Jeep 1996 Grand Cherokee Service Manual Download | Manualshive

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CIRCUIT IDENTIFICATION

All circuits in the diagrams use an alpha/numeric

code to identify the wire and its function (Fig. 3). To
identify which circuit code applies to a system, refer
to the Circuit Identification Code Chart. This chart
shows the main circuits only and does not show the
secondary codes that may apply to some models.

CONNECTORS

Connectors shown in the diagrams are identified

using the international standard arrows for male and
female terminals (Fig. 4). A connector identifier is
placed next to the arrows to indicate the connector
number (Fig. 4).

For viewing connector pin outs, with two terminals

or greater, refer to section 8W-80. This section iden-
tifies the connector by number and provides terminal
numbering, circuit identification, wire colors, and
functions.

All connectors are viewed from the terminal end

unless otherwise specified. To find the connector loca-
tion in the vehicle refer to section 8W-90. This sec-
tion uses the connector identification number from
the wiring diagrams to provide a figure number ref-
erence.

TAKE OUTS

The abbreviation T/O is used in the component

location section to indicate a point in which the wir-
ing harness branches out to a component.

SYMBOLS

Various symbols are used throughout the Wiring

Diagrams. These symbols can be identified by refer-
ring to the symbol identification chart (Fig. 5).

Fig. 3 Circuit Identification

Fig. 4 Connector Identification

ZJ

8W - 01 GENERAL INFORMATION

8W - 01 - 3

DESCRIPTION AND OPERATION (Continued)

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Summary of Contents for 1996 Grand Cherokee

Page 1: ...Welcome to the 1996 ZJ Jeep Grand Cherokee Electronic Service Manual and Supplement Click on logo to begin CLICK HERE FOR INSTRUCTIONS ...

Page 2: ...rtain service operations These special service tools or their equivalent if not obtainable through a local source are available through the following outlet C D Riley Enterprises Ltd P O Box 243 Amherstburg Ontario N9V 2Z4 Telephone 519 736 4600 FAX 519 736 8433 INTERNATIONAL The special service tools referred to herein are required for certain service operations These special service tools or the...

Page 3: ...never working on vehicles or vehicle components It is important to note that this publication contains various Cautions and Warnings These should be carefully read in order to minimize the risk of personal injury or the possibility that improper service methods may damage the vehicle or render it unsafe It is important to note that these Cautions and Warnings cover only the situations and procedur...

Page 4: ... TEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obli gations upon itself to install them on its products previously manufactured Litho in ...

Page 5: ...p The first page of the group has a contents section that lists major topics within the group If you are not sure which Group contains the infor mation you need look up the Component System in the alphabetical index located in the rear of this manual A Service Manual Comment form is included at the rear of this manual Use the form to provide Chrysler Corporation with your comments and suggestions ...

Page 6: ...Warning Systems 8K Wiper and Washer Systems 8L Lamps 8M Passive Restraint Systems 8N Electrically Heated Systems 8P Power Lock Systems 8Q Vehicle Theft Security Systems 8R Power Seat Systems 8S Power Window Systems 8T Power Mirror Systems 8U Chime Buzzer Warning Systems 8V Overhead Console Systems 8W Wiring Diagrams 9 Engine 11 Exhaust System and Intake Manifold 13 Frame and Bumpers 14 Fuel System...

Page 7: ......

Page 8: ...ing chart to determine the identification of a vehicle The Vehicle Identification Number is also imprinted on the Body Code Plate Equipment Identification Plate Vehicle Safety Certification Label Frame rail VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION INTERPRETATION CODE DESCRIPTION 1 Country of Origin 1 United States 2 Make J Jeep 3 Vehicle Type 4 MPV 4 Gross Vehicle Weight Rating G 5001...

Page 9: ...tion should be read from left to right Start with line 1 at the bot tom of the plate up to line 7 at the top of the code plate Refer to the decoding chart to decode lines 1 through 3 Lines 4 through 7 on the plate are imprinted in sequence according to the following descriptions 3 character sales code 3 digit numerical code 6 digit SEC code If there is not enough space left in the row for all of t...

Page 10: ...2 9 The metric strength class identification number is imprinted on the head of the bolt The higher the class number the greater the bolt strength Some metric nuts are imprinted with a single digit strength class on the nut face Refer to the Fastener Identification and Fastener Strength Charts METRIC SYSTEM WARNING USE OF AN INCORRECT FASTENER MAY RESULT IN COMPONENT DAMAGE OR PER SONAL INJURY Fig...

Page 11: ...l Torque Charts appear at the end of many Groups Refer to the Standard Torque Specifi cations Chart for torque references not listed in the individual torque charts INTERNATIONAL CONTROL AND DISPLAY SYMBOLS Fig 3 Thread Notation SAE and Metric 4 INTRODUCTION ZJ GENERAL INFORMATION Continued ...

Page 12: ...FASTENER IDENTIFICATION ZJ INTRODUCTION 5 GENERAL INFORMATION Continued ...

Page 13: ...FASTENER STRENGTH 6 INTRODUCTION ZJ GENERAL INFORMATION Continued ...

Page 14: ...Fig 4 Metric Prefixes CONVERSION FORMULAS AND EQUIVALENT VALUES ZJ INTRODUCTION 7 GENERAL INFORMATION Continued ...

Page 15: ...METRIC CONVERSION 8 INTRODUCTION ZJ GENERAL INFORMATION Continued ...

Page 16: ...TORQUE SPECIFICATIONS ZJ INTRODUCTION 9 GENERAL INFORMATION Continued ...

Page 17: ......

Page 18: ...ns portation Schedule B lists maintenance intervals for vehi cles that are operated under the conditions listed at the beginning of the Maintenance Schedule section Use the schedule that best describes your driving conditions Where time and mileage are listed follow the interval that occurs first PARTS AND LUBRICANT RECOMMENDATIONS When service is required Chrysler Corporation recommends that only...

Page 19: ...d products have the NLGI symbol Fig 3 on the label At the bottom NLGI symbol is the usage and quality identification letters Wheel bearing lubricant is identified by the letter G Chassis lubricant is identified by the latter L The letter following the usage letter indicates the quality of the lubricant The following symbols indi cate the highest quality FLUID CAPACITIES FUEL TANK All 87 4 L 23 gal...

Page 20: ...s dusty areas and very short trip driving UNSCHEDULED INSPECTION AT EACH STOP FOR FUEL Check engine oil level add as required Check windshield washer solvent and add if required ONCE A MONTH Check tire pressure and look for unusual wear or damage Inspect battery and clean and tighten terminals as required Check electrolyte level and add water as needed Check fluid levels of coolant reservoir power...

Page 21: ... or 24 months since last change 82 500 Miles 132 000 km or at 66 months Change engine oil Replace engine oil filter Lubricate steering linkage 4x4 only Flush and replace engine coolant if it has been 30 000 miles 48 000 km or 24 months since last change 90 000 Miles 144 000 km or at 72 months Change engine oil Replace engine oil filter Replace engine air cleaner element Replace spark plugs Inspect...

Page 22: ...nkage 4x4 only Inspect brake linings 27 000 Miles 43 000 km Change engine oil Replace engine oil filter Lubricate steering linkage 4x4 only 30 000 Miles 48 000 km Change engine oil Replace engine oil filter Replace engine air cleaner element Inspect PCV valve and replace if necessary 5 2L only Replace spark plugs Inspect drive belt Drain and refill transfer case fluid Lubricate steering linkage Th...

Page 23: ...ic transmission fluid Drain and refill front and rear axles Lubricate steering linkage 4x4 only Inspect brake linings 75 000 Miles 120 000 km Change engine oil Replace engine oil filter Inspect engine air cleaner element replace as necessary Lubricate steering linkage 78 000 Miles 125 000 km Change engine oil Replace engine oil filter Lubricate steering linkage 4x4 only 81 000 Miles 130 000 km Cha...

Page 24: ...182 000 km Change engine oil Replace engine oil filter Lubricate steering linkage 4x4 only 117 000 Miles 187 000 km Change engine oil Replace engine oil filter Lubricate steering linkage 4x4 only 120 000 Miles 192 000 km Change engine oil Replace engine oil filter Replace engine air cleaner element Replace ignition wires Replace spark plugs Inspect PCV valve and replace if necessary 5 2L only Insp...

Page 25: ...n and tension Fuel fumes or leakage correct if necessary Frozen battery Yellow or bright color test indicator if equipped Low battery fluid level CAUTION If the cause of starting problem on dis abled vehicle is severe damage to booster vehicle charging system can result 2 When using another vehicle as a booster source turn off all accessories place gear selector in park or neutral set park brake o...

Page 26: ... towed vehicle should be raised until lifted wheels are a minimum 100 mm 4 in from the ground Be sure there is adequate ground clearance at the oppo site end of the vehicle especially when towing over rough terrain or steep rises in the road If necessary remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the ground to increase the ground clearance at the opposite ...

Page 27: ... transfer case to NEUTRAL 4WD TOWING FRONT END LIFTED To prevent damage to front facia components use only a Wheel Lift type towing device or Flat Bed hauling equipment If using the wheel lift towing method install tow dollies under rear wheels EMERGENCY TOW HOOKS WARNING REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS THE TOW STRAPS CHAINS COULD BREAK AND CAUSE SERI...

Page 28: ...ED ARE FOR A COMPLETE VEHI CLE WHEN A CHASSIS OR DRIVETRAIN COMPO NENT IS REMOVED FROM A VEHICLE THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST Fig 3 Correct Vehicle Lifting Locations ZJ LUBRICATION AND MAINTENANCE 0 11 SERVICE PROCEDURES Continued ...

Page 29: ......

Page 30: ...ead position after turns CAMBER is the inward or outward tilt of the wheel relative to the center of the vehicle Tilting the top of the wheel inward provides negative camber Tilting the top of the wheel outward provides positive camber Incorrect camber will cause wear on the inside or outside edge of the tire The angle is not adjustable the damaged component s must be replaced to correct mis align...

Page 31: ...al lat eral runout and unbalance Refer to Group 22 Wheels and Tires for diagnosis information 4 Inspect ball studs linkage pivot points and steering gear for looseness roughness binding or a sticking condition Refer to Group 19 Steering for additional information 5 Inspect suspension components for wear and noise Check components for correct torque Wheel Alignment Measurements 2 2 SUSPENSION ZJ SE...

Page 32: ...SUSPENSION AND STEERING SYSTEM DIAGNOSIS ZJ SUSPENSION 2 3 SERVICE PROCEDURES Continued ...

Page 33: ...he clamp bolts as shown Fig 2 and tighten to 49Nzm 36 ft lbs NOTE Tighten clamp bolt nearest the pitman arm first Make sure the toe setting does not change during clamp tightening 5 Adjust the left wheel toe position with the tie rod Turn the sleeve until the left wheel is within 05 TOE IN position as the right wheel Position the clamp bolts as shown Fig 2 and tighten to Vehicles with 6 cyl engine...

Page 34: ... ALIGNMENT FRONT WHEELS ADJUSTMENT PREFERRED RANGE CASTER 7 6 5 to 7 5 CAMBER not adjustable NA 1 13 to 0 13 TOE IN each wheel 0 12 0 to 0 22 Toe Differential Left to Right 05 REAR AXLE ADJUSTMENT SPECIFICATION THRUST ANGLE not adjustable 25 TOTAL TOE IN not adjustable 0 00 to 0 5 ZJ SUSPENSION 2 5 SERVICE PROCEDURES Continued 1996 Grand Cherokee Publication No 81 370 6147 TSB 26 04 96 April 1996 ...

Page 35: ...PTION AND OPERATION FRONT SUSPENSION The Grand Cherokee front suspension is a link coil design comprised of Fig 1 Drive axle 4WD tube axle 2WD Track bar Stabilizer bar Upper and lower suspension arms Coil springs Dual action shock absorbers Jounce bumpers Link Coil Suspension The link coil suspension allows each wheel to adapt to different road surfaces without greatly affecting the opposite wheel...

Page 36: ...ication of the front suspension steering system components is required Refer to Group 0 Lubrication And Maintenance for the rec ommended maintenance schedule CAUTION Suspension components with rubber bushings should be tightened with the vehicle at normal height It is important to have the springs supporting the weight of the vehicle when the fas teners are torqued If springs are not at their norm...

Page 37: ...ll the jounce bumper on the upper spring mount Tighten the bolts to 42 N m 31 ft lbs 2 Position the coil spring on the axle pad Install the spring retainer and bolt 3 Raise the axle into position until the spring seats in the upper mount 4 Connect the stabilizer bar links and shock absorbers to the axle bracket Connect the track bar to the frame rail bracket 5 Install the lower suspension arm to t...

Page 38: ...om axle 2 Position Receiver 7932 1 J 35581 1 over the bushing in the axle and install Bushing Removal In staller Fig 5 3 Remove the bushing by tightening the Long Nut NOTE For two wheel drive axles and right side on Model 30 axle do not remove Receiver 7932 1 J 35581 1 at this time INSTALLATION 1 Position new bushing Receiver and Installer on axle Fig 6 2 Install the bushing by tightening the Long...

Page 39: ...d 3 Remove the supports and lower the vehicle 4 Tighten the bolt at the axle shaft tube bracket to 75 N m 55 ft lbs 5 Tighten the ball stud nut to 81 N m 60 ft lbs Install a new cotter pin 6 Check alignment if a new track bar was installed HUB BEARING The Hub Bearing is serviced as an assembly REMOVAL 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Remove the brake component...

Page 40: ...r refer to Group 5 Brakes for procedure 6 Install wheel and tire assembly use new lug nut on stud or studs that were replaced 7 Remove support and lower vehicle SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Shock Absorber Upper Nut 23 N m 17 ft lbs Lower Nut 28 N m 250 in lbs Suspension Arm Upper Nuts 75 N m 55 ft lbs Suspension Arm Lower Nuts 115 N m 85 ft lbs Stabilizer Bar Clamp Bolt 54 N m 40...

Page 41: ...SPECIAL TOOLS FRONT SUSPENSION Remover Installer Suspension Bushing 7932 J 35581 Nut Long 7603 J 21474 18 Bolt Special 7604 J 21474 19 Remover C 4150A 2 12 SUSPENSION ZJ ...

Page 42: ...nd of the vehicle over various road conditions The top of the shock absorbers are bolted to the body The bottom of the shocks are bolted to the axle shock absorber bracket Coil Springs The coil springs mount up in the fender shield that is part of the unitized body bracket There is a rubber isolator between the top of the spring and bracket to isolate road noise The bot tom of the spring seats on ...

Page 43: ...nstall lower bolt and nut finger tight 4 Remove the supports and lower the vehicle 5 Tighten the lower nut to 92 N m 68 ft lbs COIL SPRING REMOVAL 1 Raise and support the vehicle Position a hydraulic jack under the axle to support it 2 Disconnect the stabilizer bar link and shock absorber from the axle bracket 3 Disconnect the track bar from the frame rail bracket 4 Lower the axle until the spring...

Page 44: ...nd tire 2 Disconnect the stabilizer bar links from the axle brackets Fig 4 3 Lower the exhaust by disconnecting the muffler and tail pipe hangers 4 Disconnect the stabilizer bar from the links 5 Disconnect the stabilizer bar clamps from the frame rails Remove the stabilizer bar INSTALLATION 1 Position the stabilizer bar on the frame rail and install the clamps and bolts Ensure the bar is centered ...

Page 45: ...e rail bracket Loosely install the bolt and flag nut 3 Remove the supports and lower the vehicle 4 Tighten the track bar bolts 100 N m 74 ft lbs SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Shock Absorber Upper Nut 70 N m 52 ft lbs Lower Nut 92 N m 68 ft lbs Suspension Arm Upper Nuts 75 N m 55 ft lbs Suspension Arm Lower Nuts 177 N m 130 ft lbs Stabilizer Bar Clamp Bolt 54 N m 40 ft lbs Link Nut...

Page 46: ...e It must also be capable of changing length while transmitting torque The axle rides sus pended by springs in a floating motion This means the propeller shaft must be able to change angles when going over various roads This is accomplished through universal joints which permit the propeller shaft to operate at different angles The slip joints or yokes permit contraction or expansion Tubular prope...

Page 47: ... leakage and damage each time the vehicle is ser viced If seal leakage or damage exists the U joint should be replaced PRECAUTIONS Use exact replacement hardware for attaching the propeller shafts Exact replacement will ensure safe operation The specified torque must always be applied when tightening the fasteners Put reference marks on the propshaft yoke and axle or transmission yoke before servi...

Page 48: ...eline vibration can also result from loose or damaged engine mounts Refer to Group 21 Trans missions for additional information Propeller shaft vibration will increase as the vehi cle speed is increased A vibration that occurs within a specific speed range is not caused by propeller shaft unbalance Defective universal joints or an incorrect propeller shaft angle are usually the cause Fig 4 Double ...

Page 49: ...e wheel lug nuts to retain the brake drums 3 Mark and number the shaft six inches from the yoke end at four positions 90 apart 4 Run and accelerate the vehicle until vibration occurs Note the intensity and speed the vibration occurred Stop the engine 5 Install a screw clamp at position 1 Fig 7 6 Start the engine and re check for vibration If there is little or no change in vibration move the clamp...

Page 50: ...s speed ing up and slowing down of the joint must be can celled to produce a smooth power flow This is done through phasing and proper universal joint working angles A propeller shaft is properly phased when the yoke ends are on the same plane or in line A twisted shaft will throw the yokes out of phase and cause a notice able vibration When taking universal joint angle measurements or checking ph...

Page 51: ...ment will give you the transmis sion or Output Yoke Angle A 3 Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing parallel to the shaft Fig 12 Center bubble in sight glass and record measurement This measurement can also be taken at the rear end of the shaft This measurement will give you the Propeller Shaft Angle C 4 Subtract smaller figure from larger C minus A to obtain Tra...

Page 52: ... front axle pinion yoke 6 Remove bolts holding rear cardan joint to the transfer case yoke 7 Separate the cardan joint from the transfer case yoke 8 Push rear of propeller shaft upward to clear transfer case yoke 9 Separate CV joint from front axle 10 Separate propeller shaft from vehicle INSTALLATION 1 Position front propeller shaft under vehicle with rear cardan joint over the transfer case yoke...

Page 53: ...and at each end of the propeller shaft These marks will be used for installation reference 3 Remove the U joint strap bolts at the pinion shaft yoke 4 Slide the slip yoke off of the transmission transfer case output shaft and remove the propeller shaft Fig 17 INSTALLATION 1 Slide the slip yoke on the transmission transfer case output shaft Align the installation reference marks at the axle yoke an...

Page 54: ...If the bearing assembly will not pull out by hand after pressing tap the base of the lug near it to dislodge 7 To remove the opposite bearing turn the yoke over and straighten the cross in the open hole Then carefully press the end of the cross until the remain ing bearing can be removed Fig 20 CAUTION If the cross or bearing assembly are cocked when being pressed the bearing assembly will score t...

Page 55: ...ll the opposite bearing assembly If the joint is stiff strike the yoke with a soft hammer to seat the needle bearings Install a snap ring 6 Add grease to lube fitting if equipped 7 Install the propeller shaft DOUBLE CARDAN CV REMOVAL Cardan universal joints are not serviceable If worn or leaking they must be replaced as a unit 1 Remove the propeller shaft Refer to Propeller Shaft Replacement in th...

Page 56: ...oving the opposite side bearing This will then allow removal of the cross centering kit assembly and spring Fig 26 7 Press the remaining bearing assemblies out the other cross as described above to complete the disas sembly INSTALLATION During installation ensure that the spiders and yokes are aligned to the reference marks 1 Fit a cross into the tube yoke Fig 27 Fig 24 Press Out Bearing Fig 25 Re...

Page 57: ...ng assembly in place and install a snap ring Fig 29 4 Flip the tube yoke and bearing assembly instal lation on the opposite trunnion Install a snap ring Fig 30 5 Fit the center yoke on the remaining two trun nions and press bearing assemblies in place both sides Fig 31 Install a snap ring Fig 28 Install Bearing Assembly Fig 29 Press In Bearing Assembly Fig 30 Press In Bearing Assembly Fig 31 Insta...

Page 58: ...ng two bearing assemblies into place and install snap rings Fig 34 9 Tap the snap rings to allow them to seat into the grooves Fig 35 10 Check for proper assembly Flex the CV joint beyond center it should snap over center in both directions when correctly assembled Fig 36 11 Install the propeller shaft Fig 32 Install Centering Kit Fig 33 Install Remaining Cross Fig 34 Press In Bearing Assembly Fig...

Page 59: ... the pinion gear angle at the lower suspen sion arms with shims Fig 38 Adding shims will decrease the pinion gear shaft angle but will increase the caster angle The pinion gear shaft angle has pri ority over the caster angle SPECIFICATIONS TORQUE DESCRIPTION TORQUE Front Propeller Shaft Bolts Rear Yoke 27 N m 20 ft lbs Bolts Front Yoke 41 N m 30 ft lbs Nut Lock 115 N m 85 ft lbs Rear Propeller Sha...

Page 60: ...xle shafts are retained by nuts at the hub bearings The hub bearings are bolted to the steering knuckle at the outboard end of the axle tube yoke The hub bearings are serviced as an assembly The axles are equipped with ABS brake sensors The sensors are attached to the knuckle assemblies and tone rings are pressed on the axle shaft Do not damage ABS tone wheel or the sensor when removing axle shaft...

Page 61: ...D IS NO LONGER A MACHINED TO SPECI FICATIONS SURFACE DO NOT USE THIS SUR FACE FOR PINION DEPTH SET UP OR CHECKING Fig 2 Compensation for depth variance is achieved by a selected thickness oil slinger production or shims service The slinger is placed between the inner pin ion bearing cone and gear head Fig 3 The shim pack is placed under the inner rear bearing cup for service To change the pinion a...

Page 62: ...ricant will cause overheating and gear failure Gear tooth cracking and bearing spalling are indicators of this Axle component breakage is most often the result of Severe overloading Insufficient lubricant Incorrect lubricant Improperly tightened components Overloading occurs when towing heavier than rec ommended loads Component breakage can occur when the wheels are spun excessively Incorrect lubr...

Page 63: ...ed Road test the vehicle Turn the vehicle sharply to the left and to the right This will load the bearings and change the noise level Where axle bearing damage is slight the noise is usually not noticeable at speeds above 30 mph LOW SPEED KNOCK Low speed knock is generally caused by a worn U joint or by worn side gear thrust washers A worn pinion gear shaft bore will also cause low speed knock VIB...

Page 64: ...FRONT DRIVE AXLE DIAGNOSIS ZJ DIFFERENTIAL AND DRIVELINE 3 19 DIAGNOSIS AND TESTING Continued ...

Page 65: ...CONTINUED 3 20 DIFFERENTIAL AND DRIVELINE ZJ DIAGNOSIS AND TESTING Continued ...

Page 66: ...e Discon nect the drive shaft from the axle 6 Disconnect the stabilizer bar link at the axle bracket 7 Disconnect the shock absorbers from axle bracket 8 Disconnect the track bar from the axle bracket 9 Disconnect the tie rod and drag link from the steering knuckle Disconnect the steering damper from the axle bracket 10 Support the axle with a hydraulic jack under the differential 11 Disconnect th...

Page 67: ...m 74 ft lbs torque 17 Check the front wheel alignment PINION SEAL REPLACEMENT REMOVAL 1 Raise and support the vehicle 2 Remove wheel and tire assemblies 3 Mark the propeller shaft yoke and pinion yoke for installation alignment reference 4 Remove the propeller shaft from the yoke 5 Remove the pinion yoke nut and washer Use Remover C 452 and Wrench C 3281 to remove the pinion yoke Fig 5 6 Mark the ...

Page 68: ...he axle shaft from the housing Avoid damaging the axle shaft oil seals in the differ ential INSTALLATION 1 Thoroughly clean the axle shaft Fig 9 and apply a thin film of Mopar Wheel Bearing Grease to the shaft splines seal contact surface hub bore 2 Install the axle shaft into the housing and dif ferential side gears Avoid damaging the axle shaft oil seals in the differential 3 Install the hub bea...

Page 69: ...d axle shaft refer to the Removal procedure 2 Disconnect the tie rod or drag link end from the steering knuckle arm Remove the ABS sensor wire and bracket from knuckle 3 Remove the cotter pins from the upper and lower ball studs Remove the upper and lower ball stud nuts 4 Strike the steering knuckle with a brass ham mer to loosen Remove knuckle from axle tube yokes Fig 10 UPPER BALL STUD REPLACEME...

Page 70: ...le Shaft accord ing to the installation procedure 5 Reconnect the tie rod or drag link end onto the steering knuckle arm Install the ABS sensor wire and bracket to the knuckle refer to Group 5 Brakes AXLE BUSHING REPLACEMENT Refer to Axle Bushing Replacement in the Front Suspension section DIFFERENTIAL REMOVAL To service the differential the axle assembly and axle shafts must be removed Refer to t...

Page 71: ...of the pry bar against spreader Fig 15 8 Remove the case from housing Mark or tag bearing cups indicating which side they were removed Remove spreader from housing INSTALLATION 1 Position Spreader W 129 B with the tool dowel pins seated in the locating holes Fig 16 Install the holddown clamps and tighten the tool turnbuckle fin ger tight 2 Install a pilot stud at the left side of the differ ential...

Page 72: ... the inner axle shaft seals with a pry bay 2 Install oil seals with Discs 6764 and Turn buckle D 112A Fig 19 Tighten tool until disc bot toms in housing PINION GEAR REMOVAL DISASSEMBLY 1 Remove the pinion yoke nut and washer Use Remover C 452 and Wrench C 3281 to remove the pinion yoke Fig 20 Fig 17 Differential Installation Fig 18 Differential Bearing Cap Reference Letters Fig 19 Axle Seal Instal...

Page 73: ...the front pinion bearing cup and seal with Remover D 147 and Handle C 4171 Fig 22 6 Remove the rear bearing cup from housing Fig 23 Use Remover D 149 and Handle C 4171 7 Remove the inner bearing from the pinion with Puller C 293PA and Adapter C 293 39 Fig 24 Place adapter rings so they do not damage the bearing cage 8 Remove the oil slinger from the pinion gear shaft Save the slinger it is used as...

Page 74: ... until completely seated Fig 25 3 Assemble preload shims onto pinion shaft 4 Install pinion front bearing cone into cup and end yoke thrust washer 5 Apply a light coat of gear lubricant on lip of new pinion seal Install seal with Installer D 163 and Handle C 4171 Fig 26 6 Install pinion gear into differential housing 7 Install yoke with Installer W 162D and Holder 6958 Fig 27 Fig 25 Pinion Rear Be...

Page 75: ...eals spider or bearing caps are damaged or worn replace the complete U joint CAUTION Clamp only the forged portion of the yoke in the vise Also to avoid distorting the yoke do not over tighten the vise jaws 1 Remove the bearing cap retaining snap rings Fig 30 It can be helpful to saturate the bearing caps with penetrating oil prior to removal 2 Locate a socket that is larger in diameter than the b...

Page 76: ... to force the bearing caps into the yoke Force the caps enough to install the retaining clips 5 Install the bearing cap retaining clips 6 Install the axle shaft refer to Hub Bearing and Axle Shaft installation DIFFERENTIAL DISASSEMBLY 1 Remove the bearings from the differential case with Press C 293PA Plug C 293 3 Adapter C 293 39 Fig 32 Place adapter rings so they do not damage the bearing cage 2...

Page 77: ...hers Pinion gears and thrust washers Pinion gear mate shaft align holes in shaft and case 2 Install and seat the locking roll pin in the dif ferential case and mate shaft with a punch and ham mer Fig 37 Peen metal part of case over pin in two places 180 degrees apart If replacement gears and thrust washers were installed it is not necessary to measure the gear backlash Correct fit is due to close ...

Page 78: ...case as far as possible to right side Fig 40 Zero the dial indi cator pointer 4 Pry the case to left side and record the travel distance The measurement above is the shim thickness necessary for case zero end play The total thickness will be determined during the ring gear backlash adjustment 5 Remove indicator pilot stud and differential case from housing PINION GEAR DEPTH MEASUREMENT Pinion gear...

Page 79: ...one Fig 44 4 Place Arbor Disc 6732 on Arbor D 115 3 and position in the bearing cradles Fig 45 Install dif ferential bearing caps on Arbor Discs and tighten caps snug only Arbor Discs have different steps to fit other axle sizes Pick correct size step for axle being serviced Fig 41 Pinion Gear Depth Gauge Tools Fig 42 Pinion Front Bearing Cup Installation Fig 43 Pinion Rear Bearing Cup Installatio...

Page 80: ... to housing Load the indicator plunger against the back of the ring gear Fig 47 Ensure ring and pinion gear teeth are tightly meshed Zero the indicator 3 Insert a small pry bar between the bearing cap and left side of differential case Pry the case as far as possible to right side Fig 47 Zero the dial indi cator pointer 4 Repeat the measurement several times to check consistency Record the travel ...

Page 81: ...TOTAL SHIM PACK THICKNESS EXCES SIVE BEARING PRELOAD AND DAMAGE WILL OCCUR If the mesh and backlash steps have been followed good gear teeth contact patterns should exist The ring gear teeth contact patterns will show if the pinion gear depth is correct It will also show if the ring gear backlash has been adjusted correctly The backlash must be maintained within the speci fied limits until the cor...

Page 82: ...Fig 52 Gear Tooth Contact Patterns ZJ DIFFERENTIAL AND DRIVELINE 3 37 DISASSEMBLY AND ASSEMBLY Continued ...

Page 83: ...ir Cup and bearing must be replaced as a matched sets only Clean axle shaft tubes and oil channels with clean cloth Inspect for Smooth appearance with no broken dented sur faces on the bearing rollers or the roller contact sur faces Bearing cups must not be distorted or cracked Machined surfaces should be smooth and with out any raised edges Raised metal on shoulders of cup bores should be removed...

Page 84: ...SPECIAL TOOLS FRONT AXLE MODEL 30 Puller C 293 PA Extension C293 3 Adapter C 293 39 Adapter C 293 48 Puller C 452 Wrench C 3281 Dial Indicator C 3339 ZJ DIFFERENTIAL AND DRIVELINE 3 39 ...

Page 85: ...Driver C 3716 A Handle C 4171 Installer D 112 Installer D 144 Installer D 146 Remover D 147 Remover D 148 Remover D 149 3 40 DIFFERENTIAL AND DRIVELINE ZJ SPECIAL TOOLS Continued ...

Page 86: ...taller D163 Installer W 162 D Installer 6228 Remover Installer 6288 Remover Installer 6289 Tool Set Pinion Depth 6774 Installer 6764 Puller 7794 A ZJ DIFFERENTIAL AND DRIVELINE 3 41 SPECIAL TOOLS Continued ...

Page 87: ...Remover 7916 Installer 7917 Screw Forcing 7918 Support 7919 Remover 7920 3 42 DIFFERENTIAL AND DRIVELINE ZJ SPECIAL TOOLS Continued ...

Page 88: ...cant vaporization and internal expansion The axles are equipped with semi floating axle shafts meaning that loads are supported by the axle shaft and bearings The axle shafts are retained by C clips in the differential side gears The cover provides a means for servicing the differ ential without removing the axle Axles may be equipped with drum or disc brakes The axles that are equipped with ABS b...

Page 89: ...has a rolled gasket flange at the outer edge Fig 2 The Model 35 axle has shaft tubes that are 2 625 inch 66 67 mm in diameter The 8 1 4 axle has axle shaft tubes that are 3 0 inch 76 2 mm in diameter STANDARD DIFFERENTIAL OPERATION The differential gear system divides the torque between the axle shafts It allows the axle shafts to rotate at different speeds when turning corners Each differential s...

Page 90: ...ain multiple disc The clutch will have radial grooves on the plates and concentric grooves on the discs or bonded fiber material that is smooth appearance In operation the Trac lok clutches are engaged by two concurrent forces The first being preload force exerted through Belleville spring washers contained in the clutch packs The second from separating forces generated by the side gears as torque...

Page 91: ...n deceleration coast or constant load When road testing accelerate the vehicle to the speed range where the noise is the greatest Shift out of gear and coast through the peak noise range If the noise stops or changes greatly check for insuf ficient lubricant Incorrect ring gear backlash or gear damage can cause noise changes Differential side and pinion gears can be checked by turning the vehicle ...

Page 92: ... between the outside edges of the two pieces of tape Record this measurement as the rear of tire RTR measurement 5 Subtract the RTR measurement from the FTR measurement to obtain the amount of wheel toe The acceptable rear wheel toe in position is 1 16 in 1 6 mm to 3 16 inch 4 8 mm toe out 6 Rotate the rear wheels until the reference marks are facing downward Measure the distance between the outsi...

Page 93: ...SERVICE DIAGNOSIS SERVICE DIAGNOSIS 3 48 DIFFERENTIAL AND DRIVELINE ZJ DIAGNOSIS AND TESTING Continued ...

Page 94: ...SERVICE DIAGNOSIS CONT D ZJ DIFFERENTIAL AND DRIVELINE 3 49 DIAGNOSIS AND TESTING Continued ...

Page 95: ...nd rear of both front wheels 3 Raise one rear wheel until it is completely off the ground 4 Remove wheel and bolt Special Tool 6790 to studs 5 Use torque wrench on special tool to rotate wheel and read rotating torque Fig 6 6 If rotating torque is less than 22 N m 30 ft lbs or more than 271 N m 200 ft lbs on either wheel the unit should be service SERVICE PROCEDURES LUBRICANT CHANGE The gear lubri...

Page 96: ...bricated 1 Support the axle on a hydraulic jack under the differential Position the axle under the vehicle 2 Raise the axle and align the spring center bolts with the locating holes in the axle pads and plate brackets 3 Install the spring U bolts through the plate brackets and tighten to 70 N m 52 ft lbs torque 4 Install ABS wiring connections if equipped at the axle 5 Connect the brake hose at th...

Page 97: ...ue will be re adjusted after ward 4 Install a socket and inch pound torque wrench on the pinion nut 5 Rotate the shaft with the torque wrench and note the torque The required preload torque is equal to the amount recorded during removal plus an addi tional 0 56 N m 5 in lbs 6 Use Flange Wrench C 3281 to retain the yoke and shaft Fig 11 Tighten the shaft nut in very small increments 7 Continue tigh...

Page 98: ...ward to seat the C clip lock in the side gear 3 Insert the mate shaft into the case and through the thrust washers and pinion gears Align the hole in shaft with the hole in the differential case and install the lock screw with Loctitet on the threads Tighten the screw to 19 N m 14 ft lbs torque 4 Install the cover and add fluid Refer to the Drain and Refill in this section AXLE SHAFT SEAL AND BEAR...

Page 99: ...ite side of the housing Fig 17 and zero the indicator CAUTION Do not spread over 0 38 mm 0 015 in If the housing is over separated it could be distorted or damaged 5 Separate the housing enough to remove the case from the housing Measure the distance with the dial indicator Fig 17 6 Remove the dial indicator 7 Pry the differential case loose from the hous ing To prevent damage pivot on housing wit...

Page 100: ...Fig 19 Remove the spreader 7 Install the bearing caps at their original loca tions Fig 20 Tighten the bearing cap bolts to 77 N m 57 ft lbs torque DIFFERENTIAL SIDE BEARINGS REMOVAL 1 Remove Differential case from axle housing 2 Remove the bearings from the differential case with Press 938 and Adapter 1130 Fig 21 DIFFERENTIAL SIDE BEARING INSTALLATION If ring and pinion gears have been replaced ve...

Page 101: ...ture causing extensive damage 1 Invert the differential case and start two ring gear bolts This will provide case to ring gear bolt hole alignment 2 Install new ring gear bolts and alternately tighten to 95 122 N m 70 90 ft lbs torque Fig 24 3 Install differential in axle housing and verify gear mesh and contact pattern Fig 21 Differential Bearing Removal Fig 22 Install Differential Side Bearings ...

Page 102: ...d being damaged 4 Remove the pinion gear seal with a slide ham mer or pry out with bar 5 Remove oil slinger front bearing 6 Remove the front pinion bearing cup and seal with Remover D 103 and Handle C 4171 Fig 27 7 Remove the rear bearing cup from housing Fig 28 Use Remover C 4307 and Handle C 4171 Fig 25 Pinion Yoke Removal Fig 26 Remove Pinion Gear Fig 27 Front Bearing Cup Removal Fig 28 Rear Be...

Page 103: ...ess of the depth shims PINION GEAR INSTALLATION 1 Install the pinion rear bearing cup with Installer C 4308 and Driver Handle C 4171 Fig 31 Ensure cup is correctly seated 2 Install the pinion front bearing cup with Installer D 129 and Handle C 4171 Fig 32 Fig 29 Collapsible Spacer Fig 30 Inner Bearing Removal Fig 31 Pinion Rear Bearing Cup Installation Fig 32 Pinion Front Bearing Cup Installation ...

Page 104: ...pinion gear in housing Fig 35 7 Install yoke with Installer W 162D and Wrench 6719 Fig 36 8 Install the yoke washer and a new nut on the pinion gear Tighten the nut to 298 N m 220 ft lbs minimum Do not over tighten Maximum torque is 380 N m 280 ft lbs CAUTION Never loosen pinion gear nut to decrease pinion gear bearing preload torque and never exceed specified preload torque If preload torque is e...

Page 105: ...alant 3 Install the cover on the differential with the attaching bolts Install the identification tag Tighten the cover bolts to 41 N m 30 ft lbs torque CAUTION Overfilling the differential can result in lubricant foaming and overheating 4 Refill the differential housing with the speci fied quantity of Mopar Hypoid Gear Lubricant 5 Install the fill hole plug and tighten to 34 N m 25 ft lbs torque ...

Page 106: ...Lok limited slip differential compo nents are illustrated in Fig 41 Refer to this illus tration during repair service DISASSEMBLY Service to the Trac Lok differential requires the use of Tool Set 6960 Refer to Model 35 Axle section in this Group for Differential Removal and Installa tion 1 Clamp Side Gear Holding Tool 6965 in a vise 2 Position the differential case on the holding tool Fig 42 Place...

Page 107: ...y use a drift and hammer Fig 45 6 Install and lubricate Step Plate 6960 3 Fig 46 Fig 42 Differential Case Holding Tool Fig 43 Ring Gear Removal Fig 44 Mate Shaft Lock Screw Fig 45 Mate Shaft Removal Fig 46 Step Plate Tool Installation 3 62 DIFFERENTIAL AND DRIVELINE ZJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 108: ...on gears can be slightly rattled between the case and side gears 12 Insert Turning Bar 6960 2 in case Rotate case with tool until pinion gears can be removed Fig 50 13 Remove top side gear and clutch pack Keep plates in correct order during removal Fig 51 14 Remove case from fixture Remove remaining clutch pack 15 Remove clutch pack retaining clips Mark each clutch pack for installation reference ...

Page 109: ...ricated Step Plate 6960 3 on first clutch pack Fig 54 6 Install the upper side gear and clutch disc pack Fig 54 7 Hold assembly in position Insert Threaded Adapter 6960 1 into top side gear insert forcing Screw 6960 4 8 Tighten forcing screw tool to slightly compress clutch discs 9 Place pinion gears in position in side gears and verify that mate shaft hole line up Fig 51 Side Gear Clutch Disc Rem...

Page 110: ...ear for damaged bolt threads Replaced as a matched set only Pinion yoke for cracks worn splines pitted areas and a rough corroded seal contact surface Repair or replace as necessary Preload shims for damage and distortion Install new shims if necessary TRAC LOK 1 Clean all components in cleaning solvent Dry components with compressed air 2 Inspect clutch pack plates for wear scoring or damage Repl...

Page 111: ... minus 3 intersecting figure is 0 004 in 0 10 mm Add this amount to the original shim Or if the old pinion is 3 and the new pinion is 2 intersecting figure is 0 001 in 0 025 mm Sub tract this amount from original shim Refer to the Pinion Gear Depth Variance Chart PINION DEPTH MEASUREMENT AND ADJUSTMENT Pinion gear depth measurement is necessary when Axle housing or differential case is replaced Pi...

Page 112: ...distance whether inward or outward indicated by the pointer The plunger travel distance indicated plus or minus the variance etched in the gear is the required thickness for the depth shims 5 Measure the thickness of each depth shim with a micrometer and combine the shims necessary for total required shim pack thickness Include oil slinger or baffle thickness with the total shim pack thickness 6 R...

Page 113: ...on each side of case The differential bearings must be preloaded to compensate for heat and load during opera tion 9 Add an additional 0 004 in 0 1 mm to each outboard shim spacer for bearing preload 10 Remove differential from axle housing 11 Remove dummy bearings 12 Install new side bearing cones and cups 13 Install ring gear 14 Install differential and verify gear lash and contact pattern 15 Pr...

Page 114: ...ed limits until the correct tooth contact patterns are obtained 2 Apply a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth 3 Rotate the ring gear one complete revolution in both directions while a load is being applied Insert a pry bar between the differential housing and the case flange This will produce distinct contact patterns on both the driv...

Page 115: ...Fig 66 Gear Tooth Contact Patterns 3 70 DIFFERENTIAL AND DRIVELINE ZJ ...

Page 116: ...mm 0 005 0 008 in Pinion Std Depth 96 8 mm 3 813 in Pinion Bearing Preload Original Bearing 1 2N m 10 20 in lbs New Bearing 1 5 4N m 15 35 in lbs MODEL 35 AXLE DESCRIPTION TORQUE Fill Hole Plug 34 N m 25 ft lbs Diff Cover Bolt 41 N m 30 ft lbs Bearing Cap Bolt 77 N m 57 ft lbs Pinion Nut 292 427 N m 215 315 ft lbs Ring Gear Bolt 95 122 N m 70 90 ft lbs RWAL ABS Sensor Bolt 24 N m 18 ft lbs SPECIAL...

Page 117: ...Dial Indicator C 3339 Driver C 3716 A Handle C 4171 Trac lok Tool C 4487 Arbor Pinion W 115 3 Installer D 130 Installer D 146 Remover D 147 3 72 DIFFERENTIAL AND DRIVELINE ZJ SPECIAL TOOLS Continued ...

Page 118: ...Remover D 148 Installer D163 Plug SP 3289 Installer W 162 D Installer 6436 Installer 6437 Disc Axle Arbor 6732 Gauge Block 6735 ZJ DIFFERENTIAL AND DRIVELINE 3 73 SPECIAL TOOLS Continued ...

Page 119: ...Tool Set Pinion Depth 6774 Trac lok Tool Set 6960 Holder 6965 Puller 7794 A 3 74 DIFFERENTIAL AND DRIVELINE ZJ SPECIAL TOOLS Continued ...

Page 120: ...se to relieve internal pres sure caused by lubricant vaporization and internal expansion The axles are equipped with semi floating axle shafts meaning that loads are supported by the axle shaft and bearings The axle shafts are retained by C clips in the differential side gears The cover provides a means for servicing the differ ential without removing the axle The differential case is a one piece ...

Page 121: ...order to complete a turn The difference must be compensated for to prevent the tires from scuffing and skidding through turns To accomplish this the differential allows the axle shafts to turn at unequal speeds Fig 2 In this instance the input torque applied to the pinion gears is not divided equally The pinion gears now rotate around the pinion mate shaft in opposite direc tions This allows the s...

Page 122: ...celerate the vehicle to the speed range where the noise is the greatest Shift out of gear and coast through the peak noise range If the noise stops or changes greatly check for insuf ficient lubricant Incorrect ring gear backlash or gear damage can cause noise changes Differential side and pinion gears can be checked by turning the vehicle They usually do not cause noise in straight ahead driving ...

Page 123: ...de edges of the two pieces of tape Record this measurement as the front of tire FTR measurement 4 Rotate the rear wheels until both reference marks face the rear of the vehicle Measure the dis tance between the outside edges of the two pieces of tape Record this measurement as the rear of tire RTR measurement 5 Subtract the RTR measurement from the FTR measurement to obtain the amount of wheel toe...

Page 124: ...SERVICE DIAGNOSIS SERVICE DIAGNOSIS ZJ DIFFERENTIAL AND DRIVELINE 3 79 DIAGNOSIS AND TESTING Continued ...

Page 125: ...SERVICE DIAGNOSIS CONT D 3 80 DIFFERENTIAL AND DRIVELINE ZJ DIAGNOSIS AND TESTING Continued ...

Page 126: ...ark ing brake off 2 Place blocks in front and rear of both front wheels 3 Raise one rear wheel until it is completely off the ground 4 Remove wheel and bolt Special Tool 6790 to studs 5 Use torque wrench on special tool to rotate wheel and read rotating torque Fig 4 6 If rotating torque is less than 22 N m 30 ft lbs or more than 271 N m 200 ft lbs on either wheel the unit should be service SERVICE...

Page 127: ...ckets Install nuts and bolts do not tighten bolts at this time 3 Install track bar and attachment bolts do not tighten bolts at this time 4 Install shock absorber and tighten nuts to 60 N m 44 ft lbs torque 5 Install stabilizer bar link and tighten nuts to 36 N m 27 ft lbs torque 6 Install brake components refer to Group 5 Brakes 7 Install axle vent hose 8 Align propeller shaft and pinion yoke ref...

Page 128: ...ten the nut Do not exceed the bearing preload torque The collapsible preload spacer on the shaft will have to be replaced The bearing preload torque will be re adjusted afterward 4 Install a socket and inch pound torque wrench on the pinion nut 5 Rotate the shaft with the torque wrench and note the torque Fig 9 The required preload torque is equal to the amount recorded during removal plus an addi...

Page 129: ...N 1 Lubricate the bearing bore and seal lip with gear lubricant Insert the axle shaft through the seal bearing and engage it with the side gear splines Use care to prevent the shaft splines from dam aging the axle shaft seal lip 2 Insert the C clip lock in the end of the axle shaft Push the axle shaft outward to seat the C clip lock in the side gear 3 Insert the mate shaft into the case and throug...

Page 130: ...e differential bearing caps 3 Position Spreader W 129 B with the tool dowel pins seated in the locating holes Fig 16 Install the hold down clamps and tighten the tool turnbuckle finger tight 4 Install a pilot stud at the left side of the differ ential housing Attach Dial Indicator to housing pilot stud Load the indicator plunger against the opposite side of the housing Fig 16 and zero the indicato...

Page 131: ... Dial Indicator to housing pilot stud Load the indicator plunger against the opposite side of the housing Fig 16 and zero the indicator CAUTION Do not spread over 0 38 mm 0 015 in If the housing is over separated it could be distorted or damaged 3 Separate the housing enough to install the case in the housing Measure the distance with the dial indicator Fig 16 4 Remove the dial indicator 5 Install...

Page 132: ...L 1 Remove differential from axle housing 2 Place differential case in a suitable vise with soft metal jaw protectors Fig 22 3 Remove bolts holding ring gear to differential case 4 Using a soft hammer drive ring gear from dif ferential case Fig 22 RING GEAR INSTALLATION CAUTION Do not reuse the bolts that held the ring gear to the differential case The bolts can fracture causing extensive damage 1...

Page 133: ...th your hand to prevent it from falling and being damaged 4 Remove the pinion gear seal with a slide ham mer or pry out with bar 5 Remove oil slinger front bearing 6 Remove the front pinion bearing cup and seal with Remover D 103 and Handle C 4171 Fig 26 Fig 23 Ring Gear Bolt Installation Fig 24 Pinion Yoke Removal Fig 25 Remove Pinion Gear Fig 26 Front Bearing Cup Removal 3 88 DIFFERENTIAL AND DR...

Page 134: ...amage the bearing cage 10 Remove the depth shims from the pinion gear shaft Record the thickness of the depth shims PINION GEAR INSTALLATION 1 Install the pinion rear bearing cup with Installer C 4308 and Driver Handle C 4171 Fig 30 Ensure cup is correctly seated Fig 27 Rear Bearing Cup Removal Fig 28 Collapsible Spacer Fig 29 Inner Bearing Removal Fig 30 Pinion Rear Bearing Cup Installation ZJ DI...

Page 135: ... should not require replacement Refer to Pinion Gear Deptht paragraph in this sec tion to select the proper thickness shim before installing rear pinion bearing cone 4 Place the proper thickness depth shim on the pinion gear and install the rear bearing 5 Install the rear bearing and slinger if used on the pinion gear with Installer 6448 Fig 33 6 Install a new collapsible preload spacer on pin ion...

Page 136: ...d torque frequently to avoid over tightening the nut 10 Check bearing preload torque with an inch pound torque wrench Fig 37 The torque necessary to rotate the pinion gear should be Original Bearings 1 to 3 N m 10 to 20 in lbs New Bearings 2 to 5 N m 15 to 35 in lbs FINAL ASSEMBLY 1 Install the axle shafts Refer to Axle Shaft Installation within this group 2 Scrape the residual sealant from the ho...

Page 137: ...ve pinion gear mate shaft 2 Rotate the differential side gears and remove the pinion mate gears and thrust washers Fig 39 3 Remove the differential side gears and thrust washers DIFFERENTIAL ASSEMBLE 1 Differential side gears and thrust washers 2 Pinion gears and thrust washers 3 Pinion gear mate shaft align holes in shaft and case 4 Lubricate all differential components with hypoid gear lubricant...

Page 138: ...al of the ring gear is required Fig 41 3 If ring gear replacement is required remove and discard the bolts holding the ring gear to the case Tap the ring gear with a rawhide or plastic mallet and separate ring gear from case Fig 42 4 Remove the pinion gear mate shaft lock screw Fig 43 5 Remove the pinion gear mate shaft If neces sary use a drift and hammer Fig 44 Fig 41 Differential Case Holding T...

Page 139: ... to prevent adapter from turning 9 Tighten forcing screw tool 122 N m 90 ft lbs maximum to compress Belleville springs in clutch packs Fig 47 10 Using a 0 020 in feeler gauge and mallet remove thrust washers from behind the pinion gears Fig 48 Fig 45 Step Plate Tool Installation Fig 46 Threaded Adapter Installation Fig 47 Tighten Belleville Spring Compressor Tool Fig 48 Remove Pinion Thrust Washer...

Page 140: ...lutch discs are replaceable as complete sets only If one clutch disc pack is damaged both packs must be replaced Lubricate each component with gear lubricant before assembly 1 Assemble the clutch discs into packs secure disc packs with retaining clips Fig 51 2 Position assembled clutch disc packs on the side gear hubs 3 Position case on axle fixture 4 Install clutch pack and side gear in lower bor...

Page 141: ...O NOT spin bearings with compressed air Cup and bearing must be replaced as matched sets only Clean axle shaft tubes and oil channels in housing Inspect for Smooth appearance with no broken dented sur faces on the bearing rollers or the roller contact sur faces Bearing cups must not be distorted or cracked Machined surfaces should be smooth and with out any raised edges Raised metal on shoulders o...

Page 142: ...r Add or subtract the thickness of the original depth shims to compensate for the difference in the depth vari ances Refer to the Depth Variance charts Note where Old and New Pinion Marking columns intersect Intersecting figure represents plus or minus amount needed For example if old pinion is plus 1 and the new pinion is minus 3 intersecting figure is 0 004 in 0 10 mm Add this amount to the orig...

Page 143: ...r inward or outward indicated by the pointer The plunger travel distance indicated plus or minus the variance etched in the gear is the required thickness for the depth shims 5 Measure the thickness of each depth shim with a micrometer and combine the shims necessary for total required shim pack thickness Include oil slinger or baffle thickness with the total shim pack thickness 6 Remove the measu...

Page 144: ...bolts 5 Attach a dial indicator to the housing Position the indicator plunger so that it contacts the ring gear mating surface Fig 62 6 Pry the differential case to one side and zero the dial indicator pointer 7 Pry the differential case to the opposite side and record indicator reading Reading is additional shim thickness needed for zero end play For exam ple if reading was 0 008 in 0 20 mm an ad...

Page 145: ...k thickness excessive bearing preload and damage will occur The ring gear teeth contact patterns will show if the pinion gear depth shim s have the correct thick ness It will also show if the ring gear backlash has been adjusted correctly The backlash must be main tained within the specified limits until the correct tooth contact patterns are obtained 2 Apply a thin coat of hydrated ferric oxide o...

Page 146: ...Fig 65 Gear Tooth Contact Patterns ZJ DIFFERENTIAL AND DRIVELINE 3 101 SPECIFICATIONS Continued ...

Page 147: ...m 80 ft lbs Screw ABS Sensor 8 N m 70 in lbs Nuts Brake Backing Plate 61 N m 45 ft lbs Nut Pinion Gear Minimum 298 N m 220 ft lbs SPECIAL TOOLS MODEL 44 AXLE Remover C 452 Remover C 4307 Installer C 4308 Pilot C 3288 Dial Indicator C 3339 Trac lok Tool Set C 4487 3 102 DIFFERENTIAL AND DRIVELINE ZJ SPECIFICATIONS Continued ...

Page 148: ...Installer D 163 Installer D 129 Remover D 103 Installer W 162 D Splitter 1130 Remover 6310 Installer 6436 Installer 6437 ZJ DIFFERENTIAL AND DRIVELINE 3 103 SPECIAL TOOLS Continued ...

Page 149: ...Installer 6448 Holder 6719 Adapter 6790 Pinion Depth Set 6955 Adapter Set 6956 Holder 6963 Remover 7794 A 3 104 DIFFERENTIAL AND DRIVELINE ZJ SPECIAL TOOLS Continued ...

Page 150: ...AKE BLEEDING 12 BRAKE FLUID LEVEL 11 BRAKE LINE 13 DISC ROTOR MACHINING 12 MASTER CYLINDER 11 REMOVAL AND INSTALLATION BRAKE PEDAL 14 COMBINATION VALVE 14 DISC BRAKE CALIPER 16 DISC BRAKE ROTOR 19 DISC BRAKESHOE 17 FRONT PARKING BRAKE CABLE 22 MASTER CYLINDER 15 PARKING BRAKE CAM AND LEVER 24 PARKING BRAKE HAND LEVER 21 PARKING BRAKESHOES 23 POWER BRAKE BOOSTER 15 REAR DISC BRAKE CALIPER 19 REAR D...

Page 151: ...and flush the system with new brake fluid if contamina tion is suspected CAUTION Use Mopar brake fluid or an equivalent quality fluid meeting SAE DOT standards J1703 and DOT 3 Brake fluid must be clean and free of con taminants Use fresh fluid from sealed containers only to ensure proper antilock component opera tion Use Mopar multi mileage or high temperature grease to lubricate caliper slide sur...

Page 152: ... differential provides the extra apply pressure for power assist MASTER CYLINDER The master cylinder has a removable nylon reser voir Fig 2 The cylinder body is made of aluminum and contains a primary and secondary piston assem bly The cylinder body including the piston assem blies are not serviceable If diagnosis indicates an internal problem with the cylinder body it must be replaced as an assem...

Page 153: ...cting simultaneously on both piston and caliper produces a strong clamp ing action When sufficient force is applied friction will stop the rotors from turning and bring the vehi cle to a stop Application and release of the brake pedal gener ates only a very slight movement of the caliper and piston Upon release of the pedal the caliper and pis ton return to a rest position The brakeshoes do not re...

Page 154: ...ver is mounted on the floorpan adjacent to the driver NOTE Parking brake cable adjustment is con trolled by a tensioner mechanism The cable ten sioner once adjusted at the factory will not need further adjustment under normal circumstances There are only time a adjustment is required is when the tensioner or cables have been replaced or disconnected BRAKE HOSES AND LINES Flexible rubber hose is us...

Page 155: ...l leakage in the master cylinder may not be physically evident LOW PEDAL If a low pedal is experienced pump the pedal sev eral times If the pedal comes back up worn lining rotors or drums are the most likely causes SPONGY PEDAL A spongy pedal is most often caused by air in the system However thin brake drums or substandard brake lines and hoses can also cause a spongy pedal The proper course of ac...

Page 156: ...akes very lightly applied for a mile or two However if the lining is both soaked and dirt contaminated cleaning and or replacement will be necessary BRAKE SQUEAK SQUEAL Brake squeak or squeal may be due to linings that are wet or contaminated with brake fluid grease or oil Glazed linings and rotors with hard spots can also contribute to squeak Dirt and foreign material embedded in the brake lining...

Page 157: ...hissing noise indicates vacuum leak Correct any vacuum leak before proceeding 2 Stop engine and shift transmission into Neu tral 3 Pump brake pedal until all vacuum reserve in booster is depleted 4 Press and hold brake pedal under light foot pressure The pedal should hold firm if the pedal falls away master cylinder is faulty internal leak age 5 Start engine and note pedal action it should falls a...

Page 158: ...s faulty Replace combination valve assembly bleed brake system and verify proper switch and valve operation FRONT DISC BRAKE ROTOR ROTOR MINIMUM THICKNESS Rotor minimum usable thickness is 22 7 mm 0 89 in Do not resurface a rotor if machining would cause thickness to fall below this limit Measure rotor thickness at the center of the brake shoe contact surface Replace the rotor if worn below minimu...

Page 159: ...dicates pedal pulsation and rapid uneven brakelin ing wear The rotor must be securely clamped to the hub to ensure an accurate runout measurement Secure the rotor with the wheel nuts and 4 or 5 large diameter flat washers on each stud Use a dial indicator to check lateral runout Fig 11 Maximum allowable lateral runout is 0 13 mm 0 005 in PARKING BRAKE NOTE Parking brake adjustment is controlled by...

Page 160: ...assis compo nents All of these condition can lead to scuffing cracking and eventual failure The steel brake lines should be inspected periodi cally for evidence of corrosion twists kinks leaks or other damage Heavily corroded lines will eventually rust through causing leaks In any case corroded or damaged brake lines should be replaced Factory replacement brake lines and hoses are rec ommended to ...

Page 161: ...leed screws Then close each bleed screw as fluid starts to drip from it Top off master cylinder reservoir once more before proceeding 3 Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid Fig 15 Be sure end of bleed hose is immersed in fluid 4 Open up bleeder then have a helper press down the brake pedal Once the pedal is down cl...

Page 162: ... Ream cut edges of tubing to ensure proper flare 3 Install replacement tube nut on section of tube to be repaired 4 Insert tube in flaring tool Center tube in area between vertical posts 5 Place gauge form over the end of the tube 6 Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter 7 Squeeze flaring tool jaws to lock tubing in place 8 Inse...

Page 163: ...dash panel to instrument panel brace rods 4 Remove retainer clip and washers attaching booster push rod to pedal pin Fig 19 5 Remove nut securing pedal shaft in support bracket 6 Slide pedal shaft outward for clearance and remove brake pedal 7 Remove pedal bushings if they are to be replaced INSTALLATION 1 Install new bushings in pedal Lubricate bush ings and pivot pin with Mopar multi mileage gre...

Page 164: ... Remove nuts that attach master cylinder to booster studs Fig 22 Retain nuts as they are special locking types 4 Remove master cylinder from booster INSTALLATION 1 Remove protective cover from end of primary piston 2 Bleed master cylinder 3 Slide master cylinder onto booster studs Align booster push rod in cylinder primary piston and seat cylinder against booster 4 Install master cylinder mounting...

Page 165: ...t attach vacuum hose to booster check valve 9 6 Install master cylinder combination valve and HCU Refer to procedures in this section 10 7 Bleed brakes Refer to section covering brake bleeding 11 8 Install engine air cleaner and hoses DISC BRAKE CALIPER REMOVAL 1 Raise vehicle and remove front wheel and tire assemblies 2 Remove and discard brake hose mounting bolt Fig 25 3 Remove caliper mounting ...

Page 166: ... reservoir with suction gun 3 Bottom caliper piston in bore with C clamp Position clamp screw on outboard brakeshoe and clamp frame on rear of caliper Typical C clamp attachment is shown in Fig 26 Do not allow clamp screw to bear directly on outboard shoe retainer spring Use wood or metal spacer between shoe and clamp screw if necessary 4 Remove caliper mounting bolts Fig 27 5 Tilt top of caliper ...

Page 167: ...bottom mounting ledge Then install caliper over rotor and seat upper ends of brakeshoes on top mounting ledge Fig 32 CAUTION Before securing the caliper be sure the caliper brake hose is not twisted kinked or touch ing any chassis components 5 Install and tighten caliper mounting bolts to 10 20 N m 7 15 ft lbs CAUTION If new caliper bolts are being installed or if reason for repair was a drag pull...

Page 168: ...1 Raise vehicle and remove tire and wheel assemblies 2 Press caliper piston into caliper bore with C clamp Fig 35 3 Remove caliper mounting bolts Fig 36 4 Rotate caliper rearward by hand or with pry tool Then rotate caliper and brakeshoes off ledges of mounting bracket 5 Remove caliper fitting bolt and disconnect rear brake hose at caliper Discard metal washers on fit ting bolt Washers should be r...

Page 169: ...inward then pry shoe upward with suitable tool and rotate shoe out of caliper 7 Pry inboard shoe outward until shoe retainers come out of caliper piston Then remove shoe from caliper 8 Inspect caliper mounting bolt bushings and boots Replace boots if torn or cut Replace bushings or bolts if either exhibits wear or heavy corrosion INSTALLATION 1 Clean brakeshoe contact surfaces of caliper mounting ...

Page 170: ... star wheel 6 Install plug in splash shield access hole 7 Pump brake pedal to seat caliper piston and brakeshoes Do not move vehicle until firm brake pedal is obtained PARKING BRAKE HAND LEVER REMOVAL 1 Release parking brakes 2 Disconnect battery negative cable 3 Raise vehicle on hoist 4 Remove front cable adjusting nut and disen gage cable tensioner from equalizer Then remove front cable from ten...

Page 171: ...ake lever and remove cable INSTALLATION 1 Connect front cable to lever assembly 2 Seat front cable in floor pan 3 Install lever assembly 4 Install console 5 Raise vehicle 6 Assemble front cable cable tensioner and equalizer 7 Adjust parking brake system if new cable or tensioner has been installed or if tensioner mecha nism has been loosened or removed for access to other components Refer to Parki...

Page 172: ...nt 4 Remove rubber access plug from back of rear disc brake splash shield 5 Retract parking brakeshoes with brake adjuster tool Fig 46 Position tool at top of star wheel and rotate wheel downward in clockwise direc tion while facing front of vehicle 6 Remove rotor from axle hub flange 7 Remove shoe holddown clips and pins Fig 47 Clip is held in place by pin which fits in clip notch To remove clip ...

Page 173: ...eel and tire assembly 3 Remove brake caliper and rotor 4 Remove parking brakeshoes 5 Move lever forward and disconnect parking brake rear cable from lever 6 Pull lever forward through boot Disengage cam from lever and remove cam Fig 50 Note cam position for installation reference 7 Remove lever INSTALLATION 1 Lubricate replacement lever with silicone grease Then insert lever part way through boot ...

Page 174: ...ring handling 10 Note position of cam and lever for installation reference Then remove cam and lever from splash shield and bracket 11 Separate splash shield and caliper bracket Then remove lever boot from bracket Fig 53 INSTALLATION 1 If original bracket and shield will be reused clean them with Mopar carb and brake cleaner Also clean shoe contact pad surfaces of shield with 400 grit paper Lubric...

Page 175: ...nd lever Push lever through boot and seat cam between lip on shield and ledge on bracket Fig 56 Then engage lever in cable eyelet Be sure cable notch in lever is facing rearward Remove and reposition cam and lever if necessary 7 Install parking brakeshoes on splash shield Verify positioning of cam and lever shoes springs and holddown clips and pins Fig 57 8 Verify correct positioning of caliper br...

Page 176: ... and pulling free of grommets Fig 61 6 Remove old grommets from cylinder body Fig 62 INSTALLATION CAUTION Do not use any type of tool to install the grommets Tools may cut or tear the grommets creating a leak problem after installation Install the grommets using finger pressure only 1 Lubricate new grommets with clean brake fluid and Install new grommets in cylinder body Fig 63 Use finger pressure...

Page 177: ... piston out of the bore with sustained air pressure This could result in a cracked piston Use only enough air pressure to ease the piston out NEVER attempt to catch the piston as it leaves the bore This will result in per sonal injury 5 Remove caliper piston dust boot with suitable tool Fig 66 and discard boot 6 Remove caliper piston seal with wood or plastic tool Fig 67 and discard seal Do not us...

Page 178: ...aliper bore by hand use a turn and push motion to work piston into seal Fig 72 7 Press caliper piston to bottom of bore 8 Seat dust boot in caliper with Installer Tool C 4842 and Tool Handle C 4171 Fig 73 Fig 68 Mounting Bolt Bushing And Boot Fig 69 Bushings And Boots Installation Fig 70 Piston Seal Installation Fig 71 Dust Boot On Piston Fig 72 Caliper Piston Installation Fig 73 Piston Dust Boot ...

Page 179: ... piston Use only enough air pressure to ease the piston out In addition NEVER attempt to catch the piston as it leaves the bore This could result in personal injury 5 Remove caliper piston dust boot Fig 77 6 Remove and discard caliper piston seal with pencil or plastic tool Fig 78 Do not use metal tools as they will scratch piston bore ASSEMBLY 1 Lubricate caliper piston bore and new piston seal w...

Page 180: ...re seated in grooves at ends of bushings 12 Center bushing boots in caliper 13 Install brakeshoes in caliper 14 Install caliper CLEANING AND INSPECTION CALIPER CLEANING Clean the caliper components with clean brake fluid or Mopar brake cleaning solvent only Do not use gasoline kerosene thinner or similar solvents These products may leave a residue that could dam age the piston and seal Wipe the ca...

Page 181: ...r vehicle enough for access to parking brake lever Then fully apply parking brakes Leave brakes applied until adjustment is complete 8 Raise vehicle and mark tensioner rod 6 5 mm 1 4 in from tensioner bracket Fig 83 9 Tighten adjusting nut at equalizer until mark on tensioner rod moves into alignment with tensioner bracket 10 Lower vehicle until rear wheels are 15 20 cm 6 8 in off shop floor 11 Re...

Page 182: ...Max Runout 0 13 mm 0 005 in Max Thickness Variation 0 0254 mm 0 001 in Brake Booster Type Dual Diaphragm TORQUE CHART DESCRIPTION TORQUE Brake Pedal Support Bolt 23 34 N m 17 25 ft lbs Pivot Bolt Nut 27 35 N m 20 26 ft lbs Brake Booster Mounting Nuts 41 N m 30 ft lbs Master Cylinder Mounting Nuts 13 25 N m 10 18 ft lbs Primary Brakeline 15 18 N m 11 13 ft lbs Secondary Brakeline 15 18 N m 11 13 ft...

Page 183: ...t wheel brakes are controlled individually and the rear wheel brakes in tandem Fig 1 The ABS electrical system is separate from other electri cal circuits in the vehicle A specially programmed controller antilock brake unit CAB operates the sys tem components ABS system major components include Controller Antilock Brakes CAB Hydraulic Control Unit HCU Wheel Speed Sensors WSS Acceleration Switch Ma...

Page 184: ...he HCU valve body and work in pairs to either increase hold or decrease apply pressure as needed in the individual control channels The solenoid valves are not static during antilock braking They are cycled continuously to modulate pressure Solenoid cycle time in antilock mode can be measured in milliseconds CONTROLLER ANTILOCK BRAKES CAB A separate electronic control unit CAB operates the ABS sys...

Page 185: ...ase cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels At this point the CAB opens the outlet valve which also opens the return circuit to the accu mulators Fluid pressure is allowed to bleed off decrease as needed to prevent wheel lock Once the period of high wheel slip has ended the CAB closes the outlet valve and begins a pressure increase or hold cycle ...

Page 186: ...t air gap when pressed against the tone ring during installa tion As the tone ring rotates it peels the spacer off the sensor to create the required air gap Rear sensor air gap is 0 92 1 45 mm 0 036 0 057 in Sensor air gap measurement or adjustment proce dures are provided in this section Refer to the front or rear sensor removal and installation procedures as required COMBINATION VALVE The combin...

Page 187: ...e making repairs For example if the red lamp illuminates but the amber ABS lamp does not the problem is related to a service brake compo nent and not the ABS system Or if neither lamp illuminates but a brake problem is noted again the problem is with a service brake component and not with the ABS system DRB SCAN TOOL ABS diagnosis is performed with the DRB scan tool Diagnosis information is provid...

Page 188: ...ve it aside Fig 10 3 Remove combination valve 4 Remove master cylinder 5 Remove mounting nuts from HCU bracket to suspension support panel Fig 11 Retain bracket nuts 6 Disconnect HCU pump motor harness Fig 12 7 Disconnect three brakelines at rear of HCU Fig 13 8 If HCU is to be replaced remove flex lines from HCU 9 Lift HCU and bracket off mounting studs and remove assembly from engine compartment...

Page 189: ...olators if missing or damaged with factory replacement parts only Do not use substitute fasteners INSTALLATION 1 Transfer mounting bracket to new HCU Use original shoulder style bolts to attach bracket to HCU do not use substitute fasteners 2 Position stud plate on underside of panel and secure it with new retaining nuts Fig 17 Fig 13 HCU Brakeline Connections Fig 14 HCU And Bracket Fig 15 HCU Bra...

Page 190: ...and tire assembly 4 Remove bolt attaching front sensor to steering knuckle Fig 18 5 Disengage sensor wire from brackets on steer ing knuckle and frame member Fig 19 and Fig 20 6 Unseat grommet that secures sensor wire in fender panel 7 In engine compartment disconnect sensor wire connector at harness plug 8 Remove sensor and wire assembly INSTALLATION 1 Apply Mopar Lock N Seal or Loctite 242 to se...

Page 191: ...sor pickup face Set air gap to 0 92 1 45 mm 0 036 0 057 in with feeler gauge Fig 23 Tighten sensor bolt to 14 N m 11 ft lbs 5 If new sensor is being installed push card board spacer on sensor face Fig 24 against tone ring Then tighten sensor bolt to 14 N m 11 ft lbs Correct air gap will be established as tone ring rotates and peels spacer off sensor face 6 Route sensor wires to rear seat area 7 Fe...

Page 192: ...nd tighten switch attaching screws to 2 4 N m 17 32 in lbs 4 Connect harness to switch Be sure harness connector is firmly seated 5 Move rear seat back to normal position 6 Connect battery negative cable SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Acceleration Sensor Sensor Bolt 8 9 N m 71 83 in lbs Bracket Bolt 1 2 N m 13 18 in lbs Hydraulic Control Unit Mounting Nuts 10 13 N m 92 112 in lbs B...

Page 193: ......

Page 194: ...4 COOLANT LEVEL CHECK SERVICE 24 COOLING SYSTEM CLEANING REVERSE FLUSHING 25 DRAINING AND FILLING COOLING SYSTEM 24 ROUTINE COOLANT LEVEL CHECK 24 REMOVAL AND INSTALLATION AUTOMATIC BELT TENSIONER 44 BELT REPLACEMENT ADJUSTMENT 43 COOLING SYSTEM FAN 4 0L ENGINE 45 COOLING SYSTEM FAN 5 2L ENGINE 46 ENGINE BLOCK HEATER 42 RADIATOR 35 THERMOSTAT 4 0L ENGINE 32 THERMOSTAT 5 2L ENGINE 33 TRANSMISSION O...

Page 195: ...T The cooling system is designed around the coolant Coolant flows through the engine water jackets absorbing heat produced during engine operation The coolant carries heat to the radiator and heater core Here it is transferred to ambient air passing through the radiator and heater core fins The cool ant also removes heat from the automatic transmis sion fluid in vehicles equipped with an automatic...

Page 196: ...ACCESSORY DRIVE BELT TENSION Correct drive belt tension is required to ensure optimum performance of the belt driven engine acces sories If specified tension is not maintained belt slippage may cause engine overheating lack of power steering assist loss of air conditioning capac ity reduced generator output rate and greatly reduced belt life 4 0L ENGINE Belt tension is adjusted at the power steeri...

Page 197: ...t with a grounded three wire extension cord WARNING DO NOT OPERATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE THE POWER CORD MUST BE SECURED IN ITS RETAINING CLIPS AND ROUTED AWAY FROM EXHAUST MANIFOLDS AND MOVING PARTS THERMOSTAT A pellet type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to ...

Page 198: ...et Chrysler coolant specifications It s overall effec tive temperature range is smaller than that of ethyl ene glycol The freeze point of 50 50 propylene glycol and water is 32 deg C 26 deg F 5 deg C higher than ethylene glycol s freeze point The boiling point protection against summer boil over of propylene glycol is 125 deg C 257 deg F at 96 5 kPa 14 psi compared to 128 deg C 263 deg F for ethyl...

Page 199: ...mp seals are lubri cated by the antifreeze in the coolant mixture No additional lubrication is necessary CAUTION All 4 0L 6 cylinder engines are equipped with a reverse counterclockwise rotating water pump and thermal viscous fan drive assembly REVERSE is stamped or imprinted on the cover of the viscous fan drive and inner side of the fan The letter R is stamped into the back of the water pump imp...

Page 200: ...resulting in coolant loss and engine overheating Ordinary worm gear type hose clamps when equipped can be removed with a straight screw driver or a hex socket To prevent damage to hoses or clamps the hose clamps should be tightened to 4 N m 34 in lbs torque Do not over tighten hose clamps When performing a hose inspection inspect the radiator lower hose for proper position and condition of the int...

Page 201: ... NOISE NOTE It is normal for fan noise to be louder roar ing when The underhood temperature is above the engage ment point for the viscous drive coupling This may occur when ambient outside air temperature is very high Engine loads and temperatures are high such as when towing a trailer Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged warm position...

Page 202: ...er DTC s may have been erased If the lamp flashes 1 time pauses and flashes 7 more times a flashing Diagnostic Trouble Code DTC number 17 is indicated After any stored DTC information has been observed the display will end with a flashing DTC number 55 This will indicate the end of all stored information ERASING TROUBLE CODES After the problem has been repaired use the DRB scan tool to erase a DTC...

Page 203: ...f this group for additional information If the pow ertrain control module PCM detects low engine cool ant temperature it will record a Diagnostic Trouble Code DTC in the PCM memory The DTC number for low coolant temperature is 17 Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or heater performance unless a DTC number 17 is present Refer to the Diagnosis sect...

Page 204: ...SERPENTINE ACCESSORY DRIVE BELT DIAGNOSIS 4 0L 6 CYLINDER ENGINE ZJ COOLING SYSTEM 7 11 DIAGNOSIS AND TESTING Continued ...

Page 205: ...7 12 COOLING SYSTEM ZJ DIAGNOSIS AND TESTING Continued ...

Page 206: ...SERPENTINE ACCESSORY DRIVE BELT DIAGNOSIS 5 2L 8 CYLINDER ENGINE ZJ COOLING SYSTEM 7 13 DIAGNOSIS AND TESTING Continued ...

Page 207: ...be installed for model involved per manufacturer s specifications 4 RECENT SERVICE OR ACCIDENT REPAIR Determine if any recent service has been per formed on vehicle that may effect cooling system This may be Engine adjustments incorrect timing Slipping engine accessory drive belt s Brakes possibly dragging Changed parts incorrect water pump rotating in wrong direction Reconditioned radiator or coo...

Page 208: ...COOLING SYSTEM ZJ COOLING SYSTEM 7 15 DIAGNOSIS AND TESTING Continued ...

Page 209: ...7 16 COOLING SYSTEM ZJ DIAGNOSIS AND TESTING Continued ...

Page 210: ...ZJ COOLING SYSTEM 7 17 DIAGNOSIS AND TESTING Continued ...

Page 211: ...7 18 COOLING SYSTEM ZJ DIAGNOSIS AND TESTING Continued ...

Page 212: ...ZJ COOLING SYSTEM 7 19 DIAGNOSIS AND TESTING Continued ...

Page 213: ...7 20 COOLING SYSTEM ZJ DIAGNOSIS AND TESTING Continued ...

Page 214: ...from the stop tabs Wipe the inner part of the filler neck and examine the lower inside sealing seat for nicks cracks paint dirt and solder residue Inspect the reserve overflow tank tube for internal obstructions Insert a wire through the tube to be sure it is not obstructed Inspect the cams on the outside part of the filler neck If the cams are bent seating of pressure cap valve and tester seal wi...

Page 215: ...NCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE SERIOUS BURNS FROM COOLANT CAN OCCUR Drain sufficient coolant to allow for thermostat removal Refer to Thermostat Replacement Discon nect the water pump drive belt Disconnect the upper radiator hose from the ther mostat housing Remove the housing and thermostat Install the thermostat housing Add coolant to the radiator to bring the level to within 6 3 m...

Page 216: ... to remove the radiator cap except for the following purposes To check and adjust antifreeze freeze point To refill system with new antifreeze For conducting service procedures When checking for vacuum leaks WARNING IF VEHICLE HAS BEEN RUN RECENTLY WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP WITH A RAG SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE PLACE A RAG OVER THE ...

Page 217: ...hicle servicing requires a coolant level check in radiator drain several ounces of coolant from radiator drain cock Do this while observing coolant reserve overflow system tank The coolant level in reserve overflow tank should drop slightly If not inspect for a leak between radiator and coolant reserve overflow system connection Remove radiator cap The coolant level should be to top of radiator If...

Page 218: ...be performed three times Add neces sary coolant to raise tank level to the FULL mark after each cool down period COOLING SYSTEM CLEANING REVERSE FLUSHING CAUTION The cooling system normally operates at 97 to 124 kPa 14 to 18 psi pressure Exceeding this pressure may damage the radiator or hoses CLEANING Drain cooling system and refill with water Run engine with radiator cap installed until upper ra...

Page 219: ...es Refill the cooling system with the correct anti freeze water mixture CHEMICAL CLEANING In some instances use a radiator cleaner Mopar Radiator Kleen or equivalent before flushing This will soften scale and other deposits and aid the flush ing operation CAUTION Be sure instructions on the container are followed REMOVAL AND INSTALLATION TRANSMISSION OIL COOLER AUXILIARY REMOVAL 1 Disconnect negat...

Page 220: ...tion may be equipped with a forward clockwise rotating water pump Installation of the wrong water pump will cause engine over heating The water pump impeller is pressed on the rear of the pump shaft and bearing assembly The water pump is serviced only as a complete assembly WARNING DO NOT REMOVE THE BLOCK DRAIN PLUG S OR LOOSEN RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE SERIOUS BURN...

Page 221: ...ent clamp with matching number or letter 9 Remove lower radiator hose from water pump Remove heater hose from water pump fitting 10 Remove four nuts or bolts previously loosened and remove the fan blade assembly and pulley if fan is installed at pump or remove the pulley from the vehicle 11 After removing fan blade viscous fan drive assembly do not place thermal viscous fan drive in horizontal pos...

Page 222: ...ounted fan install four pump hub bolts Tighten bolts or nuts to 27 N m 20 ft lbs torque 7 Install power steering pump CAUTION When installing the serpentine engine accessory drive belt the belt MUST be routed cor rectly If not the engine may overheat due to the water pump rotating in the wrong direction Refer to the Belt Removal and Installtion in this group for appropriate belt routing You may al...

Page 223: ...N CLAMP TOOL NUMBER HPC 20 MAY BE USED FOR LARGER CLAMPS ALWAYS WEAR SAFETY GLASSES WHEN SERVIC ING CONSTANT TENSION CLAMPS CAUTION A number or letter is stamped into the tongue of constant tension clamps Fig 30 If replacement is necessary use only an original equipment clamp with matching number or letter 4 If water pump is being replaced do not unbolt fan blade assembly Fig 32 from thermal visco...

Page 224: ... 36 Tighten water pump mounting bolts to 40 N m 30 ft lbs torque 3 Position bypass hose clamp to bypass hose 4 Spin water pump to be sure that pump impel ler does not rub against timing chain case cover 5 Install a new o ring to the heater hose coolant return tube Fig 35 Coat the new o ring with anti freeze before installation 6 Install coolant return tube to engine Fig 35 Be sure the slot in tube...

Page 225: ...ND PRES SURIZED SERIOUS BURNS FROM THE COOLANT CAN OCCUR Do not waste reusable coolant If the solution is clean drain the coolant into a clean container for reuse 1 Drain the coolant from the radiator until the level is below the thermostat housing WARNING CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES WHEN REMOVING OR INSTALLING USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE ...

Page 226: ...OUS BURNS FROM COOLANT CAN OCCUR Do not waste reusable coolant If solution is clean drain coolant into a clean container for reuse If thermostat is being replaced be sure that replacement is specified thermostat for vehicle model and engine type Factory installed thermostat housings on 5 2L engines are installed on a gasket with an anti stick coating This will aid in gasket removal and clean up 1 ...

Page 227: ...sed machined groove on intake manifold Fig 42 3 Install gasket on intake manifold and over thermostat Fig 42 4 Position thermostat housing to intake manifold Note the word FRONT stamped on housing Fig 43 For adequate clearance this must be placed towards front of vehicle The housing is slightly angled for ward after installation to intake manifold 5 Install two housing to intake manifold bolts Tig...

Page 228: ...RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE SERIOUS BURNS FROM COOLANT CAN OCCUR REFER TO COOLING SYSTEM DRAIN ING IN THIS GROUP Do not waste reusable coolant If the solution is clean drain the coolant into a clean container for reuse WARNING CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES WHEN REMOVING OR INSTALLING USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE ...

Page 229: ... drive assembly from water pump by turning mounting nut counter clockwise as viewed from front Threads on viscous fan drive are RIGHT HAND A Snap On 36 MM Fan Wrench number SP346 from Snap On Cummins Die sel Tool Set number 2017DSP can be used Place a bar or screwdriver between water pump pulley bolts Fig 49 to prevent pulley from rotating Drive belt removal is not necessary for removal of fan dri...

Page 230: ... crossmember 12 Eight clips are used to retain a rubber seal Fig 51 to the body and upper radiator crossmem ber Gently pry up the outboard clips two per side until rubber seal can be removed Do not remove the clips entirely Fold back the seal on both sides for access to the hidden grille opening reinforcement mounting bolts Fig 51 Remove these two bolts 13 Remove the grill Refer to group 23 Body F...

Page 231: ...lamp and hose 24 The lower part of radiator is equipped with two alignment dowel pins Fig 50 Fig 52 They are located on the bottom of radiator tank and fit into rubber grommets These rubber grommets are pressed into the radiator lower crossmember WARNING THE AIR CONDITIONING SYSTEM IF EQUIPPED IS UNDER A CONSTANT PRESSURE EVEN WITH THE ENGINE OFF REFER TO REFRIG ERANT WARNINGS IN GROUP 24 HEATING ...

Page 232: ...n cooler lines to radia tor Refer to Group 21 for installation 17 Position the fan assembly and fan shroud as one unit to the vehicle 18 Position fan shroud to radiator Be sure the alignment tabs at the lower part of shroud are placed into the slots near lower part of radiator Be sure the upper and lower portions of the fan shroud are firmly connected All air must flow through the radiator 19 Inst...

Page 233: ...essor WARNING THE A C SYSTEM IS UNDER PRES SURE EVEN WITH ENGINE OFF REFER TO REFRIGERANT WARNINGS IN GROUP 24 HEATING AND AIR CONDITIONING 1 Disconnect negative battery cable from battery 2 Partially drain cooling system Refer to Drain ing Cooling System in this group Do not waste reusable coolant If solution is clean drain coolant into a clean container for reuse 3 Remove upper radiator hose cla...

Page 234: ...3 Secure both hose clamps Fig 53 4 Install generator A C mounting bracket assem bly to engine Tighten bolts number 1 and 2 Fig 55 to 54 N m 40 ft lbs torque Tighten bolts num ber 3 Fig 55 to 40 N m 30 ft lbs torque 5 Install a new o ring to the heater hose coolant return tube Fig 56 Coat the new o ring with anti freeze before installation 6 Install coolant return tube to engine Fig 56 Be sure the ...

Page 235: ...move heater assembly INSTALLATION 1 Thoroughly clean cylinder block core hole and block heater seat 2 Insert block heater assembly with element loop pointing down 3 With block heater fully seated tighten center screw to 2 N m 17 in lbs torque 4 Fill cooling system with recommended coolant Refer to Refilling Cooling System section in this group 5 Start and warm the engine Check for leaks Fig 59 Dra...

Page 236: ... the belt MUST be routed correctly If not the engine may overheat due to the water pump rotating in the wrong direction Fig 64 2 Install new belt Refer to the end of this group for Drive Belt Tension specifications 3 After power steering pump bracket and idler pulley has been tightened into position recheck belt tension Adjust if necessary 5 2L Engine Drive belts on the 5 2L engine are equipped wi...

Page 237: ... is being installed arrow must be within approximately 3 mm 1 8 in of indexing mark point B Fig 67 Belt is considered new if it has been used 15 minutes or less If this specifica tion cannot be met check for The wrong belt being installed incorrect length width Worn bearings on an engine accessory A C com pressor power steering pump water pump idler pulley or generator A pulley on an engine access...

Page 238: ... be torqued 5 Install drive belt Refer to Belt Removal Instal lation in this group 6 Check belt indexing marks Fig 67 COOLING SYSTEM FAN 4 0L ENGINE REMOVAL 1 Remove the four fan hub to water pump pulley mounting nuts Fig 68 Carefully remove the fan assembly from the water pump pulley and position to center of fan shroud Fan belt removal is not neces sary as the water pump studs will hold the pump...

Page 239: ... water pump pulley bolts to prevent pulley from rotating 3 Do not attempt to remove fan viscous fan drive assembly from vehicle at this time 4 Do not unbolt fan blade assembly from viscous fan drive at this time 5 Remove two fan shroud to upper crossmember nuts Fig 69 6 Remove fan shroud and fan blade viscous fan drive assembly as a complete unit from vehicle 7 After removing fan blade viscous fan...

Page 240: ... Test all blades in this manner WARNING IF FAN IS NOT WITHIN SPECIFICA TIONS DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN Inspect fan assembly for cracks bends loose rivets or broken welds Replace fan if any damage is found CAUTION If the fan blade assembly is replaced because of mechanical damage the water pump and viscous fan drive should also be inspected These components could have been damaged du...

Page 241: ...DRIVE BELT TENSION TORQUE SPECIAL TOOLS COOLING Pliers 6094 Pressure Tester 7700 A 7 48 COOLING SYSTEM ZJ SPECIFICATIONS Continued ...

Page 242: ...nduction milliampere ammeter volt ohmmeter battery charger carbon pile rheostat load tester and 12 volt test lamp may be required All OBD sensed systems are monitored by the PCM Each monitored circuit is assigned a Diagnos tic Trouble Code DTC The PCM will store a DTC in electronic memory for any failure it detects See the On Board Diagnostics Test in Group 8C Charging System for more information ...

Page 243: ...ential may be restored In addition to producing and storing electrical energy the battery serves as a capacitor or voltage stabilizer for a vehicle s electrical system It absorbs most abnormal or transient voltages caused by the switching of any of the vehicle s electrical compo nents The battery is vented to release excess hydrogen gas that is created when the battery is being charged or discharg...

Page 244: ...CH OF THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SERVICE PER SONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS The condition of a battery is determined by two cri teria 1 State Of Charge This can be determined by viewing the built in test indicator by checking the specific gravity of the electrolyte hydrometer test or by checking the battery v...

Page 245: ...Battery Diagnosis 8A 4 BATTERY ZJ DIAGNOSIS AND TESTING Continued ...

Page 246: ...TTERY IS RETURNED TO SERVICE PER SONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS Before testing visually inspect the battery for any damage a cracked case or cover loose posts etc that would cause the battery to be faulty In order to obtain correct indications from the built in test indi cator it is important that the battery be level and have a clean sight glass Addi...

Page 247: ...e bulb released CAUTION Exercise care when inserting the tip of the hydrometer into a cell to avoid damaging the plate separators Damaged plate separators can cause early battery failure To read the hydrometer correctly hold it with the top surface of the electrolyte at eye level Hydrometer floats are generally calibrated to indicate the specific gravity correctly only at 26 7 C 80 F When testing ...

Page 248: ... will not reveal its cranking capacity If a battery has an open circuit voltage reading of 12 4 volts or greater it may be load tested to reveal its cranking capacity See Load Test in this group for more infor mation LOAD TEST A battery load test will verify the battery cranking capacity The test is based on the Cold Cranking Amperage CCA rating of the battery See the Bat tery Classifications and ...

Page 249: ...load control knob to the Off position 6 The voltage drop will vary with the battery temperature at the time of the load test The battery temperature can be estimated by using the ambient temperature during the past several hours If the battery has been charged boosted or loaded a few minutes prior to the test the battery will be some what warmer See the Load Test Temperature chart for the proper l...

Page 250: ...mp will be the same as if it were con nected across the battery The test lamp must be securely clamped to the battery negative cable clamp and the battery negative terminal post If the conti nuity between the battery negative terminal post and cable clamp is lost during any part of the IOD test the electronic timer function will be activated and all tests must be repeated 5 After three minutes the...

Page 251: ...rrent Refer to the instructions provided with the battery charger to bypass the polarity sensing circuitry After the battery has been charged to 12 4 volts or greater perform a load test to determine the battery cranking capacity If the battery will endure a load test return the battery to use If the battery will not endure a load test it is faulty and must be replaced Clean and inspect the batter...

Page 252: ...CHARGING A COLD 1 C 30 F BATTERY THE BAT TERY MAY ARC INTERNALLY AND EXPLODE PER SONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT REMOVAL AND INSTALLATION BATTERY 1 Turn the ignition switch to the Off position Make sure all electrical accessories are off 2 Loosen the cable terminal clamps and discon nect both battery cables negative cable first If nec essary use a puller to remove the terminal clamps...

Page 253: ...dd distilled water to each cell until the liq uid reaches the bottom of the vent well DO NOT OVERFILL 8 Inspect the battery built in test indicator sight glass for an indication of the battery condition If the battery is discharged charge as required See Built In Test Indicator and Battery Charging in this group for more information 9 If the battery is to be reinstalled clean the out side of the b...

Page 254: ...ery terminals Reverse polarity may damage electrical components 13 Place an oiled felt washer on the battery pos itive terminal post 14 Install and tighten the battery positive cable terminal clamp Then install and tighten the nega tive cable terminal clamp Tighten both cable termi nal clamp bolts to 8 5 N m 75 in lbs 15 Apply a thin coating of petroleum jelly or chassis grease to the exposed surf...

Page 255: ......

Page 256: ...d Diagnostics Test in Group 8C Charging System for more information INTRODUCTION The starting system consists of Battery Starter relay Starter with an integral solenoid Ignition switch Park neutral position switch automatic trans mission Wiring harness and connections This group covers diagnosis of the complete start ing system except the battery However this group only covers service procedures f...

Page 257: ... only as a complete assembly If either component fails the entire assembly must be replaced CAUTION Permanent magnet starters are highly sensitive to hammering shocks and external pres sure The permanent magnets may be damaged and the starter rendered unserviceable if subjected to any of these conditions The starter motor must not be clamped in a vise by the starter field frame Doing so may dam ag...

Page 258: ...p Replace switch if required 6 See Solenoid Test in this Group Replace starter assembly if required 7 If all other starting system components and circuits check OK replace starter assembly STARTER ENGAGES FAILS TO TURN ENGINE 1 Battery discharged or faulty 2 Starting circuit wiring faulty 3 Starter assembly faulty 4 Engine seized 1 Refer to Group 8A Battery Charge or replace battery if required 2 ...

Page 259: ...n of the resistance between the two points at which the voltmeter probes are attached EXAMPLE When testing the resistance of the bat tery positive cable touch the voltmeter leads to the battery positive cable clamp and the cable connector at the starter solenoid If you probe the battery posi tive terminal post and the cable connector at the starter solenoid you are reading the combined voltage dro...

Page 260: ...ry negative cable 5 Connect the positive lead of the voltmeter to the starter housing Connect the negative lead of the voltmeter to the battery negative terminal post Fig 6 Rotate and hold the ignition switch in the Start position Observe the voltmeter If the reading is above 0 2 volt correct the poor starter to engine block ground contact If the resistance tests detect no feed circuit prob lems r...

Page 261: ...If not OK repair the open circuit to the PDC fuse as required 2 The relay normally closed terminal 87A is connected to terminal 30 in the de energized position but is not used for this application Go to Step 3 3 The relay normally open terminal 87 is con nected to the common feed terminal 30 in the ener gized position This terminal supplies battery voltage to the starter solenoid field coils There...

Page 262: ...ion Systems for the procedures 3 With the ignition switch in the On position check for continuity between the ignition switch ter minals 1 and 7 These are the terminals at each end of the switch connector There should be no continu ity If OK go to Step 4 If not OK replace the faulty switch 4 With the ignition switch held in the Start posi tion check for continuity between the ignition switch termi...

Page 263: ...rter relay by unplugging it from the PDC 5 Install the starter relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly into place 6 Install the PDC cover 7 Connect the battery negative cable 8 Test the relay operation SPECIFICATIONS STARTING SYSTEM Fig 11 Starter Remove Install 5 2L Engine Fig 12 Power Distribution Center Starter and Solenoid Manufacturer Mi...

Page 264: ... The PCM will store a DTC in electronic memory for any failure it detects See the On Board Diagnostics Test in Group 8C Charging System for more information DESCRIPTION AND OPERATION CHARGING SYSTEM OPERATION The charging system consists of Generator Electronic Voltage Regulator EVR circuitry within the Powertrain Control Module PCM Ignition switch refer to Group 8D Ignition Sys tem for informatio...

Page 265: ...e sensor is located under the vehicle battery and is attached to the battery tray Fig 1 VOLTAGE REGULATOR The Electronic Voltage Regulator EVR is not a separate component It is actually a voltage regulat ing circuit located within the Powertrain Control Module PCM The EVR is not serviced separately If replacement is necessary the PCM must be replaced Operation The amount of DC current produced by ...

Page 266: ...achometer 6 Fully engage the parking brake TEST 1 Start engine 2 Place heater blower in high position 3 Turn on headlamps and place in high beam position 4 Turn vehicle interior lamps on 5 Start engine Bring engine speed up to 2400 rpm and hold 6 Testing circuitry a Touch the negative lead of voltmeter directly to battery positive post b Touch the positive lead of voltmeter to the B output termina...

Page 267: ...Charging System Test 8C 4 CHARGING SYSTEM ZJ DIAGNOSIS AND TESTING Continued ...

Page 268: ...olt amp tester is not equipped with an engine tachometer connect a separate tachometer to the engine TEST 1 1 Perform the previous test Preparation 2 Fully engage the parking brake 3 Start engine 4 Bring engine speed to 2500 rpm 5 With engine speed held at 2500 rpm slowly adjust the rheostat control load on the tester to obtain the highest amperage reading Do not allow voltage to drop below 12 vol...

Page 269: ...odule PCM monitors critical input and output circuits of the charging sys tem making sure they are operational A Diagnostic Trouble Code DTC is assigned to each input and output circuit monitored by the OBD system Some circuits are checked continuously and some are checked only under certain conditions If the OBD system senses that a monitored circuit is bad it will put a DTC into electronic memor...

Page 270: ...olt 5 2L engines 41 N m 30 ft lbs Generator pivot bolt 5 2L engines 41 N m 30 ft lbs Generator mounting bolt 4 0L engine 55 N m 41 ft lbs Generator pivot bolt 4 0L engine 55 N m 41 ft lbs Battery terminal nut 8 5 N m 75 in lbs Ground terminal nut 8 5 N m 75 in lbs Harness holddown nut 8 5 N m 75 in lbs Field terminal nuts 2 8 N m 25 in lbs CAUTION Never force a belt over a pulley rim using a screw...

Page 271: ...PECIFICATIONS GENERATOR RATINGS TORQUE SPECIFICATIONS Description Torque Generator Mounting Bolt 5 2L Engine 41 N m 30 ft lbs Generator Pivot Bolt 5 2L Engine 41 N m 30 ft lbs Generator Mounting Bolt 4 0L Engine 55 N m 41 ft lbs Description Torque Generator Pivot Bolt 4 0L Engine 55 N m 41 ft lbs Battery Terminal Nut 8 5 N m 75 in lbs Ground Terminal Nut 8 5 N m 75 in lbs Harness Hold down Nut 8 5...

Page 272: ...TEST 6 IGNITION COIL TEST 5 IGNITION TIMING 8 INTAKE MANIFOLD AIR TEMPERATURE SENSOR 9 MAP SENSOR 8 SPARK PLUG CABLES 9 SPARK PLUG CONDITIONS 10 TESTING FOR SPARK AT COIL 5 REMOVAL AND INSTALLATION AUTOMATIC SHUTDOWN ASD RELAY 15 CAMSHAFT POSITION SENSOR 16 CRANKSHAFT POSITION SENSOR 4 0L ENGINE 15 CRANKSHAFT POSITION SENSOR 5 2L ENGINES 15 DISTRIBUTOR 4 0L ENGINE 18 DISTRIBUTOR 5 2L ENGINE 17 ENG...

Page 273: ...circuit to operate the ignition coil This is done to adjust ignition timing both initial base and advance and for changing engine operating condi tions The amount of electronic spark advance provided by the PCM is determined by five input factors engine coolant temperature engine rpm intake man ifold temperature manifold absolute pressure and throttle position DISTRIBUTOR All 4 0L 5 2L engines are...

Page 274: ... conditions The ignition coil is not oil filled The windings are embedded in an epoxy compound This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine AUTOMATIC SHUTDOWN ASD RELAY As one of its functions the ASD relay will supply battery voltage to the ignition coil The ground cir cuit for the ASD relay is controlled by the Powertrain Control Module PC...

Page 275: ...signal is used in conjunction with the crank shaft position sensor to differentiate between fuel injection and spark events It is also used to synchro nize the fuel injectors with their respective cylinders When the leading edge of the pulse ring shutter enters the sync signal generator the following occurs The interruption of magnetic field causes the voltage to switch high resulting in a sync si...

Page 276: ... arcing does not occur inspect the sec ondary coil cable Refer to Spark Plug Cables in this group Also inspect the distributor cap and rotor for cracks or burn marks Repair as necessary If steady arcing occurs connect ignition coil cable to the dis tributor cap 3 Remove a cable from one spark plug 4 Using insulated pliers hold the cable terminal approximately 12 mm 1 2 in from the engine cylin der...

Page 277: ...er wire Attach the negative side of voltmeter to a good ground Determine that sufficient battery voltage 12 4 volts is present for the starting and ignition systems 4 Determine that sufficient battery voltage 12 4 volts is present for the starting and ignition systems 5 Crank the engine for 5 seconds while monitor ing the voltage at the coil positive terminal If the voltage remains near zero durin...

Page 278: ...k for white deposits on the inside caused by condensation entering the cap through cracks Replace any cap that displays charred or eroded terminals The machined surface of a terminal end faces toward rotor will indicate some evidence of erosion from normal operation Examine the terminal ends for evi dence of mechanical interference with the rotor tip DISTRIBUTOR ROTOR Visually inspect the rotor Fi...

Page 279: ...should be open no resistance Replace sensor if a low resistance is indi cated CRANKSHAFT POSITION SENSOR 5 2L ENGINES To perform a complete test of this sensor and its circuitry refer to the DRB scan tool Also refer to the appropriate Powertrain Diagnostics Procedures man ual To test the sensor only refer to the following The sensor is located on the top of cylinder block near the rear of right cy...

Page 280: ...hicle test using the DRB scan tool 11 If voltage is present at cavity A 17 but not at the supply wire a Check continuity between the supply wire This is checked between the distributor connector and cavity A 17 at the PCM If continuity is not present repair the harness as necessary b Check for continuity between the camshaft position sensor output wire and cavity A 18 at the PCM If continuity is n...

Page 281: ... The cable running from the ignition coil to the distributor cap can be checked in the same manner Cracked dam aged or faulty cables should be replaced with resis tance type cable This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket Use an ohmmeter to test for open circuits exces sive resistance or loose terminals If equipped remove the distributor cap from the di...

Page 282: ...n older engines worn piston rings leaking valve guide seals or excessive cylinder wear can cause wet fouling In new or recently overhauled engines wet fouling may occur before break in nor mal oil control is achieved This condition can usu ally be resolved by cleaning and reinstalling the fouled plugs OIL OR ASH ENCRUSTED If one or more spark plugs are oil or oil ash encrusted Fig 20 evaluate engi...

Page 283: ...r electrode dissolves first and the ground electrode dissolves some what latter Fig 24 Insulators appear relatively deposit free Determine if the spark plug has the correct heat range rating for the engine Determine if ignition timing is over advanced or if other operating conditions are causing engine overheating The heat range rating refers to the operating temperature of a particular type spark...

Page 284: ... good connection is made between the plug cable and the distributor cap tower SPARK PLUGS On 5 2L V 8 engines spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug Fig 29 If removal of the heat shield s is necessary remove the spark plug cable and compress the sides of shield for removal Each shield is slotted to allow for compression and remov...

Page 285: ...ead spark plug wells Be sure the plugs do not drop into the plug wells as elec trodes can be damaged Always tighten spark plugs to the specified torque Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator When replacing the spark plug and ignition coil cables route the cables correctly and secure them in the appropriate retainers Failure...

Page 286: ...nstall ignition coil to bracket If nut and bolts are used to secure coil to coil bracket tighten to 11 N m 100 in lbs torque If bolts are used tighten bolts to 5 N m 50 in lbs torque 2 Connect engine harness connector to coil 3 Connect ignition coil cable to ignition coil AUTOMATIC SHUTDOWN ASD RELAY The Automatic Shutdown ASD relay is located in the Power Distribution Center PDC The PDC is locate...

Page 287: ...cated in the dis tributor on all 4 0L and 5 2L engines Fig 36 REMOVAL Distributor removal is not necessary to remove camshaft position sensor 1 5 2L Engines Remove air cleaner tube at throt tle body 2 Disconnect negative cable from battery 3 Remove distributor cap from distributor two screws 4 Disconnect camshaft position sensor wiring harness from main engine wiring harness 5 Remove distributor r...

Page 288: ...ables at distributor cap Note and mark position before removal 5 Remove distributor cap from distributor two screws 6 Mark the position of distributor housing in relationship to engine or dash panel This is done to aid in installation 7 Before distributor is removed the number one cylinder must be brought to the Top Dead Center TDC firing position 8 Attach a socket to the Crankshaft Vibration Damp...

Page 289: ...creen along with 0 This indicates correct distributor position If a plus or a minus is displayed next to the degree number and or the degree displayed is not zero loosen but do not remove the distributor hold down clamp bolt Rotate the distributor until IN RANGE appears on the screen Continue to rotate the distributor until achieving as close to 0 as pos sible After adjustment tighten clamp bolt t...

Page 290: ...tate the engine Do this until the timing index mark on the vibration damper pulley aligns with the top dead center TDC mark 0 degree on timing degree scale Fig 42 Always rotate the engine in direction of normal rotation Do not rotate the engine backward to align the timing marks 8 Remove the distributor holddown bolt and clamp 9 Remove the distributor from engine by slowly lifting straight up 10 N...

Page 291: ...ignment holes Fig 44 7 Rotate the distributor shaft and install the pin punch tool through the proper alignment hole in the plastic ring Fig 44 and into the mating access hole in the distributor housing This will prevent the dis tributor shaft and rotor from rotating 8 Clean the distributor mounting hole area of the engine block 9 Install a new distributor to engine block gasket Fig 41 10 Install ...

Page 292: ... 3 N m 26 in lbs torque 16 If removed install the spark plug cables to the distributor cap For proper firing order refer to the Specifications section at the end of this group See Engine Firing Order 17 Connect the distributor wiring harness to the main engine harness 18 Connect battery cable to battery POWERTRAIN CONTROL MODULE PCM Refer to Group 14 Fuel System for procedures IGNITION SWITCH AND ...

Page 293: ... Using a TTXR20A2 or equivalent torx bit remove key cylinder retaining screw and bracket Fig 51 or Fig 52 b Rotate key clockwise to the OFF position Key cylinder will unseat from ignition switch Fig 53 When key cylinder is unseated it will be approximately 1 8 inch away from ignition switch halo light ring Do not attempt to remove key cylinder at this time c With key cylinder in unseated position ...

Page 294: ...witch is in the lock position when column lock flag is parallel to ignition switch terminals Fig 55 c Position ignition switch park lock dowel pin so it will engage steering column park lock slider linkage Fig 56 d Apply a light coating of grease to column lock flag and park lock dowel pin 3 Place ignition switch against lock housing opening on steering column Ensure that ignition switch park lock...

Page 295: ...eration of halo light shift lock if applicable and column lock Also check for proper operation of ignition switch accessory lock off run and start positions SHIFTER IGNITION INTERLOCK On models equipped with an automatic transmis sion a cable connects the ignition switch with the floor shift lever The shifter will be locked in the PARK position when the ignition key is in the LOCK or ACCESSORY pos...

Page 296: ...R 4 0L 6 CYLINDER ENGINE ENGINE FIRING ORDER 5 2L V 8 ENGINE TORQUE SPECIFICATIONS DESCRIPTION TORQUE Crankshaft Position Sensor 4 0L Engine 7 N m 60 in lbs Crankshaft Position Sensor 5 2L Engine 8 N m 70 in lbs Distributor Hold Down Bolt All Engines 23 N m 17 ft lbs Ignition Coil Mounting if tapped bolts are used 5 N m 50 in lbs Ignition Coil Mounting if nuts bolts are used 11 N m 100 in lbs Powe...

Page 297: ...IGNITION COIL 8D 26 IGNITION SYSTEM ZJ SPECIFICATIONS Continued ...

Page 298: ...UGES LAMP 12 CLUSTER ILLUMINATION LAMPS 13 COOLANT TEMPERATURE GAUGE 10 CRUISE ON INDICATOR LAMP 13 FUEL GAUGE 10 GAUGE CLUSTER 9 GRAPHIC DISPLAY MODULE 13 HEADLAMP HIGH BEAM INDICATOR LAMP 15 LOW FUEL WARNING LAMP 15 MALFUNCTION INDICATOR LAMP 15 ODOMETER TRIP ODOMETER 10 OIL PRESSURE GAUGE 10 SEAT BELT REMINDER LAMP 16 SPEEDOMETER 11 TACHOMETER 11 TURN SIGNAL INDICATOR LAMPS 16 VEHICLE INFORMATI...

Page 299: ...anel removal If necessary the instrument panel can be removed from the vehicle as an assem bly Removal of the switch pod bezels allows access to most switches and the climate controls Removal of the instrument cluster bezel allows access to the cluster assembly and the radio Removal of the clus ter assembly allows access to the individual gauges illumination and indicator lamp bulbs and most of th...

Page 300: ...o the owner s manual for more information on the VIC controls operation and setting proce dures For diagnosis of the VIC module or the CCD data bus refer to the proper Body Diagnostic Proce dures Manual The VIC module cannot be repaired If damaged or faulty the entire module must be replaced GAUGES With the ignition switch in the On or Start posi tions voltage is supplied to all gauges through the...

Page 301: ... headlamps only The BCM is mounted under the left end of the instrument panel behind the instrument panel sup port armature and below the left switch pod For diagnosis of the BCM or the CCD data bus refer to the proper Body Diagnostic Procedures Manual The BCM can only be serviced by an authorized repair station Refer to the Warranty Policies and Proce dures Manual for a listing of authorized repa...

Page 302: ... to the BCM on the CCD data bus The BCM stores both the odometer and trip odometer distance information and sends the proper value to the instrument cluster based upon ignition key on and trip odometer reset knob messages received on the CCD data bus If the instrument cluster is not receiving distance information on the CCD data bus when the ignition switch is turned to the On position the odomete...

Page 303: ...M on the Chrysler Collision Detection CCD data bus The ACM continually monitors the airbag system circuits and sensors to decide whether the system is in good operating condition The ACM then sends the proper message to the instrument cluster on the CCD data bus to turn the lamp on or off If the ACM turns the lamp on after the bulb test it indicates the ACM has detected a system malfunction and or...

Page 304: ...tors the panel dimmer resistor switch to determine the desired dim ming level then adjusts the pulse width signal accordingly The BCM also sends the proper panel lamps dim ming level message on the Chrysler Collision Detec tion CCD data bus Other modules on the CCD data bus radio mini trip computer vehicle information center receive this message and adjust their dim ming levels to match that of th...

Page 305: ... PCM it sends a mes sage to the Body Control Module BCM on the CCD data bus for a single chime tone to sound The MIL lamp can also be used to display a stored DTC by flashing on and off Refer to Group 14 Fuel System for more information on DTCs and their retrieval MASTER LIGHTING INDICATOR LAMP Export vehicles are equipped with a master light ing indicator lamp The master lighting indicator lamp g...

Page 306: ...s equipped with a diesel engine have a water in fuel lamp The water in fuel lamp gives an indication when water in the diesel fuel exceeds a certain level The lamp is turned on by the instru ment cluster circuitry for about three seconds when the ignition switch is turned to the On position as a bulb test After the bulb test the lamp is controlled by the instrument cluster circuitry based upon a m...

Page 307: ...bed in the proper Powertrain Diagnostic Procedures Manual Diagnosis of the fuel gauge the gauge cluster cir cuitry and or the CCD data bus should be performed with the DRB scan tool as described in the proper Body Diagnostic Procedures Manual ODOMETER TRIP ODOMETER If the problem being diagnosed is related to gauge accuracy be certain to confirm that the problem is with the gauge and not with an i...

Page 308: ...lacement Refer to Group 8C Charging System for more infor mation Refer to Group 8W Wiring Diagrams for cir cuit descriptions and diagrams WARNING ON VEHICLES EQUIPPED WITH AIRBAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYS TEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COM PONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG D...

Page 309: ...quired 6 Check for continuity between the ABS warning lamp driver circuit cavities of the cluster connector and the CAB connector There should be continuity If OK refer to Group 5 Brakes for diagnosis of the CAB If not OK repair the open circuit as required BRAKE WARNING LAMP The diagnosis found here addresses an inoperative brake warning lamp condition If the brake warning lamp stays on with the ...

Page 310: ...oper Body Diagnostic Procedures Man ual for diagnosis of the BCM If not OK repair the open circuit as required CRUISE ON INDICATOR LAMP The diagnosis found here addresses an inoperative lamp condition If the problem being diagnosed is an inaccurate cruise on indicator lamp refer to Group 8H Vehicle Speed Control and or to the proper Pow ertrain Diagnostic Procedures Manual for diagnosis For circui...

Page 311: ...ntinuity between the panel lamp driver circuit cavities of the GDM connec tor and the BCM connector If OK refer to Group 8L Lamps for diagnosis of the headlamp switch and or the proper Body Diagnostic Procedures Manual for diagnosis of the BCM If not OK repair the open cir cuit as required FOUR WHEEL DRIVE INDICATOR LAMPS WARNING ON VEHICLES EQUIPPED WITH AIRBAGS REFER TO GROUP 8M PASSIVE RESTRAIN...

Page 312: ...tify a faulty low fuel warning lamp circuit For circuit descriptions and diagrams refer to 8W 40 Instrument Cluster in Group 8W Wiring Diagrams WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AI...

Page 313: ...ight or left turn signal indicator lamp circuit cavity of the cluster connector There should be a switching on and off battery voltage signal If OK replace the faulty right or left indicator bulb If not OK repair the open circuit to the turn signal multi function switch as required VEHICLE INFORMATION CENTER The Vehicle Information Center VIC has a num ber of display functions and features The dia...

Page 314: ...pen circuit as required 2 Check the transfer case switch continuity while shifting the transfer case shift lever to the proper positions The switch continuity should be as shown in Fig 2 If OK go to Step 3 If not OK replace the faulty switch 3 Disconnect and isolate the battery negative cable Remove the VIC module as described in this group Unplug the VIC module connector 4 Locate two pairs of con...

Page 315: ...GROUP 8M PASSIVE RESTRAINT SYS TEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COM PONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Unplug the washer fluid level sensor connector on the washer reservoir bottle Check for continuity between the ground circuit cavity of the connecto...

Page 316: ...VIC Initial Set Up ZJ INSTRUMENT PANEL SYSTEMS 8E 19 SERVICE PROCEDURES Continued ...

Page 317: ...VIC Reset 8E 20 INSTRUMENT PANEL SYSTEMS ZJ SERVICE PROCEDURES Continued ...

Page 318: ... side of the steering column on the upper edge of the knee blocker steer ing column cover Fig 4 4 Remove one screw securing the left end of the knee blocker to the instrument panel 5 Remove the four screws securing the lower edge of the knee blocker to the lower instrument panel reinforcement 6 Using a trim stick or other suitable wide flat bladed tool gently pry the edges of the knee blocker away...

Page 319: ...NG WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Remove the cluster bezel as described in this group 2 Remove the instrument cluster as described in this group 3 Remove the trip odometer reset knob by pulling it off of the switch stem Fig 6 4 Depress the s...

Page 320: ...T IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Remove the instrument cluster as described in this group 2 Remove the bulb and socket from the rear clus ter circuit and gauge housing by using a twisting motion Fig 8 3 Unplug the bulb from the socket 4 Reverse the removal procedures to install LEFT SWITCH POD WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RES...

Page 321: ...anel Fig 10 4 Pull the right switch pod out from the instru ment panel far enough to unplug the wiring connec tors 5 Remove the right switch pod from the instru ment panel 6 Reverse the removal procedures to install BODY CONTROL MODULE WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONEN...

Page 322: ... right instrument panel module 7 Open the glove box door and remove the four screws on the upper edge of the glove box opening in the lower right instrument panel module 8 Lower the lower right instrument panel far enough to unplug the wiring connectors for the glove box lamp switch the cigar lighter lamp and the power outlet Also remove the bulb and socket as a unit from the ash receiver lamp hoo...

Page 323: ...raighten the two mounting tabs Fig 14 3 Remove the latch striker from the upper glove box opening 4 To install the latch striker insert the mounting tabs through the slots in the upper glove box opening and bend the tabs over from the top of the lower right instrument panel module CIGAR LIGHTER WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING...

Page 324: ...using 4 To install the door insert one of the pivot pins into a pivot receptacle in the center bezel and twist the door gently until the pivot pin on the opposite side of the door snaps into the other pivot receptacle INSTRUMENT PANEL CENTER BEZEL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PA...

Page 325: ...rocedures to install GLOVE BOX HINGE 1 Remove the glove box 2 Remove the screws securing the glove box hinge to the glove box door 3 Remove the glove box hinge 4 Reverse the removal procedures to install GLOVE BOX BIN 1 Remove the glove box 2 Remove the glove box hinge as described in this group 3 Remove the screws securing each side of the bin to the glove box door 4 Remove the glove box bin 5 Re...

Page 326: ...olate the battery negative cable 2 Remove the switch pod bezels the cluster bezel the knee blocker the lower right instrument panel module and the cowl top trim panel See the procedures in this group 3 If so equipped remove the auto headlamp light sensor vehicle theft security system lamp mounting screw near the left defroster duct outlet and move it for clearance of the instrument panel top pad 4...

Page 327: ...nts and switches 7 Remove the three nuts securing the steering column toe plate at the base of the steering column 8 Remove the two nuts securing the steering col umn mounting bracket to the studs on the steering column and brake pedal support and lower the steer ing column to the floor 9 Remove the right and left cowl side trim pan els Refer to Group 23 Body Components for the procedures 10 Unplu...

Page 328: ...two bolts securing the ends of the instrument panel armature to the windshield fence 23 Remove the four nuts securing the top of the instrument panel armature to the studs on the wind shield fence 24 With the aid of an assistant lift the instru ment panel off of the windshield fence studs and maneuver the assembly out of the passenger s side front door 25 Reverse the removal procedures to install ...

Page 329: ......

Page 330: ...ceives messages on the Chrysler Collision Detection CCD data bus network from the Remote Keyless Entry RKE receiver in the Passenger Door Module PDM for the memory select function The DDM processes these inputs and sends messages to the radio on the CCD data bus for memory recall The CCD data bus network allows the sharing of sensor information This helps to reduce wiring har ness complexity reduc...

Page 331: ...At the same time this system provides increased reliability enhanced diagnostics and allows the addition of many new feature capabilities One of the functions and features that the BCM supports and controls is the remote radio switches The BCM receives hard wired resistor multiplexed inputs from the remote radio switches The program ming in the BCM allows it to process those inputs and send the pr...

Page 332: ...e secondary ignition wir ing In addition if the source of RFI or EMI noise is identified as a component on the vehicle i e gener ator blower motor etc the ground path for that component should be checked If excessive resistance is found in that circuit repair that circuit as required before considering any component replace ment If the source of the noise is identified as two way mobile radio or t...

Page 333: ...ulty 3 Wiring faulty 4 Ground faulty 5 Radio faulty 1 Check ignition off draw fuse Replace fuse if required 2 Check for loose or corroded radio connector Repair if required 3 Check for battery voltage at radio connector Repair wiring if required 4 Check for continuity between radio chassis and a known good ground There should be continuity Repair ground if required 5 Exchange or replace radio if r...

Page 334: ... WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable Wait two minutes for the airbag system capac itor to discharge before furt...

Page 335: ...8 Check the amplifier fuse in the junction block If OK go to Step 9 If not OK replace the faulty fuse 9 Install the radio Connect the battery negative cable Check for battery voltage at the two fused B circuit cavities of the amplifier connector If OK go to Step 10 If not OK repair the open circuit as required 10 Turn the ignition switch and radio switch to the On position Check for battery voltag...

Page 336: ...should be less than one ohm 3 If the resistance is more than one ohm check the braided ground strap connected to the engine and the vehicle body for being loose corroded or dam aged Repair the ground strap connection if required TEST 4 Test 4 checks the condition of the ground between the antenna base and the vehicle body as follows 1 Connect one ohmmeter test lead to the fender and the other lead...

Page 337: ...e 5 Remove the two radio mounting screws from the front of the radio Fig 3 6 Pull the radio out from the instrument panel far enough to unplug the wiring connectors and the antenna coaxial cable Fig 4 7 Remove the radio from the instrument panel 8 Reverse the removal procedures to install REMOTE RADIO SWITCHES WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS B...

Page 338: ...procedures to install Tighten the amplifier mounting screws to 2 8 N m 25 in lbs SPEAKERS INSTRUMENT PANEL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONA...

Page 339: ...at bladed tool such as a trim stick pry the trim panel away from the door around the perimeter and remove the trim panel NOTE To aid in the removal of the trim panel start at the bottom of the panel 8 Unplug the wiring connectors from the door module and the door courtesy lamp if so equipped 9 Remove the three screws holding the speaker to the lower front corner of the inner door panel Fig 12 10 D...

Page 340: ...he inner door panel Fig 14 8 Disconnect the speaker wiring connector and remove the speaker 9 Reverse the removal procedures to install Tighten the hardware as follows speaker mounting screws 1 1 N m 10 in lbs trim panel mounting screws 1 3 N m 12 in lbs ANTENNA WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN O...

Page 341: ...a coaxial cable lead connector near the junction block at the right cowl side panel Unplug the connector by pulling it apart while twist ing the metal connector halves Fig 19 Do not pull on the cable 9 Remove the antenna body and cable by pulling the cable and grommet out of the cowl side panel from inside the right front fender wheel housing 10 Reverse the removal procedures to install Tighten th...

Page 342: ...stive membrane type horn switch is installed on the back side of the driver s air bag module trim cover in the center of the steering wheel When the center area of the airbag trim cover is depressed the horn switch completes a circuit to ground for the coil side of the horn relay The steer ing wheel and steering column must be properly grounded for the horn switch to function The horn switch is on...

Page 343: ...net should be 7565 ohms If OK go to Step 3 If not OK replace the faulty relay 3 Connect a battery to terminals 85 and 86 There should now be continuity between terminals 30 and 87 and no continuity between terminals 87A and 30 If OK see the Relay Circuit Test in this group If not OK replace the faulty relay RELAY CIRCUIT TESTS 1 The relay common feed terminal cavity 30 is connected to battery volt...

Page 344: ...y If not OK replace the faulty horn switch HORN For circuit descriptions and diagrams refer to 8W 41 Horns Cigar Lighter in Group 8W Wiring Diagrams 1 Disconnect the horn wiring connector Measure the resistance between the ground circuit cavity of the horn connector and a good ground There should be zero ohms resistance If OK go to Step 2 If not OK repair the faulty horn ground circuit as required...

Page 345: ...ng connectors Fig 2 5 Remove the bolt holding the horn mounting bracket to the radiator closure extension panel and remove the horns 6 Reverse the removal procedures to install Tighten the horn bracket mounting bolt to 30 N m 22 ft lbs Fig 2 Horn Remove Install 8G 4 HORN SYSTEMS ZJ REMOVAL AND INSTALLATION Continued ...

Page 346: ...ease of vacuum to the diaphragm of the vacuum servo The servo unit cannot be repaired and is ser viced only as a complete assembly SPEED CONTROL SWITCHES Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver s airbag module Within the two switch modules five momentary contact switches supporting seven different speed control functions ...

Page 347: ...meter operates properly check for A misadjusted brake stop lamp switch This could also cause an intermittent problem Loose or corroded electrical connections at the servo Corrosion should be removed from electrical terminals and a light coating of Mopar MultiPurpose Grease or equivalent applied Loose or leaking vacuum hoses or connections Secure attachment of both ends of the speed con trol servo ...

Page 348: ...DIAGNOSIS CHART 1 ZJ VEHICLE SPEED CONTROL SYSTEM 8H 3 DIAGNOSIS AND TESTING Continued ...

Page 349: ...DIAGNOSIS CHART 2 8H 4 VEHICLE SPEED CONTROL SYSTEM ZJ DIAGNOSIS AND TESTING Continued ...

Page 350: ... are in mem ory The lamp will flash until all stored DTC s are displayed A DTC code number 55 signifies the end of tests If a DTC number 15 34 or 77 is observed refer to the appropriate Powertrain Diagnostic Procedures manual Correct any problems found in your diagno sis then recheck for a DTC after corrections are com pleted Use the DRB scan tool to erase a DTC after repair SPEED CONTROL DIAGNOST...

Page 351: ...RY NEGATIVE GROUND CABLE WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect negative battery cable Wait 2 min utes for airbag system capacitor to discharge 2 Remove the two speed control switch modules from steering wheel Refer to the removal installation section for ...

Page 352: ...ctor at servo 3 Remove 2 nuts holding servo cable sleeve 4 Pull speed control cable sleeve away from servo to expose cable retaining clip 5 Remove clip attaching cable to servo 6 Remove servo from mounting bracket 7 Reverse removal procedures to install Block throttle to full open position to align hole in cable connector with hole in servo pin and install retaining clip Tighten servo mounting nut...

Page 353: ...AL INSTALLATION 1 4 0L Engine Using finger pressure only remove speed control cable connector at throttle body bellcrank pin by pushing connector off the bellcrank towards the drivers side of vehicle Fig 5 DO NOT try to pull connector off perpendicular to the bellcrank pin Connector will be broken 2 5 2L Engine Using finger pressure only remove speed control cable connector at throttle body bellcr...

Page 354: ...y 7 Reverse removal procedures to install Tighten hardware as follows vacuum reservoir mounting bolts to 3 N m 30 in lbs battery tray mounting bolts to 10 N m 90 in lbs battery holddown bolts to 10 N m 90 in lbs battery cable clamp bolts to 8 5 N m 75 in lbs VEHICLE SPEED SENSOR For Removal Installation of the Vehicle Speed Sen sor refer to Group 21 Transaxle SPECIFICATIONS TORQUE Description Torq...

Page 355: ......

Page 356: ... and front side marker lamps flash in unison With the headlamp switch in the On position the front turn signal and front side marker lamps flash alternately HAZARD WARNING SYSTEM The hazard warning system is activated by a switch button in the multi function switch The but ton is located on the top of the steering column between the steering wheel and the instrument panel The hazard warning switch...

Page 357: ...ingle chime tone if a turn signal remains activated for more than approximately one half mile of driving Refer to Group 8E Instrument Panel Systems for diagnosis and service of the VIC module Refer to the appropriate Body Diagnostic Procedures Manual for diagnosis and service of the BCM or the CCD bus TURN SIGNAL LAMPS The exterior lamps in the turn signal and hazard warning circuits include the f...

Page 358: ...lti function switch connector as described in this group Check for continuity between the hazard signal circuit cavities of the junc tion block and the multi function switch connector There should be continuity If OK go to Step 8 If not OK repair the open circuit as required 8 Check for continuity between the turn signal cavities of the junction block and the multi function switch connector There ...

Page 359: ...ight cowl side trim panel and the fuse access panel MULTI FUNCTION SWITCH WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate...

Page 360: ...alent is required 14 Gently pull the switch away from the column Loosen the connector screw The screw will remain in the connector 15 Remove the wiring connector from the multi function switch 16 Reverse the removal procedures to install Tighten the fasteners as follows Multi function switch connector screw 1 9 N m 17 in lbs Multi function switch retaining screws 1 9 N m 17 in lbs Steering column ...

Page 361: ......

Page 362: ...Models equipped with the optional automatic head lamp system have a programmable feature in the BCM that will energize the headlamps automatically whenever the wipers are turned on Refer to the proper Body Diagnostic Procedures Manual for more information on enabling or disabling this feature The wipers will operate only when the ignition switch is in the Accessory or On positions A circuit breake...

Page 363: ...nder the wiper arm pivot end cover directly to the rear wiper motor output shaft on the liftgate panel The wiper arms and blades cannot be adjusted or repaired If faulty they must be replaced WIPER LINKAGE AND PIVOTS The wiper linkage and pivot module is fastened with screws to the cowl plenum panel beneath the cowl plenum cover grille panel The wiper motor is fastened with screws to the center of...

Page 364: ...er and rear washer motors will operate continu ously for as long as the switch is held in the momen tary Wash position The rear wiper switch cannot be repaired and if faulty the right switch pod unit must be replaced BODY CONTROL MODULE A Body Control Module BCM is used on this model to control and integrate many of the vehicle s electrical functions and features The BCM contains a central process...

Page 365: ...through a single hose attached to a nipple on the front washer pump to a tee fitting located in the cowl plenum area beneath the cowl plenum cover grille panel Hoses from the tee fitting are routed to the two nozzles which are snapped into openings in the cowl plenum cover grille panel below the windshield The two flu idic washer nozzles are not adjustable The nozzles cannot be repaired and if fau...

Page 366: ...ery voltage If OK go to Step 3 If not OK repair the open circuit as required c Measure the voltage at the wiper switch high speed output circuit cavity of the connector with the wiper switch in the High position The meter should read battery voltage If OK go to Step 4 If not OK repair the open circuit as required d Measure the voltage at the wiper park switch sense circuit cavity of the connector ...

Page 367: ... circuit cavity of the front washer pump connector The meter should read bat tery voltage If OK replace the faulty pump If not OK repair the open circuit as required 5 Disconnect and isolate the battery negative cable Unplug the white 24 way connector from the body control module Connect the battery negative cable Turn the ignition switch to the On position Check for battery voltage at the washer ...

Page 368: ...switch terminals b With the switch knob depressed in the Wash position there should be continuity between the fused ignition switch output circuit and the rear washer motor control circuit terminals c With the switch in the Intermittent position there should be continuity between the fused ignition switch output circuit and the rear wiper motor con trol intermittent circuit terminals d With the sw...

Page 369: ...ot OK repair the open circuit to the ignition switch as required 5 The coil ground terminal 85 is connected to the electromagnet in the relay It is grounded by the Body Control Module BCM to energize the relay and cycle the wiper motor Check for continuity to the intermittent wiper relay control circuit cavity of the white 24 way BCM connector There should be continuity If OK refer to the proper B...

Page 370: ...lip is released from the claw the element will slide easily out of the remaining claws 3 Install the wiper blade on the wiper arm or the wiper element in the wiper blade as follows a To install the wiper blade on the wiper arm slide the blade retainer into the U shaped forma tion on the tip of the wiper arm until the release tab snaps into its locked position Be certain that the pinch release clip...

Page 371: ...t to 18 N m 160 in lbs 4 Close the pivot cover and move the rear wiper blade to the park position on the ramp WIPER MOTOR FRONT 1 Disconnect and isolate the battery negative cable 2 Remove the wiper arms as described in this group 3 Remove the screws from the cowl plenum cov er grille panel 4 Lift the cowl plenum cover grille panel and dis connect the washer hose at the tee fitting Remove the cowl...

Page 372: ... hardware as follows motor mounting screws 1 1 7 N m 10 15 in lbs motor mounting nut 4 5 6 N m 35 50 in lbs WIPER LINKAGE AND PIVOTS The wiper linkage and pivots can only be removed from the vehicle as a unit with the wiper motor See Wiper Motors in this group for the service proce dures INTERMITTENT WIPE RELAY 1 Disconnect and isolate the battery negative cable 2 Remove the cover from the Power D...

Page 373: ...rcement 7 Using a trim stick or other suitable wide flat bladed tool gently pry the edges of the knee blocker away from the instrument panel at the locations shown Fig 12 8 Remove the knee blocker steering column cover from the vehicle 9 Remove both the upper and lower shrouds from the steering column Fig 13 10 Remove the lower fixed column shroud 11 Loosen the steering column upper bracket nuts D...

Page 374: ...Fig 15 4 Pull the right switch pod out from the instru ment panel far enough to unplug the wiring connec tors 5 Remove the right switch pod from the instru ment panel 6 Reverse the removal procedures to install WASHER PUMPS AND RESERVOIR 1 Disconnect and isolate the battery negative cable 2 Disconnect the wiring from the fluid level sen sor if equipped 3 Remove the three screws securing the washer...

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Page 376: ...TECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS PER SONAL INJURY CAN RESULT CAUTION Do not touch the glass of halogen bulbs with fingers or other possibly oily surface reduced bulb life will result Do not use bulbs with higher candle power than indicated in the Bulb Application table at the end of this group Damage to lamp can result Do not use fuses circuit breakers or relays hav ing great...

Page 377: ...m output too low 1 Test and repair charging system refer to Group 8A ABOVE IDLE 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations refer to Group 8W 3 High resistance in headlamp circuit 3 Test amperage draw of headlamp circuit 4 Both headlamp bulbs defective 4 Replace both headlamp bulbs HEADLAMPS FLASH RANDOMLY 1 Poor lighting circuit Z1 ground 1 Test for voltag...

Page 378: ...FOG LAMP DIAGNOSIS ZJ LAMPS 8L 3 DIAGNOSIS AND TESTING Continued ...

Page 379: ... 3 Check voltage on pin 3 of module refer to Group 8W 4 Check L3 circuit refer to Group 8W 5 Replace DRL module LAMP OUTAGE MODULE DIAGNOSIS NOTE The Lamp Outage Module contains an inter nal circuit breaker When the module senses an overload it will trip the circuit breaker and illumi nate a failure in the Vehicle Information Center VIC The circuit breaker will reset once the vehicle is turned off...

Page 380: ...LAMP OUTAGE MODULE DIAGNOSIS ZJ LAMPS 8L 5 DIAGNOSIS AND TESTING Continued ...

Page 381: ... to the wall 3 Measure from the floor up 1 27 meters 5 ft and tape a line on the wall at the centerline of the vehicle Sight along the centerline of the vehicle from rear of vehicle forward to verify accuracy of the line placement 4 Rock vehicle side to side three times to allow suspension to stabilize 5 Jounce front suspension three times by pushing downward on front bumper and releasing 6 Measur...

Page 382: ...ct a pattern on the alignment screen 100 mm 4 in below the fog lamp centerline and straight ahead Fig 3 Rotate the adjustment screw Fig 4 to obtain the correct pattern Fig 1 Headlamp Alignment Screen Typical Fig 2 Aero Headlamp Alignment Screws ZJ LAMPS 8L 7 SERVICE PROCEDURES Continued ...

Page 383: ...SPECIAL TOOLS SPECIAL TOOLS HEADLAMP ALIGNMENT Fig 3 Fog Lamp Alignment Typical Fig 4 Fog Lamp Headlamp Aiming Kit C 4466 A 8L 8 LAMPS ZJ ...

Page 384: ...ly refer to the Headlamp Removal Installa tion procedure for bulb replacement 2 Reach into engine compartment and locate lock ring supporting the headlamp bulb assembly 3 Rotate the lock ring 1 8 turn counterclockwise Fig 1 4 Pull the bulb straight out from the housing INSTALLATION CAUTION Do not touch the bulb glass with fin gers or other oily surfaces Reduced bulb life will result 1 Install new ...

Page 385: ... STOP TURN SIGNAL BACK UP AND SIDE MARKER LAMP BULBS The stop turn signal back up and rear side marker lamp bulbs are incorporated into the tail lamp REMOVAL 1 Remove tail lamp 2 Grasp bulb socket and rotate counterclockwise Separate socket from lamp 3 Rotate bulb in the socket counterclockwise and remove bulb from socket Fig 3 INSTALLATION 1 Position bulb in socket and rotate clockwise 2 Position...

Page 386: ...lens up to snap into housing DOME LAMP BULB REMOVAL 1 Insert a flat blade screwdriver in slot at front of lens 2 Rotate the screwdriver until lens snaps out of the housing 3 Remove lens from housing 4 Remove bulb from socket INSTALLATION 1 Insert bulb into reading lamp terminals 2 Replace lens by holding lens level and pushing rearward into housing 3 Push lens up to snap into housing READING LAMP ...

Page 387: ...wdriver upward until lens snaps out of housing 3 Remove lens from housing 4 Remove bulb from bulb socket INSTALLATION 1 Position bulb in socket and press into place 2 Insert upper tabs of lens into lens housing 3 Snap lower portion of lens into slots at lens housing 8L 12 LAMPS ZJ REMOVAL AND INSTALLATION Continued ...

Page 388: ...terclockwise and remove ring and bulb from lens INSTALLATION 1 Replace by seating the assembly in the lamp housing and turning the lock ring 1 8 turn clockwise to secure 2 Align upper adjust pivot into headlamp open ing and snap into place 3 Snap lower adjuster pivots into place FOG LAMP REMOVAL 1 Remove adjustment screw Fig 1 2 Disengage fog lamp electrical connector 3 Separate fog lamp from vehi...

Page 389: ...MARKER LAMP The stop turn signal back up and rear side marker lamps are incorporated into the tail lamp REMOVAL 1 Remove screws attaching lamp to body Fig 4 2 Remove bulb sockets from lamp 3 Separate lamp from vehicle INSTALLATION 1 Position lamp at vehicle and install bulb sock ets 2 Position lamp on vehicle and install screws LICENSE PLATE LAMP REMOVAL 1 Remove screws attaching license plate lam...

Page 390: ...rt bracket to hood Fig 6 3 Disengage connector for underhood lamp 4 Separate lamp from vehicle INSTALLATION 1 Engage connector for underhood lamp 2 Position lamp on hood and install screw VISOR VANITY LAMP REMOVAL 1 Fold down sunvisor 2 Starting at the base of the lamp assembly and working right to left use a small flat blade carefully pry lamp from visor 3 Disconnect visor lamp wire connector and...

Page 391: ...l bulb socket in lamp 3 Install door trim panel CARGO LAMP REMOVAL 1 Insert a flat blade screwdriver in slots provided at lower portion of lens 2 Rotate screwdriver upward until lens snaps out of housing 3 Remove lens from housing Fig 8 4 Remove screws attaching liftgate opening upper trim panel cargo lamp to liftgate opening roof panel 5 Separate trim panel from roof panel 6 Disengage electrical ...

Page 392: ... the rear of the vehicle can cause damage to the lamp out age module The lamp outage module is designed to handle a 5 amp current load This is adequate for the operation of the vehicles lighting system When addi tional lights are added to the system such as trailer lights the 5 amp limit can be exceeded This can cause failure of the lamp outage module If trailer towing is required and the vehicle ...

Page 393: ...lding module to inner quarter panel Fig 2 5 Disconnect wiring connectors at module 6 Separate lamp outage module from vehicle INSTALLATION 1 Connect wiring connectors at module 2 Install screw holding module to inner quarter panel 3 Install access door 4 Install spare tire 5 Connect battery negative cable Fig 2 Lamp Outage Module 8L 18 LAMPS ZJ REMOVAL AND INSTALLATION Continued ...

Page 394: ...21 Fog lamp H3 Front Turn Signal 1295NA Front Side Marker 194NA Headlamp 9004 License Plate 168 Tail Stop 2057 Rear Turn Signal 1156 Underhood Lamp 105 INTERIOR LAMPS Service procedures for most of the lamps in the instrument panel are located in Group 8E Some components have lamps that can only be serviced by an Authorized Service Center ASC after the compo nent is removed from the vehicle Contac...

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Page 396: ... DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIR BAG SYSTEM FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG SYSTEM DEPLOYMENT AND POSSIBLE PERSONAL INJURY THE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE THESE MATERIALS ...

Page 397: ...If the airbag front mounting bracket is damaged the instrument panel armature assembly must be replaced STORAGE An airbag module must be stored in its original special container until used for service Also it must be stored in a clean dry environment away from sources of extreme heat sparks and high electrical energy Always place or store an airbag module on a surface with its trim cover or airbag...

Page 398: ...in the On posi tion make sure nobody is in the vehicle 10 From outside of the vehicle away from the airbag modules in case of an accidental deployment turn the ignition switch to the Off position and then back to the On position Observe the airbag indicator lamp in the instrument cluster It should light for six to eight seconds then go out This indicates that the airbag system is functioning norma...

Page 399: ...le a second time to recover all of the powder Place the deployed airbag modules in your vehicu lar scrap pile REMOVAL AND INSTALLATION AIRBAG MODULE WARNING THE AIRBAG SYSTEM IS A SENSITIVE COMPLEX ELECTRO MECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE THE AIR BAG SYSTEM OR RELATED STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BAT...

Page 400: ...tery negative cable at this time See Airbag System in Diagnosis and Testing for the proper procedures DRIVER S AIRBAG TRIM COVER AND HORN SWITCH WARNING THE AIRBAG SYSTEM IS A SENSITIVE COMPLEX ELECTRO MECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE THE AIR BAG SYSTEM OR RELATED STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY...

Page 401: ...t the locking blocks are fully engaged on the lip of the airbag housing Fig 9 9 When installing the upper and lower trim cover retainers be certain that the tabs on each retainer are engaged in the retainer slots of the trim cover Fig 8 Tighten the retainer nuts to 10 N m 90 in lbs 10 Reverse the remaining removal procedures to complete the installation but do not connect the bat Fig 6 Horn Switch...

Page 402: ... to install Tighten the mounting bolts to 11 75 N m 105 in lbs IMPACT SENSORS The impact sensors are located on the radiator side closure panel extensions behind the grille opening reinforcement 1 Disconnect and isolate the battery negative cable If the airbag module is undeployed wait two minutes for the system capacitor to discharge before further service 2 Remove the screws securing the grille ...

Page 403: ...Y THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYS TEM FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI BLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable If the airbag is undeployed wait two minutes for the system capacitor to discharge before further service ...

Page 404: ...e steering wheel until the front wheels are in the straight ahead position before starting the repair 2 Disconnect and isolate the battery negative cable If the airbag system is undeployed wait two minutes for the system capacitor to discharge before further service 3 Remove the airbag module as described in this group 4 Unplug the wiring for the speed control and remote radio switches if equipped...

Page 405: ...OULD RESULT IN ACCIDENTAL AIR BAG SYSTEM DEPLOYMENT AND POSSIBLE PER SONAL INJURY 1 Turn the steering wheel until the front wheels are in the straight ahead position before starting the centering procedure 2 Disconnect and isolate the battery negative cable If the airbag system is undeployed wait two minutes for the system capacitor to discharge before further service 3 Remove the airbag module as...

Page 406: ...d on The defogger system will be automatically turned off after a programmed time interval of about ten minutes Any time the system is turned on again after the initial timed interval has expired the defog ger system will automatically turn off again after about five minutes The defogger system will auto matically shut off if the ignition switch is turned to the Off position or it can be turned of...

Page 407: ...is model to control and integrate many of the vehicle s electrical functions and features The BCM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection CCD data bus network The CCD data bus network allows the sharing of sensor information This helps to reduce wiring har ness complexity reduce internal controller hardware and reduce ...

Page 408: ... Group 8W Wir ing Diagrams To detect breaks in the grid lines the following procedure is required 1 Turn the ignition switch to the On position Set the rear defogger switch in the On position The indi cator lamp should light If OK go to Step 2 If not OK see the diagnosis for Defogger Relay in this group 2 Using a 12 volt DC voltmeter contact the ver tical bus bar on the passenger s side of the veh...

Page 409: ...d no continuity between terminals 87 and 30 If OK go to Step 2 If not OK replace the faulty relay 2 Resistance between terminals 85 and 86 elec tromagnet should be 75610 ohms If OK go to Step 3 If not OK replace the faulty relay 3 Connect a battery to terminals 85 and 86 There should now be continuity between terminals 30 and 87 and no continuity between terminals 87A and 30 If OK see the Relay Ci...

Page 410: ...o the area where the terminal or pigtail was fastened and onto the adjacent grid line 7 Apply a thin layer of conductive epoxy to the terminal or bare wire end of the pigtail and place in the desired location To prevent the terminal or pig tail from moving while the epoxy is curing it must be wedged or clamped 8 Carefully remove the masking tape or tem plate CAUTION Do not allow the glass surface ...

Page 411: ...ut securing the right cowl side trim to the junction block stud Fig 4 4 Remove the two screws securing the right cowl side trim to the right front door opening trim 5 Remove the right cowl side trim panel 6 Unplug the defogger relay from the junction block 7 To install the relay align the terminals with the cavities in the junction block and push the relay firmly into place 8 Connect the battery n...

Page 412: ...has been achieved the HSCM de energizes the relay The HSCM will continue to cycle the relay as needed to maintain the temperature set point The HSCM will automatically disconnect power from the heating elements if it detects an open in the sensor circuit or a short in the heating element cir cuit causing an excessive current draw The system is also turned off automatically when the ignition switch...

Page 413: ...d Seats in Group 8W Wiring Diagrams WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable Remove the...

Page 414: ...back connector 2 Check for continuity between the heated seat driver circuit cavity and the ground circuit cavity of the seat cover half of the heated seat back connector There should be continuity If OK go to Step 3 If not OK replace the faulty seat back cover 3 Check for continuity between the heated seat driver circuit cavity of the seat cover half of the heated seat back connector and the seat...

Page 415: ...wer recliner adjuster lower bracket upwards to access the heated seat control module mounting screw Fig 2 7 Remove the mounting screw from the seat cushion frame 8 Reach under the rear of the seat cushion to lower the heated seat control module and mounting bracket unit from the inside of the seat cushion frame Fig 3 9 Unplug the wiring connector and remove the module from under the seat 10 Revers...

Page 416: ...of the ignition switch The power lock system includes the front door switches door modules mounted in each front door and power lock motors mounted in each door and the liftgate POWER LIFTGLASS RELEASE SYSTEM Models equipped with the optional liftgate liftglass feature also have a power operated liftglass release system This system operates with battery power supplied through a fuse in the junctio...

Page 417: ...r s manual For diagnosis of the memory system use of a DRB scan tool and the proper Body Diagnostic Procedures Manual are rec ommended DESCRIPTION AND OPERATION POWER LOCK SWITCH The power locks are controlled by a two way switch mounted in the trim panel of each front door Each switch is illuminated by a light emitting diode when the ignition switch is turned to the On position The power lock swi...

Page 418: ...ced by an authorized repair station Refer to the Warranty Policies and Procedures Manual for a list ing of authorized repair stations POWER LOCK MOTOR In the power lock and remote keyless entry sys tems the locks are actuated by a reversible motor mounted within each door and the liftgate The left front door lock motor direction is controlled by the battery and ground feeds from the driver door mo...

Page 419: ...rocedures Man ual For circuit descriptions and diagrams refer to 8W 61 Power Door Locks in Group 8W Wiring Diagrams 1 Disconnect and isolate the battery negative cable Remove the front door trim panel as described in this group Go to Step 2 2 Check the 12 way door module wiring connec tor to see that it is fully seated in the door module receptacle If OK go to Step 3 If not OK install the connecto...

Page 420: ...Check for continuity between the two terminals of the liftglass limit switch There should be continu ity with the liftgate latch unlocked and no continuity with the latch locked If OK go to Step 5 If not OK replace the faulty limit switch 5 Unplug the liftglass push button switch connec tor With the liftgate latch unlocked check for bat tery voltage at the liftglass limit switch output circuit cav...

Page 421: ...om the trim panel 11 Reverse the removal procedures to install POWER LOCK MOTOR FRONT DOOR 1 Remove the front door trim panel as described under Door Module in this group 2 Pull back the watershield from the rear access holes of the inner door panel 3 Remove the door latch retaining screws Fig 3 4 Disconnect all of the actuating rods from the door latch Fig 4 5 Unplug the power lock motor solenoid...

Page 422: ...om the rear access holes of the inner door panel 8 Remove the door latch retaining screws Fig 6 9 Disconnect all of the actuating rods from the door latch 10 Unplug the power lock motor solenoid wire connector 11 Remove the door latch power lock motor from the door 12 Reverse the removal procedures to install Tighten the latch mounting screws to 10 N m 95 in lbs LIFTGATE 1 Disconnect and isolate t...

Page 423: ...gate Fig 9 6 Unplug the wire connector from the actuator motor 7 Remove the motor from the liftgate 8 Reverse the removal procedures to install Tighten the actuator motor mounting screws to 3 N m 28 in lbs Fig 8 Lock Actuator Motor Linkage Remove Install Fig 9 Liftgate Lock Motor Remove Install 8P 8 POWER LOCK SYSTEMS ZJ REMOVAL AND INSTALLATION Continued ...

Page 424: ...y removed from the ignition switch the headlamps are turned off and the doors are locked using the power lock switch The power lock switch will not function if the key is in the igni tion switch or the headlamps are on with the driver s door open The VTSS will not arm if either front door or the liftgate are locked using the key in the lock cylinder Active arming of the VTSS occurs when the Remote...

Page 425: ...ess the information from all of its inputs and send control outputs to the auto headlamp relay horn relay park lamp relay powertrain control module and the security set lamp The BCM is mounted under the left end of the instrument panel behind the instrument panel sup port armature and below the left switch pod Refer to Group 8E Instrument Panel Systems for removal and installation procedures For d...

Page 426: ... lamps when the body control module grounds the relay coil The park lamp relay is located in the junction block on the right cowl side panel below the instrument panel in the passenger compartment SET LAMP The VTSS set lamp is a red light emitting diode mounted with the auto headlamp ambient light sen sor on top of the instrument panel near the left defroster outlet The set lamp receives fused bat...

Page 427: ...ning Fig 2 3 Pull the switch from the mounting hole in the door opening 4 Unplug the wire connector from the switch 5 Reverse the removal procedures to install Tighten the switch mounting screw to 1 7 N m 15 in lbs DOOR LOCK CYLINDER SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove the bezel near the inside door latch release handle by inserting a straight bladed screw driver in...

Page 428: ... wire harness connector and remove the switch from inside the door 13 Reverse the removal procedures to install LIFTGATE AJAR SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove the screws securing the liftgate lower trim panel to the liftgate Fig 6 3 Using a wide flat bladed tool such as a trim stick pry the trim panel away from the liftgate around the perimeter and remove the tri...

Page 429: ...nel start at the bottom of the panel 4 Pry the liftgate lock cylinder switch off of the back of the lock cylinder Fig 9 5 Unplug the lock cylinder switch wire harness connector and remove the switch from inside the lift gate 6 Reverse the removal procedures to install LIFTGLASS AJAR SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove the screws securing the liftgate lower trim pane...

Page 430: ...d Fig 12 4 Remove the two screws securing the right cowl side trim to the right front door opening trim 5 Remove the right cowl side trim panel 6 Remove the relay by unplugging it from the junction block 7 Install the relay by aligning the relay termi nals with the cavities in the junction block and push ing the relay firmly into place 8 Reverse the remaining removal procedures to complete the ins...

Page 431: ...e instru ment panel top pad Fig 14 3 Pull the panel up far enough to unplug the wir ing connector for the solar sensor or to remove the solar sensor from the cowl top trim between the right and center defroster outlets if so equipped 4 Remove the cowl top trim panel from the vehi cle 5 Remove the auto headlamp light sensor vehicle theft security system set lamp mounting screw near the left defrost...

Page 432: ... of the memory switch on the driver s front door trim panel is depressed or when the doors are unlocked using the corresponding Driver 1 or 2 Remote Keyless Entry RKE transmitter The Driver Door Module DDM receives hard wired input from the memory set select switch on the driver s front door trim panel The DDM also receives messages on the Chrysler Collision Detection CCD data bus network from the...

Page 433: ...to the motor s are reversed through the switch con tacts This causes the motor to run in the opposite direction Each motor contains a self resetting circuit breaker to protect it from overload Consecutive or frequent resetting of the circuit breakers must not be allowed to continue or the motors may be damaged Make the necessary repairs The motors used on models with the optional memory system als...

Page 434: ...ity and grounds With the dome lamp on apply the switch in the direction of the failure If the dome lamp dims the seat adjusters may be jamming Check under and behind the seat for binding or obstructions If the dome lamp does not dim proceed with the following component tests CIRCUIT BREAKER For circuit descriptions and diagrams refer to 8W 63 Power Seat in Group 8W Wiring Diagrams 1 Locate the cor...

Page 435: ...ADJUSTER MOTOR The tests below apply to a power seat system with out the memory system option For testing of the power seats with the memory system refer to the proper Body Diagnostic Procedures Manual For cir cuit descriptions and diagrams refer to 8W 63 Power Seat in Group 8W Wiring Diagrams Operate the power seat switch to move the power recliner The recliner should move in both directions If t...

Page 436: ...ring connector 5 Remove the two screws securing the switch to the inside of the side shield Fig 3 6 Remove the switch from the side shield 7 Reverse the removal procedures to install POWER LUMBAR SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove the three screws securing the seat cushion side shield to the seat cushion frame 3 Pull the side shield away from the seat cushion far e...

Page 437: ...ket to the seat cushion frame Fig 5 6 Remove the inboard seat back pivot bolt 7 Unplug the wiring connectors depending upon how the vehicle is equipped as required to remove the seat back from the seat cushion 8 Remove the seat back cover far enough to access the two bolts securing the power recliner adjuster upper bracket to the seat back frame Fig 6 Refer to Group 23 Body components for the seat...

Page 438: ...s retainers out of the seat adjuster top rail Fig 8 10 Slide the memory seat module off of the mounting bracket slide tabs far enough to unplug the wire harness connectors 11 Remove the module from under the seat cush ion 12 Reverse the removal procedures to install 13 Following the installation it will be necessary to initialize the memory seat module This is done by moving each of the power seat...

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Page 440: ... addition several features and functions of the power window system are made possible because of the communication of the door modules on the Chrysler Collision Detection CCD data bus network This system operates with battery power supplied through a circuit breaker in the junction block only when the ignition switch is in the On position How ever a feature of this system will allow the windows to...

Page 441: ...gnition switch and the door ajar switches The programming in the BCM allows it to process the information from these inputs and send ignition switch and door ajar status messages to the DDM and PDM on the CCD data bus The DDM and PDM use this information to con trol the lighting of the switch lamps and to control the power window operation after ignition off feature The BCM is mounted under the le...

Page 442: ...ch on the driver s door use a DRB scan tool and the proper Body Diagnostic Procedures Man ual to diagnose the circuitry of the door modules and the CCD data bus NOTE The following tests may not prove conclu sive in the diagnosis of this component The most reliable efficient and accurate means to diagnose this system involves the use of a DRB scan tool and the proper Body Diagnostic Procedures Man ...

Page 443: ...te position If OK go to the Power Window Motor diagnosis in this group If not OK replace the faulty door module POWER WINDOW SWITCH This diagnosis is for the rear door power window switches The front door power window switches are integral to the door modules For diagnosis of the front door power window switches refer to Door Module in this group For circuit descriptions and diagrams refer to 8W 6...

Page 444: ... the door module and the door courtesy lamp if equipped 9 Remove the five screws securing the door mod ule to the door trim panel Fig 3 10 Remove the door module from the trim panel 11 Reverse the removal procedures to install POWER WINDOW SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove the rear door trim panel bezel near the inside door latch release handle by inserting a stra...

Page 445: ...tor assembly from inside the door 10 To install place the window regulator inside the door and slide the two loose screws into the slot ted holes in the door inner panel 11 Install the remaining regulator mounting screws and tighten to 12 N m 105 in lbs 12 Remove the tape securing the glass to the upper door window frame and lower the glass Move the glass as far rearward into the channel as possib...

Page 446: ...ulator inside the door and slide the two loose screws into the slot ted holes in the door inner panel 11 Install the remaining regulator mounting screws and tighten to 12 N m 105 in lbs 12 Remove the tape securing the glass to the upper door window frame and lower the glass Move the glass as far rearward into the channel as possible and push down Tighten the two loose window regu lator screws to 1...

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Page 448: ...smitter The Driver Door Module DDM receives hard wired input from the memory set select switch on the driver s front door trim panel The DDM also receives messages on the Chrysler Collision Detection CCD data bus network from the Remote Keyless Entry RKE receiver in the Passenger Door Module PDM for the memory select function The DDM processes these inputs and sends messages to the radio the PDM a...

Page 449: ...or accord ingly Both the PDM and DDM respond to the defogger switch status messages sent by the Body Control Module on the CCD data bus to control the heater elements of their respective mirrors Refer to Group 8N Electrically Heated Systems for more informa tion on this feature On models equipped with the memory system each door module stores the mirror position information for its respective mirr...

Page 450: ...use a DRB scan tool and the proper Body Diagnostic Procedures Man ual to test the door modules and the CCD data bus If not OK replace the faulty mirror NO MIRROR DIMMING Driver s Side Only 1 Test the operation of the Automatic Day Night Mirror as described in this group If OK go to Step 2 If not OK repair that unit as necessary before you proceed 2 Disconnect and isolate the battery negative cable...

Page 451: ...ring the door mod ule to the door trim panel Fig 3 10 Remove the door module from the trim panel 11 Reverse the removal procedures to install POWER MIRROR 1 Disconnect and isolate the battery negative cable 2 Remove the door trim panel as described under Door Module in this group 3 Unplug the electric chromatic mirror connector if equipped 4 Unclip the mirror harnesses from the inner door panel 5 ...

Page 452: ...anual con trol of whether the automatic dimming feature is operational When On is selected the mirror switch is lighted by an integral Light Emitting Diode LED The automatic dimming feature will only operate when the ignition switch is in the On position The mirror also senses the back up lamp circuit and dis ables the self dimming feature whenever the trans mission gear selector is in the Reverse...

Page 453: ... the sensor or cover the sensor completely with electrical tape 7 Shine a light into the rear facing headlamp photocell sensor The mirror should darken If OK go to Step 8 If not OK replace the faulty mirror unit 8 With the mirror darkened place the transmis sion gear selector lever in the Reverse position The mirror should return to its normal condition If not OK replace the faulty mirror unit REM...

Page 454: ...el to control and integrate many of the vehicle s electrical functions and features The BCM contains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection CCD data bus network The CCD data bus network allows the sharing of sensor information This helps to reduce wiring har ness complexity reduce internal controller hardware and reduce compon...

Page 455: ...o many features Some of the hard wired inputs used by the BCM for its chime functions include Door hood liftgate and liftglass ajar switches Driver s seat belt switch Headlamp switch Ignition switch Ignition key cylinder switch The BCM is mounted under the left end of the instrument panel behind the instrument panel sup port armature and below the left switch pod Refer to Group 8E Instrument Panel...

Page 456: ...rocessing unit and interfaces with other modules in the vehicle on the Chrysler Collision Detection CCD data bus network The CCD data bus network allows the sharing of sensor information This helps to reduce wiring har ness complexity reduce internal controller hardware and reduce component sensor current loads At the same time this system provides increased reliability enhanced diagnostics and al...

Page 457: ...or one minute then update the display to the current average temperature reading within five minutes When the outside temperature is below 3 C 37 F the thermometer will provide an ice indicator func tion to alert the driver of possible icy road conditions The ice indicator function will cause the word ICE to be flashed on the overhead console display for approximately two minutes only one time dur...

Page 458: ...test a if any segment should fail to light the unit is faulty and must be replaced If test b is failed the module will display FAIL If FAIL is displayed the unit is faulty and must be replaced If test c is failed the module will display CCD If CCD is displayed the use of a DRB scan tool and the proper Body Diagnostic Pro cedures Manual are required for further diagnosis If all tests are passed the...

Page 459: ...ic north is great enough to cause the compass to give false readings If this problem occurs the compass variance must be set To set the compass variance 1 Using the Variance Settings map find your geographic location and note the zone number Fig 1 2 Turn the ignition switch to the On position If the compass temperature option is not being dis played momentarily depress and release the Step button ...

Page 460: ...magnetize the roof panel and the console for ward mounting screw proceed as follows 1 Be certain the ignition switch is in the Off posi tion before you begin the demagnetizing procedure 2 Plug in the degaussing tool while keeping the tool at least two feet away from the compass unit 3 Slowly approach the head of the overhead con sole front mounting screw with the plastic coated tip of the degaussi...

Page 461: ...w forward of the dis play unit Fig 4 3 Using a trim stick or other suitable wide flat bladed tool pry gently downwards at the rear edge of the console housing to release the two snap clips 4 Unplug the wire harness connectors from the trip computer compass thermometer module and the power sunroof switch 5 Reverse the removal procedures to install TRIP COMPUTER COMPASS THERMOMETER DISPLAY MODULE 1 ...

Page 462: ...Group 23 Body Components for the procedure 3 Locate the temperature sensor on the radiator support behind the grille Fig 6 4 Unplug the temperature sensor wiring connec tor 5 Remove the temperature sensor mounting bolt and remove the sensor 6 Reverse the removal procedures to install READING COURTESY LAMP BULBS 1 Insert the tip of a wide flat bladed tool in the notch on the curved edge of the cour...

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Page 464: ...8W 42 AIR CONDITIONING HEATER 8W 42 1 8W 43 AIRBAG SYSTEM 8W 43 1 8W 44 INTERIOR LIGHTING 8W 44 1 8W 45 BODY CONTROL MODULE 8W 45 1 8W 46 MESSAGE CENTER 8W 46 1 8W 47 AUDIO SYSTEM 8W 47 1 8W 48 REAR WINDOW DEFOGGER 8W 48 1 8W 49 OVERHEAD CONSOLE 8W 49 1 8W 50 FRONT LIGHTING 8W 50 1 8W 51 REAR LIGHTING 8W 51 1 8W 52 TURN SIGNALS 8W 52 1 8W 53 WIPERS 8W 53 1 8W 54 TRAILER TOW 8W 54 1 8W 60 POWER WIN...

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Page 466: ...ple the headlamp switch is the main part of the exterior lighting but it also affects the interior lighting and the chime warning system It is important to real ize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle For example a short piece of wire is treated the same as a long one In addition switches and other components are shown as simply ...

Page 467: ...MISSION SHOULD BE IN NEUTRAL WARNING OPERATE THE ENGINE ONLY IN A WELL VENTILATED AREA WARNING KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING ESPECIALLY THE FAN AND BELTS WARNING TO PREVENT SERIOUS BURNS AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIA TOR EXHAUST MANIFOLD S TAIL PIPE CATA LYTIC CONVERTER AND MUFFLER WARNING DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY GASES ARE ALWAYS PRES...

Page 468: ... 8W 80 This section iden tifies the connector by number and provides terminal numbering circuit identification wire colors and functions All connectors are viewed from the terminal end unless otherwise specified To find the connector loca tion in the vehicle refer to section 8W 90 This sec tion uses the connector identification number from the wiring diagrams to provide a figure number ref erence ...

Page 469: ...Fig 5 Symbol Identification 8W 01 4 8W 01 GENERAL INFORMATION ZJ DESCRIPTION AND OPERATION Continued ...

Page 470: ...ON Most of the electrical components used in today s vehicle are solid state When checking voltages in these circuits use a meter with a 10 me gohm or greater impedance Ohmmeter Used to check the resistance between two points of a circuit Low or no resistance in a circuit means good continuity CAUTION Most of the electrical components used in today s vehicle are Solid State When checking resistanc...

Page 471: ...ness TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1 Refer to the wiring diagrams and disconnect or isolate all items on the fused circuit 2 Replace the blown fuse 3 Supply power to the fuse by turning ON the ignition switch or re connecting the battery 4 Start connecting the items in the fuse circuit one at a time When the fuse blows the circuit with the short to ground has been i...

Page 472: ...area 4 Spread the strands of the wire apart on each part of the exposed wire example 1 Fig 11 5 Push the two ends of wire together until the strands of wire are close to the insulation example 2 Fig 11 6 Twist the wires together example 3 Fig 11 7 Solder the connection together using rosin core type solder only Do not use acid core solder 8 Center the heat shrink tubing over the joint and heat usi...

Page 473: ...ECTOR REPLACEMENT 1 Disconnect battery 2 Disconnect the connector that is to be repaired from its mating half component 3 Remove the connector locking wedge if required Fig 17 4 Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680 Pull on the wire to remove the terminal from the connector Fig 18 Fig 19 5 Reset the terminal locking tang if it...

Page 474: ...nk tubing over one side of the wire Be sure the tubing will be long enough to cover and seal the entire repair area 9 Spread the strands of the wire apart on each part of the exposed wires 10 Push the two ends of wire together until the strands of wire are close to the insulation 11 Twist the wires together 12 Solder the connection together using rosin core type solder only Do not use acid core so...

Page 475: ...ir area 10 Spread the strands of the wire apart on each part of the exposed wires 11 Spread the strands of the wire apart on each part of the exposed wires 12 Push the two ends of wire together until the strands of wire are close to the insulation 13 Twist the wires together 14 Solder the connection together using rosin core type solder only Do not use acid core solder 15 Center the heat shrink tu...

Page 476: ...low is correct If necessary refer to the appropriate wiring diagram for current flow 6 Solder the connection together using rosin core type solder only Do not use acid core solder 7 Tape the diode to the harness using electrical tape making sure the diode is completely sealed from the elements 8 Re connect the battery and test affected sys tems SPECIAL TOOLS WIRING TERMINAL Fig 24 Diode Identifica...

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Page 478: ...ORMATION INTRODUCTION This section provides an alphabetical listing of all the components covered in group 8W For information on system operation refer to the appropriate section of the wiring diagrams ZJ 8W 02 COMPONENT INDEX 8W 02 1 ...

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Page 482: ...ERATION INTRODUCTION This section covers the power distribution center and all circuits involved with it For additional infor mation on system operation refer to the appropriate section of the wiring diagrams ZJ 8W 11 POWER DISTRIBUTION 8W 11 1 ...

Page 483: ...1996 Grand Cherokee Publication No 81 370 6147 TSB 26 02 96 February 1996 ...

Page 484: ...1996 Grand Cherokee Publication No 81 370 6147 TSB 26 02 96 February 1996 ...

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Page 495: ...1996 Grand Cherokee Publication No 81 370 6147 TSB 26 02 96 February 1996 ...

Page 496: ...is section covers the internal circuitry of the junction block For additional information on system operation refer to the appropriate group of the wir ing diagrams Group 02 lists components and corre sponding wiring diagram groups ZJ 8W 12 JUNCTION BLOCK 8W 12 1 ...

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Page 522: ...plices that connect to those grounds and the components that connect those grounds For additional information on system operation refer to the appropriate section of the wiring diagrams For an illustration of the phys ical location of each ground refer to group 8W 90 ZJ 8W 15 GROUND DISTRIBUTION 8W 15 1 ...

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Page 532: ...close and connect circuit F5 from the fuse 20 in the PDC to circuit A142 Circuit A142 splices to the generator field terminal The PCM has an internal voltage regulator that controls generator output The PCM controls the gen erator field on circuit K20 Circuit K20 connects to PCM cavity B10 When the engine operates and there is current in the generator field the generator produces a B volt age The ...

Page 533: ...1996 Grand Cherokee Publication No 81 370 6147 TSB 26 02 96 February 1996 ...

Page 534: ...1996 Grand Cherokee Publication No 81 370 6147 TSB 26 02 96 February 1996 ...

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Page 536: ...f the starter motor relay on circuit A41 when the key is moved to the START position and the PARK NEUTRAL position switch is closed Ground for the coil side of the starter motor relay is supplied by the case grounded PARK NEUTRAL position switch Circuit T41 connects the coil side of the relay to the PARK NEUTRAL position switch When the starter motor relay energizes and the contacts close circuit ...

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Page 540: ... the PDC at cavity A14 HELPFUL INFORMATION Circuit F5 also supplies power to the contact sides of the Automatic Shut Down ASD relay GROUND Circuit Z12 connects to cavities A31 and A32 of the PCM The Z12 circuit provides ground for PCM inter nal drivers that operate high current devices like the injectors and ignition coil Internal to the PCM the ground circuit connects to the PCM sensor return cir...

Page 541: ...ies 5 volts from the Powertrain Control Module PCM to the vehicle speed sensor The K6 circuit connects to cavity B31 of the PCM Circuit G7 from the vehicle speed sensor provides an input signal to the PCM The G7 circuit connects to cavity B27 of the PCM The PCM provides a ground for the vehicle speed sensor signal circuit G7 through circuit K4 Circuit K4 connects to cavity A4 of the PCM HELPFUL IN...

Page 542: ...n circuit K2 From circuit K2 the engine coolant tem perature sensor draws up to 5 volts from the PCM The sensor is a variable resistor As coolant temper ature changes the resistance in the sensor changes causing a change in current draw The K2 circuit connects to cavity A16 of the PCM The PCM provides a ground for the engine coolant temperature sensor signal circuit K2 through circuit K4 Circuit K...

Page 543: ...r Manifold absolute pressure sensor Engine coolant temperature sensor Vehicle speed sensor OIL PRESSURE SENSOR The oil pressure sensor is a variable resistor A change in engine oil pressure changes the resistance in the sending unit which alters the signal sensed by the Powertrain Control Module on circuit G6 Circuit G6 connects to cavity B23 of the PCM The PCM provides ground for the oil pressure...

Page 544: ... or RUN position it connects circuit A1 from fuse 8 in the Power Distribution Center PDC to circuit A21 Cir cuit A21 powers circuit F99 through PDC fuse 18 Circuit F99 powers to the Duty Cycle EVAP Purge solenoid The Powertrain Control Module PCM provides the ground path for the solenoid on circuit K52 Cir cuit K52 connects to cavity C20 of the PCM CCD BUS Circuits D1 and D2 connect the Powertrain...

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Page 566: ...lec tronic transmission relay The Powertrain Control Module PCM provides ground for the relay on cir cuit T66 Circuit T66 connects to cavity B30 of the PCM When the PCM grounds the relay the relay con tacts connect circuit F92 from fuse 17 in the PDC to circuit T20 Circuit T20 powers the solenoids TRANSMISSION SOLENOID ASSEMBLY The Torque Convertor Clutch TCC solenoid over drive solenoid and varia...

Page 567: ...n temperature exceeds a calibrated temperature the PCM sends a signal to the Vehicle Information Center VIC over the CCD bus In response the VIC displays a message to the driver HELPFUL INFORMATION Circuit K6 also supplies 5 volts to the vehicle speed sensor Circuit K4 also provides ground for the signals from the following Heated oxygen sensors Crankshaft position sensor Camshaft position sensor ...

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Page 574: ... with a range from 4 2 to 4 5 volts When the COAST switch closes the voltage level on circuit K95 at PCM cavity C32 has nominal value of 2 92 volts with a range from 2 72 to 3 02 volts When the CANCEL switch closes the voltage level on circuit K95 at PCM cavity C32 has is 0 1 volts or less The PCM controls the vent and vacuum functions of the vehicle speed control servo on circuits V35 and V36 Dep...

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Page 578: ...GH signal Circuits B8 and B9 provide signals to the CAB from the left front wheel speed sensor Circuit B8 which provides the HIGH signal connects to cavity 10 of the CAB Circuit B9 connects to cavity 9 of the CAB and provides the LOW signal Circuits B1 and B2 provide signals to the CAB from right rear wheel speed sensor Circuit B1 which provides the LOW signal connects to cavity A11 of the CAB Cir...

Page 579: ...energized The CAB illuminates the lamp by pro viding ground on circuit B205 Circuit B205 splices to connect to circuit B47 through a diode When the ABS main relay is not energized it connects circuit B47 to ground on circuit Z4 The ground path for the warning lamp is through the diode to circuit B47 through the ABS main relay to ground on circuit Z4 The diode between circuit B205 and B47 prevents ...

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Page 586: ...ave an ajar switch that connects to the Body Control Module BCM The ajar switches are normally open when the doors liftgate liftglass and hood are closed When one of them open its ajar switch closes and connects the BCM to ground In response if the Vehicle Theft Security System is armed the BCM starts the alarm Refer to the Intro duction in this section for alarm information The BCM receives the a...

Page 587: ... and contacts When the relay energizes it connects cir cuit 366 to circuit L90 Circuit L90 powers the park lamps side marker lamps and tail lamps SCHEMATICS AND DIAGRAMS WIRING DIAGRAM INDEX The following index covers all components found in this section of the wiring diagrams If the component you are looking for is not found here refer to section 8W 02 for a complete list of all components shown ...

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Page 596: ... deter mines vehicle speed from the input provided by the vehicle speed sensor TACHOMETER The Powertrain Control Module PCM transmits the engine RPM data on the CCD bus From the bus the instrument cluster calculates tachometer needle position based on the engine RPM signal VOLTMETER The Powertrain Control Module PCM broadcasts system voltage data on the CCD bus The micro pro cessor in the instrume...

Page 597: ...sor over the CCD bus to turn the high beam indicator ON or OFF Circuit F75 powers the lamp TURN SIGNAL INDICATOR LAMPS Circuits L65 and L64 from the turn signal hazard flasher circuitry in the multi function switch power the turn signal indicator lamps Circuit L64 powers the right turn signal indicator lamp Circuit L65 powers the left indicator lamp Circuits Z1 and Z2 provide ground for the lamps ...

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Page 606: ...rcuit A1 from fuse 8 in the Power Distribution Center PDC to circuit A31 Circuit A31 powers relay coil Circuit Z1 provides ground for the relay coil When the relay energizes its connects circuit F61 from fuse 10 in the PDC to circuit F30 Circuit F30 powers the cigar lighter When the operator depresses the lighter contacts inside the lighter element close and voltage from cir cuit F30 flows through...

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Page 610: ...it F250 through fuse 21 in the PDC Circuit F250 pow ers the contact side of the A C compressor clutch relay Circuit E2 from the headlamp dimmer switch pow ers the case grounded illumination lamp in the A C heater control switch BLOWER MOTOR MANUAL A C HEATER The blower motor switch has four positions LOW MEDIUM 1 MEDIUM 2 AND HIGH Circuit A19 from fuse 7 in the PDC supplies power to the blower mot...

Page 611: ...cuit F71 through fuse 12 in the junction block Circuit F71 connects to the ATC module and the recirculation door motor Circuit A7 from fuse 15 in the PDC powers circuit F60 through fuse 20 in the junction block Circuit F60 supplies power to the ATC module When the ignition switch is in the START or RUN position it connects circuit A1 from PDC fuse 8 to circuit A21 Circuit A21 powers circuit F99 th...

Page 612: ...MPERATURE CONTROL Circuit C40 from the Automatic Temperature Con trol ATC module supplies 5 volts to the position switch in the blend door motor The ATC module receives the sensor signal from the blend door motor on circuit C36 Circuit D41 provides ground for the mode door position sensor Circuit D41 connects to the ATC module The ATC module operates the mode door motor on circuits C35 and C34 BLO...

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Page 624: ...s two cir cuits that connect to the ACM From the left impact sensor Circuits R47 and R49 connect to the ACM From the right impact sensor Circuits R46 and R48 connect to the ACM AIRBAG SQUIB AIRBAG IGNITER Circuits R43 and R45 connect the ACM to the drivers airbag squib igniter after passing through the clock spring connector Circuit R43 from cavity 3 of the ACM 4 way connector connects to the squi...

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Page 628: ...ircuit E2 Headlamp switch Floor console Instrument panel Ash receiver Graphic Display or Vehicle Information Center VIC Cigar lighter Radio A C Heater control switch Circuit Z1 provides ground for the floor console lamps instrument panel lamps ash receiver lamp graphic display or VIC Circuit Z4 grounds the auto matic temperature control switch lamp Circuit Z5 grounds the radio lamp The cigar light...

Page 629: ...through fuse 16 in the junction block Circuit M1 feeds the overhead console lamps Each overhead console lamp has a switch that con nects the lamps to ground on circuit Z1 The lamps are also grounded when the Body Control Module BCM energizes the courtesy lamp relay to connect circuit M2 to ground on circuit Z1 DAY NIGHT MIRROR When the ignition switch is in the RUN position it connects circuit A1 ...

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Page 645: ...1996 Grand Cherokee Publication No 81 370 6147 TSB 26 02 96 February 1996 ...

Page 646: ...ng Intermittent Wiper Control Liftgate Courtesy Lamp Disable Mechanical Instrument Cluster Rear Window Defogger Control Remote Radio Control Seat Belt Reminder Speed Sensitive Intermittent Wipe Control Vehicle Theft Security System The BCM communicates with the following control lers and modules over the CCD bus Automatic Temperature Control ATC Module Compass Overhead Console Driver Door Module D...

Page 647: ...it F99 AJAR CHIME On models equipped with a Vehicle Information Center VIC the Body Control Module BCM sounds an audible chime when the vehicle is moving if one of the doors the hood or liftgate opens The BCM also signals the VIC over the CCD bus The VIC then displays which component is ajar KEY IN IGNITION CHIME When the key is inserted into the ignition switch the key in switch closes and connec...

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Page 660: ...n cir cuit Z1 In addition to illuminating the 4WD display the GDM also illuminates the LOW display When the transfer case switch is in Part Time 4WD position it connects circuit T107 from the GDM to ground on circuit Z1 In addition to illuminating the 4WD display the GDM also illuminates the PART TIME display When the transfer case switch is in Full Time 4WD position it connects circuit T106 from ...

Page 661: ...Washer Fluid warning when the switch closes LOW ENGINE COOLANT WARNING When the engine coolant level switch closes it con nects circuit G18 from the VIC to ground on circuit Z1 The VIC displays the Low Coolant Level warning when the switch closes DOOR AJAR AND LIFTGATE AJAR DISPLAYS Each door and the liftgate have an ajar switch that connects to the Body Control Module BCM The BCM senses when the ...

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Page 670: ...or the left rear door speaker Circuit X51 and X52 feed the speaker Circuit X58 from the speaker jumper harness connects to circuit X57 Circuit X57 is the return from the speaker to the radio Circuit X52 feeds the right rear door speaker Cir cuit X58 is the return from the speaker to the radio Circuits X52 and X58 continue through the jumper harness to the right rear door speaker POWER AMPLIFIER AN...

Page 671: ...er antenna is only used on vehicles built for export markets The power antenna relay supplies voltage to the power antenna motor The relay supplies voltage to the antenna motor to either raise or lower the antenna Circuit A7 from fuse 15 in the Power Distribution Center PDC feeds the relay switch through fuse 13 in the junction block When the radio is OFF the switch in the power antenna relay is i...

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Page 682: ...from fuse 3 in the Power Distribution Center PDC to circuit C15 Circuit C15 supplies power to the rear window defogger grid Circuit A900 also powers the coil side of the relay Circuit Z1 grounds the rear window defogger grid Internal to the junction block circuit C15 splices to feed circuit C16 through fuse 10 Circuit C16 feeds the Light Emitting Diode LED in the rear window defogger switch SCHEMA...

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Page 686: ...verhead console contains a US Metric switch The switch selects which units to show on the dis play The overhead console broadcasts the US Metric selection on the CCD bus OVERHEAD CONSOLE LAMPS Circuit A7 from fuse 15 in the Power Distribution Center PDC powers circuit M1 through fuse 16 in the junction block Circuit M1 feeds the overhead console lamps Each overhead console lamp has a switch that c...

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Page 690: ...perator selects high beam operation or flash to pass with the turn signal stalk of the multi function switch circuit L11 from fuse 19 in the junc tion block connects to circuit L3 Circuit L3 powers headlamp high beams Circuit L3 also connects to the Body Control Module BCM If the vehicle was built for sale in the Country of Canada the Daytime Running Lamps DRL module powers the headlamp high beams...

Page 691: ... 6 in the junction block Circuit F83 splices to the DRL module Circuit L3 powers the high beams of the left and right headlamps When the headlamp switch is OFF the DRL module powers the high beams on circuit L3 When the headlamps are ON the dimmer switch in the multi function switch powers the low beams on circuit L4 Circuit L3 feeds the high beams of the headlamps When the operator flashes the he...

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Page 700: ...p Lamps CHMSL Circuit Z1 provides a ground for the stop lamps and CHMSL lamps If the vehicle is equipped with a lamp outage mod ule circuit L50 connects to the module The lamp outage module powers circuit L73 L74 and L87 BACK UP LAMPS In the RUN position the ignition switch connects circuit A1 from fuse 8 in the Power Distribution Cen ter PDC to circuit A22 Circuit A22 powers circuit F83 through f...

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Page 708: ...he operator selects the right turn signal the multi function switch connects circuit L5 from the flasher relay to circuits L60 and L64 Circuit L64 feeds the right front turn signal lamp and side marker lamp Circuit L60 feeds the right rear turn signal lamp Circuit L64 also splices to power the right turn signal indicator lamp in the instrument cluster When the operator selects the left turn signal...

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Page 714: ...V23 supplies power for the rear wiper wash switch Circuit A250 from fuse 11 in the PDC powers cir cuit F70 through fuse 8 in the junction block Circuit F70 powers the rear wiper motor and the control module located internal to the motor assembly When the operator selects the ON position power is supplied through the switch to circuit V13 The V13 circuit connects from the switch to the rear wiper c...

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Page 720: ...t side of the relay Circuit L60 connects from the relay to the trailer tow connector Circuit 94 is fed power through the normally CLOSED side of the stop lamp relay by circuit F70 Circuit F70 is HOT at all times and protected by a circuit breaker located in the right rear quarter panel LEFT TURN RELAY Power for the coil side of the left turn relay is sup plied by circuit L61 This circuit connects ...

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Page 728: ... Ground for the motor is sup plied on circuit Q12 back to the switch The DDM connects circuit Q12 to ground circuit Z1 For window UP operation the circuits are reversed The PDM connects circuit Q12 to circuit F81 and connects circuit Q22 to ground circuit Z1 LEFT REAR WINDOW Circuits Q17 and Q27 connect the Driver s Door Module DDM to the left rear window switch When the operator has not selected ...

Page 729: ...20 If the operator has selected the window lock out feature the Driver s Door Module signals the PDM on the CCD bus In response the PDM will not sup ply power to the right rear window switch on circuits Q18 and Q28 Also the PDM does not illuminate the LED in the switch If the window is operated from DRIVER S switch for window DOWN operation the DDM signals the PDM over the CCD Bus In response the ...

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Page 734: ...DM over the CCD Bus When the DRIVERS door lock switch acti vates the DDM sends the appropriate signal to the PDM After receiving a LOCK signal the DDM supplies battery voltage to the left front door lock motor on circuit P36 The DDM also connects circuit P34 from the motor to ground When the DDM receives the UNLOCK signal it powers circuit P34 and grounds circuit P36 After receiving a LOCK signal ...

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Page 740: ...ment is made the DDM supplies power to the left mirror UP DOWN motor on circuit F71 and grounds circuit F73 When a DOWN adjustment is made the polarity reveres The DDM supplies power to circuit F73 and grounds circuit F71 During LEFT adjustments the DDM supplies power to the LEFT RIGHT motor on circuit F75 and grounds circuit F73 For RIGHT adjustments the polarity reverses The DDM supplies power t...

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Page 743: ...1996 Grand Cherokee Publication No 81 370 6147 TSB 26 02 96 February 1996 ...

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Page 746: ...uit F35 to circuit P15 Circuit P15 connects to the motor Ground is provided on circuit P17 circuit back to the switch A bus bar internal to the switch connects cir cuit P17 to ground on circuit Z1 For HORIZONTAL REARWARD function the cir cuits are reversed P17 is the feed and P15 is the ground When the operator selects the REAR VERTICAL UP function the switch passes power from circuit F35 to circu...

Page 747: ... the seat motor s the control module supplies the power and ground The following is a list of the circuits that connect from the control module to the seat motors P119 P121 Seat front up and down P111 P113 Rear up and down P115 P117 Seat forward and rearward P41 P43 Recliner forward and rearward P106 P107 Lumbar forward and rearward SEAT POSITION SENSORS The Memory Seat Module MSM receives seat po...

Page 748: ...hrough the resistor to circuit P7 or P8 The voltage level on circuit P7 or P8 from the switch depends on switch position LOW or HIGH After receiving a signal from its heated seat switch the heated seat control modules powers the heater grids in the seat From either control module circuit P87 powers the grid in the drivers seat cush ion Current flows out of the seat cushion on circuit P88 to the gr...

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Page 764: ...desired position A position sensor is used to prevent the sunroof from being moved to far in any one direction When the sensor detects the roof is at the end of its travel it sends a signal to the control module and voltage is shut off to the motor When the operator selects the CLOSE function voltage is provided on circuit F86 through the closed contacts in the switch to circuit Q42 Circuit Q42 co...

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Page 768: ...ircuit Z2 provides ground for the SPSCM On circuit S1 the SPSCM supplies 5 volts to the steering wheel speed sensor The sensor provides two signals to the SPSCM on circuits S3 and S4 The SPSCM provides ground for the steering wheel speed sensor on circuit S2 Circuit G7 supplies the vehicle speed sensor to the SPSCM SPEED PROPORTIONAL STEERING SOLENOID The speed proportional steering control module...

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Page 772: ...all splices in the wiring dia grams It also shows the splices in their entirety All circuits that are part of the splices are shown and the systems they affect are referenced For viewing the location of each splice in the vehicle refer to Sec tion 8W 95 ZJ 8W 70 SPLICE INFORMATION 8W 70 1 ...

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Page 816: ... INTRODUCTION The pages referenced in this section show the con nector the circuits in the connector and the pin that circuit occupies Individual connector numbers are referenced on diagram pages throughout Group 8W ZJ 8W 80 CONNECTOR PIN OUTS 8W 80 1 ...

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Page 898: ... 4 C111 BK Bottom of Windshield Washer Fluid Reservoir 4 C112 BK Center of Cowl 4 C113 BK Bottom of Windshield Washer Fluid Reservoir 4 C114 BK Below Battery Tray 4 C115 BK Right Fender Side Shield Below PDC 2 C116 BK Lower Left of Instrument Panel 13 C119 GY Left Side of Oil Pan 4 0L Engine 5 Conn Color Location Fig C119 GY Right Front of Transmission 10 C120 BK On Thermostat Housing 5 C121 GY In...

Page 899: ...ld 3 C162 RD Behind Right Kick Panel At Junction Block 12 Conn Color Location Fig C163 GY Behind Right Kick Panel At Junction Block 12 C164 BL Behind Right Kick Panel At Junction Block 12 C169 BK Left Side of Transmission 7 10 C170 BK Left Side of Transmission 7 10 C171 BK Left Side of Transmission 7 10 C172 BK Rear of Generator 8 C173 BK Near A C Compressor 6 8 C175 GY Injector No 7 9 C176 GY Inj...

Page 900: ...nn Color Location Fig C240 BK Lower Left of Instrument Panel 13 C241 WT Lower Left of Instrument Panel 13 C242 GY Top of Instrument Panel Between Steering Column and Center Floor Console 11 C243 BK Rear of Left Instrument Panel Speaker 11 C244 BK Rear of Power Outlet 11 C245 BK Center Top of Instrument Panel 11 C246 BL Left Side of HVAC Housing N S C247 RD Above Glove Box 11 C248 BK On Steering Co...

Page 901: ...Rear of Right Front Seat 16 C336 BK Top of Right A Pillar 15 C337 BK Behind Rear View Mirror 15 C338 BK Top of Left A Pillar 15 C339 RD Center of Headliner Above Rear View Mirror 15 C340 WT In Left Front Door 18 C341 NAT Behind Dome Lamp 15 C342 BK In Right Front Door 18 C343 BK In Left 9B9 Pillar 19 C344 BK In Right Front Door 18 C345 BK In Right 9B9 Pillar 19 C346 BK In Left Front Door 18 C347 B...

Page 902: ...p N S C428 GY At Lamp N S C429 BK At Lamp N S C431 BK At Lamp N S C432 BK At Lamp N S Conn Color Location Fig C433 BK At Lamp N S C434 BK Rear of Sunroof N S C435 RD Under Passenger s Seat N S C436 RD Under Passenger s Seat N S C437 BK Under Passenger s Seat N S C438 WT Under Passenger s Seat N S C439 GY Under Passenger s Seat N S C440 GN Under Passenger s Seat N S C441 BK Under Passenger s Seat N...

Page 903: ... Right Fender Side Shield 2 G107 Right Fender Side Shield 2 Conn Color Location Fig G108 Front of Left Fender Side Shield 3 G109 Front of Left Fender Side Shield 3 G300 Right Rear Quarter Panel 16 G301 Rear of Passenger s Seat 16 G302 On Floor Pan Rear of Driver s Seat 17 G303 On Floor Pan Rear of Driver s Seat 17 G304 On Floor Pan Rear of Driver s Seat 17 G305 On Floor Pan Rear of Driver s Seat 1...

Page 904: ...Fig 1 Front End Lighting ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 7 SCHEMATICS AND DIAGRAMS Continued ...

Page 905: ...Fig 2 Engine Compartment Left Side 8W 90 8 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 906: ...Fig 3 Engine Compartment Right Side ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 9 SCHEMATICS AND DIAGRAMS Continued ...

Page 907: ...Fig 4 Engine Compartment Connectors 8W 90 10 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 908: ...Fig 5 Engine Connectors 4 0L Engine ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 11 SCHEMATICS AND DIAGRAMS Continued ...

Page 909: ...Fig 6 Charging System Connectors 4 0L Engine 8W 90 12 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 910: ...Fig 7 Transmission Connectors 4 0L Engine ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 13 SCHEMATICS AND DIAGRAMS Continued ...

Page 911: ...Fig 8 Engine Connectors 5 2L Engine 8W 90 14 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 912: ...Fig 9 Engine Connectors 5 2L Engine ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 15 SCHEMATICS AND DIAGRAMS Continued ...

Page 913: ...Fig 10 Transmission Connectors 5 2L 8W 90 16 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 914: ...Fig 11 Instrument Panel Connectors ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 17 SCHEMATICS AND DIAGRAMS Continued ...

Page 915: ...Fig 12 Junction Block and HVAC Unit Connectors 8W 90 18 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued 1996 Grand Cherokee Publication No 81 370 6147 TSB 26 02 96 February 1996 ...

Page 916: ...Fig 13 Instrument Panel Connectors Left Side ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 19 SCHEMATICS AND DIAGRAMS Continued 1996 Grand Cherokee Publication No 81 370 6147 TSB 26 02 96 February 1996 ...

Page 917: ...Fig 14 Steering Column Connectors 8W 90 20 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 918: ...Fig 15 Roof Connectors ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 21 SCHEMATICS AND DIAGRAMS Continued ...

Page 919: ...Fig 16 Body Connectors Right Side 8W 90 22 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 920: ...Fig 17 Body Connectors Left Side ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 23 SCHEMATICS AND DIAGRAMS Continued ...

Page 921: ...Fig 18 Front Door Connectors 8W 90 24 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 922: ...Fig 19 Rear Door Connectors ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 25 SCHEMATICS AND DIAGRAMS Continued ...

Page 923: ...Fig 20 Factory Trailer Tow 8W 90 26 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 924: ...Fig 21 Liftgate Connectors ZJ 8W 90 CONNECTOR LOCATIONS 8W 90 27 SCHEMATICS AND DIAGRAMS Continued ...

Page 925: ...Fig 22 Underhood Lamp Fig 23 License Plate Lamps 8W 90 28 8W 90 CONNECTOR LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 926: ... Brake Warning Switch 1 S119 Left Rear of Engine Compartment 1 S120 Near T O to Low Washer Fluid Level Sensor 1 S121 Near T O to Low Washer Fluid Level Sensor 1 S122 Near Vehicle Speed Control Servo T O 1 S123 Near Vehicle Speed Control Servo T O 1 Splice Number Location Fig S124 Near Vehicle Speed Control Servo T O 1 S125 Near Controller Antilock Brakes 5 S126 Near A C High Pressure Switch T O 4 ...

Page 927: ...le 7 S304 Near Branch to Floor Console 7 S305 Near Branch to Left Rear Door 7 S306 Near Branch to Left Rear Door 7 S307 Near Branch to Left Rear Door 7 S308 Near Branch to Power Amplifier 7 S309 In Branch to Power Amplifier 7 S310 Near Branch to Power Amplifier 7 S311 Left Rear Quarter Panel 7 S312 Left Rear Quarter Panel 7 S313 Left Rear Quarter Panel 7 S314 Top of Left Rear Quarter Panel 7 S315 ...

Page 928: ...ss In Branch to Seat Switch N S S407 In Left Power Seat Harness Near Lumbar Motor T O N S S408 Near Left Front Turn Signal Bulb Socket N S Splice Number Location Fig S409 Near Left Front Turn Signal Bulb Socket N S S410 Near Left Front Park Lamp Bulb Socket N S S411 In Left Tail Lamp Harness Between Body Connector and Grommet N S S412 In Left Tail Lamp Harness Between Body Connector and Grommet N ...

Page 929: ...Fig 1 Engine Compartment Splices 8W 95 4 8W 95 SPLICE LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 930: ...Fig 2 Engine Wiring Splices 4 0L Engine ZJ 8W 95 SPLICE LOCATIONS 8W 95 5 SCHEMATICS AND DIAGRAMS Continued ...

Page 931: ...Fig 3 Engine Wiring Splices 5 2L Engine 8W 95 6 8W 95 SPLICE LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 932: ...Fig 4 Instrument Panel Splices ZJ 8W 95 SPLICE LOCATIONS 8W 95 7 SCHEMATICS AND DIAGRAMS Continued ...

Page 933: ...Fig 5 Body Splices Fig 6 HVAC Harness Splices 8W 95 8 8W 95 SPLICE LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 934: ...Fig 7 Left Body Side Wiring Splices ZJ 8W 95 SPLICE LOCATIONS 8W 95 9 SCHEMATICS AND DIAGRAMS Continued ...

Page 935: ...Fig 8 Right Side Body Wiring Splices 8W 95 10 8W 95 SPLICE LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 936: ...Fig 9 Roof Wiring Splices Fig 10 Front Door Harness Splices ZJ 8W 95 SPLICE LOCATIONS 8W 95 11 SCHEMATICS AND DIAGRAMS Continued ...

Page 937: ...Fig 11 Liftgate Splices 8W 95 12 8W 95 SPLICE LOCATIONS ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 938: ...lant material to cure This material is normally used on flexible metal flanges The regular tubes have a shelf life of one year and the power tubes a two year shelf life and will not properly cure if over aged Always inspect the package for the expiration date before use MOPART GASKET MAKER Mopart Gasket Maker normally red in color is available in six cc tubes This anaerobic type gasket material cu...

Page 939: ...the compression check g Insert compression gage adaptor into the No 1 spark plug hole Crank engine until maxi mum pressure is reached on gauge Record this pressure as No 1 cylinder pressure h Repeat for all remaining cylinders i Compression should not be less than 689 kPa 100 psi and not vary more than 172 kPa 25 psi from cylinder to cylinder j If cylinder s have abnormally low compres sion pressu...

Page 940: ...bearing to be checked This will remove the clearance between upper bearing shell and the crankshaft Place a min imum of 0 254 mm 0 010 inch shim between the bearing shell and the adjacent bearing cap Tighten the bolts to 18 N m 13 ft lbs torque ALL ENGINES When checking No 1 main bearing shim No 2 main bearing ALL ENGINES When checking No 2 main bearing shim No 1 and No 3 main bearing ALL ENGINES ...

Page 941: ...refer to Engine Specifications 5 Plastigage is available in a variety of clearance ranges The 0 025 0 076 mm 0 001 0 003 inch range is usually the most appropriate for checking engine bearing clearances REPAIR DAMAGED OR WORN THREADS Damaged or worn threads can be repaired Essen tially this repair consists of Drilling out worn or damaged threads Tapping the hole with a special Heli Coil Tap or equ...

Page 942: ... CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL PROPERLY ENGINE OIL SPECIFICATION CAUTION Do not use non detergent or straight mineral oil when adding or changing crankcase lubricant Engine failure can result API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certi fied or an oil that conforms to the API Service Grade SH or SH CD MOPAR provides engine oils that con form ...

Page 943: ...h handle held above the tip take oil level reading Fig 8 6 Add oil only if level is below the ADD mark on dipstick ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules Run engine until achieving normal operating tem perature 1 Position the vehicle on a level surface and turn engine off 2 Hoist and support vehicle on safety stands 3 Remove oil fill ca...

Page 944: ... OIL FILTER INSTALLATION 1 Lightly lubricate oil filter gasket with engine oil or chassis grease 2 Thread filter onto adapter nipple When gasket makes contact with sealing surface Fig 10 hand tighten filter one full turn do not over tighten 3 Add oil verify crankcase oil level and start engine Inspect for oil leaks USED ENGINE OIL DISPOSAL Care should be exercised when disposing used engine oil af...

Page 945: ...E FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN DO NOT WEAR LOOSE CLOTHING 1 Start the engine 2 Spray a small stream of water at the suspected leak area 3 If a change in RPM is observed the area of the suspected leak has been found 4 Repair as required CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine mal...

Page 946: ...or into water jacket Any causes for combustion compression pressure loss 1 Check the coolant level and fill as required DO NOT install the radiator cap 2 Start and operate the engine until it attains normal operating temperature then turn the engine OFF 3 Remove the spark plugs 4 Remove the oil filler cap 5 Remove the air cleaner 6 Calibrate the tester according to the manufac turer s instructions...

Page 947: ...ngine a more involved inspection is necessary The following steps should be followed to help pinpoint the source of the leak If the leakage occurs at the crankshaft rear oil seal area 1 Disconnect the battery 2 Raise the vehicle 3 Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil Use a black light to check for the oil leak a Circular spray pattern genera...

Page 948: ...oise may be dampened by applying side thrust on the valve spring If noise is not apprecia bly reduced it can be assumed the noise is in the tappet Inspect the rocker arm push rod sockets and push rod ends for wear 3 Valve tappet noise ranges from light noise to a heavy click A light noise is usually caused by exces sive leak down around the unit plunger or by the plunger partially sticking in the ...

Page 949: ...ENGINE PERFORMANCE 9 12 ENGINE ZJ DIAGNOSIS AND TESTING Continued ...

Page 950: ...ENGINE MECHANICAL ZJ ENGINE 9 13 DIAGNOSIS AND TESTING Continued ...

Page 951: ...ENGINE LUBRICATION 9 14 ENGINE ZJ DIAGNOSIS AND TESTING Continued ...

Page 952: ...DRAULIC TAPPETS 48 ROCKER ARMS AND PUSH RODS 48 SPECIFICATIONS 4 0L ENGINE SPECIFICATIONS 49 SPECIAL TOOLS 4 0L ENGINE 52 DESCRIPTION AND OPERATION ENGINE DESCRIPTION The 4 0 Liter 242 CID six cylinder engine is an In line lightweight overhead valve engine Engine Type In line 6 Cylinder Bore and Stroke 98 4 x 86 69 mm 3 88 x 3 413 in Displacement 4 0 242 cu in Compression Ratio 8 7 1 Torque 305 N ...

Page 953: ...rough an oil gallery that channels the oil up to the main gal lery which extends the entire length of the block Galleries extend downward from the main oil gal lery to the upper shell of each main bearing The crankshaft is drilled internally to pass oil from the main bearing journals except number 4 main bear ing journal to the connecting rod journals Each con necting rod bearing cap has a small s...

Page 954: ...Oil Lubrication System ZJ 4 0L ENGINE 9 17 DESCRIPTION AND OPERATION Continued ...

Page 955: ...cator pointer indicates 0 305 mm 0 012 inch travel distance lift The timing notch index on the vibration damper should be aligned with the TDC mark on the timing degree scale If the timing notch is more than 13 mm 1 2 inch away from the TDC mark in either direction the valve timing is incorrect If the valve timing is incorrect the cause may be a broken camshaft pin It is not necessary to replace t...

Page 956: ... CYLINDER BORE SIZE PISTON LETTER SIZE 98 438 to 98 448 mm 3 8755 to 3 8759 in A 98 448 to 98 458 mm 3 8759 to 3 8763 in B 98 458 to 98 468 mm 3 8763 to 3 8767 in C 98 468 to 98 478 mm 3 8767 to 3 8771 in D 98 478 to 98 488 mm 3 8771 to 3 8775 in E 98 488 to 98 498 mm 3 8775 to 3 8779 in F PISTON RING FITTING 1 Carefully clean the carbon from all ring grooves Oil drain openings in the oil ring gro...

Page 957: ...the package It is not necessary to use a tool to install the upper and lower rails Insert oil rail spacer first then side rails 6 The two compression rings are different and can not be interchanged The TOP compression ring can be identified by 1 dot on the top surface of the ring Fig 9 7 The second compression ring has a chamfer on the BOTTOM of the inside edge Fig 10 8 Using a ring installer inst...

Page 958: ...ING RODS Misaligned or bent connecting rods can cause abnormal wear on pistons piston rings cylinder walls connecting rod bearings and crankshaft con necting rod journals If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod inspect it for correct rod alignment Replace misaligned bent or twisted con necting rods BEARING TO JOURNAL CLEARANCE 1...

Page 959: ...rts Mea sure the clearance as described in the previous steps 10 The clearance is measured with a pair of 0 0254 mm 0 001 inch undersize bearing inserts installed This will determine if two 0 0254 mm 0 001 inch undersize inserts or another combination is needed to provide the correct clearance refer to Connecting Rod Bearing Fitting Chart 11 FOR EXAMPLE If the initial clearance was 0 0762 mm 0 003...

Page 960: ...is identi fied by a color coded paint mark on the adjacent cheek The rear main journal is identified by a color coded paint mark on the crankshaft rear flange When required upper and lower bearing inserts of different sizes may be used as a pair A standard size insert is sometimes used in combination with a 0 025 mm 0 001 inch undersize insert to reduce the clear ance by 0 013 mm 0 0005 inch Never...

Page 961: ...nserts would reduce the clearance by 0 0254 mm 0 001 inch The clearance would then be 0 0508 mm 0 002 inch and within the specification A 0 051 mm 0 002 inch undersize bearing insert and a 0 0254 mm 0 001 inch undersize insert would reduce the origi nal clearance an additional 0 0127 mm 0 0005 inch The clearance would then be 0 0381 mm 0 0015 inch CAUTION Never use a pair of inserts that differ mo...

Page 962: ...MAIN BEARING FITTING CHART ZJ 4 0L ENGINE 9 25 SERVICE PROCEDURES Continued ...

Page 963: ...e 2 Install the insulator assembly to the lower front sill Tighten the bolts to 65 N m 48 ft lbs torque 3 With the engine insulator assembly and engine bracket in position install the thru bolt and nut Fig 22 Fig 23 Tighten the thru bolt nut to 121 N m 89 ft lbs torque 4 Lower the vehicle 5 Remove the engine support 6 Connect the negative cable to the battery ENGINE MOUNT REAR A resilient rubber c...

Page 964: ...Fig 25 5 Remove the lower radiator hose 6 Remove upper radiator support retaining bolts and remove radiator support 7 Remove the fan assembly from the water pump 8 Remove the fan shroud Fig 25 9 Disconnect the transmission fluid cooler tubing automatic transmission 10 Vehicles with Air Conditioning a Discharge the A C system refer to Group 24 Heating and Air Conditioning b Remove the service valve...

Page 965: ...g 39 Remove the remaining converter or engine flywheel housing bolts 40 Lift the engine out of the engine compart ment INSTALLATION CAUTION When installing the engine into a vehi cle equipped with an automatic transmission be careful not to damage the trigger wheel on the engine flywheel 1 Attach a lifting device to the engine and lower the engine into the engine compartment For easier installatio...

Page 966: ...29 Install the fan assembly to the water pump 30 Place the fan shroud in position over the fan 31 Install the radiator or radiator condenser if equipped with A C 32 Connect the service valves to the A C com pressor ports if equipped with A C 33 Charge the air conditioner system refer to Group 24 Heating and Air Conditioning 34 Connect the radiator hoses and automatic transmission fluid cooler pipe...

Page 967: ...original locations Ensure that the bottom end of each push rod is centered in the tappet plunger cap seat 2 Using Mopar Engine Oil Supplement or equiv alent lubricate the area of the rocker arm that the pivot contacts Install rocker arms pivots and bridge above each cylinder in their originally position 3 Loosely install the capscrews through each bridge 4 At each bridge tighten the capscrews alte...

Page 968: ... the spark plug 5 Repeat the procedures for each remaining valve spring to be removed 6 Install the push rods Ensure the bottom end of each rod is centered in the plunger cap seat of the hydraulic valve tappet 7 Install the rocker arms pivots and bridge at their original location 8 Tighten the bridge capscrews alternately one at a time to avoid damaging the bridge Tighten the capscrews to 28 N m 2...

Page 969: ...he replacement head valve stem guide bores are reamed to accommodate oversize valve stems Remove all carbon buildup and reface the valves 1 Remove the shop towels from the cylinder bores Coat the bores with clean engine oil 2 Position the engine cylinder head gasket with the numbers facing up onto the cylinder block CAUTION Engine cylinder head bolts should be reused only once Replace the head bol...

Page 970: ...ll the cooling system Check for leaks WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN DIRECT LINE WITH THE FAN DO NOT PUT HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 26 Operate the engine with the radiator cap off Inspect for leaks and continue operating the engine until the engine thermostat opens Add coolant if required VALVES AND VALVE SPRINGS This pr...

Page 971: ...ud 3 Remove the vibration damper retaining bolt and washer 4 Use Vibration Damper Removal Tool 7697 to remove the damper from the crankshaft Fig 35 INSTALLATION 1 Apply Mopar Silicone Rubber Adhesive Sealant to the keyway in the crankshaft and insert the key With the key in position align the keyway on the vibration damper hub with the crankshaft key and tap the damper onto the crankshaft 2 Instal...

Page 972: ...over alignment tool 8 Apply a light film of engine oil on the vibration damper hub contact surface of the seal 9 Apply Mopar Silicone Rubber Adhesive Sealant to the keyway in the crankshaft and insert the key With the key inserted in the keyway in the crank shaft install the vibration damper washer and bolt Lubricate and tighten the bolt to 108 N m 80 ft lbs torque 10 Install the A C compressor if...

Page 973: ...Supplement or equivalent Install the spring and thrust pin in the preload bolt head Fig 39 7 Install the timing case cover and gasket 8 With the key installed in the crankshaft key way install the vibration damper washer and bolt Lubricate and tighten the bolt to 108 N m 80 ft lbs torque 9 Install the serpentine drive belt and tighten to the specified tension refer to Group 7 Cooling Sys tem for t...

Page 974: ...l the engine cylinder head 15 Install the push rods 16 Install the rocker arms and pivot and bridge assemblies Tighten each of the capscrews for each bridge alternately one turn at a time to avoid dam aging the bridge 17 Install the engine cylinder head cover 18 Position the oil pump gear Refer to Distribu tor in the Component Removal Installation section of Group 8D Ignition Systems 19 Install th...

Page 975: ...aft pin 16 If the pin is a spring type pin remove the bro ken pin by inserting a self tapping screw into the pin and carefully pulling the pin from the camshaft 17 If the pin is a dowel type pin center punch it Ensure the exact center is located when center punching the pin CAUTION Cover the opened oil pan area to pre vent metal chips from entering the pan 18 Drill into the pin center with a 4 mm ...

Page 976: ... crank shaft 17 Lubricate and tighten the damper bolt to 108 N m 80 ft lbs torque 18 If equipped with air conditioning a Install the A C compressor serpentine drive belt idler pulley b Install the generator c Install the A C condenser and receiver drier assembly 19 Install the serpentine drive belt on the pulleys and tighten refer to Group 7 Cooling System for the specifications and procedures 20 ...

Page 977: ... cap to ensure the crankshaft rotates freely 8 Check crankshaft end play Crankshaft end play is controlled by the thrust bearing which is flange and installed at the No 2 main bearing position a Attach a magnetic base dial indicator to the cylinder block at either the front or rear of the engine b Position the dial indicator rod so that it is parallel to the center line of the crankshaft c Pry the...

Page 978: ...ve the oil pan 13 Remove the oil pan bolts Carefully slide the oil pan and gasket to the rear If equipped with an oil level sensor take care not to damage the sensor INSTALLATION 1 Clean the block and pan gasket surfaces 2 Fabricate 4 alignment dowels from 1 1 2 x 1 4 inch bolts Cut the head off the bolts and cut a slot into the top of the dowel This will allow easier installation and removal with...

Page 979: ...il pan and gasket 9 Remove the connecting rod bearing caps and inserts Mark the caps and rods with the cylinder bore location The connecting rods and caps are stamped with a two letter combination Fig 52 10 Lower the vehicle until it is about 2 feet from the floor CAUTION Ensure that the connecting rod bolts DO NOT scratch the crankshaft journals or cylinder walls Short pieces of rubber hose slipp...

Page 980: ...d inserts in the same positions as removed CAUTION Verify that the oil squirt holes in the rods face the camshaft and that the arrows on the pistons face the front of the engine 11 Install the oil pan and gaskets as outlined in the installation procedure 12 Lower the vehicle 13 Install the engine cylinder head push rods rocker arms bridges pivots and engine cylinder head cover 14 Fill the crankcas...

Page 981: ...in mesh with the camshaft gear REMOVAL 1 Drain the engine oil 2 Remove the oil pan 3 Remove the pump to cylinder block attaching bolts Remove the pump assembly with gasket Fig 57 CAUTION If the oil pump is not to be serviced DO NOT disturb position of oil inlet tube and strainer assembly in pump body If the tube is moved within the pump body a replacement tube and strainer assembly must be install...

Page 982: ...e stems valve stem guides and head Clean all grime and gasket material from the engine cylinder head machined gasket surface Inspect for cracks in the combustion chambers and valve ports Inspect for cracks on the exhaust seat Inspect for cracks in the gasket surface at each coolant passage Inspect valves for burned cracked or warped heads Inspect for scuffed or bent valve stems Replace valves disp...

Page 983: ...tle brush 3 Insert a telescoping gauge into the valve stem guide bore approximately 9 525 mm 375 inch from the valve spring side of the head Fig 61 4 Remove and measure telescoping gauge with a micrometer 5 Repeat the measurement with contacts length wise to engine cylinder head 6 Compare the crosswise to lengthwise measure ments to determine out of roundness If the measure ments differ by more th...

Page 984: ...per 11 Install the water pump Tighten the mounting bolts to 31 N m 270 in lbs torque 12 Lubricate the oil filter seal with clean engine oil Tighten oil filter to 18 N m 13 ft lbs torque 13 Install the engine into the vehicle 14 Fill the engine with clean lubrication oil refer to Group 0 Lubrication and Maintenance 15 Fill the cooling system CLEANING AND INSPECTION ENGINE CYLINDER HEAD CLEANING Tho...

Page 985: ...ap pet tester away from the ram of the Leak Down Tester 1 Place a 7 925 7 950 mm 0 312 0 313 inch diameter ball bearing on the plunger cap of the tap pet 2 Lift the ram and position the tappet with the ball bearing inside the tester cup 3 Lower the ram then adjust the nose of the ram until it contacts the ball bearing DO NOT tighten the hex nut on the ram 4 Fill the tester cup with hydraulic valve...

Page 986: ...as been in use for a period of time HONING CYLINDER BORE The honing operation should be closely coordinated with the fitting of pistons and rings This will ensure specified clearances are maintained Refer to Standard Service Procedures in the begin ning of this Group for the proper honing of cylinder bores SPECIFICATIONS 4 0L ENGINE SPECIFICATIONS Camshaft Hydraulic Tappet Clearance Zero Lash Bear...

Page 987: ...1 Pressure Range 827 to 1 034 kPa 120 to 150 psi Max Variation Between Cylinders 206 kPa 30 psi Cylinder Head Combustion Chamber 52 22 to 58 22 cc 3 37 to 3 55 cu in Valve Guide I D Integral 7 9 mm 0 312 in Valve Stem to Guide Clearance 0 025 to 0 076 mm 0 001 to 0 003 in Intake Valve Seat Angle 44 5 Exhaust Valve Seat Angle 44 5 Valve Seat Width 1 02 to 1 52 mm 0 040 to 0 060 in Valve Seat Runout...

Page 988: ... in Piston to Pin Connecting Rod Press Fit 8 9 kN 2000 lbf Oil Pump Gear to Body Clearance Radial 0 051 to 0 102 mm 0 002 to 0 004 in Gear to Body Clearance Radial Preferred 0 051 mm 0 002 in Gear End Clearance Plastigage 0 051 to 0 152 mm 0 002 to 0 006 in Gear End Clearance Plastigage Preferred 0 051 mm 0 002 in Gear End Clearance Feeler Gauge 0 1016 to 0 2032 mm 0 004 to 0 008 in Gear End Clear...

Page 989: ...lts 102 N m 75 ft lbs Oil Galley Plug 41 N m 30 ft lbs Oil Pan 1 4 20 Bolts 14 N m 129 in lbs 5 16 18 Bolts 18 N m 156 in lbs Drain Plug 34 N m 25 ft lbs Oil Pump Short Attaching Bolts 14 N m 10 ft lbs Long Attaching Bolts 23 N m 17 ft lbs Cover Bolts 8 N m 70 in lbs Power Steering Pump Pressure Hose Nut 52 N m 38 ft lbs Rocker Arm Assembly to Cylinder Head Capscrews 28 N m 21ft lbs Spark Plugs Pl...

Page 990: ...BLOCK 80 CYLINDER HEADS 77 OIL PAN 78 OIL PUMP 78 PISTON AND CONNECTING ROD ASSEMBLY 78 SPECIFICATIONS 5 2L ENGINE 81 SPECIAL TOOLS 5 2L ENGINE 85 GENERAL INFORMATION VALVES AND VALVE SPRINGS The valves are arranged in line and inclined 18 The rocker pivot support and the valve guides are cast integral with the heads OIL PUMP PRESSURE The MINIMUM oil pump pressure is 41 4 kPa 6 psi at curb idle Th...

Page 991: ...the oil gallery on the left side of the engine Galleries extend downward from the main oil gal lery to the upper shell of each main bearing The crankshaft is drilled internally to pass oil from the main bearing journals to the connecting rod journals Each connecting rod bearing has half a hole in it oil passes through the hole when the rods rotate and the hole lines up oil is then thrown off as th...

Page 992: ...Fig 4 Oil Lubrication System ZJ 5 2L ENGINE 9 55 DESCRIPTION AND OPERATION Continued ...

Page 993: ...ous damage If reading is not within specified limits Check sprocket index marks Inspect timing chain for wear Check accuracy of DC mark on timing indicator MEASURING TIMING CHAIN STRETCH NOTE To access timing chain Refer to Timing Chain Cover in Removal and Installation Section 1 Place a scale next to the timing chain so that any movement of the chain may be measured 2 Place a torque wrench and so...

Page 994: ...2 mm 0 020 0 030 inch The oil ring gap should be 0 254 1 270 mm 0 010 0 050 inch c Rings with insufficient end gap may be prop erly filed to the correct dimension Rings with excess gaps should not be used 2 Install rings and confirm ring side clearance a Install oil rings being careful not to nick or scratch the piston Install the oil control rings accord ing to instructions in the package It is n...

Page 995: ... a new bearing half with an old bearing half DO NOT file the rods or bearing caps CRANKSHAFT MAIN BEARINGS Bearing caps are not interchangeable and should be marked at removal to ensure correct assembly Upper and lower bearing halves are NOT inter changeable Lower main bearing halves of No 2 and 4 are interchangeable Upper and lower No 3 bearing halves are flanged to carry the crankshaft thrust lo...

Page 996: ...ifting fixture 4 Raise vehicle on hoist 5 Remove the engine support insulator thru bolts and nuts Fig 15 Fig 16 6 Raise engine SLIGHTLY Remove the engine support insulator bolts Remove the engine support insulator assembly 7 If required remove the sill bracket assembly INSTALLATION 1 If the sill bracket assembly was removed install the bracket to the sill assembly a RIGHT SIDE Install the sill bra...

Page 997: ...transmission jack 7 Lower the vehicle 8 Connect the negative cable to the battery ENGINE ASSEMBLY REMOVAL 1 Scribe hood hinge outlines on hood and remove the hood 2 Remove the battery 3 Drain cooling system 4 Remove the air cleaner and tube 5 Set fan shroud aside 6 Remove radiator and heater hoses Remove the radiator refer to Group 7 Cooling System 7 Remove the vacuum lines 8 Remove the distributo...

Page 998: ...all fan shroud in position 25 Install the battery 26 Fill cooling system refer to Group 7 Cooling System for the proper procedure 27 Install the air cleaner 28 Warm engine and adjust 29 Install hood and line up 30 Road test vehicle CYLINDER HEAD COVER A steel backed silicon gasket is used with the cyl inder head cover Fig 18 This gasket can be used again REMOVAL 1 Disconnect the negative cable fro...

Page 999: ...ng sequence 1 8 4 3 6 5 7 2 Make sure piston in cylinder is at TDC on the valve spring that is being removed 12 Remove adapter from the No 1 spark plug hole 13 Install rocker arms 14 Install covers and coil wire to distributor 15 Install air cleaner 16 Road test vehicle CYLINDER HEAD REMOVAL 1 Disconnect the negative cable from the battery 2 Drain cooling system refer to Group 7 Cooling System for...

Page 1000: ...lve springs using Valve Spring Compressor Tool MD 998772A 3 Remove valve retaining locks valve spring retainers valve stem seals and valve springs 4 Before removing valves remove any burrs from valve stem lock grooves to prevent damage to the valve guides Identify valves to ensure installation in original location INSTALLATION 1 Clean valves thoroughly Discard burned warped and cracked valves 2 Re...

Page 1001: ...h washers through the puller tool and into the vibration damper Fig 21 8 Pull vibration damper off of the crankshaft INSTALLATION 1 Position the vibration damper onto the crank shaft 2 Place installing tool part of Puller Tool Set C 3688 in position and press the vibration damper onto the crankshaft Fig 22 3 Install the crankshaft bolt and washer Tighten the bolt to 183 N m 135 ft lbs torque 4 Ins...

Page 1002: ... the seal into position on the crankshaft Fig 26 6 Loosen the 4 bolts tightened in step 4 to allow realignment of front cover assembly 7 Tighten chain case cover bolts to 41 N m 30 ft lbs torque Tighten oil pan bolts to 24 N m 215 in lbs torque 8 Remove the vibration damper bolt and seal installation tool 9 Install vibration damper 10 Install water pump and housing assembly using new gaskets refer...

Page 1003: ...ten the bolt to 68 N m 50 ft lbs torque 7 Check camshaft end play The end play should be 0 051 0 152 mm 0 002 0 006 inch with a new thrust plate and up to 0 254 mm 0 010 inch with a used thrust plate If not within these limits install a new thrust plate CAMSHAFT NOTE The camshaft has an integral oil pump and distributor drive gear Fig 28 REMOVAL 1 Remove intake manifold 2 Remove cylinder head cove...

Page 1004: ...lignment of timing marks Fig 31 10 Install the camshaft bolt cup washer Tighten bolt to 68 N m 50 ft lbs torque 11 Measure camshaft end play Refer to Specifica tions for proper clearance If not within limits install a new thrust plate 12 Each tappet reused must be installed in the same position from which it was removed When camshaft is replaced all of the tappets must be replaced CAMSHAFT BEARING...

Page 1005: ... DRIVE SHAFT BUSHING REMOVAL 1 Remove distributor refer to Group 8D Ignition Systems for the proper procedure 2 Remove the intake manifold refer to Group 11 Exhaust System and Intake Manifold 3 Insert Distributor Drive Shaft Bushing Puller Tool C 3052 into old bushing and thread down until a tight fit is obtained Fig 34 4 Hold puller screw and tighten puller nut until bushing is removed INSTALLATI...

Page 1006: ...ffect fuel synchronization only OIL PAN REMOVAL 1 Disconnect the negative cable from the battery 2 Raise the vehicle 3 Remove the oil pan drain plug and drain the engine oil 4 Remove the oil filter 5 Remove the starter refer to Group 8B Battery Starter Generator Service 6 If equipped with an oil level sensor disconnect the sensor 7 Position the cooler lines out of the way 8 Disconnect the oxygen s...

Page 1007: ...ns and connecting rods must be removed from top of cylinder block When removing piston and connecting rod assemblies rotate crankshaft to cen ter the connecting rod in the cylinder bore and at BDC Be careful not to nick crankshaft journals 7 After removal install bearing cap on the mat ing rod INSTALLATION 1 Be sure that compression ring gaps are stag gered so that neither is in line with oil ring...

Page 1008: ...NOT strike rear cap more than 2 times for proper engagement 9 Clean and oil all cap bolts Install all main bearing caps Install all cap bolts and alternately tighten to 115 N m 85 ft lbs torque 10 Install oil pump 11 Install the timing chain cover 12 Install the vibration damper 13 Apply Mopart Silicone Rubber Adhesive Seal ant or equivalent at bearing cap to block joint to provide cap to block an...

Page 1009: ...d with crankshaft removed from engine or with crankshaft installed When a new upper seal is installed install a new lower seal The lower seal half can only be installed with the rear main bearing cap removed UPPER SEAL CRANKSHAFT REMOVED REMOVAL 1 Remove the crankshaft Discard the old upper seal INSTALLATION 1 Clean the cylinder block rear cap mating sur face Make sure the seal groove is free of d...

Page 1010: ...ar bearing cap 3 Rotate the new upper seal into the cylinder block being careful not to shave or cut the outer sur face of the seal To assure proper installation use the installation tool provided with the kit Install the new seal with the white paint facing towards the rear of the engine 4 Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rea...

Page 1011: ... sealant until a small amount is squeezed out Withdraw nozzle and wipe excess sealant off the oil pan seal groove 10 Immediately install the oil pan ENGINE CORE OIL AND CAMSHAFT PLUGS Engine core plugs have been pressed into the oil galleries behind the camshaft thrust plate Fig 48 This will reduce internal leakage and help maintain higher oil pressure at idle REMOVAL 1 Using a blunt tool such as ...

Page 1012: ...ppet assembly 4 Assemble tappets Fig 50 VALVE SERVICE VALVE GUIDES Measure valve stem guide clearance as follows 1 Install Valve Guide Sleeve Tool C 3973 over valve stem and install valve Fig 51 The special sleeve places the valve at the correct height for checking with a dial indicator 2 Attach Dial Indicator Tool C 3339 to cylinder head and set it at right angle of valve stem being measured Fig ...

Page 1013: ...the blue is transferred to bottom edge of valve face raise valve seat with a 60 stone 4 When seat is properly positioned the width of intake seats should be 1 016 1 524 mm 0 040 0 060 inch The width of the exhaust seats should be 1 524 2 032 mm 0 060 0 080 inch VALVE SPRING INSPECTION Whenever valves have been removed for inspection reconditioning or replacement valve springs should be tested As a...

Page 1014: ... filling rotor cavity with engine oil CYLINDER BLOCK DISASSEMBLE Engine assembly removed from vehicle 1 Remove the cylinder head 2 Remove the oil pan 3 Remove the piston and connecting rod assem blies ASSEMBLE 1 Install the piston and connecting rod assembly 2 Install the oil pan 3 Install the cylinder head 4 Install the engine into the vehicle CLEANING AND INSPECTION CYLINDER HEADS CLEANING Clean...

Page 1015: ...ant that the final paper or cloth polish be in the same direction as the engine rotates OIL PAN CLEANING Clean the block and pan gasket surfaces Trim or remove excess sealant film in the rear main cap oil pan gasket groove DO NOT remove the sealant inside the rear main cap slots If present trim excess sealant from inside the engine Clean oil pan in solvent and wipe dry with a clean cloth Clean oil...

Page 1016: ...traightedge replace pump assembly Fig 66 Inspect oil pressure relief valve plunger for scoring and free operation in its bore Small marks may be removed with 400 grit wet or dry sandpaper The relief valve spring has a free length of approx imately 49 5 mm 1 95 inches The spring should test between 19 5 and 20 5 pounds when compressed to 34 mm 1 11 32 inches Replace spring that fails to meet these ...

Page 1017: ... the block between the oil to filter and oil from filter passages Fig 68 Improper installa tion or plug missing could cause erratic low or no oil pressure The oil plug must come out the bottom Use flat dowel down the oil pressure sending unit hole from the top to remove oil plug 1 Remove oil pressure sending unit from back of block 2 Insert a 3 175 mm 1 8 in finish wire or equivalent into passage ...

Page 1018: ...SPECIFICATIONS 5 2L ENGINE ZJ 5 2L ENGINE 9 81 ...

Page 1019: ...9 82 5 2L ENGINE ZJ SPECIFICATIONS Continued ...

Page 1020: ...OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS ZJ 5 2L ENGINE 9 83 SPECIFICATIONS Continued ...

Page 1021: ...TORQUE 9 84 5 2L ENGINE ZJ SPECIFICATIONS Continued ...

Page 1022: ... 5 2L ENGINE Adapter 6633 Adapter 6716A Valve Guide Sleeve C 3973 Dial Indicator C 3339 Puller C 3688 Oil Pressure Gauge C 3292 Engine Support Fixture C 3487 A Valve Spring Compressor MD 998772 A ZJ 5 2L ENGINE 9 85 ...

Page 1023: ...taller C 3132 A Camshaft Holder C 3509 Distributor Bushing Puller C 3052 Distributor Bushing Driver Burnisher C 3053 Piston Ring Compressor C 385 Crankshaft Main Bearing Remover C 3059 Cylinder Bore Gauge C 119 9 86 5 2L ENGINE ZJ SPECIAL TOOLS Continued ...

Page 1024: ...fold and exhaust pipe to assure a tight seal and strain free connections The 5 2L exhaust manifolds are equipped with ball flange outlets to assure a tight seal and strain free connections The exhaust system must be properly aligned to prevent stress leakage and body contact If the sys tem contacts any body panel it may amplify objec tionable noises originating from the engine or body When inspect...

Page 1025: ...ur due to a temperature increase caused by unburned fuel passing through the converter DO NOT allow the engine to operate at fast idle for extended periods over 5 minutes This condition may result in excessive temperatures in the exhaust system and on the floor pan HEAT SHIELDS Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed by the catal...

Page 1026: ... exhaust clamps will be a new style band clamp Torca this will be used on all exhaust system Fig 5 DIAGNOSIS AND TESTING EXHAUST SYSTEM DIAGNOSIS Fig 5 Band Clamp Torca ZJ EXHAUST SYSTEM AND INTAKE MANIFOLD 11 3 GENERAL INFORMATION Continued ...

Page 1027: ... the catalytic converter 5 Remove the Torca clamp from the exhaust pipe and catalytic converter connection Fig 6 Fig 7 Disconnect the exhaust pipe from the catalytic con verter If needed 6 Disconnect the exhaust pipe hanger from the rear mount bracket insulator Fig 8 7 Remove the exhaust pipe INSTALLATION 1 Position the exhaust pipe onto the catalytic converter 2 Connect the exhaust pipe hanger to...

Page 1028: ...ll the muffler onto the catalytic converter until the alignment tab is inserted into the align ment slot 3 Install the Torca clamp at the muffler and cat alytic converter connection Fig 9 Tighten the clamp nuts to 71 N m 52 ft lbs torque 4 Connect oxygen sensor wiring 5 Lower the vehicle 6 Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels Adjust the ali...

Page 1029: ...e power steering pump and bracket from the intake manifold and set aside 9 Remove the fuel rail and injectors refer to Group 14 Fuel System 10 Raise the vehicle 11 Disconnect the exhaust pipe from the engine exhaust manifold Discard the seal 12 Lower the vehicle 13 Remove the intake manifold and engine exhaust manifold INSTALLATION If the manifold is being replaced ensure all the fit ting etc are ...

Page 1030: ...linkage and if so equipped the speed control and transmission kick down cables 7 Remove the return spring 8 Remove the distributor cap and wires 9 Disconnect the coil wires 10 Disconnect the heat indicator sending unit wire 11 Disconnect the heater hoses and bypass hose 12 Remove the closed crankcase ventilation and evaporation control systems 13 Remove the A C compressor bolts and set the compres...

Page 1031: ...efully lower intake manifold into position on the cylinder block and cylinder heads Use the alignment dowels in the cross over gaskets to posi tion the intake manifold After intake manifold is in place inspect to make sure seals are in place 8 The following torque sequence duplicates the expected results of the automated assembly system Fig 15 Step 1 Tighten bolts 1 through 4 in sequence to 8 N m ...

Page 1032: ...ion Control Systems 4 Raise the vehicle 5 Remove the bolts and nuts attaching the exhaust pipe to the exhaust manifold 6 Lower the vehicle 7 Remove bolts nuts and washers attaching manifold to cylinder head 8 Remove manifold from the cylinder head INSTALLATION CAUTION If the studs came out with the nuts when removing the exhaust manifold install new studs 1 Position the exhaust manifolds on the tw...

Page 1033: ...Bolts 23 N m 200 in lbs Catalytic Converter to Exhaust Pipe Band Clamp Torca 71 N m 52 ft lbs Exhaust Pipe to Manifold Nuts 31 N m 23 ft lbs Exhaust and Intake Manifold Bolts 1 5 8 11 4 0L 33 N m 24 ft lbs Exhaust Manifold Heat Shield Nuts 5 2L 27 N m 20 ft lbs Exhaust Manifold Nuts 6 7 4 0L 31 N m 23 ft lbs Exhaust Manifold Nuts Bolts 5 2L 27 N m 20 ft lbs Floor Pan Heat Shield Bolts Nuts 5 N m 4...

Page 1034: ... welded structure To replace the crossmember a frame machine should be used to cor rectly align the crossmember to the unibody 1 Remove grille screws at grille opening rein forcement GOR Fig 1 2 Unsnap lower clips at grille Remove grille from GOR 3 Remove turn signals side markers and headlamps Refer to Group 8L Lamps for service information 4 Remove the retainers at the front fascia Fig 2 5 Remov...

Page 1035: ...r 4 Remove push in retainers at each side rear wheel well 5 Remove the bolts that attach the bumper sup port brackets to the rear rails Fig 4 6 Slide the bumper beam fascia off of the retainer pegs on the side of the lower quarter panel 7 Remove the beam fascia from the vehicle 8 Remove the bumper support brackets from the bumper Fig 5 9 Remove the upper scuff pad from the bumper fascia by squeezi...

Page 1036: ...ructural mem bers The structural members provide a unibody that has great structural strength REMOVAL AND INSTALLATION FRONT TOW HOOK REMOVAL 1 Remove grille and fascia 2 Remove the nuts and bolts that attach the tow hooks to the lower crossmember Fig 1 3 Remove the tow hooks from the lower cross member INSTALLATION 1 Attach tow hook to bracket Tighten nuts to 95 N m 70 ft lbs torque 2 Position to...

Page 1037: ...20 ft lbs torque FUEL TANK SKID PLATE REMOVAL 1 Remove trailer hitch 2 Position a support under the fuel tank skid plate 3 Remove nuts attaching skid plate to frame rails Fig 4 4 Lower skid plate and remove support INSTALLATION 1 Position skid plate on a support and raise into position 2 Install nuts attaching skid plate to frame rails Tighten nuts to 74 N m 55 ft lbs torque 3 Remove support 4 Ins...

Page 1038: ...aise position hitch at proper location and support it 2 Loosely install nuts that attach towing tube to vehicle frame sills 3 Position plate bracket and install attaching bolts through vehicle rear crossmember 4 Tighten all attaching bolts nuts 5 Remove support and if removed attach trailer wire harness connector to hitch SPECIFICATIONS VEHICLE DIMENSIONS Frame dimensions are listed in metric scal...

Page 1039: ...Fig 7 Vehicle Dimensions Front Side View 13 6 FRAME AND BUMPERS ZJ SPECIFICATIONS Continued ...

Page 1040: ...Fig 8 Vehicle Dimensions Side View ZJ FRAME AND BUMPERS 13 7 SPECIFICATIONS Continued ...

Page 1041: ...Fig 9 Vehicle Dimensions Rear View And Engine Compartment 13 8 FRAME AND BUMPERS ZJ SPECIFICATIONS Continued ...

Page 1042: ...Fig 10 Frame Dimensions Side View ZJ FRAME AND BUMPERS 13 9 SPECIFICATIONS Continued ...

Page 1043: ...Fig 11 Frame Dimensions Bottom View 13 10 FRAME AND BUMPERS ZJ SPECIFICATIONS Continued ...

Page 1044: ... ft lbs Fuel Tank Skid Plate Nuts 74 N m 55 ft lbs Fuel Tank Skid Plate Mtg Studs 108 N m 80 ft lbs Rear Bumper Bolt 56 N m 41 ft lbs Rear Tow Hook Nut 100 N m 74 ft lbs Trailer Hitch Nuts Bolts 74 N m 55 ft lbs Transfer Case Skid Plate Bolts 27 N m 20 ft lbs ZJ FRAME AND BUMPERS 13 11 SPECIFICATIONS Continued ...

Page 1045: ......

Page 1046: ...mium unleaded gasolines contain more additive than regular unleaded Poor quality gasoline can cause problems such as hard starting stalling and stumble If you experi ence these problems try another brand of gasoline before considering service for the vehicle GASOLINE OXYGENATE BLENDS Some fuel suppliers blend gasoline with materials that contain oxygen such as alcohol MTBE Methyl Tertiary Butyl Et...

Page 1047: ...ted gasolines are specially blended to reduce vehicle emissions and improve air quality Chrysler Corporation strongly supports the use of reformulated gasolines whenever available Although your vehicle was designed to provide optimum perfor mance and lowest emissions operating on high qual ity unleaded gasoline it will perform equally well and produce even lower emissions when operating on reformu...

Page 1048: ...tors fuel tank accelerator pedal and throttle cable A fuel return system is used on all models all engines Fuel is returned through the fuel pump module and back into the fuel tank through the fuel pressure regulator A separate fuel return line from the engine to the tank is no longer used with any engine The fuel tank assembly consists of the fuel tank filler tube fuel gauge sending unit electric...

Page 1049: ...urpose of this feature is to prevent a false setting of misfire and fuel system monitor trouble codes This is if the fuel level in the tank is either less than 15 per cent or more than 85 percent of its rated capacity FUEL FILTER The fuel filter protects the fuel injectors from dirt water and other foreign matter The filter is located under the vehicle near the fuel tank Fig 3 Replace fuel filter ...

Page 1050: ...tag INJ 1 INJ 2 etc This is used to identify each fuel injector with its respective cylinder number The injectors are energized individually in a sequential order by the powertrain control module PCM The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off Injector pulse width is the period of time that the injector is energized The PCM will adju...

Page 1051: ...o the Removal Installation section for more information CAUTION The interior components o rings spac ers of quick connect fitting are not serviced sepa rately but new pull tabs are available for some types Do not attempt to repair damaged fittings or fuel lines tubes If repair is necessary replace the complete fuel tube assembly DIAGNOSIS AND TESTING FUEL PUMP PRESSURE TEST 4 0L ENGINE NOTE The fu...

Page 1052: ... read ing Fuel pressure should be 338 kPa 6 14 kPa 49 psi 6 2 psi at idle 3 If pressure is at O psi connect DRB scan tool and refer to operating instructions in the appropriate Powertrain Diagnostics Procedures service manual 4 If operating pressure is above 51 psi fuel pump is OK but fuel pressure regulator is defective Refer to Fuel Pressure Regulator removal installation FUEL PUMP PRESSURE TEST...

Page 1053: ...l Tubes Lines Hoses and Clamps in this section of the group for procedures Some engines may require air cleaner housing removal before line disconnection 3 Connect the appropriate Fuel Line Pressure Test Adapter Tool number 6631 6923 6541 or 6539 into the disconnected fuel supply line Insert the other end of Adaptor Tool into an approved gasoline container 4 To activate the fuel pump and pressuriz...

Page 1054: ...psi a leak can be found at a fuel tube line If no leaks are found at fuel tubes or lines replace the fuel pump module FUEL GAUGE SENDING UNIT For fuel gauge diagnosis refer to Group 8E Instrument Panel and Gauges FUEL INJECTORS To perform a complete test of the fuel injectors and their circuitry refer to DRB scan tool and appropri ate Powertrain Diagnostics Procedures manual To test the injector o...

Page 1055: ...INJECTOR DIAGNOSIS VEHICLE RUNS ROUGH AND OR HAS A MISS 14 10 FUEL SYSTEM ZJ ...

Page 1056: ...n key to OFF position CAUTION Steps 1 2 3 and 4 must be performed to relieve high pressure fuel from within the fuel rail Do not attempt to use the following steps to relieve this pressure as excessive fuel will be forced into a cylinder chamber 5 Unplug connector from any injector 6 Attach one end of a jumper wire with alligator clips 18 gauge or smaller to either injector terminal 7 Connect the ...

Page 1057: ... pull tabs are available Do not attempt to repair damaged fittings or fuel lines tubes If repair is necessary replace the complete fuel tube assembly WARNING THE FUEL SYSTEM IS UNDER A CON STANT PRESSURE EVEN WITH THE ENGINE OFF BEFORE SERVICING ANY FUEL SYSTEM HOSES FITTINGS OR LINES THE FUEL SYSTEM PRES SURE MUST BE RELEASED REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP DISCO...

Page 1058: ...ic retainer tabs Fig 18 against the sides of the quick connect fitting with your fingers Tool use is not required for removal and may damage plastic retainer Pull the fitting from the fuel system compo nent being serviced The plastic retainer will remain on the component being serviced after fitting is dis connected The o rings and spacer will remain in the quick connect fitting connector body 5 I...

Page 1059: ...ection the plastic retainer ring will remain with the quick connect fitting connector body 6 Inspect fitting connector body plastic retainer ring and fuel system component for damage Replace as necessary 7 Prior to connecting the quick connect fitting to component being serviced check condition of fitting and component Clean the parts with a lint free cloth Lubricate them with clean engine oil 8 I...

Page 1060: ...ed with a fuel pressure test port A special latch clip is used to secure the fuel line to the fuel rail on this particular engine Fig 23 DISCONNECTION CONNECTION AT FUEL RAIL 1 Disconnect the negative battery cable from bat tery 2 Perform the fuel pressure release procedure Refer to the Fuel Pressure Release Procedure in this section 3 Clean the fitting of any foreign material before disassembly 4...

Page 1061: ...ilter from mounting bracket INSTALLATION CAUTION The ends of the fuel filter are marked for correct installation Install filter with the end marked IN towards fuel tank and the end marked OUT towards engine 1 Place fuel filter in retaining strap with the marked ends in the correct position 2 Install retaining strap bolt Tighten to 7 N m 66 in lbs torque 3 Install fuel lines to filter Refer to Fuel...

Page 1062: ...the fuel pump module locknut and remove locknut Fig 28 The fuel pump module will spring up when the locknut is removed 4 Remove module from fuel tank INSTALLATION CAUTION Whenever the fuel pump module is ser viced the locknut and gasket must be replaced 1 Using a new gasket Fig 29 position fuel pump module into opening in fuel tank 2 Position new locknut over top of fuel pump module 3 Install Spec...

Page 1063: ...hose Fig 30 Due to the design of this connecting hose it does use any clamps Never attempt to install a clamping device of any kind to the hose When removing the fuel rail assembly for any reason be careful not to bend or kink the connecting hose REMOVAL 1 Remove negative battery cable at battery 2 Remove air duct at throttle body 3 Perform the fuel pressure release procedure 4 Remove throttle bod...

Page 1064: ...r 6 Install fuel rail mounting bolts 7 Connect electrical connector to intake manifold air temperature sensor 8 Connect wiring to all fuel injectors The injec tor wiring harness is numerically tagged 9 Install the A C support bracket if equipped 10 Install throttle body to intake manifold Refer to Throttle Body installation in this section of the group 11 Install fuel tube line at side of fuel rai...

Page 1065: ...sure Release Procedure To remove one or more fuel injectors the fuel rail assembly must be removed from engine REMOVAL 1 Remove air duct at throttle body 2 Remove fuel injector rail assembly Refer to Fuel Injector Rail removal in this section 3 Remove the clip s retaining the injector s to fuel rail Fig 33 or Fig 34 4 Remove injector s from fuel rail INSTALLATION 1 Apply a small amount of engine o...

Page 1066: ...ition fuel tank to hydraulic jack 4 Raise tank into position while guiding the fuel filler hoses into and through the access hole Fig 37 in body 5 Continue raising tank until positioned to body 6 Attach two fuel tank mounting straps and mounting nuts CAUTION The two mounting nuts must be tight ened until 80 mm 3 149 in is attained between the end of the mounting bolt and bottom of strap See insert...

Page 1067: ...rot tle cable core wire from upper end of pedal arm Fig 38 Plastic cable retainer clip snaps into pedal arm 2 Remove the cable core wire at pedal arm 3 From inside the vehicle pinch both sides of the cable housing retainer tabs Fig 38 at the dash panel Remove cable housing from dash panel and pull into the engine compartment 4 4 0L Engine Remove cable from clip on engine valve cover Fig 39 and cli...

Page 1068: ...elerator pedal to check for any binding SPECIFICATIONS VECI LABEL SPECIFICATIONS If anything differs between the specifications found on the Vehicle Emission Control Information VECI label and the following specifications use specifica tions on VECI label The VECI label is located in the engine compartment FUEL TANK CAPACITY FUEL SYSTEM PRESSURE 338 kPa 6 14 kPa 49 0 psi 6 2 psi TORQUE CHART DESCR...

Page 1069: ...ENGINES PCM OUTPUT 38 IGNITION COIL 5 2L ENGINES PCM OUTPUT 38 INTAKE MANIFOLD AIR TEMPERATURE SENSOR 4 0L ENGINE PCM INPUT 32 INTAKE MANIFOLD AIR TEMPERATURE SENSOR 5 2L ENGINES PCM INPUT 32 MALFUNCTION INDICATOR CHECK ENGINE LAMP PCM OUTPUT 38 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 4 0L ENGINE PCM INPUT 33 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 5 2L ENGINES PCM INPUT 33 OUTPUT SHAFT SPEED SENSOR P...

Page 1070: ...MODULE PCM 56 THROTTLE BODY 4 0L ENGINE 53 THROTTLE BODY 5 2L ENGINE 53 THROTTLE POSITION SENSOR TPS 4 0L ENGINE 54 THROTTLE POSITION SENSOR TPS 5 2L ENGINE 54 VEHICLE SPEED SENSOR 61 SPECIFICATIONS TORQUE CHART 62 VECI LABEL SPECIFICATIONS 62 SPECIAL TOOLS FUEL SYSTEM 63 GENERAL INFORMATION INTRODUCTION All engines are equipped with sequential Multi Port Fuel Injection MFI The MFI system provides...

Page 1071: ...arm up acceleration deceleration and wide open throttle modes are Open Loop modes The idle and cruise modes with the engine at operating tem perature are Closed Loop modes IGNITION SWITCH KEY ON MODE This is an Open Loop mode When the fuel system is activated by the ignition switch the following actions occur The powertrain control module PCM pre posi tions the idle air control IAC motor The PCM d...

Page 1072: ...sequence and injector pulse width by turning the ground circuit to each individ ual injector on and off The PCM monitors the O2S sensor input and adjusts air fuel ratio by varying injector pulse width It also adjusts engine idle speed through the idle air control IAC motor The PCM adjusts ignition timing by increasing and decreasing spark advance The PCM operates the A C compressor clutch through ...

Page 1073: ...nd off The PCM opens the ground circuit to the A C clutch relay to disengage the A C compressor clutch This will be done for approximately 15 seconds if the air conditioning system is operating IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position the PCM stops operating the injectors ignition coil ASD relay and fuel pump relay DESCRIPTION AND OPERATION SYSTEM DIAGNOSIS The PCM c...

Page 1074: ...ormation applies to fac tory installed air conditioning units A C SELECT SIGNAL When the A C switch is in the ON position an input signal is sent to the pow ertrain control module PCM The signal informs the PCM that the A C has been selected The PCM adjusts idle speed to a pre programmed rpm through the idle air control IAC motor to compensate for increased engine load A C REQUEST SIGNAL Once A C ...

Page 1075: ...l IAC motor The brake switch input is also used to operate the speed control system CAMSHAFT POSITION SENSOR PCM INPUT A sync signal is provide by the camshaft position sensor The sensor located in the distributor on all 4 0L 5 2L engines Fig 3 The sync signal from this sensor works in conjunction with the crankshaft posi tion sensor to provide the powertrain control module PCM with inputs This is...

Page 1076: ...olant temperature The PCM uses this input along with inputs from other sensors to deter mine injector pulse width and ignition timing As coolant temperature varies the coolant temperature sensor resistance will change This change in resis tance results in a different input voltage to the PCM When the engine is cold the PCM will operate in Open Loop cycle It will demand slightly richer air fuel mix...

Page 1077: ...njector pulse width DOWNSTREAM HEATED OXYGEN SENSOR The downstream heated oxygen sensor is located near the outlet end of the catalytic converter The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration As the con vertor deteriorates the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay By comparing the do...

Page 1078: ... voltage to change The change in MAP sensor voltage results in a different input voltage to the PCM The input volt age level supplies the PCM with information about ambient barometric pressure during engine start up cranking and engine load while the engine is run ning The PCM uses this input along with inputs from other sensors to adjust air fuel mixture The MAP sensor is mounted on the side of t...

Page 1079: ...d adjustment infor mation TRANSMISSION GOVERNOR PRESSURE SENSOR PCM INPUT Provides a signal proportional to the transmission governor pressure It provides feedback for control of the variable force solenoid which regulates transmis sion governor pressure This input is used with 4 speed electronic transmissions only TRANSMISSION TEMPERATURE SENSOR PCM INPUT This input is used in the shift operation...

Page 1080: ... A C relay is located in the Power Distribution Center PDC The PDC is located in the engine com partment Fig 12 Refer to label on PDC cover for relay location The powertrain control module PCM activates the A C compressor through the A C clutch relay The PCM regulates A C compressor operation by switch ing the ground circuit for the A C clutch relay on and off When the PCM receives a request for A...

Page 1081: ...rness connector for each fuel injector is equipped with an attached numerical tag INJ 1 INJ 2 etc This is used to identify each fuel injector with its respective cylinder number The injectors are energized individually in a sequential order by the powertrain control module PCM The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off Injector puls...

Page 1082: ...ll go out Refer to Groups 8A and 8C for charging system information IDLE AIR CONTROL IAC MOTOR 5 2L ENGINES PCM OUTPUT The IAC motor is mounted to the back of the throt tle body Fig 10 and is controlled by the powertrain control module PCM The throttle body has an air control passage that provides air for the engine at idle the throttle plate is closed The IAC motor pintle protrudes into the air c...

Page 1083: ...m certain sensors or emission related systems the lamp is turned on This is a warning that the PCM has recorded a system or sensor malfunction In some cases when a problem is declared the PCM will go into a limp in mode This is an attempt to keep the system operating It signals an immediate need for service The lamp can also be used to display a Diagnostic Trouble Code DTC Cycle the ignition switc...

Page 1084: ...rive OD torque converter clutch TCC and variable force VSS solenoids Once battery volt age is applied to the solenoids they are individually activated by the PCM through OD TCC and VSS outputs The relay is located in the Power Distribu tion Center PDC Refer to label on PDC cover for relay location VARIABLE FORCE SOLENOID PCM OUTPUT This solenoid regulates the transmission fluid line pressure to pr...

Page 1085: ...ime A thorough visual inspection will include the following checks 1 Verify that the three 32 way electrical connec tors are fully inserted into the connector of the pow ertrain control module PCM Fig 22 2 Inspect the battery cable connections Be sure that they are clean and tight 3 Inspect fuel pump relay and air conditioning compressor clutch relay if equipped Inspect the ASD relay connections I...

Page 1086: ...r 13 Inspect the air cleaner inlet and air cleaner element for dirt or restrictions 14 Inspect radiator grille area radiator fins and air conditioning condenser for restrictions 15 Verify that the intake manifold air tempera ture sensor wire connector is firmly connected to har ness connector Fig 26 16 Verify that MAP sensor electrical connector is firmly connected to MAP sensor Fig 27 Also verify...

Page 1087: ... hoses 23 Inspect for exhaust system restrictions such as pinched exhaust pipes collapsed muffler or plugged catalytic convertor 24 If equipped with automatic transmission ver ify that electrical harness is firmly connected to park neutral switch Refer to Automatic Transmission section of Group 21 25 Verify that the electrical harness connector is firmly connected to the vehicle speed sensor Fig 3...

Page 1088: ...ect the ASD relay connections Inspect starter motor relay connections Inspect relays for signs of physical dam age and corrosion The relays are located in the Power Distribution Center PDC Fig 34 Refer to label on PDC cover for relay location 4 Inspect ignition coil connections Verify that coil secondary cable is firmly connected to coil Fig 35 5 Verify that distributor cap is correctly attached t...

Page 1089: ...radiator grille area radiator fins and air conditioning condenser for restrictions 15 Verify that the intake manifold air tempera ture sensor wire connector is firmly connected to har ness connector Fig 37 16 Verify that MAP sensor electrical connector is firmly connected to MAP sensor Fig 37 Also verify that rubber L shaped fitting from MAP sensor to the throttle body is firmly connected Fig 38 1...

Page 1090: ... such as pinched exhaust pipes collapsed muffler or plugged catalytic convertor 24 If equipped with automatic transmission ver ify that electrical harness is firmly connected to park neutral switch Refer to Automatic Transmission section of Group 21 25 Verify that the electrical harness connector is firmly connected to the vehicle speed sensor Fig 42 Fig 41 Downstream Oxygen Sensor 4 0L Engine Fig...

Page 1091: ...rminals 30 and 87A The ohmmeter should show continuity between terminals 30 and 87A 4 Connect the ohmmeter between terminals 87 and 30 The ohmmeter should not show continuity at this time 5 Connect one end of a jumper wire 16 gauge or smaller to relay terminal 85 Connect the other end of the jumper wire to the ground side of a 12 volt power source 6 Connect one end of another jumper wire 16 gauge ...

Page 1092: ...lete test of MAP sensor Fig 47 and its circuitry refer to DRB scan tool and appro priate Powertrain Diagnostics Procedures manual To test the MAP sensor only refer to the following 1 Inspect the rubber L shaped fitting from the MAP sensor to the throttle body Fig 48 Repair as necessary CAUTION When testing the MAP sensor be sure that the harness wires are not damaged by the test meter probes 2 Tes...

Page 1093: ...of the O2S sensors and their circuitry refer to the DRB scan tool and appro priate Powertrain Diagnostics Procedures manual To test the O2S sensors only refer to the following The upstream O2S sensor is located on the exhaust pipe Fig 50 The downstream O2S sensor is located on the out let end of the catalytic converter Fig 51 Each O2S heating element can be tested with an ohmmeter as follows Disco...

Page 1094: ...can tool and appropriate Powertrain Diagnostics Procedures manual To test the sensor only refer to the following 1 Disconnect wire harness connector from coolant temperature sensor Fig 53 2 Engines with air conditioning When removing the connector from sensor do not pull directly on wiring harness Fabricate an L shaped hook tool from a coat hanger approximately eight inches long Place the hook par...

Page 1095: ...dures manual IDLE AIR CONTROL IAC MOTOR 4 0L ENGINE To perform a complete test of the IAC motor and its circuitry refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures manual INTAKE MANIFOLD AIR TEMPERATURE SENSOR 5 2L ENGINE To perform a complete test of the intake manifold air temperature sensor and its circuitry refer to DRB tester and appropriate Powertrain Diagnostics Proce...

Page 1096: ...00 millivolts At wide open throttle TPS output voltage must be less than 4 8 volts The output voltage should increase gradually as the throttle plate is slowly opened from idle to WOT THROTTLE POSITION SENSOR TPS 4 0L ENGINE To perform a complete test of the TPS Fig 56 and its circuitry refer to the DRB scan tool and appropri ate Powertrain Diagnostics Procedures manual To test the TPS only refer ...

Page 1097: ...uator Tests select Engine rpm and select Minimum Air Flow 9 The DRB scan tool will count down to stabilize the idle rpm and display the minimum air flow idle rpm The idle rpm should be between 500 and 900 rpm If the idle speed is outside of these specifica tions replace the throttle body Refer to Throttle Body in the Component Removal Installation section of this group 10 Disconnect the DRB scan t...

Page 1098: ...throttle body to intake manifold gasket INSTALLATION 1 Clean the mating surfaces of the throttle body and the intake manifold 2 Install new throttle body to intake manifold gasket 3 Install throttle body to intake manifold 4 Install four mounting bolts Tighten bolts to 23 N m 200 in lbs torque 5 Install control cables 6 Install vacuum line to throttle body 7 Install electrical connectors 8 Install...

Page 1099: ...body 1 Remove air duct at throttle body 2 Disconnect TPS electrical connector 3 Remove two TPS mounting bolts Fig 65 4 Remove TPS from throttle body INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS Fig 66 The TPS must be installed so that it can be rotated a few degrees If the sensor will not rotate install the sensor with the throttle shaft on the other sid...

Page 1100: ... at throttle body 2 Disconnect electrical connector from IAC motor 3 Remove two mounting bolts screws Fig 69 4 Remove IAC motor from throttle body INSTALLATION 1 Install IAC motor to throttle body 2 Install and tighten two mounting bolts screws to 7 N m 60 in lbs torque 3 Install electrical connector 4 Install air duct at throttle body IDLE AIR CONTROL IAC MOTOR 4 0L ENGINE The IAC motor is locate...

Page 1101: ...ir duct at throttle body MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 4 0L ENGINE The MAP sensor is mounted to the side of the throttle body An L shaped rubber fitting is used to connect the MAP sensor to throttle body Fig 72 REMOVAL 1 Remove air cleaner intake tube at throttle body 2 Remove two MAP sensor mounting bolts screws Fig 72 3 While removing MAP sensor slide the rubber L shaped fitting Fig 72 f...

Page 1102: ...ted in the exhaust downpipe The downstream sensor is located near outlet end of catalytic converter Refer to Fig 76 or Fig 77 REMOVAL WARNING THE EXHAUST MANIFOLD EXHAUST PIPES AND CATALYTIC CONVERTER BECOME VERY HOT DURING ENGINE OPERATION ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR 1 Raise and support the vehicle 2 Disconnect the wire connector from the O2S sensor CAUTION When disconnecti...

Page 1103: ...g the sensor electri cal connector do not pull directly on wire going into sensor 3 Remove the O2S sensor Snap On oxygen sen sor wrench number YA 8875 may be used for removal and installation INSTALLATION Threads of new oxygen sensors are factory coated with anti seize compound to aid in removal DO NOT add any additional anti seize compound to the threads of a new oxygen sensor 1 Install the O2S s...

Page 1104: ... shown in Fig 81 AIR CLEANER ELEMENT FILTER REMOVAL INSTALLATION 1 Pry back the six clips retaining the air cleaner cover to the air cleaner housing Fig 82 2 Lift the cover up and position to the side 3 Remove air cleaner element 4 Clean the inside of air cleaner housing before installing new element 5 Reverse the preceding operation for installa tion Be sure the air cleaner cover is properly seat...

Page 1105: ... Refer to Group 7 Cooling System ENGINE COOLANT TEMPERATURE SENSOR 4 0L ENGINE The coolant temperature sensor is installed in the thermostat housing Fig 84 REMOVAL 1 Partially drain cooling system until the coolant level is below the cylinder head Observe the WARN INGS in Group 7 Cooling 2 Disconnect the coolant temperature sensor wire connector 3 Remove the sensor from the thermostat hous ing INS...

Page 1106: ...cle speed sensor is located on the speed ometer pinion gear adapter Fig 87 The pinion gear adapter is located on the extension housing of the transmission drivers side REMOVAL 1 Raise and support vehicle 2 Disconnect the electrical connector from the sensor 3 Remove the sensor mounting bolt Fig 88 4 Remove the sensor pull straight out from the speedometer pinion gear adapter Fig 88 Do not remove t...

Page 1107: ...bel The VECI label is located in the engine compartment TORQUE CHART DESCRIPTION TORQUE Air Cleaner Housing Mount Nuts 10 N m 93 in lbs Engine Coolant Temperature Sensor All Engines 11 N m 96 in lbs Fuel Hose Clamps 1 N m 10 in lbs IAC Motor To Throttle Body Bolts 7 N m 60 in lbs Intake Manifold Air Temp Sensor All Engines 28 N m 20 ft lbs MAP Sensor Mounting Screws All Engines 3 N m 25 in lbs Oxy...

Page 1108: ... Sensor Remover Installer C 4907 Test Kit Fuel Pressure 5069 Test Kit Fuel Pressure C 4799 B Fuel Line Removal Tool 6782 Spanner Wrench 6856 Fitting Air Metering 6714 Adapters Fuel Pressure Test 6541 6539 6631 or 6923 ZJ FUEL SYSTEM 14 63 ...

Page 1109: ......

Page 1110: ...RING LINKAGE 28 POWER STEERING INDEX page page GENERAL INFORMATION STEERING SYSTEM 1 DIAGNOSIS AND TESTING POWER STEERING SYSTEM DIAGNOSIS CHARTS 2 GENERAL INFORMATION STEERING SYSTEM The power steering system consists of Hydraulic pump Recirculating ball steering gear Steering column Steering linkage Power Steering Gear Pump ZJ STEERING 19 1 ...

Page 1111: ...e 3 Inspect and repair steering linkage 4 Internal gear noise 4 Replace gear 5 Pressure hose in contact with other components 5 Reposition hose CHIRP OR SQUEAL 1 Loose belt 1 Adjust or replace WHINE OR GROWL 1 Low fluid level 1 Fill to proper level 2 Pressure hose in contact with other components 2 Reposition hose 3 Internal pump noise 3 Replace pump SUCKING AIR SOUND 1 Loose return line clamp 1 R...

Page 1112: ... of lubrication 3 Inspect and lubricate steering and suspension compnents 4 High friction in steering gear 4 Test and repair as necessary LOOSE STEERING AND VEHICLE LEAD CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE PLAY IN STEERING WHEEL 1 Worn or loose suspension or steering components 1 Inspect and repair as necessary 2 Worn or loose wheel bearings 2 Inspect and repair or adjust bearings 3 Stee...

Page 1113: ...alve inside the flow control valve limits the pump pressure The reservoir is attached to the pump body with spring clips The power steering pump is connected to the steering gear by the pressure and return hoses The pump shaft has a pressed on drive pulley that is belt driven by the crank shaft pulley Fig 1 NOTE Power steering pumps have different pressure rates and are not interchangeable with ot...

Page 1114: ...ressure chart CAUTION Do not force the pump to operate against the stops for more than 2 to 4 seconds at a time because pump damage will result 9 Open the test valve turn steering wheel extreme left and right positions against the stops Record the highest indicated pressure at each posi tion Compare readings to specifications If highest output pressures are not the same against either stop the gea...

Page 1115: ...lley on pump 2 Install pump on engine 3 Tighten pump bracket bolts to 47 N m 35 ft lbs 4 Install 3 pump mounting bolts and tighten to 27 N m 20 ft lbs 5 Install the pressure and return hoses to pump 6 Vehicles equipped with Speed Pro Steering connect actuator harness 7 Install drive belt refer to Group 7 Cooling 8 Add power steering fluid Refer to Power Steer ing Pump Initial Operation in this sec...

Page 1116: ...h Serpentine Belts Run engine until warm 5 min and note any belt chirp If chirp exists move pulley outward approximately 0 5 mm 0 020 in If noise increases press on 1 0 mm 0 040 in Be careful that pulley does not contact mounting bolts TC SERIES PUMP RESERVOIR REMOVAL 1 Remove power steering pump 2 Clean exterior of pump with solvent 3 Clamp the pump body in a soft jaw vice 4 Pry up tab and slide ...

Page 1117: ... Pump Bolts 27 N m 20 ft lbs Flow Control Valve 75 N m 55 ft lbs Pressure Line 28 N m 21 ft lbs SPECIAL TOOLS POWER STEERING PUMP Puller C 4333 Installer Power Steering Pulley C 4063 B Analyzer Set Power Steering Flow Pressure 6815 Adapters Power Steering Flow Pressure Tester 6893 19 8 STEERING ZJ ...

Page 1118: ...19 TORQUE CHART 20 SPECIAL TOOLS POWER STEERING GEAR 20 DESCRIPTION AND OPERATION POWER STEERING GEAR The power steering gear is a recirculating ball type gear The gear acts as a rolling thread between the worm shaft and rack piston The worm shaft is supported by a thrust bearing at the lower end and a bearing assembly at the upper end When the worm shaft is turned the rack piston moves The rack p...

Page 1119: ... washer 5 Install the retainer ring with snap ring pliers 6 Install single lip dust seal with a suitable size deep socket 7 Center the steering gear and install pitman arm 8 Add power steering fluid refer to Power Steer ing Initial Operation STEERING GEAR REMOVAL 1 Place the front wheels in the straight ahead position with the steering wheel centered 2 Remove and cap the pressure and return hoses ...

Page 1120: ...pitman shaft assembly and side cover to housing 5 Install side cover bolts and tighten to 60 N m 44 ft lbs 6 Adjust pitman shaft refer to Over Center Adjustment HOUSING END PLUG Steering gear must be removed from the vehicle for this procedure REMOVAL 1 Rotate retaining ring until one end is under the hole in the housing Unseat and force ring from groove Fig 6 2 Rotate stub shaft slowly COUNTER CL...

Page 1121: ...ust be removed from the vehicle for this procedure REMOVAL 1 Remove adjuster plug lock nut from housing 2 Remove adjuster plug from housing with Span ner Wrench C 4381 Fig 9 3 Remove thrust washer bearing retainer from adjuster plug with screwdriver Fig 10 4 Remove bearing spacer races and thrust bear ing Fig 11 5 Remove O ring seal and retaining snap ring Fig 6 End Plug Retaining Ring Fig 7 End P...

Page 1122: ...y and install dust seal into adjuster plug with remover installer C 4177 and handle C 4171 4 Install retainer snap ring 5 Install O ring seal to adjuster plug 6 Install large bearing race thrust bearing small bearing race and bearing spacer to adjuster plug 7 Install thrust washer bearing retainer to adjuster plug Fig 13 CAUTION When installing adjuster plug care should be taken not to cut the sea...

Page 1123: ...en shaft cap Then pull cap and valve body and disengage stub shaft pin from hole in valve body Fig 16 4 Remove valve spool by pulling and rotating from valve body Fig 17 5 Remove valve spool O ring seal and valve body teflon rings and O ring seals Fig 18 INSTALLATION CAUTION Speed Proportional Steering has a differ ent spool valve Do not interchange valves Steering response will be affected if wro...

Page 1124: ... AND WORM SHAFT Steering gear must be removed from the vehicle for this procedure REMOVAL 1 Remove pitman shaft and side cover 2 Remove housing end plug 3 Turn stub shaft COUNTERCLOCKWISE until the rack piston begins to come out of the housing 4 Remove rack piston plug Fig 20 5 Insert Arbor C 4175 into bore of rack piston Fig 21 Hold tool tightly against worm shaft while turning the stub shaft COU...

Page 1125: ...e balls in the rack piston circuit The black balls are smaller than the silver balls The balls must be installed alternately into the rack piston and ball guide This procedure will maintain worm shaft pre load 5 Lubricate and install rack piston balls through return guide hole while turning worm shaft COUN TERCLOCKWISE WARNING MAKE SURE ALL RACK PISTON BALLS ARE INSTALLED PROPERLY IMPROPER INSTALL...

Page 1126: ...ston plug and tighten to 150 N m 111 ft lbs 16 Install housing end plug 17 Install pitman shaft and side cover 18 Adjust steering gear PITMAN SHAFT SEALS AND BEARING REMOVAL 1 Remove pitman arm from gear 2 Clean exposed end of pitman shaft and housing with a wire brush 3 Remove single lip dust seal 4 Remove retaining ring with snap ring pliers Fig 26 5 Remove backup washers with screwdriver CAUTIO...

Page 1127: ...tments WORM THRUST BEARING PRELOAD 1 Remove adjuster plug locknut Fig 28 2 Turn the adjuster in with Spanner Wrench C 4381 Tighten the plug and thrust bearing in the housing until firmly bottomed in housing 3 Place an index mark on the housing even with one of the holes in adjuster plug Fig 29 4 Measure back counterclockwise 13 mm 0 50 in and mark housing Fig 30 5 Rotate adjustment cap back counte...

Page 1128: ... to 1 2 N m 6 0 to 10 0 in lbs more than previous reading recorded 6 Prevent the adjuster screw from turning while tightening adjuster lock nut Tighten the adjuster lock nut to 27 N m 20 ft lbs SPECIFICATIONS POWER STEERING GEAR Steering Gear Type Recirculating Ball Gear Code and Ratio BH NZ 14 1 BF XS 13 16 1 AL 12 7 1 Worm Shaft Bearing Preload 0 45 1 13 N m 4 10 in lbs Pitman Shaft Overcenter D...

Page 1129: ...Rack Piston Plug 150 N m 111 ft lbs Side Cover Bolts 60 N m 44 ft lbs Pressure Line 28 N m 21 ft lbs Return Line 28 N m 21 ft lbs Return Guide Clamp Bolt 58 N m 43 ft lbs SPECIAL TOOLS POWER STEERING GEAR Remover Pitman Shaft Bearing C 4177 Handle C 4171 Remover Installer Steering Rack Piston C 4175 Remover Installer Steering Plug C 4381 Remover Pitman Arm C 4150A 19 20 STEERING ZJ SPECIFICATIONS ...

Page 1130: ...SYSTEM IS A SENSITIVE COMPLEX ELECTRO MECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE REMOVE OR INSTALL THE AIRBAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGI NALLY USED FOR THE AIRBAG COMPONENTS HAVE SPECIAL COATINGS AND...

Page 1131: ...lot If the slider binds in the slot at any point lightly file the slider until clearance is achieved 4 If no binding is found lightly file the ramp on the ignition switch The ramp fits into the casting until binding no longer occurs REMOVAL AND INSTALLATION STEERING COLUMN CAUTION Bumping jolting and hammering on the steering column shaft and gear shift tube must be avoided during all service proc...

Page 1132: ...arness from steering col umn Fig 8 12 Remove the Interlock cable from the steering column Refer to Group 3 Differential and Driveline 13 Remove the toe plate to dash panel nuts 14 Remove the panel bracket nuts studs and remove the column INSTALLATION CAUTION If vehicle is equipped with Speed Pro portional Steering do not transfer Wheel Speed Sensor to replacement column Install new sensor only on ...

Page 1133: ...5 in lbs Ensure the nut is installed on the SHORT threaded side of the stud 7 Tighten the toe plate attaching nuts to 12 N m 105 in lbs 8 Tighten the coupler pinch bolt to 49 N m 36 ft lbs 9 Install the heater cross over tube under the col umn 10 Install the upper and lower shrouds Install the tilt lever if equipped 11 Install the trim panel column cover and sup port plate 12 Install the steering ...

Page 1134: ...ower assist providing the driver with a better feel for the road and improved directional stability When a quick steering maneuver is made while the system is operating at reduced power assist full assist is provided for the maneuver SPEED PROPORTIONAL STEERING CONTROL MODULE The control module is mounted to a bracket on the passenger side of the front cowl panel just left of the steering column F...

Page 1135: ...Group 8M Elec trical for procedure 5 Pry sensor retaining ring tabs up and remove sensor Fig 5 INSTALLATION CAUTION Never install a used sensor Once the sensor has been removed it must be replace with a new sensor 1 Install new sensor on column shaft with a piece of thin wall conduit 3 inch long by 3 4 inch ID Move turn signal canceler off to one side and ensure locat ing tab is in the proper posi...

Page 1136: ...TROL MODULE REMOVAL 1 Unplug harness from control module located left of steering column on front cowl panel 2 Slid the module off mounting bracket Fig 6 INSTALLATION 1 Slid module onto mounting bracket 2 Plug harness into module Fig 5 Steering Wheel Speed Sensor Fig 6 Speed Proportional Steering Control Module ZJ STEERING 19 27 REMOVAL AND INSTALLATION Continued ...

Page 1137: ...wear or corrosion If these conditions exist replace the tie rod A replacement seal can be installed if lubricant is in good condition Otherwise a complete replacement ball stud end should be installed Lubricate the tie rod end with MOPARt Multi Mileage Lubricant or equivalent product NOTE Use a Puller tool C 3894 A for tie rod removal Failure to use this tool could damage the ball stud and seal Fi...

Page 1138: ...l nut and tighten to 81 N m 60 ft lbs Install a new cotter pin DRAG LINK REMOVAL 1 Remove the cotter pins and nuts at the steer ing knuckle and drag link Fig 1 2 Remove the steering dampener ball stud from the drag link with a puller tool 3 Remove the drag link from the steering knuckle with a puller tool Remove the same for tie rod and pitman arm 4 If necessary loosen the end clamp bolts and remo...

Page 1139: ...bs Install a new cot ter pin SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Pitman Arm Shaft Nut 251 N m 185 ft lbs Drag Link Pitman Arm Nut 81 N m 60 ft lbs Knuckle Nut 47 N m 35 ft lbs 4 0L Clamp Bolts 27 N m 20 ft lbs 5 2L Clamp Bolts 49 N m 36 ft lbs Tie Rod Ends Ball Stud Nut 47 N m 35 ft lbs 4 0L Clamp Bolts 27 N m 20 ft lbs 5 2L Clamp Bolts 49 N m 36 ft lbs Tie Rod Ball Stud Nut 47 N m 35 f...

Page 1140: ...ERTER HOUSING FLUID LEAK DIAGNOSIS 16 CONVERTER STALL TEST 15 DIAGNOSIS TABLES AND CHARTS RE TRANSMISSION 19 EFFECTS OF INCORRECT FLUID LEVEL 10 FLUID CONTAMINATION 10 GEARSHIFT CABLE 11 HYDRAULIC PRESSURE TEST 13 OIL COOLER FLOW CHECK 11 OVERDRIVE ELECTRICAL CONTROLS 11 PARK NEUTRAL POSITION SWITCH 9 PRELIMINARY DIAGNOSIS 9 ROAD TESTING 12 STALL TEST ANALYSIS 15 TRANSMISSION CONTROL CABLE ADJUSTM...

Page 1141: ...third gear ranges are provided by the clutches bands overrunning clutch and planetary gear sets in the transmission Fourth gear range is provided by the overdrive unit that contains an over drive clutch direct clutch planetary gear set and overrunning clutch The overdrive clutch is applied in fourth gear only The direct clutch is applied in all ranges except fourth gear The 42 44 RE is equipped wi...

Page 1142: ...Fig 1 42 44 RE Transmission ZJ TRANSMISSION AND TRANSFER CASE 21 3 GENERAL INFORMATION Continued ...

Page 1143: ...es the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and is serviced as an assembly CAUTION The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid If the fluid is contaminated flush the fluid cooler and lines TRANSMISSION GEAR RATIOS 42 44 RE forward gear ratios are 2 7...

Page 1144: ...mission fluid temperature readings are sup plied to the transmission control module by the ther mistor Fig 5 The temperature readings are used to control engagement of the fourth gear overdrive clutch the converter clutch and governor pressure Normal resistance value for the thermistor at room temperature is approximately 1000 ohms The PCM prevents engagement of the converter clutch and overdrive ...

Page 1145: ...electrical components The conditions under which a shift to fourth will not occur when Overdrive switch is Off Transmission fluid temperature is below 10 C 50 F or above 121 C 250 F Shift to third not yet completed Vehicle speed too low for 3 4 shift to occur HYDRAULIC CONTROL SYSTEM The hydraulic control system provides fully auto matic operation The system performs five basic func tions which ar...

Page 1146: ...tron ically controlled and hydraulically activated Various sensor inputs are supplied to the powertrain control module to operate the overdrive solenoid on the valve body The solenoid contains a check ball that opens and closes a vent port in the 3 4 shift valve feed pas sage The overdrive solenoid and check ball are not energized in first second third or reverse gear The vent port remains open di...

Page 1147: ...d system It interconnects the automatic transmission floor mounted shifter to the steering column ignition switch Fig 7 The system locks the shifter into the PARK position The Interlock system is engaged whenever the ignition switch is in the LOCK or ACCESSORY position An additional electrically acti vated feature will prevent shifting out of the PARK position unless the brake pedal is depressed a...

Page 1148: ...o not problem is with differential or axle shafts b If propeller shaft does not turn and transmis sion is noisy stop engine Remove oil pan and check for debris If pan is clear remove transmis sion and check for damaged drive plate converter oil pump or input shaft c If propeller shaft does not turn and transmis sion is not noisy perform hydraulic pressure test to determine if problem is hydraulic ...

Page 1149: ...luid level allows the pump to take in air along with the fluid Air in the fluid will cause fluid pressures to be low and develop slower than normal If the transmission is overfilled the gears churn the fluid into foam This aerates the fluid and causing the same conditions occurring with a low level In either case air bubbles cause fluid overheating oxi dation and varnish buildup which interferes w...

Page 1150: ... is necessary Refer to Group 8W Wiring Dia grams for component locations and circuit informa tion Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range BRAKE TRANSMISSION SHIFT INTERLOCK 1 Verify that the key can only be removed in the PARK position 2 When the shift lever is in PARK And the shift handle pushbutton is in the OUT position th...

Page 1151: ...ns and engine flare which indicates slippage Note if shifts are harsh spongy delayed early or if part throttle downshifts are sensitive Slippage indicated by engine flare usually means clutch band or overrunning clutch problems If the condition is advanced an overhaul will be necessary to restore normal operation A slipping clutch or band can often be determined by comparing which internal units a...

Page 1152: ...se 100 psi Gauge C 3292 to check pressure at the accu mulator front servo and governor Use 300 psi Gauge C 3293 SP to check pressure at the rear servo and overdrive port Pressure Test Port Locations Pressure test ports locations are provided at the accumulator front servo and rear servo governor passage and overdrive clutch pressure passage Fig 12 An accurate tachometer and two test gauges are req...

Page 1153: ...Fig 12 2 Start and run engine at 1600 rpm for test 3 Move valve body selector lever four detents rearward from the full forward position This is Reverse range 4 Move throttle lever all way forward then all way rearward and note gauge readings 5 Pressure should be 145 175 psi 1000 1207 kPa with lever forward and increase to 230 280 psi 1586 1931 kPa as lever is moved rearward Test Five Governor Pre...

Page 1154: ...accelerator pedal imme diately transmission clutch slippage is occurring 7 If a second stall test is required cool down fluid before proceeding Shift into NEUTRAL and run engine at 1000 rpm for 20 30 seconds to cool fluid 8 Refer to Stall Test Analysis STALL TEST ANALYSIS Stall Speed Too High If the stall speed exceeds 1800 2300 rpm by more than 200 rpm transmission clutch slippage is indi cated S...

Page 1155: ...urce of the leak Some suspected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter housing or excess fluid spilled during factory fill or fill after repair Converter housing leaks have several potential sources Through careful observation a leak source can be identified before removing the transmission for repair Pump seal leaks ten...

Page 1156: ...s coming through the solution Some transmission openings such as the fill tube and front cooler line fitting can be closed off with a rubber plug or similar device Plugs can secured with wire or duct tape The transmission rear output shaft opening is closed off simply by leaving the transfer case bolted in place However if the transfer case has been removed a shipping plug can used to close off th...

Page 1157: ...ear cooler line fit ting Connect a length of copper tube to fitting Then attach pump hose to tube with hose clamp Fig 23 4 Apply a thick soapy water solution to suspected leak areas CAUTION The recommended test pressure is 8 psi The maximum allowable test pressure is 10 psi Do not exceed specified pressure 5 Pressurize transmission to 8 psi with air pump 6 Observe suspected leak areas Air bubbles ...

Page 1158: ...f this group outline fluid flow and hydraulic circuitry Circuit operation is provided for neutral third fourth and reverse gear ranges Nor mal working pressures are also supplied for each of the gear ranges CONDITION POSSIBLE CAUSES CORRECTION HARSH ENGAGEMENT 1 Fluid Level Low 1 Add Fluid FROM NEUTRAL TO DRIVE OR REVERSE 2 Throttle Linkage Misadjusted 2 Adjust linkage setting may be too long 3 Mo...

Page 1159: ...ut Shaft Rear Clutch Seal Rings Damaged 11 Remove and disassemble transmission and repair as necessary 12 Governor Valve Stuck 12 Remove and inspect governor components Replace worn or damaged parts 13 Regulator Valve Stuck 13 Clean 14 Cooler Plugged 14 Transfer case failure can plug cooler NO DRIVE RANGE REVERSE OK 1 Fluid Level Low 1 Add fluid and check for leaks if drive is restored 2 Gearshift...

Page 1160: ...failed components as needed 8 Park Sprag not Releasing Check Stall Speed Worn Damaged Stuck 8 Remove disassemble repair 9 Torque Converter Damage 9 Inspect and replace as required SHIFTS DELAYED OR ERRATIC SHIFTS ALSO HARSH AT TIMES 1 Fluid Level Low High 1 Correct fluid level and check for leaks if low 2 Fluid Filter Clogged 2 Replace filter If filter and fluid contained clutch material or metal ...

Page 1161: ... 2 Valve Body Malfunction 2 Repair stuck 1 2 shift valve or governor plug 3 Front Servo Kickdown Band Damaged Burned 3 Repair replace MOVES IN 2ND OR 3RD GEAR ABRUPTLY 1 Valve Body Malfunction 1 Remove clean and inspect Look for stuck 1 2 valve or governor plug DOWNSHIFTS TO LOW 2 Governor Valve Sticking 2 Remove clean and inspect Replace faulty parts 3 Governor Circuit RE Only Electrical Fault 3 ...

Page 1162: ...sadjusted 2 Adjust linkage and repair linkage if worn or damaged 3 Governor Valve Body Governor Valve Stuck Closed Loose Output Shaft Support or Governor Housing Bolts Leaking Seal Rings or Valve Body Problem i e Stuck 1 2 Shift Valve Gov Plug 3 Check line and governor pressures to determine cause Correct as required 4 Governor Component RE Only Electrical Fault 4 Check operating pressures and tes...

Page 1163: ... bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage Misadjusted 3 Adjust linkage 4 Gearshift Linkage Misadjusted 4 Adjust linkage 5 Rear Clutch Worn 5 Inspect and replace as needed 6 Low Hydraulic Pressure Due to Worn Pump Incorrect Control Pressure Adjustments Valve Body Warpage or Malfunction Sticking Governor Leaking Seal Rings Cl...

Page 1164: ...h Dragging 8 Check for plugged cooler Perform flow check Inspect pump for excessive side clearance Replace pump as required NO 4 3 DOWNSHIFT 1 Circuit Wiring and or Connectors Shorted 1 Test wiring and connectors with test lamp and volt ohmmeter Repair wiring as necessary Replace connectors and or harnesses as required 2 PCM Malfunction 2 Check PCM operation with DRB scan tool Replace PCM only if ...

Page 1165: ...r correct routing Should not touch engine or bell housing NO 3 4 UPSHIFT 1 Dash O D Switch In OFF Position 1 Turn control switch to ON position 2 Overdrive Circuit Fuse Blown 2 Replace fuse Determine why fuse failed and repair as necessary i e shorts or grounds in circuit 3 O D Switch Wire Shorted Open Cut 3 Check wires connections with 12V test lamp and voltmeter Repair damaged or loose wire conn...

Page 1166: ...or seals Make sure all valves operate freely in bores and do not bind or stick Make sure valve body screws are correctly tightened and separator plates are properly positioned 6 Overdrive Unit Thrust Bearing Failure 6 Disassemble overdrive unit and replace thrust bearing NO 1 thrust bearing is between overdrive piston and clutch hub NO 2 thrust bearing is between the planetary gear and the direct ...

Page 1167: ...ble unit and rebuild clutch pack 2 Rear Band Misadjusted 2 Adjust band 3 Front Clutch Malfunctioned Burned 3 Air pressure test clutch operation Remove and rebuild if necessary 4 Overdrive Thrust Bearing Failure 4 Disassemble geartrain and replace bearings 5 Direct Clutch Spring Collapsed Broken 5 Remove and disassemble unit Check clutch position and replace spring OIL LEAKS ITEMS LISTED REPRESENT ...

Page 1168: ...cle is used for trailer towing or similar heavy load hauling check fluid level and condition weekly Fluid level is checked with the engine running at curb idle speed the transmission in NEUTRAL and the transmission fluid at normal operating temperature FLUID LEVEL CHECK PROCEDURE 1 Transmission fluid must be at normal operat ing temperature for accurate fluid level check Drive vehicle if necessary...

Page 1169: ...r fiber contamination A light coating of clutch or band material on the bottom of the pan does not indicate a problem unless accompa nied by slipping condition or shift lag If fluid and pan are contaminated with excessive amounts or debris refer to the diagnosis section of this group Check the adjustment of the front and rear bands adjust if necessary Refer to Adjustment section of this group for ...

Page 1170: ...ocedure is exactly the same as for flow testing a cooler If the valve is restricted installed backwards or in the wrong line it will cause an overheating condition and possible transmission failure CAUTION The drainback valve is a one way flow device It must be properly oriented in terms of flow direction for the cooler to function properly The valve must be installed in the pressure line Other wi...

Page 1171: ...ine Observe for the presence of debris in the exiting fluid Con tinue until fluid exiting is clear and free from debris 3 Using compressed air under 40 psi in inter mittent spurts blow any remaining mineral spirits from the cooler again in the reverse direction 4 Pump one 1 quart of automatic transmission fluid through the cooler before reconnecting 5 If at any stage of the cleaning process the co...

Page 1172: ...ify that switch operating lever fingers are cen tered in switch opening in case Fig 30 5 Install new seal on switch and install switch in case Tighten switch to 34 N m 25 ft lbs torque 6 Test continuity of new switch with 12V test lamp 7 Connect switch wires and lower vehicle 8 Top off transmission fluid level YOKE SEAL REPLACEMENT REMOVAL 1 Raise vehicle 2 Mark propeller shaft and axle yoke for a...

Page 1173: ...0 INSTALLATION 1 Align bushing oil hole with oil slot in overdrive housing 2 Tap bushing into place with driver handle and Tool C 4171 and C 4469 Fig 33 3 Install new oil seal in housing using Seal Installer C 3972 A OUTPUT SHAFT REAR BEARING REMOVAL 1 Remove overdrive unit from the vehicle 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft rear bearing into overdriv...

Page 1174: ...juster into transmission bracket but do not lock adjuster at this time 3 Lower vehicle enough to permit access to shift lever 4 Connect new cable to shift lever Be sure lever is still in Park position before proceeding Also be sure cable is not kinked or twisted 5 Raise vehicle and connect cable eyelet to trans mission shift lever Then lock cable by pressing adjuster lock button inward until it sn...

Page 1175: ...housing CAUTION Do not over stress snap ring during removal snap ring distortion can result 4 Remove snap ring holding reaction plug in overdrive housing 5 Pull park pawl shaft from housing 6 Separate park pawl park pawl spring and reaction plug from overdrive housing Fig 38 INSTALLATION 1 Place park pawl park pawl spring and reac tion plug in position in overdrive housing 2 Insert park pawl shaft...

Page 1176: ... Place gasket in position on back of governor body Fig 42 6 Place governor body in position on valve body 7 Install bolts to hold governor body to valve body 8 Lubricate O ring on pressure solenoid with transmission fluid 9 Align pressure solenoid to bore in governor body Fig 41 10 Push solenoid into governor body 11 Place solenoid retainer in position on governor Fig 40 12 Install screws to hold ...

Page 1177: ... Fig 44 6 Position drain pan under transmission oil pan 7 Remove transmission oil pan and gasket 8 Remove fluid filter from valve body 9 Remove bolts attaching valve body to transmis sion case 10 Lower valve body enough to remove accumu lator piston and springs 11 Work manual lever shaft and electrical con nector out of transmission case Then lower valve body rotate it away from case pull park rod...

Page 1178: ...s torque 13 Install and connect park neutral position switch in case 14 Install throttle and gearshift levers on valve body manual lever shaft 15 Check and adjust front and rear bands if nec essary 16 Connect valve body overdrive and converter clutch solenoid wires to case connector 17 Install oil pan and new gasket Tighten pan bolts to 17 N m 13 ft lbs torque 18 Lower vehicle and fill transmissio...

Page 1179: ...n refer ence Fig 50 5 Position drain pan under cooler lines 6 Loosen cooler lines and remove auxiliary cooler 7 Connect cooler lines to replacement auxiliary cooler and position cooler on radiator or support Then install cooler brackets and attaching fasteners Tighten cooler line fittings and hose clamps securely 8 If condenser was removed install condenser and evacuate and recharge air conditioni...

Page 1180: ...overdrive unit does not require any service leave alignment tool in position Tool will prevent accidental misalignment of planetary gear and over running clutch splines INSTALLATION 1 Be sure overdrive unit Alignment Tool 6227 2 is fully seated before moving unit If tool is not seated and gear splines rotate out of alignment over drive unit may have to be disassembled in order to realign splines 2...

Page 1181: ...transmission assembly to perform overdrive unit repairs The entire transmission assembly must be removed in order to service the torque converter driveplate ring gear and oil pump Refer to the transmission removal and installation procedures in this section If only the overdrive unit requires service refer to the overdrive unit removal and installation proce dures CAUTION The transmission and torq...

Page 1182: ...on and crossmember Raise trans mission slightly slide exhaust hanger arm from bracket Fig 57 and Fig 58 and remove rear sup port 21 Remove bolts attaching crossmember to frame and remove crossmember 22 On 4 x 4 models disconnect speed sensor wires and vent hose from transfer case Then remove transfer case with transmission jack or aid of helper 23 Remove all converter housing bolts 24 Carefully wo...

Page 1183: ...o snap rod into grommet at assembly 20 Connect gearshift and throttle cable to trans mission 21 Connect wires to park neutral position switch transmission solenoid s and oxygen sensor Be sure transmission harnesses are properly routed CAUTION It is essential that correct length bolts be used to attach the converter to the driveplate Bolts that are too long will damage the clutch sur face inside th...

Page 1184: ... housing 8 Install the transmission in the vehicle 9 Fill the transmission with the recommended fluid DISASSEMBLY AND ASSEMBLY VALVE BODY Remove the valve body from the transmission refer to Removal and Installation procedures section in this group VALVE BODY MAIN COMPONENT DISASSEMBLE CAUTION Do not clamp any valve body compo nent in a vise This practice can damage the com ponent resulting in uns...

Page 1185: ...card solenoid O rings if worn cut or torn 7 Remove small shoulder bolt that secures sole noid harness case connector to 3 4 accumulator hous ing Fig 66 Retain shoulder bolt Either tape it to harness or thread it back into accumulator housing after connector removal 8 Unhook overdrive converter solenoid harness from 3 4 accumulator cover plate Fig 67 Fig 65 Governor Pressure Solenoid Fig 66 Solenoi...

Page 1186: ...ve boost valve cover Fig 70 12 Remove boost valve retainer valve spring and boost valve Fig 71 13 Secure detent ball and spring with Retainer Tool 6583 Fig 72 Fig 68 Solenoid Assembly Screws Fig 69 Solenoid Assembly Fig 70 Boost Valve Cover Location Fig 71 Boost Valve Components Fig 72 Detent Ball And Spring ZJ TRANSMISSION AND TRANSFER CASE 21 47 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1187: ...ully remove Retainer Tool 6583 and remove detent ball and spring Fig 75 17 Remove park rod E clip and separate rod from manual lever Fig 76 18 Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate Fig 77 Hold bracket firmly against spring tension while removing last screw Fig 73 Throttle Lever E Clip And Washer Fig 74 Manual And Throttle Lever Fig 75 Detent Ball...

Page 1188: ... 21 Carefully rotate 3 4 accumulator housing upward and remove 3 4 shift valve spring and con verter clutch valve plug and spring Fig 80 22 Remove left side screw and remove 3 4 accu mulator housing from valve body Fig 81 23 Remove pressure regulator valve spring from lower housing Fig 82 Fig 78 Adjusting Screw Bracket And Spring Fig 79 Accumulator Housing Screw Locations Fig 80 3 4 Shift And Conv...

Page 1189: ...and transfer plate Fig 85 Note position of boost valve tube brace for assembly reference 28 Remove lower housing and overdrive separa tor plate from transfer plate Fig 85 29 Remove transfer plate from upper housing Fig 86 30 Turn transfer plate over so upper housing sep arator plate is facing upward 31 Remove brace plate from lower housing sepa rator plate and transfer plate Fig 87 32 Remove upper...

Page 1190: ... retainer spring and valve if not previously removed 6 Turn upper housing over and remove switch valve regulator valve and spring and manual valve Fig 93 7 Remove kickdown detent kickdown valve and throttle valve and spring Fig 93 8 Remove throttle plug and 1 2 and 2 3 governor plugs Fig 93 Also remove shuttle valve primary spring if not removed in prior step Fig 90 Check Ball Locations In Upper H...

Page 1191: ...Fig 92 Shuttle And Boost Valve Components Fig 93 Upper Housing Control Valve Locations 21 52 TRANSMISSION AND TRANSFER CASE ZJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1192: ...LY 1 Remove end plate from housing 2 Remove piston spring 3 Remove piston Remove and discard piston seals Fig 96 VALVE BODY ASSEMBLE CAUTION Do not force valves or plugs into place during reassembly If the valve body bores valves and plugs are free of distortion or burrs the valve body components should all slide into place easily In addition do not overtighten the transfer plate and valve body sc...

Page 1193: ... 1 Install rear clutch and rear servo check balls in transfer plate Fig 97 2 Install filter screen in upper housing separator plate Fig 98 3 Align and position upper housing separator plate on transfer plate Fig 99 4 Install brace plate Fig 99 Tighten brace attaching screws to 4 N m 35 in lbs torque 5 Install remaining separator plate attaching screws Tighten screws to 4 N m 35 in lbs torque ASSEM...

Page 1194: ...late and upper housing Fig 103 5 Install and start valve body screws by hand Then tighten screws evenly to 4 N m 35 in lbs torque Start at center and work out to sides when tightening screws Fig 103 UPPER HOUSING VALVE AND PLUG INSTALLATION Refer to Fig 104 Fig 105 and Fig 106 to per form the following steps 1 Lubricate valves plugs springs with clean transmission fluid Fig 100 Check Ball Location...

Page 1195: ... shuttle valve as follows a Insert plastic guides in shuttle valve second ary spring and install spring on end of valve b Hold shuttle valve in place c Compress secondary spring and install E clip in groove at end of shuttle valve d Verify that spring and E clip are properly seated before proceeding Fig 103 Installing Lower Housing On Transfer Plate And Upper Housing Fig 104 Shuttle And Boost Valv...

Page 1196: ...to 4 N m 35 in lbs torque 8 Install 1 2 and 2 3 valve governor plugs in valve body Fig 105 Upper Housing Control Valve Locations Fig 106 Upper Housing Shift Valve And Pressure Plug Locations ZJ TRANSMISSION AND TRANSFER CASE 21 57 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1197: ...nger tighten three screws that secure tube brace to valve body housings Fig 108 7 Bend tube brace tabs up and against tube to hold it in position Fig 109 8 Tighten all valve body housing screws to 4 N m 35 in lbs torque after tube and brace are installed Tighten screws in diagonal pattern starting at center and working outward 3 4 ACCUMULATOR INSTALLATION 1 Position converter clutch valve and 3 4 ...

Page 1198: ... short upper bracket screws first and long bot tom screw last Verify that valve springs and bracket are properly aligned Then tighten all three bracket screws to 4 N m 35 in lbs torque 6 Install throttle lever in upper housing Then install manual lever over throttle lever and start manual lever into housing 7 Position detent ball on end of spring Then hold detent ball and spring in detent housing ...

Page 1199: ...ensor O rings with clean transmission fluid 4 Install governor pressure sensor in governor body Then secure sensor with M shaped retaining clip Fig 117 5 Install governor pressure solenoid in governor body Fig 118 Push solenoid in until it snaps into place in body 6 Position governor body gasket on transfer plate Fig 119 7 Install retainer plate on governor body and around solenoid Fig 120 Be sure...

Page 1200: ...cleaning operations 4 Remove shift and throttle levers from valve body manual lever shaft 5 Remove transmission speed sensor and O ring seal from overdrive unit Fig 122 Fig 118 Governor Pressure Solenoid Fig 119 Governor Body And Gasket Fig 120 Pressure Solenoid Retainer Fig 121 Governor Pressure Sensor And Solenoid Connectors Fig 122 Transmission Speed Sensor Removal Installation ZJ TRANSMISSION ...

Page 1201: ...plate from overdrive piston Fig 126 10 Place transmission in horizontal position 11 Remove transmission oil pan and gasket 12 Remove oil filter from valve body Fig 127 Keep filter screws separate from other valve body screws Filter screws are longer and should be kept with filter 13 Remove overdrive piston from retainer Fig 128 14 Remove pump oil seal with Special Tool C 3981B Fig 129 Be sure to t...

Page 1202: ...outer springs Fig 133 19 Remove front band lever shaft access plug Fig 134 Plug is accessible through converter hous ing Use 1 4 inch drive extension to remove plug as shown 20 Loosen front band adjusting screw locknut 4 5 turns Then tighten band adjusting screw until band Fig 130 Park Neutral Position Switch Removal Installation Fig 131 Valve Body Bolt Locations Fig 127 Oil Filter Removal Install...

Page 1203: ...remove pump and reaction shaft support assembly from case Fig 135 24 Loosen front band adjusting screw until band is completely loose 25 Squeeze front band together and remove band strut Fig 136 Fig 134 Removing Installing Front Band Lever Shaft Access Plug Fig 135 Removing Oil Pump And Reaction Shaft Support Assembly Fig 136 Removing Installing Front Band Strut Fig 132 Valve Body Removal Fig 133 ...

Page 1204: ...l 29 Remove front and rear clutch units as assem bly Grasp input shaft hold clutch units together and remove them from case Fig 139 30 Lift front clutch off rear clutch Fig 140 Set clutch units aside for overhaul Fig 137 Removing Front Band Lever Shaft Fig 138 Removing Installing Front Band Lever Fig 139 Removing Front Rear Clutch Assemblies Fig 140 Separating Front Rear Clutch Assemblies ZJ TRANS...

Page 1205: ...44 Support geartrain with both hands during removal Do not allow machined surfaces on interme diate shaft or overdrive piston retainer to become nicked or scratched 35 Loosen rear band adjusting screw 4 5 turns Fig 143 Front Band Removal Installation Fig 144 Removing Planetary Geartrain And Intermediate Shaft Assembly Fig 141 Removing Intermediate Shaft Thrust Washer Fig 142 Removing Intermediate ...

Page 1206: ... to remove them 39 Remove rear band lever 40 Remove low reverse drum and rear band as assembly Turn drum clockwise and pull outward to remove it from overrunning clutch Fig 148 41 Remove bolts attaching overrunning clutch cam to case Fig 149 Fig 147 Rear Band And Lever Pin Location Fig 148 Low Reverse Drum And Rear Band Removal Fig 149 Overrunning Clutch Cam Bolt Locations Fig 145 Removing Low Rev...

Page 1207: ...uring assembly Keep the transmission case and compo nents clean Also make sure the tools and workbench area used for assembly operations are equally clean Shop towels used for wiping off tools and hands must be made from lint free material Lint will stick to transmission parts and could interfere with valve operation or even restrict fluid passages Lubricate the transmission components with Mopar ...

Page 1208: ...h servo snap ring Fig 155 4 Examine bolt holes in overrunning clutch cam Note that one hole is not threaded Fig 156 This hole must align with blank area in clutch cam bolt circle Fig 157 Mark hole location on clutch cam and blank area in case with grease pencil paint stripe or scribe mark for assembly reference 5 Mark location of non threaded hole in clutch cam and blank area in bolt circle with g...

Page 1209: ...a Lubricate overrunning clutch race on drum hub with transmission fluid b Guide drum through rear band c Tilt drum slightly and start race on drum hub into overrunning clutch rollers d Press drum rearward and turn it in clock wise direction until drum seats in overrunning clutch Fig 161 e Turn drum back and forth Drum should rotate freely in clockwise direction and lock Fig 157 Location Of Blank A...

Page 1210: ...63 Then install and tighten retainer bolts to 17 N m 13 ft lbs torque 15 Install snap ring that secures low reverse drum to hub of piston retainer Fig 164 16 Install rear band lever and pivot pin Fig 165 Align lever with pin bores in case and push pivot pin into place 17 Install planetary geartrain assembly Fig 166 18 Install thrust plate on intermediate shaft hub Fig 167 Use petroleum jelly to ho...

Page 1211: ...ditional petroleum jelly to hold washer in place if necessary 21 Align clutch discs in front clutch and install front clutch on rear clutch Fig 170 Rotate front clutch retainer back and forth until completely seated on rear clutch Fig 167 Installing Intermediate Shaft Thrust Plate Fig 170 Assembling Front And Rear Clutch Units Fig 166 Installing Planetary Geartrain Fig 168 Input Shaft Seal Ring Lo...

Page 1212: ...rth to engage and seat rear clutch discs on front annulus gear Also be sure front clutch drive lugs are fully engaged in slots of driving shell after installa tion 27 Slide front band over front clutch retainer Fig 174 28 Insert front band lever pivot shaft part way into case Fig 174 29 Install front band lever strut and adjusting screw Fig 175 30 Push front band lever shaft completely into place ...

Page 1213: ...Remove pilot stud tools and install remaining oil pump bolts Tighten bolts alternately in diagonal pattern to 20 N m 15 ft lbs 38 Install new seals on overdrive piston Then lubricate seals with Mopar Door Ease or Ru Glyde 39 Install overdrive piston in retainer Align locating lugs on piston in locating bores in Fig 176 Reaction Shaft Support Seal Rings And Front Clutch Thrust Washer Fig 178 Instal...

Page 1214: ... inside diameter of bearing faces forward as well 43 Apply small amount of petroleum jelly to pilot hub of intermediate shaft 44 Verify alignment of splines in overdrive unit planetary gear and overrunning clutch Be sure Alignment Tool 6227 2 is still fully seated Fig 182 If planetary gear and overrunning clutch splines become misaligned overdrive unit can not be fully installed on intermediate sh...

Page 1215: ...at park neutral position switch has not been installed in case Valve body can not be installed if switch is in position 52 Verify that valve body solenoid harness is secured in 3 4 accumulator housing cover plate 53 Install valve body as follows a Align and carefully insert park rod into pawl Rod will make click noise as it enters pawl Move rod slightly to check engagement b Align and seat valve b...

Page 1216: ...ller tube bore etc to prevent dirt entry 62 Install torque converter Use C clamp or metal strap to hold converter in place for installation 63 Install transmission speed sensor in overdrive case Fig 187 64 Mount transmission on jack for installation in vehicle 65 Apply dielectric grease to terminal pins of solenoid case connector and neutral switch OVERRUNNING CLUTCH LOW REVERSE DRUM DISASSEMBLE I...

Page 1217: ...otation Drum should rotate freely in clockwise direction and lock when turned in counterclockwise direction as viewed from front of case 4 Note component position for assembly refer ence Bolt holes in clutch cam are countersunk on one side Be sure this side of cam will face rearward when installed Fig 192 5 Remove rear support overrunning clutch and low reverse drum Set components aside for final ...

Page 1218: ...sion reassembly REAR SERVO PISTON DISASSEMBLE 1 Remove small snap ring and remove plug and spring from servo piston Fig 194 2 Remove and discard servo piston seal ring 3 Lubricate piston and guide seals with petro leum jelly Lubricate other servo parts with Mopar ATF Plus transmission fluid ASSEMBLE 1 Install new seal ring on servo piston 2 Assemble piston plug spring and new snap ring 3 Lubricate...

Page 1219: ...ushing Installer SP 5117 Fig 200 Bushing should be flush with pump housing bore 3 Stake new pump bushing in two places with blunt punch Fig 201 Remove burrs from stake points with knife blade afterward REACTION SHAFT SUPPORT BUSHING REMOVAL 1 Assemble Bushing Remover Tools SP 1191 3633 and 5324 Fig 202 Do not clamp any part of reaction shaft or support in vise 2 Hold Cup Tool SP 3633 firmly agains...

Page 1220: ...e gear bore in pump housing with transmission fluid 2 Lubricate pump gears with transmission fluid 3 Support pump housing on wood blocks Fig 203 4 Install outer gear in pump housing Fig 203 Gear can be installed either way it is not a one way fit 5 Install pump inner gear Fig 204 CAUTION The pump inner gear is a one way fit The bore on one side of the gear inside diameter I D is chamfered Be sure ...

Page 1221: ...lot studs c Tighten support to pump bolts to 20 N m 15 ft lbs d Remove pump assembly from transmission case 12 Install new oil seal in pump with Special Tool C 4193 and Tool Handle C 4171 Fig 207 Be sure seal lip faces inward 13 Install new seal ring around pump housing Be sure seal is properly seated in groove 14 Lubricate lip of pump oil seal and O ring seal with transmission fluid FRONT CLUTCH ...

Page 1222: ...n retainer Fig 210 Use twisting motion to seat piston in bottom of retainer A thin strip of plastic about 0 0209 thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition never use any type of metal tool to help ease the piston seals into place Metal tools will cut shave or sco...

Page 1223: ... clutch plates and discs Fig 208 Install steel plate then disc until all plates and discs are installed The front clutch uses 4 clutch discs 9 Install pressure plate and waved snap ring Fig 208 10 Check clutch plate clearance Fig 213 Clear ance should be 1 70 to 3 40 mm 0 067 to 0 134 in If clearance is incorrect clutch discs plates pressure plates and snap ring may have to be changed Fig 211 Clut...

Page 1224: ... retainer hub and input shaft if necessary Fig 217 a Be sure clutch hub seal ring is fully seated in groove and is not twisted b Note that input shaft front seal ring is teflon and rear seal ring is metal Fig 218 Be sure chamfered ends of teflon ring are properly joined and that ends of rear ring are securely hooked together Lubricate both rings with transmission fluid after installation 3 Lubrica...

Page 1225: ...ase the piston seals into place Metal tools will cut shave or score the seals 8 Install piston spring in retainer and on top of piston Fig 220 Concave side of spring faces down ward toward piston 9 Install wave spring in retainer Fig 220 Be sure spring is completely seated in retainer groove 10 Install bottom pressure plate Fig 214 Ridged side of plate faces downward toward piston and flat side to...

Page 1226: ...h petroleum jelly and install washer over input shaft and into clutch retainer Fig 222 Use enough petro leum jelly to hold washer in place 16 Set rear clutch aside for installation during final assembly PLANETARY GEARTRAIN OUTPUT SHAFT DISASSEMBLE 1 Remove planetary snap ring Fig 223 2 Remove front annulus and planetary assembly from driving shell Fig 223 3 Remove snap ring that retains front plan...

Page 1227: ...parate and remove driving shell rear plane tary and rear annulus from output shaft Fig 226 9 Remove tabbed thrust washers from rear plan etary gear 10 Remove snap ring that retains sun gear in driving shell Then remove sun gear spacer and thrust plates Fig 225 Front Planetary And Annulus Gear Disassembly Fig 227 Planetary Geartrain Components Fig 226 Removing Driving Shell Rear Planetary And Rear ...

Page 1228: ...ed in gear slots 4 Install rear annulus over and onto rear plane tary gear Fig 228 5 Install assembled rear planetary and annulus gear on output shaft Fig 229 Verify that assembly is fully seated on shaft 6 Install front thrust washer on rear planetary gear Fig 230 Use enough petroleum jelly to hold washer on gear Be sure all four washer tabs are seated in slots 7 Install spacer on sun gear Fig 23...

Page 1229: ...ndy as it will also be used for geartrain end play check 11 Align rear thrust plate on driving shell and install sun gear lock ring Be sure ring is fully seated in sun gear ring groove Fig 235 12 Install assembled driving shell and sun gear on output shaft Fig 236 Fig 233 Installing Driving Shell Rear Thrust Plate Fig 232 Installing Driving Shell Front Thrust Plate On Sun Gear Fig 234 Supporting S...

Page 1230: ...thrust plate on front annulus gear support Fig 239 Note that plate has two tabs on it These tabs fit in notches of annulus hub 19 Install thrust washer in front annulus Fig 240 Align flat on washer with flat on planetary hub Also be sure washer tab is facing up 20 Install front annulus snap ring Fig 241 Use snap ring pliers to avoid distorting ring during installation Also be sure ring is fully se...

Page 1231: ... 048 in If end play is incorrect snap ring or thrust washers may have to be replaced Snap ring is available in three different thicknesses for adjustment purposes OVERDRIVE UNIT DISASSEMBLE OVERDRIVE REMOVAL 1 Remove transmission speed sensor and O ring seal from overdrive case Fig 244 2 Place transmission in upright position Fig 245 3 Remove bolts attaching overdrive unit to trans mission case Fi...

Page 1232: ...ed 2 Remove intermediate shaft spacer Fig 249 Retain spacer It is a select fit part and may possibly be reused 3 Remove overdrive piston from retainer Fig 250 Fig 246 Overdrive Unit Removal Installation Fig 247 Overdrive Piston Thrust Bearing Removal Installation Fig 248 Overdrive Piston Thrust Plate Removal Installation Fig 249 Intermediate Shaft Spacer Location Fig 250 Overdrive Piston Removal Z...

Page 1233: ...overdrive clutch wave spring Fig 254 2 Remove overdrive clutch reaction snap ring Fig 255 Note that snap ring is located in same groove as wave spring Fig 251 Removing Overdrive Clutch Pack Retaining Ring Fig 252 Overdrive Clutch Pack Removal Fig 253 Overdrive Clutch Component Position Fig 254 Overdrive Clutch Wave Spring Removal Installation Fig 255 Overdrive Clutch Reaction Snap Ring Removal Ins...

Page 1234: ...shaft bearing from locating ring Fig 258 6 Lift gear case up and off geartrain assembly Fig 259 7 Remove snap ring that retains rear bearing on output shaft Fig 260 Fig 256 Access Cover Screw Removal Installation Fig 257 Access Cover And Gasket Removal Installation Fig 258 Releasing Bearing From Locating Ring Fig 259 Removing Gear Case From Geartrain Assembly Fig 260 Rear Bearing Snap Ring Removal...

Page 1235: ...URY 1 Mount geartrain assembly in shop press Fig 262 2 Position Compressor Tool 6227 1 on clutch hub Fig 262 Support output shaft flange with steel press plates as shown and center assembly under press ram 3 Use Special Tool C 3995 A or similar size tool at top of Tool 6227 1 to help distribute load and pro vide needed extra press length Fig 262 4 Apply press pressure slowly Compress hub and sprin...

Page 1236: ...ve direct clutch hub and spring Fig 266 2 Remove sun gear and spring plate Then remove planetary thrust bearing and planetary gear Fig 267 Fig 264 Direct Clutch Hub Retaining Ring Removal Fig 265 Direct Clutch Pack Removal Fig 266 Direct Clutch Hub And Spring Removal Fig 267 Removing Sun Gear Thrust Bearing And Planetary Gear ZJ TRANSMISSION AND TRANSFER CASE 21 97 DISASSEMBLY AND ASSEMBLY Continu...

Page 1237: ...etaining ring Fig 272 9 Mark annulus gear and output shaft for assem bly alignment reference Fig 273 Use punch or scriber to mark gear and shaft 10 Remove snap ring that secures annulus gear on output shaft Fig 274 Use two screwdrivers to unseat and work snap ring out of groove as shown 11 Remove annulus gear from output shaft Fig 275 Use rawhide or plastic mallet to tap gear off shaft GEAR CASE A...

Page 1238: ...n Mopar ATF Plus transmission fluid Allow discs to soak for 10 20 minutes 2 Install new pilot bushing and clutch hub bush ing in output shaft if necessary Fig 276 Lubricate bushings with petroleum jelly or transmission fluid Fig 272 Clutch Drum Outer Retaining Ring Removal Fig 273 Marking Annulus Gear And Output Shaft For Assembly Alignment Fig 274 Annulus Gear Snap Ring Removal Fig 275 Annulus Ge...

Page 1239: ...and snap ring on output shaft Fig 280 Be sure locating ring groove in bear ing is toward rear 8 Install overrunning clutch on hub Fig 281 Note that clutch only fits one way Shoulder on clutch should seat in small recess at edge of hub Fig 277 Annulus Gear Installation Fig 278 Clutch Drum And Outer Retaining Ring Installation Fig 279 Clutch Drum Inner Retaining Ring Installation Fig 280 Rear Bearin...

Page 1240: ...tall assembly with counterclockwise twisting motion 11 Install planetary gear in annulus gear Fig 284 Be sure planetary pinions are fully seated in annulus gear before proceeding 12 Install direct clutch spring plate on sun gear Shoulder side of plate should face outward and toward front Then secure plate to sun gear with snap ring Fig 285 Fig 282 Overrunning Clutch Thrust Bearing Installation Fig...

Page 1241: ...d before proceeding 16 Mount assembled output shaft annulus gear and clutch drum in shop press Direct clutch spring hub and clutch pack are easier to install with assem bly mounted in press 17 Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227 2 Fig 288 Insert tool through sun gear and into splines of both hubs Be sure alignment tool is fully seated before proc...

Page 1242: ... and clutch pack on direct clutch spring Fig 293 Be sure hub is started on sun gear splines before proceeding WARNING THE NEXT STEP IN GEARTRAIN ASSEMBLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AND SPRING IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 830 POUNDS USE COMPRES SOR TOOL C 6227 1 AND A HYDRAULIC TYPE SHOP PRESS WITH A ...

Page 1243: ...hen set clutch pack on edge of clutch hub and compressor tool as shown 26 Slowly compress clutch hub and spring Fig 294 Compress spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 27 Realign clutch pack on hub and seat clutch discs and plates in clutch drum Fig 294 Fig 292 Correct Position Of Direct Clutch Pressure Plate Fig 293 Direct Clutch ...

Page 1244: ...nd straight end of spring is seated against case 2 Install pawl shaft retaining bolt Tighten bolt to 27 N m 20 ft lbs torque 3 Install park lock reaction plug Note that plug has locating pin at rear Fig 299 Be sure pin is seated in hole in case before installing snap ring 4 Install reaction plug snap ring Fig 300 Com press snap ring only enough for installation do not distort it Fig 296 Direct Clu...

Page 1245: ...h hub 8 Install overdrive gear case on geartrain Fig 303 9 Expand front bearing locating ring with snap ring pliers Fig 304 Then slide case downward until locating ring locks in bearing groove and release snap ring 10 Install locating ring access cover and gasket in overdrive unit case Fig 305 Fig 301 Rear Seal Installation 4x4 Gear Case Fig 302 Correct Rear Bearing Locating Ring Position Fig 303 ...

Page 1246: ...nstall first clutch disc followed by first clutch plate Then install remaining clutch discs and plates in same order 6 Verify clutch pack 3 clutch discs 2 steel plates 1 reaction plate and 1 pressure plate are required 7 Install clutch pack pressure plate Note that pressure plate is thickest plate in clutch pack 8 Install clutch pack wire type retaining ring Fig 309 Fig 306 Overdrive Clutch Reacti...

Page 1247: ...rom spacer chart based on distance measured Fig 311 e Remove Gauge Alignment Tool 6312 3 Determine correct thickness overdrive piston thrust plate as follows a Position Gauge Tool 6311 across face of over drive case Then position Dial Caliper C 4962 over gauge tool Fig 312 b Measure distance to clutch hub thrust bear ing seat at four points 90 apart Then average measurements by adding them and div...

Page 1248: ...TO AVOID PERSONAL INJURY 3 Mount geartrain in shop press 4 Position Compressor Tool 6227 1 on clutch hub Fig 315 Support output shaft flange with steel press plates as shown and center assembly under press ram 5 Apply press pressure slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap ring Fig 315 6 Remove direct clutch pack ...

Page 1249: ...b Expand pliers to grip hub splines and remove clutch with counterclockwise twisting motion 13 Remove thrust bearing from overrunning clutch hub Fig 321 14 Remove overrunning clutch from hub Fig 321 Fig 317 Direct Clutch Pack Removal Fig 318 Direct Clutch Hub And Spring Removal Fig 319 Removing Sun Gear Thrust Bearing Planetary Gear Fig 320 Removing Overrunning Clutch Assembly Fig 321 Overrunning ...

Page 1250: ... reference Fig 325 19 Remove annulus gear from output shaft Fig 326 Use rawhide or plastic mallet to tap gear off shaft 20 Remove output shaft front bearing if not pre viously removed Fig 322 Marking Direct Clutch Drum And Annulus Gear For Assembly Alignment Fig 323 Removing Clutch Drum Inner Retaining Ring Fig 324 Removing Clutch Drum Outer Retaining Ring Fig 325 Marking Annulus Gear And Output S...

Page 1251: ...recess at edge of hub 10 Install thrust bearing on overrunning clutch hub Fig 331 Use petroleum jelly to hold bearing in place during installation Bearing fits one way only Be sure bearing is seated squarely against hub Reposition bearing if it does not seat squarely 11 Install overrunning clutch Fig 332 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with co...

Page 1252: ...and seat it against spring plate as shown Bearing fits one way only If it does not seat squarely against spring plate remove and reposition bearing Fig 331 Installing Overrunning Clutch Thrust Bearing Fig 332 Overrunning Clutch Installation Fig 333 Planetary Gear Installation Fig 334 Sun Gear And Spring Plate Assembly Fig 335 Installing Planetary Thrust Bearing ZJ TRANSMISSION AND TRANSFER CASE 21...

Page 1253: ...r of hub are raised slightly and counterbore in plate fits over these splines Plate should be flush with this end of hub Fig 339 21 Install remainder of direct clutch components as follows a Install first clutch disc on reaction plate fol lowed by a steel plate b Alternately install remaining clutch discs and steel plates until required number are installed Fig 338 The clutch requires 8 discs and ...

Page 1254: ...pward and set it partially on edge of hub and compressor tool as shown in Fig 342 26 Slowly compress clutch hub and spring Fig 343 Compress spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 27 Realign clutch pack on hub and seat clutch discs and plates in clutch drum Fig 343 28 Install direct clutch pack snap ring Fig 344 Be very sure snap ri...

Page 1255: ...he electrical parts with compressed air Make sure all passages are clean and free from obstructions Do not use rags or shop towels to dry or wipe off valve body components Lint from these materials can stick to valve body parts interfere with valve operation and clog filters and fluid passages Wipe the governor pressure sensor and solenoid valve with dry lint free shop towels only The O rings on t...

Page 1256: ...rrs nicks or scores Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands Maintaining sharpness of these edges is vitally important The edges prevent foreign matter from lodging between the valves and plugs and the bore Inspect all the valve and plug bores in the valve body Use a penlight to view the bore interi...

Page 1257: ...Fig 346 Upper Housing Valves Plug Springs And Brackets 21 118 TRANSMISSION AND TRANSFER CASE ZJ CLEANING AND INSPECTION Continued ...

Page 1258: ... that all fluid passages are clear NOTE Do not use shop towels or rags to dry the case or any other transmission component unless they are made from lint free materials Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assem bly A sufficient quantity of lint can block fluid pas sages and interfere with valve body operation Inspect the case...

Page 1259: ...secure Replace the pump body if the vent is cracked broken or loose Inspect the pump bushing Then check the reaction shaft support bushing Replace either bushing only if heavily worn scored or damaged It is not necessary to replace the bushings unless they are actually dam aged Install the gears in the pump body and measure end clearance with a feeler gauge and straightedge Fig 349 Straightedge sh...

Page 1260: ...hings care fully Fig 352 The retainer bushings are NOT ser viceable It will be necessary to replace the retainer if either bushing is scored or worn Inspect the piston and retainer seal surfaces for nicks or scratches Minor scratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously scored Fig 350 Checking Pump Gear Tip Clearance Fig 351...

Page 1261: ...ratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously scored Check condition of the fiber thrust washer and metal output shaft thrust washer Replace either washer if worn or damaged Check condition of the seal rings on the input shaft and clutch retainer hub Replace the seal rings only if worn distorted or damaged The input shaft fro...

Page 1262: ...ean the geartrain Fig 355 and case components Fig 356 with solvent Dry all parts except the bear ings with compressed air Allow bearings to air dry Do not use shop towels for wiping parts dry unless the towels are made from a lint free material A suf ficient quantity of lint from shop towels cloths rags etc could plug the transmission filter and fluid pas sages Discard the old case gasket and seal...

Page 1263: ...Fig 355 Overdrive Geartrain Components 21 124 TRANSMISSION AND TRANSFER CASE ZJ CLEANING AND INSPECTION Continued ...

Page 1264: ... scores Replace the overrunning clutch assembly or the race if either assembly is worn or damaged in any way Check the machined surfaces on the output shaft These surfaces should be clean and smooth Very minor nicks or scratches can be polished down with crocus cloth Replace the shaft if worn severely scored or damaged in any way Inspect the output shaft bushings Fig 357 The small bushing is the i...

Page 1265: ...ttle valve is operated by a cam on the throttle lever The throttle lever is oper ated by an adjustable cable Fig 359 The cable is attached to an arm mounted on the throttle lever shaft A lock button at the engine end of the cable is provided for cable adjustment A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simul taneously with the throttle bod...

Page 1266: ...mission throttle lever and lever on throttle body move simul taneously as described in cable adjustment checking procedure GEARSHIFT CABLE Check adjustment by starting the engine in Park and Neutral Adjustment is OK if the engine starts only in these positions Adjustment is incorrect if the engine starts in one but not both positions If the engine starts in any position other than Park or Neu tral...

Page 1267: ...ff adjusting screw 2 turns 6 Hold adjusting screw in place and tighten lock nut to 34 N m 25 ft lbs torque 7 Position new gasket on oil pan and install pan on transmission Tighten pan bolts to 17 N m 13 ft lbs torque 8 Lower vehicle and refill transmission with Mopar ATF Plus Type 7176 fluid VALVE BODY CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body Line P...

Page 1268: ...o compress the kick down valve against the spring and bottom the throt tle valve Maintain pressure against kickdown valve spring Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool NOTE The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment SCHEMATICS AND DI...

Page 1269: ...HYDRAULIC FLOW IN PARK 21 130 TRANSMISSION AND TRANSFER CASE ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1270: ...HYDRAULIC FLOW IN NEUTRAL ZJ TRANSMISSION AND TRANSFER CASE 21 131 SCHEMATICS AND DIAGRAMS Continued ...

Page 1271: ...HYDRAULIC FLOW IN REVERSE 21 132 TRANSMISSION AND TRANSFER CASE ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1272: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR ZJ TRANSMISSION AND TRANSFER CASE 21 133 SCHEMATICS AND DIAGRAMS Continued ...

Page 1273: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR 21 134 TRANSMISSION AND TRANSFER CASE ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1274: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR ZJ TRANSMISSION AND TRANSFER CASE 21 135 SCHEMATICS AND DIAGRAMS Continued ...

Page 1275: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED 21 136 TRANSMISSION AND TRANSFER CASE ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1276: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED ZJ TRANSMISSION AND TRANSFER CASE 21 137 SCHEMATICS AND DIAGRAMS Continued ...

Page 1277: ...HYDRAULIC FLOW IN MANUAL LOW 1 21 138 TRANSMISSION AND TRANSFER CASE ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1278: ...HYDRAULIC FLOW IN MANUAL SECOND 2 ZJ TRANSMISSION AND TRANSFER CASE 21 139 SCHEMATICS AND DIAGRAMS Continued ...

Page 1279: ...HYDRAULIC FLOW DURING FULL THROTTLE 3 2 DOWNSHIFT PASSING GEAR 21 140 TRANSMISSION AND TRANSFER CASE ZJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1280: ...bs Bolt torque convertor 31 N m 23 ft lbs Bolt nut crossmember 68 N m 50 ft lbs Bolt driveplate to crankshaft 75 N m 55 ft lbs Plug front band reaction 17 N m 13 ft lbs Locknut front band adj 34 N m 25 ft lbs Switch park neutral 34 N m 25 ft lbs Bolt fluid pan 17 N m 13 ft lbs Screws fluid filter 4 N m 35 in lbs Bolt oil pump 20 N m 15 ft lbs Bolt overrunning clutch cam 17 N m 13 ft lbs Bolt O D t...

Page 1281: ... procedures in Overdrive Unit D A procedures Intermiediate shaft spacer Overdrive clutch Fourth gear only Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 896 kPa 90 130 psi at 1 2 to 3 4 throttle Line pressure at accumulator Closed throttle 372 414 kPa 54 60 psi Front servo Third gear only No more than 21 kPa 3 psi lower than line pressure Rear servo 1 range No mo...

Page 1282: ...RE Pressure Tester 7700 Extension Housing Pilot C 3288 B Pressure Gauge C 3292 Pressure Gauge C 3293SP Spring Compressor and Alignment Shaft 6227 Gauge Bar 6311 Snap ring Plier 6823 ZJ TRANSMISSION AND TRANSFER CASE 21 143 ...

Page 1283: ...g Compressor C 3422 B Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 Seal Installer C 3860 A Seal Puller C 3861 Installer C 3863 A Snap ring Plier C 3915 21 144 TRANSMISSION AND TRANSFER CASE ZJ SPECIAL TOOLS Continued ...

Page 1284: ... A Seal Puller C 3981 B Seal Remover C 3985 B Installer C 3995 A Universal Handle C 4171 Seal Installer C 4193 A Remover Installer C 4470 Dial Caliper C 4962 ZJ TRANSMISSION AND TRANSFER CASE 21 145 SPECIAL TOOLS Continued ...

Page 1285: ... B Cup Bushing Remover SP 3633 From kit C 3887 B Installer Oil Pump Bushing SP 5118 From kit C 3887 B Remover Reaction Shaft Bushing SP 5301 From kit C 3887 B Installer Reaction Shaft Bushing SP 5302 From kit C 3887 B Installer Front Clutch Bushing SP 5511 From kit C 3887 B 21 146 TRANSMISSION AND TRANSFER CASE ZJ SPECIAL TOOLS Continued ...

Page 1286: ...d in aluminum retainer housings bolted to the case halves OPERATING RANGES NV 231 operating ranges are 2 wheel drive high 2H 4 wheel drive high 4H 4 wheel drive low 4L Two wheel drive range is for use on all road surfaces The 4 wheel drive high and low ranges are not for use on paved roads They are only recommended for off road use on unpaved low traction surfaces The only time 4 wheel drive can b...

Page 1287: ...DIAGNOSIS AND TESTING NV231 DIAGNOSIS 21 148 TRANSMISSION AND TRANSFER CASE ZJ ...

Page 1288: ... Disconnect transfer case linkage rod from range lever 10 Disconnect transfer case vent hose and indi cator or vacuum switch harness 11 Support transfer case with transmission jack 12 Remove nuts attaching transfer case to trans mission 13 Secure transfer case to jack with chains 14 Pull transfer case and jack rearward to disen gage transfer case 15 Remove transfer case from under vehicle 16 If tr...

Page 1289: ...uller tool is positioned on yoke and not on slinger as slinger will be damaged 4 Remove seal washer from front output shaft Discard washer as it should not be reused 5 Remove nut and washer that attach range lever to sector shaft Then move sector to neutral position and remove range lever from shaft Fig 6 REAR RETAINER REMOVAL AND DISASSEMBLY 1 Remove mainshaft boot Spread band clamp that secures ...

Page 1290: ...ocating washer and locating retaining ring from output shaft Fig 10 5 Remove rear output bearing I D retaining ring Fig 11 6 Remove rear retainer bolts with 10mm socket and air ratchet 7 Remove rear retainer Tap retainer with mallet and pry upward to break sealer bead Then slide retainer off case and mainshaft Fig 12 Fig 8 Rear Slinger Removal Fig 9 Rear Seal Removal Fig 10 Slinger Locating Washer...

Page 1291: ... the two black finish bolts at each end of the case These bolts go through the case dowels and require a washer under the bolt head Fig 16 12 Remove rear case from front case Fig 17 Insert screwdrivers into slots cast into each end of case Then pry upward to break sealer bead and remove rear case CAUTION Do not pry on the sealing surface of either case half as the surfaces will become dam aged Fig...

Page 1292: ...move shaft drive sprocket and mode hub as assembly Fig 22 2 Remove mode hub retaining ring with heavy duty snap ring pliers Fig 23 3 Slide mode hub off mainshaft Fig 24 4 Slide drive sprocket off mainshaft Fig 25 SHIFT FORK SLEEVE HUB REMOVAL 1 Remove mode spring from end of mode fork rail Fig 18 Oil Pickup Screen Hose And Tube Removal Fig 19 Poppet Components Fig 20 Disengaging Front Output Shaft...

Page 1293: ...bly Note fork position for installation reference Fig 27 4 Remove shift sector from front case Fig 28 Fig 23 Mode Hub retaining Ring Removal Fig 24 Mode Hub Removal Fig 25 Drive Sprocket Removal Fig 26 Mode Fork And Sleeve Removal Fig 27 Range Fork And Hub Removal Fig 28 Shift Sector Removal 21 154 TRANSMISSION AND TRANSFER CASE ZJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1294: ... with drift and hammer 4 Remove input gear bearing retaining ring with heavy duty snap ring pliers Fig 31 5 Place front case in horizontal position Then remove input gear and planetary carrier as assembly Fig 32 Tap gear out of bearing with plastic mallet if necessary 6 Remove carrier lock retaining ring Fig 33 Fig 29 Sector Shaft Seal And Retainer Removal Fig 30 Input Retainer Removal Fig 31 Remo...

Page 1295: ...nut on puller bolt in clockwise direction to draw bearing out of input gear Fig 39 FRONT REAR CASE BEARING AND SEAL REMOVAL 1 Remove front output shaft front bearing and seal as follows a Remove seal from case with pry tool Fig 40 b Remove bearing retaining ring with screw driver Fig 41 c Remove bearing with Tool Handle C 4171 and Tool 5065 Fig 42 2 Remove front output shaft rear bearing from rear...

Page 1296: ...ARY CARRIER AND INPUT RETAINER INSTALLATION 1 Lubricate bearings input gear and planetary carrier with transmission fluid during installation Seals can be lubricated with transmission fluid pet rolatum or Ru Glyde if desired Fig 38 Installing Puller Bridge Fig 39 Pilot Bearing Removal Fig 40 Front Output Seal Removal Fig 41 Front Shaft Front Bearing Retaining Ring Removal Fig 42 Front Shaft Front ...

Page 1297: ... Tools C 4171 and 7934 Fig 47 6 Install pilot bearing in input gear with Tools C 4171 and 5065 Fig 48 7 Assemble input gear and planetary carrier as follows a Install rear thrust washer in carrier Be sure washer tabs are aligned and seated in carrier slots Fig 49 Also note that washers are the same and therefore interchangeable b Position front thrust washer and lock ring on input gear Then instal...

Page 1298: ...retaining rings are almost the same diameter The difference is in ring thickness with the input gear retaining ring being substan tially thicker Fig 48 Pilot Bearing Installation Fig 49 Input Gear Rear Thrust Washer Installation Fig 50 Input Gear Front Thrust Washer And Carrier Lock Ring Installation Fig 51 Carrier Lock Retaining Ring Installation Fig 52 Input Gear And Carrier Installation Fig 53 ...

Page 1299: ...INSTALLATION 1 Install shift sector O ring and nylon retainer in case bore Note that one side of retainer is slightly rounded and that the opposite side has a shallow groove Groove side goes toward seal and rounded side faces out 2 Install shift sector in case Fig 58 Lubricate sec tor shaft with transmission fluid before installation Fig 54 Input Retainer Seal Installation Fig 55 Applying Sealer B...

Page 1300: ...nshaft 4 Install mode hub retaining ring Be sure ring is fully seated in shaft groove before proceeding 5 Install assembled mainshaft sprocket and hub Fig 61 Be sure shaft is seated in pilot bearing planetary and range sleeve 6 Install new pads on mode fork if necessary 7 Insert mode sleeve in mode fork mode fork Be sure long side of sleeve is toward long end of shift rail Fig 62 8 Install assembl...

Page 1301: ... oil pump and pickup tube in rear case Be sure pickup screen is securely seated in case slot Also be sure oil pump locating tabs are outside rear case Fig 67 6 Apply bead of sealer to mating surface of front case Use Mopar Sealer P N 82300234 or Loctite Ultra Gray Sealer bead should not exceed 3 16 in in diameter 7 Lift rear case and oil pump and carefully posi tion assembly on front case Be sure ...

Page 1302: ...er by hand then carefully seat seal with hammer and Tool D 389 Fig 70 8 Install new rear slinger Use suitable size pipe tool to tap slinger into place 9 Install boot on mainshaft and slinger Secure boot to slinger with new band clamp FRONT YOKE AND SWITCH INSTALLATION 1 Install vacuum or indicator switch in front case Tighten switch to 20 34 N m 15 25 ft lbs torque 2 Lubricate yoke hub with transm...

Page 1303: ...replace the gear if any teeth are broken cracked or chipped The bearing surface on the gear can be smoothed with 300 400 grit emery cloth if necessary Examine the carrier body and pinion gears for wear or damage The carrier will have to be replaced as an assembly if the body pinion pins or pinion gears are damaged Check the lock ring and both thrust washers for wear or cracks Replace them if neces...

Page 1304: ...aces with a scraper and 3M all purpose cleaner This will ensure proper adhesion of the sealer during reassembly Replace the slinger and seal outright do not reuse either part Inspect the retaining rings and washers Replace any part if distorted bent or broken Reuse is not recommended Also replace the boot if cut or torn Replace the boot band clamps do not reuse them Fig 74 Shift Fork And Wear Pad ...

Page 1305: ...INER Inspect the cases and retainer for wear and dam age Clean the sealing surfaces with a scraper and 3M all purpose cleaner This will ensure proper sealer adhesion at assembly Replace the input retainer seal do not reuse it Check case condition If leaks were a problem look for gouges and severe scoring of case sealing sur faces Also make sure the front case mounting studs are in good condition C...

Page 1306: ...RIPTION TORQUE Plug Detent 16 24 N m 12 18 ft lbs Bolt Diff Case 17 27 N m 15 24 ft lbs Plug Drain Fill 40 45 N m 30 40 ft lbs Bolt Extension Housing 35 46 N m 26 34 ft lbs Bolt Front Brg Retainer 16 27 N m 12 20 ft lbs Bolt Case Half 35 46 N m 26 34 ft lbs Nut Front Yoke 122 176 N m 90 130 ft lbs Screw Oil Pump 1 2 1 8 N m 12 15 in lbs Nut Range Lever 27 34 N m 20 25 ft lbs Bolt Rear Retainer 35 ...

Page 1307: ...S SPECIAL TOOLS NV231 C 4171 Handle Universal Non Threaded C 4210 Installer Seal 5061 Installer Bearing 5062 Installer Bearing 5063 Installer Bearing 5064 Installer Bearing 21 168 TRANSMISSION AND TRANSFER CASE ZJ ...

Page 1308: ...aller Bearing 5066 Installer Bushing 7828 A Installer Input Gear Bearing 7888 Installer Pump Housing Seal 7889 A Remover Rear Output Shaft Bushing ZJ TRANSMISSION AND TRANSFER CASE 21 169 SPECIAL TOOLS Continued ...

Page 1309: ...ncreased low speed off road torque capability Shift Mechanism Transfer case operating ranges are selected with a floor mounted shift lever The shift lever is connected to the transfer case range lever by an adjustable linkage rod Range positions are marked on the shifter bezel plate SHIFT MECHANISM Transfer case operating ranges are selected with a floor mounted shift lever The shift lever is conn...

Page 1310: ...DIAGNOSIS AND TESTING NV249 DIAGNOSIS ZJ TRANSMISSION AND TRANSFER CASE 21 171 ...

Page 1311: ...ean adapter flange and adapter mounting surface in housing Surfaces must be clean for proper adapter alignment and speedometer oper ation 2 Install new O rings on speed sensor and speed ometer adapter if necessary Fig 2 3 Lubricate sensor and adapter O rings with transmission fluid 4 Install vehicle speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 N m 15 27 in lbs torque 5...

Page 1312: ...y chains 2 Position transfer case under vehicle 3 Align transfer case and transmission shafts and install transfer case on transmission Fig 4 4 Install and tighten transfer case attaching nuts Fig 4 Tighten 3 8 nuts to 41 47 N m 30 35 ft lbs Tighten 5 16 nuts to 30 35 N m 22 26 ft lbs 5 Install speedometer adapter if removed during service Then index adapter and install speed sensor in adapter Ref...

Page 1313: ...ainst case OUTPUT SHAFT FRONT BEARING The transfer case housing must be disassembled to replace to output shaft front bearing Fig 8 1 Remove snap ring that retains front bearing in front case Fig 9 2 Using tool 6953 remove bearing from front case Fig 10 3 Using tool 6953 install new bearing 4 Install snap ring to hold bearing into case 5 Assemble transfer case REPLACING FRONT OUTPUT SHAFT REAR BEA...

Page 1314: ...over Installer 7823 and Handle C 4171 drive front bearing from inside the annulus opening in the case Fig 15 4 If necessary install locating ring on new bear ing Fig 16 5 Position case so forward end is facing upward 6 Using Remover Installer 7823 and Handle C 4171 drive front bearing into case Fig 16 The bearing locating ring must be fully seated against case surface Fig 10 Remove Output Shaft Fr...

Page 1315: ...old retainer to transfer case REPLACING INPUT GEAR PILOT BEARING The input gear must be removed to replace the mainshaft pilot bearing 1 Using a suitable drift inserted into the splined end of the input gear drive pilot bearing from input gear Fig 17 2 Wash input gear in solvent to remove fluid res idue 3 Apply a thin coat of Mopar Lock N Seal sealer to outside surface of pilot bearing 4 Using Ins...

Page 1316: ...ng seal 2 Using Remover 6957 remove bushing from extension housing Fig 21 3 Clean fluid residue from extension housing and inspect for cracks Replace housing if damaged 4 Position replacement bushing in extension housing with fluid port in bushing aligned with slot in housing 5 Using Installer C 4735 drive bushing into housing until installer bottoms out Fig 22 6 Install extension housing seal Fig...

Page 1317: ...tput shaft Fig 24 4 Remove rear retainer bolts Fig 25 5 Remove rear bearing locating ring access cover screws cover and gasket Fig 26 6 Loosen rear retainer with pry tool to break sealer bead Pry only against retainer boss as shown Fig 27 Fig 23 Front Yoke Removal Fig 24 Yoke Seal Washer Removal Fig 25 Rear Retainer Bolt Removal Fig 26 Locating Ring Access Cover And Gasket Removal Fig 27 Loosening...

Page 1318: ...fer ence 11 Disengage oil pickup tube from oil pump and remove oil pump assembly Fig 31 12 Mount transfer case on wood blocks so rear case is facing upward 13 Remove bolts holding front case to rear case The case alignment bolt require flat washers Fig 32 Fig 28 Disengaging Rear Bearing Locating Ring Fig 29 Rear Retainer Removal Fig 30 Speedometer Drive Gear Removal Fig 31 Rear Bearing and Oil Pum...

Page 1319: ...s coupling from mainshaft Fig 36 19 Remove drive gear snap ring Fig 37 20 Disengage drive gear Fig 37 Pry gear upward and off mainshaft as shown 21 Remove front output shaft drive chain and drive gear as assembly Fig 37 22 Remove detent plug O ring detent spring and detent plunger Fig 38 Fig 33 Loosening Rear Case Fig 34 Rear Case Removal Fig 35 Oil Pickup Tube Removal Fig 36 Viscous Coupling Remo...

Page 1320: ...ainer from case and gear To avoid damaging case and retainer posi tion screwdriver blade only in slots provided in retainer Fig 42 29 Remove snap ring that retains input gear shaft in front bearing Fig 43 30 Remove input and low range gear assembly Fig 44 31 Remove range lever locknut and remove lever and washer from shift sector shaft Fig 45 32 Remove shift sector Rotate and tilt sector as needed...

Page 1321: ...ng Excess lubricant will flow into bottom of bushing bore and prevent shift rail from fully seating this can also make it dif ficult to seat rear case on front case 5 Lubricate bearings and seals in front case with transmission fluid or petroleum jelly 6 Install magnet in case 7 Align and install low range input gear assem bly in front case Fig 47 Be sure low range gear pinions are engaged in annu...

Page 1322: ...procket assem bly drive chain and drive sprocket with transmission fluid 21 Assemble drive chain drive sprocket and front output shaft Fig 52 22 Start drive sprocket on mainshaft 23 Guide front shaft into bearing and drive sprocket onto mainshaft drive gear Fig 52 24 Install drive sprocket snap ring Fig 53 25 Lubricate mainshaft splines with transmis sion fluid 26 Install coupling on mainshaft Fig...

Page 1323: ... sure tube is seated in case notch as shown Fig 55 32 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker silicone adhesive sealer or Loctite 518 to mounting flange of front case Work sealer bead around bolt holes as shown Fig 56 Fig 52 Installing Drive Chain Front Output Shaft And Drive Sprocket Fig 53 Installing Drive Sprocket Snap Ring Fig 54 Viscous Coupling And Oil Pump Ring Installation Fig 5...

Page 1324: ...ert oil pickup tube in pump Fig 61 39 Install rear bearing on mainshaft Fig 61 Locating ring groove in bearing goes toward end of mainshaft 40 Install rear bearing retaining snap ring Fig 62 41 Install speedometer drive gear Fig 63 Fig 57 Rear Case Installation Fig 58 Checking Position Of Oil Pickup Tube Fig 59 Alignment Bolt Location Fig 60 Installing Oil Pump Fig 61 Rear Bearing Installation Fig...

Page 1325: ...8 in wide bead of Mopar Gas ket Maker silicone adhesive sealer or Loctite 518 to mating surface of front bearing retainer Allow sealer to set up slightly before installing retainer 49 Install front bearing retainer Fig 67 Tighten retainer bolts to 16 24 N m 12 18 ft lbs torque 50 Install new seal washer on front output shaft Fig 68 51 Install yoke and new yoke nut on front output shaft Fig 69 52 T...

Page 1326: ...Install and tighten fill plug to 41 54 N m 30 40 ft lbs torque INPUT AND LOW RANGE GEAR DISASSEMBLE 1 Remove snap ring that retains input gear in low range gear Fig 71 2 Remove retainer Fig 72 3 Remove front tabbed thrust washer Fig 73 4 Remove input gear Fig 74 5 Remove rear tabbed thrust washer from low range gear Fig 75 Fig 69 Output Shaft Yoke Installation Fig 70 Range Lever Installation Fig 7...

Page 1327: ...ge Replace the thrust washers if worn or damaged Replace the mainshaft and sprocket gears if the teeth or gear bores are worn or damaged Replace the mainshaft bearings if worn flat spot ted brinelled or damaged in any way Replace the mainshaft if it exhibits wear or dam age to the bearing surfaces splines or gear teeth INPUT AND LOW RANGE GEARS Inspect the low range gear pinions and pinion pins Re...

Page 1328: ...y Replace both parts if either is damaged However the nylon pads in the fork can be replaced if worn or cracked Inspect the transfer case snap rings closely Do not attempt to salvage a distorted snap ring by straight ening or reshaping it Replace any snap ring that is distorted or worn Inspect the low range gear input gear and the gear thrust washers retainer and snap ring The low range gear is se...

Page 1329: ...NS TORQUE DESCRIPTION TORQUE Bolt crossmember 41 47 N m 30 35 ft lbs Plug Detent 16 24 N m 12 18 ft lbs Plugs drain fill 41 54 N m 30 40 ft lbs Switch Electric 20 34 N m 15 25 ft lbs Bolts front brg retainer 16 24 N m 12 18 ft lbs Bolts case half 27 34 N m 20 25 ft lbs Nut output yoke 122 176 N m 90 130 ft lbs Bolts rear extension 27 34 N m 20 25 ft lbs Lock nut shift 27 34 N m 20 25 ft lbs Bolt s...

Page 1330: ...SPECIAL TOOLS NV249 TRANSFER CASE Installer 5066 Installer 6952 Installer 6953 Installer 6954 Remover 6957 Adapter 7794 A Installer 7823 ZJ TRANSMISSION AND TRANSFER CASE 21 191 ...

Page 1331: ...Slide Hammer C 637 Installer C 3972 A Remover C 3985 B Handle C 4171 Installer C 4735 21 192 TRANSMISSION AND TRANSFER CASE ZJ SPECIAL TOOLS Continued ...

Page 1332: ...g habits which will shorten the life of any tire are Rapid acceleration Severe application of brakes High speed driving Taking turns at excessive speeds Striking curbs and other obstacles Radial ply tires are more prone to irregular tread wear It is important to follow the tire rotation inter val shown in the section on Tire Rotation This will help to achieve a greater tread life potential TIRE ID...

Page 1333: ...Tire Inflation Pressure Chart provided with the vehicle SPARE TIRE TEMPORARY The temporary spare tire is designed for emer gency use only The original tire should be repaired and reinstalled at the first opportunity or a new tire purchased Do not exceed speeds of 50 MPH Refer to Owner s Manual for complete details TIRE INFLATION PRESSURES Under inflation causes rapid shoulder wear tire flexing and...

Page 1334: ...ds over 90 mph 144 km h special high speed tires must be used Consult tire manufacturer for correct inflation pressure recommendations REPLACEMENT TIRES The original equipment tires provide a proper bal ance of many characteristics such as Ride Noise Handling Durability Tread life Traction Rolling resistance Speed capability It is recommend that tires equivalent to the origi nal equipment tires be...

Page 1335: ...mproper mounting vibration wheel defects or possibly tire imbalance To find out if tires are causing the noise or vibra tion drive the vehicle over a smooth road at varying speeds Note the effect of acceleration and decelera tion on noise level Differential and exhaust noises will change in intensity as speed varies while tire noise will usually remain constant LEAD CORRECTION CHART Use the follow...

Page 1336: ...ZJ TIRES AND WHEELS 22 5 DIAGNOSIS AND TESTING Continued ...

Page 1337: ...ot on the tire is marked with a paint mark or a bright colored adhe sive label on the outboard sidewall The low spot on the rim is identified with a label on the outside of the rim and a dot on the inside of the rim If the outside label has been removed the tire will have to be removed to locate the dot on the inside of the rim Before dismounting a tire from its wheel a refer ence mark should be p...

Page 1338: ...ewall Deflate tire completely before dismounting tire from the wheel Use lubrication such as a mild soap solution when dismounting or mounting tire Use tools free of burrs or sharp edges which could dam age the tire or wheel rim Before mounting tire on wheel make sure all rust is removed from the rim bead and repaint if neces sary Install wheel on vehicle and tighten to proper torque specification...

Page 1339: ...a substitute design All aluminum and some steel wheels have wheel stud nuts with an enlarged nose This enlarged nose is necessary to ensure proper retention of the wheels Before installing the wheel remove any build up of corrosion on the wheel mounting surfaces WARNING INSTALLING WHEELS WITHOUT GOOD METAL TO METAL CONTACT COULD CAUSE LOOS ENING OF WHEEL NUTS THIS COULD ADVERSELY AFFECT THE SAFETY...

Page 1340: ...l Remove tire from wheel and re mount wheel on hub in former position Check wheel radial runout Fig 3 NOTE If the vehicle is equipped with aluminum or full faced wheels the tire must be removed to check radial runout STEEL WHEELS Radial runout 0 040 in Lat eral runout 0 045 in ALUMINUM WHEELS Radial runout 0 030 in Lateral runout 0 035 in If point of greatest runout is near original chalk mark rem...

Page 1341: ... may have included severe treatment TIRE AND WHEEL BALANCE It is recommended that a two plane dynamic bal ancer be used when a wheel and tire assembly require balancing Static should be used only when a two plane balancer is not available For static imbalance find location of heavy spot causing imbalance Counter balance wheel directly opposite the heavy spot Determine weight required to counterbal...

Page 1342: ...SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Lug Nut 1 2 X 20 with 60 Cone 109 to 150 N m 80 to 110 ft lbs Fig 6 Dynamic Unbalance Balance ZJ TIRES AND WHEELS 22 11 ...

Page 1343: ......

Page 1344: ...tem can result Do not use abrasive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning sol vents on painted or upholstered surfaces Damage to finish or color can result Do not hammer or pound on plastic trim panel when servicing interior trim Plastic panels can break Chrysler Corporation uses many different types of push in fasteners to s...

Page 1345: ...formed by a trained automotive paint technician CAUTION Do not remove clear coat finish if equipped Base coat paint must retain clear coat for durability PAINTED SURFACE TOUCHUP When a painted metal surface has been scratched or chipped it should be touched up as soon as possi ble to avoid corrosion For best results use Mopart Scratch Filler Primer Touch Up Paints and Clear Top Coat Refer to Intro...

Page 1346: ... Pearl Coat RB3 18719 25047 B9528 50263 CHA95 RB3 Black Clear Coat DX8 9700 15214 99 34858 90 5950 CHA85 DX8 Opal Satin Glow SW4 93541 26090 B9621 51538 CHA96 SW4 Stone White Clear Coat SW1 83542 26089 B9622 51540 CHA96 SW1 CLADDING COLOR CHRY CODE PPG BASF DuPONT S W ACME M S AKZO NOBEL SIKKENS Flame Red PR4 4679 23043 B9326 46916 CHAPR4M Char Gold II RJ7 35748 25037 B9532 50278 CHARJ7M Dark Rose...

Page 1347: ... in ure thane it would also be unlikely they could be salvaged Before removing the windshield check the availability of the windshield and moldings from the parts supplier REMOVAL AND INSTALLATION WINDSHIELD REMOVAL 1 Remove inside rear view mirror 2 Remove cowl cover 3 Remove screws attaching windshield side mold ing to A pillar Fig 1 4 Remove upper windshield molding 5 Cut urethane bonding from ...

Page 1348: ... time 10 With aid of a helper position windshield over windshield opening Align reference marks at bottom of windshield to support spacers 11 Slowly lower windshield glass to windshield opening fence Guide top molding into proper position if necessary Push windshield inward to fence spacers at bottom and until top molding is flush to roof line 12 Clean excess urethane from exterior with Mopar Supe...

Page 1349: ...g and lock clips into place Fig 5 LIFTGATE GLASS REMOVAL 1 Cut urethane bonding from around liftgate glass using a suitable sharp cold knife A pneumatic cutting device can be used if available 2 Separate glass from vehicle INSTALLATION CAUTION Open a window before installing glass This will avoid pressurizing the passenger compart ment If a door or liftgate is slammed before ure thane is cured wat...

Page 1350: ...ng operation GLASS PANEL REMOVAL 1 Position glass to vent position 2 Remove wind deflector mechanism covers Fig 4 3 Position sunshade full rearward 4 Loosen nuts holding glass panel to side adjust ment brackets show in View B Fig 4 5 Slide glass panel rearward 12mm 0 5in and separate glass from sunroof unit INSTALLATION 1 Position glass panel in opening with logo rear ward and slide panel forward ...

Page 1351: ...al position and disengage front of bracket from unit Fig 4 INSTALLATION 1 Reverse the preceding operation Adjust glass as necessary Fig 2 Drain Tube Locations Fig 3 Deflector Assembly Fig 4 Glass Adjustment 23 8 BODY ZJ REMOVAL AND INSTALLATION Continued ...

Page 1352: ... 2 Remove headlining 3 Remove bolts holding sunroof motor to motor bracket 4 Disconnect wire connector 5 Separate motor and drive gear from drive cables Fig 6 INSTALLATION 1 Verify that sunroof is in vent position Push mechanism forward on both sides to align drive cables 2 Engage drive gears onto drive cables 3 Install motor and drive gear screws and tighten to 5 N m 44in lbs 4 Install headlining...

Page 1353: ...able out of groove for cable end 6 Pull guide outward to release from housing Separate rear end of guide from clips Slide guide out of unit Fig 9 INSTALLATION 1 Install guide cable into rear of guide assembly 2 Install guide assembly at an angle so the rear portion slips under finger clips at rear of module housing 3 Place cable in groove of cable holder 4 Install screws in track assembly 5 Instal...

Page 1354: ... 3 Close glass panel Separately loosen adjusting bolts shown in View A Fig 12 and individually adjust the corners of the glass 4 Adjust front of glass panel to 1 0 mm 0 040 in below top surface of roof panel 5 Adjust rear of glass to 1 0 mm 0 040 in above top surface of roof panel 6 Tighten adjustment bolts and install covers Fig 11 Drain Tube Locations Fig 12 Glass Adjustment ZJ BODY 23 11 ...

Page 1355: ... BUCKET SEAT BACK COVER REMOVAL 1 Remove head restraint 2 Remove seat back 3 Unfasten seat back cover zipper 4 Route zipper over power recliner motor if equipped 5 Slide hand between the face of the seat back cushion and the cushion cover and carefully separate hook and loop fastener Fig 1 6 Roll cover upward to top of seat back 7 Carefully slide cover over head restraint guide sleeves 8 Separate ...

Page 1356: ...lement connec tor if equipped 10 Slide hand between seat cushion cover and seat cushion Carefully separate hook and loop fas tener Fig 4 11 Separate seat cushion cover from seat cush ion INSTALLATION 1 Position seat cover on cushion 2 Align seat cover with cushion alignment inden tations Fig 5 3 Engage seat cushion heater element connector if equipped 4 Route seat function switches through access ...

Page 1357: ...per Fig 6 on trim cover and peel cover off pad by turning inside out 4 If necessary headrest cylinders may be removed from seatback frame Squeeze locking tabs on cylinder and slide cylinder upward and remove from frame bracket INSTALLATION Reverse removal procedure REAR SEAT CUSHION COVER REMOVAL 1 Remove seat cushion from vehicle If necessary refer to removal procedure 2 Using a trim tool disenga...

Page 1358: ... LATCH 19 HOOD RELEASE CABLE 19 HOOD 18 LICENSE PLATE LAMP HOUSING 44 LIFTGATE FLIP UP GLASS LATCH HANDLE STRIKER 44 LIFTGATE FLIP UP GLASS LATCH 44 LIFTGATE FLIP UP GLASS WEATHERSTRIP 43 LIFTGATE FLIP UP GLASS 43 LIFTGATE HINGE 41 LIFTGATE LATCH STRIKER 42 LIFTGATE LATCH 42 LIFTGATE LOCK CYLINDER 42 LIFTGATE OPENING WEATHERSTRIP 42 LIFTGATE OUTSIDE HANDLE 42 LIFTGATE TRIM PANEL 40 LIFTGATE 40 LOW...

Page 1359: ...t turns hoist the right side of the vehi cle For hoisting recommendations refer to Group 0 Lubrication and Maintenance General Information section WATER LEAK DETECTION To detect a water leak point of entry do a water test and watch for water tracks or droplets forming on the inside of the vehicle If necessary remove inte rior trim covers or panels to gain visual access to the leak area If the hose...

Page 1360: ...er is powered by the M1 circuit that supplies voltage to the driver side visor vanity lamp TRAINING THE UNIVERSAL TRANSMITTER To train the transmitter refer to the Owner s Man ual TESTING TRANSMITTER 1 Check for battery voltage at the Universal Transmitter by pressing a button and seeing if a red lamp comes on If OK go to 6 If not OK go to 2 2 Check if visor vanity lamp lights If lamp lights repla...

Page 1361: ... Installation proce dures 6 Remove headlamps 7 Remove bolts that attach grille opening rein forcement GOR to the upper and lower crossmem ber Fig 1 8 Remove grille opening reinforcement 9 If necessary remove air seals located at head lamp wiring inlets Fig 2 INSTALLATION For installation reverse removal procedure HOOD REMOVAL 1 Raise hood 2 If equipped disconnect underhood lamp con nector 3 Mark l...

Page 1362: ...release cable Position it on radiator crossmember support 2 Install nuts Tighten nuts to 11 N m 8 ft lbs torque 3 Test operation of latch release cable and latch HOOD LATCH STRIKER REMOVAL 1 Remove bolts attaching striker to hood 2 Remove striker from hood INSTALLATION 1 Position striker on hood 2 Install bolts Tighten bolts to 11 N m 8 ft lbs torque 3 Test striker hood alignment by opening and cl...

Page 1363: ...he tape stripe is protected by a carrier until installed on a body panel Carrier also is an installation alignment aid REMOVAL 1 Remove exterior trim as necessary to clear cap tured edges of tape stripe being removed 2 Remove tape stripe using a suitable heat gun or lamp This will soften adhesive backing 3 Clean adhesive residue from body finish using a suitable adhesive remover INSTALLATION The p...

Page 1364: ...ors and openings CAUTION Do not overheat tape stripe when per forming step 12 12 Apply heat to tape stripe to evaporate resid ual moisture from edges of tape stripe This will also allow tape stripe to be stretched into concave sur faces 13 Edge turn tape stripe around doors or fenders 14 Install exterior trim if necessary Small air or water bubbles under tape stripe can be pierced with a pin and s...

Page 1365: ...to Group 8L Lamps for service informa tion 2 Remove front bumper fascia Refer to Group 13 Frame and Bumpers for service information 3 Remove front wheel 4 Remove fasteners attaching inner front fender liner to fender and inner fender Fig 10 5 Remove inner fender liner 6 Right fender only a If equipped remove radio antenna mast nut pad and base from fender Refer to group 8F Audio Systems for Remova...

Page 1366: ...aching trim panel to inside release handle FRONT DOOR REMOVAL 1 Remove trim panel 2 If equipped disconnect power window regula tor power door lock motor and all other wire harness connectors 3 Slide wire harness out of boot and door 4 Mark an outline around door hinges for instal lation alignment reference 5 Remove door hinge retaining bolts plates and shims Fig 14 6 Identify and retain door hinge...

Page 1367: ...r latch Fig 16 3 If equipped disconnect security alarm switch connector from lock cylinder Fig 17 4 Remove key lock cylinder retainer clip Remove lock cylinder gasket and clip from door 5 If applicable remove door latch lock cylinder rod from original lock cylinder Connect it to replace ment lock cylinder INSTALLATION 1 Reverse removal procedure FRONT DOOR LATCH REMOVAL 1 Remove door trim panel an...

Page 1368: ...rd Disconnect handle latch and lock rods 4 Remove door inside handle actuator from door INSTALLATION 1 Reverse removal procedure FRONT DOOR INNER BELT SEAL REMOVAL 1 Remove door trim panel 2 Using a trim stick carefully pry rear inner edge of seal upward 3 Grasp seal and pull upward to separate from door flange Fig 21 INSTALLATION 1 Position seal on door flange 2 Firmly press downward to seat seal...

Page 1369: ...ner 2 Press weatherstrip into position FRONT DOOR OPENING WEATHERSTRIP REMOVAL 1 Remove A pillar trim panel 2 Remove B pillar upper trim panel 3 Remove B pillar lower trim panel 4 Grasp seal and separate from door opening INSTALLATION 1 Position weatherstrip at corners using paint dots as alignment points 2 Move upward and around edge of door opening Seat seal on flange Fig 24 3 Engage connector p...

Page 1370: ...connect the wiring connectors from power switch panel 5 Lift trim panel over inside release handle and remove trim panel from door INSTALLATION 1 If equipped connect the wiring connectors to power switch panel 2 Position trim panel on door inner panel 3 Press push in fasteners inward around perime ter of door to attach it to inner panel 4 Install armrest screw 5 Install mirror bezel screw 6 Instal...

Page 1371: ... door and vehicle body wire harness connec tors 8 Install door waterdam if removed trim panel armrest and window glass regulator handle REAR DOOR HINGE REMOVAL 1 Open and support door 2 Remove bolts attaching hinge to C pillar Fig 29 3 Separate door from vehicle INSTALLATION 1 Support door 2 Position door at C pillar 3 Install bolts attaching hinge to C pillar Tighten outer bolts to 40 N m 360 in ...

Page 1372: ...e door inside handle actuator screws Fig 32 3 Move actuator handle outward Disconnect handle latch and lock rods 4 Remove door inside release handle from door INSTALLATION Reverse removal procedure REAR DOOR INNER BELT SEAL REMOVAL 1 Remove door trim panel 2 Using a trim stick carefully pry rear inner edge of seal upward 3 Grasp seal and pull upward to separate from door flange Fig 33 INSTALLATION...

Page 1373: ... trim panel 5 Install B pillar lower trim panel 6 Install B pillar upper trim panel 7 Install C pillar trim panel REAR DOOR WINDOW REGULATOR REMOVAL 1 Remove door trim panel and waterdam If nec essary refer to removal procedure 2 Position window glass to access window track nuts Fig 35 3 Loosen window track nuts and slide track off of window 4 Remove window regulator retaining screws Fig 36 5 Lift...

Page 1374: ...ips Fig 39 2 Lift upward and remove molding INSTALLATION FRONT DOOR 1 Replace all retaining clips 2 Install molding over top of retaining clips 3 Align molding to door edges 4 Snap molding down over retaining clips REMOVAL REAR DOOR 1 Open rear door 2 Remove acorn nut at rear dogleg Fig 39 3 Using a trim stick gently lift up from bottom of cladding Unsnap molding from retaining clips INSTALLATION ...

Page 1375: ...Fig 39 Body Side Cladding Fig 40 Trim Panels 23 32 BODY ZJ REMOVAL AND INSTALLATION Continued ...

Page 1376: ...r trim panel LOWER B PILLAR TRIM PANEL REMOVAL 1 Remove the A pillar trim panel 2 Loosen upper B pillar trim panel and slide upper trim panel upward to access screws in lower B pillar trim panel 3 Remove screws attaching lower B pillar trim panel to B pillar Fig 43 4 Remove screw located closest to A pillar attach ing I P cover to I P 5 Separate lower B pillar trim panel from B pil lar 6 Route sea...

Page 1377: ...te lower trim panel from liftgate opening 8 Remove quarter trim panel mounting screws 9 If necessary remove spare tire and tire stand offs from left quarter trim panel Fig 44 10 Remove rear quarter trim panel INSTALLATION 1 Reverse removal procedure D PILLAR TRIM REMOVAL 1 Remove liftgate upper trim panel Fig 45 2 Detach and remove trim panel from D pillar Fig 40 INSTALLATION 1 Position D pillar t...

Page 1378: ...chor bolt Fig 47 3 Remove C pillar and quarter trim panel 4 Remove belt retractor anchor bolt from rear quarter rail 5 Remove retractor and shoulder belt from panel INSTALLATION SHOULDER BELT 1 Position retractor and shoulder belt on panel 2 Install belt retractor anchor bolt in rear quar ter rail Tighten anchor bolts to 37 N m 27 ft lbs 3 Install C pillar and quarter trim panel 4 Install turning ...

Page 1379: ... hinge into lower pivot 3 Push downward to engage hinge into pivot 4 Rotate cushion downward into seating position 5 Lock seat cushion down by pressing firmly on center of cushion until latch engages REAR SEATBACK REMOVAL 1 Remove lower seat cushion Refer to removal procedure 2 Remove bolts holding seatback side support brackets left side Fig 50 3 Tilt seatback forward and slide it outboard to det...

Page 1380: ...s in side support brackets with bolt holes in floor pan and install side support bracket bolts Tighten bolts to 27 N m 20 ft lbs torque 3 Install lower seat cushion CHILD SEAT MODULE REMOVAL The child seat module can be removed with the seat back installed or removed from the vehicle Fig 52 1 Pull release strap to open child seat and remove lining 2 Remove upper and lower child seat back bolts 3 S...

Page 1381: ...bracket and slide it downward onto the support bracket 2 Tighten the setscrew 1 N m 15 in lbs torque 3 If equipped connect mirror harness wire con nector REARVIEW MIRROR SUPPORT BRACKET INSTALLATION 1 Mark the position for the mirror bracket on the outside of the windshield glass with a wax pencil 2 Clean the bracket contact area on the glass Use a mild powdered cleanser on a cloth saturated with ...

Page 1382: ...fy that the mirror support bracket is cor rectly aligned because the adhesive will cure rap idly 7 Allow the adhesive to cure for 8 10 minutes Remove any excess adhesive with an alcohol damp ened cloth 8 Allow the adhesive to cure for an additional 8 10 minutes before installing the mirror SUNVISOR REMOVAL 1 Remove screws that attach sunvisor arm sup port bracket to headliner and roof panel Fig 59...

Page 1383: ...rim panel away from glass panel to release push in fasteners 4 Use a trim panel removal tool to detach push in fasteners from liftgate UPPER TRIM PANEL INSTALLATION 1 Position trim panel at liftgate and slide over lapping portions of trim panel under liftgate lower trim panel 2 Align trim panel push in fasteners with holes in liftgate inner panel Press trim panel upward to seat fasteners 3 Install...

Page 1384: ... support rod cylinders on ball studs 6 Install liftgate trim panel LIFTGATE HINGE REMOVAL It is not necessary to remove liftgate to replace one or both hinges The hinges can be replaced one at a time 1 Remove liftgate opening headliner upper trim molding 2 Disconnect wiring harness to cargo lamp 3 Remove hinge screws at roof panel Fig 65 4 Remove hinge screws at liftgate 5 Remove hinge from liftga...

Page 1385: ...5 Remove latch from liftgate INSTALLATION 1 Reverse removal procedure Tighten latch screws to 7 N m 5 ft lbs torque LIFTGATE LATCH STRIKER REMOVAL 1 Raise liftgate 2 Remove latch striker nuts from below scuff plate Access nuts from under bumper fascia beam Fig 68 3 Remove striker shim and seal plate INSTALLATION 1 Position striker shim and seal plate on vehicle 2 Install latch striker nuts Tighten...

Page 1386: ...rd to completely seat the hinges Tighten hinge nuts to 6 N m 60 in lbs 4 Install prop rods onto ball studs and compress locking caps to lock prop rods onto ball studs FLIP UP GLASS SWITCH REMOVAL 1 Remove liftgate trim panel 2 Remove license plate lamp housing nuts from liftgate 3 Squeeze switch locking tabs inward to release switch from license plate lamp housing 4 Disconnect switch harness conne...

Page 1387: ... pencil or equivalent make align ment marks on the inside and outside of the glass panel 3 Remove handle striker INSTALLATION 1 Position handle striker on glass panel and align reference marks 2 Install handle striker Tighten screws to 6 N m 60 in lbs LICENSE PLATE LAMP HOUSING REMOVAL 1 Remove liftgate trim panel 2 Remove lamp housing retaining screws from liftgate Fig 74 3 Disconnect bulb socket...

Page 1388: ...Install and tighten slide rail screws to 3 N m 28 in lbs torque ADJUSTMENTS HOOD ADJUSTMENT The hood attaching holes are enlarged to aid front back and side to side adjustment 1 If hood is low in relation to cowl panel insert shims between hinge and hood 2 Adjust hood bumper Fig 77 in or out to adjust hood to fender height alignment 3 Adjust the hood latch as necessary Tighten the nuts to 11 N m 8...

Page 1389: ... N m 30 in lbs torque 5 Test handle button and lock cylinder for proper operation LIFTGATE The position of liftgate can be adjusted upward or downward by use of slots in the hinge An inward or outward adjustment is achieved by use of slots in the body If an inward or outward adjustment is needed use 3My Fast and Firm or equivalent on the hinge to body mating surface as a sealant Fig 78 Door Latch ...

Page 1390: ... GC LB 2 EP 2 Liftgate Hinge As Required Multi Purpose Grease NLGI GC LB 2 EP 2 Liftgate Support Arms As Required Engine Oil Liftgate Latches As Required White Spray Lubricant 3 Liftgate Release Handle Pivot and Slide Contact Surfaces As Required Multi Purpose Grease NLGI GC LB 2 EP 2 Window System Components As Required White Spray Lubricant 3 Lock Cylinders Twice a Year Lock Cylinder Lubricant 4...

Page 1391: ......

Page 1392: ...ELAY 24 COMPRESSOR 23 HEATER PERFORMANCE 12 HIGH PRESSURE CUT OFF SWITCH 25 HIGH SPEED BLOWER MOTOR RELAY 25 LOW PRESSURE CYCLING CLUTCH SWITCH 25 REFRIGERANT SYSTEM LEAKS 26 VACUUM SYSTEM 12 SERVICE PROCEDURES REFRIGERANT OIL LEVEL 27 REFRIGERANT RECOVERY 26 REFRIGERANT SYSTEM CHARGE 26 REFRIGERANT SYSTEM EVACUATE 26 REMOVAL AND INSTALLATION ACCUMULATOR 34 AMBIENT TEMPERATURE SENSOR 35 BLOWER MOT...

Page 1393: ... the mode doors which are oper ated by vacuum actuator motors On ATC systems the mode control knob switches electrical current to control the mode doors which are operated by elec tronic actuator motors The outside air intake can be shut off by selecting the recirculation mode with the mode control knob This will open the recirculating air door and recircu late the air that is already inside the v...

Page 1394: ...ed to use R 134a Damage to the system will result R 12 refrigerant oil must not be mixed with the R 134a refrigerant oil They are not compatible Do not use R 12 equipment or parts on the R 134a system Damage to the system will result Do not over charge the refrigerant system This will cause excessive compressor head pressure and can cause noise and system failure In addition to the warnings and ca...

Page 1395: ... oil before installation Use only O rings approved for use with R 134a refrigerant Failure to do so may result in a leak Unified plumbing connections with aluminum gaskets cannot be serviced with O rings The gaskets are not reusable and new gaskets do not require lubrication before installing Using the proper wrenches when making a connec tion is very important Improper wrenches or improper use of...

Page 1396: ... module The blower motor cannot be repaired and if faulty must be replaced BLOWER MOTOR POWER MODULE Models equipped with the optional ATC system have a blower motor power module The power mod ule allows infinitely variable blower motor speeds The power module is mounted on the heater A C blower housing in the same location used for the blower motor resistor on manual temperature control systems T...

Page 1397: ...d a clutch plate Fig 4 The electromagnetic coil and pulley are retained on the compressor with snap rings The clutch plate is mounted on the compressor shaft and secured with a bolt These components provide the means to engage and disengage the compressor from the engine ser pentine accessory drive belt When the clutch coil is energized it magnetically draws the clutch into con tact with the pulle...

Page 1398: ...ulty The valve is part of the compressor assembly and must not be removed or otherwise disturbed HIGH SPEED BLOWER MOTOR RELAY Models equipped with the optional ATC system have a high speed blower motor relay The relay is a International Standards Organization ISO type relay The high speed blower motor relay is a electro mechanical device that switches current to the blower motor bypassing the blo...

Page 1399: ...nts A barrier hose design is used for the air conditioning system on this vehicle The ends of the refrigerant hoses are made from lightweight alumi num and use braze less fittings The refrigerant lines and hoses cannot be repaired and if faulty must be replaced REFRIGERANT OIL The oil used in the 10PA17 compressor is a poly alkylene glycol synthetic ND8 PAG wax free refrig erant oil Use only refri...

Page 1400: ...s in the evapora tor the air is cooled and the moisture is removed as it condenses on the fins During periods of high heat and humidity an air conditioning system will be more effective in the Recirc mode With the system in the Recirc mode only air from the passenger com partment passes through the evaporator As the pas senger compartment air dehumidifies the air conditioning system performance le...

Page 1401: ...s of the low pressure cycling clutch switch connector 7 With the compressor clutch engaged record the discharge air temperature and the compressor dis charge pressure 8 Compare the discharge air temperature to the Performance Temperature and Pressure chart If the discharge air temperature is high see Refrigerant System Leaks and Refrigerant System Charge in this group 9 Compare the compressor disc...

Page 1402: ...Pressure Diagnosis ZJ HEATING AND AIR CONDITIONING 24 11 DIAGNOSIS AND TESTING Continued ...

Page 1403: ...refer to Group 7 Cooling System A plugged heater core If proper coolant flow through the heater system is verified and outlet air temperature is still low a mechanical problem may exist MECHANICAL PROBLEMS Possible locations or causes of insufficient heat An obstructed cowl air intake Obstructed heater system outlets A blend air door not functioning properly TEMPERATURE CONTROL If the heater disch...

Page 1404: ...r in the connector plug holes will help the connector slide onto the switch ports LOCATING VACUUM LEAKS 1 Disconnect the vacuum connector from the back of the heater A C mode control switch on the control panel 2 Connect the test set vacuum hose probe to each port in the vacuum harness connector one at a time and pause after each connection Fig 9 The test set gauge should return to the 27 kPa 8 in...

Page 1405: ...normally dis played is called the Test Selector The Test Selector is used to display fault codes identify the test mode and show the values of the circuits being tested The following information describes how the values in the Test Selector display should be interpreted 1 The Select Test mode will have only 00 dis played in the Test Selector and no stickman will be displayed This is the self diagn...

Page 1406: ...w There are two types of cur rent faults input faults and system faults 2 Historical Fault Codes Historical or stored means the fault occurred previously but is OK right now A majority of historical fault codes are caused by intermittent wiring or connector problems NOTE A battery disconnect will erase all faults stored in Read Available Memory RAM It is recom mended that all faults be recorded be...

Page 1407: ...Current Fault Codes 24 16 HEATING AND AIR CONDITIONING ZJ DIAGNOSIS AND TESTING Continued 1996 Grand Cherokee Publication No 81 370 6147 TSB 26 01 96 January 1996 ...

Page 1408: ...Historical Fault Codes ZJ HEATING AND AIR CONDITIONING 24 17 DIAGNOSIS AND TESTING Continued 1996 Grand Cherokee Publication No 81 370 6147 TSB 26 01 96 January 1996 ...

Page 1409: ...ut put circuits can be viewed monitored overridden and tested If a failure occurs in an output circuit test the circuit by overriding the system Test the actuator through its full range of operation When the override control has been activated the display will be flashing The Test Selector will display feed back information about the output circuit being tested 1 To begin the Output Circuit Actuat...

Page 1410: ...Circuit Testing ZJ HEATING AND AIR CONDITIONING 24 19 DIAGNOSIS AND TESTING Continued 1996 Grand Cherokee Publication No 81 370 6147 TSB 26 01 96 January 1996 ...

Page 1411: ...Circuit Testing cont 24 20 HEATING AND AIR CONDITIONING ZJ DIAGNOSIS AND TESTING Continued 1996 Grand Cherokee Publication No 81 370 6147 TSB 26 01 96 January 1996 ...

Page 1412: ...e Circuit Mode Door Actuator Drive Circuit Air Inlet Recirc Door Actuator Drive Circuit Front Panel Mode Control Circuit Front Panel Blower Fan Control Circuit ZJ HEATING AND AIR CONDITIONING 24 21 DIAGNOSIS AND TESTING Continued ...

Page 1413: ...Solar Sensor Circuit In Vehicle Temperature Sensor Circuit Calibration and CPU Data 24 22 HEATING AND AIR CONDITIONING ZJ DIAGNOSIS AND TESTING Continued ...

Page 1414: ...er A C control from the instrument panel Check for continuity between the ground cir cuit cavity of the control connector and a good ground There should be continuity If OK go to Step 2 If not OK repair the open circuit to ground as required 2 With the heater A C control disconnected place the mode control knob in any position except the Off position Check for continuity between the ground termina...

Page 1415: ...lutch coil is 2 0 to 3 9 amperes with electrical system voltage at 11 5 to 12 5 volts This should only be checked with the work area temperature at 21 C 70 F If system voltage is more than 12 5 volts add electrical loads by turning on electrical accessories until the system voltage drops below 12 5 volts a If the clutch coil current reading is 4 amperes or more the coil is shorted and should be re...

Page 1416: ...ld be hot at all times If OK go to Step 2 2 The relay normally closed terminal 87A is connected to terminal 30 in the de energized position but is not used for this application Go to Step 3 3 The relay normally open terminal 87 is con nected to the common feed terminal 30 in the ener gized position This terminal supplies battery voltage to the blower motor when the relay is energized by the ATC co...

Page 1417: ...tector probe into the center panel outlet Set the blower motor switch to the lowest speed A C position and the mode control switch in the Recirc mode SERVICE PROCEDURES REFRIGERANT RECOVERY WARNING REVIEW THE WARNINGS AND CAU TIONS IN THE FRONT OF THIS GROUP BEFORE RECOVERING REFRIGERANT R 134a refrigerant is a hydrofluorocarbon HFC that does not contain chlorine A R 134a refrigerant recovery recy...

Page 1418: ...avities of the switch connector 6 Hold the engine idle speed at 1 000 rpm 7 Allow three to five minutes for the refrigerant system to stabilize then record the temperatures of the evaporator inlet and outlet tubes a If a single probe is used record the temperature of the inlet tube Then remove the probe from the inlet tube and attach it to the outlet tube just before the collar of the refrigerant ...

Page 1419: ...s may be due to a rupture or leak from a refrigerant line a compressor shaft seal an evapora tor or a condenser If a rupture occurs add 1 ounce of oil to the system after the repair has been made Oil loss at a leak point will be evident by the pres ence of a wet shiny surface around the leak Refrigerant oil must be added when a accumulator evaporator or condenser are replaced Refer to the Refriger...

Page 1420: ...crewdriver and install a new garter spring 2 Clean any dirt or foreign material from both halves of the coupling 3 Install new O rings on the male fitting CAUTION Use only the specified O rings as they are made of a special material for the R 134a sys tem The use of any other O ring may allow the con nection to leak intermittently during vehicle operation 4 Lubricate the male fitting and O ring an...

Page 1421: ...acuate and charge the refrigerant system as described in this group COMPRESSOR CLUTCH The refrigerant system can remain fully charged during compressor clutch pulley or coil replacement The compressor clutch can be serviced in the vehicle REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the compressor shaft bolt Fig 18 A band type oil filter wrench may be used to aid in securin...

Page 1422: ...it will vibrate out resulting in a clutch fail ure and severe damage to the front housing of the compressor 4 Install the pulley assembly onto the compres sor If necessary place a block of wood on the friction surface and tap gently with a hammer Fig 22 CAUTION Do not mar the pulley friction surface 5 Install the pulley assembly retaining snap ring bevel side outward with snap ring pliers Special ...

Page 1423: ...ION REMOVAL 1 Disconnect and isolate the battery negative cable 2 Recover the refrigerant from the refrigerant system as described in this group 3 Turn the relief valve counterclockwise to remove it from the compressor manifold Fig 24 4 Either install a plug in or tape over the open fitting on the compressor manifold INSTALLATION 1 Remove the plug or tape from the compressor manifold fitting 2 Ins...

Page 1424: ...g 27 7 Reach through the grille opening and remove the bolt securing the lower hood latch support to the lower front crossmember 8 The radiator upper crossmember can be adjusted left or right through the use of its slotted mounting holes Before removal mark the original position of the crossmember 9 Remove the remaining bolts securing the radi ator upper crossmember to the body Do not remove the h...

Page 1425: ...WING OPERATION REMOVAL 1 Disconnect and isolate the battery negative cable 2 Recover the refrigerant from the refrigerant system as described in this group 3 Disconnect the refrigerant line couplers at the condenser outlet line and the evaporator inlet line 4 Remove the liquid line from the vehicle INSTALLATION 1 Install the fixed orifice tube in the liquid line 2 Connect the liquid line at the ev...

Page 1426: ...S OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY REMOVAL 1 Disconnect and isolate the battery negative cable 2 Using a trim stick or other suitable wide flat bladed tool pry gently around the edges of the right switch pod bezel and remove the bezel 3 Remove the three screws securing the heater A C control to the instrum...

Page 1427: ...ter out lets 4 Use a twisting motion to remove the solar sen sor from the cowl top trim panel Fig 33 5 Pull the sensor out far enough to access the wiring connector and unplug it from the instrument panel wiring INSTALLATION 1 Connect the solar sensor connector 2 Install the solar sensor into the cowl top trim panel 3 Press the cowl top trim panel down until the snap clips engage in the top of the...

Page 1428: ... to Group 8E Instrument Panel Systems for the procedures BLOWER MOTOR REMOVAL 1 Disconnect and isolate the battery negative cable 2 Disconnect the blower motor cooling tube Fig 35 3 Remove the blower motor wiring from the retainer Unplug the wiring connector 4 Remove the blower motor and wheel assembly mounting screws 5 Remove the blower motor and wheel 6 Remove the blower motor wheel retainer cli...

Page 1429: ...e connector 3 Connect the battery negative cable HIGH SPEED BLOWER MOTOR RELAY This relay is used only on models equipped with the optional ATC system REMOVAL 1 Disconnect and isolate the battery negative cable 2 Locate the relay near the right end of the heat er A C housing under the instrument panel Fig 39 3 Unclip the relay connector from the side of the heater A C housing 4 Unplug the relay fr...

Page 1430: ...ister ducts to the instrument panel armature 3 Remove the demister ducts 4 Reverse the removal procedures to install PANEL DUCTS 1 Remove the demister ducts as described in this group 2 Remove the four screws securing the panel ducts to the instrument panel armature 3 Remove the panel ducts 4 Reverse the removal procedures to install FLOOR DUCTS 1 Remove the center floor console as described in Gr...

Page 1431: ...tainer from the pivot shaft 5 Remove the door through the top opening INSTALLATION 1 Install the panel defrost door through the top opening and place into position in the heater A C hous ing 2 Press the door pivot shaft retainer onto the pivot shaft 3 Connect the actuating rod and rod clip to the shaft retainer 4 Install the instrument panel as described in Group 8E Instrument Panel Systems 5 Conn...

Page 1432: ...sconnect the refrigerant lines from the evap orator tubes Fig 46 Install plugs in or tape over all of the open refrigerant fittings 4 Drain the cooling system Refer to Group 7 Cooling System for the procedures 5 Disconnect the heater hoses from the heater core tubes 6 Remove the coolant reserve overflow bottle 7 Remove the Powertrain Control Module PCM and set aside Do not unplug the PCM connector...

Page 1433: ...tems for the procedures 11 Fill the cooling system Refer to Group 7 Cooling System for the procedures 12 Evacuate and charge the refrigerant system as described in this group 13 Start the vehicle and check for proper opera tion of the heating and air conditioning systems HEATER CORE REMOVAL 1 Remove the heater A C housing as described in this group 2 Remove the heater core retaining screws 3 Pull ...

Page 1434: ...l the heat defrost door actuator 2 Install and tighten the retaining screws 3 Press the door pivot connection onto the door pivot pin 4 Connect the vacuum line 5 Install the heater A C housing into the vehicle PANEL DEFROST DOOR ACTUATOR This actuator is used only on models equipped with the standard manual temperature control system REMOVAL 1 Remove the heater A C housing as described in this gro...

Page 1435: ...group 2 Turn the heater A C housing upside down 3 Separate the actuator door pivot connection from the door pivot pin 4 Disconnect the vacuum line from the actuator or unplug the wiring connector from the motor as equipped 5 Remove the retaining screws holding the two halves of the heater A C housing together Remove the center heat duct adaptor and remove the screw 6 Remove the bottom half of the ...

Page 1436: ... housing as described in this group INSTALLATION 1 If the door was removed install the removed motor to the pivot connection Position the motor on the heater A C housing and tighten the screws 2 Install the temperature control door 3 Position the top half of the heater A C housing onto the bottom half Be sure the door pivot pins align with the pivot holes 4 Carefully turn the heater A C housing ov...

Page 1437: ......

Page 1438: ...ed circuit even though a malfunction has occurred This may happen because one of the DTC criteria for the circuit has not been met For example assume the diagnostic trouble code criteria requires the PCM to monitor the circuit only when the engine operates between 750 and 2000 RPM Suppose the sensor s output circuit shorts to ground when engine operates above 2400 RPM resulting in 0 volt input to ...

Page 1439: ...ion Test Mode checks for proper operation of output circuits or devices the Powertrain Control Module PCM may not internally recognize The PCM attempts to activate these outputs and allow an observer to verify proper operation Most of the tests provide an audible or visual indication of device operation click of relay contacts fuel spray etc Except for intermittent conditions if a device functions...

Page 1440: ... DIAGNOSTIC TROUBLE CODE 11 P1391 9D Intermittent Loss of CMP or CKP Intermittent loss of either camshaft or crankshaft position sensor or 28 No Crank Reference Signal at PCM No crank reference signal detected during engine cranking or P1398 BA Misfire Adaptive Numerator at Limit CKP sensor target windows have too much variation 12 Battery Disconnect Direct battery input to PCM was disconnected wi...

Page 1441: ...w Engine coolant temperature sensor input below minimum acceptable voltage or P0118 1F ECT Sensor Voltage Too High Engine coolant temperature sensor input above maximum acceptable voltage 23 P0112 39 Intake Air Temp Sensor Voltage Low Intake air temperature sensor input below the maximum acceptable voltage or P0113 3A Intake Air Temp Sensor Voltage High Intake air temperature sensor input above th...

Page 1442: ...respond properly to the control signal 5 2L only 31 P0441 71 Evap Purge Flow Monitor Failure Insufficient or excessive vapor flow detected during evaporative emission system operation or P0442 A0 Evap Sys Small Leak Hole smaller than 040 in system or P0443 12 EVAP Purge Solenoid Circuit An open or shorted condition detected in the duty cycle purge solenoid circuit or P0455 A1 Evap Sys Gross Leak H...

Page 1443: ...condition detected in the fuel pump relay control circuit or 0A Auto Shutdown Relay Control Circuit An open or shorted condition detected in the auto shutdown relay circuit or 2C No ASD Relay Output Voltage at PCM An Open condition Detected In The ASD Relay Output Circuit or 95 Fuel Level Sending Unit Volts Too Low Open circuit between BCM and fuel gauge sending unit or 96 Fuel Level Sending Unit ...

Page 1444: ...l To Target 15 20 PSI Governor mid pressure malfunction or P1763 A8 Governor Pressure Sensr Volts Too Hi Governor pressure sensor volts above rated volts or P1764 A7 Governor Pressure Sensr Volts Too Lo Governor pressure sensor volts below rated volts or P1765 AD Trans 12 Volt Supply Relay Cntrl Circuit Transmission relay circuit or P0783 A5 3 4 Shift Sol No RPM Drop 3 4 Shift 3 4 Shift Malfunctio...

Page 1445: ... engine ignition and emission systems monitors do not indicate a specific component prob lem They do indicate that there is an implied prob lem within one of the systems and that a specific problem must be diagnosed If any of these monitors detect a problem affecting vehicle emissions the Malfunction Indicator Check Engine Lamp will be illuminated These monitors generate Diagnostic Trouble Codes t...

Page 1446: ...CVV seal which contains a spring loaded vent seal valve Immediately after a cold start between predeter mined temperature thresholds limits the three port solenoid is briefly energized This initializes the pump by drawing air into the pump cavity and also closes the vent seal During non test conditions the vent seal is held open by the pump diaphragm assembly which pushes it open at the full trave...

Page 1447: ...capacity and its efficiency are both reduced By monitoring the oxygen storage capacity of a catalyst its effi ciency can be indirectly calculated The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic con verter The PCM calculates the A F mixture from the output of the O2S A low voltage indicates high oxy gen content lean mixture A high volta...

Page 1448: ...rcuits systems and conditions that could have malfunctions causing driveability problems The PCM might not store diagnostic trouble codes for these conditions However problems with these systems may cause the PCM to store diagnostic trouble codes for other sys tems or components For example a fuel pressure problem will not register a fault directly but could cause a rich lean condition or misfire ...

Page 1449: ... established high and low limits for the device If the input voltage is not within limits and other criteria are met the PCM stores a diagnos tic trouble code in memory Other diagnostic trouble code criteria might include engine RPM limits or input voltages from other sensors or switches that must be present before verifying a diagnostic trouble code condition LOAD VALUE ENGINE IDLE NEUTRAL 2500 R...

Page 1450: ...cuum to draw vapors into the com bustion chambers during certain operating condi tions All engines use a duty cycle purge system The PCM controls vapor flow by operating the duty cycle EVAP purge solenoid Refer to Duty Cycle EVAP Purge Solenoid in this section The 4 0L six cylinder engine when equipped with the California Emissions Package will also use a Leak Detection Pump LDP as part of the eva...

Page 1451: ... reaches a specified temperature and the time delay ends During closed loop operation the PCM cycles energizes and de energizes the solenoid 5 or 10 times per second depending upon operating condi tions The PCM varies the vapor flow rate by chang ing solenoid pulse width Pulse width is the amount of time that the solenoid is energized The PCM adjusts solenoid pulse width based on engine operat ing...

Page 1452: ...eak the test is terminated at the end of the test mode If there is no leak the purge monitor is run If the cycle rate increases due to the flow through the purge system the test is passed and the diagnostic is complete The canister vent valve will unseal the system after completion of the test sequence as the pump diaphragm assembly moves to the full travel position POSITIVE CRANKCASE VENTILATION ...

Page 1453: ...onal PCV system but does not use a vacuum controlled valve A molded vacuum tube connects a fitting on the intake manifold to a fixed orifice fitting of a cali brated size This fitting meters the amount of crank case vapors drawn out of the engine The fixed orifice fitting is located on the top rear of cylinder head valve cover Fig 12 Fig 6 Evaporative System Monitor Schematic Typical Fig 7 PCV Val...

Page 1454: ...n stop and go or extended engine idle service or extreme dust conditions VEHICLE EMISSION CONTROL INFORMATION VECI LABEL All vehicles are equipped with a combined VECI label This label is located in the engine compart ment Fig 14 and contains the following Engine family and displacement Evaporative family Emission control system schematic Certification application Engine timing specifications if a...

Page 1455: ...awn against the opening in the cylinder head valve cover with noticeable force This will be after allowing approximately one minute for crankcase pressure to reduce 4 Turn engine off and remove PCV valve from cylinder head valve cover The valve should rattle when shaken Fig 17 5 Replace the PCV valve and retest the system if it does not operate as described in the preceding tests Do not attempt to...

Page 1456: ...hten nuts to 9 N m 80 in lbs torque 3 Connect vacuum lines Be sure vacuum lines are firmly connected and not leaking or damaged If leaking a Diagnostic Trouble Code DTC may be set with certain emission packages 4 Install the front bumper fascia assembly and grill Refer to Group 23 Body EVAPORATIVE CANISTER PURGE SOLENOID REMOVAL The duty cycle evaporative EVAP canister purge solenoid is located in...

Page 1457: ...R TUBE CAP If replacement of the fuel tank filler tube cap is necessary it must be replaced with an identical cap to be sure of correct system operation CAUTION Remove the fuel tank filler tube cap to relieve fuel tank pressure The cap must be removed prior to disconnecting any fuel system component or before draining the fuel tank LEAK DETECTION PUMP LDP The LDP is located in the left front corne...

Page 1458: ...um lines at both the LDP and EVAP canister solenoid for damage or leaks If a leak is present a Diagnostic Trouble Code DTC may be set SPECIFICATIONS TORQUE CHART Description Torque EVAP Canister Mounting Nuts 9 N m 80 in lbs EVAP Canister Purge Solenoid Mounting Nuts 5 N m 45 in lbs LDP Pump Bracket Nuts 7 N m 60 in lbs Fig 23 Leak Detection Pump LDP Location ZJ EMISSION CONTROL SYSTEMS 25 21 DIAG...

Page 1459: ......

Page 1460: ...NE INTAKE MANIFOLD 14 50 14 60 AIR TEMPERATURE SENSOR 5 2L ENGINES PCM INPUT INTAKE MANIFOLD 14 32 AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION 21 16 AIRBAG CONTROL MODULE 8M 2 8M 8 AIRBAG IMPACT SENSORS 8W 43 1 AIRBAG INDICATOR LAMP 8E 11 8E 6 AIRBAG MODULE 8M 2 8M 4 AIRBAG REAR MOUNTING BRACKET PASSENGER S 8M 7 AIRBAG SQUIB AIRBAG IGNITER 8W 43 1 AIRBAG SYSTEM 8M 3 AIRBAG TRIM COVER AND HO...

Page 1461: ...MODULE VEHICLE THEFT SECURITY SYSTEMS 8Q 2 BODY CONTROL MODULE WIPER AND WASHER SYSTEMS 8K 3 BODY CONTROL MODULE INPUTS 8U 2 BODY LUBRICANTS 23 47 BODY LUBRICATION 23 17 BODY MINIMUM AIR FLOW CHECK PROCEDURE THROTTLE 14 51 BODY SIDE CLADDING 23 31 BODY STRIPES DECALS 23 20 BODY VALVE 21 116 21 128 21 38 21 45 BODY 4 0L ENGINE THROTTLE 14 40 14 53 BODY 5 2L ENGINE THROTTLE 14 53 BODY 5 2L ENGINES T...

Page 1462: ... CHECK RADIATOR COOLANT FLOW 7 21 CHECK ROUTINE COOLANT LEVEL 7 24 CHECK VALVE SERVICE CONVERTER DRAINBACK 21 31 CHECKING FLUID LEVEL AND CONDITION 21 9 CHECK SERVICE COOLANT LEVEL 7 24 CHECKS PRELIMINARY 7 14 CHILD SEAT MODULE 23 37 CHILD SEAT REAR SEAT BACK WITH 23 37 CHIME AJAR 8W 45 2 CHIME ENGINE TEMPERATURE CRITICAL 8W 45 2 CHIME KEY IN IGNITION 8W 45 2 CHIME LOW FUEL WARNING LAMP ANNOUNCEME...

Page 1463: ...ALVE 21 8 CONVERTER HOUSING FLUID LEAK DIAGNOSIS 21 16 CONVERTER STALL TEST 21 15 CONVERTER TORQUE 21 44 CONVERTER 4 0 5 2L ENGINES CATALYTIC 11 5 CONVERTER ELECTRONIC CLUTCH TORQUE 21 4 CONVERTOR CLUTCH TCC SOLENOID PCM OUTPUT TORQUE 14 39 COOLANT 7 2 COOLANT ADDING ADDITIONAL 7 24 COOLANT FLOW CHECK RADIATOR 7 21 COOLANT LEVEL CHECK ROUTINE 7 24 COOLANT LEVEL CHECK SERVICE 7 24 COOLANT LEVEL AER...

Page 1464: ... CONTROL MODULE 8W 45 2 DIAGRAM INDEX WIRING 8W 46 MESSAGE CENTER 8W 46 2 DIAGRAM INDEX WIRING 8W 47 AUDIO SYSTEM 8W 47 2 DIAGRAM INDEX WIRING 8W 48 REAR WINDOW DEFOGGER 8W 48 1 DIAGRAM INDEX WIRING 8W 49 OVERHEAD CONSOLE 8W 49 1 DIAGRAM INDEX WIRING 8W 50 FRONT LIGHTING 8W 50 2 DIAGRAM INDEX WIRING 8W 51 REAR LIGHTING 8W 51 1 DIAGRAM INDEX WIRING 8W 52 TURN SIGNALS 8W 52 1 DIAGRAM INDEX WIRING 8W...

Page 1465: ...FIRING ORDER 5 2L V 8 8D 25 ENGINE EXHAUST MANIFOLD 5 2L 11 10 11 9 ENGINE FIRING ORDER 4 0L 6 CYLINDER ENGINE 8D 25 ENGINE FIRING ORDER 5 2L V 8 ENGINE 8D 25 ENGINE FUEL INJECTOR RAIL 4 0L 14 19 ENGINE FUEL INJECTORS 4 0L 14 5 ENGINE FUEL PUMP PRESSURE TEST 4 0L 14 6 ENGINE IDLE AIR CONTROL IAC MOTOR 4 0L 14 50 14 55 ENGINE IDLE AIR CONTROL IAC MOTOR 5 2L 14 50 14 55 ENGINE IGNITION COIL 4 0L 8D ...

Page 1466: ... 9 71 FRONT DISC BRAKE ROTOR 5 9 FRONT DISC BRAKES 5 4 FRONT DOOR 23 23 FRONT DOOR HINGE 23 23 FRONT DOOR INNER BELT SEAL 23 25 FRONT DOOR INSIDE HANDLE ACTUATOR 23 25 FRONT DOOR LATCH 23 24 FRONT DOOR LATCH STRIKER 23 25 FRONT DOOR LOCK CYLINDER 23 24 FRONT DOOR OPENING WEATHERSTRIP 23 26 FRONT DOOR OUTER BELT SEAL 23 25 FRONT DOOR OUTSIDE HANDLE 23 24 FRONT DOOR RUN CHANNEL WEATHERSTRIP 23 26 FR...

Page 1467: ...OCK 7 42 7 4 HEATER PERFORMANCE 24 12 HEATER A C CONTROL 24 35 HEATER A C HOUSING 24 41 HEATING GRID REAR GLASS 8N 1 8N 3 HEATING GRID REPAIRS REAR GLASS 8N 5 HEIGHT ADJUSTMENT GLASS PANEL VERTICAL 23 11 HIGH AND LOW LIMITS 25 12 HIGH BEAM INDICATOR LAMP 8W 40 2 HIGH BEAM INDICATOR LAMP HEADLAMP 8E 15 8E 7 HIGH MOUNTED STOP LAMP CHMSL BULB CENTER 8L 10 HIGH MOUNTED STOP LAMP CHMSL CENTER 8L 15 HIG...

Page 1468: ... SPEED SENSOR PCM 14 33 INPUT OVERDRIVE OVERRIDE SWITCH PCM 14 33 INPUT OXYGEN SENSOR O2S PCM 14 32 INPUT SPEED CONTROL SWITCHES PCM 14 34 INPUT STOP LAMP SWITCH 8W 35 2 INPUT THROTTLE POSITION SENSOR TPS 4 0L ENGINE PCM 14 34 INPUT THROTTLE POSITION SENSOR TPS 5 2L ENGINE PCM 14 34 INPUT TRANSMISSION GOVERNOR PRESSURE SENSOR PCM 14 34 INPUT TRANSMISSION PARK NEUTRAL SWITCH PCM 14 34 INPUT TRANSMI...

Page 1469: ...WITCH COURTESY 8W 45 1 LAMP SWITCH INPUT STOP 8W 35 2 LAMP SWITCH SENSE PARK 8W 45 2 LAMP SWITCH STOP BRAKES 5 14 5 32 5 2 5 8 LAMP SWITCH STOP VEHICLE SPEED CONTROL SYSTEM 8H 1 8H 6 8H 8 LAMP SYSTEM DAYTIME RUNNING 8L 17 LAMP SYSTEMS 8L 17 LAMP TAIL STOP TURN SIGNAL BACK UP AND SIDE MARKER 8L 14 LAMP TURN SIGNAL AND SIDE MARKER 8L 14 LAMP UNDERHOOD 8W 44 INTERIOR LIGHTING 8W 44 2 LAMP UNDERHOOD L...

Page 1470: ... ABSOLUTE PRESSURE SENSOR 8W 30 4 MANIFOLD AIR TEMPERATURE SENSOR INTAKE 8D 17 8D 4 8D 9 MANIFOLD AIR TEMPERATURE SENSOR 4 0L ENGINE INTAKE 14 50 14 61 MANIFOLD AIR TEMPERATURE SENSOR 4 0L ENGINE PCM INPUT INTAKE 14 32 MANIFOLD AIR TEMPERATURE SENSOR 5 2L ENGINE INTAKE 14 50 14 60 MANIFOLD AIR TEMPERATURE SENSOR 5 2L ENGINES PCM INPUT INTAKE 14 32 MANIFOLD LEAKAGE DIAGNOSIS INTAKE 9 8 MANIFOLD 5 2...

Page 1471: ...BOARD DIAGNOSTICS 25 1 ON BOARD DIAGNOSTICS OBD 7 8 ON BOARD DIAGNOSTICS TEST 8H 2 ONLY POWER ANTENNA EXPORT 8W 47 2 OPEN CIRCUIT VOLTAGE TEST 8A 6 OPENER STORAGE BIN GARAGE DOOR 8V 2 OPENER UNIVERSAL GARAGE DOOR 8W 44 2 OPENING REINFORCEMENT GOR GRILLE 23 18 OPENING WEATHERSTRIP FRONT DOOR 23 26 OPENING WEATHERSTRIP LIFTGATE 23 42 OPENING WEATHERSTRIP REAR DOOR 23 30 OPERATION AIR TESTING TRANSMI...

Page 1472: ...AFT IGNITION SYSTEM 8D 16 8D 4 8D 8 POSITION SENSOR CRANKSHAFT 8W 30 FUEL IGNITION SYSTEMS 8W 30 3 POSITION SENSOR CRANKSHAFT FUEL SYSTEM 14 57 POSITION SENSOR THROTTLE 8W 30 FUEL IGNITION SYSTEMS 8W 30 3 POSITION SENSOR THROTTLE IGNITION SYSTEM 8D 17 8D 4 POSITION SENSOR TPS 4 0L ENGINE THROTTLE 14 51 14 54 POSITION SENSOR TPS 4 0L ENGINE PCM INPUT THROTTLE 14 34 POSITION SENSOR TPS 5 2L ENGINE T...

Page 1473: ...APORATIVE CANISTER 25 19 PURGE SOLENOID VALVE PCM OUTPUT DUTY CYCLE EVAP 14 36 PUSH RODS ROCKER ARMS 9 30 9 48 9 61 PUSH BUTTON MODULE 8V 7 QUARTER TRIM PANELS 23 34 QUARTER WINDOW APPLIQUE AIR EXHAUSTER 23 45 QUARTER WINDOW GLASS 23 6 QUICK FILL VALVE 21 7 QUICK CONNECT FITTINGS 14 12 14 6 RACK LUGGAGE 23 45 RACK PISTON AND WORM SHAFT 19 15 RADIAL PLY TIRES 22 2 RADIATOR 7 35 7 47 7 2 RADIATOR CA...

Page 1474: ...IONS LAMPS 8L 1 SAFETY PRECAUTIONS AND WARNINGS 23 1 SANDING BUFFING AND POLISHING WET 23 2 SCAN TOOL DRB 7 9 SCHEDULE A 0 3 SCHEDULE B 0 5 SCHEDULES MAINTENANCE 0 3 SCHEMATICS HYDRAULIC 21 129 SCHEMATICS VACUUM 25 19 SCREEN COWL GRILLE 23 20 SCREEN HEADLAMP ADJUSTMENT USING ALIGNMENT 8L 6 SCUFF PLATE FRONT DOOR 23 33 SCUFF PLATE REAR DOOR 23 34 SEAL AND BEARING AXLE SHAFT 3 53 3 84 SEAL AND SPRIN...

Page 1475: ... SENSOR PCM INPUT OUTPUT 14 33 SHAFT SUPPORT OIL PUMP AND REACTION 21 120 21 79 SHAFT CARDAN U JOINT AXLE 3 30 SHAFTS PROPELLER 3 1 SHIELD CALIPER BRACKET LEVER BOOT SPLASH 5 24 SHIELDS HEAT 11 2 SHIFT INTERLOCK 8W 31 1 SHIFT INTERLOCK BRAKE TRANSMISSION 21 125 21 11 21 35 SHIFT INTERLOCK MECHANISM BRAKE TRANSMISSION 21 8 SHIFT LEVER 21 149 SHIFT LINKAGE ADJUSTMENT 21 167 21 189 SHIFT SEQUENCE 3 4...

Page 1476: ...RAGE BIN SUNGLASSES 8V 2 STRAINER FUEL PUMP INLET 14 18 STRENGTH FASTENER Intro 6 STRETCH MEASURING TIMING CHAIN 9 56 STRIKER FRONT DOOR LATCH 23 25 STRIKER GLOVE BOX LATCH 8E 26 STRIKER HOOD LATCH 23 19 STRIKER LIFTGATE LATCH 23 42 STRIKER REAR DOOR LATCH 23 29 STRIKER SAFETY LATCH 23 20 STRIPES DECALS BODY 23 20 STUDS STEERING KNUCKLE AND BALL 3 24 STUDS WHEEL MOUNTING 2 11 SUNGLASSES STORAGE BI...

Page 1477: ...OR BATTERY 8W 30 FUEL IGNITION SYSTEMS 8W 30 2 TEMPERATURE SENSOR BATTERY CHARGING SYSTEM 8C 2 8C 6 8C 8 TEMPERATURE SENSOR ENGINE COOLANT 8W 30 FUEL IGNITION SYSTEMS 8W 30 3 TEMPERATURE SENSOR ENGINE COOLANT IGNITION SYSTEM 8D 17 8D 4 8D 9 TEMPERATURE SENSOR IN CAR 8W 42 2 TEMPERATURE SENSOR INTAKE AIR 8W 30 4 TEMPERATURE SENSOR INTAKE MANIFOLD AIR 8D 17 8D 4 8D 9 TEMPERATURE SENSOR IN VEHICLE 24...

Page 1478: ...UTOMATIC 21 9 TRANSMISSION DIAGNOSIS TABLES AND CHARTS RE 21 19 TRANSMISSION FILL PROCEDURE 21 31 TRANSMISSION GEAR RATIOS 21 4 TRANSMISSION GOVERNOR PRESSURE SENSOR PCM INPUT 14 34 TRANSMISSION IDENTIFICATION 21 4 TRANSMISSION OIL COOLER AUXILIARY 7 26 TRANSMISSION OIL COOLERS AUTOMATIC 7 2 TRANSMISSION PARK NEUTRAL SWITCH PCM INPUT 14 34 TRANSMISSION RELAY PCM OUTPUT 14 39 TRANSMISSION SHIFT INT...

Page 1479: ...E 7 29 WATER PUMP BYPASS HOSE 7 39 WATER PUMP BYPASS HOSE 5 2L V 8 ENGINE 7 2 WATER PUMP INSPECTION 7 47 WATER PUMP TESTS 7 9 WATER IN FUEL LAMP 8E 9 WEAR INDICATORS TREAD 22 3 WEAR PATTERNS TIRE 22 3 WEATHERSTRIP FRONT DOOR OPENING 23 26 WEATHERSTRIP FRONT DOOR RUN CHANNEL 23 26 WEATHERSTRIP LIFTGATE FLIP UP GLASS 23 43 WEATHERSTRIP LIFTGATE OPENING 23 42 WEATHERSTRIP REAR DOOR OPENING 23 30 WET ...

Page 1480: ... SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF CHRYSLER CORPORATION Chrysler Corporation reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obli gations upon itself to install them on its products previously manufactured Litho ...

Page 1481: ...e The solid bar after the group title is aligned to a solid tab on the first page of each group The first page of the group has a contents section that lists major topics within the group If you are not sure which Group contains the infor mation you need look up the Component System in the alphabetical index located in the rear of this manual A Service Manual Comment form is included at the rear o...

Page 1482: ...GROUP TAB LOCATOR 0 Lubrication and Maintenance 3 Differential and Driveline 21 Transmission and Transfer Case Component and System Index Service Manual Comment Forms Rear of Manual ...

Page 1483: ......

Page 1484: ...pts Depending on type and size of internal cooler length and inside diameter of cooler lines or use of an auxiliary cooler these figures may vary Refer to Group 21 Transmission for proper fluid fill proce dure TRANSFER CASE 242 NVG 1 4 L 3 0 pts 249 NVG 1 1 L 2 5 pts FRONT AXLE Model 30 1 18 L 2 5 pts REAR AXLE Model 35 1 6 L 3 5 pts Model 44 2 24 L 4 75 pts If the vehicle is equipped with Trac lo...

Page 1485: ......

Page 1486: ...ousing to form a one piece axle housing The integral type housing hypoid gear design has the center line of the pinion set below the center line of the ring gear The axle has a vent hose to relieve internal pres sure caused by lubricant vaporization and internal expansion The axles are equipped with semi floating axle shafts meaning that loads are supported by the axle shaft and bearings The axle ...

Page 1487: ...gear rotates the ring gear The ring gear bolted to the differential case rotates the case The differential pinion gears mounted on the pinion mate shaft in the case rotate the side gears The side gears splined to the axle shafts rotate the shafts During straight ahead driving the differential pin ion gears do not rotate on the pinion mate shaft This occurs because input torque applied to the gears...

Page 1488: ...ere the noise is the greatest Shift out of gear and coast through the peak noise range If the noise stops or changes greatly Check for insufficient lubricant Incorrect ring gear backlash Gear damage Differential side and pinion gears can be checked by turning the vehicle They usually do not cause noise in straight ahead driving The side gears are loaded during vehicle turns If noise does occur dur...

Page 1489: ...mounts Loose pinion gear nut and yoke Excessive ring gear backlash Excessive side gear case clearance The source of a snap or a clunk noise can be deter mined with the assistance of a helper Raise the vehi cle on a hoist with the wheels free to rotate Instruct the helper to shift the transmission into gear Listen for the noise a mechanics stethoscope is helpful in isolating the source of a noise T...

Page 1490: ...ZJ DIFFERENTIAL AND DRIVELINE 3 5 DIAGNOSIS AND TESTING Continued ...

Page 1491: ...3 6 DIFFERENTIAL AND DRIVELINE ZJ DIAGNOSIS AND TESTING Continued ...

Page 1492: ...ngine oil or lint free cloth Do not use water steam kerosene or gasoline for cleaning 5 Remove the original sealant from the housing and cover surfaces 6 Apply a bead of Mopart Silicone Rubber Seal ant or equivalent to the housing cover Fig 6 Install the housing cover within 5 minutes after applying the sealant 7 Install the cover and any identification tag Tighten the cover bolts to 41 N m 30 ft ...

Page 1493: ...ll the brake rotors and calipers Refer to Group 5 Brakes for proper procedures 7 Install axle vent hose 8 Align propeller shaft and pinion yoke reference marks Install U joint straps and bolts tighten to 19 N m 14 ft lbs torque 9 Install the wheels and tires 10 Check and add gear lubricant 11 Remove lifting device from axle and lower the vehicle 12 Tighten lower suspension arms bolts to 177 N m 13...

Page 1494: ... low use Holder 6958 to hold the pinion yoke Fig 12 and tighten the pinion shaft nut in 6 8 N m 5 ft lbs increments until proper rotating torque is achieved CAUTION If the maximum tightening torque is reached prior to reaching the required rotating torque the collapsible spacer may have been dam aged Replace the collapsible spacer 6 Align the installation reference marks and install the propeller ...

Page 1495: ... support the vehicle 2 Remove wheel and tire assemblies 3 Remove rear brake rotors and calipers Refer to Group 5 Brakes for proper procedures 4 Mark the propeller shaft and pinion yoke for installation reference 5 Remove the propeller shaft from the yoke 6 Rotate the pinion gear three or four times 7 Measure the amount of torque necessary to rotate the pinion gear with an in lbs dial type torque w...

Page 1496: ...nd never exceed specified preload torque If preload torque is exceeded a new collapsible spacer must be installed The torque sequence will have to be repeated NOTE A new collapsible spacer will start to crush at around 265 ft lbs torque If the spacer requires more than 280 ft lbs torque to crush the collaps ible spacer is defective 7 Using yoke holder 6958 a short length of 1 in pipe and a torque ...

Page 1497: ...up 5 Brakes for proper procedure 4 Clean all foreign material from housing cover area 5 Loosen housing cover bolts Drain lubricant from the housing and axle shaft tubes Remove hous ing cover 6 Rotate differential case so that pinion mate gear shaft lock screw is accessible Remove lock screw and pinion mate gear shaft from differential case Fig 22 7 Push axle shaft inward and remove axle shaft C cl...

Page 1498: ...same time with the bearing removal tool 3 Remove the axle shaft bearing from the tube Fig 24 with Bearing Removal Tool Set 6310 4 Inspect the axle shaft tube bore for roughness and burrs Remove as necessary INSTALLATION Do not install the original axle shaft seal Always install a new seal 1 Wipe the bore in the axle shaft tube clean 2 Install axle shaft bearing with Installer 6436 and Handle C 417...

Page 1499: ...ing holes Fig 27 Install the hold down clamps and tighten the tool turnbuckle finger tight 2 Install a pilot stud at the left side of the differ ential housing Attach dial indicator to housing pilot stud Load the indicator plunger against the opposite side of the housing Fig 27 and zero the indicator 3 Separate the housing enough to install the case in the housing Measure the distance with the dia...

Page 1500: ...31 DIFFERENTIAL SIDE BEARING INSTALLATION 1 Using tool C 4340 with handle C 4171 install differential side bearings Fig 32 2 Install differential case in axle housing Fig 29 Differential Installation Fig 30 Differential Bearing Cap Reference Letters Fig 31 Differential Bearing Removal Fig 32 Install Differential Side Bearings ZJ DIFFERENTIAL AND DRIVELINE 3 15 REMOVAL AND INSTALLATION Continued ...

Page 1501: ...lts and alternately tighten to 95 122 N m 70 90 ft lbs torque Fig 34 5 Install differential in axle housing and verify differential side bearing preload gear mesh and con tact pattern PINION GEAR REMOVAL 1 Remove differential assembly from axle hous ing 2 Mark pinion yoke and propeller shaft for installation alignment 3 Disconnect propeller shaft from pinion yoke Using suitable wire tie propeller ...

Page 1502: ...blocks so they do not damage the bearing cage 13 Remove the pinion depth shims from the pin ion gear shaft Record the total thickness of the depth shims Fig 35 Pinion Yoke Holder Fig 36 Pinion Yoke Removal Fig 37 Remove Pinion Gear Fig 38 Front Bearing Cup Removal Fig 39 Rear Bearing Cup Removal ZJ DIFFERENTIAL AND DRIVELINE 3 17 REMOVAL AND INSTALLATION Continued ...

Page 1503: ...al with Installer D 163 and Handle C 4171 Fig 44 NOTE Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh If the factory installed ring and pinion gears are reused the pin ion depth shim should not require replacement or adjustment Refer to Pinion Gear Depth paragraph in this section to select the proper thickness shim befo...

Page 1504: ...TE A new collapsible spacer will start to crush at around 265 ft lbs torque If the spacer requires more than 280 ft lbs torque to crush the collaps ible spacer is defective 10 Using yoke holder 6958 a short length of 1 in pipe and a torque wrench set at 380 N m 280 ft lbs crush collapsible spacer until bearing end play is taken up Fig 48 11 Slowly tighten the nut in 6 8 N m 5 ft lbs increments unt...

Page 1505: ... Overfilling the differential can result in lubricant foaming and overheating 3 Refill the differential housing with gear lubri cant Refer to the Lubricant Specifications for the gear lubricant requirements 4 Install the fill hole plug DISASSEMBLY AND ASSEMBLY STANDARD DIFFERENTIAL DISASSEMBLE 1 Remove pinion gear mate shaft lock screw Fig 51 2 Remove pinion gear mate shaft 3 Rotate the differenti...

Page 1506: ...ear lubricant TRAC LOK DIFFERENTIAL The Trac Lok differential components are illus trated in Fig 53 Refer to this illustration during repair service DISASSEMBLY 1 Clamp Side Gear Holding Tool 6963 A in a vise Fig 53 Trac Lok Differential Components Fig 51 Pinion Gear Mate Shaft Lock Screw Fig 52 Pinion Mate Gear Removal ZJ DIFFERENTIAL AND DRIVELINE 3 21 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1507: ...on a small screw driver in slot of Threaded Adapter C 4487 3 Fig 58 to prevent adapter from turning 9 Tighten forcing screw tool 122 N m 90 ft lbs maximum to compress Belleville springs in clutch packs Fig 59 10 Using an appropriate size feeler gauge remove thrust washers from behind the pinion gears Fig 60 11 Insert Turning Bar C 4487 4 in case Fig 61 12 Loosen the Forcing Screw C 4487 2 in small...

Page 1508: ...gear lubricant before assembly 1 Assemble the clutch discs into packs and secure disc packs with retaining clips Fig 63 2 Position assembled clutch disc packs on the side gear hubs 3 Install clutch pack and side gear in the ring gear side of the differential case Fig 64 Be sure clutch pack retaining clips remain in position and are seated in the case pockets 4 Position the differential case on Sid...

Page 1509: ... screw in order to install the pin ion gears 12 Tighten forcing screw to 122 N m 90 ft lbs to compress the Belleville springs 13 Lubricate and install thrust washers behind pinion gears and align washers with a small screw driver Insert mate shaft into each pinion gear to ver ify alignment 14 Remove forcing screw threaded adapter and step plate 15 Install pinion gear mate shaft and align holes in ...

Page 1510: ...essary Preload shims for damage and distortion Install new shims if necessary TRAC LOK Clean all components in cleaning solvent Dry com ponents with compressed air Inspect clutch pack plates for wear scoring or damage Replace both clutch packs if any one component in either pack is damaged Inspect side and pinion gears Replace any gear that is worn cracked chipped or damaged Inspect differential c...

Page 1511: ...rt PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion cups and pin ion bearings installed in housing Take measurements with Pinion Gauge Set 6955 Dummy Bearing Arbor Disc Set 6956 and Dial Indicator C 3339 Fig 68 1 Assemble Pinion Height Block 6739 Pinion Block 6734 and rear pinion bearing onto Screw 6741 Fig 68 2 Insert assembled height gauge components rear bearing and sc...

Page 1512: ...te sign on the variance number For exam ple if the depth variance is 2 add 0 002 in to the dial indicator reading 10 Remove the pinion depth gauge components from the axle housing DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH Differential side bearing preload and gear backlash is achieved by selective shims inserted between the bearing cup and the axle housing The proper shim thickness can be det...

Page 1513: ...face to pointer 11 Push and hold differential case to ring gear side of the axle housing 12 Record dial indicator reading 13 Add the dial indicator reading to the starting point shim thickness to determine total shim thick ness to achieve zero differential end play 14 Add 0 012 in 0 3 mm to the zero end play total This new total represents the thickness of shims to compress or preload the new bear...

Page 1514: ...y amount of shim thickness from one side of the axle housing to the other Fig 76 38 Verify differential case and ring gear runout by measuring ring to pinion gear backlash at several locations around the ring gear Readings should not vary more than 0 05 mm 0 002 in If readings vary more than specified the ring gear or the differential case is defective After the proper backlash is achieved perform...

Page 1515: ...Fig 77 Gear Tooth Contact Patterns 3 30 DIFFERENTIAL AND DRIVELINE ZJ ADJUSTMENTS Continued ...

Page 1516: ...Bearing Cap 85 N m 63 ft lbs Bolts Ring Gear 108 N m 80 ft lbs Screw ABS Sensor 8 N m 70 in lbs Screw Pinion Gear Mate Shaft Lock 17 6 N m 13 ft lbs Nuts Brake Backing Plate 61 N m 45 ft lbs Nut Pinion Gear Minimum 298 N m 220 ft lbs Nut Pinion Gear Maximum 380 N m 280 ft lbs NOTE Refer to Pinion Gear Removal and Instal lation procedures for proper pinion nut tightening instructions Do not exceed ...

Page 1517: ...Installer C 3718 Handle C 4171 Remover C 4307 Installer C 4308 Installer C 4340 Pilot C 3288 Dial Indicator C 3339 Trac lok Tool Set C 4487 3 32 DIFFERENTIAL AND DRIVELINE ZJ SPECIAL TOOLS Continued ...

Page 1518: ...Installer D 163 Installer D 129 Remover D 103 Spreader W 129 B Remover 6310 Installer 6436 Installer 6437 Installer 6448 ZJ DIFFERENTIAL AND DRIVELINE 3 33 SPECIAL TOOLS Continued ...

Page 1519: ...Adapter 6790 Pinion Depth Set 6955 Fig 78 Adapter Set 6956 Holder 6958 Holder 6963 A Remover 7794 A 3 34 DIFFERENTIAL AND DRIVELINE ZJ SPECIAL TOOLS Continued ...

Page 1520: ...ub The front output shaft is operated by a drive chain that connects the shaft to a drive sprocket on the mainshaft The drive sprocket is engaged disengaged by the mode fork which oper ates the mode sleeve and hub The sleeve and hub are not equipped with a synchro mechanism for shift ing The geartrain is mounted in two aluminum case halves attached with bolts The mainshaft front and rear bearings ...

Page 1521: ...MENDED LUBRICANT AND FILL LEVEL Recommended lubricant for the NV 242 transfer case is Mopart Dexron II or ATF Plus Approximate lubricant fill capacity is 1 35 liters 2 85 pints The fill and drain plugs are both in the rear case Fig 2 Correct fill level is to the bottom edge of the fill plug hole Be sure the vehicle is level to ensure an accurate fluid level check Fig 2 Fill Drain Plug And I D Tag ...

Page 1522: ...DIAGNOSIS AND TESTING NV242 DIAGNOSIS ZJ TRANSMISSION AND TRANSFER CASE 21 3 ...

Page 1523: ...7 Disconnect front rear propeller shafts at trans fer case 8 Disconnect vehicle speed sensor wires 9 Disconnect transfer case linkage rod from range lever 10 Disconnect transfer case vent hose and indica tor switch harness 11 Support transfer case with transmission jack 12 Remove nuts attaching transfer case to trans mission 13 Secure transfer case to jack with chains 14 Pull transfer case and jac...

Page 1524: ... 998056 A remove rear slinger Fig 6 3 Remove slinger stop spacer and snap ring from output shaft Fig 7 4 Remove rear seal from retainer Fig 8 Use pry tool or collapse seal with punch to remove it 5 Remove rear output bearing I D retaining ring Fig 9 6 Remove rear retainer bolts Fig 4 Transfer Case Mounting Fig 5 Output Boot Typical Fig 6 Rear Slinger Removal Fig 7 Slinger Stop Spacer and Snap ring...

Page 1525: ...3 Note position of the two black fin ish bolts at each end of the case These bolts go through the case dowels and require a washer under the bolt head 12 Remove rear case from front case Fig 14 Insert screwdrivers into slots cast into each end of case Then pry upward to break sealer bead and remove rear case CAUTION Do not pry on the sealing surface of either case half as the surfaces will become ...

Page 1526: ... positioned on yoke and not on slinger as slinger will be damaged 4 Remove seal washer from front output shaft Discard washer as it should not be reused 5 Remove nut and washer that attach range lever to sector shaft Then move sector to neutral position and remove range lever from shaft Fig 18 Fig 14 Loosening Removing Rear case Fig 15 Oil Pickup Screen Hose And Tube Removal Fig 16 Yoke Nut Remova...

Page 1527: ... fork lockpin access hole Then move shift sector to align low range fork lockpin with access hole Fig 23 3 Remove range fork lockpin with size number one easy out tool Grip easy out tool with locking pli ers and remove pin with counterclockwise twist and pull motion Fig 23 Fig 19 Drive Sprocket Snap Ring Removal Fig 20 Drive Sprocket And Chain Removal Fig 21 Removing Front Output Shaft Fig 22 Dete...

Page 1528: ... mode shift sleeve and mode fork assembly from mainshaft Fig 26 Note position of mode sleeve in fork and remove sleeve Fig 23 Low Range Fork Lockpin Removal Fig 24 Shift Rail Removal Fig 25 Mode Fork And Mainshaft Removal Fig 26 Mode Fork And Sleeve Removal ZJ TRANSMISSION AND TRANSFER CASE 21 9 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1529: ...g 30 11 Remove differential Fig 31 12 Remove differential needle bearings and both needle bearing thrust washers from mainshaft Fig 27 Intermediate Clutch Shaft Snap Ring Removal Fig 28 Clutch Shaft Thrust Ring Removal Fig 29 Intermediate Clutch Shaft Removal Fig 30 Differential Snap Ring Removal 21 10 TRANSMISSION AND TRANSFER CASE ZJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1530: ...move low range fork and hub Fig 33 15 Remove shift sector Fig 34 Fig 31 Differential Removal Fig 32 Disengaging Low Range Fork Fig 33 Low Range Fork And Hub Removal Fig 34 Shift Sector Position ZJ TRANSMISSION AND TRANSFER CASE 21 11 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1531: ...d Tool 7829A Fig 38 5 Remove low range gear snap ring Fig 39 6 Remove input gear retainer thrust washers and input gear from low range gear Fig 40 7 Inspect low range annulus gear Fig 41 Gear is not a serviceable component If damaged replace gear and front case as assembly 8 Remove oil seals from following components rear retainer oil pump case halves Fig 35 Sector Bushing And O Ring Removal Fig 3...

Page 1532: ... 5 Remove thrust washers and planet gears from case pins Fig 43 6 Remove mainshaft and sprocket gears from bottom case Fig 44 Note gear position for reference before separating them Fig 39 Low Range Gear Snap Ring Removal Installation Fig 40 Low Range Gear Disassembly Fig 41 Inspecting Low Range Annulus Gear Fig 42 Separating Differential Case Halves ZJ TRANSMISSION AND TRANSFER CASE 21 13 DISASSE...

Page 1533: ...s punch to tap bearing out of case 2 Install new front output shaft bearing with Tool Handle C 4171 and Installer 8033A with the tapered cone upward Fig 46 3 Install front bearing snap ring Fig 45 4 Install new front output shaft oil seal as fol lows a Tap seal into bore until flush with upper edge of case bore Use Installer 6888 to start seal into place Fig 47 Fig 43 Planet Gears And Thrust Washe...

Page 1534: ... with Tool Handle C 4171 and Remover C 4210 Fig 49 6 Install snap ring on new input gear bearing 7 Install new input gear bearing with Tool Han dle C 4171 and Remover C 4210 Install bearing far enough to seat snap ring against case Fig 50 8 Remove input gear pilot bearing with slide hammer and internal puller Fig 51 9 Install new pilot bearing with suitably sized driver tool Fig 47 Starting Front ...

Page 1535: ...aring with Tool Handle C 4171 and Installer 5066 Lubricate bearing after installa tion 13 Install new seal in oil pump feed housing with Special Tool 7888 Fig 54 Fig 53 Front Output Shaft Rear Bearing Installation Fig 54 Oil Pump Seal Installation Fig 51 Input Gear Pilot Bearing Removal Fig 52 Front Bearing Retainer Seal Installation 21 16 TRANSMISSION AND TRANSFER CASE ZJ DISASSEMBLY AND ASSEMBLY...

Page 1536: ...tall differential mainshaft gear Fig 57 5 Align and position differential top case on bot tom case Fig 58 Align using scribe marks made at disassembly 6 While holding differential case halves together invert the differential and start the differential case bolts 7 Tighten differential case bolts to specified torque Fig 57 Installing Mainshaft And Planet Gears Fig 58 Differential Case Assembly Fig ...

Page 1537: ... of front bearing retainer 8 Install front bearing retainer Fig 62 Tighten retainer bolts to 16 ft lbs 21 N m torque SHIFT FORKS AND MAINSHAFT ASSEMBLY AND INSTALLATION 1 Install new sector shaft O ring and bushing Fig 63 2 Install shift sector 3 Install new pads on low range fork if neces sary Fig 64 4 Assemble low range fork and hub Fig 64 5 Position low range fork and hub in case Be sure low ra...

Page 1538: ...old them in place 8 Install remaining bearing spacer on mainshaft Fig 66 Do not displace any bearings while install ing spacer Fig 63 Sector O Ring And Bushing Installation Fig 64 Assembling Low Range Fork And Hub Fig 65 Positioning Low Range Fork Fig 66 Installing Mainshaft Bearing Rollers and Spacers ZJ TRANSMISSION AND TRANSFER CASE 21 19 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1539: ... Fig 71 14 Inspect mode fork assembly Fig 72 Replace pads and bushing if necessary Replace fork tube if bushings inside tube are worn or damaged Also check springs and slider bracket Fig 72 Replace worn damaged components Fig 67 Differential Installation Fig 68 Installing Differential Snap Ring Fig 69 Installing Intermediate Clutch Shaft Fig 70 Installing Clutch Shaft Thrust Washer 21 20 TRANSMISS...

Page 1540: ...ainshaft assembly in case Fig 74 Rotate mainshaft slightly to engage shaft with low range gears 17 Rotate mode fork pin into shift sector slot Fig 71 Installing Clutch Shaft Snap Ring Fig 72 Mode Fork Assembly Inspection Fig 73 Installing Mode Fork And Sleeve Fig 74 Assembled Mainshaft And Mode Fork Installation ZJ TRANSMISSION AND TRANSFER CASE 21 21 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1541: ...in lockpin access hole 23 Install detent plunger detent spring and detent plug in case Fig 77 FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION 1 Install front output shaft Fig 78 2 Install drive chain Fig 78 Engage chain with front output shaft sprocket teeth 3 Install drive sprocket Fig 78 Engage drive sprocket teeth with chain Then engage sprocket splines with mainshaft splines 4 Install drive sp...

Page 1542: ...ear case bolts to 41 N m 30 ft lbs torque Be sure to install a washer under each bolt used at case dowel locations REAR RETAINER ASSEMBLY AND INSTALLATION 1 Remove rear bearing in retainer using a ham mer handle or a hammer and a brass drift to tap bearing from the retainer 2 Install rear bearing in retainer with Tools C 4171 and 5064 Fig 82 3 Install rear bearing O D retaining ring with snap ring...

Page 1543: ... Fig 86 FRONT YOKE AND SWITCH INSTALLATION 1 Install indicator switch in front case Tighten switch to 20 34 N m 15 25 ft lbs torque 2 Lubricate yoke hub with transmission fluid and install yoke on front shaft 3 Install new seal washer on front shaft 4 Install yoke on front shaft Secure yoke with new nut CLEANING AND INSPECTION NV242 TRANSFER CASE Clean the transfer case parts with a standard parts...

Page 1544: ...ecessary Also replace the lock retaining ring if bent distorted or broken SHIFT FORKS HUBS SLEEVES Check condition of the shift forks and mode fork shift rail Fig 88 Minor nicks on the shift rail can be smoothed with 320 400 grit emery cloth Inspect the shift fork wear pads The mode fork pads are serviceable and can be replaced if necessary The range fork pads are also serviceable Check both of th...

Page 1545: ... scored or if any sprocket teeth are cracked or broken Examine the drive chain and shaft bearings replace the chain if stretched distorted or if any of the links bind Replace the bearings if rough or noisy LOW RANGE ANNULUS GEAR Inspect annulus gear condition carefully The gear is only serviced as part of the front case If the gear is damaged it will be necessary to replace the gear and front case...

Page 1546: ...tube are the only serviceable parts and are available separately ADJUSTMENTS SHIFT LINKAGE ADJUSTMENT 1 Shift transfer case into 4L position 2 Raise vehicle 3 Loosen lock bolt on adjusting trunnion Fig 92 4 Be sure linkage rod slides freely in trunnion Clean rod and apply spray lube if necessary 5 Verify that transfer case range lever is fully engaged in 4L position 6 Tighten adjusting trunnion lo...

Page 1547: ...V242 Installer 6888 Installer C 4076 A Handle Universal C 4171 Installer Seal C 4210 Puller Slinger MD 998056 A Installer MD 998323 Installer Bearing 5064 Installer Bushing 5066 21 28 TRANSMISSION AND TRANSFER CASE ZJ ...

Page 1548: ...r 6992 Installer Input Gear Bearing 7829 A Installer Seal 7884 Installer Pump Housing Seal 7888 Installer Bearing 8033 A Installer Boot Clamp C 4975 A ZJ TRANSMISSION AND TRANSFER CASE 21 29 SPECIAL TOOLS Continued ...

Page 1549: ......

Page 1550: ... AND FILL 21 2 LEVER SHIFT 21 4 LINKAGE ADJUSTMENT SHIFT 21 27 LOW SPEED KNOCK 3 3 LUBRICANT AND FILL LEVEL RECOMMENDED 21 2 LUBRICANT CHANGE 3 7 LUBRICANT SPECIFICATIONS 3 1 MODEL 44 ALUMINUM AXLE 3 1 MODEL 44 AXLE 3 31 3 1 NOISE BEARING 3 3 NOISE GEAR 3 3 NOISE TRAC LOK DIFFERENTIAL 3 4 NV 242 TRANSFER CASE 21 1 NV242 21 28 NV242 DIAGNOSIS 21 3 NV242 TRANSFER CASE 21 24 21 1 21 5 OPERATION TRAC ...

Page 1551: ......

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