng All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil C...

Page 1092: ...40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater...

Page 1093: ...nsmission Fluid 47RE Dry Fill 17 Qts 16L Rear Axle 9 1 4 Drained 4 8 Pts 2 3L Fluid Model 248 2WD 6 3 Pts 3L Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Model 286 2W...

Page 1094: ...ure Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering Al...

Page 1095: ...BRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1...

Page 1096: ...ERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter LUBRICATION...

Page 1097: ...ned 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 96 000 MILE 160 000 KM SEVERE DUTY SERVICE 96 000 MILE 160 000 KM SEVERE DU...

Page 1098: ...Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Wheel Bearing All High Temperature Multi Grease Purporse EP Grease Automatic All ATF 2 Type 7176 Transmission Fluid Rear A...

Page 1099: ...mited Slip Differential Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Front Axle Model 216 6 8 Pts 3 6L Lubrican...

Page 1100: ...rake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID...

Page 1101: ...ith Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi M...

Page 1102: ...Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engi...

Page 1103: ...SPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Brake Linings Drive Belts Water Pump Weep Hole For Blockage SERVICE Rotate Tires Lubricate Steering Linkage Automatic Transmission Ba...

Page 1104: ...ATF Rear Axle All Mopar Hypoid Lubricant Lubricant SAE 80W 90 2 GL 5 Gear Lube 4x4 Front All Mopar Hypoid Lubricant Axle SAE 80W 90 Lubricant GL 5 Gear Lube 1 SAE 10W 30 engine oil is preferred Use on...

Page 1105: ...8 Pts 3 6L Lubricant Model 248 7 6 Pts 3 6L Transfer Case NV241 5 Pts 2 7L Fluid NV241 HD 6 5 Pts 3 5L NV241 HD W PTO 9 Pts 4 9L 1 Capacities are recommended or calculated levels Always use dipstick...

Page 1106: ...Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe...

Page 1107: ...ater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferr...

Page 1108: ...Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mo...

Page 1109: ...ands Clean Fuel Strainer REPLACE Engine Oil Engine Oil Filter Automatic Transmission Fluid Filter Rear Axle Fluid Front Axle Fluid 4x4 Fuel Filter LUBRICATION SPECIFICATIONS Material Condition Specifi...

Page 1110: ...ction Modifier such as Mopar Gear Oil Additive Friction Modifier FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Eng...

Page 1111: ...Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Aut...

Page 1112: ...ission fluid or hydroboost power steering fluid FLUID CAPACITIES FLUID CAPACITIES TABLE Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7...

Page 1113: ...f available to measure level MISCELLANEOUS NOTES Once a month check tire pressure and look for unusual wear or damage Once a month inspect battery and clean and tighten terminals as required Once a mo...

Page 1114: ...aintenance services in this article are based on Severe Duty vehicle usage ONLY Severe Duty vehicle usage is defined as any one of the following conditions Frequent short driving less than 5 Miles 8 1...

Page 1115: ...ileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engi...

Page 1116: ...All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID CAPACITIE...

Page 1117: ...re Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use on...

Page 1118: ...Yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Tem...

Page 1119: ...ry Fill 17 26 Pts 8 12 3L Transmission Fluid 47RE Dry Fill 17 33 Pts 8 15 6L Rear Axle 9 1 4 Drained 4 8 Pts 2 3L Fluid Model 248 2WD 6 3 Pts 3L Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Mod...

Page 1120: ...TION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engi...

Page 1121: ...ne Oil Filter 1 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000 miles 9 600 Km Yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Con...

Page 1122: ...t Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter 1 1 8 0L Change...

Page 1123: ...Drained 20 Qts 19L Coolant 8 0L Drained 24 Qts 22 7L 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 24 000 MILE 38 000 KM SEVERE DUTY SERVICE 24 0...

Page 1124: ...Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Automatic All ATF 2 Type 7176 Transmission Fluid Rear Axle All Mopar Hypoid Lubricant Lubricant SAE 80W 90 2 GL 5 Gea...

Page 1125: ...le Model 248 2WD 6 3 Pts 3L Limited Slip Differential Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Front Axle M...

Page 1126: ...stilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FL...

Page 1127: ...30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mo...

Page 1128: ...eage is less than 6 000 miles 9 600 Km Yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30...

Page 1129: ...VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Brake Linings Engine Air Cleaner Air Pump Filters SERVICE Lubricate Steering Linkage Autom...

Page 1130: ...opar Hypoid Lubricant Axle SAE 80W 90 Lubricant GL 5 Gear Lube 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol 2 Axles with Limited Slip Differentials require the...

Page 1131: ...8L Front Axle Model 216 6 8 Pts 3 6L Lubricant Model 248 7 6 Pts 3 6L 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 39 000 MILE 62 000 KM SEVERE D...

Page 1132: ...oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New Filter 5 Qts 4 7L 8 0L Drained W New Filter 5 Qts 4 7L 5...

Page 1133: ...Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES...

Page 1134: ...8 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage...

Page 1135: ...e Coolant Engine Air Cleaner Air Pump Filters Automatic Transmission Fluid Filter Rear Axle Fluid Front Axle Fluid 4x4 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000 m...

Page 1136: ...f a 5 Friction Modifier such as Mopar Gear Oil Additive Friction Modifier FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New Filter 5 Qts 4 7L 8 0L Drained W New Filter 5 Qt...

Page 1137: ...haust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter 1 1 8 0L Change oil filter at every oil change 5 9L If m...

Page 1138: ...ted levels Always use dipstick if available to measure level 54 000 MILE 86 000 KM SEVERE DUTY SERVICE 54 000 MILE 86 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust...

Page 1139: ...ine Oil 5 9L Drained W New Filter 5 Qts 4 7L 8 0L Drained W New Filter 5 Qts 4 7L 5 9L Drained 4 5 Qts 4 2L Engine 5 9L Drained 20 Qts 19L Coolant 8 0L Drained 24 Qts 22 7L 1 Capacities are recommende...

Page 1140: ...ge Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New Filter...

Page 1141: ...mileage is less than 6 000 miles 9 600 Km Yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W...

Page 1142: ...9L Drained 20 Qts 19L Coolant 8 0L Drained 24 Qts 22 7L Automatic 47RE Dry Fill 17 33 Pts 8 15 6L Transmission Fluid Rear Axle 9 1 4 Drained 4 8 Pts 2 3L Fluid Model 248 2WD 6 3 Pts 3L Model 248 4WD 7...

Page 1143: ...ly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperat...

Page 1144: ...oolant Level Hoses Clamps SERVICE Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter 1 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000 miles 9 600 Km Yearl...

Page 1145: ...E 110 000 KM SEVERE DUTY SERVICE 69 000 MILE 110 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Rotate...

Page 1146: ...5 Qts 4 7L 5 9L Drained 4 5 Qts 4 2L Engine 5 9L Drained 20 Qts 19L Coolant 8 0L Drained 24 Qts 22 7L 1 Capacities are recommended or calculated levels Always use dipstick if available to measure lev...

Page 1147: ...C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Automatic All ATF 2 Type 7176 Tr...

Page 1148: ...3 2L Model 286 4WD 10 1 Pts 4 8L Rear Axle Model 248 2WD 6 3 Pts 3L Limited Slip Differential Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L...

Page 1149: ...F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Link...

Page 1150: ...oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C...

Page 1151: ...SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter 1 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000 miles 9 600 Km Yearly replace th...

Page 1152: ...M 82 MONTH NORMAL SERVICE 82 500 MILE 132 000 KM 82 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed REPLACE Oxygen Sensor 5 9L Only 1 1 Requires service reminder indicator light If so equ...

Page 1153: ...5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Automatic All ATF...

Page 1154: ...del 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Rear Axle Model 248 2WD 6 3 Pts 3L Limited Slip Differential Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 2...

Page 1155: ...ent Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubrican...

Page 1156: ...Km Yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient T...

Page 1157: ...ngine Coolant Level Hoses Clamps SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter 1 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000...

Page 1158: ...1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 96 000 MILE 154 000 KM SEVERE DUTY SERVICE 96 000 MILE 154 000 KM SEVERE DUTY SERVICE VERIFY Last Ma...

Page 1159: ...age Lubricant Lubricant Wheel Bearing All High Temperature Multi Grease Purporse EP Grease Automatic All ATF 2 Type 7176 Transmission Fluid Rear Axle All Mopar Hypoid Lubricant Lubricant SAE 80W 90 2...

Page 1160: ...7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Front Axle Model 216 6 8 Pts 3 6L Lubricant Model 248 7 6 Pts 3 6L 1 Capacities...

Page 1161: ...ke Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Spe...

Page 1162: ...0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use onl...

Page 1163: ...pecification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distille...

Page 1164: ...Automatic Transmission Bands REPLACE Engine Oil Engine Oil Filter Automatic Transmission Fluid Filter Transfer Case Fluid Rear Axle Fluid Front Axle Fluid 4x4 Engine Coolant 1 8 0L Change oil filter...

Page 1165: ...th Limited Slip Differentials require the use of a 5 Friction Modifier such as Mopar Gear Oil Additive Friction Modifier FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New F...

Page 1166: ...to measure level 111 000 MILE 185 000 KM SEVERE DUTY SERVICE 111 000 MILE 185 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level...

Page 1167: ...ed W New Filter 5 Qts 4 7L 8 0L Drained W New Filter 5 Qts 4 7L 5 9L Drained 4 5 Qts 4 2L Engine 5 9L Drained 20 Qts 19L Coolant 8 0L Drained 24 Qts 22 7L 1 Capacities are recommended or calculated le...

Page 1168: ...Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New Filter 5 Qts 4 7...

Page 1169: ...olant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst S...

Page 1170: ...uid 4x4 Spark Plugs Ignition Cables PCV Valve 5 9L EGR Valve 5 9L Distributor Cap Rotor 5 9L 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000 miles 9 600 Km Yearly repla...

Page 1171: ...ive Friction Modifier FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New Filter 5 Qts 4 7L 8 0L Drained W New Filter 5 Qts 4 7L 5 9L Drained 4 5 Qts 4 2L Engine 5 9L Drained...

Page 1172: ...Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Automatic All ATF 2 Type 7176 Transmission Fluid Transfer Case All ATF 2 Type 7176 Fluid Or DEXRON III ATF Manual NV 4500 All...

Page 1173: ...ar Oil Additive Friction Modifier 3 Never add gear oil automatic transmission fluid or hydroboost power steering fluid FLUID CAPACITIES FLUID CAPACITIES TABLE Item Condition Specification 1 Engine Oil...

Page 1174: ...t Refrigerant A C System Capacity 7 75 Oz 230ML Oil Fuel Tank 119 139 Wheelbase Vehicles 26 Gal 98L All Others 35 Gal 132L 1 Capacities are recommended or calculated levels Always use dipstick if avai...

Page 1175: ...roup 34 500 60 3 3L Group 34 500 60 3 8L Std Battery Group 34 600 66 Opt Battery Group 34 685 72 Dakota Durango Std Battery Group 27 600 66 Opt Battery Group 27 750 75 Ram Pickup 3 9L 5 2L 5 9L Gasoli...

Page 1176: ...line filler door 3 Quantity includes heater and coolant recovery tank Add 2 qts 1 9L if equipped with rear heater 4 Add this amount of fluid Start engine and shift transaxle through all gears and back...

Page 1177: ...type of transmission used before servicing The AX 15 uses a flywheel housing bolted to the front of the transmission The NV 3500 uses a flywheel housing which is an integral part of the transmission h...

Page 1178: ...entified by model number stamped on identification tag on rear of transfer case just above filler plug FLUID CAPACITIES RAM PICKUP Application 1 Quantity Crankcase Includes Filter 2 3 9L 4 0 Qts 3 8L...

Page 1179: ...of transmission used before servicing The NV 3500 uses a flywheel housing which is an integral part of the transmission housing The NV 4500 uses a flywheel housing which is bolted to the front of the...

Page 1180: ...temperature Adjust fluid level to MAX mark on dipstick Approximate drain and refill capacity is 4 0 qts 3 8L 4 Quantity may vary by type of oil cooler and oil cooler lines 5 Use only Mopar power stee...

Page 1181: ...vere service Severe service is described as use of ethanol fuel frequent short trip operation of less than 5 miles long periods of engine idling trailer towing police taxi local delivery service or op...

Page 1182: ...ck Front Wheel Bearings Normal Service 18 22 500 Severe Service 2 21 000 1 Different interval may be required for normal and severe service Severe service is described as long periods of engine idling...

Page 1183: ...and severe service Severe service is described as long periods of engine idling frequent short trip operation of less than 5 miles trailer towing off highway operation snow removal operation or opera...

Page 1184: ...described as long periods of engine idling frequent short trip operation of less than 5 miles trailer towing off highway operation snow removal operation or operating in dusty or excessively hot condi...

Page 1185: ...or operating in dusty or excessively hot conditions 3 Monthly interval is not available from manufacturer 4 Inspect air filter every 15 000 miles and replace as necessary Replace at 30 000 miles unle...

Page 1186: ...o 2500 and 3500 Federal models with 8 0L engine and all 3500 models with 5 9L gasoline engine 2 Different interval may be required for normal and severe service Severe service is described as long per...

Page 1187: ...requent short trip operation of less than 5 miles trailer towing off highway operation snow removal operation or operating in dusty or excessively hot conditions 2 Service interval is not available fr...

Page 1188: ...om manufacturer 3 Inspect air filter every 15 000 miles and replace as necessary Replace at 30 000 miles unless previously replaced during inspection 4 Replace coolant at 45 000 miles or 36 months whi...

Page 1189: ...at ignition coil to prevent engine from starting Check engine compression with all spark plugs removed and throttle wide open COMPRESSION SPECIFICATIONS Application Specification Compression Ratio Car...

Page 1190: ...c lifters No adjustments are required 5 9L Diesel Ram Pickup Valve adjustment is recommended every 150 months or 150 000 miles during normal service every 135 000 miles during severe service Severe se...

Page 1191: ...ation is not available from manufacturer HIGH TENSION WIRE RESISTANCE HIGH TENSION WIRE RESISTANCE Application Ohms Caravan 1 2 4L Cylinder No 1 Or 4 4200 Cylinder No 2 Or 3 3200 3 0L Cylinder No 1 14...

Page 1192: ...ms per one inch or 3000 12 000 ohms per 12 inches SPARK PLUGS SPARK PLUG TYPE 1 Application Champion No Caravan 2 4L RC12YC5 3 0L RN11YC4 3 3L 3 8L RN14PMP5 Dakota 2 5L RC12ECC 3 9L 5 2L 5 9L RC12LC4...

Page 1193: ...y 048 053 1 22 1 35 20 27 Voyager 2 4L 048 053 1 22 1 35 20 27 3 0L 039 044 1 00 1 12 20 27 3 3L 048 053 1 22 1 35 20 27 1 Check spark plug gap specification on underhood vehicle emission control labe...

Page 1194: ...Fig 2 Firing Order Distributor Rotation 2 5L 4 Cyl Dakota...

Page 1195: ...Fig 3 Firing Order Distributor Rotation 3 0L V6 Caravan Voyager Fig 4 Firing Order 3 3L 3 8L V6 Caravan Town Country Voyager...

Page 1196: ...Fig 5 Firing Order Distributor Rotation 3 9L V6 Dakota Durango Ram Pickup Ram Van Ram Wagon...

Page 1197: ...Fig 6 Firing Order Distributor Rotation 5 2L 5 9L Gasoline V8 Dakota Durango Ram Pickup Ram Van Ram Wagon Fig 7 Firing Order 5 9L Diesel 6 Cyl Ram Pickup...

Page 1198: ...NOT attempt to adjust ignition timing NOTE On Dakota 3 9L 5 2L and 5 9L Durango Ram Pickup 3 9L 5 2L and 5 9L gasoline Ram Van and Ram Wagon the distributor can be checked for proper location See FUEL...

Page 1199: ...th engine off ignition on and using scan tool to activate fuel pump 3 Information is not available from manufacturer FUEL INJECTION PUMP FUEL TRANSFER PUMP DIESEL NOTE For fuel injection pump timing s...

Page 1200: ...Miles Or Less 3 560 910 More Than 1000 Miles 3 610 910 3 3L 3 8L 2 1000 Miles Or Less 3 525 875 More Than 1000 Miles 3 575 875 Dakota 2 5L 500 900 3 9L 5 2L 5 9L 1 500 900 Durango 1 500 900 Ram Pickup...

Page 1201: ...8 0L 1 2 At Idle 35 90 At Full Throttle Less Than 4 50 5 9L Diesel 3 Ram Van Ram Wagon 1 2 At Idle 35 90 At Full Throttle Less Than 4 50 1 Measure voltage at center terminal on throttle position senso...

Page 1202: ...moves forward and backward TROUBLE SHOOTING NOTE Before any testing is attempted the battery should be fully charged and all connections and terminals cleaned and tightened to ensure proper continuity...

Page 1203: ...and retest system 3 Remove power seat switch See POWER SEAT SWITCH under REMOVAL INSTALLATION Check for battery voltage at power supply Red wire on Ram Van and Ram Wagon Red Light Blue wire on Ram Pi...

Page 1204: ...B E B K B L Vertical Up A E A M B N B J Vertical Down A J A N B M B E Horizontal Forward B K A L Horizontal Aft B L A K Front Tilt Up B N A M Front Tilt Down A N B M Rear Tilt Up A E B J Rear Tilt Dow...

Page 1205: ...under seat Remove 4 nuts attaching seat frame to floor pan The rear nuts are accessed by lifting up the seat riser rear shield Remove seat from vehicle To install reverse removal procedure Tighten se...

Page 1206: ...nector and disconnect connector Remove 2 screws holding switch to shield Remove switch from shield To install reverse removal procedure Removal Installation Ram Van Ram Wagon Remove seat adjuster and...

Page 1207: ...Fig 3 Power Seat System Wiring Diagram Ram Pickup...

Page 1208: ...Fig 4 Power Seat System Wiring Diagram Ram Van Ram Wagon...

Page 1209: ...using Starter has serviceable gear and clutch assembly only If starter solenoid fails entire starter motor must be replaced All models use a starter relay in starter circuit between the battery and st...

Page 1210: ...KING TEST NOTE Ensure engine is at normal operating temperature High viscosity oil extreme cold temperatures or tight engine will increase amperage draw 1 Using a battery load tester connect positive...

Page 1211: ...starter solenoid or replace positive battery cable SOLENOID CIRCUIT TEST NOTE Perform SOLENOID CIRCUIT TEST before testing starter relay and starter relay circuit Ensure A T is in Park position or M...

Page 1212: ...Fig 1 Identifying Starter Relay Terminals Except Concorde Dakota Durango Intrepid LHS Ram Van Ram Wagon 300M Courtesy of Chrysler Corp...

Page 1213: ...Fig 2 Identifying Starter Relay Terminals Concorde Dakota Durango Intrepid LHS Ram Van Ram Wagon 300M Courtesy of Chrysler Corp...

Page 1214: ...switch See CLUTCH POSITION SWITCH TEST If battery voltage is not present repair wiring between ignition switch and starter relay socket as necessary 6 On M T models connect voltmeter negative lead to...

Page 1215: ...ITCH TEST NOTE For ignition switch testing procedures see appropriate STEERING COLUMN SWITCHES article in ACCESSORIES EQUIPMENT BENCH TESTING SOLENOID TEST 1 With starter removed from vehicle remove s...

Page 1216: ...Gasoline Engines 125 250 Amps Ram Van Ram Wagon 125 250 Amps No Load Test At 11 Volts Maximum Amps Caravan Town Country Voyager 73 Amps Dakota Durango 2 5L 90 Amps 3 9L 5 2L 5 9L 73 Amps Ram Pickup Ga...

Page 1217: ...n Ft Lbs N m Starter Mounting Bolts Nuts All Except Dakota Durango Ram Pickup Ram Van Ram Wagon 40 54 Dakota Durango 2 5L 33 45 3 9L 5 2L 5 9L 50 68 Ram Pickup Diesel Engines 32 43 Gasoline Engines 50...

Page 1218: ...Fig 3 Starting System Wiring Diagram Breeze Cirrus Stratus...

Page 1219: ...Fig 4 Starting System Wiring Diagram Caravan Town Country Voyager...

Page 1220: ...Fig 5 Starting System Wiring Diagram Concorde Intrepid LHS 300M...

Page 1221: ...Fig 6 Starting System Wiring Diagram Dakota...

Page 1222: ...Fig 7 Starting System Wiring Diagram Durango...

Page 1223: ...Fig 8 Starting System Wiring Diagram Neon...

Page 1224: ...Fig 9 Starting System Wiring Diagram Ram Pickup...

Page 1225: ...Fig 10 Starting System Wiring Diagram Ram Van Ram Wagon...

Page 1226: ...Fig 11 Starting System Wiring Diagram Sebring Convertible...

Page 1227: ...ounting bracket bolts must be carefully torqued to ensure proper sensor operation Never apply power to ABRS if a sensor is not rigidly attached to vehicle To avoid accidental air bag deployment while...

Page 1228: ...screws Disconnect horn wires Remove horn switch 3 Remove steering wheel retaining nut Reference mark steering wheel and steering shaft Using puller remove steering wheel To install reverse removal pro...

Page 1229: ...ig 1 Exploded View Of Steering Column Typical Courtesy of Chrysler Corp OVERHAUL NOTE Steering column is not serviceable except for trim switches and steering wheel If service is required replace colu...

Page 1230: ...ndshield wash systems use a common switch assembly multifunction switch mounted within upper steering column housing Ignition switch and lock cylinder are incorporated into an assembly attached to sid...

Page 1231: ...ire to turn signal switch Faulty switch connections Open or grounded circuit in wiring to external lights Turn Signal Inoperative One Side Faulty external bulb Poor ground at external light Open circu...

Page 1232: ...Corp IGNITION SWITCH NOTE For ignition switch circuit identification see IGNITION SWITCH CIRCUIT FUNCTIONS table Remove ignition switch See IGNITION SWITCH under REMOVAL INSTALLATION Check continuity...

Page 1233: ...of Chrysler Corp MULTIFUNCTION SWITCH Turn Signal Hazard Warning Switch Disconnect negative battery cable Remove multifunction switch See MULTIFUNCTION SWITCH under REMOVAL INSTALLATION Check continui...

Page 1234: ...relay from Power Distribution Center PDC Measure voltage between ground and horn relay terminals No 30 and 86 in PDC See Fig 4 If battery voltage exists at both terminals go to next step If battery v...

Page 1235: ...If continuity exists go to next step If continuity does not exist check for proper installation of steering column mounting nuts 2 Disable air bag system and remove driver s air bag module See appropr...

Page 1236: ...er fuse is blown repair short circuit and replace fuse 5 Check for battery voltage at hazard warning fuse in PDC Turn ignition on Check for battery voltage at turn signal fuse in junction block If bat...

Page 1237: ...Dakota and Durango is not provided by manufacturer Removal Installation Disconnect negative battery cable Remove 4 air bag nuts from back of steering wheel Pull air bag module back far enough to disc...

Page 1238: ...rk lock dowel and park lock slider linkage See Fig 6 Slide park lock slider linkage forward completely then back 25 6 mm Apply a light coating of grease to column lock flag 4 Carefully install ignitio...

Page 1239: ...cylinder turn lock cylinder to RUN position so retaining pin can be depressed Install lock cylinder in ignition switch aligning slot until retaining pin engages Turn key to OFF or LOCK position Pull...

Page 1240: ...cable On tilt columns remove tilt lever On all models remove upper and lower steering column covers Remove tamper proof Torx screws Pull switch away from column and loosen connector screw screw remai...

Page 1241: ...Lbs N m Air Bag Retaining Nuts 90 97 9 11 Ignition Switch Mounting Screw 22 30 2 5 3 5 Multifunction Switch Connector Screw 17 2 Multifunction Switch Mounting Screw 17 2 Steering Column Cover Screw 1...

Page 1242: ...Fig 10 Horn System Wiring Diagram Durango...

Page 1243: ...Fig 11 Horn System Wiring Diagram Ram Pickup...

Page 1244: ...onents with solvent and dry with compressed air Inspect all parts for burrs chips wear flat spots or cracks Replace all damaged or worn parts INSTALLATION NOTE When aligning upper ball joint nut to in...

Page 1245: ...en lug nuts to specification TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application 1 Ft Lbs N m ABS Sensor Bolt 15 11 Brake Caliper Bolt 38 52 Drag Link Nut 65 88 Hub To Steering Knuckle Bolt 125 16...

Page 1246: ...d rack piston See Fig 1 When worm shaft is turned the rack piston moves and piston teeth mesh with sector shaft teeth turning pitman arm which turns steering linkage The steering linkage consists of p...

Page 1247: ...pen shutoff valve on test gauge With a thermometer in fluid reservoir start engine and warm fluid to 150 170 F 66 77 C Turning wheels from stop to stop will aid in warming fluid DO NOT hold wheels aga...

Page 1248: ...auge and connect pressure hose LUBRICATION CAPACITY CAPACITY Models Pts L Dakota 4WD 2 5 1 2 Ram Pickup Ram Van Wagon 2 7 1 3 FLUID TYPE CAUTION DO NOT use Automatic Transmission Fluid ATF Use Mopar P...

Page 1249: ...djustments 1 Remove steering gear from vehicle See STEERING GEAR under REMOVAL INSTALLATION Ensure steering gear is empty of hydraulic fluid Rotate steering from stop to stop several times to drain fl...

Page 1250: ...stub shaft and count turns required to go from stop to stop Turn stub shaft back 1 2 number of turns to center steering gear Fig 4 Adjusting Over Center Preload Courtesy of Chrysler Corp 2 Rotate sect...

Page 1251: ...G under LUBRICATION VACUUM POWER STEERING PUMP DIESEL Removal 1 Disconnect negative battery cable Place drip pan under vacuum power steering pump Disconnect and cap power brake booster hose at vacuum...

Page 1252: ...ical connector Install oil feed line to vacuum pump and tighten to 60 INCH lbs 7 N m To complete installation reverse removal procedure Fill and bleed system See HYDRAULIC SYSTEM BLEEDING under LUBRIC...

Page 1253: ...e removing parts Remove 2 studs and fitting from back of pump See Fig 7 2 Rock reservoir by hand or tap with soft face mallet to remove Remove O ring from housing and reservoir Remove flow control val...

Page 1254: ...N m Tighten nuts and bolts to specification See TORQUE SPECIFICATIONS Add power steering fluid DO NOT use ATF Bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION Fig 7 Exploded View...

Page 1255: ...vehicle Place wheels in straight ahead position Disconnect steering linkage center link from pitman arm Disconnect stabilizer bar if necessary 2 Place reference mark on pitman arm and sector shaft Re...

Page 1256: ...t 3 minutes DO NOT turn wheels during this time Rotate wheels both directions and check for leaks Refill pump reservoir CENTER LINK Removal Installation Separate tie rods idler arm steering and drag l...

Page 1257: ...Removal Remove cotter pin and nut from tie rod end Using Tie Rod End Puller C 3894 A remove tie rod end from steering knuckle or center link Loosen lock nut or clamp bolt Remove tie rod end Note numb...

Page 1258: ...ing Studs 35 47 Pitman Arm Nut 1 185 251 Sector Shaft Adjuster Screw Lock Nut 20 27 Dakota 4WD Ram Van Wagon 20 27 Ram Pickup 43 58 Steering Gear Housing To Frame Bolt Dakota 4WD 65 88 Ram Pickup 140...

Page 1259: ...SION MODULES AIR RIDE SUSPENSION RELAYS COMPRESSOR AIR RIDE SUSPENSION SWITCHES ON OFF AIR RIDE SUSPENSION TORSION SPRINGS COUNTER BALANCING AIR RIDE SUSPENSION TUBING AIR RIDE SUSPENSION WARNING LAMP...

Page 1260: ...o the customer according to industry standards Given that the industry did not have such standards the Motorist Assurance Program successfully promulgated industry inspection communication standards i...

Page 1261: ...ts of this inspection must be explained to the customer and documented on an inspection form The condition of the vehicle and its components will indicate what services part replacements may be Requir...

Page 1262: ...s that required or suggested repair or replacement is recommended the customer must be informed of the generally acceptable repair replacement options whether or not performed by the shop When present...

Page 1263: ...hicles with height or load sensing proportioning valve equipped braking systems unless these components are original equipment AIR RIDE SUSPENSION NOTE Depending on the air suspension design there are...

Page 1264: ...replacement AIR RIDE SUSPENSION AIR SPRINGS AIR RIDE SUSPENSION AIR SPRING INSPECTION Condition Code Procedure Attaching hardware broken A Require replacement of broken part Attaching hardware incorre...

Page 1265: ...re repair or replacement Does not build pressure A 1 Further inspection required Excessive run time B 2 Further inspection required Inoperative A Require replacement Leaking A Require repair or replac...

Page 1266: ...nsor failure AIR RIDE SUSPENSION MODULES AIR RIDE SUSPENSION MODULE INSPECTION Condition Code Procedure Attaching hardware loose A Require repair or replacement of loose part Attaching hardware missin...

Page 1267: ...ing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attaching hardware threads stripped threads missing A Require replacement of part with stripped...

Page 1268: ...quire replacement Fusible link blown A Require replacement Open A Require repair or replacement Poor ground A Require repair or replacement Routed incorrectly B Require rerouting according to vehicle...

Page 1269: ...ed part if available otherwise replace ball joint Attaching hardware incorrect A Require replacement of incorrect part if available otherwise replace ball joint Attaching hardware loose A Require repa...

Page 1270: ...ill accelerate wear 5 If the greaseable ball joint still will not take grease after replacing the grease fitting suggest replacement of ball joint 6 Check for bent stud or damaged taper hole 7 Check f...

Page 1271: ...placement Surface cracking weather checked No service suggested or required 1 If noise isolated to bushing suggest repair or replacement CAUTION Use only approved lubricant on rubber bushings Petroleu...

Page 1272: ...ire repair or replacement Threads stripped threads missing A 7 Require replacement Wear exceeds manufacturer s specifications B Require replacement 1 If greaseable grease joint If problem persists or...

Page 1273: ...ds missing A Require replacement CONTROL ARMS CONTROL ARM INSPECTION Condition Code Procedure Attaching hardware bent B Require repair or replacement of bent part if available otherwise replace contro...

Page 1274: ...DRAG LINK INSPECTION Condition Code Procedure Attaching hardware incorrect A Require replacement of incorrect part if available otherwise replace drag link Attaching hardware loose A Require repair o...

Page 1275: ...e joint and will accelerate wear 4 Torn grease boot will allow contaminants to enter the joint and will accelerate wear 5 Missing grease seal will allow contaminants to enter the joint and will accele...

Page 1276: ...acement of missing part if available otherwise replace idler arm Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace idler ar...

Page 1277: ...to enter joint and will accelerate wear 6 If manufacturer s procedures and specifications exist use those procedures and specifications otherwise use an approved inspection method such as the dry par...

Page 1278: ...of missing part if available otherwise replace king pin Looseness exceeds manufacturer s specifications B Require replacement of worn parts Seized A Require replacement Threads damaged A Require repai...

Page 1279: ...es missing A Require replacement Stud bent B 8 Require replacement Stud broken A 8 Require replacement Stud loose in taper hole A 8 Require repair or replacement Taper hole elongated A 9 Require repla...

Page 1280: ...ir or replacement of the following components may be required if performed as part of a power steering pump overhaul or rebuild service to meet a minimum rebuild standard POWER STEERING HYDRAULIC PUMP...

Page 1281: ...f cap Reservoir cap missing C Require replacement of cap Seized A Require replacement Threads damaged A Require repair or replacement Threads stripped threads missing A Require replacement 1 Determine...

Page 1282: ...ng hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace relay rod Attaching hardware threads stripped threads missing A Require replacem...

Page 1283: ...S You are not required to replace shocks or struts in axle sets However when replacing a shock or strut due to the conditions that follow you may suggest replacement of the other shock or strut on the...

Page 1284: ...wise replace shock or strut Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace shock or strut Attaching hardware threads str...

Page 1285: ...e replacement Noise 2 5 Further inspection required Piston rod bent A Require replacement Piston rod broken A Require replacement Piston rod has surface defect 2 Suggest replacement Piston rod threads...

Page 1286: ...r or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attachin...

Page 1287: ...Broken all springs except secondary leave s on multi leaf springs A Require replacement Coil clash 1 Require ride height check Coil spring insulator deteriorated 2 Suggest replacement of insulator Co...

Page 1288: ...STEEL POWER STEERING LINES CAUTION When replacing steel power steering lines be sure to use a replacement product that meets or exceeds OEM design specifications STEEL POWER STEERING LINE INSPECTION C...

Page 1289: ...t with damaged threads Attaching hardware threads stripped threads missing A Require replacement of part with stripped threads Bent B Require replacement Broken A Require replacement Taper hole elonga...

Page 1290: ...pped threads if available otherwise replace steering damper Binding A Require replacement Damper body dented A 1 Further inspection required Damper body punctured A Require replacement Damping none A...

Page 1291: ...or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attaching...

Page 1292: ...sary to determine the extent of the system failure the suggestion may be made to rebuild or replace the power steering pump Repair or replacement of the following components may be required if perform...

Page 1293: ...replacement of coupler Fluid contaminated B 1 Require flushing and refilling of the system Gasket leaking A Require repair or replacement Hard steering on cold start up 1 2 Suggest repair or replaceme...

Page 1294: ...of incorrect part Attaching hardware loose A Require repair or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require...

Page 1295: ...replacement Split 1 Suggest replacement STRUT RODS STRUT ROD INSPECTION Condition Code Procedure Adjusting nut seized A 1 Require repair or replacement Attaching hardware bent B Require repair or repl...

Page 1296: ...y the bearing should be replaced if it is available separately otherwise replace the bearing plate assembly STRUT UPPER BEARING PLATE ASSEMBLY INSPECTION Condition Code Procedure Attaching hardware br...

Page 1297: ...t if available otherwise replace link Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace link Attaching hardware threads str...

Page 1298: ...WAY BAR INSPECTION Condition Code Procedure Attaching hardware broken A Require replacement of broken part if available otherwise replace sway bar Attaching hardware corroded affecting structural inte...

Page 1299: ...cement of sleeve or tie rod end Adjusting sleeve clamps out of position B Require repair Adjusting sleeve corroded affecting structural integrity A Require replacement of sleeve or tie rod end Adjusti...

Page 1300: ...oint and will accelerate wear 5 Torn grease boot will allow contaminants to enter joint and will accelerate wear 6 If greaseable tie rod end will not take grease after replacing the grease fitting sug...

Page 1301: ...ripped threads missing A 7 Require replacement Wear exceeds manufacturer s specifications B Require replacement 1 Cracked grease boot will allow contaminants to enter joint and will accelerate wear 2...

Page 1302: ...LS NOTE When replacing or repacking wheel bearings grease seal replacement is required You are not required to replace these components in axle sets Determine the need to replace based upon the indivi...

Page 1303: ...on component replacement or correction kits may be required Errors in set back and steering axis inclination SAI are often attributable to failed or damaged components and must be corrected prior to p...

Page 1304: ...d dismount or mount tires Explosions of tire and wheel assembly can result from improper mounting possibly causing serious injury or death WARNING Consult the vehicle owner s manual or vehicle placard...

Page 1305: ...ull or lead caused by tire A Require repair or replacement Radial and bias or bias belted ply tires on same axle B Require repair or replacement Radials are on the front and not on the rear B 2 Requir...

Page 1306: ...in tubeless tire Recommendation for repair or replacement should be based upon condition of tires and or wheel listed in these guidelines VALVE STEMS VALVE STEM INSPECTION Condition Code Procedure Be...

Page 1307: ...g to mount a tire of one diameter on a wheel of a different diameter or flange type may result in serious injury or death If the wheel identification stamp is not legible or cannot be found do not use...

Page 1308: ...re replacement Run out beyond OEM specs B Require replacement Stud holes elongated A 2 Require replacement Welded or brazed repair 2 Suggest replacement Welds leaking A Require replacement Wheel cente...

Page 1309: ...rol arms steering knuckles coil springs and shock absorbers See Fig 1 Upper control arms are mounted to frame side rails Lower control arms are mounted to crossmember Steering knuckles are mounted bet...

Page 1310: ...int stud Using Ball Joint Breaker C 4150A separate ball joint from steering knuckle 3 Remove lower shock bolt from suspension arm Lower jack and suspension arm until spring tension is relieved Remove...

Page 1311: ...e Remove link rod retaining nut at each end of stabilizer bar Remove outer retainers and rubber bushings from link rods Remove stabilizer bar clamps from frame rails Remove stabilizer bar from vehicle...

Page 1312: ...remaining components reverse removal procedure TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft Lbs N m Ball Joint Nuts Lower Light Duty 95 129 Heavy Duty 110 149 Upper 60 81 Lower Control A...

Page 1313: ...o the frame with 3 studs on a ring The shock is mounted at bottom of axle below the spring seat See Fig 1 A track bar is used and is attached to a frame rail bracket with a ball stud The track bar is...

Page 1314: ...IONS table LOWER CONTROL ARM Removal Installation 1 Raise and support vehicle Scribe alignment marks on cam adjusters and suspension arm for installation reference Remove lower control arm nut cam and...

Page 1315: ...Fig 2 Removing Front Shock Absorber Assembly Courtesy of Chrysler Corp STABILIZER BAR...

Page 1316: ...emoving Stabilizer Bar Assembly Courtesy of Chrysler Corp STEERING KNUCKLE Removal Installation 1 Raise and support vehicle Remove wheel and tire assembly Remove tie rod or drag link end from steering...

Page 1317: ...val Installation 1 Raise and support vehicle Remove wheel Remove caliper and rotor Remove ABS sensor if equipped Remove cotter pin and axle hub nut 2 Remove wheel bearing and hub assembly hub to knuck...

Page 1318: ...on Ft Lbs N m Anti Rattle Springs Clips 15 20 Axle Nut 175 237 Ball Joint Nut Model 44 Lower 80 108 Upper 75 102 Model 60 Lower 140 160 190 217 Upper 70 95 Cam Adjustment Nut 170 230 Control Arm Lower...

Page 1319: ...NSION MODULES AIR RIDE SUSPENSION RELAYS COMPRESSOR AIR RIDE SUSPENSION SWITCHES ON OFF AIR RIDE SUSPENSION TORSION SPRINGS COUNTER BALANCING AIR RIDE SUSPENSION TUBING AIR RIDE SUSPENSION WARNING LAM...

Page 1320: ...o the customer according to industry standards Given that the industry did not have such standards the Motorist Assurance Program successfully promulgated industry inspection communication standards i...

Page 1321: ...ts of this inspection must be explained to the customer and documented on an inspection form The condition of the vehicle and its components will indicate what services part replacements may be Requir...

Page 1322: ...s that required or suggested repair or replacement is recommended the customer must be informed of the generally acceptable repair replacement options whether or not performed by the shop When present...

Page 1323: ...hicles with height or load sensing proportioning valve equipped braking systems unless these components are original equipment AIR RIDE SUSPENSION NOTE Depending on the air suspension design there are...

Page 1324: ...replacement AIR RIDE SUSPENSION AIR SPRINGS AIR RIDE SUSPENSION AIR SPRING INSPECTION Condition Code Procedure Attaching hardware broken A Require replacement of broken part Attaching hardware incorre...

Page 1325: ...re repair or replacement Does not build pressure A 1 Further inspection required Excessive run time B 2 Further inspection required Inoperative A Require replacement Leaking A Require repair or replac...

Page 1326: ...nsor failure AIR RIDE SUSPENSION MODULES AIR RIDE SUSPENSION MODULE INSPECTION Condition Code Procedure Attaching hardware loose A Require repair or replacement of loose part Attaching hardware missin...

Page 1327: ...ing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attaching hardware threads stripped threads missing A Require replacement of part with stripped...

Page 1328: ...quire replacement Fusible link blown A Require replacement Open A Require repair or replacement Poor ground A Require repair or replacement Routed incorrectly B Require rerouting according to vehicle...

Page 1329: ...ed part if available otherwise replace ball joint Attaching hardware incorrect A Require replacement of incorrect part if available otherwise replace ball joint Attaching hardware loose A Require repa...

Page 1330: ...ill accelerate wear 5 If the greaseable ball joint still will not take grease after replacing the grease fitting suggest replacement of ball joint 6 Check for bent stud or damaged taper hole 7 Check f...

Page 1331: ...placement Surface cracking weather checked No service suggested or required 1 If noise isolated to bushing suggest repair or replacement CAUTION Use only approved lubricant on rubber bushings Petroleu...

Page 1332: ...ire repair or replacement Threads stripped threads missing A 7 Require replacement Wear exceeds manufacturer s specifications B Require replacement 1 If greaseable grease joint If problem persists or...

Page 1333: ...ds missing A Require replacement CONTROL ARMS CONTROL ARM INSPECTION Condition Code Procedure Attaching hardware bent B Require repair or replacement of bent part if available otherwise replace contro...

Page 1334: ...DRAG LINK INSPECTION Condition Code Procedure Attaching hardware incorrect A Require replacement of incorrect part if available otherwise replace drag link Attaching hardware loose A Require repair o...

Page 1335: ...e joint and will accelerate wear 4 Torn grease boot will allow contaminants to enter the joint and will accelerate wear 5 Missing grease seal will allow contaminants to enter the joint and will accele...

Page 1336: ...acement of missing part if available otherwise replace idler arm Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace idler ar...

Page 1337: ...to enter joint and will accelerate wear 6 If manufacturer s procedures and specifications exist use those procedures and specifications otherwise use an approved inspection method such as the dry par...

Page 1338: ...of missing part if available otherwise replace king pin Looseness exceeds manufacturer s specifications B Require replacement of worn parts Seized A Require replacement Threads damaged A Require repai...

Page 1339: ...es missing A Require replacement Stud bent B 8 Require replacement Stud broken A 8 Require replacement Stud loose in taper hole A 8 Require repair or replacement Taper hole elongated A 9 Require repla...

Page 1340: ...ir or replacement of the following components may be required if performed as part of a power steering pump overhaul or rebuild service to meet a minimum rebuild standard POWER STEERING HYDRAULIC PUMP...

Page 1341: ...f cap Reservoir cap missing C Require replacement of cap Seized A Require replacement Threads damaged A Require repair or replacement Threads stripped threads missing A Require replacement 1 Determine...

Page 1342: ...ng hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace relay rod Attaching hardware threads stripped threads missing A Require replacem...

Page 1343: ...S You are not required to replace shocks or struts in axle sets However when replacing a shock or strut due to the conditions that follow you may suggest replacement of the other shock or strut on the...

Page 1344: ...wise replace shock or strut Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace shock or strut Attaching hardware threads str...

Page 1345: ...e replacement Noise 2 5 Further inspection required Piston rod bent A Require replacement Piston rod broken A Require replacement Piston rod has surface defect 2 Suggest replacement Piston rod threads...

Page 1346: ...r or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attachin...

Page 1347: ...Broken all springs except secondary leave s on multi leaf springs A Require replacement Coil clash 1 Require ride height check Coil spring insulator deteriorated 2 Suggest replacement of insulator Co...

Page 1348: ...STEEL POWER STEERING LINES CAUTION When replacing steel power steering lines be sure to use a replacement product that meets or exceeds OEM design specifications STEEL POWER STEERING LINE INSPECTION C...

Page 1349: ...t with damaged threads Attaching hardware threads stripped threads missing A Require replacement of part with stripped threads Bent B Require replacement Broken A Require replacement Taper hole elonga...

Page 1350: ...pped threads if available otherwise replace steering damper Binding A Require replacement Damper body dented A 1 Further inspection required Damper body punctured A Require replacement Damping none A...

Page 1351: ...or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attaching...

Page 1352: ...sary to determine the extent of the system failure the suggestion may be made to rebuild or replace the power steering pump Repair or replacement of the following components may be required if perform...

Page 1353: ...replacement of coupler Fluid contaminated B 1 Require flushing and refilling of the system Gasket leaking A Require repair or replacement Hard steering on cold start up 1 2 Suggest repair or replaceme...

Page 1354: ...of incorrect part Attaching hardware loose A Require repair or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require...

Page 1355: ...replacement Split 1 Suggest replacement STRUT RODS STRUT ROD INSPECTION Condition Code Procedure Adjusting nut seized A 1 Require repair or replacement Attaching hardware bent B Require repair or repl...

Page 1356: ...y the bearing should be replaced if it is available separately otherwise replace the bearing plate assembly STRUT UPPER BEARING PLATE ASSEMBLY INSPECTION Condition Code Procedure Attaching hardware br...

Page 1357: ...t if available otherwise replace link Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace link Attaching hardware threads str...

Page 1358: ...WAY BAR INSPECTION Condition Code Procedure Attaching hardware broken A Require replacement of broken part if available otherwise replace sway bar Attaching hardware corroded affecting structural inte...

Page 1359: ...cement of sleeve or tie rod end Adjusting sleeve clamps out of position B Require repair Adjusting sleeve corroded affecting structural integrity A Require replacement of sleeve or tie rod end Adjusti...

Page 1360: ...oint and will accelerate wear 5 Torn grease boot will allow contaminants to enter joint and will accelerate wear 6 If greaseable tie rod end will not take grease after replacing the grease fitting sug...

Page 1361: ...ripped threads missing A 7 Require replacement Wear exceeds manufacturer s specifications B Require replacement 1 Cracked grease boot will allow contaminants to enter joint and will accelerate wear 2...

Page 1362: ...LS NOTE When replacing or repacking wheel bearings grease seal replacement is required You are not required to replace these components in axle sets Determine the need to replace based upon the indivi...

Page 1363: ...on component replacement or correction kits may be required Errors in set back and steering axis inclination SAI are often attributable to failed or damaged components and must be corrected prior to p...

Page 1364: ...d dismount or mount tires Explosions of tire and wheel assembly can result from improper mounting possibly causing serious injury or death WARNING Consult the vehicle owner s manual or vehicle placard...

Page 1365: ...ull or lead caused by tire A Require repair or replacement Radial and bias or bias belted ply tires on same axle B Require repair or replacement Radials are on the front and not on the rear B 2 Requir...

Page 1366: ...in tubeless tire Recommendation for repair or replacement should be based upon condition of tires and or wheel listed in these guidelines VALVE STEMS VALVE STEM INSPECTION Condition Code Procedure Be...

Page 1367: ...g to mount a tire of one diameter on a wheel of a different diameter or flange type may result in serious injury or death If the wheel identification stamp is not legible or cannot be found do not use...

Page 1368: ...re replacement Run out beyond OEM specs B Require replacement Stud holes elongated A 2 Require replacement Welded or brazed repair 2 Suggest replacement Welds leaking A Require replacement Wheel cente...

Page 1369: ...ght questions are asked at write up Making the Worksheets a Part of Your Normal Routine The following information contains ideas that may be helpful in forming habits that promote daily use of the Sym...

Page 1370: ...GE NOTE Have the service adviser fill out this form with the customer whenever possible Fig 1 Entire Vehicle Symptom Check List For Customer FULL VERSION ALL ON FOUR PAGES NOTE Have the service advise...

Page 1371: ...customer whenever possible Fig 2 Symptom Check List Page 1...

Page 1372: ...Fig 3 Symptom Check List Page 2...

Page 1373: ...Fig 4 Symptom Check List Page 3...

Page 1374: ...Fig 5 Symptom Check List Page 4 INDIVIDUAL SYSTEM BASED CHECK LISTS NOTE Have the service adviser fill out these forms with the customer whenever possible...

Page 1375: ...Fig 6 Engine Driveability Automatic Transmission...

Page 1376: ...Fig 7 Brakes Steering Suspension Fig 8 Air Conditioning Heater Ventilation...

Page 1377: ...Fig 9 Electrical Radio Tape CD Player...

Page 1378: ...Fig 10 Manual Transmission Clutch...

Page 1379: ...Fig 11 Squeak Rattle Noise Conditions Fig 12 Water Leak Wind Noise...

Page 1380: ...manifold air heater system perform procedures in SELF DIAGNOSTICS JEEP TRUCKS RWD VANS article INTERCOOLER Cleaning and inspection procedures for intercooler is the only information available from man...

Page 1381: ...a Diagnostic Trouble Code DTC will be stored in Powertrain Control Module PCM See SELF DIAGNOSTICS JEEP TRUCKS RWD VANS article Crankshaft Position Sensor If problem exists in crankshaft position sen...

Page 1382: ...brake pedal Disconnect electrical connector from brake switch Pull plunger on brake switch fully outward See Fig 2 2 Using ohmmeter check for continuity between terminals No 5 and 6 on brake switch S...

Page 1383: ...ls No 85 and 86 on relay Resistance should be 70 80 ohms If resistance is within specification go to next step If resistance is not within specification replace relay 3 Using ohmmeter ensure continuit...

Page 1384: ...tery voltage to relay trigger wire terminals small wire terminals at base of intake manifold air heater relay See Fig 4 Polarity is not important 4 Intake manifold air heater relay should click and oh...

Page 1385: ...power distribution center at driver s side front corner of engine compartment near battery If problem exists in transmission relay or wiring circuit a Diagnostic Trouble Code DTC will be stored in Pow...

Page 1386: ...Transmission Torque Converter Clutch Solenoid A T Models See TRANSMISSION under MISCELLANEOUS CONTROLS Fig 5 Locating Fuel System Components Courtesy of Chrysler Corp FUEL SYSTEM...

Page 1387: ...ing information is available from manufacturer Fuel Heater 1 Malfunctioning fuel heater may cause excessive wax build up in fuel filter water separator during cold ambient temperatures Wax build up ma...

Page 1388: ...metal fuel line at engine Remove clip from metal line Snap clip into fuel supply hose Install Rubber Adapter Hose 6631 into ends of disconnected fuel supply line 2 Install transducer from PEP module...

Page 1389: ...ents are made by Engine Control Module ECM If a DTC has been stored indicating an ENGINE SYNC ERROR or STATIC TIMING ERROR remove plastic access cover injection pump nut and washer 2 Locate keyway beh...

Page 1390: ...article 3 To check for defective fuel injector start and idle engine Loosen high pressure fuel line nut at fuel injector and listen for a decrease in engine speed Tighten high pressure fuel line nut...

Page 1391: ...ransmission speed sensor is located on overdrive case at rear of transmission Transmission speed sensor contains a 2 pin connector with a Dark Blue Black wire and a Light Green Black wire If problem e...

Page 1392: ...hmmeter to isolate wiring harness shorts or opens COMPUTERIZED ENGINE CONTROLS POWERTRAIN CONTROL MODULE PCM PCM power and ground circuits may be checked by performing TEST NS 1 in SELF DIAGNOSTICS JE...

Page 1393: ...VANS article SOLENOIDS Evaporative EVAP Purge Solenoid See appropriate DTC P0443 EVAP PURGE SOLENOID CIRCUIT test in SELF DIAGNOSTICS JEEP TRUCKS RWD VANS article Leak Detection Pump LDP Solenoid See...

Page 1394: ...ticle Torque Converter Clutch TCC Relay See appropriate DTC P0743 TORQUE CONVERTER CLUTCH SOLENOID TRANSMISSION RELAY CIRCUIT test in SELF DIAGNOSTICS JEEP TRUCKS RWD VANS article Transmission Governo...

Page 1395: ...filter Repair air filter if plugged If air filter is okay test is complete CRANKCASE VENTILATION CCV 8 0L 1 CCV system does NOT use a PCV valve System consists of a fixed orifice Gray color that is c...

Page 1396: ...4 If paper is held against opening performance is okay If paper is not held against opening replace PCV valve and retest If performance does not improve inspect system for restrictions and clean as ne...

Page 1397: ...SYSTEM WIRING DIAGRAMS 1999 Dodge Pickup R1500 1999 System Wiring Diagrams Dodge Pickup R1500 AIR CONDITIONING Heater Circuit...

Page 1398: ...Manual A C Circuit ANTI LOCK BRAKES...

Page 1399: ...Anti lock Brake Circuits ANTI THEFT...

Page 1400: ...Anti theft Circuit BODY COMPUTER...

Page 1401: ...Central Timer Module Circuit...

Page 1402: ...Integrated Central Electronics Module Circuit COMPUTER DATA LINES...

Page 1403: ...Computer Data Lines CRUISE CONTROL...

Page 1404: ...Cruise Control Circuit ENGINE PERFORMANCE...

Page 1405: ...3 9L 3 9L Engine Performance Circuits 1 of 3...

Page 1406: ...3 9L Engine Performance Circuits 2 of 3...

Page 1407: ...3 9L Engine Performance Circuits 3 of 3 5 2L...

Page 1408: ...5 2L Engine Performance Circuits 1 of 3...

Page 1409: ...5 2L Engine Performance Circuits 2 of 3...

Page 1410: ...5 2L Engine Performance Circuits 3 of 3 5 9L...

Page 1411: ...5 9L Engine Performance Circuits 1 of 3...

Page 1412: ...5 9L Engine Performance Circuits 2 of 3...

Page 1413: ...5 9L Engine Performance Circuits 3 of 3 EXTERIOR LIGHTS...

Page 1414: ...Back up Lamps Circuit...

Page 1415: ...Exterior Lamps Trailer connector Circuit 1 of 2...

Page 1416: ...Exterior Lamps Trailer connector Circuit 2 of 2 GROUND DISTRIBUTION...

Page 1417: ...Ground Distribution Circuit 1 of 3...

Page 1418: ...Ground Distribution Circuit 2 of 3...

Page 1419: ...Ground Distribution Circuit 3 of 3 HEADLIGHTS...

Page 1420: ...Headlight Circuit W DRL W Quad Headlights...

Page 1421: ...Headlight Circuit W DRL W O Quad Headlights...

Page 1422: ...Headlight Circuit W O DRL W Quad Headlights...

Page 1423: ...Headlight Circuit W O DRL W O Quad Headlights HORN...

Page 1424: ...Horn Circuit INSTRUMENT CLUSTER...

Page 1425: ...Instrument Cluster Circuit 1 of 2...

Page 1426: ...Instrument Cluster Circuit 2 of 2...

Page 1427: ...Overhead Console Circuit INTERIOR LIGHTS...

Page 1428: ...Courtesy Lamps Circuit...

Page 1429: ...Instrument Illumination Circuit PASSIVE RESTRAINTS...

Page 1430: ...Passive Restraint Circuit POWER DISTRIBUTION...

Page 1431: ...Power Distribution Circuit 1 of 3...

Page 1432: ...Power Distribution Circuit 2 of 3...

Page 1433: ...Power Distribution Circuit 3 of 3 POWER DOOR LOCKS...

Page 1434: ...Power Door Lock Circuit W Keyless Entry...

Page 1435: ...Power Door Lock Circuit W O Keyless Entry POWER MIRRORS...

Page 1436: ...Power Mirror Circuit POWER SEATS...

Page 1437: ...Power Seat Circuits POWER WINDOWS...

Page 1438: ...Power Window Circuit RADIO...

Page 1439: ...Radio Circuits Premium Radio...

Page 1440: ...Radio Circuits Standard STARTING CHARGING...

Page 1441: ...Charging Circuit...

Page 1442: ...Starting Circuit SUPPLEMENTAL RESTRAINTS...

Page 1443: ...Supplemental Restraint Circuit TRANSMISSION...

Page 1444: ...3 9L 3 9L A T Circuit 1 of 2...

Page 1445: ...3 9L A T Circuit 2 of 2 5 2L...

Page 1446: ...5 2L A T Circuit 1 of 2...

Page 1447: ...5 2L A T Circuit 2 of 2 5 9L...

Page 1448: ...5 9L A T Circuit 1 of 2...

Page 1449: ...5 9L A T Circuit 2 of 2 WARNING SYSTEMS...

Page 1450: ...Warning System Circuits WIPER WASHER...

Page 1451: ...Wiper Washer Circuit...

Page 1452: ...ocedures should also be used if an intermittent soft FTC was present but no problem is found during self diagnostic testing NOTE For specific testing procedures see SELF DIAGNOSTICS JEEP TRUCKS RWD VA...

Page 1453: ...lead to PCM setting a Diagnostic Trouble Code FTC which may help in diagnosis If problem vehicle does not produce DTCs monitor voltage or resistance values using a Digital Volt Ohmmeter DVOM while at...

Page 1454: ...d lead to a specific component system test or adjustment Use intermittent test procedures to locate driveability problems that do not occur when the vehicle is being tested These problems may cause a...

Page 1455: ...inimum idle airflow Check Idle Air Control IAC motor operation HESITATION OR STUMBLE Check the following Check secondary ignition system Check PCM power and ground circuits Check engine vacuum Check f...

Page 1456: ...ure Check Engine Coolant Temperature ECT sensor calibration Check Throttle Position TP sensor calibration Check Manifold Absolute Pressure MAP calibration Check minimum idle airflow Check oxygen senso...

Page 1457: ...en sensor heater Check Idle Air Control IAC motor operation Check engine mechanical condition Check evaporative system Check EGR system Check Intake Air Temperature IAT motor operation Check Park Neut...

Page 1458: ...r bend wiring harness Spray component with water Remove apply vacuum source Monitor circuit component voltage or resistance while simulating intermittent If engine is running monitor for DTCs Use test...

Page 1459: ...les or systems with which you are not completely familiar AIR INDUCTION SYSTEM INTERCOOLER NOTE Intercooler may also be referred to as a charge air cooler Intercooler is a heat exchanger used to reduc...

Page 1460: ...ler and then into intake manifold where the air is distributed into each cylinder Supplying increased airflow provides improved engine performance lower exhaust smoke density altitude compensation and...

Page 1461: ...tesy of Chrysler Corp ENGINE CONTROL MODULE ECM Engine Control Module ECM uses input signals from various switches and sensors to control output devices in order to achieve optimum engine performance...

Page 1462: ...peed control adaptive memory Camshaft Position Sensor CMP Camshaft Position CMP sensor is a hall effect sensor 0 5 volts switched located below injection pump in rear face of timing gear cover Sensor...

Page 1463: ...set Other sensor is an integral part of fuel heater See FUEL HEATER Intake Manifold Air Temperature IAT Sensor Intake manifold air temperature sensor is a variable thermistor sensor located on top of...

Page 1464: ...ion has been requested Once A C operation has been requested an A C request signal is delivered to ECM from A C high pressure switch and A C low pressure switch The A C request signal indicates evapor...

Page 1465: ...cate engine speed and crankshaft position ECM uses CKP signal along with other input signals for controlling injector firing sequence and timing Sensor is located below fuel transfer pump on side of e...

Page 1466: ...sion near shift linkage Transmission Governor Pressure Sensor A T Models Transmission governor pressure sensor delivers input signal to Powertrain Control Module PCM to indicate transmission governor...

Page 1467: ...ater In Fuel WIF Sensor Fuel Injection Pump Relay The Engine Control Module ECM energizes the fuel injection pump and integral Fuel Pump Control Module FPCM through the relay When ignition is turned o...

Page 1468: ...r relays are energized by Engine Control Module ECM based on input signals from intake manifold air temperature sensor engine speed sensor and vehicle speed Fig 5 Locating Intake Manifold Air Heater C...

Page 1469: ...n goes off as a bulb and wiring circuit test each time ignition switch is turned to the ON position If Engine Control Module ECM receives an incorrect signal or receives no signal from certain sensors...

Page 1470: ...M OUTPUT SIGNALS A C Clutch Relay The Engine Control Module ECM controls A C compressor operation by controlling ground circuit for A C clutch relay ECM de energizes A C clutch relay if engine coolant...

Page 1471: ...mission overdrive indicator light will be turned on Transmission overdrive indicator light is located on instrument panel just below the speedometer Tachometer Engine Control Module ECM delivers outpu...

Page 1472: ...ne type pump supplies low fuel pressure from fuel tank through fuel heater fuel filter water separator to fuel injection pump Fuel transfer pump contains internal check valves to prevent fuel from ble...

Page 1473: ...perate fuel heater is provided from ignition switch through fuel heater relay and to fuel heater Fuel heater and fuel heater relay are not controlled by Engine Control Module ECM EMISSION SYSTEMS INTA...

Page 1474: ...on the MIL to warn the driver that a malfunction exists in the electronic system MISCELLANEOUS CONTROLS TRANSMISSION Transmission Overdrive Solenoid A T Models Engine Control Module ECM operates tran...

Page 1475: ...Distributorless Ignition System DIS or distributor on models without DIS Crankshaft Position CKP sensor Engine Coolant Temperature ECT sensor Intake Air Temperature IAT sensor logic circuits Manifold...

Page 1476: ...in idle speed at a preprogrammed RPM when brakes are applied If PCM receives an input signal from brake switch when speed control system is on PCM will turn speed control system off Camshaft Position...

Page 1477: ...acts like a rich lean air fuel ratio switch by monitoring oxygen content in exhaust gas This information is used by PCM to adjust air fuel ratio by adjusting injector pulse width HO2S produces low vo...

Page 1478: ...ill not shift into overdrive or will downshift if already in overdrive Transmission Temperature Sensor A T Models Transmission temperature sensor monitors transmission fluid temperature and sends an i...

Page 1479: ...ator See GENERATOR under MISCELLANEOUS CONTROLS Idle Air Control IAC Motor See IDLE SPEED under FUEL SYSTEM Ignition Coil See IGNITION SYSTEM In Tank Fuel Pump See FUEL DELIVERY under FUEL SYSTEM Limp...

Page 1480: ...D RELAY FUEL PUMP RELAY under MISCELLANEOUS CONTROLS Fuel Pressure Regulator Fuel pressure regulator is a mechanical device used to maintain a constant pressure across fuel injector tip Spring and rub...

Page 1481: ...fuel pressure regulator fuel pump reservoir a separate in tank fuel filter pressure relief rollover valve fuel gauge sending unit and fuel supply line See Fig 3 Fig 3 Identifying Fuel Pump Module Com...

Page 1482: ...is is an open loop mode PCM pre positions IAC motor based on ECT sensor input PCM determines atmospheric pressure from MAP sensor and determines basic fuel strategy PCM modifies fuel strategy accordin...

Page 1483: ...re it reduces injector pulse width to lean air fuel mixture Under certain RPM and closed throttle position conditions HO2S signals are ignored and PCM cuts off fuel injection until idle speed is reach...

Page 1484: ...gine revolution may be required for PCM to determine crankshaft position during cranking Molded ignition coils are used Each coil fires 2 paired spark plugs at the same time One cylinder is on compres...

Page 1485: ...case Ventilation CCV system is used on some engines see CRANKCASE VENTILATION CCV SYSTEM SELF DIAGNOSTIC SYSTEM The PCM monitors several different circuits of engine control system If a problem is sen...

Page 1486: ...s HO2S Heating Element When ignition switch is turned to RUN position PCM energizes ASD relay and electric fuel pump relay which powers these components If PCM does not receive a CMP and CKP sensor s...

Page 1487: ...ist of 3 buttons OFF ON RESUME ACCEL and SET DECEL Speed control servo is controlled by PCM System will operate at 35 85 MPH TACHOMETER PCM provides signal to drive tachometer TORQUE CONVERTER CLUTCH...

Page 1488: ...l connector for crankshaft position sensor On 2 5L crankshaft position sensor is mounted on driver s side of transmission housing See Fig 1 On 3 9L 5 2L and 5 9L crankshaft position sensor is mounted...

Page 1489: ...n cylinder block 10 Install C clamp on edge of transmission housing to hold torque converter in place Lower transmission and remove transmission from vehicle Fig 1 Locating Crankshaft Position Sensor...

Page 1490: ...n and engine 2 Ensure area around transmission oil cooler lines fitting are clean Disengage retainer on quick disconnect cooler line fitting Pull cooler line from transmission oil cooler Remove starte...

Page 1491: ...il cooler line to ensure oil cooler line is locked in place Fill transmission with Mopar ATF Plus Type 7176 RAM VAN WAGON Removal 1 Disconnect negative battery cable Raise and support vehicle Remove e...

Page 1492: ...50 241 0 mm 3 Bolt Lug Torque Converter 46 11 7 9 50 241 0 mm 4 Bolt Lug Torque Converter 52 13 2 10 00 254 0 mm 4 Bolt Lug Torque Converter 52 13 2 10 75 273 0 mm 4 Bolt Lug Torque Converter 44 11 2...

Page 1493: ...olt Large Bolt 35 65 47 88 Small Bolt 20 40 27 54 INCH Lbs N m Crankshaft Position Sensor Bolt 70 7 9 1 Bolt torque is determined by diameter of torque converter and number of torque converter bolt lu...

Page 1494: ...ignation Dakota Durango 3 9L 42RE 5 2L 44RE 5 9L 46RE Ram Pickup 3 9L 42RE 46RE 5 2L 5 9L Gasoline 46RE 5 9L Diesel 8 0L 47RE Ram Van Wagon 3 9L 32RH 5 2L 36RH 5 2L 5 9L 46RE TRANSFER CASE APPLICATION...

Page 1495: ...transmission fluid adjust bands and replace transmission filter at specified interval See TRANSMISSION SERVICING INTERVALS table Severe service conditions are conditions such as long periods of engine...

Page 1496: ...See TRANSFER CASE SERVICING INTERVALS table Severe service conditions are conditions such as long periods of engine idling trailer towing off highway operation snow removal or operating in dusty or ex...

Page 1497: ...from rear of transfer case Fluid level should even with bottom of transfer case fill plug hole on rear of transfer case Add appropriate type of transfer case fluid if necessary See RECOMMENDED FLUID...

Page 1498: ...6RE 2 1 5 1 4 3 11 4 11 6 10 8 11 0 1 Approximate quantity listed 2 Add fluid until fluid level is at MIN arrow mark on dipstick Start engine and allow engine to idle With brakes applied shift transmi...

Page 1499: ...luid to drain from transfer case 2 Reinstall transfer case drain plug Tighten transfer case drain plug to specification See TORQUE SPECIFICATIONS Remove transfer case fill plug from rear of transfer c...

Page 1500: ...Hold kickdown band adjusting screw in this position and tighten kickdown band adjusting screw lock nut to specification See TORQUE SPECIFICATIONS KICKDOWN BAND ADJUSTMENT Application Back Off Adjusti...

Page 1501: ...TMENT table Hold low reverse band adjusting screw and tighten low reverse band adjusting screw lock nut to specification See TORQUE SPECIFICATIONS LOW REVERSE BAND ADJUSTMENT Application Back Off Adju...

Page 1502: ...cept Park or Neutral shift cable may be improperly adjusted or park neutral position switch may be defective Ram Van Wagon 1 Raise and support vehicle Ensure shift lever is in Park Unsnap shift cable...

Page 1503: ...arts in any other gears except Park and Neutral shift linkage adjustment is incorrect or park neutral position switch is defective Fig 7 Identifying Typical Shift Linkage Components Courtesy of Chrysl...

Page 1504: ...swivel lubricate shift rod as necessary 2 Ensure shift lever on transfer case is still in 4L position Ensure pin on end of adjusting swivel is centered in hole on shift arm Tighten lock bolt With all...

Page 1505: ...ransfer case is still in 2H position Tighten lock bolt With all wheels off floor start engine and shift transfer case through all ranges to ensure proper operation TORQUE SPECIFICATIONS TORQUE SPECIFI...

Page 1506: ...5 9L NV231HD Or 1 NV242HD Ram Pickup 1500 NV231HD 2500 3500 NV241 Or NV241HD 1 NV242HD is used on automatic transmission only IDENTIFICATION TRANSMISSION AX 15 identification numbers are located on b...

Page 1507: ...nsmissions fluid level should even with bottom of fill plug hole on side of transmission Add appropriate type of transmission fluid if necessary See RECOMMENDED FLUID Install and tighten transaxle fil...

Page 1508: ...ated on passenger s side of transmission On NV3500 transmission drain plug is located on bottom of transmission housing at center of transmission housing 2 On all transmissions install and tighten tra...

Page 1509: ...e drain plug is located on rear of transfer case at driver s side corner of transfer case Allow fluid to drain from transfer case 2 Reinstall transfer case drain plug Tighten transfer case drain plug...

Page 1510: ...lock bolt at adjusting swivel on shift rod See Fig 1 Ensure shift rod slides freely in adjusting swivel If shift rod fails to slide freely in adjusting swivel lubricate shift rod as necessary 3 Ensure...

Page 1511: ...PTO Cover Bolt Ram Pickup 30 40 Transfer Case Drain Plug Fill Plug 40 54 Dakota 15 25 20 25 Ram Pickup 30 40 40 54 Transmission Drain Plug Fill Plug Dakota AX 15 33 44 NV1500 25 34 NV3500 14 20 19 27...

Page 1512: ...ES article This will assist in identifying improperly routed vacuum hoses which may cause driveability and or computer indicated malfunctions VACUUM DIAGRAMS NOTE References to California models apply...

Page 1513: ...Fig 2 Vacuum Hose Diagram Caravan Voyager 2 4L Except Calif Courtesy of Chrysler Corp Fig 3 Vacuum Hose Diagram Caravan Town Country Voyager 3 3L 3 8L Calif Courtesy of Chrysler Corp...

Page 1514: ...Fig 4 Vacuum Hose Diagram Caravan Town Country Voyager 3 3L 3 8L Except Calif Courtesy of Chrysler Corp Fig 5 Vacuum Hose Diagram Dakota 2 5L Calif Courtesy of Chrysler Corp...

Page 1515: ...Fig 6 Vacuum Hose Diagram Dakota 2 5L Except Calif Courtesy of Chrysler Corp Fig 7 Vacuum Hose Diagram Dakota 3 9L 5 2L Calif Courtesy of Chrysler Corp...

Page 1516: ...Fig 8 Vacuum Hose Diagram Dakota 5 9L Calif Courtesy of Chrysler Corp Fig 9 Vacuum Hose Diagram Dakota 3 9L 5 2L Except Calif Courtesy of Chrysler Corp...

Page 1517: ...Fig 10 Vacuum Hose Diagram Dakota 5 9L Except Calif Courtesy of Chrysler Corp Fig 11 Vacuum Hose Diagram Durango 3 9L 5 2L Calif Courtesy of Chrysler Corp...

Page 1518: ...Fig 12 Vacuum Hose Diagram Durango 5 9L Calif Courtesy of Chrysler Corp Fig 13 Vacuum Hose Diagram Durango 3 9L 5 2L Except Calif Courtesy of Chrysler Corp...

Page 1519: ...Fig 14 Vacuum Hose Diagram Durango 5 9L Except Calif Courtesy of Chrysler Corp Fig 15 Vacuum Hose Diagram Ram Pickup 3 9L 5 2L Light Duty Courtesy of Chrysler Corp...

Page 1520: ...Fig 16 Vacuum Hose Diagram Ram Pickup 5 9L Light Duty Courtesy of Chrysler Corp Fig 17 Vacuum Hose Diagram Ram Pickup 3 9L 5 2L Medium Duty Calif Courtesy of Chrysler Corp...

Page 1521: ...Fig 18 Vacuum Hose Diagram Ram Pickup 5 9L Medium Duty Calif Courtesy of Chrysler Corp Fig 19 Vacuum Hose Diagram Ram Pickup 8 0L Medium Duty Courtesy of Chrysler Corp...

Page 1522: ...Fig 20 Vacuum Hose Diagram Ram Van Ram Wagon 3 9L Calif Courtesy of Chrysler Corp Fig 21 Vacuum Hose Diagram Ram Van Ram Wagon 3 9L Except Calif Courtesy of Chrysler Corp...

Page 1523: ...Fig 22 Vacuum Hose Diagram Ram Van Ram Wagon 5 2L Calif Courtesy of Chrysler Corp Fig 23 Vacuum Hose Diagram Ram Van Ram Wagon 5 2L Except Calif Courtesy of Chrysler Corp...

Page 1524: ...Fig 24 Vacuum Hose Diagram Ram Van Ram Wagon 5 2L CNG Courtesy of Chrysler Corp Fig 25 Vacuum Hose Diagram Ram Van Ram Wagon 5 9L Calif Courtesy of Chrysler Corp...

Page 1525: ...Fig 26 Vacuum Hose Diagram Ram Van Ram Wagon 5 9L Except Calif Courtesy of Chrysler Corp...

Page 1526: ...RT TO BATTERY BUS SHORT TO GROUND BUS BUS OPEN BUS OPEN OR BUS OPEN NOTE For connector terminal identification and wiring diagrams see BODY CONTROL COMPUTER INTRODUCTION article Perform VERIFICATION T...

Page 1527: ...not display BUS BUS SHORTED TOGETHER replace compass mini trip computer If scan tool displays BUS BUS SHORTED TOGETHER go to next step 5 Turn ignition off Disconnect radio connector Turn ignition on I...

Page 1528: ...repair open Black Light Green wire If resistance is more than 5 ohms go to next step 8 Measure resistance between ground and instrument cluster connector C1 terminal No 5 Black wire If resistance is...

Page 1529: ...al No 3 White Black wire Measure resistance between ground and instrument cluster connector C1 terminal No 10 Violet Brown wire If resistance is less than 5 ohms go to next step If resistance is 5 ohm...

Page 1530: ...ms or more repair open Light Green Yellow wire Replace fuse No 19 6 Using external voltmeter measure voltage between ground and voltage input side of fuse No 19 socket If voltage is 10 volts or less r...

Page 1531: ...t Green wire If resistance is 5 ohms or less go to next step 7 Turn ignition on Using scan tool perform CCD Bus test Connect jumper wire between ground and CTM 18 pin connector terminal No 16 Violet B...

Page 1532: ...BODY CONTROL COMPUTER INTRODUCTION article Perform VERIFICATION TEST VER 1 after each repair CAUTION Always turn ignition off prior to disconnecting any module connector 1 Remove and inspect fuse No...

Page 1533: ...sure voltage between ground and radio Gray terminal No 6 Red White wire If voltage is 10 volts or less repair open Red White wire If voltage is more than 10 volts go to next step 6 Inspect ground stra...

Page 1534: ...urn ignition off prior to disconnecting any module connector 1 Turn ignition off Disconnect Powertrain Control Module PCM PCM is mounted in right side of firewall Turn ignition on If scan tool does no...

Page 1535: ...fter each repair CAUTION Always turn ignition off prior to disconnecting any module connector 1 Turn ignition off Disconnect Powertrain Control Module PCM PCM is mounted in right side of firewall Turn...

Page 1536: ...displays BUS SHORT TO GROUND go to next step 2 Turn ignition off Disconnect anti lock brake controller module Controller module is mounted to top of ABS hydraulic unit Turn ignition on If scan tool do...

Page 1537: ...t connectors Turn ignition on engine off Using scan tool erase all fault messages Turn ignition off Wait 10 seconds Turn ignition on engine off Operate system that is malfunctioning If system does not...

Page 1538: ...oad coverage is because there are only a few basic ways to operate a solenoid type injector By understanding the fundamental principles you will understand all the major points of injector patterns yo...

Page 1539: ...noid light designed for full voltage Circuits with current controlled injector drivers e g Peak and Hold Basically this type of driver allows a quick burst of voltage current to flow and then throttl...

Page 1540: ...ecause it is unimportant if the flashing light is dim or bright It is only important that it flashes In any cases of doubt regarding the use of a noid light a lab scope will overcome all inherent weak...

Page 1541: ...he injector is not on This is especially true with current controlled driver circuits The Fluke 88 among others fall into this category Outside of using a Fluke 87 or equivalent in the 1 mS min max mo...

Page 1542: ...his is an approach of last resort it does provide benefits We will discuss the strengths and weaknesses in a moment but first we will look at how a duty cycle meter and dwell meter work How A Duty Cyc...

Page 1543: ...onds With exactly one crankshaft rotation in 100 milliseconds we know that the injector fires exactly one time 4 Determine the ratio of injector on time vs off time in the fixed time period then figur...

Page 1544: ...f control the current flow through the injector would cause the solenoid coil to overheat and result in a damaged injector VOLTAGE CONTROLLED CIRCUIT SATURATED SWITCH The voltage controlled driver ins...

Page 1545: ...tage controlled driver because as the name implies it has to limit current flow in addition to its ON OFF switching function Recall this driver typically requires injector circuits with a total leg re...

Page 1546: ...ance injector This will cause injector damage from solenoid coil overheating THE TWO WAYS INJECTOR CIRCUITS ARE WIRED Like other circuits injector circuits can be wired in one of two fundamental direc...

Page 1547: ...eak driver Alert readers will catch that this is exactly opposite of the current controlled type drivers explained in the next section because they bend upwards at this point How come the difference B...

Page 1548: ...ctor If you see more than one hump it is because of a distorted pintle or seat This faulty condition is known as pintle float It is important to realize that it takes a good digital storage oscillosco...

Page 1549: ...indication of a resistance problem on the ground circuit that needs repaired You might miss this fault if you do not use the negative battery post for your Lab Scope hook up so it is HIGHLY recommende...

Page 1550: ...he final turn off of the driver This spike should be like the spike on top of point D Point G shows a slight hump This is actually the mechanical injector pintle closing Recall that moving an iron cor...

Page 1551: ...t flow of 2 amps See Fig 4 Note that if just one injector has a resistance problem and partially shorts the entire parallel bank that it belongs to will draw more current This can damage the injector...

Page 1552: ...Fig 5 Injector Bank w Excessive Current Flow Current Pattern Fig 6 Single Injector w Normal Current Flow Current Pattern Fig 7 Single Injector w Excessive Current Flow Current Pattern...

Page 1553: ...e total resistance of this parallel circuit drops to 4 1 ohms Fourteen volts divided by four ohms would pull a maximum of 3 4 amps on this bank of injectors However as we discussed in EXAMPLE 1 above...

Page 1554: ...jector set point occurred at 400 milliamps and current peaked at 750 milliamps This is a good specification for this engine The next waveform pattern in Fig 11 shows an abnormality with another inject...

Page 1555: ...illiamps and the actual opening of the injector set point is just below 600 milliamps This is offered as a comparison against the Ford pattern listed above as they are both Ford SEFI injectors but wit...

Page 1556: ...aveform is from a Ford 5 0L V8 CFI VIN F See Fig 14 The pattern which is set on a 250 milliamps scale indicates a 1 25 amp peak draw and a hold at 350 milliamps Fig 14 Single Injector w Normal Current...

Page 1557: ...of intermittent computer shutdown Using a current waveform pattern is the most accurate method of pinpointing this problem Fig 15 Single Injector w Normal Current Flow Current Pattern Fig 16 Single In...

Page 1558: ...LES EXAMPLE 1 VOLTAGE CONTROLLED DRIVER These two known good waveform patterns are from a Ford 4 6L V8 VIN W Fig 18 illustrates the 64 volt inductive kick on this engine indicating no clamping is occu...

Page 1559: ...Fig 18 Injector Bank Known Good Voltage Pattern...

Page 1560: ...9 Injector Bank Known Good Voltage Pattern EXAMPLE 2 VOLTAGE CONTROLLED DRIVER The known good waveform pattern in Fig 20 is from a GM 3 8L V6 PFI VIN 3 It was taken during hot idle closed loop and no...

Page 1561: ...20 Injector Bank Known Good Voltage Pattern EXAMPLE 3 VOLTAGE CONTROLLED DRIVER This known good waveform pattern Fig 21 is from a GM 5 0L V8 TPI VIN F It was taken during hot idle closed loop and no l...

Page 1562: ...is type injector drive on their TBI equipped engines See Fig 22 for a known good pattern Instead of the ground side controlling the injector Chrysler permanently grounds out the injector and switches...

Page 1563: ...o known good waveform patterns are from a Chrysler 3 0L V6 VIN 3 The first waveform Fig 23 is a dual trace pattern that illustrates how Chrysler uses the rising edge of the engine speed signal to trig...

Page 1564: ...Fig 23 Injector Bank Known Good Voltage Pattern...

Page 1565: ...ge Pattern EXAMPLE 6 CURRENT CONTROLLED DRIVER This known good pattern from a Ford 3 0L V6 PFI VIN U illustrates that a zener diode inside the computer is used to clamp the injector s inductive kick t...

Page 1566: ...Fig 25 Injector Bank Known Good Voltage Pattern EXAMPLE 7 CURRENT CONTROLLED DRIVER This known good waveform from a Ford 5 0L V8 CFI VIN F was taken during hot idle closed loop and no load See Fig 26...

Page 1567: ...RRENT CONTROLLED DRIVER These two known good waveform patterns are from a GM 2 0L In Line 4 VIN 1 Fig 27 illustrates the 78 volt inductive spike that indicates a zener diode is not used The second wav...

Page 1568: ...Fig 27 Single Injector Known Good Voltage Pattern...

Page 1569: ...Fig 28 Single Injector Known Good Voltage Pattern...

Page 1570: ...move if present Riding height between left side and right side of vehicle should vary less than 0 5 12 7 mm Information on riding height between front and rear is not available from manufacturer See R...

Page 1571: ...way between front and rear wheels as permanent body damage could occur DO NOT place jack under an axle tube aluminum differential steering linkage engine or transmission oil pan fuel tank or front sus...

Page 1572: ...Corp CAUTION Never place jack under any part of vehicle underbody DO NOT attempt to raise one entire side of vehicle by placing a jack midway between front and rear wheels as permanent body damage cou...

Page 1573: ...ount See Fig 3 2 On 4WD models raise front end by placing floor jack under as shown See Fig 3 or 4 To raise rear end place floor jack under rear axle next to leaf spring mount Support vehicle with jac...

Page 1574: ...Fig 4 Identifying Hoisting Jacking Locations Durango Courtesy of Chrysler Corp Ram Van Wagon To raise front end place floor jack under center of front...

Page 1575: ...ot See Fig 5 To raise rear end place floor jack under rear axle next to leaf spring U bolt mount Fig 5 Identifying Hoisting Jacking Locations Ram Van Wagon Courtesy of Chrysler Corp RIDING HEIGHT SPEC...

Page 1576: ...p type drive hoists If using swiveling arm hoist ensure lifting arms pads or ramps are positioned evenly on frame rails and adequate clearance is maintained for transfer case 4WD models or skid plate...

Page 1577: ...TE Moving rear of control arm changes caster significantly Moving front of control arm changes camber significantly Fig 7 Adjusting Camber Caster Dakota Durango Ram Pickup With Independent Front Suspe...

Page 1578: ...ter cam on lower control arm See WHEEL ALIGNMENT SPECIFICATIONS table See Fig 8 Fig 8 Adjusting Caster Ram Pickup With Link Coil Suspension Courtesy of Chrysler Corp Ram Van Wagon 1 Use Adjuster Tool...

Page 1579: ...control arm See WHEEL ALIGNMENT SPECIFICATIONS table Tighten pivot retaining bolts See TORQUE SPECIFICATIONS table Fig 9 Camber Caster Angle Adjustment Tool Courtesy of Chrysler Corp FRONT WHEEL TOE A...

Page 1580: ...t steering gear to tie rod boots at tie rod Remove steering wheel clamp See Fig 10 Ram Van Wagon 4WD Models Center steering wheel and hold with steering wheel clamp Loosen tie rod adjustment sleeve cl...

Page 1581: ...ures are provided by the manufacturer TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft Lbs N m Axle Bracket Eccentric Cam Nut Ram Pickup 95 130 Pivot Bar To Frame Bolts Dakota Durango Ram Pi...

Page 1582: ...ont 0 15 0 25 To 0 55 Rear 0 0 25 To 0 25 Caster 2 1 4 0 4 To 2 4 Toe In 3 Front 0 05 1 5 0 05 To 0 15 1 5 To 4 Rear 0 0 0 2 To 0 2 5 To 5 Toe In 2 Front 0 1 0 1 To 0 3 Rear 0 0 4 To 0 4 1998 2WD AWD...

Page 1583: ...To 1 4WD Short Bed 5 5 2WD Long Bed 0 5 0 To 1 4WD Long Bed 5 5 Ram 2500 HD 2WD Long Bed 0 5 0 To 1 4WD Long Bed 5 5 2WD Club Cab Club Cab Short Bed 0 5 0 To 1 4WD Club Cab Quad Cab Short Bed 5 5 2WD...

Page 1584: ...n 3 All Models 0 05 1 5 0 To 0 1 0 To 2 5 Toe In 2 All Models 0 1 0 To 0 2 Ram Van Wagon Camber 2 0 0 6 To 0 6 Caster 2 2 5 1 5 To 3 5 Toe In 3 0 0 0 12 To 0 12 3 To 3 Toe In 2 0 25 To 0 25 1 Specific...

Page 1585: ...of same construction and tread style equal in tread wear and overall diameter Verify that radial and axial runout is not excessive Inflation should be at manufacturer s specifications Steering linkage...

Page 1586: ...caster and toe in using this sequence Follow instructions of the alignment equipment manufacturer CAUTION Do not attempt to correct alignment by straightening parts Damaged parts must be replaced Fig...

Page 1587: ...from side of vehicle See Fig 4 2 When axis is tilted backward from vertical caster is positive This creates a trailing action on front wheels When axis is tilted forward caster is negative causing a l...

Page 1588: ...tered position Face of tie rod end must be parallel with machined surface of steering rod end to prevent binding 3 When tightening clamps make certain that clamp bolts are positioned so there will be...

Page 1589: ...vel and camber should be properly adjusted See Fig 6 2 If camber cannot be brought within limits and steering axis inclination is correct steering knuckle is bent If camber and steering axis inclinati...

Page 1590: ...hes mounted in driver s door panel NOTE Power window circuits on Caravan Town Country and Voyager use Positive Temperature Coefficient PTC devices The PTC is a specified amperage solid state resettabl...

Page 1591: ...is okay 3 If voltmeter indicates battery voltage at one terminal only replace faulty circuit breaker If voltmeter indicates no voltage at either terminal check for an open or shorted circuit to circu...

Page 1592: ...indow glass tracks and regulator for sticking binding or improper adjustment Repair as necessary and recheck system operation POWER WINDOW SWITCH 1 Remove window switch from door trim panel See POWER...

Page 1593: ...sler Corp Fig 3 Identifying Driver s Passenger s Power Window Switch Terminals Dakota Ram Pickup Courtesy of Chrysler Corp Fig 4 Identifying Passenger s Power Window Switch Terminals Durango Courtesy...

Page 1594: ...indow Switch Terminals Ram Van Ram Wagon Courtesy of Chrysler Corp Fig 6 Identifying Passenger s Power Window Switch Terminals Ram Van Ram Wagon Courtesy of Chrysler Corp DRIVER S WINDOW SWITCH CONTIN...

Page 1595: ...Off 1 3 2 3 3 4 3 6 Up Left 3 4 5 6 Right 1 5 2 3 Down Left 3 6 4 5 Right 1 3 2 5 Light 3 5 DRIVER S WINDOW SWITCH CONTINUITY DURANGO Switch Position Continuity Between Terminals Off 2 5 3 5 5 6 5 11...

Page 1596: ...1 4 3 11 Light 8 11 PASSENGER S WINDOW SWITCH CONTINUITY DURANGO Switch Position Continuity Between Terminals Off 2 5 3 6 Up 2 5 3 4 Down 3 6 4 5 PASSENGER S WINDOW SWITCH CONTINUITY RAM VAN RAM WAGON...

Page 1597: ...ble Remove driver s front power window switch See POWER WINDOW SWITCH under REMOVAL INSTALLATION 3 Check for continuity between ground and terminal No 5 Black wire at driver s power window switch wiri...

Page 1598: ...or wire connector terminals of inoperative power window If continuity exists in all circuits power window switch and switch circuits are okay Check power window motor See POWER WINDOW MOTOR under COMP...

Page 1599: ...e faulty power window switch as necessary If switch is okay go to next step 5 Using an ohmmeter check continuity of each circuit between inoperative power window switch wiring harness connector and co...

Page 1600: ...k gently pry around perimeter of D pillar trim panel and separate trim panel from inner quarter panel Disconnect rear speaker connector if equipped 3 On short wheelbase models pass seat belt through s...

Page 1601: ...ith aid of an assistant lower window glass 1 2 inches Drum will rotate when glass is lowered 5 Install cover plate onto window motor Connect window motor connector Remove tape holding window in place...

Page 1602: ...w regulator to inner door panel Remove remaining window regulator mounting bolts Remove window regulator and motor assembly through access hole in inner door panel To install reverse removal procedure...

Page 1603: ...connector Remove watershield Remove inner and outer belt weatherstrip from door 2 Lower glass enough to expose window glass to regulator bolts Loosen window glass to regulator bolts Loosen bolts at fr...

Page 1604: ...To complete installation reverse removal procedure Fig 10 Removing Power Vent Motor Caravan Town Country Voyager Courtesy of Chrysler Corp POWER WINDOW SWITCH Removal Installation Caravan Town Countr...

Page 1605: ...kup Disconnect negative battery cable Using a trim stick gently pry upper edge of switch bezel to release retainer securing bezel to door trim panel Pull switch and bezel away from door trim panel and...

Page 1606: ...Fig 11 Power Window System Wiring Diagram Caravan Town Country Voyager...

Page 1607: ...Fig 12 Power Window System Wiring Diagram Dakota...

Page 1608: ...Fig 13 Power Window System Wiring Diagram Durango...

Page 1609: ...Fig 14 Power Window System Wiring Diagram Ram Pickup...

Page 1610: ...Fig 15 Power Window System Wiring Diagram Ram Van Ram Wagon...

Page 1611: ...anel outboard of glove box CTM switches an intermittent wiper relay located in Power Distribution Center PDC On high line models CTM is connected to Chrysler Collision Detection CCD data bus network t...

Page 1612: ...TTENT WIPER RELAY 1 Remove relay See INTERMITTENT WIPER RELAY under REMOVAL INSTALLATION Check continuity between relay terminals No 30 and 87A Continuity should exist Check continuity between relay t...

Page 1613: ...ith air bag restraint systems See appropriate AIR BAG RESTRAINT SYSTEMS article before servicing steering wheel or column Use extreme caution to avoid personal injury and vehicle damage NOTE If proble...

Page 1614: ...ct negative battery cable Turn ignition on While depressing washer switch check voltage at washer pump harness connector Brown wire terminal If battery voltage exists replace pump If battery voltage d...

Page 1615: ...or terminal No 12 White Dark Blue wire See Fig 3 If continuity does not exist repair open in White Dark Blue wire If continuity exists go to next step 6 Check continuity between multifunction switch h...

Page 1616: ...es equipped with air bag restraint systems see appropriate AIR BAG RESTRAINT SYSTEMS article before servicing steering wheel or column Use extreme caution to avoid personal injury and vehicle damage C...

Page 1617: ...ove wiper linkage and motor module To install reverse removal procedure Align wiper arms See WIPER BLADES under ADJUSTMENTS WIPER WASHER SWITCH NOTE Wiper washer switch is part of multifunction steeri...

Page 1618: ...voir being careful not to puncture reservoir Remove and discard grommet To install reverse removal procedure Use a NEW rubber grommet TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application INCH Lbs N...

Page 1619: ...Fig 5 Wiper Washer System Wiring Diagram Ram Pickup...

Page 1620: ...L WIRING DIAGRAMS 1999 Dodge Pickup R1500 1999 ENGINE PERFORMANCE Wiring Diagrams CHRY All Models WIRING DIAGRAMS AVENGER SEBRING COUPE Fig 1 PCM Wiring Diagram Avenger Sebring Coupe 2 0L 1 Of 3...

Page 1621: ...Fig 2 PCM Wiring Diagram Avenger Sebring Coupe 2 0L 2 Of 3...

Page 1622: ...Fig 3 PCM Wiring Diagram Avenger Sebring Coupe 2 0L 3 Of 3...

Page 1623: ...Fig 4 PCM Wiring Diagram Avenger Sebring Coupe 2 5L 1 Of 3...

Page 1624: ...Fig 5 PCM Wiring Diagram Avenger Sebring Coupe 2 5L 2 Of 3...

Page 1625: ...Fig 6 PCM Wiring Diagram Avenger Sebring Coupe 2 5L 3 Of 3 BREEZE STRATUS...

Page 1626: ...Fig 7 PCM Wiring Diagram Breeze Stratus 2 0L 2 4L 1 Of 3...

Page 1627: ...Fig 8 PCM Wiring Diagram Breeze Stratus 2 0L 2 4L 2 Of 3...

Page 1628: ...Fig 9 PCM Wiring Diagram Breeze Stratus 2 0L 2 4L 3 Of 3 CARAVAN TOWN COUNTRY VOYAGER...

Page 1629: ...Fig 10 PCM Wiring Diagram Caravan Voyager 2 4L 1 Of 3...

Page 1630: ...Fig 11 PCM Wiring Diagram Caravan Voyager 2 4L 2 Of 3...

Page 1631: ...Fig 12 PCM Wiring Diagram Caravan Voyager 2 4L 3 Of 3...

Page 1632: ...Fig 13 PCM Wiring Diagram Caravan Voyager 3 0L 1 Of 3...

Page 1633: ...Fig 14 PCM Wiring Diagram Caravan Voyager 3 0L 2 Of 3...

Page 1634: ...Fig 15 PCM Wiring Diagram Caravan Voyager 3 0L 3 Of 3...

Page 1635: ...Fig 16 PCM Wiring Diagram Caravan Town Country Voyager 3 3L 3 3L Flex Fuel 3 8L 1 Of 3...

Page 1636: ...Fig 17 PCM Wiring Diagram Caravan Town Country Voyager 3 3L 3 3L Flex Fuel 3 8L 2 Of 3...

Page 1637: ...Fig 18 PCM Wiring Diagram Caravan Town Country Voyager 3 3L 3 3L Flex Fuel 3 8L 3 Of 3 CIRRUS STRATUS...

Page 1638: ...Fig 19 PCM Wiring Diagram Cirrus Stratus 2 5L 1 Of 3...

Page 1639: ...Fig 20 PCM Wiring Diagram Cirrus Stratus 2 5L 2 Of 3...

Page 1640: ...Fig 21 PCM Wiring Diagram Cirrus Stratus 2 5L 3 Of 3 CONCORDE INTREPID LHS 300M...

Page 1641: ...Fig 22 PCM Wiring Diagram Concorde Intrepid 2 7L 1 Of 3...

Page 1642: ...Fig 23 PCM Wiring Diagram Concorde Intrepid 2 7L 2 Of 3...

Page 1643: ...Fig 24 PCM Wiring Diagram Concorde Intrepid 2 7L 3 Of 3...

Page 1644: ...Fig 25 PCM Wiring Diagram Concorde Intrepid 3 2L LHS 300M 3 5L 1 Of 3...

Page 1645: ...Fig 26 PCM Wiring Diagram Concorde Intrepid 3 2L LHS 300M 3 5L 2 Of 3...

Page 1646: ...Fig 27 PCM Wiring Diagram Concorde Intrepid 3 2L LHS 300M 3 5L 3 Of 3 DAKOTA...

Page 1647: ...Fig 28 PCM Wiring Diagram Dakota 2 5L 1 Of 3...

Page 1648: ...Fig 29 PCM Wiring Diagram Dakota 2 5L 2 Of 3...

Page 1649: ...Fig 30 PCM Wiring Diagram Dakota 2 5L 3 Of 3...

Page 1650: ...Fig 31 PCM Wiring Diagram Dakota 3 9L 5 2L 1 Of 3...

Page 1651: ...Fig 32 PCM Wiring Diagram Dakota 3 9L 5 2L 2 Of 3...

Page 1652: ...Fig 33 PCM Wiring Diagram Dakota 3 9L 5 2L 3 Of 3...

Page 1653: ...Fig 34 PCM Wiring Diagram Dakota 5 9L 1 Of 3...

Page 1654: ...Fig 35 PCM Wiring Diagram Dakota 5 9L 2 Of 3...

Page 1655: ...Fig 36 PCM Wiring Diagram Dakota 5 9L 3 Of 3 DURANGO...

Page 1656: ...Fig 37 PCM Wiring Diagram Durango 3 9L 5 2L 5 9L 1 Of 3...

Page 1657: ...Fig 38 PCM Wiring Diagram Durango 3 9L 5 2L 5 9L 2 Of 3...

Page 1658: ...Fig 39 PCM Wiring Diagram Durango 3 9L 5 2L 5 9L 3 Of 3 NEON...

Page 1659: ...Fig 40 PCM Wiring Diagram Neon 2 0L 1 Of 3...

Page 1660: ...Fig 41 PCM Wiring Diagram Neon 2 0L 2 Of 3...

Page 1661: ...Fig 42 PCM Wiring Diagram Neon 2 0L 3 Of 3 RAM PICKUP...

Page 1662: ...Fig 43 PCM Wiring Diagram Ram Pickup 3 9L 5 2L 5 9L 1 Of 3...

Page 1663: ...Fig 44 PCM Wiring Diagram Ram Pickup 3 9L 5 2L 5 9L 2 Of 3...

Page 1664: ...Fig 45 PCM Wiring Diagram Ram Pickup 3 9L 5 2L 5 9L 3 Of 3...

Page 1665: ...Fig 46 PCM Wiring Diagram Ram Pickup 2500 3500 8 0L 1 Of 3...

Page 1666: ...Fig 47 PCM Wiring Diagram Ram Pickup 2500 3500 8 0L 2 Of 3...

Page 1667: ...Fig 48 PCM Wiring Diagram Ram Pickup 2500 3500 8 0L 3 Of 3...

Page 1668: ...Fig 49 PCM Wiring Diagram Ram Pickup 2500 3500 5 9L 24 Valve Diesel 1 Of 3...

Page 1669: ...Fig 50 PCM Wiring Diagram Ram Pickup 2500 3500 5 9L 24 Valve Diesel 2 Of 3...

Page 1670: ...Fig 51 PCM Wiring Diagram Ram Pickup 2500 3500 5 9L 24 Valve Diesel 3 Of 3 RAM VAN RAM WAGON...

Page 1671: ...Fig 52 PCM Wiring Diagram Ram Van Ram Wagon 1500 3 9L 1 Of 3...

Page 1672: ...Fig 53 PCM Wiring Diagram Ram Van Ram Wagon 1500 3 9L 2 Of 3...

Page 1673: ...Fig 54 PCM Wiring Diagram Ram Van Ram Wagon 1500 3 9L 3 Of 3...

Page 1674: ...Fig 55 PCM Wiring Diagram Ram Van Ram Wagon 5 2L Gasoline 5 9L 1 Of 3...

Page 1675: ...Fig 56 PCM Wiring Diagram Ram Van Ram Wagon 5 2L Gasoline 5 9L 2 Of 3...

Page 1676: ...Fig 57 PCM Wiring Diagram Ram Van Ram Wagon 5 2L Gasoline 5 9L 3 Of 3...

Page 1677: ...Fig 58 PCM Wiring Diagram Ram Van Ram Wagon 5 2L CNG 1 Of 3...

Page 1678: ...Fig 59 PCM Wiring Diagram Ram Van Ram Wagon 5 2L CNG 2 Of 3...

Page 1679: ...Fig 60 PCM Wiring Diagram Ram Van Ram Wagon 5 2L CNG 3 Of 3 SEBRING CONVERTIBLE...

Page 1680: ...Fig 61 PCM Wiring Diagram Sebring Convertible 2 4L 1 Of 4...

Page 1681: ...Fig 62 PCM Wiring Diagram Sebring Convertible 2 4L 2 Of 4...

Page 1682: ...Fig 63 PCM Wiring Diagram Sebring Convertible 2 4L 3 Of 4...

Page 1683: ...Fig 64 PCM Wiring Diagram Sebring Convertible 2 4L 4 Of 4...

Page 1684: ...Fig 65 PCM Wiring Diagram Sebring Convertible 2 5L 1 Of 4...

Page 1685: ...Fig 66 PCM Wiring Diagram Sebring Convertible 2 5L 2 Of 4...

Page 1686: ...Fig 67 PCM Wiring Diagram Sebring Convertible 2 5L 3 Of 4...

Page 1687: ...Fig 68 PCM Wiring Diagram Sebring Convertible 2 5L 4 Of 4...

Page 1688: ......

Page 1689: ......

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