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Jeep 1997 Grand Cherokee, Service Manual

The 1997 Jeep Grand Cherokee Service Manual is a comprehensive resource for Jeep owners seeking detailed instructions and guidance for maintenance, repairs, and troubleshooting. This invaluable manual is available for free download at manualshive.com, empowering users to access the information they need to keep their vehicle in optimal condition.

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The compressor clutch and coil are the only serviced
parts on the compressor.

DIESEL ENGINE

The compressor clutch assembly consists of a sta-

tionery electromagnetic coil, a hub bearing and rotor
assembly, and a clutch plate (Fig. 5). The electromag-
netic coil and rotor are retained on the compressor
with snap rings. The clutch plate is mounted on the
compressor shaft and secured with a bolt.

The compressor is mounted on the left side of the

engine block behind the power steering pump. The
compressor is driven by a splined shaft off the rear of
the power steering pump. The splined shaft has a
drive flange mounted to it which attaches to a drive
spool. The spool links the compressor clutch plate to
the steering pump drive flange. When the clutch coil
is energized, it magnetically draws the clutch plate
into contact with the rotor and drives the compressor
shaft. When the coil is not energized, the rotor free-
wheels on the clutch hub bearing, which is part of

the rotor. The compressor clutch and coil are the only
serviced parts on the compressor.

COMPRESSOR CLUTCH RELAY

The compressor clutch relay is a International

Standards Organization (ISO) micro-relay. The termi-
nal designations and functions are the same as a con-
ventional

ISO

relay.

However,

the

micro-relay

terminal orientation (footprint) is different, the cur-
rent capacity is lower, and the relay case dimensions
are smaller than those of the conventional ISO relay.

The compressor clutch relay is a electromechanical

device that switches battery current to the compres-
sor clutch coil when the Powertrain Control Module
(PCM) grounds the coil side of the relay. The PCM
responds to inputs from the A/C compressor switch
on the heater-A/C control panel, the ATC controller,
the low pressure cycling clutch switch, and the high
pressure cut-off switch. See the Diagnosis and Test-
ing section of this group for more information on the
operation of the compressor clutch relay.

The compressor clutch relay is located in the Power

Distribution Center (PDC) in the engine compart-
ment. Refer to the PDC label for relay identification
and location.

The compressor clutch relay cannot be repaired

and, if faulty or damaged, it must be replaced.

CONDENSER

The condenser is located in front of the engine cool-

ing radiator. It is a heat exchanger that allows the
high-pressure refrigerant gas to give up its heat to
the air passing over the condenser fins. This causes
the refrigerant gas to condense into a high-pressure
liquid refrigerant.

The condenser cannot be repaired and, if faulty or

damaged, it must be replaced.

EVAPORATOR COIL

The evaporator coil is located in the heater-A/C

housing, under the instrument panel. Refrigerant
enters the evaporator as a low-temperature, low-
pressure liquid. As air passes over the fins of the
evaporator, the humidity in the air condenses on the
fins, and the heat from the air is absorbed by the
refrigerant. Heat absorption causes the refrigerant to
become a low-pressure gas before it leaves the evap-
orator.

The evaporator coil cannot be repaired and, if

faulty or damaged, it must be replaced.

FIXED ORIFICE TUBE

The fixed orifice tube is integral to the liquid line

located between the outlet tube of the condenser and
the inlet tube of the evaporator. The inlet and outlet
ends of the tube have a screen to filter the refriger-

Fig. 4 Compressor Clutch - Gasoline Engine

CLUTCH PLATE

SHAFT KEY

PULLEY

COIL

CLUTCH

SHIMS

SNAP RING

SNAP RING

Fig. 5 Compressor Clutch - Diesel Engine

COIL

CLUTCH ROTOR

CLUTCH PLATE

SNAP RING

SNAP RING

ZG

HEATING AND AIR CONDITIONING

24 - 7

DESCRIPTION AND OPERATION (Continued)

Summary of Contents for 1997 Grand Cherokee

Page 1: ...Welcome to the 1997 Jeep Grand Cherokee RHD LHD Interactive Electronic Service Manual CLICK ON VEHICLE TO BEGIN tweddle litho dom parts cdrom demo 09 96 page 4 output 1601 ET 05 06 97 ...

Page 2: ...rn Signal and Flashers 8K Windshield Wipers and Washers 8L Lamps 8M Restraint System 8N Electrically Heated Systems 8P Power Door Locks 8Q Vehicle Theft Security System 8R Power Seats 8S Power Windows 8T Power Mirrors 8U Chime Warning Reminder System 8V Overhead Console 8W Wiring Diagrams 9 Engine 11 Exhaust System and Intake Manifold 13 Bumpers and Frame 14 Fuel System 19 Steering 21 Transaxle 22...

Page 3: ...the decoding 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 Rati...

Page 4: ... located on the driver side door shut face BODY CODE PLATE A metal Body Code plate is attached to the top left side of the radiator reinforcement The information listed on the plate Fig 2 is used for manufacturing and service purposes VEHICLE DIMENSIONS The Vehicle Dimensions chart provides the dimen sions for each type of Grand Cherokee vehicle Fig 1 Vehicle Safety CertificationLabel Typical Fig ...

Page 5: ...ponds to the number of line marks plus 2 The most commonly used metric bolt strength classes are 9 8 and 12 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...

Page 6: ...FASTENER IDENTIFICATION 4 INTRODUCTION ZG GENERAL INFORMATION Continued ...

Page 7: ...o mark No mark Hexagon flange bolt w washer hexagon bolt No mark Grooved Hexagon head bolt Two protruding lines Hexagon flange bolt w washer hexagon bolt Two protruding lines Welded bolt Hexagon head bolt Three protruding lines Hexagon head bolt Four protruding lines ZG INTRODUCTION 5 GENERAL INFORMATION Continued ...

Page 8: ...0 F x 3 377 Kilopascals kPa kPa x 0 2961 Inches Hg psi x 6 895 Kilopascals kPa kPa x 0 145 psi Inches x 25 4 Millimeters mm mm x 0 03937 Inches Feet x 0 3048 Meters M M x 3 281 Feet Yards x 0 9144 Meters M M x 1 0936 Yards Miles x 1 6093 Kilometers Km Km x 0 6214 Miles mph x 1 6093 Kilometers Hr Km h Km h x 0 6214 mph Feet Sec x 0 3048 Meters Sec M S M S x 3 281 Feet Sec Kilometers Hr x 0 27778 Me...

Page 9: ...METRIC CONVERSION ZG INTRODUCTION 7 GENERAL INFORMATION Continued ...

Page 10: ...R STANDARD BOLTS Class Diameter mm Pitch mm Specified torque Hexagon head bolt Hexagon flange bolt N m kgf cm ft lbf N m kgf cm ft lbf 48 in lbf 52 in lbf 56 in lbf 65 in lbf 69 in lbf 78 in lbf 8 INTRODUCTION ZG GENERAL INFORMATION Continued ...

Page 11: ...inted 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 6000 lbs 5 Vehicle Line X Grand Cherokee 4X2 LHD Z Grand Cherokee 4X4 LHD RHD 6 Transmission B 4 Spe...

Page 12: ......

Page 13: ...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 Mopart brand parts lubri cants and chemicals be used Mo...

Page 14: ...rs 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 ENGINE OIL W FILTER CHANGE 4 0L 5 7 L 6 0 qts 5 2L 4 7 L 5 0 qts 5 9L 4 7 L 5 0 qts COOLING SYSTEM 4 0L 11 4 L 12 0 qts 5...

Page 15: ...severe operating conditions such as 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...

Page 16: ...t has been 30 000 miles 48 000 km 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 el...

Page 17: ...ge 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 5 9L only Replace spark plugs Inspect drive belt Drain and refill transfer case fluid Lubricate steering linkage ...

Page 18: ...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 19: ... 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 5 9L only In...

Page 20: ...belt condition and tension Fuel fumes or leakage correct if necessary 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 park the booster vehicle within cable reach Turn off all accessories set the parking brake place the automatic transmission in PARK or the manual transmissi...

Page 21: ...s to retain brake drums A 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 c...

Page 22: ...G REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS THE TOW STRAPS CHAINS COULD BREAK AND CAUSE SERIOUS INJURY Some Jeep vehicles are equipped with front emer gency tow hooks The tow hooks should be used for EMERGENCY purposes only CAUTION DO NOT use emergency tow hooks for tow truck hook up or highway towing HOISTING RECOMMENDATIONS FLOOR JACK When properly positioned...

Page 23: ...n Grade 10W 40 oils are also accept able Oils of the SAE 5W 30 or 10W 30 grade number are preferred when minimum temperatures consis tently fall below 12 C FLUID CAPACITIES FUEL TANK Diesel Engine Equipped Vehicles 87 4 L ENGINE OIL 2 5L Diesel Engine includes filter 6 5 L COOLING SYSTEM 2 5L Diesel 9 8 L MANUAL TRANSMISSION Recommended lubricant for AX15 transmissions is Mopart 75W 90 API Grade G...

Page 24: ...VICE STOP Check engine oil level Check engine coolant level Inspect drive belt Visually inspect intercooler for obstruction Clean as necessary Visually inspect radiator for obstruction Clean as necessary Inspect for fuel oil or coolant leaks Inspect battery cable connection and excessive corrosion Inspect for presence of water in fuel filter water separator drain if necessary SCHEDULE A 1 000 KM C...

Page 25: ...HEDULE B 500 KM Check correct torque intake manifold mounting nuts Check correct torque exhaust manifold mount ing nuts Check correct torque turbocharger mounting nuts Check correct torque water manifold bolts 1 000 KM Change engine oil Change engine oil filter Check all fluid levels 5 000 KM Change engine oil Change engine oil filter 10 000 KM Change engine oil Change engine oil filter Replace ai...

Page 26: ...ge engine oil Change engine oil filter Replace air filter element Check glow plug operation Replace drive belt Check engine smoke Replace engine coolant 85 000 KM Change engine oil Change engine oil filter 90 000 KM Change engine oil Change engine oil filter Replace air filter element Check drive belt tension Check glow plug operation 95 000 KM Change engine oil Change engine oil filter 100 000 KM...

Page 27: ...he 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 alignment WHEEL TOE POSITION is the difference between the leading inside edges and trailing inside edges of the front tires In...

Page 28: ...MBER NOT SHOWN TOP OF WHEEL OUTBOARD TRUE VER TICAL TOE A FRONT OF VEHICLE NEGATIVE TOE TOE OUT B A POSITIVE TOE TOE IN B A TRUST ANGLE ANGLE OF REAR AXLE RELATIVE TO VEHICLE CENTER LINE AXLE POINTS RIGHT AXLE POINTSLEFT CASTER KING PIN VERTICAL FRONT OF VEHICLE POSITIVE CASTER 2 2 SUSPENSION ZG GENERAL INFORMATION Continued ...

Page 29: ...ateral runout and balance 4 Inspect ball studs linkage pivot points and steering gear for looseness roughness or binding 5 Inspect suspension components for wear and noise SERVICE PROCEDURES SPECIFICATIONS ALIGNMENT FRONT WHEELS REAR AXLE 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 ADJUSTMEN...

Page 30: ...k coil design comprised of Fig 1 Drive axle 4WD tube axle 2WD Dual action shock absorbers Coil springs Upper and lower suspension arms Stabilizer bar Track bar Jounce bumpers Link Coil Suspension The link coil suspension allows each wheel to adapt to different road surfaces without greatly affecting the opposite wheel Wheels are attached to a hub bearings which bolts to the knuckles The hub bearin...

Page 31: ...e not at their normal ride position vehicle ride comfort could be affected and premature bush ing wear may occur Rubber bushings must never be lubricated NOTE Periodic lubrication of the front suspension steering system components is required Refer to Group 0 Lubrication And Maintenance for the rec ommended maintenance schedule DIAGNOSIS AND TESTING SHOCK DIAGNOSIS A knocking or rattling noise fro...

Page 32: ... torque STEERING KNUCKLE For service procedures on the steering knuckle and ball studs refer to Group 3 Differentials And Driv eline LOWER SUSPENSION ARM REMOVAL 1 Raise and support the vehicle 2 Paint or scribe alignment marks on the cam adjusters and suspension arm for installation refer ence Fig 3 3 Remove the lower suspension arm nut cam and cam bolt from the axle Fig 4 4 Remove the nut and bo...

Page 33: ...tall 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 Nut 3 Remove tools and install the upper suspension arm STABILIZER BAR REMOVAL 1...

Page 34: ...t 3 Remove the bolt and flag nut from the axle shaft tube bracket Fig 8 Remove the track bar INSTALLATION 1 Install the track bar at axle tube bracket Loosely install the retaining bolt and flag nut 2 It may be necessary to pry the axle assembly over to install the track bar at the frame rail Install track bar at the frame rail bracket Install the retaining nut on the stud 3 Tighten the ball stud ...

Page 35: ... refer to Group 5 Brakes for procedure 4 Remove stud from hub with Remover C 4150A Fig 10 INSTALLATION 1 Install new stud into hub flange 2 Install three washers onto stud then install lug nut with the flat side of the nut against the washers 3 Tighten lug nut until the stud is pulled into the hub flange Verify that the stud is properly seated into the flange 4 Remove lug nut and washers 5 Install...

Page 36: ...ar Clamp Bolt 54 N m 40 ft lbs Link Upper Nut 61 N m 45 ft lbs Link Lower Bolt 95 N m 70 ft lbs Track Bar Ball Stud Nut 81 N m 60 ft lbs Axle Bracket Bolt 75 N m 55 ft lbs Track Bar Bracket Bolts 121 N m 90 ft lbs Nut 121 N m 90 ft lbs Support Bolts 95 N m 70 ft lbs SPECIAL TOOLS FRONT SUSPENSION Remover Installer Suspension Bushing 7932 J 35581 Nut Long 7603 J 21474 18 Bolt Special 7604 J 21474 1...

Page 37: ...ck 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 the axle pad and is retained with a clip Stabilizer Bar The stabi...

Page 38: ...he lower nut and bolt from the axle bracket Remove the shock absorber INSTALLATION 1 Install the shock absorber on the upper frame rail stud Install the shock absorber on the axle bracket 2 Install the retainer and nut on the stud Tighten the upper nut to 70 N m 52 ft lbs 3 Install 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 l...

Page 39: ... the supports and lower the vehicle 4 Tighten the upper suspension arm nuts to 75 N m 55 ft lbs STABILIZER BAR REMOVAL 1 Raise and support the vehicle Remove one wheel and 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...

Page 40: ...ely 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 36 N m 27 ft lbs T...

Page 41: ...t camber will cause wear on the inside or outside edge of the tire The angle is not adjustable damaged component s must be replaced to correct the camber angle WHEEL TOE POSITION is the difference between the leading inside edges and trailing inside edges of the front tires Incorrect wheel toe position is the most common cause of unstable steering and uneven tire wear The wheel toe position is the...

Page 42: ...information 1 Inspect tires for size air pressure and tread wear 2 Inspect front wheel bearings for wear 3 Inspect front wheels for excessive radial or lat eral runout and balance 4 Inspect ball studs linkage pivot points and steering gear for looseness roughness or binding 5 Inspect suspension components for wear and noise Fig 1 Wheel Alignment Measurements 2 2 SUSPENSION ZG GENERAL INFORMATION C...

Page 43: ...1 Replace wheel bearings 2 Loose or worn steering or suspension components 2 Tighten or replace components as necessary 3 Loose or worn steering gear 3 Adjust or replace steering gear FRONT WHEELS SHIMMY 1 Loose or worn wheel bearings 1 Replace wheel bearings 2 Loose or worn steering or suspension components 2 Tighten or replace components as necessary 3 Tires worn or out of balance 3 Replace or b...

Page 44: ...e sure the toe setting does not change during clamp tightening 4 Adjust the left wheel toe position with the tie rod Turn the sleeve until the left wheel is at the same TOE IN position as the right wheel Position the clamp bolts as shown Fig 3 and tighten to Vehicles with 2 5L engine 27 N m 20 ft lbs Vehicles with 4 0L engine 27 N m 20 ft lbs Vehicles with 5 2L engine 49 N m 36 ft lbs NOTE Make su...

Page 45: ...ten to Vehicles with 2 5L engine 27 N m 20 ft lbs Vehicles with 4 0L engine 27 N m 20 ft lbs Vehicles with 5 2L engine 49 N m 36 ft lbs NOTE Make sure the toe setting does not change during clamp tightening 5 Verify the toe setting SPECIFICATIONS ALIGNMENT FRONT WHEELS REAR AXLE Fig 5 Steering Linkage RHD ADJUSTMENT PREFERRED RANGE CASTER 7 6 5 to 7 5 CAMBER not adjustable NA 1 13 to 0 13 TOE IN e...

Page 46: ...is retained with a clip Upper And Lower Suspension The suspension arms use bushings to isolate road noise The suspen sion arms are bolted to the frame and axle through the rubber bushings The lower suspension arm uses cam bolts at the axle to allow for caster and pinion angle adjustment The suspension arm travel is lim ited through the use of jounce bumpers in compres sion and shocks absorbers in ...

Page 47: ...ons exist A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit tent This condition is not repairable and the shock absorber must be replaced The shock absorbers are not refillable or adjust able If a malfunction occurs the shock absorber must be replaced To test a shock absorber hold it in an upright position and force the piston in and out of the cy...

Page 48: ... 2 and remove the spring 9 Remove the jounce bumper if necessary from the upper spring mount Fig 2 INSTALLATION 1 Install the jounce bumper on the upper spring mount 2 Position the coil spring on the axle pad Install the spring retainer and bolt Tighten bolt to 22 N m 16 ft lb 3 Raise the axle into position until the spring seats in the upper mount 4 Install lower suspension arms and rear bolts 5 ...

Page 49: ... frame rail and remove the upper suspension arm INSTALLATION 1 Position the upper suspension arm at the axle and frame rail 2 Install the bolts and finger tighten the nuts 3 Remove the supports and lower the vehicle 4 Tighten the nut at the axle and frame bracket to 75 N m 55 ft lbs AXLE BUSHING REMOVAL 1 Remove the upper suspension arm from axle 2 Position spacer 7932 1 J 35581 1 over the bushing...

Page 50: ...N m 45 ft lbs 5 Remove the supports and lower the vehicle 6 Tighten the nuts at the axle bracket end to 95 N m 70 ft lbs TRACK BAR REMOVAL 1 Raise and support the vehicle 2 Remove the cotter pin and nut from the ball stud end at the frame rail bracket Fig 8 NOTE Use a universal puller to separate the ball stud from the frame rail bracket 3 Remove the bolt and flag nut from the axle shaft tube brac...

Page 51: ...2 Install the hub to knuckle bolts and tighten to 102 N m 75 ft lbs 3 Install the hub washer and nut Tighten the hub nut to 237 N m 175 ft lbs Install the nut retainer and a new cotter pin 4 Install the brake rotor caliper and ABS wheel speed sensor refer to Group 5 Brakes 5 Install the wheel and tire assembly 6 Remove support and lower the vehicle WHEEL MOUNTING STUDS REMOVAL 1 Raise and support ...

Page 52: ...hat 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 21 ft lbs Suspension Arm Upper Nuts 75 N m 55 ft lbs Suspension Arm Lower Axle Bracket Nut 115 N m 85 ft lbs Frame Bracket Nut 176 N m 130 ft lbs Stabilizer Bar Clamp Bolt 54 N m 40 ft lbs Link Upper Nut 61 N m 45 ft lbs Link Lower Bolt 95 N...

Page 53: ...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 Remover Tie Rod End MB 990635 ZG SUSPENSION 2 13 ...

Page 54: ...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 the axle pad and is retained with a clip Stabilizer...

Page 55: ...nut and retainer from the frame rail stud Fig 2 3 Remove the lower nut and bolt from the axle bracket Remove the shock absorber INSTALLATION 1 Install the shock absorber on the upper frame rail stud Install the shock absorber on the axle bracket 2 Install the retainer and nut on the stud Tighten the upper nut to 70 N m 52 ft lbs 3 Install lower bolt and nut finger tight 4 Remove the supports and l...

Page 56: ... vehicle 4 Tighten the upper suspension arm nuts to 75 N m 55 ft lbs STABILIZER BAR REMOVAL 1 Raise and support the vehicle Remove one wheel and 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 Remov...

Page 57: ...hicle 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 36 N m 27 ft lbs Track Bar Frame Bracket Nut 100 N m 74 ft lbs Axle Bracket Bolt 100 N m 7...

Page 58: ......

Page 59: ...on 4WD vehicles to the axle Fig 1 The propeller shaft must operate through con stantly changing relative angles between the trans mission and axle 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 univer...

Page 60: ... at a common joint the bend that is formed is called the operating angle The larger the angle the larger the amount of accel eration and deceleration of the joint This speeding up and slowing down of the joint must be cancelled to produce a smooth power flow This is done through the phasing of a propeller shaft and ensuring that the proper propeller shaft joint working angles are maintained A prop...

Page 61: ...rease leakage or boot damage is found the propeller shaft must be replaced PRECAUTIONS Use the exact replacement parts when installing the propeller shafts The use of the correct replace ment parts helps to ensure safe operation All fasten ers must be torqued to the specified values for safe operation Fig 3 Double Cardan U Joint 1 LINK YOKE 2 SOCKET SPRING 3 SCOKET BALL RETAINER 4 THRUST WASHER 5 ...

Page 62: ... an incorrect propeller shaft angle are usu ally the cause of such a vibration UNBALANCE NOTE Removing and re indexing the propeller shaft 180 relative to the yoke may eliminate some vibrations If propeller shaft is suspected of being unbalanced it can be verified with the following procedure 1 Raise the vehicle 2 Clean all the foreign material from the propel ler shaft and the universal joints DR...

Page 63: ...tion test Fig 9 14 Increase distance between the clamp screws and repeat the test until the amount of vibration is at the lowest level Bend the slack end of the clamps so the screws will not loosen 15 If the vibration remains unacceptable apply the same steps to the front end of the propeller shaft 16 Install the wheel and tires Lower the vehicle RUNOUT 1 Remove dirt rust paint and undercoating fr...

Page 64: ... cap is facing downward if necessary Always make measurements from front to rear 2 Place Inclinometer on yoke bearing cap or the pinion flange ring A parallel to the shaft Fig 10 Center bubble in sight glass and record measure ment This measurement will give you the transmis sion or Output Yoke Angle A 3 Rotate propeller shaft 90 degrees and place Inclinometer on yoke bearing cap or propeller shaf...

Page 65: ...ation reference CAUTION Do not loosen lock nut on the CV joint style propeller shaft or collapse the front propeller shaft Driveline vibration can result 5 Remove bolts holding the front universal joint or CV joint to the pinion yoke or flange 6 Remove bolts holding rear universal joint to the transfer case yoke Fig 13 Universal Joint Angle Example 4 9 Angle C 3 2 Angle B Input Yoke Horizontal Lev...

Page 66: ...rt vehicle on safety stands 2 Shift the transmission and transfer case if nec essary to their Neutral positions 3 Using a suitable marker mark a line across the axle pinion yoke and the propeller shaft yoke for installation reference 4 Remove the bolts holding the universal joint clamps to the pinion yoke 5 Slide the slip yoke off of the transmission or transfer case output shaft and remove the pr...

Page 67: ...on the bearing cap will score the walls of the yoke bore and damage can occur ASSEMBLY 1 Apply extreme pressure EP N L G I Grade 1 or 2 grease to inside of yoke bores to aid in installa tion 2 Position the cross in the yoke with its lube fit ting if equipped pointing up Fig 18 3 Place a bearing cap over the trunnion and align the cap with the yoke bore Fig 19 Keep the needle bearings upright in th...

Page 68: ... positioned beneath the link yoke 5 Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and partially press one bearing cap from the outboard side of the link yoke enough to grasp the bearing cap with vise jaws Fig 21 Be sure to remove grease fittings that interfere with removal 6 Grasp the protruding bearing by vise jaws Tap the link yoke with a mal...

Page 69: ... N L G I Grade 1 or 2 grease to inside of yoke bores to aid in installa tion 2 Fit a cross into the propeller shaft yoke Fig 24 3 Place a bearing cap over the trunnion and align the cap with the yoke bore Fig 25 Keep the needle bearings upright in the bearing assembly A needle bearing lying at the bottom of the cap will prevent proper assembly 4 Press the bearing cap into the yoke bore enough to i...

Page 70: ...centering kit assembly inside the link yoke making sure the spring is properly posi tioned Fig 29 10 Place two bearing caps on opposite trunnions of the remaining cross Fit the open trunnions into the link yoke bores and the bearing caps into the centering kit Fig 30 Fig 27 Press In Bearing Cap Fig 28 Install Link Yoke Fig 29 Install Centering Kit Fig 30 Install Remaining Cross 3 12 DIFFERENTIAL A...

Page 71: ...ration replace the propeller shaft This measurement is only necessary for the CV style propeller shaft and is to be taken with the shaft installed and the vehicle at proper ride height 1 Place vehicle on floor or drive on hoist with full weight of vehicle on suspension 2 Measure the distance from the face of the CV joint cup to the end of the CV joint boot Fig 34 3 Loosen the lock nut and adjust t...

Page 72: ...order to provide adjustablity of the pinion angle Follow the proce dures supplied with the kit in order to ensure a safe installation 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 Shaft Bolts Rear Yoke 19 N m 14 ft lbs SPECIAL TOOLS PROPELLER SHAFT Fig 34 Measurement CV JOI...

Page 73: ... caused by lubricant vapor ization and internal expansion The axles are equipped with semi floating axle shafts meaning that loads are supported by the hub bearings The axle 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 For vehicles with ABS brakes the ABS wh...

Page 74: ...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 directions This allows the side gear and axle shaft attached to the outside wheel to rota...

Page 75: ...est 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 VIBRATION Vi...

Page 76: ...pairs or adjustments DIFFERENTIAL CASE CRACKED 1 Improper adjustment of differential bearings 1 Replace cracked case examine gears and bearings for possible damage At reassembly adjust differential bearings properly 2 Excessive ring gear backlash 2 Replace cracked case examine gears and bearings for possible damage At reassembly adjust ring gear backlash properly 3 Vehicle overloaded 3 Replace cra...

Page 77: ...arts for possible damage Avoid erratic clutch operation 3 Ice spotted pavements 3 Replace gears Examine the remaining parts for possible damage Replace parts as required 4 Improper adjustments 4 Replace gears Examine other parts for possible damage Ensure ring gear backlash is correct AXLE NOISE 1 Insufficient lubricant 1 Refill axle with correct amount of proper lubricant Also inspect for leaks a...

Page 78: ... tube 8 Mark the propeller shaft and yoke or pinion flange for installation alignment reference 9 Remove propeller shaft 10 Disconnect stabilizer bar links at the axle 11 Disconnect shock absorbers from axle brack ets 12 Disconnect track bar 13 Disconnect the tie rod and drag link from the steering knuckle Refer to Group 2 Suspension for proper procedures 14 Disconnect the steering damper from the...

Page 79: ...e not service able If defective they must be replaced as a unit If the bearings seals spider or bearing caps are dam aged or worn replace the complete U joint REMOVAL CAUTION Clamp only the narrow forged portion of the yoke in the vise Also to avoid distorting the yoke do not over tighten the vise jaws 1 Remove axle shaft 2 Remove the bearing cap retaining snap rings Fig 4 It can be helpful to sat...

Page 80: ...ean and inspect axle C V joint assembly and axle shaft for any signs of excessive wear If any parts show signs of excessive wear the axle shaft assembly will require replace ment Component parts of these axle shaft assemblies are not serviceable INSTALLATION 1 Slide new sealing boot large clamp over axle shaft and onto C V joint 2 Slide the axle C V joint sealing boot onto the axle shaft 3 Distrib...

Page 81: ...with a in lbs dial type torque wrench Record the torque reading for instal lation reference 8 Using a short piece of pipe and Holder 6958 to hold the pinion yoke or pinion flange remove the pinion nut and washer 9 Use Remover C 452 and Wrench C 3281 to remove the pinion yoke or pinion flange Fig 10 10 Use Remover 7794 A and slide hammer to remove the pinion shaft seal Fig 11 INSTALLATION 1 Apply a...

Page 82: ...peller shaft and yoke or pinion flange and install the propeller shaft 7 Check and fill the gear lubricant Refer to the Lubricant Specifications for gear lubricant require ments 8 Install the brake rotors and calipers Refer to Group 5 Brakes for proper procedures 9 Install wheel and tire assemblies 10 Lower the vehicle COLLAPSIBLE SPACER REMOVAL W PINION INSTALLED 1 Raise and support the vehicle 2...

Page 83: ...amount of torque necessary to rotate the pinion gear with a in lbs dial type torque wrench Record the torque reading for instal lation reference 8 Remove differential assembly from axle hous ing 9 Using Holder 6958 to hold yoke or flange and a short length of 1 in pipe remove the pinion nut and washer 10 Using Remover C 452 and Wrench C 3281 remove the pinion yoke or flange from pinion shaft Fig 1...

Page 84: ...ad torque is exceeded a new collapsible spacer must be installed The torque sequence will then have to be repeated NOTE If the spacer requires more than 353 N m 260 ft lbs of torque to crush the collapsible spacer is defective and must be replaced 8 Using yoke holder 6958 a short length of 1 in pipe and a torque wrench set at 353 N m 260 ft lbs crush collapsible spacer until bearing end play is ta...

Page 85: ...ricant requirements 15 Install wheel and tire assemblies 16 Lower vehicle HUB BEARING AND AXLE SHAFT If the axle shaft and hub bearing are being removed in order to service another component the axle shaft and hub bearing can be removed as an assembly REMOVAL 1 Raise and support the vehicle 2 Remove the wheel and tire assembly 3 Remove the brake caliper and rotor Refer to Group 5 Brakes for proper...

Page 86: ...fer to Group 5 Brakes for proper procedures 9 Install the wheel and tire assembly 10 Remove support and lower the vehicle STEERING KNUCKLE AND BALL STUDS Ball stud service procedures below require removal of the hub bearing and axle shaft Removal and installation of upper and lower ball studs require the use of Tool Kit 6289 KNUCKLE REMOVAL 1 Remove hub bearing and axle shaft 2 Disconnect the tie ...

Page 87: ... 28 Upper Ball Stud Remove Install REMOVAL INSTALLATION Fig 29 Lower Ball Stud Remove Install SPECIAL TOOL 6289 12 SPECIAL TOOL 6289 4 ZG DIFFERENTIAL AND DRIVELINE 3 29 REMOVAL AND INSTALLATION Continued ...

Page 88: ...987 with the tool dowel pins seated in the locating holes Fig 31 Install the holddown clamps and tighten the tool turnbuckle fin ger tight 8 Install a Guide Pin C 3288 B at the left side of the differential housing Attach Dial Indicator C 3339 to guide pin Load the lever adapter against the opposite side of the housing Fig 32 and zero the indicator CAUTION Do not spread over 0 50 mm 0 020 in If th...

Page 89: ...over 0 50 mm 0 020 in If the housing is over spread it could be distorted or damaged 3 Spread the housing enough to install the case in the housing Measure the distance with the dial indicator Fig 33 4 Remove the dial indicator 5 Install differential case in the housing Ensure that the differential bearing cups remain in position on the differential bearings Tap the differential case to ensure the...

Page 90: ...l assembly 3 Remove the inner axle shaft seals with a pry bay INSTALLATION 1 Remove any sealer remaining from original seals 2 Remove sealer from axle tube to housing junc tion if necessary 3 Install oil seals with Discs 8110 and Turn buckle 6797 Fig 39 Tighten tool until disc bottoms in housing 4 Install differential assembly PINION GEAR NOTE The ring and pinion gears are serviced as a matched se...

Page 91: ... front pinion bearing cup bearing oil slinger if equipped and pinion seal with Remover C 4345 and Handle C 4171 Fig 43 8 Remove the rear pinion bearing cup from axle housing Fig 44 Use Remover D 149 and Handle C 4171 9 Remove the depth shims from rear pinion bear ing cup bore in axle housing Record the thickness of the depth shims NOTE The pinion depth shims can be very thin Verify that all shims ...

Page 92: ...th to select the proper thickness shim before installing pinion gear 1 Place proper thickness depth shim in rear pin ion bearing cup bore in the axle housing 2 Apply Mopart Door Ease or equivalent stick lubricant to outside surface of rear pinion bearing cup Install the bearing cup with Installer D 146 and Fig 43 Front Bearing Cup Removal REMOVER HANDLE Fig 44 Rear Bearing Cup Removal DRIVER HANDL...

Page 93: ...flange with Installer W 162 B Cup 8109 and Holder 6958 Fig 52 9 Install the pinion washer and a new nut on the pinion gear Tighten the nut to 216 N m 160 ft lbs minimum Do not over tighten Maximum torque is 352 N m 260 ft lbs CAUTION Never loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque If preload torque is exceeded a new collapsible...

Page 94: ... inch pound torque wrench Fig 54 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 13 Install differential assembly RING GEAR The ring and pinion gears are service in a matched set Do not replace the ring gear without replacing the pinion gear Fig 51 Collapsible Preload Spacer COLLAPS IBLE SPACER SHOULDER P...

Page 95: ...ttern DISASSEMBLY AND ASSEMBLY STANDARD DIFFERENTIAL DISASSEMBLY 1 Remove the ring gear 2 Using a suitable roll pin punch drive out the roll pin holding pinion gear mate shaft in the differ ential case Fig 57 3 Remove the pinion gear mate shaft from the differential case and the pinion mate gears 4 Rotate differential side gears and remove the pinion mate gears and thrust washers Fig 58 5 Remove t...

Page 96: ...ng with gear lubri cant Refer to the Lubricant Specifications section of this group for the gear lubricant requirements 4 Install the fill hole plug CLEANING AND INSPECTION CARDAN U JOINT Clean all the U joint yoke bores with cleaning sol vent and a wire brush Ensure that all the rust and foreign matter are removed from the bores Inspect the yokes for distortion cracks and worn bearing cap bores R...

Page 97: ...ndard setting from the center line of the ring gear to the back face of the pinion is 92 08 mm 3 625 in The standard depth provides the best gear tooth contact pattern Refer to Backlash and Contact Pattern Analysis paragraph in this section for additional information Compensation for pinion depth variance is achieved with select shims The shims are placed behind the rear pinion bearing cup Fig 62 ...

Page 98: ...ifferential bearing caps on Arbor Discs and tighten cap bolts to 41 N m 30 ft lbs NOTE Arbor Discs 6732 has different step diame ters to fit other axles Choose proper step for axle being serviced 5 Assemble Dial Indicator C 3339 into Scooter Block D 115 2 and secure set screw 6 Place Scooter Block Dial Indicator in position in axle housing so dial probe and scooter block are PINION GEAR DEPTH VARI...

Page 99: ...ASH INTRODUCTION Differential side bearing preload and gear backlash is achieved by selective shims positioned behind the differ ential side bearing cones The proper shim thickness can be determined using slip fit dummy bearings D 348 in place of the differential side bearings and a dial indi cator C 3339 Before proceeding with the differential bearing preload and gear backlash measurements mea su...

Page 100: ...ing gear Fig 71 9 Attach a dial indicator C 3339 to guide stud Position the dial indicator plunger on a flat surface between the ring gear bolt heads Fig 71 10 Push and hold differential case to pinion gear side of axle housing Fig 72 11 Zero dial indicator face to pointer Fig 72 12 Push and hold differential case to ring gear side of the axle housing Fig 73 13 Record dial indicator reading Fig 73...

Page 101: ...ess shim required to achieve proper backlash 26 Subtract the backlash shim thickness from the total preload shim thickness The remainder is the shim thickness required on the pinion side of the axle housing 27 Rotate dial indicator out of the way on guide stud 28 Remove differential case and dummy bearings from axle housing 29 Install side bearing shims on differential case hubs 30 Install side be...

Page 102: ...de or equivalent to the drive and coast side of the ring gear teeth 2 Wrap twist and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion gear This will provide a more distinct contact pattern 3 Using a boxed end wrench on a ring gear bolt Rotate the differential case one complete revolution in both directions while a load is being applied from shop towel The a...

Page 103: ... OF TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP OF THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH PINION GEAR DEPTH SHIM CORRECT INCREASE RING GEAR BACKLASH ZG DIFFERENTIAL AND ...

Page 104: ...ar Bolt 95 122 N m 70 90 ft lbs Axle Nut 237 N m 175 ft lbs Hub Brg Bolt 102 N m 75 ft lbs Lower Ball Stud 108 N m 80 ft lbs Upper Ball Stud 101 N m 75 ft lbs SPECIAL TOOLS 181 FBI AXLE Puller C 293 PA Plug SP 3289 Adapter C 293 39 Puller C 452 Wrench C 3281 Dial Indicator C 3339 3 46 DIFFERENTIAL AND DRIVELINE ZG SPECIFICATIONS Continued ...

Page 105: ...Driver C 3716 A Handle C 4171 Installer D 146 Remover D 149 Installer W 162 D Cup 8109 Remover Installer 6289 Installer 6761 ZG DIFFERENTIAL AND DRIVELINE 3 47 SPECIAL TOOLS Continued ...

Page 106: ...Installer 6752 Installer Discs 8110 Turnbuckle 6797 Tool Set Pinion Depth 6774 Gauge Block 6733 Puller 7794 A Installer C 4975 A 3 48 DIFFERENTIAL AND DRIVELINE ZG SPECIAL TOOLS Continued ...

Page 107: ...Spanner 6958 Installer C 3972 A Spreader W 129 B Adapter Kit 6987 Pilot Stud C 3288 B Remover C 4345 Installer D 130 Installer W 262 ZG DIFFERENTIAL AND DRIVELINE 3 49 SPECIAL TOOLS Continued ...

Page 108: ...ation 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 For vehicles equipped with ABS brakes the axles have a tone ring pressed onto the axle shaft Use ...

Page 109: ... 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 directions This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster spe...

Page 110: ... 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 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 during straight ahead drivin...

Page 111: ...r the clutch engaged can be caused by High engine idle speed Loose engine transmission transfer case mounts Worn U joints Loose spring 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 ...

Page 112: ...justments DIFFERENTIAL CASE CRACKED 1 Improper adjustment of differential bearings 1 Replace cracked case examine gears and bearings for possible damage At reassembly adjust differential bearings properly 2 Excessive ring gear backlash 2 Replace cracked case examine gears and bearings for possible damage At reassembly adjust ring gear backlash properly 3 Vehicle overloaded 3 Replace cracked case e...

Page 113: ...for possible damage Avoid erratic clutch operation 3 Ice spotted pavements 3 Replace gears Examine the remaining parts for possible damage Replace parts as required 4 Improper adjustments 4 Replace gears Examine other parts for possible damage Ensure ring gear backlash is correct AXLE NOISE 1 Insufficient lubricant 1 Refill axle with correct amount of proper lubricant Also inspect for leaks and co...

Page 114: ...rosene 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 lbs torque 8 For Trac lok differentials a quantity of ...

Page 115: ... speed sensors if necessary Refer to Group 5 Brakes for proper procedures 7 Connect parking brake cable to brackets and lever 8 Install the brake rotors and calipers Refer to Group 5 Brakes for proper procedures 9 Connect the brake hose to the axle junction block Refer to Group 5 Brakes for proper proce dures 10 Install axle vent hose 11 Align propeller shaft and pinion yoke refer ence marks Insta...

Page 116: ...e wrench Rotating torque should be equal to the read ing recorded during removal plus an additional 0 56 N m 5 in lbs Fig 12 6 If the rotating torque is low use Holder 6958 to hold the pinion yoke Fig 13 and tighten the pinion shaft nut in 6 8 N m 5 ft lbs increments until the proper rotating torque is achieved CAUTION If the maximum tightening torque is reached prior to reaching the required rota...

Page 117: ...9 Use Remover C 452 and Wrench C 3281 to remove the pinion yoke Fig 15 10 Use Remover 7794 A and slide hammer to remove the pinion shaft seal Fig 16 11 Remove the front pinion bearing using a pair of suitable pick tools to pull the bearing straight off the pinion gear shaft It may be necessary to lightly tap the end of the pinion gear with a rawhide or rub ber mallet if the bearing becomes bound o...

Page 118: ...g 18 2 If pinion gear was removed install pinion gear in housing 3 Install pinion front bearing if necessary 4 Apply a light coating of gear lubricant on the lip of pinion seal Install seal with Installer C 3972 A and Handle C 4171 Fig 19 5 Install yoke with Screw 8112 Cup 8109 and Holder 6958 Fig 20 6 If the original pinion bearings are being used install differential assembly and axle shafts if ...

Page 119: ...le spacer Fig 22 11 Check rotating torque with an inch pound torque wrench Fig 22 The torque necessary to rotate the pinion gear should be Original Bearings The reading recorded dur ing removal plus an additional 0 56 N m 5 in lbs New Bearings 2 to 5 N m 15 to 35 in lbs 12 Install differential assembly and axle shafts if necessary 13 Align marks made previously on yoke and propeller shaft and inst...

Page 120: ...aft splines from dam aging axle shaft seal lip Also exercise care not to damage the wheel speed sensor on vehicles equipped with ABS brakes 2 Insert C clip lock in end of axle shaft Push axle shaft outward to seat C clip lock in side gear 3 Insert pinion mate shaft into differential case and through thrust washers and pinion gears 4 Align hole in shaft with hole in the differential case and instal...

Page 121: ...9 B utilizing some items from Adapter set 6987 with the tool dowel pins seated in the locating holes Fig 28 Install the hold down clamps and tighten the tool turnbuckle finger tight 8 Install a Pilot Stud C 3288 B at the left side of the differential housing Attach Dial Indicator C 3339 to pilot stud Load the indicator plunger against the opposite side of the housing Fig 29 and zero the indicator ...

Page 122: ...acklash proce dures in this section to determine the proper shim selection 1 Position Spreader W 129 B utilizing some items from Adapter set 6987 with the tool dowel pins seated in the locating holes Fig 32 Install the hold down clamps and tighten the tool turnbuckle finger tight 2 Install a Pilot Stud C 3288 B at the left side of the differential housing Attach Dial Indicator C 3339 to pilot stud...

Page 123: ...xle housing RING GEAR The ring and pinion gears are service in a matched set Do not replace the ring gear without replacing the pinion gear REMOVAL 1 Remove differential from axle housing 2 Place differential case in a suitable vise with soft metal jaw protectors Fig 55 3 Remove bolts holding ring gear to differential case 4 Using a soft hammer drive ring gear from dif ferential case Fig 55 INSTAL...

Page 124: ...ifferential from the axle housing 2 Mark pinion yoke and propeller shaft for installation alignment 3 Disconnect propeller shaft from pinion yoke Using suitable wire tie propeller shaft to underbody 4 Using Holder 6958 to hold yoke and a short length of 1 in pipe remove the pinion yoke nut and washer Fig 38 Fig 35 Install DifferentialSide Bearings HANDLE C 4171 DIFFERENTIAL BEARING TOOL C 3716 A F...

Page 125: ...e pinion shaft seal Fig 41 8 Remove oil slinger if equipped and front pin ion bearing 9 Remove the front pinion bearing cup with Remover C 4345 and Handle C 4171 Fig 42 Fig 39 Pinion Yoke Removal SPECIAL TOOL C 3281 YOKE SPECIAL TOOL C 452 Fig 40 Remove Pinion Gear RAWHIDE HAM MER Fig 41 Seal Removal SPECIAL TOOL 7794A SLIDE HAMMER PINION SEAL Fig 42 Front Bearing Cup Removal REMOVER HANDLE ZG DIF...

Page 126: ...r equivalent stick lubricant to outside surface of bearing cup 2 Install the pinion rear bearing cup with Installer D 146 and Driver Handle C 4171 Fig 46 Ensure cup is correctly seated 3 Apply Mopart Door Ease or equivalent stick lubricant to outside surface of bearing cup Fig 43 Rear Bearing Cup Removal DRIVER HANDLE Fig 44 Collapsible Spacer COLLAPS IBLE SPACER SHOULDER PINION GEAR OIL SLINGER R...

Page 127: ...Install the rear bearing and slinger if equipped on the pinion gear with Installer W 262 Fig 49 9 Install a new collapsible preload spacer on pin ion shaft and install pinion gear in housing Fig 50 10 Install pinion gear in housing 11 Install yoke with Installer Screw 8112 Cup 8109 and holder 6958 Fig 51 12 Install the yoke washer and a new nut on the pinion gear and tighten the pinion nut until t...

Page 128: ...riginal Bearings 1 to 3 N m 10 to 20 in lbs New Bearings 2 to 5 N m 15 to 35 in lbs 17 Install differential in housing FINAL ASSEMBLY 1 Scrape the residual sealant from the housing and cover mating surfaces Clean the mating surfaces with mineral spirits Apply a bead of Mopart Silicone Rubber Sealant or equivalent on the housing cover Fig 60 Install the housing cover within 5 minutes after applying...

Page 129: ...t washers 2 Install the pinion mate gears and thrust wash ers 3 Install the pinion gear mate shaft 4 Align the hole in the pinion gear mate shaft with the hole in the differential case and install the pinion gear mate shaft lock screw 5 Lubricate all differential components with hypoid gear lubricant Fig 54 Typical Housing Cover With Sealant SEALING SURFACE CONTOUR OF BEAD BEAD THICK NESS 6 35MM 1...

Page 130: ...ring gear installed 4 Remove the pinion gear mate shaft lock screw Fig 59 5 Remove the pinion gear mate shaft If neces sary use a drift and hammer Fig 60 6 Install and lubricate Step Plate C 6960 3 Fig 61 7 Assemble Threaded Adapter C 6960 1 into top side gear Thread Forcing Screw C 6960 4 into adapter until it becomes centered in adapter plate Fig 57 Trac lok Differential Components THRUST WASHER...

Page 131: ... Screw C 6960 4 Step Plate C 6960 3 and Threaded Adapter C 6960 1 16 Remove top side gear clutch pack retainer and clutch pack Keep plates in correct order during removal Fig 66 17 Remove differential case from Side Gear Hold ing Tool 6965 Remove side gear clutch pack retainer and clutch pack Keep plates in correct order during removal ASSEMBLY NOTE The clutch discs are replaceable as com plete se...

Page 132: ...k Fig 69 7 Hold assembly in position Insert Threaded Adapter C 6960 1 into top side gear 8 Insert Forcing Screw C 6960 4 9 Tighten forcing screw tool to slightly compress clutch discs 10 Place pinion gears in position in side gears and verify that the pinion mate shaft hole is aligned 11 Rotate case with Turning Bar C 6960 2 until the pinion mate shaft holes in pinion gears align with holes in cas...

Page 133: ...n 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 of cup bores should be removed with a hand stone Wear and damage to pinion gear mate shaft pinion gears side gears and thrust washers Re...

Page 134: ...n from the stan dard If the number is negative add that value to the required thickness of the depth shim s If the num ber is positive subtract that value from the thickness of the depth shim s If the number is 0 no change is necessary Refer to the Pinion Gear Depth Variance Chart PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion cups and pin ion bearings installed in hous...

Page 135: ... the arbor bar do not turn dial face Continue moving the dial probe to the crest of the arbor bar and record the highest reading If the dial indicator can not achieve the zero reading the rear bearing cup or the pinion depth gauge set is not installed correctly 9 Select a shim equal to the dial indicator read ing plus the drive pinion gear depth variance number etched in the face of the pinion gea...

Page 136: ...ess from the total overall shim thickness and select that amount for the pinion gear side of the dif ferential Fig 76 SHIM SELECTION NOTE It is difficult to salvage the differential side bearings during the removal procedure Install replacement bearings if necessary 1 Remove side bearings from differential case 2 Install ring gear if necessary on differential case and tighten bolts to specificatio...

Page 137: ...ess required on the pinion side of the axle housing 26 Rotate dial indicator out of the way on guide stud 27 Remove differential case and dummy bearings from axle housing 28 Install new side bearing cones and cups on differential case 29 Install spreader W 129 B utilizing some com ponents of Adapter Set 6987 on axle housing and spread axle opening enough to receive differential case 30 Place side ...

Page 138: ...inct contact pattern 3 Using a boxed end wrench on a ring gear bolt Rotate the differential case one complete revolution in both directions while a load is being applied from shop towel The areas on the ring gear teeth with the greatest degree of contact against the pinion gear teeth will squeegee the compound to the areas with the least amount of contact Note and compare patterns on the ring gear...

Page 139: ...E OF TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP OF THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH PINION GEAR DEPTH SHIM CORRECT INCREASE RING GEAR BACKLASH ZG DIFFERENTIAL AND...

Page 140: ...0 0 15 mm 0 005 0 008 in Pinion Std Depth 92 08 mm 3 625 in Pinion Bearing Preload Original Bearings 1 2 N m 10 20 in lbs Pinion Bearing Preload New Bearings 1 5 4 N m 15 35 in lbs 194 RBI AXLE DESCRIPTION TORQUE Bolt Diff Cover 41 N m 30 ft lbs Bolot Bearing Cap 77 N m 57 ft lbs Nut Pinion 271 474 N m 200 350 ft lbs Screw Pinion Mate Shaft Lock 16 25 N m 12 ft lbs Bolt Ring Gear 95 122 N m 70 90 ...

Page 141: ...Wrench C 3281 Installer C 3972 A Spanner 6958 Installer Screw 8112 Cup 8109 Handle C 4171 Driver C 3716 A Installer D 130 ZG DIFFERENTIAL AND DRIVELINE 3 83 SPECIAL TOOLS Continued ...

Page 142: ...Installer D 146 Remover C 4345 Remover D 149 Installer W 262 Installer 6436 Installer 6437 Disc Axle Arbor 6732 Gauge Block 6735 3 84 DIFFERENTIAL AND DRIVELINE ZG SPECIAL TOOLS Continued ...

Page 143: ...Set Pinion Depth 6774 Trac lok Tool Set 6960 Holder 6965 Puller 7794 A Starting Point Shim 8107 Spreader W 129 B Adapter Kit 6987 Guide Pin C 3288 B ZG DIFFERENTIAL AND DRIVELINE 3 85 SPECIAL TOOLS Continued ...

Page 144: ...Bearing Remover Tool Set 6310 Hub Puller 6790 Dial Indicator C 3339 3 86 DIFFERENTIAL AND DRIVELINE ZG SPECIAL TOOLS Continued ...

Page 145: ...ization and internal expansion The axles are equipped with semi floating axle shafts meaning that vehicle load is 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 For vehicles equipped with ABS brakes the axles have a tone ring pressed onto the axle sh...

Page 146: ...ust 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 directions This allows the side gear and axle shaft attached to the ou...

Page 147: ... 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 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 during straight ahead drivin...

Page 148: ...r the clutch engaged can be caused by High engine idle speed Loose engine transmission transfer case mounts Worn U joints Loose spring mounts Loose pinion gear nut and yoke Excessive ring gea r 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...

Page 149: ...justments DIFFERENTIAL CASE CRACKED 1 Improper adjustment of differential bearings 1 Replace cracked case examine gears and bearings for possible damage At reassembly adjust differential bearings properly 2 Excessive ring gear backlash 2 Replace cracked case examine gears and bearings for possible damage At reassembly adjust ring gear backlash properly 3 Vehicle overloaded 3 Replace cracked case e...

Page 150: ...for possible damage Avoid erratic clutch operation 3 Ice spotted pavements 3 Replace gears Examine the remaining parts for possible damage Replace parts as required 4 Improper adjustments 4 Replace gears Examine other parts for possible damage Ensure ring gear backlash is correct AXLE NOISE 1 Insufficient lubricant 1 Refill axle with correct amount of proper lubricant Also inspect for leaks and co...

Page 151: ...rosene 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 lbs torque 8 For Trac lok differentials a quantity of ...

Page 152: ...heel speed sensors if necessary Refer to Group 5 Brakes for proper procedures 7 Connect parking brake cable to brackets and lever 8 Install the brake rotors and calipers Refer to Group 5 Brakes for proper procedures 9 Connect the brake hose to the axle junction block Refer to Group 5 Brakes for proper proce dures 10 Install axle vent hose 11 Align propeller shaft and pinion yoke refer ence marks I...

Page 153: ...nut only enough to remove the shaft end play 4 Rotate the pinion shaft using a in lbs torque wrench Rotating resistance torque should be equal to the reading recorded during removal plus an addi tional 0 56 N m 5 in lbs Fig 12 Fig 8 Pinion Yoke Removal SPECIAL TOOL C 3281 YOKE SPECIAL TOOL C 452 Fig 9 Seal Removal SPECIAL TOOL 7794A SLIDE HAMMER PINION SEAL Fig 10 Pinion Seal Installation SPECIAL ...

Page 154: ... reading for instal lation reference 8 Using a short piece of pipe and Holder 6958 to hold the pinion yoke remove the pinion nut and washer Fig 14 9 Use Remover C 452 and Wrench C 3281 to remove the pinion yoke Fig 15 10 Use Remover 7794 A and slide hammer to remove the pinion shaft seal Fig 16 11 Remove the front pinion bearing using a pair of suitable pick tools to pull the bearing straight off ...

Page 155: ...r lubricant on the lip of pinion seal Install seal with Installer C 3972 A and Handle C 4171 Fig 19 5 Install yoke with Installer C 3718 and Holder 6958 Fig 20 6 If the original pinion bearings are being used install differential assembly and axle shafts if neces sary NOTE If new pinion bearings were installed do not install the differential assembly and axle shafts until after the pinion bearing ...

Page 156: ...ear should be Original Bearings The reading recorded dur ing removal plus an additional 0 56 N m 5 in lbs New Bearings 2 to 5 N m 15 to 35 in lbs 11 Install differential assembly and axle shafts if necessary 12 Align marks made previously on yoke and propeller shaft and install propeller shaft 13 Install rear brake rotors and calipers Refer to Group 5 Brakes for proper procedures 14 Add gear lubri...

Page 157: ...lock in end of axle shaft Push axle shaft outward to seat C clip lock in side gear 3 Insert pinion mate shaft into differential case and through thrust washers and pinion gears 4 Align hole in shaft with hole in the differential case and install lock screw with Loctitet on the threads Tighten lock screw to 19 N m 14 ft lbs torque 5 Install cover and add fluid Refer to Lubricant Change procedure in...

Page 158: ...d the housing enough to remove the case from the housing Measure the distance with the dial indicator Fig 28 CAUTION Do not spread over 0 50 mm 0 020 in If the housing is over spread it could be distorted or damaged 8 Remove the dial indicator 9 Pry the differential case loose from the hous ing To prevent damage pivot on housing with the end of the pry bar against spreader Fig 29 10 Remove the cas...

Page 159: ...L 1 Remove differential case from axle housing 2 Remove the bearings from the differential case with Puller Press C 293 PA Adapters C 293 42 and Plug C 293 3 Fig 32 INSTALLATION 1 Using tool C 4340 with handle C 4171 install differential side bearings Fig 33 2 Install differential case in axle housing RING GEAR The ring and pinion gears are service in a matched set Do not replace the ring gear wit...

Page 160: ...y tighten to 95 122 N m 70 90 ft lbs torque Fig 35 4 Install differential in axle housing and verify gear mesh and contact pattern Fig 32 Differential Bearing Removal SPECIAL TOOL C 293 42 BEARING DIFFERENTIAL SPECIAL TOOL C 293 3 SPECIAL TOOL C 293 PA Fig 33 Install Differential Side Bearings HANDLE C 4171 DIFFEREN TIAL BEARING TOOLC 4340 Fig 34 Ring Gear Removal CASE RING GEAR RAWHIDE HAM MER Fi...

Page 161: ...emove the pinion gear from housing Fig 38 Catch the pinion with your hand to prevent it from falling and being damaged 7 Remove the pinion seal with a slide hammer or pry out with bar 8 Remove oil slinger if equipped and the front pinion bearing 9 Remove the front pinion bearing cup with Remover D 103 and Handle C 4171 Fig 39 10 Remove the rear bearing cup from housing Fig 40 Use Remover C 4307 an...

Page 162: ... Installer C 4308 and Driver Handle C 4171 Fig 43 Ensure cup is correctly seated 2 Apply Mopart Door Ease stick lubricant to out side surface of bearing cup Install the pinion front bearing cup with Installer D 129 and Handle C 4171 Fig 44 Fig 40 Rear Bearing Cup Removal DRIVER HANDLE Fig 41 Collapsible Spacer COLLAPS IBLE SPACER SHOULDER PINION GEAR OIL SLINGER REAR BEAR ING Fig 42 Inner Bearing ...

Page 163: ...ar 5 Install the rear bearing and slinger if used on the pinion gear with Installer 6448 Fig 46 6 Install a new collapsible preload spacer on pin ion shaft Fig 47 7 Install pinion gear in housing 8 Install yoke with Installer C 3718 and holder 6958 Fig 48 9 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 3...

Page 164: ...3 Align previously made marks on yoke and propeller shaft and install propeller shaft 14 Install differential housing into the axle hous ing FINAL ASSEMBLY 1 Scrape the residual sealant from the housing and cover mating surfaces Clean the mating surfaces with mineral spirits Apply a bead of Mopart Silicone Rubber Sealant or equivalent on the housing cover Fig 60 Install the housing cover within 5 ...

Page 165: ...c Lok differential components are illus trated in Fig 54 Refer to this illustration during repair service DISASSEMBLY 1 Clamp Side Gear Holding Tool 6963 A in a vise 2 Position the differential case on Side Gear Holding Tool 6963 A Fig 55 3 Remove ring gear if necessary Ring gear removal is necessary only if the ring gear is to be replaced The Trac Lok differential can be serviced with the ring ge...

Page 166: ...appropriate size feeler gauge remove thrust washers from behind the pinion gears Fig 61 11 Insert Turning Bar C 4487 4 in case Fig 62 12 Loosen the Forcing Screw C 4487 2 in small increments until the clutch pack tension is relieved and the differential case can be turned using Turning Bar C 4487 4 Fig 54 Trac Lok Differential Components THRUST WASHER PINION SHAFT LOCK SCREW Fig 55 Differential Ca...

Page 167: ...cks must be replaced Lubricate each component with gear lubricant before assembly 1 Assemble the clutch discs into packs and secure disc packs with retaining clips Fig 64 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 65 Be sure clutch pack retaining clips remain in position and are seated in the c...

Page 168: ...ears align with holes in case It may be necessary to slightly tighten the forcing 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 thre...

Page 169: ... pinion gears side gears and thrust washers Replace as a matched set only Ring and pinion gear for worn and chipped teeth Ring gear 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 Clean all ...

Page 170: ...isc Set 6956 and Dial Indicator C 3339 Fig 69 1 Assemble Pinion Height Block 6739 Pinion Block 8144 and rear pinion bearing onto Screw 6741 Fig 69 2 Insert assembled height gauge components rear bearing and screw into axle housing through pinion bearing cups Fig 70 3 Install front pinion bearing and Cone 6740 hand tight Fig 69 4 Place Arbor Disc 6927 on Arbor D 115 3 in posi tion in axle housing s...

Page 171: ...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 determined using slip fit dummy bearings 6929 A in place of the differential side bear ings and a dial indicator C 3339 Before proceeding with the dif...

Page 172: ...3 DIFFERENTIAL PRELOAD AND GEAR BACKLASH SHIM SELECTION NOTE It is difficult to salvage the differential side bearings during the removal procedure Install replacement bearings if necessary 1 Remove side bearings from differential case 2 Install ring gear on differential case and tighten bolts to specification 3 Install dummy side bearings 6929 A on differ ential case 4 Install differential case i...

Page 173: ...lash shim thickness from the total preload shim thickness The remainder is the shim thickness required on the pinion side of the axle housing 26 Rotate dial indicator out of the way on guide stud 27 Remove differential case and dummy bearings from axle housing 28 Install new side bearing cones and cups on differential case 29 Install spreader W 129 B on axle housing and spread axle opening enough ...

Page 174: ...plied from shop towel The areas on the ring gear teeth with the greatest degree of contact against the pinion gear teeth will squeegee the compound to the areas with the least amount of contact Note and compare patterns on the ring gear teeth to Gear Tooth Contact Patterns chart Fig 78 and adjust pinion depth and gear backlash as necessary Fig 76 Ring Gear Backlash Measurement DIAL INDI CATOR Fig ...

Page 175: ...E OF TOOTH BUT MAY BE SLIGHTLY TOWARD THE TOE THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP OF THE TOOTH RING GEAR BACKLASH CORRECT THINNER PINION GEAR DEPTH SHIM REQUIRED RING GEAR BACKLASH CORRECT THICKER PINION GEAR DEPTH SHIM REQUIRED PINION GEAR DEPTH SHIM CORRECT DECREASE RING GEAR BACKLASH PINION GEAR DEPTH SHIM CORRECT INCREASE RING GEAR BACKLASH ZG DIFFERENTIAL AND...

Page 176: ... Diff 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 Installa tion procedures for proper pinion nut tightening instructions Do not e...

Page 177: ...Holder C 3281 Installer C 3718 Handle C 4171 Remover C 4307 Installer C 4308 Installer C 4340 Guide Pin C 3288 B Dial Indicator C 3339 ZG DIFFERENTIAL AND DRIVELINE 3 119 SPECIAL TOOLS Continued ...

Page 178: ...Trac lok Tool Set C 4487 Installer C 3972 A Installer D 129 Remover D 103 Spreader W 129 B Remover 6310 Installer 6436 Installer 6437 3 120 DIFFERENTIAL AND DRIVELINE ZG SPECIAL TOOLS Continued ...

Page 179: ...aller 6448 Adapter 6790 Pinion Depth Set 6955 Adapter Set 6956 Gauge Block 8144 Starting Point Shim 8107 Holder 6958 Holder 6963 A Remover 7794 A ZG DIFFERENTIAL AND DRIVELINE 3 121 SPECIAL TOOLS Continued ...

Page 180: ......

Page 181: ...EDING 12 BRAKE FLUID LEVEL 11 BRAKE LINE 13 DISC ROTOR MACHINING 13 MASTER CYLINDER BLEEDING 11 REMOVAL AND INSTALLATION BRAKE PEDAL 14 COMBINATION VALVE 15 DISC BRAKE CALIPER 16 DISC BRAKE ROTOR 19 DISC BRAKE SHOES 17 FRONT PARKING BRAKE CABLE 22 MASTER CYLINDER 15 PARKING BRAKE CAM AND LEVER 24 PARKING BRAKE HAND LEVER 22 PARKING BRAKE SHOES 23 POWER BRAKE BOOSTER 16 REAR DISC BRAKE CALIPER 19 R...

Page 182: ...ese are the only cleaning materials recommended If system contam ination is suspected check the fluid for dirt discol oration or separation into distinct layers Drain 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 f...

Page 183: ...ly controls meters fluid flow during high effort brake stops FRONT DISC BRAKES The calipers are a single piston type The calipers are free to slide laterally this allows continuous com pensation for lining wear When the brakes are applied fluid pressure is exerted against the caliper piston The fluid pressure is exerted equally and in all directions This means pressure exerted against the caliper ...

Page 184: ...ation disc brake rotor and parking brake drum The rear cables are connected to a cam and lever mechanism the cam and lever operates the shoes The cable is connected to the lever by a rectangu lar eyelet on the cable end A retainer on the cable secures it in a bracket attached to the rear of the cal iper bracket The lever is mounted on the floorpan adjacent to the driver NOTE Parking brake cable ad...

Page 185: ...nt and rear of vehicle and listen for noise that might be caused by loose worn or damaged suspension or steering components 3 Inspect brake fluid level and condition Note that the front disc brake reservoir fluid level will decrease in proportion to normal lining wear Also note that brake fluid tends to darken over time This is normal and should not be mistaken for contamination a If fluid level i...

Page 186: ...es and hoses HARD PEDAL OR HIGH PEDAL EFFORT A hard pedal or high pedal effort may be due to lining that is water soaked contaminated glazed or badly worn The power booster or check valve could also be faulty PEDAL PULSATION Pedal pulsation is caused by components that are loose or beyond tolerance limits The primary cause of pulsation are disc brake rotors with excessive lateral runout or thickne...

Page 187: ... squeak Dirt and foreign material embedded in the brake lining will also cause squeak squeal A very loud squeak or squeal is frequently a sign of severely worn brake lining If the lining has worn through to the brake shoes in spots metal to metal contact occurs If the condition is allowed to continue rotors and drums can become so scored that replace ment is necessary BRAKE CHATTER Brake chatter i...

Page 188: ... action it should fall away slightly under light foot pressure then hold firm If no pedal action is discernible power booster vacuum supply or vacuum check valve is faulty Pro ceed to the POWER BOOSTER VACUUM TEST 6 If the POWER BOOSTER VACUUM TEST passes rebuild booster vacuum reserve as follows Release brake pedal Increase engine speed to 1500 rpm close the throttle and immediately stop turn off...

Page 189: ...s to fall below this limit Measure rotor thickness at the center of the brake shoe contact surface Replace the rotor if worn below minimum thickness or if refinishing would reduce thickness below the allowable minimum FRONT ROTOR THICKNESS VARIATION Variations in rotor thickness will cause pedal pul sation noise and shudder Measure rotor thickness at four to six points around the rotor face Positi...

Page 190: ... to check lateral runout Fig 10 Maximum allowable lateral runout is 0 13 mm 0 005 in PARKING BRAKE NOTE Parking brake adjustment is controlled by a cable tensioner Once the tensioner is adjusted at the factory it should not require further attention However there are two instances when adjustment will be required The first is when a new tensioner or cables have been installed And the second is whe...

Page 191: ... damaged brake lines should be replaced Factory replacement brake lines and hoses are rec ommended to ensure quality correct length and supe rior fatigue life Care should be taken to make sure that brake line and hose mating surfaces are clean and free from nicks and burrs Also remember that right and left brake hoses are not interchangeable Use new copper seal washers at all caliper connec tions ...

Page 192: ...valve right rear wheel left rear wheel right front wheel left front wheel MANUAL BLEEDING 1 Remove reservoir filler caps and fill reservoir with Mopar or equivalent quality DOT 3 brake fluid 2 If calipers or wheel cylinders were overhauled open all caliper and wheel cylinder bleed screws Then close each bleed screw as fluid starts to drip from it Top off master cylinder reservoir once more before ...

Page 193: ...will be required CAUTION Do not machine the rotor if it will cause the rotor to fall below minimum allowable thick ness BRAKE LINE Mopar preformed metal brake line is recommended and preferred for all repairs However double wall steel line can be used for emergency repair when fac tory replacement parts are not readily available Special heavy duty tube bending and flaring equipment is required to ...

Page 194: ...f adjusts BRAKE PEDAL REMOVAL 1 Remove lower trim panel and air conditioning duct if necessary 2 Remove steering column lower trim panel and bezel 3 Remove necessary dash panel to instrument panel brace rods 4 Remove retainer clip and washers attaching booster push rod to pedal pin Fig 20 5 Remove nut securing pedal shaft in support bracket 6 Slide pedal shaft outward for clearance and remove brak...

Page 195: ...kage 3 Connect wire to differential pressure switch in combination valve 4 Tighten brake line fittings at master cylinder just enough to prevent leakage 5 Attach HCU solenoid harness connectors to combination valve bracket 6 Bleed brakes MASTER CYLINDER REMOVAL 1 Remove brake lines from master cylinder 2 Remove combination valve 3 Remove nuts that attach master cylinder to booster studs Fig 23 Ret...

Page 196: ...eads INSTALLATION 1 Check condition of grommet that secures check valve in booster Replace grommet if cut torn or loose no longer secures valve tightly 2 Wipe booster mounting surface of dash panel clean with shop towel 3 Align and position booster on engine compart ment side of dash panel 4 Inside passenger compartment a Lubricate pedal pin and bushing with Mopar multi mileage grease b Install bo...

Page 197: ...of all chassis components and tighten caliper fitting bolt to 31 N m 23 ft lbs CAUTION Be sure the brake hose is not twisted or kinked at any point Also be sure the hose is clear of all steering and suspension components Loosen and reposition the hose if necessary 6 Install wheel and tire assembly 7 Fill master cylinder and bleed brake system DISC BRAKE SHOES REMOVAL 1 Raise vehicle and remove fro...

Page 198: ...opar multi mileage grease to slide surfaces Lubricate mounting bolts and bushings with silicone grease Fig 32 2 Install inboard shoe in caliper and verify shoe retaining springs are fully seated into the piston 3 Install outboard shoe in caliper by starting one end of shoe in caliper and rotating shoe downward into place Verify shoe locating lugs and shoe spring are seated 4 Install caliper by pos...

Page 199: ...etor cleaner 2 Install rotor on hub 3 Install caliper 4 Install new spring nuts on wheel studs 5 Install wheel and tire assembly REAR DISC BRAKE CALIPER REMOVAL 1 Raise vehicle and remove tire and wheel assemblies 2 Press caliper piston into caliper bore with C clamp Fig 36 3 Remove caliper mounting bolts Fig 37 4 Rotate caliper rearward by hand or with pry tool Then rotate caliper and brake shoes...

Page 200: ...heel and tire assemblies 3 Press caliper piston back into caliper bore with large Cackling 4 Remove caliper mounting bolts 5 Rotate caliper rearward and off rotor Fig 39 Support caliper with wire attached to nearby suspen sion component Do not allow brake hose to sup port caliper weight 6 Press one corner of outboard shoe inward then pry shoe upward with suitable tool and rotate shoe out of calipe...

Page 201: ... star wheel in counterclockwise direction Direction of rotation is while looking from rear to front of vehicle 5 If rotor and or axle hub contact surfaces are heavily rusted apply rust penetrant oil to rotor and axle hub and through spaces around wheel studs 6 Remove push nuts securing rotor to axle shaft studs 7 Work rotor off axle hub and studs Use plastic or rawhide mallet to loosen rotor if ne...

Page 202: ...dule wires harnesses 6 Install parking lever cover 7 Install center console refer to Group 23 Body 8 Raise vehicle 9 Assemble front cable cable tensioner and cable bracket 10 Adjust parking brake front cable 11 Lower vehicle 12 Connect battery negative cable FRONT PARKING BRAKE CABLE REMOVAL 1 Release parking brakes 2 Disconnect battery negative cable and raise vehicle on hoist 3 Remove front cabl...

Page 203: ...r Do not allow brake hose to support caliper weight Support caliper with wire attached to suspension component 4 Remove rubber access plug from back of rear disc brake splash shield 5 Retract parking brake shoes with brake adjuster tool Fig 47 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 Rem...

Page 204: ...on both sides REMOVAL 1 Raise vehicle 2 Remove wheel and tire assembly 3 Remove brake caliper and rotor 4 Remove parking brake shoes 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 51 Note cam position for installation reference 7 Remove lever INSTALLATION 1 Lubricate replacement lever with silico...

Page 205: ...shield and caliper bracket from axle studs and work lever out of rear cable eyelet 8 Mark position of splash shield and bracket for assembly reference Use paint or scribe to mark parts 9 Drill out rivets that retain splash shield to cal iper bracket Fig 53 If rivet heads did not come completely off after drilling remove remaining pieces with small chisel Note that the rivets do not have to be repl...

Page 206: ... to 43 61 N m 32 45 ft lbs 6 Assemble and install cam and lever Push lever through boot and seat cam between lip on shield and ledge on bracket Fig 57 Then engage lever in cable eyelet Be sure cable notch in lever is facing rear ward Remove and reposition cam and lever if neces sary 7 Install parking brake shoes on splash shield Verify positioning of cam and lever shoes springs and hold down clips...

Page 207: ...om grommets with pry tool Fig 61 5 Remove reservoir by rocking it to one side and pulling free of grommets Fig 62 6 Remove old grommets from cylinder body Fig 63 Fig 59 Checking Caliper Bracket And Shield Position BRAKESHOE LEDGE 12 O CLOCK POSITION SPLASH SHIELD CALIPER LEDGES TO REAR Fig 60 Reservoir Retaining Pins PIN PUNCH RESERVOIR BODY ROLL PINS Fig 61 Loosening Reservoir PRY TOOL RESERVOIR ...

Page 208: ...Drain brake fluid out of caliper 3 Pad interior of caliper with minimum 2 54 cm 1 in thickness of shop towels or rags Fig 65 Tow els are needed to protect caliper piston during removal 4 Remove caliper piston with short bursts of low pressure compressed air Direct air through fluid inlet port and ease piston out of bore Fig 66 CAUTION Do not blow the piston out of the bore with sustained air press...

Page 209: ...rior of bushing boots with Dielectric silicone grease 3 Install bushing boots in caliper then insert bushing into boot and push bushing into place Fig 70 4 Install new piston seal into seal groove with finger Fig 71 Fig 67 Caliper Piston Dust Boot Removal COLLAPSE BOOT WITH PUNCH OR SCREWDRIVER PISTON DUST BOOT Fig 68 Piston Seal Removal REMOVE SEAL WITH WOOD PEN CIL OR SIM ILAR TOOL PISTON SEAL F...

Page 210: ... low pressure compressed air Direct air through fluid inlet port and ease piston out of bore Fig 77 CAUTION Do not blow the 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 In addition NEVER attempt to catch the piston as it leaves the bore This could result in personal injury 5 Remove caliper piston dust b...

Page 211: ... or bench vise Fig 80 CAUTION Position a protective wood block between the piston and C clamp or vise jaws The wood block will avoid chipping or cracking the pis ton while pressing it into place 5 Install dust boot on piston Be sure boot lip is fully seated in groove at top of caliper piston 6 Seat dust boot in caliper either by hand or with a suitable size installer tool Fig 81 Fig 77 Caliper Pis...

Page 212: ...ces are different for resin and steel pistons Do not intermix these components at any time The bore can be lightly polished with a brake hone to remove very minor surface imperfections Fig 83 The caliper should be replaced if the bore is severely corroded rusted scored or if polishing would increase bore diameter more than 0 025 mm 0 001 inch ADJUSTMENTS STOP LAMP SWITCH 1 Press and hold brake ped...

Page 213: ...splash shield access hole 8 Install wheel and tire assemblies SPECIFICATIONS BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards No other type of brake fluid is recommended or approved for usage in the vehicle brake system Use only Mopar brake fluid or an equivalent from a tightly sealed container CAUTION Never use reclaimed brake fluid or ...

Page 214: ...16 N m 144 in lbs Combination Valve Mounting Nuts 18 N m 155 in lbs Primary Secondary Brake Lines 21 N m 185 in lbs Front Caliper Mounting Bolts 10 20 N m 7 15 ft lbs Brake Hose Bolt 31 N m 23 ft lbs Rear Caliper Mounting Bolts 10 20 N m 7 15 ft lbs Brake Hose Bolt 31 N m 23 ft lbs Parking Brake Lever Screws 10 14 N m 7 10 ft lbs Lever Bracket Screws 10 14 N m 7 10 ft lbs Cable Retainer Nut 1 2 N ...

Page 215: ...r electri cal circuits in the vehicle A specially programmed controller antilock brake unit operates the system components ABS system major components include Controller Antilock Brakes CAB Hydraulic Control Unit HCU Wheel Speed Sensors WSS Acceleration Switch ABS Warning Light DESCRIPTION AND OPERATION ANTILOCK BRAKE SYSTEM Battery voltage is supplied to the CAB ignition ter minal when the igniti...

Page 216: ...separate from other vehicle elec trical circuits CAB voltage source is through the ignition switch in the RUN position The CAB contains dual microprocessors A logic block in each microprocessor receives identical sensor signals These signals are processed and compared simultaneously The CAB contains a self check program that illu minates the ABS warning light when a system fault is detected Faults...

Page 217: ... sensors have a resistance between 900 and 1300 ohms SPEED SENSOR AIR GAP FRONT SENSOR Front sensor air gap is fixed and not adjustable Only rear sensor air gap is adjustable Although front air gap is not adjustable it can be checked if diagnosis indicates this is necessary Front air gap should be 0 36 to 1 5 mm 0 014 to 0 059 in If gap is incorrect the sensor is either loose or dam aged REAR SENS...

Page 218: ... informa tion refer to the Antilock Brake section in Group 8W For test procedures refer to the Chassis Diag nostic Manual SERVICE PROCEDURES BLEEDING ABS BRAKE SYSTEM ABS system bleeding requires conventional bleed ing methods plus use of the DRB scan tool The pro cedure involves performing a base brake bleeding followed by use of the scan tool to cycle and bleed the HCU pump and solenoids A secon...

Page 219: ...ckle Fig 7 5 Disengage sensor wire from brackets on steer ing knuckle and frame member Fig 8 and Fig 9 6 Unseat grommet that secures sensor wire in fender panel 7 In engine compartment disconnect sensor wire connector at harness plug Fig 5 CAB Connector Release HCU CAB ASSEMBLY CONNECTOR RELEASE Fig 6 HCU CAB Assembly HCU CAB ASSEMBLY MOTOR FWD MOUNTING BRACKET Fig 7 Sensor Location FRONT SENSOR S...

Page 220: ...eld bracket INSTALLATION 1 Insert sensor through splash shield hole 2 Apply Mopar Lock N Seal or Loctite 242 to original sensor bolt Use new bolt if original is worn or damaged 3 Install sensor bolt finger tight only at this time 4 If original sensor is being installed or adjusted remove any remaining pieces of cardboard spacer from sensor pickup face Set air gap to 0 92 to 1 275 mm 0 036 to 0 05 ...

Page 221: ...harness to switch Be sure harness connector is firmly seated 5 Move rear seat back to normal position 6 Connect battery negative cable DISASSEMBLY AND ASSEMBLY HYDRAULIC CONTROL UNIT CONTROLLER ANTILOCK BRAKE DISASSEMBLY 1 Remove pump motor connector from the CAB 2 Remove CAB mounting screws from the HCU Fig 14 3 Remove CAB from the HCU Fig 12 Acceleration Switch Mounting SENSOR BOLT ACCELERATION ...

Page 222: ...PTION 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 Controller Antilock Brakes Mounting Nuts 12 N m 9 ft lbs Brake Lines 16 N m 12 ft lbs CAB Screws 1 8 N m 16 in lbs Wheel Speed Sensors Front Sensor Bolt 4 6 34 50 in lbs Rear Sensor Bolt 12 14 N m 106 124 in lbs 5 42 BRAKES ZG DISASSEMBLY AND ASSEMBLY Continued ...

Page 223: ...The reservoir fluid level will actually increase as normal clutch wear occurs For this rea son it is important to avoid over filling or remov ing fluid from the reservoir If inspection indicates additional fluid is needed add fluid from a sealed container only Use Mopart brake fluid or an equivalent meeting standards SAE J1703 and DOT 3 Do not use any other type of fluid REMOVAL AND INSTALLATION C...

Page 224: ...marked be sure flat side of disc hub is placed toward the flywheel 5 Insert clutch alignment tool Fig 3 in clutch disc and pilot bearing 6 Position clutch cover over disc and on flywheel 7 Install clutch cover bolts finger tight 8 Starting with the bolts marked P on the cover first tighten clutch cover bolts in a star pattern to 50 N m torque 9 Apply light coat of Mopart high temperature bearing g...

Page 225: ...ar ing out of retainer INSTALLATION CAUTION The bearing can be installed incorrectly if care is not exercised Check bearing position before installing it Make sure the bearing seal and the letters on the bearing will both be facing out toward the clutch after installation 1 Install new pilot bearing with hammer and tool handle C 4171 Fig 6 Seat bearing flush with lower Fig 3 Clutch Disc Alignment ...

Page 226: ...urfaces clutch con tact surface and ring gear Check condition of fly wheel hub and attaching bolts Replace flywheel if hub exhibits cracks in the area of attaching bolt holes Replace ring gear if the teeth are damaged Resurface the flywheel if the clutch contact surface is scored or rough refer to flywheel finishing and ring gear replacement information in this section Check flywheel runout if mis...

Page 227: ...nsion is approximately 350 375 CAUTION Do not use an oxy acetylene torch to remove the old gear or to heat and expand a new gear The high temperature of the torch flame can cause localized heating that will damage the fly wheel In addition using the torch to heat a replace ment gear will cause uneven heating and expansion The torch flame can also anneal the gear teeth resulting in rapid wear and d...

Page 228: ......

Page 229: ...T REPLACEMENT ADJUSTMENT 39 COOLING SYSTEM FAN 4 0L ENGINE 42 COOLING SYSTEM FAN 5 2 5 9L ENGINES 43 ENGINE BLOCK HEATER 38 RADIATOR 32 THERMOSTAT 4 0L ENGINE 29 THERMOSTAT 5 2 5 9L ENGINES 30 VISCOUS FAN DRIVE 43 WATER PUMP 4 0L ENGINE 24 WATER PUMP 5 2 5 9L ENGINES 26 WATER PUMP BYPASS HOSE 36 CLEANING AND INSPECTION FAN BLADE INSPECTION 44 RADIATOR CAP 44 RADIATOR 44 WATER PUMP INSPECTION 44 SP...

Page 230: ... cap Thermostat Coolant reserve overflow system Transmission oil cooler if equipped with an automatic transmission Coolant Water pump Hoses and hose clamps Accessory drive belt SYSTEM COOLANT ROUTING For cooling system routings refer to Fig 1 Fig 2 Fig 1 Engine Cooling System 4 0LEngine Typical HEATER CORE TO COOLANT RESERVE OVERFLOW TANK THERMOSTAT HOUSING RADIATORWATER PUMP Fig 2 Engine Cooling ...

Page 231: ... coolant type which con sists of plates mounted in the radiator outlet tank and is also supplied as optional equipment NOTE IF A VEHICLE WITH THE TRAILER TOWING OPTION DOES NOT HAVE AN EXTERNAL AUXIL IARY TRANSMISSION COOLER THAN IT IS EQUIPPED WITH THE INTERNAL HIGH EFFICIENCY COOLER COOLANT RESERVE OVERFLOW SYSTEM This system works along with the radiator pres sure cap This is done by using ther...

Page 232: ...d in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant Connect power cord to a grounded 110 120 volt AC electrical outlet 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 CLI...

Page 233: ...eg C 257 deg F at 96 5 kPa 14 psi compared to 128 deg C 263 deg F for ethylene gly col Use of propylene glycol can result in boil over or freeze up in Chrysler vehicles which are designed for ethylene glycol Propylene glycol also has poorer heat transfer characteristics than ethylene glycol This can increase cylinder head temperatures under cer tain conditions Propylene glycol Ethylene glycol Mixt...

Page 234: ... have been equipped with a forward clockwise rotating water pump Installation of the wrong water pump or vis cous fan drive will cause engine over heating A quick test to determine if the pump is working is to check if the heater warms properly A defective water pump will not be able to circulate heated cool ant through the long heater hose to the heater core 5 2 5 9L ENGINES One of the heater hos...

Page 235: ...es to the water pump shaft The coupling allows the fan to be driven in a normal manner This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit Fig 12 Fig 13 This spring coil reacts to the temperature of the radiator discharge ai...

Page 236: ...s 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 This can occur during the first 15 seconds to one minute after engine start up on a cold engine LEAKS Viscous fan drive operation is not affected by small oil stains near the drive bearing If leakage appears excessive replace the fan drive unit D...

Page 237: ...e other 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 ...

Page 238: ... 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 section of this group for other probable causes For other DTC numbers refer to On Board Diagnostics in Group 25 Emission Control Systems The DTC can also be accessed through...

Page 239: ...es 4 Pulley misalignment 4 Align component 5 Belt cordline is broken 5 Replace belt BELT BROKEN NOTE IDENTIFY AND CORRECT PROBLEM BEFORE NEW BELT IS INSTALLED 1 Excessive tension 1 Replace belt and adjust tension to specification 2 Tensile member damaged during belt instalation 2 Replace belt 3 Severe misalignment 3 Align pulley s 4 Bracket pulley or bearing failure 4 Replace defective component a...

Page 240: ...iven component bearing failure 4 replace faulty component bearing 5 Belt glazed and hardened from heat and excessive slippage 5 Replace belt GROOVE JUMPING BELT DOES NOT MAINTAIN CORRECT POSITION ON PULLEY 1 Belt tension either too high or too low 1 Replace automatic belt tensioner 2 Incorrect belt 2 Replace belt 3 Pulley s not within design tolerance 3 Replace pulley s 4 Foreign object s in groov...

Page 241: ...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 242: ...perature gauge The gauge should return to the normal range If the gauge does not return to normal range determine the cause for overheating and repair Refer to POSSIBLE CAUSES numbers 2 through 18 2 Is temperature gauge if equipped reading correctly 2 Check gauge Refer to Group 8E Repair as necessary 3 Is temperature warning lamp if equipped illuminating unnecessarily 3 Check warning lamp operatio...

Page 243: ... shorted Also corroded or loose wiring in the circuit 2 Check operation of gauge and repair if necessary Refer to Group 8E Instrument Panel and Gauges 3 Gauge reading rises when vehicle is brought to a stop after heavy use engine still running 3 A normal condition No correction is necessary Gauge reading should return to normal range after vehicle is driven 4 Gauge reading high after restarting a ...

Page 244: ...sects leaves etc 1 Remove restriction and or clean as necessary Refer to Radiator Cleaning in this group 2 Thermal viscous fan drive is free wheeling 2 Refer to Viscous Fan Drive for diagnosis Repair as necessary 3 Engine is overheating heat may be transferred from radiator to A C condenser High underhood temperatures due to engine overheating may also transfer heat to A C components 3 Correct ove...

Page 245: ...rvice manual for checking the thermostat using the DRB scan tool Replace thermostat if necessary STEAM IS COMING FROM FRONT OF VEHICLE NEAR GRILL AREA WHEN WEATHER IS WET ENGINE IS WARMED UP AND RUNNING AND VEHICLE IS STATIONARY TEMPERATURE GAUGE IS IN NORMAL RANGE 1 During wet weather moisture snow ice or rain condensation on the radiator will evaporate when the thermostat opens This opening allo...

Page 246: ...r 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 will be affected Replace cap if ca...

Page 247: ...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 248: ...ap 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 CAP AND WITHOUT PUSHING D...

Page 249: ...e 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 not...

Page 250: ...eces 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 radia tor hose is hot Stop engin...

Page 251: ...t 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 EXTERNAL TRANSMISSION OIL COOLER AUXILIARY REMOVAL 1 Disconnect negative battery cable at battery 2 Remo...

Page 252: ...lockwise 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 BURNS FROM COOLANT CAN OCCUR DO NOT WASTE...

Page 253: ...ater 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 position If stored horizontally silicone fluid in viscous fan drive could drain into its bearing assembly and cont...

Page 254: ...eering 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 also refer to the Belt Routing Label in the vehicle engine compart ment 8 Adjust accessory drive belt refer ...

Page 255: ...r 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 viscous fan drive 5 Remove two fan shroud to radiator nuts Fig 33 Do not attempt to remove fan shroud at this time 6 Remove fan shroud and fan blad...

Page 256: ...amp 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 bracket is bottomed to the mounting bolt This will properly position return tube 7 Connec...

Page 257: ... 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 OF CLAMP SUCH AS SPECIAL CLAMP TOOL NUMBER 6094 Fig 53 SNAP ON CLAMP TOOL NUMBER HPC 20 MAY BE USED FOR LARGER CLAMPS...

Page 258: ... 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 2 5 9L engines are installed on a gasket with an anti stick coating This will aid in gasket removal and clean up 1 Disconnect negative battery cable at battery 2 Drain cooli...

Page 259: ...nifold 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 Tighten bolts to 23 N m 200 in lbs torque CAUTION Housing must be tightened ev...

Page 260: ... 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 OF CLAMP SUCH AS SPECIAL CLAMP TOOL NUMBER 6094 Fig 45 SNAP ON CLAMP TOOL NUMBER HPC 20 MAY BE USED FOR LARGER CLAMPS ALWAYS WEAR SAFETY GLASS...

Page 261: ...en water pump pulley bolts Fig 49 to prevent pulley from rotating Drive belt removal is not necessary for removal of fan drive 7 Do not attempt to remove fan viscous fan drive assembly from vehicle at this time 8 Remove the two fan shroud to upper radiator crossmember mounting nuts Fig 50 9 Remove the fan assembly and fan shroud as one unit from vehicle 10 Special quick connect fittings are used t...

Page 262: ...ounting nuts Fig 51 16 Working through grill opening remove the lower bracket bolt securing lower part of hood latch Fig 48 Fan Mounting Nuts 4 0L 6 Cyl Engine THERMAL VIS COUS FAN DRIVE 4 FAN BLADE TO VISCOUS DRIVE BOLTS 4 FAB HUB TO PUMP PULLEY STUDS WATER PUMP WATER PUMP PUL LEY FAN BLADE 4 FAN HUB TO PUMP PULLEY NUTS Fig 49 Fan Blade and Viscous Fan Drive 5 2 5 9LV 8 Engines THREADED NUT FAN B...

Page 263: ...CONSTANT PRESSURE EVEN WITH THE ENGINE OFF REFER TO REFRIG ERANT WARNINGS IN GROUP 24 HEATING AND AIR CONDITIONING BEFORE HANDLING ANY AIR CONDITIONING COMPONENT 25 If equipped with an auxiliary automatic trans mission oil cooler use caution when removing radia tor The oil cooler lines are routed through a rubber air seal on the left side of radiator Do not cut or tear this seal 26 Gently lift up ...

Page 264: ...s 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 Install the two nuts securing the fan shroud to the upper radiator crossmember Fig 50 20 4 0L Engine Install the four nuts securing the fan assembly to the water pump Fig 48 Tighten nuts to 27 N m 20 ft lbs torque 21 5 2 5 9L Engines Install the fan vi...

Page 265: ... into a clean container for reuse 3 Remove upper radiator hose clamp Fig 53 and hose at radiator 4 Unplug wiring harness from A C compressor 5 Remove air duct at throttle body 6 Disconnect A C lines from clip at intake mani fold 7 Remove heater hose coolant return tube mount ing bolt and nut Fig 56 Remove tube from engine and discard the old tube o ring 8 Remove accessory drive belt as follows The...

Page 266: ...olant 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 slot in tube bracket is bottomed to the mounting bolt This will properly position return tube 7 Connect throttle body control cables 8 Install oil dipstick mounting bolt 9 Install idler pulley Tighten pulley bolt to 54 N m 40 ft lbs torque 10 Relax tension fr...

Page 267: ...m with recommended coolant Refer to Refilling Cooling System section in this group 5 Start and warm the engine Check for leaks BELT REPLACEMENT ADJUSTMENT NOTE The belt routing schematics are published from the latest information available at the time of publication If anything differs between these sche matics and the Belt Routing Label use the sche matics on Belt Routing Label This label is loca...

Page 268: ...has been tightened into position recheck belt tension Adjust if necessary 5 2 5 9L Engines Drive belts on the 5 2 5 9L engines are equipped with a spring loaded automatic belt tensioner Fig 65 CAUTION Do not attempt to check belt tension with a belt tension gauge on vehicles equipped with an automatic belt tensioner Refer to Automatic Belt Tensioner in this group REMOVAL 1 Attach a socket wrench t...

Page 269: ... width Worn bearings on an engine accessory A C com pressor power steering pump water pump idler pul ley or generator A pulley on an engine accessory being loose Misalignment of an engine accessory Belt incorrectly routed NOTE A used belt should be replaced if tensioner indexing arrow has moved to point A Fig 67 Ten sioner travel stops at point A REMOVAL 1 Remove accessory drive belt Refer to Belt...

Page 270: ... and position to center of fan shroud Fan belt removal is not neces sary as the water pump studs will hold the pump pulley in position Do not remove fan assembly from vehicle at this time 2 Remove the two fan shroud to upper radiator crossmember mounting nuts Fig 69 3 Remove fan viscous fan drive and fan shroud as an assembly from the vehicle 4 Remove the four fan blade to viscous fan drive mounti...

Page 271: ...ly 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 drive assembly do not place viscous fan drive in horizon tal position If stored horizontally silicone fluid in the viscous fan drive could drain into its bearing assembly a...

Page 272: ...mp and viscous fan drive should also be inspected These components could have been damaged due to excessive vibration WATER PUMP INSPECTION Replace water pump assembly if it has any of the following conditions The body is cracked or damaged Water leaks from shaft seal This is evident by traces of coolant below vent hole Loose or rough turning bearing Also inspect vis cous fan drive Impeller rubs e...

Page 273: ...to Viscous Drive 4 0L Bolts 23 N m 200 in lbs Fan Drive Assy to Water Pump 4 0L Nuts 23 N m 200 in lbs Generator Mounting 4 0L Bolts 57 N m 42 ft lbs Radiator Upper Isolator to Crossmember Nuts 3 N m 20 in lbs Radiator Upper Isolator to Radiator Nuts 4 N m 36 in lbs Radiator Brace Bolts 10 N m 90 in lbs Thermostat Housing Bolts 22 N m 16 ft lbs Transmission Auxiliary Oil Cooler Bolts 10 N m 90 in ...

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Page 275: ...IFICATIONS 26 GENERAL INFORMATION COOLING SYSTEM The cooling system regulates engine operating tem perature It allows the engine to reach normal oper ating temperature as quickly as possible maintains normal operating temperature and prevents over heating The cooling system also provides a means of heat ing the passenger compartment The cooling system is pressurized and uses a centrifugal water pu...

Page 276: ...ne accessory drive belt the belt MUST be routed correctly If not the engine may overheat due to water pump rotat ing in wrong direction Refer to the engine Belt Schematic in Specification section at the end of this group for the correct belt routing COOLANT TANK A pressurized plastic coolant tank is used with the cooling system This separate tank should be consid ered part of the radiator The tank...

Page 277: ...nkshaft by a drive belt The water pump is bolted to the water pump adapter Fig 3 The water pump adapter is bolted to the engine The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing The bottom of the housing is equipped with a small vent tube Fig 3 to allow seepage to escape A drain hose is attached to this tube The water pump seals are lubri...

Page 278: ... at pressures slightly above atmospheric pressure This results in a higher coolant boiling point allowing increased radi ator cooling capacity The cap contains a spring loaded pressure relief valve This valve opens when system pressure reaches approximately 103 kPa 15 psi When the engine is cooling down vacuum is formed within the cooling system To prevent collapse of the radiator and coolant hose...

Page 279: ...ith normal field equipment and can cause problems associated with 100 percent ethyl ene glycol COOLING SYSTEM HOSES Rubber hoses route coolant to and from the radia tor water manifold and heater core Models equipped with air conditioning have a heater water control shut off valve This is located in line with the heater core inlet and outlet hoses It controls coolant flow to the heater core when th...

Page 280: ...CAUTION Some engines equipped with serpentine drive belts have reverse rotating fans and viscous fan drives They are marked with the word REVERSE to designate their usage Installation of the wrong fan or viscous fan drive can result in engine overheating 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 c...

Page 281: ...em such as the following may be the cause 1 PROLONGED IDLE VERY HIGH AMBIENT TEMPERATURE SLIGHT TAIL WIND AT IDLE SLOW TRAFFIC TRAFFIC JAMS HIGH SPEED OR STEEP GRADES Driving techniques that avoid overheating are Idle with A C off when temperature gauge is at end of normal range Increasing engine speed for more air flow is rec ommended 2 TRAILER TOWING Consult Trailer Towing section of owners manu...

Page 282: ...COOLING SYSTEM DIAGNOSIS DIESEL ENGINE 7 8 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...

Page 283: ...ZG COOLING SYSTEM 7 9 DIAGNOSIS AND TESTING Continued ...

Page 284: ...7 10 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...

Page 285: ...ZG COOLING SYSTEM 7 11 DIAGNOSIS AND TESTING Continued ...

Page 286: ...7 12 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...

Page 287: ...too late Replace thermostat 8 If the valve refuses to move at any time replace thermostat VISCOUS FAN DRIVE TESTING If the fan assembly free wheels without drag the fan blades will revolve more than five turns when spun by hand replace the fan drive This spin test must be performed when the engine is cool The cooling system must be in good condition This is checked prior to performing the followin...

Page 288: ...ne turned off attach the cooling system pressure tester and test the sys tem as described below Recheck the system cold if the cause of coolant loss is not located during warm engine examination Operate the tester pump to apply 103 kPa 15 psi pressure to the system If the hoses enlarge exces sively or bulge while testing replace as necessary Observe the gauge pointer and determine the condi tion o...

Page 289: ...k The baffles in the pressurized coolant tank degasser bottle will not allow you to see the fluid level Check the coolant level through the pressur ized coolant tank For better visibility of the coolant level use a shop lamp to light the pressurized cool ant tank and look through the pressurized coolant tank If the coolant level in the radiator drops below the top of radiator core tubes air will e...

Page 290: ...SERPENTINE DRIVE BELT DIAGNOSIS 7 16 COOLING SYSTEM ZG DIAGNOSIS AND TESTING Continued ...

Page 291: ...ENTLY WAIT AT LEAST 15 MINUTES BEFORE REMOVING COOLANT TANK CAP WITH A RAG SQUEEZE THE UPPER RADIATOR HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE PLACE A RAG OVER THE CAP VERY SLOWLY ROTATE THE CAP COUNTERCLOCKWISE ALLOWING PRESSURE TO SLOWLY RELEASE AFTER ALL PRESSURE HAS BEEN RELEASED REMOVE THE COOLANT TANK CAP COMPLETELY DO NOT WASTE reusable coolant If the solution is clean drain the coolant in...

Page 292: ...dd coolant when the engine is cold Coolant level in a warm engine will be higher in the tank due to ther mal expansion 11 After the engine has been operated through a few heat up and cool down cycles recheck the coolant level in the tank COOLANT REPLACEMENT It is recommended that the cooling system be drained and flushed at 84 000 kilometers 52 500 miles or 3 years whichever occurs first Then ever...

Page 293: ...wels on the bot tom of radiator into the rubber grommets in front lower crossmember Fig 16 2 If equipped with air conditioning attach con denser to radiator with mounting brackets 3 Install radiator upper crossmember 4 Install hood latch striker 5 Connect radiator upper and lower hoses 6 Insert alignment tabs at bottom of fan shroud into slots in bracket at bottom of radiator Install and tighten f...

Page 294: ...al manner This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds A bimetallic spring coil is located on the front face This spring coil reacts to the temper ature of the radiator discharge air It engages the viscous fan drive for higher fan speed if the air tem perature from the radiator rises above a certain point Until a...

Page 295: ...is necessary use only an original equipment clamp with matching number or letter 2 Remove the upper radiator hose at the thermo stat housing 3 Remove the four thermostat housing bolts Fig 19 4 Remove the thermostat housing from the water manifold 5 Remove the thermostat and rubber seal from the water manifold 6 Thoroughly clean the rubber seal mating sur faces INSTALLATION 1 Install a new rubber s...

Page 296: ...coolant If the solution is clean drain coolant into a clean container for reuse 1 Disconnect negative battery cable at battery 2 Drain the cooling system Refer to Draining Cooling System in this group 3 The thermal viscous fan drive and the fan blade assembly are attached threaded to the fan pulley shaft Fig 22 Remove the fan fan drive assembly from the fan pulley by turning the mount ing nut coun...

Page 297: ...his tube to the engine Disconnect the hose clamp and rubber hose at the back of the ther mostat Position the hose to the side 10 Remove the 3 water pump pulley bolts Fig 21 11 Remove the water pump pulley from the water pump 12 Disconnect the drain hose from the vent tube at the bottom of water pump Fig 21 13 Remove the 4 water pump mounting bolts Fig 21 14 Remove water pump from engine INSTALLATI...

Page 298: ...NSPECTION WATER PUMP INSPECTION Replace the water pump assembly if it has any of the following conditions The body is cracked or damaged Water leaks from the shaft seal This is evident by traces of coolant below the vent tube drain hose Loose or rough turning bearing Impeller rubs either the water pump body or water pump adapter RADIATOR CLEANING The radiator and air conditioning fins should be cl...

Page 299: ...r is filled apply air in short blasts allowing radiator to refill between blasts Con tinue this reverse flushing until clean water flows out through rear of radiator cooling tube passages For more information refer to operating instructions supplied with flushing equipment Have radiator cleaned more extensively by a radiator repair shop REVERSE FLUSHING ENGINE Drain the cooling system Remove the t...

Page 300: ...tic Belt Tensioner to Mounting Bracket Bolt 1 75 N m Automatic Belt Tensioner to Block Bolts 2 121 N m Coolant Tank Cap 5 N m Fan Shroud to Radiator Mounting Bolts 3 N m Fan Blade to Thermal Viscous Fan Drive Bolts 23 N m Hose Clamps 4 N m Radiator to A C Condenser Isolator Nuts 6 N m Thermal Viscous Fan Drive to Fan Hub Bolts 56 N m Thermostat Housing Bolts 11 N m Water Pump Mounting Bolts 24 N m...

Page 301: ...harger 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 INTRODUCTION This section covers only battery diagno...

Page 302: ... similar chem ically and the electrolyte becomes less acid the volt age potential of each cell is reduced However by charging the battery with a voltage higher than that of the battery the battery discharging process is reversed Charging the battery gradually changes the sul fated lead plates back into sponge lead and lead oxide and the water back into sulfuric acid This action restores the differ...

Page 303: ... the proper specifica tions Improper holddown fastener tightness whether too loose or too tight can result in damage to the battery See the Battery Removal and Installation procedures for the correct holddown fastener tight ness specifications DIAGNOSIS AND TESTING BATTERY The battery must be completely charged and the top posts and terminal clamps should be properly cleaned before diagnostic proc...

Page 304: ...art the engine 1 The battery has an incorrect size or rating for this vehicle 2 The battery is physically damaged 3 The battery terminal connections are loose or corroded 4 The battery is discharged 5 The electrical system is faulty 6 The battery is faulty 7 The starting system is faulty 8 The charging system is faulty 1 See Specifications in this group Replace the incorrect battery with the corre...

Page 305: ... tighten the battery terminal connections if required 3 Refer to Group 7 Cooling Systems for more information Replace or adjust the generator drive belt if required 4 See the Ignition Off Draw Test in this group Repair the electrical system if required 5 See the Load Test in this group to determine the battery condition Replace the battery if required 6 Refer to Group 8B Starting Systems for more ...

Page 306: ...LACE AND TIGHT BEFORE THE BATTERY 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 h...

Page 307: ...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 Then remove the cell caps and check the electrolyte level Add distilled water if the electrolyte level is below the top of the battery plates Refer to the instructions supplied with the hydrom e...

Page 308: ...LOW ELECTRO LYTE LEVEL DO NOT TEST ASSIST BOOST OR CHARGE THE BATTERY MAY ARC INTERNALLY AND EXPLODE PERSONAL INJURY AND OR VEHI CLE DAMAGE MAY RESULT EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY DO NOT SMOKE USE FLAME OR CREATE SPARKS NEAR THE BATTERY PERSONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT THE BATTERY CONTAINS SULFURIC ACID WHICH IS POISONOUS AND CAUSTIC AVOID CON TACT WITH TH...

Page 309: ...tery Charging pro cedure in this group 1 Disconnect and isolate both battery cables neg ative cable first The battery top and posts should be clean 2 Connect a suitable volt ammeter load tester Fig 6 to the battery posts Fig 7 Refer to the operating instructions provided with the tester being used Check the open circuit voltage no load of the battery Open circuit voltage must be 12 4 volts or grea...

Page 310: ...ction of these systems to automatically shut off time out This may take up to three minutes 2 Determine that the underhood lamp is operat ing properly then unplug the lamp wire harness con nector or remove the lamp bulb 3 Disconnect the battery negative cable 4 Set an electronic digital multi meter to its highest amperage scale Connect the multi meter between the disconnected battery negative cabl...

Page 311: ...ING IF THE BATTERY SHOWS SIGNS OF FREEZ ING LEAKING LOOSE POSTS OR LOW ELECTRO LYTE LEVEL DO NOT TEST ASSIST BOOST OR CHARGE THE BATTERY MAY ARC INTERNALLY AND EXPLODE PERSONAL INJURY AND OR VEHI CLE DAMAGE MAY RESULT EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY DO NOT SMOKE USE FLAME OR CREATE SPARKS NEAR THE BATTERY PERSONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT THE BATTERY CONTAINS ...

Page 312: ...cable 4 Connect the voltmeter to measure between the battery negative terminal post and a good clean ground on the engine block Fig 14 Rotate and hold the ignition switch in the Start position Observe the voltmeter If the reading is above 0 2 volt clean and tighten the battery negative cable attachment on the engine block Repeat the test If the reading is still above 0 2 volt replace the faulty ba...

Page 313: ...nt 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 battery h...

Page 314: ... MAY ARC INTERNALLY AND EXPLODE PERSONAL 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 turned 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 from the battery posts Fig 16 3 Inspec...

Page 315: ...e battery case and the top cover with a sodium bicarbonate baking soda and warm water cleaning solution to remove any acid film Fig 20 Rinse the battery with clean water Ensure that the cleaning solution does not enter the battery cells through the vent holes If the battery is being replaced see the Battery Ratings and Classifications chart in Specifications at the back of this group Con firm that...

Page 316: ... of the cable terminal clamps and battery terminal posts Fig 20 Clean Battery Typical TEST INDICA TOR BATTERY CLEANING BRUSH WARM WATER AND BAKING SODA SOLU TION Fig 21 Clean Battery Terminal Post Typical BATTERY TEST INDI CATOR TERMINAL BRUSH BATTERY CABLE Fig 22 Battery Cables NEGATIVE CABLE POWER DISTRIBUTION CEN TER 8A 16 BATTERY ZG REMOVAL AND INSTALLATION Continued ...

Page 317: ... Cold Crank ing Amper age Reserve Capacity Ampere Hours Load Test Amperage Gasoline 34 H6 600 120 Minutes 66 300 Diesel H7 700 135 Minutes 63 350 DIN is a European specification and is used to identify the size of batteries installed in vehicles that are built outside of North America ZG BATTERY 8A 17 ...

Page 318: ......

Page 319: ...s 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 INTRODUCTION The starting system consists of Battery Starter relay Starter with an integral solenoid Ignition switch Clutch pedal position switch manual transmis sion Park neutral position switch automa...

Page 320: ... releases the ignition switch to the On position the starter relay coil is de energized This causes the relay contacts to open When the relay contacts open the starter solenoid plunger hold in coil is de energized When the solenoid plunger hold in coil is de ener gized the solenoid plunger return spring returns the plunger to its relaxed position This causes the con tact disc to open the starter f...

Page 321: ...c tions Battery Visually inspect the battery for indi cations of physical damage and loose or corroded cable connections Determine the state of charge and cranking capacity of the battery Charge or replace the battery if required Refer to Group 8A Battery for more information Ignition Switch Visually inspect the ignition switch for indications of physical damage and loose or corroded wire harness ...

Page 322: ...tery 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 See Cold Cranking Test in this group Test and repair feed and or control circuits if required 3 If all other starting system components and circuits check OK replace starter assembly 4 Refer to Group 9 Engine for diagnostic and ser...

Page 323: ...uit Test procedures in this group c If the voltage reads 12 5 volts or greater and the starter does not turn see the Control Circuit Test procedures in this group d If the voltage reads 12 5 volts or greater and the starter turns very slowly see the Feed Circuit Test procedures in this group NOTE A cold engine will increase the starter cur rent amperage draw reading and reduce the bat tery voltage...

Page 324: ...ted correct the poor contact between the cable clamp and the terminal post 3 Connect the voltmeter to measure between the battery positive terminal post and the starter sole noid battery terminal stud Fig 6 Rotate and hold the ignition switch in the Start position Observe the voltmeter If the reading is above 0 2 volt clean and tighten the battery cable connection at the solenoid Repeat the test I...

Page 325: ...r continuity between the solenoid ter minal and the field coil terminal with a continuity tester Fig 9 There should be continuity If OK go to Step 3 If not OK replace the faulty starter assem bly 3 Check for continuity between the solenoid ter minal and the solenoid case Fig 10 There should be continuity If OK go to Step 4 If not OK replace the faulty starter assembly 4 Connect the solenoid field ...

Page 326: ...ssion check for an open or short circuit to the ignition switch and repair if required If the circuit to the ignition switch is OK see the Ignition Switch Test procedure in this group If not OK with a manual transmission check the circuit between the relay and the clutch pedal position switch for an open or a short If the circuit is OK see the Clutch Pedal Position Switch Test procedure in this gr...

Page 327: ...eptacle There should be no continuity 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 two fused B terminals of the ignition switch terminals 1 and 7 There should now be continuity If not OK replace the faulty switch REMOVAL AND INSTALLATION STARTER 2 5L DIESEL ENGINE 1 Disconnect and isolate the battery ...

Page 328: ...on from the starter solenoid Fig 13 4 Remove the lower starter mounting bolt and the exhaust brace Fig 15 5 Remove the upper starter mounting nut lock washer and automatic transmission oil cooler line bracket 6 Move the starter towards the front of the vehi cle until the starter gear housing nose clears the bell housing Then tilt the starter nose downwards past the exhaust pipe 7 Reverse the remov...

Page 329: ... Bosch Mitsubishi Mitsubishi Engine Application 2 5L Diesel 4 0L Gasoline 5 2L 5 9L Gasoline Power Rating 2 2 Kilowatt 1 4 Kilowatt 1 4 Kilowatt Voltage 12 Volts 12 Volts 12 Volts Number of Fields 4 4 4 Number of Poles 4 4 4 Number of Brushes 4 4 4 Drive Type Planetary Gear Reduction Planetary Gear Reduction Planetary Gear Reduction Free Running Test Voltage 11 5 Volts 11 2 Volts 11 2 Volts Free R...

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Page 331: ...s from the sole noid 8 Remove the starter from the vehicle 9 Reverse the removal procedures to install Tighten the starter hardware as follows Battery cable terminal nut 27 N m 20 ft lbs Starter mounting bolts 27 N m 20 ft lbs Front starter support bracket nuts 10 N m 90 in lbs Front starter support bracket bolt 47 N m 35 ft lbs STARTER RELAY 1 Disconnect and isolate the battery negative cable 2 R...

Page 332: ...4 Drive Type Planetary Gear Reduction Free Running Test Voltage 11 5 Volts Free Running Test Maximum Amperage Draw 160 Amperes Free Running Test Minimum Speed 5500 rpm Solenoid Closing Maximum Voltage 7 8 Volts Cranking Amperage Draw test 350 Amperes Test at operating temperature Cold engine tight new engine or heavy oil will increase starter amperage draw 8B 2 STARTING SYSTEMS ZG ...

Page 333: ...e 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 information Battery refer to...

Page 334: ...he battery charging rate System voltage will be higher at colder temperatures and is gradually reduced at warmer temperatures ELECTRONIC 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 replace...

Page 335: ...oltmeter directly to battery positive post b Touch the positive lead of voltmeter to the B output terminal stud on the generator not the terminal mounting nut Voltage should be no higher than 0 6 volts If voltage is higher than 0 6 volts touch test lead to terminal mounting stud nut and then to the wiring connector If voltage is now below 0 6 volts look for dirty loose or poor connection at this p...

Page 336: ...obtain the highest amperage reading Do not allow voltage to drop below 12 volts Record the reading This load test must be performed within 15 sec onds to prevent damage to test equipment On certain brands of test equipment this load will be applied automatically Refer to the operating manual supplied with test equipment 6 The ammeter reading must meet the Minimum Test Amps specifications as displa...

Page 337: ...ngine wiring harness 2 Disconnect the two wire pigtail harness from the engine harness 3 Attach ohmmeter leads to the wire terminals of the pigtail harness 4 At room temperature of 25 C 75 80 F an ohmmeter reading of 9 000 9K to 11 000 11K ohms should be observed 5 If reading is above or below the specification replace the sensor 6 Refer to the Removal and Installation section for procedures ON BO...

Page 338: ...ewdriver The synthetic fiber of the belt can be damaged CAUTION When installing a serpentine accessory drive belt the belt MUST be routed correctly The water pump will be rotating in the wrong direction if the belt is installed incorrectly causing the engine to overheat Refer to belt routing label in engine compartment or refer to Belt Schematics in Group 7 Cooling System Fig 3 Remove Install Gene...

Page 339: ...UE SPECIFICATIONS Description Torque Generator Mounting Bolt 5 2L 5 9L Engines 41 N m 30 ft lbs Generator Pivot Bolt Nut 2L 5 9L Engines 41 N m 30 ft lbs Generator Mounting Bolt 4 0L Engine 55 N m 41 ft lbs Generator Pivot Bolt Nut 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 N m 75 in lbs Field Terminal Nuts 2 ...

Page 340: ......

Page 341: ...ing in the wrong direction if the belt is installed incorrectly causing the engine to overheat Refer to belt routing label in engine compartment or refer to Belt Schematics in Group 7 Cooling System 1 Disconnect negative battery cable 2 Remove generator vacuum pump drive belt Refer to Group 7 Cooling System for procedure 3 Remove the nut securing battery output cable to B terminal Fig 1 at rear of...

Page 342: ...erator Mounting Bolt 47 N m Upper Generator Mounting Bolt 27 5 N m Vacuum Pump Oil Feed Hose Banjo Bolt 15 N m Fig 1 Generator Terminals Fig 2 Generator Vacuum Pump Remove Install Fig 3 Vacuum Pump Oil Feed Hose 8C 2 CHARGING SYSTEM ZG REMOVAL AND INSTALLATION Continued ...

Page 343: ...5 2L 5 9L ENGINES 16 ENGINE COOLANT TEMPERATURE SENSOR 15 IGNITION COIL 4 0L ENGINE 13 IGNITION COIL 5 2L 5 9L ENGINES 13 IGNITION SWITCH AND KEY CYLINDER 20 INTAKE MANIFOLD AIR TEMPERATURE SENSOR 15 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 15 POWERTRAIN CONTROL MODULE PCM 20 SHIFTER IGNITION INTERLOCK 23 SPARK PLUG CABLES 11 SPARK PLUGS 12 THROTTLE POSITION SENSOR 15 SPECIFICATIONS ENGINE FIRING ORD...

Page 344: ...ing is not adjustable on any of these engines On the 4 0L 6 cylinder engine the distributor is locked in place by a fork with a slot located on the distributor housing base The distributor holddown clamp bolt passes through this slot when installed Because the distributor position is locked when installed its rotational position can not be changed Do not attempt to modify the distributor hous ing ...

Page 345: ...l magnet It is also sensitive to steel within a certain distance from it On 5 2L 5 9L V 8 engines the flywheel drive plate has 8 single notches spaced every 45 degrees at its outer edge Fig 3 The notches cause a pulse to be generated when they pass under the sensor The pulses are the input to the PCM For each engine revolution there are 8 pulses generated on V 8 engines The engine will not operate...

Page 346: ...witch and Key Cylinder Removal Installation in this group On vehicles equipped with an automatic transmis sion a cable connects an interlock device within the steering column assembly to the transmission floor shift lever This interlock device is used to lock the transmission shifter in the PARK position when the key is in the LOCKED or ACCESSORY position The interlock device is not serviceable If...

Page 347: ...ons Test the coil primary and secondary resistance Replace any coil that does not meet specifications Refer to the Ignition Coil Resistance chart If the ignition coil is being replaced the secondary spark plug cable must also be checked Replace cable if it has been burned or damaged Arcing at the tower will carbonize the cable boot which if it is connected to a new ignition coil will cause the coi...

Page 348: ... generated at the coil cable when the ground is removed 8 If spark is generated replace the PCM 9 If spark is not seen use the special jumper to ground the coil negative terminal directly 10 If spark is produced repair wiring harness for an open condition 11 If spark is not produced replace the ignition coil DISTRIBUTOR CAP Remove the distributor cap and wipe it clean with a dry lint free cloth Vi...

Page 349: ...e DRB scan tool Also refer to the appropriate Powertrain Diagnostics Procedures man ual CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the dis tributor Fig 13 on all engines To perform a complete test of this sensor and its circuitry refer to the appropriate Powertrain Diag nostics Procedures service manual To test the sensor only refer to the following For this test an analog...

Page 350: ... voltmeter crank the engine with ignition switch The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking This verifies that the camshaft position sensor in the distributor is operating prop erly and a sync pulse signal is being generated If sync pulse signal is not present replacement of the camshaft position sensor is necessary ENGINE COOLANT TEMPERATURE SENSOR Fo...

Page 351: ...d in the Spark Plug Cable Resistance chart replace the cable Test all spark plug cables in this manner To test ignition coil to distributor cap cable do not remove the cable from the cap Connect ohmmeter to rotor button center contact of distributor cap and terminal at ignition coil end of cable If resistance is not within specifications as found in the Spark Plug Cable Resistance chart remove the...

Page 352: ...eposits in the combustion chamber These deposits accumulate on the spark plugs during continuous stop and go driving When the engine is suddenly subjected to a high torque load deposits partially liq uefy and bridge the gap between electrodes Fig 17 This short circuits the electrodes Spark plugs with electrode gap bridging can be cleaned using standard procedures SCAVENGER DEPOSITS Fuel scavenger ...

Page 353: ...consider ably in excess of 0 001 inch per 1000 miles of opera tion This suggests that a plug with a cooler heat range rating should be used Over advanced ignition timing detonation and cooling system malfunctions can also cause spark plug overheating REMOVAL AND INSTALLATION SPARK PLUG CABLES CAUTION When disconnecting a high voltage cable from a spark plug or from the distributor cap twist the ru...

Page 354: ...eign material from entering the combustion chamber 3 Remove the spark plug using a quality socket with a rubber or foam insert 4 Inspect the spark plug condition Refer to Spark Plug Condition in the Diagnostics and Testing section of this group PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment After clean ing file the center electrode flat with a sma...

Page 355: ...xy filled type If the coil is replaced it must be replaced with the same type REMOVAL The coil is mounted to a bracket that is bolted to the front of the right engine cylinder head Fig 27 This bracket is mounted on top of the automatic belt tensioner bracket using common bolts 1 Disconnect the primary wiring from the igni tion coil 2 Disconnect the secondary spark plug cable from the ignition coil...

Page 356: ...C relay connector for corrosion or damage before installation CRANKSHAFT POSITION SENSOR 5 2L 5 9L ENGINES REMOVAL The sensor is bolted to the top of the cylinder block near the rear of right cylinder head Fig 30 1 Disconnect crankshaft position sensor pigtail harness 3 way connector from main wiring harness 2 Remove two sensor recessed hex head mount ing bolts Fig 30 3 Remove sensor from engine I...

Page 357: ... Remove distributor rotor from distributor shaft 6 Lift the camshaft position sensor assembly from the distributor housing Fig 32 INSTALLATION 1 Install camshaft position sensor to distributor Align sensor into notch on distributor housing 2 Connect wiring harness 3 Install rotor 4 Install distributor cap Tighten mounting screws 5 5 2L 5 9L Engines Install air cleaner tube to throttle body MANIFOL...

Page 358: ...aft vibration damper is aligned to 0 degree TDC mark on timing chain cover Fig 33 10 The distributor rotor should now be aligned to the CYL NO 1 alignment mark stamped into the camshaft position sensor Fig 34 If not rotate the crankshaft through another complete 360 degree turn Note the position of the number one cylinder spark plug cable on the cap in relation to rotor Rotor should now be aligned...

Page 359: ... on the screen 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 cla...

Page 360: ...irection while lifting up the distributor The oil pump gear will also rotate slightly in a coun terclockwise direction while lifting up the distributor This is due to the helical cut gears on distributor and camshaft 11 Note removed position of rotor during distrib utor removal During installation this will be referred to as the Pre position 12 Observe slot in oil pump gear through hole on side of...

Page 361: ... installa tion This is due to the helical cut gears on the dis tributor and camshaft When distributor is fully seated to engine block the centerline of base slot should be aligned to clamp bolt mounting hole on engine Fig 42 The rotor should also be pointed at 5 o clock position It may be necessary to rotate rotor and distributor shaft very slightly to engage distributor shaft with slot in oil pum...

Page 362: ...e harness 18 Connect battery cable to battery POWERTRAIN CONTROL MODULE PCM Refer to Group 14 Fuel System for procedures IGNITION SWITCH AND KEY CYLINDER The ignition key must be in the key cylinder for cylinder removal KEY CYLINDER REMOVAL 1 Disconnect negative cable from battery 2 If equipped with tilt column remove tilt lever by turning it counterclockwise 3 Remove upper and lower covers shroud...

Page 363: ...step must be done to allow tang Fig 48 on key cylinder to fit into slots Fig 45 within ignition switch 2 With key into ignition key cylinder rotate key clockwise until retaining pin can be depressed Fig 48 or Fig 49 3 Install key cylinder into ignition switch by aligning retaining pin into retaining pin slot Fig 49 Push key cylinder into switch until retaining pin engages After pin engages rotate ...

Page 364: ...age Before installing switch push the park lock slider linkage Fig 51 forward until it bot toms Do a final positioning by pulling it rearward about one quarter inch 9 Apply a light coating of grease to both column lock flag and shaft at end of flag 10 Place ignition switch into openings on steering column a Automatic Transmission Only Be sure park lock dowel pin on rear of ignition switch enters s...

Page 365: ...e adjusted or replaced Refer to Group 21 Transmissions for procedures The ignition interlock device within the steering column is not serviceable If service is nec essary the steering column must be replaced Refer to Group 19 Steering for procedures SPECIFICATIONS VECI LABEL If anything differs between the specifications found on the Vehicle Emission Control Information VECI label and the followin...

Page 366: ... 8 RC12LC4 1 01 mm 040 in 5 9L V 8 RC12YC 0 89 mm 035 in MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12 000 Ohms Per Foot COIL TOYODENSO DIAMOND Primary Resistance 95 1 20 Ohms 96 1 18 Ohms Secondary Resistance at 70 80 F 11 300 13 300 Ohms 11 300 15 300 Ohms 8D 24 IGNITION SYSTEM ZG SPECIFICATIONS Continued ...

Page 367: ...TEMPERATURE GAUGE 10 CRUISE ON INDICATOR LAMP 14 FUEL GAUGE 10 GRAPHIC DISPLAY MODULE 14 HEADLAMP HIGH BEAM INDICATOR LAMP 15 INSTRUMENT CLUSTER 10 LOW FUEL WARNING LAMP 16 MALFUNCTION INDICATOR LAMP 16 MASTER LIGHTING INDICATOR LAMP 16 ODOMETER AND TRIP ODOMETER 11 OIL PRESSURE GAUGE 11 SEAT BELT REMINDER LAMP 17 SPEEDOMETER 11 TACHOMETER 11 TURN SIGNAL INDICATOR LAMP 17 UPSHIFT INDICATOR LAMP 17...

Page 368: ...ally be applied to either version Exceptions to this rule have been clearly identified as LHD or RHD if a special illustration or procedure is required INSTRUMENT PANEL Modular instrument panel construction allows all of the gauges and controls to be serviced from the front of the panel In addition most of the instru ment panel wiring or heating and air conditioning components can be accessed with...

Page 369: ...operating systems and alert the driver of a malfunction in a monitored sys tem Provide service reminders or the distance to the next service interval The current transfer case mode of operation four wheel drive models The display language choices include English French German Italian Spanish The VIC receives input from hard wired sensors and over the Chrysler Collision Detection CCD data bus netwo...

Page 370: ...tside mirror control Intermittent wipe control Monitoring and transmitting door hood liftgate liftglass ajar data Monitoring and transmitting outside ambient temperature data Monitoring and transmitting air conditioning select switch data Courtesy lamp time out Gulf coast country over speed warning Door lock inhibit Electronic odometer and trip odometer Brake warning lamp Check gauges lamp High be...

Page 371: ...lectrical contact on the pivot end of the swing arm wipes across a resistor coil which changes the internal electrical resistance of the sending unit Refer to Group 14 Fuel Systems for more informa tion on the PCM and for the fuel gauge sending unit service procedures ODOMETER AND TRIP ODOMETER The odometer and the trip odometer share the same vacuum fluorescent digital display tube in the instrum...

Page 372: ...pon an engine speed message received from the Powertrain Control Module PCM on the Chrysler Collision Detection CCD data bus The PCM uses an input from the crankshaft posi tion sensor and internal programming to decide what engine speed message is required The PCM then sends the proper message to the instrument cluster on the CCD data bus The crankshaft position sensor is installed near the rear o...

Page 373: ...bus to turn the lamp on or off The brake warning switch closes to ground when it senses unequal hydraulic pressures in the two halves of the split brake hydraulic system possibly due to low brake fluid level or brake fluid leakage The parking brake switch closes to ground when the parking brake is applied Refer to Group 5 Brakes for more information CHECK GAUGES LAMP The check gauges lamp gives an...

Page 374: ...ircuitry lights the lamp for about four seconds when the ignition switch is turned to the On position as a bulb test After the bulb test the instrument cluster circuitry controls the lamp based upon a message received from the Body Control Module BCM on the Chrysler Collision Detection CCD data bus The BCM uses a fuel level message received from the Powertrain Control Module PCM on the CCD data bu...

Page 375: ... lamp gives an indication when the driver should shift to the next highest gear for the best fuel economy The lamp is turned on by the instrument cluster cir cuitry 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 message received from the Powertrain Control Modul...

Page 376: ...ter circuitry and the CCD data bus with a DRB scan tool If not OK repair the open circuit to ground as required COOLANT TEMPERATURE GAUGE If the problem being diagnosed is related to gauge accuracy be certain to confirm that the problem is with the gauge and not with cooling system perfor mance The actual engine coolant temperature should be checked with a test gauge or thermometer and compared to...

Page 377: ...r the Powertrain Control Module PCM should be per formed with the DRB scan tool as described in the proper Powertrain Diagnostic Procedures manual Diagnosis of the oil pressure gauge the instrument cluster circuitry or the CCD data bus should be per formed with the DRB scan tool as described in the proper Body Diagnostic Procedures manual SPEEDOMETER If the problem being diagnosed is related to ga...

Page 378: ...ve seconds or the duration of the airbag system mal function whichever is longer If the airbag indicator lamp fails to light when the ignition switch is turned to the On position and the seat belt reminder lamp flashes following its normal display function about seven seconds after the igni tion switch is turned to the On position replace the airbag indicator lamp bulb with a known good unit If th...

Page 379: ...el Ignition Systems 8W 40 Instrument Cluster and 8W 45 Body Con trol Module 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 I...

Page 380: ...nosis below Refer to 8W 46 Message Center in Group 8W Wir ing Diagrams for complete circuit descriptions and diagrams GDM ILLUMINATION The diagnosis found here addresses an inoperative illumination lamp condition If the problem being diagnosed is related to the dimming level of the illu mination lamps diagnosis should be performed with a DRB scan tool as described in the proper Body Diagnostic Pro...

Page 381: ...roblem being diagnosed is related to inoperative headlamp high beams refer to Group 8L Lamps for diagnosis of the headlamp system For circuit descriptions and diagrams refer to 8W 40 Instru ment 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 DIA...

Page 382: ...t three seconds after the igni tion switch is turned to the On position replace the malfunction indicator lamp bulb with a known good unit If the indicator lamp still fails to operate diag nosis of the lamp the instrument cluster circuitry or the CCD data bus should be performed with a DRB scan tool as described in the proper Body Diagnostic Procedures manual Diagnosis of the Powertrain Con trol M...

Page 383: ...uster bezel and the cluster assembly as described in this group 2 Connect the battery negative cable Activate the hazard warning system by depressing the hazard warning switch Check for battery voltage at the inoperative right or left turn signal indicator lamp circuit cavity of the cluster wire harness connector There should be a switching on and off battery volt age signal If OK replace the faul...

Page 384: ...th a unit from another vehicle The VIC module uses the VIN message received on the CCD data bus from the PCM to determine if the vehicle is equipped with two wheel drive or four wheel drive If a four wheel drive vehicle has a two wheel drive VIN entered in the PCM the VIC will ignore all transfer case switch inputs If a two wheel drive vehicle has a four wheel drive VIN entered in the PCM the rear...

Page 385: ...tance message received on the CCD data bus from the Powertrain Control Module to control this message If testing of the L5 circuit between the VIC module wire harness connector and the combination flasher cavity in the junction block reveals no problem use a DRB scan tool and the proper Body Diagnostic Pro cedures manual to diagnose the VIC module and the CCD data bus Refer to 8W 46 Message Center...

Page 386: ...rain Diagnostic Procedures manual For circuit descriptions and dia grams 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 AIR BAG DEP...

Page 387: ...can tool as described in the proper Body Diagnostic Pro cedures manual Diagnosis of the Powertrain Control Module PCM should be performed with a DRB scan tool as described in the proper Powertrain Diagnostic Procedures manual SERVICE PROCEDURES VEHICLE INFORMATION CENTER The following flow charts describe the procedures to perform an initial setup of the Vehicle Information Center VIC and how to r...

Page 388: ...T TING IS DIS PLAYED VIC DISPLAYS CURRENT CLOCK MODE SETTING AVAILABLE CLOCK MODES ARE 12 HOUR CLOCK AND 24 HOUR CLOCK VIC DIS PLAYS CUR RENT SER VICE INTERVAL SET TING AVAIL ABLE INTER VALS ARE FROM 7500 TO 2000 MILES IN 500 MILE INCRE MENTS OR FROM 12 000 TO 3000 KMS IN 1000 KM INCRE MENTS DEPRESS AND RELEASE THE SELECT BUTTON TO TOGGLE THROUGH THE AVAILABLE SRVICE INTERVALS UNTIL THE DESIRED SE...

Page 389: ...VIC Reset TO RESET VIC SERVICE REMINDER FEATURE AFTER RECOMMENDED SERVICE HAS BEEN PERFORMED PROCEED AS FOLLOWS ZG INSTRUMENT PANEL SYSTEMS 8E 23 SERVICE PROCEDURES Continued ...

Page 390: ...eering column cover to the instrument panel Fig 4 4 Remove the one screw that secures the out board end of the knee blocker to the instrument panel 5 Remove the four screws that secure 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 from the instrument panel at ...

Page 391: ...T 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 snap clips that secure the cluster len...

Page 392: ...ument cluster as described in this group 2 Remove the bulb and holder from the rear of the cluster housing by turning the holder counter clockwise Fig 8 3 Unplug the bulb from the holder CAUTION Always use the correct bulb size and type for replacement An incorrect bulb size or type may overheat and cause damage to the instrument cluster printed circuit and or the gauges 4 Reverse the removal proc...

Page 393: ...ove the inboard switch pod bezel as described in this group 3 Remove the two screws that secure the inboard switch pod to the instrument panel Fig 10 4 Pull the inboard switch pod out from the instrument panel far enough to unplug the wire har ness connectors 5 Remove the inboard switch pod from the instrument panel 6 Reverse the removal procedures to install Fig 8 Cluster Bulb Locations CLUSTER I...

Page 394: ...3 Remove the ash receiver from the instrument panel center bezel 4 Remove the two screws in the back of the ash receiver opening that secure the instrument panel center bezel to the instrument panel armature 5 Remove the screw that secures the courtesy lamp located under the outboard end of the glove box module 6 Open the passenger side front door and remove the screw that secures the outboard end...

Page 395: ...of the glove box module and push in on the unit firmly until the retaining tabs snap into place 4 Reverse the remaining removal procedures to complete the installation GLOVE BOX LATCH STRIKER 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 P...

Page 396: ...escribed in this group 2 From the rear of the instrument panel center bezel unscrew the power outlet shell clamp from the power outlet base 3 Remove the power outlet base from the front of the instrument panel center bezel 4 Reverse the removal procedures to install POWER OUTLET DOOR 1 Insert a wide flat bladed tool such as a trim stick between the side of the power outlet housing in the instrumen...

Page 397: ...cribed in this group GLOVE BOX BEZEL 1 Open the glove box 2 Remove the two screws that secure the bezel at the top of the glove box inner door panel Fig 18 3 Carefully pry the bezel away from the outside of the glove box door There is double faced adhesive tape between the bezel and the outer door panel 4 Reverse the removal procedures to install GLOVE BOX HINGE 1 Remove the glove box as described...

Page 398: ... 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 2 Using a wide flat bladed tool such as a trim stick gently pry the cowl top trim panel off of the instrument panel top pad Fig 21 3 Pull the panel up far enough to unplug the wire harness connector for the solar sensor or t...

Page 399: ...ures the right cowl side trim panel to the junction block stud Fig 22 4 Remove the two screws that secure the right cowl side trim panel to the right front door opening trim 5 Remove the right cowl side trim panel 6 Unplug all of the wire harness connectors from the junction block cavities 7 Remove the bolt that secures the junction block to the cowl side panel Fig 23 8 On Left Hand Drive LHD mode...

Page 400: ...anel 13 Unplug the radio antenna coaxial cable con nector near the right cowl side panel 14 Unplug all of the instrument panel wire har ness connectors from the junction block on the right cowl side panel 15 If the vehicle is so equipped disconnect the in car temperature sensor aspirator hose at the cou pling near the passenger side of the transmission floor tunnel 16 On Left Hand Drive LHD models...

Page 401: ...nstru ment panel off of the windshield fence studs and maneuver the assembly out of the vehicle through the passenger side front door 25 Reverse the removal procedures to install Tighten the mounting hardware as follows Instrument panel center bracket to floor pan transmission tunnel fasteners 28 N m 250 in lbs Instrument panel to windshield fence bolts and nuts 12 N m 105 in lbs Instrument panel ...

Page 402: ......

Page 403: ...TEMPERATURE GAUGE 10 CRUISE ON INDICATOR LAMP 13 FUEL GAUGE 10 GRAPHIC DISPLAY MODULE 14 HEADLAMP HIGH BEAM INDICATOR LAMP 15 INSTRUMENT CLUSTER 10 LOW FUEL WARNING LAMP 15 MALFUNCTION INDICATOR LAMP 16 MASTER LIGHTING INDICATOR LAMP 16 ODOMETER AND TRIP ODOMETER 11 OIL PRESSURE GAUGE 11 SEAT BELT REMINDER LAMP 16 SPEEDOMETER 11 TACHOMETER 11 TURN SIGNAL INDICATOR LAMP 17 UPSHIFT INDICATOR LAMP 17...

Page 404: ...ally be applied to either version Exceptions to this rule have been clearly identified as LHD or RHD if a special illustration or procedure is required INSTRUMENT PANEL Modular instrument panel construction allows all of the gauges and controls to be serviced from the front of the panel In addition most of the instru ment panel wiring or heating and air conditioning components can be accessed with...

Page 405: ...terval The current transfer case mode of operation four wheel drive models The display language choices include English French German Italian Spanish The VIC receives input from hard wired sensors and over the Chrysler Collision Detection CCD data bus network In response to these inputs the VIC offers a combination of graphic and message displays and provides requests for audible chime alerts to t...

Page 406: ... hood liftgate liftglass ajar data Monitoring and transmitting outside ambient temperature data Monitoring and transmitting air conditioning select switch data Courtesy lamp time out Gulf coast country over speed warning Door lock inhibit Electronic odometer and trip odometer Brake warning lamp Check gauges lamp High beam indicator lamp Seatbelt reminder lamp and chime Speed sensitive intermittent...

Page 407: ...lectrical contact on the pivot end of the swing arm wipes across a resistor coil which changes the internal electrical resistance of the sending unit Refer to Group 14 Fuel Systems for more informa tion on the PCM and for the fuel gauge sending unit service procedures ODOMETER AND TRIP ODOMETER The odometer and the trip odometer share the same vacuum fluorescent digital display tube in the instrum...

Page 408: ...pon an engine speed message received from the Powertrain Control Module PCM on the Chrysler Collision Detection CCD data bus The PCM uses an input from the crankshaft posi tion sensor and internal programming to decide what engine speed message is required The PCM then sends the proper message to the instrument cluster on the CCD data bus The crankshaft position sensor is installed near the rear o...

Page 409: ...bus to turn the lamp on or off The brake warning switch closes to ground when it senses unequal hydraulic pressures in the two halves of the split brake hydraulic system possibly due to low brake fluid level or brake fluid leakage The parking brake switch closes to ground when the parking brake is applied Refer to Group 5 Brakes for more information CHECK GAUGES LAMP The check gauges lamp gives an...

Page 410: ...ircuitry lights the lamp for about four seconds when the ignition switch is turned to the On position as a bulb test After the bulb test the instrument cluster circuitry controls the lamp based upon a message received from the Body Control Module BCM on the Chrysler Collision Detection CCD data bus The BCM uses a fuel level message received from the Powertrain Control Module PCM on the CCD data bu...

Page 411: ... lamp gives an indication when the driver should shift to the next highest gear for the best fuel economy The lamp is turned on by the instrument cluster cir cuitry 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 message received from the Powertrain Control Modul...

Page 412: ...an tool If not OK repair the open circuit to ground as required COOLANT TEMPERATURE GAUGE If the problem being diagnosed is related to gauge accuracy be certain to confirm that the problem is with the gauge and not with cooling system perfor mance The actual engine coolant temperature should be checked with a test gauge or thermometer and compared to the gauge readings before you proceed with gaug...

Page 413: ...ment cluster circuitry or the CCD data bus should be per formed with the DRB scan tool as described in the proper Body Diagnostic Procedures manual SPEEDOMETER 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 incorrect speedome ter pinion gear axle ratio or tire size Refer to Group 21 Transmission for more informat...

Page 414: ...n good unit If the airbag indicator lamp still fails to operate diagnosis of the lamp the instrument cluster cir cuitry the CCD data bus and the Body Control Mod ule BCM should be performed with a DRB scan tool as described in the proper Body Diagnostic Proce dures manual ANTI LOCK BRAKE SYSTEM LAMP The diagnosis found here addresses an inoperative Anti lock Brake System ABS lamp condition If the ...

Page 415: ... check gauges lamp bulb with a known good unit If the check gauges lamp still fails to operate diagnosis of the lamp the instrument cluster circuitry the CCD data bus and the Body Control Module BCM should be performed with a DRB scan tool as described in the proper Body Diagnostic Procedures manual CLUSTER ILLUMINATION LAMP The diagnosis found here addresses an inoperative cluster illumination la...

Page 416: ...lamps are inopera tive replace the faulty bulbs If all of the illumina tion lamps are inoperative proceed as follows 1 Disconnect and isolate the battery negative cable Remove the GDM as described in this group Unplug the GDM wire harness connector and connect the battery negative cable 2 Turn the park lamps on with the headlamp switch Adjust the panel lamp dimmer switch knob to its highest level ...

Page 417: ...or lamp fails to light during the bulb test about four seconds after the ignition switch is turned to the On position replace the headlamp high beam indicator lamp bulb with a known good unit If the indicator lamp still fails to operate diagnosis of the lamp the instru ment cluster circuitry the CCD data bus or the Body Control Module BCM should be performed with a DRB scan tool as described in th...

Page 418: ...s the same cir cuitry as the cluster illumination lamps and will brighten and dim when the panel lamp dimmer switch is adjusted The diagnosis found here addresses an inoperative master lighting indicator lamp condition If the problem being diagnosed is related to the dimming level of the master lighting indicator lamp diagnosis should be performed with a DRB scan tool as described in the proper Bo...

Page 419: ...d be performed with a DRB scan tool as described in the proper Powertrain Diag nostic Procedures manual 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 COM PONENT DIAGNOSIS OR SERVICE FAILURE ...

Page 420: ...he short circuit start at Step 3 of the following diag nostic procedure Two wheel drive models do have the same VIC wire harness provisions as four wheel drive models WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COM PONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD ...

Page 421: ... the VIC module and the CCD data bus Refer to 8W 46 Message Center in Group 8W Wiring Diagrams for complete circuit descriptions and diagrams WASHER LEVEL LOW WASHER SENSOR BAD If the problem being diagnosed is related to lamp accuracy be certain to confirm that the problem is with the lamp and sensor and not with the washer fluid level The actual fluid level should be checked before you proceed w...

Page 422: ...NT AND POSSI BLE PERSONAL INJURY If the wait to start lamp fails to light during the bulb test about four seconds after the ignition switch is turned to the On position replace the wait to start lamp bulb with a known good unit If the lamp still fails to operate diagnosis of the lamp the instrument cluster circuitry or the CCD data bus should be performed with a DRB scan tool as described in the p...

Page 423: ...VIC Initial Set Up ZG INSTRUMENT PANEL SYSTEMS 8E 21 SERVICE PROCEDURES Continued ...

Page 424: ...VIC Reset 8E 22 INSTRUMENT PANEL SYSTEMS ZG SERVICE PROCEDURES Continued ...

Page 425: ...olumn that secures the upper edge of the knee blocker steering column cover to the instrument panel Fig 4 4 Remove the one screw that secures the out board end of the knee blocker to the instrument panel 5 Remove the four screws that secure 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 edge...

Page 426: ... 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 snap clips that secure the cluster lens to the cluster hood and gently pull the lens away from the hood 5 Depress the snap clips that secure the cluster hood to the cluster circuit and gauge housing and gently pull the hood away fr...

Page 427: ...OLUMN OR INSTRUMENT PANEL COM PONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI BLE PERSONAL INJURY 1 Remove the instrument cluster as described in this group 2 Remove the bulb and holder from the rear of the cluster housing by turning the holder counter clockwise Fig 8 Fig 7 Gauge Mounting Screws Fig 8 Cluster Bulb Locations ...

Page 428: ...battery negative cable 2 Remove the inboard switch pod bezel as described in this group 3 Remove the three screws that secure the inboard switch pod to the instrument panel Fig 10 4 Pull the inboard switch pod out from the instrument panel far enough to unplug the wire har ness connectors 5 Remove the inboard switch pod from the instrument panel 6 Reverse the removal procedures to install BODY CON...

Page 429: ...x opening that secure the upper edge of the glove box module to the instru ment panel armature 9 Lower the glove box module far enough to unplug the wire harness connectors from the glove box lamp and switch the cigar lighter and lamp and the power outlet Also remove the ash receiver lamp bulb and socket as a unit by gently pulling it out of the ash receiver lamp hood 10 Remove the glove box modul...

Page 430: ...ll the latch striker out 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 glove box module CIGAR LIGHTER WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COM PON...

Page 431: ...oor 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 PANEL COM PONENT DIAGNOSIS...

Page 432: ...E BOX HINGE 1 Remove the glove box as described in this group 2 Remove the screws that secure the glove box hinge to the glove box inner door panel 3 Remove the glove box hinge 4 Reverse the removal procedures to install GLOVE BOX BIN 1 Remove the glove box as described in this group 2 Remove the glove box hinge as described in this group 3 Remove the screws that secure each side of the bin to the...

Page 433: ...MPONENT DIAGNOSIS OR SERVICE FAIL URE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Remove both switch pod bezels the cluster bezel the knee blocker the glove box module and the cowl top trim panel See the procedures in this group 3 If the vehicle is so equipped remove the screw that se...

Page 434: ...r as described in this group 4 Remove the bolts that secure the lower instru ment panel reinforcement to the instrument panel armature and remove the reinforcement Fig 24 5 Remove the upper and lower steering column shrouds Refer to Group 19 Steering for the proce dures 6 Unplug all of the wire harness connectors on the steering column mounted components and switches 7 Remove the three nuts that s...

Page 435: ...upport 20 Remove the two bolts that secure the ends of the instrument panel armature to the cowl side pan els 21 Remove the cowl top trim panel as described in this group 22 Remove the two bolts that secure the ends of the instrument panel armature to the windshield fence 23 Remove the four nuts that secure the top of the instrument panel armature to the studs on the windshield fence 24 With the a...

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Page 437: ... power lumbar and recliner positions and both outside power mirror positions for two drivers For vehicles with a radio connected to the Chrysler Collision Detection CCD data bus network the memory system is also able to store and recall ten radio station presets including last station tuned for two drivers The memory system will automatically return to all of these settings when the correspond ing...

Page 438: ... North Amer ica with the AM FM cassette 5 band graphic equal izer RBN sales code with CD changer control feature or the AM FM CD cassette 3 band graphic equalizer RAZ sales code radio receivers Two rock er type switches are mounted on the back instru ment panel side of the steering wheel spokes The switch on the left spoke is the seek switch and has seek up seek down and preset station advance fun...

Page 439: ...akers ANTENNA Antenna availability is affected by the country for which the vehicle is manufactured All models built for sale in North America use a fixed length stainless steel rod type antenna mast Models built for sale outside North America use a power operated tele scoping type antenna extended and retracted by a reversible electric motor Either antenna type is mounted on the right front fende...

Page 440: ... 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 telephone equipment check the equipment installation for the following Power connections should be made directly to the battery and fused as closely to the battery as possible The antenna should be mounted o...

Page 441: ...nd 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 required POOR RADIO RECEPTIO...

Page 442: ...between the radio chassis and a good ground There should be continuity If OK go to Step 5 If not OK repair the open radio chassis ground circuit as required 5 Connect the battery negative cable Turn the ignition switch to the On position Check for battery voltage at the fused ignition switch output circuit cavity of the left gray radio wire harness connector If OK go to Step 6 If not OK repair the...

Page 443: ...n the radio and test the speaker operation If OK replace the faulty radio If not OK turn the radio off turn the ignition switch to the Off position disconnect and isolate the battery negative cable remove the test radio and go to Step 5 5 Unplug the speaker wire harness connector at the inoperative speaker Check for continuity between the speaker feed circuit cavities of the radio wire harness con...

Page 444: ... model has a two piece antenna coaxial cable Tests 2 and 4 must be conducted in two steps to isolate a coaxial cable problem from the coaxial cable connection under the right end of the instrument panel near the right cowl side panel to the antenna base and then from the coaxial cable connection to the radio chassis connection TEST 1 Test 1 determines if the antenna mast is insulated from the base...

Page 445: ...ting beyond the antenna up and down limits a To test the antenna Up operation connect the ground jumper to the power antenna up control circuit cavity of the power antenna motor wire har ness connector and connect the battery feed jumper to the power antenna driver circuit cavity of the power antenna motor wire harness connec tor b To test the antenna Down operation connect the ground jumper to th...

Page 446: ... faceplate The word code should appear on the radio display 3 Enter the four digit radio security code by depressing the radio station preset buttons in the proper sequence 4 The radio is now ready for normal operation The security code must be reentered any time the radio or vehicle is disconnected from battery feed If an attempt is made to enter an incorrect security code into the radio the radi...

Page 447: ...connectors from the back of the airbag module 4 Remove the airbag module from the steering wheel 5 Remove the screws that secure the speed con trol switches to the steering wheel and lower the switches from the steering wheel spokes Fig 6 6 Remove the two screws that secure the remote radio switch to the steering wheel spoke Fig 7 7 Unplug the wire harness connector from the remote radio switch 8 ...

Page 448: ...EPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Using a wide flat bladed tool such as a trim stick gently pry the cowl top trim panel off of the instrument panel top pad Fig 9 3 If the vehicle is so equipped pull the panel up far enough to unplug the wire harness connector for the solar sensor or to remove the solar sensor from the cowl top trim 4 Remov...

Page 449: ...the door courtesy lamp 9 Remove the three screws that secure the speaker to the lower front corner of the inner door panel Fig 12 10 Pull the speaker away from the inner door panel far enough to unplug the speaker wire harness connector 11 Remove the speaker from the door 12 Reverse the removal procedures to install Tighten the hardware as follows Speaker mounting screws 1 1 N m 10 in lbs Trim pan...

Page 450: ...cut and remove the push nut type retainer that secures the tweeter to the sound bar Fig 15 4 Push the tweeter out of the mounting hole from the inside of the sound bar 5 Reverse the removal procedures to install Always use a new push nut retainer on the tweeter WOOFER 1 Remove the sound bar from the vehicle as described in this group 2 Unplug the wire harness connector from the woofer 3 From the i...

Page 451: ...e antenna body through the right front fender wheel housing Fig 19 6 Remove the fuse access panel in the right cowl side trim panel and remove the push nut that secures the trim panel to the junction block Fig 20 7 Remove the two screws that secure the right cowl side trim panel to the front door opening trim and remove the cowl side kick panel trim 8 Locate the antenna coaxial cable connector nea...

Page 452: ...Unplug the connector by pulling it apart while twist ing the metal connector halves Fig 21 Do not pull on the cable 7 Unplug the power antenna wire harness con nector from the junction block 8 Remove the antenna mounting bolts Fig 22 9 Disengage the coaxial cable grommet from the hole in the right cowl side outer panel Access the grommet from inside the right front fender wheel housing Fig 19 Fixe...

Page 453: ...Y 1 Disconnect and isolate the battery negative cable 2 Remove the fuse access panel by unsnapping it from the right cowl side trim panel 3 Remove the push nut that secures the right cowl side trim panel to the junction block stud Fig 23 4 Remove the two screws that secure the right cowl side trim panel to the right front door opening trim 5 Remove the right cowl side trim panel 6 Unplug the anten...

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Page 455: ...lay coil See the Diagnosis and Testing section of this group for more information on the operation of the horn relay The horn relay is located in the Power Distribution Center PDC in the engine compartment Refer to the PDC label for relay identification and location If a problem is encountered with a continuously sounding horn it can usually be quickly resolved by removing the horn relay from the ...

Page 456: ...ER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY RELAY TEST The horn relay is located in the Power Distribution Center PDC in the engine compartment Refer to the PDC label for horn relay identification and loca tion Remove the horn relay from the PDC as described in this group to perform the following tests 1 A relay in the de energized position should hav...

Page 457: ... repair the short circuit as required 3 Check for continuity between the steering col umn half of the horn switch feed wire harness con nector and the horn relay control circuit cavity for the horn relay in the PDC There should be continu ity If OK go to Step 4 If not OK repair the open circuit as required 4 Check for continuity between the horn switch feed wire and the horn switch ground wire on ...

Page 458: ...REFER TO GROUP 8M PAS SIVE RESTRAINT SYSTEMS FOR THE SERVICE PROCEDURES HORN 1 Disconnect and isolate the battery negative cable 2 Raise and support the vehicle 3 Remove the radiator lower air deflector Refer to Group 7 Cooling System for the procedures 4 Unplug the horn wire harness connectors Fig 2 5 Remove the screw that secures the horn mounting bracket to the radiator closure extension panel ...

Page 459: ...ing bracket The PCM controls the solenoid valve body The solenoid valve body controls the application and release 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 With...

Page 460: ...ter indicates a problem which might cause surging in the speed control sys tem The cause of any speedometer problems should be corrected before proceeding Refer to Group 8E Instrument Panel and Gauges for speedometer diag nosis If a road test verifies a system problem and the speedometer operates properly check for A Diagnostic Trouble Code DTC If a flash lamp code 15 34 or 77 exists at the Check ...

Page 461: ... seconds 2 Count the number of times the MIL check engine lamp on the instrument panel flashes on and off The number of flashes represents the trouble code There is a slight pause between the flashes rep resenting the first and second digits of the code Longer pauses separate individual two digit trouble codes An example of a flashed DTC is as follows 3 Lamp flashes 1 time pauses and then flashes ...

Page 462: ...n detected in the speed control vacuum or vent solenoid circuits or 57 Speed Control Switch Always Low Speed control switch input below the minimum acceptable voltage or 56 Speed Control Switch Always High Speed control switch input above the maximum acceptable voltage 55 Completion of fault code display on Check Engine lamp 77 52 S C Power Ckt No power at speed control circuit Check Engine Lamp M...

Page 463: ...ING WHEEL AND STEERING COL UMN COMPONENTS YOU MUST FIRST DISCON NECT AND ISOLATE THE BATTERY 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...

Page 464: ... vehicle may accelerate and exceed the desired set speed by up to 5 MPH 8 km h and then decelerate to less than the desired set speed before finally achieving the desired set speed The Speed Control has an adaptive strategy that compensates for vehicle to vehicle variations in speed control cable lengths When the speed control is set with the vehicle operators foot off of the accelerator pedal the...

Page 465: ... mounting screw 2 Tighten screw to 1 5 N m 15 in lbs torque 3 Install electrical connector to switch 4 Install airbag module Refer to Group 8M Pas sive Restraint Systems for procedures 5 Connect negative battery cable STOP LAMP SWITCH Refer to Stop Lamp Switch in Group 5 Brakes for removal installation and adjustment procedures SERVO CABLE REMOVAL 1 Disconnect negative battery cable at battery 2 4...

Page 466: ...y tray 5 Pull up battery tray and remove vacuum hose from reservoir Fig 8 6 Remove 2 screws holding reservoir to battery tray INSTALLATION 1 Install vacuum reservoir Tighten bolts screws to 3 N m 30 in lbs torque 2 Connect vacuum hose at reservoir 3 Install battery tray mounting bolts Tighten to 10 N m 90 in lbs torque 4 Install battery 5 Install battery holddown and bolts Tighten to 10 N m 90 in ...

Page 467: ...rque Servo Mounting Bracket to Servo Nuts 8 5 N m 75 in lbs Servo Mounting Bracket to Body Nuts 5 N m 47 in lbs Switch Module Mounting Screws 1 5 N m 15 in lbs Vacuum Reservoir Mounting Bolts 3 N m 30 in lbs ZG VEHICLE SPEED CONTROL SYSTEM 8H 9 ...

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Page 469: ...ed control system operation is restricted to speeds between 56 km h 35 MPH to 145 km h 90 MPH Inputs to the MSA that allow speed control oper ation are from the vehicle speed sensor and the Speed Control Switch Two separate speed control switch modules are mounted on the steering wheel to the left and right side of the driver s airbag module Switch features are a Within the two switch modules five...

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Page 471: ... the multi function switch lever is released When the turn signal switch is in a detent posi tion it is turned off by one of two cancelling cam lobes molded into the hub of the clockspring mecha nism When turning the steering wheel causes one of the cam lobes to contact a cancel actuator in the multi function switch the turn signal switch auto matically returns to the off position When the turn si...

Page 472: ...proper group However the multi function switch cannot be repaired If any function of the multi func tion switch is faulty or if the switch is damaged the entire switch assembly must be replaced TURN SIGNAL INDICATOR LAMP The turn signal indicator lamps are located in the instrument cluster They flash with the exterior turn signal lamps to give the driver a visual indication that a turn signal or t...

Page 473: ...witch to the On position Check for battery voltage at the fused ignition switch output circuit cavity for the combination flasher in the junction block If OK go to Step 6 If not OK repair the open circuit to the turn signal fuse as required 6 Turn the ignition switch to the Off position Check for battery voltage at the fused B circuit cavity for the combination flasher in the junction block If OK ...

Page 474: ...move the push nut that secures the right cowl side trim panel to the junction block stud Fig 3 4 Remove the two screws that secure the right cowl side trim panel to the right front door opening trim 5 Remove the right cowl side trim panel 6 Unplug the combination flasher from the junc tion block 7 Install the combination flasher by aligning the flasher terminals with the cavities in the junction b...

Page 475: ...e of the knee blocker to the lower instrument panel reinforcement 7 Using a trim stick or another suitable wide flat bladed tool gently pry the edges of the knee blocker away from the instrument panel at the snap clip retainer locations Fig 4 8 Remove the knee blocker and steering column cover from the vehicle 9 Remove both the upper and lower shrouds from the steering column Fig 5 10 Remove the l...

Page 476: ...nector from the multi function switch 16 Reverse the removal procedures to install Tighten the fasteners as follows Multi function switch wire harness connector screw 2 N m 17 in lbs Multi function switch retaining screws 2 N m 17 in lbs Steering column upper bracket nuts 12 N m 110 in lbs 8J 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS ZG REMOVAL AND INSTALLATION Continued ...

Page 477: ...eds or the intermittent wipe mode The intermittent wipe mode is provided by delay logic and relay control circuitry contained within the Body Control Module BCM and an intermittent wipe relay The intermittent wipe mode delay times are speed sensitive Above about sixteen kilometers per hour ten miles per hour the delay is driver adjustable from about one half second to about eighteen sec onds Below...

Page 478: ...iodic cleaning of the squeegees is suggested to remove deposits of salt and road film The wiper blades arms and windshield or rear glass should be cleaned with a sponge or cloth and windshield washer fluid a mild detergent or a non abrasive cleaner If the squeegees continue to streak or smear they should be replaced The blades are mounted to spring loaded wiper arms The spring tension of the wiper...

Page 479: ...ng Headlamp beam selection Headlamp optical horn Windshield wipers Windshield washers The information contained in this group addresses only the switch functions for the windshield wiper and washer systems For information relative to the other switch functions refer to the proper group However the multi function switch cannot be repaired If any function of the multi function switch is faulty or if...

Page 480: ... secured to the left front inner fender shield behind the front wheelhouse in the engine compart ment Each washer pump and motor unit has a threaded nipple which is installed through a rubber grommet seal inserted in a hole near the bottom of the reser voir A plastic nut and washer that secures the washer pump nipple from the inside of the reservoir can be accessed through the reservoir filler nec...

Page 481: ...nector Check for continuity between the wiper switch mode sense cavities of the multi function switch wire harness connector and the BCM white 24 way wire harness connector There should be continuity If OK go to Step 6 If not OK repair the open circuit as required 6 Unplug the black 24 way BCM wire harness connector Check for continuity between the wind shield wiper switch signal cavities of the m...

Page 482: ...the battery negative cable Turn the ignition switch to the On position Place the rear wiper switch in the Wipe position Check for battery voltage at the rear wiper motor control circuit cavity of the rear wiper motor wire harness connector Repeat the test for the rear wiper motor control intermittent circuit cavity with the rear wiper switch in the Intermittent position then at the rear washer mot...

Page 483: ...e between the ground cir cuit cavity of the rear washer pump wire harness connector and a good ground The meter should read zero ohms If OK go to Step 3 If not OK repair the circuit to ground as required 3 Connect the battery negative cable Turn the ignition switch to the On position Depress the rear washer switch Measure the voltage at the rear washer motor control circuit cavity of the rear wash...

Page 484: ...intermittent wipe relay identification and location Remove the intermittent wipe relay from the PDC as described in this group to perform the following tests 1 A relay in the de energized position should have continuity between terminals 87A and 30 and 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 troma...

Page 485: ...er arm to raise the wiper blade and element off of the windshield glass 3 Remove the wiper blade from the wiper arm or the wiper element from the wiper blade as follows a To remove the wiper blade from the wiper arm push the release tab under the arm tip and slide the blade away from the tip towards the pivot end of the arm Fig 3 b To remove the wiper element from the wiper blade pinch the notched...

Page 486: ...the blade are engaged in the wiper element retaining clip notches WIPER ARM FRONT CAUTION The use of a screwdriver or other prying tool to remove a wiper arm may distort it This dis tortion could allow the arm to come off of the pivot shaft regardless of how carefully it is installed 1 Open the hood of the vehicle 2 Lift the wiper arm to permit the latch to be pulled out to its holding position th...

Page 487: ... remove the nut that secures the wiper motor crank arm to the motor output shaft 12 Remove the three screws that secure the wiper motor to the wiper module and remove the motor 13 Reverse the removal procedures to install Tighten the mounting hardware as follows Wiper motor screws 5 to 7 N m 44 to 62 in lbs Crank arm nut 10 to 12 N m 88 to 106 in lbs Wiper module mounting screws 8 N m 72 in lbs RE...

Page 488: ...e the cover from the Power Distribution Center PDC Fig 11 3 Refer to the label on the PDC for intermittent wipe relay identification and location 4 Unplug the intermittent wipe relay from the PDC 5 Install the intermittent wipe 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 Te...

Page 489: ...wide flat bladed tool gently pry the edges of the knee blocker away from the instrument panel at the snap clip retainer locations 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 Do not remove the nuts 12 Move the ...

Page 490: ...o install WASHER PUMP AND RESERVOIR 1 Disconnect and isolate the battery negative cable 2 Remove the three screws that secure the washer reservoir to the inner fender shield Fig 16 3 Lift the reservoir far enough to access the washer pump wire harness connectors and hoses 4 Remove the washer hoses from the washer pumps and drain the washer fluid from the reservoir into a clean container for reuse ...

Page 491: ...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 492: ...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 493: ...ices refer to Group 8W FOG LAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system refer to Group 8A 2 Poor fog lamp circuit ground 2 Test voltage drop across Z 1 ground refer to Group 8W 3 High resistance in fog lamp circuit 3 Test amperage draw of fog lamp circuit 4 Both fog lamp bulbs defective 4 Replace both fog lamp bulbs FOG LAMPS FLASH...

Page 494: ...t DRL module 2 Parking brake engaged 3 Parking brake circuit shorted to ground 4 Headlamp circuit shorted to ground 5 Defective DRL module 1 Secure connector on DRL module 2 Disengage parking brake 3 Check voltage on pin 3 of module refer to Group 8W 4 Check L3 circuit refer to Group 8W 5 Replace DRL module 8L 4 LAMPS ZG DIAGNOSIS AND TESTING Continued ...

Page 495: ...ESET VIC BY CYCLING IGNITION SWITCH ON OFF ON DONE ARE THE TAIL STOP AND CHMSL LAMPS FUNC TIONAL NO YES DO TAIL STOP AND CHMSL LAMPS HAVE CORRECT BULBS REFER TO BULB APPLICATION CHART NO REPLACE ALL FAULTY OR INCORRECT BULBS REFER TO BULB APPLICATION CHART ZG LAMPS 8L 5 DIAGNOSIS AND TESTING Continued ...

Page 496: ...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 for approximately 60 seconds Contin uous tripping of the circuit breaker may indicate a circuit problem 8L 6 LAMPS ZG DIAGNOSIS AND TESTING Continued ...

Page 497: ...ocedures The preferred headlamp alignment setting is 0 for the left right adjustment and 1 down for the up down adjustment SERVICE PROCEDURES HEADLAMP ALIGNMENT PREPARATION 1 Verify headlamp dimmer switch and high beam indicator operation 2 Correct defective components that could hinder proper headlamp alignment 3 Verify proper tire inflation 4 Clean headlamp lenses 5 Verify that luggage area is n...

Page 498: ...nt screen with tape Use this line for up down adjustment reference 7 Measure distance from the centerline of the vehicle to the center of each headlamp being aligned Transfer measurements to screen with tape to each side of vehicle centerline Use these lines for left right adjustment reference HEADLAMP ADJUSTMENT USING ALIGNMENT SCREEN A properly aimed low beam will project the top edge of high in...

Page 499: ...o obtain the correct pattern SPECIAL TOOLS SPECIAL TOOLS HEADLAMP ALIGNMENT Fig 3 Fog Lamp Alignment Typical VEHICLE CENTERLINE CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS HIGH INTENSITY AREA FLOOR TO CENTER OF FOG LAMP LENS 100 mm 4 in 7 62 METERS 25 FEET FRONT OF FOG LAMP Fig 4 Fog Lamp ADJUSTMENT SCREW BRACKET CLIP BULB SOCKET ACCESS COVER FOG LAMP Headlamp Aiming Kit C 4466 A ZG LAMPS 8L 9 SE...

Page 500: ...rocedure 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 bulb 2 Position bulb assembly in the lamp housin...

Page 501: ... 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 Pull bulb from socket Fig 3 INSTALLATION 1 Position bulb in socket and push into place 2 Position bulb socket in lamp and rotate clock wise 3 Install lamp LICENSE PLATE LAMP BULB REMOVAL 1 Remove screws attaching license plate l...

Page 502: ...Replace lens by holding lens level and pushing rearward into housing 3 Push lens up to snap into housing READING 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 terminals INSTALLATION 1 Insert bulb into reading lamp terminals 2 Replace lens by holding lens level a...

Page 503: ... 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 vehicle INSTALLATION 1 Position fog lamp at vehicle 2 Engage fog lamp electrical connector 3 Install adjustment screw Fig ...

Page 504: ...ck ets 2 Position lamp on vehicle and install screws LICENSE PLATE LAMP REMOVAL 1 Remove screws attaching license plate lamp to license plate housing 2 Separate lamp from housing 3 Grip bulb socket rotate counterclockwise and separate bulb socket from license plate lamp INSTALLATION 1 Position bulb socket in license plate lamp and turn clockwise 2 Position license plate lamp in license plate housi...

Page 505: ...ng 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 remove from vehicle INSTALLATION 1 Position visor lamp at visor and connect visor lamp wire connector 2 Position visor lamp in visor and press into place DOME READING LAMP REMOVAL 1 Insert a flat blade screwdriver in slot at the center of the...

Page 506: ...tate 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 connector for cargo lamp INSTALLATION 1 Position trim panel cargo lamp at liftgate open ing 2 Engage electrical connector for cargo lamp 3 Install s...

Page 507: ...use 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 is not equipped with a trailer ...

Page 508: ...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 ZG REMOVAL AND INSTALLATION Continued ...

Page 509: ...22 Fog lamp H3 Front Turn Signal 1295NA Front Side Marker 194NA Headlamp 9004 License Plate 168 Tail Stop 3057 Rear Turn Signal 3057 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 511: ...passenger or cargo load The headlamp beam height is controlled by a motor attached to each headlamp and is adjusted by a switch located on the console DIAGNOSIS AND TESTING HEADLAMP MOTOR DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION ONE MOTOR DOES NOT OPERATE 1 Poor connection at motor 2 No voltage at motor 3 Defective motor 1 Secure connector on motor 2 Repair circuit 3 Replace motor MOTORS DO N...

Page 512: ...ank should be FULL Add 2 94 kg 6 5 lbs of weight over the fuel tank for each estimated gallon of missing fuel ALIGNMENT SCREEN PREPARATION 1 Position vehicle on a level surface perpendicu lar to a flat wall 10 meters away from front of head lamp lens Fig 1 2 If necessary tape a line on the floor 10 meters away from and parallel to the wall 3 Measure from the floor up 1 27 meters 5 feet and tape a ...

Page 513: ...mp being aligned Transfer measurements to screen with tape to each side of vehicle centerline Use these lines for left right adjustment reference HEADLAMP ADJUSTMENT A properly aimed low beam headlamp will project the top edge of high intensity pattern on screen from 150 mm below headlamp centerline Fig 1 The angle between the horizontal and the inclined part of the light dark boundary may not var...

Page 514: ...the lamp housing 2 Engage bulb retaining clip 3 Install protective boot on rear of headlamp 4 Engage electrical connector 5 Install headlamp SIDE REPEATER LAMP BULB REMOVAL 1 Insert a flat blade or similar tool between lamp and fender opening and pry the lamp away from the fender Fig 3 The retaining tabs are located at the top and bottom of the lamp 2 Twist lamp 1 4 turn clockwise and pull lamp fr...

Page 515: ...eparate socket from lamp 3 Rotate bulb in the socket counterclockwise and remove bulb from socket INSTALLATION 1 Position the bulb in the socket and rotate clock wise 2 Position the bulb socket in the lamp and rotate clockwise 3 Install the tail lamp Fig 4 Fog Lamp Bulb ZG LAMPS 8L 5 REMOVAL AND INSTALLATION Continued ...

Page 516: ...ng the upper pivot of the headlamp to the headlamp leveling motor 4 Install the park lamp SIDE REPEATER LAMP REMOVAL 1 Insert a small flat blade between lamp and body panel Disengage lamp retaining tabs Fig 1 2 Twist bulb socket 1 4 turn and separate bulb socket from lamp Fig 2 INSTALLATION 1 Position socket in lamp and twist socket 1 4 turn 2 Position lamp into body opening and push into place RE...

Page 517: ...INSTALLATION 1 Position the reflector on the rear bumper Fig 3 2 Install the nut attaching the reflector to the rear bumper Fig 3 Rear Bumper Reflector ZG LAMPS 8L 7 REMOVAL AND INSTALLATION Continued ...

Page 518: ...o grille opening reinforcement GOR Fig 1 3 Gently push leveling motor downward and pull from GOR 4 Squeeze electrical connector tabs inward and pull connector from leveling motor 5 Separate leveling motor from vehicle INSTALLATION 1 Engage electrical connector to leveling motor 2 Position leveling motor in GOR and install screws 3 Install headlamp Fig 1 Headlamp Leveling Motor 8L 8 LAMPS ZG ...

Page 519: ...CATIONS EXTERIOR LAMPS LAMP BULB Front Fog Lamp H3 Front Turn Signal Lamp P21W Headlamp H4 License Plate Lamp W5W Park Lamp W3W Park Lamp Japan Only W3W Rear Fog Lamp P21W Rear Turn Signal Lamp P21W Side Repeater Lamp T4W Stop Lamp P21 5W Tail Lamp P21 5W ZG LAMPS 8L 9 ...

Page 520: ......

Page 521: ... frontal impact of the vehicle To test this passive restraint system refer to the proper Diagnostic Procedures manual If an airbag module assembly is defective and non deployed refer to the Chrysler Corporation current parts return list in the Warranty Policies and Procedures manual for the proper handling procedures Following are general descriptions of the major components in the airbag system R...

Page 522: ...nder the airbag module trim cover are the horn switch the airbag cushion and the air bag cushion supporting components The airbag mod ule includes a housing to which the cushion and inflator are attached and sealed The airbag module cannot be repaired and must be replaced if deployed or in any way damaged The inflator assembly is mounted to the back of the airbag module The inflator seals the hole...

Page 523: ...ng must be replaced AIRBAG CONTROL MODULE The Airbag Control Module ACM contains the impact sensor and a microprocessor that monitors the impact sensor signals and the airbag system elec trical circuits to determine the system readiness The ACM contains On Board Diagnostics OBD and will send an airbag lamp on message to the instrument cluster on the Chrysler Collision Detection CCD data bus to lig...

Page 524: ...es the clockspring the instrument panel top pad and the passenger side airbag rear mounting bracket replaced These components will be damaged or weakened as a result of an airbag deployment which may or may not be obvious during a visual inspec tion and are not intended for reuse Other vehicle components should be closely inspected but are to be replaced only as required by the extent of the visib...

Page 525: ...underside of the steering wheel remove the three screws that secure the driver side airbag module to the steering wheel Fig 4 3 Pull the airbag module away from the steering wheel far enough to unplug the airbag module and horn switch wire harness connectors from the back of the airbag module 4 Remove the airbag module from the steering wheel 5 If the airbag has been deployed see the proce dure fo...

Page 526: ...ATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYS TEM CAPACITOR TO DISCHARGE BEFORE FUR THER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY THE HORN SWITCH IS INTEGRAL TO THE AIR BAG MODULE TRIM COVER SERVICE OF THIS COMPONENT SHOULD BE PERFORMED ONLY BY CHRYSLER TRAINE...

Page 527: ...is time See Airbag System in Diagnosis and Testing for the proper procedures PASSENGER SIDE AIRBAG REAR MOUNTING BRACKET 1 Remove the passenger side airbag module as described in this group Fig 6 Horn Switch Feed Wires Remove Install HORN SWITCH FEED WIRE HORN SWITCH GROUNDWIRE WIRE RETAINERS Fig 7 Airbag Trim Cover Retainers Remove Install INFLATOR UPPER RETAINER AIRBAG HOUSING STUDS NUT 4 LOWER ...

Page 528: ...ttery negative cable If the airbag has not been deployed wait two minutes for the system capacitor to discharge before further service 2 If the vehicle is equipped with an automatic transmission pull the transmission shift lever handle straight up firmly and quickly to remove the handle If the vehicle is equipped with a manual transmis sion remove the shift lever knob by removing the bezel and nut...

Page 529: ...TEM IS A SENSITIVE COMPLEX ELECTROMECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR BAG SYSTEM OR RELATED STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYS TEM CAPACITOR TO DISCHARGE BEFORE FUR THER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTE...

Page 530: ...e shrouds 14 The front wheels should still be in the straight ahead position Install the steering wheel being certain to fit the flats on the hub of the steer ing wheel onto the formations on the inside of the clockspring Pull the wire harnesses from the clock spring through the upper and lower holes in the steering wheel hub Tighten the steering wheel nut to 61 N m 45 ft lbs Be certain not to pin...

Page 531: ...ravel rotate the rotor two and one half turns counterclockwise The horn wire harness should end up at the top and the airbag wire harness at the bottom 9 The front wheels should still be in the straight ahead position Install the steering wheel being cer tain to fit the flats on the hub of the steering wheel onto the formations on the inside of the clockspring Pull the wire harnesses from the cloc...

Page 532: ......

Page 533: ... the steering column in the inboard switch pod on the instrument panel A Light Emit ting Diode LED above the switch button in the switch pod will light to indicate when the defogger system is turned on The Body Control Module BCM which contains the defogger system timer logic monitors the state of the defogger switch through a hard wired input The BCM circuitry con trols the defogger system throug...

Page 534: ...ontrol Module BCM each time it is depressed The BCM rear window defogger timer and logic circuitry responds by energizing or de energizing the rear win dow defogger relay Energizing the rear window defogger relay pro vides electrical current to the rear window defogger grid and the Light Emitting Diode LED indicator in the switch which lights to indicate that the defogger system is turned On The d...

Page 535: ...ated in the following manner 1 Confirm that the ignition switch is in the On position 2 Ensure that the rear glass heating grid feed and ground wires are connected to the glass Confirm that the ground wire has continuity to ground 3 Check the fuses in the Power Distribution Cen ter PDC and in the junction block The fuses must be tight in their receptacles and all electrical connec tions must be se...

Page 536: ...nuity If OK go to Step 5 If not OK replace the faulty inboard switch pod 5 Unplug the white 24 way wire harness connec tor from the Body Control Module BCM Check for continuity between the rear window defogger switch sense circuit cavity of the inboard switch pod 10 way wire harness connector and a good ground There should be no continuity If OK go to Step 6 If not OK repair the short circuit as r...

Page 537: ...HE AFFECTED AREAS WITH SOAP AND WATER FOR CONTACT WITH THE EYES FLUSH WITH PLENTY OF WATER DO NOT TAKE INTERNALLY IF TAKEN INTER NALLY INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY USE WITH ADEQUATE VENTILA TION DO NOT USE NEAR FIRE OR FLAME CON TAINS FLAMMABLE SOLVENTS KEEP OUT OF THE REACH OF CHILDREN 1 Mask the repair area so that the conductive epoxy can be applied neatly Extend the epoxy a...

Page 538: ...e wire harness connectors from the inboard switch pod 6 Remove the inboard switch pod from the instrument panel 7 Reverse the removal procedures to install DEFOGGER RELAY WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTION...

Page 539: ...oint 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 turn off the heating elements if it detects an open in the sensor circuit or a short in the heating element circuit causing an excessive current draw The system is also turned off automatically when the ignition switch is turne...

Page 540: ...nts in the heated seat system check the following If the heated seat switch LED doesn t light with the ignition switch in the On position and the heated seat switch in the Low or High position check the fuse in the junction block If the fuse is OK test the heated seat switch as described in this group If the heated seat switch LED lights but the heating elements don t heat check the circuit breake...

Page 541: ...heated seat cushion wire harness connector 2 Check for continuity between the two heated seat driver circuit cavities of the seat cover half of the heated seat cushion wire harness connector There should be continuity If OK go to Step 3 If not OK replace the faulty seat cushion cover 3 Check for continuity between one of the heated seat driver circuit cavities of the seat cover half of the heated ...

Page 542: ...bracket can be accessed 5 Disconnect and isolate the battery negative cable 6 Remove the two bolts that secure the power recliner adjuster lower bracket to the seat cushion frame 7 Gently pry the power recliner adjuster lower bracket upwards to access the heated seat control module mounting screw Fig 2 8 Remove the heated seat control module mount ing screw from the seat cushion frame 9 Reach unde...

Page 543: ...ed and feasible the RHD versions of affected vehicle components have been constructed as mirror image of the LHD versions While most of the illustrations used in this group represent only the LHD version the diagnostic and service procedures outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD or RHD if a special illustration or procedure ...

Page 544: ... from the RKE receiver in the Passenger Door Module PDM for the memory select function The DDM processes these inputs and sends messages to the radio if the radio is CCD data bus capable the PDM and the Memory Seat Module MSM on the CCD data bus for memory recall The CCD data bus network allows the sharing of sensor information This helps to reduce wire har ness complexity reduce internal controll...

Page 545: ...ler hardware and reduce component sensor current loads 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 on models so equipped is the Remote Keyless Entry RKE Panic Mode The BCM receives input from the RKE receiver in the Passen ger Door Modul...

Page 546: ...keyless entry transmitter Then proceed as follows If the system fails to function with either the switches or the transmitter see the Circuit Breaker diagnosis in this group If the system functions with both switches but not with the transmitter see the Remote Keyless Entry Transmitter diagnosis in this group If the system functions with the transmitter but not with one or both switches see the Do...

Page 547: ...llows Unplug the wire harness connector at the inoperative motor Apply 12 volts to the motor terminals to check its operation in one direction Reverse the polarity to check the operation in the other direction If OK repair the short or open circuits to the door module as required If not OK replace the faulty lock motor REMOTE KEYLESS ENTRY TRANSMITTER 1 Replace the Remote Keyless Entry RKE transmi...

Page 548: ... RKE transmitter access codes into the RKE receiver in the passenger door module requires the use of a DRB scan tool Refer to the proper Body Diagnostic Proce dures manual for more information REMOVAL AND INSTALLATION DOOR MODULE 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 the notche...

Page 549: ... end and prying gently upwards 3 Remove the door trim panel mounting screw located in the bezel opening near the inside door latch release handle Fig 5 4 Remove the trim cap and screw near the rear of the door armrest 5 Using a wide flat 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...

Page 550: ...ate latch handle Fig 8 5 Remove the two screws that secure the lock actuator motor to the liftgate Fig 9 6 Unplug the wire harness 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 6 Door Latch Remove Install Typical LATCH SCREWS LATCH ADJUST MENT SCREW Fig 7 Liftgate ...

Page 551: ...st unauthorized vehi cle use by preventing the engine from operating while the system is armed The vehicle immobilizer system can only be disarmed using the Remote Key less Entry RKE transmitters Following are some general descriptions of the fea tures of the VTSS and the vehicle immobilizer sys tem Refer to the vehicle owner s manual for more information on the use and operation of these sys tems...

Page 552: ...e doors and or the liftgate are open when the RKE transmitter Lock button is depressed However the VTSS arming will not be complete until all the doors and the liftgate are closed Following successful passive or active VTSS arm ing the VTSS set lamp on the top of the instrument panel will flash rapidly for about fifteen seconds after the illuminated entry system times out This indi cates that VTSS...

Page 553: ...erts the driver that the VTSS was activated while the vehicle was unattended DESCRIPTION AND OPERATION BODY CONTROL MODULE A Body Control Module BCM is used on this model to control and integrate many of the electronic functions and features on the vehicle The BCM con tains a central processing unit and interfaces with other modules in the vehicle on the Chrysler Colli sion Detection CCD data bus ...

Page 554: ...M grounds the relay coil See the Diagnosis and Testing section of this group for more information on the operation of the auto headlamp relay The auto headlamp relay is located in the junction block on the right cowl side panel below the instru ment panel in the passenger compartment The auto headlamp relay cannot be repaired and if faulty or damaged it must be replaced HORN RELAY The horn relay i...

Page 555: ... in the engine compartment The auto headlamp and park lamp relays are located in the junction block in the passenger compartment Each of these relays can be tested as described in the fol lowing procedure however the circuits they are used in do vary To test the relay circuits refer to the cir cuit descriptions and diagrams in 8W 39 Vehicle Theft Security System in Group 8W Wiring Dia grams WARNIN...

Page 556: ... rod from the door latch by unsnapping the retainer from the rod 11 Pull the lock cylinder out from the outer door panel far enough to pry the lock cylinder switch off of the back of the lock cylinder Fig 4 12 Unplug the lock cylinder switch 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 t...

Page 557: ... 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 that secure the liftgate lower trim panel to the liftgate Fig 9 Fig 4 Door Lock Cylinder Switch Remove Install Typical DOOR DIS ARM SWITCH LOCK CYLIN DER Fi...

Page 558: ...IS 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 2 Remove the fuse access panel by unsnapping it from the right cowl side trim panel 3 Remove the push nut that secures the right cowl side trim to the junction block stud Fig 11 4 Remove the two screws that secure the r...

Page 559: ...N 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 2 Using a wide flat bladed tool such as a trim stick pry the cowl top trim panel off of the instru ment panel top pad Fig 13 3 If the vehicle is so equipped pull the panel up far e...

Page 560: ......

Page 561: ...for complete circuit descriptions and dia grams NOTE This group covers both Left Hand Drive LHD and Right Hand Drive RHD versions of this model Whenever required and feasible the RHD versions of affected vehicle components have been constructed as mirror image of the LHD versions While most of the illustrations used in this group represent only the LHD version the diagnostic and service procedures...

Page 562: ...educe component sensor current loads 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 Vehicle Theft Security System VTSS In addition to the information received on the CCD data bus the BCM receives hard wired inputs from the door ajar ...

Page 563: ...elay The horn relay is a electromechanical device that switches battery current to the horns when the horn switch or the Body Control Module BCM grounds the relay coil See the Diagnosis and Testing section of this group for more information on the operation of the horn relay The horn relay is located in the Power Distribution Center PDC in the engine compartment Refer to the PDC label for relay id...

Page 564: ...to the Vehicle Theft Security System menu item on the DRB scan tool for the procedures The immobilizer receiver recognizes the Lock and Unlock signals received from the programmed immo bilizer transmitters The receiver then uses the pro grammed immobilizer system logic to decide whether other monitored conditions are proper for an engine Lock or Unlock message to be sent If the pro grammed conditi...

Page 565: ...ocedures Manual for more information on this feature RELAYS The horn relay is located in the Power Distribution Center PDC in the engine compartment The auto headlamp and park lamp relays are located in the junction block in the passenger compartment Each of these relays can be tested as described in the fol lowing procedure however the circuits they are used in do vary To test the relay circuits ...

Page 566: ...If not OK repair the open circuit to ground as required 4 Connect the battery negative cable Check for battery voltage at the fused B circuit cavity of the immobilizer receiver wire harness connector If OK refer to the Vehicle Theft Security System menu item on the DRB scan tool for further diagnosis If not OK repair the open circuit to the PDC fuse as required ENABLING The vehicle immobilizer sys...

Page 567: ... harness connector 5 Reverse the removal procedures to install 6 Refer to the Vehicle Theft Security System menu item on the DRB scan tool for the procedures to program transmitter vehicle access codes into the memory of the new immobilizer receiver HOOD SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove the screw securing the hood switch to the right inner fender ledge Fig 2 3 Un...

Page 568: ...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 7 Unplug the wire harness connectors from the door module and set the trim panel aside 8 Pull the watershield away from the rear access holes in the inner door panel 9 Remove the U clip retainer that secures the lock cylinder to the outer do...

Page 569: ...ll Tighten the latch mounting screws to 7 N m 62 in lbs LIFTGATE LOCK CYLINDER SWITCH 1 Disconnect and isolate the battery negative cable 2 Remove the screws that secure the liftgate lower trim panel to the liftgate Fig 9 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 trim panel NOTE To aid in the removal of the tr...

Page 570: ...EMS BEFORE ATTEMPTING ANY 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 2 Remove the fuse access panel by unsnapping it from the right cowl side trim panel 3 Remove the push nut that secures the ri...

Page 571: ...AUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Using a wide flat bladed tool such as a trim stick pry the cowl top trim panel off of the instru ment panel top pad Fig 15 3 If the vehicle is so equipped pull the panel up far enough to unplug the wire harness connector from the solar sensor or to remove the sol...

Page 572: ......

Page 573: ...r procedure is required MEMORY SYSTEM An electronic memory system is an available option on this model The memory system is able to store and recall the driver side power seat positions including power lumbar and recliner positions and both outside power mirror positions for two drivers For vehicles with a radio connected to the Chrysler Collision Detection CCD data bus network the memory system i...

Page 574: ... pushed to the Up or Down position both the front and rear motors operate in unison moving the entire seat up or down The forward rearward motor is operated by pushing the seat switch to its forward or rearward position When a switch is actuated a battery feed and a ground path are applied through the switch contacts to the motor s The motor s operate to move the seat in the selected direction unt...

Page 575: ...ircuits CIRCUIT BREAKER For circuit descriptions and diagrams refer to 8W 63 Power Seat in Group 8W Wiring Diagrams 1 Locate the correct circuit breaker in the junc tion block Pull out the circuit breaker slightly but be sure that the terminals still contact the terminals in the junction block cavities 2 Connect the negative lead of a 12 volt DC volt meter to a good ground 3 With the voltmeter pos...

Page 576: ...at in Group 8W Wiring Diagrams Operate the power seat switch to move the power recliner in each direction The recliner should move in both directions If the power recliner fails to oper ate in only one direction move the seat a short dis tance in the opposite direction and test again to be certain the adjuster is not at its travel limit If the power recliner still fails to operate in only one dire...

Page 577: ...he switch and the motor for shorts or opens If the cir cuits check OK replace the faulty power lumbar adjuster and motor which are serviced with the seat back frame assembly If the circuits are not OK repair the wire harness as required REMOVAL AND INSTALLATION POWER SEAT SWITCH 1 Disconnect and isolate the battery negative cable 2 Using a trim stick or other suitable wide flat bladed tool gently ...

Page 578: ... battery negative cable 5 Remove the two bolts that secure the power recliner adjuster lower bracket to the seat cushion frame Fig 5 6 Remove the inboard seat back pivot bolt 7 Unplug the wire harness 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 that secure the power r...

Page 579: ...retainers that secure the mem ory seat module wire harness to the inboard seat adjuster top rail Fig 8 9 Slide the memory seat module off of the mount ing bracket slide tabs far enough to unplug the wire harness connectors 10 Remove the module from under the seat cush ion 11 Reverse the removal procedures to install NOTE Following the installation it will be neces sary to initialize the memory sea...

Page 580: ......

Page 581: ...indows to be opened or closed by operating a switch on the trim panel for that door The master switches on the driver side front door trim panel can be oper ated to open or close any of the door windows In addition a lockout switch on the driver side front door trim panel allows the driver to disable all of the passenger door window switches The power window system includes the door mod ules mount...

Page 582: ...ows The DDM can control the PDM output by sending control mes sages to the PDM over the CCD data bus Some of the features and functions of the power window system made possible because of the commu nication of the door modules on the CCD data bus network include Power window operation after ignition off fea ture Power window lockout function Power window switch LED illumination control function Fo...

Page 583: ...d the proper Body Diag nostic Procedures manual to diagnose the door mod ules and the CCD data bus If not OK repair the open circuit to the junction block as required ONE WINDOW INOPERATIVE The window glass must be free to slide up and down for the power window motor to function prop erly If the glass is not free to move up and down the motor will overload and trip the integral circuit breaker To ...

Page 584: ...ns There should be bat tery voltage for as long as the switch is held in both the up and down positions and no voltage in the neutral position If OK see the diagnosis for Power Window Motors If not OK replace the faulty door module 9 Disconnect and isolate the battery negative cable Remove the rear door power window switch as described in this group Check the rear door power window switch continui...

Page 585: ...ass and lift mechanism through its complete up and down travel There should be no binding or sticking of the window glass or lift mechanism through the entire travel range If not OK refer to Group 23 Body to check the win dow glass tracks and regulator for sticking binding or improper adjustment REMOVAL AND INSTALLATION DOOR MODULE 1 Disconnect and isolate the battery negative cable 2 Remove the b...

Page 586: ...move the trim panel NOTE To aid in the removal of the trim panel start at the bottom of the panel 6 Unplug the wire harness connector from the door power window switch 7 Unsnap the switch from the receptacle in the trim panel Fig 5 8 Reverse the removal procedures to install POWER WINDOW MOTOR FRONT DOOR 1 Remove the front door trim panel as described under Door Module in this group 2 Remove the w...

Page 587: ...rocedures to complete the installation REAR DOOR 1 Remove the rear door trim panel as described under Power Window Switch in this group 2 Remove the watershield from the inner door panel 3 Loosen the two nuts that secure the door glass to the window regulator lift plate Fig 8 4 Slide the door glass forward to remove it from the nuts 5 Pull the door glass to the full up position and tape the glass ...

Page 588: ...holes on the regulator lift plate Tighten the nuts to 12 N m 105 in lbs 14 Plug in the wire harness connector to the power window motor 15 Use an adhesive sealant to install the plastic watershield to the door inner panel 16 Reverse the remaining removal procedures to complete the installation 8S 8 POWER WINDOW SYSTEMS ZG REMOVAL AND INSTALLATION Continued ...

Page 589: ...dure is required MEMORY SYSTEM An electronic memory system is an available option on this model The memory system is able to store and recall the driver side power seat positions including power lumbar and recliner positions and both outside power mirror positions for two drivers For vehicles with a radio connected to the Chrysler Collision Detection CCD data bus network the memory system is also ...

Page 590: ...or switch cannot be repaired and if faulty or damaged the DDM unit must be replaced DOOR MODULE A Driver Door Module DDM and a Passenger Door Module PDM are used on this model to control and integrate many of the electronic features and functions on the vehicle The DDM and PDM commu nicate with each other and with other vehicle mod ules on the Chrysler Collision Detection CCD data bus network The ...

Page 591: ...r as shown in the Mirror Test chart Fig 1 If the mirror tests OK use a DRB scan tool and the proper Body Diagnostic Procedures manual to test the door module and the CCD data bus If the mirror does not test OK replace the faulty mirror NO MIRROR HEAT If both mirror heaters are inoperative refer to Group 8N Electrically Heated Systems to test the Rear Defogger System 1 Disconnect and isolate the ba...

Page 592: ...ker grille 7 Using a wide flat 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 wire harness connectors from the door module and the door courtesy lamp if equipped 9 Remove the five screws that secure the door module to the door trim panel ...

Page 593: ...or if equipped 4 Unclip the mirror wire harness es from the inner door panel 5 Remove the mirror flag seal Fig 4 6 Remove the three nuts that secure the mirror to the door 7 Remove the mirror from the door 8 Reverse the removal procedures to install Tighten the mirror mounting nuts to 7 4 N m 65 in lbs Fig 4 Power Mirror Remove Install ZG POWER MIRROR SYSTEMS 8T 5 REMOVAL AND INSTALLATION Continue...

Page 594: ...too great the light level received at the rear of the mirror is much higher than at the front of the mirror the mirror begins to darken The mirror switch allows the driver a manual 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...

Page 595: ...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 reflectance If not OK replace the faulty mirror unit REMOVAL AND INSTALLATION AUTOMATIC DAY NIGHT MIRROR 1 Disconnect and isolate the battery negative cable 2 If so equipped remove ...

Page 596: ......

Page 597: ...ntrol Module in Group 8W Wiring Diagrams for complete circuit descriptions and diagrams NOTE This group covers both Left Hand Drive LHD and Right Hand Drive RHD versions of this model Whenever required and feasible the RHD versions of affected vehicle components have been constructed as mirror image of the LHD versions While most of the illustrations used in this group represent only the LHD versi...

Page 598: ...laced Refer to Group 8D Ignition Systems for the service procedures HEADLAMP SWITCH The headlamp switch is integral to the outboard switch pod located in the instrument panel outboard of the steering column It provides a battery voltage signal to the Body Control Module BCM park lamp relay output circuit when the park or head lamps are turned on The headlamp switch opens the park lamp relay output...

Page 599: ...ERING 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 steering column shrouds Refer to Group 8D Ignition Systems for the procedures Unplug the key in ignition switch wire harness con nector from th...

Page 600: ...relay output circuit cavities of the headlamp switch wire harness connector and the black 24 way BCM wire harness connector There should be continuity If OK use a DRB scan tool and the proper Diagnostic Procedures manual to test the BCM If not OK repair the open circuit as required REMOVAL AND INSTALLATION CHIME WARNING SYSTEM SWITCHES Service procedures for the various hard wired switches used in...

Page 601: ...d and feasible the RHD versions of affected vehicle components have been constructed as mirror image of the LHD versions While most of the illustrations used in this group represent only the LHD version the diagnostic and service procedures outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD or RHD if a special illustration or procedure i...

Page 602: ... button located just rearward of the display module The displayed temperature is not an instant reading of conditions but an average temperature It may take the thermometer display several minutes to respond to a major temperature change such as driving out of a heated garage into winter tempera tures When the ignition switch is turned to the Off posi tion the last displayed temperature reading st...

Page 603: ...e CCD data bus If not OK repair the open circuit to the courtesy lamp relay as required SELF DIAGNOSTIC TEST A self diagnostic test is used to determine that the trip computer compass thermometer and all of the display module segments are operating properly elec trically Initiate the self diagnostic test as follows 1 With the ignition switch in the Off position simultaneously press and hold the St...

Page 604: ...black 24 way BCM wire harness connector and a good ground There should be no continuity If OK go to Step 5 If not OK repair the short circuit as required 5 Check for continuity between the ambient tem perature sensor signal circuit cavity of the black 24 way BCM wire harness connector and a good ground There should be no continuity If OK see the Trip Computer Compass and Thermometer Display Module...

Page 605: ... still indicated in the compass display the area selected for calibration may be too close to a strong magnetic field Repeat the calibration procedure in another location COMPASS DEMAGNETIZING A degaussing tool Special Tool 6029 is used to demagnetize or degauss the overhead console for ward mounting screw and the roof panel Equivalent units must be rated as continuous duty for 110 115 volts and 6...

Page 606: ...ass and adjust the compass variance as described in this group REMOVAL AND INSTALLATION OVERHEAD CONSOLE LONG TYPE 1 Disconnect and isolate the battery negative cable 2 Remove the forward mounting screw located in front of the display module Fig 3 3 Slide the console forward until the rear of the console separates from the rear mounting bracket 4 Unplug the wire harness connector from the trip com...

Page 607: ...on sole 5 Reverse the removal procedures to install READING AND COURTESY LAMP BULB 1 Insert a long narrow flat bladed tool at the notch on the curved edge of the reading and courtesy lamp lens 2 Gently pry the lens downward from the over head console housing and pivot the lens down It may be necessary to move the tool along the edge of the lens to free the lens from the console housing 3 Remove th...

Page 608: ... 3 Locate the temperature sensor on the radiator support behind the grille Fig 6 4 Unplug the temperature sensor wire harness connector 5 Remove the temperature sensor mounting bolt and remove the sensor 6 Reverse the removal procedures to install Fig 6 Temperature Sensor Remove Install 8V 8 OVERHEAD CONSOLE SYSTEMS ZG REMOVAL AND INSTALLATION Continued ...

Page 609: ...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...

Page 610: ......

Page 611: ...adlamp 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 as possibl...

Page 612: ...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 613: ...ponent connectors by name If a component has two or more connectors they will be identified as C1 C2 C3 etc This sections also provides terminal numbering cir cuit 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 nu...

Page 614: ...Fig 5 Symbol Identification 8W 01 4 8W 01 GENERAL INFORMATION ZG DESCRIPTION AND OPERATION Continued ...

Page 615: ...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 616: ...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 617: ...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 618: ... the wire and tool 6934 and slowly remove the wire and terminal from the connector 6 Repair or replace the terminal 7 Install the wire and terminal in the connector Fully seat the terminal in the connector 8 Push in the single lock tab on the side of the connector Fig 16 CONNECTOR REPLACEMENT 1 Disconnect battery 2 Disconnect the connector that is to be repaired from its mating half component 3 Re...

Page 619: ... as was done on the harness side of the repair Allow extra length for soldered connections Check that the overall length is the same as the original Fig 20 7 Remove 1 inch of insulation from each wire 8 Place a piece of heat shrink 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 ...

Page 620: ...e to the insulation 12 Twist the wires together 13 Solder the connection together using rosin core type solder only Do not use acid core solder 14 Center the heat shrink tubing over the joint and heat using a heat gun Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 15 Insert the repaired wire into the connector 16 Install the connector locking wed...

Page 621: ... 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 Probing Tool Package 6807 Terminal Pick 6680 Terminal Remov3ing Tool 6932 Terminal Removing Tool 6934 ZG 8W 0...

Page 622: ......

Page 623: ...aft Position CKP Sensor 8W 30 Cruise Lamp 8W 40 Component Page Cylinder Lock Switches 8W 39 Data Link Connector 8W 30 Daytime Running Lamp DRL Module 8W 50 Dome Reading Lamp 8W 44 Door Ajar Switches 8W 39 44 45 Door Courtesy Lamps 8W 44 Door Lock Motors 8W 61 Door Speakers 8W 47 Driver Door Module 8W 60 61 62 63 Driver Heated Seat Back 8W 63 Driver Heated Seat Cushion 8W 63 Driver Lumbar Motor 8W ...

Page 624: ...re Gauge 8W 40 Oil Pressure Sensor 8W 30 Output Shaft Speed Sensor 8W 30 31 Overhead Console 8W 49 Park Brake Switch 8W 45 50 Park Lamp Relay 8W 12 45 50 51 Park Lamps 8W 50 52 Park Neutral Position Switch 8W 30 44 Passenger Door Module 8W 60 61 62 Passenger Heated Seat Back 8W 63 Passenger Heated Seat Cushion 8W 63 Passenger Lumbar Motor 8W 63 Passenger Lumbar Switch 8W 63 Passenger Power Mirror ...

Page 625: ...y 8W 30 31 Transmission Solenoid Assembly 8W 30 31 Component Page Turn Signal Indicator Lamps 8W 40 Turn Signal Lamps 8W 40 50 52 Turn Signal Hazard Warning Switch 8W 52 Underhood Lamp 8W 44 Universal Garage Door Opener 8W 44 Variable Force Solenoid 8W 31 Vehicle Information Center 8W 46 Vehicle Speed Control Servo 8W 33 Vehicle Speed Control Horn Switch 8W 30 33 39 41 47 Vehicle Speed Sensor 8W 3...

Page 626: ...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 8W 02 4 8W 02 COMPONENT INDEX ZG ...

Page 627: ...y 8W 10 14 15 Fuse 1 8W 10 3 4 9 Fuse 2 8W 10 9 Fuse 3 8W 10 3 4 9 Fuse 4 8W 10 3 8 18 Fuse 5 8W 10 3 5 8 Fuse 6 8W 10 5 8 Fuse 7 8W 10 3 6 10 Fuse 8 8W 10 3 7 10 Fuse 9 8W 10 10 Fuse 10 8W 10 3 4 9 Fuse 11 8W 10 3 8 10 Fuse 12 8W 10 8 Component Page Fuse 13 8W 10 3 11 12 Fuse 14 8W 10 3 9 10 Fuse 15 8W 10 3 12 Fuse 16 8W 10 3 12 13 14 Fuse 17 8W 10 3 11 14 Fuse 18 8W 10 8 13 14 Fuse 19 8W 10 3 12...

Page 628: ...1 11 12 14 13 16 15 2 5 3 4 1 16 19 18 20 17 11 13 15 14 12 2 4 5 3 1 7 10 8 9 6 6 9 8 10 7 1 3 5 4 2 12 14 15 13 11 17 20 18 19 16 13 12 14 11 10 2 8 5 9 6 3 1 4 7 D C B A ENGINE STARTER MOTOR RELAY WIPER RELAY INTERMITTENT ABS MAIN RELAY RELAY CLUTCH COMPRESSOR A C RELAY SHUT DOWN AUTOMATIC HORN RELAY TRANSMISSION CONTROL RELAY FUEL PUMP RELAY POWER DISTRIBUTION CENTER SEE PAGE 8W 10 17 FOR PDC ...

Page 629: ...0 A19 A11 A12 24 17 27 20 28 21 TO BRAKE ANTI LOCK CONTROLLER TO RELAY PUMP TO CENTER DISTRIBUTION POWER BRAKE 19 26 FUSE 30A 13 A6 14 RD LB JUNCTION BLOCK TO A6 14 RD LB DAYTIME RUNNING LAMP MODULE TO 19 20A A18 FUSE A17 RD BLOCK JUNCTION TO 18 F62 A12 RD TN 12 3 30A FUSE 10 4 CENTER DISTRIBUTION POWER TO DIESEL TO CENTER DISTRIBUTION POWER RD WT A1 12 GAS GAS 16 A11 15A A12 FUSE C131 TO WT RD 18...

Page 630: ... 18 DB YL A C COMPRESSOR CLUTCH 5 2L CENTER DISTRIBUTION POWER A900 12 OR YL REAR WINDOW DEFOGGER RELAY JUNCTION BLOCK 87 30 86 10A FUSE 10 C15 12 BK WT 1 C301 C15 12 BK WT 2 C322 C15 12 BK LB S332 C15 12 BK C15 12 BK LB DEFOGGER WINDOW REAR LIFT GLASS C6 3 C2 3 OTHERS DIESEL AND 4 0L 8W 10 3 8W 10 3 8W 10 3 8W 48 2 8W 12 9 8W 12 2 8W 48 2 8W 42 10 8W 42 11 8W 42 10 8W 42 11 8W 20 2 8W 20 3 8W 10 ...

Page 631: ...ROLLER ANTI LOCK BRAKE BATT A0 5 12 6 FUSE 20A RELAY HORN A2 A3 A1 FUSED B X2 16 DG YL S106 X2 16 DG YL X2 16 DG YL 1 1 NO 1 HORN NO 2 HORN 8W 39 6 8W 41 2 8W 10 3 8W 10 3 8W 39 6 8W 41 2 8W 39 6 8W 41 2 8W 35 2 ZG 8W 10 POWER DISTRIBUTION 8W 10 5 ZG001004 J978W 3 ...

Page 632: ...RD 2 5 1 3 BLOWER POWER MODULE A19 10 RD 1 C42 12 BR RD C42 12 BR RD C42 12 RD C42 12 BR RD M C206 C42 18 PK DB D2 MODULE CONTROL TEMPERATURE AUTOMATIC S224 BATT A0 HIGH SPEED BLOWER MOTOR RELAY OUTPUT RELAY MOTOR BLOWER SPEED HIGH M 8W 42 2 8W 42 3 8W 10 3 8W 10 3 8W 42 3 8W 42 3 8W 42 3 8W 10 6 8W 10 POWER DISTRIBUTION ZG J978W 3 ZG001005 ...

Page 633: ... 12 RD WT A1 12 RD WT A21 12 DB GY ST RUN A21 A41 14 YL E4 C233 C8 IN PDC RELAY MOTOR STARTER ENGINE A141 14 YL RD A31 12 RD BK RUN ACC A31 5 A22 12 BK OR RUN A22 3 0 2 1 3 0 2 1 1 2 0 3 3 G9 18 GY BK F5 C234 G9 16 GY BK BRAKE WARNING SWITCH 2 M DIESEL GAS 1 SWITCH INTERLOCK CLUTCH 8W 21 3 8W 10 3 8W 40 6 8W 10 8 8W 10 8 8W 10 9 8W 10 3 8W 21 3 8W 21 4 8W 21 3 8W 21 4 8W 21 3 8W 21 4 ZG 8W 10 POWE...

Page 634: ...FUSE 15A A15 CENTER DISTRIBUTION POWER A21 12 DB GY 4 FUSE 10A JUNCTION BLOCK 10A FUSE 22 10A FUSE 12 10A FUSE 11 15A FUSE 6 A22 12 BK OR 10 C6 C2 1 C5 3 0 2 1 8W 10 13 8W 10 14 8W 10 3 8W 10 7 8W 10 7 8W 12 6 8W 12 9 8W 12 10 8W 12 23 8W 12 2 8W 12 5 8W 12 2 8W 12 5 8W 10 8 8W 10 POWER DISTRIBUTION ZG J978W 3 ZG001007 ...

Page 635: ...OR F61 16 WT OR A31 12 RD BK 4 C6 JUNCTION BLOCK 14 FUSE 15A 10A FUSE 1 15A FUSE 2 10A FUSE 3 20A 1 BREAKER CIRCUIT C6 1 BATT A1 3 0 2 1 8W 10 3 8W 10 7 8W 10 3 8W 12 4 8W 12 4 8W 12 3 8W 12 3 8W 12 3 8W 12 2 ZG 8W 10 POWER DISTRIBUTION 8W 10 9 ZG001008 J978W 3 FUSE 10A 15 8W 12 20 87 REAR FOG LAMP RELAY 8W 51 7 30 ...

Page 636: ...UNCTION BLOCK 30A 2 BREAKER CIRCUIT 15A FUSE 9 BATT A0 20A FUSE 7 20A FUSE 8 14 FUSE 20A 27 20 A20 14 RD LG 9 CONTROLLER ANTI LOCK BRAKE FUSED B 8W 10 3 8W 10 3 8W 35 2 8W 12 8 8W 12 8 8W 12 7 8W 12 7 8W 12 2 8W 10 10 8W 10 POWER DISTRIBUTION ZG J978W 3 ZG001009 ...

Page 637: ...WITCH FUNCTION MULTI PART OF SWITCH DIMMER HEADLAMP A6 14 RD LB 11 9 25A BREAKER CIRCUIT 4 LOW 3 PARK 2 OFF 1 AUTO SWITCH HEADLAMP JUNCTION BLOCK F34 16TN BK 9 C5 AUTOMATIC HEADLAMP RELAY 4 3 2 1 8W 10 3 8W 10 3 8W 50 2 8W 12 2 8W 50 5 8W 50 2 8W 12 14 8W 50 2 ZG 8W 10 POWER DISTRIBUTION 8W 10 11 ZG001010 J978W 3 ...

Page 638: ... A0 A7 12 YL RD C2 2 JUNCTION BLOCK 15A FUSE 13 16 FUSE 10A 15A FUSE 19 20 FUSE 15A 15A FUSE 21 20A 3 BREAKER CIRCUIT 8W 10 3 8W 10 3 8W 12 18 8W 12 16 8W 12 16 8W 12 16 8W 12 12 8W 12 11 8W 12 2 8W 10 12 8W 10 POWER DISTRIBUTION ZG J978W 3 ZG001011 ...

Page 639: ...10 15 A18 RD 18 F62 A17 20A FUSE 19 5 JUNCTION BLOCK C1 87 30 86 FOG LAMP RELAY 8 C7 4 C1 FOG LAMP LEFT 2 2 RIGHT LAMP FOG 4 HEADLAMP SWITCH 20 LB L39 18 LB L39 L39 18 LB L39 18 LB S105 C4 WT RD 18 F6 FUSED B 8W 12 24 8W 50 7 8W 50 6 8W 50 6 8W 50 6 8W 12 2 8W 10 3 8W 10 8 8W 10 3 8W 30 22 ZG 8W 10 POWER DISTRIBUTION DIESEL ENGINE 8W 10 13 ZG001012 J978W 3 ...

Page 640: ...SION SOLENOID ASSEMBLY A16 A15 15A FUSE 18 ST RUN A21 F99 18 OR TO S101 A 8W 10 15 A18 RD 18 F62 A17 20A FUSE 19 5 JUNCTION BLOCK C1 87 30 86 FOG LAMP RELAY 8 C7 4 C1 FOG LAMP LEFT 2 2 RIGHT LAMP FOG 4 HEADLAMP SWITCH 20 LB L39 18 LB L39 L39 18 LB L39 18 LB S105 CONTROL 8W 12 24 8W 50 7 8W 50 6 8W 50 6 8W 50 6 8W 12 2 8W 10 3 8W 31 2 8W 10 8 8W 10 3 8W 31 2 8W 31 3 8W 30 16 8W 30 16 8W 10 14 8W 10...

Page 641: ...UT AUTOMATIC F99 20 OR F99 20 OR 1 SOLENOID PURGE EVAP CYCLE DUTY 2 PUMP DETECTION LEAK SYSTEM EVAPORATIVE S101 A 8W 10 13 FROM CENTER DISTRIBUTION POWER F99 20 OR MODULE CONTROL BODY GAS GAS GAS GAS GAS MSA CONTROLLER 38 DIESEL F99 OR 20 18 OR F99 S138 FUEL RELAY DIESEL HEATER D13 18 OR F99 8W 30 27 8W 30 22 8W 45 2 8W 30 4 8W 30 4 8W 30 4 8W 30 5 8W 30 16 8W 42 10 8W 30 4 8W 30 22 8W 10 14 ZG 8W...

Page 642: ... YL C1 A22 MODULE CONTROL POWERTRAIN FUSED B F5 18 RD YL B16 B17 IN PDC RELAY DOWN SHUT AUTOMATIC C12 C3 AUTOMATIC SHUT DOWN RELAY OUTPUT A142 18 DG OR A142 18 DG OR TO C131 S100 B 8W 10 17 8W 10 3 8W 10 3 8W 30 5 8W 30 4 8W 30 5 8W 10 16 8W 10 POWER DISTRIBUTION GAS ENGINES ZG J978W 3 ZG001014 ...

Page 643: ...XYGEN HEATED UPSTREAM DOWNSTREAM HEATED OXYGEN SENSOR S129 B 8W 10 16 AUTOMATIC SHUT DOWN RELAY FROM FUEL INJECTOR NO 2 NO 4 INJECTOR FUEL FUEL INJECTOR NO 6 4 0L NO 1 INJECTOR FUEL FUEL INJECTOR NO 3 4 0L 4 0L NO 5 INJECTOR FUEL FUEL INJECTOR NO 1 5 2L 5 2L NO 5 INJECTOR FUEL 5 2L NO 7 INJECTOR FUEL 5 2L NO 3 INJECTOR FUEL 5 2L NO 8 INJECTOR FUEL 8W 30 12 8W 30 11 8W 30 11 8W 30 11 8W 30 11 8W 30...

Page 644: ...16 RD YL B20 F5 16 RD YL 42 AUTOMATIC SHUTDOWN RELAY CONTROL TO S129 AUTOMATIC SHUT DOWN RELAY IN PDC K900 20 PK BK K900 20 PK BK A142 16 DG OR A142 16 DG OR 14 C132 12 C131 CONTROLLER MSA IN PDC RELAY HEATER FUEL 8W 10 9 8W 10 3 8W 30 27 8W 30 27 8W 10 18 8W 10 POWER DISTRIBUTION DIESEL ENGINE ZG J978W 3 ZG001017 ...

Page 645: ...UTPUT RELAY SHUTDOWN AUTOMATIC AUTOMATIC SHUTDOWN RELAY OUTPUT A142 16 DG OR A142 16 DG OR A142 14 DG OR OUTPUT RELAY SHUTDOWN AUTOMATIC OUTPUT RELAY SHUTDOWN AUTOMATIC 9 10 FUEL PUMP MODULE AUTOMATIC SHUTDOWN RELAY OUTPUT 3 MODULE FLOW AIR MASS GENERATOR 1 A142 16 DG OR A142 14 DG OR A142 18 DG OR A142 16 DG OR C 8W 10 18 8W 30 26 8W 30 27 8W 30 28 8W 30 25 8W 30 26 8W 20 2 ZG 8W 10 POWER DISTRIB...

Page 646: ... 8W 10 7 FUSED B SPARE 18 19 20 21 20 20 15 15 20 40 20 30 50 20 40 40 20 50 30 40 175 F31 16VT A10 10RD DB A900 12OR YL A1 12RD WT FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED IGNITION SWITCH OUTPUT ST RUN 15 F250 18RD GY FUSED B FEED CIRCUIT FUSED CIRCUIT FUSED B 17 FUSED B 25 20 F5 14RD YL GAS DIESEL 8W 10 20 8W 10...

Page 647: ...IT FUNCTION A6 F92 18LG FUSED B ABS WARNING LAMP RELAY OUTPUT F250 18RD GY B1 FUNCTION CIRCUIT CAV B2 C2 18DB YL AUTOMATIC SHUT DOWN RELAY OUTPUT FUSED IGNITION SWITCH OUPUT RUN F99 20OR B3 B4 CLUTCH COMPRESSOR A C RELAY A10 B120 12BR WT ABS PUMP MOTOR RELAY OUTPUT X4 20GY OR A5 HORN RELAYCONTROL F31 16VT FUSED B B5 C13 18DB RD A C COMPRESSOR CLUTCH RELAY CONTROL ZG 8W 10 POWER DISTRIBUTION 8W 10 ...

Page 648: ...LG RD C2 C3 F86 16LG RD RELAY WIPER INTERMITTENT K900 20PK WT B20 AUTOMATIC SHUT DOWN RELAY CONTROL C5 C4 V66 18VT WT V18 20YL LG WIPER PARK SWITCH SENSE INTERMITTENT WIPER RELAY CONTROL FUSED B FUSED B 8W 10 22 8W 10 POWER DISTRIBUTION ZG J978W 3 ZG001021 DIESEL GAS B16 FUSED B B16 B17 B17 F5 16 RD YL FUSED B FUSED B F5 16RD YL F5 16RD YL A142 16DG OR FUSED B A142 18DG OR FUSED B ...

Page 649: ...P FUEL Z4 20BK C10 PARK NEUTRAL POSITION SWITCH SENSE C20 C19 K81 18DB FUEL PUMP RELAY CONTROL FUSED IGNITION SWITCH OUTPUT ST RUN ENGINE STARTER MOTOR RELAY ZG 8W 10 POWER DISTRIBUTION 8W 10 23 ZG001022 J978W 3 PARK NEUTRAL POSITION SWITCH SENSE C10 T41 20BK WT FUEL HEATER FEED GROUND D14 DIESEL RELAY HEATER FUEL D12 D13 D11 CAV D10 A64 14OR DB A12 12RD TN CIRCUIT Z4 20BK FUSED B FUNCTION F99 20O...

Page 650: ...RIPTION AND OPERATION This section covers the power distribution center and all circuits involved with it For additional infor mation on system operation refer to the appropriate wiring diagrams 8W 10 24 8W 10 POWER DISTRIBUTION ZG ...

Page 651: ...mponent Page Horn Relay 8W 12 23 Instrument Cluster 8W 12 5 8 17 Intermittent Wiper Relay 8W 12 4 Intermittent Wiper Switch 8W 12 4 Junction Block 8W 12 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 22 23 24 Key In Switch Halo Lamp 8W 12 12 22 Lamp 8W 12 20 Lamp Outage Module 8W 12 5 15 20 Left Back Up Lamp 8W 12 17 Left Courtesy Lamp 8W 12 12 22 Left Fog Lamp 8W 12 24 Left Front Park Lamp 8W 12 15 L...

Page 652: ... 4 10A 16 22 5 11A 17 6 12A 18 CB1 20A 1 2 2 1 20A CB2 CB3 20A 1 2 2 6 10 5 4 3 1 7 8 9 2 6 10 9 5 4 8 7 3 1 I P I P A B E I P 1 4 9 10 5 6 11 12 7 2 2 7 12 11 6 5 10 9 4 1 I P D 8 3 3 8 3 1 2 4 I P C 3 8 2 7 12 11 6 5 10 9 4 1 O H O H 1 4 9 10 5 6 11 12 7 2 8 3 8 3 G I P 1 4 9 10 5 6 11 12 7 2 AUTO HEADLAMP RELAY PARK LAMP RELAY POWER ANTENNA RELAY EXPORT ONLY COUTESY LAMP RELAY ELECTRONIC FLASHE...

Page 653: ...DIO X12 18 RD GY A31 18 RD BK 87 30 86 15A FUSE 14 C4 3 BLOCK JUNCTION C4 4 BATT F61 1 LIGHTER CIGAR F30 18 RD DB C10 9 NOT USED CIGAR LIGHTER RELAY BLOCK JUNCTION 8W 47 2 8W 41 3 8W 10 9 8W 10 9 8W 41 3 ZG 8W 12 JUNCTION BLOCK 8W 12 3 ZG001202 J978W 3 ...

Page 654: ...B SWITCH MULTI FUNCTION PART OF SWITCH WIPER INTERMITTENT S207 C5 G10 C235 G20 MODULE CONTROL BODY C2 23 V18 20 YL LG V18 20 YL LG C4 7 4 INTERMITTENT WIPER SWITCH PART OF MULTI FUNCTION SWITCH F86 16 LG BK F86 16 LG BK 5 C231 F86 16 LG BK TO S320 A 8W 12 5 LG RD F86 16 DIESEL GAS F86 LG RD 18 DIESEL LG RD LG RD 16 F86 GAS 18 F86 LG RD DIESEL GAS LG RD 16 F86 18 F86 8W 53 3 8W 10 9 8W 53 2 8W 45 7...

Page 655: ...G CONTROL MODULE 10A FUSE 5 7 C13 C9 3 C13 7 10 LAMP OUTAGE MODULE FUSED IGN ST RUN G5 18 DB WT F87 18 WT PK F87 20 BK WT F87 20 BK WT F87 20 BK WT S215 5 INSTRUMENT CLUSTER 2 INTERLOCK SHIFT NOT USED S320 A 8W 12 4 FUSED IGN ST RUN C1 DIESEL GAS CLUSTER INSTRUMENT 5 BK WT 20 F87 8W 40 5 8W 12 2 8W 10 8 8W 31 5 8W 40 5 8W 51 2 8W 43 2 8W 10 3 8W 10 13 8W 10 14 8W 64 2 8W 64 2 ZG 8W 12 JUNCTION BLO...

Page 656: ...3 16 GRAPHIC DISPLAY MODULE VEHICLE INFORMATION CENTER MINI OVERHEAD CONSOLE CONSOLE OVERHEAD FLASHER ELECTRONIC FUSED IGN RUN 2 3 C15 OVERHEAD CONSOLE OTHERS F83 20 YL DG F83 20 BK VT B 8W 12 7 TO S323 C 8W 12 7 AUTOMATIC DAY NIGHT MIRROR TO SWITCH LAMP DIESEL 1 YL DG F83 18 BACK UP C131 13 YL DG F83 18 18 F83 YL DG G12 C235 5 18 YL DG F83 HEADLAMP SWITCH LEVELING 8W 50 11 8W 51 5 8W 12 2 8W 10 8...

Page 657: ...ER CIRCUIT 3 C10 L16 18 RD LG 6 STOP LAMP SWITCH 9 C14 F81 10 TN F81 12 TN 3 C334 3 C351 F81 12 TN F81 12 TN 12 DRIVER DOOR MODULE MODULE DOOR PASSENGER 12 C 8W 12 6 JUNCTION BLOCK FROM B 8W 12 6 FROM BLOCK JUNCTION C1 FUSED B C1 8W 12 2 8W 44 6 8W 44 7 8W 10 10 8W 60 3 8W 61 3 8W 60 2 8W 61 2 8W 33 2 8W 49 2 ZG 8W 12 JUNCTION BLOCK 8W 12 7 ZG001206 J978W 3 ...

Page 658: ...CIRCUIT TOW TRAILER S315 7 FUSE 20A 8 C13 2 F75 16 VT F75 16 VT 17 C1 C1 POWER AMPLIFIER PREMIUM S318 F75 14 VT C4 8 F75 18 VT 3 INSTRUMENT CLUSTER F75 18 VT 16 LINK DATA CONNECTOR F75 18 VT 1 LED VTSS SENSOR LIGHT HEADLAMP AUTOMATIC F75 18 VT S201 8 C4 F75 18 VT C2 8 MODULE CONTROL BODY F70 16 PK BK 6 C372 7 8W 12 2 8W 10 10 8W 45 4 8W 50 5 8W 30 2 8W 30 30 8W 40 5 8W 47 10 8W 54 2 8W 54 5 8W 54 ...

Page 659: ...5 12 BK LB S332 REAR WINDOW DEFOGGER DEFOGGER WINDOW REAR C16 20 LB YL 10 SWITCH DEFOGGER WINDOW REAR 2 C13 C13 3 10A FUSE 11 RUN A22 C13 6 F12 20 DB WT 23 CONTROLLER ANTI LOCK BRAKE NOT USED MODULE CONTROL BODY USED NOT 3 12 C15 BK LB WINDOW REAR DEFOGGER C322 2 DIESEL GAS 8W 48 2 8W 12 2 8W 45 3 8W 10 4 8W 10 8 8W 35 2 8W 48 2 8W 48 2 8W 48 2 ZG 8W 12 JUNCTION BLOCK 8W 12 9 ZG001208 J978W 3 ...

Page 660: ... PK DG S317 F71 18 PK DG F71 18 PK DG F87 18 PK DG F87 18 WT BK 1 1 MODULE CONTROL HEATER SEAT PASSENGER DRIVER SEAT HEATER CONTROL MODULE S218 4 C9 F71 20 DG PK 6 A C HEATER CONTROL C12 MODULE CONTROL TEMPERATURE AUTOMATIC F71 20 DG PK F71 20 DG PK MANUAL A C HEATER ATC ATC HEATER A C MANUAL 8W 12 2 8W 42 7 8W 10 8 8W 42 9 8W 42 5 8W 63 14 8W 63 13 8W 44 11 8W 42 9 8W 12 10 8W 12 JUNCTION BLOCK Z...

Page 661: ...04 S202 S216 S220 POWER ANTENNA EXPORT X14 20 WT X16 20 GY X17 20 DG 3 4 TURN SIGNAL 5 C7 C5 1 L5 18 OR BK L12 18 VT TN 17 13 SWITCH HAZARD SIGNAL TURN RADIO 12V OUTPUT RADIO 12V OUTPUT WARNING SIGNAL HAZARD OUTPUT C1 DG RD 14 18 X60 12V RADIO POWER AMPLIFIER LTD PREMIUM INFORMATION VEHICLE CENTER L5 18 OR BK 4 8W 46 6 8W 47 3 8W 47 3 8W 47 4 8W 47 3 8W 10 12 8W 52 2 8W 15 17 8W 15 17 8W 15 18 8W ...

Page 662: ... 4 RIGHT COURTESY LAMP LAMP COURTESY LEFT LAMP HALO SWITCH KEY IN LAMP CARGO M1 18 PK M1 18 PK 6 C8 3 C8 5 C13 11 C8 M1 20 PK M1 20 PK M1 20 PK M1 20 PK C15 9 M1 20 PK TO S321 BATT A7 D 8W 12 13 8W 12 2 8W 10 12 8W 44 5 8W 44 2 8W 44 2 8W 44 2 8W 44 2 8W 44 2 8W 44 8 8W 12 12 8W 12 JUNCTION BLOCK ZG J978W 3 ZG001211 ...

Page 663: ...SOR RIGHT LEFT VISOR VANITY LAMP A M1 20 PK M1 20 PK DOME READING LAMP C 6 OVERHEAD CONSOLE M1 20 PK S321 M1 20 PK D 8W 12 12 JUNCTION BLOCK FROM 8W 49 3 8W 44 3 8W 44 5 8W 44 5 ZG 8W 12 JUNCTION BLOCK 8W 12 13 ZG001212 J978W 3 ...

Page 664: ... 16 SWITCH HEADLAMP 9 C5 9 A6 14 RD LB 366 16 PK OR L90 20 DB RD 11 C10 C2 21 17 C1 PARK LAMP RELAY CONTROL PARK LAMP RELAY OUTPUT L90 20 DB RD L79 20 TN E 8W 12 15 MODULE CONTROL BODY TO JUNCTION BLOCK 8W 12 2 8W 45 4 8W 10 11 8W 50 7 8W 12 14 8W 12 JUNCTION BLOCK ZG J978W 3 ZG001213 ...

Page 665: ...D L90 18 DB RD S103 L90 18 DB RD A LAMP PARK FRONT S410 FRONT PARK LAMP A DB RD 18 L90 S415 11 VEHICLE INFORMATION CENTER C8 5 L90 20 DB RD L90 20 DB RD 4 RADIO 4 C8 C15 1 9 C8 E 8W 12 14 NOT USED PARK LAMP RELAY OUTPUT OUTPUT RELAY LAMP PARK NOT USED RELAY LAMP PARK C1 LEFT RIGHT C1 C1 C1 8W 12 2 8W 50 9 8W 50 10 8W 47 2 8W 46 6 8W 51 2 ZG 8W 12 JUNCTION BLOCK 8W 12 15 ZG001214 J978W 3 ...

Page 666: ... AUTOMATIC F60 20 RD WT C9 10 7 RADIO 5 C9 2 2 F60 20 WT RD F60 20 WT RD GRAPHIC DISPLAY MODULE VEHICLE INFORMATION CENTER PREMIUM OVERHEAD CONSOLE OTHERS 3 C13 15A FUSE 21 C9 2 F38 18 OR 1 OUTLET POWER NOT USED F60 20 WT RD C1 8W 12 2 8W 10 12 8W 41 3 8W 46 4 8W 46 2 8W 47 2 8W 42 2 8W 50 2 8W 12 16 8W 12 JUNCTION BLOCK ZG J978W 3 ZG001215 ...

Page 667: ...FACTORY 3 C328 A LEFT BACK UP LAMP L10 18 BR LG L10 18 BR LG A C320 3 LAMP BACK UP RIGHT L10 18 BR LG L10 18 BR LG S311 11 C3 L64 18 TN DB L64 18 TN DB L64 18 TN DB S412 2 1 FRONT TURN SIGNAL SWITCH RIGHT RIGHT REPEATER SIDE 8W 52 8 8W 12 2 8W 44 6 8W 52 2 8W 52 8 8W 51 6 8W 51 6 8W 54 4 8W 44 6 8W 40 4 ZG 8W 12 JUNCTION BLOCK 8W 12 17 ZG001216 J978W 3 B L64 TN DB 18 8W 52 3 RIGHT SIGNAL FRONT LAM...

Page 668: ...ER LUMBAR SWITCH S405 12 C13 F35 16 RD 1 C329 F35 14 RD F35 14 RD 10 MODULE SEAT MEMORY 19 F35 16 RD F35 16 RD 2 DRIVER SEAT HEATER CONTROL MODULE 5 SWITCH SEAT POWER DRIVER F35 16 RD F35 16 RD 3 F35 18 RD DRIVER LUMBAR SWITCH S403 FUSED B FUSED B C2 C2 8W 12 2 8W 10 12 8W 63 3 8W 63 8 8W 63 14 8W 63 2 8W 63 4 8W 63 13 8W 63 9 8W 12 18 8W 12 JUNCTION BLOCK ZG J978W 3 ZG001217 ...

Page 669: ... G28 20 LG OR G28 20 LG OR G42 20 LB RD G42 20 LB RD C3 3 C5 6 2 C5 JUNCTION BLOCK G28 20 LG OR 11 C132 G28 20 LG OR 3 SWITCH DRIVE WHEEL FOUR VEHICLE INFORMATION CENTER MODULE DISPLAY GRAPHIC CONSOLE PREMIUM OVERHEAD OTHERS 8W 46 3 8W 46 5 8W 12 2 8W 46 3 8W 46 5 8W 46 3 8W 46 5 ZG 8W 12 JUNCTION BLOCK 8W 12 19 ZG001218 J978W 3 ...

Page 670: ...JUNCTION A16 A15 85 15 SWITCH HEADLAMP 7 C7 C7 10 3 C7 L95 18 DG YL A RELAY LAMP FOG REAR C7 6 1 LAMP OUTAGE MODULE L96 20 LG RD L36 18 LG L36 18 LG OR C307 8W 10 9 8W 12 2 8W 51 7 8W 51 7 8W 12 20 8W 12 JUNCTION BLOCK ZG J978W 3 ZG001219 ...

Page 671: ...IGHT DAY AUTOMATIC CONSOLE OVERHEAD Z1 20 BK 2 Z1 20 BK S322 Z1 16 BK F 8W 12 22 JUNCTION BLOCK TO OVERHEAD CONSOLE 4 M2 20 YL M2 20 YL B DOME READING LAMP M2 20 YL M2 20 YL M2 20 YL S334 OTHERS SUNROOF G 8W 12 22 JUNCTION BLOCK TO H 8W 12 22 TO BLOCK JUNCTION BASE PREMIUM 8W 44 6 8W 44 3 8W 64 2 8W 44 3 8W 49 3 8W 49 3 8W 44 5 8W 44 5 8W 46 2 ZG 8W 12 JUNCTION BLOCK 8W 12 21 ZG001220 J978W 3 ...

Page 672: ...2 21 H 8W 12 21 FROM LAMP READING DOME M2 20 YL M2 20 YL C15 11 F 8W 12 21 C15 2 Z1 16 BK FROM S322 30 87 COURTESY LAMP RELAY Z1 18 BK S220 Z1 16 BK S216 Z1 16 BK S202 Z1 14 BK 2 C301 Z1 14 BK G304 OTHERS SUNROOF OVERHEAD CONSOLE FROM 8W 12 2 8W 15 8 8W 15 18 8W 15 17 8W 15 17 8W 44 8 8W 44 5 8W 44 2 8W 44 2 8W 44 2 8W 12 22 8W 12 JUNCTION BLOCK ZG J978W 3 ZG001221 ...

Page 673: ...Y OR 5 SWITCH HORN CONTROL SPEED VEHICLE C2 13 MODULE CONTROL BODY X4 20 GY OR 10A FUSE 22 RUN A22 C13 1 AIRBAG CONTROL MODULE 20 FUSED IGN RUN F20 18 WT RELAY HORN 8W 12 2 8W 43 2 8W 10 8 8W 45 3 8W 41 2 8W 41 2 ZG 8W 12 JUNCTION BLOCK 8W 12 23 ZG001222 J978W 3 ...

Page 674: ...4 16TN BK 714 20 BK OR C2 12 MODULE CONTROL BODY JUNCTION BLOCK C10 1 C2 22 MODULE CONTROL BODY L95 20 DG YL L39 18 LB L39 18 LB 2 LEFT FOG LAMP LAMP FOG RIGHT 2 S105 L39 18 LB 4 C1 C7 8 L39 20 LB 4 SWITCH HEADLAMP 8W 45 5 8W 12 2 8W 10 11 8W 10 13 8W 10 14 8W 50 7 8W 50 6 8W 50 6 8W 45 5 8W 50 2 8W 50 2 8W 12 24 8W 12 JUNCTION BLOCK ZG J978W 3 ZG001223 ...

Page 675: ...20A A250 10RD C15 12BK WT 10A C16 20LB YL A22 12BK OR 10A F12 20DB WT F12 20DB WT F71 20PK DG 10A A22 12BK OR 15A F71 20PK DG A7 12YL RD INTERNAL F61 12WT OR INTERNAL MI 18PK 10A A7 12YL RD FEED CIRCUIT 1 2 9 10 11 12 13 14 15 16 17 20 19 18 21 22 15A NOT USED 15A 15A NOT USED 15A 15A 10A A7 12YL RD A7 12YL RD A6 14RD LB A22 12BK OR A7 12YL RD F60 20RD WT L11 16LG BK 366 16PK OR M1 20PK 7 WIRES F2...

Page 676: ...Z1 20BK GROUND FUSED IGNITION SWITCH OUPUT RUN A31 RD BK 86 87 FUSED IGNITION SWITCH OUTPUT ACC RUN F30 18RD DB RELAY LIGHTER CIGAR B 87A 20A A7 12YL RD A250 10RD 87A NO FUSED CIRCUIT F86 16LG BK F86 16LG BK 2 3 F86 16LG RD F81 10TN F81 12TN 35 16RD F35 16RD RELAYS CIRCUIT BREAKERS FUSED B GROUND A REAR FOG LAMP RELAY 8W 12 26 8W 12 JUNCTION BLOCK ZG J978W 3 ZG001225 A31 12RD BK 20A 1 F86 18LG BK ...

Page 677: ...IO 12 VOLT OUTPUT POWER ANTENNA DOWN CONTROL 5 4 3 2 1 CAVITY X16 GY X14 WT 6 POWER ANTENNA UP CONTROL X60 DG RD INTERNAL Z1 BK X17 GN POWER ANTENNA RELAY H EXPORT ONLY G RELAY DEFOGGER WINDOW REAR INTERNAL INTERNAL L12 18VT TN L5 18OR BK Z1 18BK CAVITY 1 2 3 4 5 TURN SIGNAL HAZARD SIGNAL GROUND CIRCUIT FUNCTION FUSED B FUSED IGNITION SWITCH OUTPUT RUN ELECTRONIC FLASHER I ZG 8W 12 JUNCTION BLOCK ...

Page 678: ...AMP RELAY CONTROL FUSED B F62 RD 30 FUNCTION CIRCUIT CAVITY CAVITY CIRCUIT FUNCTION 30 366 PK OR PARK LAMP FEED PARK LAMP RELAY CONTROL L79 TN 85 86 366 PK OR PARK LAMP FEED 87 L90 DB RD PARK LAMP RELAY OUTPUT 87A PARK LAMP RELAY E F RELAY HEADLAMP AUTO 87A AUTO HEADLAMP RELAY OUTPUT F34 TN BK 87 FUSED B A6 RD LB 86 85 714 BK OR AUTO HEADLAMP RELAY CONTROL FUSED B A6 RD LB 30 FUNCTION CIRCUIT CAVI...

Page 679: ...N AND OPERATION This section covers the junction block and all cir cuits involved with it For additional information on system operation please refer to the appropriate sec tion of the wiring diagrams ZG 8W 12 JUNCTION BLOCK 8W 12 29 ...

Page 680: ......

Page 681: ...onent Page Left Courtesy Lamp 8W 15 12 Left Fog Lamp 8W 15 4 5 Left Front Park Lamp 8W 15 4 5 Left Front Turn Signal Lamp 8W 15 4 5 Left Headlamp 8W 15 4 5 Left License Lamp 8W 15 10 Left Rear Fog Lamp 8W 15 9 Left Rear Power Window Switch 8W 15 15 Left Rear Turn Signal Lamp 8W 15 9 Left Side Repeater 8W 15 4 Left Tail Stop Lamp 8W 15 9 Left Visor Vanity Lamp 8W 15 16 Liftgate Ajar Switch 8W 15 10...

Page 682: ...TOR 5 G103 H11 H12 C236 Z1 18 BK 1 2 C132 Z1 18 BK Z1 18 BK Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR C1 A31 A32 C1 MODULE CONTROL POWERTRAIN G104 Z12 14 BK TN Z12 14 BK TN 1 8W 20 2 8W 20 3 8W 30 2 8W 30 18 8W 30 19 8W 30 3 8W 15 2 8W 15 GROUND DISTRIBUTION GAS ENGINES ZG J978W 3 ZG001501 ...

Page 683: ...1 18 BK Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR C4 12 11 C4 MODULE CONTROL POWERTRAIN GROUND GROUND G104 Z12 16 BK TN Z12 16 BK TN 46 24 1 CONTROLLER MSA Z12 14 BK TN Z12 16 BK TN Z12 16 BK TN Z12 10 BK TN S130 8W 30 30 8W 30 31 8W 30 32 8W 30 22 8W 30 22 ZG 8W 15 GROUND DISTRIBUTION DIESEL ENGINE 8W 15 3 ZG001515 J978W 3 ...

Page 684: ...SHIELD WIPER MOTOR 4 2 MOTOR PUMP WASHER REAR SENSOR LEVEL FLUID WIPER B 16 BK 18 BK 18 BK 18 BK Z2 20 BK S121 12 BK Z2 Z2 Z2 Z2 Z2 LEFT LEFT STOP LAMP C235 G8 DB LG 20 V30 Z1 18 BK 2 UNDERHOOD LAMP C159 2 BK Z1 18 Z1 18 BK 1 LEFT REPEATER SIDE SWITCH G2 8W 52 8 8W 44 2 8W 33 2 8W 33 4 8W 50 9 8W 46 6 8W 53 5 8W 53 5 8W 53 3 8W 53 2 8W 50 3 8W 50 6 8W 52 3 8W 15 4 8W 15 GROUND DISTRIBUTION DIESEL ...

Page 685: ...Z1 16 BK G109 10 MODULE STEERING PROPORTIONAL SPEED B MOTOR PUMP WASHER WINDSHIELD WINDSHIELD WIPER MOTOR 4 2 MOTOR PUMP WASHER REAR SENSOR LEVEL FLUID WIPER B 16 BK 18 BK 18 BK 18 BK Z2 20 BK S121 12 BK Z2 Z2 Z2 Z2 Z2 LEFT LEFT 8W 50 9 8W 46 6 8W 53 5 8W 53 5 8W 53 3 8W 53 2 8W 65 2 8W 50 3 8W 50 6 8W 52 3 ZG 8W 15 GROUND DISTRIBUTION GAS ENGINES 8W 15 5 ZG001516 J978W 3 ...

Page 686: ...Z1 16 BK Z1 16 BK Z1 18 BK Z1 10 BK Z1 18 BK 3 C150 Z1 18 BK B LAMP PARK FRONT RIGHT TURN SIGNAL LAMP G S152 Z1 18 BK Z1 18 BK G106 Z1 16 BK A 8W 15 4 FROM S109 S104 FRONT RIGHT BK Z1 20 BK Z1 14 Z1 18 BK 4 SOLENOID EGR 8W 30 28 8W 39 6 8W 41 2 8W 50 10 8W 52 3 8W 39 6 8W 41 2 8W 50 6 8W 52 8 8W 50 3 8W 30 28 8W 30 26 8W 46 3 8W 46 5 8W 15 6 8W 15 GROUND DISTRIBUTION DIESEL ENGINE ZG J978W 3 ZG001...

Page 687: ...1 18 BK 1 RIGHT FOG LAMP 2 NO 1 HORN HORN NO 2 2 Z1 16 BK Z1 16 BK Z1 18 BK Z1 14 BK Z1 18 BK 3 C150 Z1 18 BK B LAMP PARK FRONT RIGHT TURN SIGNAL LAMP G S152 Z1 18 BK Z1 18 BK G106 Z1 16 BK K 8W 15 5 FROM S109 S104 FRONT RIGHT Z1 18 BK SIDE REPEATER RIGHT 1 8W 52 8 8W 39 6 8W 41 2 8W 50 10 8W 52 3 8W 39 6 8W 41 2 8W 50 6 8W 42 12 8W 46 6 8W 50 3 8W 46 3 8W 46 5 8W 30 13 8W 30 14 8W 30 13 8W 30 14 ...

Page 688: ...2 C159 Z1 18 BK 2 LAMP UNDERHOOD 4 SERVO CONTROL SPEED VEHICLE Z4 20 BK Z4 18 BK Z4 10 BK G107 8 24 Z2 12 BK Z2 12 BK S125 G108 S124 Z2 12 BK BRAKE ANTI LOCK CONTROLLER C1 GAS GAS BK Z4 20 D11 DIESEL FUEL HEATER RELAY IN PDC BK 10 Z4 DIESEL IN PDC RELAY MOTOR C10 STARTER ENGINE 8W 21 3 8W 21 4 8W 30 27 8W 35 2 8W 33 2 8W 44 2 8W 42 5 8W 42 3 8W 42 3 8W 42 2 8W 15 8 8W 15 GROUND DISTRIBUTION ZG J97...

Page 689: ...STOP TAIL LEFT B Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK 4 C328 Z1 18 BK D 8W 15 12 TO S314 C372 8 Z1 12 BK Z1 12 BK E 8W 15 12 TO S314 S411 S330 RELAY LAMP STOP TOW TRAILER TRAILER TOW LEFT TURN RELAY TRAILER TOW RIGHT TURN RELAY LAMP SIGNAL TURN LEFT REAR FOG LAMP REAR FACTORY TRAILER TOW CONNECTOR LEFT 8W 51 7 8W 52 5 8W 52 7 8W 54 3 8W 54 3 8W 54 3 8W 51 4 8W 51 6 8W 54 3 8W 51 5 8W 51 5 ...

Page 690: ...Z1 12 BK REAR WINDOW DEFOGGER 2 SWITCH LOCK CYLINDER LIFTGATE 1 LIFTGLASS AJAR SWITCH Z1 20 BK Z1 20 BK 1 SWITCH AJAR LIFTGATE Z1 20 BK 2 LIFTGLASS RELEASE SOLENOID Z1 14 BK S328 J 8W 15 11 TO C325 8W 51 6 8W 51 6 8W 53 4 8W 48 2 8W 39 5 8W 44 14 8W 44 14 8W 61 5 8W 15 10 8W 15 GROUND DISTRIBUTION ZG J978W 3 ZG001506 ...

Page 691: ... BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK 4 C320 Z1 18 BK G300 Z1 12 BK Z1 18 BK 2 C326 Z1 18 BK FROM C359 S316 2 C325 Z1 12 BK Z1 12 BK Z1 12 BK TO S314 B 8W 15 9 C 8W 15 12 J 8W 15 10 TO S328 TURN RIGHT 8W 52 5 8W 52 7 8W 51 7 8W 51 6 8W 51 4 ZG 8W 15 GROUND DISTRIBUTION 8W 15 11 ZG001507 J978W 3 ...

Page 692: ...2 BK 2 LAMP COURTESY LEFT 7 DRIVER DOOR MODULE Z1 20 BK Z1 12 BK Z1 12 BK 1 C334 Z1 12 BK FULL OPTION POWER GROUP G302 Z1 12 BK FROM S316 C328 FROM FROM C372 Z1 12 BK Z1 12 BK Z1 18 BK S314 S324 C 8W 15 11 D 8W 15 9 E 8W 15 9 C1 C1 C2 8W 44 2 8W 60 2 8W 61 2 8W 62 2 8W 60 2 8W 61 2 8W 62 2 8W 46 6 8W 51 5 8W 15 12 8W 15 GROUND DISTRIBUTION ZG J978W 3 ZG001508 ...

Page 693: ...ER PASSENGER A PASSENGER HEATED SEAT BACK 7 MODULE CONTROL HEATER SEAT PASSENGER Z1 18 BK Z1 16 BK Z1 18 BK 2 4 PASSENGER LUMBAR SWITCH D CUSHION SEAT HEATED PASSENGER Z1 18 BK Z1 18 BK Z1 20 BK S406 Z1 14 BK F 8W 15 14 TO C335 PREMIUM RADIO OTHER C2 C2 8W 63 12 8W 63 4 8W 63 13 8W 63 12 8W 63 9 8W 43 2 8W 47 10 8W 47 2 ZG 8W 15 GROUND DISTRIBUTION 8W 15 13 ZG001509 J978W 3 ...

Page 694: ...PTION POWER GROUP S325 1 C351 Z1 12 BK 6 WINDOW POWER REAR RIGHT FROM S406 2 C335 Z1 14 BK Z1 16 BK D C345 Z1 16 BK Z1 16 BK S333 Z1 12 BK G301 Z1 10 BK TO S304 F 8W 15 13 G 8W 15 15 SWITCH C1 C1 8W 60 4 8W 44 2 8W 60 3 8W 61 3 8W 62 3 8W 60 3 8W 61 3 8W 62 3 8W 15 14 8W 15 GROUND DISTRIBUTION ZG J978W 3 ZG001510 ...

Page 695: ...LE Z1 16 BK Z1 16 BK 1 SWITCH SEAT POWER DRIVER Z1 16 BK 7 Z1 16 BK MODULE CONTROL HEATER SEAT DRIVER BK 20 Z1 D BK 16 Z1 DRIVER HEATED SEAT BACK A BK 18 Z1 BK 18 Z1 SWITCH LUMBAR DRIVER 4 2 CUSHION SEAT HEATED DRIVER 2 C329 Z1 16 BK Z1 14 BK S402 G 8W 15 14 C2 C2 8W 60 4 8W 30 16 8W 45 4 8W 44 11 8W 63 2 8W 63 8 8W 63 14 8W 63 11 8W 63 2 8W 63 11 ZG 8W 15 GROUND DISTRIBUTION 8W 15 15 ZG001511 J97...

Page 696: ...P B Z1 20 BK Z1 20 BK A Z1 20 BK DOME READING LAMP 2 MIRROR NIGHT DAY AUTOMATIC Z1 20 BK S322 C5 4 C15 2 Z1 16 BK Z1 18 BK H 8W 15 17 TO S220 JUNCTION BLOCK 5 87 COURTESY LAMP RELAY ELECTRONIC FLASHER 8W 52 2 8W 44 8 8W 12 2 8W 44 7 8W 64 2 8W 44 3 8W 44 5 8W 44 5 8W 49 2 8W 15 16 8W 15 GROUND DISTRIBUTION ZG J978W 3 ZG001512 ...

Page 697: ...0 GRAPHIC DISPLAY MODULE 20 VEHICLE INFORMATION CENTER Z1 20 BK Z1 20 BK OTHERS 2 POD SWITCH 1 LAMP HALO SWITCH KEY IN 1 INSTRUMENT CLUSTER S220 Z1 16 BK Z1 20 BK Z1 20 BK Z1 20 BK Z1 16 BK I 8W 15 18 TO S202 S216 ACTUATOR DOOR BLEND CONSOLE OVERHEAD PREMIUM 85 CIGAR LIGHTER RELAY C2 8W 41 3 8W 44 11 8W 42 7 8W 40 2 8W 44 2 8W 46 4 8W 46 2 8W 12 2 8W 44 12 8W 42 5 8W 44 2 8W 41 3 8W 41 3 ZG 8W 15 ...

Page 698: ...R Z2 18 BK OR S205 Z2 18 BK OR 8 C307 Z2 18 BK OR S302 2 5 SWITCH HEADLAMP Z1 16 BK Z1 16 BK C2 24 MODULE CONTROL BODY Z1 16 BK 2 STOP LAMP SWITCH Z1 20 BK I 8W 15 17 FROM S216 Z1 16 BK Z1 14 BK 2 C301 Z1 14 BK Z2 18 BK OR G304 S202 GRAPHIC SPEED CONTROL LEVELING SWITCH 1 HEADLAMP BK 20 Z1 8W 50 11 8W 33 2 8W 45 2 8W 50 5 8W 45 2 8W 33 3 8W 40 2 8W 46 2 8W 46 4 8W 15 18 8W 15 GROUND DISTRIBUTION Z...

Page 699: ...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 ZG 8W 15 GROUND DISTRIBUTION 8W 15 19 ...

Page 700: ......

Page 701: ...y 8W 20 5 Fuse 1 8W 20 2 3 Fuse 8 8W 20 5 Fuse 18 8W 20 5 Fuse 20 8W 20 4 5 G100 8W 20 2 3 G101 8W 20 2 3 Generator 8W 20 2 3 Ignition Coil 8W 20 5 Component Page MSA Controller 8W 20 4 Power Distribution Center 8W 20 2 3 4 5 Powertrain Control Module 8W 20 2 3 4 5 S100 8W 20 5 S101 8W 20 5 S126 8W 20 3 S128 8W 20 5 S129 8W 20 2 4 5 S137 8W 20 3 Transmission Control Relay 8W 20 3 ZG 8W 20 CHARGING...

Page 702: ... BK A11 6 RD BK GENERATOR FIELD DRIVER MODULE CONTROL POWERTRAIN 20 C4 3 1 K20 18 DG YL GENERATOR 16 B17 DG OR 12 C131 A142 DG OR 16 A142 DG OR 16 A142 RELAY SHUT IN PDC AUTOMATIC S129 DOWN 8W 70 7 8W 30 5 8W 10 4 8W 10 3 8W 21 3 8W 20 2 8W 20 CHARGING SYSTEM DIESEL ENGINE ZG J978W 3 ZG002001 1 8W 30 23 ...

Page 703: ...IVER DG 18 K20 DG VT 18 K72 C3 C25 MODULE CONTROL POWERTRAIN B10 C2 B30 C2 TRANSMISSION RELAY CONTROL G101 Z0 8 BK Z0 6 BK S126 1 3 2 K20 18 DG 2 C144 K20 18 DG C132 6 K72 18 DG VT T66 20 BR OR 7 C132 T66 18 BR OR GENERATOR SOURCE GENERATOR FIELD 1 TRANSMISSION 8W 15 2 8W 15 2 8W 15 2 8W 15 2 8W 31 2 8W 30 3 8W 10 4 8W 10 3 8W 21 4 ZG 8W 20 CHARGING SYSTEM GAS ENGINES 8W 20 3 ZG002003 J978W 3 ...

Page 704: ...Y IN PDC AUTOMATIC SHUT DOWN RELAY CONTROL PK BK 20 K900 A142 16 DG OR 12 C131 DG OR 16 A142 S129 A142 16 DG OR 57 F5 RD YL 16 C4 AUTOMATIC CONTROL RELAY DOWN SHUT MODULE CONTROL POWERTRAIN C132 14 20 PK BK K900 8W 30 27 8W 10 3 8W 70 7 8W 30 27 8W 10 16 8W 10 3 8W 20 4 8W 20 CHARGING SYSTEM DIESEL ENGINE ZG J978W 3 ZG002002 ...

Page 705: ...7 B20 B18 B16 AUTOMATIC SHUT DOWN RELAY IN PDC AUTOMATIC SHUT DOWN RELAY CONTROL A142 18 DG OR PK WT 18 K900 A142 18 DG OR 4 C131 5 2L 4 0L DG OR 18 A142 S129 A142 18 DG OR DG OR 18 A142 S128 A142 18 DG OR IGNITION COIL 2 OUTPUT AUTOMATIC RELAY DOWN SHUT ST RUN A21 8W 10 8 8W 10 3 8W 30 5 8W 70 7 8W 70 7 8W 30 5 8W 21 4 8W 10 7 8W 10 14 8W 10 15 8W 10 16 8W 10 16 8W 10 3 ZG 8W 20 CHARGING SYSTEM G...

Page 706: ...eld 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 generator supplies B voltage to the battery through the A11 and A0 circuits HELPFUL INFORMATION Circuit A21 passes through the junction block before reaching fuse 18 in the PDC The ASD relay supplies battery voltage for the fuel inje...

Page 707: ...Switch 8W 21 3 Engine Starter Motor 8W 21 3 4 Engine Starter Motor Relay 8W 21 3 4 Fuse 8 8W 21 2 4 G107 8W 21 3 Ignition Switch 8W 21 2 4 Component Page Park Neutral Position Switch 8W 21 4 Power Distribution Center 8W 21 2 3 4 Powertrain Control Module 8W 21 4 S124 8W 21 3 S134 8W 21 4 S210 8W 21 2 4 ZG 8W 21 STARTING SYSTEM 8W 21 1 ...

Page 708: ... 12 RD WT B 8W 21 3 ENGINE STARTER MOTOR RELAY TO A1 12 RD WT A1 12 RD WT S210 E1 C233 3 0 2 1 1 7 3 ACC 0 OFF 2 RUN 1 START SWITCH IGNITION A41B 14 YL A 8W 21 3 TO SWITCH INTERLOCK CLUTCH A1 12 RD WT 8W 10 7 8W 10 3 8W 10 7 8W 10 7 8W 21 2 8W 21 STARTING SYSTEM DIESEL ENGINE ZG J978W 3 ZG002102 ...

Page 709: ...ARTER MOTOR RELAY IN PDC Z4 20 BK Z4 10 BK G107 S124 B 8W 21 2 A1 12 RD WT ENGINE STARTER MOTOR 1 ROLL IN 2 HOLD IN A 8W 21 2 IGNITION SWITCH FROM A41B 14 YL 2 1 T141 14 YL RD E4 C233 T141 14 YL RD CLUTCH INTERLOCK SWITCH FROM CENTER DISTRIBUTION POWER 8W 15 8 8W 15 8 ZG 8W 21 STARTING SYSTEM DIESEL ENGINE 8W 21 3 ZG002101 J978W 3 ...

Page 710: ...BATTERY 1 PULL IN 2 HOLD IN A1 12 RD WT C233 E1 RD WT 12 A1 7 T141 14 YL RD 1 2 SWITCH POSITION NEUTRAL PARK T41 20 BK WT C132 4 BK WT 20 T41 POWERTRAIN CONTROL MODULE BK WT 18 T41 A6 PARK NEUTRAL POSITION SWITCH SENSE S134 3 0 2 1 3 ACC 0 OFF 2 RUN 1 START SWITCH IGNITION S210 A41 14 YL M C1 8W 10 7 8W 10 3 8W 44 6 8W 30 10 8W 10 7 8W 10 7 8W 21 4 8W 21 STARTING SYSTEM GAS ENGINES ZG J978W 3 ZG00...

Page 711: ...h When the starter motor relay energizes and the contacts close circuit T40 supplies battery voltage to the starter motor solenoid Circuit A0 from the bat tery supplies voltage to the starter motor when the solenoid energizes STARTING SYSTEM DIESEL Power for the coil side of the engine starter motor relay is supplied on circuit T141 This circuit is HOT when the operator has moved the ignition key ...

Page 712: ......

Page 713: ...0 Diesel Engine 8W 30 27 Fuse 20 Gas Engines 8W 30 4 5 G103 Diesel Engine 8W 30 30 G103 Gas Engines 8W 30 2 G104 Diesel Engine 8W 30 22 Component Page G104 Gas Engines 8W 30 3 G105 4 0L Engine 8W 30 14 G105 5 2L Engine 8W 30 13 G106 Diesel Engine 8W 30 26 28 G107 Diesel Engine 8W 30 27 G123 Diesel Engine 8W 30 24 G304 Gas Engines 8W 30 10 G305 Diesel Engine 8W 30 28 G305 Gas Engines 8W 30 16 Gener...

Page 714: ... CONTROL POWERTRAIN CONTROLLER ANTI LOCK BRAKE MODULE STEERING PROPORTIONAL SPEED S200 C1 20 SCI TRANSMIT SCI RECEIVE RECEIVE SCI RECEIVE SCI TRANSMIT SCI 4 C235 F14 C234 6 D84 20 BK WT D84 18 BK WT F15 C234 Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR Z1 18 BK Z1 18 BK Z1 18 BK 2 1 C132 C236 G103 H11 H12 8W 65 2 8W 35 2 8W 12 8 8W 12 2 8W 10 10 8W 12 8 8W 30 2 8W 30 FUEL IGNITION SYSTEM GAS ENGINES ZG J97...

Page 715: ...2 C2 TORQUE CONVERTER CLUTCH SOLENOID CONTROL CONTROL SOLENOID FORCE VARIABLE O D CONTROL RELAY TRANSMISSION C2 B30 T66 20 BR OR T66 18 BR OR 7 C132 CENTER DISTRIBUTION POWER CENTER DISTRIBUTION POWER MODULE CONTROL POWERTRAIN POWERTRAIN CONTROL MODULE SOLENOID CONTROL TORQUE CLUTCH CONVERTER SOLENOID FORCE SOLENOID VARIABLE SOLENOID CONTROL O D G104 BK TN 14 BK TN 14 Z12 GROUND A31 C1 Z12 GROUND ...

Page 716: ...NOID VAPOR CANISTER CANISTER SWITCH PUMP DRIVE VAPOR DUTY PURGE EVAP CYCLE 5 C13 C3 OVERDRIVE SWITCH 6 20 OR T9 SENSE SWITCH OFF OVERDRIVE 18 T9 OR F20 C234 BR YL 20 G68 OVERDRIVE OFF C235 G68 BR YL 18 9 DRIVER LAMP C6 C3 7 VEHICLE SPEED CONTROL SERVO 1 2 SPEED CONTROL VACUUM SOLENOID CONTROL SPEED CONTROL VENT SOLENOID CONTROL TN RD V36 18 SOLENOID CONTROL C4 C3 VACUUM SPEED CONTROL LG RD V35 18 ...

Page 717: ... RELAY ASD C12 C3 CENTER DISTRIBUTION POWER F5 18 RD YL S100 A142 18 DG OR A142 18 DG OR A142 18 DG OR 4 C131 1 2 IGNITION COIL A7 C1 K19 18 GY WT A142 18 DG OR A142 18 DG OR A142 18 DG OR A142 18 DG OR S128 S129 4 0L 5 2L DRIVER NO 1 COIL IGNITION RELAY IN PDC 8W 70 7 8W 70 7 8W 10 16 8W 10 3 8W 10 15 8W 10 8 8W 10 3 8W 10 14 8W 10 16 ZG 8W 30 FUEL IGNITION SYSTEM GAS ENGINES 8W 30 5 ZG003004 J97...

Page 718: ...4 18 BK LB K4 18 BK LB K4 18 BK LB S127 K6 18 VT WT K6 18 VT WT S132 4 0L 5 2L 5V SUPPLY C2 MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN A C LOW PRESSURE SWITCH 18 DB BK 1 PRESSURE SWITCH C3 A C CONTROL COMPRESSOR C3 RELAY DB RD CLUTCH C1 A C C13 18 C3 C22 B5 A C CLUTCH RELAY COMPRESSOR IN PDC 8W 31 3 8W 70 3 8W 70 2 8W 30 6 8W 30 FUEL IGNITION SYSTEM GAS ENGINES ZG J978W 3 ZG003005 ...

Page 719: ...SHAFT A4 SENSOR GROUND SIGNAL SENSOR POSITION CRANKSHAFT A8 K24 18 GY BK K4 20 BK LB K4 20 BK LB K27 18 RD LG K4 18 BK LB C1 C1 C1 MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN THROTTLE POSITION SENSOR WT BK 20 K25 1 S133 3 K25 20 WT BK SENSOR PRESSURE ABSOLUTE MANIFOLD S136 4 0L 4 0L 5 2L 5 2L S135 S135 K4 18 BK LB 8W 70 3 8W 70 3 8W 70 4 8W 30 8 8W 30 9 8W 30 8 8W 30 9 ZG 8W 30 FUEL IGNITI...

Page 720: ...B K4 18 BK LB K4 16 BK LB K2 16 TN BK K4 18 BK LB K21 16 BK RD S135 K70 18 RD WT K22 18 OR DB 1 2 1 2 SENSOR TEMPERATURE COOLANT ENGINE INTAKE AIR TEMPERATURE SENSOR 2 3 1 1 2 3 SIGNAL SENSOR IAT SENSOR PRESSURE ABSOLUTE MANIFOLD THROTTLE POSITION SENSOR MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN 8W 30 7 8W 70 4 8W 70 3 8W 30 8 8W 30 FUEL IGNITION SYSTEM 5 2L ENGINE ZG J978W 3 ZG003007 ...

Page 721: ...B K4 18 BK LB K4 16 BK LB K2 16 TN BK K4 18 BK LB K21 16 BK RD S135 K70 18 RD WT K22 18 OR DB 1 2 1 2 SENSOR TEMPERATURE COOLANT ENGINE INTAKE AIR TEMPERATURE SENSOR 2 1 3 1 2 3 SIGNAL SENSOR IAT SENSOR PRESSURE ABSOLUTE MANIFOLD THROTTLE POSITION SENSOR MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN 8W 30 7 8W 70 2 8W 70 3 ZG 8W 30 FUEL IGNITION SYSTEM 4 0L ENGINE 8W 30 9 ZG003008 J978W 3 ...

Page 722: ...G6 18 GY WT K4 18 BK LB K4 20 BK LB T41 18 BK WT T41 20 BK WT S135 S134 2 L53 L53 L53 SENSE SWITCH LAMP STOP 1 F13 C24 S206 BR 20 20 BR C3 18 BR Z1 BK 14 2 BK 14 Z1 BK 2 20 Z1 G304 C301 S202 SWITCH LAMP STOP SPEED CONTROL ON OFF SWITCH SENSE C234 YL RD 18 V32 3 C3 C11 F9 V32 20 YL RD SERVO CONTROL SPEED VEHICLE OUTPUT SWITCH ON OFF CONTROL SPEED DB LG 3 V30 20 2 8 DB LG C235 20 V30 4 8W 33 2 8W 33...

Page 723: ...NO 7 DRIVER K11 18 WT DB K13 18 YL WT K17 18 DB WT GY 18 K38 DRIVER NO 5 INJECTOR FUEL 1 2 DG OR 18 A142 C2 B6 NO 1 INJECTOR FUEL FUEL INJECTOR NO 3 FUEL INJECTOR NO 7 FUEL INJECTOR NO 5 SHUT AUTOMATIC B16 B17 BATT F5 S129 MODULE CONTROL POWERTRAIN CENTER DISTRIBUTION POWER DOWN RELAY 8W 70 7 8W 10 16 8W 70 7 8W 10 3 8W 20 5 ZG 8W 30 FUEL IGNITION SYSTEM 5 2L ENGINE 8W 30 11 ZG003010 J978W 3 ...

Page 724: ...DRIVER K12 18 TN K14 18 LB BR K18 18 DB YL BR YL 18 K58 DRIVER NO 6 INJECTOR FUEL 1 2 DG OR 18 A142 C2 B12 NO 2 INJECTOR FUEL FUEL INJECTOR NO 4 FUEL INJECTOR NO 8 FUEL INJECTOR NO 6 SHUT AUTOMATIC B16 B17 BATT F5 S128 MODULE CONTROL POWERTRAIN CENTER DISTRIBUTION POWER DOWN RELAY 8W 10 16 8W 70 7 8W 10 3 8W 20 5 8W 30 12 8W 30 FUEL IGNITION SYSTEM 5 2L ENGINE ZG J978W 3 ZG003011 ...

Page 725: ...TREAM SENSOR OXYGEN HEATED DOWNSTREAM DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL K141 18 BK PK K41 18 BK OR K4 18 BK LB K4 18 BK LB S135 K4 18 BK LB SENSOR GROUND SIGNAL SENSOR OXYGEN HEATED UPSTREAM S128 A142 18 DG OR CENTER DISTRIBUTION POWER POWERTRAIN CONTROL MODULE MODULE CONTROL POWERTRAIN DOWN RELAY 8W 10 16 8W 70 7 8W 15 7 8W 15 7 8W 70 3 8W 70 7 8W 10 3 8W 20 5 ZG 8W 30 FUEL IGNITION SYSTEM 5...

Page 726: ...SENSOR OXYGEN HEATED DOWNSTREAM DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL K141 18 BK PK K41 18 BK OR K4 18 BK LB K4 18 BK LB S135 K4 18 BK LB SENSOR GROUND SIGNAL SENSOR OXYGEN HEATED UPSTREAM S127 K4 18 BK LB CENTER DISTRIBUTION POWER POWERTRAIN CONTROL MODULE MODULE CONTROL POWERTRAIN DOWN RELAY C1 A24 8W 10 16 8W 70 7 8W 15 7 8W 15 7 8W 70 3 8W 70 2 8W 10 3 8W 20 5 8W 30 14 8W 30 FUEL IGNITION SYS...

Page 727: ...TOR NO 3 SHUT AUTOMATIC B16 B17 BATT F5 MODULE CONTROL POWERTRAIN S128 NO 5 INJECTOR FUEL NO 6 INJECTOR FUEL A142 18 DG OR 2 1 K38 18 GY BR YL 18 K58 2 1 DG OR 18 A142 B6 C2 FUEL INJECTOR NO 5 DRIVER FUEL INJECTOR NO 6 DRIVER DRIVER NO 4 INJECTOR FUEL POWERTRAIN CONTROL MODULE DRIVER NO 2 INJECTOR FUEL C2 B15 B16 C2 C2 B12 S129 A142 18 DG OR CENTER DISTRIBUTION POWER DOWN RELAY 8W 10 16 8W 70 7 8W...

Page 728: ...TROL SENSE FUEL LOW C26 C3 G40 20 LB BK G40 18 LB BK 10 C304 K4 20 BK LB K167 20 BR YL C304 C3 C15 MODULE CONTROL POWERTRAIN BATTERY TEMPERATURE SENSE SENSOR TEMPERATURE BATTERY 2 1 S102 T222 18 RD YL K4 18 BK LB K4 20 BK LB C131 5 2L 4 0L K4 20 BK LB K4 18 BK LB C1 A4 SENSOR GROUND K4 18 BK LB S135 CENTER DISTRIBUTION POWER 15 10 M SIGNAL 8W 10 14 8W 10 14 8W 10 3 8W 10 8 8W 10 15 8W 15 15 8W 15 ...

Page 729: ... C3 C2 B31 S132 S131 B27 C2 3 1 5 VOLT SUPPLY SENSOR SPEED VEHICLE C1 A4 SENSOR GROUND 2 K6 18 VT WT K6 18 VT WT G7 18 WT OR G7 18 WT OR K95 18 PK F19 C234 K95 20 PK 4 0L 5 2L BK LB 18 K4 K4 20 BK LB K4 18 BK LB F8 C234 S102 BK LB 20 K4 BK LB 20 K4 10 C131 BK LB 18 K4 GROUND SENSOR BK LB 18 K4 2 S135 SIGNAL SENSOR VEHICLE SPEED 8W 70 3 8W 70 6 8W 70 2 8W 70 2 ZG 8W 30 FUEL IGNITION SYSTEM GAS ENGI...

Page 730: ...E MEMORY SEAT MODULE DRIVER DOOR MODULE PASSENGER DOOR MODULE D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 20 WT BK D2 18 WT BK D2 18 WT BK 4 C329 12 C334 12 C351 C1 CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS PAIR TWISTED PAIR TWISTED PAIR TWISTED TWISTED PAIR PAIR TWISTED TWISTED PAIR TWISTED PAIR TWISTED PAIR PAIR TWISTED PAIR TWISTED PAIR TWIST...

Page 731: ...NTROL MODULE MEMORY SEAT MODULE DRIVER DOOR MODULE PASSENGER DOOR MODULE D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 20 VT BR D1 18 VT BR D1 18 VT BR 3 C329 13 C334 13 C351 CCD BUS BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD C1 PAIR TWISTED PAIR TWISTED PAIR TWISTED TWISTED PAIR TWISTED PAIR PAIR TWISTED TWISTED PAIR TWISTED PAIR TWISTED PAIR PAIR TWISTED...

Page 732: ...RIVER DRIVER NO 2 MOTOR IAC IAC MOTOR NO 1 DRIVER DRIVER NO 4 MOTOR IAC MODULE CONTROL POWERTRAIN K40 16 BR WT K60 16 YL BK K39 16 GY RD K59 16 VT BK NO 3 MOTOR IAC MOTOR NO 2 IAC NO 1 MOTOR IAC NO 4 MOTOR IAC 8W 30 20 8W 30 FUEL IGNITION SYSTEM 5 2L ENGINE ZG J978W 3 ZG003019 ...

Page 733: ...RIVER DRIVER NO 2 MOTOR IAC IAC MOTOR NO 1 DRIVER DRIVER NO 4 MOTOR IAC MODULE CONTROL POWERTRAIN K40 16 BR WT K60 16 YL BK K39 16 GY RD K59 16 VT BK NO 3 MOTOR IAC MOTOR NO 2 IAC IAC NO 1 MOTOR NO 4 MOTOR IAC ZG 8W 30 FUEL IGNITION SYSTEM 4 0L ENGINE 8W 30 21 ZG003020 J978W 3 ...

Page 734: ...D GROUND ST RUN OUTPUT SWITCH IGN FUSED 38 1 F99 20 RD OR 24 GROUND S130 Z12 14 BK TN Z12 16 BK TN Z12 16 BK TN Z12 16 BK TN Z12 16 BK TN G104 CONTROLLER MSA Z12 10 BK TN 8W 12 20 8W 10 8 8W 10 3 8W 10 13 8W 10 15 8W 10 15 8W 10 3 8W 30 22 8W 30 FUEL IGNITION SYSTEM DIESEL ENGINE ZG J978W 3 ZG003021 A C SIGNAL 37 SWITCH CONTROL COMPRESSOR CLUTCH RELAY A C 28 1 59 DG 20 C103 DB RD C13 16 DB RD 16 C...

Page 735: ...DB PEDAL POSITION SENSOR LOW IDLE POSITION SWITCH THROTTLE POSITION SENSOR SIGNAL SWITCH POSITION IDLE LOW C4 C4 C4 FLT SIGNAL 27 COIL DRIVER 2 WAIT TO START LAMP 26 K255 20 WT DG K255 20 WT DG K151 20 WT K151 20 WT K6 20 VT WT K6 20 VT WT K22 20 OR DB K22 20 OR DB K92 20 PK K185 18 OR LB K48 18 OR RD D12 C307 D11 D10 D9 1 2 3 4 C182 ZG 8W 30 FUEL IGNITION SYSTEM DIESEL ENGINE 8W 30 23 ZG003022 J9...

Page 736: ...VEHICLE 23 6 47 MODULE CONTROL POWERTRAIN G7 20 WT OR G7 20 WT OR S140 CONTROLLER MSA 2 3 VEHICLE SPEED SENSOR SIGNAL SUPPLY 5V 1 K7 20 OR WT VEHICLE SPEED SENSOR SENSOR GROUND 4 SENSOR GROUND POWERTRAIN CONTROL MODULE K167 20 BR YL K167 20 BR YL C4 C4 C4 C4 2 1 SENSOR FUEL IN WATER G123 20 DG WT K167 20 BR YL S141 G7 20 WT RD 8W 33 5 8W 70 9 8W 30 24 8W 30 FUEL IGNITION SYSTEM DIESEL ENGINE ZG J9...

Page 737: ...L GROUND K134 20 LB BK K57 20 LG OR K135 20 WT BK K238 16 VT K153 20 OR K156 20 GY S144 K140 14 TN WT K140 16 TN WT K140 16 TN WT K140 16 TN WT 4 5 49 MSA CONTROLLER GROUND GROUND GROUND 68 45 23 16 16 DG OR 14 A142 A142 DG OR DG OR A142 A142 DG OR 16 14 DG OR A142 10 9 SHUT DOWN RELAY OUTPUT AUTO AUTO OUTPUT RELAY DOWN SHUT RELAY DOWN SHUT AUTO OUTPUT OUTPUT AUTO SHUT DOWN RELAY OUTPUT AUTO SHUT ...

Page 738: ...ULE FLOW AIR MASS 4 Z1 20 BK Z1 12 BK Z1 12 BK Z1 16 BK G106 S104 10 C131 S134 13 CONTROLLER MSA AIR FLOW METER SIGNAL 4 1 2 3 RELAY PLUG GLOW 50 GLOW PLUG RELAY CONTROL SENSE K155 20 DB K152 16 WT A0 14 RD A0 10 RD S421 BATT A0 GLOW PLUG K154 10 GY A142 16 DG OR S129 8W 70 8 8W 70 7 8W 15 6 8W 15 6 8W 15 6 8W 10 3 8W 70 7 8W 30 26 8W 30 FUEL IGNITION SYSTEM DIESEL ENGINE ZG J978W 3 ZG003025 ...

Page 739: ... PK BK K900 20 PK BK 14 C132 A12 12 RD TN F99 18 OR F99 20 OR S101 IN PDC RELAY HEATER FUEL D10 D13 D11 D14 B 8W 30 28 TO SOLENOID EGR A142 16 DG OR A142 16 DG OR 12 C131 C4 57 S129 A142 16 DG OR A142 16 DG OR CONTROL RELAY SHUTDOWN AUTOMATIC MODULE CONTROL POWERTRAIN C 8W 30 28 TO S420 A64 14 OR DB G107 Z4 20 BK Z4 10 BK S124 8W 10 16 8W 10 3 8W 10 18 8W 10 3 8W 12 20 8W 10 8 8W 12 5 8W 39 2 8W 1...

Page 740: ... 3 UNIT SENDER FUEL A64 16 OR DB A64 16 DG WT 18 C304 10 G40 20 LB BK G40 18 LB BK 3 C131 C4 1 MODULE CONTROL POWERTRAIN G40 18 LB BK Z1 16 BK Z1 12 BK S304 G305 K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL S102 12 C132 S141 C4 4 MODULE CONTROL POWERTRAIN 15 C304 EGR SOLENOID LOW FUEL SENSE SENSOR GROUND RELAY 8W 15 6 8W 15 6 8W 70 9 8W 15 15 8W 15 15 8W 70 9 8W 70 9 8W 30...

Page 741: ... B A C SENSOR TEMPERATURE COOLANT ENGINE K222 20 TN RD K2 20 TN BK K4 20 BK LB K4 20 BK LB S136 14 33 ENGINE COOLANT TEMPERATURE SIGNAL GROUND SENSOR MODULE CONTROL POWERTRAIN CONTROLLER MSA 8W 70 9 8W 70 9 8W 70 8 ZG 8W 30 FUEL IGNITION SYSTEM DIESEL ENGINE 8W 30 29 ZG003028 J978W 3 5 20 ON OFF SWITCH CONTROL SPEED SENSE STOP SENSE SWITCH LAMP 44 3 V32 20 YL RD L50 18 WT TN V32 YL RD 20 V32 YL RD...

Page 742: ...35 4 NO CONNECTION D83 20 BK PK D83 20 BK PK F14 C234 S200 C235 7 D83 20 BK PK C1 20 D83 20 BK PK SCI RECEIVE RECEIVE SCI 61 D83 20 BK PK CONTROLLER ANTI LOCK BRAKE CONTROLLER MSA D83 20 BK PK 2 C144 D83 20 BK PK C4 25 SCI RECEIVE TRANSMIT SCI 45 C4 MODULE CONTROL POWERTRAIN D83 20 BK PK D84 20 BK WT D84 20 BK WT D84 20 BK WT 3 C144 F15 C234 S142 8W 12 8 8W 10 10 8W 12 2 8W 12 8 8W 30 2 8W 35 2 8W...

Page 743: ... BK D2 18 WT BK S203 2 C302 2 C231 10 C235 19 C1 C1 9 9 S307 AIRBAG CONTROL MODULE MEMORY SEAT MODULE DRIVER DOOR MODULE PASSENGER DOOR MODULE D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK 4 C329 12 C334 12 C351 C1 CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS D2 18 WT BK 4 C132 8W 49 2 8W 40 3 8W 42 9 8W 46 7 8W 47 2 ...

Page 744: ... BR D1 18 VT BR S204 1 C302 1 C231 11 C235 18 C1 C1 8 8 S306 AIRBAG CONTROL MODULE MEMORY SEAT MODULE DRIVER DOOR MODULE PASSENGER DOOR MODULE D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 18 VT BR 3 C329 13 C334 13 C351 CCD BUS BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD C1 D1 18 VT BR 5 C132 8W 49 2 8W 40 3 8W 42 9 8W 46 7 8W 47 2 ...

Page 745: ...e START or RUN position it connects circuit A1 to circuit A21 In the ACCESSORY or RUN position the ignition switch connects to circuit A31 In the START posi tion the ignition switch connects circuit A1 to circuit A41 When the ignition switch is in the RUN position it connects circuit A1 to circuit A22 Also in the START position the case grounded ignition switch grounds circuit G9 from the brake wa...

Page 746: ...controlled by the Powertrain Control Module PCM on circuit K900 When the PCM provides a ground for the coil side of the relay the contacts in the relay CLOSE and connect circuits F5 and A142 The A142 circuit sup plies power to various components and modules in the fuel system HELPFUL INFORMATION Check the 25 amp fuse located in the PDC Refer to the appropriate section of the service manual or Diag...

Page 747: ...K141 supplies the signal from the downstream heated oxygen sensor to the PCM Cir cuit K141 connects to PCM cavity A25 The PCM provides a ground for the heated oxygen sensor signals circuits K41 and K141 through cir cuit K4 Circuit K4 connects to cavity A4 of the PCM connector Circuit Z12 provides ground for the heater circuit in each sensor HELPFUL INFORMATION Circuit A142 also supplies battery vo...

Page 748: ... 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 K4 connects to cavity A4 of the PCM con nector HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following Battery ...

Page 749: ...y A4 of the PCM HELPFUL INFORMATION Refer to Group 14 for MAP sensor operation Circuit K25 splices to supply 5 volts to the cam shaft position sensor crankshaft position sensor and throttle position sensor Circuit K4 splices to supply ground for the signals from the following Battery temperature sensor Camshaft position sensor Crankshaft position sensor Downstream heated oxygen sensor Engine coola...

Page 750: ...e PCM Circuit K11 provides ground for injector number one The K11 circuit connects to cavity B4 of the PCM Circuit K12 provides ground for injector number two The K12 circuit connects to cavity B15 of the PCM Circuit K13 provides ground for injector number three The K13 circuit connects to cavity B5 of the PCM Circuit K14 provides ground for injector number four The K14 circuit connects to cavity ...

Page 751: ...uit K19 connects to cavity A7 of the PCM HELPFUL INFORMATION Circuit A142 splices to supply voltage to the fuel injectors PCM heated oxygen sensors and generator IDLE AIR CONTROL IAC MOTOR The Powertrain Control Module PCM operates the idle air control motor through 4 circuits K39 K40 K59 and K60 Each circuit connects to separate cavities in the PCM connector Circuit K39 connects to cavity A20 of ...

Page 752: ......

Page 753: ...Distribution Center 8W 31 2 Powertrain Control Module 8W 31 2 3 4 5 6 S127 8W 31 3 4 S131 8W 31 4 S132 8W 31 3 4 S133 8W 31 4 Component Page S135 8W 31 3 4 S136 8W 31 4 S202 8W 31 5 S206 8W 31 5 S215 8W 31 5 S216 8W 31 5 S218 8W 31 5 Shift Interlock 8W 31 5 Stop Lamp Switch 8W 31 5 Throttle Position Sensor 8W 31 4 Torque Converter Clutch Solenoid 8W 31 2 Transmission Control Relay 8W 31 2 Transmis...

Page 754: ...8 DG LB C2 C2 C2 TORQUE CONVERTER CLUTCH SOLENOID CONTROL CONTROL SOLENOID FORCE VARIABLE O D CONTROL RELAY TRANSMISSION C2 B30 T66 20 BR OR T66 18 BR OR 7 C132 CENTER DISTRIBUTION POWER CENTER DISTRIBUTION POWER MODULE CONTROL POWERTRAIN POWERTRAIN CONTROL MODULE SOLENOID CONTROL TORQUE CLUTCH CONVERTER SOLENOID FORCE SOLENOID VARIABLE SOLENOID CONTROL O D 8W 30 3 8W 30 3 8W 10 3 8W 10 3 8W 10 3 ...

Page 755: ...ATURE SENSOR SIGNAL GROUND SENSOR GOVERNOR PRESSURE SIGNAL S135 K4 18 BK LB K4 18 BK LB K4 18 BK LB K4 18 BK LB S127 K6 18 VT WT K6 18 VT WT S132 4 0L 5 2L 5V SUPPLY C2 MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN 8W 30 6 8W 30 6 8W 70 2 8W 70 2 8W 70 3 ZG 8W 31 TRANSMISSION SYSTEM 8W 31 3 ZG003102 J978W 3 ...

Page 756: ...LB K4 18 BK LB K4 18 BK LB K4 20 BK LB S127 S136 SUPPLY 5V SIGNAL SENSOR SPEED VEHICLE SENSOR GROUND A4 C1 K4 18 BK LB K6 18 VT WT G7 18 WT OR S135 S132 S131 2 1 3 G7 18 WT OR K6 18 VT WT K4 18 BK LB VEHICLE SPEED SENSOR SIGNAL SUPPLY 5V SENSOR GROUND VEHICLE SPEED SENSOR 4 0L 5 2L MODULE CONTROL POWERTRAIN K25 18 WT BK S133 1 2 3 5 2L V 8 4 0L I 6 8W 70 2 8W 70 4 8W 70 3 8W 70 2 8W 70 2 8W 30 8 8...

Page 757: ...24 C3 SENSE SWITCH LAMP STOP C3 C6 G68 20 BR YL G68 18 BR YL 9 C235 OVERDRIVE OFF LAMP DRIVER F71 20 PK DG F71 20 PK DG S218 JUNCTION BLOCK MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN 8 C9 C9 9 OVERDRIVE OFF SWITCH SENSE SWITCH PRESSURE OVERDRIVE SWITCH POD PART OF 8W 10 5 8W 12 5 8W 12 10 8W 12 5 8W 33 2 8W 15 18 8W 15 18 8W 15 17 8W 12 10 8W 10 8 8W 10 8 8W 12 2...

Page 758: ...K151 20 WT K6 20 VT WT 1 4 3 K6 20 VT WT K151 20 WT K255 20 WT DG LOW IDLE POSITION SWITCH SUPPLY 5V PEDAL POSITION SENSOR POWERTRAIN CONTROL MODULE SIGNAL SENSOR POSITION THROTTLE 2 CONTROLLER MSA PEDAL POSITION SENSOR SENSOR POSITION PEDAL K22 20 OR DB K22 20 OR DB K22 20 OR DB K6 20 VT WT K151 20 WT K255 20 WT DG 1 2 3 4 12 11 10 9 C307 C182 8W 70 2 8W 30 23 8W 31 6 8W 31 TRANSMISSION SYSTEM DI...

Page 759: ...ol 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 variable force solenoid are molded together Circuit T20...

Page 760: ...K4 If transmission 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 Battery temperature sensor Camshaft position sensor Crank...

Page 761: ...oller 8W 33 4 5 Powertrain Control Module 8W 33 2 3 4 5 Right Switch 8W 33 3 5 S102 8W 33 3 5 S121 8W 33 4 S124 8W 33 2 S131 8W 33 3 Component Page S132 8W 33 3 S135 8W 33 3 S136 8W 33 5 S140 8W 33 5 S141 8W 33 5 S202 8W 33 2 4 S206 8W 33 2 S211 8W 33 5 S312 8W 33 2 4 Stop Lamp Switch 8W 33 2 4 Vehicle Speed Control Servo 8W 33 2 Vehicle Speed Control Horn Switch 8W 33 3 5 Vehicle Speed Sensor 8W ...

Page 762: ...RD 18 V32 3 C3 C11 2 F9 V32 20 YL RD S206 L53 20 BR 8 C235 2 V30 20 DB LG Z1 20 BK Z1 14 BK S202 G304 2 C301 Z1 14 BK SPEED CONTROL VACUUM SOLENOID CONTROL SPEED CONTROL VENT SOLENOID CONTROL SPEED CONTROL ON OFF SWITCH OUTPUT STOP LAMP SWITCH 5 6 15A FUSE 9 C10 3 BATT A250 JUNCTION BLOCK L16 18 RD LG L50 18 WT TN L50 18 WT TN 12 C305 S312 TO 9 8W 70 5 8W 10 10 8W 12 2 8W 12 7 8W 15 18 8W 15 18 8W...

Page 763: ...3 C2 B31 S132 S131 B27 C2 3 1 5 VOLT SUPPLY SIGNAL VSS SENSOR SPEED VEHICLE C1 A4 SENSOR GROUND 2 CLOCKSPRING K6 18 VT WT K6 18 VT WT G7 18 WT OR G7 18 WT OR K95 18 PK F19 C234 K95 20 PK 4 0L 5 2L BK LB 18 K4 K4 20 BK LB K4 18 BK LB F8 C234 S102 BK LB 20 K4 BK LB 20 K4 10 C131 BK LB 18 K4 GROUND SENSOR BK LB 18 K4 2 S135 8W 30 17 8W 70 2 8W 70 2 8W 70 6 8W 70 3 ZG 8W 33 VEHICLE SPEED CONTROL GAS E...

Page 764: ...L RD L53 20 BR G8 C235 G2 Z1 20 BK Z1 14 BK S202 G304 2 C301 Z1 14 BK STOP LAMP SWITCH CONTROLLER MSA F9 F13 C234 V32 20 YL RD 6 5 9 FUSE 15A BATT A250 JUNCTION BLOCK 3 C10 L16 18 RD LG L50 18 WT TN L50 18 WT TN 12 C305 9 TO S312 8W 15 8 8W 15 4 8W 15 5 8W 15 18 8W 15 18 8W 50 11 8W 12 7 8W 10 10 8W 12 2 8W 70 5 8W 33 4 8W 33 VEHICLE SPEED CONTROL DIESEL ENGINE ZG J978W 3 ZG003303 8W 30 29 ...

Page 765: ...NTROLLER MSA 6 C4 C4 47 1 3 S140 S141 G7 20 WT OR G7 20 WT OR G7 20 WT OR K7 20 OR K167 20 BR YL K167 20 BR YL SENSOR SPEED VEHICLE SENSOR GROUND SUPPLY 5V VEHICLE SPEED SENSOR SIGNAL SENSOR GROUND SUPPLY 5V VEHICLE SPEED SENSOR SIGNAL C234 F19 K95 20 PK K4 20 BK LB K4 20 BK LB K4 18 BK LB K4 18 BK LB K4 18 BK LB K4 18 BK LB S136 6 C131 S102 F8 C234 S211 8W 30 24 8W 30 24 8W 30 24 8W 70 9 8W 70 8 ...

Page 766: ...round on circuit Z1 When the brake pedal is depressed the stop lamp switch opens and disconnects circuits L53 and Z1 and circuits V32 and V30 When the stop lamp switch disconnects circuits V32 and V30 power is removed from the speed control servo HELPFUL INFORMATION Circuit K4 also provides ground for some of the engine control sensors that provide inputs to the PCM VEHICLE SPEED CONTROL DIESEL Th...

Page 767: ...strument Cluster 8W 35 3 Junction Block 8W 35 2 3 Left Front Wheel Speed Sensor 8W 35 4 Left Rear Wheel Speed Sensor 8W 35 4 Component Page Power Distribution Center 8W 35 2 Powertrain Control Module 8W 35 2 Right Front Wheel Speed Sensor 8W 35 4 Right Rear Wheel Speed Sensor 8W 35 4 S125 8W 35 2 S142 8W 35 2 S200 8W 35 2 S312 8W 35 3 Speed Proportional Steering Module 8W 35 2 Stop Lamp Switch 8W ...

Page 768: ... PK D83 20 BK PK FUSED IGN ST RUN GROUND GROUND FUSED B FUSED B JUNCTION BLOCK MODULE STEERING PROPORTIONAL SPEED S200 BK PK D83 20 2 C144 BK PK D83 20 SCI RECEIVE SCI RECEIVE 12 S142 BK PK D83 20 BK PK 20 D83 20 C1 BRAKE ANTI LOCK CONTROLLER POWERTRAIN 25 MODULE CONTROL C3 8W 30 2 8W 30 30 8W 30 2 8W 65 2 8W 10 3 8W 10 8 8W 12 2 8W 15 8 8W 12 9 8W 10 5 8W 10 10 8W 10 3 8W 35 2 8W 35 ANTI LOCK BRA...

Page 769: ... 6 7 B41 20 YL VT 6 C304 7 B41 20 YL VT B42 20 TN WT B42 20 TN WT ACCEL SENSOR NO 1 NO 2 SENSOR ACCEL STOP LAMP SWITCH OUTPUT 16 4 G5 C235 205 20 WT VT 205 20 WT VT INSTRUMENT CLUSTER ABS WARNING LAMP DRIVER ABS WARNING LAMP L50 18 WT TN 12 C305 STOP LAMP SWITCH SENSOR GROUND 1 13 9 8W 33 2 8W 10 10 8W 40 5 8W 70 5 8W 12 2 8W 12 7 ZG 8W 35 ANTI LOCK BRAKES 8W 35 3 ZG003502 J978W 3 ...

Page 770: ...PEED SENSOR SENSOR SPEED WHEEL FRONT RIGHT 3 SENSOR SPEED WHEEL FRONT RIGHT A B 17 RIGHT REAR WHEEL SPEED SENSOR SENSOR SPEED WHEEL REAR RIGHT 1 SENSOR SPEED WHEEL REAR RIGHT B8 20 RD DB RD 20 B9 WT 20 B7 WT DB 20 B6 B3 20 LG DB B3 20 LG DB 12 C304 13 LG 20 B4 LG 20 B4 3 YL DB 20 B1 YL DB 20 B1 C304 4 YL 20 B2 YL 20 B2 PAIR TWISTED PAIR TWISTED PAIR TWISTED PAIR TWISTED PAIR TWISTED PAIR TWISTED 8...

Page 771: ...cuits B4 and B3 provide signals to the CAB from the left rear wheel speed sensor G SWITCH During four wheel drive operation the G switch provides deceleration data to the Controller Anti Lock Brakes CAB Refer to Group 5 Brakes for additional information Circuits B41 B42 and B43 connect the G switch to the CAB Circuits B41 and B42 provide switch states while circuit B43 provides ground ABS WARNING ...

Page 772: ......

Page 773: ...8W 39 6 Ignition Switch 8W 39 2 Junction Block 8W 39 2 3 6 Left Front Cylinder Lock Switch 8W 39 5 Left Front Door Ajar Switch 8W 39 5 Component Page Left Rear Door Ajar Switch 8W 39 5 Liftgate Ajar Switch 8W 39 4 Liftgate Cylinder Lock Switch 8W 39 5 Liftglass Ajar Switch 8W 39 4 Park 8W 39 3 Power Distribution Center 8W 39 2 3 6 Relay 8W 39 3 Right Front Cylinder Lock Switch 8W 39 5 Right Front ...

Page 774: ...R ENGINE BODY CONTROL MODULE A1 12 RD WT A1 12 RD WT 10A FUSE 3 BLOCK JUNCTION A31 12 RD BK 1 C6 DB GY 12 A21 C6 2 C2 15 BR PK 20 V23 5 C10 FUSED IGN RUN ACC 1 C2 A21 12 DB GY ST RUN IGN FUSED 18 C1 F99 18 OR F99 20 OR H8 C236 F99 20 OR S101 S210 8W 10 15 8W 12 2 8W 12 4 8W 45 2 8W 21 3 8W 21 4 8W 10 7 8W 10 13 8W 10 14 8W 10 3 8W 10 3 8W 10 7 8W 39 2 8W 39 VEHICLE THEFT SECURITY SYSTEM ZG J978W 3...

Page 775: ...LED VTSS SENSOR LIGHT HEADLAMP AUTOMATIC G69 20 BK LG C1 23 VTSS INDICATOR LAMP DRIVER F75 18 VT F75 18 VT 8 C4 C4 9 11 C10 10 C10 S201 CONTROL RELAY LAMP PARK C2 21 17 C1 PARK LAMP RELAY OUTPUT B FUSED C2 8 L79 20 TN L90 20 DB RD F75 18 VT 8W 12 8 8W 45 4 8W 50 5 8W 12 2 8W 12 14 8W 12 8 8W 45 4 8W 10 10 8W 10 3 8W 10 3 8W 10 11 ZG 8W 39 VEHICLE THEFT SECURITY SYSTEM 8W 39 3 ZG003902 J978W 3 ...

Page 776: ...BR TN 20 G70 HOOD SWITCH SENSE SWITCH AJAR LIFTGATE TN BK 20 G78 1 C3 9 C321 G78 20 TN BK G78 20 TN BK 2 1 SWITCH AJAR LIFTGLASS BK 20 Z1 Z1 20 BK LIFTGATE AJAR SWITCH 1 2 TN BK 20 G78 S329 S328 G300 Z1 12 BK 2 C325 Z1 12 BK Z1 12 BK S316 G304 Z2 18 BK OR 6 3 8W 15 18 8W 15 18 8W 15 18 8W 45 2 8W 45 10 8W 44 14 8W 45 11 8W 15 10 8W 15 11 8W 15 11 8W 15 18 8W 39 4 8W 39 VEHICLE THEFT SECURITY SYSTE...

Page 777: ...R RIGHT 10 C3 G71 20 VT YL VTSS DISARM SENSE G71 20 VT YL 3 C321 VT YL 20 G71 LIFTGATE CYLINDER LOCK SWITCH 1 2 Z1 20 BK Z1 12 BK G300 S328 2 C325 Z1 12 BK Z1 12 BK S316 BK 12 Z1 C351 1 S325 G301 BK 12 Z1 BK 20 Z1 2 1 G71 20 VT YL C351 14 VT YL 20 G71 BK 12 Z1 C334 1 S324 G302 BK 12 Z1 BK 20 Z1 2 1 G71 20 VT YL C334 14 VT YL 20 G71 S305 LEFT FRONT CYLINDER LOCK SWITCH LOCK CYLINDER FRONT RIGHT SWI...

Page 778: ... 1 Z1 16 BK Z1 16 BK S104 Z1 14 BK G106 X4 20 GY OR 1 C1 BLOCK JUNCTION SWITCH HORN CONTROL SPEED VEHICLE 5 BODY CONTROL MODULE HORN RELAY CONTROL 13 C2 7 C10 C7 12 X4 20 GY OR X4 20 GY OR CLOCKSPRING HORN SWITCH F31 16 VT 8W 45 3 8W 12 2 8W 15 6 8W 15 7 8W 15 6 8W 15 7 8W 10 3 8W 10 3 8W 10 5 8W 39 6 8W 39 VEHICLE THEFT SECURITY SYSTEM ZG J978W 3 ZG003905 ...

Page 779: ... Vehicle Theft Security Sys tem is armed the BCM starts the alarm Refer to the Introduction in this section for alarm information The BCM receives the ajar switch signals on the following circuits Circuit G75 provides the left front door ajar switch signal Circuit G74 provides the right front door ajar switch signal Circuit G77 provides the left rear door ajar switch signal Circuit G76 provides th...

Page 780: ......

Page 781: ...igh Beam Indicator Lamp 8W 40 5 Ignition Switch 8W 40 6 Illumination Lamps 8W 40 4 Instrument Cluster 8W 40 2 3 4 5 Junction Block 8W 40 2 4 5 Left Front Turn Signal Lamp 8W 40 4 Left Turn Signal Indicator Lamp 8W 40 4 Component Page Low Fuel Warning Lamp 8W 40 2 Oil Pressure Gauge 8W 40 3 Powertrain Control Module 8W 40 3 Right Turn Signal Indicator Lamp 8W 40 4 S109 8W 40 4 S149 8W 40 4 S201 8W ...

Page 782: ...ING FUEL LOW LAMP ENGINE CHECK FUSED B GROUND 1 2 Z1 20 BK S216 Z1 16 BK S202 Z1 14 BK 2 C301 Z1 14 BK BK OR 18 Z2 S205 BK OR 20 Z2 8 C307 Z2 18 BK OR S302 Z2 18 BK OR G304 INSTRUMENT CLUSTER 8W 10 10 8W 12 8 8W 12 2 8W 12 8 8W 15 17 8W 15 18 8W 15 18 8W 15 18 8W 15 18 8W 40 2 8W 40 INSTRUMENT CLUSTER ZG J978W 3 ZG004001 ...

Page 783: ...D1 VT BR 18 D1 S306 S307 S204 D2 18 WT BK D2 18 WT BK C302 2 WT BK 18 D2 WT BK 18 D2 WT BK 18 D2 D1 18 VT BR MODULE CONTROL BODY CCD BUS BUS CCD 19 20 CCD BUS BUS CCD POWERTRAIN CONTROL MODULE D1 18 VT BR 19 VT BR 18 D1 D2 18 WT BK C235 20 WT BK 18 D2 10 11 C30 C3 C28 C3 S203 C1 C1 PAIR TWISTED TWISTED PAIR TWISTED PAIR PAIR TWISTED PAIR TWISTED TWISTED PAIR C132 5 4 8W 30 18 8W 30 31 8W 30 18 8W ...

Page 784: ...WARNING HAZARD SIGNAL TURN L65 18 LG DB F10 C234 L65 18 LG DB 1 C102 L64 18 TN DB S409 L64 18 TN DB A G Z1 18 BK S149 Z1 18 BK 3 C102 Z1 18 BK G106 1 7 L64 18 TN DB BLOCK JUNCTION 1 L64 18 TN DB GROUND LEFT TURN SIGNAL LAMP C4 C4 SWITCH 11 FRONT S109 16 BK Z1 8W 15 4 8W 15 5 8W 52 2 8W 12 2 8W 15 6 8W 15 7 8W 15 4 8W 15 5 8W 44 11 8W 45 10 8W 50 5 8W 40 4 8W 40 INSTRUMENT CLUSTER ZG J978W 3 ZG0040...

Page 785: ...7 Z2 18 BK OR S302 Z2 18 BK OR G304 5 FUSE 10A BLOCK JUNCTION 8 C9 F87 20 BK WT S215 F87 20 BK WT 5 ABS WARNING LAMP 205 20 WT VT C235 5 VT WT 20 205 4 16 BRAKE ANTI LOCK CONTROLLER DRIVER LAMP WARNING ABS ST RUN A21 CLUSTER INSTRUMENT 8W 10 8 8W 35 3 8W 12 5 8W 12 2 8W 12 5 8W 15 18 8W 15 18 8W 15 18 8W 15 18 8W 15 17 8W 12 8 8W 12 8 8W 10 10 ZG 8W 40 INSTRUMENT CLUSTER 8W 40 5 ZG004004 J978W 3 B...

Page 786: ...GY BK GAS OTHERS 2 C304 G9 20 GY BK S303 G9 20 GY BK 2 C3 BRAKE SWITCH SENSE BODY CONTROL MODULE 3 0 2 1 IGNITION SWITCH 1 START 2 RUN 0 OFF 3 ACC 2 1 GY BK 20 G9 8W 10 7 8W 45 9 8W 45 9 8W 50 4 8W 45 9 8W 50 4 8W 40 6 8W 40 INSTRUMENT CLUSTER ZG J978W 3 ZG004005 ...

Page 787: ...ol Module The PCM 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 cesso...

Page 788: ...ircuit 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 ILLUMINATION LAMPS Circuit E2 from the headlamp switch powers th...

Page 789: ...2 Fuse 2 8W 41 3 Fuse 6 8W 41 2 Fuse 14 8W 41 3 Fuse 21 8W 41 3 G106 8W 41 2 G304 8W 41 3 Horn No 1 8W 41 2 Horn No 2 8W 41 2 Component Page Horn Relay 8W 41 2 Horn Switch 8W 41 2 Junction Block 8W 41 2 3 Power Distribution Center 8W 41 2 Power Outlet 8W 41 3 S104 8W 41 2 S106 8W 41 2 S202 8W 41 3 S216 8W 41 3 S220 8W 41 3 Vehicle Speed Control Horn Switch 8W 41 2 ZG 8W 41 HORN CIGAR LIGHTER 8W 41...

Page 790: ...BK G106 X4 20 GY OR 1 C1 BLOCK JUNCTION SWITCH HORN CONTROL SPEED VEHICLE 5 BODY CONTROL MODULE HORN RELAY CONTROL 13 C2 7 C10 C7 12 X4 20 GY OR X4 20 GY OR CLOCKSPRING HORN SWITCH F31 16 VT HORN RELAY A3 A1 A5 A2 8W 45 3 8W 45 3 8W 12 2 8W 15 6 8W 15 7 8W 15 6 8W 15 7 8W 10 3 8W 10 3 8W 10 5 8W 41 2 8W 41 HORN CIGAR LIGHTER POWER OUTLET ZG J978W 3 ZG004101 ...

Page 791: ... G304 Z1 16 BK BLOCK JUNCTION S216 Z1 16 BK S202 Z1 14 BK 2 C301 Z1 14 BK 15A FUSE 21 14 FUSE 15A 2 C9 BLOCK JUNCTION C10 9 NO CONNECTION 2 FUSE 15A C7 4 RUN ACC A31 BATT F61 BATT A7 8W 10 12 8W 10 9 8W 10 9 8W 12 3 8W 12 2 8W 12 3 8W 12 16 8W 15 18 8W 15 17 8W 12 2 8W 15 18 8W 15 17 ZG 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 3 ZG004102 J978W 3 ...

Page 792: ... The relay energizes when the ignition switch is in the ACCESSORY or RUN position In the ACCES SORY or RUN position the switch connects circuit 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 c...

Page 793: ...Link Connector 8W 42 9 Fuse 3 8W 42 11 Fuse 7 8W 42 2 3 Fuse 12 8W 42 5 7 9 Fuse 18 8W 42 10 Fuse 20 8W 42 2 11 Fuse 21 8W 42 10 11 G106 8W 42 12 G107 8W 42 2 4 7 G304 8W 42 7 High Speed Blower Motor Relay 8W 42 3 In Car Temperature Sensor 8W 42 6 Component Page Junction Block 8W 42 2 5 7 9 Mode Door Actuator 8W 42 6 8 MSA Controller 8W 42 13 Power Distribution Center 8W 42 2 3 10 11 Powertrain Co...

Page 794: ...6 6 BATT A0 40A FUSE 7 13 CENTER DISTRIBUTION POWER A19 12 RD VT A19 12 RD 1 C160 1 2 A C HEATER MANUAL MOTOR BLOWER C7 12 BK S221 3 3 A C HEATER CONTROL BLOCK RESISTOR MOTOR BLOWER C7 12 BK C7 12 BK TN C7 12 BK TN B C206 BLOWER MOTOR SWITCH M C1 8W 42 5 8W 10 3 8W 10 6 8W 10 3 8W 15 8 8W 15 8 8W 15 8 8W 12 2 8W 10 12 8W 12 16 8W 42 2 8W 42 AIR CONDITIONING HEATER ZG J978W 3 ZG004201 ...

Page 795: ...MOTOR RELAY OUTPUT SIGNAL RELAY MOTOR BLOWER SPEED HIGH MODULE CONTROL TEMPERATURE AUTOMATIC C42 12 BR RD C42 18 PK DB C41 20 BR C41 20 GY DB M L C206 1 2 BLOWER MOTOR C42 12 RD 5 A 8W 42 4 B 8W 42 4 C 8W 42 4 TO S226 TO S226 TO C206 C43 18 BR YL Z4 18 BK Z4 12 BK CENTER DISTRIBUTION POWER BLOWER MOTOR DRIVER FUSED B OUTPUT GROUND M 8W 10 3 8W 10 3 8W 10 6 ZG 8W 42 AIR CONDITIONING HEATER 8W 42 3 ...

Page 796: ...7 AUTOMATIC TEMPERATURE CONTROL MODULE 2 C160 P C206 A C SELECT INPUT C6 C2 7 C90 20 LG MODULE CONTROL BODY A C SELECT INPUT N C206 FROM MODULE MOTOR BLOWER C43 18 BR YL BLOWER MOTOR FROM MODULE MOTOR BLOWER FROM LAMP PANEL D13 PANEL DRIVER LAMP 16 C2 E2 OR 20 S214 S209 OR E2 20 OR 20 E2 8W 44 11 8W 44 12 8W 44 11 8W 45 9 8W 15 8 8W 15 8 8W 42 4 8W 42 AIR CONDITIONING HEATER ZG J978W 3 ZG004203 ...

Page 797: ... 10A RUN A22 JUNCTION BLOCK C9 4 F71 20 DG PK 1 4 2 3 BLOCK RESISTOR MOTOR BLOWER C4 14 TN C4 14 TN C5 14 LG C5 14 LG C6 14 LB C6 14 LB C7 12 BK C7 12 BK TN C7 12 BK TN E C206 B D C S221 2 MOTOR BLOWER C7 12 BK C2 7 C90 20 LG A C SELECT INPUT D 8W 42 6 TO S214 E2 20 OR C1 14 DG C34 20 VT WT C36 20 DB RD F 8W 42 7 G 8W 42 7 H 8W 42 7 TO C206 TO S220 TO C206 7 C2 HEATER A C MANUAL MODULE CONTROL BOD...

Page 798: ...C1 AMBIENT TEMPERATURE SENSOR SIGNAL RETURN SENSOR BODY CONTROL MODULE D13 DRIVER LAMP PANEL 16 C2 MODULE CONTROL TEMPERATURE AUTOMATIC E2 20 OR E2 20 OR E2 20 OR S209 S214 D 8W 42 5 E2 20 DR FROM CONTROL HEATER A C PANEL LAMP DRIVER S219 LG WT 20 D41 D41 20 LG WT D9 GROUND SENSOR S C206 D41 20 LG WT D41 20 LG WT 3 MODE DOOR ACTUATOR D41 20 LG WT 3 ATC ACTUATOR DOOR BLEND S222 SENSOR SENSOR GROUND...

Page 799: ... C36 20 DB RD C36 20 DB RD F C206 2 C40 20 WT YL F71 20 PK DG F71 20 PK DG S218 F71 20 PK DG G C206 F 8W 42 5 G 8W 42 5 H 8W 42 5 FROM CONTROL HEATER A C A C HEATER CONTROL FROM FROM CONTROL HEATER A C C206 FUSED IGN RUN BLEND AIR DOOR POSITION SWITCH SIGNAL COMMON DOOR NOT USED 8W 12 2 8W 10 8 8W 12 10 8W 15 8 8W 15 8 8W 15 17 8W 15 18 8W 15 17 8W 15 18 8W 12 10 ZG 8W 42 AIR CONDITIONING HEATER M...

Page 800: ...RIVER SIGNAL FEEDBACK DOOR AIR BLEND DRIVER MOTOR DOOR AIR BLEND C35 20 DG YL C35 20 DB WT C34 20 DB WT C34 20 VT WT C E C206 C36 20 RD WT C36 20 DB RD D C206 C40 20 DG YL C40 20 DG YL D41 20 LG WT D41 20 LG WT C38 20 DG C38 20 DB C37 20 TN BK C37 20 YL C39 20 YL C39 20 WT S222 C40 20 DG YL C40 20 BR WT C206 S223 J B C206 A C206 S219 C206 S LG WT 20 D41 LG WT 20 D41 LG WT 20 D41 D9 K SENSOR GROUND...

Page 801: ...TOR DOOR RECIRCULATION C32 20 LB DG C33 20 VT OR C12 9 C9 4 C9 JUNCTION BLOCK RUN A22 RECIRC DOOR MOTOR MOTOR DOOR RECIRC IGN FUSED RUN 18 18 VT BR WT BK CCD BUS 18 VT BR D1 D1 3 LINK DATA S203 CONNECTOR S204 D2 WT BK 18 D2 BUS CCD 11 C10 C11 CCD BUS BUS CCD PAIR TWISTED 8W 30 19 8W 30 32 8W 30 18 8W 30 19 8W 30 31 8W 30 32 8W 30 18 8W 30 31 8W 10 8 8W 12 2 8W 12 10 8W 12 10 ZG 8W 42 AIR CONDITION...

Page 802: ... YL 1 C144 7 C131 C2 18 DB YL C13 18 DB RD E 8W 42 12 TO MODULE CONTROL POWERTRAIN 4 0L 5 2L BATT A900 21 FUSE 15A A21 A22 F250 18 RD GY CLUTCH COMPRESSOR A C A C COMPRESSOR CLUTCH RELAY IN PDC GAS DIESEL F 8W 42 5 TO C131 8W 10 4 8W 10 4 8W 10 8 8W 10 3 8W 10 15 8W 10 13 8W 42 7 8W 42 10 8W 42 AIR CONDITIONING HEATER GAS ENGINES ZG J978W 3 ZG004209 ...

Page 803: ...2 13 BATT A0 20 FUSE 25A A20 A19 CLUTCH COMPRESSOR A C A C COMPRESSOR CLUTCH RELAY IN PDC IN PDC RELAY DOWN SHUT AUTOMATIC B17 B18 B16 TO C131 A142 16 DG OR F5 16 RD YL F5 16 RD YL 9 2 40A FUSE 3 A900 16 OR YL 8W 10 4 8W 10 3 8W 10 18 8W 10 3 8W 10 4 ZG 8W 42 AIR CONDITIONING HEATER DIESEL ENGINE 8W 42 11 ZG004211 J978W 3 ...

Page 804: ...POWERTRAIN C13 18 DB RD A C PRESSURE SWITCH C22 C3 C3 18 DB BK 1 2 SWITCH PRESSURE LOW A C C21 18 DB OR C21 18 DB OR A C HIGH PRESSURE SWITCH 2 1 5 C144 G106 Z1 18 BK Z1 18 BK 4 C144 Z1 14 BK S104 RELAY 8W 15 7 8W 15 7 8W 30 6 8W 42 12 8W 42 AIR CONDITIONING HEATER GAS ENGINES ZG J978W 3 ZG004210 ...

Page 805: ...4 14 C131 28 CONTROLLER MSA A C COMPRESSOR CLUTCH RELAY CONTROL C13 16 DB RD C13 16 DB RD 10 C132 A C COMPRESSOR CLUTCH RELAY FROM I 8W 42 11 8W 30 29 ZG 8W 42 AIR CONDITIONING HEATER DIESEL ENGINE 8W 42 13 ZG004212 J978W 3 SWITCH SIGNAL A C 37 8W 30 22 POWERTRAIN CONTROL MODULE DG C103 20 59 C4 A C SIGNAL SWITCH ...

Page 806: ... 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 motor Ground for the blower motor is supplied on circuit C7 through the blower motor...

Page 807: ...e 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 through fuse 18 in the PDC Circuit F99 powers the coil side of the A C compressor clutch relay Circuit A19 from fuse 7 in the PDC connects t...

Page 808: ... door motor on circuits C37 and C38 BLEND DOOR MOTOR AUTOMATIC TEMPERATURE 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 AT...

Page 809: ... 8W 43 3 Driver Side Airbag 8W 43 2 Fuse 4 8W 43 2 Fuse 7 8W 43 3 Fuse 22 8W 43 2 G303 8W 43 2 G304 8W 43 3 Instrument Cluster 8W 43 3 Junction Block 8W 43 2 3 Passenger Side Airbag 8W 43 2 Component Page S201 8W 43 3 S202 8W 43 3 S203 8W 43 3 S204 8W 43 3 S205 8W 43 3 S216 8W 43 3 S302 8W 43 3 S306 8W 43 3 S307 8W 43 3 ZG 8W 43 AIRBAG SYSTEM 8W 43 1 ...

Page 810: ...E 2 AIRBAG DRIVER DRIVER AIRBAG LINE 1 LINE 2 AIRBAG DRIVER SIDE AIRBAG AIRBAG SIDE PASSENGER AIRBAG LINE 2 LINE 1 AIRBAG PASSENGER PASSENGER AIRBAG LINE 2 LINE 1 AIRBAG PASSENGER A R44 18 DG YL 6 5 BK YL 18 R42 B A C300 B R42 18 VT R44 18 DB 10 GROUND G303 Z6 16 BK PK PAIR TWISTED PAIR TWISTED DRIVER PASSENGER 8W 15 13 8W 12 23 8W 10 8 8W 10 8 8W 12 2 8W 12 5 8W 43 2 8W 43 AIRBAG SYSTEM ZG J978W ...

Page 811: ...75 18 VT F75 18 VT S201 CCD BUS BUS CCD 8 9 D1 18 VT BR D1 18 VT BR D1 18 VT BR 1 C302 2 WT BK 18 D2 WT BK 18 D2 WT BK 18 D2 S204 S203 S306 S307 19 18 CCD BUS CCD BUS AIRBAG CONTROL MODULE 3 PAIR TWISTED 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 12 8 8W 40 2 8W 40 3 8W 12 2 8W 12 8 8W 15 18 8W 15 18 8W 15 18 8W 15 18 8W 15 17 8W 10 10 ZG 8W 43 AIRBAG SYSTEM 8W 43 3...

Page 812: ...warning lamp in the instru ment cluster AIRBAG IMPACT SENSOR The Airbag system uses a sensor internal to the Airbag Control Module ACM to detect impact For information regarding operation of this sensor refer to the appropriate group of the Service Manual AIRBAG SQUIB AIRBAG IGNITER Circuits R43 and R45 connect the ACM to the drivers airbag squib igniter after passing through the clock spring conn...

Page 813: ...y Lamp 8W 44 2 8 Left Door Courtesy Lamp 8W 44 9 Left Front Door Ajar Switch 8W 44 14 Left Rear Door Ajar Switch 8W 44 14 Left Visor Vanity Lamp 8W 44 5 Liftgate Ajar Switch 8W 44 14 Liftglass Ajar Switch 8W 44 14 Mercury Switch 8W 44 2 Overhead Console 8W 44 4 Component Page Park Neutral Position Switch 8W 44 6 Passenger Door Module 8W 44 10 Radio 8W 44 8 Rear Wiper Module 8W 44 14 Right Courtesy...

Page 814: ...20 YL M2 20 YL Z1 14 BK S220 S202 2 C301 G304 MERCURY SWITCH UNDERHOOD LAMP 1 2 G107 Z4 18 BK Z4 10 BK S124 M1 18 PK M1 18 PK 1 C159 JUNCTION BLOCK SWITCH SWITCH KEY IN HALO LAMP 2 1 14 MODULE CONTROL BODY C1 SWITCH IGN KEY IN SENSE BK 20 Z1 S216 LB 20 G26 C159 2 G107 S109 BK Z4 10 BK Z4 18 BK 14 Z1 GAS DIESEL 8W 15 4 8W 15 5 8W 15 8 8W 15 17 8W 45 3 8W 12 2 8W 15 8 8W 15 8 8W 15 18 8W 15 18 8W 15...

Page 815: ...ME M2 20 YL M2 20 YL M2 20 YL M2 20 YL S334 87 30 C15 11 COURTESY LAMP RELAY JUNCTION BLOCK 2 C15 Z1 20 BK Z1 16 BK S322 OTHERS SUNROOF JUNCTION BLOCK 8W 12 2 8W 15 16 8W 12 2 8W 44 8 8W 12 21 8W 12 13 8W 10 12 8W 12 12 ZG 8W 44 INTERIOR LIGHTING 8W 44 3 ZG004402 J978W 3 ...

Page 816: ...0 YL M2 20 YL S334 87 30 C15 11 COURTESY LAMP RELAY JUNCTION BLOCK 2 C15 Z1 20 BK Z1 16 BK S322 OTHERS SUNROOF OVERHEAD CONSOLE JUNCTION BLOCK 8W 49 2 8W 49 3 8W 12 2 8W 15 16 8W 12 2 8W 44 8 8W 12 21 8W 12 13 8W 10 12 8W 12 12 8W 44 4 8W 44 INTERIOR LIGHTING ZG J978W 3 ZG004403 ...

Page 817: ... PK 20 M1 LAMP VANITY VISOR LEFT RIGHT VISOR VANITY LAMP LAMP CARGO C B A C13 5 M1 20 PK 3 C14 C3 6 LIFTGATE COURTESY LAMP DISABLE M2 20 YL M4 20 WT LG OPENER DOOR GARAGE UNIVERSAL JUNCTION BLOCK MODULE CONTROL BODY 8W 45 10 8W 12 2 8W 12 13 8W 12 21 8W 12 2 8W 44 8 8W 10 12 8W 12 12 ZG 8W 44 INTERIOR LIGHTING 8W 44 5 ZG004404 J978W 3 ...

Page 818: ...OUTPUT SWITCH LAMP BACK UP 8W 12 6 8W 10 8 8W 12 2 8W 12 6 8W 12 6 8W 12 7 8W 44 6 8W 44 INTERIOR LIGHTING ZG J978W 3 ZG004405 2 L10 BK RD 20 GROUND 3 S322 8W 12 6 Z1 16 BK MIRROR NIGHT DAY AUTOMATIC DAY NIGHT MIRROR AUTOMATIC DRIVER POWER MIRROR 8W 62 4 YL BK YL BK 18 P114 20 18 P114 18 5 9 YL BK 20 P114 A 3 4 C235 7 P112 YL WT 20 C302 11 YL WT 18 P112 C334 B YL WT 20 P112 C353 DAY NIGHT MIRROR A...

Page 819: ...2 22 8W 15 14 8W 15 14 8W 15 15 8W 15 15 ZG 8W 44 INTERIOR LIGHTING 8W 44 7 ZG004406 J978W 3 POSITION NEUTRAL PARK SWITCH 1 3 SWITCH POSITION NEUTRAL PARK L10 18 BR LG C3 2 C15 7 6 C131 BR LG L10 18 2 L10 20 BK RD F83 YL DG 18 S134 BK WT 20 T41 BK WT 18 T41 A6 C1 C 8W 44 6 FROM S322 B 8W 44 6 C132 A 8W 44 6 FROM MIRROR NIGHT DAY AUOMATIC FROM ...

Page 820: ... 20 OR 5 RADIO C1 Z5 16 BK Z5 14 BK LB 9 C305 Z5 14 BK LB Z5 14 BK LB Z5 14 BK LB S309 G303 OTHERS AMPLIFIER POWER A 8W 44 12 FROM S214 30 C8 12 7 C8 B COURTESY LAMP LEFT M2 YL 20 COURTESY LAMP RIGHT 20 YL M2 B 12 COURTESY LAMP RELAY 8W 44 2 8W 44 2 8W 15 13 8W 15 13 8W 47 2 8W 15 17 8W 15 17 8W 15 18 8W 15 18 8W 45 3 8W 12 2 8W 12 12 8W 10 12 8W 44 8 8W 44 INTERIOR LIGHTING ZG J978W 3 ZG004407 ...

Page 821: ...8 VT BR D1 18 VT BR D1 18 VT BR D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK 12 C334 S307 2 C302 S203 S204 1 S306 13 Z1 12 BK Z1 12 BK Z1 12 BK Z1 12 BK Z1 20 BK M1 20 PK 2 1 LAMP COURTESY DOOR Z1 12 BK FULL OPTION S324 1 C334 G302 POWER GROUP PAIR TWISTED LEFT 8W 15 12 8W 15 12 8W 30 19 8W 30 32 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 45 2 8W 60 2 8W 12 7 8W 10 10 ...

Page 822: ...8 VT BR D1 18 VT BR D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK 12 C351 S307 2 C302 S203 S204 1 S306 13 Z1 12 BK Z1 12 BK Z1 12 BK Z1 12 BK Z1 20 BK M1 20 PK 2 1 LAMP COURTESY DOOR Z1 12 BK FULL OPTION OTHERS S325 1 C351 G301 C1 C1 C1 C1 C1 PAIR TWISTED RIGHT 8W 12 2 8W 10 10 8W 12 7 8W 60 3 8W 45 2 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 19 8W 30 32 8W 15 14 8W...

Page 823: ...8 OR 6 C302 3 1 LAMPS CONSOLE FLOOR Z1 20 BK Z1 12 BK G305 S304 Z2 20 BK OR Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR S205 S302 G304 8 C307 OR 20 E2 LAMPS ILLUM 1 SWITCH HEADLAMP S209 E2 20 OR E2 20 OR S214 1 ASH RECEIVER LAMP 8W 45 2 8W 40 2 8W 40 5 8W 15 17 8W 15 18 8W 15 15 8W 15 15 8W 15 18 8W 15 18 8W 45 2 8W 15 18 8W 50 2 8W 50 5 8W 50 7 8W 44 12 8W 44 12 ZG 8W 44 INTERIOR LIGHTING 8W 44 11 ZG0044...

Page 824: ...4 CONTROL HEATER A C CIGAR LIGHTER LAMP E2 20 OR E2 20 OR D13 MODULE CONTROL TEMPERATURE AUTOMATIC E2 20 OR S209 MANUAL A C HEATER ATC A 8W 44 8 TO RADIO GRAPHIC DISPLAY MODULE CENTER INFORMATION VEHICLE 10 20 E2 20 OR Z1 20 BK OTHERS OVERHEAD CONSOLE LAMP PANEL PREMIUM 8W 42 5 8W 46 4 8W 46 2 8W 44 11 8W 42 4 8W 15 18 8W 15 18 8W 15 17 8W 15 17 8W 45 2 8W 44 12 8W 44 INTERIOR LIGHTING ZG J978W 3 ...

Page 825: ...CH SIGNAL PANEL LAMP DRIVER BODY CONTROL MODULE 2 Z1 16 BK Z1 14 BK Z1 14 BK E2 20 OR 707 20 BK WT G304 S202 2 C301 E2 20 OR 20 C2 16 C2 1 8 S209 LAMPS ILLUMINATION BATT A6 15A FUSE 17 11 C9 366 16 PK OR 15 JUNCTION BLOCK ZG 8W 44 INTERIOR LIGHTING 8W 44 13 ZG004412 J978W 3 ...

Page 826: ...CH SENSE SENSE SWITCH AJAR DOOR REAR RIGHT LIFTGATE AJAR SWITCH SENSE C3 1 1 2 1 2 SWITCH AJAR LIFTGATE LIFTGLASS AJAR SWITCH G75 18 TN G77 18 TN OR G74 18 TN RD G76 18 TN YL G78 20 TN BK G78 20 TN BK G78 20 TN BK G78 20 TN BK Z1 20 BK Z1 20 BK Z1 12 BK Z1 12 BK Z1 12 BK G300 S328 S329 S316 9 C321 3 C325 MODULE REAR WIPER 6 TN BK G78 20 6 2 8W 53 4 8W 15 11 8W 15 10 8W 45 11 8W 15 11 8W 45 8 8W 44...

Page 827: ... 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 lighter lamp and A C He...

Page 828: ... lamps in the mirrors to circuit Z1 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 con nects the lamps to ground on circuit Z1 The lamps are also grounded when the Body Control Module BCM energizes the courtesy lamp re...

Page 829: ...nt Cluster 8W 45 10 Intermittent Wiper Relay 8W 45 7 Intermittent Wiper Switch 8W 45 7 Junction Block 8W 45 2 3 4 5 7 Key In Switch Halo Lamp 8W 45 3 Left Front Cylinder Lock Switch 8W 45 8 Left Front Door Ajar Switch 8W 45 8 Left Rear Door Ajar Switch 8W 45 8 Component Page Liftgate Ajar Switch 8W 45 11 Liftgate Cylinder Lock Switch 8W 45 8 Liftglass Ajar Switch 8W 45 11 Park Brake Switch 8W 45 9...

Page 830: ... BK OR Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR Z1 16 BK Z1 14 BK Z1 14 BK S205 8 C307 C301 2 S202 CENTER DISTRIBUTION POWER RUN ST A21 C10 5 CONNECTOR LINK DATA 3 11 18 VT BR D1 19 C1 18 WT BK D2 20 C1 CCD BUS BUS CCD S204 S203 18 D1 VT BR WT BK 18 D2 CCD BUS BUS CCD PAIR TWISTED 8W 12 4 8W 12 2 8W 10 13 8W 10 14 8W 10 15 8W 15 18 8W 15 18 8W 15 18 8W 10 7 8W 10 3 8W 10 7 8W 45 2 8W 45 BOD...

Page 831: ...OWER JUNCTION BLOCK BK 20 Z1 S220 S216 BK 16 Z1 BK 18 Z1 LB 20 G26 KEY IN IGN SWITCH SENSE CONTROL RELAY LAMP COURTESY 2 1 BR LG 20 M112 14 C1 C2 6 87 85 LAMP HALO SWITCH KEY IN HORN RELAY WINDOW REAR 30 85 DEFOGGER RELAY LAMP RELAY COURTESY A5 A3 3 C2 8 C10 8W 44 8 8W 12 9 8W 48 2 8W 39 6 8W 41 2 8W 15 17 8W 15 17 8W 12 2 8W 10 3 8W 10 5 8W 10 3 8W 10 3 ZG 8W 45 BODY CONTROL MODULE 8W 45 3 ZG0045...

Page 832: ...C2 C2 9 ULTRALIGHT SENSOR DRIVER DRIVER SENSOR ULTRALIGHT F75 18 VT F75 18 VT S201 G69 20 BK LG L109 20 WT L110 20 OR BK SEAT BELT SWITCH SENSE 14 C3 G10 20 LG RD G305 Z1 20 BK Z1 12 BK 2 1 S304 SWITCH BELT SEAT JUNCTION BLOCK MODULE CONTROL BODY LED AUTOMATIC HEADLAMP LIGHT SENSOR VTSS PARK LAMP RELAY 8W 12 14 8W 12 8 8W 12 8 8W 15 15 8W 15 15 8W 10 10 8W 10 11 8W 12 2 8W 45 4 8W 45 BODY CONTROL ...

Page 833: ...1 12 18 HEADLAMP DIMMER SWITCH JUNCTION BLOCK L4 16 VT OR L3 16 RD OR F12 C234 L95 20 DG YL 714 20 BK OR L3 16 RD OR L3 16 RD OR L3 16 RD OR S107 F2 C234 CONTROL RELAY LAMP FOG 85 RELAY FOG LAMP 85 RELAY HEADLAMP AUTOMATIC C10 C10 8W 12 24 8W 50 2 8W 12 24 8W 50 6 8W 50 3 8W 12 2 8W 50 2 ZG 8W 45 BODY CONTROL MODULE 8W 45 5 ZG004504 J978W 3 ...

Page 834: ... PARK 1 LOW 0 OFF SWITCH HEADLAMP 6 COURTESY LAMP SENSE SWITCH HEADLAMP AUTOMATIC L35 20 BR WT 707 20 BK WT L24 20 LB RD 2 1 0 3 FOG LAMP SWITCH MODULE CONTROL BODY 6 C1 3 M11 20 PK LB SWITCHED COURTESY LAMP FEED Z1 16 BK S202 Z1 14 BK 2 C301 G304 Z1 14 BK 8W 15 18 8W 15 18 8W 50 7 8W 50 5 8W 45 6 8W 45 BODY CONTROL MODULE ZG J978W 3 ZG004505 ...

Page 835: ...N BK V66 18 VT WT V66 18 VT WT V66 16 VT WT V18 20 YL LG V18 20 YL LG 709 20 RD BK 13 20 C235 10 17 S120 RUN ACC A31 JUNCTION BLOCK 20A 1 BREAKER CIRCUIT 12 7 8 4 SWITCH MULTI FUNCTION PART OF SWITCH WIPER INTERMITTENT F86 16 LG BK V6 16 DB V6 16 DB S207 F18 C234 C1 F86 16 LG RD F86 16 LG RD F86 16 LG RD S122 C1 C4 C2 C3 INTERMITTENT WIPER SWITCH PART OF MULTI FUNCTION SWITCH 8W 47 12 8W 53 3 8W 5...

Page 836: ...OCK CYLINDER LIFTGATE CYLINDER FRONT RIGHT LEFT FRONT CYLINDER G71 20 VT YL G71 20 VT YL G71 20 VT YL G71 20 VT YL G71 20 VT YL G71 20 VT YL 3 C321 14 C351 14 C334 1 1 1 SWITCH LOCK SWITCH LOCK LEFT REAR DOOR AJAR SWITCH SENSE DOOR AJAR SENSE SWITCH LEFT FRONT SWITCH DOOR SENSE AJAR FRONT RIGHT DOOR AJAR SENSE SWITCH RIGHT REAR VTSS DISARM SENSE 6 8W 39 5 8W 39 5 8W 39 5 8W 39 5 8W 45 8 8W 45 BODY...

Page 837: ... AUTOMATIC 2 1 D41 20 LG WT D41 20 LG WT S219 D41 20 LG WT D41 20 LG WT D41 20 LG WT D41 20 LG WT C8 20 DG RD C8 20 DG RD F11 C234 19 C235 11 SWITCH BRAKE PARK S303 G9 20 GY BK G9 18 GY BK G9 20 GY BK 2 C304 G9 16 GY BK G9 16 GY BK G9 20 GY BK S117 G9 16 GY BK 1 BRAKE WARNING SWITCH SENSOR TEMPERATURE AMBIENT A C AMBIENT TEMPERATURE SENSOR SIGNAL OTHERS DRL ATC MANUAL A C ATC MANUAL A C 8W 40 6 8W...

Page 838: ...DY G70 20 BR TN G70 20 BR TN 4 C235 6 HOOD SWITCH VTSS G78 20 TN BK A 8W 45 11 TO S329 9 C321 M4 20 WT LG 6 C302 3 LIFTGATE AJAR SWITCH HOOD SWITCH AJAR LIFTGATE COURTESY LAMP DISABLE DRIVER LAMP PANEL LAMP RECEIVER ASH S214 20 OR E2 E2 20 OR 6 8W 44 12 8W 44 12 8W 44 5 8W 44 11 8W 40 4 8W 44 11 8W 44 11 8W 45 10 8W 45 BODY CONTROL MODULE ZG J978W 3 ZG004509 ...

Page 839: ...E LIFTGLASS 1 SWITCH AJAR 2 A 8W 45 10 C321 FROM G78 TN BK 20 TN BK G78 20 20 G78 TN BK REAR WIPER MODULE 6 Z1 BK 20 12 BK Z1 20 BK Z1 BK 12 Z1 S328 12 BK Z1 G300 S328 2 8W 15 11 8W 15 10 8W 53 4 ZG 8W 45 BODY CONTROL MODULE 8W 45 11 ZG004510 J978W 3 ...

Page 840: ...strument 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 DDM Mechanical Instrument Cluster Memory Seat Module Passenger Door Module ...

Page 841: ...The BCM senses when the ignition switch is in the START or RUN position on circuit 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 ...

Page 842: ......

Page 843: ... 8W 46 6 G304 8W 46 2 4 Graphic Display Module 8W 46 2 3 Headlamp Switch 8W 46 6 Junction Block 8W 46 2 3 4 5 6 Lamp Outage Module 8W 46 6 Power Distribution Center 8W 46 2 4 Component Page Powertrain Control Module 8W 46 6 7 S104 8W 46 6 S121 8W 46 6 S130 8W 46 3 5 S202 8W 46 2 4 S203 8W 46 7 S204 8W 46 7 S205 8W 46 2 4 S209 8W 46 2 4 S212 8W 46 2 4 S214 8W 46 2 4 S216 8W 46 2 4 S302 8W 46 2 4 S3...

Page 844: ...MP DRIVER BODY CONTROL MODULE Z2 20 BK OR Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR Z1 20 BK Z1 16 BK Z1 14 BK Z1 14 BK S205 8 C307 S302 2 C301 G304 S202 S216 MODULE DISPLAY GRAPHIC CENTER DISTRIBUTION POWER JUNCTION BLOCK RUN A22 16 C2 8W 10 7 8W 12 2 8W 10 3 8W 10 3 8W 15 17 8W 15 18 8W 15 18 8W 15 18 8W 45 2 8W 15 18 8W 45 10 8W 44 11 8W 44 12 8W 12 6 8W 12 6 8W 12 16 8W 10 12 8W 46 2 8W 46 MESSAGE C...

Page 845: ... A B C212 3 1 4 2 G28 20 LG OR G28 20 LG OR T107 20 BK RD T107 20 BK RD 8 C131 10 9 C132 T106 20 GY OR T106 20 GY OR C132 9 T106 20 GY OR G105 Z12 20 BK TN Z12 16 BK TN S130 1 2 3 4 MODULE DISPLAY GRAPHIC JUNCTION BLOCK 4 NEUTRAL 2 P T 4WD 3 F T 4WD FOUR WHEEL DRIVE SWITCH 1 LOW 4WD 8W 15 7 8W 15 7 8W 12 2 ZG 8W 46 MESSAGE CENTER STANDARD 8W 46 3 ZG004602 J978W 3 ...

Page 846: ...VER BODY CONTROL MODULE Z2 20 BK OR Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR Z1 20 BK Z1 16 BK Z1 14 BK Z1 14 BK S205 8 C307 S302 2 C301 G304 S202 S216 CENTER INFORMATION VEHICLE CENTER DISTRIBUTION POWER JUNCTION BLOCK RUN A22 16 C2 8W 12 2 8W 10 7 8W 10 3 8W 10 3 8W 15 17 8W 15 18 8W 15 18 8W 15 18 8W 45 2 8W 15 18 8W 45 10 8W 44 11 8W 44 12 8W 12 6 8W 12 6 8W 12 16 8W 10 12 8W 46 4 8W 46 MESSAGE CEN...

Page 847: ...212 3 1 4 2 G28 20 LG OR G28 20 LG OR T107 20 BK RD T107 20 BK RD 8 C131 10 9 C132 T106 20 GY OR T106 20 GY OR C132 9 T106 20 GY OR G105 Z12 20 BK TN Z12 16 BK TN S130 1 2 3 4 CENTER INFORMATION VEHICLE JUNCTION BLOCK 4 NEUTRAL 2 P T 4WD 3 F T 4WD FOUR WHEEL DRIVE SWITCH 1 LOW 4WD 8W 15 7 8W 15 7 8W 12 2 ZG 8W 46 MESSAGE CENTER OVERHEAD CONSOLE 8W 46 5 ZG004604 J978W 3 ...

Page 848: ...VEL SENSOR G46 20 BK LB 5 C307 LAMP OUTAGE MODULE OTHERS G302 S314 Z1 12 BK Z1 18 BK G46 20 LB BK G46 20 LB BK 9 LAMP OUTAGE MODULE REAR LAMP OUT INDICATOR DRIVER 9 C316 VEHICLE INFORMATION CENTER JUNCTION BLOCK JUNCTION BLOCK SWITCH WARNING HAZARD SIGNAL TURN OR BK L5 1 C5 18 2 ELECTRONIC FLASHER C1 DIESEL GAS PK DB G118 54 MODULE CONTROL POWERTRAIN C4 20 8 C131 G118 PK DB 20 8W 30 29 8W 52 6 8W ...

Page 849: ...03 S204 D2 18 WT BK D2 18 WT BK D1 18 VT BR D1 18 VT BR 19 20 C235 10 11 CCD BUS BUS CCD CCD BUS CCD BUS MODULE CONTROL POWERTRAIN PAIR TWISTED PAIR TWISTED PAIR TWISTED TWISTED PAIR 8W 30 18 8W 30 19 8W 30 18 8W 30 19 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 45 2 ZG 8W 46 MESSAGE CENTER OVERHEAD CONSOLE 8W 46 7 ZG004606 J978W 3 ...

Page 850: ... to illuminating the 4WD dis play 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 Z12 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 the GDM to ground on ci...

Page 851: ...UID WARNING When the low washer fluid switch closes it con nects circuit G29 from the VIC to ground on circuit Z1 The VIC displays the Low 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 ...

Page 852: ......

Page 853: ... Park Lamp Relay 8W 47 2 Power Amplifier 8W 47 3 4 5 6 7 9 10 11 13 Power Antenna 8W 47 3 4 Power Antenna Relay 8W 47 3 4 Powertrain Control Module 8W 47 12 Radio 8W 47 2 3 4 8 9 10 12 Rear Speaker 8W 47 11 13 Component Page Right Front Door Speaker 8W 47 5 6 8 Right Instrument Panel Speaker 8W 47 5 6 Right Radio Remote Switch 8W 47 12 Right Rear Door Speaker 8W 47 7 8 11 S202 8W 47 3 4 S203 8W 47...

Page 854: ...8 VT BR 20 C1 2 C2 S203 D2 18 WT BK D2 18 WT BK C2 16 C1 5 E2 20 OR E2 20 OR E2 20 OR S214 S209 MODULE CONTROL BODY CCD BUS BUS CCD PANEL LAMP DRIVER PANEL LAMP DRIVER CCD BUS BUS CCD 9 C305 Z5 16 BK Z5 14 BK LB G303 PAIR TWISTED TWISTED PAIR 12 PARK LAMP RELAY 8W 12 14 8W 12 3 8W 12 16 8W 12 2 8W 10 9 8W 10 11 8W 10 12 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 44 12 8W 44 11 8W 45 2 8W 45 10 8W 15 1...

Page 855: ... 2 C11 1 C11 C5 4 X60 18 DG RD X60 20 DG RD M POWER ANTENNA EXPORT 1 DOWN X14 20 WT X16 20 GY X17 20 DG G304 Z1 18 BK Z1 16 BK Z1 16 BK Z1 14 BK Z1 14 BK C301 S220 S216 S202 COAX ANTENNA RADIO ANTENNA COAX 2 1 2 JUNCTION BLOCK 2 UP 2 UP 8W 10 12 8W 12 2 8W 15 18 8W 15 17 8W 15 17 8W 15 18 8W 12 11 ZG 8W 47 AUDIO SYSTEM LTD AND POWER AMP 8W 47 3 ZG004702 J978W 3 ...

Page 856: ...ATT A7 2 C11 1 C11 C5 4 X60 18 DG RD X60 20 DG RD M POWER ANTENNA EXPORT 1 DOWN X14 20 WT X16 20 GY X17 20 DG G304 Z1 18 BK Z1 16 BK Z1 16 BK Z1 14 BK Z1 14 BK C301 S220 S216 S202 COAX ANTENNA RADIO ANTENNA COAX 2 1 2 JUNCTION BLOCK 2 UP 2 UP 8W 12 2 8W 10 12 8W 15 18 8W 15 17 8W 15 17 8W 15 18 8W 12 11 8W 47 4 8W 47 AUDIO SYSTEM PREMIUM ZG J978W 3 ZG004703 ...

Page 857: ...G BK C2 9 X85 16 LG BK POWER AMPLIFIER AMPLIFIED LEFT FRONT AMPLIFIED LEFT FRONT LB DG 16 X80 2 C1 LB BK 20 X80 C307 2 LB DG 16 X80 LB BK 16 X80 S319 C351 8 DB RD 20 X56 RIGHT FRONT DOOR SPEAKER RIGHT INSTRUMENT PANEL SPEAKER VT 20 X54 S335 LB RD 20 X82 C307 1 C351 6 LB RD 16 X82 LB RD 16 X82 LB RD 16 X82 1 C1 FRONT RIGHT AMPLIFIED FRONT RIGHT AMPLIFIED A B B A B A B A ZG 8W 47 AUDIO SYSTEM PREMIU...

Page 858: ... LG BK C2 11 X85 16 LG BK POWER AMPLIFIER AMPLIFIED LEFT FRONT AMPLIFIED LEFT FRONT LB DG 16 X80 2 C2 LB RD 20 X80 C307 2 LB DG 16 X80 LB DG 16 X80 S319 C351 8 DB RD 20 X56 RIGHT FRONT DOOR SPEAKER RIGHT INSTRUMENT PANEL SPEAKER VT 20 X54 S335 LB BK 20 X82 C307 1 C351 6 LB RD 16 X82 LB RD 16 X82 LB RD 16 X82 1 C2 FRONT RIGHT AMPLIFIED FRONT RIGHT AMPLIFIED A B B A B A B A 8W 47 6 8W 47 AUDIO SYSTE...

Page 859: ...PEAKER DOOR REAR LEFT RIGHT REAR DOOR SPEAKER C343 C345 C2 1 POWER AMPLIFIER A C343 X93 16 WT RD X52 20 DB WT 3 C1 X94 16 TN RD A C345 X52 20 DB WT AMPLIFIED LEFT REAR REAR RIGHT AMPLIFIED B B AMPLIFIED RIGHT REAR REAR RIGHT AMPLIFIED ZG 8W 47 AUDIO SYSTEM PREMIUM 8W 47 7 ZG004706 J978W 3 ...

Page 860: ...C1 3 RIGHT FRONT FRONT RIGHT 5 C3 C3 4 LEFT FRONT FRONT LEFT 2 C1 B A X53 16 DG X53 20 DG X55 20 BR RD X55 16 BR RD DOOR FRONT LEFT C334 SPEAKER C305 X53 20 DG X55 20 BR RD X54 20 VT YL X56 20 DB X51 20 BR YL X57 20 BR LB X52 20 DB WT X58 20 DB OR 6 6 A A 8 8 B B 14 13 11 10 8 7 5 6 1 2 14 13 11 10 8 7 PAIR TWISTED PAIR TWISTED TWISTED PAIR TWISTED PAIR PAIR TWISTED PAIR TWISTED TWISTED PAIR PAIR ...

Page 861: ...DG X53 20 DG X55 16 BR RD X55 20 BR RD X51 16 BR YL X51 20 BR YL X57 16 BR LB X57 20 BR LB X54 16 VT X54 20 VT YL X56 16 DB X56 20 DB X52 16 DB WT X52 20 DB WT X58 16 DB OR X58 20 DB WT 7 C305 14 13 8 8 13 7 14 11 10 10 11 5 2 6 1 Z5 16 BK LB Z5 16 BK LB Z5 14 BK LB G303 S309 B FUSED 17 C1 ANTENNA 7 FUSE 20A BATT A250 BLOCK JUNCTION F75 16 VT F75 16 VT F75 14 VT S318 ANTENNA C1 C1 C1 C1 C1 C1 C1 C...

Page 862: ...OWER AMPLIFIER RADIO X53 16 DG X53 20 DG X55 16 BR RD X55 20 BR RD X51 16 BR YL X51 20 BR YL X57 16 BR LB X57 20 BR LB X54 16 VT X54 20 VT YL X56 16 DB X56 20 DB X52 16 DB WT X52 20 DB WT X58 16 DB OR X58 20 DB OR 7 C305 14 13 8 8 13 7 14 11 10 10 11 5 2 6 1 Z5 16 BK LB Z5 16 BK LB Z5 14 BK LB G303 S309 B FUSED 8 C2 ANTENNA 7 FUSE 20A BATT A250 BLOCK JUNCTION F75 16 VT F75 16 VT F75 14 VT S318 ANT...

Page 863: ... A C343 X93 16 WT RD X52 20 DB WT 8 C2 X94 16 TN RD A C345 X58 20 DB OR AMPLIFIED LEFT REAR REAR RIGHT AMPLIFIED B B SPEAKER REAR C D A B X95 16 BR YL X98 16 DB OR X97 16 BR LB X98 16 DB WT 4 C2 C2 6 C2 5 7 C2 AMPLIFIED REAR REAR AMPLIFIED AMPLIFIED REAR REAR AMPLIFIED AMPLIFIED RIGHT REAR AMPLIFIED LEFT REAR B A ZG 8W 47 AUDIO SYSTEM LTD 8W 47 11 ZG004710 J978W 3 ...

Page 864: ...2 18 BK OR Z2 18 BK OR G304 S302 S205 C307 CLOCKSPRING G20 G10 G11 G19 8 MODULE CONTROL POWERTRAIN MODULE CONTROL BODY C235 D1 18 VT BR RADIO LEFT RADIO REMOTE SWITCH RIGHT RADIO REMOTE SWITCH VEHICLE SPEED CONTROL SWITCH HORN 8 7 6 9 10 7 SEEK DN 9 VOL DN 8 SEEK UP 6 PRESET 10 VOL UP 8W 45 2 8W 45 7 8W 30 18 8W 30 19 8W 30 18 8W 30 19 8W 15 18 8W 15 18 8W 45 2 8W 15 18 8W 30 19 8W 30 32 8W 30 18 ...

Page 865: ...REAR HIGH HIGH REAR LEFT 7 C2 C2 5 RIGHT REAR HIGH HIGH REAR RIGHT 6 C2 POWER AMPLIFIER LTD B C D A REAR SPEAKER X95 16 BR YL X97 16 BR LB X96 16 DB OR X98 16 DB WT ZG 8W 47 AUDIO SYSTEM 8W 47 13 ZG004712 J978W 3 ...

Page 866: ...d SPEAKERS STANDARD SYSTEM The standard system uses four speakers Circuit X53 feeds the speaker in the left front door Circuit X55 is the return from the speaker to the radio Circuit X54 feeds the right front door speaker Cir cuit X56 is the return from the speaker to the radio From the radio circuit X51 connects to circuit X52 at the jumper harness for the left rear door speaker Circuit X51 and X...

Page 867: ...ted selection LIMITED PLUS SYSTEM The circuits for the Limited Plus system are the same as the Premium System except for the sound bar mounted on the inside roof headliner just for ward of the liftgate For the speakers housed in the sound bar circuit X95 from the amplifier is the feed for the left speak ers Circuit X97 is the return to the amplifier for the left speakers Circuit X98 from the ampli...

Page 868: ......

Page 869: ...ody Control Module 8W 48 2 Fuse 10 8W 48 2 G300 8W 48 2 G304 8W 48 2 Junction Block 8W 48 2 Rear Window Defogger 8W 48 2 Rear Window Defogger Relay 8W 48 2 Component Page Rear Window Defogger Switch 8W 48 2 S202 8W 48 2 S216 8W 48 2 S316 8W 48 2 S328 8W 48 2 S332 8W 48 2 ZG 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

Page 870: ...DEFOGGER WINDOW REAR BODY CONTROL MODULE 2 G304 Z1 14 BK Z1 14 BK Z1 16 BK Z1 20 BK S202 S216 2 C301 C15 12 BK WT C15 12 BK WT 1 C301 2 C322 LIFTGLASS OTHERS C15 12 BK LB C15 12 BK LB C15 12 BK S332 DEFOGGER WINDOW REAR JUNCTION BLOCK 3 C6 BATT A900 10 2 SWITCH POD PART OF 3 8W 10 4 8W 12 2 8W 15 17 8W 15 18 8W 15 18 8W 45 3 8W 45 9 8W 45 3 8W 45 9 8W 12 9 8W 15 10 8W 45 11 8W 15 11 8W 15 11 8W 48...

Page 871: ...window defogger relay on circuit C14 When the BCM grounds the rear window defogger relay coil the contacts close and connect circuit A900 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 circui...

Page 872: ......

Page 873: ...49 2 Courtesy Lamp Relay 8W 49 3 Fuse 6 8W 49 2 Fuse 16 8W 49 3 G304 8W 49 3 Junction Block 8W 49 2 3 Overhead Console 8W 49 2 3 Powertrain Control Module 8W 49 2 S202 8W 49 3 Component Page S203 8W 49 2 S204 8W 49 2 S216 8W 49 3 S220 8W 49 3 S321 8W 49 3 S322 8W 49 3 S323 8W 49 2 S334 8W 49 3 ZG 8W 49 OVERHEAD CONSOLE 8W 49 1 ...

Page 874: ... 20 C1 MODULE CONTROL BODY 6 FUSE 15A 3 RUN A22 BLOCK JUNCTION C15 1 IGN FUSED RUN F83 20 YL DG F83 20 YL DG S323 CCD BUS BUS CCD BUS CCD CCD BUS CCD BUS BUS CCD MODULE CONTROL POWERTRAIN PAIR TWISTED PAIR TWISTED TWISTED PAIR PAIR TWISTED PAIR TWISTED 8W 10 8 8W 30 18 8W 30 19 8W 12 7 8W 12 2 8W 12 6 8W 45 2 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 49 2 8W 49 OVERHEAD CONSOLE ZG J978W 3 ZG004901 ...

Page 875: ... Z1 18 BK M2 20 YL M2 20 YL M2 20 YL S334 Z1 16 BK Z1 14 BK Z1 14 BK G304 S202 S216 2 C301 OVERHEAD CONSOLE OTHERS 30 87 IN JB RELAY LAMP COURTESY JUNCTION BLOCK 16 BK Z1 8W 12 2 8W 10 12 8W 44 8 8W 15 17 8W 15 18 8W 15 18 8W 12 21 8W 15 17 8W 12 21 8W 15 16 8W 12 13 8W 12 2 8W 12 12 ZG 8W 49 OVERHEAD CONSOLE 8W 49 3 ZG004902 J978W 3 ...

Page 876: ...ity The overhead console receives the fuel percentage and distance information on the CCD bus from the Powertrain Control Module PCM The overhead 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 c...

Page 877: ... 8W 50 8 Left Fog Lamp 8W 50 6 Left Front Park Lamp 8W 50 9 Left Front Turn Signal Lamp 8W 50 9 Left Headlamp 8W 50 3 Left Headlamp Leveling Motor 8W 50 11 Park Brake Switch 8W 50 4 Park Lamp Relay 8W 50 7 8 Power Distribution Center 8W 50 2 4 6 Radio 8W 50 8 Right Fog Lamp 8W 50 6 Component Page Right Front Park Lamp 8W 50 10 Right Front Turn Signal Lamp 8W 50 10 Right Headlamp 8W 50 3 Right Head...

Page 878: ...16 TN BK F34 16 TN BK L3 16 RD OR TO C234 C1 9 BODY CONTROL MODULE DIMMER SWITCH LOW BEAM OUTPUT CONTROL RELAY HEADLAMP AUTOMATIC 12 C2 L4 16 VT OR C234 TO L4 16 VT OR 714 20 BK OR B 8W 50 3 A 8W 50 3 CENTER DISTRIBUTION POWER JUNCTION BLOCK 1 2 1 3 SWITCH 3 HIGH 2 FLASH TO PASS 1 LOW AUTOMATIC HEADLAMP RELAY 8W 12 2 8W 10 3 8W 10 3 8W 45 5 8W 12 16 8W 10 11 8W 10 12 8W 50 2 8W 50 FRONT LIGHTING Z...

Page 879: ... 16 RD OR L4 16 VT OR Z1 16 BK Z1 16 BK Z1 16 BK Z1 14 BK G106 S104 S109 LEFT HEADLAMP RIGHT HEADLAMP OUTPUT BEAM HIGH SWITCH DIMMER MODULE CONTROL BODY 24 B 8W 50 2 A 8W 50 2 F12 C234 L3 16 RD OR C1 BK 16 Z1 16 BK Z1 G109 GAS DIESEL 8W 15 4 8W 15 5 8W 45 5 8W 15 4 8W 15 5 8W 52 8 8W 15 6 8W 15 7 8W 52 8 8W 15 6 8W 15 7 ZG 8W 50 FRONT LIGHTING 8W 50 3 ZG005002 J978W 3 ...

Page 880: ...1 BRAKE WARNING SWITCH 2 C304 S303 G9 20 GY BK G9 18 GY BK SWITCH BRAKE PARK G9 20 GY BK MODULE CONTROL BODY C3 2 BRAKE SWITCH SENSE 8W 45 9 8W 40 6 8W 50 4 8W 50 FRONT LIGHTING ZG J978W 3 ZG005003 ...

Page 881: ... SWITCH SENSE DRIVER SENSOR LIGHT ULTRA 2 C2 C2 9 ULTRA LIGHT SENSOR SIGNAL 3 4 LED VTSS SENSOR LIGHT HEADLAMP AUTOMATIC L109 20 WT L110 20 OR BK 2 Z1 14 BK S202 3 LOW 2 PARK 0 OFF 1 AUTO SWITCH HEADLAMP 3 2 0 1 3 2 0 1 1 S209 OR 20 E2 OR 20 E2 C2 PANEL LAMPS DRIVER 16 SWITCH MULTI FUNCTION PART OF 8W 45 5 8W 44 11 8W 15 18 8W 10 11 8W 45 5 8W 45 5 8W 15 18 ZG 8W 50 FRONT LIGHTING 8W 50 5 ZG005004...

Page 882: ...CH LAMP FOG L39 20 LB L39 18 LB 1 2 1 2 L39 18 LB L39 18 LB S105 Z1 18 BK Z1 18 BK Z1 16 BK Z1 10 BK S109 S104 G106 RELAY LAMP FOG LAMP FOG LEFT RIGHT FOG LAMP CENTER DISTRIBUTION POWER JUNCTION BLOCK GAS DIESEL Z1 14 BK 8W 12 2 8W 10 3 8W 10 3 8W 15 6 8W 15 7 8W 52 8 8W 52 8 8W 12 24 8W 45 5 8W 10 13 8W 50 6 8W 50 FRONT LIGHTING ZG J978W 3 ZG005005 ...

Page 883: ...ADLAMP 6 5 15 C1 C2 21 L79 20 TN L90 20 DB RD L35 20 BR WT Z1 16 BK Z1 14 BK Z1 14 BK S202 C301 G304 PARK LAMP RELAY CONTROL SENSE SWITCH LAMP FOG MODULE CONTROL BODY JUNCTION BLOCK 366 16 PK OR 3 2 0 1 4 16 PANEL LAMP DIMMER 20 C2 BK WT 707 20 8 SWITCH SENSE 2 8W 10 11 8W 12 2 8W 45 4 8W 45 6 8W 15 18 8W 15 18 8W 12 14 ZG 8W 50 FRONT LIGHTING 8W 50 7 ZG005006 J978W 3 ...

Page 884: ... TO C102 TO C150 S103 C 8W 50 9 D 8W 50 10 JUNCTION BLOCK 30 85 4 C8 DB RD 20 L90 4 C1 RADIO L90 20 DB RD 11 5 C8 CENTER VEHICLE INFORMATION PARK LAMP RELAY OUTPUT 3 MODULE LAMP OUTAGE 4 OUTPUT RELAY PARK LAMP LAMP PARK RELAY OUTPUT 5 DB RD 18 L90 4 C8 OPTIONAL DB RD L90 18 L90 DB RD 18 C1 C1 C1 8W 51 2 8W 46 6 8W 47 2 8W 12 2 8W 10 11 8W 45 4 8W 12 14 8W 50 8 8W 50 FRONT LIGHTING ZG J978W 3 ZG005...

Page 885: ...10 C234 S409 S147 S103 FROM Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 16 BK L64 18 TN DB G106 3 C102 S109 S149 16 G A SWITCH WARNING HAZARD SIGNAL TURN LEFT TURN SIGNAL FEED LAMP PARK FRONT SIGNAL INDICATOR LEFT TURN LEFT L65 LG DB 18 8W 52 2 8W 15 4 8W 15 4 8W 15 5 8W 15 6 8W 15 7 8W 52 8 8W 15 5 8W 40 4 ZG 8W 50 FRONT LIGHTING 8W 50 9 ZG005008 J978W 3 ...

Page 886: ... RD S150 S103 FROM 1 C4 5 C4 11 C1 Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 14 BK G106 3 C150 S104 7 11 S152 FEED SIGNAL TURN RIGHT TURN SIGNAL HAZARD WARNING SWITCH FRONT PARK LAMP INDICATOR SIGNAL RIGHT TURN RIGHT C150 S408 TN DB 18 L64 8W 12 17 8W 52 2 8W 15 6 8W 15 7 8W 15 6 8W 15 7 8W 15 6 8W 15 7 8W 52 8 8W 12 2 8W 40 4 8W 50 10 8W 50 FRONT LIGHTING ZG J978W 3 ZG005009 ...

Page 887: ...L104 4 3 2 1 S114 S113 S112 S115 S110 S111 L101 20 RD L101 20 RD L106 20 YL L106 20 YL L105 20 PK L105 20 PK L102 20 WT L102 20 WT L103 20 LB L103 20 LB L104 20 LG L104 20 LG H5 C236 H4 H3 H6 H7 H2 6 2 8 7 3 4 5 SWITCH LEVELING HEADLAMP F83 18 YL DG 1 G304 Z1 20 BK Z1 14 BK Z1 14 BK S202 2 C301 FROM BLOCK JUNCTION GROUND FUSED IGN RUN 8W 15 18 8W 12 2 ZG 8W 50 FRONT LIGHTING 8W 50 11 ZG005010 J978...

Page 888: ... 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 on circuit L3 when the headlamp switch is off and the ig...

Page 889: ... Power Distribution Center PDC powers the relay coil and contacts When the fog lamp relay energizes it connects cir cuit F62 from fuse 19 in the Power Distribution Cen ter PDC to circuit L39 Circuit L39 powers the fog lamps and the fog lamp switch LED Circuit Z1 pro vides ground for the lamps and the LED ZG 8W 50 FRONT LIGHTING 8W 50 13 DESCRIPTION AND OPERATION Continued ...

Page 890: ......

Page 891: ...Junction Block 8W 51 2 5 6 7 Lamp Outage Module 8W 51 2 3 4 5 6 7 Left Back Up Lamp 8W 51 6 Left License Lamp 8W 51 6 Left Rear Fog Lamp 8W 51 7 Left Tail Stop Lamp 8W 51 3 4 Park Lamp Relay 8W 51 2 Park Neutral Position Switch 8W 51 5 Component Page Rear Fog Lamp Relay A 8W 51 7 Right Back Up Lamp 8W 51 6 Right License Lamp 8W 51 6 Right Rear Fog Lamp 8W 51 7 Right Tail Stop Lamp 8W 51 3 4 S119 8...

Page 892: ... CONTROL PARK RELAY LAMP OUTPUT F87 18 WT PK 10 3 C13 4 2 6 7 8 S312 L50 18 WT TN L50 18 WT TN L50 18 WT TN L50 18 WT TN LAMP OUTAGE MODULE 4 5 L90 18DB RD L90 18DB RD PARK LAMP RELAY RELAY LAMP PARK PARK LAMP RELAY L90 18 DB RD FUSED STOP LAMP SWITCH SWITCH LAMP STOP STOP LAMP SWITCH INPUT SWITCH LAMP STOP BATT A6 IGN ST RUN INPUT INPUT INPUT INPUT INPUT INPUT C1 C1 C1 C1 C1 C1 C1 C1 8W 12 2 8W 1...

Page 893: ... L22 18 LB L22 18 LB B B 1 C320 L74 18 PK BK A LAMP STOP TAIL RIGHT L73 18 PK WT L73 18 PK WT 1 C328 L73 18 PK WT LEFT TAIL STOP LAMP A L87 18 DG WT 1 C326 L87 18 DG WT A C359 L87 20 DG WT 1 LAMP STOP MOUNTED HIGH CENTER LAMP STOP TAIL RIGHT LEFT TAIL STOP LAMP 1 C372 L50 18 WT TN RELAY LAMP STOP TOW TRAILER NO 1 MOUNTED LAMP NO 3 CENTER HIGH STOP 1 CENTER MOUNTED LAMP NO 2 1 STOP HIGH DG WT 20 L8...

Page 894: ... RELAY LAMP PARK STOP LAMP SWITCH OUPUT STOP LAMP SWITCH OUPUT 5 4 7 6 LAMP OUTAGE MODULE LAMP STOP TAIL RIGHT G B A A B G LEFT TAIL STOP LAMP S411 S417 Z1 18 BK Z1 18 BK Z1 18 BK 4 C328 Z1 18 BK S314 Z1 12 BK Z1 18 BK 4 C320 S316 Z1 18 BK Z1 12 BK G300 C2 C2 C2 C2 8W 15 11 8W 15 11 8W 15 12 8W 15 11 8W 15 9 8W 51 4 8W 51 REAR LIGHTING ZG J978W 3 ZG005103 ...

Page 895: ... 20BK B C359 Z1 18 BK S316 Z1 12 BK Z1 20 BK 7 C326 Z1 18 BK G300 S314 Z1 18 BK Z1 12 BK G302 18 F83 C132 8 YL DG 18 F83 YL DG 18 F83 YL DG 18 F83 S119 18 C235 12 YL DG 18 F83 YL DG 18 F83 S212 BLOCK JUNCTION 1 C8 RUN A22 6 FUSE 15A BR LG 18 L10 PARK NEUTRAL POSITION SWITCH 3 1 YL DG TO BLOCK JUNCTION A 8W 51 6 BR LG 18 L10 C131 6 SPEED PROPORTIONAL STEERING OTHERS 2 C2 1 C2 C1 DIESEL GAS YL DG 2 ...

Page 896: ...ARK LAMP RELAY OUTPUT A 8W 51 5 FROM C131 L10 18 BR LG C14 1 C3 2 JUNCTION BLOCK L10 18 BR LG L10 18 BR LG L10 18 BR LG S311 3 C328 C320 3 L10 18 BR LG L10 18 BR LG G A G A LAMP BACK UP LEFT RIGHT BACK UP LAMP Z1 18 BK S417 Z1 18 BK 4 C320 Z1 18 BK S411 Z1 18 BK Z1 18 BK 4 C328 S314 Z1 18 BK Z1 12 BK G302 TOW CONNECTOR TRAILER FACTORY C2 4 3 AFTERMARKET TRAILER TOW CONNECTOR 8W 54 5 8W 15 12 8W 15...

Page 897: ...L36 18 LG OR 7 C307 1 1 LAMP OUTAGE MODULE G A L36 18 LG OR L36 18 LG BK 6 C328 LAMP FOG REAR LEFT RIGHT REAR FOG LAMP A G L36 18 LG BK L36 18 LG OR C320 6 Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 12 BK S202 S417 S411 4 C328 4 C320 S316 G300 8W 12 14 8W 10 11 8W 12 2 8W 12 20 8W 10 9 8W 50 2 8W 50 5 8W 50 7 8W 15 18 8W 51 2 8W 51 3 8W 51 4 8W 51 5 8W 51 6 8W 15 18 8W 15 11 8W 15 9 ...

Page 898: ... Stop 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 REAR FOG LAMPS The rear fog lamps are powered by the rear fog lamp relay on circuit L36 The relay coil and contacts are powered by circuit L95 from fuse 15 in the fuse block T...

Page 899: ...W 52 8 Park Lamp Relay 8W 52 8 Right Front Park Lamp 8W 52 3 Right Front Side Marker Lamp 8W 52 3 Right Front Turn Signal 8W 52 8 Right Front Turn Signal Lamp 8W 52 3 Right Park Lamp 8W 52 8 Right Rear Turn Signal Lamp 8W 52 5 7 Right Side Repeater 8W 52 8 Component Page S103 8W 52 8 S104 8W 52 3 8 S109 8W 52 3 8 S147 8W 52 8 S149 8W 52 8 S150 8W 52 8 S152 8W 52 8 S202 8W 52 2 6 S216 8W 52 2 6 S22...

Page 900: ...STER L65 18 LG DB F10 C234 L65 18 LG DB 1 C102 L64 18 TN DB JUNCTION BLOCK C3 11 C4 5 1 C4 7 L64 18 TN DB JUNCTION BLOCK 2 1 LEFT TURN SIGNAL INDICATOR INDICATOR SIGNAL TURN RIGHT 0 OFF 2 LT TURN 1 RT TURN SWITCH WARNING HAZARD SIGNAL TURN 4 HAZARD 2 1 4 0 VEHICLE INFORMATION CENTER TO OR BK 18 L5 SWITCH PART OF MULTI FUNCTION 8W 46 6 8W 12 2 8W 10 8 8W 10 12 8W 12 2 8W 40 4 8W 15 18 8W 15 18 8W 1...

Page 901: ...3 B A BK 18 Z1 BK 18 Z1 BK 18 Z1 B A BK 18 Z1 A G TN DB 18 L64 TN DB 18 L64 TN DB 18 L64 Z1 14 BK G106 S104 A 8W 52 2 B 8W 52 2 JUNCTION BLOCK FROM LAMP MARKER SIDE FRONT LAMP PARK FRONT FRONT PARK LAMP FRONT SIDE MARKER LAMP LEFT LEFT RIGHT RIGHT 8W 15 4 8W 15 5 8W 12 15 8W 12 15 8W 15 6 8W 15 7 8W 15 6 8W 15 7 8W 52 8 ZG 8W 52 TURN SIGNALS 8W 52 3 ZG005202 J978W 3 L64 18 TN DB L65 18 LG DB 1 C10...

Page 902: ...A22 L5 18 OR BK L12 18 VT TN C 8W 52 5 D 8W 52 5 JUNCTION BLOCK FLASHER ELECTRONIC 4 VEHICLE INFORMATION CENTER L5 18 OR BK 2 1 0 OFF 2 LT TURN 1 RT TURN SWITCH WARNING HAZARD SIGNAL TURN 4 HAZARD 2 1 4 0 PART OF MULTI FUNCTION SWITCH 8W 46 6 8W 52 2 8W 10 8 8W 12 2 8W 12 6 8W 52 4 8W 52 TURN SIGNALS ZG J978W 3 ZG005203 ...

Page 903: ...BK 18 Z1 BK 18 Z1 G300 LAMP SIGNAL TURN REAR RIGHT A G C320 5 LG 18 L61 TN 18 L60 LG 18 L61 4 L61 18 LG C372 5 1 1 RELAY TURN LEFT TOW TRAILER TRAILER TOW RIGHT TURN RELAY C 8W 52 4 D 8W 52 4 TURN SIGNAL HAZARD WARNING SWITCH TO TO SWITCH WARNING HAZARD SIGNAL TURN 8W 15 12 8W 15 12 8W 15 9 8W 15 11 8W 15 11 8W 15 11 8W 54 3 8W 54 3 ZG 8W 52 TURN SIGNALS FACTORY TRAILER TOW 8W 52 5 ZG005204 J978W ...

Page 904: ... Z1 14 BK Z1 14 BK S220 S216 S202 2 C301 G304 L61 18 DG E 8W 52 7 TO C307 F 8W 52 7 TO C307 L60 18 TN JUNCTION BLOCK 2 1 SWITCH WARNING HAZARD SIGNAL TURN 2 1 4 0 VEHICLE INFORMATION CENTER TO OR BK 18 L5 MULTI FUNCTION SWITCH PART OF 4 HAZARD 2 LT TURN 0 OFF 1 RT TURN 8W 46 6 8W 12 2 8W 10 8 8W 10 12 8W 15 18 8W 15 18 8W 15 17 8W 15 17 8W 12 6 8W 12 11 8W 52 6 8W 52 TURN SIGNALS ZG J978W 3 ZG0052...

Page 905: ... 18 Z1 BK 18 Z1 BK 18 Z1 G300 LAMP SIGNAL TURN REAR RIGHT A G C320 5 TN 18 L60 LG 18 L61 E 8W 52 6 F 8W 52 6 C307 C14 8 20A FUSE 8 BATT A250 JUNCTION BLOCK D S315 F70 14 PK BK F70 14 PK BK TURN SIGNAL HAZARD WARNING SWITCH TO TO SWITCH WARNING HAZARD SIGNAL TURN 8W 54 4 8W 15 12 8W 15 12 8W 15 9 8W 15 11 8W 15 11 8W 15 11 8W 12 8 8W 10 10 8W 39 3 8W 12 2 8W 12 8 ZG 8W 52 TURN SIGNALS AFTERMARKET T...

Page 906: ... L90 18 DB RD S103 L90 18 DB RD 2 C102 2 1 RIGHT PARK LAMP L90 18 DB RD L90 18 DB RD L90 18 DB RD C150 2 S150 S152 C150 3 BK 18 Z1 Z1 18 BK BK 18 Z1 18 Z1 BK Z1 16 BK G106 S104 Z1 18 BK L64 18 LG DB C150 1 LG DB 18 L64 LG DB 18 L64 LG DB 18 L64 S412 G 8W 52 2 TURN SIGNAL HAZARD WARNING FROM JUNCTION BLOCK FROM RIGHT SIDE REPEATER SIGNAL TURN FRONT RIGHT 1 2 2 1 87 IN JB RELAY LAMP PARK 8W 50 7 8W ...

Page 907: ...rear turn signal lamps on circuits L60 and L61 and the front turn signal and side marker lamps on circuits L64 and L65 TURN SIGNALS When the 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 Circu...

Page 908: ......

Page 909: ...ction Block 8W 53 2 4 Lift Gate Ajar Switch 8W 53 5 Lift Glass Ajar Switch 8W 53 5 Rear Washer Pump Motor 8W 53 5 Rear Wiper Module 8W 53 4 Rear Wiper Motor 8W 53 4 Component Page Rear Wiper Washer Switch 8W 53 4 S120 8W 53 3 S121 8W 53 2 3 5 S122 8W 53 3 S315 8W 53 4 S316 8W 53 5 S328 8W 53 5 S329 8W 53 5 S336 8W 53 4 Vehicle Information Center 8W 53 5 Windshield Washer Pump Motor 8W 53 2 Windshi...

Page 910: ...V50 18 LG WT V51 18 WT V11 18 TN BK V11 18 TN BK C234 F1 V11 18 TN BK A B Z2 18 BK G109 Z2 12 BK S121 MOTOR PUMP WASHER WINDSHIELD B 8W 53 3 JUNCTION BLOCK M 0 1 5 6 C235 BR WT BR WT 5 V3 18 16 14 V3 18 WIPER MOTOR WINDSHIELD 6 RD YL V4 18 C234 F4 RD YL V4 18 BR WT V3 9 18 2 3 4 5 0 0 M 8 7 DB 16 V6 DB 16 V6 16 DB V6 F18 C234 MULTI FUNCTION SWITCH PART OF S121 BK 12 Z2 G109 BK 18 Z2 4 8W 52 8 8W 1...

Page 911: ...18 VT WT F86 16 LG RD 5 6 INTERMITTENT WIPER SWITCH V4 18 RD YL V4 18 RD YL F4 C234 V3 18 BR WT V3 18 BR WT C235 16 14 1 2 4 3 Z2 18 BK Z2 12 BK S121 G109 RELAY WIPER INTERMITTENT S120 B 8W 53 2 A 8W 53 2 V18 20 YL LG 10 C235 20 V18 20 YL LG F86 16LG RD F86 16 LG RD BODY CONTROL MODULE INTERMITTENT CONTROL RELAY WIPER C2 23 C4 IN PDC 8W 45 7 8W 15 4 8W 15 5 8W 15 4 8W 15 5 8W 53 2 8W 45 7 ZG 8W 53...

Page 912: ...18 BR LG V13 18 BR LG V24 18 BR OR V24 18 BR OR V24 18 BR OR V20 18 WT BK V20 18 BK WT V20 18 BK WT 6 C307 3 C305 4 V20 18 WT BK V20 18 WT BK F17 C234 REAR WASHER PUMP MOTOR TO REAR WIPER MOTOR F70 16 PK BK 1 6 4 C324 TO S329 TO S328 Z1 14 BK G78 20 TN BK RUN ACC A31 1 ON 2 INTERMITTENT REAR WIPER WASHER SWITCH 0 OFF D 8W 53 5 C 8W 53 5 2 1 0 3 4 E 8W 53 5 M JUNCTION BLOCK 2 4 9 11 8W 10 9 8W 10 1...

Page 913: ...5 FROM C234 V20 18 WT BK 1 2 MOTOR PUMP WASHER REAR Z2 18 BK Z2 18 BK G109 Z2 16 BK A B 13 VEHICLE INFORMATION CENTER G29 20 BK TN G29 16 BK TN F7 C234 S121 Z1 20 BK WASHER FLUID LEVEL SENSE C 8W 53 4 D 8W 53 4 E 8W 53 4 SENSOR LEVEL FLUID WIPER G78 20 TN BK M 2 8W 44 14 8W 45 11 8W 15 10 8W 45 11 8W 15 11 8W 15 11 8W 15 4 8W 15 5 8W 46 6 8W 15 4 8W 15 5 ZG 8W 53 WIPERS 8W 53 5 ZG005304 J978W 3 ...

Page 914: ...uit A1 from fuse 8 in the Power Distribution Center PDC to circuit A31 Circuit A31 powers circuit V23 through fuse 3 in the junction block Circuit 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 th...

Page 915: ...5 Junction Block 8W 54 2 4 5 Lamp Outage Module 8W 54 3 4 5 Park Neutral Position Switch 8W 54 2 4 S311 8W 54 2 4 S312 8W 54 5 S313 8W 54 4 Component Page S314 8W 54 3 S315 8W 54 2 4 5 S330 8W 54 3 S331 8W 54 2 3 Stop Lamp Switch 8W 54 5 Trailer Brake Provision 8W 54 2 4 Trailer Tow Circuit Breaker 8W 54 2 5 Trailer Tow Left Turn Relay 8W 54 3 Trailer Tow Right Turn Relay 8W 54 3 Trailer Tow Stop ...

Page 916: ... 2 1 SWITCH POSITION NEUTRAL PARK 2 C3 C14 1 L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG 3 C331 3 C372 S311 6 C131 7 CONNECTOR TOW TRAILER FACTORY JUNCTION BLOCK JUNCTION BLOCK BATT A250 BREAKER CIRCUIT TOW TRAILER 3 F70 PK BK 16 RELAY LAMP TRAILER TOW STOP 8W 54 3 8W 12 2 8W 12 2 8W 10 10 8W 12 17 8W 44 6 8W 12 8 8W 12 8 8W 54 2 8W 54 TRAILER TOW ZG J978W 3 ZG005...

Page 917: ...12 BK S330 5 6 9 1 4 5 6 C331 4 CONNECTOR TOW TRAILER FACTORY G302 Z1 12 BK Z1 12 BK Z1 12 BK S314 8 C372 L50 18 WT TN L50 18 WT TN 1 C372 2 STOP LAMP SWITCH OUTPUT LAMP OUTAGE MODULE L60 18 TN L60 18 TN L60 18 TN 4 5 12 15 L61 18 LG L61 18 LG L61 18 DG C307 3 4 94 18DG 95 18PK 95 18PK 94 18DG S331 SWITCH WARNING HAZARD SIGNAL TURN 5 4 5 4 C2 8W 52 5 8W 54 2 8W 51 3 8W 15 12 8W 15 12 ZG 8W 54 TRAI...

Page 918: ...C372 TRAILER BRAKE PROVISION 2 1 SWITCH POSITION NEUTRAL PARK 2 C3 C14 1 L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG 3 C331 3 C372 S311 6 C131 7 S313 BATT A250 JUNCTION BLOCK JUNCTION BLOCK TURN SIGNAL HAZARD WARNING SWITCH AFTERMARKET TRAILER CONNECTOR TOW C2 8W 52 5 8W 12 2 8W 12 2 8W 10 10 8W 52 7 8W 12 17 8W 44 6 8W 51 3 8W 12 8 8W 12 8 8W 54 4 8W 54 TRAILER T...

Page 919: ...TPUT STOP LAMP SWITCH OUTPUT PARK LAMP RELAY OUTPUT L90 18 DB RD L90 18 DB RD L90 18 DB RD L90 18 DB RD B 3 2 C331 2 C372 CONNECTOR TOW TRAILER FACTORY AFTERMARKET TRAILER TOW CONNECTOR PK BK 14 F70 PK BK 16 F70 S315 A TRAILER TOW CIRCUIT BREAKER B 15A PK BK 16 F70 20A FUSE 8 C14 8 JUNCTION BLOCK BATT A250 6 C331 F70 18 PK BK 4 JUNCTION BLOCK FACTORY AFTERMARKET CIRCUIT BREAKER C372 6 F70 16 PK BK...

Page 920: ...e coil in the relay to ground causing the contacts in the relay to switch from the normally CLOSED position to connect circuits 94 and L60 Circuit 94 is the feed for the contact 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 protecte...

Page 921: ...n Block 8W 60 2 3 Left Front Power Window Motor 8W 60 2 Left Rear Power Window Motor 8W 60 4 Left Rear Power Window Switch 8W 60 4 Passenger Door Module 8W 60 3 4 Right Front Power Window Motor 8W 60 3 Component Page Right Rear Power Window Motor 8W 60 4 Right Rear Power Window Switch 8W 60 4 S203 8W 60 2 3 S204 8W 60 2 3 S304 8W 60 4 S306 8W 60 2 3 S307 8W 60 2 3 S324 8W 60 2 S325 8W 60 3 S333 8W...

Page 922: ...BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK S307 S203 12 C334 2 C302 C1 19 20 C1 BODY CONTROL MODULE GROUP POWER OPTION FULL F18 12 TN 3 C334 F18 10 TN C14 7 30A 2 BREAKER CIRCUIT BLOCK JUNCTION CCD BUS BUS CCD CCD BUS BUS CCD BATT A250 1 2 PAIR TWISTED TWISTED PAIR TWISTED PAIR 8W 10 10 8W 12 2 8W 12 7 8W 45 2 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 19 8W 30 32 8W 15 12...

Page 923: ...K D2 18 WT BK D2 18 WT BK D2 18 WT BK S307 S203 12 C351 2 C302 C1 19 20 C1 BODY CONTROL MODULE GROUP POWER OPTION FULL F81 12 TN 3 C351 F81 12 TN C14 9 30A 2 BREAKER CIRCUIT BLOCK JUNCTION CCD BUS CCD BUS CCD BUS BUS CCD BATT A250 1 2 C1 C1 C1 C1 C1 PAIR TWISTED TWISTED PAIR TWISTED PAIR 8W 10 10 8W 12 2 8W 12 7 8W 45 2 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 19 8W 30 32 8W 15 ...

Page 924: ...WITCH 1 2 Z1 16 BK Z1 16 BK Z1 12 BK G305 S304 D C343 C345 D S333 G301 BK 12 Z1 BK 16 Z1 BK 16 Z1 2 1 SWITCH WINDOW POWER REAR RIGHT 2 DOWN 1 UP 6 ILLUMINATION SWITCH DOOR REAR RIGHT RIGHT REAR WINDOW DRIVER UP DOWN DRIVER WINDOW REAR RIGHT MODULE DOOR PASSENGER 10 C1 C1 3 4 C1 OR DG 20 E20 OR DB 18 E20 OR DB 18 E20 GY BK 16 Q18 GY BK 14 Q18 GY BK 16 Q18 C351 4 5 7 E C345 2 C330 1 DG WT 16 Q28 DG ...

Page 925: ... 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 the window lock out feat...

Page 926: ...rcuits Q22 and Z1 provide ground The right rear window switch contains a Light Emitting Diode LED The PDM illuminates the LED on circuit E20 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...

Page 927: ...1 2 Left Rear Door Lock Motor 8W 61 4 Liftgate Lock Motor 8W 61 4 Liftglass Limit Switch 8W 61 5 Liftglass Push Button 8W 61 5 Liftglass Release Solenoid 8W 61 5 Passenger Door Module 8W 61 3 Right Front Door Lock Motor 8W 61 4 Component Page Right Rear Door Lock Motor 8W 61 4 S203 8W 61 2 3 S204 8W 61 2 3 S306 8W 61 2 3 S307 8W 61 2 3 S308 8W 61 4 S310 8W 61 4 S315 8W 61 5 S316 8W 61 5 S324 8W 61...

Page 928: ...Y CONTROL MODULE S204 S203 1 2 P34 18 PK BK P35 18 OR VT 5 C1 6 C1 7 C1 9 C1 8 C1 3 C334 12 C1 7 C14 S306 S307 BLOCK JUNCTION CCD BUS BUS CCD CCD BUS BUS CCD 1 2 FULL OPTION GROUP POWER 19 C1 20 C1 BATT A250 D2 18 WT BK MOTOR LEFT FRONT DOOR LOCK M 2 PAIR TWISTED 12 TWISTED PAIR PAIR TWISTED 8W 10 10 8W 12 2 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 45 2 8W 15 12 8...

Page 929: ... 18 VT BR D1 18 VT BR D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK C1 19 20 C1 S203 S204 1 2 C302 S307 S306 13 12 C351 2 UNLOCK 1 LOCK MODULE DOOR PASSENGER BODY CONTROL MODULE 1 2 CCD BUS BUS CCD CCD BUS BUS CCD JUNCTION BLOCK C1 C1 C1 C1 C1 C1 PAIR TWISTED PAIR TWISTED TWISTED PAIR 8W 10 10 8W 12 2 8W 45 2 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W ...

Page 930: ...K P34 14 PK BK P34 14 PK BK P34 16 PK BK 1 2 M S310 S308 P34 14 PK BK P34 18 PK BK P2 16 BK WT P2 18 BK WT 3 C323 C C345 3 C330 3 C326 9 C351 10 C351 B A M 1 2 M LIFTGATE LOCK MOTOR P2 16 BK WT P2 18 BK WT P34 14 PK BK P34 18 PK BK C343 C C309 3 S326 S327 MOTOR RIGHT FRONT DOOR LOCK LOCK DOOR REAR RIGHT MOTOR MOTOR LEFT REAR DOOR LOCK 1 1 8W 61 4 8W 61 POWER DOOR LOCKS ZG J978W 3 ZG006103 ...

Page 931: ...14 BK S336 S315 2 C323 A B 1 2 2 1 Z1 12 BK Z1 12 BK Z1 12 BK G301 S328 S316 2 C325 JUNCTION BLOCK SOLENOID RELEASE LIFTGLASS LIFTGLASS SWITCH LIMIT BUTTON LIFTGLASS PUSH 3 7 8 C14 8W 12 2 8W 10 10 8W 15 11 8W 15 10 8W 45 11 8W 15 14 8W 12 8 8W 12 8 8W 12 8 ZG 8W 61 POWER DOOR LOCKS 8W 61 5 ZG006104 J978W 3 ...

Page 932: ...ither the passenger door lock switch activates or it receives input from the RKE transmitter the PDM sends the appropriate signal to the DDM 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 fro...

Page 933: ... Module 8W 62 2 3 Circuit Breaker 2 8W 62 2 3 Driver Door Module 8W 62 2 4 Driver Power Mirror 8W 62 4 G301 8W 62 3 G302 8W 62 2 Junction Block 8W 62 2 3 Passenger Door Module 8W 62 3 5 Component Page Passenger Power Mirror 8W 62 5 S203 8W 62 2 3 S204 8W 62 2 3 S306 8W 62 2 3 S307 8W 62 2 3 S324 8W 62 2 S325 8W 62 3 ZG 8W 62 POWER MIRRORS 8W 62 1 ...

Page 934: ...Y CONTROL MODULE Z1 12 BK Z1 12 BK Z1 12 BK S306 S307 S203 S204 Z1 12 BK Z1 12 BK 1 C334 G302 FUSED B CCD BUS BUS CCD C1 C1 C1 C1 C1 C1 BATT A250 BLOCK JUNCTION 30A 2 BREAKER CIRCUIT 7 F81 10 TN 3 C334 C14 FULL OPTION POWER GROUP S324 12 8W 15 12 8W 10 10 8W 12 7 8W 12 2 8W 15 12 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 45 2 8W 62 2 8W 62 POWER MIRRORS ZG J978W 3 ...

Page 935: ...D BODY CONTROL MODULE Z1 12 BK Z1 12 BK Z1 12 BK S306 S307 S203 S204 Z1 12 BK Z1 12 BK 1 C351 G301 FUSED B CCD BUS BUS CCD BATT A250 BLOCK JUNCTION 30A 2 BREAKER CIRCUIT 9 F81 12 TN 3 C351 C14 C1 C1 C1 C1 FULL OPTION POWER GROUP S325 C1 C1 8W 15 14 8W 10 10 8W 12 7 8W 12 2 8W 15 14 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 45 2 ZG 8W 62 POWER MIRRORS 8W 62 3 ZG0062...

Page 936: ...3 20 DB F71 20 WT F85 20 GN F86 20 GY F84 20 VT Z1 20 BK C16 20 BK P114 20 YL BK P114 20 YL BK P114 18 YL BK P114 20 YL BK P114 20 BK YL 4 8 9 A B C353 11 C334 7 C302 3 C231 P112 20 BK WT P112 20 YL WT P112 18 YL WT P112 20 YL WT P112 20 YL WT C2 AUTO DAY NIGHT MIRROR MIRROR NIGHT DAY AUTO AUTO DAY NIGHT MIRROR MIRROR NIGHT DAY AUTO MIRROR NIGHT DAY AUTOMATIC C2 C2 C2 C2 C2 C2 C2 8W 44 6 8W 44 7 8...

Page 937: ... SIGNAL VERTICAL DRIVER DRIVER COMMON HORIZONTAL DRIVER SENSOR GROUND VERTICAL POSITION SENSOR SIGNAL HEATER SWITCHED GROUND SUPPLY 12V HEATER F75 20 WT F73 20 DB F71 20 YL F85 20 VT F86 20 GY F84 20 GN Z1 20 BK C16 20 BK C2 C2 C2 C2 C2 C2 C2 C2 ZG 8W 62 POWER MIRRORS 8W 62 5 ZG006204 J978W 3 ...

Page 938: ...irror to the automatic day night rear view mirror LEFT MIRROR ADJUSTMENT The DDM adjusts the position of the left mirror When an UP adjustment 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...

Page 939: ...3 11 14 Fuse 12 8W 63 13 14 G304 8W 63 13 14 G305 8W 63 2 3 4 8 9 10 11 12 Heated Seat Switch 8W 63 11 12 13 14 Junction Block 8W 63 2 3 4 8 9 10 13 14 Memory Seat Module 8W 63 2 5 6 7 8 15 Memory Set Switch 1 Set 8W 63 15 Passenger Door Module 8W 63 15 Component Page Passenger Heated Seat Back 8W 63 12 Passenger Heated Seat Cushion 8W 63 12 Passenger Lumbar Motor 8W 63 4 Passenger Lumbar Switch 8...

Page 940: ...329 DRIVER LUMBAR SWITCH 1 FILL 2 VENT C1 8 19 MEMORY SEAT MODULE 10 1 Z1 16 BK Z1 16 BK F35 16 RD F35 16 RD 1 2 C1 16 LG DB 20 P105 5 JUNCTION BLOCK 12 C2 C2 C2 C2 LUMBAR FORWARD SWITCH SENSE BACKWARD SENSE SWITCH LUMBAR B FUSED B FUSED GROUND GROUND C13 8W 10 12 8W 12 2 8W 15 15 8W 15 15 8W 15 15 8W 12 18 8W 12 18 8W 63 2 8W 63 POWER SEAT ZG J978W 3 ZG006301 ...

Page 941: ... P107 18 OR BK P106 18 DG WT 1 2 MOTOR LUMBAR DRIVER Z1 18 BK Z1 18 BK S402 Z1 14 BK Z1 16 BK G305 Z1 12 BK S304 2 C329 DRIVER LUMBAR SWITCH 1 FILL 2 VENT 1 2 JUNCTION BLOCK C13 M 8W 12 2 8W 10 12 8W 15 15 8W 15 15 8W 15 15 8W 12 18 8W 12 18 ZG 8W 63 POWER SEAT 8W 63 3 ZG006302 J978W 3 ...

Page 942: ...6 18 DG WT 1 2 MOTOR LUMBAR PASSENGER Z1 18 BK Z1 18 BK S406 Z1 14 BK Z1 16 BK G305 Z1 12 BK S333 2 C335 PASSENGER LUMBAR SWITCH 1 FILL 2 VENT S304 Z1 10 BK 1 2 JUNCTION BLOCK 12 M C13 8W 10 12 8W 12 2 8W 15 15 8W 15 14 8W 15 15 8W 15 13 8W 12 18 8W 12 18 8W 63 4 8W 63 POWER SEAT ZG J978W 3 ZG006303 ...

Page 943: ...106 16 DG WT P107 16 OR BK P29 20 BR WT P29 20 BR WT S401 M 6V SENSOR SUPPLY LUMBAR VENT DRIVER DRIVER FILL LUMBAR 3 4 20 DB WT P103 BR RD P28 20 20 S400 BR RD P28 7 C1 LUMBAR SENSOR POSITION 2 C1 GROUND SENSOR 8W 70 4 8W 63 6 ZG 8W 63 POWER SEAT 8W 63 5 ZG006304 J978W 3 ...

Page 944: ...43 16 GY LB MEMORY SEAT MODULE DRIVER POWER SEAT HORIZONTAL MOTOR MOTOR RECLINER SEAT POWER DRIVER BR WT 20 P29 5 BR WT 20 P29 C BR WT 20 P29 SENSOR MOTOR RISER FRONT SEAT POWER DRIVER DRIVER POWER SEAT REAR RISER MOTOR SENSOR MOTOR SENSOR LUMBAR DRIVER M M 6V SENSOR SUPPLY RECLINER DRIVER RECLINER DRIVER HORIZONTAL POSITION SENSE SENSOR GROUND RECLINER POSITION SENSE MOTOR MOTOR C HORIZONTAL MOTO...

Page 945: ...6 RD BK P111 16 YL DB P121 16 RD GY P119 16 YL RD MEMORY SEAT MODULE DRIVER POWER SEAT REAR RISER SENSOR SENSOR RISER FRONT SEAT POWER DRIVER MOTOR MOTOR MOTOR RISER FRONT SEAT POWER DRIVER REAR RISER POSITION SENSE GROUND SENSOR SENSE POSITION RISER FRONT REAR RISER DOWN DRIVER DRIVER UP RISER REAR FRONT RISER DOWN DRIVER DRIVER UP RISER FRONT M M 6V SENSOR SUPPLY 8W 63 5 8W 63 6 8W 70 4 ZG 8W 63...

Page 946: ...MORY SEAT MODULE BATT A7 Z1 16 BK Z1 14 BK Z1 16 BK Z1 16 BK S304 G305 S402 2 C329 FRONT RISER DOWN SWITCH SENSE SENSE SWITCH UP RISER FRONT SENSE SWITCH DOWN RISER REAR SENSE SWITCH UP RISER REAR SENSE SWITCH FORWARD HORIZONTAL SENSE SWITCH DOWN RECLINER SENSE SWITCH UP RECLINER HORIZONTAL REARWARD SWITCH SENSE JUNCTION BLOCK 4 DOWN 12 C1 C1 C1 C1 C1 C1 C1 C1 C13 8W 10 12 8W 12 2 8W 15 15 8W 15 1...

Page 947: ... P44 16 GY LB 4 3 4 3 2 1 4 3 BATT A7 Z1 18 BK Z1 14 BK Z1 10 BK Z1 12 BK S304 G305 S406 2 C329 MOTOR PASSENGER POWER SEAT FRONT RISER 2 1 RISER REAR SEAT POWER PASSENGER MOTOR 2 1 1 2 PASSENGER POWER SEAT HORIZONTAL MOTOR MOTOR RECLINER SEAT POWER PASSENGER B A M M M M S333 Z1 16 BK JUNCTION BLOCK 4 DOWN C14 8W 10 12 8W 12 2 8W 15 14 8W 15 13 8W 15 15 8W 15 15 8W 12 18 8W 12 18 ZG 8W 63 POWER SEA...

Page 948: ...ATT A7 Z1 16 BK Z1 14 BK Z1 12 BK S304 G305 S402 2 C329 MOTOR DRIVER POWER SEAT FRONT RISER 2 1 RISER REAR SEAT POWER DRIVER MOTOR 2 1 1 2 DRIVER POWER SEAT HORIZONTAL MOTOR MOTOR RECLINER SEAT POWER DRIVER B A M M M M Z1 16 BK JUNCTION BLOCK 4 DOWN 2 FWD 3 UP DRIVER POWER SEAT SWITCH 1 BACK 10 C13 8W 10 12 8W 12 2 8W 15 15 8W 15 15 8W 15 15 8W 12 18 8W 12 18 8W 63 10 8W 63 POWER SEAT ZG J978W 3 Z...

Page 949: ... BK P7 18 LB BK Z1 16 BK Z1 14 BK Z1 16 BK Z1 12 BK S407 S402 2 C329 S304 G305 CUSHION SEAT HEATED DRIVER DRIVER HEATED SEAT BACK 1 P7 18 LB BK P7 18 LB BK P7 20 LB 5 C329 3 C301 HEATED SEAT SWITCH A D BK Z1 16 BK Z1 20 B P88 16 BR BK 8W 63 14 8W 15 15 8W 15 15 8W 15 15 ZG 8W 63 POWER SEAT HEATED SEAT 8W 63 11 ZG006310 J978W 3 ...

Page 950: ...S304 G305 CUSHION SEAT HEATED PASSENGER PASSENGER HEATED SEAT BACK 4 P8 18 LB WT P8 20 LB WT 3 C335 4 C301 HEATED SEAT SWITCH A D BK Z1 16 BK Z1 20 B P88 16 BR BK PASSENGER HEATED SEAT SWITCH OUTPUT HEATED SEAT DRIVER GROUND 16 Z1 BK S333 8W 15 14 8W 63 13 8W 15 15 8W 15 15 8W 15 13 8W 63 12 8W 63 POWER SEAT HEATED SEAT ZG J978W 3 ZG006311 ...

Page 951: ...ULE CONTROL HEATER SEAT PASSENGER P8 18 LB WT P8 18 LB WT S404 4 C301 G304 Z1 20 BK Z1 16 BK Z1 14 BK Z1 14 BK S202 S216 2 C301 S405 SWITCH POD PART OF SWITCH SEAT HEATED FUSED B FUSED IGN RUN OUTPUT SWITCH SEAT HEATED PASSENGER JUNCTION BLOCK 9 C9 C13 1 HIGH 2 LOW 0 OFF 8W 12 2 8W 10 8 8W 10 12 8W 12 18 8W 15 17 8W 15 18 8W 15 18 8W 63 12 8W 12 10 8W 12 10 8W 12 18 8W 12 10 ZG 8W 63 POWER SEAT HE...

Page 952: ...8 LB BK MODULE CONTROL HEATER SEAT DRIVER P7 18 LB BK P7 18 LB BK S407 3 C301 G304 Z1 20 BK Z1 16 BK Z1 14 BK Z1 14 BK S202 S216 2 C301 S403 SWITCH POD PART OF SWITCH SEAT HEATED FUSED B FUSED IGN RUN DRIVER HEATED SEAT JUNCTION BLOCK C9 C13 1 HIGH 0 OFF 2 LOW 8W 10 12 8W 12 2 8W 10 8 8W 12 18 8W 15 17 8W 15 18 8W 15 18 8W 63 11 8W 12 10 8W 12 10 8W 12 18 8W 12 10 8W 63 14 8W 63 POWER SEAT HEATED ...

Page 953: ...1 18 VT BR 13 12 C351 8 9 D1 18 VT BR D1 18 VT BR 13 C334 D2 18 WT BK D2 18 WT BK 12 C334 SWITCHED MUX LED SUPPLY 5V SUPPLY GROUND CCD BUS CCD BUS BUS CCD BUS CCD CCD BUS CCD BUS MEMORY SEAT MODULE 8 9 C329 DRIVER DOOR MODULE MODULE DOOR PASSENGER C1 C1 C3 C3 C3 C3 C1 C1 SET LED DRIVER 8W 60 3 8W 61 3 8W 62 3 8W 30 18 8W 30 31 8W 30 19 8W 30 32 ZG 8W 63 POWER SEAT MEMORY SEAT 8W 63 15 ZG006314 J97...

Page 954: ... 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 circuit P11 Circuit P11 connects to the motor Ground is provided on circuit P13 ...

Page 955: ...er 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 position inputs from five sensors in the driver s seat ...

Page 956: ...tion detentes have a resistor in series between the detente and cir cuit P7 or P8 Internal to the switch voltage from circuit F71 passes through 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 eit...

Page 957: ... 8W 64 2 Electronic Flasher 8W 64 2 Fuse 13 8W 64 2 G304 8W 64 2 Junction Block 8W 64 2 S202 8W 64 2 S216 8W 64 2 S220 8W 64 2 Component Page S320 8W 64 2 S322 8W 64 2 Sliding Roof Motor 8W 64 3 Sliding Roof Position Switch 8W 64 3 Sunroof Control Module 8W 64 2 3 Sunroof Switch 8W 64 2 ZG 8W 64 POWER SUNROOF 8W 64 1 ...

Page 958: ... YL 1 4 C371 5 C231 5 1 3 2 CLOSE 1 OPEN SWITCH SUNROOF 1 2 F86 16 LG BK Q42 16 LB S320 3 2 C371 Q42 16 WT Q41 16 WT Q41 16 LB MODULE CONTROL SUNROOF FUSED B GROUND GROUND JUNCTION BLOCK 5 C5 1 C15 C4 FUSED IGN RUN ACC SUNROOF SWITCH OUTPUT CLOSED OPEN OUTPUT SWITCH SUNROOF 8W 10 9 8W 12 2 8W 10 12 8W 12 5 8W 15 18 8W 15 18 8W 15 17 8W 15 17 8W 15 16 8W 52 2 8W 52 6 8W 12 4 8W 12 11 8W 64 2 8W 64 ...

Page 959: ...ING ROOF POSITION SWITCH OUTPUT OUTPUT SWITCH POSITION ROOF SLIDING SLIDING ROOF POSITION SWITCH OUTPUT DRIVER MOTOR ROOF SLIDING SLIDING ROOF MOTOR DRIVER MODULE CONTROL SUNROOF 18 WT 18 GN 18 BR 18 BK 18 GN ZG 8W 64 POWER SUNROOF 8W 64 3 ZG006402 J978W 3 ...

Page 960: ...ween the switch and the control module The control module then activates the motor and moves the sunroof to the 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 fun...

Page 961: ...1 8W 65 3 S2 8W 65 3 S3 8W 65 3 S4 8W 65 3 S98 8W 65 3 S99 8W 65 3 S119 8W 65 2 Component Page S121 8W 65 2 S131 8W 65 2 S200 8W 65 2 S212 8W 65 2 Speed Proportional Steering Control Module 8W 65 3 Speed Proportional Steering Module 8W 65 2 Speed Proportional Steering Solenoid 8W 65 3 Steering Wheel Speed Sensor 8W 65 3 Vehicle Speed Sensor 8W 65 2 ZG 8W 65 SPEED PROPORTIONAL STEERING 8W 65 1 ...

Page 962: ...6 C235 D98 20 WT D98 20 WT SCI TRANSMIT SCI RECEIVE 6 5 C132 G7 18 WT OR G7 18 WT OR S131 G7 18 WT OR 3 VEHICLE SPEED SENSOR VEHICLE SPEED SENSOR SIGNAL S121 Z2 20 BK Z2 12 BK G109 GROUND 612 4 MODULE STEERING PROPORTIONAL SPEED 8W 10 8 8W 15 4 8W 15 5 8W 15 4 8W 15 5 8W 33 3 8W 33 3 8W 70 2 8W 30 2 8W 30 2 8W 12 6 8W 12 6 8W 12 2 8W 12 6 8W 65 2 8W 65 SPEED PROPORTIONAL STEERING GAS ENGINES ZG J9...

Page 963: ...RING CONTROL MODULE SIGNAL B SIGNAL A GROUND SUPPLY 5V S1 20 BK YL S1 20 BK YL S2 20 BK LG S2 20 BK LG S3 20 PK WT S3 20 PK WT S4 20 VT S4 20 VT 2 SOLENOID STEERING PROPORTIONAL SPEED 1 2 CONTROL LOW CONTROL HIGH HIGH CONTROL LOW CONTROL 1 S99 18 LG S98 18 LB ZG 8W 65 SPEED PROPORTIONAL STEERING GAS ENGINES 8W 65 3 ZG006502 J978W 3 ...

Page 964: ...EED PROPORTIONAL STEERING CONTROL MODULE Circuit F83 powers the Speed Proportional Steer ing Control Module SPSCM Circuit 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 ve...

Page 965: ... 39 2 S211 8W 70 8 S212 8W 12 6 8W 50 11 S214 8W 44 12 S215 8W 12 5 S216 8W 15 17 S218 8W 12 10 S219 8W 42 6 S220 8W 15 17 S221 8W 42 2 5 Component Page S222 8W 42 6 8 S223 8W 42 8 S224 8W 10 6 8W 42 3 S225 8W 10 6 8W 42 3 S226 8W 15 8 8W 42 4 S300 8W 47 5 6 S301 8W 47 5 6 S302 8W 15 18 8W 45 2 S303 8W 45 9 8W 50 4 S304 8W 15 15 S305 8W 39 5 S306 8W 30 19 32 S307 8W 30 18 31 S308 8W 61 4 S309 8W 1...

Page 966: ...OSITION CAMSHAFT 2 S135 S127 4 0L S131 3 G7 18 WT OR WT OR 18 G7 6 G7 18 WT OR MODULE STEERING PROPORTIONAL SPEED G7 18 WT OR 5 C132 POWERTRAIN CONTROL MODULE SENSOR SPEED VEHICLE VEHICLE SPEED SENSOR MODULE CONTROL POWERTRAIN K6 18 VT WT VT WT 18 K6 1 S132 B27 C2 C2 B31 2 VT WT 18 K6 TRANSMISSION SOLENOID ASSEMBLY 8W 31 3 8W 30 17 8W 30 17 8W 33 3 8W 30 17 8W 33 3 8W 30 17 8W 65 2 8W 70 3 8W 30 7...

Page 967: ...4 18 BK LB SENSOR OXYGEN HEATED DOWNSTREAM BK LB 18 K4 3 5 2L SENSOR OXYGEN HEATED UPSTREAM 2 K4 20 BK LB BK LB 18 K4 3 2 K4 20 BK LB 4 0L SENSOR POSITION CRANKSHAFT TRANSMISSION SOLENOID ASSEMBLY 5 2L 4 0L SENSOR POSITION CAMSHAFT A 8W 70 4 S136 5 2L TO S135 8W 30 7 8W 31 3 8W 30 7 8W 30 13 8W 30 13 8W 33 3 8W 30 6 8W 30 7 8W 30 8 8W 30 9 8W 30 13 8W 30 14 8W 30 16 8W 30 17 8W 30 10 8W 70 2 8W 31...

Page 968: ...2L MEMORY SEAT MODULE BR RD 20 P28 BR RD 20 P28 A P28 20 BR RD C SENSOR MOTOR HORIZONTAL SEAT POWER DRIVER DRIVER POWER SEAT RECLINER MOTOR SENSOR C BR RD 20 P28 2 C1 SENSOR MOTOR RISER FRONT SEAT POWER DRIVER DRIVER POWER SEAT REAR RISER MOTOR SENSOR A P28 20 BR RD BR RD 20 P28 3 S400 MEMORY SEATS MOTOR SENSOR LUMBAR DRIVER 8W 63 5 8W 63 6 8W 63 7 8W 63 5 8W 63 7 8W 63 7 8W 63 6 8W 63 6 8W 30 8 8...

Page 969: ... C320 1 PK WT 18 L73 RIGHT TAIL STOP LAMP L50 18 WT TN 6 MODULE OUTAGE LAMP A CONTROLLER ANTI LOCK BRAKE 12 WT TN 18 L50 16 C304 L50 18 WT TN 5 L50 18 WT TN STOP LAMP SWITCH 12 C305 L50 18 WT TN S312 NO 2 NO 3 CENTER HIGH MOUNTED STOP LAMP NO 1 LAMP STOP MOUNTED HIGH CENTER LAMP OUTAGE MODULE TRAILER TOW MODULE OUTAGE LAMP TOW TRAILER TRAILER TOW LAMP OUTAGE MODULE LAMP OUTAGE MODULE TRAILER TOW F...

Page 970: ...67 20 BR YL K167 20 BR YL K167 20 BR YL 15 C304 C4 4 MODULE CONTROL POWERTRAIN K167 20 BR YL K167 20 BR YL K167 20 BR YL 12 C132 S141 8W 30 28 8W 30 29 8W 30 24 8W 30 28 8W 30 29 8W 70 9 8W 70 6 8W 70 SPLICE INFORMATION GAS ENGINE ZG J978W 3 ZG007005 ...

Page 971: ...TIC SHUT DOWN S128 S129 A142 16 DG OR A142 14 DG OR A142 16 DG OR A142 16 DG OR A142 14 DG OR A142 16 DG OR A142 16 DG OR A142 16 DG OR A142 16 DG OR A142 16 DG OR A142 14 DG OR A142 16 DG OR 12 C131 RELAY 8W 30 26 8W 30 22 8W 20 2 8W 30 28 8W 30 27 8W 30 26 8W 30 27 ZG 8W 70 SPLICE INFORMATION DIESEL ENGINE 8W 70 7 ZG007006 J978W 3 ...

Page 972: ...CLOCKSPRING K4 18 BK LB F8 C234 H13 C236 NO CONNECTION K4 18 BK LB K4 18 BK LB K4 18 BK LB K4 20 BK LB K4 20 BK LB K4 20 BK LB K4 20 BK LB 6 C131 S119 S136 33 MODULE MODULE PUMP FUEL BK LB 18 K4 4 8W 30 29 8W 30 29 8W 30 23 8W 31 6 8W 33 3 8W 30 26 8W 30 26 8W 70 8 8W 70 SPLICE INFORMATION DIESEL ENGINE ZG J978W 3 ZG007007 ...

Page 973: ...TRAIN SENSOR PRESSURE OIL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL 12 C132 3 C917 S102 S141 C4 8W 30 29 8W 33 5 8W 30 24 8W 30 24 8W 30 28 8W 30 29 8W 30 29 ZG 8W 70 SPLICE INFORMATION DIESEL ENGINE 8W 70 9 ZG007008 J978W 3 ...

Page 974: ......

Page 975: ...0 12 C141 Diesel 8W 80 13 C150 8W 80 13 C159 8W 80 13 C160 8W 80 13 C182 Diesel 8W 80 13 C206 with Manual A C heater 8W 80 14 C206 with Automatic Temperature Control 8W 80 14 C212 8W 80 15 C229 8W 80 15 C231 8W 80 15 C233 8W 80 15 C234 8W 80 16 Component Page C235 8W 80 16 C236 8W 80 17 C300 8W 80 17 C301 8W 80 17 C302 8W 80 17 C304 8W 80 18 C305 Gas 8W 80 18 C305 Diesel 8W 80 19 C307 8W 80 19 C31...

Page 976: ... Switch 8W 80 39 High Speed Blower Motor Relay 8W 80 39 Horn No 1 8W 80 39 Horn No 2 8W 80 39 Component Page Idle Air Control Motor with 4 0L Engine 8W 80 40 Idle Air Control Motor with 5 2L Engine 8W 80 40 Ignition Coil 8W 80 40 Ignition Switch 8W 80 40 In Car Temperature Sensor 8W 80 40 Injector No 1 8W 80 41 Injector No 2 8W 80 41 Injector No 3 8W 80 41 Injector No 4 8W 80 41 Injector No 5 8W 8...

Page 977: ... Control Module C3 8W 80 66 Powertrain Control Module C4 Diesel 8W 80 67 Radio C1 8W 80 68 Component Page Radio C2 8W 80 68 Radio C3 8W 80 68 Rear Speaker 8W 80 68 Rear Washer Pump Motor 8W 80 69 Rear Wiper Module 8W 80 69 Rear Wiper Washer Switch 8W 80 69 Recirculation Door Actuator with ATC 8W 80 69 Right Airbag Sensor 8W 80 70 Right Back Up Lamp 8W 80 70 Right Courtesy Lamp 8W 80 70 Right Door ...

Page 978: ...80 80 Vehicle Speed Control Horn Switch 8W 80 80 Vehicle Speed Sensor Diesel 8W 80 81 Vehicle Speed Sensor Gas 8W 80 80 Component Page Water In Fuel Sensor Diesel 8W 80 81 Windshield Washer Pump Motor 8W 80 81 Windshield Wiper Motor 8W 80 81 Wiper Fluid Level Sensor 8W 80 81 8W 80 4 8W 80 CONNECTOR PIN OUTS ZG DESCRIPTION AND OPERATION Continued ...

Page 979: ...GNAL FUSED B CAV A B C D L50 18WT TN L90 18DB RD L60 18TN F70 18PK BK CIRCUIT FUNCTION LOW BLOWER MOTOR DRIVER M1 BLOWER MOTOR DRIVER HIGH BLOWER MOTOR DRIVER GROUND M2 BLOWER MOTOR DRIVER CAV 1 2 3 4 5 C4 14TN C5 14LG C7 12BK TN C1 14DG C6 14LB A C HEATER CONTROL C1 BLACK 4 2 3 1 5 CIRCUIT FUNCTION A C PRESSURE SWITCH SENSE A C COMPRESSOR CLUTCH GROUND CAV 1 2 2 C21 18DB OR C3 18DB BK Z1 18BK A C...

Page 980: ...NITION FUSED OUTPUT RUN GROUND BACK UP LAMP SWITCH OUTPUT ELECTRIC CHROMATIC MIRROR ELECTRIC CHROMATIC MIRROR CAV 1 2 3 4 5 6 7 F83 20BK VT Z1 20BK L10 20BK RD P112 20BK WT P114 20BK YL AUTOMATIC DAY NIGHT MIRROR BLACK 1 7 12 11 22 CIRCUIT FUNCTION SENSOR RETURN AMBIENT TEMPERATURE SENSOR SIGNAL CAV 1 2 D41 20LG WT C8 20DG RD AMBIENT TEMPERATURE SENSOR BLACK 2 1 CIRCUIT FUNCTION FUSED B VTSS INDIC...

Page 981: ...NSOR SIGNAL PANEL LAMP DRIVER SOLAR SENSOR SIGNAL CAV C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 C37 20YL C35 20DG YL C39 20WT C90 20LG C40 20BR WT C43 18YL BR D1 18VT BR D2 18WT BK F71 20DG PK F60 20WT RD C36 20RD WT C38 20DB C42 18PK DB C32 20DB GY C33 20DB RD C41 20GY DB C34 20DB WT Z4 20PK D41 20LG WT C10 20RD TN E2 20OR C47 20...

Page 982: ...GNAL COMMON DOOR DRIVER CAV 1 2 3 4 5 6 C40 20WT YL F71 20PK DG C36 20DB RD C34 20VT WT BLEND DOOR ACTUATOR WITH MANUAL A C HEATER 6 5 4 3 2 1 BLACK CIRCUIT FUNCTION BLOWER MOTOR DRIVER GROUND CAV 1 2 A19 12RD C7 12BK BLOWER MOTOR WITH MANUAL A C HEATER NATURAL 2 1 CIRCUIT FUNCTION HIGH SPEED BLOWER MOTOR RELAY SIGNAL GROUND CAV 1 2 C42 12RD Z4 12BK CIRCUIT FUNCTION LOW BLOWER MOTOR DRIVER M2 BLOW...

Page 983: ...D IGNITION SWITCH OUTPUT START RUN CCD BUS CCD BUS VTSS INDICATOR LAMP DRIVER DIMMER SWITCH HIGH BEAM OUTPUT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 V51 18WT D41 20LG WT C8 20DG RD M11 20PK LB L24 20LB RD C80 20DB YL L4 16VT OR G70 20BR TN G26 20LB L35 20BR WT Z2 20BK OR L90 20DB RD F99 20OR D1 18VT BR D2 18WT BK G69 20BK LG L3 16RD OR BODY CONTROL MODULE C1 BLACK 24 16 ...

Page 984: ...H OUTPUT ACC RUN PANEL LAMP DRIVER WASHER SWITCH OUTPUT WIPER SWITCH MODE SENSE PANEL LAMP DIMMER SWITCH SIGNAL PARK LAMP RELAY CONTROL FOG LAMP RELAY CONTROL INTERMITTENT WIPER RELAY CONTROL GROUND CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 L109 20WT 709 20RD BK V66 16VT WT M112 20BR LG C90 20LG F75 18VT L110 20OR BK 714 20BK OR X4 20GY OR C14 20WT RD V23 20BR PK E2 20OR V...

Page 985: ...DOOR AJAR SWITCH SENSE VTSS DISARM SENSE LEFT REAR DOOR AJAR SWITCH SENSE SEAT BELT SWITCH SENSE CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 G78 20TN BK G9 20GY BK G76 18TN YL G75 18TN M4 20WT LG Z2 18BK OR G74 18TN RD G71 20VT YL G77 18TN OR G10 20LG RD BLACK 5 9 14 1 6 10 BODY CONTROL MODULE C3 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 G40 18LB BK F99 20OR G18 20PK BK K4 18BK LB L10 18BR LG G118 20P...

Page 986: ...K 14 1 8 7 14 1 8 7 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 10 T20 18LB F99 20OR A142 18DG OR F5 14RD YL L10 18BR LG C2 18DB YL G28 20LG OR K4 20BK LB CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 10 T20 18LB F99 18OR A142 18DG OR F5 14RD YL L10 18BR LG C2 18DB YL G28 20LG OR K4 18BK LB K4 20BK LB CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 Z1 18BK Z2 18BK OR T41 20BK WT G7 18WT OR K20 18DG T66 20BR OR F83 18YL DG T106 20GY OR ...

Page 987: ...V 1 2 3 L64 18LG DB L90 18DB RD Z1 18BK CIRCUIT CAV 1 2 3 L64 18LG DB L90 18DB RD Z1 18BK C150 C150 CIRCUIT CAV 1 2 2 M1 18PK Z1 18BK CIRCUIT CAV 1 2 2 M1 18PK Z1 18PK Z4 18BK C159 CIRCUIT CAV 1 2 A19 12RD VT Z4 12BK CIRCUIT CAV 1 1 2 A1910RD A19 12RD Z4 12BK C160 C160 GAS DIESEL 1 2 3 1 BLACK 3 1 BLACK 2 1 2 BLACK 1 2 BLACK C159 BLACK 1 2 5 1 6 10 5 1 6 10 CIRCUIT CAV 1 2 3 4 K255 20WT DG K151 20...

Page 988: ...20VT WT Z4 12BK CIRCUIT CAV A B C D E F G H J K L M N P R S C39 20WT C37 20YL C35 20DG YL C36 20RD WT C34 20DB WT F71 20PK DG C33 20DB RD C32 20DB GY C38 20DB C40 20BR WT C41 20GY DB C42 18PK DB C43 18YL BR Z4 20PK D41 20LG WT C206 WITH AUTOMATIC TEMPERATURE CONTROL CIRCUIT CAV A B C D E F G H J K L M N P R S C39 20YL C37 20TN BK C35 20DB WT C36 20DB RD C34 20VT WT F71 20PK DG C33 20VT OR C32 20LB...

Page 989: ...1 14YL RD C229 C229 MANUAL TRANS ONLY CIRCUIT CAV 1 2 3 4 5 6 D1 18VT BR D2 18WT BK P112 20YL WT P114 20YL BK F86 16LG BK C231 C231 CIRCUIT CAV 1 2 3 4 5 6 D1 18VT BR D2 18WT BK P112 20YL WT P114 20YL BK F86 16LG BK CIRCUIT CAV E1 E2 E4 E4 A1 12RD WT F61 16WT OR T141 14YL RD CIRCUIT CAV E1 E2 E4 E4 A1 12RD WT F61 16WT OR A41 14YL T141 14YL RD C233 C233 2 1 BLACK 1 2 BLACK RED A B A B RED 2 1 6 3 1...

Page 990: ...18 16PK BK G29 20BK TN K4 18BK LB V32 20YL RD L65 18LG DB C8 20DG RD L3 16RD OR L53 20BR D83 20BK PK D84 20BK WT V20 18WT BK V6 16DB K95 20PK T9 20OR GAS DIESEL CIRCUIT CAV G1 G2 G3 G4 G5 G6 G7 G8 G9 G10 G11 G12 G13 G14 G15 G16 G17 G18 G19 G20 G68 18BR YL V30 20DB LG T106 20GY OR 205 20WT VT D98 20WT G68 18BR YL V18 20YL LG D41 20LG WT S1 20BK YL S2 20BK LG S3 20PK WT S4 20VT V3 18BR WT V66 18VT W...

Page 991: ... 20YL F99 20OR Z1 18BK Z2 18BK OR C236 CIRCUIT CAV A B R44 18DG YL R42 18BK YL C300 CIRCUIT CAV A B R44 18DB R42 18VT C300 CIRCUIT CAV 1 2 3 4 C15 12BK WT Z1 14BK P7 18LB BK P8 18LB WT C301 CIRCUIT CAV 1 2 3 4 C15 12BK WT Z1 14BK P7 20LB P8 20LB WT C301 CIRCUIT CAV 1 2 3 4 5 6 7 8 D1 18VT BR D2 18WT BK F71 18PK DG E2 18OR P112 18YL WT P114 18YL BK C302 CIRCUIT CAV 1 2 3 4 5 6 7 8 D1 18VT BR D2 18W...

Page 992: ...DB B4 20LG K4 20BK LB K167 20BR YL L50 18WT TN A64 14DG WT A64 16DG WT C304 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 V24 18BR OR V20 18BK WT X55 16BR RD X55 16BR RD X53 16DG X53 16DG X54 16VT X54 16VT X56 16DB X56 16DB Z5 14BK LB Z5 14BK LB X51 16BR YL X51 16BR YL X57 16BR LB X57 16BR LB L50 18WT TN X52 16DB WT X52 16DB WT X58 16DB OR X58 16DB OR CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X5...

Page 993: ...X54 20VT YL X56 20DB Z5 16BK X51 20BR YL X57 20BR LB L50 18WT TN X52 20DB WT X58 20DB OR C305 DIESEL 6 14 1 7 C305 DIESEL 1 BLACK 7 6 14 CIRCUIT CAV 1 2 3 3 4 4 4 5 6 7 8 9 10 11 12 13 14 X82 16LB RD X80 16LB DG A 61 18LG L61 18LG L60 18TN L60 18TN L60 18TN G46 20LB BK V13 18BR LG L36 18LG OR Z2 18BK OR K255 20WT DG K151 20WT K6 20VT WT K22 20OR DB X85 16LG BK X87 16LG RD C307 CIRCUIT CAV 1 2 3 4 ...

Page 994: ... 4 5 6 9 10 11 G71 20VT YL L78 20DB RD G90 20DB RD C321 C321 OPTIONAL DIESEL BLACK 1 6 3 4 GRAY GRAY 1 3 4 6 BLACK 4 6 5 11 10 9 CONNECTOR RETAINER CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 L36 18LG OR L50 18WT TN L90 18DB RD L90 18DB RD L90 18DB RD L90 18DB RD L90 18DB RD L50 18WT TN L50 18WT TN L50 18WT TN G46 20LB BK F87 18WT PK C316 1 10 5 6 5 6 1 10 BLACK BLACK CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 L36 18L...

Page 995: ...CONNECTOR RETAINER 1 8 7 C323 CIRCUIT CAV 1 2 3 4 5 6 V13 18BR LG V20 18BK WT V24 18BR OR CIRCUIT CAV 4 5 6 9 10 11 V13 18BR LG V24 18BR OR V20 18BK WT C324 BLACK 1 6 3 4 CONNECTOR RETAINER BLACK 6 5 4 11 10 9 CIRCUIT CAV 1 2 Z1 12BK CIRCUIT CAV 2 3 Z1 12BK C325 CIRCUIT CAV 1 2 3 L87 18DG WT Z1 18BK P34 14PK BK CIRCUIT CAV 1 7 8 P34 16PK BK Z1 18BK L87 18DG WT C326 CONNECTOR RETAINER BLACK GRAY BL...

Page 996: ...Q18 16GY BK Q28 16DG WT P34 18PK BK C330 CIRCUIT CAV 1 2 3 4 5 6 F35 16RD Z1 16BK D1 18VT BR D2 18WT BK P7 18LB BK F71 18PK DG C329 CIRCUIT CAV 1 2 3 4 5 6 F35 14RD Z1 14BK D1 20VT BR D2 20WT BK P7 18LB BK F87 18PK DG C331 GRAY BLACK BLACK GRAY 1 2 3 10 5 6 1 10 5 6 1 1 2 3 BLACK BLACK 3 1 1 4 3 6 4 6 C329 C330 C331 CIRCUIT CAV 1 2 3 4 5 5 6 L73 18PK WT L21 18LB WT L10 18BR LG Z1 18BK L61 18LG L61...

Page 997: ...T X53 20DG Q27 16RD BK X55 20BR RD P114 20YL BK P112 20YL WT D2 18WT BK D1 18VT BR G71 20VT YL C334 C335 CIRCUIT CAV 1 2 3 4 F35 16RD Z1 16BK P8 18LB WT F71 18PK DG CIRCUIT CAV 1 2 3 4 F35 14RD Z1 14BK P8 18LB WT F87 18WT BK BLACK 1 8 4 1 BLACK BLACK 4 1 BLACK 7 14 1 8 7 14 C334 C335 C343 CIRCUIT CAV A A B B C D E X93 16WT RD X51 16BR YL X91 16WT BK X57 16BR LB P2 16BK WT Z1 16BK E21 18OR RD CIRCU...

Page 998: ... 8 9 10 11 12 13 14 Z1 12BK F81 12TN E20 18OR DB Q18 14GY BK X54 16VT X82 16LB RD Q28 14DG WT X56 16DB X80 16LB DG P2 14BK WT P34 14PK BK D2 18WT BK D1 18VT BR G71 20VT YL CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Z1 12BK F81 12TN E20 18OR DB Q18 16GY BK Q28 16DG WT P2 14BK WT P34 14PK BK D2 18WT BK D1 18VT BR G71 20VT YL C351 WITH PREMIUM RADIO WITH STANDARD RADIO C351 C345 CIRCUIT CAV A B P11...

Page 999: ...CAV 1 2 3 4 Z1 16BK Q41 16WT Q42 16LB F86 16LG BK C371 CIRCUIT CAV 1 2 3 4 Z1 16BK Q41 16LB Q42 16WT F86 16RD YL CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 L50 18WT TN L90 18DB RD L10 18BR LG L61 18LG L60 18TN F70 16PK BK B40 12LB Z1 12BK C372 WITH FACTORY TRAILER TOW CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 L50 18WT TN L90 18DB RD L10 18BR LG L61 18LG L61 18LG L60 18TN L60 18TN F70 16PK BK B40 12LB Z1 12BK BLACK 1...

Page 1000: ...ABLE CAV A B C M2 20YL M1 20PK M4 20WT LG BLACK C A CARGO LAMP CIRCUIT FUNCTION STOP LAMP SWITCH OUTPUT STOP LAMP SWITCH OUTPUT GROUND GROUND CAV 1 2 L87 20DG WT L87 20DG WT Z1 20BK Z1 20BK BLACK CENTER HIGH MOUNTED STOP LAMP NO 1 1 2 CIRCUIT FUNCTION STOP LAMP SWITCH OUTPUT GROUND CAV 1 2 L87 20DG WT Z1 20BK BLACK CENTER HIGH MOUNTED STOP LAMP NO 2 1 2 CIRCUIT CAV 1 2 3 T40 14LG BK G60 20GY YL K1...

Page 1001: ...R LEFT REAR WHEEL SPEED SENSOR RIGHT FRONT WHEEL SPEED SENSOR LEFTT FRONT WHEEL SPEED SENSOR G SWITCH NO 1 SENSE G SWITCH NO 2 SENSE GROUND SYSTEM RELAY LEFT REAR WHEEL SPEED SENSOR LEFT FRONT WHEEL SPEED SENSOR STOP LAMP SWITCH OUTPUT G SWITCH SENSOR GROUND ABS WARNING LAMP DRIVER RIGHT REAR WHEEL SPEED SENSOR RIGHT FRONT WHEEL SPEED SENSOR SCI RECEIVE FUSED IGNITION SWITCH OUTPUT RUN GROUND FUSE...

Page 1002: ... 18VT DATA LINK CONNECTOR 16 9 8 1 BLACK DIESEL CIRCUIT FUNCTION SENSOR GROUND CRANKSHAFT POSITION SENSOR SIGNAL CAV 1 2 3 K4 20BK LB K24 20GY BK CIRCUIT FUNCTION 5 VOLT SUPPLY SENSOR GROUND CRANKSHAFT POSITION SENSOR SIGNAL CAV 1 2 3 K25 20WT BK K4 20BK LB K27 18RD LG CRANKSHAFT POSITION SENSOR DIESEL CRANKSHAFT POSITION SENSOR GAS CIRCUIT FUNCTION ENGINE COOLANT LEVEL SENSE GROUND CAV 1 2 G18 16...

Page 1003: ... UP LEFT REAR WINDOW DRIVER DOWN LEFT FRONT DOOR UNLOCK DRIVER LEFT FRONT DOOR LOCK DRIVER GROUND CCD BUS CCD BUS LEFT REAR DOOR SWITCH ILLUMINATION MUX COURTESY LAMP DRIVER FUSED B CAV 1 2 3 4 5 6 7 8 9 10 11 12 Q11 16LB Q21 16WT Q17 16DB WT Q27 16RD BK P34 18PK BK P35 18OR VT Z1 12BK D1 18VT BR D2 18WT BK E21 18OR M1 20PK F81 12TN 1 6 12 10 9 7 DRIVER DOOR MODULE C1 WHITE CIRCUIT FUNCTION HORIZO...

Page 1004: ...IT FUNCTION GROUND HEATED SEAT DRIVER CAV A B Z1 16BK P88 16BR BK BLACK DRIVER HEATED SEAT BACK A B CIRCUIT FUNCTION HEATED SEAT DRIVER HEATED SEAT DRIVER DRIVER HEATED SEAT SWITCH OUTPUT GROUND CAV A B C D P87 16BK OR P88 16BR BK P7 18LB BK Z1 20BK BLACK DRIVER HEATED SEAT CUSHION D A C B CIRCUIT FUNCTION LUMBAR FORWARD DRIVER LUMBAR REARWARD DRIVER CAV 1 2 P106 18DG WT P107 18OR BK BLACK DRIVER ...

Page 1005: ... LB CIRCUIT FUNCTION 6 VOLT SENSOR SUPPLY HORIZONTAL POSITION SENSE SENSOR GROUND CAV A B C P29 20BR WT P25 20VT RD P28 20BR RD BLACK DRIVER POWER SEAT HORIZONTAL MOTOR SENSOR C A WITH MEMORY SEATS RED DRIVER POWER SEAT FRONT RISER MOTOR 1 2 CIRCUIT FUNCTION FRONT RISER DOWN DRIVER FRONT RISER DOWN SWITCH SENSE FRONT RISER UP DRIVER FRONT RISER UP SWITCH SENSE CAV 1 2 P121 16RD GY P21 16RD LG P119...

Page 1006: ...NCTION REAR RISER DOWN DRIVER REAR RISER DOWN SWITCH SENSE REAR RISER UP DRIVER REAR RISER UP SWITCH SENSE CAV 1 2 P113 16RD BK P13 16RD WT P111 16YL DB P11 16YL WT RED DRIVER POWER SEAT REAR RISER MOTOR 1 2 CIRCUIT FUNCTION SENSOR GROUND REAR RISER POSITION SENSE 6 VOLT SENSOR SUPPLY CAV A B C P28 20BR RD P27 20LB RD P29 20BR WT BLACK DRIVER POWER SEAT REAR RISER MOTOR SENSOR C A CIRCUIT FUNCTION...

Page 1007: ...WITCH SENSE REAR RISER UP SWITCH SENSE REAR RISER UP SWITCH SENSE REAR RISER DOWN SWITCH SENSE REAR RISER DOWN SWITCH SENSE FRONT RISER DOWN SWITCH SENSE FRONT RISER DOWN SWITCH SENSE CAV 1 2 2 3 3 4 4 5 6 6 7 7 8 8 9 9 10 10 Z1 16BK P40 18GY LB P43 16GY LB P17 18RD LB P17 16RD LB P48 18GY WT P41 16GY WT F35 16RD P15 18YL LB P15 16YL LB P19 18YL LG P19 16YL LG P11 18YL WT P11 16YL WT P13 18RD WT P...

Page 1008: ...ENOID GROUND CAV 1 2 4 A142 16DG OR K35 16GY YL Z1 18BK EGR SOLENOID DIESEL CIRCUIT FUNCTION ENGINE COOLANT TEMPERATURE SENSOR SIGNAL SENSOR GROUND SECONDARY ENGINE COOLANT TEMP SENSOR CAV A B C K2 20TN BK K4 20BK LB K222 20TN RD ENGINE COOLANT TEMPERATURE SENSOR DIESEL DIESEL 2 1 3 4 A B C CIRCUIT FUNCTION ENGINE COOLANT TEMPERATURE SENSOR SIGNAL SENSOR GROUND CAV 1 2 K2 16TN BK K4 16BK LB ENGINE...

Page 1009: ...VT RD BLACK EVAPORATIVE SYSTEM LEAK DETECTION PUMP 4 1 CIRCUIT FUNCTION GROUND TRAILER TOW OUTPUT PARK LAMP RELAY OUTPUT FUSED B LEFT TURN SIGNAL RIGHT TURN SIGNAL BACK UP LAMP SWITCH OUTPUT CAV 1 2 3 4 5 6 7 Z1 12BK B40 12LB L90 18DB RD F70 18PK BK L61 18LG L60 18TN L10 18BR LG 7 4 6 2 3 1 5 FACTORY TRAILER TOW CONNECTOR BLACK BLACK 3 1 FLOOR CONSOLE LAMPS CIRCUIT FUNCTION GROUND PANEL LAMP DRIVE...

Page 1010: ... A142 16DG OR FUEL PUMP MODULE DIESEL CIRCUIT FUNCTION FUEL PUMP RELAY OUTPUT LOW SENSOR RETURN GROUND CAV 1 3 4 6 A64 16DG WT G40 20LB BK K167 20BR YL Z1 16BK FUEL PUMP MODULE GAS CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL TIMING SHUTOFF SOLENOID SHUTOFF CAV 1 2 3 A142 16DG BK D238 16VT K153 20OR FUEL TIMING SOLENOID DIESEL CIRCUIT FUNCTION ELECTRIC PUMP FEED GROUND CAV 1 2 A64 14OR D...

Page 1011: ...OR K20 18DG YL GENERATOR DIESEL CIRCUIT FUNCTION GROUND AUTOMATIC SHUT DOWN RELAY OUTPUT GENERATOR FIELD DRIVER CAV 1 2 3 4 Z0 8BK K72 18DG VT K20 18DG GENERATOR GAS CIRCUIT FUNCTION BATTERY POSITIVE GLOW PLUG RELAY CONTROL SENSE FUSED IGNITION SWITCH OUTPUT GLOW PLUG RELAY CONTROL CAV 1 2 3 4 A0 10RD K152 16WT A142 16DG OR K154 10GY GLOW PLUG RELAY DIESEL CIRCUIT FUNCTION FUSED B GROUND CAV 1 2 M...

Page 1012: ...OR REAR WHEELS IN ALL TIME GROUND CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 G18 20PK BK F60 20RD WT Z2 20BK OR L5 18OR BK G46 20BK LB D1 18VT BR D2 18WT BK E2 20OR L90 20DB RD G29 2OBK TN 107 20BK RD T106 20GY OR F83 18YL DG T19 20YL BK G42 20LB RD G28 20LG OR Z1 20BK GRAPHIC DISPLAY MODULE OR VEHICLE INFORMATION CENTER BLACK 10 1 20 11 CIRCUIT FUNCTION GROUND HD LP LEVELING POSITION ...

Page 1013: ... 13 14 15 16 E2 20OR Z1 16BK M11 20PK LB L39 20LB Z1 16BK L35 20BR WT L96 20LG RD 707 20BK WT A6 14RD LB F34 16TN BK L24 20LB RD 366 16PK OR L90 20DB RD HEADLAMP SWITCH 9 BLACK 1 16 8 CIRCUIT FUNCTION FUSED B BLOWER MOTOR DRIVER HIGH BLOWER MOTOR RELAY CONTROL FUSED B CAV 1 2 3 4 5 6 A19 14RD VT C42 12BR RD C41 20BR A19 12DG RD HIGH SPEED BLOWER MOTOR RELAY BLACK 1 2 3 4 5 CIRCUIT FUNCTION HORN RE...

Page 1014: ...K59 16VT BK K40 16BR WT K39 16GY RD BLACK IDLE AIR CONTROL MOTOR 4 0L I 6 4 1 CIRCUIT FUNCTION IGNITION COIL NO 1 DRIVER AUTOMATIC SHUT DOWN RELAY OUTPUT CAV 1 2 K19 18GY WT A142 18DG OR IGNITION COIL 1 BLACK 2 CIRCUIT FUNCTION IGNITION SWITCH OUTPUT START IGNITION SWITCH OUTPUT START RUN RED BRAKE WARNING LAMP DRIVER FUSED B IGNITION SWITCH OUTPUT RUN IGNITION SWITCH OUTPUT ACC RUN FUSED B CAV 1 ...

Page 1015: ... 18TN GRAY 2 FUEL INJECTOR NO 1 1 GRAY 2 FUEL INJECTOR NO 2 1 CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT INJECTOR NO 3 DRIVER CAV 1 2 A142 18DG OR K13 18YL WT GRAY 2 FUEL INJECTOR NO 3 1 CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT INJECTOR NO 4 DRIVER CAV 1 2 A142 18DG OR K14 18LB BR GRAY 2 FUEL INJECTOR NO 4 1 CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT INJECTOR NO 5 DRIVER CAV...

Page 1016: ...5 6 7 8 9 10 11 12 M1 18PK L10 18BR LG L39 18LB F62 18RD T107 20BK RD A6 14RD LB L90 18DB RD F12 20DB WT F86 18LG RD CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT INJECTOR NO 8 DRIVER CAV 1 2 A142 18DG OR K18 18DB YL GRAY 2 FUEL INJECTOR NO 8 WITH 5 2L ENG 1 CIRCUIT FUNCTION GROUND GROUND FUSED B ABS WARNING LAMP DRIVER FUSED IGNITION SWITCH OUTPUT START RUN LEFT TURN SIGNAL INDICATOR LAMP RIG...

Page 1017: ...R LAMP 4 WHEEL DRIVE PART TIME LAMP FUSED IGNITION SWITCH OUTPUT ACC RUN FUSED IGNITION SWITCH OUTPUT ACC RUN FUSED B FUSED B CAV 1 2 3 4 5 6 7 8 9 10 L64 18TN DB 107 20BK RD F30 18RD DB A31 18RD BK L64 18TN DB 107 20BK RD F86 16LG BK F86 16LG BK F75 18VT F75 18VT WITH POWER SUNROOF 7 3 1 10 6 2 JUNCTION BLOCK C5 RED CIRCUIT FUNCTION TURN SIGNAL 2 WHEEL DRIVE OR REAR WHEEL IN ALL TIME GROUND RADIO...

Page 1018: ...REAR FOG LAMP FOG LAMP RELAY OUTPUT GROUND FOG LAMP RELAY CONTROL HORN RELAY CONTROL CAV 1 2 3 4 5 6 7 8 9 10 11 12 X12 18RD GY L11 16LG BK L95 18DG YL A31 18RD BK L12 18VT TN L36 18LG L96 20LG RD L39 20LB Z1 18BK L95 18DG YL X4 20GY OR CIRCUIT FUNCTION FUSED IGNITION SWITCH OUTPUT RUN COURTESY LAMP RELAY OUTPUT FUSED B PARK LAMP SWITCH OUTPUT PARK LAMP SWITCH OUTPUT FUSED B COURTESY LAMP RELAY OU...

Page 1019: ... LAMP RELAY CONTROL HORN RELAY CONTROL REAR WINDOW DEFOGGER RELAY CONTROL PARK LAMP RELAY CONTROL PARK LAMP SWITCH OUTPUT AUTO HEADLAMP RELAY CONTROL CAV 1 2 3 4 5 6 7 8 9 10 11 12 L95 20DG YL V23 18BR PK L16 18RD LG V23 20BR PK M112 20BR LG X4 20GY OR C14 20WT RD L79 20TN L90 20DB RD 714 20BK OR CIRCUIT FUNCTION POWER ANTENNA UP CONTROL POWER ANTENNA DOWN CONTROL POWER ANTENNA DRIVER CAV 1 2 3 X1...

Page 1020: ... 20YL X60 18DG RD F81 10TN F70 14PK BK F81 12TN F35 16RD CIRCUIT FUNCTION GROUND FUSED IGNITION SWITCH OUTPUT RUN FUSED IGNITION SWITCH OUTPUT RUN BACK UP LAMP SWITCH OUTPUT FUSED B COURTESY LAMP RELAY OUTPUT CAV 1 2 3 3 4 5 6 7 8 9 10 11 12 Z1 16BK F83 20YL DG F83 20BK VT L10 20BK RD M1 20PK M2 20YL 8 3 1 2 7 12 JUNCTION BLOCK C15 OVERHEAD CONSOLE BLACK CIRCUIT FUNCTION GROUND KEY IN IGNITION SWI...

Page 1021: ...AGE MODULE C2 CIRCUIT FUNCTION NOT USED STOP LAMP SWITCH OUTPUT PARK LAMP RELAY OUTPUT PARK LAMP RELAY OUTPUT PARK LAMP RELAY OUTPUT PARK LAMP RELAY OUTPUT PARK LAMP RELAY OUTPUT STOP LAMP SWITCH OUTPUT STOP LAMP SWITCH OUTPUT STOP LAMP SWITCH OUTPUT REAR LAMP OUT INDICATOR DRIVER FUSED IGNITION SWITCH OUTPUT START RUN CAV 1 2 3 4 5 6 7 8 9 10 L36 18LG OR L50 18WT TN L90 18DB RD L90 18DB RD L90 18...

Page 1022: ...D B COURTESY LAMP RELAY OUTPUT CAV A B M1 20PK M2 20YL LEFT COURTESY LAMP BLACK CIRCUIT FUNCTION FUSED B GROUND CAV 1 2 M1 20PK Z1 20BK BLACK 1 2 LEFT DOOR COURTESY LAMP CIRCUIT FUNCTION GROUND FOG LAMP RELAY SWITCH OUTPUT CAV 1 2 Z1 18BK L39 18LB LEFT FOG LAMP BLACK 2 1 CIRCUIT FUNCTION VTSS DISARM SENSE GROUND CAV 1 2 G71 20VT YL Z1 20BK BLACK 2 1 LEFT FRONT CYLINDER LOCK SWITCH ...

Page 1023: ... A B X53 20DG X55 20BR RD B LEFT FRONT DOOR SPEAKER BLACK A CIRCUIT FUNCTION LEFT FRONT WINDOW DRIVER UP LEFT FRONT WINDOW DRIVER DOWN CAV 1 2 Q11 16LB Q21 16WT BLACK LEFT FRONT POWER WINDOW MOTOR 2 1 CIRCUIT FUNCTION PARK LAMP RELAY OUTPUT GROUND CAV A B L90 18DB RD Z1 18BK WHITE LEFT FRONT PARK LAMP B A CIRCUIT FUNCTION PARK LAMP RELAY OUTPUT TURN SIGNAL SWITCH OUTPUT CAV A B L90 18DB RD L64 18T...

Page 1024: ...ENSOR BLACK 2 1 CIRCUIT FUNCTION GROUND DIMMER SWITCH LOW BEAM OUTPUT DIMMER SWITCH HIGH BEAM OUTPUT CAV 1 2 3 Z1 16BK L4 16VT OR L3 16RD OR LEFT HEADLAMP BLACK 1 2 3 CIRCUIT FUNCTION AMPLIFIED LEFT FRONT AMPLIFIED LEFT FRONT CAV A B X87 20LG RD X85 20LG BK LEFT INSTRUMENT PANEL SPEAKER BLACK A B CIRCUIT FUNCTION POSITION 4 POSITION 3 POSITION 2 POSITION 5 POSITION 6 POSITION 1 CAV 1 2 3 4 5 6 L10...

Page 1025: ...UNCTION DOOR UNLOCK DRIVER DOOR LOCK DRIVER CAV 1 2 P34 18PK BK P2 18BK WT LEFT REAR DOOR LOCK MOTOR BLACK 1 2 CIRCUIT FUNCTION LEFT REAR LEFT REAR CAV A B X52 20DB WT X58 20DB OR B LEFT REAR DOOR SPEAKER BLACK A CIRCUIT FUNCTION LEFT FRONT T S FEED PARK LAMP SWITCH OUTPUT GROUND CAV 1 2 3 L65 18LG DB L90 18DB RD Z1 18BK LEFT PARK TURN SIGNAL MARKER 1 2 CIRCUIT FUNCTION REAR FOG LAMP GROUND CAV A ...

Page 1026: ...LAMP SWITCH OUTPUT CAV 1 2 Z1 18BK L22 18LB NATURAL LEFT REAR SIDE MARKER LAMP 1 2 CIRCUIT FUNCTION GROUND LEFT FRONT TURN SIGNAL FEED CAV 1 2 Z1 18BK L65 18LG DB LEFT SIDE REPEATER CIRCUIT FUNCTION TURN SIGNAL SWITCH OUTPUT GROUND CAV A G L60 18TN Z1 18BK BLACK LEFT REAR TURN SIGNAL LAMP A G CIRCUIT FUNCTION LEFT REAR WHEEL SPEED SENSOR LEFT REAR WHEEL SPEED SENSOR CAV A B B3 20LG DB B4 20LG LEFT...

Page 1027: ...TION FUSED B GROUND CAV A B M1 20PK Z1 20BK A LEFT VISOR VANITY MIRROR BLACK B CIRCUIT FUNCTION GROUND LIFTGATE AJAR SWITCH SENSE CAV 1 2 3 Z1 20BK G78 20TN BK 1 LIFTGATE AJAR SWITCH BLACK 3 CIRCUIT FUNCTION VTSS DISARM SENSE GROUND CAV 1 2 G71 20VT YL Z1 20BK 1 LIFTGATE CYLINDER LOCK SWITCH BLACK 2 CIRCUIT FUNCTION DOOR LOCK DRIVER DOOR UNLOCK DRIVER CAV A B P2 16BK WT P34 16PK BK B LIFTGATE LOCK...

Page 1028: ...R PK A LIFTGLASS LIMIT SWITCH NATURAL B CIRCUIT FUNCTION LIFTGLASS PUSH BUTTON OUTPUT LIFTGLASS LIMIT SWITCH OUTPUT CAV 1 2 P100 14OR BR P101 16OR PK 1 LIFTGLASS PUSH BUTTON BLACK 2 CIRCUIT FUNCTION LIFTGLASS PUSH BUTTON OUTPUT GROUND CAV 1 2 P100 14OR BR Z1 14BK 2 LIFTGLASS RELEASE SOLENOID BLACK 1 CIRCUIT FUNCTION SENSOR GROUND MAP SENSOR SIGNAL 5 VOLT SUPPLY CAV 1 2 3 K4 20BK LB K70 18RD WT K25...

Page 1029: ... SPEED SENSOR SIGNAL SPEED CONTROL ON OFF SWITCH SENSE AUTO SHUT DOWN RELAY POWER GROUND FUEL QUANTITY ACTUATOR GROUND GLOW PLUG RELAY CONTROL SENSE FUEL TIMING SHUTOFF SENSOR SLEEVE POSITION SENSOR SHUTOFF FEED PEDAL POSITION SENSOR 5 VOLT SUPPLY SCI RECEIVE FUEL TEMPERATURE SENSOR SIGNAL LOW IDLE POSITION SWITCH LEFT FRONT DECAY SOLENOID CONTROL CAV 1 2 3 4 5 7 8 11 12 13 14 15 20 23 24 25 26 27...

Page 1030: ...20BR WT P28 20BR RD P25 20VT RD P26 20BR P27 20LB RD P47 20LB P103 20DB WT P21 18RD LG P19 18YL LG P13 18RD WT P11 18YL WT P15 18YL LB P17 18RD LB P40 18GY LB P48 18GY WT P105 20LG DB P104 20YL RD D1 20VT BR D2 20WT BK BLACK MEMORY SEAT MODULE C1 1 11 10 20 CIRCUIT FUNCTION GROUND HORIZONTAL FORWARD DRIVER HORIZONTAL REARWARD DRIVER RECLINER REARWARD DRIVER RECLINER FORWARD DRIVER GROUND LUMBAR RE...

Page 1031: ...R SWITCH LOW SPEED OUTPUT WIPER SWITCH LOW SPEED OUTPUT FUSED IGNITION SWITCH OUTPUT ACC RUN FUSED IGNITION SWITCH OUTPUT ACC RUN WIPER SWITCH LOW SPEED OUTPUT RIGHT TURN SIGNAL INDICATOR LAMP LEFT TURN SIGNAL INDICATOR LAMP HAZARD SIGNAL TURN SIGNAL SWITCH OUTPUT TURN SIGNAL SWITCH OUTPUT TURN SIGNAL SWITCH OUTPUT TURN SIGNAL TURN SIGNAL DIMMER SWITCH LOW BEAM OUTPUT DIMMER SWITCH LOW BEAM OUTPUT...

Page 1032: ...T SHAFT SPEED SENSOR SIGNAL OUTPUT SHAFT SPEED SENSOR SIGNAL CAV 1 2 T14 18LG WT T13 18DB BK OUTPUT SHAFT SPEED SENSOR BLACK 1 2 CIRCUIT FUNCTION FUSED IGNITION SWITCH OUTPUT RUN GROUND CCD BUS COURTESY LAMP RELAY OUTPUT CCD BUS FUSED B CAV 1 2 3 4 5 6 F83 20YL DG Z1 20BK D1 18VT BR M2 20YL D2 18WT BK M1 20PK OVERHEAD CONSOLE RED 3 4 1 6 DIESEL CIRCUIT FUNCTION NEEDLE MOVEMENT SENSOR NEEDLE MOVEME...

Page 1033: ... WINDOW DRIVER DOWN RIGHT FRONT DOOR UNLOCK DRIVER RIGHT FRONT DOOR LOCK DRIVER GROUND CCD BUS CCD BUS RIGHT REAR DOOR SWITCH ILLUMINATION MUX COURTESY LAMP DRIVER FUSED B CAV 1 2 3 4 5 6 7 8 9 10 11 12 Q12 16BR Q22 16VT Q18 16GY BK Q28 16DG WT P34 18PK BK P2 18BK WT Z1 12BK D1 18VT BR D2 18WT BK E20 18OR DB M1 20PK F81 12TN PASSENGER DOOR MODULE C1 WHITE 6 12 7 1 CIRCUIT FUNCTION HORIZONTAL DRIVE...

Page 1034: ...T SWITCH OUTPUT GROUND CAV A B C D P87 16BK OR P88 16BR BK P8 18LB WT Z1 20BK BLACK PASSENGER HEATED SEAT CUSHION A D B C CIRCUIT FUNCTION LUMBAR FORWARD DRIVER LUMBAR REARWARD DRIVER CAV 1 2 P106 18DG WT P107 18OR BK BLACK PASSENGER LUMBAR MOTOR 1 2 CIRCUIT FUNCTION LUMBAR REARWARD DRIVER GROUND FUSE B GROUND LUMBAR FORWARD DRIVER CAV 1 2 3 4 5 P107 18OR BK Z1 18BK F35 18RD Z1 18BK P106 18DG WT W...

Page 1035: ...CAV 1 2 P12 16RD WT P10 16YL WT RED PASSENGER POWER SEAT REAR RISER MOTOR 1 2 CIRCUIT FUNCTION RECLINER DOWN DRIVER RECLINER UP DRIVER CAV A B P42 16GY WT P44 16GY LB BLACK PASSENGER POWER SEAT RECLINER MOTOR A B CIRCUIT FUNCTION GROUND RECLINER UP DRIVER HORIZONTAL REARWARD SWITCH SENSE RECLINER DOWN DRIVER FUSED B HORIZONTAL FORWARD SWITCH SENSE FRONT RISER DOWN SWITCH SENSE REAR RISER DOWN SWIT...

Page 1036: ...16TN RD X54 16VT X58 16DB OR X52 16DB WT X60 18DG RD X92 16TN BK X56 16DB CIRCUIT FUNCTION AMPLIFIED LEFT REAR FUSED B AMPLIFIED LEFT FRONT LEFT REAR LEFT FRONT AMPLIFIED LEFT REAR FUSED B AMPLIFIED LEFT FRONT GROUND GROUND LEFT REAR LEFT FRONT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X93 16WT RD F75 16VT X87 16LG RD X51 16BR YL X53 16DG X91 16WT BK F75 16VT X85 16LG BK Z5 16BK LB Z5 16BK LB X57 16BR ...

Page 1037: ...WT X53 16DG X54 16VT X60 18DG RD Z5 16BK LB F75 16VT POWER AMPLIFIER LTD C1 CIRCUIT FUNCTION AMPLIFIED RIGHT DOOR SPEAKER AMPLIFIED RIGHT SPEAKER DOOR AMPLIFIED LO LEFT REAR SPEAKER AMPLIFIED HI LEFT REAR SPEAKER AMPLIFIED RIGHT REAR SPEAKER AMPLIFIED RIGHT REAR SPEAKER AMPLIFIED HI RELT REAR SPEAKER RIGHT REAR SPEAKER RIGHT REAR SPEAKER AMPLIFIED LO LEFT REAR SPEAKER AMPLIFIED LEFT DOOR SPEAKER A...

Page 1038: ...ON SENSOR SIGNAL IDLE AIR CONTROL NO 2 DRIVER IDLE AIR CONTROL NO 1 DRIVER FUSED B THROTTLE POSITION SENSOR SIGNAL UPSTREAM HEATED OXYGEN SENSOR SIGNAL DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL MAP SENSOR SIGNAL GROUND GROUND F99 18OR K4 18BK LB T41 18BK WT K19 18GY WT K27 18RD LG K59 16VT BK K40 16BR WT K21 16BK RD K2 16TN BK K25 18WT BK K24 18GY BK K60 16YL BK K39 16GY RD F5 14RD YL K22 18OR DB K41...

Page 1039: ...E SENSOR SIGNAL OUTPUT SHAFT SPEED SENSOR SIGNAL VEHICLE SPEED SENSOR SIGNAL OUTPUT SHAFT SPEED SENSOR SIGNAL GOVERNOR PRESSURE SIGNAL TRANSMISSION RELAY CONTROL 5 VOLT SUPPLY T54 18VT K17 18DB WT K11 18WT DB K13 18YL WT K38 18GY T59 18PK K20 18DG T22 18DG LB K58 18BR YL K18 18DB YL K12 18TN K14 18LB BR T60 18BR G6 18GY WT T13 18DB BK G7 18WT OR T14 18LG WT T25 18LG T66 18BR OR K6 18VT WT CAV B1 B...

Page 1040: ...EVAPORATIVE EMISSION SOLENOID CONTROL A C PRESSURE SWITCH SENSE STOP LAMP SWITCH SENSE VOLTAGE REGULATOR SIGNAL LOW FUEL SENSE SCI RECEIVE CCD BUS SCI TRANSMIT CCD BUS SPEED CONTROL SWITCH SIGNAL C13 18DB RD K900 18PK WT V36 18TN RD V35 18LG RD G68 18BR YL J95 18DG RD V32 18YL RD A142 18DG OR T9 18OR J96 18VT RD T222 18RD YL K81 18DB K52 18PK BK C3 18DB BK L53 18BR K72 18DG VT G40 18LB BK D83 18BK...

Page 1041: ...IT TO START LAMP SCI TRANSMIT CCD BUS VEHICLE SPEED SENSOR SIGNAL ENGINE COOLANT LEVEL SIGNAL AUTOMATIC SHUT DOWN RELAY OUTPUT A C SWITCH SIGNAL G40 18LB BK F6 18WT RD K167 20BR YL K7 20OR WT G18 20PK BK F99 18OR Z12 16BK TN Z12 16BK TN K20 18DG YL K222 20TN RD K48 18OR RD G123 20DG WT G21 20GY LB D83 20BK PK D1 18VT BR L53 20BR K92 20PK G60 20GY YL K185 18OR LB D84 20BK WT D2 18WT BK G7 20WT OR G...

Page 1042: ...18RD GY F60 20RD WT RADIO C1 GRAY 1 7 CIRCUIT FUNCTION CCD BUS CCD BUS CAV 1 2 D1 18VT BR D2 18WT BK BLACK RADIO C2 2 1 CIRCUIT FUNCTION RADIO 12 VOLT OUTPUT LEFT REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR CAV 1 2 3 4 5 6 7 X60 20DG RD X51 20BR YL X52 20DB WT X53 20DG X54 20VT YL X57 20BR LB X58 20DB OR BLACK 1 RADIO C3 7 CIRCUIT FUNCTION CAV A B C D X96 16DB OR X98 16DB WT X97 16...

Page 1043: ...V20 18BK WT G78 20TN BK BLACK 3 REAR WIPER MODULE 4 1 6 CIRCUIT FUNCTION REAR WIPER MOTOR CONTROL FUSED IGNITION SWITCH OUTPUT ACC RUN REAR WIPER MOTOR CONTROL INT REAR WASHER MOTOR CONTROL REAR WASHER MOTOR CONTROL CAV 1 2 3 4 V13 18BR LG V23 18BR PK V24 18BR OR V20 18WT BK V20 18WT BK REAR WIPER WASHER SWITCH 1 BLACK 4 CIRCUIT FUNCTION RECIRCULATION DOOR MOTOR DRIVER RECIRCULATION DOOR MOTOR DRI...

Page 1044: ...IT FUNCTION BACK UP LAMP SWITCH OUTPUT GROUND CAV A G L10 18BR LG Z1 18BK BLACK RIGHT BACK UP LAMP A G CIRCUIT FUNCTION FUSED B COURTESY LAMP RELAY OUTPUT CAV A B M1 20PK M2 20YL RIGHT COURTESY LAMP BLACK CIRCUIT FUNCTION FUSED B GROUND CAV 1 2 M1 20PK Z1 20BK BLACK 2 1 RIGHT DOOR COURTESY LAMP CIRCUIT FUNCTION GROUND FOG LAMP RELAY OUTPUT CAV 1 2 Z1 18BK L39 18LB RIGHT FOG LAMP 1 2 BLACK ...

Page 1045: ...AV 1 2 P34 14PK BK P2 14BK WT BLACK 2 1 RIGHT FRONT DOOR LOCK MOTOR CIRCUIT FUNCTION RIGHT FRONT RIGHT FRONT CAV A B X54 20VT X56 20DB RD RIGHT FRONT DOOR SPEAKER BLACK A B CIRCUIT FUNCTION PARK LAMP RELAY OUTPUT GROUND CAV A B L90 18DB RD Z1 18BK WHITE RIGHT FRONT PARK LAMP B A CIRCUIT FUNCTION RIGHT FRONT WINDOW DRIVER UP RIGHT FRONT WINDOW DRIVER DOWN CAV 1 2 Q12 16BR Q22 16VT BLACK RIGHT FRONT...

Page 1046: ...SPEED SENSOR CAV 1 2 B6 20WT DB B7 20WT RIGHT FRONT WHEEL SPEED SENSOR 1 BLACK 2 CIRCUIT FUNCTION GROUND DIMMER SWITCH LOW BEAM OUTPUT DIMMER SWITCH HIGH BEAM OUTPUT CAV 1 2 3 Z1 16BK L4 16VT OR L3 16RD OR BLACK RIGHT HEADLAMP 1 2 3 CIRCUIT FUNCTION AMPLIFIED RIGHT FRONT AMPLIFIED RIGHT FRONT CAV A B X82 20LB RD X80 20LB BK RIGHT INSTRUMENT PANEL SPEAKER BLACK A B EXPORT CIRCUIT FUNCTION POSITION ...

Page 1047: ...R LOCK MOTOR BLACK 1 2 CIRCUIT FUNCTION RIGHT REAR RIGHT REAR CAV A B X52 20DB WT X58 20DB OR B RIGHT REAR DOOR SPEAKER BLACK A CIRCUIT FUNCTION PARK LAMP RELAY OUTPUT GROUND CAV 1 2 L90 18DB RD Z1 18BK NATURAL RIGHT PARK LAMP 1 2 CIRCUIT FUNCTION REAR FOG LAMP GROUND CAV A G L36 18LG BK Z1 18BK RIGHT REAR FOG LAMP CIRCUIT FUNCTION RIGHT TURN SIGNAL PARK LAMP SWITCH OUTPUT GROUND CAV 1 2 3 L64 18T...

Page 1048: ...GHT REAR WHEEL SPEED SENSOR CAV A B B1 20YL DB B2 20YL RIGHT REAR WHEEL SPEED SENSOR A B RED CIRCUIT FUNCTION RIGHT REAR WINDOW DRIVER UP RIGHT REAR WINDOW DRIVER UP RIGHT REAR DOOR SWITCH ILLUMINATION RIGHT REAR WINDOW DRIVER DOWN RIGHT REAR WINDOW DRIVER DOWN GROUND CAV 1 2 3 4 5 6 Q18 16GY BK Q12 16BR E20 20OR DG Q28 16DG WT Q22 16VT Z1 16BK 1 4 3 6 RIGHT REAR POWER WINDOW SWITCH BLUE CIRCUIT F...

Page 1049: ...T INTERLOCK SOLENOID SENSE FUSED IGNITION SWITCH OUTPUT CAV 1 2 L53 20BR F87 20BK WT SHIFT INTERLOCK SOLAR SENSOR CIRCUIT FUNCTION SOLOR SENSOR SIGNAL SENSOR GROUND CAV A B C47 20BK WT D41 20LG WT A RED B 1 BLACK 2 1 BLACK 2 CIRCUIT FUNCTION STOP LAMP SWITCH OUTPUT PARK LAMP SWITCH OUTPUT GROUND CAV A B G L74 18PK BK L21 18LB WT Z1 18BK BLACK RIGHT TAIL STOP LAMP B A G FUNCTION CIRCUIT GROUND RIGH...

Page 1050: ...LY VEHICLE SPEED SENSOR SIGNAL FUSED IGNITION SWITCH OUTPUT RUN STEERING WHEEL SPEED SENSOR SIGNAL B GROUND SCI TRANSMIT SCI RECEIVE STEERING WHEEL SPEED SENSOR SIGNAL A CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 S99 18LG S98 18LB S2 20BK LG S1 20BK YL G7 18WT OR F83 20YL DG S4 20VT Z2 20BK D83 20BK PK D98 20WT S3 20PK WT 14 7 6 1 CIRCUIT FUNCTION SPS SOLENOID CTL HIGH SPS SOLENOID CTL LOW CAV 1 2 S98 1...

Page 1051: ... OFF LAMP DRIVER REAR WINDOW DEFOGGER SWITCH SENSE FUSED REAR WINDOW DEFOGGER RELAY OUTPUT CAV 1 2 3 4 5 6 7 8 9 10 P7 20LB Z1 20BK E2 20OR P8 20LB WT F71 20PK DG T9 20OR G68 20BR YL C80 20DB YL C16 20LB YL SWITCH POD 1 BLACK 10 CIRCUIT FUNCTION GROUND POWER SUNROOF OPEN POWER SUNROOF CLOSE FUSED IGNITION SWITCH OUTPUT CAV 1 2 3 4 Z1 16BK Q41 18WT Q42 18LB F86 18LG BK SUNROOF CONTROL MODULE CIRCUI...

Page 1052: ...NAL GROUND LEFT TURN SIGNAL FACTORY TRAILER TOW RELAY OUTPUTS FACTORY TRAILER TOW RELAY OUTPUTS FACTORY TRAILER TOW RELAY OUTPUTS FACTORY TRAILER TOW RELAY OUTPUTS CAV 1 2 3 4 5 L61 18LG Z1 18BK L61 18LG OR 95 18PK 95 18PK 94 18DG 94 18DG TRAILER TOW LEFT TURN RELAY BLACK 3 5 2 4 1 CAV 3 2 1 5 2L V 8 4 0L I 6 CIRCUIT FUNCTION RIGHT TURN SIGNAL GROUND RIGHT TURN SIGNAL FACTORY TRAILER TOW RELAY OUT...

Page 1053: ...L VARIABLE FORCE SOLENOID CONTROL OVERDRIVE SOLENOID CONTROL TORQUE CONVERTER CLUTCH SOLENOID OUTPUT TRANSMISSION TEMPERATURE SENSOR SIGNAL CAV 1 2 3 4 5 6 7 8 T20 18LB K6 18VT WT K4 18BK LB T25 18LG T59 18PK T60 18BR T22 18DG LB T54 18VT 1 2 3 4 5 6 7 8 BLACK TRANSMISSION SOLENOID ASSEMBLY CIRCUIT FUNCTION FUSED B GROUND CAV 1 2 M1 18PK Z1 18BK UNDERHOOD LAMP BLACK 1 2 GRAY CIRCUIT FUNCTION AUTOM...

Page 1054: ... SWITCH 1 5 CIRCUIT FUNCTION ENGINE COOLANT LEVEL SWITCH SENSE FUSED B GROUND TURN SIGNAL REAR LAMP OUT INDICATOR DRIVER CCD BUS CCD BUS PANEL LAMP DRIVER PARK LAMP RELAY OUTPUT WASHER FLUID LEVEL SENSE 4 WHEEL DRIVE PART TIME LAMP 4 WHEEL DRIVE FULL TIME LAMP FUSED IGNITION SWITCH OUTPUT RUN 4 WHEEL DRIVE PART TIME LAMP ALL TIME FRONT WHEELS 2 WHEEL DRIVE OR REAR WHEELS IN ALL TIME GROUND CAV 1 2...

Page 1055: ...6LG RD V66 18VT WT Z2 18BK V3 18BR WT V4 18RD YL WINDSHIELD WASHER PUMP MOTOR WINDSHIELD WIPER MOTOR BLACK A B BLACK 1 4 3 6 CIRCUIT FUNCTION WASHER FLUID LEVEL SENSE GROUND CAV A B G29 16BK TN Z2 16BK WIPER FLUID LEVEL SENSOR BLACK B A CIRCUIT FUNCTION 8 VOLT SUPPLY SENSOR GROUND VEHICLE SPEED SENSOR SIGNAL CAV 1 2 3 K7 20OR K167 20BR YL G7 20WT OR VEHICLE SPEED SENSOR CIRCUIT FUNCTION WATER IN F...

Page 1056: ......

Page 1057: ...eering Column and Center Floor Console 14 Automatic Day Night Rearview Mirror BK Behind Rear View Mirror 18 Automatic Temperature Control Module BK Left Side of HVAC Housing N S Battery Temperature Sensor BK Below Battery Tray 4 Blend Air Door Motor BK On Bottom of HVAC Unit N S Blend Air Actuator BK On Bottom of HVAC Unit N S Connector Name Number Color Location Fig Blower Motor NAT Right Side of...

Page 1058: ...onnector Name Number Color Location Fig C309 GY In Left Rear Door 22 C320 GY Right Rear Quarter Panel Near Bottom of Liftgate Opening 19 C321 BK In Liftgate 24 C322 GN In Liftgate 24 C323 GY In Liftgate 24 C324 BK In Liftgate 24 C325 BK In Liftgate 24 C326 GY In Liftgate 24 C328 GY Left Rear Quarter Panel Near Bottom of Liftgate Opening 20 C329 BK Below Left Rear Passenger Seat 20 C330 GY In Right...

Page 1059: ...tor Sensor BK Under Driver s Seat N S Connector Name Number Color Location Fig Driver Power Seat Horizontal Motor BK Under Driver s Seat N S Driver Power Seat Horizontal Motor Sensor BK Under Driver s Seat N S Driver Power Seat Lumbar Motor Sensor BK Under Driver s Seat N S Driver Power Seat Lumbar Switch BK Under Driver s Seat N S Driver Power Seat Rear Riser Motor RD Under Driver s Seat N S Driv...

Page 1060: ...ht Rear Quarter Panel 19 Connector Name Number Color Location Fig G301 Rear of Passenger s Seat 19 G302 On Floor Pan Rear of Driver s Seat 20 G303 On Floor Pan Rear of Driver s Seat 20 G304 On Floor Pan Rear of Driver s Seat 20 G305 On Floor Pan Rear of Driver s Seat 20 G Switch BK Below Right Rear Passenger Seat 19 Generator BK At Generator 6 Glove Box Lamp BK At Glove Box Lamp 14 Glow Plug Relay...

Page 1061: ...BK Behind Right Kick Panel N S Key In Switch Halo Lamp GY On Steering Column Near Ignition Switch 17 Connector Name Number Color Location Fig Lamp Outage Module C1 BK Left Rear Quarter Panel Near Bottom of Liftgate Opening 20 Lamp Outage Module C2 BK Left Rear Quarter Panel Near Bottom of Liftgate Opening 20 Left Back Up Lamp BK At Lamp N S Left Courtesy Lamp BK At Lamp 14 Left Door Courtesy Lamp ...

Page 1062: ...s Seat N S Mode Door Motor BK Left Side of HVAC N S Connector Name Number Color Location Fig Multi Function Switch BK On Steering Column 17 Oil Pressure Sensor BK Near Distributor 5 9 Output Shaft Speed Sensor BK Left Side of Transmission 7 10 Overhead Console RD Center of Headliner Above Rear View Mirror 18 Overhead Console Junction Block BK Behind Right Kick Panel At Junction Block 15 Park Neutr...

Page 1063: ...oor 21 Right Fog Lamp BK Rear of Fog Lamp 1 Connector Name Number Color Location Fig Right Front Cylinder Lock Switch BK In Right Front Door 21 Right Front Door Lock Motor BK In Right Front Door 21 Right Front Door Speaker BK In Right Front Door 21 Right Front Park Lamp WT At Lamp N S Right Front Power Window Motor BK In Right Front Door 21 Right Front Side Marker Lamp GY At Lamp N S Right Front T...

Page 1064: ...witch Pod BK Rear of Overdrive Switch 14 Connector Name Number Color Location Fig Throttle Position Sensor BK On Throttle Body 5 9 Trailer Tow Circuit Breaker BK Right Rear Quarter Panel 23 Trailer Tow Left Turn Relay BK Right Rear Quarter Panel 23 Trailer Tow Right Turn Relay BK Right Rear Quarter Panel 23 Trailer Tow Stop Lamp Relay BK Right Rear Quarter Panel 23 Transmission Solenoid Assembly B...

Page 1065: ...Fig 1 Front End Lighting ZG 8W 90 CONNECTOR LOCATIONS 8W 90 9 DESCRIPTION AND OPERATION Continued ...

Page 1066: ...Fig 2 Engine Compartment Left Side 8W 90 10 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1067: ...Fig 3 Engine Compartment Right Side ZG 8W 90 CONNECTOR LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued ...

Page 1068: ...Fig 4 Engine Compartment Connectors 8W 90 12 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1069: ...Fig 5 Engine Connectors 4 0L Engine ZG 8W 90 CONNECTOR LOCATIONS 8W 90 13 DESCRIPTION AND OPERATION Continued ...

Page 1070: ...Fig 6 Charging System Connectors 4 0L Engine 8W 90 14 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1071: ...Fig 7 Transmission Connectors 4 0L Engine ZG 8W 90 CONNECTOR LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued ...

Page 1072: ...Fig 8 Engine Connectors 5 2L Engine 8W 90 16 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1073: ...Fig 9 Engine Connectors 5 2L Engine ZG 8W 90 CONNECTOR LOCATIONS 8W 90 17 DESCRIPTION AND OPERATION Continued ...

Page 1074: ...Fig 10 Transmission Connectors 5 2L 8W 90 18 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1075: ...Fig 11 Engine Connectors Diesel Engine ZG 8W 90 CONNECTOR LOCATIONS 8W 90 19 DESCRIPTION AND OPERATION Continued ...

Page 1076: ...Fig 12 Battery and Starter Motor Connectors Diesel Engine 8W 90 20 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1077: ...Fig 13 Transmission Connectors Diesel Engine ZG 8W 90 CONNECTOR LOCATIONS 8W 90 21 DESCRIPTION AND OPERATION Continued ...

Page 1078: ...Fig 14 Instrument Panel Connectors 8W 90 22 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1079: ...Fig 15 Junction Block and HVAC Unit Connectors ZG 8W 90 CONNECTOR LOCATIONS 8W 90 23 DESCRIPTION AND OPERATION Continued ...

Page 1080: ...Fig 16 Instrument Panel Connectors Left Side 8W 90 24 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1081: ...Fig 17 Steering Column Connectors ZG 8W 90 CONNECTOR LOCATIONS 8W 90 25 DESCRIPTION AND OPERATION Continued ...

Page 1082: ...Fig 18 Roof Connectors 8W 90 26 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1083: ...Fig 19 Body Connectors Right Side ZG 8W 90 CONNECTOR LOCATIONS 8W 90 27 DESCRIPTION AND OPERATION Continued ...

Page 1084: ...Fig 20 Body Connectors Left Side 8W 90 28 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1085: ...Fig 21 Front Door Connectors ZG 8W 90 CONNECTOR LOCATIONS 8W 90 29 DESCRIPTION AND OPERATION Continued ...

Page 1086: ...Fig 22 Rear Door Connectors 8W 90 30 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1087: ...Fig 23 Factory Trailer Tow ZG 8W 90 CONNECTOR LOCATIONS 8W 90 31 DESCRIPTION AND OPERATION Continued ...

Page 1088: ...Fig 24 Liftgate Connectors 8W 90 32 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1089: ...Fig 25 Underhood Lamp Fig 26 License Plate Lamps ZG 8W 90 CONNECTOR LOCATIONS 8W 90 33 DESCRIPTION AND OPERATION Continued ...

Page 1090: ......

Page 1091: ... Vehicle Speed Control Servo T O 1 S125 Near Controller Antilock Brakes 6 S126 Near A C High Pressure Switch T O 4 0L Engine 1 S126 In Branch to Starter Motor 5 2L Engine 3 S127 Near Injector No 3 T O 4 0L Engine 2 S128 Near Injector No 5 T O 4 0L Engine 2 Splice Number Location Fig S128 Near T Os for Injectors 6 and 8 5 2L Engine 3 S128 Near T Os for A C Compressor 4 S129 Rear of Engine 4 0L Engi...

Page 1092: ...nel 8 Splice Number Location Fig S313 Left Rear Quarter Panel 8 S314 Top of Left Rear Quarter Panel 8 S315 Top of Left Rear Quarter Panel 8 S316 Near Right Side T O for Liftgate 9 S317 In Branch to Power Amplifier 8 S318 In Branch to Power Amplifier 8 S319 Near Branch to Right Rear Door Ajar Switch 9 S320 In Branch to Dome Reading Lamp 9 S321 Between Day Night Mirror T O and Right Vanity Mirror T ...

Page 1093: ...n Left Tail Lamp Harness Between Body Connector and Grommet N S Splice Number Location Fig S412 In Left Tail Lamp Harness Between Body Connector and Grommet N S S413 Near Right Front Turn Signal Bulb Socket N S S414 Near Right Front Turn Signal Bulb Socket N S S415 Near Right Front Park Lamp Bulb Socket N S S416 In Right Tail Lamp Harness Between Body Connector and Grommet N S S417 In Right Tail L...

Page 1094: ...Fig 1 Engine Compartment Splices 8W 95 4 8W 95 SPLICE LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1095: ...Fig 2 Engine Wiring Splices 4 0L Engine ZG 8W 95 SPLICE LOCATIONS 8W 95 5 DESCRIPTION AND OPERATION Continued ...

Page 1096: ...Fig 3 Engine Wiring Splices 5 2L Engine 8W 95 6 8W 95 SPLICE LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1097: ...Fig 4 Engine and Transmission Wiring Splices Diesel Engine ZG 8W 95 SPLICE LOCATIONS 8W 95 7 DESCRIPTION AND OPERATION Continued ...

Page 1098: ...Fig 5 Instrument Panel Splices 8W 95 8 8W 95 SPLICE LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1099: ...Fig 6 Body Splices Fig 7 HVAC Harness Splices ZG 8W 95 SPLICE LOCATIONS 8W 95 9 DESCRIPTION AND OPERATION Continued ...

Page 1100: ...Fig 8 Left Body Side Wiring Splices 8W 95 10 8W 95 SPLICE LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1101: ...Fig 9 Right Side Body Wiring Splices ZG 8W 95 SPLICE LOCATIONS 8W 95 11 DESCRIPTION AND OPERATION Continued ...

Page 1102: ...Fig 10 Roof Wiring Splices Fig 11 Front Door Harness Splices 8W 95 12 8W 95 SPLICE LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1103: ...Fig 12 Liftgate Splices ZG 8W 95 SPLICE LOCATIONS 8W 95 13 DESCRIPTION AND OPERATION Continued ...

Page 1104: ......

Page 1105: ...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...

Page 1106: ......

Page 1107: ...adlamp 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 as possibl...

Page 1108: ...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 1109: ...ponent connectors by name If a component has two or more connectors they will be identified as C1 C2 C3 etc This sections also provides terminal numbering cir cuit 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 nu...

Page 1110: ...Fig 5 Symbol Identification 8W 01 4 8W 01 GENERAL INFORMATION ZG DESCRIPTION AND OPERATION Continued ...

Page 1111: ...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 1112: ...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 1113: ...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 1114: ... the wire and tool 6934 and slowly remove the wire and terminal from the connector 6 Repair or replace the terminal 7 Install the wire and terminal in the connector Fully seat the terminal in the connector 8 Push in the single lock tab on the side of the connector Fig 16 CONNECTOR REPLACEMENT 1 Disconnect battery 2 Disconnect the connector that is to be repaired from its mating half component 3 Re...

Page 1115: ... as was done on the harness side of the repair Allow extra length for soldered connections Check that the overall length is the same as the original Fig 20 7 Remove 1 inch of insulation from each wire 8 Place a piece of heat shrink 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 ...

Page 1116: ...e to the insulation 12 Twist the wires together 13 Solder the connection together using rosin core type solder only Do not use acid core solder 14 Center the heat shrink tubing over the joint and heat using a heat gun Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 15 Insert the repaired wire into the connector 16 Install the connector locking wed...

Page 1117: ...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 Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 ZG 8W 0...

Page 1118: ......

Page 1119: ...8W 30 Courtesy Lamp Relay 8W 44 Courtesy Lamps 8W 44 Component Page Crankshaft Position CKP Sensor 8W 30 Cruise Lamp 8W 40 Cylinder Lock Switches 8W 39 Data Link Connector 8W 30 Daytime Running Lamp DRL Module 8W 50 Dome Reading Lamp 8W 44 Door Ajar Switches 8W 39 44 45 Door Courtesy Lamps 8W 44 Door Lock Motors 8W 61 Door Speakers 8W 47 Driver Door Module 8W 60 61 62 63 Driver Heated Seat Back 8W...

Page 1120: ...ge Memory Set Switch 1 Set 8W 63 Mercury Switch 8W 44 Mode Door Actuator 8W 42 MSA Controller 8W 10 30 33 Needle Sensor 8W 30 Oil Pressure Gauge 8W 40 Oil Pressure Sensor 8W 30 Output Shaft Speed Sensor 8W 30 31 Overhead Console 8W 49 Park Brake Switch 8W 45 50 Park Lamp Relay 8W 12 45 50 51 Park Lamps 8W 50 52 Park Neutral Position Switch 8W 30 44 Passenger Door Module 8W 60 61 62 Passenger Heate...

Page 1121: ...4 Trailer Tow Stop Lamp Relay 8W 54 Trailer Tow Turn Relays 8W 54 Component Page Transmission Control Relay 8W 30 31 Transmission Solenoid Assembly 8W 30 31 Turn Signal Indicator Lamps 8W 40 Turn Signal Lamps 8W 40 50 52 Turn Signal Hazard Warning Switch 8W 52 Underhood Lamp 8W 44 Universal Garage Door Opener 8W 44 Variable Force Solenoid 8W 31 Vehicle Information Center 8W 46 Vehicle Speed Contro...

Page 1122: ...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 8W 02 4 8W 02 COMPONENT INDEX ZG ...

Page 1123: ...y 8W 10 14 15 Fuse 1 8W 10 3 4 9 Fuse 2 8W 10 9 Fuse 3 8W 10 3 4 9 Fuse 4 8W 10 3 8 18 Fuse 5 8W 10 3 5 8 Fuse 6 8W 10 5 8 Fuse 7 8W 10 3 6 10 Fuse 8 8W 10 3 7 10 Fuse 9 8W 10 10 Fuse 10 8W 10 3 4 9 Fuse 11 8W 10 3 8 10 Fuse 12 8W 10 8 Component Page Fuse 13 8W 10 3 11 12 Fuse 14 8W 10 3 9 10 Fuse 15 8W 10 3 12 Fuse 16 8W 10 3 12 13 14 Fuse 17 8W 10 3 11 14 Fuse 18 8W 10 8 13 14 Fuse 19 8W 10 3 12...

Page 1124: ...11 12 14 13 16 15 2 5 3 4 1 16 19 18 20 17 11 13 15 14 12 2 4 5 3 1 7 10 8 9 6 6 9 8 10 7 1 3 5 4 2 12 14 15 13 11 17 20 18 19 16 13 12 14 11 10 2 8 5 9 6 3 1 4 7 D C B A ENGINE STARTER MOTOR RELAY WIPER RELAY INTERMITTENT ABS MAIN RELAY RELAY CLUTCH COMPRESSOR A C RELAY SHUT DOWN AUTOMATIC HORN RELAY TRANSMISSION CONTROL RELAY FUEL PUMP RELAY POWER DISTRIBUTION CENTER SEE PAGE 8W 10 20 FOR PDC PI...

Page 1125: ...A19 A11 A12 24 17 27 20 28 21 TO BRAKE ANTI LOCK CONTROLLER TO RELAY PUMP TO CENTER DISTRIBUTION POWER BRAKE 19 26 FUSE 30A 13 A6 14 RD LB JUNCTION BLOCK TO A6 14 RD LB DAYTIME RUNNING LAMP MODULE TO 19 20A A18 FUSE A17 RD BLOCK JUNCTION TO 18 F62 A12 RD TN 12 3 30A FUSE 10 4 CENTER DISTRIBUTION POWER TO DIESEL TO CENTER DISTRIBUTION POWER RD WT A1 12 GAS GAS 16 A11 15A A12 FUSE C131 TO WT RD 18 F...

Page 1126: ...TCH 5 2L A900 12 OR YL REAR WINDOW DEFOGGER RELAY JUNCTION BLOCK 87 30 86 10A FUSE 10 C15 12 BK WT 1 C301 C15 12 BK WT 2 C322 C15 12 BK LB S332 C15 12 BK C15 12 BK LB DEFOGGER WINDOW REAR LIFT GLASS C6 3 C2 3 OTHERS DIESEL AND 4 0L CENTER DISTRIBUTION POWER CENTER DISTRIBUTION POWER 85 8W 10 3 8W 48 2 8W 12 9 8W 12 2 8W 48 2 8W 42 10 8W 42 11 8W 42 10 8W 42 11 8W 20 2 8W 20 3 8W 10 3 8W 10 3 8W 10...

Page 1127: ...A0 5 12 6 FUSE 20A RELAY HORN A2 A3 A1 FUSED B X2 16 DG YL S106 X2 16 DG YL X2 16 DG YL 1 1 NO 1 HORN NO 2 HORN CENTER DISTRIBUTION POWER 8W 39 6 8W 41 2 8W 10 3 8W 39 6 8W 41 2 8W 39 6 8W 41 2 8W 35 2 8W 10 3 ZG RHD 8W 10 POWER DISTRIBUTION 8W 10 5 ZGR01004 J978W 3 ...

Page 1128: ...LE A19 10 RD 1 C42 12 BR RD C42 12 BR RD C42 12 RD C42 12 BR RD M C206 C42 18 PK DB D2 MODULE CONTROL TEMPERATURE AUTOMATIC S224 BATT A0 HIGH SPEED BLOWER MOTOR RELAY OUTPUT RELAY MOTOR BLOWER SPEED HIGH M CENTER DISTRIBUTION POWER 8W 42 2 8W 42 3 8W 10 3 8W 42 3 8W 42 3 8W 42 3 8W 10 3 8W 10 6 8W 10 POWER DISTRIBUTION ZG RHD J978W 3 ZGR01005 ...

Page 1129: ...2 RD WT A1 12 RD WT A21 12 DB GY ST RUN A21 A41 14 YL E4 C233 C8 IN PDC RELAY MOTOR STARTER ENGINE A141 14 YL RD A31 12 RD BK RUN ACC A31 5 A22 12 BK OR RUN A22 3 0 2 1 3 0 2 1 1 2 0 3 3 G9 18 GY BK F5 C234 G9 16 GY BK BRAKE WARNING SWITCH 2 M DIESEL GAS 1 SWITCH INTERLOCK CLUTCH 8W 21 3 8W 10 3 8W 40 6 8W 10 8 8W 10 8 8W 10 9 8W 10 3 8W 21 3 8W 21 4 8W 21 3 8W 21 4 8W 21 3 8W 21 4 ZG RHD 8W 10 PO...

Page 1130: ...SE 15A A15 A21 12 DB GY 4 FUSE 10A JUNCTION BLOCK 10A FUSE 22 10A FUSE 12 10A FUSE 11 15A FUSE 6 A22 12 BK OR 10 C6 C2 1 C5 3 0 2 1 CENTER DISTRIBUTION POWER 8W 10 13 8W 10 14 8W 10 7 8W 10 7 8W 12 6 8W 12 9 8W 12 10 8W 12 23 8W 12 2 8W 12 5 8W 12 2 8W 12 5 8W 10 3 8W 10 8 8W 10 POWER DISTRIBUTION ZG RHD J978W 3 ZGR01007 ...

Page 1131: ...4 C6 JUNCTION BLOCK 14 FUSE 15A 10A FUSE 1 15A FUSE 2 10A FUSE 3 20A 1 BREAKER CIRCUIT C6 1 BATT A1 3 0 2 1 10A FUSE 15 30 87 REAR FOG LAMP RELAY CENTER DISTRIBUTION POWER A 8W 10 12 8W 10 7 8W 10 3 8W 12 4 8W 12 4 8W 12 3 8W 12 3 8W 12 3 8W 12 2 8W 51 7 8W 10 3 ZG RHD 8W 10 POWER DISTRIBUTION 8W 10 9 ZGR01008 J978W 3 ...

Page 1132: ...CIRCUIT 15A FUSE 9 BATT A0 20A FUSE 7 20A FUSE 8 14 FUSE 20A 27 20 A20 14 RD LG 9 CONTROLLER ANTI LOCK BRAKE FUSED B CENTER DISTRIBUTION POWER 8W 10 3 8W 35 2 8W 12 8 8W 12 8 8W 12 7 8W 12 7 8W 12 2 8W 10 3 8W 10 10 8W 10 POWER DISTRIBUTION ZG RHD J978W 3 ZGR01009 ...

Page 1133: ...T OF SWITCH DIMMER HEADLAMP A6 14 RD LB 11 9 25A BREAKER CIRCUIT 4 LOW 3 PARK 2 OFF 1 AUTO SWITCH HEADLAMP JUNCTION BLOCK F34 16TN BK 9 C5 AUTOMATIC HEADLAMP RELAY 4 3 2 1 CENTER DISTRIBUTION POWER 8W 10 3 8W 50 2 8W 12 2 8W 50 5 8W 50 2 8W 12 14 8W 10 3 ZG RHD 8W 10 POWER DISTRIBUTION 8W 10 11 ZGR01010 J978W 3 ...

Page 1134: ...N BLOCK 15A FUSE 13 16 FUSE 10A 15A FUSE 19 20 FUSE 15A 15A FUSE 21 20A 3 BREAKER CIRCUIT CENTER DISTRIBUTION POWER 8W 10 3 8W 12 18 8W 12 16 8W 12 16 8W 12 16 8W 12 12 8W 12 11 8W 12 2 8W 10 3 8W 10 12 8W 10 POWER DISTRIBUTION ZG RHD J978W 3 ZGR01011 ...

Page 1135: ...FUSE 19 5 JUNCTION BLOCK C1 87 30 86 FOG LAMP RELAY 8 C7 4 C1 FOG LAMP LEFT 2 2 RIGHT LAMP FOG 4 HEADLAMP SWITCH 20 LB L39 18 LB L39 L39 18 LB L39 18 LB S105 C4 WT RD 18 F6 FUSED B CENTER DISTRIBUTION POWER 8W 12 24 8W 50 7 8W 50 6 8W 50 6 8W 50 6 8W 12 2 8W 10 8 8W 10 3 8W 30 22 8W 10 3 ZG RHD 8W 10 POWER DISTRIBUTION DIESEL ENGINE 8W 10 13 ZGR01012 J978W 3 ...

Page 1136: ......

Page 1137: ...SHUT AUTOMATIC F99 20 OR F99 20 OR 1 SOLENOID PURGE EVAP CYCLE DUTY 2 PUMP DETECTION LEAK SYSTEM EVAPORATIVE S101 A 8W 10 13 FROM CENTER DISTRIBUTION POWER F99 20 OR MODULE CONTROL BODY GAS GAS GAS GAS GAS MSA CONTROLLER 38 DIESEL F99 OR 20 18 OR F99 S138 FUEL RELAY DIESEL HEATER D13 20 OR F99 8W 30 27 8W 30 22 8W 45 2 8W 30 4 8W 30 4 8W 30 5 8W 30 16 8W 42 10 8W 30 4 8W 30 22 8W 10 14 ZG RHD 8W 1...

Page 1138: ...WERTRAIN FUSED B F5 18 RD YL B16 B17 IN PDC RELAY DOWN SHUT AUTOMATIC C12 C3 AUTOMATIC SHUT DOWN RELAY OUTPUT A142 18 DG OR A142 18 DG OR TO C131 S100 B 8W 10 17 CENTER DISTRIBUTION POWER 8W 10 3 8W 30 5 8W 30 4 8W 30 5 8W 10 3 8W 10 16 8W 10 POWER DISTRIBUTION GAS ENGINES ZG RHD J978W 3 ZGR01014 ...

Page 1139: ...GEN HEATED UPSTREAM DOWNSTREAM HEATED OXYGEN SENSOR S129 B 8W 10 16 AUTOMATIC SHUT DOWN RELAY FROM FUEL INJECTOR NO 2 NO 4 INJECTOR FUEL FUEL INJECTOR NO 6 4 0L NO 1 INJECTOR FUEL FUEL INJECTOR NO 3 4 0L 4 0L NO 5 INJECTOR FUEL FUEL INJECTOR NO 1 5 2L 5 2L NO 5 INJECTOR FUEL 5 2L NO 7 INJECTOR FUEL 5 2L NO 3 INJECTOR FUEL 5 2L NO 8 INJECTOR FUEL 8W 30 12 8W 30 11 8W 30 11 8W 30 11 8W 30 11 8W 30 1...

Page 1140: ...AUTOMATIC SHUTDOWN RELAY CONTROL TO S129 AUTOMATIC SHUT DOWN RELAY IN PDC K900 20 PK BK K900 20 PK BK A142 16 DG OR A142 16 DG OR 14 C132 12 C131 CONTROLLER MSA IN PDC RELAY HEATER FUEL CENTER DISTRIBUTION POWER 8W 10 9 8W 30 27 8W 30 27 8W 10 3 8W 10 18 8W 10 POWER DISTRIBUTION DIESEL ENGINE ZG RHD J978W 3 ZGR01017 ...

Page 1141: ...PUT RELAY SHUTDOWN AUTOMATIC AUTOMATIC SHUTDOWN RELAY OUTPUT A142 16 DG OR A142 16 DG OR A142 14 DG OR OUTPUT RELAY SHUTDOWN AUTOMATIC OUTPUT RELAY SHUTDOWN AUTOMATIC 9 10 FUEL PUMP MODULE AUTOMATIC SHUTDOWN RELAY OUTPUT 3 MODULE FLOW AIR MASS GENERATOR 1 A142 16 DG OR A142 14 DG OR A142 18 DG OR A142 16 DG OR C 8W 10 18 8W 30 26 8W 30 27 8W 30 28 8W 30 25 8W 30 26 8W 20 2 ZG RHD 8W 10 POWER DISTR...

Page 1142: ...W 10 7 FUSED B SPARE 18 19 20 21 20 20 15 15 20 40 20 30 50 20 40 40 20 50 30 40 175 F31 16VT A10 10RD DB A900 12OR YL A1 12RD WT FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED B FUSED IGNITION SWITCH OUTPUT ST RUN 15 F250 18RD GY FUSED B FEED CIRCUIT FUSED CIRCUIT FUSED B 17 FUSED B 25 20 F5 14RD YL GAS DIESEL 16 15 A61 18WT R...

Page 1143: ... FUNCTION A6 F92 18LG FUSED B ABS WARNING LAMP RELAY OUTPUT F250 18RD GY B1 FUNCTION CIRCUIT CAV B2 C2 18DB YL AUTOMATIC SHUT DOWN RELAY OUTPUT FUSED IGNITION SWITCH OUPUT RUN F99 20OR B3 B4 CLUTCH COMPRESSOR A C RELAY A10 B120 12BR WT ABS PUMP MOTOR RELAY OUTPUT X4 20GY OR A5 HORN RELAYCONTROL F31 16VT FUSED B B5 C13 18DB RD A C COMPRESSOR CLUTCH RELAY CONTROL ZG RHD 8W 10 POWER DISTRIBUTION 8W 1...

Page 1144: ...6LG RD RELAY WIPER INTERMITTENT A142 18DG OR B17 FUSED B C5 C4 V66 18VT WT V18 20YL LG WIPER PARK SWITCH SENSE INTERMITTENT WIPER RELAY CONTROL FUSED B FUSED B AUTOMATIC SHUT DOWN RELAY CONTROL B20 K900 20PK WT FUSED B FUSED B A142 16DG OR B17 B18 F5 16RD YL FUSED IGNITION SWITCH OUTPUT ST RUN F99 20OR B18 B20 A142 18DG OR FUSED B K900 20PK WT AUTOMATIC SHUT DOWN RELAY CONTROL DIESEL GAS 8W 10 22 ...

Page 1145: ...P FUEL Z4 20BK C10 PARK NEUTRAL POSITION SWITCH SENSE C20 C19 K81 18DB FUEL PUMP RELAY CONTROL FUSED IGNITION SWITCH OUTPUT ST RUN ENGINE STARTER MOTOR RELAY PARK NEUTRAL POSITION SWITCH SENSE C10 T41 20BK WT FUEL HEATER FEED A64 14OR DB D13 D14 FUEL HEATER RELAY F99 20OR D12 D11 Z4 20BK D10 CAV CIRCUIT FUNCTION A12 12RD TN FUSED B GROUND DIESEL FUSED IGNITION SWITCH OUTPUT ST RUN GAS DIESEL ZG RH...

Page 1146: ...RIPTION AND OPERATION This section covers the power distribution center and all circuits involved with it For additional infor mation on system operation refer to the appropriate wiring diagrams 8W 10 24 8W 10 POWER DISTRIBUTION ZG ...

Page 1147: ...adlamp Leveling Switch 8W 12 6 Component Page Headlamp Switch 8W 12 14 20 24 Horn Relay 8W 12 23 Instrument Cluster 8W 12 5 8 17 Intermittent Wiper Relay 8W 12 4 Intermittent Wiper Switch 8W 12 4 Key In Switch Halo Lamp 8W 12 12 22 Lamp 8W 12 20 Lamp Outage Module 8W 12 5 15 20 Left Back Up Lamp 8W 12 17 Left Courtesy Lamp 8W 12 12 22 Left Fog Lamp 8W 12 24 Left Front Park Lamp 8W 12 15 Left Visor...

Page 1148: ... 10A 16 22 5 11A 17 6 12A 18 CB1 20A 1 2 2 1 20A CB2 CB3 20A 1 2 2 6 10 5 4 3 1 7 8 9 2 6 10 9 5 4 8 7 3 1 I P I P A B E I P 1 4 9 10 5 6 11 12 7 2 2 7 12 11 6 5 10 9 4 1 I P D 8 3 3 8 3 1 2 4 I P C 3 8 2 7 12 11 6 5 10 9 4 1 O H O H 1 4 9 10 5 6 11 12 7 2 8 3 8 3 G I P 1 4 9 10 5 6 11 12 7 2 AUTO HEADLAMP RELAY PARK LAMP RELAY POWER ANTENNA RELAY EXPORT ONLY COUTESY LAMP RELAY ELECTRONIC FLASHER ...

Page 1149: ... RD GY A31 18 RD BK 87 30 86 15A FUSE 14 C4 3 BLOCK JUNCTION C4 4 BATT F61 1 LIGHTER CIGAR F30 18 RD DB C10 9 NOT USED CIGAR LIGHTER RELAY BLOCK JUNCTION 8W 12 2 8W 12 2 8W 41 3 8W 10 9 8W 10 9 8W 41 3 8W 47 2 ZG RHD 8W 12 JUNCTION BLOCK 8W 12 3 ZGR01202 J978W 3 ...

Page 1150: ...NCTION PART OF SWITCH WIPER INTERMITTENT S207 C5 G10 C235 G20 MODULE CONTROL BODY C2 23 V18 20 YL LG V18 20 YL LG C4 7 4 INTERMITTENT WIPER SWITCH PART OF MULTI FUNCTION SWITCH F86 16 LG BK F86 16 LG BK 5 C231 F86 16 LG BK TO S320 A 8W 12 5 LG RD F86 16 DIESEL GAS F86 LG RD 18 DIESEL LG RD LG RD 16 F86 GAS 18 F86 LG RD DIESEL GAS LG RD 16 F86 18 F86 JUNCTION BLOCK 8W 53 3 8W 10 9 8W 53 2 8W 45 7 8...

Page 1151: ...10A FUSE 5 7 C13 C9 7 C13 7 10 LAMP OUTAGE MODULE FUSED IGN ST RUN G5 18 DB WT F87 18 WT PK F87 20 BK WT F87 20 BK WT F87 20 BK WT S215 5 INSTRUMENT CLUSTER 2 INTERLOCK SHIFT NOT USED S320 A 8W 12 4 FUSED IGN ST RUN C1 DIESEL GAS CLUSTER INSTRUMENT 5 BK WT 20 F87 JUNCTION BLOCK 8W 40 5 8W 10 8 8W 31 5 8W 40 5 8W 51 2 8W 43 2 8W 10 3 8W 10 13 8W 10 14 8W 64 2 8W 64 2 8W 12 2 ZG RHD 8W 12 JUNCTION B...

Page 1152: ...LAY MODULE VEHICLE INFORMATION CENTER MINI OVERHEAD CONSOLE CONSOLE OVERHEAD FLASHER ELECTRONIC FUSED IGN RUN 2 3 C15 OVERHEAD CONSOLE OTHERS F83 20 YL DG F83 20 BK VT B 8W 12 7 TO S323 C 8W 12 7 AUTOMATIC DAY NIGHT MIRROR TO SWITCH LAMP DIESEL 1 YL DG F83 18 BACK UP C131 13 YL DG F83 18 18 F83 YL DG G12 C235 5 18 YL DG F83 HEADLAMP SWITCH LEVELING G18 JUNCTION BLOCK 8W 50 11 8W 51 5 8W 10 8 8W 52...

Page 1153: ...L16 18 RD LG 6 STOP LAMP SWITCH 9 C14 F81 10 TN F81 12 TN 3 C334 3 C351 F81 12 TN F81 12 TN 12 DRIVER DOOR MODULE MODULE DOOR PASSENGER 12 C 8W 12 6 JUNCTION BLOCK FROM B 8W 12 6 FROM BLOCK JUNCTION C1 FUSED B C1 JUNCTION BLOCK 8W 44 6 8W 44 7 8W 10 10 8W 60 3 8W 61 3 8W 60 2 8W 61 2 8W 33 2 8W 49 2 8W 12 2 ZG RHD 8W 12 JUNCTION BLOCK 8W 12 7 ZGR01206 J978W 3 ...

Page 1154: ...ER S315 7 FUSE 20A 8 C13 2 F75 16 VT F75 16 VT 17 C1 C1 POWER AMPLIFIER PREMIUM S318 F75 14 VT C4 8 F75 18 VT 3 INSTRUMENT CLUSTER F75 18 VT 16 LINK DATA CONNECTOR F75 18 VT 1 LED VTSS SENSOR LIGHT HEADLAMP AUTOMATIC F75 18 VT S201 9 C4 F75 18 VT C2 8 MODULE CONTROL BODY F70 16 PK BK 6 C372 7 JUNCTION BLOCK 8W 10 10 8W 45 4 8W 50 5 8W 30 2 8W 30 30 8W 40 5 8W 47 10 8W 54 2 8W 54 5 8W 54 4 8W 61 5 ...

Page 1155: ...EAR WINDOW DEFOGGER DEFOGGER WINDOW REAR C16 20 LB YL 10 SWITCH DEFOGGER WINDOW REAR 2 C13 C13 3 10A FUSE 11 RUN A22 C13 6 F12 20 DB WT 23 CONTROLLER ANTI LOCK BRAKE NOT USED MODULE CONTROL BODY USED NOT 3 12 C15 BK LB WINDOW REAR DEFOGGER C322 2 DIESEL GAS JUNCTION BLOCK 8W 48 2 8W 45 3 8W 10 4 8W 10 8 8W 35 2 8W 48 2 8W 48 2 8W 48 2 8W 12 2 ZG RHD 8W 12 JUNCTION BLOCK 8W 12 9 ZGR01208 J978W 3 ...

Page 1156: ... PK DG F71 18 PK DG F87 18 PK DG F87 18 WT BK 1 1 MODULE CONTROL HEATER SEAT PASSENGER DRIVER SEAT HEATER CONTROL MODULE S218 4 C9 F71 20 DG PK 6 A C HEATER CONTROL C12 MODULE CONTROL TEMPERATURE AUTOMATIC F71 20 DG PK F71 20 DG PK MANUAL A C HEATER ATC ATC HEATER A C MANUAL C2 JUNCTION BLOCK 8W 42 7 8W 10 8 8W 42 9 8W 42 5 8W 63 14 8W 63 13 8W 44 11 8W 42 9 8W 12 2 8W 12 10 8W 12 JUNCTION BLOCK Z...

Page 1157: ...EXPORT X14 20 WT X16 20 GY X17 20 DG 3 4 TURN SIGNAL 5 C7 C5 1 L5 18 OR BK L12 18 VT TN 17 13 SWITCH HAZARD SIGNAL TURN RADIO 12V OUTPUT RADIO 12V OUTPUT WARNING SIGNAL HAZARD OUTPUT C1 DG RD 14 18 X60 12V RADIO POWER AMPLIFIER LTD PREMIUM INFORMATION VEHICLE CENTER L5 18 OR BK 4 PART OF MULTI FUNCTION SWITCH JUNCTION BLOCK 8W 46 6 8W 47 3 8W 47 3 8W 47 4 8W 47 3 8W 10 12 8W 15 17 8W 15 17 8W 15 1...

Page 1158: ... LAMP LAMP COURTESY LEFT LAMP HALO SWITCH KEY IN LAMP CARGO M1 18 PK M1 18 PK 6 C8 3 C8 5 C13 11 C8 M1 20 PK M1 20 PK M1 20 PK M1 20 PK C15 9 M1 20 PK TO S321 BATT A7 D 8W 12 13 JUNCTION BLOCK 8W 10 12 8W 44 5 8W 44 2 8W 44 2 8W 44 2 8W 44 2 8W 44 2 8W 44 8 8W 12 2 8W 12 12 8W 12 JUNCTION BLOCK ZG RHD J978W 3 ZGR01211 ...

Page 1159: ...R RIGHT LEFT VISOR VANITY LAMP A M1 20 PK M1 20 PK DOME READING LAMP C 6 OVERHEAD CONSOLE M1 20 PK S321 M1 20 PK D 8W 12 12 JUNCTION BLOCK FROM 8W 49 3 8W 44 3 8W 44 5 8W 44 5 ZG RHD 8W 12 JUNCTION BLOCK 8W 12 13 ZGR01212 J978W 3 ...

Page 1160: ...MP 9 C5 9 A6 14 RD LB 366 16 PK OR L90 20 DB RD 11 C10 C2 21 17 C1 PARK LAMP RELAY CONTROL PARK LAMP RELAY OUTPUT L90 20 DB RD L79 20 TN E 8W 12 15 MODULE CONTROL BODY TO JUNCTION BLOCK JUNCTION BLOCK 8W 45 4 8W 10 11 8W 50 7 8W 12 2 8W 12 14 8W 12 JUNCTION BLOCK ZG RHD J978W 3 ZGR01213 ...

Page 1161: ...03 L90 18 DB RD A LAMP PARK FRONT S410 FRONT PARK LAMP A DB RD 18 L90 S415 11 VEHICLE INFORMATION CENTER C8 5 L90 20 DB RD L90 20 DB RD 4 RADIO 4 C8 C15 1 9 C8 E 8W 12 14 NOT USED PARK LAMP RELAY OUTPUT OUTPUT RELAY LAMP PARK NOT USED RELAY LAMP PARK C1 LEFT RIGHT C1 C1 C1 JUNCTION BLOCK 8W 50 9 8W 50 10 8W 47 2 8W 46 6 8W 51 2 8W 12 2 ZG RHD 8W 12 JUNCTION BLOCK 8W 12 15 ZGR01214 J978W 3 ...

Page 1162: ... RD WT C9 10 7 RADIO 5 C9 2 2 F60 20 WT RD F60 20 WT RD GRAPHIC DISPLAY MODULE VEHICLE INFORMATION CENTER PREMIUM OVERHEAD CONSOLE OTHERS 3 C13 15A FUSE 21 C9 2 F38 18 OR 1 OUTLET POWER NOT USED F60 20 WT RD C1 JUNCTION BLOCK 8W 10 12 8W 41 3 8W 46 4 8W 46 2 8W 47 2 8W 42 2 8W 50 2 8W 12 2 8W 12 16 8W 12 JUNCTION BLOCK ZG RHD J978W 3 ZGR01215 ...

Page 1163: ...328 A LEFT BACK UP LAMP L10 18 BR LG L10 18 BR LG A C320 3 LAMP BACK UP RIGHT L10 18 BR LG L10 18 BR LG S311 11 C3 L64 18 TN DB L64 18 TN DB L64 18 TN DB S412 2 1 FRONT SWITCH RIGHT RIGHT REPEATER SIDE JUNCTION BLOCK RIGHT RIGHT LAMP MARKER SIDE FRONT B A S413 TN DB 18 L64 TN DB 18 L64 FRONT TURN SIGNAL LAMP TURN SIGNAL C150 1 1 C150 SIDE REPEATER LAMPS OTHERS 8W 44 6 8W 52 2 8W 51 6 8W 51 6 8W 54...

Page 1164: ... LUMBAR SWITCH S405 12 C13 F35 16 RD 1 C329 F35 14 RD F35 14 RD 10 MODULE SEAT MEMORY 19 F35 16 RD F35 16 RD 2 DRIVER SEAT HEATER CONTROL MODULE 5 SWITCH SEAT POWER DRIVER F35 16 RD F35 16 RD 3 F35 18 RD DRIVER LUMBAR SWITCH S403 FUSED B FUSED B C2 C2 8W 10 12 8W 63 3 8W 63 8 8W 63 14 8W 63 2 8W 63 4 8W 63 13 8W 63 9 8W 12 2 8W 12 18 8W 12 JUNCTION BLOCK ZG RHD J978W 3 ZGR01217 ...

Page 1165: ...28 20 LG OR G28 20 LG OR G42 20 LB RD G42 20 LB RD C3 3 C5 6 2 C5 G28 20 LG OR 11 C132 G28 20 LG OR 3 SWITCH DRIVE WHEEL FOUR VEHICLE INFORMATION CENTER MODULE DISPLAY GRAPHIC CONSOLE PREMIUM OVERHEAD OTHERS JUNCTION BLOCK 8W 46 3 8W 46 5 8W 46 3 8W 46 5 8W 46 3 8W 46 5 8W 12 2 ZG RHD 8W 12 JUNCTION BLOCK 8W 12 19 ZGR01218 J978W 3 ...

Page 1166: ...5 15 SWITCH HEADLAMP 7 C7 C7 10 3 C7 L95 18 DG YL A RELAY LAMP FOG REAR C7 6 1 LAMP OUTAGE MODULE L96 20 LG RD L36 18 LG L36 18 LG OR 7 C307 JUNCTION BLOCK 8W 10 9 8W 50 7 8W 51 7 8W 12 2 8W 12 20 8W 12 JUNCTION BLOCK ZG RHD J978W 3 ZGR01219 ...

Page 1167: ...HT DAY AUTOMATIC CONSOLE OVERHEAD Z1 20 BK 2 Z1 20 BK S322 Z1 16 BK F 8W 12 22 JUNCTION BLOCK TO OVERHEAD CONSOLE 4 M2 20 YL M2 20 YL B DOME READING LAMP M2 20 YL M2 20 YL M2 20 YL S334 OTHERS SUNROOF G 8W 12 22 JUNCTION BLOCK TO H 8W 12 22 TO BLOCK JUNCTION BASE PREMIUM 8W 44 6 8W 44 3 8W 64 2 8W 44 3 8W 49 3 8W 49 3 8W 44 5 8W 44 5 8W 46 2 ZG RHD 8W 12 JUNCTION BLOCK 8W 12 21 ZGR01220 J978W 3 ...

Page 1168: ...ROM LAMP READING DOME M2 20 YL M2 20 YL C15 11 F 8W 12 21 C15 2 Z1 16 BK FROM S322 30 87 COURTESY LAMP RELAY Z1 18 BK S220 Z1 16 BK S216 Z1 16 BK S202 Z1 14 BK 2 C301 Z1 14 BK G304 OTHERS SUNROOF OVERHEAD CONSOLE FROM JUNCTION BLOCK 8W 15 8 8W 15 18 8W 15 17 8W 15 17 8W 44 8 8W 44 5 8W 44 2 8W 44 2 8W 44 2 8W 12 2 8W 12 22 8W 12 JUNCTION BLOCK ZG RHD J978W 3 ZGR01221 ...

Page 1169: ...N CONTROL SPEED VEHICLE C2 13 MODULE CONTROL BODY X4 20 GY OR 10A FUSE 22 RUN A22 C13 1 AIRBAG CONTROL MODULE 20 FUSED IGN RUN F20 18 WT RELAY HORN JUNCTION BLOCK 8W 43 2 8W 10 8 8W 45 3 8W 41 2 8W 41 2 8W 12 2 ZG RHD 8W 12 JUNCTION BLOCK 8W 12 23 ZGR01222 J978W 3 ...

Page 1170: ...F34 16TN BK 714 20 BK OR C2 12 MODULE CONTROL BODY C10 1 C2 22 MODULE CONTROL BODY L95 20 DG YL L39 18 LB L39 18 LB 2 LEFT FOG LAMP LAMP FOG RIGHT 2 S105 L39 18 LB 4 C1 C7 8 L39 20 LB 4 SWITCH HEADLAMP JUNCTION BLOCK 8W 45 5 8W 10 11 8W 10 13 8W 50 7 8W 50 6 8W 50 6 8W 45 5 8W 50 2 8W 50 2 8W 12 2 8W 12 24 8W 12 JUNCTION BLOCK ZG RHD J978W 3 ZGR01223 ...

Page 1171: ...A A250 10RD C15 12BK WT 10A C16 20LB YL A22 12BK OR 10A F12 20DB WT F12 20DB WT F71 20PK DG 10A A22 12BK OR 15A F71 20PK DG A7 12YL RD INTERNAL F61 12WT OR INTERNAL MI 18PK 10A A7 12YL RD FUSED CIRCUIT 1 2 9 10 11 12 13 14 15 16 17 20 19 18 21 22 15A NOT USED 15A 15A NOT USED 15A 15A 10A A7 12YL RD A7 12YL RD A6 14RD LB A22 12BK OR A7 12YL RD F60 20RD WT L11 16LG BK 366 16PK OR M1 20PK 7 WIRES F20...

Page 1172: ...5 Z1 20BK GROUND FUSED IGNITION SWITCH OUPUT RUN A31 RD BK 86 87 FUSED IGNITION SWITCH OUTPUT ACC RUN F30 18RD DB RELAY LIGHTER CIGAR B 87A 20A A7 12YL RD A250 10RD 87A NO FUSED CIRCUIT F86 16LG BK F86 16LG BK 2 3 F86 16LG RD F81 10TN F81 12TN 35 16RD F35 16RD RELAYS CIRCUIT BREAKERS FUSED B GROUND A REAR FOG LAMP RELAY A31 12 RD BK 20A 1 F86 18 LG BK 8W 12 26 8W 12 JUNCTION BLOCK ZG RHD J978W 3 Z...

Page 1173: ...DIO 12 VOLT OUTPUT POWER ANTENNA DOWN CONTROL 5 4 3 2 1 CAVITY X16 GY X14 WT 6 POWER ANTENNA UP CONTROL X60 DG RD INTERNAL Z1 BK X17 GN POWER ANTENNA RELAY H EXPORT ONLY G RELAY DEFOGGER WINDOW REAR INTERNAL INTERNAL L12 VT TN L5 OR BK Z1 BK CAVITY 1 2 3 4 5 TURN SIGNAL HAZARD SIGNAL GROUND CIRCUIT FUNCTION FUSED B FUSED IGNITION SWITCH OUTPUT RUN ELECTRONIC FLASHER I ZG RHD 8W 12 JUNCTION BLOCK 8...

Page 1174: ...P RELAY CONTROL FUSED B F62 RD 30 FUNCTION CIRCUIT CAVITY CAVITY CIRCUIT FUNCTION 30 366 PK OR PARK LAMP FEED PARK LAMP RELAY CONTROL L79 TN 85 86 366 PK OR PARK LAMP FEED 87 L90 DB RD PARK LAMP RELAY OUTPUT 87A PARK LAMP RELAY E F RELAY HEADLAMP AUTO 87A AUTO HEADLAMP RELAY OUTPUT F34 TN BK 87 FUSED B A6 RD LB 86 85 714 BK OR AUTO HEADLAMP RELAY CONTROL FUSED B A6 RD LB 30 FUNCTION CIRCUIT CAVITY...

Page 1175: ...N AND OPERATION This section covers the junction block and all cir cuits involved with it For additional information on system operation please refer to the appropriate sec tion of the wiring diagrams ZG 8W 12 JUNCTION BLOCK 8W 12 29 ...

Page 1176: ......

Page 1177: ... 8W 15 9 Component Page Left Door Courtesy Lamp 8W 15 12 Left Fog Lamp 8W 15 4 5 Left Front Park Lamp 8W 15 4 5 Left Front Turn Signal Lamp 8W 15 4 5 Left Headlamp 8W 15 4 5 Left License Lamp 8W 15 10 Left Rear Fog Lamp 8W 15 9 Left Rear Power Window Switch 8W 15 15 Left Rear Turn Signal Lamp 8W 15 9 Left Side Repeater 8W 15 4 Left Tail Stop Lamp 8W 15 9 Left Visor Vanity Lamp 8W 15 16 Liftgate Aj...

Page 1178: ...R 5 G103 H11 H12 C236 Z1 18 BK 1 2 C132 Z1 18 BK Z1 18 BK Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR C1 A31 A32 C1 MODULE CONTROL POWERTRAIN G104 Z12 14 BK TN Z12 14 BK TN 1 8W 20 2 8W 20 3 8W 30 2 8W 30 18 8W 30 19 8W 30 3 8W 15 2 8W 15 GROUND DISTRIBUTION GAS ENGINES ZG RHD J978W 3 ZGR01501 ...

Page 1179: ...18 BK Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR C4 12 11 C4 MODULE CONTROL POWERTRAIN GROUND GROUND G104 Z12 16 BK TN Z12 16 BK TN 46 24 1 CONTROLLER MSA Z12 14 BK TN Z12 16 BK TN Z12 16 BK TN Z12 10 BK TN S130 8W 30 30 8W 30 31 8W 30 32 8W 30 22 8W 30 22 ZG RHD 8W 15 GROUND DISTRIBUTION DIESEL ENGINE 8W 15 3 ZGR01515 J978W 3 ...

Page 1180: ...IELD WIPER MOTOR 4 2 MOTOR PUMP WASHER REAR SENSOR LEVEL FLUID WIPER B 16 BK 18 BK 18 BK 18 BK Z2 20 BK S121 12 BK Z2 Z2 Z2 Z2 Z2 LEFT LEFT STOP LAMP C235 G8 DB LG 20 V30 Z1 18 BK 2 UNDERHOOD LAMP C159 2 BK Z1 18 Z1 18 BK 1 LEFT REPEATER SIDE SWITCH G2 8W 52 8 8W 44 2 8W 33 2 8W 33 4 8W 50 9 8W 46 6 8W 53 5 8W 53 5 8W 53 3 8W 53 2 8W 50 3 8W 50 6 8W 52 3 8W 15 4 8W 15 GROUND DISTRIBUTION DIESEL EN...

Page 1181: ... 16 BK G109 10 MODULE STEERING PROPORTIONAL SPEED B MOTOR PUMP WASHER WINDSHIELD WINDSHIELD WIPER MOTOR 4 2 MOTOR PUMP WASHER REAR SENSOR LEVEL FLUID WIPER B 16 BK 18 BK 18 BK 18 BK Z2 20 BK S121 12 BK Z2 Z2 Z2 Z2 Z2 LEFT LEFT 8W 50 9 8W 46 6 8W 53 5 8W 53 5 8W 53 3 8W 53 2 8W 65 2 8W 50 3 8W 50 6 8W 52 3 ZG RHD 8W 15 GROUND DISTRIBUTION GAS ENGINES 8W 15 5 ZGR01516 J978W 3 ...

Page 1182: ... 16 BK Z1 16 BK Z1 18 BK Z1 10 BK Z1 18 BK 3 C150 Z1 18 BK B LAMP PARK FRONT RIGHT TURN SIGNAL LAMP G S152 Z1 18 BK Z1 18 BK G106 Z1 16 BK A 8W 15 4 FROM S109 S104 FRONT RIGHT BK Z1 20 BK Z1 14 Z1 18 BK 4 SOLENOID EGR 8W 30 28 8W 39 6 8W 41 2 8W 50 10 8W 52 3 8W 39 6 8W 41 2 8W 50 6 8W 52 8 8W 50 3 8W 30 28 8W 30 26 8W 46 3 8W 46 5 8W 15 6 8W 15 GROUND DISTRIBUTION DIESEL ENGINE ZG RHD J978W 3 ZGR...

Page 1183: ...18 BK 1 RIGHT FOG LAMP 2 NO 1 HORN HORN NO 2 2 Z1 16 BK Z1 16 BK Z1 18 BK Z1 14 BK Z1 18 BK 3 C150 Z1 18 BK B LAMP PARK FRONT RIGHT TURN SIGNAL LAMP G S152 Z1 18 BK Z1 18 BK G106 Z1 16 BK K 8W 15 5 FROM S109 S104 FRONT RIGHT Z1 18 BK SIDE REPEATER RIGHT 1 8W 52 8 8W 39 6 8W 41 2 8W 50 10 8W 52 3 8W 39 6 8W 41 2 8W 50 6 8W 42 12 8W 46 6 8W 50 3 8W 46 3 8W 46 5 8W 30 13 8W 30 14 8W 30 13 8W 30 14 ZG...

Page 1184: ...K 2 C159 Z1 18 BK 2 LAMP UNDERHOOD 4 SERVO CONTROL SPEED VEHICLE Z4 20 BK Z4 18 BK Z4 10 BK G107 8 24 Z2 12 BK Z2 12 BK S125 G108 S124 Z2 12 BK BRAKE ANTI LOCK CONTROLLER C1 GAS GAS BK Z4 20 D11 DIESEL FUEL HEATER RELAY IN PDC BK 20 Z4 DIESEL IN PDC RELAY MOTOR C10 STARTER ENGINE 8W 21 3 8W 30 27 8W 35 2 8W 33 2 8W 44 2 8W 42 5 8W 42 3 8W 42 3 8W 42 2 8W 15 8 8W 15 GROUND DISTRIBUTION ZG RHD J978W...

Page 1185: ...OP TAIL LEFT B Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK 4 C328 Z1 18 BK D 8W 15 12 TO S314 C372 8 Z1 12 BK Z1 12 BK E 8W 15 12 TO S314 S411 S330 RELAY LAMP STOP TOW TRAILER TRAILER TOW LEFT TURN RELAY TRAILER TOW RIGHT TURN RELAY LAMP SIGNAL TURN LEFT REAR FOG LAMP REAR FACTORY TRAILER TOW CONNECTOR LEFT 8W 51 7 8W 52 5 8W 52 7 8W 54 3 8W 54 3 8W 54 3 8W 51 4 8W 51 6 8W 54 3 8W 51 5 8W 51 5 8W...

Page 1186: ...1 12 BK REAR WINDOW DEFOGGER 2 SWITCH LOCK CYLINDER LIFTGATE 1 LIFTGLASS AJAR SWITCH Z1 20 BK Z1 20 BK 1 SWITCH AJAR LIFTGATE Z1 20 BK 2 LIFTGLASS RELEASE SOLENOID Z1 14 BK S328 J 8W 15 11 TO C325 8W 51 6 8W 51 6 8W 53 4 8W 48 2 8W 39 5 8W 44 14 8W 44 14 8W 61 5 8W 15 10 8W 15 GROUND DISTRIBUTION ZG RHD J978W 3 ZGR01506 ...

Page 1187: ...K Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK 4 C320 Z1 18 BK G300 Z1 12 BK Z1 18 BK 2 C326 Z1 18 BK FROM C359 S316 2 C325 Z1 12 BK Z1 12 BK Z1 12 BK TO S314 B 8W 15 9 C 8W 15 12 J 8W 15 10 TO S328 TURN RIGHT 8W 52 5 8W 52 7 8W 51 7 8W 51 6 8W 51 4 ZG RHD 8W 15 GROUND DISTRIBUTION 8W 15 11 ZGR01507 J978W 3 ...

Page 1188: ... BK 2 COURTESY DOOR LEFT 7 DRIVER DOOR MODULE Z1 20 BK Z1 12 BK Z1 12 BK 1 C334 Z1 12 BK FULL OPTION POWER GROUP G302 Z1 12 BK FROM S316 C328 FROM FROM C372 Z1 12 BK Z1 12 BK Z1 18 BK S314 S324 C 8W 15 11 D 8W 15 9 E 8W 15 9 C1 C1 C2 LAMP 8W 60 2 8W 61 2 8W 62 2 8W 60 2 8W 61 2 8W 62 2 8W 46 6 8W 51 5 8W 15 12 8W 15 GROUND DISTRIBUTION ZG RHD J978W 3 ZGR01508 ...

Page 1189: ...ASSENGER A PASSENGER HEATED SEAT BACK 7 MODULE CONTROL HEATER SEAT PASSENGER Z1 18 BK Z1 16 BK Z1 18 BK 2 4 PASSENGER LUMBAR SWITCH D CUSHION SEAT HEATED PASSENGER Z1 18 BK Z1 18 BK Z1 20 BK S406 Z1 14 BK F 8W 15 14 TO C335 PREMIUM RADIO OTHER C2 C2 8W 63 12 8W 63 4 8W 63 13 8W 63 12 8W 63 9 8W 43 2 8W 47 10 8W 47 2 ZG RHD 8W 15 GROUND DISTRIBUTION 8W 15 13 ZGR01509 J978W 3 ...

Page 1190: ... POWER GROUP S325 1 C351 Z1 12 BK 6 WINDOW POWER REAR RIGHT FROM S406 2 C335 Z1 14 BK Z1 16 BK D C345 Z1 16 BK Z1 16 BK S333 Z1 12 BK G301 Z1 10 BK TO S304 F 8W 15 13 G 8W 15 15 SWITCH C1 C1 LAMP 8W 60 4 8W 44 2 8W 60 3 8W 61 3 8W 62 3 8W 60 3 8W 61 3 8W 62 3 8W 15 14 8W 15 GROUND DISTRIBUTION ZG RHD J978W 3 ZGR01510 ...

Page 1191: ... Z1 16 BK Z1 16 BK 1 SWITCH SEAT POWER DRIVER Z1 16 BK 7 Z1 16 BK MODULE CONTROL HEATER SEAT DRIVER BK 20 Z1 D BK 16 Z1 DRIVER HEATED SEAT BACK A BK 18 Z1 BK 18 Z1 SWITCH LUMBAR DRIVER 4 2 CUSHION SEAT HEATED DRIVER 2 C329 Z1 16 BK Z1 14 BK S402 G 8W 15 14 C2 C2 8W 60 4 8W 30 16 8W 45 4 8W 44 11 8W 63 2 8W 63 8 8W 63 14 8W 63 11 8W 63 2 8W 63 11 ZG RHD 8W 15 GROUND DISTRIBUTION 8W 15 15 ZGR01511 J...

Page 1192: ...B Z1 20 BK Z1 20 BK A Z1 20 BK DOME READING LAMP 2 MIRROR NIGHT DAY AUTOMATIC Z1 20 BK S322 C5 4 C15 2 Z1 16 BK Z1 18 BK H 8W 15 17 TO S220 JUNCTION BLOCK 5 87 COURTESY LAMP RELAY ELECTRONIC FLASHER 8W 52 2 8W 44 8 8W 12 2 8W 44 7 8W 64 2 8W 44 3 8W 44 5 8W 44 5 8W 49 2 8W 15 16 8W 15 GROUND DISTRIBUTION ZG RHD J978W 3 ZGR01512 ...

Page 1193: ...GRAPHIC DISPLAY MODULE 20 VEHICLE INFORMATION CENTER Z1 20 BK Z1 20 BK OTHERS 2 POD SWITCH 1 LAMP HALO SWITCH KEY IN 1 INSTRUMENT CLUSTER S220 Z1 16 BK Z1 20 BK Z1 20 BK Z1 20 BK Z1 16 BK I 8W 15 18 TO S202 S216 ACTUATOR DOOR BLEND CONSOLE OVERHEAD PREMIUM 85 CIGAR LIGHTER RELAY C2 8W 41 3 8W 44 11 8W 42 7 8W 40 2 8W 44 2 8W 46 4 8W 46 2 8W 12 2 8W 44 12 8W 42 5 8W 44 2 8W 41 3 8W 41 3 ZG RHD 8W 1...

Page 1194: ...Z2 18 BK OR S205 Z2 18 BK OR 8 C307 Z2 18 BK OR S302 2 5 SWITCH HEADLAMP Z1 16 BK Z1 16 BK C2 24 MODULE CONTROL BODY Z1 16 BK 2 STOP LAMP SWITCH Z1 20 BK I 8W 15 17 FROM S216 Z1 16 BK Z1 14 BK 2 C301 Z1 14 BK Z2 18 BK OR G304 S202 GRAPHIC SPEED CONTROL LEVELING SWITCH 1 HEADLAMP BK 20 Z1 8W 50 11 8W 33 2 8W 45 2 8W 50 5 8W 45 2 8W 33 3 8W 40 2 8W 46 2 8W 46 4 8W 15 18 8W 15 GROUND DISTRIBUTION ZG ...

Page 1195: ...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 ZG 8W 15 GROUND DISTRIBUTION 8W 15 19 ...

Page 1196: ......

Page 1197: ...y 8W 20 5 Fuse 1 8W 20 2 3 Fuse 8 8W 20 5 Fuse 18 8W 20 5 Fuse 20 8W 20 4 5 G100 8W 20 2 3 G101 8W 20 2 3 Generator 8W 20 2 3 Ignition Coil 8W 20 5 Component Page MSA Controller 8W 20 4 Power Distribution Center 8W 20 2 3 4 5 Powertrain Control Module 8W 20 2 3 4 5 S100 8W 20 5 S101 8W 20 5 S126 8W 20 3 S128 8W 20 5 S129 8W 20 2 4 5 S137 8W 20 3 Transmission Control Relay 8W 20 3 ZG 8W 20 CHARGING...

Page 1198: ...BK A11 6 RD BK GENERATOR FIELD DRIVER MODULE CONTROL POWERTRAIN 20 C4 3 1 K20 18 DG YL GENERATOR 16 B17 DG OR 12 C131 A142 DG OR 16 A142 DG OR 16 A142 RELAY SHUT IN PDC AUTOMATIC S129 DOWN 8W 70 7 8W 30 5 8W 10 4 8W 10 3 8W 21 3 8W 30 23 8W 20 2 8W 20 CHARGING SYSTEM DIESEL ENGINE ZG RHD J978W 3 ZGR02001 ...

Page 1199: ...ER DG 18 K20 DG VT 18 K72 C3 C25 MODULE CONTROL POWERTRAIN B10 C2 B30 C2 TRANSMISSION RELAY CONTROL G101 Z0 8 BK Z0 6 BK S126 1 3 2 K20 18 DG 2 C144 K20 18 DG C132 6 K72 18 DG VT T66 20 BR OR 7 C132 T66 20 BR OR GENERATOR SOURCE GENERATOR FIELD 1 TRANSMISSION 8W 15 2 8W 15 2 8W 15 2 8W 15 2 8W 31 2 8W 30 3 8W 10 4 8W 10 3 8W 21 4 ZG RHD 8W 20 CHARGING SYSTEM GAS ENGINES 8W 20 3 ZGR02003 J978W 3 ...

Page 1200: ...IN PDC AUTOMATIC SHUT DOWN RELAY CONTROL PK BK 20 K900 A142 16 DG OR 12 C131 DG OR 16 A142 S129 A142 16 DG OR 57 F5 RD YL 16 C4 AUTOMATIC CONTROL RELAY DOWN SHUT MODULE CONTROL POWERTRAIN C132 14 20 PK BK K900 8W 30 27 8W 10 3 8W 70 7 8W 30 27 8W 10 16 8W 10 3 8W 20 4 8W 20 CHARGING SYSTEM DIESEL ENGINE ZG RHD J978W 3 ZGR02002 ...

Page 1201: ...B20 B18 B16 AUTOMATIC SHUT DOWN RELAY IN PDC AUTOMATIC SHUT DOWN RELAY CONTROL A142 18 DG OR PK WT 18 K900 A142 18 DG OR 4 C131 5 2L 4 0L DG OR 18 A142 S129 A142 18 DG OR DG OR 18 A142 S128 A142 18 DG OR IGNITION COIL 2 OUTPUT AUTOMATIC RELAY DOWN SHUT ST RUN A21 8W 10 8 8W 10 3 8W 30 5 8W 70 7 8W 70 7 8W 30 5 8W 21 4 8W 10 7 8W 10 14 8W 10 15 8W 10 16 8W 10 16 8W 10 3 ZG RHD 8W 20 CHARGING SYSTEM...

Page 1202: ...eld 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 generator supplies B voltage to the battery through the A11 and A0 circuits HELPFUL INFORMATION Circuit A21 passes through the junction block before reaching fuse 18 in the PDC The ASD relay supplies battery voltage for the fuel inje...

Page 1203: ...Switch 8W 21 3 Engine Starter Motor 8W 21 3 4 Engine Starter Motor Relay 8W 21 3 4 Fuse 8 8W 21 2 4 G107 8W 21 3 Ignition Switch 8W 21 2 4 Component Page Park Neutral Position Switch 8W 21 4 Power Distribution Center 8W 21 2 3 4 Powertrain Control Module 8W 21 4 S124 8W 21 3 S134 8W 21 4 S210 8W 21 2 4 ZG 8W 21 STARTING SYSTEM 8W 21 1 ...

Page 1204: ...2 RD WT B 8W 21 3 ENGINE STARTER MOTOR RELAY TO A1 12 RD WT A1 12 RD WT S210 E1 C233 3 0 2 1 1 7 3 ACC 0 OFF 2 RUN 1 START SWITCH IGNITION A41 14 YL A 8W 21 3 TO SWITCH INTERLOCK CLUTCH A1 12 RD WT 8W 10 7 8W 10 3 8W 10 7 8W 10 7 8W 21 2 8W 21 STARTING SYSTEM DIESEL ENGINE ZG RHD J978W 3 ZGR02102 ...

Page 1205: ...TER MOTOR RELAY IN PDC Z4 20 BK Z4 10 BK G107 S124 B 8W 21 2 A1 12 RD WT ENGINE STARTER MOTOR 1 ROLL IN 2 HOLD IN A 8W 21 2 IGNITION SWITCH FROM A41 14 YL 2 1 T141 14 YL RD E4 C233 T141 14 YL RD CLUTCH INTERLOCK SWITCH FROM CENTER DISTRIBUTION POWER 8W 15 8 8W 15 8 ZG RHD 8W 21 STARTING SYSTEM DIESEL ENGINE 8W 21 3 ZGR02101 J978W 3 ...

Page 1206: ...TERY 1 PULL IN 2 HOLD IN A1 12 RD WT C233 E1 RD WT 12 A1 7 T141 14 YL RD 1 2 SWITCH POSITION NEUTRAL PARK T41 20 BK WT C132 4 BK WT 20 T41 POWERTRAIN CONTROL MODULE BK WT 18 T41 A6 PARK NEUTRAL POSITION SWITCH SENSE S134 3 0 2 1 3 ACC 0 OFF 2 RUN 1 START SWITCH IGNITION S210 A41 14 YL M C1 8W 10 7 8W 10 3 8W 44 7 8W 30 10 8W 10 7 8W 10 7 8W 21 4 8W 21 STARTING SYSTEM GAS ENGINES ZG RHD J978W 3 ZGR...

Page 1207: ...h When the starter motor relay energizes and the contacts close circuit T40 supplies battery voltage to the starter motor solenoid Circuit A0 from the bat tery supplies voltage to the starter motor when the solenoid energizes STARTING SYSTEM DIESEL Power for the coil side of the engine starter motor relay is supplied on circuit T141 This circuit is HOT when the operator has moved the ignition key ...

Page 1208: ......

Page 1209: ... 22 27 Fuse 18 Gas Engines 8W 30 4 5 16 Fuse 20 Diesel Engine 8W 30 27 Fuse 20 Gas Engines 8W 30 4 5 Component Page Generator Gas Engines 8W 30 3 Generator Diesel Engine 8W 30 23 Glow Plug Diesel Engine 8W 30 26 Glow Plug Relay Diesel Engine 8W 30 26 Idle Air Control Motor 4 0L Engine 8W 30 21 Idle Air Control Motor 5 2L Engine 8W 30 20 Ignition Coil Gas Engines 8W 30 5 Instrument Cluster Diesel E...

Page 1210: ...ONTROL POWERTRAIN CONTROLLER ANTI LOCK BRAKE MODULE STEERING PROPORTIONAL SPEED S200 C1 20 SCI TRANSMIT SCI RECEIVE RECEIVE SCI RECEIVE SCI TRANSMIT SCI 4 C235 F14 C234 6 D84 20 BK WT D84 18 BK WT F15 C234 Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR Z1 18 BK Z1 18 BK Z1 18 BK 2 1 C132 C236 G103 H11 H12 8W 65 2 8W 35 2 8W 12 8 8W 12 2 8W 10 10 8W 12 8 8W 30 2 8W 30 FUEL IGNITION SYSTEM GAS ENGINES ZG RHD J...

Page 1211: ...C2 TORQUE CONVERTER CLUTCH SOLENOID CONTROL CONTROL SOLENOID FORCE VARIABLE O D CONTROL RELAY TRANSMISSION C2 B30 T66 20 BR OR T66 20 BR OR 7 C132 CENTER DISTRIBUTION POWER CENTER DISTRIBUTION POWER MODULE CONTROL POWERTRAIN POWERTRAIN CONTROL MODULE SOLENOID CONTROL TORQUE CLUTCH CONVERTER SOLENOID FORCE SOLENOID VARIABLE SOLENOID CONTROL O D G104 BK TN 14 BK TN 14 Z12 GROUND A31 C1 Z12 GROUND A3...

Page 1212: ...ID VAPOR CANISTER CANISTER SWITCH PUMP DRIVE VAPOR DUTY PURGE EVAP CYCLE 5 C13 C3 OVERDRIVE SWITCH 6 20 OR T9 SENSE SWITCH OFF OVERDRIVE 18 T9 OR F20 C234 BR YL 20 G68 OVERDRIVE OFF C235 G68 BR YL 18 9 DRIVER LAMP C6 C3 7 VEHICLE SPEED CONTROL SERVO 1 2 SPEED CONTROL VACUUM SOLENOID CONTROL SPEED CONTROL VENT SOLENOID CONTROL TN RD V36 18 SOLENOID CONTROL C4 C3 VACUUM SPEED CONTROL LG RD V35 18 C3...

Page 1213: ...ELAY ASD C12 C3 CENTER DISTRIBUTION POWER F5 18 RD YL S100 A142 18 DG OR A142 18 DG OR A142 18 DG OR 4 C131 1 2 IGNITION COIL A7 C1 K19 18 GY WT A142 18 DG OR A142 18 DG OR A142 18 DG OR A142 18 DG OR S128 S129 4 0L 5 2L DRIVER NO 1 COIL IGNITION RELAY IN PDC 8W 70 7 8W 70 7 8W 10 16 8W 10 3 8W 10 15 8W 10 8 8W 10 3 8W 10 14 8W 10 16 ZG RHD 8W 30 FUEL IGNITION SYSTEM GAS ENGINES 8W 30 5 ZGR03004 J...

Page 1214: ...8 BK LB K4 18 BK LB S127 K6 18 VT WT K6 18 VT WT S132 4 0L 5 2L 5V SUPPLY C2 MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN A C LOW PRESSURE SWITCH 18 DB BK 1 PRESSURE SWITCH C3 A C CONTROL COMPRESSOR C3 RELAY DB RD CLUTCH C1 A C C13 18 C3 C22 B5 A C CLUTCH RELAY COMPRESSOR IN PDC 8W 31 3 8W 42 10 8W 42 12 8W 70 2 8W 70 2 8W 70 3 8W 30 6 8W 30 FUEL IGNITION SYSTEM GAS ENGINES ZG RHD J978W 3 Z...

Page 1215: ...N CRANKSHAFT A4 SENSOR GROUND SIGNAL SENSOR POSITION CRANKSHAFT A8 K24 18 GY BK K4 20 BK LB K4 20 BK LB K27 18 RD LG K4 18 BK LB C1 C1 C1 MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN THROTTLE POSITION SENSOR WT BK 20 K25 1 S133 3 K25 20 WT BK SENSOR PRESSURE ABSOLUTE MANIFOLD S136 4 0L 4 0L 5 2L 5 2L S135 S135 K4 18 BK LB 3 8W 70 3 8W 70 3 8W 70 4 8W 30 8 8W 30 9 8W 30 8 8W 30 9 ZG RHD 8W 3...

Page 1216: ...K4 18 BK LB K4 16 BK LB K2 16 TN BK K4 18 BK LB K21 16 BK RD S135 K70 18 RD WT K22 18 OR DB 1 2 1 2 SENSOR TEMPERATURE COOLANT ENGINE INTAKE AIR TEMPERATURE SENSOR 2 3 1 1 2 3 SIGNAL SENSOR IAT SENSOR PRESSURE ABSOLUTE MANIFOLD THROTTLE POSITION SENSOR MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN 8W 30 7 8W 70 4 8W 70 3 8W 30 8 8W 30 FUEL IGNITION SYSTEM 5 2L ENGINE ZG RHD J978W 3 ZGR03007 ...

Page 1217: ...K4 18 BK LB K4 16 BK LB K2 16 TN BK K4 18 BK LB K21 16 BK RD S135 K70 18 RD WT K22 18 OR DB 1 2 1 2 SENSOR TEMPERATURE COOLANT ENGINE INTAKE AIR TEMPERATURE SENSOR 2 1 3 1 2 3 SIGNAL SENSOR IAT SENSOR PRESSURE ABSOLUTE MANIFOLD THROTTLE POSITION SENSOR MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN 8W 30 7 8W 70 2 8W 70 3 ZG RHD 8W 30 FUEL IGNITION SYSTEM 4 0L ENGINE 8W 30 9 ZGR03008 J978W 3 ...

Page 1218: ...GY WT K4 18 BK LB K4 20 BK LB T41 18 BK WT T41 20 BK WT S135 S134 2 L53 L53 L53 SENSE SWITCH LAMP STOP 1 F13 C24 S206 BR 20 20 BR C3 18 BR Z1 BK 14 2 BK 14 Z1 BK 2 20 Z1 G304 C301 S202 SWITCH LAMP STOP SPEED CONTROL ON OFF SWITCH SENSE C234 YL RD 18 V32 3 C3 C11 F9 V32 20 YL RD SERVO CONTROL SPEED VEHICLE OUTPUT SWITCH ON OFF CONTROL SPEED DB LG 3 V30 20 2 8 DB LG C235 20 V30 4 8W 33 2 8W 33 2 8W ...

Page 1219: ... 7 DRIVER K11 18 WT DB K13 18 YL WT K17 18 DB WT GY 18 K38 DRIVER NO 5 INJECTOR FUEL 1 2 DG OR 18 A142 C2 B6 NO 1 INJECTOR FUEL FUEL INJECTOR NO 3 FUEL INJECTOR NO 7 FUEL INJECTOR NO 5 SHUT AUTOMATIC B16 B17 BATT F5 S129 MODULE CONTROL POWERTRAIN CENTER DISTRIBUTION POWER DOWN RELAY 8W 70 7 8W 10 16 8W 70 7 8W 10 3 8W 20 5 ZG RHD 8W 30 FUEL IGNITION SYSTEM 5 2L ENGINE 8W 30 11 ZGR03010 J978W 3 ...

Page 1220: ...IVER K12 18 TN K14 18 LB BR K18 18 DB YL BR YL 18 K58 DRIVER NO 6 INJECTOR FUEL 1 2 DG OR 18 A142 C2 B12 NO 2 INJECTOR FUEL FUEL INJECTOR NO 4 FUEL INJECTOR NO 8 FUEL INJECTOR NO 6 SHUT AUTOMATIC B16 B17 BATT F5 S128 MODULE CONTROL POWERTRAIN CENTER DISTRIBUTION POWER DOWN RELAY 8W 10 16 8W 70 7 8W 10 3 8W 20 5 8W 30 12 8W 30 FUEL IGNITION SYSTEM 5 2L ENGINE ZG RHD J978W 3 ZGR03011 ...

Page 1221: ...EAM SENSOR OXYGEN HEATED DOWNSTREAM DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL K141 18 BK PK K41 18 BK OR K4 18 BK LB K4 18 BK LB S135 K4 18 BK LB SENSOR GROUND SIGNAL SENSOR OXYGEN HEATED UPSTREAM S128 A142 18 DG OR CENTER DISTRIBUTION POWER POWERTRAIN CONTROL MODULE MODULE CONTROL POWERTRAIN DOWN RELAY 8W 10 16 8W 70 7 8W 15 7 8W 15 7 8W 70 3 8W 70 7 8W 10 3 8W 20 5 ZG RHD 8W 30 FUEL IGNITION SYSTEM...

Page 1222: ...NSOR OXYGEN HEATED DOWNSTREAM DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL K141 18 BK PK K41 18 BK OR K4 18 BK LB K4 18 BK LB S135 K4 18 BK LB SENSOR GROUND SIGNAL SENSOR OXYGEN HEATED UPSTREAM S127 K4 18 BK LB CENTER DISTRIBUTION POWER POWERTRAIN CONTROL MODULE MODULE CONTROL POWERTRAIN DOWN RELAY C1 A24 8W 10 16 8W 70 7 8W 15 7 8W 15 7 8W 70 3 8W 70 2 8W 10 3 8W 20 5 8W 30 14 8W 30 FUEL IGNITION SYSTE...

Page 1223: ...R NO 3 SHUT AUTOMATIC B16 B17 BATT F5 MODULE CONTROL POWERTRAIN S128 NO 5 INJECTOR FUEL NO 6 INJECTOR FUEL A142 18 DG OR 2 1 K38 18 GY BR YL 18 K58 2 1 DG OR 18 A142 B6 C2 FUEL INJECTOR NO 5 DRIVER FUEL INJECTOR NO 6 DRIVER DRIVER NO 4 INJECTOR FUEL POWERTRAIN CONTROL MODULE DRIVER NO 2 INJECTOR FUEL C2 B15 B16 C2 C2 B12 S129 A142 18 DG OR CENTER DISTRIBUTION POWER DOWN RELAY 8W 10 16 8W 70 7 8W 7...

Page 1224: ...OL SENSE FUEL LOW C26 C3 G40 20 LB BK G40 18 LB BK 10 C304 K4 20 BK LB K167 20 BR YL C304 C3 C15 MODULE CONTROL POWERTRAIN BATTERY TEMPERATURE SENSE SENSOR TEMPERATURE BATTERY 2 1 S102 T222 18 RD YL K4 18 BK LB K4 20 BK LB C131 5 2L 4 0L K4 20 BK LB K4 18 BK LB C1 A4 SENSOR GROUND K4 18 BK LB S135 CENTER DISTRIBUTION POWER 15 10 M SIGNAL 8W 10 14 8W 10 14 8W 10 3 8W 10 8 8W 10 15 8W 15 15 8W 15 15...

Page 1225: ...3 C2 B31 S132 S131 B27 C2 3 1 5 VOLT SUPPLY SENSOR SPEED VEHICLE C1 A4 SENSOR GROUND 2 K6 18 VT WT K6 18 VT WT G7 18 WT OR G7 18 WT OR K95 18 PK F19 C234 K95 20 PK 4 0L 5 2L BK LB 18 K4 K4 20 BK LB K4 18 BK LB F8 C234 S102 BK LB 20 K4 BK LB 20 K4 10 C131 BK LB 18 K4 GROUND SENSOR BK LB 18 K4 2 S135 SIGNAL SENSOR VEHICLE SPEED 8W 70 3 8W 70 6 8W 70 2 8W 70 2 ZG RHD 8W 30 FUEL IGNITION SYSTEM GAS EN...

Page 1226: ...TROL MODULE MEMORY SEAT MODULE DRIVER DOOR MODULE PASSENGER DOOR MODULE D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 20 WT BK D2 18 WT BK D2 18 WT BK 4 C329 12 C334 12 C351 C1 CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS PAIR TWISTED PAIR TWISTED PAIR TWISTED TWISTED PAIR PAIR TWISTED TWISTED PAIR TWISTED PAIR TWISTED PAIR PAIR TWISTED PAIR TWISTED ...

Page 1227: ...ROL MODULE MEMORY SEAT MODULE DRIVER DOOR MODULE PASSENGER DOOR MODULE D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 20 VT BR D1 18 VT BR D1 18 VT BR 3 C329 13 C334 13 C351 CCD BUS BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD C1 PAIR TWISTED PAIR TWISTED PAIR TWISTED TWISTED PAIR TWISTED PAIR PAIR TWISTED TWISTED PAIR TWISTED PAIR TWISTED PAIR PAIR TWISTED P...

Page 1228: ...VER DRIVER NO 2 MOTOR IAC IAC MOTOR NO 1 DRIVER DRIVER NO 4 MOTOR IAC MODULE CONTROL POWERTRAIN K40 16 BR WT K60 16 YL BK K39 16 GY RD K59 16 VT BK NO 3 MOTOR IAC MOTOR NO 2 IAC NO 1 MOTOR IAC NO 4 MOTOR IAC 8W 30 20 8W 30 FUEL IGNITION SYSTEM 5 2L ENGINE ZG RHD J978W 3 ZGR03019 ...

Page 1229: ...VER DRIVER NO 2 MOTOR IAC IAC MOTOR NO 1 DRIVER DRIVER NO 4 MOTOR IAC MODULE CONTROL POWERTRAIN K40 16 BR WT K60 16 YL BK K39 16 GY RD K59 16 VT BK NO 3 MOTOR IAC MOTOR NO 2 IAC IAC NO 1 MOTOR NO 4 MOTOR IAC ZG RHD 8W 30 FUEL IGNITION SYSTEM 4 0L ENGINE 8W 30 21 ZGR03020 J978W 3 ...

Page 1230: ...GROUND ST RUN OUTPUT SWITCH IGN FUSED 38 1 F99 20 RD OR 24 GROUND S130 Z12 14 BK TN Z12 16 BK TN Z12 16 BK TN Z12 16 BK TN Z12 16 BK TN G104 CONTROLLER MSA Z12 10 BK TN 37 A C SWITCH SIGNAL 28 A C COMPRESSOR CLUTCH RELAY CONTROL C103 20 DG C13 16 DB RD C13 16 DB RD C132 1 59 SIGNAL SWITCH A C MODULE CONTROL POWERTRAIN SWITCH PRESSURE LOW A C 8W 12 20 8W 10 8 8W 10 3 8W 10 13 8W 10 15 8W 10 15 8W 1...

Page 1231: ... PEDAL POSITION SENSOR LOW IDLE POSITION SWITCH THROTTLE POSITION SENSOR SIGNAL SWITCH POSITION IDLE LOW C4 C4 C4 FLT SIGNAL 27 COIL DRIVER 2 WAIT TO START LAMP 26 K255 20 WT DG K255 20 WT DG K151 20 WT K151 20 WT K6 20 VT WT K6 20 VT WT K22 20 OR DB K22 20 OR DB K92 20 PK K185 18 OR LB K48 18 OR RD D12 C307 D11 D10 D9 1 2 3 4 C182 GENERATOR FIELD DRIVER 20 C4 3 GENERATOR K20 18 DG YL 8W 20 2 ZG R...

Page 1232: ...HICLE 23 6 47 MODULE CONTROL POWERTRAIN G7 20 WT OR G7 20 WT OR S140 CONTROLLER MSA 2 3 VEHICLE SPEED SENSOR SIGNAL SUPPLY 5V 1 K7 20 OR WT VEHICLE SPEED SENSOR SENSOR GROUND 4 SENSOR GROUND POWERTRAIN CONTROL MODULE K167 20 BR YL K167 20 BR YL C4 C4 C4 C4 2 1 SENSOR FUEL IN WATER G123 20 DG WT K167 20 BR YL S141 G7 20 WT RD DIESEL K4 20 BK LB S136 C4 SIGNAL TACH 24 TACH SIGNAL 2 G21 20 GY LB 8W 3...

Page 1233: ...GROUND K134 20 LB BK K57 20 LG OR K135 20 WT BK K238 16 VT K153 20 OR K156 20 GY S144 K140 14 TN WT K140 16 TN WT K140 16 TN WT K140 16 TN WT 4 5 49 MSA CONTROLLER GROUND GROUND GROUND 68 45 23 16 16 DG OR 14 A142 A142 DG OR DG OR A142 A142 DG OR 16 14 DG OR A142 10 9 SHUT DOWN RELAY OUTPUT AUTO AUTO OUTPUT RELAY DOWN SHUT RELAY DOWN SHUT AUTO OUTPUT OUTPUT AUTO SHUT DOWN RELAY OUTPUT AUTO SHUT DO...

Page 1234: ...OW AIR MASS 4 Z1 20 BK Z1 12 BK Z1 12 BK Z1 16 BK G106 S104 10 C131 S134 13 CONTROLLER MSA AIR FLOW METER SIGNAL 4 1 2 3 RELAY PLUG GLOW 50 GLOW PLUG RELAY CONTROL SENSE K155 20 DB K152 16 WT A0 14 RD A0 10 RD S421 BATT A0 GLOW PLUG K154 10 GY A142 16 DG OR S129 8W 70 8 8W 70 7 8W 15 6 8W 15 6 8W 15 6 8W 10 3 8W 70 7 8W 30 25 8W 30 26 8W 30 FUEL IGNITION SYSTEM DIESEL ENGINE ZG RHD J978W 3 ZGR0302...

Page 1235: ...900 20 PK BK K900 20 PK BK 14 C132 A12 12 RD TN F99 18 OR F99 20 OR S101 IN PDC RELAY HEATER FUEL D10 D13 D11 D14 B 8W 30 28 TO SOLENOID EGR A142 16 DG OR A142 16 DG OR 12 C131 C4 57 S129 A142 16 DG OR A142 16 DG OR CONTROL RELAY SHUTDOWN AUTOMATIC MODULE CONTROL POWERTRAIN C 8W 30 28 TO S420 A64 14 OR DB G107 Z4 20 BK Z4 10 BK S124 8W 10 16 8W 10 3 8W 10 18 8W 10 3 8W 12 20 8W 10 8 8W 10 15 8W 70...

Page 1236: ... UNIT SENDER FUEL A64 16 OR DB A64 16 DG WT 18 C304 10 G40 20 LB BK G40 18 LB BK 3 C131 C4 1 MODULE CONTROL POWERTRAIN G40 18 LB BK Z1 16 BK Z1 12 BK S304 G305 K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL S102 12 C132 S141 C4 4 MODULE CONTROL POWERTRAIN 15 C304 EGR SOLENOID LOW FUEL SENSE SENSOR GROUND RELAY 8W 15 6 8W 15 6 8W 70 9 8W 15 15 8W 15 15 8W 70 9 8W 70 9 8W 30 2...

Page 1237: ... SENSOR TEMPERATURE COOLANT ENGINE K222 20 TN RD K2 20 TN BK K4 20 BK LB K4 20 BK LB S136 14 33 ENGINE COOLANT TEMPERATURE SIGNAL GROUND SENSOR MODULE CONTROL POWERTRAIN CONTROLLER MSA 24 C4 STOP LAMP SWITCH SENSE SPEED CONTROL ON OFF SWITCH SENSE SENSE SWITCH LAMP STOP 44 20 3 SWITCH LAMP STOP 5 V32 20 YL RD V32 20 YL RD V32 20 YL RD L50 18 WT TN L50 18 WT TN L50 18 WT TN 8 9 C132 F9 S337 S312 9 ...

Page 1238: ... 4 NO CONNECTION D83 20 BK PK D83 20 BK PK F14 C234 S200 C235 7 D83 20 BK PK C1 20 D83 20 BK PK SCI RECEIVE RECEIVE SCI 61 D83 20 BK PK CONTROLLER ANTI LOCK BRAKE CONTROLLER MSA D83 20 BK PK 2 C144 D83 20 BK PK C4 25 SCI RECEIVE TRANSMIT SCI 45 C4 MODULE CONTROL POWERTRAIN D83 20 BK PK D84 20 BK WT D84 20 BK WT D84 20 BK WT 3 C144 F15 C234 S142 8W 12 8 8W 10 10 8W 12 2 8W 12 8 8W 30 2 8W 35 2 8W 3...

Page 1239: ...K D2 18 WT BK S203 2 C302 2 C231 10 C235 19 C1 C1 9 9 S307 AIRBAG CONTROL MODULE MEMORY SEAT MODULE DRIVER DOOR MODULE PASSENGER DOOR MODULE D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK 4 C329 12 C334 12 C351 C1 CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS D2 18 WT BK 4 C132 8W 49 2 8W 40 3 8W 42 9 8W 46 7 8W 47 2 8W...

Page 1240: ...R D1 18 VT BR S204 1 C302 1 C231 11 C235 18 C1 C1 8 8 S306 AIRBAG CONTROL MODULE MEMORY SEAT MODULE DRIVER DOOR MODULE PASSENGER DOOR MODULE D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 18 VT BR D1 18 VT BR 3 C329 13 C334 13 C351 CCD BUS BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD BUS CCD C1 D1 18 VT BR 5 C132 8W 49 2 8W 40 3 8W 42 9 8W 46 7 8W 47 2 8W...

Page 1241: ...e START or RUN position it connects circuit A1 to circuit A21 In the ACCESSORY or RUN position the ignition switch connects to circuit A31 In the START posi tion the ignition switch connects circuit A1 to circuit A41 When the ignition switch is in the RUN position it connects circuit A1 to circuit A22 Also in the START position the case grounded ignition switch grounds circuit G9 from the brake wa...

Page 1242: ...controlled by the Powertrain Control Module PCM on circuit K900 When the PCM provides a ground for the coil side of the relay the contacts in the relay CLOSE and connect circuits F5 and A142 The A142 circuit sup plies power to various components and modules in the fuel system HELPFUL INFORMATION Check the 25 amp fuse located in the PDC Refer to the appropriate section of the service manual or Diag...

Page 1243: ...K141 supplies the signal from the downstream heated oxygen sensor to the PCM Cir cuit K141 connects to PCM cavity A25 The PCM provides a ground for the heated oxygen sensor signals circuits K41 and K141 through cir cuit K4 Circuit K4 connects to cavity A4 of the PCM connector Circuit Z12 provides ground for the heater circuit in each sensor HELPFUL INFORMATION Circuit A142 also supplies battery vo...

Page 1244: ... 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 K4 connects to cavity A4 of the PCM con nector HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following Battery ...

Page 1245: ...y A4 of the PCM HELPFUL INFORMATION Refer to Group 14 for MAP sensor operation Circuit K25 splices to supply 5 volts to the cam shaft position sensor crankshaft position sensor and throttle position sensor Circuit K4 splices to supply ground for the signals from the following Battery temperature sensor Camshaft position sensor Crankshaft position sensor Downstream heated oxygen sensor Engine coola...

Page 1246: ... PCM Circuit K11 provides ground for injector number one The K11 circuit connects to cavity B4 of the PCM Circuit K12 provides ground for injector number two The K12 circuit connects to cavity B15 of the PCM Circuit K13 provides ground for injector number three The K13 circuit connects to cavity B5 of the PCM Circuit K14 provides ground for injector number four The K14 circuit connects to cavity B...

Page 1247: ...it K19 connects to cavity A7 of the PCM HELPFUL INFORMATION Circuit A142 splices to supply voltage to the fuel injectors PCM heated oxygen sensors and genera tor IDLE AIR CONTROL IAC MOTOR The Powertrain Control Module PCM operates the idle air control motor through 4 circuits K39 K40 K59 and K60 Each circuit connects to separate cavities in the PCM connector Circuit K39 connects to cavity A20 of ...

Page 1248: ......

Page 1249: ...Distribution Center 8W 31 2 Powertrain Control Module 8W 31 2 3 4 5 6 S127 8W 31 3 4 S131 8W 31 4 S132 8W 31 3 4 S133 8W 31 4 Component Page S135 8W 31 3 4 S136 8W 31 4 S202 8W 31 5 S206 8W 31 5 S215 8W 31 5 S216 8W 31 5 S218 8W 31 5 Shift Interlock 8W 31 5 Stop Lamp Switch 8W 31 5 Throttle Position Sensor 8W 31 4 Torque Converter Clutch Solenoid 8W 31 2 Transmission Control Relay 8W 31 2 Transmis...

Page 1250: ...DG LB C2 C2 C2 TORQUE CONVERTER CLUTCH SOLENOID CONTROL CONTROL SOLENOID FORCE VARIABLE O D CONTROL RELAY TRANSMISSION C2 B30 T66 20 BR OR T66 20 BR OR 7 C132 CENTER DISTRIBUTION POWER CENTER DISTRIBUTION POWER MODULE CONTROL POWERTRAIN POWERTRAIN CONTROL MODULE SOLENOID CONTROL TORQUE CLUTCH CONVERTER SOLENOID FORCE SOLENOID VARIABLE SOLENOID CONTROL O D 8W 30 3 8W 30 3 8W 10 3 8W 10 3 8W 10 3 8W...

Page 1251: ...URE SENSOR SIGNAL GROUND SENSOR GOVERNOR PRESSURE SIGNAL S135 K4 18 BK LB K4 18 BK LB K4 18 BK LB K4 18 BK LB S127 K6 18 VT WT K6 18 VT WT S132 4 0L 5 2L 5V SUPPLY C2 MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN 8W 30 6 8W 30 6 8W 70 2 8W 70 2 8W 70 3 ZG RHD 8W 31 TRANSMISSION SYSTEM 8W 31 3 ZGR03102 J978W 3 ...

Page 1252: ... K4 18 BK LB K4 18 BK LB K4 20 BK LB S127 S136 SUPPLY 5V SIGNAL SENSOR SPEED VEHICLE SENSOR GROUND A4 C1 K4 18 BK LB K6 18 VT WT G7 18 WT OR S135 S132 S131 2 1 3 G7 18 WT OR K6 18 VT WT K4 18 BK LB VEHICLE SPEED SENSOR SIGNAL SUPPLY 5V SENSOR GROUND VEHICLE SPEED SENSOR 4 0L 5 2L MODULE CONTROL POWERTRAIN K25 18 WT BK S133 1 2 3 5 2L V 8 4 0L I 6 8W 70 2 8W 70 4 8W 70 3 8W 70 2 8W 70 2 8W 30 8 8W ...

Page 1253: ... C24 C3 SENSE SWITCH LAMP STOP C3 C6 G68 20 BR YL G68 18 BR YL 9 C235 OVERDRIVE OFF LAMP DRIVER F71 20 PK DG F71 20 PK DG S218 JUNCTION BLOCK MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN 8 C9 C9 9 OVERDRIVE OFF SWITCH SENSE SWITCH PRESSURE OVERDRIVE SWITCH POD PART OF 8W 12 5 8W 12 10 8W 12 5 8W 33 2 8W 15 18 8W 15 18 8W 15 17 8W 12 10 8W 10 8 8W 10 8 8W 12 2 8W 30...

Page 1254: ...ITCH SUPPLY 5V PEDAL POSITION SENSOR POWERTRAIN CONTROL MODULE SIGNAL SENSOR POSITION THROTTLE 10 CONTROLLER MSA PEDAL POSITION SENSOR SENSOR POSITION PEDAL K22 20 OR DB K22 20 OR DB K22 20 OR DB K6 20 VT WT K151 20 WT K255 20 WT DG 1 2 3 4 12 11 10 9 C307 C182 8 SENSOR GROUND K4 18 BK LB K4 18 BK LB K4 18 BK LB K4 18 BK LB K4 18 BK LB K4 18 BK LB S211 F8 C234 S119 6 C131 S136 33 GROUND SENSOR 8W ...

Page 1255: ...ol 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 variable force solenoid are molded together Circuit T20...

Page 1256: ...K4 If transmission 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 Battery temperature sensor Camshaft position sensor Crank...

Page 1257: ...oller 8W 33 4 5 Powertrain Control Module 8W 33 2 3 4 5 Right Switch 8W 33 3 5 S102 8W 33 3 5 S121 8W 33 4 S124 8W 33 2 S131 8W 33 3 Component Page S132 8W 33 3 S135 8W 33 3 S136 8W 33 5 S140 8W 33 5 S141 8W 33 5 S202 8W 33 2 4 S206 8W 33 2 S211 8W 33 5 S312 8W 33 2 4 Stop Lamp Switch 8W 33 2 4 Vehicle Speed Control Servo 8W 33 2 Vehicle Speed Control Horn Switch 8W 33 3 5 Vehicle Speed Sensor 8W ...

Page 1258: ...3 4 YL RD 18 V32 3 C3 C11 2 F9 V32 20 YL RD S206 L53 20 BR 8 C235 2 V30 20 DB LG Z1 20 BK Z1 14 BK S202 G304 2 C301 Z1 14 BK SPEED CONTROL VACUUM SOLENOID CONTROL SPEED CONTROL VENT SOLENOID CONTROL SPEED CONTROL ON OFF SWITCH OUTPUT STOP LAMP SWITCH 5 6 15A FUSE 9 C10 3 BATT A250 JUNCTION BLOCK L16 18 RD LG L50 18 WT TN L50 18 WT TN 12 C305 S312 TO 9 8W 70 5 8W 10 10 8W 12 2 8W 12 7 8W 15 18 8W 1...

Page 1259: ...C2 B31 S132 S131 B27 C2 3 1 5 VOLT SUPPLY SIGNAL VSS SENSOR SPEED VEHICLE C1 A4 SENSOR GROUND 2 CLOCKSPRING K6 18 VT WT K6 18 VT WT G7 18 WT OR G7 18 WT OR K95 18 PK F19 C234 K95 20 PK 4 0L 5 2L BK LB 18 K4 K4 20 BK LB K4 18 BK LB F8 C234 S102 BK LB 20 K4 BK LB 20 K4 10 C131 BK LB 18 K4 GROUND SENSOR BK LB 18 K4 2 S135 8W 30 17 8W 70 2 8W 70 2 8W 70 6 8W 70 3 ZG RHD 8W 33 VEHICLE SPEED CONTROL GAS...

Page 1260: ...RD L53 20 BR G8 C235 G2 Z1 20 BK Z1 14 BK S202 G304 2 C301 Z1 14 BK STOP LAMP SWITCH CONTROLLER MSA F9 F13 C234 V32 20 YL RD 6 5 9 FUSE 15A BATT A250 JUNCTION BLOCK 3 C10 L16 18 RD LG L50 18 WT TN L50 18 WT TN 12 C305 9 TO S312 8W 15 8 8W 15 4 8W 15 5 8W 15 18 8W 15 18 8W 50 11 8W 12 7 8W 10 10 8W 12 2 8W 70 5 8W 30 29 8W 33 4 8W 33 VEHICLE SPEED CONTROL DIESEL ENGINE ZG RHD J978W 3 ZGR03303 ...

Page 1261: ...ROLLER MSA 6 C4 C4 47 1 3 S140 S141 G7 20 WT OR G7 20 WT OR G7 20 WT OR K7 20 OR K167 20 BR YL K167 20 BR YL SENSOR SPEED VEHICLE SENSOR GROUND SUPPLY 5V VEHICLE SPEED SENSOR SIGNAL SENSOR GROUND SUPPLY 5V VEHICLE SPEED SENSOR SIGNAL C234 F19 K95 20 PK K4 20 BK LB K4 20 BK LB K4 18 BK LB K4 18 BK LB K4 18 BK LB K4 18 BK LB S136 6 C131 S102 F8 C234 S211 8W 30 24 8W 30 24 8W 30 24 8W 70 9 8W 70 8 8W...

Page 1262: ...round on circuit Z1 When the brake pedal is depressed the stop lamp switch opens and disconnects circuits L53 and Z1 and circuits V32 and V30 When the stop lamp switch disconnects circuits V32 and V30 power is removed from the speed control servo HELPFUL INFORMATION Circuit K4 also provides ground for some of the engine control sensors that provide inputs to the PCM VEHICLE SPEED CONTROL DIESEL Th...

Page 1263: ...strument Cluster 8W 35 3 Junction Block 8W 35 2 3 Left Front Wheel Speed Sensor 8W 35 4 Left Rear Wheel Speed Sensor 8W 35 4 Component Page Power Distribution Center 8W 35 2 Powertrain Control Module 8W 35 2 Right Front Wheel Speed Sensor 8W 35 4 Right Rear Wheel Speed Sensor 8W 35 4 S125 8W 35 2 S142 8W 35 2 S200 8W 35 2 S312 8W 35 3 Speed Proportional Steering Module 8W 35 2 Stop Lamp Switch 8W ...

Page 1264: ...K D83 20 BK PK FUSED IGN ST RUN GROUND GROUND FUSED B FUSED B JUNCTION BLOCK MODULE STEERING PROPORTIONAL SPEED S200 BK PK D83 20 2 C144 BK PK D83 20 SCI RECEIVE SCI RECEIVE 12 S142 BK PK D83 20 BK PK 20 D83 20 C1 BRAKE ANTI LOCK CONTROLLER POWERTRAIN 25 MODULE CONTROL C3 8W 30 2 8W 30 30 8W 30 2 8W 65 2 8W 10 3 8W 10 8 8W 12 2 8W 15 8 8W 12 9 8W 10 5 8W 10 10 8W 10 3 8W 35 2 8W 35 ANTI LOCK BRAKE...

Page 1265: ... 7 B41 20 YL VT 6 C304 7 B41 20 YL VT B42 20 TN WT B42 20 TN WT ACCEL SENSOR NO 1 NO 2 SENSOR ACCEL STOP LAMP SWITCH OUTPUT 16 4 G5 C235 205 20 WT VT 205 20 WT VT INSTRUMENT CLUSTER ABS WARNING LAMP DRIVER ABS WARNING LAMP L50 18 WT TN 12 C305 STOP LAMP SWITCH SENSOR GROUND 1 13 9 8W 33 2 8W 10 10 8W 40 5 8W 70 5 8W 12 2 8W 12 7 ZG RHD 8W 35 ANTI LOCK BRAKES 8W 35 3 ZGR03502 J978W 3 ...

Page 1266: ...ED SENSOR SENSOR SPEED WHEEL FRONT RIGHT 3 SENSOR SPEED WHEEL FRONT RIGHT A B 17 RIGHT REAR WHEEL SPEED SENSOR SENSOR SPEED WHEEL REAR RIGHT 1 SENSOR SPEED WHEEL REAR RIGHT B8 20 RD DB RD 20 B9 WT 20 B7 WT DB 20 B6 B3 20 LG DB B3 20 LG DB 12 C304 13 LG 20 B4 LG 20 B4 3 YL DB 20 B1 YL DB 20 B1 C304 4 YL 20 B2 YL 20 B2 PAIR TWISTED PAIR TWISTED PAIR TWISTED PAIR TWISTED PAIR TWISTED PAIR TWISTED 8W ...

Page 1267: ...cuits B4 and B3 provide signals to the CAB from the left rear wheel speed sensor G SWITCH During four wheel drive operation the G switch provides deceleration data to the Controller Anti Lock Brakes CAB Refer to Group 5 Brakes for additional information Circuits B41 B42 and B43 connect the G switch to the CAB Circuits B41 and B42 provide switch states while circuit B43 provides ground ABS WARNING ...

Page 1268: ......

Page 1269: ...8W 39 6 Ignition Switch 8W 39 2 Junction Block 8W 39 2 3 6 Left Front Cylinder Lock Switch 8W 39 5 Left Front Door Ajar Switch 8W 39 5 Component Page Left Rear Door Ajar Switch 8W 39 5 Liftgate Ajar Switch 8W 39 4 Liftgate Cylinder Lock Switch 8W 39 5 Liftglass Ajar Switch 8W 39 4 Park 8W 39 3 Power Distribution Center 8W 39 2 3 6 Relay 8W 39 3 Right Front Cylinder Lock Switch 8W 39 5 Right Front ...

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Page 1271: ......

Page 1272: ......

Page 1273: ......

Page 1274: ......

Page 1275: ...e 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 ajar switch signals on the following circuits Circuit G75 provides the left front door ajar switch signal Circuit G74 provides the right front door ajar switch signal Circuit G77 provides the left rear door ajar switch signal Circuit G76 provides t...

Page 1276: ......

Page 1277: ...igh Beam Indicator Lamp 8W 40 5 Ignition Switch 8W 40 6 Illumination Lamps 8W 40 4 Instrument Cluster 8W 40 2 3 4 5 Junction Block 8W 40 2 4 5 Left Front Turn Signal Lamp 8W 40 4 Left Turn Signal Indicator Lamp 8W 40 4 Component Page Low Fuel Warning Lamp 8W 40 2 Oil Pressure Gauge 8W 40 3 Powertrain Control Module 8W 40 3 Right Turn Signal Indicator Lamp 8W 40 4 S109 8W 40 4 S149 8W 40 4 S201 8W ...

Page 1278: ...G FUEL LOW LAMP ENGINE CHECK FUSED B GROUND 1 2 Z1 20 BK S216 Z1 16 BK S202 Z1 14 BK 2 C301 Z1 14 BK BK OR 18 Z2 S205 BK OR 20 Z2 8 C307 Z2 18 BK OR S302 Z2 18 BK OR G304 INSTRUMENT CLUSTER 8W 10 10 8W 12 8 8W 12 2 8W 12 8 8W 15 17 8W 15 18 8W 15 18 8W 15 18 8W 15 18 8W 40 2 8W 40 INSTRUMENT CLUSTER ZG RHD J978W 3 ZGR04001 ...

Page 1279: ... VT BR 18 D1 S306 S307 S204 D2 18 WT BK D2 18 WT BK C302 2 WT BK 18 D2 WT BK 18 D2 WT BK 18 D2 D1 18 VT BR MODULE CONTROL BODY CCD BUS BUS CCD 19 20 CCD BUS BUS CCD POWERTRAIN CONTROL MODULE D1 18 VT BR 19 VT BR 18 D1 D2 18 WT BK C235 20 WT BK 18 D2 10 11 C30 C3 C28 C3 S203 C1 C1 PAIR TWISTED TWISTED PAIR TWISTED PAIR PAIR TWISTED PAIR TWISTED TWISTED PAIR C132 5 4 8W 30 18 8W 30 31 8W 30 18 8W 30...

Page 1280: ...RNING HAZARD SIGNAL TURN L65 18 LG DB F10 C234 L65 18 LG DB 1 C102 L64 18 TN DB S409 L64 18 TN DB A G Z1 18 BK S149 Z1 18 BK 3 C102 Z1 18 BK G106 1 7 L64 18 TN DB BLOCK JUNCTION 1 L64 18 TN DB GROUND LEFT TURN SIGNAL LAMP C4 C4 SWITCH 11 FRONT S109 16 BK Z1 8W 15 4 8W 15 5 8W 52 2 8W 12 2 8W 15 6 8W 15 7 8W 15 4 8W 15 5 8W 44 11 8W 45 10 8W 50 5 8W 40 4 8W 40 INSTRUMENT CLUSTER ZG RHD J978W 3 ZGR0...

Page 1281: ... C307 Z2 18 BK OR S302 Z2 18 BK OR G304 5 FUSE 10A BLOCK JUNCTION 8 C9 F87 20 BK WT S215 F87 20 BK WT 5 ABS WARNING LAMP 205 20 WT VT C235 5 VT WT 20 205 4 16 BRAKE ANTI LOCK CONTROLLER DRIVER LAMP WARNING ABS ST RUN A21 CLUSTER INSTRUMENT F87 20 BK WT GAS DIESEL 8W 10 8 8W 35 3 8W 12 5 8W 12 2 8W 12 5 8W 15 18 8W 15 18 8W 15 18 8W 15 18 8W 15 17 8W 12 8 8W 12 8 8W 10 10 ZG RHD 8W 40 INSTRUMENT CL...

Page 1282: ...G9 16 GY BK GAS OTHERS 2 C304 G9 20 GY BK S303 G9 20 GY BK 2 C3 BRAKE SWITCH SENSE BODY CONTROL MODULE 3 0 2 1 IGNITION SWITCH 1 START 2 RUN 0 OFF 3 ACC 2 1 GY BK 20 G9 8W 10 7 8W 45 9 8W 45 9 8W 50 4 8W 40 6 8W 40 INSTRUMENT CLUSTER ZG RHD J978W 3 ZGR04005 ...

Page 1283: ...ol Module The PCM 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 cesso...

Page 1284: ...ircuit 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 ILLUMINATION LAMPS Circuit E2 from the headlamp switch powers th...

Page 1285: ...2 Fuse 2 8W 41 3 Fuse 6 8W 41 2 Fuse 14 8W 41 3 Fuse 21 8W 41 3 G106 8W 41 2 G304 8W 41 3 Horn No 1 8W 41 2 Horn No 2 8W 41 2 Component Page Horn Relay 8W 41 2 Horn Switch 8W 41 2 Junction Block 8W 41 2 3 Power Distribution Center 8W 41 2 Power Outlet 8W 41 3 S104 8W 41 2 S106 8W 41 2 S202 8W 41 3 S216 8W 41 3 S220 8W 41 3 Vehicle Speed Control Horn Switch 8W 41 2 ZG 8W 41 HORN CIGAR LIGHTER 8W 41...

Page 1286: ... G106 X4 20 GY OR 1 C1 BLOCK JUNCTION SWITCH HORN CONTROL SPEED VEHICLE 5 BODY CONTROL MODULE HORN RELAY CONTROL 13 C2 7 C10 C7 12 X4 20 GY OR X4 20 GY OR CLOCKSPRING HORN SWITCH F31 16 VT HORN RELAY A3 A1 A5 A2 8W 45 3 8W 45 3 8W 12 2 8W 15 6 8W 15 7 8W 15 6 8W 15 7 8W 10 3 8W 10 3 8W 10 5 8W 41 2 8W 41 HORN CIGAR LIGHTER POWER OUTLET ZG RHD J978W 3 ZGR04101 ...

Page 1287: ...304 Z1 16 BK BLOCK JUNCTION S216 Z1 16 BK S202 Z1 14 BK 2 C301 Z1 14 BK 15A FUSE 21 14 FUSE 15A 2 C9 BLOCK JUNCTION C10 9 NO CONNECTION 2 FUSE 15A C7 4 RUN ACC A31 BATT F61 BATT A7 8W 10 12 8W 10 9 8W 10 9 8W 12 3 8W 12 2 8W 12 3 8W 12 16 8W 15 18 8W 15 17 8W 12 2 8W 15 18 8W 15 17 ZG RHD 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 3 ZGR04102 J978W 3 ...

Page 1288: ... The relay energizes when the ignition switch is in the ACCESSORY or RUN position In the ACCES SORY or RUN position the switch connects circuit 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 c...

Page 1289: ...ink Connector 8W 42 9 Fuse 3 8W 42 11 Fuse 7 8W 42 2 3 Fuse 12 8W 42 5 7 9 Fuse 18 8W 42 10 Fuse 20 8W 42 2 11 Fuse 21 8W 42 10 11 G106 8W 42 12 G107 8W 42 2 4 7 G304 8W 42 7 High Speed Blower Motor Relay 8W 42 3 In Car Temperature Sensor 8W 42 6 Component Page Junction Block 8W 42 2 5 7 9 Mode Door Actuator 8W 42 6 8 MSA Controller 8W 42 13 Power Distribution Center 8W 42 2 3 10 11 Powertrain Con...

Page 1290: ...TT A0 40A FUSE 7 13 CENTER DISTRIBUTION POWER A19 12 RD VT A19 12 RD 1 C160 1 2 A C HEATER MANUAL MOTOR BLOWER C7 12 BK S221 3 3 A C HEATER CONTROL C7 12 BK C7 12 BK TN C7 12 BK TN B C206 BLOWER MOTOR SWITCH M C1 BLOCK RESISTOR MOTOR BLOWER 8W 42 5 8W 10 3 8W 10 6 8W 10 3 8W 15 8 8W 15 8 8W 15 8 8W 12 2 8W 10 12 8W 12 16 8W 42 5 8W 42 2 8W 42 AIR CONDITIONING HEATER ZG RHD J978W 3 ZGR04201 ...

Page 1291: ...TOR RELAY OUTPUT SIGNAL RELAY MOTOR BLOWER SPEED HIGH MODULE CONTROL TEMPERATURE AUTOMATIC C42 12 BR RD C42 18 PK DB C41 20 BR C41 20 GY DB M L C206 1 2 BLOWER MOTOR C42 12 RD 5 A 8W 42 4 B 8W 42 4 C 8W 42 4 TO S226 TO S226 TO C206 C43 18 BR YL Z4 18 BK Z4 12 BK CENTER DISTRIBUTION POWER BLOWER MOTOR DRIVER FUSED B OUTPUT GROUND M 8W 10 3 8W 10 3 8W 10 6 ZG RHD 8W 42 AIR CONDITIONING HEATER 8W 42 ...

Page 1292: ...AUTOMATIC TEMPERATURE CONTROL MODULE 2 C160 P C206 A C SELECT INPUT C6 C2 7 C90 20 LG MODULE CONTROL BODY A C SELECT INPUT N C206 FROM MODULE MOTOR BLOWER C43 18 BR YL BLOWER MOTOR FROM MODULE MOTOR BLOWER FROM LAMP PANEL D13 PANEL DRIVER LAMP 16 C2 E2 OR 20 S214 S209 OR E2 20 OR 20 E2 8W 44 11 8W 44 12 8W 44 11 8W 45 9 8W 15 8 8W 15 8 8W 42 4 8W 42 AIR CONDITIONING HEATER ZG RHD J978W 3 ZGR04203 ...

Page 1293: ...0A RUN A22 JUNCTION BLOCK C9 4 F71 20 DG PK 1 4 2 3 BLOCK RESISTOR MOTOR BLOWER C4 14 TN C4 14 TN C5 14 LG C5 14 LG C6 14 LB C6 14 LB C7 12 BK C7 12 BK TN C7 12 BK TN E C206 B D C S221 2 MOTOR BLOWER C7 12 BK C2 7 C90 20 LG A C SELECT INPUT D 8W 42 6 TO S214 E2 20 OR C1 14 DG C34 20 VT WT C36 20 DB RD F 8W 42 7 G 8W 42 7 H 8W 42 7 TO C206 TO S220 TO C206 7 C2 HEATER A C MANUAL MODULE CONTROL BODY ...

Page 1294: ... AMBIENT TEMPERATURE SENSOR SIGNAL RETURN SENSOR BODY CONTROL MODULE D13 DRIVER LAMP PANEL 16 C2 MODULE CONTROL TEMPERATURE AUTOMATIC E2 20 OR E2 20 OR E2 20 OR S209 S214 D 8W 42 5 E2 20 DR FROM CONTROL HEATER A C PANEL LAMP DRIVER S219 LG WT 20 D41 D41 20 LG WT D9 GROUND SENSOR S C206 D41 20 LG WT D41 20 LG WT 3 MODE DOOR ACTUATOR D41 20 LG WT 3 ATC ACTUATOR DOOR BLEND S222 SENSOR SENSOR GROUND 8...

Page 1295: ...36 20 DB RD C36 20 DB RD F C206 2 C40 20 WT YL F71 20 PK DG F71 20 PK DG S218 F71 20 PK DG G C206 F 8W 42 5 G 8W 42 5 H 8W 42 5 FROM CONTROL HEATER A C A C HEATER CONTROL FROM FROM CONTROL HEATER A C C206 FUSED IGN RUN BLEND AIR DOOR POSITION SWITCH SIGNAL COMMON DOOR NOT USED 8W 12 2 8W 10 8 8W 12 10 8W 15 8 8W 15 8 8W 15 17 8W 15 18 8W 15 17 8W 15 18 8W 12 10 ZG RHD 8W 42 AIR CONDITIONING HEATER...

Page 1296: ...VER SIGNAL FEEDBACK DOOR AIR BLEND DRIVER MOTOR DOOR AIR BLEND C35 20 DG YL C35 20 DB WT C34 20 DB WT C34 20 VT WT C E C206 C36 20 RD WT C36 20 DB RD D C206 C40 20 DG YL C40 20 DG YL D41 20 LG WT D41 20 LG WT C38 20 DG C38 20 DB C37 20 TN BK C37 20 YL C39 20 YL C39 20 WT S222 C40 20 DG YL C40 20 BR WT C206 S223 J B C206 A C206 S219 C206 S LG WT 20 D41 LG WT 20 D41 LG WT 20 D41 D9 K SENSOR GROUND 8...

Page 1297: ...R DOOR RECIRCULATION C32 20 LB DG C33 20 VT OR C12 9 C9 4 C9 JUNCTION BLOCK RUN A22 RECIRC DOOR MOTOR MOTOR DOOR RECIRC IGN FUSED RUN 18 18 VT BR WT BK CCD BUS 18 VT BR D1 D1 3 LINK DATA S203 CONNECTOR S204 D2 WT BK 18 D2 BUS CCD 11 C10 C11 CCD BUS BUS CCD PAIR TWISTED 8W 30 19 8W 30 32 8W 30 18 8W 30 19 8W 30 31 8W 30 32 8W 30 18 8W 30 31 8W 10 8 8W 12 2 8W 12 10 8W 12 10 ZG RHD 8W 42 AIR CONDITI...

Page 1298: ...18 DB YL C2 18 DB YL 1 C144 7 C131 C2 18 DB YL C13 18 DB RD E 8W 42 12 TO MODULE CONTROL POWERTRAIN 4 0L 5 2L BATT A900 21 FUSE 15A A21 A22 F250 18 RD GY CLUTCH COMPRESSOR A C A C COMPRESSOR CLUTCH RELAY IN PDC 8W 10 4 8W 10 4 8W 10 8 8W 10 3 8W 10 15 8W 10 13 8W 42 10 8W 42 AIR CONDITIONING HEATER GAS ENGINES ZG RHD J978W 3 ZGR04209 ...

Page 1299: ...13 BATT A0 20 FUSE 25A A20 A19 CLUTCH COMPRESSOR A C A C COMPRESSOR CLUTCH RELAY IN PDC IN PDC RELAY DOWN SHUT AUTOMATIC B17 B18 B16 TO C131 A142 16 DG OR F5 16 RD YL F5 16 RD YL 9 2 40A FUSE 3 A900 16 OR YL 8W 10 4 8W 10 3 8W 10 16 8W 10 3 8W 10 4 ZG RHD 8W 42 AIR CONDITIONING HEATER DIESEL ENGINE 8W 42 11 ZGR04211 J978W 3 ...

Page 1300: ...WERTRAIN C13 18 DB RD A C PRESSURE SWITCH C22 C3 C3 18 DB BK 1 2 SWITCH PRESSURE LOW A C C21 18 DB OR C21 18 DB OR A C HIGH PRESSURE SWITCH 2 1 5 C144 G106 Z1 18 BK Z1 18 BK 4 C144 Z1 14 BK S104 RELAY 8W 15 7 8W 15 7 8W 30 6 8W 42 12 8W 42 AIR CONDITIONING HEATER GAS ENGINES ZG RHD J978W 3 ZGR04210 ...

Page 1301: ...14 C131 28 CONTROLLER MSA A C COMPRESSOR CLUTCH RELAY CONTROL C13 16 DB RD C13 16 DB RD 10 C132 A C COMPRESSOR CLUTCH RELAY FROM I 8W 42 11 DG 20 C103 37 A C SWITCH SIGNAL 59 C4 POWERTRAIN CONTROL MODULE A C SWITCH SIGNAL 8W 30 29 8W 30 22 ZG RHD 8W 42 AIR CONDITIONING HEATER DIESEL ENGINE 8W 42 13 ZGR04212 J978W 3 ...

Page 1302: ... 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 motor Ground for the blower motor is supplied on circuit C7 through the blower motor...

Page 1303: ...e 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 through fuse 18 in the PDC Circuit F99 powers the coil side of the A C compressor clutch relay Circuit A19 from fuse 7 in the PDC connects t...

Page 1304: ... door motor on circuits C37 and C38 BLEND DOOR MOTOR AUTOMATIC TEMPERATURE 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 AT...

Page 1305: ... 8W 43 3 Driver Side Airbag 8W 43 2 Fuse 4 8W 43 2 Fuse 7 8W 43 3 Fuse 22 8W 43 2 G303 8W 43 2 G304 8W 43 3 Instrument Cluster 8W 43 3 Junction Block 8W 43 2 3 Passenger Side Airbag 8W 43 2 Component Page S201 8W 43 3 S202 8W 43 3 S203 8W 43 3 S204 8W 43 3 S205 8W 43 3 S216 8W 43 3 S302 8W 43 3 S306 8W 43 3 S307 8W 43 3 ZG 8W 43 AIRBAG SYSTEM 8W 43 1 ...

Page 1306: ...2 AIRBAG DRIVER DRIVER AIRBAG LINE 1 LINE 2 AIRBAG DRIVER SIDE AIRBAG AIRBAG SIDE PASSENGER AIRBAG LINE 2 LINE 1 AIRBAG PASSENGER PASSENGER AIRBAG LINE 2 LINE 1 AIRBAG PASSENGER A R44 18 DG YL 6 5 BK YL 18 R42 B A C300 B R42 18 VT R44 18 DB 10 GROUND G303 Z6 16 BK PK PAIR TWISTED PAIR TWISTED DRIVER PASSENGER 8W 15 13 8W 12 23 8W 10 8 8W 10 8 8W 12 2 8W 12 5 8W 43 2 8W 43 AIRBAG SYSTEM ZG RHD J978...

Page 1307: ... 18 VT F75 18 VT S201 CCD BUS BUS CCD 8 9 D1 18 VT BR D1 18 VT BR D1 18 VT BR 1 C302 2 WT BK 18 D2 WT BK 18 D2 WT BK 18 D2 S204 S203 S306 S307 19 18 CCD BUS CCD BUS AIRBAG CONTROL MODULE 3 PAIR TWISTED 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 12 8 8W 40 2 8W 40 3 8W 12 2 8W 12 8 8W 15 18 8W 15 18 8W 15 18 8W 15 18 8W 15 17 8W 10 10 ZG RHD 8W 43 AIRBAG SYSTEM 8W 43...

Page 1308: ...warning lamp in the instru ment cluster AIRBAG IMPACT SENSOR The Airbag system uses a sensor internal to the Airbag Control Module ACM to detect impact For information regarding operation of this sensor refer to the appropriate group of the Service Manual AIRBAG SQUIB AIRBAG IGNITER Circuits R43 and R45 connect the ACM to the drivers airbag squib igniter after passing through the clock spring conn...

Page 1309: ...y Lamp 8W 44 2 8 Left Door Courtesy Lamp 8W 44 9 Left Front Door Ajar Switch 8W 44 14 Left Rear Door Ajar Switch 8W 44 14 Left Visor Vanity Lamp 8W 44 5 Liftgate Ajar Switch 8W 44 14 Liftglass Ajar Switch 8W 44 14 Mercury Switch 8W 44 2 Overhead Console 8W 44 4 Component Page Park Neutral Position Switch 8W 44 6 Passenger Door Module 8W 44 10 Radio 8W 44 8 Rear Wiper Module 8W 44 14 Right Courtesy...

Page 1310: ... YL M2 20 YL Z1 14 BK S220 S202 2 C301 G304 MERCURY SWITCH UNDERHOOD LAMP 1 2 G107 Z4 18 BK Z4 10 BK S124 M1 18 PK M1 18 PK 1 C159 JUNCTION BLOCK SWITCH SWITCH KEY IN HALO LAMP 2 1 14 MODULE CONTROL BODY C1 SWITCH IGN KEY IN SENSE BK 20 Z1 S216 LB 20 G26 C159 2 G107 S109 BK Z4 10 BK Z4 18 BK 14 Z1 GAS DIESEL 8W 15 4 8W 15 5 8W 15 8 8W 15 17 8W 45 3 8W 12 2 8W 15 8 8W 15 8 8W 15 18 8W 15 18 8W 15 1...

Page 1311: ... M2 20 YL M2 20 YL M2 20 YL M2 20 YL S334 87 30 C15 11 COURTESY LAMP RELAY JUNCTION BLOCK 2 C15 Z1 20 BK Z1 16 BK S322 OTHERS SUNROOF JUNCTION BLOCK 8W 12 2 8W 15 16 8W 12 2 8W 44 8 8W 12 21 8W 12 13 8W 10 12 8W 12 12 ZG RHD 8W 44 INTERIOR LIGHTING 8W 44 3 ZGR04402 J978W 3 ...

Page 1312: ...YL M2 20 YL S334 87 30 C15 11 COURTESY LAMP RELAY JUNCTION BLOCK 2 C15 Z1 20 BK Z1 16 BK S322 OTHERS SUNROOF OVERHEAD CONSOLE JUNCTION BLOCK 8W 49 2 8W 49 3 8W 12 2 8W 15 16 8W 12 2 8W 44 8 8W 12 21 8W 12 13 8W 10 12 8W 12 12 8W 44 4 8W 44 INTERIOR LIGHTING ZG RHD J978W 3 ZGR04403 ...

Page 1313: ...K 20 M1 LAMP VANITY VISOR LEFT RIGHT VISOR VANITY LAMP LAMP CARGO C B A C13 5 M1 20 PK 3 C14 C3 6 LIFTGATE COURTESY LAMP DISABLE M2 20 YL M4 20 WT LG OPENER DOOR GARAGE UNIVERSAL JUNCTION BLOCK MODULE CONTROL BODY 8W 45 10 8W 12 2 8W 12 13 8W 12 21 8W 12 2 8W 44 8 8W 10 12 8W 12 12 ZG RHD 8W 44 INTERIOR LIGHTING 8W 44 5 ZGR04404 J978W 3 ...

Page 1314: ...AY NIGHT MIRROR DRIVER POWER MIRROR P114 20 YL BK P114 18 YL BK P114 20 YL BK P112 20 YL WT P112 18 YL WT P112 20 YL WT 11 C334 7 C302 3 C231 B C353 A 9 8 4 AUTOMATIC NIGHT DAY AUTOMATIC MIRROR S322 BK 16 Z1 BK 20 Z1 2 C 8W 44 7 JUNCTION BLOCK TO L10 20 BK RD B 8W 44 7 JUNCTION BLOCK TO BK RD 20 L10 A 8W 44 7 PARK NEUTRAL POSITION SWITCH TO GROUND AUTOMATIC DAY NIGHT MIRROR MIRROR NIGHT DAY AUTOMA...

Page 1315: ...0 PARK NEUTRAL POSITION SWITCH 3 1 YL DG 18 F83 C 8W 44 6 FROM S322 B 8W 44 6 AUTOMATIC DAY NIGHT MIRROR FROM T41 20 BK WT 2 S134 T41 18 BK WT C1 A6 POWERTRAIN CONTROL MODULE PARK NEUTRAL POSITION SWITCH SENSE A 8W 44 6 FROM C132 8W 12 2 8W 15 17 8W 15 17 8W 15 18 8W 15 18 8W 15 6 8W 21 4 8W 30 10 ZG RHD 8W 44 INTERIOR LIGHTING 8W 44 7 ZGR04406 J978W 3 ...

Page 1316: ...0 OR 5 RADIO C1 Z5 16 BK Z5 14 BK LB 9 C305 Z5 14 BK LB Z5 14 BK LB Z5 14 BK LB S309 G303 OTHERS AMPLIFIER POWER D 8W 44 12 FROM S214 30 C8 12 7 C8 B COURTESY LAMP LEFT M2 YL 20 COURTESY LAMP RIGHT 20 YL M2 B 12 COURTESY LAMP RELAY 8W 44 2 8W 44 2 8W 15 13 8W 15 13 8W 47 2 8W 15 17 8W 15 17 8W 15 18 8W 15 18 8W 45 3 8W 12 2 8W 12 12 8W 10 12 8W 44 8 8W 44 INTERIOR LIGHTING ZG RHD J978W 3 ZGR04407 ...

Page 1317: ...VT BR D1 18 VT BR D1 18 VT BR D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK 12 C334 S307 2 C302 S203 S204 1 S306 13 Z1 12 BK Z1 12 BK Z1 12 BK Z1 12 BK Z1 20 BK M1 20 PK 2 1 LAMP COURTESY DOOR Z1 12 BK FULL OPTION S324 1 C334 G302 POWER GROUP PAIR TWISTED LEFT 8W 15 12 8W 15 12 8W 30 19 8W 30 32 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 45 2 8W 60 2 8W 12 7 8W 10 10 8W...

Page 1318: ...VT BR D1 18 VT BR D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK 12 C351 S307 2 C302 S203 S204 1 S306 13 Z1 12 BK Z1 12 BK Z1 12 BK Z1 12 BK Z1 20 BK M1 20 PK 2 1 LAMP COURTESY DOOR Z1 12 BK FULL OPTION OTHERS S325 1 C351 G301 C1 C1 C1 C1 C1 PAIR TWISTED RIGHT 8W 12 2 8W 10 10 8W 12 7 8W 60 3 8W 45 2 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 19 8W 30 32 8W 15 14 8W 1...

Page 1319: ...OR 6 C302 3 1 LAMPS CONSOLE FLOOR Z1 20 BK Z1 12 BK G305 S304 Z2 20 BK OR Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR S205 S302 G304 8 C307 OR 20 E2 LAMPS ILLUM 1 SWITCH HEADLAMP S209 E2 20 OR E2 20 OR S214 1 ASH RECEIVER LAMP 8W 45 2 8W 40 2 8W 40 5 8W 15 17 8W 15 18 8W 15 15 8W 15 15 8W 15 18 8W 15 18 8W 45 2 8W 15 18 8W 50 2 8W 50 5 8W 50 7 8W 44 12 8W 44 12 ZG RHD 8W 44 INTERIOR LIGHTING 8W 44 11 ZGR0...

Page 1320: ...CONTROL HEATER A C CIGAR LIGHTER LAMP E2 20 OR E2 20 OR D13 MODULE CONTROL TEMPERATURE AUTOMATIC E2 20 OR S209 MANUAL A C HEATER ATC D 8W 44 8 TO RADIO GRAPHIC DISPLAY MODULE CENTER INFORMATION VEHICLE 10 20 E2 20 OR Z1 20 BK OTHERS OVERHEAD CONSOLE LAMP PANEL PREMIUM 8W 42 5 8W 46 4 8W 46 2 8W 44 11 8W 42 4 8W 15 18 8W 15 18 8W 15 17 8W 15 17 8W 45 2 8W 44 12 8W 44 INTERIOR LIGHTING ZG RHD J978W ...

Page 1321: ... SIGNAL PANEL LAMP DRIVER BODY CONTROL MODULE 2 Z1 16 BK Z1 14 BK Z1 14 BK E2 20 OR 707 20 BK WT G304 S202 2 C301 E2 20 OR 20 C2 16 C2 1 8 S209 LAMPS ILLUMINATION BATT A6 15A FUSE 17 11 C9 366 16 PK OR 15 JUNCTION BLOCK ZG RHD 8W 44 INTERIOR LIGHTING 8W 44 13 ZGR04412 J978W 3 ...

Page 1322: ... SENSE SENSE SWITCH AJAR DOOR REAR RIGHT LIFTGATE AJAR SWITCH SENSE C3 1 1 2 1 2 SWITCH AJAR LIFTGATE LIFTGLASS AJAR SWITCH G75 18 TN G77 18 TN OR G74 18 TN RD G76 18 TN YL G78 20 TN BK G78 20 TN BK G78 20 TN BK G78 20 TN BK Z1 20 BK Z1 20 BK Z1 12 BK Z1 12 BK Z1 12 BK G300 S328 S329 S316 9 C321 3 C325 MODULE REAR WIPER 6 TN BK G78 20 6 2 8W 53 4 8W 15 11 8W 15 10 8W 45 11 8W 15 11 8W 45 8 8W 44 1...

Page 1323: ... 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 lighter lamp and A C He...

Page 1324: ... lamps in the mirrors to circuit Z1 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 con nects the lamps to ground on circuit Z1 The lamps are also grounded when the Body Control Module BCM energizes the courtesy lamp re...

Page 1325: ...nt Cluster 8W 45 10 Intermittent Wiper Relay 8W 45 7 Intermittent Wiper Switch 8W 45 7 Junction Block 8W 45 2 3 4 5 7 Key In Switch Halo Lamp 8W 45 3 Left Front Cylinder Lock Switch 8W 45 8 Left Front Door Ajar Switch 8W 45 8 Left Rear Door Ajar Switch 8W 45 8 Component Page Liftgate Ajar Switch 8W 45 11 Liftgate Cylinder Lock Switch 8W 45 8 Liftglass Ajar Switch 8W 45 11 Park Brake Switch 8W 45 9...

Page 1326: ...K OR Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR Z1 16 BK Z1 14 BK Z1 14 BK S205 8 C307 C301 2 S202 CENTER DISTRIBUTION POWER RUN ST A21 C10 5 CONNECTOR LINK DATA 3 11 18 VT BR D1 19 C1 18 WT BK D2 20 C1 CCD BUS BUS CCD S204 S203 18 D1 VT BR WT BK 18 D2 CCD BUS BUS CCD PAIR TWISTED 8W 12 4 8W 12 2 8W 10 13 8W 10 14 8W 10 15 8W 15 18 8W 15 18 8W 15 18 8W 10 7 8W 10 3 8W 10 7 8W 45 2 8W 45 BODY ...

Page 1327: ...ER JUNCTION BLOCK BK 20 Z1 S220 S216 BK 16 Z1 BK 18 Z1 LB 20 G26 KEY IN IGN SWITCH SENSE CONTROL RELAY LAMP COURTESY 2 1 BR LG 20 M112 14 C1 C2 6 87 85 LAMP HALO SWITCH KEY IN HORN RELAY WINDOW REAR 30 85 DEFOGGER RELAY LAMP RELAY COURTESY A5 A3 3 C2 8 C10 8W 44 8 8W 12 9 8W 48 2 8W 39 6 8W 41 2 8W 15 17 8W 15 17 8W 12 2 8W 10 3 8W 10 5 8W 10 3 8W 10 3 ZG RHD 8W 45 BODY CONTROL MODULE 8W 45 3 ZGR0...

Page 1328: ... C2 9 ULTRALIGHT SENSOR DRIVER DRIVER SENSOR ULTRALIGHT F75 18 VT F75 18 VT S201 G69 20 BK LG L109 20 WT L110 20 OR BK SEAT BELT SWITCH SENSE 14 C3 G10 20 LG RD G305 Z1 20 BK Z1 12 BK 2 1 S304 SWITCH BELT SEAT JUNCTION BLOCK MODULE CONTROL BODY LED AUTOMATIC HEADLAMP LIGHT SENSOR VTSS PARK LAMP RELAY 8W 12 14 8W 12 8 8W 12 8 8W 15 15 8W 15 15 8W 10 10 8W 10 11 8W 12 2 8W 45 4 8W 45 BODY CONTROL MO...

Page 1329: ...12 18 HEADLAMP DIMMER SWITCH JUNCTION BLOCK L4 16 VT OR L3 16 RD OR F12 C234 L95 20 DG YL 714 20 BK OR L3 16 RD OR L3 16 RD OR L3 16 RD OR S107 F2 C234 CONTROL RELAY LAMP FOG 85 RELAY FOG LAMP 85 RELAY HEADLAMP AUTOMATIC C10 C10 8W 12 24 8W 50 2 8W 12 24 8W 50 6 8W 50 3 8W 12 2 8W 50 2 ZG RHD 8W 45 BODY CONTROL MODULE 8W 45 5 ZGR04504 J978W 3 ...

Page 1330: ...ARK 1 LOW 0 OFF SWITCH HEADLAMP 6 COURTESY LAMP SENSE SWITCH HEADLAMP AUTOMATIC L35 20 BR WT 707 20 BK WT L24 20 LB RD 2 1 0 3 FOG LAMP SWITCH MODULE CONTROL BODY 6 C1 3 M11 20 PK LB SWITCHED COURTESY LAMP FEED Z1 16 BK S202 Z1 14 BK 2 C301 G304 Z1 14 BK 8W 15 18 8W 15 18 8W 50 7 8W 50 5 8W 45 6 8W 45 BODY CONTROL MODULE ZG RHD J978W 3 ZGR04505 ...

Page 1331: ... TN BK V66 18 VT WT V66 18 VT WT V66 16 VT WT V18 20 YL LG V18 20 YL LG 709 20 RD BK 13 20 C235 10 17 S120 RUN ACC A31 JUNCTION BLOCK 20A 1 BREAKER CIRCUIT 12 7 8 4 SWITCH MULTI FUNCTION PART OF SWITCH WIPER INTERMITTENT F86 16 LG BK V6 16 DB V6 16 DB S207 F18 C234 C1 F86 16 LG RD F86 16 LG RD F86 16 LG RD S122 C1 C4 C2 C3 INTERMITTENT WIPER SWITCH PART OF MULTI FUNCTION SWITCH 8W 47 12 8W 53 3 8W...

Page 1332: ...K CYLINDER LIFTGATE CYLINDER FRONT RIGHT LEFT FRONT CYLINDER G71 20 VT YL G71 20 VT YL G71 20 VT YL G71 20 VT YL G71 20 VT YL G71 20 VT YL 3 C321 14 C351 14 C334 1 1 1 SWITCH LOCK SWITCH LOCK LEFT REAR DOOR AJAR SWITCH SENSE DOOR AJAR SENSE SWITCH LEFT FRONT SWITCH DOOR SENSE AJAR FRONT RIGHT DOOR AJAR SENSE SWITCH RIGHT REAR VTSS DISARM SENSE 6 8W 39 5 8W 39 5 8W 39 5 8W 39 5 8W 45 8 8W 45 BODY C...

Page 1333: ... C C6 MODULE CONTROL TEMPERATURE AUTOMATIC 2 1 D41 20 LG WT D41 20 LG WT S219 D41 20 LG WT D41 20 LG WT D41 20 LG WT D41 20 LG WT C8 20 DG RD C8 20 DG RD F11 C234 19 C235 11 SWITCH BRAKE PARK S303 G9 20 GY BK G9 18 GY BK G9 20 GY BK 2 C304 G9 16 GY BK 1 BRAKE WARNING SWITCH SENSOR TEMPERATURE AMBIENT A C AMBIENT TEMPERATURE SENSOR SIGNAL ATC MANUAL A C ATC MANUAL A C 8W 40 6 8W 42 6 8W 42 4 8W 42 ...

Page 1334: ... G70 20 BR TN G70 20 BR TN 4 C235 6 HOOD SWITCH VTSS G78 20 TN BK A 8W 45 11 TO S329 9 C321 M4 20 WT LG 6 C302 3 LIFTGATE AJAR SWITCH HOOD SWITCH AJAR LIFTGATE COURTESY LAMP DISABLE DRIVER LAMP PANEL LAMP RECEIVER ASH S214 20 OR E2 E2 20 OR 6 8W 44 12 8W 44 12 8W 44 5 8W 44 11 8W 40 4 8W 44 11 8W 44 11 8W 45 10 8W 45 BODY CONTROL MODULE ZG RHD J978W 3 ZGR04509 ...

Page 1335: ...LIFTGLASS 1 SWITCH AJAR 2 A 8W 45 10 C321 FROM G78 TN BK 20 TN BK G78 20 20 G78 TN BK REAR WIPER MODULE 6 Z1 BK 20 12 BK Z1 20 BK Z1 BK 12 Z1 S328 12 BK Z1 G300 S328 2 8W 15 11 8W 15 10 8W 53 4 ZG RHD 8W 45 BODY CONTROL MODULE 8W 45 11 ZGR04510 J978W 3 ...

Page 1336: ...strument 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 DDM Mechanical Instrument Cluster Memory Seat Module Passenger Door Module ...

Page 1337: ...The BCM senses when the ignition switch is in the START or RUN position on circuit 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 ...

Page 1338: ......

Page 1339: ... 8W 46 6 G304 8W 46 2 4 Graphic Display Module 8W 46 2 3 Headlamp Switch 8W 46 6 Junction Block 8W 46 2 3 4 5 6 Lamp Outage Module 8W 46 6 Power Distribution Center 8W 46 2 4 Component Page Powertrain Control Module 8W 46 6 7 S104 8W 46 6 S121 8W 46 6 S130 8W 46 3 5 S202 8W 46 2 4 S203 8W 46 7 S204 8W 46 7 S205 8W 46 2 4 S209 8W 46 2 4 S212 8W 46 2 4 S214 8W 46 2 4 S216 8W 46 2 4 S302 8W 46 2 4 S3...

Page 1340: ... DRIVER BODY CONTROL MODULE Z2 20 BK OR Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR Z1 20 BK Z1 16 BK Z1 14 BK Z1 14 BK S205 8 C307 S302 2 C301 G304 S202 S216 MODULE DISPLAY GRAPHIC CENTER DISTRIBUTION POWER JUNCTION BLOCK RUN A22 16 C2 8W 10 7 8W 12 2 8W 10 3 8W 10 3 8W 15 17 8W 15 18 8W 15 18 8W 15 18 8W 45 2 8W 15 18 8W 45 10 8W 44 11 8W 44 12 8W 12 6 8W 12 6 8W 12 16 8W 10 12 8W 46 2 8W 46 MESSAGE CEN...

Page 1341: ... B C212 3 1 4 2 G28 20 LG OR G28 20 LG OR T107 20 BK RD T107 20 BK RD 8 C131 10 9 C132 T106 20 GY OR T106 20 GY OR C132 9 T106 20 GY OR G105 Z12 20 BK TN Z12 16 BK TN S130 1 2 3 4 MODULE DISPLAY GRAPHIC JUNCTION BLOCK 4 NEUTRAL 2 P T 4WD 3 F T 4WD FOUR WHEEL DRIVE SWITCH 1 LOW 4WD 8W 15 7 8W 15 7 8W 12 2 ZG RHD 8W 46 MESSAGE CENTER STANDARD 8W 46 3 ZGR04602 J978W 3 ...

Page 1342: ...RIVER BODY CONTROL MODULE Z2 20 BK OR Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR Z1 20 BK Z1 16 BK Z1 14 BK Z1 14 BK S205 8 C307 S302 2 C301 G304 S202 S216 CENTER INFORMATION VEHICLE CENTER DISTRIBUTION POWER JUNCTION BLOCK RUN A22 16 C2 8W 12 2 8W 10 7 8W 10 3 8W 10 3 8W 15 17 8W 15 18 8W 15 18 8W 15 18 8W 15 18 8W 45 10 8W 44 11 8W 44 12 8W 12 6 8W 12 6 8W 12 16 8W 10 12 8W 46 4 8W 46 MESSAGE CENTER OV...

Page 1343: ...2 3 1 4 2 G28 20 LG OR G28 20 LG OR T107 20 BK RD T107 20 BK RD 8 C131 10 9 C132 T106 20 GY OR T106 20 GY OR C132 9 T106 20 GY OR G105 Z12 20 BK TN Z12 16 BK TN S130 1 2 3 4 CENTER INFORMATION VEHICLE JUNCTION BLOCK 4 NEUTRAL 2 P T 4WD 3 F T 4WD FOUR WHEEL DRIVE SWITCH 1 LOW 4WD 8W 15 7 8W 15 7 8W 12 2 ZG RHD 8W 46 MESSAGE CENTER OVERHEAD CONSOLE 8W 46 5 ZGR04604 J978W 3 ...

Page 1344: ...L SENSOR G46 20 BK LB 5 C307 LAMP OUTAGE MODULE OTHERS G302 S314 Z1 12 BK Z1 18 BK G46 20 LB BK G46 20 LB BK 9 LAMP OUTAGE MODULE REAR LAMP OUT INDICATOR DRIVER 9 C316 VEHICLE INFORMATION CENTER JUNCTION BLOCK JUNCTION BLOCK SWITCH WARNING HAZARD SIGNAL TURN OR BK L5 1 C5 18 2 ELECTRONIC FLASHER C1 DIESEL GAS PK DB G118 54 MODULE CONTROL POWERTRAIN C4 20 8 C131 G118 PK DB 20 8W 30 29 8W 52 6 8W 52...

Page 1345: ...8 C3 S203 S204 D2 18 WT BK D2 18 WT BK D1 18 VT BR D1 18 VT BR 19 20 C235 10 11 CCD BUS BUS CCD CCD BUS CCD BUS MODULE CONTROL POWERTRAIN PAIR TWISTED PAIR TWISTED PAIR TWISTED TWISTED PAIR 8W 30 18 8W 30 19 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 45 2 ZG RHD 8W 46 MESSAGE CENTER OVERHEAD CONSOLE 8W 46 7 ZGR04606 J978W 3 ...

Page 1346: ... to illuminating the 4WD dis play 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 Z12 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 the GDM to ground on ci...

Page 1347: ...UID WARNING When the low washer fluid switch closes it con nects circuit G29 from the VIC to ground on circuit Z1 The VIC displays the Low 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 ...

Page 1348: ......

Page 1349: ... Park Lamp Relay 8W 47 2 Power Amplifier 8W 47 3 4 5 6 7 9 10 11 13 Power Antenna 8W 47 3 4 Power Antenna Relay 8W 47 3 4 Powertrain Control Module 8W 47 12 Radio 8W 47 2 3 4 8 9 10 12 Rear Speaker 8W 47 11 13 Component Page Right Front Door Speaker 8W 47 5 6 8 Right Instrument Panel Speaker 8W 47 5 6 Right Radio Remote Switch 8W 47 12 Right Rear Door Speaker 8W 47 7 8 11 S202 8W 47 3 4 S203 8W 47...

Page 1350: ...VT BR 20 C1 2 C2 S203 D2 18 WT BK D2 18 WT BK C2 16 C1 5 E2 20 OR E2 20 OR E2 20 OR S214 S209 MODULE CONTROL BODY CCD BUS BUS CCD PANEL LAMP DRIVER PANEL LAMP DRIVER CCD BUS BUS CCD 9 C305 Z5 16 BK Z5 14 BK LB G303 PAIR TWISTED TWISTED PAIR 12 PARK LAMP RELAY 8W 12 14 8W 12 3 8W 12 16 8W 12 2 8W 10 9 8W 10 11 8W 10 12 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 44 12 8W 44 11 8W 45 2 8W 45 10 8W 15 13 ...

Page 1351: ...11 1 C11 C5 4 X60 18 DG RD X60 20 DG RD M POWER ANTENNA EXPORT 1 DOWN X14 20 WT X16 20 GY X17 20 DG G304 Z1 18 BK Z1 16 BK Z1 16 BK Z1 14 BK Z1 14 BK C301 S220 S216 S202 COAX ANTENNA RADIO ANTENNA COAX 2 1 2 JUNCTION BLOCK 2 UP 2 UP 8W 10 12 8W 12 2 8W 15 18 8W 15 17 8W 15 17 8W 15 18 8W 12 11 ZG RHD 8W 47 AUDIO SYSTEM LTD AND POWER AMP 8W 47 3 ZGR04702 J978W 3 ...

Page 1352: ...T A7 2 C11 1 C11 C5 4 X60 18 DG RD X60 20 DG RD M POWER ANTENNA EXPORT 1 DOWN X14 20 WT X16 20 GY X17 20 DG G304 Z1 18 BK Z1 16 BK Z1 16 BK Z1 14 BK Z1 14 BK C301 S220 S216 S202 COAX ANTENNA RADIO ANTENNA COAX 2 1 2 JUNCTION BLOCK 2 UP 2 UP 8W 12 2 8W 10 12 8W 15 18 8W 15 17 8W 15 17 8W 15 18 8W 12 11 8W 47 4 8W 47 AUDIO SYSTEM PREMIUM ZG RHD J978W 3 ZGR04703 ...

Page 1353: ...BK C2 9 X85 16 LG BK POWER AMPLIFIER AMPLIFIED LEFT FRONT AMPLIFIED LEFT FRONT LB DG 16 X80 2 C1 LB BK 20 X80 C307 2 LB DG 16 X80 LB BK 16 X80 S319 C351 8 DB RD 20 X56 RIGHT FRONT DOOR SPEAKER RIGHT INSTRUMENT PANEL SPEAKER VT 20 X54 S335 LB RD 20 X82 C307 1 C351 6 LB RD 16 X82 LB RD 16 X82 LB RD 16 X82 1 C1 FRONT RIGHT AMPLIFIED FRONT RIGHT AMPLIFIED A B B A B A B A ZG RHD 8W 47 AUDIO SYSTEM PREM...

Page 1354: ...G BK C2 11 X85 16 LG BK POWER AMPLIFIER AMPLIFIED LEFT FRONT AMPLIFIED LEFT FRONT LB DG 16 X80 2 C2 LB RD 20 X80 C307 2 LB DG 16 X80 LB DG 16 X80 S319 C351 8 DB RD 20 X56 RIGHT FRONT DOOR SPEAKER RIGHT INSTRUMENT PANEL SPEAKER VT 20 X54 S335 LB BK 20 X82 C307 1 C351 6 LB RD 16 X82 LB RD 16 X82 LB RD 16 X82 1 C2 FRONT RIGHT AMPLIFIED FRONT RIGHT AMPLIFIED A B B A B A B A 8W 47 6 8W 47 AUDIO SYSTEM ...

Page 1355: ...AKER DOOR REAR LEFT RIGHT REAR DOOR SPEAKER C343 C345 C2 1 POWER AMPLIFIER A C343 X93 16 WT RD X52 20 DB WT 3 C1 X94 16 TN RD A C345 X52 20 DB WT AMPLIFIED LEFT REAR REAR RIGHT AMPLIFIED B B AMPLIFIED RIGHT REAR REAR RIGHT AMPLIFIED ZG RHD 8W 47 AUDIO SYSTEM PREMIUM 8W 47 7 ZGR04706 J978W 3 ...

Page 1356: ... 3 RIGHT FRONT FRONT RIGHT 5 C3 C3 4 LEFT FRONT FRONT LEFT 2 C1 B A X53 16 DG X53 20 DG X55 20 BR RD X55 16 BR RD DOOR FRONT LEFT C334 SPEAKER C305 X53 20 DG X55 20 BR RD X54 20 VT YL X56 20 DB X51 20 BR YL X57 20 BR LB X52 20 DB WT X58 20 DB OR 6 6 A A 8 8 B B 14 13 11 10 8 7 5 6 1 2 14 13 11 10 8 7 PAIR TWISTED PAIR TWISTED TWISTED PAIR TWISTED PAIR PAIR TWISTED PAIR TWISTED TWISTED PAIR PAIR TW...

Page 1357: ... X53 20 DG X55 16 BR RD X55 20 BR RD X51 16 BR YL X51 20 BR YL X57 16 BR LB X57 20 BR LB X54 16 VT X54 20 VT YL X56 16 DB X56 20 DB X52 16 DB WT X52 20 DB WT X58 16 DB OR X58 20 DB WT 7 C305 14 13 8 8 13 7 14 11 10 10 11 5 2 6 1 Z5 16 BK LB Z5 16 BK LB Z5 14 BK LB G303 S309 B FUSED 17 C1 ANTENNA 7 FUSE 20A BATT A250 BLOCK JUNCTION F75 16 VT F75 16 VT F75 14 VT S318 ANTENNA C1 C1 C1 C1 C1 C1 C1 C1 ...

Page 1358: ...ER AMPLIFIER RADIO X53 16 DG X53 20 DG X55 16 BR RD X55 20 BR RD X51 16 BR YL X51 20 BR YL X57 16 BR LB X57 20 BR LB X54 16 VT X54 20 VT YL X56 16 DB X56 20 DB X52 16 DB WT X52 20 DB WT X58 16 DB OR X58 20 DB OR 7 C305 14 13 8 8 13 7 14 11 10 10 11 5 2 6 1 Z5 16 BK LB Z5 16 BK LB Z5 14 BK LB G303 S309 B FUSED 17 C1 ANTENNA 7 FUSE 20A BATT A250 BLOCK JUNCTION F75 16 VT F75 16 VT F75 14 VT S318 ANTE...

Page 1359: ... C343 X93 16 WT RD X52 20 DB WT 8 C2 X94 16 TN RD A C345 X58 20 DB OR AMPLIFIED LEFT REAR REAR RIGHT AMPLIFIED B B SPEAKER REAR C D A B X95 16 BR YL X98 16 DB OR X97 16 BR LB X98 16 DB WT 4 C2 C2 6 C2 5 7 C2 AMPLIFIED REAR REAR AMPLIFIED AMPLIFIED REAR REAR AMPLIFIED AMPLIFIED RIGHT REAR AMPLIFIED LEFT REAR B A ZG RHD 8W 47 AUDIO SYSTEM LTD 8W 47 11 ZGR04710 J978W 3 ...

Page 1360: ...R Z2 18 BK OR Z2 18 BK OR Z2 18 BK OR G304 S302 S205 C307 CLOCKSPRING G20 G10 G11 G19 8 MODULE CONTROL POWERTRAIN MODULE CONTROL BODY C235 D1 18 VT BR RADIO LEFT RADIO REMOTE SWITCH RIGHT RADIO REMOTE SWITCH VEHICLE SPEED CONTROL SWITCH HORN 8 7 6 9 10 7 SEEK DN 9 VOL DN 8 SEEK UP 6 PRESET 10 VOL UP 8W 45 2 8W 45 7 8W 30 18 8W 30 19 8W 15 18 8W 15 18 8W 45 2 8W 15 18 8W 30 19 8W 30 32 8W 30 18 8W ...

Page 1361: ...AR HIGH HIGH REAR LEFT 7 C2 C2 5 RIGHT REAR HIGH HIGH REAR RIGHT 6 C2 POWER AMPLIFIER LTD B C D A REAR SPEAKER X95 16 BR YL X97 16 BR LB X96 16 DB OR X98 16 DB WT ZG RHD 8W 47 AUDIO SYSTEM 8W 47 13 ZGR04712 J978W 3 ...

Page 1362: ...d SPEAKERS STANDARD SYSTEM The standard system uses four speakers Circuit X53 feeds the speaker in the left front door Circuit X55 is the return from the speaker to the radio Circuit X54 feeds the right front door speaker Cir cuit X56 is the return from the speaker to the radio From the radio circuit X51 connects to circuit X52 at the jumper harness for the left rear door speaker Circuit X51 and X...

Page 1363: ...ted selection LIMITED PLUS SYSTEM The circuits for the Limited Plus system are the same as the Premium System except for the sound bar mounted on the inside roof headliner just for ward of the liftgate For the speakers housed in the sound bar circuit X95 from the amplifier is the feed for the left speak ers Circuit X97 is the return to the amplifier for the left speakers Circuit X98 from the ampli...

Page 1364: ......

Page 1365: ...ody Control Module 8W 48 2 Fuse 10 8W 48 2 G300 8W 48 2 G304 8W 48 2 Junction Block 8W 48 2 Rear Window Defogger 8W 48 2 Rear Window Defogger Relay 8W 48 2 Component Page Rear Window Defogger Switch 8W 48 2 S202 8W 48 2 S216 8W 48 2 S316 8W 48 2 S328 8W 48 2 S332 8W 48 2 ZG 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

Page 1366: ...WITCH DEFOGGER WINDOW REAR BODY CONTROL MODULE 2 G304 Z1 14 BK Z1 14 BK Z1 16 BK Z1 20 BK S202 S216 2 C301 C15 12 BK WT C15 12 BK WT 1 C301 2 C322 LIFTGLASS OTHERS C15 12 BK LB C15 12 BK LB C15 12 BK S332 DEFOGGER WINDOW REAR JUNCTION BLOCK 3 C6 BATT A900 10 2 SWITCH POD PART OF 3 8W 10 4 8W 12 2 8W 15 17 8W 15 18 8W 15 18 8W 45 3 8W 45 9 8W 12 9 8W 15 10 8W 45 11 8W 15 11 8W 15 11 8W 48 2 8W 48 R...

Page 1367: ...window defogger relay on circuit C14 When the BCM grounds the rear window defogger relay coil the contacts close and connect circuit A900 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 circui...

Page 1368: ......

Page 1369: ...49 2 Courtesy Lamp Relay 8W 49 3 Fuse 6 8W 49 2 Fuse 16 8W 49 3 G304 8W 49 3 Junction Block 8W 49 2 3 Overhead Console 8W 49 2 3 Powertrain Control Module 8W 49 2 S202 8W 49 3 Component Page S203 8W 49 2 S204 8W 49 2 S216 8W 49 3 S220 8W 49 3 S321 8W 49 3 S322 8W 49 3 S323 8W 49 2 S334 8W 49 3 ZG 8W 49 OVERHEAD CONSOLE 8W 49 1 ...

Page 1370: ...0 C1 MODULE CONTROL BODY 6 FUSE 15A 3 RUN A22 BLOCK JUNCTION C15 1 IGN FUSED RUN F83 20 YL DG F83 20 YL DG S323 CCD BUS BUS CCD BUS CCD CCD BUS CCD BUS BUS CCD MODULE CONTROL POWERTRAIN PAIR TWISTED PAIR TWISTED TWISTED PAIR PAIR TWISTED PAIR TWISTED 8W 10 8 8W 30 18 8W 30 19 8W 12 7 8W 12 2 8W 12 6 8W 45 2 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 49 2 8W 49 OVERHEAD CONSOLE ZG RHD J978W 3 ZGR04901 ...

Page 1371: ...1 18 BK M2 20 YL M2 20 YL M2 20 YL S334 Z1 16 BK Z1 14 BK Z1 14 BK G304 S202 S216 2 C301 OVERHEAD CONSOLE OTHERS 30 87 IN JB RELAY LAMP COURTESY JUNCTION BLOCK 16 BK Z1 8W 12 2 8W 10 12 8W 44 8 8W 15 17 8W 15 18 8W 15 18 8W 12 21 8W 15 17 8W 12 21 8W 15 16 8W 12 13 8W 12 2 8W 12 12 ZG RHD 8W 49 OVERHEAD CONSOLE 8W 49 3 ZGR04902 J978W 3 ...

Page 1372: ...ity The overhead console receives the fuel percentage and distance information on the CCD bus from the Powertrain Control Module PCM The overhead 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 c...

Page 1373: ... 8W 50 8 Left Fog Lamp 8W 50 6 Left Front Park Lamp 8W 50 9 Left Front Turn Signal Lamp 8W 50 9 Left Headlamp 8W 50 3 Left Headlamp Leveling Motor 8W 50 11 Park Brake Switch 8W 50 4 Park Lamp Relay 8W 50 7 8 Power Distribution Center 8W 50 2 4 6 Radio 8W 50 8 Right Fog Lamp 8W 50 6 Component Page Right Front Park Lamp 8W 50 10 Right Front Turn Signal Lamp 8W 50 10 Right Headlamp 8W 50 3 Right Head...

Page 1374: ... TN BK F34 16 TN BK L3 16 RD OR TO C234 C1 9 BODY CONTROL MODULE DIMMER SWITCH LOW BEAM OUTPUT CONTROL RELAY HEADLAMP AUTOMATIC 12 C2 L4 16 VT OR C234 TO L4 16 VT OR 714 20 BK OR B 8W 50 3 A 8W 50 3 CENTER DISTRIBUTION POWER JUNCTION BLOCK 1 2 1 3 SWITCH 3 HIGH 2 FLASH TO PASS 1 LOW AUTOMATIC HEADLAMP RELAY 8W 12 2 8W 10 3 8W 10 3 8W 45 5 8W 12 16 8W 10 11 8W 10 12 8W 50 2 8W 50 FRONT LIGHTING ZG ...

Page 1375: ...2 3 L3 16 RD OR L4 16 VT OR Z1 16 BK Z1 16 BK Z1 16 BK Z1 14 BK G106 S104 S109 LEFT HEADLAMP RIGHT HEADLAMP OUTPUT BEAM HIGH SWITCH DIMMER MODULE CONTROL BODY 24 B 8W 50 2 A 8W 50 2 F12 C234 L3 16 RD OR C1 BK 16 Z1 16 BK Z1 G109 GAS DIESEL 8W 15 4 8W 15 5 8W 45 5 8W 15 4 8W 15 5 8W 15 6 8W 15 7 8W 15 6 8W 15 7 ZG RHD 8W 50 FRONT LIGHTING 8W 50 3 ZGR05002 J978W 3 ...

Page 1376: ...1 BRAKE WARNING SWITCH 2 C304 S303 G9 20 GY BK G9 18 GY BK SWITCH BRAKE PARK G9 20 GY BK MODULE CONTROL BODY C3 2 BRAKE SWITCH SENSE 8W 45 9 8W 40 6 8W 50 4 8W 50 FRONT LIGHTING ZG RHD J978W 3 ZGR05003 ...

Page 1377: ...ADLAMP SWITCH SENSE DRIVER SENSOR LIGHT ULTRA 2 C2 C2 9 ULTRA LIGHT SENSOR SIGNAL 3 4 LED VTSS SENSOR LIGHT HEADLAMP AUTOMATIC L109 20 WT L110 20 OR BK 2 Z1 14 BK S202 3 LOW 2 PARK 0 OFF 1 AUTO SWITCH HEADLAMP 3 2 0 1 3 2 0 1 1 S209 OR 20 E2 OR 20 E2 C2 PANEL LAMPS DRIVER 16 SWITCH MULTI FUNCTION PART OF 8W 44 11 8W 15 18 8W 10 11 8W 45 5 8W 15 18 ZG RHD 8W 50 FRONT LIGHTING 8W 50 5 ZGR05004 J978W...

Page 1378: ... LAMP FOG L39 20 LB L39 18 LB 1 2 1 2 L39 18 LB L39 18 LB S105 Z1 18 BK Z1 18 BK Z1 16 BK Z1 10 BK S109 S104 G106 RELAY LAMP FOG LAMP FOG LEFT RIGHT FOG LAMP CENTER DISTRIBUTION POWER JUNCTION BLOCK GAS DIESEL Z1 14 BK 8W 12 2 8W 10 3 8W 10 3 8W 15 6 8W 15 7 8W 52 8 8W 52 8 8W 12 24 8W 45 5 8W 10 13 8W 50 6 8W 50 FRONT LIGHTING ZG RHD J978W 3 ZGR05005 ...

Page 1379: ...LAMP 6 5 15 C1 C2 21 L79 20 TN L90 20 DB RD L35 20 BR WT Z1 16 BK Z1 14 BK Z1 14 BK S202 C301 G304 PARK LAMP RELAY CONTROL SENSE SWITCH LAMP FOG MODULE CONTROL BODY JUNCTION BLOCK 366 16 PK OR 3 2 0 1 4 16 PANEL LAMP DIMMER 20 C2 BK WT 707 20 8 SWITCH SENSE 2 8W 10 11 8W 12 2 8W 45 4 8W 45 6 8W 15 18 8W 15 18 8W 12 14 ZG RHD 8W 50 FRONT LIGHTING 8W 50 7 ZGR05006 J978W 3 ...

Page 1380: ...O C102 TO C150 S103 C 8W 50 9 D 8W 50 10 JUNCTION BLOCK 30 85 4 C8 DB RD 20 L90 4 C1 RADIO L90 20 DB RD 11 5 C8 CENTER VEHICLE INFORMATION PARK LAMP RELAY OUTPUT 3 MODULE LAMP OUTAGE 4 OUTPUT RELAY PARK LAMP LAMP PARK RELAY OUTPUT 5 DB RD 18 L90 4 C8 OPTIONAL DB RD L90 18 L90 DB RD 18 C1 C1 C1 8W 51 2 8W 46 6 8W 47 2 8W 12 2 8W 10 11 8W 45 4 8W 12 14 8W 50 8 8W 50 FRONT LIGHTING ZG RHD J978W 3 ZGR...

Page 1381: ... C234 S409 S147 S103 FROM Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 16 BK L64 18 TN DB G106 3 C102 S109 S149 16 G A SWITCH WARNING HAZARD SIGNAL TURN LEFT TURN SIGNAL FEED LAMP PARK FRONT SIGNAL INDICATOR LEFT TURN LEFT L65 LG DB 18 8W 52 2 8W 15 4 8W 15 4 8W 15 5 8W 15 6 8W 15 7 8W 52 8 8W 15 5 8W 40 4 ZG RHD 8W 50 FRONT LIGHTING 8W 50 9 ZGR05008 J978W 3 ...

Page 1382: ...D S150 S103 FROM 1 C4 5 C4 11 C1 Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 14 BK G106 3 C150 S104 7 11 S152 FEED SIGNAL TURN RIGHT TURN SIGNAL HAZARD WARNING SWITCH FRONT PARK LAMP INDICATOR SIGNAL RIGHT TURN RIGHT C150 S408 TN DB 18 L64 8W 12 17 8W 52 2 8W 15 6 8W 15 7 8W 15 6 8W 15 7 8W 15 6 8W 15 7 8W 52 8 8W 12 2 8W 40 4 8W 50 10 8W 50 FRONT LIGHTING ZG RHD J978W 3 ZGR05009 ...

Page 1383: ...04 4 3 2 1 S114 S113 S112 S115 S110 S111 L101 20 RD L101 20 RD L106 20 YL L106 20 YL L105 20 PK L105 20 PK L102 20 WT L102 20 WT L103 20 LB L103 20 LB L104 20 LG L104 20 LG H5 C236 H4 H3 H6 H7 H2 6 2 8 7 3 4 5 SWITCH LEVELING HEADLAMP F83 18 YL DG 1 G304 Z1 20 BK Z1 14 BK Z1 14 BK S202 2 C301 FROM BLOCK JUNCTION GROUND FUSED IGN RUN 8W 15 18 8W 12 2 ZG RHD 8W 50 FRONT LIGHTING 8W 50 11 ZGR05010 J9...

Page 1384: ... 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 on circuit L3 when the headlamp switch is off and the ig...

Page 1385: ... Power Distribution Center PDC powers the relay coil and contacts When the fog lamp relay energizes it connects cir cuit F62 from fuse 19 in the Power Distribution Cen ter PDC to circuit L39 Circuit L39 powers the fog lamps and the fog lamp switch LED Circuit Z1 pro vides ground for the lamps and the LED ZG 8W 50 FRONT LIGHTING 8W 50 13 DESCRIPTION AND OPERATION Continued ...

Page 1386: ......

Page 1387: ...Junction Block 8W 51 2 5 6 7 Lamp Outage Module 8W 51 2 3 4 5 6 7 Left Back Up Lamp 8W 51 6 Left License Lamp 8W 51 6 Left Rear Fog Lamp 8W 51 7 Left Tail Stop Lamp 8W 51 3 4 Park Lamp Relay 8W 51 2 Park Neutral Position Switch 8W 51 5 Component Page Rear Fog Lamp Relay A 8W 51 7 Right Back Up Lamp 8W 51 6 Right License Lamp 8W 51 6 Right Rear Fog Lamp 8W 51 7 Right Tail Stop Lamp 8W 51 3 4 S119 8...

Page 1388: ...ONTROL PARK RELAY LAMP OUTPUT F87 18 WT PK 10 3 C13 4 2 6 7 8 S312 L50 18 WT TN L50 18 WT TN L50 18 WT TN L50 18 WT TN LAMP OUTAGE MODULE 4 5 L90 18DB RD L90 18DB RD PARK LAMP RELAY RELAY LAMP PARK PARK LAMP RELAY L90 18 DB RD FUSED STOP LAMP SWITCH SWITCH LAMP STOP STOP LAMP SWITCH INPUT SWITCH LAMP STOP BATT A6 IGN ST RUN INPUT INPUT INPUT INPUT INPUT INPUT C1 C1 C1 C1 C1 C1 C1 C1 8W 12 2 8W 12 ...

Page 1389: ...22 18 LB L22 18 LB B B 1 C320 L74 18 PK BK A LAMP STOP TAIL RIGHT L73 18 PK WT L73 18 PK WT 1 C328 L73 18 PK WT LEFT TAIL STOP LAMP A L87 18 DG WT 1 C326 L87 18 DG WT A C359 L87 20 DG WT 1 LAMP STOP MOUNTED HIGH CENTER LAMP STOP TAIL RIGHT LEFT TAIL STOP LAMP 1 C372 L50 18 WT TN RELAY LAMP STOP TOW TRAILER NO 1 MOUNTED LAMP NO 3 CENTER HIGH STOP 1 CENTER MOUNTED LAMP NO 2 1 STOP HIGH DG WT 20 L87 ...

Page 1390: ...ELAY LAMP PARK STOP LAMP SWITCH OUPUT STOP LAMP SWITCH OUPUT 5 4 7 6 LAMP OUTAGE MODULE LAMP STOP TAIL RIGHT G B A A B G LEFT TAIL STOP LAMP S411 S417 Z1 18 BK Z1 18 BK Z1 18 BK 4 C328 Z1 18 BK S314 Z1 12 BK Z1 18 BK 4 C320 S316 Z1 18 BK Z1 12 BK G300 C2 C2 C2 C2 8W 15 11 8W 15 11 8W 15 12 8W 15 11 8W 15 9 8W 51 4 8W 51 REAR LIGHTING ZG RHD J978W 3 ZGR05103 ...

Page 1391: ...1 20BK B C359 Z1 18 BK S316 Z1 12 BK Z1 20 BK 7 C326 Z1 18 BK G300 S314 Z1 18 BK Z1 12 BK G302 18 F83 C132 8 YL DG 18 F83 YL DG 18 F83 YL DG 18 F83 S119 18 C235 12 YL DG 18 F83 YL DG 18 F83 S212 BLOCK JUNCTION 1 C8 RUN A22 6 FUSE 15A BR LG 18 L10 PARK NEUTRAL POSITION SWITCH 1 YL DG TO BLOCK JUNCTION A 8W 51 6 BR LG 18 L10 C131 6 SPEED PROPORTIONAL STEERING OTHERS 2 C2 1 C2 C1 DIESEL GAS YL DG 2 F...

Page 1392: ...K LAMP RELAY OUTPUT A 8W 51 5 FROM C131 L10 18 BR LG C14 1 C3 2 JUNCTION BLOCK L10 18 BR LG L10 18 BR LG L10 18 BR LG S311 3 C328 C320 3 L10 18 BR LG L10 18 BR LG G A G A LAMP BACK UP LEFT RIGHT BACK UP LAMP Z1 18 BK S417 Z1 18 BK 4 C320 Z1 18 BK S411 Z1 18 BK Z1 18 BK 4 C328 S314 Z1 18 BK Z1 12 BK G302 TOW CONNECTOR TRAILER FACTORY C2 4 3 AFTERMARKET TRAILER TOW CONNECTOR 8W 54 5 8W 15 12 8W 15 1...

Page 1393: ...A2 C301 L36 18 LG L36 18 LG OR 7 C307 1 1 LAMP OUTAGE MODULE G A L36 18 LG OR L36 18 LG BK 6 C328 LAMP FOG REAR LEFT RIGHT REAR FOG LAMP A G L36 18 LG BK L36 18 LG OR C320 6 Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 12 BK S202 S417 S411 4 C328 4 C320 S316 G300 8W 10 14 8W 10 11 8W 12 2 8W 10 12 8W 10 9 8W 50 2 8W 50 5 8W 50 7 8W 15 18 8W 15 18 8W 15 11 8W 15 9 8W 15 11 8W 15 11 ZG R...

Page 1394: ... Stop 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 REAR FOG LAMPS The rear fog lamps are powered by the rear fog lamp relay on circuit L36 The relay coil and contacts are powered by circuit L95 from fuse 15 in the fuse block T...

Page 1395: ...W 52 8 Park Lamp Relay 8W 52 8 Right Front Park Lamp 8W 52 3 Right Front Side Marker Lamp 8W 52 3 Right Front Turn Signal 8W 52 8 Right Front Turn Signal Lamp 8W 52 3 Right Park Lamp 8W 52 8 Right Rear Turn Signal Lamp 8W 52 5 7 Right Side Repeater 8W 52 8 Component Page S103 8W 52 8 S104 8W 52 3 8 S109 8W 52 3 8 S147 8W 52 8 S149 8W 52 8 S150 8W 52 8 S152 8W 52 8 S202 8W 52 2 6 S216 8W 52 2 6 S22...

Page 1396: ... 3 6 INSTRUMENT CLUSTER L65 18 LG DB JUNCTION BLOCK C1 11 1 C4 7 L64 18 TN DB L64 18 TN DB JUNCTION BLOCK 2 1 LEFT TURN SIGNAL INDICATOR INDICATOR SIGNAL TURN RIGHT 0 OFF 2 LT TURN 1 RT TURN SWITCH WARNING HAZARD SIGNAL TURN 4 HAZARD 2 1 4 0 VEHICLE INFORMATION CENTER TO OR BK 18 L5 SWITCH PART OF MULTI FUNCTION 5 C4 G 8W 52 8 TO S412 GAS DIESEL 8W 46 6 8W 12 2 8W 10 8 8W 10 12 8W 12 2 8W 40 4 8W ...

Page 1397: ...L90 S414 DB RD 18 L90 C150 3 B A BK 18 Z1 BK 18 Z1 BK 18 Z1 B A BK 18 Z1 A G TN DB 18 L64 TN DB 18 L64 TN DB 18 L64 Z1 14 BK G106 S104 A 8W 52 2 FROM B 8W 52 2 JUNCTION BLOCK FROM LAMP MARKER SIDE FRONT LAMP PARK FRONT FRONT PARK LAMP FRONT SIDE MARKER LAMP LEFT LEFT RIGHT RIGHT L65 18 LG DB 1 C102 F10 C234 HAZARD WARNING SWITCH TURN SIGNAL 8W 15 5 8W 12 15 8W 12 15 8W 15 7 8W 15 7 ZG RHD 8W 52 TU...

Page 1398: ...2 L5 18 OR BK L12 18 VT TN C 8W 52 5 D 8W 52 5 JUNCTION BLOCK FLASHER ELECTRONIC 4 VEHICLE INFORMATION CENTER L5 18 OR BK 2 1 0 OFF 2 LT TURN 1 RT TURN SWITCH WARNING HAZARD SIGNAL TURN 4 HAZARD 2 1 4 0 PART OF MULTI FUNCTION SWITCH 8W 46 6 8W 52 2 8W 10 8 8W 12 2 8W 12 6 8W 52 4 8W 52 TURN SIGNALS ZG RHD J978W 3 ZGR05203 ...

Page 1399: ... 18 Z1 BK 18 Z1 G300 LAMP SIGNAL TURN REAR RIGHT A G C320 5 LG 18 L61 TN 18 L60 LG 18 L61 4 L61 18 LG C372 5 1 1 RELAY TURN LEFT TOW TRAILER TRAILER TOW RIGHT TURN RELAY C 8W 52 4 D 8W 52 4 TURN SIGNAL HAZARD WARNING SWITCH TO TO SWITCH WARNING HAZARD SIGNAL TURN 8W 15 12 8W 15 12 8W 15 9 8W 15 11 8W 15 11 8W 15 11 8W 54 3 8W 54 3 ZG RHD 8W 52 TURN SIGNALS FACTORY TRAILER TOW 8W 52 5 ZGR05204 J978...

Page 1400: ...1 14 BK Z1 14 BK S220 S216 S202 2 C301 G304 L61 18 DG E 8W 52 7 TO C307 F 8W 52 7 TO C307 L60 18 TN JUNCTION BLOCK 2 1 SWITCH WARNING HAZARD SIGNAL TURN 2 1 4 0 VEHICLE INFORMATION CENTER TO OR BK 18 L5 MULTI FUNCTION SWITCH PART OF 4 HAZARD 2 LT TURN 0 OFF 1 RT TURN 8W 46 6 8W 12 2 8W 10 8 8W 10 12 8W 15 18 8W 15 18 8W 15 17 8W 15 17 8W 12 6 8W 12 11 8W 52 6 8W 52 TURN SIGNALS ZG RHD J978W 3 ZGR0...

Page 1401: ...BK 18 Z1 BK 18 Z1 BK 18 Z1 G300 LAMP SIGNAL TURN REAR RIGHT A G C320 5 TN 18 L60 LG 18 L61 E 8W 52 6 F 8W 52 6 C307 C14 8 20A FUSE 8 BATT A250 JUNCTION BLOCK D S315 F70 14 PK BK F70 14 PK BK TURN SIGNAL HAZARD WARNING SWITCH TO TO SWITCH WARNING HAZARD SIGNAL TURN 8W 54 4 8W 15 12 8W 15 12 8W 15 9 8W 15 11 8W 15 11 8W 15 11 8W 12 8 8W 10 10 8W 12 2 8W 12 8 ZG RHD 8W 52 TURN SIGNALS AFTERMARKET TRA...

Page 1402: ...90 18 DB RD S103 L90 18 DB RD 2 C102 2 1 RIGHT PARK LAMP L90 18 DB RD L90 18 DB RD L90 18 DB RD C150 2 S150 S152 C150 3 BK 18 Z1 Z1 18 BK BK 18 Z1 18 Z1 BK Z1 16 BK G106 S104 Z1 18 BK L64 18 LG DB C150 1 LG DB 18 L64 LG DB 18 L64 LG DB 18 L64 S408 G 8W 52 2 TURN SIGNAL HAZARD WARNING FROM JUNCTION BLOCK FROM RIGHT SIDE REPEATER SIGNAL TURN FRONT RIGHT 1 2 2 1 87 IN JB RELAY LAMP PARK SWITCH 8W 50 ...

Page 1403: ...rear turn signal lamps on circuits L60 and L61 and the front turn signal and side marker lamps on circuits L64 and L65 TURN SIGNALS When the 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 Circu...

Page 1404: ......

Page 1405: ...ction Block 8W 53 2 4 Lift Gate Ajar Switch 8W 53 5 Lift Glass Ajar Switch 8W 53 5 Rear Washer Pump Motor 8W 53 5 Rear Wiper Module 8W 53 4 Rear Wiper Motor 8W 53 4 Component Page Rear Wiper Washer Switch 8W 53 4 S120 8W 53 3 S121 8W 53 2 3 5 S122 8W 53 3 S315 8W 53 4 S316 8W 53 5 S328 8W 53 5 S329 8W 53 5 S336 8W 53 4 Vehicle Information Center 8W 53 5 Windshield Washer Pump Motor 8W 53 2 Windshi...

Page 1406: ...0 18 LG WT V51 18 WT V11 18 TN BK V11 18 TN BK C234 F1 V11 18 TN BK A B Z2 18 BK G109 Z2 12 BK S121 MOTOR PUMP WASHER WINDSHIELD B 8W 53 3 JUNCTION BLOCK M 0 1 5 6 C235 BR WT BR WT 5 V3 18 16 14 V3 18 WIPER MOTOR WINDSHIELD 6 RD YL V4 18 C234 F4 RD YL V4 18 BR WT V3 9 18 2 3 4 5 0 0 M 8 7 DB 16 V6 DB 16 V6 16 DB V6 F18 C234 MULTI FUNCTION SWITCH PART OF S121 BK 12 Z2 G109 BK 18 Z2 4 8W 52 8 8W 15 ...

Page 1407: ... VT WT F86 16 LG RD 5 6 INTERMITTENT WIPER SWITCH V4 18 RD YL V4 18 RD YL F4 C234 V3 18 BR WT V3 18 BR WT C235 16 14 1 2 4 3 Z2 18 BK Z2 12 BK S121 G109 RELAY WIPER INTERMITTENT S120 B 8W 53 2 A 8W 53 2 V18 20 YL LG 10 C235 20 V18 20 YL LG F86 16LG RD F86 16 LG RD BODY CONTROL MODULE INTERMITTENT CONTROL RELAY WIPER C2 23 C4 IN PDC 8W 45 7 8W 15 4 8W 15 5 8W 15 4 8W 15 5 8W 53 2 8W 45 7 ZG RHD 8W ...

Page 1408: ... BR LG V13 18 BR LG V24 18 BR OR V24 18 BR OR V24 18 BR OR V20 18 WT BK V20 18 BK WT V20 18 BK WT 6 C307 3 C305 4 V20 18 WT BK V20 18 WT BK F17 C234 REAR WASHER PUMP MOTOR TO REAR WIPER MOTOR F70 16 PK BK 1 6 4 C324 TO S329 TO S328 Z1 14 BK G78 20 TN BK RUN ACC A31 1 ON 2 INTERMITTENT REAR WIPER WASHER SWITCH 0 OFF D 8W 53 5 C 8W 53 5 2 1 0 3 4 E 8W 53 5 M JUNCTION BLOCK 2 4 9 11 8W 10 9 8W 10 10 ...

Page 1409: ...325 FROM C234 V20 18 WT BK 1 2 MOTOR PUMP WASHER REAR Z2 18 BK Z2 18 BK G109 Z2 16 BK A B 13 VEHICLE INFORMATION CENTER G29 20 BK TN G29 16 BK TN F7 C234 S121 Z1 20 BK WASHER FLUID LEVEL SENSE C 8W 53 4 D 8W 53 4 E 8W 53 4 SENSOR LEVEL FLUID WIPER G78 20 TN BK M 2 8W 44 14 8W 45 11 8W 15 10 8W 15 11 8W 15 11 8W 15 4 8W 15 5 8W 46 6 8W 15 4 8W 15 5 ZG RHD 8W 53 WIPERS 8W 53 5 ZGR05304 J978W 3 ...

Page 1410: ...uit A1 from fuse 8 in the Power Distribution Center PDC to circuit A31 Circuit A31 powers circuit V23 through fuse 3 in the junction block Circuit 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 th...

Page 1411: ...5 Junction Block 8W 54 2 4 5 Lamp Outage Module 8W 54 3 4 5 Park Neutral Position Switch 8W 54 2 4 S311 8W 54 2 4 S312 8W 54 5 S313 8W 54 4 Component Page S314 8W 54 3 S315 8W 54 2 4 5 S330 8W 54 3 S331 8W 54 2 3 Stop Lamp Switch 8W 54 5 Trailer Brake Provision 8W 54 2 4 Trailer Tow Circuit Breaker 8W 54 2 5 Trailer Tow Left Turn Relay 8W 54 3 Trailer Tow Right Turn Relay 8W 54 3 Trailer Tow Stop ...

Page 1412: ...2 C3 C14 1 L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG 3 C331 3 C372 S311 6 C131 7 CONNECTOR TOW TRAILER FACTORY JUNCTION BLOCK JUNCTION BLOCK BATT A250 BREAKER CIRCUIT TOW TRAILER 3 F70 PK BK 16 RELAY LAMP TRAILER TOW STOP 8W 54 3 8W 12 2 8W 12 2 8W 10 10 8W 12 17 8W 44 7 8W 12 8 8W 12 8 8W 54 2 8W 54 TRAILER TOW ZG RHD J978W 3 ZGR05401 ...

Page 1413: ... BK S330 5 6 9 1 4 5 6 C331 4 CONNECTOR TOW TRAILER FACTORY G302 Z1 12 BK Z1 12 BK Z1 12 BK S314 8 C372 L50 18 WT TN L50 18 WT TN 1 C372 2 STOP LAMP SWITCH OUTPUT LAMP OUTAGE MODULE L60 18 TN L60 18 TN L60 18 TN 4 5 12 15 L61 18 LG L61 18 LG L61 18 DG C307 3 4 94 18DG 95 18PK 95 18PK 94 18DG S331 SWITCH WARNING HAZARD SIGNAL TURN 5 4 5 4 C2 8W 52 5 8W 54 2 8W 51 3 8W 15 12 8W 15 12 ZG RHD 8W 54 TR...

Page 1414: ...72 TRAILER BRAKE PROVISION 2 1 SWITCH POSITION NEUTRAL PARK 2 C3 C14 1 L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG L10 18 BR LG 3 C331 3 C372 S311 6 C131 7 S313 BATT A250 JUNCTION BLOCK JUNCTION BLOCK TURN SIGNAL HAZARD WARNING SWITCH AFTERMARKET TRAILER CONNECTOR TOW C2 8W 52 5 8W 12 2 8W 12 2 8W 10 10 8W 52 7 8W 12 17 8W 44 6 8W 51 3 8W 12 8 8W 12 8 8W 54 4 8W 54 TRAILER TOW...

Page 1415: ...UT STOP LAMP SWITCH OUTPUT PARK LAMP RELAY OUTPUT L90 18 DB RD L90 18 DB RD L90 18 DB RD L90 18 DB RD B 3 2 C331 2 C372 CONNECTOR TOW TRAILER FACTORY AFTERMARKET TRAILER TOW CONNECTOR PK BK 14 F70 PK BK 16 F70 S315 A TRAILER TOW CIRCUIT BREAKER B 15A PK BK 16 F70 20A FUSE 8 C14 8 JUNCTION BLOCK BATT A250 6 C331 F70 18 PK BK 4 JUNCTION BLOCK FACTORY AFTERMARKET CIRCUIT BREAKER C372 6 F70 16 PK BK 9...

Page 1416: ...e coil in the relay to ground causing the contacts in the relay to switch from the normally CLOSED position to connect circuits 94 and L60 Circuit 94 is the feed for the contact 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 protecte...

Page 1417: ...n Block 8W 60 2 3 Left Front Power Window Motor 8W 60 2 Left Rear Power Window Motor 8W 60 4 Left Rear Power Window Switch 8W 60 4 Passenger Door Module 8W 60 3 4 Right Front Power Window Motor 8W 60 3 Component Page Right Rear Power Window Motor 8W 60 4 Right Rear Power Window Switch 8W 60 4 S203 8W 60 2 3 S204 8W 60 2 3 S304 8W 60 4 S306 8W 60 2 3 S307 8W 60 2 3 S324 8W 60 2 S325 8W 60 3 S333 8W...

Page 1418: ... D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK S307 S203 12 C334 2 C302 C1 19 20 C1 BODY CONTROL MODULE GROUP POWER OPTION FULL F18 12 TN 3 C334 F18 10 TN C14 7 30A 2 BREAKER CIRCUIT BLOCK JUNCTION CCD BUS BUS CCD CCD BUS BUS CCD BATT A250 1 2 PAIR TWISTED TWISTED PAIR TWISTED PAIR 8W 10 10 8W 12 2 8W 12 7 8W 45 2 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 19 8W 30 32 8W 15 12 8...

Page 1419: ...D2 18 WT BK D2 18 WT BK D2 18 WT BK S307 S203 12 C351 2 C302 C1 19 20 C1 BODY CONTROL MODULE GROUP POWER OPTION FULL F81 12 TN 3 C351 F81 12 TN C14 9 30A 2 BREAKER CIRCUIT BLOCK JUNCTION CCD BUS CCD BUS CCD BUS BUS CCD BATT A250 1 2 C1 C1 C1 C1 C1 PAIR TWISTED TWISTED PAIR TWISTED PAIR 8W 10 10 8W 12 2 8W 12 7 8W 45 2 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 19 8W 30 32 8W 15 14...

Page 1420: ...TCH 1 2 Z1 16 BK Z1 16 BK Z1 12 BK G305 S304 D C343 C345 D S333 G301 BK 12 Z1 BK 16 Z1 BK 16 Z1 2 1 SWITCH WINDOW POWER REAR RIGHT 2 DOWN 1 UP 6 ILLUMINATION SWITCH DOOR REAR RIGHT RIGHT REAR WINDOW DRIVER UP DOWN DRIVER WINDOW REAR RIGHT MODULE DOOR PASSENGER 10 C1 C1 3 4 C1 OR DG 20 E20 OR DB 18 E20 OR DB 18 E20 GY BK 16 Q18 GY BK 14 Q18 GY BK 16 Q18 C351 4 5 7 E C345 2 C330 1 DG WT 16 Q28 DG WT...

Page 1421: ... 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 the window lock out feat...

Page 1422: ...rcuits Q22 and Z1 provide ground The right rear window switch contains a Light Emitting Diode LED The PDM illuminates the LED on circuit E20 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...

Page 1423: ...1 2 Left Rear Door Lock Motor 8W 61 4 Liftgate Lock Motor 8W 61 4 Liftglass Limit Switch 8W 61 5 Liftglass Push Button 8W 61 5 Liftglass Release Solenoid 8W 61 5 Passenger Door Module 8W 61 3 Right Front Door Lock Motor 8W 61 4 Component Page Right Rear Door Lock Motor 8W 61 4 S203 8W 61 2 3 S204 8W 61 2 3 S306 8W 61 2 3 S307 8W 61 2 3 S308 8W 61 4 S310 8W 61 4 S315 8W 61 5 S316 8W 61 5 S324 8W 61...

Page 1424: ...CONTROL MODULE S204 S203 1 2 P34 18 PK BK P35 18 OR VT 5 C1 6 C1 7 C1 9 C1 8 C1 3 C334 12 C1 7 C14 S306 S307 BLOCK JUNCTION CCD BUS BUS CCD CCD BUS BUS CCD 1 2 FULL OPTION GROUP POWER 19 C1 20 C1 BATT A250 D2 18 WT BK MOTOR LEFT FRONT DOOR LOCK M 2 PAIR TWISTED 12 TWISTED PAIR PAIR TWISTED 8W 10 10 8W 12 2 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 45 2 8W 15 12 8W ...

Page 1425: ...8 VT BR D1 18 VT BR D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK D2 18 WT BK C1 19 20 C1 S203 S204 1 2 C302 S307 S306 13 12 C351 2 UNLOCK 1 LOCK MODULE DOOR PASSENGER BODY CONTROL MODULE 1 2 CCD BUS BUS CCD CCD BUS BUS CCD JUNCTION BLOCK C1 C1 C1 C1 C1 C1 PAIR TWISTED PAIR TWISTED TWISTED PAIR 8W 10 10 8W 12 2 8W 45 2 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 15...

Page 1426: ...P34 14 PK BK P34 14 PK BK P34 16 PK BK 1 2 M S310 S308 P34 14 PK BK P34 18 PK BK P2 16 BK WT P2 18 BK WT 3 C323 C C345 3 C330 3 C326 9 C351 10 C351 B A M 1 2 M LIFTGATE LOCK MOTOR P2 16 BK WT P2 18 BK WT P34 14 PK BK P34 18 PK BK C343 C C309 3 S326 S327 MOTOR RIGHT FRONT DOOR LOCK LOCK DOOR REAR RIGHT MOTOR MOTOR LEFT REAR DOOR LOCK 1 1 8W 61 4 8W 61 POWER DOOR LOCKS ZG RHD J978W 3 ZGR06103 ...

Page 1427: ... BK S336 S315 2 C323 A B 1 2 2 1 Z1 12 BK Z1 12 BK Z1 12 BK G301 S328 S316 2 C325 JUNCTION BLOCK SOLENOID RELEASE LIFTGLASS LIFTGLASS SWITCH LIMIT BUTTON LIFTGLASS PUSH 3 7 8 C14 8W 12 2 8W 10 10 8W 15 11 8W 15 10 8W 45 11 8W 15 14 8W 12 8 8W 12 8 8W 12 8 ZG RHD 8W 61 POWER DOOR LOCKS 8W 61 5 ZGR06104 J978W 3 ...

Page 1428: ...ither the passenger door lock switch activates or it receives input from the RKE transmitter the PDM sends the appropriate signal to the DDM 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 fro...

Page 1429: ... Module 8W 62 2 3 Circuit Breaker 2 8W 62 2 3 Driver Door Module 8W 62 2 4 Driver Power Mirror 8W 62 4 G301 8W 62 3 G302 8W 62 2 Junction Block 8W 62 2 3 Passenger Door Module 8W 62 3 5 Component Page Passenger Power Mirror 8W 62 5 S203 8W 62 2 3 S204 8W 62 2 3 S306 8W 62 2 3 S307 8W 62 2 3 S324 8W 62 2 S325 8W 62 3 ZG 8W 62 POWER MIRRORS 8W 62 1 ...

Page 1430: ...CONTROL MODULE Z1 12 BK Z1 12 BK Z1 12 BK S306 S307 S203 S204 Z1 12 BK Z1 12 BK 1 C334 G302 FUSED B CCD BUS BUS CCD C1 C1 C1 C1 C1 C1 BATT A250 BLOCK JUNCTION 30A 2 BREAKER CIRCUIT 7 F81 10 TN 3 C334 C14 FULL OPTION POWER GROUP S324 12 8W 15 12 8W 10 10 8W 12 7 8W 12 2 8W 15 12 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 45 2 8W 62 2 8W 62 POWER MIRRORS ZG RHD J978W ...

Page 1431: ...BODY CONTROL MODULE Z1 12 BK Z1 12 BK Z1 12 BK S306 S307 S203 S204 Z1 12 BK Z1 12 BK 1 C351 G301 FUSED B CCD BUS BUS CCD BATT A250 BLOCK JUNCTION 30A 2 BREAKER CIRCUIT 9 F81 12 TN 3 C351 C14 C1 C1 C1 C1 FULL OPTION POWER GROUP S325 C1 C1 8W 15 14 8W 10 10 8W 12 7 8W 12 2 8W 15 14 8W 30 19 8W 30 32 8W 30 18 8W 30 31 8W 30 18 8W 30 31 8W 30 19 8W 30 32 8W 45 2 ZG RHD 8W 62 POWER MIRRORS 8W 62 3 ZGR0...

Page 1432: ...20 DB F71 20 WT F85 20 GN F86 20 GY F84 20 VT Z1 20 BK C16 20 BK P114 20 YL BK P114 20 YL BK P114 18 YL BK P114 20 YL BK P114 20 BK YL 4 8 9 A B C353 11 C334 7 C302 3 C231 P112 20 BK WT P112 20 YL WT P112 18 YL WT P112 20 YL WT P112 20 YL WT C2 AUTO DAY NIGHT MIRROR MIRROR NIGHT DAY AUTO AUTO DAY NIGHT MIRROR MIRROR NIGHT DAY AUTO MIRROR NIGHT DAY AUTOMATIC C2 C2 C2 C2 C2 C2 C2 8W 44 6 8W 44 7 8W ...

Page 1433: ...IGNAL VERTICAL DRIVER DRIVER COMMON HORIZONTAL DRIVER SENSOR GROUND VERTICAL POSITION SENSOR SIGNAL HEATER SWITCHED GROUND SUPPLY 12V HEATER F75 20 WT F73 20 DB F71 20 YL F85 20 VT F86 20 GY F84 20 GN Z1 20 BK C16 20 BK C2 C2 C2 C2 C2 C2 C2 C2 ZG RHD 8W 62 POWER MIRRORS 8W 62 5 ZGR06204 J978W 3 ...

Page 1434: ...irror to the automatic day night rear view mirror LEFT MIRROR ADJUSTMENT The DDM adjusts the position of the left mirror When an UP adjustment 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...

Page 1435: ...3 11 14 Fuse 12 8W 63 13 14 G304 8W 63 13 14 G305 8W 63 2 3 4 8 9 10 11 12 Heated Seat Switch 8W 63 11 12 13 14 Junction Block 8W 63 2 3 4 8 9 10 13 14 Memory Seat Module 8W 63 2 5 6 7 8 15 Memory Set Switch 1 Set 8W 63 15 Passenger Door Module 8W 63 15 Component Page Passenger Heated Seat Back 8W 63 12 Passenger Heated Seat Cushion 8W 63 12 Passenger Lumbar Motor 8W 63 4 Passenger Lumbar Switch 8...

Page 1436: ...9 DRIVER LUMBAR SWITCH 1 FILL 2 VENT C1 8 19 MEMORY SEAT MODULE 10 1 Z1 16 BK Z1 16 BK F35 16 RD F35 16 RD 1 2 C1 16 LG DB 20 P105 5 JUNCTION BLOCK 12 C2 C2 C2 C2 LUMBAR FORWARD SWITCH SENSE BACKWARD SENSE SWITCH LUMBAR B FUSED B FUSED GROUND GROUND C13 8W 10 12 8W 12 2 8W 15 15 8W 15 15 8W 15 15 8W 12 18 8W 12 18 8W 63 2 8W 63 POWER SEAT ZG RHD J978W 3 ZGR06301 ...

Page 1437: ...107 18 OR BK P106 18 DG WT 1 2 MOTOR LUMBAR DRIVER Z1 18 BK Z1 18 BK S402 Z1 14 BK Z1 16 BK G305 Z1 12 BK S304 2 C329 DRIVER LUMBAR SWITCH 1 FILL 2 VENT 1 2 JUNCTION BLOCK C13 M 8W 12 2 8W 10 12 8W 15 15 8W 15 15 8W 15 15 8W 12 18 8W 12 18 ZG RHD 8W 63 POWER SEAT 8W 63 3 ZGR06302 J978W 3 ...

Page 1438: ...18 DG WT 1 2 MOTOR LUMBAR PASSENGER Z1 18 BK Z1 18 BK S406 Z1 14 BK Z1 16 BK G305 Z1 12 BK S333 2 C335 PASSENGER LUMBAR SWITCH 1 FILL 2 VENT S304 Z1 10 BK 1 2 JUNCTION BLOCK 12 M C13 8W 10 12 8W 12 2 8W 15 15 8W 15 14 8W 15 15 8W 15 13 8W 12 18 8W 12 18 8W 63 4 8W 63 POWER SEAT ZG RHD J978W 3 ZGR06303 ...

Page 1439: ...6 16 DG WT P107 16 OR BK P29 20 BR WT P29 20 BR WT S401 M 6V SENSOR SUPPLY LUMBAR VENT DRIVER DRIVER FILL LUMBAR 3 4 20 DB WT P103 BR RD P28 20 20 S400 BR RD P28 7 C1 LUMBAR SENSOR POSITION 2 C1 GROUND SENSOR 8W 70 4 8W 63 6 ZG RHD 8W 63 POWER SEAT 8W 63 5 ZGR06304 J978W 3 ...

Page 1440: ...16 GY LB MEMORY SEAT MODULE DRIVER POWER SEAT HORIZONTAL MOTOR MOTOR RECLINER SEAT POWER DRIVER BR WT 20 P29 5 BR WT 20 P29 C BR WT 20 P29 SENSOR MOTOR RISER FRONT SEAT POWER DRIVER DRIVER POWER SEAT REAR RISER MOTOR SENSOR MOTOR SENSOR LUMBAR DRIVER M M 6V SENSOR SUPPLY RECLINER DRIVER RECLINER DRIVER HORIZONTAL POSITION SENSE SENSOR GROUND RECLINER POSITION SENSE MOTOR MOTOR C MOTOR MOTOR DRIVER...

Page 1441: ...RD BK P111 16 YL DB P121 16 RD GY P119 16 YL RD MEMORY SEAT MODULE DRIVER POWER SEAT REAR RISER SENSOR SENSOR RISER FRONT SEAT POWER DRIVER MOTOR MOTOR MOTOR RISER FRONT SEAT POWER DRIVER REAR RISER POSITION SENSE GROUND SENSOR SENSE POSITION RISER FRONT REAR RISER DOWN DRIVER DRIVER UP RISER REAR FRONT RISER DOWN DRIVER DRIVER UP RISER FRONT M M 6V SENSOR SUPPLY 8W 63 5 8W 63 6 8W 70 4 ZG RHD 8W ...

Page 1442: ...RY SEAT MODULE BATT A7 Z1 16 BK Z1 14 BK Z1 16 BK Z1 16 BK S304 G305 S402 2 C329 FRONT RISER DOWN SWITCH SENSE SENSE SWITCH UP RISER FRONT SENSE SWITCH DOWN RISER REAR SENSE SWITCH UP RISER REAR SENSE SWITCH FORWARD HORIZONTAL SENSE SWITCH DOWN RECLINER SENSE SWITCH UP RECLINER HORIZONTAL REARWARD SWITCH SENSE JUNCTION BLOCK 4 DOWN 12 C1 C1 C1 C1 C1 C1 C1 C1 C13 8W 10 12 8W 12 2 8W 15 15 8W 15 15 ...

Page 1443: ...44 16 GY LB 4 3 4 3 2 1 4 3 BATT A7 Z1 18 BK Z1 14 BK Z1 10 BK Z1 12 BK S304 G305 S406 2 C329 MOTOR PASSENGER POWER SEAT FRONT RISER 2 1 RISER REAR SEAT POWER PASSENGER MOTOR 2 1 1 2 PASSENGER POWER SEAT HORIZONTAL MOTOR MOTOR RECLINER SEAT POWER PASSENGER B A M M M M S333 Z1 16 BK JUNCTION BLOCK 4 DOWN C14 8W 10 12 8W 12 2 8W 15 14 8W 15 13 8W 15 15 8W 15 15 8W 12 18 8W 12 18 ZG RHD 8W 63 POWER S...

Page 1444: ...T A7 Z1 16 BK Z1 14 BK Z1 12 BK S304 G305 S402 2 C329 MOTOR DRIVER POWER SEAT FRONT RISER 2 1 RISER REAR SEAT POWER DRIVER MOTOR 2 1 1 2 DRIVER POWER SEAT HORIZONTAL MOTOR MOTOR RECLINER SEAT POWER DRIVER B A M M M M Z1 16 BK JUNCTION BLOCK 4 DOWN 2 FWD 3 UP DRIVER POWER SEAT SWITCH 1 BACK 10 C13 8W 10 12 8W 12 2 8W 15 15 8W 15 15 8W 15 15 8W 12 18 8W 12 18 8W 63 10 8W 63 POWER SEAT ZG RHD J978W 3...

Page 1445: ...K P7 18 LB BK Z1 16 BK Z1 14 BK Z1 16 BK Z1 12 BK S407 S402 2 C329 S304 G305 CUSHION SEAT HEATED DRIVER DRIVER HEATED SEAT BACK 1 P7 18 LB BK P7 18 LB BK P7 20 LB 5 C329 3 C301 HEATED SEAT SWITCH A D BK Z1 16 BK Z1 20 B P88 16 BR BK 8W 63 14 8W 15 15 8W 15 15 8W 15 15 ZG RHD 8W 63 POWER SEAT HEATED SEAT 8W 63 11 ZGR06310 J978W 3 ...

Page 1446: ...04 G305 CUSHION SEAT HEATED PASSENGER PASSENGER HEATED SEAT BACK 4 P8 18 LB WT P8 20 LB WT 3 C335 4 C301 HEATED SEAT SWITCH A D BK Z1 16 BK Z1 20 B P88 16 BR BK PASSENGER HEATED SEAT SWITCH OUTPUT HEATED SEAT DRIVER GROUND 16 Z1 BK S333 8W 15 14 8W 63 13 8W 15 15 8W 15 15 8W 15 13 8W 63 12 8W 63 POWER SEAT HEATED SEAT ZG RHD J978W 3 ZGR06311 ...

Page 1447: ...E CONTROL HEATER SEAT PASSENGER P8 18 LB WT P8 18 LB WT S404 4 C301 G304 Z1 20 BK Z1 16 BK Z1 14 BK Z1 14 BK S202 S216 2 C301 S405 SWITCH POD PART OF SWITCH SEAT HEATED FUSED B FUSED IGN RUN OUTPUT SWITCH SEAT HEATED PASSENGER JUNCTION BLOCK 9 C9 C13 1 HIGH 2 LOW 0 OFF 8W 12 2 8W 10 8 8W 10 12 8W 12 18 8W 15 17 8W 15 18 8W 15 18 8W 63 12 8W 12 10 8W 12 10 8W 12 18 8W 12 10 ZG RHD 8W 63 POWER SEAT ...

Page 1448: ...LB BK MODULE CONTROL HEATER SEAT DRIVER P7 18 LB BK P7 18 LB BK S407 3 C301 G304 Z1 20 BK Z1 16 BK Z1 14 BK Z1 14 BK S202 S216 2 C301 S403 SWITCH POD PART OF SWITCH SEAT HEATED FUSED B FUSED IGN RUN DRIVER HEATED SEAT JUNCTION BLOCK C9 C13 1 HIGH 0 OFF 2 LOW 8W 10 12 8W 12 2 8W 10 8 8W 12 18 8W 15 17 8W 15 18 8W 15 18 8W 63 11 8W 12 10 8W 12 10 8W 12 18 8W 12 10 8W 63 14 8W 63 POWER SEAT HEATED SE...

Page 1449: ...18 VT BR 13 12 C351 8 9 D1 18 VT BR D1 18 VT BR 13 C334 D2 18 WT BK D2 18 WT BK 12 C334 SWITCHED MUX LED SUPPLY 5V SUPPLY GROUND CCD BUS CCD BUS BUS CCD BUS CCD CCD BUS CCD BUS MEMORY SEAT MODULE 8 9 C329 DRIVER DOOR MODULE MODULE DOOR PASSENGER C1 C1 C3 C3 C3 C3 C1 C1 SET LED DRIVER 8W 60 3 8W 61 3 8W 62 3 8W 30 18 8W 30 31 8W 30 19 8W 30 32 ZG RHD 8W 63 POWER SEAT MEMORY SEAT 8W 63 15 ZGR06314 J...

Page 1450: ... 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 circuit P11 Circuit P11 connects to the motor Ground is provided on circuit P13 ...

Page 1451: ...er 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 position inputs from five sensors in the driver s seat ...

Page 1452: ...tion detentes have a resistor in series between the detente and cir cuit P7 or P8 Internal to the switch voltage from circuit F71 passes through 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 eit...

Page 1453: ... 8W 64 2 Electronic Flasher 8W 64 2 Fuse 13 8W 64 2 G304 8W 64 2 Junction Block 8W 64 2 S202 8W 64 2 S216 8W 64 2 S220 8W 64 2 Component Page S320 8W 64 2 S322 8W 64 2 Sliding Roof Motor 8W 64 3 Sliding Roof Position Switch 8W 64 3 Sunroof Control Module 8W 64 2 3 Sunroof Switch 8W 64 2 ZG 8W 64 POWER SUNROOF 8W 64 1 ...

Page 1454: ...4 C371 5 C231 5 1 3 2 CLOSE 1 OPEN SWITCH SUNROOF 1 2 F86 16 LG BK Q42 16 LB S320 3 2 C371 Q42 16 WT Q41 16 WT Q41 16 LB MODULE CONTROL SUNROOF FUSED B GROUND GROUND JUNCTION BLOCK 5 C5 1 C15 C4 FUSED IGN RUN ACC SUNROOF SWITCH OUTPUT CLOSED OPEN OUTPUT SWITCH SUNROOF 1 4 3 2 8W 10 9 8W 12 2 8W 10 12 8W 12 5 8W 15 18 8W 15 18 8W 15 17 8W 15 17 8W 15 16 8W 52 2 8W 52 6 8W 12 4 8W 12 11 8W 64 2 8W 6...

Page 1455: ...G ROOF POSITION SWITCH OUTPUT OUTPUT SWITCH POSITION ROOF SLIDING SLIDING ROOF POSITION SWITCH OUTPUT DRIVER MOTOR ROOF SLIDING SLIDING ROOF MOTOR DRIVER MODULE CONTROL SUNROOF 18 WT 18 GN 18 BR 18 BK 18 GN ZG RHD 8W 64 POWER SUNROOF 8W 64 3 ZGR06402 J978W 3 ...

Page 1456: ...ween the switch and the control module The control module then activates the motor and moves the sunroof to the 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 fun...

Page 1457: ...1 8W 65 3 S2 8W 65 3 S3 8W 65 3 S4 8W 65 3 S98 8W 65 3 S99 8W 65 3 S119 8W 65 2 Component Page S121 8W 65 2 S131 8W 65 2 S200 8W 65 2 S212 8W 65 2 Speed Proportional Steering Control Module 8W 65 3 Speed Proportional Steering Module 8W 65 2 Speed Proportional Steering Solenoid 8W 65 3 Steering Wheel Speed Sensor 8W 65 3 Vehicle Speed Sensor 8W 65 2 ZG 8W 65 SPEED PROPORTIONAL STEERING 8W 65 1 ...

Page 1458: ...NECTOR 12 6 C235 D98 20 WT D98 20 WT SCI TRANSMIT SCI RECEIVE 6 5 C132 G7 18 WT OR G7 18 WT OR S131 G7 18 WT OR 3 VEHICLE SPEED SENSOR VEHICLE SPEED SENSOR SIGNAL S121 Z2 20 BK Z2 12 BK G109 GROUND G12 4 MODULE STEERING PROPORTIONAL SPEED 8W 10 8 8W 15 5 8W 15 5 8W 33 3 8W 70 2 8W 30 2 8W 30 2 8W 12 6 8W 12 6 8W 12 2 8W 12 6 8W 65 2 8W 65 SPEED PROPORTIONAL STEERING GAS ENGINES ZG RHD J978W 3 ZGR0...

Page 1459: ...NG CONTROL MODULE SIGNAL B SIGNAL A GROUND SUPPLY 5V S1 20 BK YL S1 20 BK YL S2 20 BK LG S2 20 BK LG S3 20 PK WT S3 20 PK WT S4 20 VT S4 20 VT 2 SOLENOID STEERING PROPORTIONAL SPEED 1 2 CONTROL LOW CONTROL HIGH HIGH CONTROL LOW CONTROL 1 S99 18 LG S98 18 LB ZG RHD 8W 65 SPEED PROPORTIONAL STEERING GAS ENGINES 8W 65 3 ZGR06502 J978W 3 ...

Page 1460: ...EED PROPORTIONAL STEERING CONTROL MODULE Circuit F83 powers the Speed Proportional Steer ing Control Module SPSCM Circuit 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 ve...

Page 1461: ... 10 7 8W 39 2 S211 8W 70 8 S212 8W 12 6 8W 50 11 S214 8W 44 12 S215 8W 12 5 S216 8W 15 17 S218 8W 12 10 S219 8W 42 6 S220 8W 15 17 S221 8W 42 2 5 Component Page S222 8W 42 6 8 S223 8W 42 8 S224 8W 10 6 8W 42 3 S225 8W 10 6 8W 42 3 S226 8W 15 8 8W 42 4 S300 8W 47 5 6 S301 8W 47 5 6 S302 8W 15 18 8W 45 2 S303 8W 45 9 8W 50 4 S304 8W 15 15 S305 8W 39 5 S306 8W 30 19 32 S307 8W 30 18 31 S308 8W 61 4 S...

Page 1462: ...ITION CAMSHAFT 2 S135 S127 4 0L S131 3 G7 18 WT OR WT OR 18 G7 6 G7 18 WT OR MODULE STEERING PROPORTIONAL SPEED G7 18 WT OR 5 C132 POWERTRAIN CONTROL MODULE SENSOR SPEED VEHICLE VEHICLE SPEED SENSOR MODULE CONTROL POWERTRAIN K6 18 VT WT VT WT 18 K6 1 S132 B27 C2 C2 B31 2 VT WT 18 K6 TRANSMISSION SOLENOID ASSEMBLY 8W 31 3 8W 30 17 8W 30 17 8W 33 3 8W 30 17 8W 33 3 8W 30 17 8W 65 2 8W 70 3 8W 30 7 8...

Page 1463: ... C1 3 K4 18 BK LB SENSOR OXYGEN HEATED DOWNSTREAM BK LB 18 K4 3 5 2L SENSOR OXYGEN HEATED UPSTREAM 2 K4 20 BK LB BK LB 18 K4 3 2 K4 20 BK LB 4 0L SENSOR POSITION CRANKSHAFT TRANSMISSION SOLENOID ASSEMBLY 5 2L 4 0L SENSOR POSITION CAMSHAFT A 8W 70 4 S136 5 2L TO S135 8W 30 7 8W 31 3 8W 30 7 8W 30 13 8W 30 13 8W 33 3 8W 30 2 8W 30 3 8W 30 7 8W 30 8 8W 30 13 8W 30 16 8W 30 10 8W 70 2 8W 31 3 8W 70 6 ...

Page 1464: ... MEMORY SEAT MODULE BR RD 20 P28 BR RD 20 P28 A P28 20 BR RD C SENSOR MOTOR HORIZONTAL SEAT POWER DRIVER DRIVER POWER SEAT RECLINER MOTOR SENSOR C BR RD 20 P28 2 C1 SENSOR MOTOR RISER FRONT SEAT POWER DRIVER DRIVER POWER SEAT REAR RISER MOTOR SENSOR A P28 20 BR RD BR RD 20 P28 3 S400 MEMORY SEATS MOTOR SENSOR LUMBAR DRIVER 8W 63 5 8W 63 6 8W 63 7 8W 63 5 8W 63 7 8W 63 7 8W 63 6 8W 63 6 8W 30 8 8W ...

Page 1465: ...L74 PK BK C320 1 PK WT 18 L73 RIGHT TAIL STOP LAMP L50 18 WT TN 6 MODULE OUTAGE LAMP A CONTROLLER ANTI LOCK BRAKE 12 WT TN 18 L50 16 C304 L50 18 WT TN 5 L50 18 WT TN STOP LAMP SWITCH 12 C305 L50 18 WT TN S312 NO 2 NO 3 CENTER HIGH MOUNTED STOP LAMP NO 1 LAMP STOP MOUNTED HIGH CENTER LAMP OUTAGE MODULE TRAILER TOW MODULE OUTAGE LAMP TOW TRAILER TRAILER TOW LAMP OUTAGE MODULE LAMP OUTAGE MODULE TRAI...

Page 1466: ...167 20 BR YL K167 20 BR YL K167 20 BR YL 15 C304 C4 4 MODULE CONTROL POWERTRAIN K167 20 BR YL K167 20 BR YL K167 20 BR YL 12 C132 S141 8W 30 28 8W 30 29 8W 30 28 8W 30 29 8W 70 9 8W 70 6 8W 70 SPLICE INFORMATION DIESEL ENGINE ZG RHD J978W 3 ZGR07005 ...

Page 1467: ...C SHUT DOWN S128 S129 A142 16 DG OR A142 14 DG OR A142 16 DG OR A142 16 DG OR A142 14 DG OR A142 16 DG OR A142 16 DG OR A142 16 DG OR A142 16 DG OR A142 16 DG OR A142 14 DG OR A142 16 DG OR 12 C131 RELAY 8W 30 26 8W 30 22 8W 20 2 8W 30 28 8W 30 27 8W 30 26 8W 30 27 ZG RHD 8W 70 SPLICE INFORMATION DIESEL ENGINE 8W 70 7 ZGR07006 J978W 3 ...

Page 1468: ...OCKSPRING K4 18 BK LB F8 C234 H13 C236 NO CONNECTION K4 18 BK LB K4 18 BK LB K4 18 BK LB K4 20 BK LB K4 20 BK LB K4 20 BK LB K4 20 BK LB 6 C131 S119 S136 33 MODULE MODULE PUMP FUEL BK LB 18 K4 4 8W 30 29 8W 30 29 8W 30 23 8W 31 6 8W 33 3 8W 30 26 8W 30 26 8W 70 8 8W 70 SPLICE INFORMATION DIESEL ENGINE ZG RHD J978W 3 ZGR07007 ...

Page 1469: ...AIN SENSOR PRESSURE OIL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL 12 C132 3 C917 S102 S141 C4 8W 30 29 8W 33 5 8W 30 24 8W 30 24 8W 30 28 8W 30 29 8W 30 29 ZG RHD 8W 70 SPLICE INFORMATION DIESEL ENGINE 8W 70 9 ZGR07008 J978W 3 ...

Page 1470: ......

Page 1471: ...0 12 C141 Diesel 8W 80 13 C150 8W 80 13 C159 8W 80 13 C160 8W 80 13 C182 Diesel 8W 80 13 C206 with Manual A C heater 8W 80 14 C206 with Automatic Temperature Control 8W 80 14 C212 8W 80 15 C229 8W 80 15 C231 8W 80 15 C233 8W 80 15 C234 8W 80 16 Component Page C235 8W 80 16 C236 8W 80 17 C300 8W 80 17 C301 8W 80 17 C302 8W 80 17 C304 8W 80 18 C305 Gas 8W 80 18 C305 Diesel 8W 80 19 C307 8W 80 19 C31...

Page 1472: ...W 80 38 Headlamp Switch 8W 80 39 High Speed Blower Motor Relay 8W 80 39 Horn No 1 8W 80 39 Component Page Horn No 2 8W 80 39 Idle Air Control Motor with 4 0L Engine 8W 80 40 Idle Air Control Motor with 5 2L Engine 8W 80 40 Ignition Coil 8W 80 40 Ignition Switch 8W 80 40 In Car Temperature Sensor 8W 80 40 Injector No 1 8W 80 41 Injector No 2 8W 80 41 Injector No 3 8W 80 41 Injector No 4 8W 80 41 In...

Page 1473: ...ontrol Module C2 8W 80 65 Powertrain Control Module C3 8W 80 66 Powertrain Control Module C4 Diesel 8W 80 67 Component Page Radio C1 8W 80 68 Radio C2 8W 80 68 Radio C3 8W 80 68 Rear Speaker 8W 80 68 Rear Washer Pump Motor 8W 80 69 Rear Wiper Module 8W 80 69 Rear Wiper Washer Switch 8W 80 69 Recirculation Door Actuator with ATC 8W 80 69 Right Airbag Sensor 8W 80 70 Right Back Up Lamp 8W 80 70 Righ...

Page 1474: ...ed Control Servo 8W 80 80 Vehicle Speed Control Horn Switch 8W 80 80 Vehicle Speed Sensor Diesel 8W 80 81 Component Page Vehicle Speed Sensor Gas 8W 80 80 Water In Fuel Sensor Diesel 8W 80 81 Windshield Washer Pump Motor 8W 80 81 Windshield Wiper Motor 8W 80 81 Wiper Fluid Level Sensor 8W 80 81 8W 80 4 8W 80 CONNECTOR PIN OUTS ZG DESCRIPTION AND OPERATION Continued ...

Page 1475: ...SIGNAL FUSED B CAV A B C D L50 18WT TN L90 18DB RD L60 18TN F70 18PK BK CIRCUIT FUNCTION LOW BLOWER MOTOR DRIVER M1 BLOWER MOTOR DRIVER HIGH BLOWER MOTOR DRIVER GROUND M2 BLOWER MOTOR DRIVER CAV 1 2 3 4 5 C4 14TN C5 14LG C7 12BK TN C1 14DG C6 14LB A C HEATER CONTROL C1 BLACK 4 2 3 1 5 CIRCUIT FUNCTION A C PRESSURE SWITCH SENSE A C COMPRESSOR CLUTCH GROUND CAV 1 2 2 C21 18DB OR C3 18DB BK Z1 18BK A...

Page 1476: ...IGNITION FUSED OUTPUT RUN GROUND BACK UP LAMP SWITCH OUTPUT ELECTRIC CHROMATIC MIRROR ELECTRIC CHROMATIC MIRROR CAV 1 2 3 4 5 6 7 F83 20BK VT Z1 20BK L10 20BK RD P112 20BK WT P114 20BK YL AUTOMATIC DAY NIGHT MIRROR BLACK 1 7 12 11 22 CIRCUIT FUNCTION SENSOR RETURN AMBIENT TEMPERATURE SENSOR SIGNAL CAV 1 2 D41 20LG WT C8 20DG RD AMBIENT TEMPERATURE SENSOR BLACK 2 1 CIRCUIT FUNCTION FUSED B VTSS IND...

Page 1477: ...SENSOR SIGNAL PANEL LAMP DRIVER SOLAR SENSOR SIGNAL CAV C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D15 D16 C37 20YL C35 20DG YL C39 20WT C90 20LG C40 20BR WT C43 18YL BR D1 18VT BR D2 18WT BK F71 20DG PK F60 20WT RD C36 20RD WT C38 20DB C42 18PK DB C32 20DB GY C33 20DB RD C41 20GY DB C34 20DB WT Z4 20PK D41 20LG WT C10 20RD TN E2 20OR C47 ...

Page 1478: ...SIGNAL COMMON DOOR DRIVER CAV 1 2 3 4 5 6 C40 20WT YL F71 20PK DG C36 20DB RD C34 20VT WT BLEND DOOR ACTUATOR WITH MANUAL A C HEATER 6 5 4 3 2 1 BLACK CIRCUIT FUNCTION BLOWER MOTOR DRIVER GROUND CAV 1 2 A19 12RD C7 12BK BLOWER MOTOR WITH MANUAL A C HEATER NATURAL 2 1 CIRCUIT FUNCTION HIGH SPEED BLOWER MOTOR RELAY SIGNAL GROUND CAV 1 2 C42 12RD Z4 12BK CIRCUIT FUNCTION LOW BLOWER MOTOR DRIVER M2 BL...

Page 1479: ...SED IGNITION SWITCH OUTPUT START RUN CCD BUS CCD BUS VTSS INDICATOR LAMP DRIVER DIMMER SWITCH HIGH BEAM OUTPUT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 V51 18WT D41 20LG WT C8 20DG RD M11 20PK LB L24 20LB RD C80 20DB YL L4 16VT OR G70 20BR TN G26 20LB L35 20BR WT Z2 20BK OR L90 20DB RD F99 20OR D1 18VT BR D2 18WT BK G69 20BK LG L3 16RD OR BODY CONTROL MODULE C1 BLACK 24 1...

Page 1480: ...TCH OUTPUT ACC RUN PANEL LAMP DRIVER WASHER SWITCH OUTPUT WIPER SWITCH MODE SENSE PANEL LAMP DIMMER SWITCH SIGNAL PARK LAMP RELAY CONTROL FOG LAMP RELAY CONTROL INTERMITTENT WIPER RELAY CONTROL GROUND CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 L109 20WT 709 20RD BK V66 16VT WT M112 20BR LG C90 20LG F75 18VT L110 20OR BK 714 20BK OR X4 20GY OR C14 20WT RD V23 20BR PK E2 20OR...

Page 1481: ...T DOOR AJAR SWITCH SENSE VTSS DISARM SENSE LEFT REAR DOOR AJAR SWITCH SENSE SEAT BELT SWITCH SENSE CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 G78 20TN BK G9 20GY BK G76 18TN YL G75 18TN M4 20WT LG Z2 18BK OR G74 18TN RD G71 20VT YL G77 18TN OR G10 20LG RD BLACK 5 9 14 1 6 10 BODY CONTROL MODULE C3 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 G40 18LB BK F99 20OR G18 20PK BK K4 18BK LB L10 18BR LG G118 2...

Page 1482: ...20PK BK 14 1 8 7 14 1 8 7 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 10 T20 18LB F99 20OR A142 18DG OR F5 14RD YL L10 18BR LG C2 18DB YL G28 20LG OR K4 20BK LB CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 10 T20 18LB F99 18OR A142 18DG OR F5 14RD YL L10 18BR LG C2 18DB YL G28 20LG OR K4 18BK LB K4 20BK LB CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 Z1 18BK Z2 18BK OR T41 20BK WT G7 18WT OR K20 18DG T66 20BR OR F83 18YL DG T106 20...

Page 1483: ...CAV 1 2 3 L64 18LG DB L90 18DB RD Z1 18BK CIRCUIT CAV 1 2 3 L64 18LG DB L90 18DB RD Z1 18BK C150 C150 CIRCUIT CAV 1 2 2 M1 18PK Z1 18BK CIRCUIT CAV 1 2 2 M1 18PK Z1 18PK Z4 18BK C159 CIRCUIT CAV 1 2 A19 12RD VT Z4 12BK CIRCUIT CAV 1 1 2 A1910RD A19 12RD Z4 12BK C160 C160 GAS DIESEL 1 2 3 1 BLACK 3 1 BLACK 2 1 2 BLACK 1 2 BLACK C159 BLACK 1 2 5 1 6 10 5 1 6 10 CIRCUIT CAV 1 2 3 4 K255 20WT DG K151 ...

Page 1484: ...4 20VT WT Z4 12BK CIRCUIT CAV A B C D E F G H J K L M N P R S C39 20WT C37 20YL C35 20DG YL C36 20RD WT C34 20DB WT F71 20PK DG C33 20DB RD C32 20DB GY C38 20DB C40 20BR WT C41 20GY DB C42 18PK DB C43 18YL BR Z4 20PK D41 20LG WT C206 WITH AUTOMATIC TEMPERATURE CONTROL CIRCUIT CAV A B C D E F G H J K L M N P R S C39 20YL C37 20TN BK C35 20DB WT C36 20DB RD C34 20VT WT F71 20PK DG C33 20VT OR C32 20...

Page 1485: ...141 14YL RD C229 C229 MANUAL TRANS ONLY CIRCUIT CAV 1 2 3 4 5 6 D1 18VT BR D2 18WT BK P112 20YL WT P114 20YL BK F86 16LG BK C231 C231 CIRCUIT CAV 1 2 3 4 5 6 D1 18VT BR D2 18WT BK P112 20YL WT P114 20YL BK F86 16LG BK CIRCUIT CAV E1 E2 E4 E4 A1 12RD WT F61 16WT OR T141 14YL RD CIRCUIT CAV E1 E2 E4 E4 A1 12RD WT F61 16WT OR A41 14YL T141 14YL RD C233 C233 2 1 BLACK 1 2 BLACK RED A B A B RED 2 1 6 3...

Page 1486: ... G18 16PK BK G29 20BK TN K4 18BK LB V32 20YL RD L65 18LG DB C8 20DG RD L3 16RD OR L53 20BR D83 20BK PK D84 20BK WT V20 18WT BK V6 16DB K95 20PK T9 20OR GAS DIESEL CIRCUIT CAV G1 G2 G3 G4 G5 G6 G7 G8 G9 G10 G11 G12 G13 G14 G15 G16 G17 G18 G19 G20 G68 18BR YL V30 20DB LG T106 20GY OR 205 20WT VT D98 20WT G68 18BR YL V18 20YL LG D41 20LG WT S1 20BK YL S2 20BK LG S3 20PK WT S4 20VT V3 18BR WT V66 18VT...

Page 1487: ...06 20YL F99 20OR Z1 18BK Z2 18BK OR C236 CIRCUIT CAV A B R44 18DG YL R42 18BK YL C300 CIRCUIT CAV A B R44 18DB R42 18VT C300 CIRCUIT CAV 1 2 3 4 C15 12BK WT Z1 14BK P7 18LB BK P8 18LB WT C301 CIRCUIT CAV 1 2 3 4 C15 12BK WT Z1 14BK P7 20LB P8 20LB WT C301 CIRCUIT CAV 1 2 3 4 5 6 7 8 D1 18VT BR D2 18WT BK F71 18PK DG E2 18OR P112 18YL WT P114 18YL BK C302 CIRCUIT CAV 1 2 3 4 5 6 7 8 D1 18VT BR D2 1...

Page 1488: ...G DB B4 20LG K4 20BK LB K167 20BR YL L50 18WT TN A64 14DG WT A64 16DG WT C304 CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 V24 18BR OR V20 18BK WT X55 16BR RD X55 16BR RD X53 16DG X53 16DG X54 16VT X54 16VT X56 16DB X56 16DB Z5 14BK LB Z5 14BK LB X51 16BR YL X51 16BR YL X57 16BR LB X57 16BR LB L50 18WT TN X52 16DB WT X52 16DB WT X58 16DB OR X58 16DB OR CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ...

Page 1489: ...G X54 20VT YL X56 20DB Z5 16BK X51 20BR YL X57 20BR LB L50 18WT TN X52 20DB WT X58 20DB OR C305 DIESEL 6 14 1 7 C305 DIESEL 1 BLACK 7 6 14 CIRCUIT CAV 1 2 3 3 4 4 4 5 6 7 8 9 10 11 12 13 14 X82 16LB RD X80 16LB DG A 61 18LG L61 18LG L60 18TN L60 18TN L60 18TN G46 20LB BK V13 18BR LG L36 18LG OR Z2 18BK OR K255 20WT DG K151 20WT K6 20VT WT K22 20OR DB X85 16LG BK X87 16LG RD C307 CIRCUIT CAV 1 2 3 ...

Page 1490: ...AV 4 5 6 9 10 11 G71 20VT YL L78 20DB RD G90 20DB RD C321 C321 OPTIONAL DIESEL BLACK 1 6 3 4 GRAY GRAY 1 3 4 6 BLACK 4 6 5 11 10 9 CONNECTOR RETAINER CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 L36 18LG OR L50 18WT TN L90 18DB RD L90 18DB RD L90 18DB RD L90 18DB RD L90 18DB RD L50 18WT TN L50 18WT TN L50 18WT TN G46 20LB BK F87 18WT PK C316 1 10 5 6 5 6 1 10 BLACK BLACK CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 L36 1...

Page 1491: ...AV 1 2 3 4 5 6 V13 18BR LG V20 18BK WT V24 18BR OR CIRCUIT CAV 4 5 6 9 10 11 V13 18BR LG V24 18BR OR V20 18BK WT C324 BLACK 1 6 3 4 CONNECTOR RETAINER BLACK 6 5 4 11 10 9 CIRCUIT CAV 1 2 Z1 12BK CIRCUIT CAV 2 3 Z1 12BK C325 CIRCUIT CAV 1 2 3 L87 18DG WT Z1 18BK P34 14PK BK CIRCUIT CAV 1 7 8 P34 16PK BK Z1 18BK L87 18DG WT C326 CONNECTOR RETAINER BLACK GRAY BLACK 1 2 1 2 3 2 3 GRAY CONNECTOR RETAIN...

Page 1492: ......

Page 1493: ... WT X53 20DG Q27 16RD BK X55 20BR RD P114 20YL BK P112 20YL WT D2 18WT BK D1 18VT BR G71 20VT YL C334 C335 CIRCUIT CAV 1 2 3 4 F35 16RD Z1 16BK P8 18LB WT F71 18PK DG CIRCUIT CAV 1 2 3 4 F35 14RD Z1 14BK P8 18LB WT F87 18WT BK BLACK 1 8 4 1 BLACK BLACK 4 1 BLACK 7 14 1 8 7 14 C334 C335 C343 CIRCUIT CAV A A B B C D E X93 16WT RD X51 16BR YL X91 16WT BK X57 16BR LB P2 16BK WT Z1 16BK E21 18OR RD CIR...

Page 1494: ... 8 8 9 10 11 12 13 14 Z1 12BK F81 12TN E20 18OR DB Q18 14GY BK X54 16VT X82 16LB RD Q28 14DG WT X56 16DB X80 16LB DG P2 14BK WT P34 14PK BK D2 18WT BK D1 18VT BR G71 20VT YL CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Z1 12BK F81 12TN E20 18OR DB Q18 16GY BK Q28 16DG WT P2 14BK WT P34 14PK BK D2 18WT BK D1 18VT BR G71 20VT YL C351 WITH PREMIUM RADIO WITH STANDARD RADIO C351 C345 CIRCUIT CAV A B P...

Page 1495: ...T CAV 1 2 3 4 Z1 16BK Q41 16WT Q42 16LB F86 16LG BK C371 CIRCUIT CAV 1 2 3 4 Z1 16BK Q41 16LB Q42 16WT F86 16RD YL CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 L50 18WT TN L90 18DB RD L10 18BR LG L61 18LG L60 18TN F70 16PK BK B40 12LB Z1 12BK C372 WITH FACTORY TRAILER TOW CIRCUIT CAV 1 2 3 4 5 6 7 8 9 10 L50 18WT TN L90 18DB RD L10 18BR LG L61 18LG L61 18LG L60 18TN L60 18TN F70 16PK BK B40 12LB Z1 12BK BLACK...

Page 1496: ...ISABLE CAV A B C M2 20YL M1 20PK M4 20WT LG BLACK C A CARGO LAMP CIRCUIT FUNCTION STOP LAMP SWITCH OUTPUT STOP LAMP SWITCH OUTPUT GROUND GROUND CAV 1 2 L87 20DG WT L87 20DG WT Z1 20BK Z1 20BK BLACK CENTER HIGH MOUNTED STOP LAMP NO 1 1 2 CIRCUIT FUNCTION STOP LAMP SWITCH OUTPUT GROUND CAV 1 2 L87 20DG WT Z1 20BK BLACK CENTER HIGH MOUNTED STOP LAMP NO 2 1 2 CIRCUIT CAV 1 2 3 T40 14LG BK G60 20GY YL ...

Page 1497: ...SOR LEFT REAR WHEEL SPEED SENSOR RIGHT FRONT WHEEL SPEED SENSOR LEFTT FRONT WHEEL SPEED SENSOR G SWITCH NO 1 SENSE G SWITCH NO 2 SENSE GROUND SYSTEM RELAY LEFT REAR WHEEL SPEED SENSOR LEFT FRONT WHEEL SPEED SENSOR STOP LAMP SWITCH OUTPUT G SWITCH SENSOR GROUND ABS WARNING LAMP DRIVER RIGHT REAR WHEEL SPEED SENSOR RIGHT FRONT WHEEL SPEED SENSOR SCI RECEIVE FUSED IGNITION SWITCH OUTPUT RUN GROUND FU...

Page 1498: ...75 18VT DATA LINK CONNECTOR 16 9 8 1 BLACK DIESEL CIRCUIT FUNCTION SENSOR GROUND CRANKSHAFT POSITION SENSOR SIGNAL CAV 1 2 3 K4 20BK LB K24 20GY BK CIRCUIT FUNCTION 5 VOLT SUPPLY SENSOR GROUND CRANKSHAFT POSITION SENSOR SIGNAL CAV 1 2 3 K25 20WT BK K4 20BK LB K27 18RD LG CRANKSHAFT POSITION SENSOR DIESEL CRANKSHAFT POSITION SENSOR GAS CIRCUIT FUNCTION ENGINE COOLANT LEVEL SENSE GROUND CAV 1 2 G18 ...

Page 1499: ...1 16LB Q21 16WT Q17 16DB WT Q27 16RD BK P34 18PK BK P35 18OR VT Z1 12BK D1 18VT BR D2 18WT BK E21 18OR M1 20PK F81 12TN 1 6 12 10 9 7 DRIVER DOOR MODULE C1 WHITE CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT GROUND SENSOR GROUND DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL CAV 1 2 3 4 A142 18DG OR Z12 18BK TN K4 18BK LB K141 18BK PK BLACK DOWNSTREAM HEATED OXYGEN SENSOR 2 4 1 3 CIRCUIT FUNCTION HORI...

Page 1500: ...CUIT FUNCTION GROUND HEATED SEAT DRIVER CAV A B Z1 16BK P88 16BR BK BLACK DRIVER HEATED SEAT BACK A B CIRCUIT FUNCTION HEATED SEAT DRIVER HEATED SEAT DRIVER DRIVER HEATED SEAT SWITCH OUTPUT GROUND CAV A B C D P87 16BK OR P88 16BR BK P7 18LB BK Z1 20BK BLACK DRIVER HEATED SEAT CUSHION D A C B CIRCUIT FUNCTION LUMBAR FORWARD DRIVER LUMBAR REARWARD DRIVER CAV 1 2 P106 18DG WT P107 18OR BK BLACK DRIVE...

Page 1501: ...RD LB CIRCUIT FUNCTION 6 VOLT SENSOR SUPPLY HORIZONTAL POSITION SENSE SENSOR GROUND CAV A B C P29 20BR WT P25 20VT RD P28 20BR RD BLACK DRIVER POWER SEAT HORIZONTAL MOTOR SENSOR C A WITH MEMORY SEATS RED DRIVER POWER SEAT FRONT RISER MOTOR 1 2 CIRCUIT FUNCTION FRONT RISER DOWN DRIVER FRONT RISER DOWN SWITCH SENSE FRONT RISER UP DRIVER FRONT RISER UP SWITCH SENSE CAV 1 2 P121 16RD GY P21 16RD LG P1...

Page 1502: ...FUNCTION REAR RISER DOWN DRIVER REAR RISER DOWN SWITCH SENSE REAR RISER UP DRIVER REAR RISER UP SWITCH SENSE CAV 1 2 P113 16RD BK P13 16RD WT P111 16YL DB P11 16YL WT RED DRIVER POWER SEAT REAR RISER MOTOR 1 2 CIRCUIT FUNCTION SENSOR GROUND REAR RISER POSITION SENSE 6 VOLT SENSOR SUPPLY CAV A B C P28 20BR RD P27 20LB RD P29 20BR WT BLACK DRIVER POWER SEAT REAR RISER MOTOR SENSOR C A CIRCUIT FUNCTI...

Page 1503: ... SWITCH SENSE REAR RISER UP SWITCH SENSE REAR RISER UP SWITCH SENSE REAR RISER DOWN SWITCH SENSE REAR RISER DOWN SWITCH SENSE FRONT RISER DOWN SWITCH SENSE FRONT RISER DOWN SWITCH SENSE CAV 1 2 2 3 3 4 4 5 6 6 7 7 8 8 9 9 10 10 Z1 16BK P40 18GY LB P43 16GY LB P17 18RD LB P17 16RD LB P48 18GY WT P41 16GY WT F35 16RD P15 18YL LB P15 16YL LB P19 18YL LG P19 16YL LG P11 18YL WT P11 16YL WT P13 18RD WT...

Page 1504: ...OLENOID GROUND CAV 1 2 4 A142 16DG OR K35 16GY YL Z1 18BK EGR SOLENOID DIESEL CIRCUIT FUNCTION ENGINE COOLANT TEMPERATURE SENSOR SIGNAL SENSOR GROUND SECONDARY ENGINE COOLANT TEMP SENSOR CAV A B C K2 20TN BK K4 20BK LB K222 20TN RD ENGINE COOLANT TEMPERATURE SENSOR DIESEL DIESEL 2 1 3 4 A B C CIRCUIT FUNCTION ENGINE COOLANT TEMPERATURE SENSOR SIGNAL SENSOR GROUND CAV 1 2 K2 16TN BK K4 16BK LB ENGI...

Page 1505: ...18VT RD BLACK EVAPORATIVE SYSTEM LEAK DETECTION PUMP 4 1 CIRCUIT FUNCTION GROUND TRAILER TOW OUTPUT PARK LAMP RELAY OUTPUT FUSED B LEFT TURN SIGNAL RIGHT TURN SIGNAL BACK UP LAMP SWITCH OUTPUT CAV 1 2 3 4 5 6 7 Z1 12BK B40 12LB L90 18DB RD F70 18PK BK L61 18LG L60 18TN L10 18BR LG 7 4 6 2 3 1 5 FACTORY TRAILER TOW CONNECTOR BLACK BLACK 3 1 FLOOR CONSOLE LAMPS CIRCUIT FUNCTION GROUND PANEL LAMP DRI...

Page 1506: ...OR A142 16DG OR FUEL PUMP MODULE DIESEL CIRCUIT FUNCTION FUEL PUMP RELAY OUTPUT LOW SENSOR RETURN GROUND CAV 1 3 4 6 A64 16DG WT G40 20LB BK K167 20BR YL Z1 16BK FUEL PUMP MODULE GAS CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL TIMING SHUTOFF SOLENOID SHUTOFF CAV 1 2 3 A142 16DG BK D238 16VT K153 20OR FUEL TIMING SOLENOID DIESEL CIRCUIT FUNCTION ELECTRIC PUMP FEED GROUND CAV 1 2 A64 14OR...

Page 1507: ...R K20 18DG YL GENERATOR DIESEL CIRCUIT FUNCTION GROUND AUTOMATIC SHUT DOWN RELAY OUTPUT GENERATOR FIELD DRIVER CAV 1 2 3 4 Z0 8BK K72 18DG VT K20 18DG GENERATOR GAS CIRCUIT FUNCTION BATTERY POSITIVE GLOW PLUG RELAY CONTROL SENSE FUSED IGNITION SWITCH OUTPUT GLOW PLUG RELAY CONTROL CAV 1 2 3 4 A0 10RD K152 16WT A142 16DG OR K154 10GY GLOW PLUG RELAY DIESEL CIRCUIT FUNCTION FUSED B GROUND CAV 1 2 M1...

Page 1508: ...E OR REAR WHEELS IN ALL TIME GROUND CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 G18 20PK BK F60 20RD WT Z2 20BK OR L5 18OR BK G46 20BK LB D1 18VT BR D2 18WT BK E2 20OR L90 20DB RD G29 2OBK TN 107 20BK RD T106 20GY OR F83 18YL DG T19 20YL BK G42 20LB RD G28 20LG OR Z1 20BK GRAPHIC DISPLAY MODULE OR VEHICLE INFORMATION CENTER BLACK 10 1 20 11 CIRCUIT FUNCTION GROUND HD LP LEVELING POSITIO...

Page 1509: ...12 13 14 15 16 E2 20OR Z1 16BK M11 20PK LB L39 20LB Z1 16BK L35 20BR WT L96 20LG RD 707 20BK WT A6 14RD LB F34 16TN BK L24 20LB RD 366 16PK OR L90 20DB RD HEADLAMP SWITCH 9 BLACK 1 16 8 CIRCUIT FUNCTION FUSED B BLOWER MOTOR DRIVER HIGH BLOWER MOTOR RELAY CONTROL FUSED B CAV 1 2 3 4 5 6 A19 14RD VT C42 12BR RD C41 20BR A19 12DG RD HIGH SPEED BLOWER MOTOR RELAY BLACK 1 2 3 4 5 CIRCUIT FUNCTION HORN ...

Page 1510: ...K K59 16VT BK K40 16BR WT K39 16GY RD BLACK IDLE AIR CONTROL MOTOR 4 0L I 6 4 1 CIRCUIT FUNCTION IGNITION COIL NO 1 DRIVER AUTOMATIC SHUT DOWN RELAY OUTPUT CAV 1 2 K19 18GY WT A142 18DG OR IGNITION COIL 1 BLACK 2 CIRCUIT FUNCTION IGNITION SWITCH OUTPUT START IGNITION SWITCH OUTPUT START RUN RED BRAKE WARNING LAMP DRIVER FUSED B IGNITION SWITCH OUTPUT RUN IGNITION SWITCH OUTPUT ACC RUN FUSED B CAV ...

Page 1511: ...12 18TN GRAY 2 FUEL INJECTOR NO 1 1 GRAY 2 FUEL INJECTOR NO 2 1 CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT INJECTOR NO 3 DRIVER CAV 1 2 A142 18DG OR K13 18YL WT GRAY 2 FUEL INJECTOR NO 3 1 CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT INJECTOR NO 4 DRIVER CAV 1 2 A142 18DG OR K14 18LB BR GRAY 2 FUEL INJECTOR NO 4 1 CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT INJECTOR NO 5 DRIVER C...

Page 1512: ...4 5 6 7 8 9 10 11 12 M1 18PK L10 18BR LG L39 18LB F62 18RD T107 20BK RD A6 14RD LB L90 18DB RD F12 20DB WT F86 18LG RD CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT INJECTOR NO 8 DRIVER CAV 1 2 A142 18DG OR K18 18DB YL GRAY 2 FUEL INJECTOR NO 8 WITH 5 2L ENG 1 CIRCUIT FUNCTION GROUND GROUND FUSED B ABS WARNING LAMP DRIVER FUSED IGNITION SWITCH OUTPUT START RUN LEFT TURN SIGNAL INDICATOR LAMP R...

Page 1513: ...TOR LAMP 4 WHEEL DRIVE PART TIME LAMP FUSED IGNITION SWITCH OUTPUT ACC RUN FUSED IGNITION SWITCH OUTPUT ACC RUN FUSED B FUSED B CAV 1 2 3 4 5 6 7 8 9 10 L64 18TN DB 107 20BK RD F30 18RD DB A31 18RD BK L64 18TN DB 107 20BK RD F86 16LG BK F86 16LG BK F75 18VT F75 18VT WITH POWER SUNROOF 7 3 1 10 6 2 JUNCTION BLOCK C5 RED CIRCUIT FUNCTION TURN SIGNAL 2 WHEEL DRIVE OR REAR WHEEL IN ALL TIME GROUND RAD...

Page 1514: ...L REAR FOG LAMP FOG LAMP RELAY OUTPUT GROUND FOG LAMP RELAY CONTROL HORN RELAY CONTROL CAV 1 2 3 4 5 6 7 8 9 10 11 12 X12 18RD GY L11 16LG BK L95 18DG YL A31 18RD BK L12 18VT TN L36 18LG L96 20LG RD L39 20LB Z1 18BK L95 18DG YL X4 20GY OR CIRCUIT FUNCTION FUSED IGNITION SWITCH OUTPUT RUN COURTESY LAMP RELAY OUTPUT FUSED B PARK LAMP SWITCH OUTPUT PARK LAMP SWITCH OUTPUT FUSED B COURTESY LAMP RELAY ...

Page 1515: ...SY LAMP RELAY CONTROL HORN RELAY CONTROL REAR WINDOW DEFOGGER RELAY CONTROL PARK LAMP RELAY CONTROL PARK LAMP SWITCH OUTPUT AUTO HEADLAMP RELAY CONTROL CAV 1 2 3 4 5 6 7 8 9 10 11 12 L95 20DG YL V23 18BR PK L16 18RD LG V23 20BR PK M112 20BR LG X4 20GY OR C14 20WT RD L79 20TN L90 20DB RD 714 20BK OR CIRCUIT FUNCTION POWER ANTENNA UP CONTROL POWER ANTENNA DOWN CONTROL POWER ANTENNA DRIVER CAV 1 2 3 ...

Page 1516: ... 18DG RD F81 10TN F70 14PK BK F81 12TN F35 16RD CIRCUIT FUNCTION GROUND FUSED IGNITION SWITCH OUTPUT RUN FUSED IGNITION SWITCH OUTPUT RUN BACK UP LAMP SWITCH OUTPUT FUSED B COURTESY LAMP RELAY OUTPUT CAV 1 2 3 3 4 5 6 7 8 9 10 11 12 Z1 16BK F83 20YL DG F83 20BK VT L10 20BK RD M1 20PK M2 20YL 8 3 1 2 7 12 JUNCTION BLOCK C15 OVERHEAD CONSOLE BLACK CIRCUIT FUNCTION GROUND KEY IN IGNITION SWITCH SENSE...

Page 1517: ...UTAGE MODULE C2 CIRCUIT FUNCTION NOT USED STOP LAMP SWITCH OUTPUT PARK LAMP RELAY OUTPUT PARK LAMP RELAY OUTPUT PARK LAMP RELAY OUTPUT PARK LAMP RELAY OUTPUT PARK LAMP RELAY OUTPUT STOP LAMP SWITCH OUTPUT STOP LAMP SWITCH OUTPUT STOP LAMP SWITCH OUTPUT REAR LAMP OUT INDICATOR DRIVER FUSED IGNITION SWITCH OUTPUT START RUN CAV 1 2 3 4 5 6 7 8 9 10 L36 18LG OR L50 18WT TN L90 18DB RD L90 18DB RD L90 ...

Page 1518: ...SED B COURTESY LAMP RELAY OUTPUT CAV A B M1 20PK M2 20YL LEFT COURTESY LAMP BLACK CIRCUIT FUNCTION FUSED B GROUND CAV 1 2 M1 20PK Z1 20BK BLACK 1 2 LEFT DOOR COURTESY LAMP CIRCUIT FUNCTION GROUND FOG LAMP RELAY SWITCH OUTPUT CAV 1 2 Z1 18BK L39 18LB LEFT FOG LAMP BLACK 2 1 CIRCUIT FUNCTION VTSS DISARM SENSE GROUND CAV 1 2 G71 20VT YL Z1 20BK BLACK 2 1 LEFT FRONT CYLINDER LOCK SWITCH ...

Page 1519: ...AV A B X53 20DG X55 20BR RD B LEFT FRONT DOOR SPEAKER BLACK A CIRCUIT FUNCTION LEFT FRONT WINDOW DRIVER UP LEFT FRONT WINDOW DRIVER DOWN CAV 1 2 Q11 16LB Q21 16WT BLACK LEFT FRONT POWER WINDOW MOTOR 2 1 CIRCUIT FUNCTION PARK LAMP RELAY OUTPUT GROUND CAV A B L90 18DB RD Z1 18BK WHITE LEFT FRONT PARK LAMP B A CIRCUIT FUNCTION PARK LAMP RELAY OUTPUT TURN SIGNAL SWITCH OUTPUT CAV A B L90 18DB RD L64 1...

Page 1520: ... SENSOR BLACK 2 1 CIRCUIT FUNCTION GROUND DIMMER SWITCH LOW BEAM OUTPUT DIMMER SWITCH HIGH BEAM OUTPUT CAV 1 2 3 Z1 16BK L4 16VT OR L3 16RD OR LEFT HEADLAMP BLACK 1 2 3 CIRCUIT FUNCTION AMPLIFIED LEFT FRONT AMPLIFIED LEFT FRONT CAV A B X87 20LG RD X85 20LG BK LEFT INSTRUMENT PANEL SPEAKER BLACK A B CIRCUIT FUNCTION POSITION 4 POSITION 3 POSITION 2 POSITION 5 POSITION 6 POSITION 1 CAV 1 2 3 4 5 6 L...

Page 1521: ... FUNCTION DOOR UNLOCK DRIVER DOOR LOCK DRIVER CAV 1 2 P34 18PK BK P2 18BK WT LEFT REAR DOOR LOCK MOTOR BLACK 1 2 CIRCUIT FUNCTION LEFT REAR LEFT REAR CAV A B X52 20DB WT X58 20DB OR B LEFT REAR DOOR SPEAKER BLACK A CIRCUIT FUNCTION LEFT FRONT T S FEED PARK LAMP SWITCH OUTPUT GROUND CAV 1 2 3 L65 18LG DB L90 18DB RD Z1 18BK LEFT PARK TURN SIGNAL MARKER 1 2 CIRCUIT FUNCTION REAR FOG LAMP GROUND CAV ...

Page 1522: ...K LAMP SWITCH OUTPUT CAV 1 2 Z1 18BK L22 18LB NATURAL LEFT REAR SIDE MARKER LAMP 1 2 CIRCUIT FUNCTION GROUND LEFT FRONT TURN SIGNAL FEED CAV 1 2 Z1 18BK L65 18LG DB LEFT SIDE REPEATER CIRCUIT FUNCTION TURN SIGNAL SWITCH OUTPUT GROUND CAV A G L60 18TN Z1 18BK BLACK LEFT REAR TURN SIGNAL LAMP A G CIRCUIT FUNCTION LEFT REAR WHEEL SPEED SENSOR LEFT REAR WHEEL SPEED SENSOR CAV A B B3 20LG DB B4 20LG LE...

Page 1523: ...NCTION FUSED B GROUND CAV A B M1 20PK Z1 20BK A LEFT VISOR VANITY MIRROR BLACK B CIRCUIT FUNCTION GROUND LIFTGATE AJAR SWITCH SENSE CAV 1 2 3 Z1 20BK G78 20TN BK 1 LIFTGATE AJAR SWITCH BLACK 3 CIRCUIT FUNCTION VTSS DISARM SENSE GROUND CAV 1 2 G71 20VT YL Z1 20BK 1 LIFTGATE CYLINDER LOCK SWITCH BLACK 2 CIRCUIT FUNCTION DOOR LOCK DRIVER DOOR UNLOCK DRIVER CAV A B P2 16BK WT P34 16PK BK B LIFTGATE LO...

Page 1524: ...6OR PK A LIFTGLASS LIMIT SWITCH NATURAL B CIRCUIT FUNCTION LIFTGLASS PUSH BUTTON OUTPUT LIFTGLASS LIMIT SWITCH OUTPUT CAV 1 2 P100 14OR BR P101 16OR PK 1 LIFTGLASS PUSH BUTTON BLACK 2 CIRCUIT FUNCTION LIFTGLASS PUSH BUTTON OUTPUT GROUND CAV 1 2 P100 14OR BR Z1 14BK 2 LIFTGLASS RELEASE SOLENOID BLACK 1 CIRCUIT FUNCTION SENSOR GROUND MAP SENSOR SIGNAL 5 VOLT SUPPLY CAV 1 2 3 K4 20BK LB K70 18RD WT K...

Page 1525: ...LE SPEED SENSOR SIGNAL SPEED CONTROL ON OFF SWITCH SENSE AUTO SHUT DOWN RELAY POWER GROUND FUEL QUANTITY ACTUATOR GROUND GLOW PLUG RELAY CONTROL SENSE FUEL TIMING SHUTOFF SENSOR SLEEVE POSITION SENSOR SHUTOFF FEED PEDAL POSITION SENSOR 5 VOLT SUPPLY SCI RECEIVE FUEL TEMPERATURE SENSOR SIGNAL LOW IDLE POSITION SWITCH LEFT FRONT DECAY SOLENOID CONTROL CAV 1 2 3 4 5 7 8 11 12 13 14 15 20 23 24 25 26 ...

Page 1526: ...9 20BR WT P28 20BR RD P25 20VT RD P26 20BR P27 20LB RD P47 20LB P103 20DB WT P21 18RD LG P19 18YL LG P13 18RD WT P11 18YL WT P15 18YL LB P17 18RD LB P40 18GY LB P48 18GY WT P105 20LG DB P104 20YL RD D1 20VT BR D2 20WT BK BLACK MEMORY SEAT MODULE C1 1 11 10 20 CIRCUIT FUNCTION GROUND HORIZONTAL FORWARD DRIVER HORIZONTAL REARWARD DRIVER RECLINER REARWARD DRIVER RECLINER FORWARD DRIVER GROUND LUMBAR ...

Page 1527: ...PER SWITCH LOW SPEED OUTPUT WIPER SWITCH LOW SPEED OUTPUT FUSED IGNITION SWITCH OUTPUT ACC RUN FUSED IGNITION SWITCH OUTPUT ACC RUN WIPER SWITCH LOW SPEED OUTPUT RIGHT TURN SIGNAL INDICATOR LAMP LEFT TURN SIGNAL INDICATOR LAMP HAZARD SIGNAL TURN SIGNAL SWITCH OUTPUT TURN SIGNAL SWITCH OUTPUT TURN SIGNAL SWITCH OUTPUT TURN SIGNAL TURN SIGNAL DIMMER SWITCH LOW BEAM OUTPUT DIMMER SWITCH LOW BEAM OUTP...

Page 1528: ...PUT SHAFT SPEED SENSOR SIGNAL OUTPUT SHAFT SPEED SENSOR SIGNAL CAV 1 2 T14 18LG WT T13 18DB BK OUTPUT SHAFT SPEED SENSOR BLACK 1 2 CIRCUIT FUNCTION FUSED IGNITION SWITCH OUTPUT RUN GROUND CCD BUS COURTESY LAMP RELAY OUTPUT CCD BUS FUSED B CAV 1 2 3 4 5 6 F83 20YL DG Z1 20BK D1 18VT BR M2 20YL D2 18WT BK M1 20PK OVERHEAD CONSOLE RED 3 4 1 6 DIESEL CIRCUIT FUNCTION NEEDLE MOVEMENT SENSOR NEEDLE MOVE...

Page 1529: ...AR WINDOW DRIVER DOWN RIGHT FRONT DOOR UNLOCK DRIVER RIGHT FRONT DOOR LOCK DRIVER GROUND CCD BUS CCD BUS RIGHT REAR DOOR SWITCH ILLUMINATION MUX COURTESY LAMP DRIVER FUSED B CAV 1 2 3 4 5 6 7 8 9 10 11 12 Q12 16BR Q22 16VT Q18 16GY BK Q28 16DG WT P34 18PK BK P2 18BK WT Z1 12BK D1 18VT BR D2 18WT BK E20 18OR DB M1 20PK F81 12TN PASSENGER DOOR MODULE C1 WHITE 6 12 7 1 CIRCUIT FUNCTION HORIZONTAL DRI...

Page 1530: ...EAT SWITCH OUTPUT GROUND CAV A B C D P87 16BK OR P88 16BR BK P8 18LB WT Z1 20BK BLACK PASSENGER HEATED SEAT CUSHION A D B C CIRCUIT FUNCTION LUMBAR FORWARD DRIVER LUMBAR REARWARD DRIVER CAV 1 2 P106 18DG WT P107 18OR BK BLACK PASSENGER LUMBAR MOTOR 1 2 CIRCUIT FUNCTION LUMBAR REARWARD DRIVER GROUND FUSE B GROUND LUMBAR FORWARD DRIVER CAV 1 2 3 4 5 P107 18OR BK Z1 18BK F35 18RD Z1 18BK P106 18DG WT...

Page 1531: ...E CAV 1 2 P12 16RD WT P10 16YL WT RED PASSENGER POWER SEAT REAR RISER MOTOR 1 2 CIRCUIT FUNCTION RECLINER DOWN DRIVER RECLINER UP DRIVER CAV A B P42 16GY WT P44 16GY LB BLACK PASSENGER POWER SEAT RECLINER MOTOR A B CIRCUIT FUNCTION GROUND RECLINER UP DRIVER HORIZONTAL REARWARD SWITCH SENSE RECLINER DOWN DRIVER FUSED B HORIZONTAL FORWARD SWITCH SENSE FRONT RISER DOWN SWITCH SENSE REAR RISER DOWN SW...

Page 1532: ...4 16TN RD X54 16VT X58 16DB OR X52 16DB WT X60 18DG RD X92 16TN BK X56 16DB CIRCUIT FUNCTION AMPLIFIED LEFT REAR FUSED B AMPLIFIED LEFT FRONT LEFT REAR LEFT FRONT AMPLIFIED LEFT REAR FUSED B AMPLIFIED LEFT FRONT GROUND GROUND LEFT REAR LEFT FRONT CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X93 16WT RD F75 16VT X87 16LG RD X51 16BR YL X53 16DG X91 16WT BK F75 16VT X85 16LG BK Z5 16BK LB Z5 16BK LB X57 16B...

Page 1533: ...B WT X53 16DG X54 16VT X60 18DG RD Z5 16BK LB F75 16VT POWER AMPLIFIER LTD C1 CIRCUIT FUNCTION AMPLIFIED RIGHT DOOR SPEAKER AMPLIFIED RIGHT SPEAKER DOOR AMPLIFIED LO LEFT REAR SPEAKER AMPLIFIED HI LEFT REAR SPEAKER AMPLIFIED RIGHT REAR SPEAKER AMPLIFIED RIGHT REAR SPEAKER AMPLIFIED HI RELT REAR SPEAKER RIGHT REAR SPEAKER RIGHT REAR SPEAKER AMPLIFIED LO LEFT REAR SPEAKER AMPLIFIED LEFT DOOR SPEAKER...

Page 1534: ...TION SENSOR SIGNAL IDLE AIR CONTROL NO 2 DRIVER IDLE AIR CONTROL NO 1 DRIVER FUSED B THROTTLE POSITION SENSOR SIGNAL UPSTREAM HEATED OXYGEN SENSOR SIGNAL DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL MAP SENSOR SIGNAL GROUND GROUND F99 18OR K4 18BK LB T41 18BK WT K19 18GY WT K27 18RD LG K59 16VT BK K40 16BR WT K21 16BK RD K2 16TN BK K25 18WT BK K24 18GY BK K60 16YL BK K39 16GY RD F5 14RD YL K22 18OR DB K...

Page 1535: ...URE SENSOR SIGNAL OUTPUT SHAFT SPEED SENSOR SIGNAL VEHICLE SPEED SENSOR SIGNAL OUTPUT SHAFT SPEED SENSOR SIGNAL GOVERNOR PRESSURE SIGNAL TRANSMISSION RELAY CONTROL 5 VOLT SUPPLY T54 18VT K17 18DB WT K11 18WT DB K13 18YL WT K38 18GY T59 18PK K20 18DG T22 18DG LB K58 18BR YL K18 18DB YL K12 18TN K14 18LB BR T60 18BR G6 18GY WT T13 18DB BK G7 18WT OR T14 18LG WT T25 18LG T66 20BR OR K6 18VT WT CAV B1...

Page 1536: ...L EVAPORATIVE EMISSION SOLENOID CONTROL A C PRESSURE SWITCH SENSE STOP LAMP SWITCH SENSE VOLTAGE REGULATOR SIGNAL LOW FUEL SENSE SCI RECEIVE CCD BUS SCI TRANSMIT CCD BUS SPEED CONTROL SWITCH SIGNAL C13 18DB RD K900 18PK WT V36 18TN RD V35 18LG RD G68 18BR YL J95 18DG RD V32 18YL RD A142 18DG OR T9 18OR J96 18VT RD T222 18RD YL K81 18DB K52 18PK BK C3 18DB BK L53 18BR K72 18DG VT G40 18LB BK D83 18...

Page 1537: ...WAIT TO START LAMP SCI TRANSMIT CCD BUS VEHICLE SPEED SENSOR SIGNAL ENGINE COOLANT LEVEL SIGNAL AUTOMATIC SHUT DOWN RELAY OUTPUT A C SWITCH SIGNAL G40 18LB BK F6 18WT RD K167 20BR YL K7 20OR WT G18 20PK BK F99 18OR Z12 16BK TN Z12 16BK TN K20 18DG YL K222 20TN RD K48 18OR RD G123 20DG WT G21 20GY LB D83 20BK PK D1 18VT BR L53 20BR K92 20PK G60 20GY YL K185 18OR LB D84 20BK WT D2 18WT BK G7 20WT OR...

Page 1538: ...2 18RD GY F60 20RD WT RADIO C1 GRAY 1 7 CIRCUIT FUNCTION CCD BUS CCD BUS CAV 1 2 D1 18VT BR D2 18WT BK BLACK RADIO C2 2 1 CIRCUIT FUNCTION RADIO 12 VOLT OUTPUT LEFT REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT REAR RIGHT REAR CAV 1 2 3 4 5 6 7 X60 20DG RD X51 20BR YL X52 20DB WT X53 20DG X54 20VT YL X57 20BR LB X58 20DB OR BLACK 1 RADIO C3 7 CIRCUIT FUNCTION CAV A B C D X96 16DB OR X98 16DB WT X97 ...

Page 1539: ...R V20 18BK WT G78 20TN BK BLACK 3 REAR WIPER MODULE 4 1 6 CIRCUIT FUNCTION REAR WIPER MOTOR CONTROL FUSED IGNITION SWITCH OUTPUT ACC RUN REAR WIPER MOTOR CONTROL INT REAR WASHER MOTOR CONTROL REAR WASHER MOTOR CONTROL CAV 1 2 3 4 V13 18BR LG V23 18BR PK V24 18BR OR V20 18WT BK V20 18WT BK REAR WIPER WASHER SWITCH 1 BLACK 4 CIRCUIT FUNCTION RECIRCULATION DOOR MOTOR DRIVER RECIRCULATION DOOR MOTOR D...

Page 1540: ...CUIT FUNCTION BACK UP LAMP SWITCH OUTPUT GROUND CAV A G L10 18BR LG Z1 18BK BLACK RIGHT BACK UP LAMP A G CIRCUIT FUNCTION FUSED B COURTESY LAMP RELAY OUTPUT CAV A B M1 20PK M2 20YL RIGHT COURTESY LAMP BLACK CIRCUIT FUNCTION FUSED B GROUND CAV 1 2 M1 20PK Z1 20BK BLACK 2 1 RIGHT DOOR COURTESY LAMP CIRCUIT FUNCTION GROUND FOG LAMP RELAY OUTPUT CAV 1 2 Z1 18BK L39 18LB RIGHT FOG LAMP 1 2 BLACK ...

Page 1541: ... CAV 1 2 P34 14PK BK P2 14BK WT BLACK 2 1 RIGHT FRONT DOOR LOCK MOTOR CIRCUIT FUNCTION RIGHT FRONT RIGHT FRONT CAV A B X54 20VT X56 20DB RD RIGHT FRONT DOOR SPEAKER BLACK A B CIRCUIT FUNCTION PARK LAMP RELAY OUTPUT GROUND CAV A B L90 18DB RD Z1 18BK WHITE RIGHT FRONT PARK LAMP B A CIRCUIT FUNCTION RIGHT FRONT WINDOW DRIVER UP RIGHT FRONT WINDOW DRIVER DOWN CAV 1 2 Q12 16BR Q22 16VT BLACK RIGHT FRO...

Page 1542: ......

Page 1543: ... LOCK MOTOR BLACK 1 2 CIRCUIT FUNCTION RIGHT REAR RIGHT REAR CAV A B X52 20DB WT X58 20DB OR B RIGHT REAR DOOR SPEAKER BLACK A CIRCUIT FUNCTION PARK LAMP RELAY OUTPUT GROUND CAV 1 2 L90 18DB RD Z1 18BK NATURAL RIGHT PARK LAMP 1 2 CIRCUIT FUNCTION REAR FOG LAMP GROUND CAV A G L36 18LG BK Z1 18BK RIGHT REAR FOG LAMP CIRCUIT FUNCTION RIGHT TURN SIGNAL PARK LAMP SWITCH OUTPUT GROUND CAV 1 2 3 L64 18TN...

Page 1544: ...RIGHT REAR WHEEL SPEED SENSOR CAV A B B1 20YL DB B2 20YL RIGHT REAR WHEEL SPEED SENSOR A B RED CIRCUIT FUNCTION RIGHT REAR WINDOW DRIVER UP RIGHT REAR WINDOW DRIVER UP RIGHT REAR DOOR SWITCH ILLUMINATION RIGHT REAR WINDOW DRIVER DOWN RIGHT REAR WINDOW DRIVER DOWN GROUND CAV 1 2 3 4 5 6 Q18 16GY BK Q12 16BR E20 20OR DG Q28 16DG WT Q22 16VT Z1 16BK 1 4 3 6 RIGHT REAR POWER WINDOW SWITCH BLUE CIRCUIT...

Page 1545: ...IFT INTERLOCK SOLENOID SENSE FUSED IGNITION SWITCH OUTPUT CAV 1 2 L53 20BR F87 20BK WT SHIFT INTERLOCK SOLAR SENSOR CIRCUIT FUNCTION SOLOR SENSOR SIGNAL SENSOR GROUND CAV A B C47 20BK WT D41 20LG WT A RED B 1 BLACK 2 1 BLACK 2 CIRCUIT FUNCTION STOP LAMP SWITCH OUTPUT PARK LAMP SWITCH OUTPUT GROUND CAV A B G L74 18PK BK L21 18LB WT Z1 18BK BLACK RIGHT TAIL STOP LAMP B A G FUNCTION CIRCUIT GROUND RI...

Page 1546: ...PPLY VEHICLE SPEED SENSOR SIGNAL FUSED IGNITION SWITCH OUTPUT RUN STEERING WHEEL SPEED SENSOR SIGNAL B GROUND SCI TRANSMIT SCI RECEIVE STEERING WHEEL SPEED SENSOR SIGNAL A CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 S99 18LG S98 18LB S2 20BK LG S1 20BK YL G7 18WT OR F83 20YL DG S4 20VT Z2 20BK D83 20BK PK D98 20WT S3 20PK WT 14 7 6 1 CIRCUIT FUNCTION SPS SOLENOID CTL HIGH SPS SOLENOID CTL LOW CAV 1 2 S98...

Page 1547: ...VE OFF LAMP DRIVER REAR WINDOW DEFOGGER SWITCH SENSE FUSED REAR WINDOW DEFOGGER RELAY OUTPUT CAV 1 2 3 4 5 6 7 8 9 10 P7 20LB Z1 20BK E2 20OR P8 20LB WT F71 20PK DG T9 20OR G68 20BR YL C80 20DB YL C16 20LB YL SWITCH POD 1 BLACK 10 CIRCUIT FUNCTION GROUND POWER SUNROOF OPEN POWER SUNROOF CLOSE FUSED IGNITION SWITCH OUTPUT CAV 1 2 3 4 Z1 16BK Q41 18WT Q42 18LB F86 18LG BK SUNROOF CONTROL MODULE CIRC...

Page 1548: ...IGNAL GROUND LEFT TURN SIGNAL FACTORY TRAILER TOW RELAY OUTPUTS FACTORY TRAILER TOW RELAY OUTPUTS FACTORY TRAILER TOW RELAY OUTPUTS FACTORY TRAILER TOW RELAY OUTPUTS CAV 1 2 3 4 5 L61 18LG Z1 18BK L61 18LG OR 95 18PK 95 18PK 94 18DG 94 18DG TRAILER TOW LEFT TURN RELAY BLACK 3 5 2 4 1 CAV 3 2 1 5 2L V 8 4 0L I 6 CIRCUIT FUNCTION RIGHT TURN SIGNAL GROUND RIGHT TURN SIGNAL FACTORY TRAILER TOW RELAY O...

Page 1549: ...NAL VARIABLE FORCE SOLENOID CONTROL OVERDRIVE SOLENOID CONTROL TORQUE CONVERTER CLUTCH SOLENOID OUTPUT TRANSMISSION TEMPERATURE SENSOR SIGNAL CAV 1 2 3 4 5 6 7 8 T20 18LB K6 18VT WT K4 18BK LB T25 18LG T59 18PK T60 18BR T22 18DG LB T54 18VT 1 2 3 4 5 6 7 8 BLACK TRANSMISSION SOLENOID ASSEMBLY CIRCUIT FUNCTION FUSED B GROUND CAV 1 2 M1 18PK Z1 18BK UNDERHOOD LAMP BLACK 1 2 GRAY CIRCUIT FUNCTION AUT...

Page 1550: ...UND TURN SIGNAL REAR LAMP OUT INDICATOR DRIVER CCD BUS CCD BUS PANEL LAMP DRIVER PARK LAMP RELAY OUTPUT WASHER FLUID LEVEL SENSE 4 WHEEL DRIVE PART TIME LAMP 4 WHEEL DRIVE FULL TIME LAMP FUSED IGNITION SWITCH OUTPUT RUN 4 WHEEL DRIVE PART TIME LAMP ALL TIME FRONT WHEELS 2 WHEEL DRIVE OR REAR WHEELS IN ALL TIME GROUND CAV 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 G18 20PK BK F60 20RD WT Z2...

Page 1551: ...LG RD V66 18VT WT Z2 18BK V3 18BR WT V4 18RD YL WINDSHIELD WASHER PUMP MOTOR WINDSHIELD WIPER MOTOR BLACK A B BLACK 1 4 3 6 CIRCUIT FUNCTION WASHER FLUID LEVEL SENSE GROUND CAV A B G29 16BK TN Z2 16BK WIPER FLUID LEVEL SENSOR BLACK B A CIRCUIT FUNCTION 8 VOLT SUPPLY SENSOR GROUND VEHICLE SPEED SENSOR SIGNAL CAV 1 2 3 K7 20OR K167 20BR YL G7 20WT OR VEHICLE SPEED SENSOR DIESEL CIRCUIT FUNCTION WATE...

Page 1552: ......

Page 1553: ...enter Floor Console 14 Automatic Day Night Rearview Mirror BK Behind Rear View Mirror 17 Automatic Temperature Control Module BK Left Side of HVAC Housing 14 Battery Temperature Sensor BK Below Battery Tray 3 Blend Air Door Motor BK On Bottom of HVAC Unit N S Blend Air Actuator BK On Bottom of HVAC Unit N S Blower Motor NAT Right Side of HVAC N S Connector Name Number Color Location Fig Blower Mot...

Page 1554: ...ger Seat 19 Connector Name Number Color Location Fig C330 GY In Right Rear Door 21 C334 BK In Left Front Door 20 C335 BK Below Left Rear Passenger Seat 18 C343 BK In Left Rear Door 21 C345 BK In Right Rear Door 21 C351 GY In Right Front Door 20 C353 BK In Left Front Door 20 C359 BK In Liftgate 23 C364 BK In Liftgate 23 C372 BK Right Rear Quarter Panel 22 C906 BK Rear of Engine Diesel 11 C907 BK At...

Page 1555: ...ch GN Under Driver s Seat N S Driver Seat Heater Control Module BK Under Driver s Seat N S Driver Side Airbag YL Lower Instrument Panel 16 Connector Name Number Color Location Fig Duty Cycle EVAP Purge Solenoid BK Front of Left Fender Side Shield 4 Engine Coolant Level Sensor BK Top of Reserve Tank 3 Engine Coolant Temperature Sensor BK On Thermostat Housing Rear of Generator 5 8 Engine Starter Mo...

Page 1556: ...t Panel 15 Connector Name Number Color Location Fig Injector No 1 GY At Injector 5 9 Injector No 2 GY At Injector 5 8 Injector No 3 GY At Injector 5 9 Injector No 4 GY At Injector 5 8 Injector No 5 GY At Injector 5 9 Injector No 6 GY At Injector 5 8 Injector No 7 GY At Injector 9 Injector No 8 GY At Injector 8 Instrument Cluster BK Rear of Instrument Cluster 14 Intake Air Temperature Sensor GY On ...

Page 1557: ...Rear Power Window switch BL In Left Rear Door 21 Left Rear Side Marker Lamp NAT At Lamp N S Connector Name Number Color Location Fig Left Rear Turn Signal Lamp BK At Lamp N S Left Rear Wheel Speed Sensor BK Below Right Rear Passenger Seat 18 Left Side Repeater Lamp BK At Lamp N S Left Tail Stop Lamp BK At Lamp N S Left Visor Vanity Mirror BK Top of Left A Pillar 17 Liftgate Ajar Switch BK In Liftg...

Page 1558: ...rain Control Module C1 BK Right Rear Corner of Engine Compartment At PCM 3 Connector Name Number Color Location Fig Powertrain Control Module C2 WT Right Rear Corner of Engine Compartment At PCM 3 Powertrain Control Module C3 GY Right Rear Corner of Engine Compartment At PCM 3 Radio C1 GY Rear of Radio 14 Radio C2 BK Rear of Radio 14 Radio C3 BK Rear of Radio 14 Rear Speaker BK Rear Door 21 Rear W...

Page 1559: ...ed Proportional Steering Solenoid BK On Power Steering Pump 4 Connector Name Number Color Location Fig Stop Lamp Switch GY Top of Brake Pedal Arm 15 Sunroof Control Module BK Rear of Sunroof N S Sunroof Motor BK Rear of Sun Roof N S Sunroof Switch NAT Center of Headliner Above Rear View Mirror 17 Switch Pod BK Rear of Overdrive Switch N S Throttle Position Sensor BK On Throttle Body 5 9 Trailer To...

Page 1560: ...Fig 1 Front End Lighting 8W 90 8 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1561: ...Fig 2 Engine Compartment Right Side ZG 8W 90 CONNECTOR LOCATIONS 8W 90 9 DESCRIPTION AND OPERATION Continued ...

Page 1562: ...Fig 3 Engine Compartment 8W 90 10 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1563: ...Fig 4 Engine Compartment Left Side ZG 8W 90 CONNECTOR LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued ...

Page 1564: ...Fig 5 Engine Connectors 4 0L Engine 8W 90 12 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1565: ...Fig 6 Charging System Connectors 4 0L Engine ZG 8W 90 CONNECTOR LOCATIONS 8W 90 13 DESCRIPTION AND OPERATION Continued ...

Page 1566: ...Fig 7 Transmission Connectors 4 0L Engine 8W 90 14 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1567: ...Fig 8 Engine Connectors 5 2L Engine ZG 8W 90 CONNECTOR LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued ...

Page 1568: ...Fig 9 Engine Connectors 5 2L Engine 8W 90 16 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1569: ...Fig 10 Transmission Connectors 5 2L ZG 8W 90 CONNECTOR LOCATIONS 8W 90 17 DESCRIPTION AND OPERATION Continued ...

Page 1570: ...Fig 11 Engine Connectors Diesel Engine 8W 90 18 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1571: ...Fig 12 Battery and Starter Motor Connectors Diesel Engine ZG 8W 90 CONNECTOR LOCATIONS 8W 90 19 DESCRIPTION AND OPERATION Continued ...

Page 1572: ...Fig 13 Transmission Connectors Diesel Engine 8W 90 20 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1573: ...Fig 14 Instrument Panel Connectors ZG 8W 90 CONNECTOR LOCATIONS 8W 90 21 DESCRIPTION AND OPERATION Continued ...

Page 1574: ...Fig 15 Instrument Panel Connectors 8W 90 22 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1575: ...Fig 16 Steering Column Connectors ZG 8W 90 CONNECTOR LOCATIONS 8W 90 23 DESCRIPTION AND OPERATION Continued ...

Page 1576: ...Fig 17 Roof Connectors 8W 90 24 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1577: ...Fig 18 Body Connectors Right Side ZG 8W 90 CONNECTOR LOCATIONS 8W 90 25 DESCRIPTION AND OPERATION Continued ...

Page 1578: ...Fig 19 Body Connectors Left Side 8W 90 26 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1579: ...Fig 20 Front Door Connectors ZG 8W 90 CONNECTOR LOCATIONS 8W 90 27 DESCRIPTION AND OPERATION Continued ...

Page 1580: ...Fig 21 Rear Door Connectors 8W 90 28 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1581: ...Fig 22 Factory Trailer Tow ZG 8W 90 CONNECTOR LOCATIONS 8W 90 29 DESCRIPTION AND OPERATION Continued ...

Page 1582: ...Fig 23 Liftgate Connectors 8W 90 30 8W 90 CONNECTOR LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1583: ...Fig 24 Underhood Lamp Fig 25 License Plate Lamps ZG 8W 90 CONNECTOR LOCATIONS 8W 90 31 DESCRIPTION AND OPERATION Continued ...

Page 1584: ......

Page 1585: ...nt 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 S124 Near Vehicle Speed Control Servo T O 1 S125 Near Controller Antilock Brakes 6 Splice Number Location Fig S126 Near A C High Pressure Switch T O 4 0L Engine 1 S126 In Branch to Starter Motor 5 2L Engine 3 ...

Page 1586: ...plice Number Location Fig S222 On HVAC Harness 7 S223 On HVAC Harness 7 S224 On HVAC Harness 7 S225 On HVAC Harness 7 S226 On HVAC Harness 7 S300 Near Left Kick Panel 6 S301 Near Left Kick Panel 6 S302 Near Left Kick Panel 6 S303 Near Branch to Floor Console 8 S304 Near Branch to Floor Console 8 S305 Near Branch to Left Rear Door 8 S306 Near Branch to Left Rear Door 8 S307 Near Branch to Left Rear...

Page 1587: ...Seat Motor T Os N S S405 In Right Power Seat Harness Near Seat Motor T Os N S S406 In Right Power Seat Harness In Branch to Seat Switch N S Splice Number Location Fig S407 In Left Power Seat Harness Near Lumbar Motor T O N S S408 Near Left Front Turn Signal Bulb Socket N S 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...

Page 1588: ...Fig 1 Engine Compartment Splices 8W 95 4 8W 95 SPLICE LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1589: ...Fig 2 Engine Wiring Splices 4 0L Engine ZG 8W 95 SPLICE LOCATIONS 8W 95 5 DESCRIPTION AND OPERATION Continued ...

Page 1590: ...Fig 3 Engine Wiring Splices 5 2L Engine 8W 95 6 8W 95 SPLICE LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1591: ...Fig 4 Engine and Transmission Wiring Splices Diesel Engine ZG 8W 95 SPLICE LOCATIONS 8W 95 7 DESCRIPTION AND OPERATION Continued ...

Page 1592: ...Fig 6 Body Splices Fig 7 HVAC Harness Splices 8W 95 8 8W 95 SPLICE LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1593: ...Fig 5 Instrument Panel Splices 8W 95 8 8W 95 SPLICE LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1594: ...Fig 8 Left Body Side Wiring Splices 8W 95 10 8W 95 SPLICE LOCATIONS ZG DESCRIPTION AND OPERATION Continued ...

Page 1595: ...Fig 10 Roof Wiring Splices Fig 11 Front Door Harness Splices ZG 8W 95 SPLICE LOCATIONS 8W 95 11 DESCRIPTION AND OPERATION Continued ...

Page 1596: ...Fig 9 Right Side Body Wiring Splices ZG 8W 95 SPLICE LOCATIONS 8W 95 11 DESCRIPTION AND OPERATION Continued ...

Page 1597: ...Fig 12 Liftgate Splices ZG 8W 95 SPLICE LOCATIONS 8W 95 13 DESCRIPTION AND OPERATION Continued ...

Page 1598: ......

Page 1599: ... color is available in both three ounce tubes and four and one half ounce power tubes Mois ture in the air causes the sealant 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 G...

Page 1600: ...des for abnormal firing indicators fouled hot oily etc Record cylinder number of spark plug for future reference e Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire f Be sure throttle blades are fully open during the compression check g Insert compression gage adaptor into the No 1 spark plug hole Crank engine until maxi mum pressure is reached...

Page 1601: ...cedures for the use of Plastigage 1 Remove oil film from surface to be checked Plastigage is soluble in oil 2 The total clearance of the main bearings can only be determined by removing the weight of the crankshaft This can be accomplished by either of two methods METHOD 1 PREFERRED Shim the bearings adjacent to the bearing to be checked This will remove the clearance between upper bearing shell a...

Page 1602: ...width of the flattened Plastigage with the scale provided on the package Fig 2 Plastigage generally comes in 2 scales one scale is in inches and the other is a met ric scale Locate the band closest to the same width This band shows the amount of clearance Differ ences in readings between the ends indicate the amount of taper present Record all readings taken refer to Engine Specifications 5 Plasti...

Page 1603: ... INTERNAL COMBUSTION CAN BE HAZARDOUS TO YOUR HEALTH THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER DO NOT WASH SKIN WITH GASOLINE DIESEL FUEL THINNER OR SOLVENTS HEALTH PROBLEMS CAN RESULT DO NOT POLLUTE DISPOSE OF USED ENGINE OIL PROPERLY ENGINE OIL SPECIFICATION CAUTION Do not use non detergent or straight mineral oil when adding or changing crankcase lubricant Engine failure can result API S...

Page 1604: ...case remove engine oil dipstick 3 Wipe dipstick clean 4 Install dipstick and verify it is seated in the tube 5 Remove dipstick with 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 peratu...

Page 1605: ...pter nipple tip gasket end upward to minimize oil spill Remove fil ter from vehicle 5 With a wiping cloth clean the gasket sealing surface Fig 10 of oil and grime 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 tight...

Page 1606: ...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 1607: ...h cylinder according to the tester manufacturer s instructions While testing listen for pressurized air escaping through the throttle body tailpipe and oil filler cap opening Check for bubbles in the radiator coolant All gauge pressure indications should be equal with no more than 25 leakage FOR EXAMPLE At 552 kPa 80 psi input pres sure a minimum of 414 kPa 60 psi should be main tained in the cyli...

Page 1608: ... 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 generally indicates seal leakage or crankshaft damage b Where leakage tends to run straight down possible causes are a porous block distributor seal camshaft bore cup plugs oil galley pipe plugs oil filter runoff and...

Page 1609: ...ced 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 tappet body cylinder The tappet should be replaced A heavy click is caused by a tappet check valve...

Page 1610: ...orn distributor shaft 3 Remove and repair distributor refer to Group 8D Ignition System 4 Dirty or incorrectly gapped spark plugs 4 Clean plugs and set gap refer to Group 8D Ignition System 5 Dirt or water in fuel system 5 Clean system and repalce fuel filter 6 Faulty fuel pump 6 Install new fuel pump 7 Incorrect valve timing 7 Correct valve timing 8 Blown cylinder head gasket 8 Install new cylind...

Page 1611: ...oup 0 Lubrication and Maintenance 2 Low oil pressure 2 Check engine oil level Inspect oil pump relief valve and spring 3 Thin or diluted oil 3 Change oil to correct viscosity 4 Excessive bearing clearance 4 Measure bearings for correct clearance Repair as necessary 5 Connecting rod journal out of round 5 Replace crankshaft or grind journals 6 Misaligned connecting rods 6 Replace bent connecting ro...

Page 1612: ... out otherwise replace the part OIL PRESSURE DROP 1 Low oil level 1 Check engine oil level 2 Faulty oil pressure sending unit 2 Install new sending unit 3 Low oil pressure 3 Check sending unit and check main bearing oil clearance 4 Clogged oil filter 4 Install new oil filter 5 Worn parts in oil pump 5 Replace worn parts or pump 6 Thin or diluted oil 6 Change oil to correct viscosity 7 Excessive be...

Page 1613: ...49 ROCKER ARMS AND PUSH RODS 49 SPECIFICATIONS 4 0L ENGINE SPECIFICATIONS 51 SPECIAL TOOLS SPECIAL TOOLS 54 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 m 225 ft lbs 4...

Page 1614: ...hannels 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 squirt hole oil passes throu...

Page 1615: ...Oil Lubrication System OIL GALLERY CAMSHAFT BEARING NUMBER 1 CAMSHAFT BEARING JOURNAL CAMSHAFT SPROCKET ZG 4 0L ENGINE 9 17 DESCRIPTION AND OPERATION Continued ...

Page 1616: ...tes 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 the camshaft because ...

Page 1617: ...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 groove and pin boss must be clear DO NOT remove metal from the grooves or lands Th...

Page 1618: ...sary 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 cannot be interchanged The top compression ring can be identified by the shiny coating on the outer sealing surface and can be installed with either side up Fig 10 7 The second compression ring has a slight chamfer on the bottom of the inside edge and a...

Page 1619: ...S 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 Fig 12 Compression Ring Chamfer Locat...

Page 1620: ...dth of the insert If the clearance varies it may be caused by either a tapered journal bent connecting rod or foreign material trapped between the insert and cap or rod 8 If the correct clearance is indicated replace ment of the bearing inserts is not necessary Remove the Plastigage from crankshaft journal and bearing insert Proceed with installation 9 If bearing to journal clearance exceeds the s...

Page 1621: ...atterns are illustrated Fig 20 NOTE If any of the crankshaft journals are scored remove the engine for crankshaft repair Inspect the back of the inserts for fractures scrap ings or irregular wear patterns Inspect the upper insert locking tabs for damage Replace all damaged or worn bearing inserts FITTING BEARINGS CRANKSHAFT INSTALLED The main bearing caps numbered front to rear from 1 through 7 ha...

Page 1622: ...age across full width of the crankshaft journal to be checked Install the bearing cap and tighten the bolts to 108 N m 80 ft lbs torque NOTE DO NOT rotate the crankshaft This will cause the Plastigage to shift resulting in an inaccu rate reading Plastigage must not be permitted to crumble If brittle obtain fresh stock Remove the bearing cap Determine the amount of clearance by measuring the width ...

Page 1623: ...haft bore in the cylinder block may be mis aligned which requires cylinder block replacement or machining to true bore Replace the crankshaft or grind to accept the appropriate undersize bearing inserts if Journal diameters 1 through 6 are less than 63 4517 mm 2 4981 inches Journal 7 diameter is less than 63 4365 mm 2 4975 inches Once the proper clearances have been obtained proceed to Crankshaft ...

Page 1624: ...0 254 mm 0 010 in Red Undersize 0 254 mm 0 010 in 2 4901 2 4896 in 0 254 mm 0 010 in Undersize Crankshaft Journal 7 Only Corresponding Bearing Insert Color Code Diameter Upper Insert Size Lower Insert Size Yellow 63 4873 63 4746 mm Yellow Standard Yellow Standard 2 4995 2 4990 in Orange 63 4746 63 4619 mm Yellow Standard Blue Undersize 0 025 mm 0 001 in 2 4996 2 4991 in 0 0127 mm 0 0005 in Undersi...

Page 1625: ... 48 ft lbs torque 3 With the engine insulator assembly and engine bracket in position install the thru bolt and nut Fig 24 Fig 25 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 cushion bracket assembly sup ports the transmission at the rear This bracket is attache...

Page 1626: ...ompartment lamp Remove the hood 3 Remove the radiator drain cock and radiator cap to drain the coolant DO NOT waste usable cool ant If the solution is clean drain the coolant into a clean container for reuse 4 Remove the upper radiator hose and coolant recovery hose Fig 28 5 Remove the lower radiator hose 6 Remove upper radiator support retaining bolts and remove radiator support 7 Remove the fan ...

Page 1627: ...fold 29 Disconnect the vehicle speed sensor wire con nection 30 Remove the exhaust pipe support 31 Remove the engine flywheel converter housing access cover 32 Vehicles with Automatic Transmission a Mark the converter and drive plate location b Remove the converter to drive plate bolts 33 Remove the upper engine flywheel converter housing bolts and loosen the bottom bolts 34 Remove the engine moun...

Page 1628: ...t the fuel rail Verify that the quick connect fitting assem bly fits securely over the fuel lines by giving the fuel lines a firm tug 22 Install the fuel line bracket to the intake manifold 23 Connect the distributor electrical connector and oil pressure switch connector 24 Connect the injection system wires to the injectors 25 Connect the line pressure cable if equipped with automatic transmissio...

Page 1629: ...ylinder head cover and gasket Tighten the mounting bolts to 8 5 N m 75 in lbs torque 3 Connect the CCV hoses 4 Install control cables and bracket on intake manifold and tighten bolts to 8 7 N m 77 in lbs torque 5 Connect control cables to throttle body linkage 6 Snap control cables into cylinder head cover clip 7 Connect negative cable to battery ROCKER ARMS AND PUSH RODS This procedure can be don...

Page 1630: ...seats For vehicles equipped with an air conditioner use a flexible air adaptor when servicing the No 1 cylinder 7 Tap the retainer or tip with a rawhide hammer to loosen the lock from the retainer Use Valve Spring Compressor Tool MD 998772A to compress the spring and remove the locks Fig 34 8 Remove valve spring and retainer Fig 34 9 Remove valve stem oil seals Fig 34 Note the valve seals are diff...

Page 1631: ...o and then suspend the bolt in this position tape around the bolt 17 Remove the engine cylinder head and gasket Fig 35 18 If this was the first time the bolts were removed put a paint dab on the top of the bolt If the bolts have a paint dab on the top of the bolt or it isn t known if they were used before discard the bolts 19 Stuff clean lint free shop towels into the cyl inder bores INSTALLATION ...

Page 1632: ...mp to turn in the opposite direction caus ing the engine to overheat 16 Install the serpentine drive belt and correctly tension the belt refer to Group 7 Cooling System for the proper procedure 17 Install the air cleaner and ducting 18 Install the engine cylinder head cover 19 Connect the hoses to the engine thermostat housing and fill the cooling system to the specified level refer to Group 7 Coo...

Page 1633: ...ne Oil Supple ment or equivalent 2 Use Hydraulic Valve Tappet Removal Installa tion Tool to install each tappet in the same bore from where it was originally removed 3 Install the cylinder head assy Refer to cylinder head r i in this section 4 Install the push rods in their original locations 5 Install the rocker arms and bridge and pivot assemblies at their original locations Loosely install the ...

Page 1634: ...ft preload bolt 4 Insert Timing Case Cover Alignment and Seal Installation Tool 6139 in the crankshaft opening in the cover Fig 40 5 Install the timing case cover to cylinder block and the oil pan to timing case cover bolts 6 Tighten the 1 4 inch cover to block bolts to 7 N m 60 in lbs torque Tighten the 5 16 inch front cover to block bolts to 22 N m 192 in lbs torque Tighten the oil pan to cover ...

Page 1635: ...ming chain crankshaft sprocket and camshaft sprocket with the timing marks aligned Fig 43 1 Apply Mopar Silicone Rubber Adhesive Sealant to the keyway in the crankshaft and insert the key With the key in the keyway on the crankshaft install the assembly on the crankshaft and camshaft 2 Install the camshaft sprocket retaining preload bolt and washer Fig 42 Tighten the preload bolt to 108 N m 80 ft ...

Page 1636: ...mper 13 Remove the timing case cover 14 Remove the timing chain and sprockets 15 Remove the front bumper and or grille as required 16 Remove the camshaft Fig 44 INSTALLATION 1 Inspect the cam lobes for wear 2 Inspect the bearing journals for uneven wear pattern or finish 3 Inspect the bearings for wear 4 Inspect the distributor drive gear for wear 5 If the camshaft appears to have been rubbing aga...

Page 1637: ...T PIN REPLACEMENT REMOVAL WARNING DO NOT LOOSEN THE RADIATOR DRAIN COCK WITH THE SYSTEM HOT AND PRES SURIZED BECAUSE SERIOUS BURNS FROM COOL ANT CAN OCCUR 1 Disconnect negative cable from battery 2 Drain the radiator DO NOT waste reusable coolant Drain the coolant into a clean container 3 Remove the fan and shroud 4 Disconnect the radiator overflow tube radiator hoses automatic transmission fluid ...

Page 1638: ... correct installation of the timing chain turn the crankshaft to position the camshaft sprocket timing mark as shown in Fig 47 Count the number of chain pins between the timing marks of both sprockets There must be 15 pins 6 Install the crankshaft oil slinger 7 Tighten the camshaft sprocket preload bolt to 108 N m 80 ft lbs torque 8 Check the valve timing 9 Lubricate the tension spring the thrust ...

Page 1639: ...kshaft jour nal oil hole Bend the cotter pin as illustrated to fab ricate the tool Fig 51 With the cotter pin tool in place rotate the crankshaft so that the upper bear ing insert will rotate in the direction of its locking tab Because there is no hole in the No 3 main jour nal use a tongue depressor or similar soft faced tool to remove the bearing insert Fig 51 After moving the insert approximate...

Page 1640: ...o 23 N m 17 ft lbs 12 Install the oil pan 13 Install the drain plug Tighten the plug to 34 N m 25 ft lbs torque 14 Lower the vehicle 15 Install the spark plugs Tighten the plugs to 37 N m 27 ft lbs torque 16 Fill the oil pan with engine oil to the full mark on the dipstick level 17 Connect negative cable to battery OIL PAN REMOVAL 1 Disconnect negative cable from battery 2 Raise the vehicle 3 Remo...

Page 1641: ...e oil pan drain plug Fig 55 Tighten the plug to 34 N m 25 ft lbs torque 15 Lower the vehicle 16 Connect negative cable to battery 17 Fill the oil pan with engine oil to the specified level WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 18 Start the engine and inspect ...

Page 1642: ...nal In production the select fit is obtained by using various sized color coded bear ing inserts as listed in the Connecting Rod Bearing Fitting Chart The color code appears on the edge of the bearing insert The size is not stamped on inserts used for production of engines 8 The rod journal is identified during the engine production by a color coded paint mark on the adja cent cheek or counterweig...

Page 1643: ...the upper seal into the groove in the cylinder block The lip of the seal faces toward the front of the engine 5 Place the lower half of the seal into bearing cap No 7 Fig 59 6 Coat the outer curved surface of the lower seal with soap and the lip of the seal with engine oil Fig 59 7 Position the lower seal into the bearing cap recess and seat it firmly Be sure the seal is flush with the cylinder bl...

Page 1644: ...over Alignment and Seal Installation Tool 6139 with seal open end facing inward Apply a light film of Perfect Seal or equivalent on the outside diameter of the seal Lightly coat the crankshaft with engine oil 2 Position the tool and seal over the end of the crankshaft and insert a draw screw tool into Seal Installation Tool 6139 Fig 62 Tighten the nut against the tool until it contacts the cover 3...

Page 1645: ... the seals have deteriorated VALVE GUIDES The valve guides are an integral part of the engine cylinder head and are not replaceable When the valve stem guide clearance is excessive the valve guide bores must be reamed oversize Ser vice valves with oversize stems are available in 0 076 mm 0 003 inch and 0 381 mm 0 015 inch incre ments Corresponding oversize valve stem seals are also available and m...

Page 1646: ...ings that are not within specifica tions CYLINDER BLOCK DISASSEMBLY Refer to the applicable sections for detailed instructions 1 Drain the engine oil Remove and discard the oil filter 2 Remove the water pump from the cylinder block 3 Remove the vibration damper 4 Remove the timing case cover and lay the cover upside down 5 Position a drift punch into the slot in the back of the cover and tap the o...

Page 1647: ... the gasket material are missing or are compressed replace the engine cylinder head cover However sections with minor damage such as small cracks cuts or chips may be repaired with a hand held applicator The new mate rial must be smoothed over to maintain gasket height Allow the gasket material to cure prior to engine cylinder head cover installation ROCKER ARMS AND PUSH RODS CLEANING Clean all th...

Page 1648: ...ck has been completely cleaned apply Loctite PST pipe sealant with Teflon 592 to the threads of the front and rear oil galley plugs Tighten the plugs to 34 N m 25 ft lbs torque INSPECTION CYLINDER BORE 1 It is mandatory to use a dial bore gauge to measure each cylinder bore diameter Fig 69 To correctly select the proper size piston a cylinder bore gauge capable of reading in 0 003 mm 0001 in INCRE...

Page 1649: ... 30 18 mm 1 182 to 1 188 in Main Bearing Clearance 0 03 to 0 06 mm 0 001 to 0 0025 in Main Bearing Clearance Preferred 0 051 mm 0 002 in Connecting Rod Journal Diameter 53 17 to 53 23 mm 2 0934 to 2 0955 in Connecting Rod Journal Width 27 18 to 27 33 mm 1 070 to 1 076 in Out of Round Max All Journals 0 013 mm 0 0005 in Taper Max All Journals 0 013 mm 0 0005 in Cylinder Block Deck Height 240 03 to ...

Page 1650: ...5 Valve Face Angle Exhaust 45 Tip Refinishing Max Allowable 0 25 mm 0 010 in Valve Springs Free Length Approx 47 65 mm 1 876 in Spring Tension Valve Closed 271 to 307 N 41 656 mm 61 to 69 lbf 1 64 in Spring Tension Valve Open 818 5 to 871 9 N 30 89 mm 184 to 196 lbf 1 216 in Inside Diameter 21 0 mm to 21 51 mm 0 827 to 0 847 in Pistons Weight Less Pin 563 to 567 grams 19 86 to 20 00 oz Piston Pin ...

Page 1651: ...s Nuts 41 N m 30 ft lbs DESCRIPTION TORQUE Support Cushion Bracket Bolts 54 N m 40 ft lbs Support Cushion Bracket Stud Nuts 41 N m 30 ft lbs Support Cushion Thru Bolt 65 N m 48 ft lbs Engine Mounts Rear Crossmember to Sill Bolts Automatic 41 N m 30 ft lbs Insulator Stud Assembly Nut 41 N m 30 ft lbs Support Cushion Crossmember Nuts 22 N m 192 in lbs Support Cushion Bracket Nuts Manual 75 N m 55 ft...

Page 1652: ... Body Bolts 10 N m 90 in lbs Vibration Damper Bolts 108 N m 80 ft lbs Water Pump Block Bolts 31 N m 23 ft lbs SPECIAL TOOLS SPECIAL TOOLS Valve Spring Compressor Tool MD 998772A Timing Case Cover Alignment and Sealinstallation Tool 6139 Vibration Damper Removal Tool 7697 Rear Main Seal Installer Tool 6271A 9 54 4 0L ENGINE ZG SPECIFICATIONS Continued ...

Page 1653: ...T JOURNALS 82 CYLINDER BLOCK 84 CYLINDER HEADS 82 OIL PAN 82 OIL PUMP 82 PISTON AND CONNECTING ROD ASSEMBLY 82 SPECIFICATIONS 5 2L ENGINE 85 SPECIAL TOOLS 5 9L 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 kP...

Page 1654: ...ter element the oil passes from the center outlet of the filter through an oil gallery that channels the oil up to the main gallery which extends the entire length on the right side of the block The oil then goes down to the No 1 main bear ing back up to the left side of the block and into the oil gallery on the left side of the engine Galleries extend downward from the main oil gal lery to the up...

Page 1655: ...Fig 3 Oil Lubrication System ZG 5 2L ENGINE 9 57 DESCRIPTION AND OPERATION Continued ...

Page 1656: ...ge 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 socket ove...

Page 1657: ... be between 0 508 0 762 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 according to instructions i...

Page 1658: ... 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 loads They are NOT interchangeable with any other bearing halves in the engine Fig 12 Bearing shells are available in stan dard a...

Page 1659: ...Remove the engine support insulator thru bolts and nuts Fig 14 Fig 15 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 Fig 12 Main Bearing Identification UPPER LOWER Fig 13 Location of Crankshaf...

Page 1660: ...ly removed Position the rear mount bracket assembly onto the transmission and install the bolts Tighten the bolts to 46 N m 34 ft lbs 2 Position mount into mount bracket and install thru bolt and nut DO NOT tighten the bolt at this time 3 Lower the transmission until the mount fasten ing studs are in position in the crossmember 4 Remove transmission jack 5 Install the mount fastening nuts and tigh...

Page 1661: ...ing for service procedures 17 Using a new gasket install throttle body Tighten the throttle body bolts to 23 N m 200 in lbs torque 18 Connect the accelerator linkage 19 Connect the starter wires 20 Connect the oil pressure wire 21 Install the distributor cap and wiring 22 Install vacuum lines 23 Install radiator radiator hoses and heater hoses refer to Group 7 Cooling System 24 Install fan shroud ...

Page 1662: ...ion down against valve guides 10 The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as a guide DO NOT force seal against top of guide When installing the valve retainer locks compress the spring only enough to install the locks 11 Follow the same procedure on the remaining 7 cylinders using the firing sequence 1 8 4 3 6 5 7 2 Make sure piston...

Page 1663: ...cylinder head covers Tighten the bolts to 11 N m 95 in lbs torque 18 Install closed crankcase ventilation system 19 Connect the evaporation control system 20 Install the air cleaner 21 Fill cooling system refer to Group 7 Cooling System for proper procedure 22 Connect the negative cable to the battery VALVES AND VALVE SPRINGS REMOVAL 1 Remove the cylinder head 2 Compress valve springs using Valve ...

Page 1664: ... the negative cable from the battery 2 Remove fan shroud retainer bolts and set shroud back over engine 3 Remove the cooling system fan 4 Remove the serpentine belt refer to Group 7 Cooling System 5 Remove the vibration damper pulley 6 Remove vibration damper bolt and washer from end of crankshaft 7 Install bar and screw from Puller Tool Set C 3688 Install 2 bolts with washers through the puller t...

Page 1665: ...eal Installation Tool 6635 Fig 23 Seat the oil seal in the groove of the tool 3 Position the seal and tool onto the crankshaft Fig 24 4 Tighten the 4 lower chain case cover bolts to 13N m 10 ft lbs to prevent the cover from tipping during seal installation 5 Using the vibration damper bolt tighten the bolt to draw the seal into position on the crankshaft Fig 25 6 Loosen the 4 bolts tightened in st...

Page 1666: ...ts tight against the chain in position as described 5 Slide both sprockets evenly over their respec tive shafts and use a straightedge to check alignment of timing marks Fig 26 6 Install the camshaft bolt Tighten 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 thru...

Page 1667: ...s 7 Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in cam shaft sprocket 8 Lift sprockets and chain keep sprockets tight against the chain in position as described 9 Slide both sprockets evenly over their respec tive shafts and use a straightedge to check alignment of timing marks Fig 30 10 Install the camshaft bolt cup washer Tighten bolt to 68 N m 50 ft l...

Page 1668: ... Main Bearing Remover Installer Tool C 3059 into oil hole of crankshaft Fig 32 2 Slowly rotate crankshaft counterclockwise slid ing the bearing into position Remove Tool C 3059 3 Install the bearing caps Clean and oil the bolts Tighten the capbolts to 115 N m 85 ft lbs torque 4 Install the oil pump 5 Install the oil pan DISTRIBUTOR DRIVE SHAFT BUSHING REMOVAL 1 Remove distributor refer to Group 8D...

Page 1669: ... 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 sensor 9 Remove exhaust pipe 10 Remove the oil pan bolts Carefully slide the oil pan and gasket to the rear I...

Page 1670: ... 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 rail gap 2 Before installing the ring compressor make sure the oil ring expander ends are butted and the rail gaps located properly Fig 39 3 Immerse the piston head and rings in clean ...

Page 1671: ...the sealant to contact the rubber seal Assemble bearing cap to cylinder block immediately after sealant appli cation 8 To align the bearing cap use cap slot align ment dowel and cap bolts DO NOT remove excess material after assembly DO 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 tighte...

Page 1672: ...position on the crankshaft Fig 44 8 Remove the vibration damper bolt and seal installation tool 9 Inspect the seal flange on the vibration damper 10 Install the vibration damper 11 Connect the negative cable to the battery CRANKSHAFT REAR OIL SEALS The service seal is a 2 piece viton seal The upper seal half can be installed with crankshaft removed from engine or with crankshaft installed When a n...

Page 1673: ...fore oil seal installation Check for burr at the oil hole on the cylinder block mating surface to rear cap 2 Lightly oil the new upper seal lips with engine oil To allow ease of installation of the seal loosen at least the 2 main bearing caps forward of the rear 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 assur...

Page 1674: ...Silicone Rubber Adhesive Sealant or equivalent at bearing cap to block joint to provide cap to block and oil pan sealing Fig 46 Apply enough 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 camsha...

Page 1675: ...clearance as follows 1 Install Valve Guide Sleeve Tool C 3973 over valve stem and install valve Fig 50 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 51 3 Move valve to and from the indicator The total dial indicator reading should not exceed...

Page 1676: ...e 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 an example the compression length of the spring to be test...

Page 1677: ...ng new parts as required 2 Position the oil pump cover onto the pump body Tighten cover bolts to 11 N m 95 in lbs torque 3 Install the relief valve and spring Insert the cotter pin 4 Tap on a new retainer cap 5 Prime oil pump before installation by 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 ...

Page 1678: ... holes and clean out all oil passages CAUTION After any journal grind it is important 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 in...

Page 1679: ... a straightedge across the face of the pump between bolt holes If a feeler gauge of 0 102 mm 0 004 inch or more can be inserted between rotors and the straightedge replace pump assembly Fig 65 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 ...

Page 1680: ...d in the vertical passage at the rear of the block between the oil to filter and oil from filter passages Fig 67 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...

Page 1681: ... 010 in Main Bearing Journals Diameter 63 487 63 513 mm 2 4995 2 5005 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm 0 001 in Cylinder Block Cylinder Bore Diameter 99 314 99 365 mm 3 910 3 912 in Out of Round Max 0 127 mm 0 005 in Taper Max 0 254 mm 0 010 in Oversize Max 1 016 mm 0 040 in Distributor Lower Drive Shaft Bushing Press Fit in Block 0 0127 0 3556 mm 0 0005 0 0140 in Shaft t...

Page 1682: ... Rings Ring Gap Compression Rings 0 254 0 508 mm 0 010 0 020 in Oil Control Steel Rails 0 254 1 270 mm 0 010 0 050 in Ring Side Clearance Compression Rings 0 038 0 076 mm 0 0015 0 0030 in Oil Ring Steel Rails 0 06 0 21 mm 0 002 0 008 in Ring Width Compression Rings 1 971 1 989 mm 0 0776 0 0783 in Oil Ring Steel Rails 3 848 3 975 mm 0 1515 0 1565 in Valves Face Angle 43 25 43 75 Head Diameter Intak...

Page 1683: ... AND UNDERSIZE ENGINE COMPONENT MARKINGS CONDITION IDENTIFICATION LOCATION OF IDENTIFICATION CRANKSHAFT JOURNALS UNDERSIZE 0 0254 mm 0 001 in R or M M 2 3 etc indicating no 2 and 3 main bearing journal and or R 1 4 etc indicating no 1 and 4 connecting rod journal Milled flat on no 8 crankshaft counterweight HYDRAULIC TAPPETS OVERSIZE 0 2032 mm 0 008 in l Diamond shaped stamp top pad front of engin...

Page 1684: ...TORQUE 9 86 5 2L ENGINE ZG SPECIFICATIONS Continued ...

Page 1685: ... 5 9L ENGINE Oil Pressure Gauge C 3292 Engine Support Fixture C 3487 A Valve Spring Compressor MD 998772 A Adapter 6633 Adapter 6716A Valve Guide Sleeve C 3973 Dial Indicator C 3339 Puller C 3688 ZG 5 2L ENGINE 9 87 ...

Page 1686: ...staller C 3132 A Camshaft Holder C 3509 Distributor Bushing Puller C 3052 Distributor Bushing Driver BurnisherC 3053 Piston Ring Compressor C 385 Crankshaft Main Bearing Remover C 3059 Cylinder Bore Gauge C 119 9 88 5 2L ENGINE ZG SPECIAL TOOLS Continued ...

Page 1687: ...JOURNALS 114 CYLINDER BLOCK 116 CYLINDER HEADS 114 OIL PAN 114 OIL PUMP 114 PISTON AND CONNECTING ROD ASSEMBLY 114 SPECIFICATIONS 5 9L ENGINE 117 SPECIAL TOOLS 5 9L ENGINE 120 GENERAL INFORMATION OIL PUMP PRESSURE The MINIMUM oil pump pressure is 41 4 kPa 6 psi at curb idle The MAXIMUM oil pump pressure is 207 552 kPa 30 80 psi at 3 000 RPM or more CAUTION If oil pressure is ZERO at curb idle DO N...

Page 1688: ... of the block The oil then goes down to the No 1 main bear ing back up to the left side of the block and into 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 ...

Page 1689: ...Fig 3 Oil Lubrication System ZG 5 9L ENGINE 9 91 DESCRIPTION AND OPERATION Continued ...

Page 1690: ...d center Remove spacer CAUTION DO NOT turn crankshaft any further clockwise as valve spring might bottom and result in serious 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 Sectio...

Page 1691: ...rted piston can be used to push the rings down to ensure positioning rings squarely in the cylinder bore before measur ing b Insert feeler gauge in the gap The top com pression ring gap should be between 0 254 0 508 mm 0 010 0 020 inch The second compression ring gap should be between 0 508 0 762 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 insufficie...

Page 1692: ...ze Install the bearings in pairs DO NOT use a new bearing half with an old bearing half DO NOT file the rods or bearing caps FITTING 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 h...

Page 1693: ...ing DO NOT nick crank pin or bearing fillets After grinding remove rough edges from crankshaft oil holes and clean out all oil passages CAUTION After any journal grind it is important that the final paper or cloth polish be in the same direction as the engine rotates REMOVAL AND INSTALLATION ENGINE MOUNTS FRONT REMOVAL 1 Disconnect the negative cable from the battery 2 Position fan to assure clear...

Page 1694: ...e transmission and engine SLIGHTLY 5 Remove engine mount bracket thru bolt and nut Fig 16 6 Remove the rear mount assy 7 If necessary remove the bolts holding the rear mount bracket to the transmission Remove the bracket from the exhaust pipe hanger Remove the bracket INSTALLATION 1 Position the rear mount bracket onto the exhaust hanger if previously removed Position the rear mount bracket assemb...

Page 1695: ...e repair stand and posi tion in the engine compartment 2 Install engine support fixture 3 Raise and support the vehicle on a hoist 4 Position the torque converter and drive plate Install torque converter drive plate bolts Tighten the bolts to 31 N m 270 in lbs torque 5 Install the engine front mount thru bolts 6 Install bell housing bolts Tighten the bolts to 41 N m 30 ft lbs torque 7 Remove C cla...

Page 1696: ...ark plugs 4 Remove coil wire from distributor and secure to good ground to prevent engine from starting 5 Using suitable socket and flex handle at crank shaft retaining bolt turn engine so the No 1 piston is at TDC on the compression stroke 6 Remove rocker arms 7 With air hose attached to an adapter installed in No 1 spark plug hole apply 620 689 kPa 90 100 psi air pressure 8 Using Valve Spring Co...

Page 1697: ... torque 7 Adjust spark plugs to specifications refer to Group 8D Ignition System Install the plugs and tighten to 41 N m 30 ft lbs torque 8 Install coil wires 9 Connect heat indicator sending unit wire 10 Connect the heater hoses and bypass hose 11 Install distributor cap and wires 12 Hook up the return spring 13 Connect the accelerator linkage and if so equipped the speed control and transmission...

Page 1698: ...rsize Replace with oversize tappet 2 Lubricate tappets 3 Install tappets and push rods in their original positions Ensure that the oil feed hole in the side of the tappet body faces up away from the crankshaft 4 Install aligning yokes with ARROW toward camshaft 5 Install yoke retainer Tighten the bolts to 23 N m 200 in lbs torque Install intake manifold 6 Install push rods in original positions 7 ...

Page 1699: ...y install chain case cover to avoid damaging oil pan gasket Use a small amount of Mopart Silicone Rubber Adhe sive Sealant or equivalent at the joint between tim ing chain cover gasket and the oil pan gasket Finger tighten the timing chain cover bolts at this time 2 Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 Fig 23 Seat the oil seal in the groove of the t...

Page 1700: ...rockets tight against the chain in position as described 5 Slide both sprockets evenly over their respec tive shafts and use a straightedge to check alignment of timing marks Fig 26 6 Install the camshaft bolt Tighten 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...

Page 1701: ...marks on exact imaginary center line through both camshaft and crankshaft bores 6 Place timing chain around both sprockets 7 Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in cam shaft sprocket 8 Lift sprockets and chain keep sprockets tight against the chain in position as described 9 Slide both sprockets evenly over their respec tive shafts and use a stra...

Page 1702: ...g service procedures are to be cleaned and oiled before instal lation When installing a new upper bearing shell slightly chamfer the sharp edges from the plain side 1 Start bearing in place and insert Crankshaft Main Bearing Remover Installer Tool C 3059 into oil hole of crankshaft Fig 32 2 Slowly rotate crankshaft counterclockwise slid ing the bearing into position Remove Tool C 3059 3 Install th...

Page 1703: ...stem Do not attempt to adjust ignition timing by rotating the distributor It has no effect on igni tion timing Adjusting distributor position will effect 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...

Page 1704: ...inder head 3 Remove the oil pan 4 Remove top ridge of cylinder bores with a reli able ridge reamer before removing pistons from cyl inder block Be sure to keep tops of pistons covered during this operation 5 Be sure the connecting rod and connecting rod cap are identified with the cylinder number Remove connecting rod cap Install connecting rod bolt guide set on connecting rod bolts 6 Pistons and ...

Page 1705: ...d rear cap mating surface Do this before applying the Loctite drop and the installation of rear cap 2 Lightly oil the new upper seal lips with engine oil 3 Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine 4 Position the crankshaft into the cylinder block 5 Lightly oil the new lower seal lips with engine oil 6 Install the new lower rear bearing ...

Page 1706: ...damage the crankshaft seal bore of cover 5 Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 Fig 42 Seat the oil seal in the groove of the tool 6 Position the seal and tool onto the crankshaft Fig 43 7 Using the vibration damper bolt tighten the bolt to draw the seal into position on the crankshaft Fig 44 8 Remove the vibration damper bolt and seal installation ...

Page 1707: ... caps Install all cap bolts and alternately tighten to 115 N m 85 ft lbs torque 10 Install oil pump 11 Apply Mopar Silicone Rubber Adhesive Seal ant or equivalent at bearing cap to block joint to provide cap to block and oil pan sealing Fig 46 Apply enough sealant until a small amount is squeezed out Withdraw nozzle and wipe excess seal ant off the oil pan seal groove 12 Install new front cranksha...

Page 1708: ...5 mm 0 20 in drop of Loctite 518 or equivalent on each side of the rear main bearing cap Fig 45 DO NOT over apply sealant or allow the sealant to contact the rubber seal Assemble bearing cap to cylinder block immediately after sealant appli cation 6 To align the bearing cap use cap slot align ment dowel and cap bolts DO NOT remove excess material after assembly DO NOT strike rear cap more than 2 t...

Page 1709: ...t for further ser vice with new assemblies 3 If plunger shows signs of scoring or wear install a new tappet assembly If valve is pitted or valve seat on end of plunger is prevented from seat ing install a new tappet assembly 4 Assemble tappets Fig 49 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 F...

Page 1710: ...hen refacing valve seats it is important that the correct size valve guide pilot be used for reseat ing stones A true and complete surface must be obtained 2 Measure the concentricity of valve seat using a dial indicator Total runout should not exceed 0 051 mm 0 002 inch total indicator reading 3 Inspect the valve seat with Prussian blue to determine where the valve contacts the seat To do this co...

Page 1711: ... not meet specifications OIL PUMP DISASSEMBLE 1 Remove the relief valve as follows a Remove cotter pin Drill a 3 175 mm 1 8 inch hole into the relief valve retainer cap and insert a self threading sheet metal screw b Clamp screw into a vise and while support ing oil pump remove cap by tapping pump body using a soft hammer Discard retainer cap and remove spring and relief valve Fig 57 2 Remove oil ...

Page 1712: ...uld be checked for excessive wear taper and scor ing The maximum taper or out of round on any crankshaft journal is 0 025 mm 0 001 inch Journal grinding should not exceed 0 305 mm 0 012 inch under the standard journal diameter DO NOT grind thrust faces of No 3 main bearing DO NOT nick crank pin or bearing fillets After grinding remove rough edges from crankshaft oil holes and clean out all oil pas...

Page 1713: ...ightedge across the face of the pump between bolt holes If a feeler gauge of 0 102 mm 0 004 inch or more can be inserted between rotors and the straightedge replace pump assembly Fig 65 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...

Page 1714: ...and oil from filter passages Fig 67 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 3 Plug should be 190 0 to 195 2 mm 7 ...

Page 1715: ... 0 038 mm 0 0005 0 0015 in Max Allowable No 1 0 0381 mm 0 0015 in Nos 2 3 4 and 5 0 013 0 051 mm 0 005 0 0020 in Max Allowable Nos 2 3 4 5 0 064 mm 0 0025 in End Play 0 051 0 178 mm 0 002 0 007 in Max Allowable 0 254 mm 0 010 in Main Bearing Journals Diameter 71 361 71 387 mm 2 8095 2 8105 in Out of Round Max 0 0254 mm 0 001 in Taper Max 0 0254 mm 0 001 in Cylinder Block Cylinder Bore Diameter 101...

Page 1716: ...0 80 mm 0 022 0 031 in Oil Control Steel Rails 0 381 1 397 mm 0 015 0 055 in Ring Side Clearance Compression Rings 0 040 0 085 mm 0 0016 0 0033 in Oil Ring Steel Rails 0 05 0 21 mm 0 002 0 008 in Ring Width Compression Rings 1 530 1 555 mm 0 060 0 061 in Oil Ring Steel Rails Max 0 447 0 473 mm 0 018 0 019 in Valves Face Angle 43 25 43 75 Head Diameter Intake 47 752 mm 1 88 in Exhaust 41 072 mm 1 6...

Page 1717: ... 85 ft lbs Crankshaft Pulley Bolts 24 N m 210 in lbs Cylinder Head Bolts Step 1 Initial 68 N m 50 ft lbs Step 2 Final 143 N m 105 ft lbs Cylinder Head Cover Bolts 11 N m 95 in lbs Exhaust Manifold to Cylinder Head Bolts Nuts 34 N m 25 ft lbs Flywheel Bolts 75 N m 55 ft lbs Front Engine Mount Bracket to Block Bolts 81 N m 60 ft lbs Front Engine Mount Through Bolt Nut 68 N m 50 ft lbs Generator Moun...

Page 1718: ...uts 204 N m 150 ft lbs Vibration Damper Bolt 183 N m 135 ft lbs Water Pump to Chain Case Cover Bolt 41 N m 30 ft lbs SPECIAL TOOLS 5 9L ENGINE Oil Pressure Gauge C 3292 Engine Support Fixture C 3487 A Valve Spring Compressor MD 998772 A Adaptor 6633 Adaptor 6716A Valve Guide Sleeve C 3973 9 120 5 9L ENGINE ZG SPECIFICATIONS Continued ...

Page 1719: ...ont Oil Seal Installer 6635 Cam Bearing Remover Installer C 3132 A Camshaft Holder C 3509 Distributor Bushing Puller C 3052 Distributor Bushing Driver BurnisherC 3053 Piston Ring Compressor C 385 ZG 5 9L ENGINE 9 121 SPECIAL TOOLS Continued ...

Page 1720: ...Crankshaft Main Bearing Remover C 3059 Cylinder Bore Gauge C 119 9 122 5 9L ENGINE ZG SPECIAL TOOLS Continued ...

Page 1721: ...L PAN 27 OIL PUMP 28 INTERNAL VACUUM PUMP 28 OIL PUMP PRESSURE RELIEF VALVE 29 OIL FILTER ADAPTER 29 PISTONS AND CONNECTING ROD ASSEMBLY 30 CYLINDER WALL LINER ASSEMBLY 33 CRANKSHAFT MAIN BEARINGS 35 ENGINE MOUNTS FRONT 14 ENGINE MOUNT REAR 15 DISASSEMBLY AND ASSEMBLY HYDRAULIC TAPPETS 38 CLEANING AND INSPECTION CYLINDER HEAD 38 ROCKER ARMS AND PUSH RODS 39 PISTONS AND CONNECTING ROD ASSEMBLY 39 C...

Page 1722: ...iner to the pump cover including the relief valve retainer cap When tappet noise is due to aeration it may be intermittent or constant and usually more than 1 tappet will be noisy When oil level and leaks have been corrected operate the engine at fast idle Run engine for a suf ficient time to allow all of the air inside the tappets to be bled out DESCRIPTION AND OPERATION LUBRICATION SYSTEM The pr...

Page 1723: ...DIAGNOSIS AND TESTING SERVICE DIAGNOSIS DIESEL PERFORMANCE ZG ENGINE 9 3 ...

Page 1724: ...9 4 ENGINE ZG DIAGNOSIS AND TESTING Continued ...

Page 1725: ...ZG ENGINE 9 5 DIAGNOSIS AND TESTING Continued ...

Page 1726: ...9 6 ENGINE ZG DIAGNOSIS AND TESTING Continued ...

Page 1727: ...ZG ENGINE 9 7 DIAGNOSIS AND TESTING Continued ...

Page 1728: ...9 8 ENGINE ZG DIAGNOSIS AND TESTING Continued ...

Page 1729: ...SERVICE DIAGNOSIS DIESEL MECHANICAL ZG ENGINE 9 9 DIAGNOSIS AND TESTING Continued ...

Page 1730: ...9 10 ENGINE ZG DIAGNOSIS AND TESTING Continued ...

Page 1731: ...ZG ENGINE 9 11 DIAGNOSIS AND TESTING Continued ...

Page 1732: ...e making the noise In general if more than one tappet seems to be noisy its probably not the tappets SERVICE PROCEDURES VALVE SERVICE This procedure is done with the engine cylinder head removed from the block DISASSEMBLY 1 Remove the engine cylinder head from the cyl inder block refer to cylinder head removal in this section 2 Use Valve Spring Compressor Tool and com press each valve spring 3 Rem...

Page 1733: ...o its respective valve guide 3 Using a straight edge and feeler gauge Fig 5 check valve head stand down Inlet valve head stand down 80 to 1 2 mm 031 to 047 in and exhaust valve stand down 79 to 1 19 mm 031 to 047 in 4 If valve head stand down is not in accordance with above discard original valves check stand down with new valves and recut valve seat inserts to obtain correct stand down VALVE GUID...

Page 1734: ...rough bolt 9 Remove insulator 10 Remove engine bracket INSTALLATION RIGHT SIDE 1 Install the engine support bracket and bolts tighten bolts to 61 N m 45 ft lbs 2 Secure the insulator assembly on the lower sill Tighten the bolts to 65 N m 48 ft lbs 3 Lower engine and place the insulator assembly into the bracket 4 Install the through bolt nut Tighten the through bolt nut to 65 N m 48 ft lbs 5 Remov...

Page 1735: ...er vehicle 6 Connect negative battery cable ENGINE ASSEMBLY REMOVAL 1 Disconnect the battery cables Remove the bat tery 2 Mark the hinge locations on the hood panel for alignment reference during installation Disconnect the engine compartment lamp wiring connection Remove the hood WARNING THE COOLANT IN A RECENTLY OPER ATED ENGINE IS HOT AND PRESSURIZED USE CARE TO PREVENT SCALDING BY HOT COOLANT ...

Page 1736: ...Intake Manifolds 24 Remove rear crossmember and transmission mount support transmission 25 Tip transmission to remove four bolts on top of transmission to engine block Disconnect wiring from transmission 26 Support transmission remove lower bolts and brackets remove transmission 27 Remove the engine support cushion to engine compartment bracket nuts 28 Lower the vehicle 29 Attach a lifting device ...

Page 1737: ...cable WARNING DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN COCK WITH THE SYSTEM HOT AND PRES SURIZED BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR 2 Drain the cooling system refer to Group 7 Cooling 3 Discharge the air conditioning system if equipped refer to Group 24 Heating and Air Condi tioning for service procedures 4 If equipped with air conditioning remove the...

Page 1738: ...nstallation in orig inal location 4 Remove cylinder head intake manifold and exhaust manifold refer to cylinder head removal in this section 5 Remove yoke retainer and aligning yokes Fig 15 6 Slide Hydraulic Tappet Remover Installer Tool through opening in block and seat tool firmly in the head of tappet 7 Pull tappet out of bore with a twisting motion If all tappets are to be removed identify tap...

Page 1739: ... hose 6 Install generator bracket tighten bolts to 7 N m 4 ft lbs 7 Connect the service valves to the A C compres sor ports if equipped with air conditioning 8 If equipped evacuate and charge the air condi tioning system refer to Group 24 Heater and Air Conditioning 9 Connect battery cable VALVE SPRINGS This procedure can be done with the engine cylin der head installed on the block REMOVAL Each v...

Page 1740: ...fer to Group 24 Heating and Air Condi tioning for service procedures 4 If equipped with air conditioning remove the A C lines at the compressor and cap refer to Group 24 Heating and Air Conditioning Remove A C line bracket attached to cylinder head cover and move A C lines away from cylinder head 5 Remove air cleaner hose from turbocharger and breather hose 6 Remove the air cleaner assembly and br...

Page 1741: ... Remove the push rods and place them on a bench in the same order as removed 33 Mark cylinder head positions 34 Remove the engine cylinder head bolts with special tool VM 1018 and VM 1019 35 Remove the engine cylinder head and gasket 36 Stuff clean lint free shop towels into the cyl inder bores CYLINDER HEAD GASKETS A steel cylinder head gasket is used for all four cyl inder heads Cylinder head ga...

Page 1742: ... DO NOT use a gasket sealing compound on the gasket INSTALLATION 1 Remove the shop towels from the cylinder bores Coat the bores with clean engine oil 2 Install cylinder head alignment studs VM 1009 3 After determining the correct head gasket thickness clean the block and head mating surfaces place the engine cylinder head gasket over the dow els 4 Place the engine cylinder head over the dowels CA...

Page 1743: ...bolts as follows Central bolts A L Starting from bolt A slacken and re torque it immediately to 30 N m 65 Rotate the bolt an additional 65 Then proceed in the same way bolt by bolt following alphabetical order as indicated Side bolts M1 M2 Without slackening torque bolts M1 then bolts M2 to 90 N m 66 ft lbs 11 Tighten intake nuts to 30 N m 22 ft lbs and exhaust manifolds nuts to 30 N m 22 ft lbs s...

Page 1744: ...UTION 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 41 Operate the engine with the radiator cap off Inspect for leaks and continue operating the engine until the thermostat opens Add coolant if required CAUTION After rebuild or cylinder head gasket replacement the cylinder head must be retorqued withi...

Page 1745: ...ng 4 Remove vibration damper nut 5 Install tool VM 1000 2 to remove vibration damper 6 Remove fan pulley 7 Remove idler pulley and bracket Idler pulley bolt have left hand threads 8 Remove the automatic belt tensioner 9 Disconnect the oil drain back hose from exter nal vacuum pump to timing cover 10 Remove Power steering pulley 11 Remove cover INSTALLATION 1 Be sure mating surfaces of chain case c...

Page 1746: ...ve cylinder head refer to cylinder head removal in this section 4 Remove rocker arms push rods and hydraulic tappets refer to the respective groups in this section 5 Remove fan and set fan inside fan shroud then remove fan shroud and fan as an assembly 6 Remove accessary drive belt 7 Remove radiator refer to Group 7 Cooling 8 Remove A C condenser refer to Group 24 Heating and Air Conditioning 9 Re...

Page 1747: ... radiator cap off Inspect for leaks and continue operating the engine until the thermostat opens Add coolant if required CAMSHAFT BEARINGS This procedure requires that the engine is removed from the vehicle REMOVAL 1 With engine completely disassembled remove camshaft rear plate and o ring 2 Install proper size adapters and horseshoe wash ers part of Camshaft Bearing Remover Installer Tool at back...

Page 1748: ... Fig 35 INSTALLATION 1 Install new O ring and lubricate with clean engine oil 2 Install oil pump and tighten retaining screws to 24 5 29 9 N m 22 7 28 3 ft lbs Check for normal backlash between pump and crankshaft gears 3 Install front cover refer to front cover installa tion in this section INTERNAL VACUUM PUMP REMOVAL 1 Remove the front cover refer to front cover removal in this section 2 Remove...

Page 1749: ...free length is 57 5mm 2 263 in If spring length is less or spring is distorted it must be replaced 5 Check plunger for scoring replace if necessary INSTALLATION 1 Thoroughly clean all components and relief valve pocket in cylinder block 2 Fit plunger spring and cap into block 3 Compress spring and install retaining clip Ensure clip is completely seated in groove OIL FILTER ADAPTER REMOVAL 1 Remove...

Page 1750: ...onnecting rods must be removed from top of cylinder block Rotate crankshaft so that each connecting rod is centered in cylinder bore 7 Remove connecting rod cap Install connecting rod bolt protectors on connecting rod bolts Push each piston and rod assembly out of cylinder bore NOTE Be careful not to nick crankshaft journals 8 After removal install bearing cap on the mat ing rod PISTON PIN REMOVAL...

Page 1751: ...s exceed dimension given new rings or cylinder liners must be fitted Keep piston rings in piston sets 3 Check piston ring to groove clearance Top com pression ring gap 08 to 130mm 0031 to 0051 in Second compression ring gap 070 to 102mm 0027 to 0040 in Oil control ring gap 040 to 072mm 0015 to 0028 in PISTON RINGS INSTALLATION 1 Install rings on the pistons using a suitable ring expander Fig 46 Fi...

Page 1752: ...n con rod big end should also face in the same direction To insert piston into cylinder use a ring compressor as shown in Fig 46 PISTON PIN INSTALLATION 1 Secure connecting rod in soft jawed vice 2 Lubricate piston pin and piston with clean oil 3 Position piston on connecting rod CAUTION Ensure combustion recess in piston crown and the bearing cap numbers on the con necting rod are on the same sid...

Page 1753: ... oiled rod bolts and tighten nuts to 29 5 N m 22 ft lb plus 60 CYLINDER WALL LINER ASSEMBLY REMOVAL 1 Remove cylinder heads 2 Remove Oil pan 3 Remove pistons 4 Use tool VM 1001 to remove liners Fig 50 5 Remove shims from cylinder liner or cylinder block recess Keep shims with each cylinder liner INSTALLATION 1 Carefully clean residual LOCTITE from liner and crankcase and degrease the crankcase whe...

Page 1754: ...AVX to the corner of the liner seat Apply LOCTITE AVX uniformly to the upper part of the liner at area 8 Fit the liners in the crankcase making sure that the shim is positioned correctly in the seat Lock the liners in position using special tool VM 1016 and bolts Fig 53 Clean the residual LOCTITE on the upper surface of the block deck 9 Recheck the liner protrusion It should be 0 01 0 06 mm NOTE A...

Page 1755: ...turbo charger refer to Group 11 Exhaust System and Intake Manifold 8 Remove water manifold 9 Remove oil feed lines to rocker arms 10 Remove cylinder heads 11 Remove oil pan and oil pick up 12 Remove piston and connecting rods from crankshaft journals 13 Remove pistons and connecting rods from block 14 Remove vibration damper refer to vibration damper removal in this section 15 Remove front cover r...

Page 1756: ...s being checked and figures are not within specifications new bearings must be used 4 Check crankshaft main bearing journals to bearing clearances Clearances of main bearings is 03 to 088mm 0011 to 0035 in NOTE Assemble engine according to sequence described thus saving time and preventing dam ages to engine components Clean parts with a suit able solvent and dry them with compressed air before as...

Page 1757: ...ied crankshaft end play from figure obtained Crankshaft end play 153 to 304mm 0060 to 0119 in 21 Select thrust washers which will give correct end play 22 Remove tools and flywheel 23 Lubricate thrust washer halves and fit them into the rear main bearing carrier 24 Ensure that crankshaft end and flywheel mat ing surfaces are clean and dry Install O ring in fly wheel groove 25 To verify correct end...

Page 1758: ... and plunger spring Check valve could be flat or ball ASSEMBLE 1 Clean all tappet parts in a solvent that will remove all varnish and carbon 2 Replace tappets that are unfit for further ser vice with new assemblies 3 If plunger shows signs of scoring or wear install a new tappet assembly If valve is pitted or valve seat on end of plunger is prevented from seat ing install a new tappet assembly 4 A...

Page 1759: ... 05mm 0019in 3 The piston diameter should be measured approximately 15 mm 590 in up from the base 4 Skirt wear should not exceed 0 1 mm 00039 in 5 The clearance between the cylinder liner and piston should not exceed 0 25 mm 0009 in 6 Make sure the weight of the pistons does not differ by more than 5 g INSPECTION CONNECTING ROD 1 Assemble bearing shells and bearing caps to their respective connect...

Page 1760: ...137 in BEARING TO JOURNAL CLEARANCE Compare internal diameters of connecting rod with crankshaft journal diameter Maximum clearance between connecting rod and crankshaft journals 022 to 076mm 0008 to 0029 in CYLINDER WALL LINER ASSEMBLY INSPECTION The cylinder walls should be checked for out of round and taper with dail bore gauge The cylinder bore out of round is 0 100 mm 0039 inch maximum and cy...

Page 1761: ... pump check pump bore depth in block A and pump body height B Fig 67 Difference between A and B should be 0 020 0 082 mm 2 Check clearance between rotors Fig 69 Fig 66 Liner Inspection Fig 67 Oil Pump Bore Depth Fig 68 Oil Pump Inner and Outer Rotors Fig 69 Checking Rotor Clearance ZG ENGINE 9 41 CLEANING AND INSPECTION Continued ...

Page 1762: ...SPECIFICATIONS ENGINE SPECIFICATIONS 9 42 ENGINE ZG ...

Page 1763: ...ZG ENGINE 9 43 SPECIFICATIONS Continued ...

Page 1764: ...st manifold collar Mounting nut 24 5 to 29 5 N m Exhaust manifold Mounting nut 32 5 N m Fan drive To fan hub 56 N m Flywheel Lock bolt 20 N m 60 Flywheel plate Mounting bolt 47 N m DESCRIPTION TORQUE Front timing cover 6 mm bolts 10 N m 8 mm bolts 26 N m Fuel filter Nuts 28 N m Glow plug Torque 13 0 N m Idler pulley bracket Bolts 40 N m Idler pulley Bolt left hand thread 47 N m Injection pump fuel...

Page 1765: ... m Turbocharger oil drain Plug 10 8 N m Vacuum pump Torque 27 N m Water manifold Bolts 12 N m Water pump pulley Nut 27 N m SPECIAL TOOLS SPECIAL TOOLS Crankshaft Pulley and Gear Remover VM 1000A Cylinder Liner Puller VM 1001 Crankshaft Bearing Remover Replacer VM 1002 Injection Pump Puller and Gear retainer VM 1003 ZG ENGINE 9 45 SPECIFICATIONS Continued ...

Page 1766: ...cer Sleeve VM 1004 Torque Angle Gauge VM 1005 Cylinder Head Bolt Wrench VM 1006A Cylinder Head Guide Studs VM 1009 Cylinder Liner Protrusion Tool VM 1010 Bosch Pump Timing Adapter VM 1011 9 46 ENGINE ZG SPECIAL TOOLS Continued ...

Page 1767: ... Socket VM 1012 Dial Indicator Gauge VM 1013 Flywheel Locking Tool VM 1014 Timing Cover Oil Seal Replacer VM 1015 Cylinder Retainer VM 1016 Crankshaft and Water Pump Pulley Holder VM 1017 ZG ENGINE 9 47 SPECIAL TOOLS Continued ...

Page 1768: ...Cylinder Head Bolt Wrench M12 VM 1018 Cylinder Head Bolt Wrench M14 VM 1019 Cylinder Leakage Tester Adapter VM 1021 9 48 ENGINE ZG SPECIAL TOOLS Continued ...

Page 1769: ...e muffler with a single monolithic type catalytic converter The 4 0L engines use a seal between the exhaust manifold and exhaust pipe to assure a tight seal and strain free connections The 5 2 5 9L 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 s...

Page 1770: ... the catalyst core DO NOT remove spark plug wires from plugs or by any other means short out cylinders Failure of the catalytic converter can occur 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...

Page 1771: ...ust manifold Tighten the nuts to 31 N m 23 ft lbs torque 4 Position the exhaust clamp over the exhaust pipe catalytic converter connection Fig 5 Fig 6 Tighten the nuts to 61 N m 45 ft lbs torque 5 Coat the oxygen sensor with anti seize com pound Install the sensor and tighten the nut to 48 N m 35 ft lbs torque 6 Lower the vehicle 7 Start the engine and inspect for exhaust leaks and exhaust system ...

Page 1772: ...n verter and exhaust pipe connection Fig 8 4 Remove exhaust clamp from the catalytic con verter and muffler connection Fig 8 5 Disconnect oxygen sensor wiring 6 Heat the exhaust pipe catalytic converter and muffler connections with an torch until the metal becomes cherry red Fig 5 Exhaust System 4 0L Engine Fig 6 Exhaust Pipe 4 7LEngines Fig 7 Rear Mount Bracket Insulator REAR MOUNT BRACKET INSULA...

Page 1773: ...atalytic converter and muffler connection Fig 8 4 Heat the catalytic converter to muffler connec tion with an torch until the metal becomes cherry red 5 While the metal is still cherry red remove the tailpipe muffler assembly from the catalytic con verter 6 Remove the tailpipe from the tailpipe hanger Fig 9 7 Remove the tailpipe muffler assembly INSTALLATION 1 If the tailpipe hanger assembly was r...

Page 1774: ...ket to the intake manifold Tighten the belt to specification refer to Group 7 Cooling System for the proper pro cedures 9 Install the fuel system supply and return lines to the fuel rail assembly Before connecting the fuel system lines to the fuel rail replace the O rings in the quick connect fuel line cou plings Refer to Group 14 Fuel System for the proper procedure 10 Connect all electrical conn...

Page 1775: ...Position the pan over the gasket Align all the gasket and pan holes with the intake manifold c Hand start all bolts d Tighten the bolts in sequence Fig 11 as follows Step 1 Tighten bolts to 2 7 N m 24 in lbs torque Step 2 Tighten bolts to 5 4 N m 48 in lbs torque Step 3 Tighten bolts to 9 5 N m 84 in lbs torque Step 4 Check that all bolts are tighten to 9 5 N m 84 in lbs torque 2 Using a new gaske...

Page 1776: ...ssion kick down cables 16 Install the fuel lines and fuel rail refer to Group 14 Fuel System 17 Install the support bracket to the intake man ifold and the mounting bracket 18 Install the generator and drive belt Tighten generator mounting bolt to 41 N m 30 ft lbs torque Tighten the adjusting strap bolt to 23 N m 200 in lbs torque Refer to Group 7 Cooling Sys tem for the proper adjusting of belt t...

Page 1777: ...LD 4 0L ENGINE Clean the mating surfaces of the cylinder head and the manifold if the original manifold is to be installed INTAKE MANIFOLD 5 2 5 9L ENGINE CLEANING Clean manifold in solvent and blow dry with com pressed air Clean cylinder block front and rear gasket surfaces using a suitable solvent The plenum pan rail must be clean and dry free of all foreign material INSPECTION Inspect manifold ...

Page 1778: ...d 4 0L Nuts 6 7 31 N m 23 ft lbs Exhaust Manifold 5 2 5 9L Nuts Bolts 27 N m 20 ft lbs Floor Pan Heat Shield Bolts Nuts 5 N m 45 in lbs Generator Mounting Bolts 41 N m 30 ft lbs Intake Manifold 5 2 5 9L Bolts Refer to Procedure in This Section Muffler to Catalytic Converter U bolt rod clamp 61 N m 45 ft lbs Oxygen Sensor Sensor 48 N m 35 ft lbs Plenum Pan 5 2 5 9L Bolts Refer to Procedure in This ...

Page 1779: ...ts stripped screw or bolt threads corrosion damage and worn cracked or broken hangers Replace all components that are badly corroded or damaged DO NOT attempt to repair When replacement is required use original equip ment parts or equivalent This will assure proper alignment and provide acceptable exhaust noise lev els CAUTION Avoid application of rust prevention compounds or undercoating material...

Page 1780: ...ice replacement mufflers and exhaust tailpipes are either clamped together or welded together WARNING IF TORCHES ARE USED WHEN WORK ING ON THE EXHAUST SYSTEM DO NOT ALLOW THE FLAME NEAR THE FUEL LINES REMOVAL 1 Raise and support the vehicle 2 Remove the front muffler clamp from the exhaust pipe and muffler connection 3 Remove the rear exhaust tailpipe hanger clamp and remove the exhaust tailpipe f...

Page 1781: ...e nut to 26 N m 9 Tighten EGR tube flange bolts to 26 N m 10 Connect all components to intake manifold 11 Connect charge air cooler hoses to turbo charger and intake manifold 12 Install air cleaner assembly 13 Connect air cleaner hose to turbocharger 14 Raise the vehicle 15 Install turbocharger drain line 16 Lower the vehicle 17 Connect the battery negative cable 18 Start the engine and check for ...

Page 1782: ...e Support Clamp Bolts 22 5 N m Exhaust Pipe Support Clamp Screw 22 5 N m Intake Manifold Nuts 30 N m Muffler to Exhaust Pipe Clamp Nuts 43 N m Tail Pipe Clamp Hanger bolt 22 5 N m Turbocharger to Exhaust manifold Nuts 27 N m Turbocharger Oil Feed Line 27 4 N m Turbocharger Down Pipe to Exhaust Pipe Bolts Nuts 22 5 N m Turbocharger Down Pipe to Turbocharger Bolts 27 N m 11 4 EXHAUST SYSTEM AND INTA...

Page 1783: ...3 Unsnap lower clips at grille Remove grille from GOR 4 Remove turn signals side markers and head lamps Refer to Group 8L Lamps for service informa tion 5 Remove the retainers at the front fascia Fig 2 6 Remove the plastic rivets at each front wheel well Fig 3 7 Slide the fascia off of the retainer pegs at the side of the fender attach brackets Using a small screwdriver pull up on locating tangs u...

Page 1784: ...er 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 squeezing fasteners and pushing through slots 10 Remove the lower retainers from the bumper fascia 11 Remove the bumper fascia from the bumper INSTALLATION 1 Install brackets onto bumper beam 2 Install beam brackets onto vehicle rails ...

Page 1785: ...RONT 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 tow eye bracket at crossmember Insert bolts thru the bracket and into the reinforce ment 3 Position the tows hooks at the ...

Page 1786: ...s that attach skid plate to trans mission support crossmember and frame sill Fig 5 3 Remove support and skid plate from vehicle INSTALLATION 1 Install nutserts if removed 2 Position and support skid plate at the frame sill and transmission support crossmember 3 Attach skid plate to frame sill and crossmem ber with the bolts Tighten bolts to 27 N m 20 ft lbs torque Fig 2 Brush Guard BRUSH GUARD TOW...

Page 1787: ...tow hook to bracket Tighten nut to 95 N m 70 ft lbs torque 2 Position reinforcement plate on top of body lip 3 Install the bolts and nuts that attach tow hook Tighten nut to 95 N m 70 ft lbs torque TRAILER HITCH REMOVAL 1 If necessary remove trailer tow wire harness connector from hitch 2 Support hitch 3 Remove nuts that attach the towing tube to frame sills Fig 8 NOTE Reinforcement brackets are r...

Page 1788: ...cle 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 scale All dimensions are from center to center of Principal Locating Point PLP or from center to center of PLP and fastener location Fig 9 Fig 10 Fig 11 Fig 12 and Fig 13 13 6 FRAME AND BUMPERS...

Page 1789: ...ont door lower rear corner radius to center of A pillar radius D Center of door hinge mount to center of door striker mount E Center of radius at bottom front to center of radius at top rear F Center of radius at bottom rear to center of radius at lower A pillar ZG FRAME AND BUMPERS 13 7 SPECIFICATIONS Continued ...

Page 1790: ...ter of front lower door radius to center of rear upper door radius D Rear door hinge mount to rear door striker mount A Center of upper and lower rear quarter window opening B Center of radius front lower corner to center of radius rear upper corner C Center of radius front upper corner to center of radius rear lower corner 13 8 FRAME AND BUMPERS ZG SPECIFICATIONS Continued ...

Page 1791: ...r of upper liftgate opening to liftgate striker mount B C Center of radius upper corner to center of radius lower corner D Distance between outer quarter panel to tail lamp mounting panel to inner quarter panel seams ZG FRAME AND BUMPERS 13 9 SPECIFICATIONS Continued ...

Page 1792: ...DIAMETERS A Bolt B 14mm C Front Fender Bolt D Bolt E Bolt F Bolt G 19mm x 25mm H 19mm I 19mm x 25mm J 19mm K Bolt L Bolt M Bolt N 19mm x 25mm O 13mm SIDE VIEW Datum Height Dimensions are PERPENDICULAR to Datum Plane Datum Length Dimensions are PARALLEL to Centerline of Vehicle and are Measured Center to Center 13 10 FRAME AND BUMPERS ZG SPECIFICATIONS Continued ...

Page 1793: ... in m BOTTOM VIEW BOTTOM VIEW POINT TO POINT DIMENSIONS ARE TAKEN WITH TRAM BAR POINTERS SET AT EQUAL LENGTHS Bolts and Studs are Measured to Center Holes are Measured to Closest Edge DRIVER SIDE FRONT ZG FRAME AND BUMPERS 13 11 SPECIFICATIONS Continued ...

Page 1794: ... 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 13 12 FRAME AND BUMPERS ZG SPECIFICATIONS Continued ...

Page 1795: ...tain detergents corrosion and stability additives are recommended Using gasolines that have these additives will help improve fuel economy reduce emissions and main tain vehicle performance 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 ...

Page 1796: ...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 reformulated gasoline Materials Added to Fuel Indiscriminate ...

Page 1797: ...ION FUEL DELIVERY SYSTEM The fuel delivery system consists of the fuel pump module containing the electric fuel pump fuel filter fuel pressure regulator fuel gauge sending unit fuel level sensor and a separate fuel filter located at bottom of pump module fuel tubes lines hoses quick connect fittings fuel injector rail fuel injectors fuel tank fuel tank filler vent tube assembly fuel tank filler tu...

Page 1798: ...el pump module Fig 2 The sending unit consists of a float an arm and a variable resistor track The resistor track is used to send electrical signals to the Powertrain Control Module PCM for fuel gauge operation and for OBD II emission requirements For fuel gauge operation As fuel level increases the float and arm move up This decreases the sending unit resistance causing the fuel gauge to read ful...

Page 1799: ...he vapors are drawn into intake manifold Refer to Group 25 Emission Control System for additional information ROLLOVER VALVE S Refer to Group 25 Emission Control System for information FUEL INJECTORS 5 2L 5 9L ENGINES The fuel injectors are attached to the fuel rail Fig 4 5 2L V 8 engines use eight injectors The nozzle ends of the injectors are positioned into openings in the intake manifold just ...

Page 1800: ...ver 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 FUEL TANK FILLER TUBE CAP The loss of any fuel or vapor out of filler neck is prevented by the use of a pressure vacuum fuel tank filler tube cap Relief valves inside cap will release only under significant pressure of 6 58 to 8 44 ...

Page 1801: ...ere between fuel rail and fuel pump module If line is not kinked replace fuel pump module assembly Refer to Fuel Pump Module Removal Installation 4 If operating pressure is above 54 2 psi electric fuel pump is OK but fuel pressure regulator is defec tive Replace fuel filter fuel pressure regulator Refer to Fuel Filter Fuel Pressure Regulator Removal In stallation FUEL PUMP PRESSURE TEST 5 2L 5 9L ...

Page 1802: ...gasoline will remain in fuel supply line between the check valve and fuel injectors Fuel pressure that has dropped to 0 psi on a cooled down vehicle engine off is a normal condition When the elec tric fuel pump is activated fuel pressure should immediately rise to specification NOTE The fuel pressure test port is used on cer tain 5 2L 5 9L engines only If equipped the test port will be located on ...

Page 1803: ...fication but fuel pump can be heard operating through fuel fill cap opening check for a kinked damaged fuel sup ply line somewhere between fuel rail and fuel pump module b If line is not kinked damaged and fuel pres sure is OK but capacity is low replace fuel filter fuel pressure regulator The filter regulator may be serviced separately on certain applications Refer to Fuel Filter Fuel Pressure Re...

Page 1804: ...T The fuel gauge sending unit contains a variable resistor track As the float moves up or down elec trical resistance will change Refer to Group 8E Instrument Panel and Gauges for Fuel Gauge test ing To test the gauge sending unit only it must be removed from vehicle The unit is part of the fuel pump module Refer to Fuel Pump Module Removal Installation for procedures Measure the resistance across...

Page 1805: ...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 other end of the jumper wire to the positive side of the battery 8 Connect one end of a second jumper wire to the remaining injector terminal CAUTION Supplying power to an injector for more than 4 seconds will pe...

Page 1806: ...d the quick connect fitting can be separated from the fuel system component CAUTION The interior components o rings spac ers of this type of quick connect fitting are not ser viced separately but new 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 PRESSU...

Page 1807: ...l Pressure Release Procedure in this section 3 Clean the fitting of any foreign material before disassembly 4 To disconnect the quick connect fitting squeeze the plastic retainer tabs Fig 16 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...

Page 1808: ... retainer ring to aid in disconnection 5 After disconnection 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 li...

Page 1809: ...GINES Use the following procedure if the fuel rail is not equipped 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 21 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 ...

Page 1810: ...g 23 6 Before discarding filter regulator assembly inspect assembly to verify that o rings Fig 24 are intact If the smallest of the two o rings can not be found on bottom of filter regulator it may be neces sary to remove it from the fuel inlet passage in fuel pump module INSTALLATION 1 Clean recessed area in pump module where fil ter regulator is to be installed 2 Obtain new filter regulator two ...

Page 1811: ...move module from fuel tank INSTALLATION CAUTION Whenever the fuel pump module is ser viced the module gasket must be replaced 1 Using a new gasket position fuel pump module into opening in fuel tank 2 Position locknut over top of fuel pump module 3 Rotate module until arrow Fig 22 is pointed toward front of vehicle 12 o clock position This step must be done to prevent float float rod assembly from...

Page 1812: ...SURE EVEN WITH THE ENGINE TURNED OFF BEFORE SERVICING THE FUEL RAIL ASSEMBLY THE FUEL SYSTEM PRESSURE MUST BE RELEASED To release fuel pressure refer to the Fuel System Pressure Release Procedure found in this group CAUTION The left and right fuel rails are replaced as an assembly Do not attempt to separate the rail halves at the connecting hose Fig 30 Due to the design of this connecting hose it ...

Page 1813: ...e injector o ring 5 Push the right fuel rail down until fuel injec tors have bottomed on injector shoulder Push the left fuel rail down until fuel injectors have bottomed on injector shoulder 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 ...

Page 1814: ...tor bore in the intake manifold Seat injectors into manifold 3 Tighten fuel rail mounting bolts to 27 N m 20 ft lbs torque 4 Install cable mounting bracket and cables to intake manifold 5 Connect injector harness connectors to appro priate tagged injector 6 Connect fuel line and fuel line latch clip to fuel rail Refer to this group for procedures 7 Install protective cap to pressure test port fit ...

Page 1815: ...edures REMOVAL 1 Disconnect negative battery cable at battery 2 Release fuel system pressure Refer to the Fuel System Pressure Release Procedure in this group 3 Raise and support vehicle 4 Remove fuel tank fill hose and vent hose clamps at fuel tank filler tube Fig 36 Remove both hoses at fuel filler tube Fig 36 5 Remove rear tow hooks if equipped 6 Remove fuel tank skid plate mounting nuts bolts ...

Page 1816: ...to hydraulic jack 5 Raise tank into position while guiding fuel fill and vent hoses into and through access hole in body 6 Continue raising tank until positioned to body 7 Attach two fuel tank mounting straps and mounting nuts CAUTION The two mounting nuts must be tight ened until 83 86 mm 3 27 in 3 39 in is attained between end of mounting bolt and bottom of strap See insert Fig 37 Do not over ti...

Page 1817: ...nto opening in top of pedal arm Push plastic cable retainer clip into pedal arm opening until it snaps into place 3 Before starting engine operate accelerator pedal to check for any binding THROTTLE CABLE REMOVAL 1 From inside the vehicle hold up accelerator pedal Remove plastic cable retainer clip and throt tle cable core wire from upper end of pedal arm Fig 40 Plastic cable retainer clip snaps i...

Page 1818: ...edal arm Push cable retainer clip into pedal arm opening until it snaps in place 6 Before starting engine operate accelerator pedal to check for any binding SPECIFICATIONS VECI LABEL 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 co...

Page 1819: ... lbs Fuel Pump Module Locknut 34 N m 25 ft lbs Fuel Rail Mounting Bolts 4 0L Engine 11 N m 100 in lbs Fuel Rail Mounting Bolts 5 2L 5 9L Engines 23 N m 200 in lbs Fuel Tank Mounting Nuts Refer To Manual Text Fuel Hose Clamps 1 N m 15 in lbs ZG FUEL SYSTEM 14 25 SPECIFICATIONS Continued ...

Page 1820: ...ERATOR OUTPUT PCM INPUT 34 GOVERNOR PRESSURE SOLENOID PCM OUTPUT 41 IDLE AIR CONTROL IAC MOTOR 4 0L ENGINE PCM OUTPUT 40 IDLE AIR CONTROL IAC MOTOR 5 2L 5 9L ENGINES PCM OUTPUT 39 IGNITION CIRCUIT SENSE PCM INPUT 34 IGNITION COIL 4 0L ENGINES PCM OUTPUT 40 IGNITION COIL 5 2L 5 9L ENGINES PCM OUTPUT 40 INTAKE MANIFOLD AIR TEMPERATURE SENSOR 4 0L ENGINE PCM INPUT 34 INTAKE MANIFOLD AIR TEMPERATURE S...

Page 1821: ...RE SENSOR 4 0L ENGINE 65 INTAKE MANIFOLD AIR TEMPERATURE SENSOR 5 2L 5 9L ENGINES 64 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 4 0L ENGINE 60 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 5 2L 5 9L ENGINES 59 OXYGEN SENSOR 4 0L ENGINE 62 OXYGEN SENSOR 5 2L 5 9L ENGINES 61 POWERTRAIN CONTROL MODULE PCM 60 THROTTLE BODY 4 0L ENGINE 57 THROTTLE BODY 5 2L 5 9L ENGINES 56 THROTTLE POSITION SENSOR TPS 4 0L ENGINE 5...

Page 1822: ...atio during this mode of operation ENGINE START UP MODE This is an Open Loop mode The following actions occur when the starter motor is engaged The powertrain control module PCM receives inputs from Battery voltage Engine coolant temperature sensor Crankshaft position sensor Intake manifold air temperature sensor Manifold absolute pressure MAP sensor Throttle position sensor TPS Starter motor rela...

Page 1823: ... train control module PCM receives inputs from Air conditioning select signal if equipped Air conditioning request signal if equipped Battery voltage Engine coolant temperature sensor Crankshaft position sensor Intake manifold air temperature sensor Manifold absolute pressure MAP sensor Throttle position sensor TPS Camshaft position sensor signal in the distribu tor Park neutral switch gear indica...

Page 1824: ...e powertrain control module PCM Fig 1 oper ates the fuel system The PCM was formerly referred to as the SBEC or engine controller The PCM is a pre programmed tripple microprocessor digital com puter It regulates ignition timing air fuel ratio emission control devices charging system certain transmission features speed control air conditioning compressor clutch engagement and idle speed The PCM can...

Page 1825: ...d A C REQUEST SIGNAL Once A C has been selected the powertrain control module PCM receives the A C request signal from the clutch cycling pressure switch The input indicates that the evaporator pressure is in the proper range for A C application The PCM uses this input to cycle the A C compressor clutch through the A C relay It will also determine the correct engine idle speed through the idle air...

Page 1826: ...tion with the crankshaft position sensor to provide the powertrain control module PCM with inputs This is done to establish and maintain correct injector firing order Refer to Camshaft Position Sensor in Group 8D Ignition System for more information CRANKSHAFT POSITION SENSOR 5 2L 5 9L ENGINES PCM INPUT This sensor is a hall effect device that detects notches in the flywheel manual transmission or...

Page 1827: ...y richer air fuel mixtures and higher idle speeds This is done until normal operating temperatures are reached ENGINE COOLANT TEMPERATURE SENSOR 4 0L ENGINE PCM INPUT The engine coolant temperature sensor is installed in the thermostat housing Fig 7 and protrudes into the water jacket The sensor provides an input volt age to the powertrain control module PCM relating coolant temperature The PCM us...

Page 1828: ...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 downstream heated oxygen sensor input to the input from the upstream sensor the PCM calculates cata lytic ...

Page 1829: ...ltage to the powertrain control module PCM As engine load changes manifold pressure varies The change in manifold pressure causes MAP sensor 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...

Page 1830: ...automatic transmission is in Park Neutral or a drive gear selection This input is used to determine idle speed varying with gear selection fuel injector pulse width ignition timing advance and vehicle speed control operation Refer to Group 21 Transmis sions for testing replacement and adjustment infor mation TRANSMISSION GOVERNOR PRESSURE SENSOR PCM INPUT Provides a signal proportional to the tran...

Page 1831: ...rol IAC motor to maintain a desired MAP value Under idle conditions the PCM adjusts the IAC motor to maintain a desired engine speed POWER GROUND The power ground is used to control ground cir cuits for the following powertrain control module PCM loads Generator field winding Fuel injectors Ignition coil Certain relays solenoids AIR CONDITIONING A C CLUTCH RELAY PCM OUTPUT The A C relay is located...

Page 1832: ...tru ment panel to the left of the steering column Fig 14 For operation of the DRB scan tool refer to the appropriate Powertrain Diagnostic Procedures ser vice manual DUTY CYCLE EVAP PURGE SOLENOID VALVE PCM OUTPUT Refer to Group 25 Emission Control System for information FUEL INJECTORS 5 2L 5 9L ENGINES PCM OUTPUT The fuel injectors are attached to the fuel rail Fig 15 5 2L 5 9L V 8 engines use ei...

Page 1833: ...he Powertrain Control Module PCM regulates charging system voltage to the gen erator field source circuit The voltage range is 12 9 to 15 0 volts Jeep models of previous years had used the ASD relay to apply the 12 volt power sup ply to the generator field source circuit Refer to Groups 8A and 8C for charging system information GENERATOR FIELD DRIVER PCM OUTPUT This output from the Powertrain Cont...

Page 1834: ...w All idle speed functions are controlled by the PCM IGNITION COIL 5 2L 5 9L ENGINES PCM OUTPUT System voltage is supplied to the ignition coil pos itive terminal The powertrain control module PCM operates the ignition coil Base initial ignition timing is not adjustable The PCM adjusts ignition timing to meet changing engine operating conditions The ignition coil is located near the front of the r...

Page 1835: ...agement The powertrain control module PCM will deter mine when to engage and disengage the solenoid by monitoring vehicle miles per hour mph versus the output voltage of the throttle position sensor Also needed are various inputs from Transmission temperature sensor Output shaft speed sensor Module timer Engine rpm MAP sensor Brake switch MANUAL TRANSMISSION If equipped with a manual transmission ...

Page 1836: ...ions A throttle valve plate is used to supply air for above idle conditions The throttle position sensor TPS idle air control IAC motor and manifold absolute pressure sensor MAP are attached to the throttle body The acceler ator pedal cable speed control cable and transmis sion control cable when equipped are connected to the throttle arm A factory adjusted set screw is used to mechani cally limit...

Page 1837: ... wire con nector at the distributor is firmly connected to har ness connector Inspect spark plug condition Refer to Group 8D Ignition Connect vehicle to an oscilloscope and inspect spark events for fouled or damaged spark plugs or cables 6 Verify that generator output wire generator connector and ground wire are firmly connected to the generator 7 Inspect the system body grounds for loose or dirty...

Page 1838: ...y connected to injectors in the correct order Each harness connector is numerically tagged with the injector number INJ 1 INJ 2 etc of its corresponding fuel injector and cylinder number 18 Verify harness connectors are firmly con nected to idle air control IAC motor throttle posi tion sensor TPS and manifold absolute pressure MAP sensor Fig 28 19 Verify that wire harness connector is firmly conne...

Page 1839: ...or 27 Inspect fuel hoses at fuel pump gauge sender unit for cracks or leaks 28 Inspect transmission torque convertor housing automatic transmission or clutch housing manual transmission for damage to timing ring on drive plate flywheel 29 Verify that battery cable and solenoid feed wire connections to the starter solenoid are tight and clean Inspect for chaffed wires or wires rubbing up against ot...

Page 1840: ...nections Verify that coil secondary cable is firmly connected to coil Fig 37 5 Verify that distributor cap is correctly attached to distributor Be sure that spark plug cables are firmly connected to the distributor cap and the spark plugs are in their correct firing order Fig 38 Be sure that coil cable is firmly connected to distributor cap and coil Be sure that camshaft position sensor wire conne...

Page 1841: ...oning condenser for restrictions 15 Verify that the intake manifold air tempera ture sensor wire connector is firmly connected to har ness connector Fig 39 16 Verify that MAP sensor electrical connector is firmly connected to MAP sensor Fig 39 Also verify that rubber L shaped fitting from MAP sensor to the throttle body is firmly connected Fig 40 17 Verify that fuel injector wire harness connec to...

Page 1842: ...witch Refer to Automatic Transmission section of Group 21 25 Verify that the electrical harness connector is firmly connected to the vehicle speed sensor Fig 44 or Fig 45 26 Verify that fuel pump gauge sender unit wire connector is firmly connected to harness connector 27 Inspect fuel hoses at fuel pump gauge sender unit for cracks or leaks 28 Inspect transmission torque convertor housing automati...

Page 1843: ... between terminals 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 wir...

Page 1844: ...at sensor connector terminal A Fig 49 and PCM connector A 4 Repair the wire harness if necessary Refer to Group 8W Wiring Diagrams for cavity locations MANIFOLD ABSOLUTE PRESSURE MAP SENSOR TEST 4 0L ENGINE To perform a complete test of MAP sensor Fig 50 and its circuitry refer to DRB scan tool and appro priate Powertrain Diagnostics Procedures manual To test the MAP sensor only refer to the follo...

Page 1845: ...ons OXYGEN O2S SENSORS 5 2L 5 9L ENGINES To perform a complete test 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 52 The downstream O2S sensor is located on the out let end of the catalytic converter Fig 53 Fig ...

Page 1846: ...5 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 part of tool under the connector for removal The connector is snapped onto the sensor It is not equipped with a lock type tab 3 Test the resistance of the sensor with a high input impedance...

Page 1847: ...te Powertrain Diagnostics Proce dures manual To test the sensor only refer to the following 1 Disconnect the wire harness connector from the intake manifold air temperature sensor Fig 57 2 Test the resistance of the sensor with an input impedance digital volt ohmmeter The resistance as measured across the sensor terminals should be as shown in the previous Coolant Temperature sensor Intake Air Tem...

Page 1848: ... wire of the connector Check this at idle throttle plate closed and at wide open throttle WOT At idle TPS output voltage should be greater than 350 millivolts but less than 900 millivolts At wide open throttle TPS output voltage must be less than 4 5 volts The out put voltage should increase gradually as the throttle plate is slowly opened from idle to WOT THROTTLE POSITION SENSOR TPS 4 0L ENGINE ...

Page 1849: ... the left of the steering column Refer to the appropriate Powertrain Diagnostic Pro cedures service manual for DRB operation 7 Start the engine and allow to warm up 8 Using the DRB scan tool scroll through the menus as follows select Stand Alone DRB III select 1994 1997 Diagnostics select Engine select Sys tem Test select Minimum Air Flow 9 The DRB scan tool will count down to stabilize the idle r...

Page 1850: ...r attempt to adjust the engine idle speed using this screw All idle speed functions are controlled by the powertrain control module PCM REMOVAL 1 Remove the air duct at throttle body 2 Disconnect throttle body electrical connectors at MAP sensor IAC motor and TPS Fig 64 3 Remove vacuum line at throttle body 4 Remove all control cables from throttle body lever arm Refer to the Accelerator Pedal and...

Page 1851: ...4 Install four mounting bolts Tighten bolts to 11 N m 100 in lbs torque 5 Install control cables 6 Install electrical connectors 7 Install air duct at throttle body THROTTLE POSITION SENSOR TPS 5 2L 5 9L ENGINES REMOVAL The TPS is located on the side of the throttle body 1 Remove air duct at throttle body 2 Disconnect TPS electrical connector 3 Remove two TPS mounting bolts Fig 67 4 Remove TPS fro...

Page 1852: ...n when rotated 1 Install the TPS and retaining screws 2 Tighten screws to 7 N m 60 in lbs torque 3 Connect TPS electrical connector to TPS 4 Manually operate the throttle by hand to check for any TPS binding before starting the engine IDLE AIR CONTROL IAC MOTOR 5 2L 5 9L ENGINES The IAC motor is located on the back of the throt tle body REMOVAL 1 Remove air duct at throttle body 2 Disconnect elect...

Page 1853: ...rubber fitting is used to connect the MAP sensor to throttle body Fig 74 REMOVAL 1 Remove air duct at throttle body 2 Disconnect electrical connector at sensor 3 Remove two MAP sensor mounting bolts screws Fig 74 4 While removing MAP sensor slide the vacuum rubber L shaped fitting Fig 74 from the throttle body 5 Remove rubber L shaped fitting from MAP sen sor INSTALLATION 1 Install rubber L shaped...

Page 1854: ...ll air cleaner intake tube DUTY CYCLE EVAP CANISTER PURGE SOLENOID Refer to Group 25 Emission Control System for removal installation procedures POWERTRAIN CONTROL MODULE PCM The PCM is located on the cowl panel in the right rear side of the engine compartment Fig 77 REMOVAL 1 Disconnect the negative battery cable at bat tery 2 Remove cover over electrical connectors Cover snaps onto PCM 3 Remove ...

Page 1855: ...ed near outlet end of catalytic converter Refer to Fig 80 or Fig 81 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 vehicle 2 Downstream Sensor Only Disconnect O2S wir ing connector clip Fig 81 at body Remove clip from O2S electrical connector and discard 3 Disc...

Page 1856: ...d discard 3 Disconnect O2S pigtail harness wire connector from main connector CAUTION When disconnecting the sensor electri cal connector do not pull directly on wire going into sensor 4 Remove O2S sensor Snap On oxygen sensor 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 NO...

Page 1857: ...ck the six clips retaining the air cleaner cover to the air cleaner housing Fig 86 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 seated to air cleaner housing Fig 83 Air Cleaner 5 2L V 8 EngineShown CLAMPS ...

Page 1858: ...URE SENSOR 4 0L ENGINE The coolant temperature sensor is installed in the thermostat housing Fig 88 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 INSTALLATION 1 Apply sealant to sensor threads 2 Install co...

Page 1859: ...peed ometer pinion gear adapter Fig 91 or Fig 92 The pinion gear adapter is located on the extension hous ing of the transmission drivers side REMOVAL 1 Raise and support vehicle Fig 89 Air Temperature Sensor 5 2L 5 9LEngines Typical INTAKE MANIFOLD AIR TEMPERATURE SENSOR GENERATOR Fig 90 Intake Air Sensor Location 4 0LEngine IDLE AIR CONTROL PAS SAGE INLET IDLE AIR CONTROL MOTOR Fig 91 Vehicle Sp...

Page 1860: ...ecifica tions on VECI label 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 ensor All Engines 28 N m 20 ft lbs MAP Sensor Mounting Screws All Engi...

Page 1861: ...ir Metering 6714 Adapters Fuel Pressure Test 6541 6539 6631 or 6923 Pump IM240 EVAP Service Pressure 6917 O2S Oxygen Sensor Remover Installer C 4907 Test Kit Fuel Pressure 5069 Test Kit Fuel Pressure C 4799 B Fuel Line Removal Tool 6782 ZG FUEL SYSTEM 14 67 ...

Page 1862: ......

Page 1863: ...d the timing of when it is delivered to the engine The MSA controller is located under the left side rear seat The Powertrain Control Module PCM is mounted to a bracket located in the right rear side of the engine compartment behind the cool ant tank It interfaces with the MSA electronically to control other components The Fuel System consists of the fuel tank fuel injection pump engine mounted fu...

Page 1864: ...te fuel line The Fuel Tank Assembly consists of the fuel tank two pressure relief rollover valves fuel filler tube fuel tank module containing a fuel gauge send ing unit and a pressure vacuum filler cap FUEL REQUIREMENTS 2 5L DIESEL Refer to the Lubrication and Maintenance section of this manual for information Also refer to the Owner Manual Fig 2 MSA Controller Location 14 2 FUEL SYSTEM 2 5L DIES...

Page 1865: ...EATER RELAY 17 FUEL HEATER 17 FUEL INJECTION PUMP 18 FUEL INJECTORS 21 FUEL LEVEL SENSOR 17 FUEL RESERVOIR MODULE 23 FUEL TANK 22 HIGH PRESSURE LINES 24 SPECIFICATIONS FUEL INJECTOR FIRING SEQUENCE 25 FUEL SYSTEM PRESSURE 25 FUEL TANK CAPACITY 24 IDLE SPEED 25 DESCRIPTION AND OPERATION INTRODUCTION This Fuel Delivery section will cover components not controlled by the PCM For components con trolle...

Page 1866: ...sed for fuel gauge operation As the fuel level increases the float and arm move up This decreases the sending unit resistance caus ing the PCM to send a signal to the fuel gauge on the instrument panel to read full As the fuel level decreases the float and arm move down This increases the sending unit resistance causing the PCM to send a signal to the fuel gauge on the instru ment panel to read em...

Page 1867: ...g 5 In the electronically controlled injection pump the pump plunger works the same as the pump plunger in a mechanically controlled injection pump but the amount of fuel and the time the fuel is injected is controlled by the vehicle s MSA instead of by a mechanical governor assembly A solenoid controlled by the MSA is used in place of the mechanical gover nor assembly and it moves a control sleev...

Page 1868: ...refer to Fuel Injection Pump Timing in the Service Proce dures section of this group FUEL INJECTORS Fuel drain tubes Fig 6 are used to route excess fuel back to the overflow valve Fig 4 at the rear of the injection pump This excess fuel is then returned to the fuel tank through the fuel return line The injectors are connected to the fuel injection pump by the high pressure fuel lines A separate in...

Page 1869: ...stem components These are a single tab type a two tab type or a plastic retainer ring type Fig 8 Refer to Quick Connect Fittings in the Removal Installation section for more informa tion 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 I...

Page 1870: ... 7 C 45 F the resistance of the PTC element is lowered and allows current to flow through the fuel heater element warming the fuel When the tem perature is above 29 C 85 F the PTC element s resistance rises and current flow through the heater element stops Voltage to operate the fuel heater is supplied from the ignition key switch and through the fuel heater relay Refer to the following Fuel Heate...

Page 1871: ...system A visual check will help find these conditions It also saves unnecessary test and diag nostic time A thorough visual inspection of the fuel injection system includes the following checks 1 Be sure that the battery connections are tight and not corroded 2 Be sure that the 60 way connector is fully engaged with the PCM Fig 12 3 Be sure that the 68 way connector is fully engaged with the MSA F...

Page 1872: ...tom of the fuel filter water separator Inspect the connector for corrosion or damaged wires 11 Verify that the electrical pigtail connector sensor connector Fig 17 for the fuel injector sen sor is firmly connected to the engine wiring harness Inspect the connector for corrosion or damaged wires This sensor is used on the 1 cylinder injector only 12 Inspect for exhaust system restrictions such as p...

Page 1873: ...o the charge air cooler inter cooler inlet tube Verify that the charge air cooler output hose is properly connected to the cooler and the intake manifold Refer to Group 11 Exhaust Sys tem and Intake Manifold for information 21 Be sure that the vacuum hoses to the vacuum pump are connected and not leaking There are two pumps One is located on the front of engine inter nal and is driven from the cra...

Page 1874: ...pening into the engine s combustion chamber If the fuel injector does not operate properly the engine may misfire or cause other driveability problems A leak in the injection pump to injector high pres sure fuel line can cause many of the same symptoms as a malfunctioning injector Inspect for a leak in the high pressure lines before checking for a malfunc tioning fuel injector WARNING THE INJECTIO...

Page 1875: ...ystem in this group for more information on the Limp Home mode Fuel supply line restrictions can cause starting prob lems and prevent the engine from revving up The starting problems include low power and blue or white fog like exhaust Test all fuel supply lines for restrictions or blockage Flush or replace as neces sary Bleed the fuel system of air once a fuel supply line has been replaced Refer ...

Page 1876: ...proce dures WARNING DO NOT BLEED AIR FROM THE FUEL SYSTEM OF A HOT ENGINE DO NOT ALLOW FUEL TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN BLEEDING AIR FROM THE FUEL SYSTEM Some air enters the fuel system when the fuel fil ter or injection pump supply line is changed This small amount of air is vented automatically from the injection pump through the fuel drain manifold tubes if the filter was changed ac...

Page 1877: ...EN BLEEDING HIGH PRESSURE FUEL LINES WARNING DO NOT BLEED AIR FROM THE FUEL SYSTEM OF A HOT ENGINE DO NOT ALLOW FUEL TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN BLEEDING AIR FROM THE FUEL SYSTEM Bleed air from one injector at time 1 Loosen the high pressure fuel line fitting at the injector Fig 27 2 Crank the engine until all air has been bled from the line Do not operate the starter motor for longer ...

Page 1878: ...uel filter water separator assembly contains the fuel filter fuel heater element and fuel drain valve Fig 30 DRAINING WATER FROM FILTER BOWL Moisture water collects at the bottom of the filter separator in a plastic bowl Water entering the fuel injection pump can cause serious damage to the pump Note that the bulb will be illuminated for approximately 2 seconds each time the key is initially place...

Page 1879: ...an any resi due between the two metal probes at the top of the water in fuel sensor Do not use chemical cleaners as damage to the plastic bowl may result 5 Pour diesel fuel into the plastic bowl before installing bowl to bottom of fuel filter Do this to help prevent air from entering fuel injection pump while attempting to starting engine 6 Install filter bowl to bottom of filter 7 Install the ele...

Page 1880: ...erature sensor Fig 35 7 Disconnect the Fuel Injection Pump electrical connector at fuel pump Fig 34 8 Disconnect the main engine wiring harness from the glow plugs 9 Disconnect the four high pressure fuel lines from the fuel injection pump Also disconnect fuel lines at the fuel injectors For procedures refer to High Pressure Fuel Lines in this group Place a rag beneath the fittings to catch excess...

Page 1881: ...p shaft a Thread the adapter Fig 38 into the timing cover b Thread the gear puller into the injection pump drive gear Fig 38 This tool is also used to hold the gear in synchronization during pump removal c Remove the three injection pump to gear cover mounting nuts Fig 39 CAUTION This step must be done to prevent breakage of the three injection pump mounting flanges while gear is being removed d I...

Page 1882: ...nter clockwise as viewed from front until thedial indicator stops mov ing This rotation is about 20 to 30 11 Set the dial indicator to 0 mm Be sure the tip of dial indicator is touching the tip inside the adapter tool 12 Very slowly rotate the crankshaft clockwise until movement on dial indicator needle has stopped Do not rotate crankshaft after needle move ment has stopped Engine should be at TDC...

Page 1883: ... 29 Install engine accessory drive belt Refer to Group 7 Cooling System for procedures 30 Install negative battery cable to battery 31 Start the engine and bring to normal operat ing temperature 32 Check for fuel leaks FUEL INJECTORS Four fuel injectors are used on each engine Of these four two different types are used The fuel injector used on cylinder number one is equipped with a fuel injector ...

Page 1884: ...connect both the fuel fill and fuel vent rub ber hoses at the fuel tank 6 Disconnect fuel supply and return lines from the steel supply line Fig 45 The fuel reservoir module electrical connec tor has a retainer that locks it in place 7 Slide electrical connector lock to unlock 8 Push down on connector retainer Fig 47 and pull connector off module 9 Use a transmission jack to support fuel tank Remo...

Page 1885: ...e vehicle on hoist 4 Use a transmission jack to support the fuel tank Remove bolts from fuel tank straps Lower tank slightly 5 Clean area around fuel reservoir module and tank to keep dirt and foreign material out of tank 6 Disconnect fuel lines from fuel module by depressing quick connect retainers with thumb and fore finger 7 Slide module electrical connector lock to unlock 8 Push down on connec...

Page 1886: ...ng Do not bend the line while removing CAUTION Be sure that the high pressure fuel lines are installed in the same order that they were removed Prevent the injection pump delivery valve holders Fig 50 from turning when removing or installing high pressure lines from injection pump INSTALLATION 1 Carefully position each high pressure fuel line to the fuel injector and fuel injection pump delivery v...

Page 1887: ...INJECTOR FIRING SEQUENCE 1 3 4 2 FUEL SYSTEM PRESSURE Peak Injection Pressure Fuel Injection Pump Operating Pressure 40 000 45 000 kPa 5801 6526 psi Opening Pressure of Fuel Injector 15 000 15 800 kPa 2175 2291 psi ZG FUEL SYSTEM 2 5L DIESEL ENGINE 14 25 SPECIFICATIONS Continued ...

Page 1888: ...ION A C CLUTCH RELAY 36 ASD RELAY 36 ENGINE COOLANT TEMPERATURE SENSOR 37 ENGINE SPEED SENSOR 37 GLOW PLUG RELAY 38 GLOW PLUGS 38 POWERTRAIN CONTROL MODULE PCM 38 VEHICLE SPEED SENSOR 39 SPECIFICATIONS GLOW PLUG CURRENT DRAW 40 TORQUE CHART 2 5L DIESEL 40 GENERAL INFORMATION INTRODUCTION This section will cover components either regulated or controlled by the MSA controller and the Power train Con...

Page 1889: ...s through different system components These compo nents are referred to as MSA Outputs The sensors and switches that provide inputs to the MSA are con sidered MSA Inputs MSA Inputs are Air Conditioning Selection Theft Alarm ASD Relay Control Sleeve Position Sensor Fuel Temperature Sensor Mass Air Flow Sensor Accelerator Pedal Position Sensor Engine Coolant Temperature Sensor Low Idle Position Swit...

Page 1890: ...ill start to blink and the vehicle will not start The PCM cannot be flashed to remove the VTA BATTERY VOLTAGE PCM INPUT The battery voltage input provides power to the PCM It also informs the PCM what voltage level is being supplied by the generator once the vehicle is running The battery input also provides the voltage that is needed to keep the PCM memory alive The memory stores Diagnostic Troub...

Page 1891: ...housing at the left rear side of the engine block Fig 5 The engine speed sensor produces its own output signal If this signal is not received the MSA will not allow the engine to start The engine speed sensor input is used in conjunc tion with the first injector sensor to establish fuel injection pump timing The flywheel has four notches at its outer edge Fig 6 Each notch is spaced equally every 9...

Page 1892: ...s closed until the brake pedal is pressed DATA LINK CONNECTOR PCM AND MSA INPUT AND OUTPUT The 16 way data link connector diagnostic scan tool connector links the Diagnostic Readout Box DRB scan tool with the PCM and MSA The data link connector is located under the instrument panel near the bottom of steering column Fig 7 VEHICLE SPEED SENSOR MSA INPUT The vehicle speed sensor is located in the ex...

Page 1893: ...or additional information GLOW PLUG LAMP PCM OUTPUT The Glow Plug lamp malfunction indicator lamp illuminates on the message center each time the igni tion key switch is turned on It will stay on for about two seconds as a bulb test If the PCM receives an incorrect signal or no signal from certain sensors or components the lamp BLINKS This is a warning that the PCM has recorded a system or sensor ...

Page 1894: ...activated it will control the 12V 100 amp circuit for the operation of the four glow plugs With a cold engine the glow plug relay and glow plugs may be activated for a maximum time of 200 seconds Refer to the following Glow Plug Control chart for a temperature time comparison of glow plug relay operation In this chart Pre Heat and Post Heat times are mentioned Pre heat is the amount of time the gl...

Page 1895: ...E SPEED SENSOR TEST To perform a test of the engine speed sensor and its related circuitry refer to the DRB scan tool Diagnostic Trouble Codes Refer to On Board Diagnostics in Group 25 Emission Control System for a list of Diagnostic Trouble Codes DTC s for cer tain fuel system components ENGINE COOLANT TEMPERATURE SENSOR TEST The sensor is located on the side of cylinder head near the rear of fue...

Page 1896: ...ge color after 5 seconds If the tip did not glow after 5 seconds replace the glow plug Before discarding the glow plug check the position of the circuit breaker on the bottom of the plug tester It may have to be reset Reset if necessary b Continue to hold the tester button while observing the amp gauge and the 4 timer lamps When all 4 lamps are illuminated indicating a 20 second time lapse the amp...

Page 1897: ...her with the relay or the relay input from the MSA To test the relay only refer to Relays Operation Test ing in this section of the group If the relay test is good refer to the DRB scan tool Diagnostic Trouble Codes Refer to On Board Diagnostics in Group 25 Emission Control System for a list of Diagnostic Trouble Codes DTC s for cer tain fuel system components RELAYS OPERATION TESTING The followin...

Page 1898: ...nals 87A and 30 8 Disconnect jumper wires 9 Replace the relay if it did not pass the continu ity and resistance tests If the relay passed the tests it operates properly Check the remainder of the ASD and other relay circuits Refer to group 8W Wiring Diagrams MASS AIR FLOW SENSOR The Mass Air Flow MAF sensor can only be tested by checking for a fault code stored in the MSA If the mass air flow sens...

Page 1899: ...d near the rear of fuel injection pump Fig 20 REMOVAL WARNING HOT PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOV ING THE COOLANT TEMPERATURE SENSOR REFER TO GROUP 7 COOLING 1 Partially drain cooling system Refer to Group 7 Cooling 2 Disconnect electrical connector from sensor 3 Remove sensor from cylinder head INSTALLATION 1 Install a new cop...

Page 1900: ...e negative battery cable at the battery 2 Remove relay mounting bolt 3 Disconnect electrical connector at relay and remove relay INSTALLATION 1 Check condition of electrical connector for dam age or corrosion Repair as necessary 2 Install electrical connector to relay 3 Install relay to inner fender 4 Connect battery cable to battery POWERTRAIN CONTROL MODULE PCM The PCM is mounted to a bracket lo...

Page 1901: ...necessary 2 Engage 60 way connector into PCM Move slide bar to lock connector 3 Connect negative cable to battery VEHICLE SPEED SENSOR The vehicle speed sensor Fig 25 is located on the extension housing of the transmission for 2 wheel drive vehicle or on the transfer case housing for 4 wheel drive vehicles Fig 26 Fig 24 PCM Location Fig 25 Vehicle Speed Sensor Location 2 Wheel Drive Fig 26 Vehicle...

Page 1902: ...er gear adapter 2 Tighten sensor mounting bolt To prevent dam age to sensor or speedometer adapter be sure the sensor is mounted flush to the adapter before tight ening 3 Connect electrical connector to sensor SPECIFICATIONS GLOW PLUG CURRENT DRAW Initial Current Draw Approximately 22 25 amps per plug After 20 seconds of operation Approximately 9 12 amps per plug TORQUE CHART 2 5L DIESEL Fig 27 Se...

Page 1903: ...urn hoses The steering gear Fig 1 used 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 piston teeth mesh with the pitman shaft Turn ing the worm shaft turns the pitman shaft w...

Page 1904: ... 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 Repl...

Page 1905: ...on 3 Inspect and lubricate steering and suspension compnents 4 High friction in steering gear 4 Test and adjust 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 Steering gear mou...

Page 1906: ...Fig 1 NOTE Power steering pumps have different pres sure rates and are not interchangeable with other pumps DIAGNOSIS AND TESTING POWER STEERING PUMP The following procedure is used to test the opera tion of the power steering system on the vehicle This test will provide the flow rate of the power steering pump along with the maximum relief pressure Per form test any time a power steering system p...

Page 1907: ...essures are not the same against either stop the gear is leaking internally and must be repaired PUMP LEAKAGE DIAGNOSIS SERVICE PROCEDURES POWER STEERING PUMP INITIAL OPERATION WARNING THE FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING COMPONENTS CAUTION Use MOPAR Power Steering Fluid or equivalent Do not use automatic transmission fluid and do not overfill Wipe filler...

Page 1908: ... bolts Fig 3 6 Tilt pump downward and remove from engine 7 Remove pulley from pump INSTALLATION 1 Install pulley 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 ref...

Page 1909: ...mp assembly 4 With 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 DISASSEMBLY 1 Remove power steering pump 2 Clean exterior of pump 3 Clamp the pump body in a soft jaw vice 4 Pry up tab an...

Page 1910: ...nstall power steering pump Refer to Pump Replacement in this section SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Power Steering Pump Bracket Bolts 41 N m 30 ft lbs 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 Installer Power Steering PulleyC 4063 B Analyzer Set Power Steering Flow Pressure6815 Adapters Power Ste...

Page 1911: ...he power steering gear is a recirculating ball type gear Fig 1 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 piston teeth mesh with the pitman shaft Turn ing the worm shaft turns the pitman shaft which turns...

Page 1912: ... SHAFT WORM RACE BEARING THRUST VALVE CHECK HOUSING SCREW CLAMP GUIDE BALL BALLS PISTON RACK PLUG BEARING NEEDLE WASHER BACKUP RING RETAINING SHAFT STUB SPOOL VALVE BODY VALVE NUT COUPLING SHIELD RET AND LOCK THRUST SUPPORT ASSEM BLY SEAL PITMAN SHAFT SEAL DUST NUT ADJUSTER 19 10 STEERING ZG DESCRIPTION AND OPERATION Continued ...

Page 1913: ...o 88 N m 65 ft lbs torque 2 Install the column coupler shaft 3 Install the pitman arm and tighten nut to 251 N m 185 ft lbs 4 Connect pressure and return hoses to steering gear and tighten to 28 N m 21 ft lbs Fig 2 Coupling Shaft DASH PANEL COUPLER SHAFT BOLT GEAR BOLT COLUMN 1 SIDE COVER LEAK TORQUE SIDE COVER BOLTS TO SPECIFICATION REPLACE THE SIDE COVER SEAL IF THE LEAKAGE PERSISTS 2 ADJUSTER P...

Page 1914: ...posed end of pitman shaft and housing with a wire brush 2 Remove preload adjuster nut Fig 8 3 Rotate stub shaft to center the gear 4 Remove side cover bolts and remove side cover gasket and pitman shaft as an assembly Fig 8 5 Remove pitman shaft from the side cover 6 Remove dust seal from the housing with a seal pick Fig 9 CAUTION Use care not to score the housing bore when prying out seals and wa...

Page 1915: ...adjustment has been made 9 Install gasket to side cover and bend tabs around edges of side cover 10 Install pitman shaft assembly and side cover to housing 11 Install side cover bolts and tighten to 60 N m 44 ft lbs 12 Adjust Over Center Rotation Torque SPOOL VALVE DISASSEMBLY 1 Remove lock nut Fig 11 and Fig 8 Side Cover and Pitman Shaft SIDE COVER BOLTS PRELOAD ADJUSTER NUT SIDE COVER Fig 9 Pitm...

Page 1916: ...t and the stub shaft ASSEMBLY NOTE Clean and dry all components then lubri cate with power steering fluid 1 Install spool valve spool O ring 2 Install spool valve in valve body by pushing and rotating Hole in spool valve for stub shaft pin must be accessible from opposite end of valve body 3 Install stub shaft in valve spool and engage locating pin on stub shaft into spool valve hole Fig 17 NOTE N...

Page 1917: ...ly NOTE If any component of the thrust support assembly are damaged Fig 19 the assembly must be replaced 8 Install adjuster nut and lock nut 9 Adjust Thrust Bearing Preload and Over Cen ter Rotating Torque Fig 16 Valve Seals O RING SEALS Fig 17 Stub Shaft Installation NOTCH IN CAP VALVE BODY PIN Fig 18 Stub Shaft O Ring SPOOL VALVE BODY STUB SHAFT O RING Fig 19 Thrust Support Assembly SEAL SUPPORT...

Page 1918: ...ack piston balls 10 Remove clamp bolts clamp and ball guide Fig 22 11 Remove teflon ring and O ring from the rack piston Fig 23 12 Remove the adjuster lock nut and adjuster nut 13 Pull the stub shaft with the spool valve and thrust support assembly out of the housing 14 Remove the worm shaft from the housing Fig 24 ASSEMBLY NOTE Clean and dry all components and lubricate with power steering fluid ...

Page 1919: ...and hold tool tightly against worm shaft 8 Turn the worm shaft COUNTERCLOCKWISE while pushing on the arbor This will force the rack piston onto the arbor and hold the rack piston balls in place 9 Install the races and thrust bearing on the worm shaft and install shaft in the housing Fig 24 10 Install the stub shaft with spool valve thrust support assembly and adjuster nut in the housing 11 Install...

Page 1920: ...Fig 28 5 Measure back counterclockwise 13 mm 0 50 in and mark housing Fig 29 6 Rotate adjustment cap back counterclockwise with spanner wrench until hole is aligned with the second mark Fig 30 7 Install and tighten locknut to 108 N m 80 ft lbs Be sure adjustment cap does not turn while tightening the locknut OVER CENTER ROTATION TORQUE 1 Rotate the stub shaft back and forth to drain the remaining ...

Page 1921: ...he gear should be readjusted 7 If an adjustment is necessary turn the pitman shaft adjuster screw to obtain the correct preload 0 7 1 7 N m 6 15 in lbs NOTE To increase the preload turn the screw CLOCKWISE 8 Prevent the adjuster screw from turning while tightening adjuster lock nut Tighten the adjuster lock nut to 49 N m 36 ft lbs Fig 30 Aligning To The Second Mark FIRST MARK SECOND MARK SPANNER W...

Page 1922: ...SCRIPTION TORQUE Power Steering Gear Adjustment Cap Locknut 108 N m 80 ft lbs Adjustment Screw Locknut 49 N m 36 ft lbs Gear to Frame Bolts 88 N m 65 ft lbs Pitman Shaft Nut 251 N m 185 ft lbs 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 Re...

Page 1923: ...efer to Group 8 M and follow all WARNINGS and CAUTIONS WARNING THE AIRBAG 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 ...

Page 1924: ...ION STEERING COLUMN WARNING BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DIS ARMED FAILURE TO DO SO MAY RESULT IN ACCI DENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY REFER TO GROUP 8M RESTRAINT SYSTEMS FOR SERVICE PROCE DURES REMOVAL 1 Position front wheels straight ahead 2 Disconnect the negative ground cable from the battery 3 Remove airbag steering wheel and cloc...

Page 1925: ...olumn to coupler Do not apply force at the top of the steering col umn shaft 2 Remove the column shaft shipping lock pin installed in service column 3 Ensure the ground clip is on spacer slot Fig 8 4 Install the Interlock cable from the steering column Refer to Group 21 Transmission and Trans fer Case Fig 6 Trim Panel Column Cover KNEE BLOCKER TRIM PANEL Fig 7 Steering Column Wiring Harness AIR BA...

Page 1926: ...the toe plate attaching nuts to 12 N m 105 in lbs 11 Tighten the coupler pinch bolt to 49 N m 36 ft lbs 12 Install the heater cross over tube under the column 13 Install the upper and lower shrouds and tilt lever 14 Install the trim panel column cover and sup port plate 15 Install the clockspring steering wheel and airbag refer to Group 8M Passive Restraint Sys tems for procedures 16 Connect the b...

Page 1927: ...a tion And Maintenance for the recommended mainte nance schedule SERVICE PROCEDURES STEERING LINKAGE NOTE If any steering components are replaced or serviced an alignment must be performed to ensure the vehicle meets all alignment specifica tions The tie rod end and ball stud seals should be inspected during all oil changes If a seal is damaged it should be replaced Before installing a new seal in...

Page 1928: ...e cotter pin and nut from the drag link at the pitman arm 2 Remove the drag link ball stud from the pit man arm with a puller 3 Remove the nut and washer from the steering gear shaft Mark the pitman shaft and pitman arm for installation reference Remove the pitman arm from steering gear with Puller C 4150A Fig 5 INSTALLATION 1 Align and install the pitman arm on steering gear shaft 2 Install the w...

Page 1929: ...Remove the steering dampener retaining nut and bolt from the axle bracket Fig 1 3 Remove the cotter pin and nut from the ball stud at the drag link 4 Remove the steering dampener ball stud from the drag link using C 3894 A puller INSTALLATION 1 Install the steering dampener to the axle bracket and drag link 2 Install the steering dampener bolt in the axle bracket and tighten nut to 74 N m 55 ft lb...

Page 1930: ......

Page 1931: ...g Solenoid SPSS Speed Proportional Steering Gear SPSG Speed Proportional Steering provides variable power assist based on inputs from the Vehicle Speed Sensor and Steering Wheel Speed Sensor The sen sors are monitored by the Speed Proportional Steer ing Control Module The module controls the operation of the Speed Proportional Steering Solenoid which regulated power steering pump flow rate When pa...

Page 1932: ...AL STEERING SOLENOID The solenoid is mounted to the power steering pump outlet port Fig 3 The solenoid controls pump output volume by moving a metering rod in and out of a fixed orifice The SPSCM energizes and de ener gizes the solenoid to move the metering rod up to 250 times per second By varying the time energized ver sus de energize steering pump output volume and steering assist is controlled...

Page 1933: ...onduit 3 inch long by 3 4 inch ID Move turn signal canceller off to one side and insure locat ing tab is in the proper position and push the sensor down on the shaft CAUTION The pipe installer must only touch the inner metal ring of the sensor and not the plastic housing or the sensor will be damaged 2 Install clock spring refer to Group 8M Electri cal for procedure 3 Install steering wheel 4 Inst...

Page 1934: ......

Page 1935: ...CHARTS RE TRANSMISSION 15 GEARSHIFT CABLE 9 HYDRAULIC PRESSURE TEST 11 OVERDRIVE ELECTRICAL CONTROLS 9 PARK NEUTRAL POSITION SWITCH 9 PRELIMINARY DIAGNOSIS 8 ROAD TESTING 10 STALL TEST ANALYSIS 13 THROTTLE VALVE CABLE 9 SERVICE PROCEDURES ALUMINUM THREAD REPAIR 28 CONVERTER DRAINBACK CHECK VALVE SERVICE 26 FLUID AND FILTER REPLACEMENT 25 FLUID LEVEL CHECK 25 FLUSHING COOLERS AND TUBES 27 OIL COOLE...

Page 1936: ... 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 torque converter clutch is controlled by the Powertrain Control Mod u...

Page 1937: ...Fig 1 42 44 RE Transmission ZG TRANSMISSION AND TRANSFER CASE 21 3 GENERAL INFORMATION Continued ...

Page 1938: ...replaced if a transmission failure results in large amounts of metal or fiber contamination in the fluid TRANSMISSION GEAR RATIOS Gear ratios are 1st 2 74 1 2nd 1 54 1 3rd 1 00 1 4th 0 69 1 Rev 2 21 GEARSHIFT MECHANISM The shift mechanism is cable operated and pro vides six shift positions The shift positions are Park P Reverse R Neutral N Drive D Manual Second 2 Manual Low 1 Manual low 1 range pr...

Page 1939: ...gagement of the fourth gear overdrive clutch the converter clutch and governor pressure Normal resistance value for the thermistor at room tempera ture is approximately 1000 ohms The PCM prevents engagement of the converter clutch and overdrive clutch when fluid temperature is below approximately 10 C 50 F If fluid temperature exceeds 126 C 260 F the PCM causes a 4 3 downshift and engage the con v...

Page 1940: ...ttle position Shift Valve Flow Control The manual valve is operated by the gearshift link age and provides the operating range selected by the driver The 1 2 shift valve provides 1 2 or 2 1 shifts and the 2 3 shift valve provides 2 3 or 3 2 shifts The kickdown valve provides forced 3 2 or 3 1 downshifts depending on vehicle speed Downshifts occur when the throttle is opened beyond downshift detent...

Page 1941: ...he overdrive piston into contact with the overdrive clutch The direct clutch is disengaged before the overdrive clutch is engaged The boost valve provides increased fluid apply pressure to the overdrive clutch during 3 4 upshifts and when accel erating in fourth gear The 3 4 accumulator cushions overdrive clutch engagement to smooth 3 4 upshifts The accumulator is charged at the same time as apply...

Page 1942: ...ck fluid level and condition 3 Adjust throttle and gearshift linkage if com plaint was based on delayed erratic or harsh shifts 4 Road test and note how transmission upshifts downshifts and engages 5 Perform stall test if complaint is based on slug gish acceleration Or if abnormal throttle opening is needed to maintain normal speeds with a properly tuned engine 6 Perform hydraulic pressure test if...

Page 1943: ...en the shifter is in any other gear or neu tral position the ignition key cylinder should not rotate to the LOCK position 3 Shifting out of PARK should be possible when the ignition key cylinder is in the OFF position 4 Shifting out of PARK should not be possible while applying 25 lb maximum handle pushbutton force and ignition key cylinder is in the RUN or START positions unless the foot brake pe...

Page 1944: ...overrunning clutch is faulty Similarly if slippage occurs in any two forward gears the rear clutch is slipping Applying the same method of analysis note that the front and rear clutches are applied simulta neously only in D range third and fourth gear If the transmission slips in third gear either the front clutch or the rear clutch is slipping If the transmission slips in fourth gear but not in t...

Page 1945: ...rotate freely 2 Connect 100 psi Gauge C 3292 to accumulator port Then connect 300 psi Gauge C 3293 SP to rear servo port 3 Disconnect throttle and gearshift cables from levers on transmission valve body manual shaft 4 Have helper start and run engine at 1000 rpm 5 Move transmission shift lever fully forward into 1 range 6 Gradually move transmission throttle lever from full forward to full rearwar...

Page 1946: ...n firmly apply service brakes so wheels will not rotate 4 Note governor pressure Governor pressure should be no more than 20 6 kPa 3 psi at curb idle speed and wheels not rotat ing If pressure exceeds 20 6 kPa 3 psi a fault exists in governor pressure control system 5 Release brakes slowly increase engine speed and observe speedometer and pressure test gauge do not exceed 30 mph on speedometer Gov...

Page 1947: ...y Stall Speed Normal But Acceleration Poor If stall speeds are normal 1800 2300 rpm but abnormal throttle opening is required for accelera tion or to maintain cruise speed the converter over running clutch is seized The torque converter will have to be replaced Converter Noise During Test A whining noise caused by fluid flow is normal dur ing a stall test However loud metallic noises indi cate a d...

Page 1948: ...s two items must be established before repair 1 Verify that a leak condition actually exists 2 Determined the true source 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 Throug...

Page 1949: ...ter hub with transmission fluid or petroleum jelly and install con verter 9 Install transmission and converter housing dust shield 10 Lower vehicle DIAGNOSIS TABLES AND CHARTS RE TRANSMISSION The diagnosis charts provide additional reference when diagnosing a transmission fault The charts provide general information on a variety of transmis sion overdrive unit and converter clutch fault condi tion...

Page 1950: ...AYED ENGAGEMENT FROM NEUTRAL TO DRIVE OR REVERSE 1 Fluid Level Low 1 Correct level and check for leaks 2 Filter Clogged 2 Change filter 3 Gearshift Linkage Misadjusted 3 Adjust linkage and repair linkage if worn or damaged 4 Torque Converter Drain Back Oil drains from torque converter into transmission sump 4 If vehicle moves normally after 5 seconds after shifting into gear no repair is necessary...

Page 1951: ... and reassemble linkage as needed Replace worn damaged parts 3 U Joint Axle Transfer Case Broken 3 Perform preliminary inspection procedure for vehicle that will not move Refer to procedure in diagnosis section 4 Filter Plugged 4 Remove and disassemble transmission Repair or replace failed components as needed Replace filter If filter and fluid contained clutch material or metal particles an overh...

Page 1952: ...y if needed NO REVERSE D RANGES OK 1 Gearshift Linkage Cable Misadjusted Damaged 1 Repair or replace linkage parts as needed 2 Park Sprag Sticking 2 Replace overdrive annulus gear 3 Rear Band Misadjusted Worn 3 Adjust band replace 4 Valve Body Malfunction 4 Remove and service valve body Replace valve body if any valves or valve bores are worn or damaged 5 Rear Servo Malfunction 5 Remove and disass...

Page 1953: ... repair as required 5 Valve Body Malfunction 5 Perform hydraulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 6 TPS Malfunction 6 Replace sensor check with DRB scan tool 7 PCM Malfunction 7 Check with DRB II and replace if required 8 Valve Body Malfunction 8 Repair sticking 1 2 2 3 shift valves governor plugs 3 4 solenoid 3 4 shift va...

Page 1954: ...o determine cause 7 Rear Servo Leaking 7 Air pressure check clutch servo operation and repair as required 8 Band Linkage Binding 8 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level Low 1 Add fluid and check for leaks 2 Fluid Foaming 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage...

Page 1955: ... required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan 8 Converter Clutch 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 ...

Page 1956: ...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 connection as necessary 4 Distance or Coolant Sensor Malfunction 4 Test both sensors with test lamp or volt ohmmeter and replace faulty sensor 5 TPS Malfunction 5 Check with DRB scan tool and replace if necessary ...

Page 1957: ...ttle Valve Cable Misadjusted 2 Adjust throttle valve cable 3 Overdrive Clutch Pack Worn Burnt 3 Remove unit and rebuild clutch pack 4 TPS Faulty 4 Test with DRB scan tool and replace TPS 5 Overdrive Clutch Bleed Orifice Plugged 5 Disassemble transmission and replace orifice 6 Overdrive Solenoid or Wiring Shorted Open 6 Test solenoid and check wiring for loose corroded connections or shorts grounds...

Page 1958: ...rews 8 Gasket Damaged or Bolts are Loose 8 Replace bolts or gasket or tighten both 9 Adapter Extension Gasket Damaged Leaks Damaged 9 Replace gasket 10 Neutral Switch Leaks Damaged 10 Replace switch and gasket 11 Converter Housing Area Leaks 11 Check for leaks at seal caused by worn seal or burr on converter hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged...

Page 1959: ...g may cause leakage out the pump vent which can be mistaken for a pump seal leak Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train This will significantly reduce fluid life FLUID AND FILTER REPLACEMENT Refer to the Maintenance Schedules in Group 0 Lubrication and Maintenance for proper service intervals The service fluid fill afte...

Page 1960: ... fluid level If level is low add fluid to bring level to MIN mark on dipstick 7 Drive vehicle until transmission fluid is at nor mal operating temperature 8 With the engine running at curb idle speed the gear selector in NEUTRAL and the parking brake applied check the transmission fluid level CAUTION Do not overfill transmission fluid foam ing and shifting problems can result 9 Add fluid to bring ...

Page 1961: ... or any other corrosive liquids 2 Reinstall filler plug on Tool 6906 3 Verify pump power switch is turned OFF Con nect red alligator clip to positive battery post Connect black alligator clip to a good ground 4 Disconnect the cooler lines at the transmission NOTE When flushing transmission cooler and lines ALWAYS reverse flush 5 Connect the BLUE pressure line to the OUT LET From cooler line 6 Conn...

Page 1962: ...er access cover 8 If transmission is being removed for overhaul remove transmission oil pan drain fluid and reinstall pan 9 Remove fill tube bracket bolts and pull tube out of transmission Retain fill tube O ring On 4 x 4 models it will also be necessary to remove bolt attaching transfer case vent tube to converter hous ing Fig 16 10 Mark torque converter and drive plate for assembly alignment Not...

Page 1963: ...ate 13 Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft 14 Install bolts attaching converter housing to engine 15 Install rear support Then lower transmission onto crossmember and install bolts attaching trans mission mount to crossmember 16 Remove engine support fixture 17 Install crankshaft position sensor 18 Install vehicle speed senso...

Page 1964: ... into oil pump 5 While pushing torque converter inward rotate converter until converter is fully seated in the oil pump gears 6 Check converter seating with a scale and straightedge Fig 18 Surface of converter lugs should be 1 2 in to rear of straightedge when con verter is fully seated 7 If necessary temporarily secure converter with C clamp attached to the converter housing 8 Install the transmi...

Page 1965: ... Do this before installing assembly in housing Then lubricate pinion teeth with transmission fluid 7 Note index numbers on adapter body Fig 22 These numbers will correspond to number of teeth on pinion 8 Install speedometer assembly in housing 9 Rotate adapter until required range numbers are at 6 o clock position Be sure range index num bers correspond to number of teeth on pinion gear 10 Install...

Page 1966: ... lock button 7 Remove and discard the shift cable adjustment gauge clip from the park gate of the shifter BRAKE TRANSMISSION SHIFT INTERLOCK REMOVAL 1 Lower the steering column 2 Remove two screws retaining the interlock mechanism to the column Fig 24 Unsnap the mechanism from column 3 Remove the center console and related trim Refer to Group 23 Body for proper procedures 4 Disconnect and remove t...

Page 1967: ...ody Fig 28 9 Remove governor body gasket 10 Remove retainer holding pressure sensor to governor body 11 Pull pressure sensor from governor body Fig 29 INSTALLATION Before installing the pressure sensor and solenoid in the governor body replace O ring seals clean the gasket surfaces and replace gasket 1 Lubricate O ring on pressure sensor with transmission fluid 2 Align pressure sensor to bore in g...

Page 1968: ...lve body assembly REMOVAL 1 Shift transmission into NEUTRAL 2 Raise vehicle 3 Remove gearshift and throttle levers from shaft of valve body manual lever 4 Disconnect wires at solenoid case connector Fig 30 5 Position drain pan under transmission oil pan 6 Remove transmission oil pan and gasket 7 Remove fluid filter from valve body 8 Remove bolts attaching valve body to transmis sion case 9 Lower v...

Page 1969: ...d into this cavity 8 Install accumulator springs and piston into case Then swing valve body over piston and outer spring to hold it in place 9 Align accumulator piston and outer spring manual lever shaft and electrical connector in case 10 Then seat valve body in case and install one or two bolts to hold valve body in place 11 Tighten valve body bolts alternately and evenly to 11 N m 100 in lbs to...

Page 1970: ...gasket drain oil and reinstall pan 6 If overdrive unit had malfunctioned or if fluid is contaminated remove entire transmission If diag nosis indicated overdrive problems only remove just the overdrive unit 7 Support transmission with transmission jack 8 Remove rear crossmember 9 Remove vehicle speed sensor and speedometer adapter if necessary 10 Remove bolts attaching overdrive unit to transmissi...

Page 1971: ...hrust bearing in overdrive unit sliding hub Use petroleum jelly to hold bearing in position CAUTION Be sure the shoulder on the inside diameter of the bearing is facing forward 8 Verify that splines in overdrive planetary gear and overrunning clutch hub are aligned with Align ment Tool 6227 2 Overdrive unit cannot be installed if splines are not aligned If splines have rotated out of alignment uni...

Page 1972: ... hous ing 2 Using a suitable driver drive bearing into housing until the snap ring groove is visible 3 Install snap ring to hold bearing into housing Fig 41 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehicle OUTPUT SHAFT FRONT BEARING REMOVAL 1 Remove overdrive unit from the vehicle 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft front ...

Page 1973: ... 44 4 Remove retainer plate governor body and gas ket from transfer plate Fig 45 5 Disconnect wires from governor pressure sen sor if not done previously 6 Remove governor pressure sensor from gover nor body Sensor is retained in body with M shaped spring clip Fig 46 Remove clip with small pointed tool and slide sensor out of body 7 Remove governor pressure solenoid by pulling it straight out of b...

Page 1974: ...INING CLIP GOVERNOR BODY GOVERNOR PRESSURE SENSOR TRANSMISSION FLUID TEMPERATURE THERMISTOR Fig 47 Governor Pressure Solenoid PRESSURE SOLENOID O RING GOVERNOR Fig 48 Solenoid Harness Case Connector ShoulderBolt SOLENOID HARNESS CASE CONNECTOR 3 4 ACCUMULA TOR HOUSING Fig 49 Unhooking Solenoid Harness From AccumulatorCover Plate OVERDRIVE CON VERTER SOLENOID WIRE HARNESS 3 4 ACCUMULA TOR COVER PLA...

Page 1975: ...L TOOL 6583 POSI TIONED ON DETENT HOUS ING Fig 55 Park Rod MANUAL LEVER E CLIP PARK ROD Fig 51 Solenoid Assembly CASE CON NECTOR GOVERNOR SOLENOID WIRES CONVERTER CLUTCH SOLE NOID SOLENOID SCREWS OVERDRIVE SOLENOID GOVERNOR SENSOR WIRES HARNESS Fig 52 Boost Valve Cover Location BOOST VALVE HOUSING AND COVER BOOST VALVE TUBE Fig 53 Boost Valve Components SPRING AND VALVE RETAINER COVER SCREWS BOOST...

Page 1976: ...Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate Fig 59 Hold bracket firmly against spring tension while removing last screw Fig 56 Throttle Lever E Clip And Washer THROTTLE LEVER SHAFT E CLIP AND WASHER MANUAL SHAFT Fig 57 Manual And Throttle Lever PARK ROD MANUAL LEVER ASSEMBLY THROTTLE LEVER Fig 58 Detent Ball And Spring DETENT HOUS ING DETENT SPRING DET...

Page 1977: ...sing from valve body Fig 64 27 Bend back tabs on boost valve tube brace Fig 65 28 Remove boost valve connecting tube Fig 66 Disengage tube from upper housing port first Then rock opposite end of tube back and forth to work it out of lower housing CAUTION Do not use tools to loosen or pry the connecting tube out of the valve body housings Loosen and remove the tube by hand only Fig 60 Adjusting Scr...

Page 1978: ... 35 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 70 VALVE BODY UPPER HOUSING DISASSEMBLY 1 Note location of check balls in valve body upper housing Fig 71 Then remove the one large diame ter and the six smaller diameter check balls 2 Remove governor plug and shuttle valve covers Fig 73 Fig 63 3 4 Shift And Converter Clutch Va...

Page 1979: ...trol valve and spring Fig 74 10 Remove 1 2 shift valve and spring Fig 74 11 Remove 2 3 shift valve and spring from valve body Fig 74 12 Remove pressure plug cover Fig 74 13 Remove line pressure plug sleeve throttle pressure plug and spring Fig 74 Fig 68 Transfer Plate UPPER HOUS ING TRANSFER PLATE Fig 69 Upper Housing Separator Plate TRANSFER PLATE UPPER HOUSING SEPARA TOR PLATE FILTER SCREEN BRAC...

Page 1980: ...ER HOUSING BOOST VALVE COVER Fig 74 Upper Housing Shift Valve And PressurePlug Locations UPPER HOUSING 1 2 SHIFT VALVE AND SPRING 2 3 SHIFT VALVE AND SPRING 2 3 THROTTLE PLUG LIMIT VALVE HOUSING LIMIT VALVE COVER LIMIT VALVE AND SPRING RETAINER 1 2 SHIFT CONTROL VALVE AND SPRING PRESSURE PLUG COVER LINE PRESSURE PLUG PLUG SLEEVE THROTTLE PRESSURE SPRING AND PLUG 21 46 TRANSMISSION AND TRANSFER CAS...

Page 1981: ...ition do not overtighten the transfer plate and valve body screws during reassembly Over tightening can distort the housings resulting in valve sticking cross leakage and unsatisfactory operation Tighten valve body screws to recom mended torque only Fig 75 Lower Housing Shift Valves And Springs 3 4 ACCUMULATOR PISTON AND SPRING 3 4 ACCUMULATOR HOUSING 3 4 SHIFT VALVE AND SPRING PLUG SPRING RETAINE...

Page 1982: ...4 Install end plate on housing TRANSFER PLATE ASSEMBLY 1 Install rear clutch and rear servo check balls in transfer plate Fig 77 2 Install filter screen in upper housing separator plate Fig 78 3 Align and position upper housing separator plate on transfer plate Fig 79 4 Install brace plate Fig 79 Tighten brace attaching screws to 4 N m 35 in lbs torque 5 Install remaining separator plate attaching...

Page 1983: ... out to sides when tighten ing screws Fig 83 UPPER HOUSING VALVE AND PLUG ASSEMBLY Refer to Fig 84 Fig 85 and Fig 86 to perform the following steps 1 Lubricate valves plugs springs with clean transmission fluid 2 Assemble regulator valve line pressure plug sleeve throttle plug and spring Insert assembly in upper housing and install cover plate Tighten cover plate screws to 4 N m 35 in lbs torque 3...

Page 1984: ...g 8 Install shuttle valve cover plate Tighten cover plate screws to 4 N m 35 in lbs torque 9 Install 1 2 and 2 3 valve governor plugs in valve body 10 Install shuttle valve primary spring and throttle plug 11 Align and install governor plug cover Tighten cover screws to 4 N m 35 in lbs torque Fig 84 Shuttle And Boost Valve Components RETAINER BOOST VALVE BOOST VALVE PLUG SPRING GUIDES E CLIP SHUTT...

Page 1985: ...Fig 85 Upper Housing Control Valve Locations Fig 86 Upper Housing Shift Valve And PressurePlug Locations ZG TRANSMISSION AND TRANSFER CASE 21 51 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1986: ... 2 Loosely attach accumulator housing with right side screw Fig 90 Install only one screw at this time as accumulator must be free to pivot upward for ease of installation 3 Install 3 4 shift valve and spring 4 Install converter clutch timing valve and spring 5 Position plug on end of converter clutch valve spring Then compress and hold springs and plug in place with fingers of one hand 6 Swing ac...

Page 1987: ...l short upper bracket screws first and long bottom 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 17 Lubricate solenoid case connector O rings and shaft of manual lever with light coat of petroleum jelly 18 Obtain new fluid filter for valve body but do not install filter at this time 19 If line pressure and or t...

Page 1988: ...e Then install and tighten governor body screws to 4 N m 35 in lbs torque 9 Connect harness wires to governor pressure solenoid and governor pressure sensor Fig 100 10 Perform Line Pressure and Throttle Pressure adjustments refer to adjustment section of this group for proper procedures 11 Install fluid filter and pan 12 Lower vehicle 13 Fill transmission with recommended fluid and road test vehic...

Page 1989: ...f 10 bolts are used Note different bolt lengths for assembly refer ence 10 Remove valve body assembly Push valve body harness connector out of case Then work park rod and valve body out of case Fig 103 Fig 98 Governor Body And Gasket GOVERNOR BODY GASKET Fig 99 Pressure Solenoid Retainer PRESSURE SOLENOID RETAINER GOVERNOR Fig 100 Governor Pressure Sensor And SolenoidConnectors PRESSURE SENSOR PRE...

Page 1990: ...p slide hammer weights outward to remove pump and reaction shaft support assembly from case Fig 105 17 Loosen front band adjusting screw until band is completely loose 18 Squeeze front band together and remove band strut Fig 106 Fig 103 Valve Body Removal GOVERNOR PRESSURE SENSOR GOVERNOR PRESSURE SOLENOID VALVE BODY PARK ROD ACCUMULATOR PISTON Fig 104 Accumulator Piston And Springs ACCUMULATOR PI...

Page 1991: ...109 Set clutch units aside for overhaul 24 Remove intermediate shaft thrust washer from front end of shaft or from rear clutch hub Fig 110 Fig 107 Removing Installing Front Band Lever FRONT BANDLEVER Fig 108 Removing Front Rear Clutch Assemblies INPUT SHAFT FRONT CLUTCH REAR CLUTCH Fig 109 Separating Front Rear Clutch Assemblies FRONT CLUTCH REAR CLUTCH Fig 110 Removing Intermediate Shaft ThrustWa...

Page 1992: ...w reverse drum snap ring Fig 114 31 Remove low reverse drum and reverse band 32 Remove overrunning clutch roller and spring assembly as a unit Fig 115 33 Compress front servo rod guide about 1 8 inch with Valve Spring Compressor C 3422 B Fig 116 34 Remove front servo rod guide snap ring Exercise caution when removing snap ring Fig 111 Removing Intermediate Shaft ThrustPlate INTERMEDIATE SHAFT HUB ...

Page 1993: ...seals and O rings to ease installation Petroleum jelly can also be used to hold thrust washers thrust plates and gaskets in position during assembly However do not use chassis grease bear ing grease white grease or similar lubricants on any transmission part These types of lubricants can eventually block or restrict fluid passages and inter fere with valve operation Use petroleum jelly only Do not...

Page 1994: ... 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 122 e Turn drum back and forth Drum should rotate freely in clockwise direction and lock in counterclockwise direction as viewed from front of case Fig 11...

Page 1995: ...g 125 Fig 122 Installing Low Reverse Drum REAR BAND LOW REVERSE DRUM Fig 123 Installing Low Reverse Drum RetainingSnap Ring LOW REVERSE DRUM HUB OF OVERDRIVE PIS TON RETAINER LOW REVERSE DRUM SNAP RING Fig 124 Rear Band Lever And Pivot Pin Installation REAR BAND LEVER LEVER PIVOT PIN Fig 125 Installing Planetary Geartrain PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT ASSEMBLY ZG TRANSMISSION AND TRAN...

Page 1996: ...ll front clutch on rear clutch Fig 129 Rotate front clutch retainer back and forth until completely seated on rear clutch retainer Fig 126 Installing Intermediate Shaft ThrustPlate INTERMEDIATE SHAFT HUB INTERMEDIATE SHAFT THRUST PLATE Fig 127 Input Shaft Seal Ring Location INPUT SHAFTTEFLON SEAL RING METAL SEAL RING REAR CLUTCH RETAINER Fig 128 Installing Rear Clutch Thrust Washer REAR CLUTCH RET...

Page 1997: ... and rear clutch units as assembly Fig 132 Align rear clutch with front annulus gear and install assembly in driving shell Be sure out put shaft thrust washer and thrust plate are not displaced during installation 19 Carefully work assembled clutches back and forth 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 ...

Page 1998: ...t in and out and record read ing End play should be 0 56 2 31 mm 0 022 0 091 in Proceed to next step if end play is not within specified limits d Intermediate shaft thrust washer in hub of rear clutch retainer controls end play Washer is a select fit part and can be changed to adjust end play If end play turns out to be incorrect remove oil pump and clutches Then install thinner thicker thrust was...

Page 1999: ... shaft and into case Seat seal with 15 16 inch deep well socket 39 Install throttle valve and shift selector levers on valve body manual lever shaft 40 Cap or cover transmission openings cooler line fittings filler tube bore etc to prevent dirt entry 41 Install torque converter Use C clamp or metal strap to hold converter in place for installation OVERRUNNING CLUTCH CAM OVERDRIVE PISTON RETAINER D...

Page 2000: ... is correctly installed Bolt holes in cam are slightly counter sunk on one side Be sure this side of cam faces rearward toward piston retainer 4 Verify that non threaded hole in clutch cam is properly aligned Check alignment by threading a Fig 141 Overdrive Piston Removal OVERDRIVE CLUTCH PISTON INTERMEDIATE SHAFT SELECTIVE SPACER PISTON RETAINER Fig 142 Overrunning Clutch Cam Removal ALIGN MARKS ...

Page 2001: ...holes in retainer a Aligning locating lugs on overdrive piston to the two mating holes in retainer b Lubricate overdrive piston seals with Mopart Door Ease or equivalent c Install piston over Seal Guide 8114 2 and inside Guide Ring 8114 1 d Push overdrive piston into position in retainer e Verify that the locating lugs entered the lug bores in the retainer NOTE INSTALL THE REMAINING TRANSMISSION C...

Page 2002: ...pump housing and support assembly for alignment reference 3 Remove bolts attaching pump body to support Fig 151 4 Separate support from pump housing Fig 152 5 Remove inner and outer gears from reaction shaft support Fig 153 Fig 148 Front Servo PISTON RINGS SERVO PISTON O RING SNAP RING PISTON ROD GUIDE SEAL RING SNAP RING SERVO SPRING WASHER SPRING PISTONROD Fig 149 Rear Servo Components SNAP RING...

Page 2003: ...n against remover cup to pull bushing from shaft Clean all chips from shaft after bushing removal 4 Lightly grip old bushing in vise or with pliers and back remover tool out of bushing 5 Assemble Bushing Installer Tools C 4171 and SP 5325 Fig 157 6 Slide new bushing onto Installer Tool SP 5325 7 Position reaction shaft support upright on a clean smooth surface 8 Align bushing in bore Then tap bush...

Page 2004: ...o 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge c Clearance between outer gear and pump housing should also be 0 010 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge ASSEMBLY 1 Lubricate gear bore in pump housing with transmission fluid 2 Lubricate pump gears with transmission fluid 3 Support pump housing on wood blocks Fig 158 4 In...

Page 2005: ...ansmission case 12 Install new oil seal in pump with Special Tool C 4193 and Tool Handle C 4171 Fig 162 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 NOTE The 42RE transmission uses four plates and discs for the front clutch The 44RE uses fiv...

Page 2006: ...smission fluid while assembling other clutch parts 2 Install new seals on piston and in hub of retainer Be sure lip of each seal faces interior of clutch retainer 3 Lubricate lips of piston and retainer seals with liberal quantity of Mopart Door Ease Then lubricate retainer hub bore and piston with light coat of trans mission fluid 4 Install clutch piston in retainer Fig 165 Use twisting motion to...

Page 2007: ...ate then disc until all plates and discs are installed The front clutch uses 4 clutch discs and plates in a 42RE transmission In a 44RE transmis sion 5 discs and plates are used 9 Install pressure plate and waved snap ring Fig 163 Front clutch clearance specifications for the 42RE and 44RE transmission are the same Clearance should be 1 70 to 3 40 mm 0 067 to 0 134 in If clearance is incorrect clu...

Page 2008: ... input shaft if necessary Fig 170 a Be sure clutch hub seal ring is fully seated in groove and is not twisted 3 Lubricate splined end of input shaft and clutch retainer with transmission fluid Then press input shaft into retainer Use a suitably sized press tool to support retainer as close to input shaft as possible 4 Install input shaft snap ring Fig 169 5 Invert retainer and press input shaft in...

Page 2009: ... toward piston and flat side toward clutch pack 12 Install first clutch disc in retainer on top of bottom pressure plate Then install a clutch plate fol lowed by a clutch disc until entire clutch pack is installed 4 discs and 3 plates are required Fig 168 13 Install top pressure plate 14 Install selective snap ring Be sure snap ring is fully seated in retainer groove 15 Using a suitable gauge bar ...

Page 2010: ...t washer with petro leum jelly and install washer over input shaft and into clutch retainer Fig 175 Use enough petroleum jelly to hold washer in place 17 Set rear clutch aside for installation during final assembly Fig 173 Piston Spring Wave Spring Position REAR CLUTCH RETAINER PISTON SPRING WAVE SPRING CLUTCH PISTON Fig 174 Checking Rear Clutch Pack Clearance DIAL INDICATOR PRESSURE PLATE SNAP RI...

Page 2011: ...ove front planetary rear thrust washer from driving shell 9 Remove tabbed thrust washers from rear plan etary gear 10 Remove lock ring that retains sun gear in driving shell Then remove sun gear spacer and thrust plates Fig 176 Front Annulus And Planetary AssemblyRemoval DRIVING SHELL FRONT ANNULUS AND PLANETARY ASSEMBLYPLANETARY SNAP RING Fig 177 Front Planetary Snap Ring Removal FRONT ANNU LUS G...

Page 2012: ...ng shell thrust plates are interchangeable Use either plate on sun gear and at front rear of shell 9 Hold sun gear in place and install thrust plate over sun gear at rear of driving shell Fig 186 10 Position wood block on bench and support sun gear on block Fig 187 This makes it easier to align and install sun gear lock ring Keep wood block handy as it will also be used for geartrain end play chec...

Page 2013: ... tabs are seated Fig 182 Installing Rear Annulus And PlanetaryOn Output Shaft REAR ANNULUS AND PLAN ETARY GEAR ASSEMBLY OUTPUT SHAFT Fig 183 Installing Rear Planetary Front ThrustWasher FRONT TABBED THRUST WASHER REAR PLANETARY GEAR Fig 184 Installing Spacer On Sun Gear SUNGEAR SUN GEAR SPACER Fig 185 Installing Driving Shell Front ThrustPlate On Sun Gear SPACER SUN GEAR THRUST PLATE Fig 186 Insta...

Page 2014: ... on planetary hub Also be sure washer tab is facing up 20 Install front annulus snap ring Fig 194 Use snap ring pliers to avoid distorting ring during installation Also be sure ring is fully seated Fig 187 Supporting Sun Gear On Wood Block SUNGEAR DRIVING SHELL WOOD BLOCK Fig 188 Installing Sun Gear Lock Ring LOCK RING GROOVE SUN GEAR LOCK RING DRIVING SHELL REAR THRUST PLATE Fig 189 Installing As...

Page 2015: ...or thrust washers may have to be replaced Snap ring is available in three different thicknesses for adjustment purposes OVERDRIVE UNIT DISASSEMBLY 1 Remove transmission speed sensor and O ring seal from overdrive case Fig 197 Fig 192 Positioning Thrust Plate On FrontAnnulus Support FRONT ANNULUS THRUSTPLATE Fig 193 Installing Front Annulus Thrust Washer WASHER FLAT ALIGNS WITH FLAT ON PLANE TARY H...

Page 2016: ...verdrive clutch pack wire retaining ring Fig 202 Fig 197 Transmission Speed Sensor Removal Installation SOCKET AND WRENCH SPEED SENSOR O RING Fig 198 Overdrive Piston Thrust Bearing Removal Installation THRUST BEAR ING OVERDRIVE PISTON THRUST PLATE Fig 199 Overdrive Piston Thrust Plate Removal Installation OVERDRIVE PISTON OVERDRIVE PISTON SPACER SELECT FIT Fig 200 Intermediate Shaft Spacer Locati...

Page 2017: ...1 Remove overdrive clutch wave spring Fig 205 Fig 202 Removing Overdrive Clutch Pack RetainingRing OVERDRIVE CLUTCH PACK RETAININGRING Fig 203 Overdrive Clutch Pack Removal OVERDRIVE CLUTCH PACK Fig 204 42RE Overdrive Clutch Component Position PRESSURE PLATE TO FRONT OVERDRIVE CLUTCH PACK CLUTCH DISC 3 CLUTCH PLATE 2 REACTION PLATE TO REAR Fig 205 Overdrive Clutch Wave Spring Removal Installation ...

Page 2018: ...ng on output shaft 8 Remove rear bearing from output shaft Fig 211 Fig 206 Overdrive Clutch Reaction Snap RingRemoval Installation REACTION RING CLUTCH HUB Fig 207 Access Cover Screw Removal Installation TORX SCREWDRIVER T25 ACCESS COVER SCREWS Fig 208 Access Cover And Gasket Removal Installation ACCESS COVER AND GAS KET Fig 209 Releasing Bearing From Locating Ring EXPAND BEARING LOCAT ING RING WI...

Page 2019: ... 3 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 212 4 Remove direct clutch pack snap ring Fig 213 5 Remove direct clutch hub retaining ring Fig 214 6 Release press load slowly and completely Fig 215 7 Remove Special Tool 6227 1 Then remove clutch pack from hub Fig 215 Geartrain Disassembl...

Page 2020: ...reference Fig 219 Use small center punch or scriber to make alignment marks Fig 215 Direct Clutch Pack Removal SPECIAL TOOL 6227 1 DIRECT CLUTCH HUB DIRECT CLUTCH PACK Fig 216 Direct Clutch Hub And Spring Removal DIRECT CLUTCHSPRING DIRECT CLUTCH HUB Fig 217 Removing Sun Gear Thrust BearingAnd Planetary Gear PLANETARY GEAR PLANETARY THRUST BEARING CLUTCH SPRINGPLATE SPRING PLATE SNAP RING SUN GEAR...

Page 2021: ... AND PARK LOCK DISASSEMBLY 1 Remove locating ring from gear case 2 Remove park pawl shaft retaining bolt and remove shaft pawl and spring 3 Remove reaction plug snap ring and remove reaction plug 4 Remove output shaft seal Fig 220 Clutch Drum Inner Retaining RingRemoval INNER RETAIN ING RING DIRECT CLUTCH DRUM ANNULUS GEAR Fig 221 Clutch Drum Outer Retaining RingRemoval OUTER RETAINING RING Fig 22...

Page 2022: ...tput shaft Fig 229 Be sure locating ring groove in bear ing is toward rear 8 Install overrunning clutch on hub Fig 230 Note that clutch only fits one way Shoulder on clutch should seat in small recess at edge of hub 9 Install thrust bearing on overrunning clutch hub Use generous amount of petroleum jelly to hold bearing in place for installation Bearing fits one Fig 225 Output Shaft Pilot Bushing ...

Page 2023: ...g in place during installation 13 Install planetary thrust bearing on sun gear Fig 233 Slide bearing onto gear 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 230 Assembling Overrunning Clutch AndHub CLUTCH HUB OVERRUNNING CLUTCH Fig 231 Overrunning Clutch Installation CLUTCH DRUM OVERRUNNING CL...

Page 2024: ...k components Fig 237 or Fig 238 b Install direct clutch reaction plate on clutch hub first Note that one side of reaction plate is counterbored Be sure this side faces rear ward Splines at rear of hub are raised slightly Counterbore in plate fits over raised splines Plate should be flush with this end of hub Fig 239 c Install first clutch disc followed by a steel plate until all discs and plates h...

Page 2025: ...ion on hub and hold it in place 22 Slowly compress clutch hub and spring Com press spring and hub only enough to expose ring grooves for clutch pack snap ring and clutch hub retaining ring 23 Realign clutch pack on hub and seat clutch discs and plates in clutch drum 24 Install direct clutch pack snap ring Fig 242 Be very sure snap ring is fully seated in clutch drum ring groove 25 Install clutch h...

Page 2026: ...utchPressure Plate DIRECT CLUTCH PRES SURE PLATE CLUTCH PACK BE SURE SHOULDER SIDE OF PLATE FACES UPWARD Fig 241 Direct Clutch Pack And Clutch HubInstallation CLUTCH HUB DIRECT CLUTCH PACK CLUTCH DRUM Fig 242 Direct Clutch Pack Snap Ring Installation SPECIAL TOOL 6227 1 DIRECT CLUTCH PACK SNAP RING Fig 243 Clutch Hub Retaining Ring Installation SPECIAL TOOL6227 1 CLUTCH HUB RETAINING RING 21 92 TR...

Page 2027: ... Fig 246 7 Support geartrain on Tool 6227 1 Fig 247 Be sure tool is securely seated in clutch hub 8 Install overdrive gear case on geartrain Fig 247 9 Expand front bearing locating ring with snap ring pliers Fig 248 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 249 Fig 244 React...

Page 2028: ...utch plate Then install remaining clutch discs and plates in same order 6 Install clutch pack pressure plate 7 Install clutch pack wire type retaining ring Fig 253 INTERMEDIATE SHAFT SPACER SELECTION 1 Place overdrive unit in vertical position Mount it on blocks or in workbench with appropriate size mounting hole cut into it Be sure unit is facing upward for access to direct clutch hub Also be sur...

Page 2029: ...accurate measurement 2 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 256 b Measure distance to clutch hub thrust bear ing seat at four points 90 apart Then average measurements by adding them and dividing by 4 c Select and install required thrust plate from informa...

Page 2030: ...towels only The O rings on the sensor and solenoid valve are the only service able components Be sure the vent ports in the sole noid valve are open and not blocked by dirt or debris Replace the valve and or sensor only when DRB scan tool diagnosis indicates this is necessary Or if either part has sustained physical damage dented deformed broken etc CAUTION Do not turn the small screw at the end o...

Page 2031: ...all seats must not be worn or damaged Trial fit each valve and plug in its bore to check freedom of operation When clean and dry the valves and plugs should drop freely into the bores Valve body bores do not change dimensionally with use If the valve body functioned correctly when new it will continue to operate properly after cleaning and inspection It should not be necessary to replace a valve b...

Page 2032: ...Fig 258 Upper Housing Valves Plug SpringsAnd Brackets 21 98 TRANSMISSION AND TRANSFER CASE ZG CLEANING AND INSPECTION Continued ...

Page 2033: ...se 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 for cracks porous spots worn bores or damaged t...

Page 2034: ...tainer if either is distorted warped or broken Check the lug grooves in the clutch retainer The steel plates should slide freely in the slots Replace the retainer if the grooves are worn or damaged Check action of the check ball in the retainer Fig 261 The ball must move freely and not stick NOTE Inspect the clutch retainer bushings care fully Fig 262 The retainer bushings are NOT ser viceable It ...

Page 2035: ...specially at the gov ernor valve shaft bore The annulus gears can be removed from their sup ports if necessary Just remove the snap rings and separate the two parts when replacement is neces sary In addition the annulus gear bushings can be replaced if severely worn or scored However it is not necessary to replace the bushings if they only exhibit normal wear Check bushing fit on the output shaft ...

Page 2036: ...ccess to park interlock cable 4 Pull cable lock button up to release cable Fig 263 5 Pull cable forward Then release cable and press lock button down until it snaps in place BTSI FUNCTION CHECK 1 Verify removal of ignition key allowed in park position only 2 When the shift lever is in park and the shift handle push button is in the out position the igni tion key cylinder should rotate freely from ...

Page 2037: ... both levers move simultaneously from idle to half throttle and back to idle position adjustment is correct If transmission throttle lever moves ahead of or lags behind throttle body lever cable adjustment will be necessary Or if throttle body lever prevents transmission lever from returning to closed position cable adjustment will be necessary Throttle Valve Cable Adjustment Procedure 1 Turn igni...

Page 2038: ...s torque with Inch Pound Torque Wrench C 3380 A a 3 in extension and 5 16 socket CAUTION If Adapter C 3705 is needed to reach the adjusting screw Fig 268 tighten the screw to only 5 N m 47 50 in lbs torque 42RE TRANSMISSION Back off front band adjusting screw 3 5 8 turns Hold adjuster screw in position and tighten lock nut to 41 N m 30 ft lbs torque 44RE TRANSMISSION Back off front band adjusting ...

Page 2039: ...is an approximate setting Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure One complete turn of the adjusting screw changes line pressure approximately 1 2 3 psi 9 kPa Turning the adjusting screw counterclockwise increases pressure while turning the screw clockwise decreases pressure THROTTLE PRESSURE ADJUSTMENT Insert Gauge Tool C 3763 between ...

Page 2040: ...HYDRAULIC FLOW IN PARK 21 106 TRANSMISSION AND TRANSFER CASE ZG SCHEMATICS AND DIAGRAMS Continued ...

Page 2041: ...HYDRAULIC FLOW IN NEUTRAL ZG TRANSMISSION AND TRANSFER CASE 21 107 SCHEMATICS AND DIAGRAMS Continued ...

Page 2042: ...HYDRAULIC FLOW IN REVERSE 21 108 TRANSMISSION AND TRANSFER CASE ZG SCHEMATICS AND DIAGRAMS Continued ...

Page 2043: ...HYDRAULIC FLOW IN DRIVE FIRST GEAR ZG TRANSMISSION AND TRANSFER CASE 21 109 SCHEMATICS AND DIAGRAMS Continued ...

Page 2044: ...HYDRAULIC FLOW IN DRIVE SECOND GEAR 21 110 TRANSMISSION AND TRANSFER CASE ZG SCHEMATICS AND DIAGRAMS Continued ...

Page 2045: ...HYDRAULIC FLOW IN DRIVE THIRD GEAR ZG TRANSMISSION AND TRANSFER CASE 21 111 SCHEMATICS AND DIAGRAMS Continued ...

Page 2046: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH NOT APPLIED 21 112 TRANSMISSION AND TRANSFER CASE ZG SCHEMATICS AND DIAGRAMS Continued ...

Page 2047: ...HYDRAULIC FLOW IN DRIVE FOURTH GEAR CONVERTER CLUTCH APPLIED ZG TRANSMISSION AND TRANSFER CASE 21 113 SCHEMATICS AND DIAGRAMS Continued ...

Page 2048: ...HYDRAULIC FLOW IN MANUAL LOW 1 21 114 TRANSMISSION AND TRANSFER CASE ZG SCHEMATICS AND DIAGRAMS Continued ...

Page 2049: ...HYDRAULIC FLOW IN MANUAL SECOND 2 ZG TRANSMISSION AND TRANSFER CASE 21 115 SCHEMATICS AND DIAGRAMS Continued ...

Page 2050: ...HYDRAULIC FLOW DURING FULL THROTTLE3 2 DOWNSHIFT PASSING GEAR 21 116 TRANSMISSION AND TRANSFER CASE ZG SCHEMATICS AND DIAGRAMS Continued ...

Page 2051: ... lbs Locknut rear band 41 N m 30 ft lbs Bolt speedometer adapter 11 N m 8 ft lbs Bolt valve body to case 12 N m 100 in lbs Sensor trans speed 27 N m 20 ft lbs Screw solenoid wiring connector 4 N m 35 in lbs Screw solenoid to transfer plate 4 N m 35 in lbs Component Metric Inch Planetary end play 0 127 1 22 mm 0 005 0 048 in Input shaft end play 0 56 2 31 mm 0 022 0 091 in Clutch pack clearance Fro...

Page 2052: ... 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 2053: ...NS Spring Compressor and Alignment Shaft 6227 Gauge Bar 6311 Extension Housing Pilot C 3288 B Pressure Gauge C 3292 Pressure Gauge C 3293SP Dial Indicator C 3339 Spring Compressor C 3422 B ZG TRANSMISSION AND TRANSFER CASE 21 119 ...

Page 2054: ... Gauge Throttle Setting C 3763 Seal Installer C 3860 A Seal Remover C 3985 B Installer C 3995 A Universal Handle C 4171 Seal Installer C 4193 A Dial Caliper C 4962 21 120 TRANSMISSION AND TRANSFER CASE ZG SPECIAL TOOLS Continued ...

Page 2055: ...P 1191 From kit C 3887 J Cup Bushing Remover SP 3633 From kit C 3887 J Remover Bushing SP 3551 Installer Bushing SP 5117 Remover Bushing SP 5324 Installer Bushing SP 5325 Compressor Spring C 3575 A ZG TRANSMISSION AND TRANSFER CASE 21 121 SPECIAL TOOLS Continued ...

Page 2056: ...Gauge 6312 Adapter C 3705 Flusher 6906 Installer 8114 Remover 6957 Installer 6951 Retainer 6583 21 122 TRANSMISSION AND TRANSFER CASE ZG SPECIAL TOOLS Continued ...

Page 2057: ... range provides a 2 72 1 reduction ratio The input gear is splined to the transmission out put shaft It drives the mainshaft through the plan etary gear and range hub 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...

Page 2058: ...sfer case model number assembly number serial number and low range ratio The transfer case serial number also represents the date of build RECOMMENDED LUBRICANT AND FILL LEVEL Recommended lubricant for the NV242 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 t...

Page 2059: ...d inspection may be required to locate source of noise LUBRICANT LEAKING FROM OUTPUT SHAFT SEALS OR FROM VENT 1 Transfer case overfilled 1 Drain to correct level 2 Vent closed or restricted 2 Clear or replace vent if necessary 3 Output shaft seals damaged or installed incorrectly 3 Replace seals Be sure seal lip faces interior of case when installed Also be sure yoke seal surfaces are not scored o...

Page 2060: ... jack rearward to disen gage transfer case 15 Remove transfer case from under vehicle INSTALLATION 1 Mount transfer case on a transmission jack 2 Secure transfer case to jack with chains 3 Position transfer case under vehicle 4 Align transfer case and transmission shafts and install transfer case on transmission 5 Install and tighten transfer case attaching nuts to 35 N m 26 ft lbs torque Fig 3 6 ...

Page 2061: ...osition lever assembly on floorpan and install assembly attaching screws 2 Install console Refer to Group 23 Body for proper procedures 3 Raise vehicle 4 Connect trunnion to torque shaft arm Or slide shift rod into trunnion on range lever Be sure shift rod slides freely in trunnion 5 Verify that range lever is in 4L position Then tighten trunnion lock bolt 6 Lower vehicle and check transfer case s...

Page 2062: ...te index numbers on adapter body Fig 6 These numbers will correspond to number of teeth on pinion 8 Install speedometer assembly in housing 9 Rotate adapter until required range numbers are at 6 o clock position Be sure range index num bers correspond to number of teeth on pinion gear 10 Install speedometer adapter clamp and retain ing screw Tighten clamp screw to 10 12 N m 90 110 in lbs torque 11...

Page 2063: ...utput shaft Fig 11 4 Remove rear seal from retainer Fig 12 Use pry tool or collapse seal with punch to remove it 5 Remove rear output bearing I D retaining ring Fig 13 6 Remove speedometer adapter 7 Remove rear retainer bolts Fig 6 Location Of Index Numbers On SpeedometerAdapter SPEEDOMETER ADAPTER INDEX NUMBER LOCA TION Fig 7 Remove Front Output Shaft Seal OUTPUT SHAFT SEAL PRYBAR Fig 8 Front Out...

Page 2064: ... 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 13 Remove rear case from front case Fig 18 Insert screwdrivers into slots cast into each end of Fig 11 Slinger Stop Spacer and Snap ring SNAP RING OUTPUT SHAFT STOP SPACER SEAL Fig 12 Rear Seal Removal REAR RETAINER OUTPUT SHAFT SEAL Fig 13 Rear Bearing I D Retaining ...

Page 2065: ...front output shaft Discard washer as it should not be reused 4 Remove nut and washer that attach range lever to sector shaft Then move sector to neutral position and remove range lever from shaft Fig 22 FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL 1 Remove drive sprocket snap ring Fig 23 2 Remove drive sprocket and chain Fig 24 3 Remove front output shaft Fig 25 Fig 17 Spline And Dowel Bolt Location...

Page 2066: ...easy out tool into lock pin with hammer until tool is securely engaged into the lock pin c Install a t handle such as from a tap and die set onto the easy out tool d Securely tighten the t handle onto the tool Fig 22 Range Lever Removal RANGE LEVER SECTOR SHAFT Fig 23 Drive Sprocket Snap Ring Removal DRIVE SPROCKET DRIVE SPROCKET SNAP RING Fig 24 Drive Sprocket And Chain Removal DRIVE SPROCKET DRI...

Page 2067: ...ainshaft Fig 29 Note position of mode sleeve in fork and remove sleeve 7 Remove intermediate clutch shaft snap ring Fig 30 Fig 27 Shift Rail Removal SHIFT RAIL MODE FORK Fig 28 Mode Fork And Mainshaft Removal MAINSHAFT ASSEMBLY MODE FORK Fig 29 Mode Fork And Sleeve Removal MAINSHAFT SLEEVE MODE FORK ASSEMBLY Fig 30 Intermediate Clutch Shaft Snap RingRemoval SNAP RING INTERMEDIATE CLUTCH SHAFT ZG T...

Page 2068: ...e bearings and both needle bearing thrust washers from mainshaft Fig 31 Clutch Shaft Thrust Ring Removal CLUTCH SHAFT THRUST RING Fig 32 Intermediate Clutch Shaft Removal INTERMEDIATE CLUTCH SHAFT Fig 33 Differential Snap Ring Removal DIFFERENTIAL SNAP RING Fig 34 Differential Removal DIFFERENTIAL MAINSHAFT 21 134 TRANSMISSION AND TRANSFER CASE ZG DISASSEMBLY AND ASSEMBLY Continued ...

Page 2069: ...ion screwdriver in slots cast into retainer 3 Remove input gear snap ring Fig 40 4 Remove input low range gear assembly from bearing with Tool Handle C 4171 and Tool 7829A Fig 41 5 Remove low range gear snap ring Fig 42 Fig 35 Disengaging Low Range Fork SHIFT SECTOR LOW RANGE FORK PIN SLOT Fig 36 Low Range Fork And Hub Removal LOW RANGE FORK FORK HUB Fig 37 Shift Sector Position SHIFT SECTOR LOW R...

Page 2070: ...NTIAL DISASSEMBLY 1 Mark differential case halves for reference 2 Remove differential case bolts 3 Invert differential on workbench Fig 39 Front Bearing Retainer Removal FRONT BEARING RETAINER RETAINER SLOT Fig 40 Input Gear Snap Ring Removal INPUT GEAR SNAP RING Fig 41 Input And Low Range Gear AssemblyRemoval INPUT LOW RANGE GEARS SPECIAL TOOL 7829A SPECIAL TOOL C 4171 Fig 42 Low Range Gear Snap ...

Page 2071: ...mbly THRUST WASHERS LOW RANGE GEAR INPUT GEAR RETAINER Fig 44 Inspecting Low Range Annulus Gear LOW RANGE ANNULUS GEAR Fig 45 Separating Differential Case Halves TOP CASE CASE BOLTS CASE BOLTS CASE SLOTS CASE BOLTS Fig 46 Planet Gears And Thrust Washer Removal BOTTOM CASE THRUST WASHERS 12 PLANET GEARS 6 ZG TRANSMISSION AND TRANSFER CASE 21 137 DISASSEMBLY AND ASSEMBLY Continued ...

Page 2072: ... 48 Then remove bearing Use hammer handle or hammer and brass punch to tap bearing out of case 2 Install new front output shaft front bearing with Tool Handle C 4171 and Installer 8033A with the tapered cone upward Fig 49 3 Install front bearing snap ring Fig 48 4 Remove front output shaft seal using an appro priate pry tool Fig 50 or slide hammer mounted screw Fig 47 Mainshaft And Sprocket Gear R...

Page 2073: ...gear pilot bearing by insert ing a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 54 Fig 50 Remove Front Output Shaft Seal OUTPUT SHAFT SEAL PRYBAR Fig 51 Install Front Output Shaft Seal INSTALLER 6952 A TRANSFER CASE Fig 52 Input Gear Bearing Removal SPECIAL TOOL C 4171SPECIAL TOOL C 4210 Fig 53 Seating Input Gear Bearing SN...

Page 2074: ...er 5066 Fig 58 Lubricate bearing after installation Fig 55 Install Input Gear Pilot Bearing HANDLE C 4171 INSTALLER 8128 INPUT GEAR Fig 56 Front Bearing Retainer Seal Installation FRONT BEARING RETAINER SPECIAL TOOL 7884 Fig 57 Remove Front Output Shaft Rear Bearing REAR CASE SPECIAL TOOL L 4454 1 AND L 4454 3 SPECIAL TOOL 8148 Fig 58 Install Front Putput Shaft Rear Bearing HANDLE C 4171 OUTPUT SH...

Page 2075: ...g 62 5 Align and position differential top case on bot tom case Fig 63 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 59 Oil Pump Seal Installation HOUSING SEAL SPECIAL TOOL 7888 OIL PUMP FEED HOUSING Fig 60 Pickup Tube O Ring Insta...

Page 2076: ...Apply 3 mm 1 8 in wide bead of Mopart gas ket maker or silicone adhesive sealer to seal surface of front bearing retainer 8 Install front bearing retainer Fig 67 Tighten retainer bolts to 16 ft lbs 21 N m torque Fig 63 Differential Case Assembly TOP CASE BOTTOM CASE CASE ALIGNMENT MARKS Fig 64 Low Range And Input Gear Assembly THRUST WASHERS LOW RANGE GEAR INPUT GEAR RETAINER Fig 65 Install Low Ra...

Page 2077: ...ge fork and hub in case Be sure low range fork pin is engaged in shift sector slot Fig 70 Fig 67 Installing Front Bearing Retainer FRONT BEARING RETAINER Fig 68 Sector O Ring And Bushing Installation SECTOR BUSHING O RING Fig 69 Assembling Low Range Fork And Hub LOW RANGE FORK PADS HUB Fig 70 Positioning Low Range Fork SHIFT SECTOR LOW RANGE FORK PIN SLOT ZG TRANSMISSION AND TRANSFER CASE 21 143 D...

Page 2078: ...ial Fig 72 Do not displace mainshaft bearings when installing differential 10 Install differential snap ring Fig 73 11 Install intermediate clutch shaft Fig 74 Fig 71 Installing Mainshaft Bearing Rollersand Spacers MAINSHAFT BEARING ROLL ERS BEARING SPACERS Fig 72 Differential Installation DIFFERENTIAL MAINSHAFT Fig 73 Installing Differential Snap Ring DIFFERENTIAL SNAP RING Fig 74 Installing Inte...

Page 2079: ...ork on mainshaft Be sure mode sleeve splines are engaged in differen tial splines 16 Install mode fork and mainshaft assembly in case Fig 79 Rotate mainshaft slightly to engage shaft with low range gears Fig 75 Installing Clutch Shaft Thrust Washer CLUTCH SHAFT THRUST RING Fig 76 Installing Clutch Shaft Snap Ring SNAP RING INTERMEDIATE CLUTCH SHAFT Fig 77 Mode Fork Assembly Inspection SLIDER MODE ...

Page 2080: ...ockpin through access hole and into shift fork Fig 81 Then remove easy out and seat the pin with pin punch 22 Install plug in lockpin access hole 23 Install detent plunger detent spring and detent plug in case Fig 82 Fig 79 Assembled Mainshaft And Mode ForkInstallation MAINSHAFT ASSEMBLY MODE FORK Fig 80 Shift Rail Installation SHIFT RAIL MODE FORK Fig 81 Installing Low Range Fork Lockpin LOW RANG...

Page 2081: ...tall magnet in front case pocket Fig 86 3 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to seal surface of front case 4 Align and install rear case on front case Be sure case locating dowels are in place and that main shaft splines are engaged in oil pump inner gear 5 Install and tighten front case to rear case bolts to 41 N m 30 ft lbs torque Be sure to install a ...

Page 2082: ... and seal onto output shaft 9 Slide Installer C 4076 B onto seal protector with the recessed side of the tool toward the seal Drive seal into rear bearing retainer with installer C 4076 B and handle MD 998323 Fig 90 10 Install rear slinger with installer C 4076 A and handle MD 998323 Fig 90 11 Install boot on output shaft slinger and crimp retaining clamp with tool C 4975 A Fig 91 FRONT YOKE AND S...

Page 2083: ...Check the teeth on the gear Fig 92 Minor nicks can be dressed off with an oilstone but 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 damag...

Page 2084: ...s surface must be clean and smooth to ensure proper seal life Replace the yoke nut and seal washer as neither part should be reused Inspect the shaft threads sprocket teeth and bear ing surfaces Minor nicks on the teeth can be smoothed with an oilstone Use 320 400 grit emery to smooth minor scratches on the shaft bearing sur faces Rough threads on the shaft can be chased if necessary Replace the s...

Page 2085: ...ed with Helicoil stainless steel inserts if required OIL PUMP OIL PICKUP Examine the oil pump pickup parts Replace the pump if any part appears to be worn or damaged Do not disassemble the pump as individual parts are not available The pump is only available as a complete assembly The pickup screen hose and tube are the only serviceable parts and are available separately ADJUSTMENTS SHIFT LINKAGE ...

Page 2086: ...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 46 N m 26 34 ft lbs Nuts Mounting 35 47 N m 26 35 ft lbs Bolts U Joint 19 N m 17 ft lbs SPECIAL TOOLS SPECIAL TOOLS NV242 Installer C 4076 B Handle Universal C 4171 Remover C 4210 Puller Slinger MD 998056 A Installer MD 998323 Installer Bearing 5064 21 1...

Page 2087: ...ller 8128 Installer 5066 Installer 6952 A Remover L 4454 Cup 8148 Seal Protector 6992 Installer Input Gear Bearing 7829 A Installer Seal 7884 ZG TRANSMISSION AND TRANSFER CASE 21 153 SPECIAL TOOLS Continued ...

Page 2088: ...Installer Pump Housing Seal 7888 Installer Bearing 8033 A Installer Boot Clamp C 4975 A 21 154 TRANSMISSION AND TRANSFER CASE ZG SPECIAL TOOLS Continued ...

Page 2089: ...provided by a gear reduction system for increased low speed off road torque capability 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 TRANSFER CASE IDENTIFICATION A circular I D tag is attached to the rear case of each NV249 ...

Page 2090: ...S Type 7176 or DEXRON II Automatic Transmission Fluid Check for leaks and repair if necessary If unit is still noisy after drain and refill disassembly and inspection may be required to locate source of noise NOISY IN OR JUMPS OUT OF FOUR WHEEL DRIVE LOW RANGE a Transfer case not completely engaged in 4L position a Stop vehicle shift transfer case to Neutral then shift back into 4L position b Shif...

Page 2091: ... 2 Secure transfer case to jack with chains 3 Position transfer case under vehicle 4 Align transfer case and transmission shafts and install transfer case on transmission 5 Install and tighten transfer case attaching nuts to 35 N m 26 ft lbs torque Fig 3 6 Connect vehicle speed sensor wires and vent hose 7 Connect indicator switch harness to transfer case switch if necessary Secure wire harness to...

Page 2092: ...tion Then tighten trunnion lock bolt 6 Lower vehicle and check transfer case shift operation SPEEDOMETER REMOVAL 1 Raise vehicle 2 Disconnect wires from vehicle speed sensor 3 Remove adapter clamp and screw Fig 5 4 Remove speed sensor and speedometer adapter as an assembly 5 Remove speed sensor retaining screw and remove sensor from adapter 6 Remove speedometer pinion from adapter Replace pinion i...

Page 2093: ... body Fig 6 These numbers will correspond to number of teeth on pinion 8 Install speedometer assembly in housing 9 Rotate adapter until required range numbers are at 6 o clock position Be sure range index num bers correspond to number of teeth on pinion gear 10 Install speedometer adapter clamp and retain ing screw Tighten clamp screw to 10 12 N m 90 110 in lbs torque 11 Connect wires to vehicle s...

Page 2094: ...ng a suitable pry tool or slide hammer mounted screw remove the rear retainer seal 4 Using Remover 6957 remove bushing from rear retainer Fig 9 INSTALLATION 1 Clean fluid residue from sealing surface and inspect for defects 2 Position replacement bushing in rear retainer with fluid port in bushing aligned with slot in retainer 3 Using Installer 8145 drive bushing into retainer until installer seat...

Page 2095: ...g 14 5 Remove rear retainer as follows a Spread rear bearing locating ring with snap ring pliers Fig 15 b Then slide retainer off mainshaft and rear bearing Fig 16 6 Remove speedometer drive gear Fig 17 Fig 11 Install Rear Retainer Seal SPECIAL TOOL C 4171 SPECIAL TOOL C 3995 A Fig 12 Rear Retainer Bolt Removal REAR RETAINER Fig 13 Locating Ring Access Cover And GasketRemoval REAR BEAR ING LOCAT I...

Page 2096: ...tch 2 Remove front yoke nut as follows a Move range lever to 4L position b Remove nut with socket and impact wrench Fig 21 3 Remove yoke If yoke is difficult to remove by hand remove it with bearing splitter or with stan dard two jaw puller Fig 22 Be sure puller tool is positioned on yoke and not on slinger as slinger will be damaged Fig 16 Rear Retainer Removal REAR CASE REAR RETAINER Fig 17 Spee...

Page 2097: ...rs Fig 24 3 Loosen rear case with flat blade screwdriver to break sealer bead Insert screwdriver blade only into notches provided at each end of case Fig 25 4 Remove rear case Fig 26 Fig 21 Yoke Nut Removal IMPACT WRENCH SOCKET YOKE Fig 22 Yoke Removal PULLER TOOL YOKE Fig 23 Range Lever Removal RANGE LEVER SECTOR SHAFT Fig 24 Rear Case Alignment Bolt Locations ALIGNMENT BOLT AND WASHER AT EACH EN...

Page 2098: ...ly Fig 31 Lift shift rail upward rotate fork out of shift sector and remove assembly 5 Remove shift sector Rotate and tilt sector as needed to remove it Fig 32 6 Remove shift sector bushing and O ring Fig 33 Fig 27 Oil Pickup Tube Removal OIL PICKUP TUBE Fig 28 Front Output Shaft Drive Gear AndChain Removal REAR HOUSING OUTPUT SHAFT AND SPROCKET MAINSHAFT SPROCKET SNAP RING DRIVE CHAIN Fig 29 Dete...

Page 2099: ...nap ring that retains input gear shaft in front bearing Fig 36 5 Remove input and low range gear assembly Fig 37 6 Remove oil seals from following components front bearing retainer rear retainer case halves Fig 32 Shift Sector Removal SHIFT SEC TOR Fig 33 Sector Bushing And O Ring Removal SHIFT SEC TOR BUSHING O RING Fig 34 Front Bearing Retainer Bolt Removal FRONT BEARING RETAINER Fig 35 Front Be...

Page 2100: ... where indicated during assembly CAUTION The bearing bores in various transfer case components contain oil feed holes Make sure replacement bearings do not block the holes Fig 37 Input And Low Range Gear AssemblyRemoval INPUT AND LOW RANGE GEAR ASSEMBLY Fig 38 Input Gear Snap Ring Removal INPUT GEAR SNAP RING Fig 39 Input Gear Retainer Removal INPUT GEAR LOW RANGE GEAR RETAINER Fig 40 Front Tabbed...

Page 2101: ...h light taps from ham mer Fig 46 Once seal is started continue tap ping seal into bore until installer tool bottoms against case 7 Remove the output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 47 Fig 42 Rear Tabbed Thrust Washer Removal LOW RANGE GEAR REAR TABBED THRUST WASHER Fig 43 Remove Front Output Shaft Seal OUTPUT SHAFT SEAL PRYBAR Fig 44 Output Shaft Fro...

Page 2102: ...2 Using Remover C 4210 and Handle C 4171 drive input shaft bearing into case The bearing locating ring must be fully seated against case sur face Fig 51 Fig 47 Output Shaft Rear Bearing Removal REAR CASE SPECIAL TOOL L 4454 1 AND L 4454 3 SPECIAL TOOL 8148 Fig 48 Output Shaft Rear Bearing Installation HANDLE C 4171 OUTPUT SHAFT INNER BEARING INSTALLER 5066 Fig 49 Output Shaft Rear Bearing Installa...

Page 2103: ...ring retainer seal with suit able pry tool 16 Install new front bearing retainer with Installer 7884 Fig 54 Fig 51 Seating Input Shaft Bearing SNAP RING INPUT SHAFT BEARING Fig 52 Remove Input Gear Pilot Bearing DRIFT INPUT GEAR Fig 53 Install Input Gear Pilot Bearing HANDLE C 4171 INSTALLER 8128 INPUT GEAR Fig 54 Install Front Bearing Retainer Seal FRONT BEARING RETAINER SPECIAL TOOL 7884 ZG TRAN...

Page 2104: ...nput low range gear into front bearing Fig 57 3 Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage 4 Apply a 3 mm 1 8 in bead of Mopart gasket maker or silicone adhesive to sealing surface of retainer 5 Align cavity in seal retainer with fluid return hole in front of case CAUTION Do not block fluid return cavity on seal ing surface of retainer when applying M...

Page 2105: ...te sector to Neutral position 9 Install new O ring on detent plug Fig 63 10 Lubricate detent plunger with transmission fluid or light coat of petroleum jelly 11 Install detent plunger spring and plug Fig 63 12 Verify that plunger is properly engaged in sec tor 13 Insert mainshaft into input gear pilot bearing Fig 59 Sector O Ring And Bushing Installation SECTOR BUSHING O RING Fig 60 Shift Sector I...

Page 2106: ... in front case pocket Fig 68 10 Align and install rear case on front case Fig 69 11 Verify that oil pickup tube is still seated in case notch and tube end is pointed toward mainshaft Fig 70 12 Install case attaching bolts Alignment bolts at each end of case are only ones requiring washers Fig 71 13 Tighten case bolts to 27 34 N m 20 25 ft lbs torque YOKE AND RANGE LEVER INSTALLATION 1 Install indi...

Page 2107: ...new yoke nut on front output shaft Fig 73 Fig 67 Oil Pickup Tube Installation CASE NOTCH OIL PICKUP TUBE ASSEMBLY CASE SLOT Fig 68 Installing Case Magnet MAGNET Fig 69 Rear Case Installation REAR CASE FRONT CASE Fig 70 Checking Position Of Oil Pickup Tube TUBE O RING CORRECT PICKUP TUBE POSITION Fig 71 Alignment Bolt Location ALIGNMENT BOLT AND WASHER AT EACH END OF CASE Fig 72 Range Lever Install...

Page 2108: ...retainer if ring was removed during overhaul 8 Apply 3 mm 1 8 in wide bead of Mopart gas ket maker or silicone adhesive sealer to mounting surface of rear retainer Allow sealer to set up slightly before proceeding 9 Slide rear retainer onto mainshaft Fig 80 10 Spread rear bearing locating ring and slide rear retainer into place on rear case Fig 81 11 Install and tighten rear retainer bolts to 27 3...

Page 2109: ...clear them of any residue MAINSHAFT Examine the mainshaft components carefully for evidence of wear or damage 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 sur...

Page 2110: ...uitable size driver Recess the bushing slightly below the edge of the bore but do not seat it all the into the case GEARTRAIN Inspect the mainshaft splines gear teeth and bear ing surfaces carefully for evidence of wear or dam age Replace the shaft if necessary do not attempt to salvage it if damaged The shift rail and range fork are an assembly Replace both parts if either is damaged However the ...

Page 2111: ...UE 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 shift ro...

Page 2112: ...SPECIAL TOOLS NV249 TRANSFER CASE Installer 5066 Installer 6952 A Installer 6953 Remover 6957 Installer C 3995 A Handle C 4171 Installer 8145 Remover C 4210 21 178 TRANSMISSION AND TRANSFER CASE ZG ...

Page 2113: ...Remover L 4454 Cup 8148 Installer 8128 Installer 7884 ZG TRANSMISSION AND TRANSFER CASE 21 179 SPECIAL TOOLS Continued ...

Page 2114: ......

Page 2115: ...mechanism is integral and mounted in the shift tower portion of the adapter housing Fig 1 TRANSMISSION IDENTIFICATION The AX 15 identification code numbers are on the bottom surface of the transmission gear case Fig 2 The first number is year of manufacture The sec ond and third numbers indicate month of manufac ture The next series of numbers is the transmission serial number Fig 1 AX 15 Manual T...

Page 2116: ...1 Fifth gear 0 79 1 Reverse 4 22 1 TRANSMISSION ASSEMBLY INFORMATION Lubricate the transmission components with gear lubricant during assembly Use petroleum jelly to lubricate seal lips and or hold parts in place during installation DIAGNOSIS AND TESTING LOW LUBRICANT LEVEL A low transmission lubricant level is generally the result of a leak inadequate lubricant fill or an incor rect lubricant lev...

Page 2117: ...n damaged pressure plate or disc can cause incorrect release If the clutch problem is advanced gear clash during shifts can result Worn or damaged synchro rings can cause gear clash when shifting into any forward gear In some new or rebuilt transmissions new synchro rings may tend to stick slightly causing hard or noisy shifts In most cases this condition will decline as the rings wear in TRANSMIS...

Page 2118: ...olts to 74 6 N m 4 Install the clutch slave cylinder to the clutch housing 5 Install the engine speed sensor crankshaft posi tion sensor to the vehicle Fig 9 6 Install the two 2 upper clutch housing to engine bolts Tighten the bolts to 36 6 N m 7 Install the two 2 mid clutch housing to engine bolts Tighten the bolts to 58 3 N m 8 Raise the engine and transmission with the adjustable jackstand 9 In...

Page 2119: ...Fig 10 Transmission to Engine Mounting Fig 11 Clutch Housing to Transmission Fig 12 Fill Plug Location ZG TRANSMISSION AND TRANSFER CASE 21 5 REMOVAL AND INSTALLATION Continued ...

Page 2120: ...ing to Engine Mid Point 2 Bolts 58 3 N m 43 ft lbs Clutch Housing to Engine Bottom 2 Bolts 74 6 N m 55 ft lbs Clutch Housing to Transmission bolts 38 0 N m 28 ft lbs Transfer Case to Transmission Attaching Nuts 35 N m 26 ft lbs Propeller Shaft Bolts 26 5 N m 19 5 ft lbs 21 6 TRANSMISSION AND TRANSFER CASE ZG ...

Page 2121: ...re for off road use only They are not for use on hard surface roads The only exception being when the road surface is covered by ice and snow The low range reduction gear system is operative in 4 Lo range only This range is for extra pulling power in off road situations Low range reduction ratio is 2 72 1 SHIFT MECHANISM Operating ranges are selected with a floor mounted shift lever The shift leve...

Page 2122: ...DIAGNOSIS AND TESTING NV231 DIAGNOSIS 21 8 TRANSMISSION AND TRANSFER CASE ZG ...

Page 2123: ... tighten transfer case attaching nuts to 35 N m Fig 2 6 Connect vehicle speed sensor wires and vent hose 7 Connect indicator switch harness to transfer case switch if necessary Secure wire harness to clips on transfer case 8 Align and connect propeller shafts Tighten shaft attaching bolts to 26 5 N m torque 9 Fill transfer case with correct fluid Refer to Recommended Lubricant And Fill Level secti...

Page 2124: ...aulty or if pins are loose severely corroded or damaged INSTALLATION AND INDEXING 1 Thoroughly clean 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 Fig 4 if necessary 3 Lubricate sensor and adapter O rings with transmission fluid 4 Install vehicle sp...

Page 2125: ...against case REAR RETAINER BUSHING AND SEAL REMOVAL 1 Raise vehicle 2 Remove rear propeller shaft Refer to Group 3 Differential and Driveline for proper procedure 3 Using a suitable pry tool or slide hammer mounted screw remove the rear retainer seal 4 Using Remover 6957 remove bushing from rear retainer Fig 8 INSTALLATION 1 Clean fluid residue from sealing surface and inspect for defects 2 Positi...

Page 2126: ...luid level 7 Lower vehicle SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plug Drain Fill 40 N m Nuts Mounting 35 N m Switch Indicator 26 N m SPECIAL TOOLS SPECIAL TOOLS NV231 Fig 9 Rear Retainer Bushing Install Fig 10 Install Rear Retainer Seal Installer Seal 8143 Remover Bushing 6957 Installer Bushing 8160 Installer Seal C 3995 A 21 12 TRANSMISSION AND TRANSFER CASE ZG REMOVAL AND INSTALLATION Continu...

Page 2127: ...ch 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 IDENTIFICATION...

Page 2128: ...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 can result in tire failure Fig 2 Over inflation causes rapid center wear and loss of the tire s ability to cushion shocks Fig 3 Improper inflation can cause Uneven wear patte...

Page 2129: ...any 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 used when replacement is needed Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehi cle The use of oversize tires not listed in the specifica tion charts may caus...

Page 2130: ...m The high spot 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 mar...

Page 2131: ...PAIRING LEAKS For proper repairing a radial tire must be removed from the wheel Repairs should only be made if the defect or puncture is in the tread area Fig 10 The tire should be replaced if the puncture is located in the sidewall 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 o...

Page 2132: ... of tires Remove protective coating by Applying warm water Letting it soak one minute Scrubbing the coating away with a soft bristle brush Steam cleaning may also be used for cleaning DO NOT use gasoline or wire brush for cleaning DO NOT use mineral oil or an oil based solvent Fig 10 Tire Repair Area REPAIR ABLE AREA 22 6 TIRES AND WHEELS ZG ...

Page 2133: ...me 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 AND HANDLING OF YOUR VEHICLE DIAGNOSIS...

Page 2134: ... mark tire sidewall wheel and stud at point of maximum runout and proceed to Method 2 METHOD 2 RELOCATE TIRE ON WHEEL Rotating tire on wheel is particularly effective when there is runout in both tire and wheel Remove tire from wheel and mount wheel on ser vice dynamic balance machine Check wheel radial runout Fig 3 and lateral runout Fig 4 STEEL WHEELS Radial runout 0 040 in Lat eral runout 0 045...

Page 2135: ...ammering heating or welding are not allowed Original equipment wheels are available through your dealer Replacement wheels from any other source should be equivalent in Load carrying capacity Diameter Width Offset Mounting configuration Failure to use equivalent replacement wheels may affect the safety and handling of your vehicle Replacement with used wheels is not recommended Their service histo...

Page 2136: ...ccomplished with either on or off vehicle equipment When using on vehicle balancing equipment remove the opposite wheel tire 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 Static Unbalance Balance HEAVYSPOT OF SPINDLE ADD BALANCE WEIGHTS HERE CORRECTIVE WEIGHT LOCATION TIRE OR WHEEL TRAMP OR WHEEL HOP Fig 7 Dynamic Unbalance Balan...

Page 2137: ...cal system 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 fastene...

Page 2138: ...ormed 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 Introd...

Page 2139: ...CLADDING COLOR CHRY CODE PPG BASF DuPONT S W ACME M S AKZO NOBEL SIKKENS Flame Red PR4 4679 23043 B9326 46916 CHAPR4M Medium Driftwood MFD 27360 23054 C9321 48024 CHA93 MFD Dark Rosewood REG 4966 25041 B9519 50266 CHAREGM Deep Hunter Green SG8 47439 26078 B9609 51062 CHASG8M Moss Green RJN 47383 25036 B9533 50277 CHARJNM Black DX8 9700 15214 F0204 34858 90 5950 CHADX8M Dark Neutral Gray HS5 34349 ...

Page 2140: ...dshield to the fence is difficult to cut or clean from any surface If the moldings are set in urethane 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 ...

Page 2141: ...d 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 Super Clean or equivalent 13 Install windshield side...

Page 2142: ...nd edge of glass Wipe with clean dry lint free cloth 3 Apply fence primer around edge of fence Allow at least eighteen minutes drying time 4 Apply a 10 mm 0 4 in bead of urethane around window vinyl border location Position glass into window opening and lock clips into place Fig 5 Fig 3 Center Windshield and Mark at SupportSpacers A PILLAR WINDSHIELD MARKS SUPPORT SPACER COWL Fig 4 Work Surface Se...

Page 2143: ... water leaks can result The window opening fence should be cleaned of old urethane bonding material 1 Clean inside of glass with Mopar Glass Cleaner and lint free cloth 2 Apply PVC vinyl primer 25 mm 1 in wide around edge of glass Wipe with clean dry lint free cloth 3 Apply fence primer around edge of fence Allow at least eighteen minutes drying time 4 Apply a 10 mm 0 4 in bead of urethane around ...

Page 2144: ...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 12 mm 0 5in 2 Verify that attaching nuts are...

Page 2145: ... as necessary Fig 2 Drain Tube Locations FWD INDEX DRAIN TUBE FWD BODY DRAIN TUBE FWD CLAMP PLUG ADAPTER REAR LEFT SIDE SHOWN RIGHT SIDE SIMILAR Fig 3 Deflector Assembly TOP SURFACE OF ROOF PANEL WIND DEFLECTOR Fig 4 Glass Adjustment VIEW A MECHANISM COVER ADJUSTMENT BRACKET STUD VIEW B GLASS ATTACHMENT NUT ADJUSTMENT BOLTS ZG BODY 23 9 REMOVAL AND INSTALLATION Continued ...

Page 2146: ...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 DRIVE CABLES REMOVAL 1 Open sunroof to vent position 2 Remove head...

Page 2147: ...ate 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 Install wind deflector mechanism covers glass panel drain channel sunshade and drive cabl...

Page 2148: ...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 12 Glass Adjustment VIEW A MECHANISM COVER ADJUSTMENT BRACKET STUD VIEW B GLASS ATTACHMENT NUT ADJUSTMENT BOLTS Fig 11 Drain Tube Locations FWD INDEX DRAIN TUBE FWD BODY DRAIN TUBE FWD CLAMP PLUG ADAPTER REAR LEFT SIDE SHOWN RIGHT SIDE SIMILAR CLAMP SECTION A A ...

Page 2149: ...e 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 cover from seat back INSTALLATION 1 Pos...

Page 2150: ...n 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 hole on outboard side of seat cushion if equipped 5 Engage J strap attaching seat cove...

Page 2151: ...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 disengage seat cover retain ers that hol...

Page 2152: ...TCH 20 HOOD RELEASE CABLE 20 HOOD 19 LICENSE PLATE LAMP HOUSING 45 LIFTGATE FLIP UP GLASS LATCH HANDLE STRIKER 45 LIFTGATE FLIP UP GLASS LATCH 44 LIFTGATE FLIP UP GLASS WEATHERSTRIP 44 LIFTGATE FLIP UP GLASS 43 LIFTGATE HINGE 42 LIFTGATE LATCH STRIKER 43 LIFTGATE LATCH 42 LIFTGATE LOCK CYLINDER 42 LIFTGATE OPENING WEATHERSTRIP 43 LIFTGATE OUTSIDE HANDLE 42 LIFTGATE TRIM PANEL 41 LIFTGATE 41 LOWER ...

Page 2153: ...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 2154: ... security system s The transmitter 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 Step 6 If not OK go to Step 2 2 Check if vis...

Page 2155: ... 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 location of the hood hinge...

Page 2156: ...latch INSTALLATION 1 Connect latch to latch 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 T...

Page 2157: ...d to seat it BODY STRIPES DECALS Body stripes are durable weather resistant tape stripes with pressure sensitive backing The 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 w...

Page 2158: ... trimming tape stripe to size 11 Trim tape stripe to size using a razor knife Leave at least 13 mm 0 5 in for edges of doors 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 f...

Page 2159: ...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 Removal Installation procedures 7 From inside wheel well remove bolts at rear of fender reinforcements Fig 11 8 Remove bolts at front fender bracket Fig 12 9 Remove bolts at lower rear of fender at A pillar 10 Remove upper mounting bolts at...

Page 2160: ...trim panel 2 Peel the insulator and waterdam from the door 3 Route all harnesses through waterdam as nec essary 4 Separate insulator and waterdam from door Fig 14 INSTALLATION 1 Waterdam contact surface must be free of con taminants Clean as necessary 2 Route all harnesses through waterdam as nec essary 3 Position waterdam and insulator on door and align all holes 4 Press waterdam and insulator on...

Page 2161: ... hinge to B pillar Tighten outer bolts to 40 N m 360 in lbs and inner bolts 34 N m 300 in lbs torque FRONT DOOR OUTSIDE HANDLE REMOVAL 1 Remove door trim panel and waterdam 2 Remove access hole cover and door handle retaining nuts 3 Disconnect handle latch rod from latch Fig 17 INSTALLATION 1 Reverse removal procedure FRONT DOOR LOCK CYLINDER REMOVAL 1 Remove door trim panel and waterdam If nec es...

Page 2162: ...screws to 5 N m 45 in lbs torque FRONT DOOR INSIDE HANDLE ACTUATOR REMOVAL 1 Remove door trim panel and waterdam If nec essary refer to removal procedure 2 Remove door inside latch release handle screws Fig 21 3 Move door release handle outward Disconnect handle latch and lock rods 4 Remove door inside handle actuator from door Fig 18 Security Alarm Switch SECURITY ALARM SWITCH FRONT DOOR LOCK CYL...

Page 2163: ...orce the seal onto door flange Con tinue rearward until it is seated on flange 4 Install the screw securing the seal to the outer door panel FRONT DOOR RUN CHANNEL WEATHERSTRIP REMOVAL 1 Lower window glass 2 Grasp seal from upper run channel corner and firmly separate weatherstrip from flange Fig 24 INSTALLATION NOTE Soapy water may be used to aid in installa tion 1 Position weatherstrip on flange...

Page 2164: ...strip seals 3 Remove window track retaining nuts 4 Lift window glass upward and out of door INSTALLATION 1 Lower window glass into position 2 Install window track retaining nuts 3 Install beltline molding and weatherstrip seals 4 Install door trim panel and waterdam REAR DOOR TRIM PANEL REMOVAL 1 Remove screw attaching trim panel to inside release handle Fig 28 2 Remove screw at armrest 3 Using tr...

Page 2165: ...necessary refer to applicable procedures 3 Position door in body opening 4 Align door hinges plates and shims with bolt holes Install but do not tighten hinge bolts 5 Adjust door to reference marks If necessary refer to adjustment procedure Tighten hinge bolts to 28 N m 250 in lbs torque 6 Adjust latch striker as necessary 7 If applicable route and connect harness con nectors to door and vehicle b...

Page 2166: ...re REAR DOOR LATCH STRIKER REMOVAL 1 Open door 2 Remove screws attaching striker to C pillar Fig 32 3 Separate striker and spacer from vehicle INSTALLATION 1 Position striker and spacer on C pillar 2 Install screws Tighten to 28 N m 250 in lbs torque REAR DOOR INSIDE HANDLE ACTUATOR REMOVAL 1 Remove door trim panel and waterdam 2 Remove door inside handle actuator screws Fig 33 3 Move actuator han...

Page 2167: ... 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 25 3 Engage connector plug with each end of weath erstrip at bottom of door opening 4 Install screws at the front of the quarter trim panel 5 Install B pillar lower trim panel 6 Install B pillar upper trim panel 7 Install C pillar ...

Page 2168: ...ndow beltline molding 7 Install door waterdam and trim panel If neces sary refer to installation procedure FUEL DOOR REMOVAL 1 Open fuel door 2 Remove rear quarter trim panel 3 Remove screw attaching fuel door to body panel Fig 39 4 Separate fuel door from vehicle INSTALLATION 1 Position fuel door at vehicle 2 Install screw attaching fuel door to body panel 3 Install rear quarter trim panel 4 Clos...

Page 2169: ...PANEL 1 Replace all retaining clips 2 Install molding over top of retainer clips 3 Snap molding down over retaining clips 4 Install screws into wheel opening A PILLAR TRIM REMOVAL 1 Using a trim stick carefully pry A pillar trim from A pillar Fig 41 INSTALLATION 1 Position A pillar trim panel at A pillar and snap into place 2 Ensure that the A pillar covers the inner edge of the door opening weath...

Page 2170: ...e the trip panel covers the inner edge of the door opening weatherstrip 3 Install front seat belt turning loop 4 Install the A pillar trim panel Fig 41 Trim Panels BODY B PILLAR UPPER TRIM C PILLAR TRIM D PILLAR TRIM PANEL QUARTER TRIM PANEL B PILLAR LOWER TRIM COWL TRIM A PILLAR TRIM PANEL Fig 42 Assist Handle MOUNTING SCREW HEADLINER FRONT ASSIST HANDLE Fig 43 Scuff Plates REAR DOOR SCUFF PLATE ...

Page 2171: ...arefully pry C pillar trim panel from vehicle Fig 41 INSTALLATION 1 Position C pillar trim panel on C pillar Ensure the adjustable turning loop is aligned with the trim panel slider and snap into place 2 Install rear seat belt turning loop QUARTER TRIM PANELS 1 Pull rear seat bottom forward and fold down rear seat 2 Remove lower retaining screw at rear door opening Fig 41 3 If equipped remove suns...

Page 2172: ...P BELT BUCKLE REMOVAL LAP BELT BUCKLE 1 Pull rear seat release loop and tilt seat bottom forward Remove seat bottom from lower latch 2 Unlatch seat back and tilt forward 3 Remove shoulder belt buckle and lap belt buckle anchor plate bolts from the floor panel Fig 48 INSTALLATION LAP BELT BUCKLE 1 Position shoulder belt buckle and lap belt buckle on the floor panel 2 Install bolts attaching lap bel...

Page 2173: ...ONSOLE REMOVAL 1 Pull transmission shift lever handle straight up and remove handle 2 Remove transmission and transfer case shift indicator bezels by prying upward to release them Position flat screwdriver between bezel and console to remove indicator bezel Fig 50 3 Disconnect lamp sockets from bezels 4 Remove console retaining screws 5 Remove console from floor INSTALLATION 1 Reverse removal proc...

Page 2174: ...s as applicable 3 As necessary remove trim panels and mold ings 4 Remove floor console 5 Remove all other interfering components 6 Remove carpet and mat from floor panel Fig 52 INSTALLATION 1 Reverse removal procedure CARGO CARPET MAT REMOVAL 1 Remove quarter trim panels 2 Remove liftgate trim panel 3 Drill out retaining rivet heads and remove cargo tie down footman loops from carpet Fig 53 4 Remo...

Page 2175: ...nutes Do not touch the bracket contact surface after the accelerator has been applied 5 Apply adhesive accelerator to the bracket con tact surface on the windshield glass Allow the accel erator to dry for one minute Do not touch the glass contact surface after the accelerator has been applied 6 Install the bracket according to the following instructions Apply one drop of adhesive at the center of ...

Page 2176: ...ter of headliner 2 If equipped remove sound bar Refer to group 8F Audio Systems for Service procedures 3 Remove upper liftgate trim molding 4 Remove D pillar trim molding 5 Remove sunvisors from front of roof panel Dis connect vanity lamp wiring if applicable 6 Remove assist handles from side of roof rails 7 Remove push plugs from roof support Fig 58 8 Remove dome reading lamp or overhead console ...

Page 2177: ...ws attaching lower trim panel to liftgate Fig 60 2 Use a trim panel removal tool to detach push in fasteners from liftgate LOWER TRIM PANEL INSTALLATION 1 Position trim panel on liftgate 2 Align trim panel push in fasteners with holes in liftgate inner panel Press trim panel inward to seat fasteners 3 Install screws attaching lower trim panel to liftgate LIFTGATE REMOVAL WARNING DO NOT DISCONNECT ...

Page 2178: ...tside handle to lift gate Fig 64 4 Separate outside handle from liftgate INSTALLATION 1 Position outside handle on liftgate 2 Install nuts attaching outside handle to lift gate 3 Install liftgate latch and actuator linkages 4 Install liftgate lower trim panel LIFTGATE LOCK CYLINDER For service refer to the Liftgate Outside Handle Removal Installation procedure in this group LIFTGATE LATCH REMOVAL ...

Page 2179: ...E FLIP UP GLASS CLOSED THE PROP ROD PISTONS ARE OPER ATED BY HIGH PRESSURE GAS THIS PRESSURE COULD CAUSE DAMAGE AND OR PERSONAL INJURY IF THEY ARE REMOVED WHILE THE PIS TONS ARE COMPRESSED 1 Remove liftgate upper trim panel 2 Open liftgate flip up glass Support glass for ease of repair 3 Using a small flat blade or equivalent tool gen tly pry open the locking caps on the end of the prop rod 4 Remo...

Page 2180: ...opening Remove it from vehicle 2 Clean seal flange as necessary INSTALLATION 1 Position weatherstrip seal with paint dots aligned with window opening corners 2 Seat seal firmly around entire liftgate Fig 70 3 Butt seal ends together and smooth out any remaining length Weathersrtip break should be 120 mm left of latch opening 4 If necessary cut surplus from weatherstrip non plug end only LIFTGATE F...

Page 2181: ...p housing 4 Disconnect Flip Up glass switch connector if equipped 5 Remove housing from liftgate INSTALLATION 1 Position lamp housing at liftgate 2 Connect bulb socket to lamp housing 3 Connect Flip Up glass switch connector if equipped 4 Install lamp housing retaining screws in lift gate Tighten screws securely 5 Install liftgate trim panel QUARTER WINDOW APPLIQUE AIR EXHAUSTER REMOVAL 1 Using a ...

Page 2182: ... a small flat blade carefully pry off riser cover Fig 75 2 If necessary depress the lock buttons on the crossbars and slide crossbars inward to expose the screws attaching the side rails to the risers and adapter plates Fig 76 3 Remove the screws attaching the side rails to the risers and adapter plates Fig 77 4 Separate the luggage rack from the adapter plates 5 Remove the screws attaching the ad...

Page 2183: ...DOWN 1 Loosen the latch striker 2 Tap the latch striker downward if the door character line is higher than the body character line or tap the latch striker upward if the door character line is lower than the body character line 3 Inspect alignment If correct tighten striker with 28 N m 21 ft lbs torque DOOR LATCH ADJUSTMENT 1 Locate access hole Fig 79 2 Insert a 5 32 inch hex wrench through hole a...

Page 2184: ...se NLGI 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 Lubr...

Page 2185: ...OMPRESSOR 25 HEATER PERFORMANCE 14 HIGH PRESSURE CUT OFF SWITCH 27 HIGH SPEED BLOWER MOTOR RELAY 27 LOW PRESSURE CYCLING CLUTCH SWITCH 27 REFRIGERANT SYSTEM LEAKS 28 VACUUM SYSTEM 14 SERVICE PROCEDURES REFRIGERANT OIL LEVEL 30 REFRIGERANT RECOVERY 28 REFRIGERANT SYSTEM CHARGE 29 REFRIGERANT SYSTEM EVACUATE 28 REMOVAL AND INSTALLATION ACCUMULATOR 39 AMBIENT TEMPERATURE SENSOR 39 BLOWER MOTOR RESIST...

Page 2186: ...els is designed for the use of non CFC R 134a refrigerant The air con ditioning system has an evaporator to cool and dehu midify the incoming fresh or recirculated air prior to blending it with the heated air This air conditioning system uses a fixed orifice tube in the condenser out let line to meter refrigerant flow to the evaporator coil To maintain minimum evaporator temperature and prevent ev...

Page 2187: ...D MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROP ERTY DAMAGE CAUTION Liquid refrigerant is corrosive to metal sur faces Follow the operating instructions supplied with the service equipment being used Never add R 12 to a refrigerant system designed to use R 134a Damage to the system will result R 12 refrigerant oil must not be mixed with R 134a refrigerant oil They are not compatible Do no...

Page 2188: ...erature and pressure are attained before opening the cooling system Refer to Group 7 Cooling System for more information REFRIGERANT HOSES LINES TUBES PRECAUTIONS Kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire system High pressures are produced in the system when it is oper ating Extreme care must be exercised to make sure that all refrigerant system connec...

Page 2189: ...radiator and con denser can affect the accuracy of this sensor input when the vehicle is not moving this input is only used by the ATC system when the vehicle is in motion The ambient temperature sensor cannot be adjusted or repaired and if faulty or damaged it must be replaced BLOWER MOTOR The blower motor and blower wheel are located in the passenger side end of the heater A C housing below the ...

Page 2190: ...he blower motor ground path through the heater A C mode control switch The blower motor switch directs this ground path to the blower motor through the blower motor resistor wires or directly to the blower motor as required to achieve the selected blower motor speed On ATC systems the blower motor switch is just one of many inputs to the ATC controller In the manual blower modes the ATC controller...

Page 2191: ...ater A C control panel the ATC controller the low pressure cycling clutch switch and the high pressure cut off switch See the Diagnosis and Test ing section of this group for more information on the operation of the compressor clutch relay The compressor clutch relay is located in the Power Distribution Center PDC in the engine compart ment Refer to the PDC label for relay identification and locat...

Page 2192: ...estricted or an overcharge of refrigerant The valve closes with a minimum pressure of 2756 kPa 400 psi The high pressure relief valve vents only enough refrigerant to reduce system pressure then re seats itself The majority of the refrigerant is conserved in the system If the valve vents refrigerant it does not mean the valve is faulty The valve is only serviced as part of the compressor assembly ...

Page 2193: ...le with R 134a refrigerant and must be replaced with O rings made of the same material REFRIGERANT LINE The refrigerant lines are used to carry the refrig erant between the various air conditioning system components A barrier hose design is used for the air conditioning system on this vehicle The ends of the refrigerant hoses are made from lightweight aluminum and use braze less fittings The refri...

Page 2194: ... door position as needed to maintain the selected comfort level The solar sensor cannot be adjusted or repaired and if faulty or damaged it must be replaced VACUUM CHECK VALVE A one way vacuum check valve is installed in the accessory vacuum supply line near the vacuum tap on the engine intake manifold This check valve helps to maintain the system vacuum needed to retain the selected heater A C mo...

Page 2195: ...tored as a result of this unseated wire har ness connector condition are Codes 36 38 and 39 Review the Service Warnings and Precautions in the front of this group before performing this proce dure The air temperature in the test room and in the vehicle must be a minimum of 21 C 70 F for this test 1 Connect a tachometer and a manifold gauge set 2 Set the heater A C controls in the A C Panel and Rec...

Page 2196: ...mperature and Pressure chart If the discharge air temperature is high see Refrigerant Sys tem Leaks and Refrigerant System Charge in this group 9 Compare the compressor discharge pressure to the Performance Temperature and Pressure chart If the compressor discharge pressure is high see the Pressure Diagnosis chart Fig 8 Low Pressure Cycling Clutch Switch CLUTCH CYCLING PRES SURE SWITCH ACCUMULATOR...

Page 2197: ...ER WIRE REFER TO GROUP 8 WIRING DIA GRAMS PRESSURES OK SYSTEM IS NORMAL CORRECT EVAPORATOR INLET GAUGE PRESSURE CORRECT COM PRESSOR DISCHARGE GAUGE PRESSURE PRESSURES ABNORMAL EVAPORATOR PRESSURE LOWER THAN NORMAL COMPRESSOR DISCHARGE PRESSURE LOWER THAN NOR MAL ORIFICE TUBE RESTRICTED OR PLUGGED EVAPORATOR RESTRICTED OR PLUGGED EVAPORATOR PRES SURE SLIGHTLY HIGHER THAN NORMAL COMPRESSOR DISCHARGE...

Page 2198: ...er 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 discharge air temperature cannot be adjusted with the temperature ...

Page 2199: ... 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 11 The test set gauge should return to the 27 kPa 8 in Hg set ting shortly after each connection is made If OK replace the faulty mode control switch If not O...

Page 2200: ...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 stick man will be displayed This is the self diagnostic mode from which the various tests may be selected 2 If the stick man floor arrow bottom is show ing the displayed Tes...

Page 2201: ...ns the fault occurred previously but is OK right now A majority of historical fault codes are caused by inter mittent wire harness or wire harness connector problems NOTE A battery disconnect will erase all faults stored in Read Available Memory RAM It is recommended that all faults be recorded before they are erased RETRIEVING FAULT CODES 1 To begin the Fault Code Tests you must be in the Select ...

Page 2202: ...r Door Feedback Circuit 13 Circuit shorted Mode Door Feedback Circuit 14 Feedback too low Blower Fan Feedback Circuit 15 Door not responding Mode Door Feedback Circuit 16 Door not responding Blend Air Door Actuator Drive Circuit 17 Door travel range too small Mode Door Feedback Circuit 18 Door travel range too large Mode Door Feedback Circuit 19 Door travel range too small Blend Air Door Actuator ...

Page 2203: ...back Circuit 40 Circuit was shorted Mode Door Feedback Circuit 41 Feedback was too low Blower Fan Feedback Circuit 42 Door was not responding Mode Door Feedback Circuit 43 Door was not responding Blend Air Door Actuator Drive Circuit 44 Door travel range was too small Mode Door Feedback Circuit 45 Door travel range was too large Mode Door Feedback Circuit 46 Door travel range was too small Blend A...

Page 2204: ...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 2205: ...osition beyond the stops The motor will try to move there 11 Mode Motor O A Mode Door System Pressing A C or RECIRC button for 3 sec begins reinitalization 00 searching for panel stop 01 searching for defrost stop 02 moving toward panel 03 moving toward defrost 04 in position 05 stalled moving toward panel 06 stalled moving toward defrost 07 feedback error 12 Mode Motor Drive Lines O Mode Door Sys...

Page 2206: ...3 moving to cooler 04 in position 05 stalled moving to warmer 06 stalled moving to cooler 07 feedback error 25 Blend Door Motor O A Blend Door System 00 255 It is possible to command the door position beyond the stops The motor will try to move there 26 Blend Door Motor Lines O A Blend Door System 00 stopped lines low 01 toward cold 02 toward hot 03 stopped lines high 27 Lights On I Headlight Swit...

Page 2207: ...M MODE VREF BLEND FEED BACK MODE Air Inlet Recirc Door Actuator DriveCircuit ATC CONTROL MODULE AIR INLET RECIRC DOOR MOTOR AIR INLET RECIRC IGNITION Front Panel Mode Control Circuit ATC CONTROL MODULE FRONT PANEL MODE CONTROL POTENTI OMETER GROUND A D Front Panel Blower Fan Control Circuit ATC CONTROL MODULE FRONT PANEL BLOWER FAN CON TROL POTENTIOM ETER GROUND A D ZG HEATING AND AIR CONDITIONING...

Page 2208: ... ATC CONTROL MODULE IN VEHICLE SENSOR SIG NAL COMMON RETURN IN VEHICLE TEMPERATURE SENSOR Calibration and CPU Data ATC CONTROL MODULE WATCHDOG CIRCUIT MICROPRO CESSOR CPU ACTUATOR DRIV ERS ACTUATORS COLLAGE SENSOR INPUTS CCD BUS CHIP POWERTRAIN CONTROL MODULE 24 24 HEATING AND AIR CONDITIONING ZG DIAGNOSIS AND TESTING Continued ...

Page 2209: ...tion Remove the heater A C control from the instrument panel Check for continuity between the ground cir cuit cavity of the control wire harness 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 wire harness con nector unplugged place the mode control switch knob in any position except the...

Page 2210: ...eptable if the current draw measured at the clutch 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 turn ing on electrical accessories until the system voltage drops below 12 5 volts a If the clutch coil current reading is 4 ampere...

Page 2211: ...y 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 TEST For circuit descriptions and diagrams refer to 8W 42 Air Conditioning Heater in Group 8W Wir ing Diagrams 1 The relay common feed terminal cavity 30 is connected to battery voltage and should be hot at all times If OK go t...

Page 2212: ...in the Recircu lation mode SYSTEM LOW 1 Position the vehicle in a wind free work area This will aid in detecting small leaks 2 Bring the refrigerant system up to operating temperature and pressure This is done by allowing the engine to run with the air conditioning system on for five minutes 3 With the engine not running use a electronic R 134a leak detector and search for leaks Move the leak dete...

Page 2213: ...st make contact with the bottom surfaces of the inlet and outlet tubes 3 Open all of the windows or doors of the passen ger compartment Set the air conditioning controls to A C Panel Recirc temperature control knob in the full cool position and the blower motor switch on High 4 Start the engine and hold the engine idle speed at 1 000 rpm Allow the engine to warm up to normal operating temperature ...

Page 2214: ...stem after the repair has been made Oil loss at a leak point will be evident by the presence of a wet shiny surface around the leak Refrigerant oil must be added when a accumulator evaporator or condenser are replaced See the Refrig erant Oil Capacities chart When a compressor is replaced the oil must be drained from the old com pressor and measured Drain all the oil from the new compressor then f...

Page 2215: ...hey 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 and the inside of the female fitting with clean R 134a refrig erant oil Use only refrigerant oil of the type recom mended for the compressor in the vehicle 5 Fit the female fitting to the male fitting...

Page 2216: ...tings 6 Raise and support the vehicle 7 Remove the bolts that secure the compressor clutch drive spool to the power steering pump drive flange 8 Remove the four compressor mounting bolts and spacers and remove the compressor and clutch unit from the engine block 9 Remove the compressor clutch and drive spool from the compressor as described in this group INSTALLATION NOTE If a replacement compress...

Page 2217: ...ed if there is excessive wear or scoring If the friction surfaces are oily inspect the shaft and nose area of the compressor for oil Remove the felt from the front cover If the felt is saturated with oil the shaft seal is leaking and the compressor must be replaced Check the clutch pulley bearing for roughness or excessive leakage of grease Replace the bearing if required INSTALLATION 1 Align the ...

Page 2218: ...0 65 mm 0 014 to 0 026 in If the proper air gap is not obtained add or subtract shims as needed until the desired air gap is obtained 9 Install the compressor shaft bolt Tighten the bolt to 13 N m 115 in lbs NOTE The shims may compress after tightening the shaft bolt Check the air gap in four or more places to verify the air gap is still correct Spin the pulley before performing a final check of t...

Page 2219: ...coil with the hole in the compressor front hous ing and press the field coil into place 2 Install the clutch coil wire lead retaining clip on the compressor front housing and tighten the retaining screw 3 Install the clutch field coil and snap ring with snap ring pliers The bevel side of the snap ring must be facing outward Press the snap ring to make sure it is properly seated in the groove CAUTI...

Page 2220: ...R CLUTCH RELAY 1 Disconnect and isolate the battery negative cable 2 Remove the cover from the Power Distribution Center PDC Fig 31 3 Refer to the label on the PDC for compressor clutch relay identification and location 4 Unplug the compressor clutch relay from the PDC 5 Install the compressor clutch relay by aligning the relay terminals with the cavities in the PDC and pushing the relay firmly in...

Page 2221: ... two radiator braces Fig 35 6 Remove the two nuts that secure the radiator to the crossmember Fig 36 7 Reach through the grille opening and remove the bolt that secures 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...

Page 2222: ...C CON DENSER AND RADIATOR RADIATOR TO BODY SEAL RIGHT UPPER SEALS BETWEEN RADI ATOR AND UPPER CROSSMEM BER RADIATOR ALIGNMENT DOWELS 2 RADIATOR TO BODY SEAL LEFT LOWER SEAL A C CONDENSER Fig 35 Condenser Mounting CONDENSER BOLT FAN SHROUD MOUNTING NUTS UPPER BRACE BOLTS CONDENSER BOLT ALIGNMENT DOWELS LOWER BRACKET BOLT HOOD LATCH BRACKET Fig 36 Radiator Upper Crossmember Typical CONDENSER TO RA D...

Page 2223: ...he open refrigerant fittings 4 Unplug the wire harness connector from the low pressure cycling clutch switch Fig 37 5 Loosen the screw that secures the accumulator band to the support bracket 6 Remove the accumulator INSTALLATION 1 Install the accumulator band screw in the sup port bracket 2 Tighten the band screw in the support bracket 3 Plug the wire harness connector into the low pressure cycli...

Page 2224: ...G ANY 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 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 inboard switch pod bezel and remove the b...

Page 2225: ...l to release the snap clip retainers Fig 42 3 Lift the cowl top trim panel far enough to reach underneath it to access the solar sensor which is located between the passenger side and center defroster outlets 4 Use a twisting motion to remove the solar sen sor from the cowl top trim panel Fig 43 5 Pull the sensor out far enough to access the wire harness connector and unplug it from the instrument...

Page 2226: ...to Group 8E Instrument Panel Systems for the procedures 6 Connect the battery negative cable BLOWER MOTOR REMOVAL 1 Disconnect and isolate the battery negative cable 2 Disconnect the blower motor cooling tube Fig 45 3 Remove the blower motor wire harness from the retainer Unplug the wire harness connector from the blower motor 4 Remove the screws that secure the blower motor and wheel assembly to ...

Page 2227: ...HIGH SPEED BLOWER MOTOR RELAY This relay is used only on models equipped with the optional Automatic Temperature Control ATC system WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DE...

Page 2228: ...rument panel from the vehicle as described in Group 8E Instrument Panel Sys tems 2 Remove the three screws that secure the defroster duct to the instrument panel armature 3 Remove the defroster duct 4 Reverse the removal procedures to install DEMISTER DUCTS 1 Remove the defroster duct as described in this group 2 Remove the four screws that secure the demis ter ducts to the instrument panel armatu...

Page 2229: ...op pad as described in Group 8E Instrument Panel Systems 2 Remove the two screws that secure each outlet to the top pad 3 Remove the outlet from the top pad 4 Reverse the removal procedures to install PANEL DEFROST DOOR REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the instrument panel as described in Group 8E Instrument Panel Systems 3 Disconnect the panel defrost door actu...

Page 2230: ...nstrument Panel Systems 6 Connect the battery negative cable HEATER A C HOUSING 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 lines from the evap orator tubes Fig 56 Install plugs in or tape over all of the open refrigerant fittings 4 Drain the cooling system Refer to Group 7...

Page 2231: ...ptor Check that the carpet is not interfering with any duct outlets 9 Plug in the heater A C housing wire harness connectors 10 Install the instrument panel Refer to Group 8E Instrument Panel Systems 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 Connect the battery negativ...

Page 2232: ...tor 4 Install the heater A C housing as described in this group NOTE If the evaporator was replaced add 2 ounces of refrigerant oil to the refrigerant system HEAT 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 from the vehi cle as described in this group 2 Turn the heater A C housing up...

Page 2233: ...rol ATC system REMOVAL 1 Remove the heater A C housing from the vehi cle as described in this group 2 Turn the heater A C housing upside down 3 Unplug the wire harness connector from the motor Fig 63 4 Remove the screws that secure the motor to the heater A C housing 5 Remove the motor from the housing INSTALLATION 1 Position the heat defrost or panel defrost door motor on the heater A C housing 2...

Page 2234: ...or pivot shaft retainer onto the shaft 3 Connect the recirculating air door actuator rod and retainer clip to the door lever 4 Install the heater A C housing as described in this group TEMPERATURE BLEND AIR DOOR REMOVAL 1 Remove the heater A C housing as described in this group 2 Turn the heater A C housing upside down 3 Remove the screws securing the two housing halves to each other Remove the ce...

Page 2235: ...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 2236: ...gnize 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 properly during testing assume the device its associated wiring and driver circuit work cor rectly Connect the DRB scan tool to ...

Page 2237: ...delay between numbers 3 A DTC number 55 will always be the last code to be displayed This indicates the end of all stored codes After code 55 has been displayed the odometer will return to its normal mode DIAGNOSTIC TROUBLE CODE DESCRIPTIONS HEX CODE MIL CODE GENERIC SCAN TOOL CODE DRB SCAN TOOL DISPLAY DESCRIPTION OF DIAGNOSTIC TROUBLE CODE 12 Battery Disconnect Direct battery input to PCM was di...

Page 2238: ...hrottle Position Sensor Voltage High Throttle position sensor input above the maximum acceptable voltage 1E 22 P0117 ECT Sensor Voltage Too Low Engine coolant temperature sensor input below minimum acceptable voltage or 1F P0118 ECT Sensor Voltage Too High Engine coolant temperature sensor input above maximum acceptable voltage 21 17 Engine Is Cold Too Long Engine did not reach operating temperatu...

Page 2239: ...r 46 P0206 Injector 6 Control Circuit Injector 6 output driver does not respond properly to the control signal 4A 45 P0712 Trans Temp Sensor Voltage Too Low Voltage less than 1 55 volts or 4B P0713 Trans Temp Sensor Voltage Too High Voltage greater than 3 76 volts 4F 27 P0207 Injector 7 Control Circuit Injector 7 output driver does not respond properly to the control signal or 50 P0208 Injector 8 ...

Page 2240: ...uto trans only 76 52 P0172 Left Bank or Fuel System Rich A rich air fuel mixture has been indicated by an abnormally lean correction factor 77 51 P0171 Right Rear or just Fuel System Lean A lean air fuel mixture has been indicated by an abnormally rich correction factor 7E 21 P0138 Left Bank Downstream or Downstream and Pre Catalyst O2S Shorted to Voltage Oxygen sensor input voltage maintained abo...

Page 2241: ...nstream and Pre Catalyst O2S Shorted to Ground O2 sensor voltage too low tested after cold start 9D 11 P1391 Intermittent Loss of CMP or CKP Intermittent loss of either camshaft or crankshaft position sensor A0 31 P0442 Evap Leak Monitor Small Leak Detected A small leak has been detected by the leak detection monitor or A1 P0455 Evap Leak Monitor Large Leak Detected The leak detection monitor is u...

Page 2242: ... Circuit Leak detection pump solenoid circuit fault open or short or B8 P1494 Leak detection pump SW or mechanical fault Leak detection pump switch does not respond to input BA 11 P1398 Mis fire Adaptive Numerator at Limit CKP sensor target windows have too much variation BB 31 P1486 Evap leak monitor pinched hose found Plug or pinch detected between purge solenoid and fuel tank BC 45 O D Switch P...

Page 2243: ...of the exhaust gas The output voltage of the O2S ranges from 0 to 1 volt A good sensor can easily generate any output voltage in this range as it is exposed to different con centrations of oxygen To detect a shift in the A F mixture lean or rich the output voltage has to change beyond a threshold value A malfunctioning sensor could have difficulty changing beyond the threshold value MIL 21 OXYGEN ...

Page 2244: ...an attempt to see a shift in the 02 control system If fuel vapor indicated by a shift in the 02 control is present the test is passed If not it is assumed that the purge system is not functioning in some respect The LDP is again turned off and the test is ended MIL 43 MISFIRE MONITOR Excessive engine misfire results in increased cata lyst temperature and causes an increase in HC emis sions Severe ...

Page 2245: ...eak Detection Pump Monitor if equipped EGR Monitor if equipped Oxygen Sensor Heater Monitor fails twice in a row and turns ON the MIL re run ning that monitor which previously failed on the next start up and passing the monitor is considered to be a Good Trip If any other Emission DTC is set not an OBDII Monitor a Good Trip is considered to be when the Oxygen Sensor Monitor and Catalyst Monitor ha...

Page 2246: ...though the PCM monitors engine exhaust oxygen content when the system is in closed loop it cannot determine excessive oil consumption THROTTLE BODY AIR FLOW The PCM cannot detect a clogged or restricted air cleaner inlet or filter element VACUUM ASSIST The PCM cannot detect leaks or restrictions in the vacuum circuits of vacuum assisted engine control system devices However these could cause the P...

Page 2247: ...y cycle EVAP purge solenoid Refer to Duty Cycle EVAP Canister Purge Solenoid in this section When equipped with the California Emissions Package a Leak Detection Pump LDP will be used as part of the evaporative system This pump is used as part of OBD II requirements Refer to Leak Detec tion Pump in this group for additional information NOTE The evaporative system uses specially man ufactured hoses...

Page 2248: ...K DETECTION PUMP LDP WITH CALIFORNIA EMISSIONS PACKAGE The leak detection pump LDP is used with 4 0L 6 cylinder and 5 2L V 8 engines if equipped with the California Emission Package It is not used with the 5 9L engine The LDP is a device used to detect a leak in the evaporative system The pump contains a 3 port solenoid a pump that contains a switch a spring loaded canister vent valve seal 2 check...

Page 2249: ...e test sequence as the pump diaphragm assembly moves to the full travel position POSITIVE CRANKCASE VENTILATION PCV SYSTEM 5 2L 5 9L ENGINE The 5 2L 5 9L V 8 engine is equipped with a closed crankcase ventilation system and a positive crank case ventilation PCV valve The 4 0L 6 cylinder engine is not equipped with a PCV valve Refer to Crankcase Ventilation System 4 0L Engine for information This s...

Page 2250: ...inder engines are equipped with a Crankcase Ventilation CCV system The CCV sys tem performs the same function as a conventional 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 l...

Page 2251: ...nd cannot be removed without defacing information and destroying label DIAGNOSIS AND TESTING PCV VALVE TEST 5 2L 5 9L ENGINE 1 With engine idling remove the PCV valve from cylinder head valve cover If the valve is not plugged a hissing noise will be heard as air passes through the valve Also a strong vacuum should be felt at the valve inlet Fig 13 2 Install the PCV valve Remove the crankcase breat...

Page 2252: ...removing any metal from the fitting VACUUM SCHEMATICS A vacuum schematic for emission related items can be found on the Vehicle Emission Control Informa tion VECI Label Refer to VECI Label in this group for label location LEAK DETECTION PUMP LDP Refer to the appropriate Powertrain Diagnostic Procedures service manual for LDP testing proce dures REMOVAL AND INSTALLATION EVAPORATIVE EVAP CANISTER Th...

Page 2253: ...ver valves s are is molded into the fuel tank and are not serviced separately If replacement is necessary the fuel tank must be replaced Refer to Fuel Tank Removal Installation in Group 14 Fuel System for procedures LEAK DETECTION PUMP LDP The LDP is located in the left front corner of the engine compartment below the EVAP canister purge solenoid Fig 18 REMOVAL INSTALLATION 1 Remove air cleaner ho...

Page 2254: ...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 25 20 EMISSION CONTROL SYSTEMS ZG REMOVAL AND INSTALLATION Continued ...

Page 2255: ...uit or the system A DTC may indicate the result of a failure but never identify the failed component directly There are several operating conditions that the MSA does not monitor and set a DTC for Refer to the following Monitored Circuits and Non Monitored Circuits in this section MONITORED CIRCUITS The MSA can detect certain problems in the elec trical system Open or Shorted Circuit The MSA can d...

Page 2256: ...s from other sensors or switches The other inputs might have to be sensed by the MSA when it senses a high or low input volt age from the control system device in question DESCRIPTION AND OPERATION DIAGNOSTIC TROUBLE CODES On the following pages a list of DTC s is provided for the 2 5L diesel engine A DTC indicates that the PCM has recognized an abnormal signal in a circuit or the system A DTC may...

Page 2257: ...uel Quantity Actuator Neg Gov Deviation Warm Fuel Quantity Actuator Pos Gov Deviation Cold Fuel Quantity Actuator Pos Gov Deviation Warm P1225 Control Sleeve Sensor Signal High Exceeded Control Sleeve Sensor Start End Pos Not Attained Control Sleeve Sensor Stop End Pos Not Attained P1230 Timing Control Negative Governing Governor Deviation Timing Control Positive Governing Governor Deviation P1515...

Page 2258: ...ility Func Switch Wrong or Missing EEPROM Plausibility Ver Number Not Corresponding P1685 Vehicle Theft Alarm Code Line Breakdown P1703 Brake Signal Plaus With Redundant Contact P1740 Clutch Signal Plausibilty P1725 Inductive Aux Speed Sensor Dynamic Plausibilty Inductive Aux Speed Sensor Overspeed Recognition Inductive Aux Speed Sensor Plausibilty Inductive Aux Speed Sensor Static Plausibilty PCM...

Page 2259: ...the engine exhaust This is accomplished by allow ing a predetermined amount of hot exhaust gas to recirculate and dilute the incoming fuel air mixture A malfunctioning EGR system can cause engine stumble sags or hesitation rough idle engine stall ing and poor driveability EGR SYSTEM OPERATION The system consists of An EGR valve assembly The valve is located behind the intake manifold Fig 2 An Elec...

Page 2260: ...d on the EGR valve vacuum motor Fig 2 2 Disconnect the rubber hose from the vacuum supply fitting Fig 2 3 Connect a hand held vacuum pump to this fit ting 4 Start the engine 5 Slowly apply 10 inches of vacuum to the fitting on the EGR valve motor Vacuum should hold steady at 10 inches If not replace the EGR valve If vac uum holds steady at 10 inches proceed to next step 6 While applying vacuum and...

Page 2261: ...2 3 Loosen fitting at exhaust manifold end of tube Fig 2 4 Remove EGR tube and discard old gasket 5 Clean gasket mating surfaces and EGR tube flange gasket surfaces 6 Check for signs of leakage or cracked surfaces at both ends of tube exhaust manifold and EGR valve INSTALLATION 1 Install a new gasket to EGR valve end of EGR tube 2 Position EGR tube to engine 3 Loosely tighten fitting at exhaust ma...

Page 2262: ...RQUE CHART 2 5L DIESEL Description Torque EGR Valve Mounting Bolts 23 N m 204 in lbs EGR Tube Mounting Bolts 23 N m 204 in lbs EVM Electric Vacuum Modulator Mounting Bolt 2 N m 20 in lbs 25 8 EMISSION CONTROL SYSTEM ZG ...

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