Chrysler Dodge Caravan 2002 Скачать руководство пользователя страница 486 | Manualshive

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Chrysler Dodge Caravan 2002 Скачать руководство пользователя страница 486

IGNITION CONTROL

TABLE OF CONTENTS

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GLOW PLUG

. . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

GLOW PLUG RELAY

. . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CAMSHAFT POSITION SENSOR

. . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

. . . . . . . . . . . . . . . . . . . . . . . . . . 2

GLOW PLUG

DESCRIPTION

Glow plugs are used to help start a cold or cool

engine (Fig. 1). The glow plugs will heat up and glow
to heat the combustion chamber of each cylinder. An
individual glow plug is used for each cylinder. Each
glow plug is threaded into the left side of the cylinder
head below the cylinder head cover/intake manifold.

OPERATION

Each glow plug will momentarily draw approxi-

mately 25 amps of electrical current during the ini-
tial key “ON” cycle. This is on a cold or cool engine.
After heating the current draw will drop to approxi-
mately 9–12 amps per plug.

Total momentary cuurent draw for all four glow

plugs is approximately 100 amps on a cold engine
dropping to a total of approximately 40 amps after
the plugs are heated.

Electrical operation of the glow plugs is controlled

by two glow plug relays. Each glow plug relay con-
trols two glow plugs. Refer to glow plug relays for
more information.

GLOW PLUG RELAY

DESCRIPTION

There are two glow plug relays. These relays are

located in the Power Distribution Center (PDC) in
the engine compartment (Fig. 2).

OPERATION

When the ignition (key) switch is place in the ON

position, a signal is sent to the ECM relating current
engine coolant temperature. This signal is sent from
the engine coolant temperature sensor.

After receiving this signal, the ECM will determine

if, when and for how long of a period the glow plug
relays should be activated. This is done before, dur-
ing and after the engine is started. Whenever the
glow plug relays are activated, it will control the 12
volt 100 amp circuit for the operation of the four
glow plugs. Each relay control two glow plugs.

Fig. 1 GLOW PLUG

Fig. 2 RELAY LOCATIONS

1 - GLOW PLUG RELAY
2 - RADIATOR SUPPORT
3 - CHARGE AIR COOLER OUTLET HOSE
4 - COOLING FAN RELAY
5 - UPPER RADIATOR HOSE
6 - EGR SOLENOID

RG

IGNITION CONTROL

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Содержание Dodge Caravan 2002

Страница 1: ...s 8H Horn 8I Ignition Control 8Ia Ignition Control 8J Instrument Cluster 8L Lamps 8M Message Systems 8N Power Systems 8O Restraints 8P Speed Control 8Q Vehicle Theft Security 8R Wipers Washers 8W Wiri...

Страница 2: ...ate Fig 1 is located in the engine compartment on the radiator closure panel crossmember There are seven lines of information on the body code plate Lines 4 5 6 and 7 are not used to define service in...

Страница 3: ...OUGH 23 Vehicle Identification Number Refer to Vehicle Identification Number VIN paragraph for proper breakdown of VIN code IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate wil...

Страница 4: ...Fig 2 FASTENER IDENTIFICATION RS INTRODUCTION 3 FASTENER IDENTIFICATION Continued...

Страница 5: ...Fig 3 FASTENER STRENGTH 4 INTRODUCTION RS FASTENER IDENTIFICATION Continued...

Страница 6: ...procedures INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart Fig 4 are used to identify various instrument con trols Th...

Страница 7: ...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 x 1 0936 Yards mph x 1 6093 Kilometers Hr Km h Km h x 0 6214 mph Feet Sec x 0 3048 Meters Sec M...

Страница 8: ...Fig 5 METRIC CONVERSION CHART RS INTRODUCTION 7 METRIC SYSTEM Continued...

Страница 9: ...N Individual Torque Charts appear within many or the Groups Refer to the Standard Torque Specifica tions Chart for torque references not listed in the individual torque charts Fig 6 Fig 6 TORQUE SPECI...

Страница 10: ...o use the check digit is not released to the general public VIN CODE BREAKDOWN CHART POSITION INTERPRETATION CODE DESCRIPTION 1 Country of Origin 1 Built in the United States by DaimlerChrysler 2 Buil...

Страница 11: ...hort Wheelbase with CYX Less AS8 7 Comercial Van Short Wheelbase with AS8 8 Comercial Van Long Wheelbase Highline with CYX 9 Comercial Van Long Wheelbase Premium Line with CYX CYX No Rear Seat Package...

Страница 12: ...Regulation Number Regulation Amendment Number Approval Number VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Infor mation VECI Label Chrysler permanently attaches the label in the e...

Страница 13: ......

Страница 14: ...CAPACITIES DESCRIPTION SPECIFICATION Fuel Tank Gas 75 L 20 gal Fuel Tank Diesel 75 L 20 gal Engine Oil 2 4 L 4 7 L 5 0 qts Engine Oil 3 3 3 8 L 4 0 L 4 5 qts Engine Oil 2 5 L Diesel 6 0 L 6 3 qts Coo...

Страница 15: ...m Institute API National Lubricating Grease Institute NLGI API SERVICE GRADE CERTIFIED Use an engine oil that is API Certified MOPARt provides engine oils that meet or exceed this requirement SAE VISC...

Страница 16: ...t from engine metal in the cylinder head area near the exhaust valves and engine block Then coolant carries the heat to the radiator where the tube fin radiator can transfer the heat to the air The us...

Страница 17: ...peration DESCRIPTION AUTOMATIC TRANSMISSION FLUID NOTE Refer to the maintenance schedules for the recommended maintenance fluid filter change intervals for this transaxle NOTE All transaxles have a co...

Страница 18: ...r not his her gasoline contains MMT It is even more important to look for gasoline with out MMT in Canada because MMT can be used at levels higher than allowed in the United States MMT is prohibited i...

Страница 19: ...ld starting and warm up perfor mance DESCRIPTION ENGINE OIL DIESEL ENGINES Use only Diesel Engine Oil meeting standard MIL 2104C or API Classification CD or higher or CCML D4 D5 SAE VISCOSITY GRADE CA...

Страница 20: ...URE WARNING DO NOT JUMP START A FROZEN BAT TERY PERSONAL INJURY CAN RESULT WARNING DO NOT JUMP START WHEN MAINTE NANCE FREE BATTERY INDICATOR DOT IS BRIGHT COLOR WARNING DO NOT ALLOW JUMPER CABLE CLAM...

Страница 21: ...D cable clamp from battery posi tive terminal on disabled vehicle TOWING STANDARD PROCEDURE TOWING WARNINGS AND CAUTIONS WARNING DO NOT ALLOW TOWING ATTACHMENT DEVICES TO CONTACT THE FUEL TANK OR LINE...

Страница 22: ...omponents or engine mounts damage to vehicle can result The vehicle can be tied to a flat bed device using the two pair of front slots on the bottom surface of the rails behind the front wheels The tw...

Страница 23: ......

Страница 24: ...TESTING LOWER BALL JOINT 10 LOWER BALL JOINT SEAL BOOT DESCRIPTION EXPORT 10 REMOVAL REMOVAL BALL JOINT SEAL BOOT 11 REMOVAL EXPORT 11 INSTALLATION INSTALLATION BALL JOINT SEAL BOOT 11 INSTALLATION E...

Страница 25: ...the lower ball joint turn as an assembly STANDARD PROCEDURE LUBRICATION There are no serviceable lubrication points on the front suspension The ball joints are sealed for life and require no maintenan...

Страница 26: ...ts 65 45 Hub And Bearing Axle Hub Nut 244 180 Lower Control Arm Pivot Bolt 183 135 Stabilizer Bar Bushing Retainer Bolts 68 50 Stabilizer Bar Link Nuts 88 65 Strut Body Tower Mounting Nuts 28 21 250 S...

Страница 27: ...all the two nuts and tighten to 68 N m 50 ft lbs torque 5 Reattach emission leak detection pump to cra dle crossmember reinforcement with two mounting bolts 6 Lower the vehicle HUB BEARING DESCRIPTION...

Страница 28: ...ring knuckle The steering knuckle will require removal from the vehi cle to allow the hub bearing assembly to be pressed out of the steering knuckle Refer to 2 SUSPENSION FRONT KNUCKLE REMOVAL 1 Raise...

Страница 29: ...tud nuts in proper sequence until all nuts are torqued to half specifica tion Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs 7 Lower vehicle to the ground 8 Che...

Страница 30: ...end stud while loosening and removing nut with a wrench Fig 11 7 Remove tie rod end from steering knuckle using Remover Special Tool C 3894 A Fig 12 8 If equipped with antilock brakes remove the front...

Страница 31: ...le faces outward 14 Remove the nut from the top of the ball joint stud 15 Remove the steering knuckle from the vehicle 16 If the hub and bearing needs to be trans ferred remove the four bolts attachin...

Страница 32: ...teering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation Install nuts while holding bolts stationary in the steering knuckle CAUTION If the vehicle bei...

Страница 33: ...lower control arm of this vehicle is a sealed for life ball joint and requires no maintenance lubrication The ball joint has been lubricated for life during the manufacturing process A special fittin...

Страница 34: ...at the socket 2 Install a NEW seal boot by hand as far as pos sible on the ball joint Installation of the seal boot is to be with the shield positioned as shown Fig 18 CAUTION Do not use an arbor pre...

Страница 35: ...rossmember Fig 1 The lower control arm is an iron casting with two rubber bushings and a ball joint The lower control arm front bushing is the spool type and is pressed into the lower control arm The...

Страница 36: ...ithout using excessive clamping force 3 Using a sharp knife such as a razor slit the bushing lengthwise Fig 23 to allow its removal from the lower control arm Fig 23 4 Remove the bushing from the lowe...

Страница 37: ...ntrol arm bushing 1 Apply Mopar Silicone Spray Lube or an equiv alent to the hole in lower control arm rear bushing This will aid in the installation of the bushing on the lower control arm 2 With the...

Страница 38: ...f the bushing 4 Begin to tighten forcing screw As bushing nears lower control arm flange place Spacer Plate Special Tool 8460 4 between flange and bushing inner sleeve straddling the stem as shown Fig...

Страница 39: ...3 N m 135 ft lbs 10 Install the wheel and tire assembly Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specifica tion Then repeat the tightening...

Страница 40: ...d of the stabilizer bar link do not allow the stud to rotate in it s socket Hold the stud from rotating by placing an open end wrench on the flat machined into the stud Fig 33 5 Remove the stabilizer...

Страница 41: ...ers onto crossmember aligning raised bead on retainer with cutouts in bushings Fig 36 Do not tighten Stabilizer bar bushing retainers bolts at this time 3 Check position of the stabilizer bar in the f...

Страница 42: ...s going through the strut clevis bracket and steering knuckle The top of the strut mounts directly to the strut tower of the vehicle using the threaded studs on the strut assemblies upper mount The st...

Страница 43: ...leakage will be a stream of fluid running down the side and dripping off lower end of unit A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect perf...

Страница 44: ...turned during removal Remove nuts while holding bolts stationary in the steering knuckles 6 Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts Fig 42 Fig 39 Strut Assembly...

Страница 45: ...the coil spring so the strut is held in place once the strut shaft nut is removed 3 Compress the coil spring until all coil spring tension is removed from the upper mount 4 Install Strut Nut Socket S...

Страница 46: ...top to bottom Left and right springs must not be interchanged NOTE If the coil spring has been removed from the spring compressor proceed with the next step oth erwise proceed with step 5 1 Place the...

Страница 47: ...ing Fig 49 If necessary reposition the strut or coil spring in the compressor so both of these line up straight outward away from the compressor to the 6 o clock position Install the clamp to hold the...

Страница 48: ...mbly with steering knuckle Position arm of steering knuckle into strut assembly clevis bracket Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes Install t...

Страница 49: ...ALLATION 43 SPRING MOUNTS REAR REMOVAL 43 INSTALLATION 44 STABILIZER BAR DESCRIPTION 44 OPERATION 44 REMOVAL REMOVAL AWD 44 REMOVAL FWD 44 INSTALLATION INSTALLATION AWD 44 INSTALLATION FWD 45 TRACK BA...

Страница 50: ...spension A hub and bearing assembly is used Fig 1 Front Wheel Drive Rear Suspension 1 SHACKLE 7 LEAF SPRING MONO LEAF 2 REAR MOUNT HANGER 8 ISOLATOR 3 TRACK BAR 9 FWD REAR AXLE 4 SPRING PLATE 10 STABI...

Страница 51: ...Mount To Body Bolts 61 45 Leaf Spring Shackle Plate Nuts 61 45 Shock Absorber Mounting Bolts 88 65 Stabilizer Bar Bushing Retainer Bolts 61 45 Stabilizer Bar Link Nuts 61 45 Stabilizer Bar Link Frame...

Страница 52: ...e a wooden block between the spring and vehicle to hold forward end of the spring in place 6 Remove leaf spring forward pivot bolt then remove mounting bracket 7 Straighten the retainer tabs on the bu...

Страница 53: ...nder vehicle 11 Tighten the spring front pivot bolt to 156 N m 115 ft lbs torque 12 Tighten the lower shock absorber mounting bolt to 88 N m 65 ft lbs torque HUB BEARING DESCRIPTION The rear wheel bea...

Страница 54: ...is some times noticeable at lower speeds and at other times is more noticeable at speeds above 105 km h 65 mph REMOVAL FRONT WHEEL DRIVE VEHICLES 1 Raise vehicle Refer to LUBRICATION MAINTENANCE HOIST...

Страница 55: ...18 from the stub shaft of the outer C V joint 5 Remove the spring washer Fig 17 from the stub shaft of the outer C V joint 6 Remove the hub nut and washer Fig 16 from the stub shaft of the outer C V j...

Страница 56: ...4 bolts in a crisscross pat tern until the hub and bearing and brake support plate is fully and squarely seated onto flange of rear axle Tighten the 4 mounting bolts to a torque of 129 N m 95 ft lbs N...

Страница 57: ...cross thread the cal iper guide pin bolts 6 Install the disc brake caliper guide pin bolts Fig 15 Tighten the guide pin bolts to a torque of 35 N m 26 ft lbs Fig 12 Hub Bearing Removal And Installatio...

Страница 58: ...the outer C V joint 15 Install the wheel speed sensor on the hub bearing and adapter Install the wheel speed sensor attaching bolt Fig 19 Tighten the wheel speed sen sor attaching bolt to a torque of...

Страница 59: ...bolt attaching the jounce bumper to frame rail Fig 21 2 Remove the jounce bumper from the frame rail INSTALLATION INSTALLATION AWD AND HEAVY DUTY 1 Install jounce bumper through bumper support plate...

Страница 60: ...wer mounting bolt deflects upward during removal raise axle by adjusting the support jack If the lower shock absorber bolt deflects downward during removal lower the axle by adjusting the support jack...

Страница 61: ...wer mounting bolt securing the lower end of the shock absorber to the axle 3 Remove the support jack 4 Lower the vehicle to the ground so the full curb weight of the vehicle is supported by the suspen...

Страница 62: ...r of the spring hanger and the spring 9 Remove the rear leaf spring from the outer half of the spring shackle 10 Remove the leaf spring from the vehicle 11 Loosen and remove the pivot bolt from the fr...

Страница 63: ...ting bolt to 102 N m 75 ft lbs torque SPRING FWD DESCRIPTION The leaf springs used on the rear suspension of this vehicle are of either a mono leaf or multi leaf design depending on model and options...

Страница 64: ...remove the hanger plate from the hanger and remove the spring from the spring hanger Fig 35 10 Remove the leaf spring from the vehicle 11 Loosen and remove the pivot bolt from the front mount of the r...

Страница 65: ...ue 13 Tighten rear spring shackle pin nuts to 61 N m 45 ft lbs torque 14 Tighten rear spring shackle inner to outer half retaining bolts to 61 N m 45 ft lbs torque 15 Tighten the lower shock absorber...

Страница 66: ...as a guide When the four mounting bolt holes line up with their threads in the body Install the mounting bolts Fig 37 Tighten the four mounting bolts to 61 N m 45 ft lbs torque 4 Raise or lower the ja...

Страница 67: ...rear frame rails is through rubber isolated bushings The 2 rubber isolated links are connected to the rear frame rails by brackets These brackets are bolted to the bottom of the frame rails OPERATION...

Страница 68: ...e rear axle The track bar is used to keep the location of the axle in the correct position for optimum handling and control of the vehicle REMOVAL 1 Remove the nut and bolt mounting the track bar to t...

Страница 69: ...tion s wheel alignment spec ifications differ On this vehicle the suspension angles that can be adjusted are as follows Front Camber with camber bolt package and standard procedure Front Toe Check the...

Страница 70: ...ar a caster imbalance between the two front wheels may cause the vehicle to lead to the side with the least positive caster CROSS CASTER Cross caster is the difference between left and right caster TO...

Страница 71: ...t necessary to check or adjust front or rear dynamic toe pattern when doing a normal wheel alignment The only time dynamic toe pattern needs to be checked or adjusted is if the frame of the vehi cle h...

Страница 72: ...e wheel bearing 2 Incorrect wheel alignment 2 Check and reset wheel alignment 3 Worn tires 3 Replace tires Front End Growl Or Grinding On Turns 1 Defective wheel bearing 1 Replace wheel bearing 2 Engi...

Страница 73: ...t 1 Replace engine mount 2 Worn or defective transaxle gears or bearings 2 Replace transaxle gears or bearings 3 Loose lug nuts 3 Verify wheel lug nut torque 4 Worn or broken C V joint 4 Replace C V j...

Страница 74: ...ght will affect the curb height of the vehicle and the alignment angles 2 The passenger and luggage compartments of the vehicle should be free of any load that is not fac tory equipment 3 Check the ti...

Страница 75: ...nd 4 nuts This package services both sides of the vehicle Use the package to attach the strut clevis bracket to the steering knuckle after the strut clevis bracket has been modified To install and adj...

Страница 76: ...t the front camber to the preferred set ting by rotating the lower eccentric cam bolt against the cam stop areas on the strut clevis bracket Fig 11 When camber is set tighten the upper strut cle vis b...

Страница 77: ...e same size as stan dard equipment Vehicle height is checked with the fuel tank full of fuel and no passenger or luggage compartment load Vehicle height is not adjustable If the measure ment is not wi...

Страница 78: ...measure ment is not within specifications inspect the vehicle for bent or weak suspension components Compare the parts tag on the suspect coil spring s to the parts book and the vehicle sales code ch...

Страница 79: ...e to side difference 0 0 1 00 TOTAL TOE 0 10 20 10 to 0 30 Maximum side to side difference 0 0 0 06 REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE CAMBER 0 0 0 25 to 0 25 TOTAL TOE 0 0 20 20...

Страница 80: ...pen sion On vehicles equipped with ABS brakes the outer CV joint is equipped with a tone wheel used to deter mine vehicle speed for ABS brake operation The inner tripod joint of both half shafts is sp...

Страница 81: ...ce tires or wheels Refer to 22 TIRES WHEELS STANDARD PROCEDURE Improper tire and or wheel runout Refer to 22 TIRES WHEELS DIAGNOSIS AND TESTING REMOVAL 1 Raise vehicle 2 Remove the cotter pin and nut...

Страница 82: ...rake rotor from the hub and bear ing assembly 10 Remove the steering knuckle to strut attach ment bolts Fig 6 from the steering knuckle 11 Pull the steering knuckle from the strut clevis bracket NOTE...

Страница 83: ...til snap ring is engaged with trans axle side gear Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand If snap ring is fully engaged with si...

Страница 84: ...f shaft and securely tighten nut 12 Install front wheel and tire assembly Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specificat...

Страница 85: ...g which retains spider assem bly to interconnecting shaft Fig 13 Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft 7 Remove the spider assembly fr...

Страница 86: ...arings in an attempt to install spider assem bly on interconnecting shaft Fig 14 Spider Assembly Removal from Interconnecting Shaft 1 SPIDER ASSEMBLY 2 DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN REMOVIN...

Страница 87: ...clamp evenly on sealing boot 7 Place crimping tool C 4975 A over bridge of clamp Fig 20 8 Tighten nut on crimping tool C 4975 A until jaws on tool are closed completely together face to face Fig 21 Fi...

Страница 88: ...re trim stick is held flat and firmly against the tripod housing If this is not done damage to the sealing boot can occur 12 With trim stick inserted between sealing boot insert and the CV joint housi...

Страница 89: ...joint to interconnecting shaft retaining ring 6 Spread ears apart on CV joint assembly to interconnecting shaft retaining ring Fig 28 7 Slide outer CV joint assembly off end of inter connecting shaft...

Страница 90: ...oint sealing boot onto interconnecting shaft Outer CV joint seal boot MUST be posi tioned on interconnecting shaft so that only the thinnest sight groove on interconnecting shaft is visible Fig 30 5 P...

Страница 91: ...A until jaws on tool are closed completely together face to face Fig 34 11 Install the half shaft requiring boot replace ment back on the vehicle Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT INSTALLA...

Страница 92: ...flush against the face of the outer CV joint interference with steering knuckle will occur when driveshaft is installed 3 Using a hammer drive the bearing shield on the outer CV joint until it is flu...

Страница 93: ...VIBRATION IN TURNS A clicking noise and or a vibration in turns could be caused by one of the following conditions Damaged outer CV or inner tripod joint seal boot or seal boot clamps This will result...

Страница 94: ...l downward to clear rear differential output flange Then pull half shaft assembly outward to remove Fig 3 INSTALLATION 1 Install the outer CV joint stub shaft through the hub bearing Fig 4 2 The half...

Страница 95: ...6 Install rear wheel Torque the lug nuts to 135 N m 100 ft lbs SPECIFICATIONS HALF SHAFT FRONT TORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs Nut Hub 244 180 Nuts Rear Wheel Lug 135 100 Bolt Half...

Страница 96: ...lamps holding the CV boot to the CV joint and the interconnecting shaft Fig 8 4 Pull the boot back from the CV joint Fig 9 5 Remove the CV housing from the interconnect ing shaft and tripod assembly F...

Страница 97: ...idual grease and dirt 2 Slide the new small diameter retaining clamp onto the interconnecting shaft 3 Install the CV boot onto the interconnecting shaft Fig 14 Fig 12 Slide Tripod Off The Shaft 1 TRIP...

Страница 98: ...tripod housing Put the remaining amount into the sealing boot 8 Install the CV housing onto the interconnecting shaft and tripod assembly Fig 17 9 Clamp the half shaft into a suitable vise with prote...

Страница 99: ...sure in boot and shape it by hand 14 Position CV boot into the CV housing retain ing groove Install the boot large diameter retaining clamp evenly onto the boot 15 Clamp the CV joint boot to the CV jo...

Страница 100: ...wer band of clamp Fig 24 16 Install the half shaft into the vehicle Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT INSTALLATION Fig 21 Crimping Tool Installed on Sealing Boot Clamp Typical 1 CLAMP 2 TRI...

Страница 101: ...Center support bearing Rubber coupler at driveline module flange The front shaft segment utilizes a CV joint at the power transfer unit connection and a plunging CV joint at the center bearing locati...

Страница 102: ...t shaft with two hands 5 Lower propeller shaft assembly to ground using care not to damage fore and aft flanges Fig 1 INSTALLATION CAUTION Propeller shaft installation is a two man operation Never all...

Страница 103: ...es Mopart ATF 4 Automatic Transmission Fluid Type 9602 or equiv alent The differential assembly requires Driveline module service is limited to the following components Differential Assembly serviced...

Страница 104: ...E MODULE NOISE Different sources can be the cause of noise that the rear driveline module assembly is suspected of mak ing Refer to the following causes for noise diagnosis DRIVELINE MODULE ASSEMBLY N...

Страница 105: ...of insufficient or incorrect lubricant in the carrier housing Abnormal gear noise can be easily recognized It produces a cycling tone that will be very pronounced within a given speed range The noise...

Страница 106: ...wer transfer unit components as necessary Vibration at all speeds continuous torque transfer 1 Mis matched tires worn tires on front axle 1 Replace worn or incorrect mis matched tires with same make a...

Страница 107: ...Tool 6958 and a breaker bar Fig 5 3 Remove input flange Fig 6 4 Remove input flange seal from overrunning clutch housing using suitable screwdriver Fig 7 Fig 4 Torque Arm Fasteners 1 TORQUE ARM ASSEMB...

Страница 108: ...rom vis cous coupler Fig 9 10 Remove viscous coupler from differential pin ion shaft Fig 10 11 Remove shim select from differential pinion gear Fig 11 Fig 8 Overrunning Clutch Housing Bolts 1 OVERRUNN...

Страница 109: ...stall output flange seals using tools C4171 and 8493 Fig 15 2 Install large overrunning clutch housing o ring to differential assembly Fig 14 3 Install shim to differential pinion shaft Fig 16 Fig 12...

Страница 110: ...NG 3 INPUT FLANGE SHIELD 8 O RING 13 SHIM SELECT 4 SEAL INPUT FLANGE 9 WASHER 14 DIFFERENTIAL ASSEMBLY 5 OVERRUNNING CLUTCH HOUSING BOLT 10 BI DIRECTIONAL OVERRUNNING CLUTCH Fig 16 Shim Select 1 SHIM...

Страница 111: ...clock position Fig 19 9 Install overrunning clutch housing into posi tion making sure ground tab engages with notch in housing Fig 20 Fig 17 Viscous Coupler 1 VISCOUS COUPLER 2 DIFFERENTIAL PINION Fi...

Страница 112: ...23 13 Install input flange washer and nut Using tool 6958 Fig 24 torque nut to 135 N m 100 ft lbs Fig 21 Overrunning Clutch Housing Bolts 1 OVERRUNNING CLUTCH HOUSING 2 BOLT FOUR Fig 22 Input Flange S...

Страница 113: ...all and torque torque arm mount to body bolts to 54 N m 40 ft lbs 5 Install halfshafts to differential output flanges and torque bolts Fig 27 to 61 N m 45 ft lbs 6 Install propeller shaft Refer to 3 D...

Страница 114: ...ch Housing to Differential 60 44 Bolt Torque Arm to Differential Assembly 60 44 Bolt Torque Arm Mount to Body 54 40 Nut Input Flange 135 100 Plug Differential Drain Fill 35 26 Plug Overrunning Clutch...

Страница 115: ...ential instabilities on a slippery surface The BOC de couples the rear driv eline as soon the rear wheels begin to spin faster than the front wheels front wheels locked in order to provide increased b...

Страница 116: ...oupler 1 POWERFLOW BOC OVERUNNING 6 VISCOUS COUPLER 2 POWERFLOW BOC LOCKED 7 BOC ROLLER CAGE 3 BOC GROUND TAB 8 BOC INPUT SHAFT 4 FRICTION BRAKE SHOES 9 INPUT FLANGE 5 BOC ROLLERS RS REAR DRIVELINE MO...

Страница 117: ...running under these conditions at low vehicle speeds the drag shoes and the cage keep the rollers up on the left side forward side of the inner shaft flats This is what is known as overrunning mode N...

Страница 118: ...ion ground due to centrifugal forces at higher rotational speeds To keep the rollers in the overrunning position and avoid undesired 9high speed lockup9 a high speed latch Fig 33 positions the cage be...

Страница 119: ...the high speed latch is activated propeller shaft speed reaches X amount the cage is partially fixed and cannot lock on the wrong side of the flat as shown Fig 34 The high speed latch is a one way de...

Страница 120: ...d are free to rotate on the shaft The pinion gear is fitted in a bore in the differential case and is positioned at a right angle to the axle shafts OPERATION In operation power flow occurs as follows...

Страница 121: ...in the bottom of the differential assem bly case toward the rear of the unit The fill plug Fig 41 for the differential assembly is located on the rear of the assembly case The correct fill level is to...

Страница 122: ...ft lbs 5 Re position the drain pan under the overrun ning clutch housing fill plug 6 Remove fill plug Fig 44 7 Using a suction gun Fig 45 add 0 58 L 1 22 pts of Mopart ATF 4 Automatic Transmission Flu...

Страница 123: ...les in them In the shear mode normal operation the plates are evenly spaced and the torque is created by the shearing of the plates through the fluid and 90 100 of the torque is applied to the rear ax...

Страница 124: ...cous Coupler Powerflow 1 POWERFLOW BOC OVERUNNING 6 VISCOUS COUPLER 2 POWERFLOW BOC LOCKED 7 BOC ROLLER CAGE 3 BOC GROUND TAB 8 BOC INPUT SHAFT 4 FRICTION BRAKE SHOES 9 INPUT FLANGE 5 BOC ROLLERS RS R...

Страница 125: ...2 Install rear driveline module assembly Refer to 3 DIFFERENTIAL DRIVELINE REAR DRIV ELINE MODULE INSTALLATION 3 Lower vehicle INPUT FLANGE SEAL REMOVAL 1 Raise vehicle on hoist 2 Remove propeller sh...

Страница 126: ...Using tool 6958 torque flange nut to 135 N m 100 ft lbs Fig 53 4 Install propeller shaft Refer to 3 DIFFER ENTIAL DRIVELINE PROPELLER SHAFT INSTALLATION 5 Lower vehicle Fig 50 Input Flange Seal Remov...

Страница 127: ...ential housing casting pry output flange out of differential Fig 55 4 Use suitable screwdriver to remove output flange seal Fig 56 Fig 54 Inner Half Shaft Bolts 1 SHAFT 2 FLANGE Fig 55 Output Flange R...

Страница 128: ...Install rear halfshaft inner joint to output flange 4 Install and torque bolts to 61 N m 45 ft lbs Fig 58 5 Check differential assembly fluid level and adjust as required Refer to 3 DIFFERENTIAL DRIVE...

Страница 129: ......

Страница 130: ...REAR 15 DESCRIPTION DISC BRAKES EXPORT 15 DESCRIPTION DRUM BRAKES REAR 16 OPERATION OPERATION DISC BRAKES FRONT 16 OPERATION DISC BRAKES REAR 16 DIAGNOSIS AND TESTING DRUM BRAKE AUTOMATIC ADJUSTER 16...

Страница 131: ...SPECIFICATIONS BRAKE FLUID 35 JUNCTION BLOCK DESCRIPTION NON ABS JUNCTION BLOCK 36 OPERATION NON ABS JUNCTION BLOCK 36 REMOVAL NON ABS JUNCTION BLOCK 36 INSTALLATION NON ABS JUNCTION BLOCK 36 MASTER C...

Страница 132: ...lamp switch Brake fluid level switch Parking brakes Front disc brakes control the braking of the front wheels rear braking is controlled by rear drum brakes or rear disc brakes depending on options Th...

Страница 133: ...or nicking of brake lining on the brake shoes CAUTION At no time when servicing a vehicle can a sheet metal screw bolt or other metal fastener be installed in the shock tower to take the place of an o...

Страница 134: ...HIRP 1 Excessive brake rotor runout 1 Follow brake rotor diagnosis and testing Correct as necessary 2 Lack of lubricant on brake caliper slides 2 Lubricate brake caliper slides 3 Caliper shoes not ful...

Страница 135: ...oze up 1 Check cable routing Replace cables as necessary 2 Parking brake cable return spring not returning shoes 2 Replace cables as necessary 3 Service brakes not adjusted properly rear drum brakes o...

Страница 136: ...of adjustment 1 Replace brake lamp switch 2 Brake pedal binding 2 Inspect and replace as necessary 3 Obstruction in pedal linkage 3 Remove obstruction 4 Power Brake Booster not allowing pedal to retu...

Страница 137: ...amount of fluid to expel all the trapped air from the brake system Be sure to monitor the fluid level in the master cylinder so it stays at a proper level so air will not enter the brake system throu...

Страница 138: ...e Pedal Position Sensor Mounting Screws 7 5 66 Adjustable Pedal Module Mounting Screws 2 0 15 DESCRIPTION N m Ft Lbs In Lbs Brake Tube Nuts 17 145 Brake Hose Intermediate Bracket Bolt 12 105 Brake Hos...

Страница 139: ...he Full mark with DOT 3 brake fluid If the brake fluid level has dropped below the add line in the master cylinder fluid reservoir the entire brake hydraulic system should be checked for evidence of a...

Страница 140: ...Disconnect parking brake release link at release handle 5 Compress tabs on sides of data link diagnostic connector and remove it from knee blocker reinforce ment plate 6 Remove screws securing knee b...

Страница 141: ...ble to negative post of bat tery 11 Connect scan tool DRBIIIt to data link diag nostic connector located below steering column 12 Turn ignition key to ON position 13 Using scan tool check for and clea...

Страница 142: ...or against mounting bracket and into brake pedal Fig 12 Move carriage as necessary to align slot with pin Install two mounting screws Tighten screws to 7 5 N m 66 in lbs torque 3 Align the bulkhead co...

Страница 143: ...ning a single piston 66 mm diam eter bore Fig 13 with a phenolic piston The caliper mounts to a caliper adapter using two guide pin bolts that thread into the caliper adapter and slide on bushings mou...

Страница 144: ...to the caliper adapter and uses the interior of the rear disc brake rotor as a drum hat section of drum in hat style brake rotor The outboard rear disc brake shoes pads are side oriented The shoes ar...

Страница 145: ...ATION DISC BRAKES REAR The rear disc brakes operate similarly to front disc brakes however there are some features that require different service procedures DIAGNOSIS AND TESTING DRUM BRAKE AUTOMATIC...

Страница 146: ...of the hose can take place with possible burst failure Faulty installation can cause twisting resulting in wheel tire or chassis interference The brake tubing should be inspected periodically for evid...

Страница 147: ...PRACTICES PRESCRIBED BY THE OCCUPA TIONAL SAFETY AND HEALTH ADMINISTRATION OSHA AND THE ENVIRONMENTAL PROTECTION AGENCY EPA FOR THE HANDLING PROCESSING AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN...

Страница 148: ...w caliper hold down spring anti rattle clip on the outboard side of the caliper Start the spring into the holes on the caliper then stretch the clip legs past the abutments on the caliper adapter 11 R...

Страница 149: ...e outboard brake shoe from the cali per Brake shoe is removed by pushing the shoe toward the piston disengaging the two metal protru sions on the shoe back then sliding the brake shoe off the caliper...

Страница 150: ...ould be replaced For rear disc brake shoes when a set of brake shoes are worn to a thickness of approximately 7 0 mm 9 32 inch they should be replaced Typically if front shoes are worn out both fronts...

Страница 151: ...INTENANCE HOISTING STANDARD PROCE DURE 2 Remove the rear wheel and tire assemblies from the vehicle 3 Remove rear brake drum to hub retaining clips if equipped then remove rear brake drums Refer to 5...

Страница 152: ...AUTOMATIC ADJUSTER LEVER Fig 30 Remove Install Brake Shoe Lower Return Spring 1 ANCHOR PLATE 2 LOWER BRAKE SHOE RETURN SPRING 3 REAR BRAKE SHOE 4 FRONT BRAKE SHOE 5 BRAKE SUPPORT PLATE Fig 31 Brake S...

Страница 153: ...36 from the brake shoe Remove the leading brake shoe from the brake support plate Fig 33 Brake Shoe Upper Return Spring 1 BRAKE SHOE RETURN SPRING 2 LEADING BRAKE SHOE 3 TRAILING BRAKE SHOE Fig 34 Tra...

Страница 154: ...g the required special Mopart Brake Lubricant or equiva lent 2 Install leading brake shoe on brake support plate Install the leading brake shoe hold down spring and pin Fig 36 on the brake shoe 3 Inst...

Страница 155: ...fore raising the vehicle verify the parking brake lever is fully released 1 Raise the vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 2 Remove rubber plug from rear brake adjusti...

Страница 156: ...the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehi cle so brake fluid cannot get on these components Remove the brake shoes and place a small piece of wood betwe...

Страница 157: ...oot Damaged dry or brittle guide pin dust boots If caliper fails inspection disassemble and recondi tion caliper replacing the seals and dust boots ASSEMBLY ASSEMBLY CALIPER GUIDE PIN BUSHINGS DISC DI...

Страница 158: ...and increased stopping distance can occur 1 Completely retract the caliper piston back into piston bore of the caliper Use a C clamp to retract the piston if necessary Place a wood block over the pis...

Страница 159: ...rake caliper adapter 3 Align the caliper guide pin bolt holes with the guide pins Install the caliper guide pin bolts and tighten them to a torque of 35 N m 26 ft lbs Fig 40 4 Install the banjo bolt c...

Страница 160: ...nect the brake fluid flex hose from the caliper assembly and remove it from the vehicle CAUTION Do not use excessive force when clamp ing caliper in vise Excessive vise pressure will cause bore distor...

Страница 161: ...any fluid containing mineral oil to clean the caliper These flu ids will damage rubber cups and seals INSPECTION CALIPER Inspect the disc brake caliper for the following Brake fluid leaks in and aroun...

Страница 162: ...Tighten the guide pin bolts to a torque of 35 N m 26 ft lbs CAUTION When connecting the brake hose to the caliper install new brake hose to caliper special washers 5 Install the brake hose on the cal...

Страница 163: ...adjust brake fluid level as neces sary DISC BRAKE CALIPER GUIDE PINS REMOVAL DISC BRAKE CALIPER GUIDE PINS DISC DRUM BRAKES 1 Raise the vehicle Refer to HOISTING in LUBRICATION AND MAINTENANCE 2 Remo...

Страница 164: ...tions of fluid contamination are swollen or deteriorated rubber parts Swollen rubber parts indicate the presence of petroleum in the brake fluid To test for contamination put a small amount of drained...

Страница 165: ...ake pedal to a position past its first 1 inch of travel This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the junction block 2 Disconnect the...

Страница 166: ...with CAUTION Master cylinders are not interchangeable between systems Performance and stopping dis tance issues will result if the incorrect master cyl inder is installed on the vehicle For informatio...

Страница 167: ...r Master cylinder outlet ports vary in size and type depending on whether master cylin der is for a vehicle equipped with traction control or not Traction control equipped master cylinders require the...

Страница 168: ...not running pump brake pedal until a firm pedal is achieved 4 5 strokes 2 Disconnect negative battery terminal 3 Disconnect positive battery terminal 4 Remove battery shield 5 Remove nut and clamp se...

Страница 169: ...brake vacuum booster the master cylinder and vacuum booster must be thoroughly cleaned This must be done to prevent dirt particles from falling into the power brake vacuum booster 9 Clean area where m...

Страница 170: ...ster cylinders are used on this vehicle depending on brake options If a new master cylinder is being installed be sure it is the correct master cylinder for the type of brake system the vehicle is equ...

Страница 171: ...ensure proper operation of brakes PEDAL ADJUSTABLE DESCRIPTION The Adjustable Pedals System APS is designed to enable the fore and aft repositioning of the brake and accelerator pedals This results in...

Страница 172: ...ic connector and remove it from knee blocker reinforce ment plate 6 Remove screws securing knee blocker reinforce ment plate in place then remove reinforcement plate Fig 62 7 Remove screws securing in...

Страница 173: ...ove the pinch bolt securing column cou pling to intermediate shaft Fig 67 Fig 64 Steering Column Shrouds 1 FIXED SHROUD 2 UPPER SHROUD 3 CLOCKSPRING 4 LOWER SHROUD 5 STEERING COLUMN Fig 65 Pedal Switc...

Страница 174: ...d off pedal pin 29 Remove the four nuts attaching power brake booster to dash panel Fig 71 30 Remove two brake pedal upper mounting bolts at instrument panel dash bracket Fig 71 31 Disconnect accelera...

Страница 175: ...ct column wiring harness connectors to SKIM if equipped BTSI solenoid ignition switch halo lamp multi function switch and clockspring 16 Install the upper shroud Refer to 19 STEERING COLUMN LOWER SHRO...

Страница 176: ...icle to ensure proper opera tion of the steering and brake systems PEDAL TORQUE SHAFT RHD REMOVAL 1 Remove the instrument panel Refer to 23 BODY INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY REMOVAL 2 Re...

Страница 177: ...rly or has been removed for some service a new switch must be installed and adjusted 10 Remove and replace the brake lamp switch with a NEW switch Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BRAKE L...

Страница 178: ...pistons in the master cylinder move forward this creates the hydraulic pressure in the brake system DIAGNOSIS AND TESTING POWER BRAKE BOOSTER BASIC TEST 1 With engine off depress and release the brake...

Страница 179: ...ve battery cable terminal from battery 4 Remove battery thermal guard shield 5 Remove battery clamp nut and battery from the battery tray 6 Remove screw securing engine coolant filler tube to battery...

Страница 180: ...pedal pin retaining clip Fig 79 19 Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin Then pull retaining clip off brake pedal pin Discard retaining cli...

Страница 181: ...h in master cylinder fluid res ervoir Fig 82 CAUTION Before removing the master cylinder from the power brake vacuum booster the master cylinder and vacuum booster must be thoroughly cleaned This must...

Страница 182: ...he power brake vacuum booster It is serviced ONLY as a complete assembly INSTALLATION INSTALLATION LHD 1 Position power brake booster on dash panel using the reverse procedure of its removal Fig 81 It...

Страница 183: ...ower brake booster CAUTION The master cylinder and its rear seal is used to create the seal for holding vacuum in the vacuum booster The vacuum seal on the master cylinder MUST be replaced with a NEW...

Страница 184: ...the mounting nuts to a torque of 29 N m 250 in lbs 3 Using lubriplate or equivalent coat the sur face of the brake pedal torque shaft pin where it con tacts the booster input rod CAUTION When installi...

Страница 185: ...of the brakes PROPORTIONING VALVE DESCRIPTION PROPORTIONING VALVE HEIGHT SENSING NOTE Only vehicles without antilock brakes ABS have a proportioning valve Vehicles with ABS uti lize electronic brake d...

Страница 186: ...ings on this vehicle will cause the height sens ing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes This inap propriate reduction in hydraulic pressure potentia...

Страница 187: ...VALVE SPECIFICATIONS WHEEL BASE DRIVE TRAIN SALES CODE BRAKE SYSTEM SPLIT POINT SLOPE INLET PRESSURE PSI OUTLET PRESSURE PSI SWB FWD BRB BGF 159 DISC DRUM W O ANTILOCK VAR 59 1000 PSI 675 875 PSI REM...

Страница 188: ...rake shoes are installed improper wear of the shoes will result If a vehicle has not been driven for a period of time the rotor s braking surface will rust in the areas not covered by the brake shoes...

Страница 189: ...e a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken This way the original mounting spot of the rotor on the hub is indexed Fig 96 Remove...

Страница 190: ...maintain the rotor within service tolerances to ensure proper brake action If the rotor surface is deeply scored or warped or there is a complaint of brake roughness or brake pedal pulsation the rotor...

Страница 191: ...g the disc brake caliper adapter with brake caliper to the steering knuckle Fig 102 4 Remove the disc brake caliper and adapter as an assembly from the steering knuckle Fig 102 Hang the assembly out o...

Страница 192: ...0 0003 in 0 035 mm 0 0014 in Rear Rotor 12 4 12 6 mm 0 488 0 496 in 11 25 mm 0 443 in 0 013 mm 0 0005 in 0 14 mm 0 0055 in TIR Total Indicator Reading Measured On Vehicle BRAKE ROTOR EXPORT NOTE Use...

Страница 193: ...hub and bearing to axle mounting bolts into the mounting holes in the flange of the rear axle 2 Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle F...

Страница 194: ...ly cleaned inspected and new parts installed If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid the brake shoes must be replaced INSTALLATION 1 Apply sealant su...

Страница 195: ...lizer bracket is used at the rear end of the front parking brake cable to distribute tension equally to each parking brake cable STANDARD PROCEDURE STANDARD PROCEDURE PARKING BRAKE AUTOMATIC ADJUSTER...

Страница 196: ...a hoist Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCEDURE 2 Manually release the automatic self adjusting mechanism tension of the parking brake lever pedal assembly Refer to 5 BRAKES STAND...

Страница 197: ...e cable connector attaching it to the right rear parking brake cable Fig 112 Remove the lock ing nut securing the intermediate cable housing to the side bracket on the frame rail Fig 112 6 If the vehi...

Страница 198: ...racket slide a 14 mm box end wrench over the end of cable retainer to compress the retaining fingers Fig 115 The alternate method using an aircraft type hose clamp will not work on the right side of t...

Страница 199: ...king brake cable equalizer Fig 118 6 To remove parking brake cable housing from the body bracket slide a 14 mm box end wrench over retainer end compressing the three fingers Fig 119 Alternate method i...

Страница 200: ...ually reset the automatic self adjusting mechanism tension of the parking brake lever pedal assembly Refer to 5 BRAKES STANDARD PRO CEDURE 10 Assemble the park brake cables onto the park brake cable e...

Страница 201: ...le housing retainer fingers lock the housing firmly into place 5 Connect rear parking brake cable to the equal izer bracket Fig 118 6 Install brake drum and wheel and tire assem bly 7 Remove the locki...

Страница 202: ...mechanism Tap end housing for front park brake cable out of park brake pedal mech anism INSTALLATION 1 Install park brake cable end housing into park brake pedal mechanism 2 Install cable retainer on...

Страница 203: ...king brake cable just rear ward of the second body outrigger bracket Fig 123 3 Remove the left rear and intermediate parking brake cables from the parking brake cable equalizer Fig 124 4 Remove the eq...

Страница 204: ...bracket Press the cable housing into the outrigger hole until all three retaining fin gers lock the cable in place 10 Grasp the exposed section of the front parking brake cable and pull rearward on it...

Страница 205: ...sc brake caliper to adapter guide pin bolts Fig 129 10 Remove rear caliper from adapter using the following procedure First rotate front of caliper up from the adapter Then pull the rear of the calipe...

Страница 206: ...press the locking tabs on the park brake cable retainer Fig 130 Removing Installing Caliper 1 LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST 2 DISC BRAKE CALIPER 3 ADAPTER ABUTMENT 4 OUTBOARD BRAKE...

Страница 207: ...ull back on wheel speed sensor head removing it from hub and bearing c Remove wheel speed sensor from hub bear ing 18 Remove the hub bearing to axle mounting bolts Fig 136 19 Remove the hub bearing Fi...

Страница 208: ...Remover Special Tool 8214 1 on the cast housing of hub bearing Fig 138 Do not position the special tool on the inner race of hub bearing Lightly strike the Remover with a hammer to remove the hub bea...

Страница 209: ...e removed from the brake shoe anchor Then remove the upper return springs Fig 143 from the leading brake shoe Fig 140 Lower Return Spring 1 ADAPTER 2 LEADING PARK BRAKE SHOE 3 RETURN SPRING 4 TRAILING...

Страница 210: ...e at the upper anchor and rotate the bottom of the shoe outward until correctly installed on the adapter 6 Install the adjuster Fig 142 between the leading and trailing park brake shoe NOTE When the h...

Страница 211: ...m in hat brake shoes Refer to 5 BRAKES PARKING BRAKE SHOES ADJUSTMENTS 20 Install the rotor on the hub bearing 21 Carefully lower caliper and brake shoes over rotor and onto the adapter using the reve...

Страница 212: ...the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum 5 Using Brake Shoe Gauge Special Tool C 3919 or equivalent accurately meas...

Страница 213: ...rake shoes are dragging remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum Continue with the previous step until brake shoes are not dragging on brake...

Страница 214: ...3 ASSEMBLY ICU 103 INSTALLATION INSTALLATION LHD 104 INSTALLATION RHD 105 BRAKES ABS DESCRIPTION DESCRIPTION ANTILOCK BRAKE SYSTEM This section covers the physical and operational descriptions and the...

Страница 215: ...lectrical signal Wheel lockup may be perceived at the very end of an ABS stop and is considered nor mal During an ABS stop the brakes hydraulic system is still diagonally split However the brake syste...

Страница 216: ...alve is switched off and the inlet valve is pulsed This increases the pressure to the rear brakes This back and forth pro cess will continue until the required slip difference is obtained At the end o...

Страница 217: ...with approved removal and installation procedures in this manual should be serviced CAUTION If welding work is to be performed on the vehicle using an electric arc welder the CAB con nector should be...

Страница 218: ...system 7 Fill the master cylinder reservoir to the full level 8 Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy SPECIFICATIONS ABS F...

Страница 219: ...e metal clip to rear of axle Remove metal clip from cable if necessary CAUTION If speed sensor head has seized due to corrosion do not use pliers on speed sensor head in an attempt to remove it Use a...

Страница 220: ...moval or installation of the speed sensor cable 3 Carefully remove speed sensor cable from press in routing clips Fig 3 4 Remove bolt securing metal routing clip to rear of axle and remove sensor cabl...

Страница 221: ...replacement the drive shaft must be replaced No attempt should be made to replace just the tone wheel Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL If a rear tone wheel is found to need replace...

Страница 222: ...g operation NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION The hydraulic diagram Fig 6 shows the vehicle in the normal braking mode of the base brake hydraulic system The diagram shows n...

Страница 223: ...hat the brake fluid from the low pressure accumulators is returned to the master cylinder circuits The brake fluid is routed to either the master cylinder or the wheel brake depending on the posi tion...

Страница 224: ...om the low pressure accumulators is returned to the master cylinder circuits The brake fluid will then be routed to either the master cylinder or the wheel brake depending on the position of the norma...

Страница 225: ...age the brakes and stop the vehicle the hydraulic shuttle valve closes with every brake pedal application so pressure is not created at the inlet to the pump motor Fig 9 ABS With Traction Control Norm...

Страница 226: ...he pump motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits The brake fluid is routed to either the master cylinder or the wheel...

Страница 227: ...inder at a fixed pressure setting The normally open and normally closed valves modulate build decay the brake pressure as required to the spinning wheel Fig 11 Traction Control Hydraulic Circuit 1 OUT...

Страница 228: ...at the HCU pump motor is sending to the front driving wheels when traction control is being applied The rear brakes need to be isolated from the master cylinder when traction control is being applied...

Страница 229: ...nents of the ICU are the HCU and the CAB No attempt should be made to service any individual components of the HCU or CAB For information on the CAB Refer to 8 ELECTRICAL ELECTRONIC CONTROL MOD ULES C...

Страница 230: ...es 4 from the outlet ports on the HCU Fig 14 13 Remove the primary and secondary brake tubes from the inlet ports on the HCU Fig 14 14 Center and prop the steering wheel 15 Remove the silencer panel u...

Страница 231: ...ll raise and unlock the 24 way connector from the socket on the CAB CAUTION Before removing the brake tubes from the HCU the HCU must be thoroughly cleaned This must be done to prevent dirt particles...

Страница 232: ...ll the CAB Fig 24 on the HCU 2 Install the 4 bolts mounting the CAB Fig 23 to the HCU Tighten the CAB mounting bolts to a torque of 2 N m 17 in lbs 3 Plug the pump motor wiring harness into the CAB 4...

Страница 233: ...ct each other or other vehicle components when installed Also after the brake tubes are installed on the HCU ensure all spacer clips are reinstalled on the brake tubes 8 Install the primary and second...

Страница 234: ...ICU bracket to the front suspen sion crossmember 2 Install the ICU and its mounting bracket as an assembly on the front suspension crossmember Install the 3 bolts attaching the ICU bracket to the cro...

Страница 235: ...tive cable back on negative post of the battery 9 Bleed the base and ABS hydraulic systems Refer to 5 BRAKES STANDARD PROCEDURE 10 Road test vehicle to ensure proper operation of the base and antilock...

Страница 236: ...OVAL 13 INSTALLATION 13 CLUTCH DESCRIPTION CLUTCH COMPONENTS Models equipped with a 2 4L Gas engine utilize a modular clutch assembly Fig 1 The modular clutch consists of a single dry type clutch disc...

Страница 237: ...er bore displacing fluid through the master cylinder plumbing This fluid displace ment forces the slave cylinder piston to travel forc ing the clutch release bearing into the clutch diaphragm spring v...

Страница 238: ...rear main or transaxle input shaft seal Correct leak and replace modular clutch assembly 2 4L Gas or clutch cover and disc 2 5L TD Too much grease applied to splines of disc and input shaft Apply ligh...

Страница 239: ...leaking seals Replace modular clutch assembly 2 4L Gas or clutch cover and disc 2 5L TD Excessive amount of grease applied to input shaft splines Apply less grease to input shaft Replace modular clut...

Страница 240: ...ic circuit Allow system to self bleed or replace hydraulic components Leak in clutch hydraulic circuit Replace worn damaged leaking hydraulic components Clutch pedal requires excessive force high rele...

Страница 241: ...see if the release bearing is sticky or binding Replace bearing if needed c Check linkage for excessive wear on the pivot stud and fork fingers Replace all worn parts d Check clutch assembly for cont...

Страница 242: ...Install clutch release bearing to lever Apply grease to interface points Make sure release bearing retainers engage lever pocket as shown in Fig 10 3 Apply grease to pivot ball and on release lever a...

Страница 243: ...UMBING REFRIGERANT STANDARD PROCEDURE 7 Remove suction discharge line from evaporator junction block 8 Using tool 6638A disconnect clutch hydraulic quick connect fitting Fig 12 9 Remove clutch master...

Страница 244: ...iesel models Install wiper module assembly Refer to 8 ELECTRICAL WIPERS WASHERS WIPER MODULE INSTALLATION 9 Install battery and tray 10 Connect battery negative cable 11 Charge Air Conditioning system...

Страница 245: ...t to bend or kink plumbing Note plumbing routing to aid in installa tion INSTALLATION 1 Install master cylinder into position while routing plumbing as originally installed 2 Insert master cylinder pu...

Страница 246: ...ls Remove underbody splash shield 2 Using Tool 6638A disconnect hydraulic clutch circuit quick connect fitting 3 Remove clutch slave cylinder Fig 20 by lifting nylon tab with a small screwdriver and t...

Страница 247: ...place as necessary Refer to 6 CLUTCH CLUTCH RELEASE BEARING REMOVAL INSTALLATION 1 Install clutch release bearing and lever if removed Refer to 6 CLUTCH CLUTCH RELEASE BEARING INSTALLATION 2 Install c...

Страница 248: ...STALLATION 1 Install NEW flywheel to crankshaft bolts by hand 2 Torque bolts in a criss cross sequence to 25 N m 18 ft lbs Fig 22 3 Torque bolts in a criss cross sequence an addi tional 60 4 Install c...

Страница 249: ......

Страница 250: ...ITY 6 ACCESSORY DRIVE BELT TENSION 6 TORQUE 6 SPECIAL TOOLS COOLING SYSTEM 7 ACCESSORY DRIVE 8 ENGINE 14 TRANSMISSION 38 COOLING DESCRIPTION DESCRIPTION COOLING SYSTEM The cooling system components co...

Страница 251: ...nt flow circuits for the 2 4L and 3 3 3 8L engines are shown in Fig 2 OPERATION HOSE CLAMPS The spring type hose clamp applies constant ten sion on a hose connection To remove a spring type hose clamp...

Страница 252: ...mal amount of coolant or steam emits from the tailpipe it may indicate a coolant leak caused by a faulty head gas ket cracked engine block or cracked cylinder head There may be internal leaks that can...

Страница 253: ...OM THE COOLANT CAN OCCUR 1 Without removing radiator pressure cap and with system not under pressure open the draincock The draincock is located on the lower left side of radiator Fig 5 2 After the co...

Страница 254: ...removing the radiator cap With the engine cold and not running simply observe the level of the coolant in the recovery reserve container Fig 7 The coolant level should be between the MIN and MAX mark...

Страница 255: ...me 3 3 3 8L ENGINES Air Conditioning Compressor Dynamic Tensioner Generator Water Pump Power Steering TORQUE DESCRIPTION N m Ft Lbs In Lbs Accessory Drive Belt Tensioner Assembly 3 3 3 8L Bolt 28 250...

Страница 256: ...Pliers 6094 Hose Clamp Pliers 8495A Cooling System Tester 7700 Coolant Refractometer 8286 DRB IIIT with PEP Module OT CH6010A Belt Tension Gauge Adapter 8371 Belt Tension Gauge 7198A Cooler Flusher 6...

Страница 257: ...LTS REMOVAL 4 Remove the belt tensioner Fig 1 INSTALLATION 1 Install belt tensioner and bolt Fig 1 Tighten bolt to 54 N m 40 ft lbs 2 Install generator A C compressor drive belt Refer to 7 COOLING ACC...

Страница 258: ...ed belts b Adjust power steering belt tension 4 cyl engine 2 Belt excessively glazed or worn 2 Replace and tighten as specified BELT SQUEAL WHEN ACCELERATING ENGINE 1 Belts too loose 1 a Replace belt...

Страница 259: ...le tool The frequency of the belt in hertz Hz will display on DRBIIIt screen 4 Adjust belt to obtain proper frequency ten sion Refer to ACCESSORY DRIVE BELT TENSION CHART for belt tension specificatio...

Страница 260: ...are not Fig 6 NOTE Do not use any type of belt dressing or restorer on Poly V Belts INSTALLATION GENERATOR AND AIR CONDITIONING BELT 1 Install belt onto all pulleys except for the crankshaft Fig 7 2 R...

Страница 261: ...ehicle on a hoist and the remove the splash shield to gain access to the drive belts if nec essary Adjust belt tension for either a New or Used belt For specifications Refer to 7 COOLING AC CESSORY DR...

Страница 262: ...t use any type of belt dressing or restorer on Poly V Belts INSTALLATION 1 Route and position the drive belt onto all pul leys except for the crankshaft Fig 11 2 Rotate belt tensioner counterclockwise...

Страница 263: ...T THERMOSTAT 2 4L REMOVAL 23 INSTALLATION 23 ENGINE COOLANT THERMOSTAT 3 3 3 8L REMOVAL 24 INSTALLATION 24 RADIATOR DESCRIPTION 25 OPERATION 25 REMOVAL 25 INSTALLATION 26 RADIATOR DRAINCOCK REMOVAL 27...

Страница 264: ...ed hoses Loose damaged hose clamps Damaged incorrect engine thermostat Damaged cooling fan motor fan blade and fan shroud Damaged head gasket Damaged water pump Damaged radiator Damaged coolant recove...

Страница 265: ...necessary d Reserve overflow container is internally blocked Clean and repair as necessary INADEQUATE AIR CONDITIONER PERFORMANCE COOLING SYSTEM SUSPECTED 1 Radiator and or A C condenser is restricted...

Страница 266: ...Repair as necessary 4 Undercoating been applied to an unnecessary component 4 Clean undercoating as necessary 5 Engine may be running rich causing the catalytic converter to overheat 5 Refer to Appro...

Страница 267: ...UATES CYCLES OR IS ERRATIC 1 Normal reaction to fan and or thermostat cycle Fig 1 Examples B and C During cold weather operation with the heater blower in the high position the gauge reading may drop...

Страница 268: ...erio ration and leaks Inspect radiator and heater core for leaks COOLANT DIAGNOSIS AND TESTING COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was add...

Страница 269: ...ing losses DIAGNOSIS AND TESTING COOLANT RECOVERY SYSTEM The cooling system is closed and designed to main tain coolant level to the top of the radiator 1 With the engine off and cooling system not un...

Страница 270: ...adiator and cylinder block Refer to 7 COOLING STANDARD PROCEDURE 2 Disconnect the power cord plug from heater 3 Loosen screw in center of heater Remove the heater assembly INSTALLATION 1 Clean block c...

Страница 271: ...racket Fig 5 4 Disconnect coolant sensor electrical connector Fig 6 5 Remove coolant sensor Fig 6 INSTALLATION 1 Install engine coolant temperature sensor Fig 6 Tighten sensor to 7 N m 60 in lbs 2 Con...

Страница 272: ...open Do not attempt to free up a thermo stat with a screwdriver Thermostat diagnostics is included in powertrain control module s PCM programing for on board diagnosis The malfunction indicator light...

Страница 273: ...ement ther mostat carefully remove the bulged metal from the wall of the outlet connector recess that was created during the staking procedure that held the OEM thermostat in place Fig 11 It is not ne...

Страница 274: ...ow across the exterior of the radiator tubes This heat is then transferred from the coolant and into the passing air REMOVAL 1 Disconnect negative cable from battery 2 Remove radiator upper crossmembe...

Страница 275: ...nditioning condenser onto the radiator lower mounts and install upper screws Fig 15 Tighten fasteners to 5 N m 45 in lbs 3 Install the radiator upper and lower hoses Fig 13 or Fig 14 4 Connect the coo...

Страница 276: ...Pa 14 18 psi The cooling system will operate at higher than atmospheric pressure The higher pressure raises the coolant boiling point thus allowing increased radia tor cooling capacity There is also a...

Страница 277: ...ach the Radiator Pressure Tool to the filler neck nipple and pump air into the radiator Pressure cap upper gas ket should relieve at 69 124 kPa 10 18 psi and hold pressure at 55 kPa 8 psi minimum WARN...

Страница 278: ...n consist of the fan blade electric motor and a support shroud which are all serviced as an assembly OPERATION RADIATOR FAN OPERATION CHART COOLANT TEMPERATURE A C PRESSURE TRANSAXLE OIL TEMPERATURE F...

Страница 279: ...or wiring defective 1 Refer to Appropriate Diagnostic Information Repair as necessary 2 Check for low coolant level 2 Add coolant as necessary 3 Defective A C pressure transducer 3 Refer to Appropria...

Страница 280: ...n noise A C performance better engine cooling and additional vehicle power To control operation of the relay the PCM looks at inputs from Engine coolant temperature A C pressure transducer Ambient tem...

Страница 281: ...VAL 12 Remove the generator and bracket Fig 24 13 Remove water pump to engine attaching screws Fig 25 CLEANING Clean gasket mating surfaces as necessary INSPECTION Replace water pump body assembly if...

Страница 282: ...UNT 5 BOLT 2 BOLT 6 TENSIONER DRIVE BELT 3 GENERATOR 7 BOLT 4 BOLT 8 BOLT Fig 25 Water Pump 2 4L 1 CYLINDER BLOCK 2 WATER PUMP Fig 26 Water Pump Body 1 IMPELLER 2 WATER PUMP BODY 3 O RING LOCATING GRO...

Страница 283: ...head heater core and radiator REMOVAL 1 Drain the cooling system Refer to 7 COOL ING STANDARD PROCEDURE 2 Remove the accessory drive belt shield 3 Remove the accessory drive belt Refer to 7 COOLING AC...

Страница 284: ...ns unchanged do not replace the water pump for this condition Replace the water pump if a steady flow of engine coolant is evident from the weep hole reservoir slot Fig 30 shaft seal failure Be sure t...

Страница 285: ...tall inlet tube into the cylinder block opening Fig 32 3 Install the two inlet tube fasteners and tighten to 12 N m 105 in lbs 4 Connect the radiator lower hose Fig 7 and heater hose to inlet tube Fig...

Страница 286: ...r vehicle 7 Fill the cooling system Refer to 7 COOLING STANDARD PROCEDURE Fig 34 RAD HOSES TO ENGINE 3 3 3 8L 1 UPPER HOSE 2 LOWER HOSE Fig 35 Engine Oil Cooler Hoses Engine Oil Cooler Equipped 1 OIL...

Страница 287: ...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 NOTE When flushing trans...

Страница 288: ...or Refer to 7 COOLING ENGINE RADIATOR INSTALLATION 4 Start engine Check and adjust the fluid level as necessary TRANSMISSION OIL COOLER LINES REMOVAL 1 Using appropriate hose clamp pliers release tens...

Страница 289: ...Connect hoses to cooler and transaxle fittings Fig 3 or Fig 4 2 Using appropriate pliers position clamps over fittings and release tension 3 Start engine and check transaxle fluid level Adjust fluid l...

Страница 290: ...coolant tank A pressure vent cap on the coolant tank Fan shroud Thermostat Coolant Low coolant warning lamp Coolant temperature gauge Water pump Hoses and hose clamps DIAGNOSIS AND TESTING DIAGNOSIS...

Страница 291: ...ry Refer to Heating and Air Conditioning for procedures TEMPERATURE GAUGE READS HIGH COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM COOLING SYSTEM 1 Trailer is being towed a steep hill is being climbe...

Страница 292: ...heck thermostat and replace if necessary 14 Cylinder head gasket leaking 14 Check cylinder head gasket for leaks 15 Heater core leaking 15 Check heater cor for leaks Repair as necessary TEMPERATURE GA...

Страница 293: ...ND OR COOLANT TEMPERATURE GAUGE READING MAY BE ABOVE NORMAL BUT NOT HIGH COOLANT LEVEL MAY BE HIGH IN COOLANT TANK 1 Pressure relief valve in pressure vent cap is defective 1 Check condition of pressu...

Страница 294: ...evel low 2 Pressure test cooling system Repair leaks as necessary 3 Obstruction in heater hose fitting at engine 3 Remove heater hoses and check for obstructions Repair as necessary 4 Heater hose kink...

Страница 295: ...M TO PREVENT SCALDING OR INJURY THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE With engine not running remove pressure vent cap from the coolant recovery pressure con...

Страница 296: ...nlet tank runs full and the low pressure outlet tank drops resulting in cooling system aera tion Aeration will draw air into the water pump resulting in the following High reading shown on the tempera...

Страница 297: ...27 5 21 Accessory Drive Belt Tensioner Bolt 47 1 35 Accessory Drive Belt Idler Bolt 53 39 SPECIFICATIONS COOLING SYSTEM CAPACITY SPECIFICATIONS DESCRIPTION SPECIFICATION Cooling System With Auxiliary...

Страница 298: ...LT TENSIONER REMOVAL WARNING BECAUSE OF HIGH SPRING TENSION DO NOT ATTEMPT TO DISASSEMBLE THE AUTO MATIC BELT TENSIONER THE TENSIONER IS SER VICED AS AN ASSEMBLY 1 Remove the power steering belt Refer...

Страница 299: ...r belt tension DESCRIPTION POWER STEERING BELT The power steering belt is a serpentine type belt Fig 3 Satisfactory performance of this belt depends on condition of the belt OPERATION OPERATION ACCESS...

Страница 300: ...s 5 Non uniform groove or eccentric pulley 5 Replace pulley BELT ROLLED OVER IN GROOVE OR BELT JUMPS OFF 1 Broken cord in belt 1 Replace belt 2 Belt too loose or too tight 2 Replace belt 3 Misaligned...

Страница 301: ...LEY 6 WRENCH Fig 5 LOCKING LOCKING BELT TENSIONER Fig 6 POWER STEERING BELT REMOVAL TOOL 1 VIBRATION DAMPER 2 POWER STEERING PULLEY 3 POWER STEERING BELT 4 POWER STEERING BELT REMOVER Fig 7 POWER STEE...

Страница 302: ...shaft clockwise until belt is fully installed on crankshaft Fig 10 3 Remove installation tool from crankshaft 4 Install right front fender inner splash shield 5 Lower vehicle from hoist Fig 8 ACCESSOR...

Страница 303: ...OVAL 22 INSTALLATION 22 WATER PUMP DESCRIPTION 23 OPERATION 23 REMOVAL REMOVAL WATER PUMP 23 REMOVAL WATER PUMP HOUSING 23 CLEANING 23 INSTALLATION INSTALLATION WATER PUMP 23 INSTALLATION WATER PUMP H...

Страница 304: ...er boil over of propylene glycol is 125 deg C 257 deg F at 96 5 kPa 14 psi compared to 128 deg C 263 deg F for ethylene gly col Use of propylene glycol can result in boil over or freeze up in Chrysler...

Страница 305: ...YPES DESCRIPTION STANDARD PROCEDURE COOLANT LEVEL CHECK NOTE Do not remove pressure vent cap for routine coolant level inspections The coolant reserve system provides a quick visual method for determi...

Страница 306: ...iner is empty then remove coolant pressure vent cap COOLANT RECOVERY PRESS CONTAINER DESCRIPTION The coolant recovery pressure container is mounted in the engine compartment next to the bat tery The c...

Страница 307: ...tall in mounting bracket 2 Connect coolant recovery pressure container retaining clip Fig 5 3 Connect coolant bypass and overflow hoses to coolant recovery pressure container 4 Refill cooling system R...

Страница 308: ...S HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM THE COOLANT CAN OCCUR 1 Drain the cooling system Refer to 7 COOL ING ENGINE COOLANT STANDARD PROCE DURE 2 Disconnect coolant temperature sensor elec...

Страница 309: ...t be replaced as an assembly 1 Disconnect negative battery cable 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remove front wiper unit to gain access to ther mostat hou...

Страница 310: ...NING DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR 3 Drain the cooling system Refer to 7 COOL ING...

Страница 311: ...er to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 8 Connect negative cable to battery RADIATOR DRAINCOCK REMOVAL CAUTION Use of pliers on draincock is not recom mended Damage may occur to radiator or...

Страница 312: ...le 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remove both outer and inner timing belt covers Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 4 Disco...

Страница 313: ...ter pump housing to thermostat housing bypass hose Fig 16 6 Install both inner and outer timing belt covers Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 7 Refill cooling syste...

Страница 314: ...lting is loss of coolant and eventual overheating due to low coolant level in radiator and engine DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING COOLING SYSTEM PRESSURE CAP Dip the pressure cap in water...

Страница 315: ...W TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COM PLETELY SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL TO CHECK PR...

Страница 316: ...repair as necessary 3 Air obstructions at radiator or A C condenser 3 Remove obstructions and or clean debris 4 Electric fan motor defective 4 Replace fan assembly Refer to 7 COOLING ENGINE RADIATOR...

Страница 317: ...oved Tighten to 8 N m 70 in lbs 6 Install the radiator upper hose to the support clip 2 4L engine HOSE CLAMPS DESCRIPTION HOSE CLAMPS The cooling system uses spring type hose clamps If a spring type c...

Страница 318: ...CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE 1 Remove engine cover Refer to 9 ENGINE REMOVAL 2 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Remov...

Страница 319: ...pass hose Fig 26 INSTALLATION INSTALLATION UPPER RADIATOR HOSE 1 Install upper radiator hose Fig 26 2 Refill cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 3 Install engine cover...

Страница 320: ...FM Cassette with single Compact Disc Player and Compact Disc changer controls AM FM Cassette with Compact Disc changer controls AM FM Cassette with Compact Disc player rear seat audio system and Compa...

Страница 321: ...KERS FAULTY 6 SEE SPEAKER DIAGNOSIS IN THIS GROUP NO DISPLAY 1 FUSE FAULTY 1 CHECK RADIO FUSES IN FUSE BLOCK MODULE REPLACE FUSES IF REQUIRED 2 RADIO CONNECTOR FAULTY 2 CHECK FOR LOOSE OR CORRODED RAD...

Страница 322: ...ION 1 FAULTY CD 1 INSERT KNOWN GOOD CD AND TEST OPERATION 2 FOREIGN MATERIAL ON CD 2 CLEAN CD AND TEST OPERATION 3 CONDENSATION ON CD OR OPTICS 3 ALLOW TEMPERATURE OF VEHICLE INTERIOR TO STABILIZE AND...

Страница 323: ...na coaxial cable from the radio chassis and isolate Remove the antenna mast 2 Connect an ohmmeter test lead to the inside center of the antenna base Connect the other test lead to a metallic portion o...

Страница 324: ...a base to front fender Fig 4 12 Remove antenna base from under front fender INSTALLATION 1 Install antenna base to underside of front fender 2 Install cap nut holding antenna base to front fender 3 In...

Страница 325: ...io signals supplied by the side window integral radio antenna system and selectively amplifies them The amplified signal is then sent through the body length coax cable to the radio input DIAGNOSIS AN...

Страница 326: ...anger with the exception of the CD load and eject functions which are controlled by buttons located on the front of the CD changer All features you would expect such as Disc Up Down Track Up Down Rand...

Страница 327: ...tenna element is bonded to the right rear quarter glass and is replaced with the glass assembly only Fig 7 OPERATION The integral antenna receives RF Radio Frequen cies and sends them to the antenna m...

Страница 328: ...e Integrated Power Module IPM If OK go to Step 2 If not OK repair the shorted circuit or component as required and replace the faulty fuse s 2 Check for battery voltage at the fuse in the IPM If OK go...

Страница 329: ...s and other on board electrical com ponents such as generators wiper motors blower motors and fuel pumps that have been found to be potential sources of RFI or EMI OPERATION There are two common strat...

Страница 330: ...OTE SWITCHES WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO ELECTRICAL RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE T...

Страница 331: ...efore further service 2 Remove the driver side airbag module from the vehicle Refer to ELECTRICAL RESTRAINTS DRIVER AIR BAG 3 Remove the steering wheel from the steering column Refer to STEERING COLUM...

Страница 332: ...s connector for con tinuity to ground There should be no continuity If OK go to Step 5 If not OK repair the shorted speaker feed and or return circuits s to the speaker as required 5 Disconnect wire h...

Страница 333: ...nstall jack cover left side 8 Connect battery negative cable FRONT DOOR SPEAKER 1 Connect the wire harness connector and install speaker to door 2 Install the speaker mounting screws 3 Install the fro...

Страница 334: ...mph OPERATION The Chime Buzzer Warning System is diagnosed using a DRB lllt scan tool Refer to the proper Body Diagnostic Procedures Manual HIGH SPEED WARNING EXPORT When the vehicle speed sensor see...

Страница 335: ...ver s door OPEN door ajar switch is closed to ground and Dome lamps are ON dome lamp switch is closed to ground The chime will sound continuously until the driv ers door is closed dome lamps turned OF...

Страница 336: ...1 minute before starting the test Turn the ignition switch to the on position with the driver s seat belt not buck led The seat belt warning lamp should light and the chime should sound 4 to 8 seconds...

Страница 337: ...airbag door ajar or gate ajar lamps are first illuminated the chime will sound one tone The door liftgate ajar warning lamp announcement chime sounds only if the vehicle speed is above 4 m p h Two sec...

Страница 338: ...TION 11 POWERTRAIN CONTROL MODULE DESCRIPTION DESCRIPTION 11 DIAGNOSTIC TROUBLE CODE 13 OPERATION SENSOR RETURN PCM INPUT 25 OPERATION SCI RECEIVE PCM INPUT 25 OPERATION IGNITION SENSE PCM INPUT 25 OP...

Страница 339: ...get to the Select System menu and select ENGINE MISCELLANEOUS and SRI MEMORY CHECK 8 The DRB III will ask Is odometer reading between XX and XX Select the YES or NO button on the DRB III If NO is sel...

Страница 340: ...ts the internal circuitry and programming of the BCM allow it to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmis sion of el...

Страница 341: ...NT FOG LAMPS POWER SLIDING DOOR PCI IFR RECEIVED FROM MODULE THE BCM HAS FOUR SWITCH INPUTS FOR THE POWER SLIDING DOOR FEATURE LOCATED IN THE OVERHEAD CONSOLE ARE THE LEFT AND RIGHT SIDE SLIDING DOOR...

Страница 342: ...stall the BCM to the mounting bracket 2 Install the screws holding the BCM to the bulkhead 3 Connect the five wire connectors to the bottom of the Body Control Module BCM 4 Install the knee blocker an...

Страница 343: ...ll be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3 500 miles CAB INPUTS Wheel speed sensors four Brake lamp switch Ignition switch System and...

Страница 344: ...POWER MODULE DESCRIPTION OPERATION As messages are sent over the Programmable Com munications Interface PCI data bus the Front Con trol Module FCM reads these messages and controls power to some of th...

Страница 345: ...lly charged and all wire harness and ground connections inspected around the affected areas on the vehicle REMOVAL 1 Disconnect the positive and negative battery cables from the battery 2 Remove the b...

Страница 346: ...the heated seat sensor inputs from the seat cushions of each front seat In response to those inputs the heated seat module controls battery current feeds to the heated seat elements and controls the g...

Страница 347: ...ess connec tors INSTALLATION 1 Connect the module wire harness connectors 2 Snap the module on the seat cushion pan 3 Install the appropriate front seat in the vehicle Refer to 23 BODY SEATS SEAT INST...

Страница 348: ...NTROL MODULE DESCRIPTION DESCRIPTION The Powertrain Control Module PCM is a digital computer containing a microprocessor Fig 11 The PCM receives input signals from various switches and sensors referre...

Страница 349: ...ake Switch Engine Coolant Temperature Engine Speed crankshaft position sensor Park Neutral transmission gear selection Transaxle Gear Engagement Throttle Position Vehicle Speed from Transmission Contr...

Страница 350: ...ndition detected in the oxygen sensor heater element control feedback sense circuit P0044 O2 sensor 1 3 Heater Circuit Shorted condition detected in the oxygen sensor heater element control feedback s...

Страница 351: ...h MAP TPS signal does not correlate to MAP sensor signal P0122 M Throttle Position Sensor Voltage Low Throttle position sensor input below the acceptable voltage range P0123 M Throttle Position Sensor...

Страница 352: ...tained above normal operating range P0153 M 2 1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required switching frequency P0154 M 2 1 O2 Sensor Stays at Center Neither rich or le...

Страница 353: ...l P0208 Injector 8 Control Circuit Injector 8 output driver stage does not respond properly to the control signal P0209 Injector 9 Control Circuit Injector 9 output driver stage does not respond prope...

Страница 354: ...current not achieved with maximum dwell time High Impedance P0355 M Ignition Coil Primary 5 Circuit Peak primary circuit current not achieved with maximum dwell time High Impedance P0356 M Ignition Co...

Страница 355: ...rad fan relay control circuit P0481 High Speed Fan Relay Control Circuit An open or shorted condition detected in the high speed rad fan relay control circuit P0498 NVLD Canister Vent Valve Solenoid C...

Страница 356: ...circuit P0586 Speed Control Vent Solenoid Circuit An open or shorted condition detected in speed control vent solenoid control circuit P0594 Speed Control Servo Power Circuit An open or shorted condit...

Страница 357: ...0 Low Output SPD Sensor RPM Above 15 MPH The relationship between the Output Shaft Speed Sensor and vehicle speed is not within acceptable limits P0740 M Torque Con Clu No RPM Drop at Lockup Relations...

Страница 358: ...or Volts Too Low Radiator coolant temperature sensor input below the minimum acceptable voltage P1281 Engine is Cold Too Long Engine coolant temperature remains below normal operating temperatures dur...

Страница 359: ...f secondary air injection detected during aspirator test was P0411 P1477 Too Much Secondary Air Excessive flow of secondary air injection detected during aspirator test was P0411 P1478 M Battery Temp...

Страница 360: ...tected in the control circuit of the 3 high speed radiator fan control relay P1594 G Charging System Voltage Too High Battery voltage sense input above target charging voltage during engine operation...

Страница 361: ...transmission control module EATX or the Aisin transmission controller P1719 Skip Shift Solenoid Circuit An open or shorted condition detected in the transmission 2 3 gear lock out solenoid control cir...

Страница 362: ...e as many as three different ground pins There are power grounds and sensor grounds The power grounds are used to control the ground side of any relay solenoid ignition coil or injector The signal gro...

Страница 363: ...efer to the Battery section for more information 3 Remove the 2 upper PCM bracket bolts Fig 12 4 Remove the 2 PCM connectors 5 Remove the headlamp refer to the Lamps sec tion for more information 6 Re...

Страница 364: ...ds an 9invalid key9 message to the PCM The PCM will enable or disable engine operation based upon the status of the SKIM messages It is important to note that the default condition in the PCM is 9inva...

Страница 365: ...ed Sensor Some examples of indirect inputs to the TCM are Engine Body Identification Manifold Pressure Target Idle Torque Reduction Confirmation Speed Control ON OFF Switch Engine Coolant Temperature...

Страница 366: ...hanges as clutches are applied and released By monitoring the length of time it takes for the gear ratio to change following a shift request the TCM can determine the volume of fluid used to apply or...

Страница 367: ...stdown shift approximately 30 mph Early 3 2 coastdown shift approximately 17 mph High speed 4 2 3 2 2 1 kickdown shifts are prevented No EMCC Warm Oil temperature at start up above 36 F and below 80 d...

Страница 368: ...nt Solenoid Pressure Switch Assembly Replacement Clutch Plate and or Seal Replacement Valve Body Replacement or Recondition To perform the Quick Learn Procedure the follow ing conditions must be met T...

Страница 369: ...splash shield into position with fasten ers 4 Install left front wheel tire assembly 5 Lower vehicle 6 Connect battery negative cable 7 If TCM was replaced reset Pinion Factor and Quick Learn Refer t...

Страница 370: ...Look for broken bent pushed out or corroded terminals If any of the above conditions are present repair as necessary If not use a DRB IIIt scan tool and the proper Diagnostic Procedures Manual to tes...

Страница 371: ...ops any problems the control module will store and recall Diagnostic Trouble Codes DTC The use of a diagnostic scan tool such as the DRB IIIt is required to read and troubleshoot these trouble codes R...

Страница 372: ...hat are programmed into it for that device If the input voltage is not within the specifications and other trouble code criteria are met a DTC will be stored in the ECM memory ECM OPERATING MODES As i...

Страница 373: ...at is not current every time the ECM SKIM checks the circuit or function is an intermit tent code Most intermittent DTCs are caused by wiring or connector problems Problems that come and go like this...

Страница 374: ...sories are turned off Also monitor the battery state and connect a battery charger if necessary 6 Press ENTER to transfer the secret key the SKIM will send the secret key to the PCM 7 Press Page Back...

Страница 375: ...emove ECM upper mounting bolts Fig 3 5 Lift ECM from radiator support 6 Disconnect ECM electrical connectors 7 Separate ECM from mounting bracket INSTALLATION 1 Install ECM on mounting bracket 2 Conne...

Страница 376: ...5 REMOVAL 15 INSTALLATION 16 BATTERY CABLES DESCRIPTION 16 OPERATION 16 DIAGNOSIS AND TESTING BATTERY CABLE 16 REMOVAL 18 INSTALLATION 18 BATTERY TRAY DESCRIPTION 18 OPERATION 19 REMOVAL 19 INSTALLATI...

Страница 377: ...lectrical components or circuits in the vehicle DIAGNOSIS AND TESTING BATTERY SYSTEM The battery starting and charging systems in the vehicle operate with one another and must be tested as a complete...

Страница 378: ...nal connections are loose or corroded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Clean and tighten the battery terminal connections as required 5 The batte...

Страница 379: ...g procedures Repair the faulty charging system as required 7 Electrical loads exceed the output of the charging system 7 Inspect the vehicle for aftermarket electrical equipment which might cause exce...

Страница 380: ...lacement battery is the correct size and has the correct ratings for the vehicle 4 Clean the battery thermowrap with a sodium bicarbonate baking soda and warm water cleaning solution using a soft bris...

Страница 381: ...nk ing Amperage CCA rating specifies how much cur rent in amperes the battery can deliver for thirty seconds at 18 C 0 F Terminal voltage must not fall below 7 2 volts during or after the thirty secon...

Страница 382: ...water within the electrolyte eliminating the need to add distilled water Therefore these batteries have non removable battery vent caps Fig 4 Water can not be added to this battery The acid inside an...

Страница 383: ...ls that are connected in series Each cell contains positively charged plate groups that are connected with lead straps to the positive terminal post and negatively charged plate groups that are connec...

Страница 384: ...to produce high amperage cur rent over an extended period A battery must also be able to accept a charge so that its voltage potential may be restored The battery is vented to release excess hydrogen...

Страница 385: ...ery hold downs tray terminals posts and top before completing battery service Refer to Battery System Cleaning for the proper battery system cleaning procedures and Bat tery System Inspection for the...

Страница 386: ...battery to its full potential failure to use the spiral plate battery charging procedure could result in damage to the battery or personal injury Battery charging is the means by which the bat tery ca...

Страница 387: ...l not accept charging cur rent See the instructions provided by the manufac turer of the battery charger for details on how to bypass the polarity sensing circuitry 3 Battery chargers vary in the amou...

Страница 388: ...IOD identifies a nor mal condition where power is being drained from the battery with the ignition switch in the Off position A normal vehicle electrical system will draw from five to thirty five mil...

Страница 389: ...ch the multi meter to progressively lower amperage scales and if necessary repeat the fuse and circuit breaker remove and replace process to identify and correct all sources of excessive IOD It is now...

Страница 390: ...ed to the proper specifications Improper hold down fastener tightness whether too loose or too tight can result in damage to the battery the vehicle or both Refer to Battery Hold Downs in this section...

Страница 391: ...e potential of the battery The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts The ter...

Страница 392: ...he ignition switch in the Start position Observe the voltmeter If voltage is detected correct the poor con nection between the battery negative cable terminal clamp and the battery negative terminal p...

Страница 393: ...ect the battery cable retaining fasteners and routing clips until the desired cable is free from the vehicle 6 Feed the battery cable out of the vehicle INSTALLATION 1 Position the battery cable in th...

Страница 394: ...1 Disconnect and isolate the negative battery cable 2 Remove the battery from the vehicle Refer to the procedure in this section 3 Remove the battery tray retaining fasteners Fig 18 4 Pull battery tra...

Страница 395: ...helps to insulate the sides of the battery case from the air temperature found in the surrounding engine compartment REMOVAL 1 Disconnect and isolate the negative battery cable 2 Disconnect the positi...

Страница 396: ...lay is energized when the PCM grounds the ASD control circuit This voltage is connected through the PCM or IPM intelligent power module if equipped and supplied to one of the generator field terminals...

Страница 397: ...stand what caused a DTC to be set ERASING DIAGNOSTIC TROUBLE CODES The DRBIIIt Scan Tool must be used to erase a DTC The following procedures may be used to diagnose the charging system if the check g...

Страница 398: ...ENERATOR Type Engine Minimun Test Amperage Denso 2 4 L 125 Amp Denso 3 3 3 8L 135 Amp or 145 Amp Test Specification 1 Engine RPM 2500 RPM 20 RPM 2 Voltage Output 14 0 V 0 5 V 3 Field Current 5 amps 0...

Страница 399: ...current it also provides the current needed to energize the rotor The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for rectification From the d...

Страница 400: ...l nut to hold B wire terminal to back of generator 7 Connect the push in field wire connector into back of generator 8 Raise vehicle and support 9 Install the lower mounting bolt and tighten 10 Instal...

Страница 401: ...Raise vehicle and support 4 Remove the right front lower splash shield 5 Remove accessory drive belt refer to the Cool ing System section for proper procedures Fig 5 6 Lower vehicle 7 Remove the Air...

Страница 402: ...ng the ground path to control the strength of the rotor magnetic field The EVR circuitry monitors system line voltage B and calculated battery temperature or inlet air tempera ture sensor refer to Inl...

Страница 403: ...ARTING SYSTEM TEST For circuit descriptions and diagrams refer to the Wiring Diagrams WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO THE PASSIVE RESTRAINT SYS TEMS BEFORE ATTEMPTING STEERING WHEE...

Страница 404: ...r corroded wire harness connections at main engine ground and remote jump post Power Distribution Center PDC Visually inspect the B connections at the PDC for physical damage and loose or corroded har...

Страница 405: ...SSEMBLY IF NECESSARY 8 STARTER ASSEMBLY FAULTY 8 IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK REPLACE STARTER ASSEMBLY 9 FAULTY TEETH ON RING GEAR 9 ROTATE FLYWHEEL 360 AND INSPECT TE...

Страница 406: ...the Power Distribution Center PDC Refer to the PDC cover for the proper relay location STARTER SOLENOID WARNING CHECK TO ENSURE THAT THE TRANS MISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE AP...

Страница 407: ...to Step 4 If not OK repair the open circuit to the starter solenoid as required 4 The coil battery terminal 86 is connected to the electromagnet in the relay It is energized when the ignition switch i...

Страница 408: ...ct positive lead of the voltmeter to the battery positive post and negative lead to the bat tery positive cable clamp Rotate and hold the igni tion switch key in the START position Observe the voltmet...

Страница 409: ...e below 9 6 volts and amperage draw above 300 amps the problem is the starter Replace the starter refer to starter removal 6 After the starting system problems have been corrected verify the battery s...

Страница 410: ...solenoid wire connector from termi nal Fig 5 4 Remove nut holding B wire to terminal 5 Disconnect solenoid and B wires from starter terminals 6 Remove the lower bolt 7 Remove the upper bolt and groun...

Страница 411: ...ion on starter terminals Fig 5 5 Install nut to hold B wire to terminal 6 Connect solenoid wire connector onto terminal 7 Connect battery negative cable 8 Verify starter operation INSTALLATION 3 3 3 8...

Страница 412: ...5 REMOVAL 16 INSTALLATION 16 BATTERY CABLES DESCRIPTION 16 OPERATION 16 DIAGNOSIS AND TESTING BATTERY CABLE 16 REMOVAL 18 INSTALLATION 18 BATTERY TRAY DESCRIPTION 18 OPERATION 19 REMOVAL 19 INSTALLATI...

Страница 413: ...ectrical components or circuits in the vehicle DIAGNOSIS AND TESTING BATTERY SYSTEM The battery starting and charging systems in the vehicle operate with one another and must be tested as a complete s...

Страница 414: ...nal connections are loose or corroded 4 Refer to Battery Cables for the proper battery cable diagnosis and testing procedures Clean and tighten the battery terminal connections as required 5 The batte...

Страница 415: ...st procedures Replace the faulty battery as required 5 The starting system is faulty 5 Determine if the starting system is performing to specifications Refer to Starting System for the proper starting...

Страница 416: ...rocedures be per formed any time the battery or related components must be removed for vehicle service 1 Clean the battery cable terminal clamps of all corrosion Remove any corrosion using a wire brus...

Страница 417: ...SPECIFICATIONS The battery Group Size number the Cold Cranking Amperage CCA rating and the Reserve Capacity RC rating or Ampere Hours AH rating can be found on the original equipment battery label Be...

Страница 418: ...di tional batteries lead and sulfuric acid to the next level By tightly winding layers of spiral grids and acid permeated vitreous separators into cells the manufacturer has developed a battery with m...

Страница 419: ...larger in diameter than the nega tive terminal post for easy identification The letters POS and NEG are also molded into the top of the battery case adjacent to their respective positive and negative...

Страница 420: ...rough the load device attached to the battery ter minals As the plate materials become more similar chem ically and the electrolyte becomes less acid the volt age potential of each cell is reduced How...

Страница 421: ...he touch If the battery feels hot to the touch turn off the charger and let the battery cool before continu ing the charging operation Damage to the battery may result After the battery has been charg...

Страница 422: ...pecific gravity of the electrolyte will gradually rise The Battery Charging Time Table gives an indica tion of the time required to charge a typical battery at room temperature based upon the battery...

Страница 423: ...e dure is properly followed a good battery may be needlessly replaced 1 Measure the voltage at the battery posts with a voltmeter accurate to 1 10 0 10 volt Fig 8 If the reading is below ten volts the...

Страница 424: ...attery voltage to stabilize 2 Disconnect and isolate both battery cables neg ative cable first 3 Using a voltmeter connected to the battery posts see the instructions provided by the manufac turer of...

Страница 425: ...iate wiring information in this service manual for complete Inte grated Power Module fuse circuit breaker and cir cuit identification This will isolate each circuit and identify the circuit that is th...

Страница 426: ...ositive cable first Torque terminal fasteners to 8 5 N m 75 in lbs BATTERY HOLDDOWN DESCRIPTION The battery hold down hardware consists of a molded plastic lip that is integral to the outboard edge of...

Страница 427: ...ts for the generator and other components on some models Refer to Wiring Diagrams in the index of this service manual for the location of more information on the various wiring circuits included in th...

Страница 428: ...voltmeter to the battery negative cable terminal clamp Fig 13 Rotate and hold the ignition switch in the Start position Observe the voltmeter If voltage is detected correct the poor con nection betwe...

Страница 429: ...le is free from the vehicle 6 Feed the battery cable out of the vehicle INSTALLATION 1 Position the battery cable in the vehicle 2 One at a time trace and install the battery cable retaining fasteners...

Страница 430: ...attery tray retaining fasteners Fig 18 4 Pull battery tray up far enough to disconnect the engine vacuum harness hose from the battery tray mounted vacuum reservoir 5 Remove the battery tray from the...

Страница 431: ...is on when the engine is running and the ASD relay is energized The ASD relay is energized when the PCM grounds the ASD control circuit This voltage is connected through the PCM or IPM intelligent pow...

Страница 432: ...n be the reason for another DTC to be set Therefore it is important that the test pro cedures be followed in sequence to understand what caused a DTC to be set ERASING DIAGNOSTIC TROUBLE CODES The DRB...

Страница 433: ...t engine if equipped They should all be clean and tight Repair as required SPECIFICATIONS GENERATOR Type Engine Minimun Test Amperage Denso 2 4 L 125 Amp Denso 3 3 3 8L 135 Amp or 145 Amp Test Specifi...

Страница 434: ...rator assembly subcompo nents generator and decoupler pulley must be inspected for individual failure and replaced accord ingly OPERATION As the energized rotor begins to rotate within the generator t...

Страница 435: ...ne cover Fig 2 3 Raise vehicle and support 4 Turn wheels to the right Remove the right front splash shield Fig 3 5 Remove the generator drive belt Fig 4 Fig 1 BATTERY CONNECTION Fig 2 ENGINE COVER Fig...

Страница 436: ...sconnect the push in field wire connector from back of generator 4 Remove nut holding B wire terminal to back of generator 5 Separate B terminal from generator 6 Raise vehicle and support 7 Remove the...

Страница 437: ...the generator from vehicle Fig 10 REMOVAL 3 5L 1 Disconnect the negative battery cable 2 Turn wheels to the right 3 Raise and support the vehicle 4 Remove the right front tire 5 Remove the front axle...

Страница 438: ...e the axle from vehicle oil will leak from transmission 15 Remove the 3 mounting bolts for generator 16 Remove generator from vehicle Fig 16 INSTALLATION INSTALLATION 2 4L 1 Install the generator 2 In...

Страница 439: ...cedures 12 Install the right front lower splash shield 13 Lower vehicle 14 Install wiring harness to the oil dip stick tube 15 Connect battery negative cable 16 Verify generator output rate INSTALLATI...

Страница 440: ...ght front lower splash shield 5 Remove accessory drive belt refer to the Cool ing System section for proper procedures Fig 18 6 Lower vehicle 7 Remove the Air Box refer to the Engine section for more...

Страница 441: ...This circuitry is connected in series with the generators second rotor field terminal and its ground Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field...

Страница 442: ...ring harness Battery Starter motor with an integral solenoid Powertrain Control Module PCM OPERATION These components form two separate circuits A high amperage circuit that feeds the starter motor up...

Страница 443: ...rroded wire harness connections Starter Visually inspect the starter for indica tions of physical damage and loose or corroded wire harness connections Starter Solenoid Visually inspect the starter so...

Страница 444: ...SSEMBLY IF NECESSARY 8 STARTER ASSEMBLY FAULTY 8 IF ALL OTHER STARTING SYSTEM COMPONENTS AND CIRCUITS CHECK OK REPLACE STARTER ASSEMBLY 9 FAULTY TEETH ON RING GEAR 9 ROTATE FLYWHEEL 360 AND INSPECT TE...

Страница 445: ...he Power Distribution Center PDC Refer to the PDC cover for the proper relay location STARTER SOLENOID WARNING CHECK TO ENSURE THAT THE TRANS MISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE APP...

Страница 446: ...o Step 4 If not OK repair the open circuit to the starter solenoid as required 4 The coil battery terminal 86 is connected to the electromagnet in the relay It is energized when the ignition switch is...

Страница 447: ...ct positive lead of the voltmeter to the battery positive post and negative lead to the bat tery positive cable clamp Rotate and hold the igni tion switch key in the START position Observe the voltmet...

Страница 448: ...below 9 6 volts and amperage draw above 300 amps the problem is the starter Replace the starter refer to starter removal 6 After the starting system problems have been corrected verify the battery st...

Страница 449: ...solenoid wire connector from termi nal Fig 5 4 Remove nut holding B wire to terminal 5 Disconnect solenoid and B wires from starter terminals 6 Remove the lower bolt 7 Remove the upper bolt and groun...

Страница 450: ...Remove starter from bellhousing Fig 9 8 Separate starter spacer from transaxle bell housing REMOVAL 3 5L 1 Disconnect the negative battery cable 2 Raise vehicle and support 3 Disconnect the battery p...

Страница 451: ...g bolt 8 Remove the middle mounting bolts Fig 12 9 Remove the lower mounting bolt Fig 13 10 Remove starter REMOVAL 2 5L 1 Disconnect the negative battery cable 2 Raise vehicle and support 3 Remove the...

Страница 452: ...starter 5 Install nut to hold B terminal to starter sole noid 6 Lower vehicle 7 Connect battery negative cable 8 Verify starter operation INSTALLATION 3 5L 1 Install starter 2 Install the middle Fig 1...

Страница 453: ......

Страница 454: ...GER GRID STANDARD PROCEDURE GRID LINE REPAIR REAR 2 REAR WINDOW DEFOGGER SWITCH DESCRIPTION 2 OPERATION 2 WINDSHIELD GRID DIAGNOSIS AND TESTING SYSTEM TEST 3 STANDARD PROCEDURE GRID LINE AND TERMINAL...

Страница 455: ...tay ON until the another mode is selected For circuit information and component location refer to appropriate section for Wiring Diagrams CAUTION Since grid lines can be damaged or scraped off with sh...

Страница 456: ...IPM Rear window defogger relay control circuity in the FCM portion of the IPM Check for loose connector or a wire pushed out of connector Rear window or the windshield grid lines all grid lines would...

Страница 457: ...ermi nal from falling off use a wooden wedge to secure it 8 Carefully remove masking tape from grid line CAUTION Do not allow the laminated windshield glass surface to exceed 82 C 180 F or the glass m...

Страница 458: ...rear window defog ger switch The heated mirror is ON when the rear window defogger is ON 1 The mirror glass should be warm to the touch 2 If not check the 20 amp fuse 11 in the Power Distribution Cen...

Страница 459: ...iew mirrors The defogger relay will be on for approximately 10 minutes or until the control switch or ignition is turned off HEATED MIRROR GRID STANDARD PROCEDURE HEATED MIRROR Replacement of the mirr...

Страница 460: ...mental elec trical seat heating HI LO or no seat heating to suit their individual comfort requirements The heated seat system for this vehicle includes the following major components which are describ...

Страница 461: ...the ignition switch is turned to any position except On or Acces sory Also the heated seat system will not operate when the surface temperature of the seat cushion cover at either heated seat sensor i...

Страница 462: ...t to the seat heater elements of the selected seat The Low heat position set point is about 36 C 97 F and the High heat position set point is about 41 C 105 F DIAGNOSIS AND TESTING DRIVER HEATED SEAT...

Страница 463: ...SISTANCE OHMS Off Pin 4 5 OPEN Low Pin 4 5 3570 High Pin 4 5 1430 All resistance values are 1 4 Reconnect the instrument panel switch bank and test the heated seat system for proper operation If the s...

Страница 464: ...onnect the seat electrical connectors just use care not to damage the attached wire harnesses while testing NOTE WHEN CHECKING HEATED SEAT ELE MENTS FOR CONTINUITY BE CERTAIN TO MOVE THE HEATING ELEME...

Страница 465: ...securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover HEATED SEAT SENSOR DESCRIPTION Two heated seat sensors are used per vehicle one in each front seat cushi...

Страница 466: ...to the seat heater elements of the selected seat The Low heat position set point is about 36 C 97 F and the High heat position set point is about 41 C 105 F DIAGNOSIS AND TESTING PASSENGER HEATED SEA...

Страница 467: ...SWITCH TEST SWITCH POSITION RESISTANCE BETWEEN RESISTANCE OHMS Off Pin 3 4 OPEN Low Pin 3 4 3570 High Pin 3 4 1430 All resistance values are 1 4 Reconnect the instrument panel switch bank and test the...

Страница 468: ...e heated seat switch to the back of the instrument panel center bezel Tighten the screws to 1 5 N m 13 in lbs Fig 8 3 Install the center bezel onto the instrument panel Refer to Instrument Panel Cente...

Страница 469: ......

Страница 470: ...more than 30 seconds Once the switch is OPEN a 20 30 second delay will occur before the horns are functional again DIAGNOSIS AND TESTING HORN SYSTEM WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER T...

Страница 471: ...RONT CONTROL MODULE HORN SOUND INTERMITTENTLY AS THE STEERING WHEEL IS TURNED 1 HORN RELAY CONTROL CIRCUIT X3 IS SHORTED TO GROUND INSIDE STEERING COLUMN OR WHEEL 1 REMOVE DRIVER AIRBAG MODULE AND OR...

Страница 472: ...nd wire for continu ity to ground 6 If no ground repair as necessary 7 If wires test OK and horn does not sound replace horn HORNS SOUND CONTINUOUSLY CAUTION Continuous sounding of horns may cause rel...

Страница 473: ...nuity from the X3 cavity of the horn relay to ground a If continuity is detected proceed to Step 3 b If NO continuity proceed to Step 4 3 Using a suitable jumper wire jump across the fuse F62 cavity a...

Страница 474: ...und b If NO voltage check fuse 8 of the intelligent power module c If incorrect voltage repair as necessary 5 Insert a jumper wire between terminal 30 and 87 of the intelligent power module a If horn...

Страница 475: ......

Страница 476: ...10 IGNITION CONTROL DESCRIPTION IGNITION SYSTEM NOTE All engines use a fixed ignition timing sys tem Basic ignition timing is not adjustable All spark advance is determined by the Powertrain Control...

Страница 477: ...10 7 SPARK PLUG CABLE RESISTANCE 2 4L CABLE Maximum Resistance 1 2 3 4 10 8K ohms 3 3 3 8L CABLE Maximum Resistance 1 22 5K ohms 2 22 8K ohms 3 19 3K ohms 4 19 3K ohms 5 13 6K ohms 6 16 4K ohms SPARK...

Страница 478: ...o the PCM for diagnostic purposes If the PCM does not receive 12 volts from this input after grounding the ASD relay it sets a Diagnostic Trouble Code DTC The PCM energizes the ASD any time there is a...

Страница 479: ...tal to high notch then back to low The number of notches determine the amount of pulses If available an oscilloscope can display the square wave patterns of each timing event Top Dead Center TDC does...

Страница 480: ...make removal difficult A light tap to top of sensor prior to removal may reduce force needed for removal Fig 3 EGR CAM SENSOR 2 4L Fig 4 Target Magnet Removal Installation 1 TARGET MAGNET 2 MOUNTING B...

Страница 481: ...ft position sensor electrical connector to harness connector 5 Install the air box cover and inlet hose Fig 5 6 Connect the negative battery cable IGNITION COIL DESCRIPTION The ignition coil assembly...

Страница 482: ...ering reservoir Fig 11 6 Remove the ignition cables from the ignition coil 7 Disconnect the electrical connector from the ignition coil 8 Remove 2 nuts from the ignition coil studs 9 Remove 2 bolts fr...

Страница 483: ...retard uses its own short term and long term memory program Long term memory stores previous detonation information in its battery backed RAM The maxi mum authority that long term memory has over tim...

Страница 484: ...r schedule A in this manual The spark plugs have a recommended service life of 75 000 miles for severe driving conditions per schedule B in this manual A thin platinum pad is welded to both or center...

Страница 485: ...s with insulators that are cracked or torn must be replaced Clean Spark Plug cables with a cloth moistened with a non flammable solvent Wipe the cables dry Check for brittle or cracked insulation The...

Страница 486: ...0 amps after the plugs are heated Electrical operation of the glow plugs is controlled by two glow plug relays Each glow plug relay con trols two glow plugs Refer to glow plug relays for more informat...

Страница 487: ...MP sensor is mounted in the top of cylinder head cover intake manifold at the rear of the engine The CMP sensor is a hall effect device Fig 3 OPERATION The CMP sensor is a hall effect switch A tooth m...

Страница 488: ...lt Door Ajar Coolant Temperature Anti Lock Brake Brake Airbag Traction Control Autostick The mechanical instrument cluster without a tachometer also has the following warning lamps Turns Signals High...

Страница 489: ...ULT 100 4 FCM COMMUNICATION FAULT 100 5 ORC COMMUNICATION FAULT 100 6 SBEC DEC MCM COMMUNICATION FAULT 200 0 AIRBAG LED SHORT 200 1 AIRBAG LED OPEN 200 2 ABS LED SHORT 200 3 ABS LED OPEN 200 6 EL INVE...

Страница 490: ...HARNESS CONNECTOR FOR SPREAD TERMINAL IF OK LOOK FOR ANOTHER POSSIBLE CAUSE FOR THE CLUSTER FAILURE IF NOT OK REPAIR CONNECTOR BCM IS NOT RECEIVING PROPER INPUT FROM THE IGNITION SWITCH 1 USE A DRB II...

Страница 491: ...O THE INSTRUMENT PANEL 2 NO SPEED PCI BUS MESSAGE OR ZERO MPH PCI SPEED BUS MESSAGE 2 A CHECK THE PCM CODE 10 USING A DRB IIIT SCAN TOOL IF OK GO TO STEP 2 B IF NOT OK REFER TO THE PROPER POWERTRAIN D...

Страница 492: ...HE FOLLOWING SOURCES A DISTANCE SENSOR FOR VEHICLES WITH 3 SPEED AUTOMATIC TRANSMISSION CHECK CONTINUITY FROM DISTANCE SENSOR TO PCM IF OK REPLACE DISTANCE SENSOR IF NOT OK REPAIR WIRING THE TCM FOR V...

Страница 493: ...O SEE IF THE CORRECT TIRE SIZE HAS BEEN PROGRAMMED INTO THE TCM IF THE INCORRECT TIRE SIZE WAS SELECTED SELECT THE PROPER TIRE SIZE IF THE CORRECT TIRE SIZE WAS SELECTED CHECK SPEED SENSOR 3 BAD SPEED...

Страница 494: ...E CLUSTER ASSEMBLY FUEL GAUGE DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION NO POINTER MOVEMENT 1 INTERNAL CLUSTER FAILURE 1 PERFORM CLUSTER SELF DIAGNOSTIC TEST IF FUEL GAUGE POINTER MOVES TO CALIBR...

Страница 495: ...E TO THE CALIBRATION POINTS REPLACE CLUSTER ASSEMBLY 2 FUEL LEVEL SENDING UNIT IS OUT OF CALIBRATION 2 REFER TO THE FUEL SECTION OF THE SERVICE MANUAL FOR TESTING AND REPAIR PROCEDURE TEMPERATURE GAUG...

Страница 496: ...TIC TEST IF POINTER IS ACCURATE TO THE CALIBRATION POINTS LOOK FOR ANOTHER POSSIBLE CAUSE OF FAILURE IF POINTER IS INACCURATE TO THE CALIBRATION POINTS REPLACE CLUSTER ASSEMBLY 2 COOLANT SENSOR OUT OF...

Страница 497: ...ESN T WORK IF CLUSTER WILL NOT GO INTO SELF DIAGNOSTIC MODE AND TRIP ODOMETER WILL NOT RESET REPLACE CLUSTER ELECTRONIC GEAR INDICATOR DISPLAY DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION NO DISPLAY...

Страница 498: ...LACE CLIP ON INDICATOR INDICATOR DOES NOT MAKE FULL TRAVEL P 1 1 CABLE DISLODGED FROM ITS PATH ON THE INDICATOR BASE 1 VERIFY CORRECT ATTACHMENT OF INDICATOR CABLE TO SHIFT LEVER PIN UNDER HOOP OF TRA...

Страница 499: ...ent clus ter to instrument panel 5 Position cluster bezel into place 6 Install the four bezel attaching screws 7 Install the Over Steering Column Bezel by firmly snapping into place 8 Connect the clip...

Страница 500: ...ck by the ignition switch every time the ignition switch is placed in the crank position OPERATION The red BRAKE warning indicator lamp is sup plied a 12 volt ignition feed anytime the ignition switch...

Страница 501: ......

Страница 502: ...LAMP UNIT ALIGNMENT EXPORT 10 REMOVAL 11 INSTALLATION 11 FRONT POSITION LAMP EXPORT REMOVAL 11 INSTALLATION 11 HEADLAMP DIAGNOSIS AND TESTING HEADLAMP 12 REMOVAL 14 INSTALLATION 14 HEADLAMP EXPORT RE...

Страница 503: ...it ground Refer to the appropriate wiring information AUTOMATIC HEADLAMP SYSTEM The Automatic Headlamp system turns the instru mentation and exterior illumination lamps ON when the ambient light level...

Страница 504: ...OFF and headlamp switch OFF The BCM will allow the headlamps to remain ON for 90 seconds config urable before they automatically turn off If the key is in the ignition during the headlamp time delay m...

Страница 505: ...witches assume the opposite positions The switch for terminals 1 and 2 is now open while the other two switches are now closed completing their circuits A lever on the back of the switch is used to se...

Страница 506: ...stall the switch replace it Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR BRAKE LAMP SWITCH INSTALLATION CAUTION The switch can only be adjusted once That is during initial installation of the switch...

Страница 507: ...silencer panel below steering column knee blocker 3 Reconnect the battery negative terminal 4 Check the stop lamps to verify they are operat ing properly and not staying on when the pedal is in the r...

Страница 508: ...not holding the com ponent in place FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF 1 Loose or corroded battery cables 1 Clean and s...

Страница 509: ...erminals or splices in circuit 4 Inspect and repair all connectors and splices Refer to Electrical Wiring Information 5 Is relay engaging properly 5 Verify function of fog lamp relay in IPM 6 PCI Bus...

Страница 510: ...MOVAL 1 Disconnect and isolate the battery negative cable 2 Remove access cover from under bumper fascia 3 Disengage spring clip from fog lamp Fig 8 4 Remove bulb from lamp 5 Disconnect wire harness c...

Страница 511: ...ustment screw located through the lens on Dodge vehicles and by a knob on the back of the lamp STANDARD PROCEDURE FOG LAMP UNIT ALIGNMENT EXPORT Prepare an alignment screen Refer to 8 ELEC TRICAL LAMP...

Страница 512: ...AMP EXPORT REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the headlamp unit Fig 11 3 Remove the plastic cover from the back of the headlamp unit 4 Pull front position lamp socket...

Страница 513: ...t in place HEADLAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF 1 Loose or corroded battery cables 1 Clean and secure battery cable clamp...

Страница 514: ...mp switch HEADLAMPS DO NOT ILLUMINATE 1 No voltage to headlamps 1 Repair open headlamp circuit refer to Electrical Wiring Information 2 No Z343 Z344 ground at headlamps 2 Repair circuit ground refer t...

Страница 515: ...REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the headlamp unit 3 Remove the cover high beam lamp or rubber boot low beam lamp to access bulbs Fig 13 4 Disconnect the wire harne...

Страница 516: ...amp leveling switch operation 2 No voltage at leveling motors 2 Repair no voltage condition Refer to Wiring Diagrams 3 No ground at leveling motors 3 Repair no ground condition Refer to Wiring Diagram...

Страница 517: ...amp leveling switch If the headlamp leveling switch is faulty the headlamp switch must be replaced HEADLAMP SWITCH DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING HEADLAMP SWITCH Using a Digital Multi met...

Страница 518: ...SWITCH POSITION 13 WAY CONNECTOR TERMINAL RESISTANCE 0 1 TO 7 3238 3456 V 1 TO 2 3181 3400 V 1 1 TO 7 1195 1225 V 2 1 TO 7 746 765 V REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remo...

Страница 519: ...18 2 If necessary tape a line on the floor 7 62 meters 25 ft away from and parallel to the wall 3 Rock vehicle side to side three times and allow suspension to stabilize 4 Jounce front suspension thre...

Страница 520: ...e perpendicu lar to a flat wall 10 meters 32 8 ft away from front of headlamp lens Fig 20 2 If necessary tape a line on the floor 10 meters 32 8 ft away from and parallel to the wall 3 Rock vehicle si...

Страница 521: ...ORT 1 CENTER OF VEHICLE 5 10 METERS 32 8 FT 2 CENTER OF HEADLAMPS 6 HORIZONTAL CUT OFF LINE 3 15 CUT OFF LINE 7 110 mm 4 3 in 4 FRONT OF HEADLAMP Fig 21 HEADLAMP UNIT ADJUSTMENT 1 HEADLAMP ADJUSTMENT...

Страница 522: ...resistive MUX switch that feeds inputs to the BCM OPERATION TURN SIGNAL SYSTEM Lane change signaling is actuated by applying par tial turn signal stalk movement toward the direction desired until the...

Страница 523: ...ering column adapter collar 5 Remove the multi function switch INSTALLATION 1 Position the switch on to the steering column 2 Install the two retaining screws 3 Connect the wire harness connector 4 In...

Страница 524: ...negative cable 2 Remove the tail lamp unit Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR TAIL LAMP UNIT REMOVAL 3 Squeeze the tabs on the bulb socket and remove from tail lamp unit Fig 28 4 Pull bulb...

Страница 525: ...Disconnect wire harness connector from tail lamp unit by sliding the red lock then pressing release tab Fig 31 INSTALLATION 1 Reconnect wire harness connector to the tail lamp Slide lock into positio...

Страница 526: ...LARM SET PC74 AUTOSTICK VFD BRAKE SYSTEM WARNING LED CONSOLE 194 CRUISE INDICATOR VFD DOME RAIL LAMPS 578 DOOR AJAR INDICATOR LED DOOR COURTESY LAMP 578 FRONT DOOR COURTESY 567 GLOVE BOX 194 HIGH BEAM...

Страница 527: ...Installation COURTESY LAMP REMOVAL 1 Disconnect and isolate the battery negative cable 2 Using a trim stick pry lamp from door panel Fig 1 3 Disconnect wire harness from the lamp 4 Remove lens from t...

Страница 528: ...y negative cable READING LAMP REMOVAL The front reading lamps are incorporated into the overhead console If the reading lamps require replacement the overhead console must be replaced Refer to 8 ELECT...

Страница 529: ...y 1 Disconnect and isolate the battery negative cable 2 Using a pick or other suitable tool pry the lens from the lamp Fig 8 3 Remove bulb INSTALLATION 1 Install bulb 2 Snap lamp lens into position 3...

Страница 530: ...ea tures The overhead console is mounted with one screw and two snap clips to a molded plastic retainer bracket located above the headliner DESCRIPTION COMPASS All the available overhead consoles on t...

Страница 531: ...egrated power module as required 3 Check the fused ignition switch output run start fuse in the integrated power module If OK go to Step 4 If not OK repair the shorted circuit or component as required...

Страница 532: ...pass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use If the compass read ings appear to be erratic or out of calibration per form the foll...

Страница 533: ...degaussing tool connected 9 Contact the roof panel with the plastic coated tip of the degaussing tool Be sure that the template is in place to avoid scratching the roof panel Using a slow back and fo...

Страница 534: ...e correct directions are now indicated by the compass REMOVAL OVERHEAD CONSOLE 1 Disconnect and isolate the remote negative bat tery cable 2 Remove the overhead console retaining screw located in the...

Страница 535: ...f battery current so that some of its features remain operational at any time while others may only operate with the ignition switch in the On position When the ignition switch is turned to the On pos...

Страница 536: ...able features appear in the selected language DISPLAY U S OR METRIC The options include U S and M The default is U S This feature toggles the trip computer temperature fuel economy and odometer displa...

Страница 537: ...ption When Off is selected the headlamp delay feature is disabled HEADLAMPS ON WITH WIPERS This pro grammable feature only applies to vehicles equipped with the optional Auto Headlamps The options inc...

Страница 538: ...TC and Com pass Temperature CT data is obtained from the Body Control Module BCM on the J1850 Data Bus circuit The CMTC and CT will display dashes for any of the screens it did not receive the bus mes...

Страница 539: ...universal transmitter with a known good transmitter as instructed in the owner s manual and test the universal transmitter operation again If the unit is still inoperative replace the faulty universa...

Страница 540: ...turn circuit and the ambient temperature sensor signal circuit cavities of the Front Control Module wire har ness connector There should be continuity If OK go to Step 4 If not OK repair the open sens...

Страница 541: ......

Страница 542: ...LATION 9 FULL OPEN SWITCH DESCRIPTION 10 OPERATION 10 REMOVAL 10 INSTALLATION 10 LIFTGATE MOTOR DESCRIPTION 10 OPERATION 11 REMOVAL 11 INSTALLATION 11 ENGAGE ACTUATOR DESCRIPTION 11 OPERATION 11 REMOV...

Страница 543: ...part of the liftgate gear motor assembly The pawl and ratchet switches are part of the latch assembly The pinch sensor or sensors are located along the right and left sides of the power liftgate just...

Страница 544: ...ol module BCM The BCM then sends a signal out on the J1850 PCI Data Bus circuit to the power liftgate module The power liftgate module then signals the power liftgate motor to start an open or close c...

Страница 545: ...G NEVER STICK OBJECTS IN THE POWER LIFTGATE WHEN CINCHING CLOSED YOU COULD DAMAGE THE VEHICLE POWER LIFTGATE SYS TEM COMPONENTS AND OR CAUSE PERSONAL INJURY DIAGNOSIS AND TESTING POWER LIFTGATE SYSTEM...

Страница 546: ...he necessary components Failure of latch assembly Check wire connections and for blown fuse Check for foreign matter preventing the operation of latch assembly Replace latch assembly if necessary Bind...

Страница 547: ...nding and replace necessary components Failure of Power Liftgate or Body Control Module Disconnect then reconnect battery to reset module function liftgate if no function exists check for loose wire c...

Страница 548: ...t then reconnect battery to reset module function liftgate if no function exists check for loose wire connections see Body Diagnostic Manual for detailed procedures Failure of liftgate motor assembly...

Страница 549: ...ilure of liftgate motor assembly Check wire connections Replace motor assembly if necessary Failure of liftgate prop rods Replace prop rods if necessary Binding or sticking of components Establish loc...

Страница 550: ...ng a power close cycle OPERATION During a power liftgate close cycle if either of the two conductive rubber strips tapeswitch of the pinch sensor come in contact with an obstacle the pinch sensor circ...

Страница 551: ...re ends and reinstall in the main lift gate motor electrical connector 2 Position and install the full open switch retain ing screw 3 Install the power liftgate lift gear and link rod assembly Refer t...

Страница 552: ...bolts from the motor housing and the one bolt from the transverse mount bracket 5 Grab the liftgate motor assembly and lift upward and out to unhook the motor assembly from the D pillar 6 Remove the...

Страница 553: ...ve battery cable 6 Using an appropriate scan tool check and erase any power liftgate control module diagnostic trouble codes 7 Verify power liftgate system and engage actua tor operation Cycle the pow...

Страница 554: ...or assembly electrical con nector and engage retaining pushpin 6 Install the appropriate D pillar trim from the vehicle Refer to Body for the procedure LIFT GEAR LINK ROD DESCRIPTION Vehicles equipped...

Страница 555: ...ease latch This latch performs the same features as a manual liftgate latch as well as the power cinch and or release capability A second type of power latch can also be found on some RS models this l...

Страница 556: ...d close cycle this will allow the power liftgate control module to relearn its cycle with the new components 8 Verify power liftgate manual operation Using liftgate key rotate the lock cylinder to ver...

Страница 557: ...unted can be used to perform a full power open cycle The exterior handle switch is a serviceable compo nent Consult your Mopar parts catalog for a spe cific part number OPERATION When the exterior han...

Страница 558: ...tion provides an audible chime sound which is controlled by the power liftgate module The chime thermistor assembly is hardwired to the power liftgate module Second the thermistor provides a outside t...

Страница 559: ...a right side power door or right and left side power doors This power sliding door system is a complex system consisting of many components Some of these components are the door motor latch assembly...

Страница 560: ...liding door system through a 40 amp fuse located in the Intelligent Power Module IPM assembly Fig 3 The child lockout switch pre vents children from opening or actuating the power sliding door system...

Страница 561: ...s made the module must re learn the effort required to open or close the door A learn cycle can be performed with a Diagnostic Scan Tool such as the DRB IIIt or with a complete cycle of the door using...

Страница 562: ...ining many compo nents and modules In order to obtain conclusive testing the Programmable Communications Interface J1850 data bus network and all of the electronic modules that provide inputs to or re...

Страница 563: ...ble connections at latch and handle assembly Check for binds or kinks in cable Check for foreign matter preventing the operation of handle assembly Replace the handle if necessary Failure of latch ass...

Страница 564: ...nect then reconnect battery to reset module function door if no function exists check for loose wire connections see Body Diagnostic Manual for detailed procedures Failure of latch assembly Check wire...

Страница 565: ...s check for loose wire connections see Body Diagnostic Manual for detailed procedures Door seal force too high Inspect seals for damage mis assembly foreign matter Refer to Door adjustment in the Body...

Страница 566: ...Replace BCM if necessary Failure of key fob Replace key fob battery Replace key fob if necessary Failure of sliding door control module Disconnect then reconnect battery to reset module function door...

Страница 567: ...ics Refer to wiring diagrams Door continues to open during power mode runaway motor Failure of sliding door control or body control module Disconnect then reconnect battery to reset module function do...

Страница 568: ...at the system is performing properly and is able to be returned to ser vice To perform a power door learn cycle do the fol lowing 1 Obtain a DRB IIIt scan tool Connect the DRB IIIt to the vehicle and...

Страница 569: ...ual door latch as well as power cinch release lock and unlock operations The power latch mounted actuator cinches the door closed and latches it in its primary latched position During a power close cy...

Страница 570: ...DESCRIPTION Vehicles equipped with a power sliding door utilize a door motor assembly The door motor is located in the center of the side door Fig 7 and is comprised of three parts The three parts of...

Страница 571: ...cedure FULL OPEN SWITCH DESCRIPTION Vehicles equipped with a power sliding door utilize a full open switch This switch is located in the hold open latch Fig 9 under the side door lower hinge When the...

Страница 572: ...appropriate power side door The B pillar switches are replaceable Consult your Mopar parts catalog for a specific part number OPERATION When the Pillar switch is depressed a signal is sent to the Body...

Страница 573: ...e flex drive collar straight on until the it snaps in place Fig 12 3 Install the lower drive unit retaining fasteners Fig 12 Torque the larger allen headed center stud to 9 N m 80 in lbs Torque the sm...

Страница 574: ...le 2 Remove the side door sill plate from the lower of the door opening Refer to the Body section for the procedure 3 Remove the hold open striker Refer to Body for the procedure 4 Position a floor ja...

Страница 575: ...ground and other various electrical connections to the side sliding door During sliding door movement the wir ing track folds and unfolds like the links in a chain REMOVAL 1 Disconnect and isolate th...

Страница 576: ...the Body section for the procedure 10 Connect the negative battery cable FLEX DRIVE DESCRIPTION Vehicles equipped with a power sliding side door utilize a flex drive assembly The flex drive assembly i...

Страница 577: ...traight off the lower drive unit 8 Remove the flex drive assembly from the vehi cle INSTALLATION 1 Position the flex drive assembly in the vehicle 2 Install the flex drive on the lower drive unit Push...

Страница 578: ...uter for the power sliding side door system All power door functions are processed through the power door control module and or the vehicles body control module BCM At the start of a power open comman...

Страница 579: ...odule from the vehicle INSTALLATION 1 Position the control module and install the retaining screw 2 Connect the control module electrical connec tors Slide the locking tab into the locked position 3 I...

Страница 580: ...Rolling automatic lock ENABLE doors auto matically lock at approximately at 25 7 Km h 16 mph No rolling automatic lock DISABLE doors do not automatically lock when the vehicle is moving AUTOMATIC DOO...

Страница 581: ...l power door lock function ing shall be disabled when activating either door lock switch Also if the Vehicle Theft Alarm VTA is armed the door lock switch UNLOCK feature will be disabled until the veh...

Страница 582: ...r set ting 1 or 2 Two additional key fob transmitters can be added but they will not be able to operate the mem ory seat and mirror system Refer to 8 ELECTRI CAL POWER SEATS OPERATION and Refer to 8 E...

Страница 583: ...t the motor connectors one at a time while operating the door lock switch In the event that none of the motors work the problem may be caused by a shorted motor or a bad switch Disconnecting the defec...

Страница 584: ...or all transmitters STANDARD PROCEDURE BATTERY REPLACEMENT 1 With the transmitter buttons facing down use a coin a penny is suggested to pry the two halves of the transmitter apart Fig 3 Make sure not...

Страница 585: ...LOCK button for a minimum five seconds maximum ten seconds 5 While still holding UNLOCK button and before ten seconds passes press the PANIC button and release both at the same time A single chime wil...

Страница 586: ...nd pad as necessary 4 Remove latch lock control cover 5 Remove latch lock control 6 Remove screws holding door lock motor to latch lock control Fig 5 7 Remove lock motor from control INSTALLATION 1 Po...

Страница 587: ...An optional driver side outside electrochromic mir ror is able to automatically change its reflectance level This mirror is controlled by the circuitry of the automatic day night inside rear view mirr...

Страница 588: ...or is able to automat ically change its reflectance A thin layer of electro chromic material between two pieces of conductive glass make up the face of the mirror Two photocell sensors are used to mon...

Страница 589: ...wire harness connector and a good ground There should be conti nuity If OK go to Step 5 If not OK repair the cir cuit to ground as required 5 Turn the ignition switch to the On position Set the parkin...

Страница 590: ...onnect wire connector from power mirror switch 5 Disengage lock tabs above and below the mir ror switch 6 Remove power mirror switch from headlamp switch bezel INSTALLATION 1 Install power mirror swit...

Страница 591: ...ting and retention connector pin out information and location views for the various wire harness connectors splices and grounds REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the...

Страница 592: ...system option allows the driver and front seat passenger to electrically adjust their seating positions for optimum control and comfort using the power seat switches located on the out board seat cush...

Страница 593: ...d or when the doors are unlocked using the corresponding Remote Keyless Entry RKE transmitter A customer programmable feature of the memory system allows the RKE recall of memory features to be disabl...

Страница 594: ...ons are requested the priority for response will be as follows Seat Track Rearward or Forward Seat Front Down or Up Seat Rear Down or Up Recliner Rearward or Forward The inputs from these switches to...

Страница 595: ...direction of the failure If the dome lamp dims the seat may be jamming Check under and behind the seat for binding or obstructions If the dome lamp does not dim proceed with testing of the individual...

Страница 596: ...on the power seat switch functions and the seat adjusting procedures DIAGNOSIS AND TESTING DRIVER SEAT SWITCH 1 Remove the power seat switch refer to the Switch Removal and Installation procedures in...

Страница 597: ...en the screws to 1 5 N m 14 in lbs 6 Install the switch knobs on the switch control levers if equipped 7 Reconnect the battery negative cable MEMORY SET SWITCH DESCRIPTION Vehicles equipped with the m...

Страница 598: ...o screws that secure the memory switch to the back of the driver side front door trim panel switch bezel Tighten the screws to 2 2 N m 20 in lbs 2 Reconnect the memory switch wire harness connector to...

Страница 599: ...TER SWITCH FORWARD PIN 5 3 PIN 1 10 CENTER SWITCH REARWARD PIN 5 10 PIN 3 1 REAR RISER UP PIN 5 8 PIN 1 7 REAR RISER DOWN PIN 5 7 PIN 1 8 RECLINER UP PIN 5 2 PIN 4 1 RECLINER DOWN PIN 5 4 PIN 2 1 REMO...

Страница 600: ...re recommended The MSMM cannot be repaired and if faulty or damaged it must be replaced Refer to Memory System in the Power Seat or Power Mirror section of this manual for more information on the memo...

Страница 601: ...ve unit in the selected direc tion until the switch is released or until the travel limit of the adjuster is reached When the switch is moved in the opposite direction the battery feed and ground path...

Страница 602: ...e seat cushion pan 9 Remove the power seat track from the seat INSTALLATION 1 Position the seat cushion on the seat track 2 Install the four seat track retaining bolts in the seat cushion pan Torque t...

Страница 603: ...n to be certain that the adjuster is not at its travel limit If the power seat track adjuster still fails to operate in only one direction refer to Diagnosis and Testing Power Seat Switch in this sect...

Страница 604: ...Remove the power seat track from the seat INSTALLATION 1 Position the seat cushion on the seat track 2 Install the four seat track retaining bolts in the seat cushion pan Torque the bolts to 28 5 N m...

Страница 605: ...hrough these same two connections will cause the motor to rotate in the opposite direction Refer to the appropriate wiring information The wir ing information includes wiring diagrams proper wire and...

Страница 606: ...pillar trim panel necessary to gain access to power vent window motor wire connector Refer to 23 BODY INTERIOR LEFT D PILLAR TRIM PANEL REMOVAL or Refer to 23 BODY INTERIOR RIGHT D PILLAR TRIM PANEL...

Страница 607: ...ITCH POSITION CONTINUITY BETWEEN OFF 13 and 1 13 and 2 13 and 3 13 and 4 13 and 5 13 and 6 13 and 7 13 and 8 UP DRIVER 11 and 8 DOWN DRIVER 11 and 6 X DOWN DRIVER 11and 6 UP PASSENGER 9 and 4 DOWN PAS...

Страница 608: ...motor The AUTO feature can be cancelled by actuat ing the switch UP or DOWN while window is in motion If the electronic circuit in the switch fails to detect a stall current the auto down circuit wil...

Страница 609: ......

Страница 610: ...D SWB THREE DOOR REMOVAL 8 INSTALLATION 8 SEAT BELT FIRST ROW OUTBOARD SWB FOUR DOOR REMOVAL 9 INSTALLATION 9 SEAT BELT FIRST ROW OUTBOARD LWB FOUR DOOR REMOVAL 10 INSTALLATION 10 SEAT BELT SECOND RIG...

Страница 611: ...IN PERSONAL INJURY WHEN CARRYING OR HANDLING AN UNDEPLOYED AIRBAG MODULE THE TRIM SIDE OF THE AIRBAG SHOULD BE POINTING AWAY FROM THE BODY TO MINIMIZE POSSIBILITY OF INJURY IF ACCIDENTAL DEPLOYMENT O...

Страница 612: ...travel rotate the rotor two turns counterclockwise until the wires end up at the top 7 Install steering wheel and airbag WARNING DO NOT CONNECT THE BATTERY NEG ATIVE CABLE REFER TO ELECTRICAL RESTRAI...

Страница 613: ...er airbag from steering wheel 4 Disconnect wire connectors from Airbag and Clock Spring 5 Adjust the steering wheel so that the tires are in a straight ahead position Remove steering wheel Refer to 19...

Страница 614: ...us injury caused by a frontal impact of the vehicle The Occupant Restraint Controller ORC contains the impact sensor and energy reserve capacitor It is mounted on a bracket under the instrument panel...

Страница 615: ...river Airbag Passenger Airbag Upper Instrument Panel with Pad CARE OF UNDEPLOYED AIRBAGS Airbags must be stored in their original special container until used for service At no time should a source of...

Страница 616: ...l tear open and allow the side airbag to fully inflate and quickly deflate SEAT BELT OUTBOARD FRONT REMOVAL Inspect the condition of the shoulder belt and lap belt Replace any belt that is cut frayed...

Страница 617: ...ve lower quarter trim panel 12 Route seat belt webbing and turning loop through access hole in lower quarter trim panel 13 Remove bolt attaching seat belt retractor to quarter panel 14 Lift retractor...

Страница 618: ...lt from vehicle INSTALLATION 1 Install seat belt into position 2 Lower retractor into position to quarter panel 3 Install bolt attaching seat belt retractor to quarter panel Tighten seat belt anchor b...

Страница 619: ...djuster 13 Install first and second row seats Refer to Owner s manual for proper procedures NOTE The tightening specification for all seat belt anchor bolts is 39 N m 29 ft lbs torque SEAT BELT SECOND...

Страница 620: ...el Fig 8 d Remove screws attaching upper evaporator housing to lower evaporator housing e Remove coolant line retaining bracket hold down bolt 13 Remove bolts attaching seat belt guide loop to inner q...

Страница 621: ...er anchor cover from over the anchor shoulder nut 3 Remove lower anchor shoulder nut 4 Remove lower anchor from wheelhouse Fig 9 5 Remove D pillar trim panel 6 Route seat belt webbing and turning loop...

Страница 622: ...move side cover from seat 4 Remove bolts attaching recliner bracket to seat cushion 5 Remove recliner bracket from seat 6 Remove bolt attaching seat belt buckle to seat track Fig 10 7 Remove buckle fr...

Страница 623: ...nt in their respective seat by retracting the seat belt up to four inches They are integral to the front seat belt buckles and cannot be serviced If found defective they must be replaced After an airb...

Страница 624: ...2 Install screws attaching shoulder belt height adjuster to pillar Tighten seat belt anchor bolts to 39 N m 29 ft lbs torque 3 Install B or C pillar trim cover SHOULDER BELT HEIGHT ADJUSTER KNOB REMOV...

Страница 625: ...require airbag protection the SIACM microprocessor sends a signal to deploy the side airbag that completes the electrical circuits to the right or left side airbag The sensor is cali brated for the sp...

Страница 626: ...d on the right side of the airbag module Fig 1 The system is designed to operate at speeds above 30 mph 48 km h WARNING THE USE OF SPEED CONTROL IS NOT RECOMMENDED WHEN DRIVING CONDITIONS DO NOT PERMI...

Страница 627: ...de the interactive speed con trol tries to maintain the set speed by increasing the throttle opening while inhibiting delaying down shifts OPERATION If opening the throttle alone cannot maintain the s...

Страница 628: ...eter operation should be smooth and without flut ter at all speeds Flutter in the speedometer indicates a problem which might cause surging in the speed control sys tem The cause of any speedometer pr...

Страница 629: ...enoids Vacuum Vent Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage OPERATION The PCM controls the solenoid valve body The solenoid valve body control...

Страница 630: ...and are located on the steering wheel OPERATION The speed control system has five separate resis tive switches that provide a single multiplexed MUX voltage inputs to the PCM The switch names are ON...

Страница 631: ...ment It is made of plastic OPERATION The reservoir stores engine vacuum Manifold vac uum is supplied from the brake booster check valve The speed control vacuum supply hose has a check valve at the so...

Страница 632: ...n with the molded integral antenna mounted on the ignition housing The indicator light is located in the message center OPERATION VEHICLE THEFT SECURITY SYSTEM Upon failure of proper SKIM communicatio...

Страница 633: ...y locking the front doors with the doors closed and the ignition locked will begin the arming time out period If method A 16 second time out sequence was in process when method B was actuated the 16 s...

Страница 634: ...use a DRB IIIt scan tool and the proper Body Diagnostic Procedures manual to complete the diagnosis of the SKIS If not OK repair the open circuit to the fuse in the IPM as required DIAGNOSIS AND TEST...

Страница 635: ...plete this task since you will need it to enter the Secured Access Mode in the SKIM The following steps must be completed using a DRB IIIt scan tool 1 Insert the blank key into the ignition and turn i...

Страница 636: ...if It sees a non blank Sentry Key when it should see a blank If it has already programmed eight 8 valid Sentry Keys If the ignition switch is turned to the OFF posi tion for more than about fifty 50 s...

Страница 637: ......

Страница 638: ...AR WIPER MOTOR REMOVAL 16 INSTALLATION 16 REAR WIPER WASHER SWITCH DESCRIPTION 16 OPERATION 16 WASHER FLUID LEVEL SWITCH REMOVAL 16 INSTALLATION 17 WASHER HOSES REMOVAL 17 INSTALLATION 17 WASHER RESER...

Страница 639: ...ery 7 seconds The intermit tent delay time is also adjusted based upon vehicle speed With the vehicle traveling greater than 50 mph the cycle changes to every 5 seconds DIAGNOSIS AND TESTING DIAGNOSIS...

Страница 640: ...TO WIPER ARM REMOVAL AND INSTALLATION 3 MOTOR CRANK LOOSE AT OUTPUT SHAFT 3 REMOVE WIPER ARM RUN WIPER MOTOR TO PARK POSITION AND REMOVE THE MODULE WITHOUT ROTATING THE MOTOR OUTPUT SHAFT REMOVE THE...

Страница 641: ...ACE WIPER MOTOR REFER TO WIPER MOTOR REMOVAL AND INSTALLATION WIPER MOTOR WILL NOT RUN 1 BLOWN FUSE 1 REPLACE FUSE AND RUN SYSTEM 2 NEW FUSE BLOWS 2 CHECK FOR SHORT IN WIRING OR SWITCH 3 NEW FUSE BLOW...

Страница 642: ...E 2 PROPERLY INSTALL IPM FUSE 33 IN SOCKET BLOWN FUSE WHEN IGNITION SWITCH IS IN THE RUN OR ACCESSORY POSITION 1 SHORT IN IPM BETWEEN FUSE 33 AND PIN 11 OR PIN 1 1 REFER TO IPM DIAGNOSTIC PROCEDURES I...

Страница 643: ...IRCUIT BETWEEN IPM BODY CONTROLLER PIN 22 AND WASHER SELECT SWITCH PIN 2 IF NOT OK REPAIR CIRCUIT 7 OPEN OR DEFECTIVE WASHER SELECT SWITCH 7 Refer to 8 ELECTRICAL LAMPS LIGHTING EXTERIOR MULTI FUNCTIO...

Страница 644: ...OUTPUT IS LOW 1 PARTIALLY PINCHED HOSE 1 ASSURE WASHER HOSE IS NOT PARTIALLY PINCHED IF NOT OK PROPERLY ROUTE HOSE 2 REVERSE POLARITY TO PUMP 2 CHECK FOR CROSSED CIRCUIT TO PUMP IF NOT OK REPAIR CIRCU...

Страница 645: ...4 REFER TO IPM DIAGNOSTIC PROCEDURES IN WIRING DIAGRAMS 5 FLUID LEVEL SENSOR SWITCH OPEN OR DEFECTIVE 5 APPLY OHMMETER TO THE SWITCH TERMINALS TO CHECK FOR COMPLETE CIRCUIT CYCLE SWITCH FLOAT BACK AND...

Страница 646: ...nst the reservoir and that pump connector is fac ing up in the fully seated position Assure the pump is aligned to and fully seated in the reservoir cavity 3 Push filler neck and front washer hose thr...

Страница 647: ...EMOVAL 1 Remove the front wiper motor from vehicle Refer to 8 ELECTRICAL WIPERS WASHERS WIPER MODULE REMOVAL 2 Remove four backwall bolts and four brace nuts 3 Remove wiper linkage from wiper module 4...

Страница 648: ...rs headlamps ON and windshield washer control depressed the headlamp washers will spray its two timed pulses every fourth request from the washer control DIAGNOSIS AND TESTING HEADLAMP WASHERS EXPORT...

Страница 649: ...IPER WASHER SWITCH TERMINAL 1 AND 2 AND DEPRESS WASHER BUTTON AND CHECK FOR CONTINUITY IF NOT OK REFER TO WIPER WASHER SWITCH DIAGNOSTIC PROCEDURES 8 OPEN POWER CIRCUIT TO MOTOR 8 OPEN OR DEFECTIVE CI...

Страница 650: ...firmly until snap is heard 8 Remove vehicle from hoist or jack stands 9 Connect the battery negative cable 10 Verify vehicle and system operation HEADLAMP WASHER HOSE EXPORT REMOVAL The headlamp washe...

Страница 651: ...r hose by firmly pushing hose onto inlet until a snap is heard 8 Connect the left right front wheelhouse splash shield and move aside Refer to 23 BODY EXTERI OR WHEELHOUSE SPLASH SHIELD INSTALLA TION...

Страница 652: ...evel sen sor Slide the red lock on the connector to the closed or locked position 6 Assure that washer hose is properly routed to prevent pinching and possible inoperative washers 7 Connect the left r...

Страница 653: ...REAR WIPER WASHER SWITCH DESCRIPTION The rear window wiper washer switches are located on the center bezel with the hazard and heated seat switches Fig 7 They are not service able separately from the...

Страница 654: ...sh filler neck and front washer hose through the opening in the front fender side shield Connect the reservoir to the body mount by lowering the res ervoir down 4 Install the two reservoir mounting sc...

Страница 655: ...hat the reservoir filler neck and front washer hose pull through the opening in the front fender side shield INSTALLATION 1 Push filler neck and front washer hose through the opening in the front fend...

Страница 656: ...iper unit 4 Remove cowl cover brackets from the wiper unit 5 Remove nuts holding linkage to the wiper unit 6 Remove the wiper linkage from the wiper unit 7 Disconnect the wire connectors from back of...

Страница 657: ...nector to the wiper module Fig 11 7 Connect the positive lock on the wiper module wire connector Fig 10 CAUTION Do not allow wiper module to rest on brake master cylinder reservoir damage to brake sys...

Страница 658: ...USTER 8W 40 1 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 AIR CONDITIONING HEATER 8W 42 1 AIRBAG SYSTEM 8W 43 1 INTERIOR LIGHTING 8W 44 1 BODY CONTROL MODULE 8W 45 1 MESSAGE CENTER 8W 46 1 AUDIO SYSTEM 8W...

Страница 659: ......

Страница 660: ...iring content In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles it is important to understand all of their features and characteris tics Diagr...

Страница 661: ...Fig 1 WIRING DIAGRAM EXAMPLE 1 8W 01 2 8W 01 WIRING DIAGRAM INFORMATION RS WIRING DIAGRAM INFORMATION Continued...

Страница 662: ...Fig 2 WIRING DIAGRAM EXAMPLE 2 RS 8W 01 WIRING DIAGRAM INFORMATION 8W 01 3 WIRING DIAGRAM INFORMATION Continued...

Страница 663: ...Fig 3 WIRING DIAGRAM SYMBOLS 8W 01 4 8W 01 WIRING DIAGRAM INFORMATION RS WIRING DIAGRAM INFORMATION Continued...

Страница 664: ...t Vehicles Built For Sale In North America DESCRIPTION CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit part of the main circuit gage of wire and c...

Страница 665: ...r group it will be shown complete all wires connectors and pins within that group For exam ple the Auto Shutdown Relay is most likely to be found in Group 30 so it is shown there complete It can howev...

Страница 666: ...general warnings that should be followed any time a vehicle is being serviced WARNING ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION WARNING USE SAFETY STANDS ANYTIME A PRO CEDURE REQUIRES BEING UNDER...

Страница 667: ...for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify these add on items are not the cause of the problem 1 Verify...

Страница 668: ...r lead to the other end of the circuit being tested Low or no resistance means good continuity STANDARD PROCEDURE TESTING FOR A SHORT TO GROUND 1 Remove the fuse and disconnect all items involved with...

Страница 669: ...round has been isolated STANDARD PROCEDURE TESTING FOR A VOLTAGE DROP 1 Connect the positive lead of the voltmeter to the side of the circuit closest to the battery Fig 9 2 Connect the other lead of t...

Страница 670: ...moved terminal in the same cavity on the repair connector 2 Repeat steps for each terminal in the connec tor being sure that all wires are inserted into the proper cavities For additional connector pi...

Страница 671: ...Fig 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 Secondary Terminal Lock 8W 01 12 8W 01 WIRING DIAGRAM INFORMATION RS CONNECTOR Continued...

Страница 672: ...APEX CONNECTOR 4 PICK FROM SPECIAL TOOL KIT 6680 5 AUGAT CONNECTOR 6 SPECIAL TOOL 6932 7 MOLEX CONNECTOR 8 SPECIAL TOOL 6742 9 THOMAS AND BETTS CONNECTOR 10 SPECIAL TOOL 6934 11 TYCO CONNECTOR 12 SPE...

Страница 673: ...ected sys tems TERMINAL REMOVAL 1 Follow steps for removing terminals described in the connector removal section 2 Cut the wire 6 inches from the back of the con nector INSTALLATION 1 Select a wire fr...

Страница 674: ...of the splice clip Fig 14 4 Using crimping tool Mopar p n 05019912AA crimp the splice clip and wires together Fig 15 5 Solder the connection together using rosin core type solder only Fig 16 CAUTION...

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Страница 676: ...trol Module 8W 30 Engine Coolant Temp Sensor 8W 30 Engine Oil Pressure Switch 8W 30 EVAP Purge Solenoid 8W 30 Evaporator Temperature Sensor 8W 42 Floor Console Lamp 8W 44 Component Page Fog Lamps 8W 5...

Страница 677: ...W 42 Rear Blower Motor 8W 42 Rear Blower Rear Control Switch 8W 42 Rear Intrusion Sensor 8W 39 Component Page Rear Lamp Assemblies 8W 51 Rear Mode Motor 8W 42 Rear Power Outlet 8W 41 Rear Temperature...

Страница 678: ...dule 8W 10 19 38 Front Blower Motor Relay 8W 10 18 19 38 63 Front Cigar Lighter 8W 10 16 32 Front Control Module 8W 10 15 16 17 18 19 20 22 24 26 27 28 29 30 31 36 37 38 39 45 47 52 53 54 57 58 59 60...

Страница 679: ...ror Switch 8W 10 22 24 46 47 Power Outlet 8W 10 36 Component Page Power Seat Circuit Breaker 8W 10 25 49 Power Window Circuit Breaker 8W 10 16 31 Power Window Switch 8W 10 34 Powertrain Control Module...

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Страница 746: ...Ajar Switch 8W 15 14 Left Sliding Door Motor 8W 15 14 Left Stop Turn Signal Relay 8W 15 24 Left Turn Signal Lamp 8W 15 18 Left Visor Vanity Lamp 8W 15 21 License Lamp 8W 15 23 26 Lift Pump Motor 8W 15...

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Страница 772: ...8W 18 2 3 G101 8W 18 2 3 G300 8W 18 2 3 Instrument Cluster 8W 18 4 Component Page Integrated Power Module 8W 18 2 3 Integrated Power Module 8W 18 4 Left Side Impact Airbag Control Module 8W 18 5 Left...

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Страница 778: ...sor 8W 20 3 ECM PCM Relay 8W 20 3 Engine Control Module 8W 20 3 Fuse 16 8W 20 2 3 Fuse 17 8W 20 2 Component Page Fuselink 8W 20 2 3 G100 8W 20 2 3 G101 8W 20 2 3 Generator 8W 20 2 3 Integrated Power M...

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Страница 782: ...W 21 2 Engine Control Module 8W 21 3 Front Control Module 8W 21 2 Fuse 9 8W 21 2 3 Fuselink 8W 21 2 3 Component Page G101 8W 21 2 3 Generator 8W 21 2 3 Ignition Switch 8W 21 2 3 Integrated Power Modul...

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Страница 786: ...id 8W 30 20 Fuel Pump Module 8W 30 4 19 Fuel Pump Relay 8W 30 4 Fuse 14 8W 30 17 Fuse 15 8W 30 22 29 Fuse 16 8W 30 2 5 7 8 12 13 18 20 24 26 28 Fuse 17 8W 30 2 4 19 29 Component Page Fuse 18 8W 30 18...

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Страница 818: ...8W 31 5 Ignition Switch 8W 31 9 Component Page Input Speed Sensor 8W 31 5 Integrated Power Module 8W 31 2 4 5 6 7 8 9 Output Speed Sensor 8W 31 5 Park Neutral Position Switch 8W 31 9 Powertrain Contr...

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Страница 828: ...33 4 Engine Control Module 8W 33 4 G103 8W 33 3 G300 8W 33 4 Component Page Left Speed Control Switch 8W 33 2 4 Powertrain Control Module 8W 33 2 3 Right Speed Control Switch 8W 33 2 4 Speed Control...

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Страница 832: ...ol Module 8W 35 3 Fuse 9 8W 35 2 Fuse 21 8W 35 2 Fuse 26 8W 35 3 G100 8W 35 2 Component Page G200 8W 35 2 G300 8W 35 3 Integrated Power Module 8W 35 2 3 Left Front Wheel Speed Sensor 8W 35 4 Left Rear...

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Страница 836: ...ontrol Module 8W 39 9 10 Component Page Left Sliding Door Latch Sensing Switch 8W 39 9 Left Sliding Door Lock Motor 8W 39 10 Left Sliding Door Lock Motor Ajar Switch 8W 39 11 Liftgate Ajar Switch 8W 3...

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Страница 852: ...itch 8W 40 3 Left Sliding Door Control Module 8W 40 4 Left Sliding Door Latch Sensing Switch 8W 40 4 Component Page Left Sliding Door Lock Motor Ajar Switch 8W 40 4 Left Speed Control Switch 8W 40 9 L...

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Страница 864: ...3 Front Control Module 8W 41 2 3 4 Fuse 5 8W 41 3 4 Fuse 6 8W 41 3 4 Fuse 8 8W 41 2 G102 8W 41 2 G200 8W 41 3 4 Component Page G302 8W 41 3 4 High Note Horn 8W 41 2 Horn Relay 8W 41 2 Horn Switch 8W...

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Страница 868: ...7 Fuse 18 8W 42 14 16 Fuse 27 8W 42 15 18 Fuselink 8W 42 17 G102 8W 42 15 18 Component Page G103 8W 42 14 16 G200 8W 42 2 3 4 6 8 9 11 12 G300 8W 42 7 13 G302 8W 42 12 Integrated Power Module 8W 42 2...

Страница 869: ...2002 RS Service Manual Publication No 81 370 02062 TSB 26 12 01 December 2001...

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Страница 873: ...2002 RS Service Manual Publication No 81 370 02062 TSB 26 12 01 December 2001...

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Страница 886: ...nsioner 8W 43 3 Front Control Module 8W 43 2 6 7 G200 8W 43 2 G201 8W 43 2 6 7 Component Page Instrument Cluster 8W 43 2 Integrated Power Module 8W 43 2 6 7 Left Seat Airbag 8W 43 6 Left Side Impact A...

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Страница 894: ...alo Lamp 8W 44 2 Headlamp Switch 8W 44 3 5 6 7 8 Component Page Instrument Cluster 8W 44 7 Instrument Panel Switch Bank 8W 44 7 Integrated Power Module 8W 44 4 Left Liftgate Flood Lamp 8W 44 2 Left Mi...

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Страница 902: ...r Lock Motor 8W 45 7 Left Sliding Door Lock Motor Ajar Switch 8W 45 7 8 Component Page Left Stop Turn Signal Relay 8W 45 5 Left Visor Vanity Lamp 8W 45 13 License Lamp 8W 45 8 Liftgate Ajar Switch 8W...

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Страница 922: ...6 MESSAGE CENTER Component Page Body Control Module 8W 46 2 Fuse 24 8W 46 2 Instrument Cluster 8W 46 2 Component Page Integrated Power Module 8W 46 2 Message Center 8W 46 2 RS 8W 46 MESSAGE CENTER 8W...

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Страница 924: ...tegrated Power Module 8W 47 2 5 6 Left Door Speaker 8W 47 3 8 9 Component Page Left Instrument Panel Speaker 8W 47 3 8 Left Rear Pillar Speaker 8W 47 10 Left Rear Speaker 8W 47 4 6 10 Left Remote Radi...

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Страница 936: ...gger Relay 8W 48 2 Electric Wiper De Icer 8W 48 2 Front Control Module 8W 48 2 Fuse 11 8W 48 2 Fuse 13 8W 48 2 Component Page G200 8W 48 3 G400 8W 48 2 Integrated Power Module 8W 48 2 Left Power Mirro...

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Страница 940: ...49 2 3 4 Diagnostic Junction Port 8W 49 4 Front Control Module 8W 49 2 Front Reading Lamps Switch 8W 49 4 Fuse 14 8W 49 2 Component Page G301 8W 49 4 Integrated Power Module 8W 49 2 Left Power Mirror...

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Страница 944: ...7 8 9 10 11 Left Fog Lamp 8W 50 11 Left Front Park Turn Signal Lamp 8W 50 4 Component Page Left Headlamp 8W 50 3 Left Headlamp Leveling Motor 8W 50 6 10 Left High Beam Lamp 8W 50 6 7 Left Low Beam La...

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Страница 956: ...se 2 8W 51 2 4 Fuse 3 8W 51 2 4 5 Fuse 26 8W 51 2 4 G101 8W 51 5 G103 8W 51 5 Component Page G302 8W 51 2 3 4 5 G400 8W 51 6 Integrated Power Module 8W 51 2 4 5 Left Rear Lamp Assembly 8W 51 2 3 4 5 L...

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Страница 962: ...Park Turn Signal Lamp 8W 52 2 Left Rear Lamp Assembly 8W 52 4 Component Page Left Repeater Lamp 8W 52 6 Left Stop Turn Signal Relay 8W 52 4 5 Left Turn Signal Lamp 8W 52 3 Multi Function Switch 8W 52...

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Страница 968: ...8W 53 2 Fuse 4 8W 53 2 Fuse 11 8W 53 3 Fuse 30 8W 53 4 Fuse 33 8W 53 3 G102 8W 53 4 Component Page G200 8W 53 6 G300 8W 53 2 G400 8W 53 3 Headlamp Washer Pump Motor 8W 53 4 Headlamp Washer Relay 8W 53...

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Страница 974: ...W 54 2 G302 8W 54 2 Integrated Power Module 8W 54 2 Left Combination Relay 8W 54 3 Component Page Left Rear Lamp Assembly 8W 54 2 Left Stop Turn Signal Relay 8W 54 2 3 Park Lamp Relay 8W 54 2 Right Co...

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Страница 978: ...l Module 8W 60 2 Fuse 28 8W 60 2 G300 8W 60 3 4 7 G301 8W 60 5 6 Component Page Integrated Power Module 8W 60 2 Left Rear Vent Motor 8W 60 3 6 Passenger Power Window Motor 8W 60 5 7 Passenger Power Wi...

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Страница 986: ...61 7 9 Left Sliding Door Lock Motor 8W 61 13 Component Page Left Sliding Door Lock Motor Ajar Switch 8W 61 14 Left Sliding Door Motor 8W 61 8 License Lamp 8W 61 18 19 Liftgate Ajar Switch 8W 61 15 Li...

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Страница 1006: ...W 62 2 3 4 5 10 Integrated Power Module 8W 62 2 3 4 5 9 10 Left Power Mirror 8W 62 2 4 7 8 9 10 Component Page Memory Seat Mirror Module 8W 62 3 6 7 8 Memory Set Switch 8W 62 3 Passenger Folding Mirro...

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Страница 1016: ...ecliner Motor 8W 63 2 7 Driver Power Seat Recliner Position Sensor 8W 63 8 Component Page Driver Power Seat Switch 8W 63 2 6 Fuse 22 8W 63 2 4 G200 8W 63 2 4 6 9 G301 8W 63 3 10 Instrument Panel Switc...

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Страница 1026: ...05 8W 42 7 S206 8W 10 50 S207 8W 42 5 S208 8W 45 10 S209 8W 18 5 S210 8W 10 45 47 S211 8W 47 7 Component Page S212 8W 47 7 S302 8W 18 5 S303 8W 10 35 S304 8W 10 65 S305 8W 63 8 S306 8W 45 5 6 S307 8W...

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Страница 1032: ...W 80 17 C102 3 3L 3 8L 8W 80 17 C102 3 3L 3 8L 8W 80 18 C103 Diesel 8W 80 18 C103 Diesel 8W 80 18 C106 Built Up Export 8W 80 18 C106 Built Up Export 8W 80 19 C107 Built Up Export 8W 80 19 C107 Built U...

Страница 1033: ...W 80 50 Driver Power Seat Horizontal Motor 8W 80 50 Driver Power Seat Horizontal Position Sensor 8W 80 51 Driver Power Seat Rear Riser Motor 8W 80 51 Driver Power Seat Rear Riser Position Sensor 8W 80...

Страница 1034: ...uilt Up Export 8W 80 74 Component Page Left Instrument Panel Speaker 8W 80 75 Left Liftgate Flood Lamp 8W 80 75 Left Low Beam Lamp Built Up Export 8W 80 75 Left Mid Reading Lamp Premium Luxury 8W 80 7...

Страница 1035: ...Fan Relay Gas 8W 80 96 Radiator Fan Relay No 1 Diesel 8W 80 97 Radiator Fan Relay No 2 Diesel 8W 80 97 Radiator Fan Relay No 3 Diesel 8W 80 97 Radio C1 8W 80 98 Radio C2 8W 80 98 Radio Choke 8W 80 99...

Страница 1036: ...tor Power Sliding Door 8W 80 110 Right Speed Control Switch 8W 80 110 Right Stop Turn Signal Relay Trailer Tow 8W 80 110 Component Page Right Turn Signal Lamp Built Up Export 8W 80 111 Right Visor Van...

Страница 1037: ...ENSOR GROUND 3 C22 20LB WT 3 ZONE HVAC REAR TEMPERATURE FEEDBACK SIGNAL 4 5 F850 20LB PK 3 ZONE HVAC 5 VOLT SUPPLY 6 C900 18LB VT WIPER DE ICER DRIVER 7 C32 20DB TN RECIRCULATION DOOR DRIVER A 8 C54 2...

Страница 1038: ...2 20OR DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL 8 K167 20BR YL ACCELERATOR PEDAL POSITION SENSOR GROUND 9 10 F852 20VT PK ACCELERATOR PEDAL POSITION SENSOR 5 VOLT SUPPLY ADJUSTABLE PEDALS MODULE EX...

Страница 1039: ...18LG OR DRIVER SQUIB 1 LINE 2 13 14 F201 18PK OR FCM OUTPUT ORC RUN START DRIVER 15 F100 18PK VT FCM OUTPUT ORC RUN ONLY DRIVER 16 Z12 18BK OR GROUND 17 R59 18LG TN DRIVER SEAT BELT SWITCH LINE 1 18 R...

Страница 1040: ...R GY PANEL LAMPS DRIVER 4 A114 20GY RD FUSED B I O D 5 F504 20GY PK FUSED IGNITION SWITCH OUTPUT RUN 6 D25 20WT VT PCI BUS 7 C56 20DB LB BLOWER MOTOR CONTROL 8 C59 20DB LB REAR BLOWER MOTOR CONTROL 9...

Страница 1041: ...TN BATTERY TEMPERATURE SENSOR SIGNAL 2 K900 20DB DG SENSOR GROUND BLOWER MOTOR RESISTOR C1 MTC BLACK 6 WAY CAV CIRCUIT FUNCTION 1 C75 12DB GY BLOWER MOTOR HIGH DRIVER 2 C74 12DB WT BLOWER MOTOR M3 DRI...

Страница 1042: ...DRIVER 13 14 15 Z15 18BK TN GROUND 16 G920 20VT YL MEMORY MEMORY SELECT SWITCH RETURN 17 G153 20VT YL POWER LIFTGATE LIFTGATE MODULE WAKE UP SIGNAL 18 P32 20TN VT LEFT SLIDING DOOR LOCK DRIVER 19 Z10...

Страница 1043: ...G165 20VT GY LIFTGATE CYLINDER LOCK SWITCH MUX 14 G163 20VT LB LEFT CYLINDER LOCK SWITCH MUX 15 G162 20VT WT EXCEPT BUILT UP EXPORT RIGHT CYLINDER LOCK SWITCH MUX 15 G162 20VT TN BUILT UP EXPORT RIGH...

Страница 1044: ...IVER 10 F504 20GY PK FUSED IGNITION SWITCH OUTPUT RUN 11 E14 20OR TN PANEL LAMPS DRIVER RADIO 12 E13 20OR YL PANEL LAMPS DRIVER INSTRUMENT CLUSTER 13 X920 20GY OR RADIO CONTROL MUX RETURN 14 G900 20VT...

Страница 1045: ...ASHER SWITCH MUX 28 W26 20BR DB REAR WIPER SWITCH MUX 29 W52 20BR YL FRONT WIPER SWITCH MUX 30 E2 20OR BR PANEL LAMPS DIMMER SIGNAL 31 L305 20WT LB TURN SIGNAL SWITCH MUX 32 33 34 L39 20WT OR HIGH LIN...

Страница 1046: ...TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL 2 F2 18PK YL FCM OUTPUT UNLOCK RUN START C100 BLACK BODY SIDE CAV CIRCUIT 1 D21 20WT DG BUILT UP EXPORT 1 D21 20WT BR EXCEPT BUILT UP EXPORT 2 D16 20WT O...

Страница 1047: ...BRAKES 14 B2 18DG LB ANTILOCK BRAKES C101 LT GRAY BODY SIDE CAV CIRCUIT 1 L50 18WT TN 2 3 F853 20LG PK DIESEL 4 K900 18DB DG DIESEL 5 B4 18DG GY ANTILOCK BRAKES 6 B3 18DG YL ANTILOCK BRAKES 7 F500 18D...

Страница 1048: ...K POWERTRAIN SIDE CAV CIRCUIT 1 K11 16BR YL 2 K12 16BR DB 3 K13 16BR LB 4 K14 16BR TN 5 K342 16BR WT 6 K900 18DB DG 7 K2 18VT OR 8 K1 18VT BR 9 10 F855 18PK YL C102 3 3L 3 8L BLACK FUEL RAIL SIDE CAV...

Страница 1049: ...CIRCUIT 1 K342 16BR WT 2 K342 16BR WT 3 N122 20DB YL 4 N210 20DB DG 5 A201 12RD LG 6 C103 DIESEL BLACK FRONT END LIGHTING SIDE CAV CIRCUIT 1 K342 16BR WT 2 K342 16BR WT 3 N122 20DB YL 4 N210 18DB DG 5...

Страница 1050: ...BLACK FRONT END LIGHTING SIDE CAV CIRCUIT 1 L44 16WT TN 2 L34 16WT GY 3 L78 18WT OR 4 L60 16WT TN 5 Z344 16BK TN 6 L13 20WT YL 7 Z203 20BK YL 8 Z378 18BK TN DIESEL 8 Z378 18BK LB GAS C107 BUILT UP EX...

Страница 1051: ...PORT AUTOMATIC TEMPERATURE CONTROL 12 C153 12DB BR 3 ZONE HVAC 13 Z849 12BK OR 14 A105 16DB RD BUILT UP EXPORT 14 A105 18DB RD EXCEPT BUILT UP EXPORT 15 A114 16GY RD 16 F306 16DB PK 17 C154 20LB OR 3...

Страница 1052: ...EPT BUILT UP EXPORT POWER MIRRORS TOWN COUNTRY 47 D23 20WT BR RHD 48 P114 20TN WT EXCEPT BUILT UP EXPORT POWER MIRRORS 48 B25 20DG WT BUILT UP EXPORT 49 C154 20LB OR AUTOMATIC TEMPERATURE CONTROL 3 ZO...

Страница 1053: ...PERATURE CONTROL 13 Z849 12BK OR 14 A105 16DB RD 15 A114 16GY RD 16 F306 16DB PK 17 C169 20DB OR AUTOMATIC TEMPERATURE CONTROL 17 C154 20LB OR 3 ZONE HVAC 18 C121 20DB DG 3 ZONE HVAC 18 D22 20WT TN EX...

Страница 1054: ...LB PREMIUM 8 SPEAKER 52 X154 20GY YL PREMIUM 8 SPEAKER 53 R57 18LG GY 54 R58 18LB GY 55 R59 18LG TN 56 R60 18DB LB 57 T55 20YL VT AUTOSTICK 57 P162 20LG DG BUILT UP EXPORT 58 T751 20YL 59 X15 16GY DG...

Страница 1055: ...RE CONTROL 12 C21 20DB LG 13 C121 20DB DG C202 GRAY COMPONENT SIDE CAV CIRCUIT 1 Z134 12BK OR AUTOMATIC TEMPERATURE CONTROL 2 C34 20DB LB MANUAL TEMPERATURE CONTROL 2 C56 20DB LB AUTOMATIC TEMPERATURE...

Страница 1056: ...16WT PK EXCEPT POWER WINDOWS 9 10 11 Q13 16OR DB POWER WINDOWS 12 Q23 16OR LB POWER WINDOWS 13 Q14 16OR GY POWER WINDOWS 14 Q24 16OR DG POWER WINDOWS C300 LHD BLACK BODY SIDE CAV CIRCUIT 1 G75 20VT 2...

Страница 1057: ...8 F304 12WT PK 9 10 C301 LT GRAY LEFT DOOR SIDE CAV CIRCUIT 1 M21 20YL BR 2 X13 16DG GY 3 X15 16GY DG 4 X153 20DG YL 5 X155 20DG LB 6 G163 20VT LB POWER LOCKS 7 G200 20VT BR MEMORY 8 G920 20VT YL MEMO...

Страница 1058: ...GY YL 5 X156 20GY LB 6 G162 20VT TN POWER LOCKS BUILT UP EXPORT 6 G162 20VT WT POWER LOCKS EXCEPT BUILT UP EXPORT 7 G200 20VT BR RHD MEMORY 8 G920 20VT YL RHD MEMORY 9 Q16 12OR TN 10 Q26 12OR GY C303...

Страница 1059: ...AV CIRCUIT 1 G74 20VT WT 2 Z821 12BK BR 3 X54 20GY 4 X56 20GY BR 5 G160 20VT LG 6 P2 20TN GY 7 P4 20TN BR 8 F304 12WT PK 9 10 11 Q13 16OR DB 12 Q23 16OR LB 13 Q14 16OR GY 14 Q24 16OR DG C303 RHD BLACK...

Страница 1060: ...4 R33 18LG WT C305 GRAY BODY SIDE CAV CIRCUIT 1 Z849 12BK OR 2 R57 18LG GY 3 R59 18LG TN 4 P7 20LG DG 5 A210 14OR RD 6 F503 20WT PK 7 A110 12OR RD 8 9 10 11 12 13 C305 GRAY SEAT SIDE CAV CIRCUIT 1 Z84...

Страница 1061: ...DG RHD 2 R56 18LB DG LHD 3 R32 18LB OR 4 R34 18LB WT C307 GRAY BODY SIDE CAV CIRCUIT 1 Z848 12BK OR 2 R58 18LB GY 3 R60 18LB TN 4 P8 20LG WT 5 A210 14OR RD 6 F503 20WT PK 7 8 9 10 11 12 C307 GRAY SEAT...

Страница 1062: ...L SLIDING DOOR 1 Z825 14BK WT BUILT UP EXPORT MANUAL SLIDING DOOR POWER SLIDING DOOR 2 P32 20TN VT 3 G77 20VT GY 4 P5 20TN OR 5 6 7 G151 20VT BR POWER SLIDING DOOR 8 D25 20WT VT POWER SLIDING DOOR 9 1...

Страница 1063: ...8DB RD C310 FRONT CONSOLE BLACK FRONT CONSOLE SIDE CAV CIRCUIT 1 Z746 16BK 1 Z746 16BK 2 M27 18OR 3 A105 16RD C311 GRAY REAR A C JUMPER SIDE CAV CIRCUIT 1 C153 12 DB BR 3 ZONE HVAC 2 F850 20LB PK 3 ZO...

Страница 1064: ...20BK OR 3 ZONE HVAC 9 Z27 18BK DG AUTOMATIC TEMPERATURE CONTROL 10 C50 12DB OR 3 ZONE HVAC C312 GRAY HEADLINER SIDE CAV CIRCUIT 1 M27 20YL LB 2 M22 20YL OR 3 G23 20VT DB EXCEPT BASE 4 G25 20VT TN EXCE...

Страница 1065: ...OR EXCEPT BUILT UP EXPORT POWER MIRRORS TOWN COUNTRY 10 P114 20TN WT EXCPET BUILT UP EXPORT POWER MIRRORS 11 M24 20YL WT 12 Z837 20BK WT 13 Z13 20BK WT 14 Z113 20BK WT 15 16 17 18 19 20 C313 REAR CON...

Страница 1066: ...K C314 HIGH LINE BLACK LIFTGATE SIDE CAV CIRCUIT 1 G32 20VT LB POWER LIFTGATE 2 L77 18WT BR 3 L50 18WT TN 4 P30 20TN DG 5 P31 20TN YL POWER RELEASE 6 Q60 20OR YL POWER LIFTGATE 7 Q84 18TN GY POWER LIF...

Страница 1067: ...IDE CAV CIRCUIT 1 P5 20BK DB 2 P32 20BK TN 3 G77 20BK DG 4 Z825 14BK 5 6 7 G151 20BK GY 8 D25 20BK VT 9 10 A113 14BK RD C316 POWER SLIDING DOOR BLACK LEFT SLIDING DOOR SIDE CAV CIRCUIT 1 P5 20TN OR 2...

Страница 1068: ...18WT LG 5 Z363 18BK DG 6 L50 18WT TN C318 TRAILER TOW BLACK HARNESS SIDE CAV CIRCUIT 1 L63 18WT DG 1 L63 18WT DG 2 L62 18WT BR 3 L77 18WT BR 3 L77 18WT BR 4 L1 18WT LG 5 Z363 18BK DG 5 Z1 18BK DG 6 L5...

Страница 1069: ...20YL VT 8 W13 18BR LG 9 F302 18GY PK 10 Z800 12BK C320 DK GRAY SEAT SIDE CAV CIRCUIT 1 Z849 14BK OR 2 A210 14OR RD C320 DK GRAY POWER SEAT SIDE CAV CIRCUIT 1 Z849 14BK OR 2 A210 14OR RD C321 DK GRAY S...

Страница 1070: ...UP EXPORT 10 P71 18TN DG EXCEPT BUILT UP EXPORT 10 P71 18TN GY BUILT UP EXPORT 11 P70 18TN LB 12 P74 18TN DB 13 P72 18TN GY 14 C322 MEMORY BLACK POWER SEAT SIDE CAV CIRCUIT 1 P69 20TN WT 2 P67 20OR 3...

Страница 1071: ...AL SLIDING DOOR BLACK RIGHT MANUAL SLIDING DOOR SIDE CAV CIRCUIT 1 P38 20BK DB 2 P34 20BK TN 3 G76 20BK DG 4 Z76 20BK C326 YELLOW SEAT SIDE CAV CIRCUIT 1 2 3 R33 18LG WT 4 R31 18LG OR C326 YELLOW SAFE...

Страница 1072: ...Z201 18BK OR 3 N1 16DB OR 4 Z201 18BK OR 5 F853 20LG PK 6 K900 18DB DG C329 DIESEL BLACK LIFT PUMP SIDE CAV CIRCUIT 1 N2 18OR 2 Z201 18OR 3 N1 16RD 4 Z201 18RD 5 F853 20RD 6 K900 18RD C330 DIESEL LT...

Страница 1073: ...20LB 2 C169 20DB OR 3 C51 12LB BR 4 C59 20DB LB 5 6 Z135 12BK LB 7 C54 20LB YL 8 C154 20LB OR 9 10 C200 20LB DG C332 ATC BLACK COMPONENT SIDE CAV CIRCUIT 1 C53 18LB 2 C169 18LB TN 3 C51 12DB BR 4 C59...

Страница 1074: ...SUPPLY 2 K900 18DB DG SENSOR GROUND 3 K44 18DB GY CAMSHAFT POSITION SENSOR SIGNAL CD CHANGER 8 WAY CAV CIRCUIT FUNCTION 1 X40 24GY WT AUDIO OUT RIGHT 2 E14 18OR TN PANEL LAMPS DRIVER 3 D25 20WT VT EX...

Страница 1075: ...SQUIB 2 LINE 2 3 R43 18LG BR DRIVER SQUIB 1 LINE 1 4 R45 18LG OR DRIVER SQUIB 1 LINE 2 CLOCKSPRING C3 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 2 Z23 20BK VT RIGHT SPEED CONTROL SWITCH GROUND 2 Z23 20BK VT L...

Страница 1076: ...CAV CIRCUIT FUNCTION 1 T141 20YL OR IGNITION SWITCH OUTPUT START 2 T751 20YL IGNITION SWITCH OUTPUT START CLUTCH PEDAL INTERLOCK SWITCH JUMPER ATX BLACK 2 WAY CAV CIRCUIT FUNCTION 1 T141 20YL OR IGNI...

Страница 1077: ...DG YL LEFT REAR WHEEL SPEED SENSOR SIGNAL 20 B4 18DG GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUPPLY 21 22 B8 18DG TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL 23 B9 18DG WT 3 3L 3 8L LEFT FRONT WHEEL SPEED...

Страница 1078: ...EXPORT SCI TRANSMIT 8 9 D23 20WT BR FLASH PROGRAM ENABLE 10 11 12 13 14 D16 20WT OR GAS SCI RECEIVE 15 16 A105 20DB RD FUSED B DIAGNOSTIC JUNCTION PORT BLACK 16 WAY CAV CIRCUIT FUNCTION 1 D25 20WT VT...

Страница 1079: ...18OR LB DRIVER SQUIB 2 LINE 1 2 R63 18TN LB DRIVER SQUIB 2 LINE 2 DRIVER BLEND DOOR ACTUATOR ATC GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C61 20DB LG DRIVER BLEND DOOR DRIVER A 2 C161 20LB WT DRIVER BLEND DO...

Страница 1080: ...SEAT BACK GREEN 2 WAY CAV CIRCUIT FUNCTION 1 S2 18BK RHD DRIVER SEAT BACK HEATER GROUND 1 S2 18DG LHD DRIVER SEAT BACK HEATER GROUND 2 S1 18RD RHD DRIVER SEAT BACK HEATER B DRIVER 2 S1 18DB LHD DRIVER...

Страница 1081: ...RIVER 1 P19 14LG LB DRIVER FRONT UP SWITCH SENSE 2 P121 14LG DB MEMORY SEAT FRONT DOWN DRIVER 2 P21 14LG TN DRIVER FRONT DOWN SWITCH SENSE DRIVER POWER SEAT FRONT RISER POSITION SENSOR BLACK 3 WAY CAV...

Страница 1082: ...RISER POSITION SENSOR BLACK 3 WAY CAV CIRCUIT FUNCTION A P28 20LG BR SEAT POSITION SENSOR GROUND B P27 20LG LB REAR RISER POSITION SIGNAL C P29 20LG WT SEAT SENSOR 5 VOLT SUPPLY DRIVER POWER SEAT REC...

Страница 1083: ...P13 20LG OR MEMORY SEAT REAR DOWN SWITCH SENSE 9 P13 14LG OR DRIVER SEAT REAR DOWN SWITCH SENSE 10 P21 14LG TN DRIVER FRONT DOWN SWITCH SENSE 10 P21 20LG TN MEMORY SEAT FRONT DOWN SWITCH SENSE DRIVER...

Страница 1084: ...R GY MASTER WINDOW SWITCH PASSENGER DOWN 5 Q13 16OR DB DRIVER SIDE REAR WINDOW CLOSE 6 Q16 12OR TN MASTER WINDOW SWITCH PASSENGER UP 7 Q24 16OR DG PASSENGER SIDE REAR WINDOW OPEN 8 F304 16WT PK FUSED...

Страница 1085: ...AY CAV CIRCUIT FUNCTION 1 K35 18DB VT EGR SOLENOID CONTROL 2 F202 18PK GY FUSED IGNITION SWITCH OUTPUT RUN START ELECTRIC WIPER DE ICER C1 WHITE 2 WAY CAV CIRCUIT FUNCTION 1 F302 18GY PK FUSED ACCESSO...

Страница 1086: ...4 K3 20BR OR CRANKSHAFT POSITION SENSOR SIGNAL NO 1 25 26 27 28 29 30 G6 20VT GY ENGINE OIL PRESSURE SENSOR SIGNAL 31 F853 20LG PK WATER IN FUEL SENSOR SIGNAL 32 K25 20BR TN BATTERY TEMPERATURE SENSOR...

Страница 1087: ...20WT LOW IDLE POSITION SWITCH SENSE 65 66 K936 20BR YL ENGINE OIL PRESSURE SENSOR GROUND 67 68 69 C13 20LB OR A C COMPRESSOR CLUTCH RELAY CONTROL 70 N210 20DB DG LOW SPEED RADIATOR FAN RELAY CONTROL 7...

Страница 1088: ...09 110 111 112 K119 20DB LG CLUTCH PEDAL UPSTOP SWITCH SENSE 113 114 115 K14 14LB BR FUEL INJECTOR NO 4 CONTROL 116 K111 14DB LB COMMON INJECTOR DRIVER 117 118 K11 14WT DB FUEL INJECTOR NO 1 CONTROL 1...

Страница 1089: ...936 20BR YL ENGINE OIL PRESSURE SENSOR GROUND ENGINE OIL PRESSURE SWITCH GAS LT GREEN 2 WAY CAV CIRCUIT FUNCTION 1 G6 16VT GY ENGINE OIL PRESSURE SWITCH SENSE 2 ENGINE OIL TEMPERATURE SENSOR DIESEL BL...

Страница 1090: ...RD REAR CONSOLE ACCESSORY RELAY POSITION FUSED ACCESSORY RELAY OUTPUT 1 F307 16RD REAR CONSOLE BATTERY POSITION FUSED B 1 A105 16RD FRONT CONSOLE FUSED B 2 3 Z747 16BK REAR CONSOLE GROUND 3 Z746 16BK...

Страница 1091: ...20BK LB GROUND 3 4 M27 20YL LB READING LAMPS DRIVER 5 M24 20YL WT COURTESY LAMPS DRIVER 6 FRONT WASHER PUMP MOTOR BLACK 2 WAY CAV CIRCUIT FUNCTION 1 W10 18BR FRONT WASHER PUMP MOTOR CONTROL 2 F300 18...

Страница 1092: ...R NO 2 DRIVER FUEL INJECTOR NO 2 DIESEL BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K111 14DB LB COMMON INJECTOR DRIVER 2 K12 14TN FUEL INJECTOR NO 2 CONTROL FUEL INJECTOR NO 3 2 4L 3 3L 3 8L BLACK 2 WAY CAV C...

Страница 1093: ...O 5 3 3L 3 8L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K38 16BR OR FUEL INJECTOR NO 5 DRIVER FUEL INJECTOR NO 6 3 3L 3 8L BLACK 2 WAY CAV CIRCUIT FUNCTION 1 K...

Страница 1094: ...1 K342 16BR WT DIESEL ECM PCM RELAY OUTPUT 1 K342 16BR WT GAS AUTOMATIC SHUT DOWN RELAY OUTPUT 2 K20 14BR GY DIESEL GENERATOR FIELD CONTROL 2 K20 18BR GY GAS GENERATOR FIELD CONTROL GLOVE BOX LAMP BLU...

Страница 1095: ...MUX 12 E2 20OR BR PANEL LAMPS DIMMER SIGNAL 13 HEADLAMP WASHER PUMP MOTOR BUILT UP EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 V53 12BR OR HEADLAMP WASHER RELAY OUTPUT 2 Z243 12BK OR GROUND HIGH NOTE HO...

Страница 1096: ...DRIVER 2 K342 16BR WT AUTOMATIC SHUT DOWN RELAY OUTPUT 3 K19 16DB DG IGNITION COIL NO 1 DRIVER 4 K17 16DB TN IGNITION COIL NO 2 DRIVER IGNITION SWITCH BLACK 5 WAY CAV CIRCUIT FUNCTION 1 G900 20VT OR...

Страница 1097: ...8DG WT LHD BUILT UP EXPORT PARK BRAKE SWITCH SENSE 10 B25 20DG WT RHD PARK BRAKE SWITCH SENSE 10 B25 16DG WT LHD EXCEPT BUILT UP EXPORT PARK BRAKE SWITCH SENSE 11 G26 20VT OR CHIME DRIVER 12 G150 20VT...

Страница 1098: ...LEFT 17 18 G931 18VT BR EXCEPT BASE AMBIENT TEMPERATURE SENSOR RETURN 19 W20 18BR YL REAR WASHER PUMP MOTOR CONTROL 20 W10 18BR FRONT WASHER PUMP MOTOR CONTROL INTEGRATED POWER MODULE C2 GREEN BLUE 1...

Страница 1099: ...UTPUT 20 INTEGRATED POWER MODULE C3 GAS NATURAL RED 20 WAY CAV CIRCUIT FUNCTION 1 Z115 20BK OR EATX 3 3L 3 8L GROUND 1 Z115 18BK OR EATX 2 4L GROUND 2 F1 18PK WT EATX FCM OUTPUT UNLOCK RUN START 3 T75...

Страница 1100: ...D ANTILOCK BRAKES FUSED B 9 A710 14RD BR DIESEL B HAZARD FEED 9 A701 14BR RD GAS B HAZARD FEED 10 INTEGRATED POWER MODULE C5 BLACK 4 WAY CAV CIRCUIT FUNCTION 1 A1 4RD B 2 3 4 INTEGRATED POWER MODULE C...

Страница 1101: ...18PK WT GAS FCM OUTPUT UNLOCK RUN START 14 15 A114 16GY RD FUSED B I O D 16 D23 20WT BR FLASH PROGRAM ENABLE 17 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 18 X1 16DG BR PREMIUM 8 SPEAKER NAME BRAND SPEAKER...

Страница 1102: ...9 A115 12YL RD POWER LIFTGATE FUSED B 10 F302 18GY PK FUSED ACCESSORY RELAY OUTPUT KNOCK SENSOR 2 4L GRAY 2 WAY CAV CIRCUIT FUNCTION 1 K42 18DB YL KNOCK SENSOR SIGNAL 2 K900 18DB DG SENSOR GROUND KNO...

Страница 1103: ...FUNCTION 1 L63 18WT DG LEFT REAR TURN SIGNAL DRIVER 2 Z1 18BK DG GROUND 2 Z1 18BK DG GROUND 3 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 3 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 4 L615 18OR LEFT COMBINATION S...

Страница 1104: ...20VT LEFT FRONT DOOR AJAR SWITCH SENSE 2 Z75 20BK VT GROUND LEFT FRONT DOOR LOCK MOTOR AJAR SWITCH EXCEPT BASE BLACK 4 WAY CAV CIRCUIT FUNCTION 1 G75 20VT LEFT FRONT DOOR AJAR SWITCH SENSE 2 Z75 20BK...

Страница 1105: ...EN SWITCH SENSE 2 Z77 20BK GY GROUND LEFT HEADLAMP EXCEPT BUILT UP EXPORT BLACK 3 WAY CAV CIRCUIT FUNCTION 1 L43 18WT DB LEFT LOW BEAM DRIVER 2 Z343 18BK LG GROUND 3 L33 18WT LG LEFT HIGH BEAM DRIVER...

Страница 1106: ...SY LAMPS DRIVER LEFT LOW BEAM LAMP BUILT UP EXPORT BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z343 16BR GROUND 2 L43 16WT LEFT LOW BEAM DRIVER LEFT MID READING LAMP PREMIUM LUXURY GRAY 3 WAY CAV CIRCUIT FUNCT...

Страница 1107: ...AY CAV CIRCUIT FUNCTION 1 L63 18WT DG EXCEPT BUILT UP EXPORT LEFT REAR TURN SIGNAL DRIVER 1 Z363 18BK DG BUILT UP EXPORT GROUND 2 L62 18WT BR EXCEPT BUILT UP EXPORT RIGHT REAR TURN SIGNAL DRIVER 2 L63...

Страница 1108: ...1 Q13 16OR DB LHD DRIVER SIDE REAR WINDOW CLOSE 2 Q24 16OR DG RHD PASSENGER SIDE REAR WINDOW OPEN 2 Q23 16OR LB LHD DRIVER SIDE REAR WINDOW OPEN 3 LEFT REAR WHEEL SPEED SENSOR BLACK 2 WAY CAV CIRCUIT...

Страница 1109: ...OR OPEN DRIVER 3 Q69 16TN OR LEFT SLIDING DOOR CLOSE DRIVER 4 5 A113 14WT RD FUSED B 6 7 8 Z123 14BK WT GROUND LEFT SLIDING DOOR CONTROL MODULE C2 POWER SLIDING DOOR BLACK RED 20 WAY CAV CIRCUIT FUNCT...

Страница 1110: ...OR BLACK 4 WAY CAV CIRCUIT FUNCTION 1 P5 20BK DB LEFT SLIDING DOOR UNLOCK DRIVER 2 P32 20BK TN LEFT SLIDING DOOR LOCK DRIVER 3 G77 20BK DG LEFT SLIDING DOOR AJAR SWITCH SENSE 4 Z77 20BK GROUND LEFT SL...

Страница 1111: ...FT FRONT TURN SIGNAL DRIVER LEFT VISOR VANITY LAMP PREMIUM LUXURY BLACK 2 WAY CAV CIRCUIT FUNCTION A Z327 20BK OR GROUND B M27 20YL LB READING LAMP DRIVER LICENSE LAMP MANUAL RELEASE DK GRAY 2 WAY CAV...

Страница 1112: ...G78 20VT OR LIFTGATE AJAR SWITCH SENSE LIFTGATE AJAR SWITCH POWER RELEASE BLACK 4 WAY CAV CIRCUIT FUNCTION 1 Z78 20BK OR GROUND 2 G78 20VT OR LIFTGATE AJAR SWITCH SENSE 3 P31 20TN YL LIFTGATE RELEASE...

Страница 1113: ...SENSOR POWER LIFTGATE BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Q77 20OR DB RIGHT PINCH SENSOR SIGNAL 2 Z78 20BK OR GROUND LOW NOTE HORN BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z298 18BK DB GROUND 2 X2 18DG OR HO...

Страница 1114: ...MIRROR VERTICAL POSITION SIGNAL 8 P21 20LG TN SEAT FRONT DOWN SWITCH SENSE 9 P13 20LG OR SEAT REAR DOWN SWITCH SENSE 10 P15 20LG WT SEAT HORIZONTAL FORWARD SWITCH SENSE 11 P43 14LG VT RECLINER UP SWI...

Страница 1115: ...V CIRCUIT FUNCTION 1 P111 14LG YL SEAT REAR UP DRIVER 2 P115 14LG SEAT HORIZONTAL FORWARD DRIVER 3 P119 14LG DG SEAT FRONT UP DRIVER 4 P113 14LG WT SEAT REAR DOWN DRIVER 5 P121 14LG DB SEAT FRONT DOWN...

Страница 1116: ...DRIVER 11 G69 20VT WT RHD VTSS INDICATOR DRIVER 12 L134 20WT GY LHD HIGH BEAM INDICATOR DRIVER 13 G3 20VT LB RHD MALFUNCTION INDICATOR LAMP DRIVER 14 L161 20WT LG RHD LEFT TURN INDICATOR DRIVER MODE...

Страница 1117: ...P FEED 9 10 11 L24 20BK GY EXCEPT BUILT UP EXPORT PREMIUM LUXURY AUTOMATIC HEADLAMP SWITCH SENSOR 12 L1 20BK WT PREMIUM LUXURY BACK UP LAMP FEED RADIATOR FAN RELAY NO 1 DIESEL BLUE 9 WAY CAV CIRCUIT F...

Страница 1118: ...4 WAY CAV CIRCUIT FUNCTION 1 R42 18LB BR PASSENGER SQUIB 1 LINE 2 2 R44 18LB OR PASSENGER SQUIB 1 LINE 1 3 R62 18LB PK PASSENGER SQUIB 2 LINE 2 4 R64 18LB WT PASSENGER SQUIB 2 LINE 1 PASSENGER BLEND D...

Страница 1119: ...IT FUNCTION 1 2 3 4 A108 18LG RD FUSED B 5 P164 18LG DB PASSENGER FOLDING MIRROR RELAY INPUT 6 P162 18LG DG PASSENGER FOLDING MIRROR RELAY CONTROL 7 8 P160 18TN LG PASSENGER FOLDING MIRROR RELAY OUTPU...

Страница 1120: ...UND 2 S1 18WT PASSENGER SEAT BACK HEATER B DRIVER PASSENGER HEATED SEAT MODULE C3 GREEN 4 WAY CAV CIRCUIT FUNCTION 1 P87 16LG OR PASSENGER SEAT CUSHION HEATER GROUND 2 P89 20LG BR SEAT SENSOR 5 VOLT S...

Страница 1121: ...SWITCH SENSE PASSENGER POWER SEAT SWITCH GREEN 10 WAY CAV CIRCUIT FUNCTION 1 Z848 14BK OR GROUND 2 P44 14LG VT PASSENGER RECLINER UP SWITCH SENSE 3 P16 14LG WT PASSENGER HORIZONTAL REARWARD SWITCH SEN...

Страница 1122: ...NDOW CIRCUIT BREAKER OUTPUT 7 Z422 20BK BR GROUND 8 Q12 14OR BR PASSENGER WINDOW DRIVER UP PASSENGER SEAT BELT SWITCH 2 WAY CAV CIRCUIT FUNCTION 1 R60 18LB TN PASSENGER SEAT BELT SWITCH LINE 1 2 R58 1...

Страница 1123: ...AJAR SWITCH SENSE 13 Q60 20OR YL LIFTGATE PAWL SWITCH SENSE 14 Q51 20OR LIFTGATE FULL OPEN SWITCH SENSE 15 16 G32 20VT LB LIFTGATE TEMPERATURE SENSOR SIGNAL 17 Q91 20TN LG LIFTGATE HALL EFFECT SIGNAL...

Страница 1124: ...RIVER 9 A108 18LG RD FUSED B 10 11 Z408 18BK LG GROUND 12 P71 20TN DG LEFT MIRROR UP DRIVER 12 P71 18TN DG MEMORY LEFT MIRROR UP DRIVER 13 P72 18TN GY MEMORY RIGHT MIRROR UP DRIVER 13 P72 20TN GY RIGH...

Страница 1125: ...IL PRESSURE SWITCH SENSE 13 K11 16BR YL FUEL INJECTOR NO 1 DRIVER 14 K58 16BR VT 3 3L 3 8L FUEL INJECTOR NO 6 DRIVER 15 K38 16BR OR 3 3L 3 8L FUEL INJECTOR NO 5 DRIVER 16 K14 16BR TN FUEL INJECTOR NO...

Страница 1126: ...WT SECONDARY BRAKE SWITCH SIGNAL 63 T10 18DG LG EATX TORQUE MANAGEMENT REQUEST SENSE 64 C13 18LB OR A C COMPRESSOR CLUTCH RELAY CONTROL 65 D21 18WT BR SCI TRANSMIT 66 N7 18DB OR VEHICLE SPEED SENSOR...

Страница 1127: ...R FAN NO 2 DIESEL GRAY 2 WAY CAV CIRCUIT FUNCTION 1 Z823 12BK GROUND 2 N112 12DB OR RADIATOR FAN RELAY NO 2 AND NO 3 COMMON OUTPUT RADIATOR FAN NO 2 GAS BLACK 2 WAY CAV CIRCUIT FUNCTION 1 N23 12DB DG...

Страница 1128: ...2DB OR RADIATOR FAN RELAY NO 2 AND NO 3 COMMON OUTPUT 3 4 K342 16BR WT ECM PCM RELAY OUTPUT 5 6 N122 18DB YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL 7 8 A112 12OR RD FUSED B 9 RADIATOR FAN RELAY NO...

Страница 1129: ...BUILT UP EXPORT GROUND 11 Z333 16BK PK EXCEPT BUILT UP EXPORT GROUND 12 A114 16GY RD EXCEPT BUILT UP EXPORT FUSED B I O D 13 X60 20GY YL BUILT UP EXPORT RADIO 12 VOLT OUTPUT 14 D25 18WT VT EXCEPT BUIL...

Страница 1130: ...B YL REAR BLEND DOOR DRIVER 8 C154 20LB OR REAR COMMON DOOR DRIVER 9 10 C200 20LB DG TXV SOLENOID FEED REAR AUTO TEMP CONTROL SWITCH ATC BLACK 13 WAY CAV CIRCUIT FUNCTION 1 F504 20GY PK FUSED IGNITION...

Страница 1131: ...WAY CAV CIRCUIT FUNCTION 1 C153 12DB BR REAR BLOWER MOTOR HIGH 2 C152 16LB LG REAR BLOWER MOTOR MED 3 C151 18LB DG REAR BLOWER MOTOR LOW 4 C50 12DB OR REAR BLOWER FRONT CONTROL FEED REAR BLOWER REAR...

Страница 1132: ...7 16BK LB GROUND REAR TEMPERATURE MOTOR ATC GRAY 2 WAY CAV CIRCUIT FUNCTION 1 C54 18LB YL REAR BLEND DOOR DRIVER A 2 C169 18LB TN REAR BLEND DOOR DRIVER B REAR WASHER PUMP MOTOR BLACK 2 WAY CAV CIRCUI...

Страница 1133: ...TRY ANTENNA 2 D10 18WT LB REMOTE KEYLESS ENTRY ANTENNA REMOTE KEYLESS ENTRY MODULE BLACK RED 6 WAY CAV CIRCUIT FUNCTION 1 G96 20VT DG REMOTE KEYLESS ENTRY INTERFACE 2 D9 20WT GY RKE MODULE PROGRAM ENA...

Страница 1134: ...PUT 4 L605 18DG RIGHT COMBINATION SIGNAL 5 RIGHT CYLINDER LOCK SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 Z462 20BK WT GROUND 2 G162 20VT WT RIGHT CYLINDER LOCK SWITCH MUX RIGHT DOOR SPEAKER BLACK RED...

Страница 1135: ...VT WT RIGHT FRONT DOOR AJAR SWITCH SENSE 2 Z74 20BK WT GROUND 3 P4 20TN BR RIGHT FRONT DOOR UNLOCK DRIVER 4 P2 20TN GY RIGHT FRONT DOOR LOCK DRIVER RIGHT FRONT PARK TURN SIGNAL LAMP EXCEPT BUILT UP EX...

Страница 1136: ...RIGHT HEADLAMP LEVELING MOTOR BUILT UP EXPORT WHITE 3 WAY CAV CIRCUIT FUNCTION 1 Z203 16BR GROUND 2 L78 16BK FUSED PARK LAMP RELAY OUTPUT RIGHT 3 L13 16RD HEADLAMP ADJUST SIGNAL RIGHT HIGH BEAM LAMP...

Страница 1137: ...RK LAMP RELAY OUTPUT RIGHT RIGHT POWER MIRROR BLACK 12 WAY CAV CIRCUIT FUNCTION 1 P174 20TN LB BUILT UP EXPORT RIGHT FOLDING MIRROR UNFOLD DRIVER 2 3 4 P68 20TN YL MEMORY RIGHT MIRROR HORIZONTAL POSIT...

Страница 1138: ...R SPEAKER 2 X152 20GY WT RIGHT REAR PILLAR SPEAKER RIGHT REAR READING LAMP LUXURY GRAY 3 WAY CAV CIRCUIT FUNCTION 1 M22 20YL OR COURTESY LAMPS DRIVER 2 Z327 20BK OR GROUND 3 M27 20YL LB READING LAMPS...

Страница 1139: ...0WT VT RIGHT SIDE REPEATER LAMP FEED RIGHT SEAT AIRBAG YELLOW 2 WAY CAV CIRCUIT FUNCTION 1 R32 18LB OR EXCEPT BUILT UP EXPORT RIGHT SEAT SQUIB LINE 1 1 R34 18WT BK BUILT UP EXPORT RIGHT SEAT SQUIB LIN...

Страница 1140: ...CH DRIVER 9 Q48 18TN WT RIGHT CINCH RELEASE MOTOR UNLATCH DRIVER 10 11 D25 20WT VT PCI BUS 12 G76 20TN OR RIGHT SLIDING DOOR AJAR SWITCH SENSE 13 Q58 20OR YL RIGHT PAWL SWITCH SENSE 14 Q52 20OR RIGHT...

Страница 1141: ...SUPPLY 3 Q68 16TN BR RIGHT SLIDING DOOR OPEN DRIVER 4 Z164 18BK TN GROUND 5 Q64 18OR TN RIGHT DOOR MOTOR CLUTCH DRIVER 6 Q70 16TN OR RIGHT SLIDING DOOR CLOSE DRIVER 7 Z34 20BK TN GROUND 8 Q74 20TN YL...

Страница 1142: ...ED B I O D SIREN UNITED KINGDOM BLACK 4 WAY CAV CIRCUIT FUNCTION 1 D97 18WT OR SIREN SIGNAL OUTPUT 2 D96 18WT LB SIREN SIGNAL CONTROL 3 A600 18RD LB SIREN SUPPLY 4 G944 18LB BR SIREN SIGNAL RETURN SOL...

Страница 1143: ...L CONTROL 7 F20 20PK WT FUSED IGNITION SWITCH OUTPUT RUN START 8 G944 20LB BR SIREN SIGNAL RETURN 9 10 11 G922 20GY VTSS INDICATOR DRIVER 12 13 D25 20WT VT PCI BUS 14 15 L91 20WT DB HAZARD SWITCH SENS...

Страница 1144: ...OID CONTROL TRACTION CONTROL SWITCH BLACK 2 WAY CAV CIRCUIT FUNCTION 1 B27 20DG WT TRACTION CONTROL SWITCH SENSE 2 Z427 20BK WT GROUND TRAILER TOW CONNECTOR EXCEPT BUILT UP EXPORT 4 WAY CAV CIRCUIT FU...

Страница 1145: ...R TRANSMISSION CONTROL RELAY CONTROL 16 T16 18YL OR TRANSMISSION CONTROL RELAY OUTPUT 17 T16 18YL OR TRANSMISSION CONTROL RELAY OUTPUT 18 19 T19 18YL DB 2 4 SOLENOID CONTROL 20 T20 18DG WT LOW REVERSE...

Страница 1146: ...T1 SENSE 8 T3 18DG DB TRS T3 SENSE 9 T42 18DG YL TRS T42 SENSE 10 T41 18YL DB PARK NEUTRAL POSITION SWITCH SENSE TRS T41 TXV SOLENOID ATC 2 WAY CAV CIRCUIT FUNCTION 1 C200 18LB DG TXV SOLENOID FEED 2...

Страница 1147: ...GNAL 2 K900 18RD SENSOR GROUND WIPER MODULE DK GRAY 4 WAY CAV CIRCUIT FUNCTION 1 W3 12BR WT FRONT WIPER HIGH LOW RELAY LOW SPEED OUTPUT 2 W7 20BR GY FRONT WIPER PARK SWITCH SENSE 3 W4 12BR OR FRONT WI...

Страница 1148: ...Position Sensor Diesel BK At Accelerator Pedal 36 Airbag Control Module YL RD Right Side of Instrument Panel 15 19 20 Ambient Temperature Sensor BK On Radiator Closure Panel 1 ATC Remote Sensor Above...

Страница 1149: ...er N S C300 RHD BK Right Front Door Lower C301 LTGY Left Front Door Upper N S C302 LTGY Right Front Door Upper 8 33 37 C303 LHD BK Right Front Door Lower 8 37 C303 RHD BK Left Front Door Lower 33 37 C...

Страница 1150: ...At Switch Driver Side 36 Clutch Pedal Upstop Switch Diesel BK At Switch Driver Side 36 Controller Anti Lock Brake BK Right Side of Engine Compartment 9 10 12 13 14 Crank Case Ventilation Heater Diesel...

Страница 1151: ...l BK Right Side of Engine 11 Engine Coolant Temperature Sensor Gas BK On Cylinder Block N S Engine Coolant Temperature Sensor Diesel BL On Cylinder Block 11 Engine Oil Pressure Sensor Diesel BK Rear o...

Страница 1152: ...ngine 14 Ignition Switch BK Rear of Switch at Steering Column 15 16 17 18 26 Inlet Air Temperature Sensor BK Top Left of Engine N S Instrument Cluster BK Rear of Cluster 15 16 23 Instrument Panel Swit...

Страница 1153: ...Rear Speaker BK At Speaker 40 Left Rear Vent Motor NAT At Motor 39 40 Left Rear Wheel Speed Sensor BK Center Rear of Floor Pan 40 Left Remote Radio Switch Steering Wheel N S Left Repeater Lamp GY Lef...

Страница 1154: ...ear Vertical Motor RD Under Seat N S Memory Seat Rear Vertical Position Sensor BK Under Seat N S Memory Seat Recliner Motor GN Under Seat N S Memory Seat Recliner Position Sensor BK Under Seat N S Mem...

Страница 1155: ...r of Switch 25 Power Outlet NAT Instrument Panel 15 18 20 Power Seat Circuit Breaker GY Under Seat N S Powertrain Control Module C1 GY BK LT Fender Side Shield N S Powertrain Control Module C2 GY LT F...

Страница 1156: ...Front Door Lock Motor Ajar Switch BK Right Front Door 37 Right Front Park Turn Signal Lamp BK At Lamp 1 3 Right Front Wheel Speed Sensor GY Right Fender Side Shield 9 12 13 Right Full Open Switch BK R...

Страница 1157: ...Siren United Kingdom BK Left Front Body N S Solenoid Pressure Switch Assembly EATX BK Side of Transmission N S Speed Control Servo BK Near Controller Antilock Brake 14 Thatcham Alarm Module C1 BK Top...

Страница 1158: ...or 11 S106 3 3L 3 8L Near T O for G103 14 S107 2 4L In T O for EGR Solenoid 10 S107 2 5L Between T O for Engine Starter Motor and T O for Engine Control Module C1 12 S107 3 3L 3 8L In T O for EGR Sole...

Страница 1159: ...O for Intelligent Power Module C3 N S S134 Near T O for Controller Antilock Brake N S S135 2 5L Near T O for Glow Plug No 2 11 S136 2 5L Between T O for Radiator Fan No 2 and T O for G102 N S S137 2 5...

Страница 1160: ...g Column Wiring Assembly N S S302 In Floor Pan Track Wiring 31 S303 In T O to Data Link Connector 31 S304 Near T O for C307 32 S305 Near T O for Memory Seat Mirror Module C2 N S S306 In Floor Pan Trac...

Страница 1161: ...S346 Near T O for Driver Power Window Switch 37 S347 Near T O for Right Sliding Door Lock Motor 39 S348 Near T O for Left Sliding Door Lock Motor 39 S349 In T O to Left Sliding Door Control Module C2...

Страница 1162: ...Fig 1 HEADLAMP CONNECTORS RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 15 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1163: ...Fig 2 LEFT FRONT ENGINE COMPARTMENT Fig 3 WASHER PUMP CONNECTORS 8W 91 16 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1164: ...Fig 4 LEFT REPEATER LAMP Fig 5 LEFT FENDER SHIELD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 17 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1165: ...Fig 6 LEFT SIDE ENGINE COMPARTMENT 8W 91 18 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1166: ...Fig 7 INTEGRATED POWER MODULE RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 19 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1167: ...Fig 8 RIGHT FRONT WHEEL HOUSING 8W 91 20 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1168: ...Fig 9 2 4 LITER ENGINE CONNECTORS REAR RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 21 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1169: ...Fig 10 2 4 LITER ENGINE FRONT 8W 91 22 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1170: ...Fig 11 2 5 LITER DIESEL ENGINE FRONT RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 23 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1171: ...Fig 12 2 5 LITER DIESEL ENGINE REAR 8W 91 24 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1172: ...Fig 13 3 3 3 8 LITER ENGINE REAR RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 25 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1173: ...Fig 14 3 3 3 8 LITER ENGINE FRONT 8W 91 26 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1174: ...Fig 15 INSTRUMENT PANEL HARNESS LHD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 27 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1175: ...Fig 16 LEFT SIDE INSTRUMENT PANEL LHD 8W 91 28 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1176: ...Fig 17 STEERING COLUMN RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 29 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1177: ...Fig 18 CENTER INSTRUMENT PANEL 8W 91 30 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1178: ...Fig 19 RIGHT SIDE INSTRUMENT PANEL RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 31 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1179: ...Fig 20 CENTER INSTRUMENT PANEL RHD 8W 91 32 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1180: ...Fig 21 INSTRUMENT PANEL RHD Fig 22 LEFT SIDE INSTRUMENT PANEL UPPER RHD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 33 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1181: ...Fig 23 RIGHT SIDE INSTRUMENT PANEL UPPER RHD Fig 24 LEFT SIDE INSTRUMENT PANEL LOWER RHD 8W 91 34 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1182: ...Fig 25 RIGHT SIDE INSTRUMENT PANEL LOWER RHD Fig 26 STEERING COLUMN CONNECTORS RHD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 35 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1183: ...Fig 27 LEFT SIDE BODY LHD 8W 91 36 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1184: ...Fig 28 RIGHT SIDE BODY RHD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 37 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1185: ...Fig 29 BODY HARNESS SPLICES 8W 91 38 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1186: ...Fig 30 BODY HARNESS SPLICES Fig 31 LEFT FRONT BODY SPLICES RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 39 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1187: ...Fig 32 REAR BODY SPLICES 8W 91 40 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1188: ...Fig 33 RIGHT B PILLAR Fig 34 LEFT B PILLAR RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 41 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1189: ...Fig 35 LEFT SIDE KICK PANEL LHD 8W 91 42 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1190: ...Fig 36 RIGHT SIDE KICK PANEL RHD RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 43 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1191: ...Fig 37 PASSENGER DOOR Fig 38 RIGHT SLIDING DOOR 8W 91 44 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1192: ...Fig 39 LIFTGATE AND SLIDING DOOR MODULES RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 45 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1193: ...Fig 40 LEFT REAR BODY 8W 91 46 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1194: ...Fig 41 RIGHT QUARTER RS 8W 91 CONNECTOR GROUND SPLICE LOCATION 8W 91 47 CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1195: ...Fig 42 LIFTGATE 8W 91 48 8W 91 CONNECTOR GROUND SPLICE LOCATION RS CONNECTOR GROUND SPLICE LOCATION Continued...

Страница 1196: ...esetting circuit breakers Blade type fuses Bus bars Cartridge fuses Circuit splice blocks Flashers Fusible links Relays Following are general descriptions of the major components in the power distribu...

Страница 1197: ...n the Inte grated Power Module IPM in the engine compart ment For complete circuit diagrams refer to Wiring Diagrams 1 Remove the accessory relay from the IPM Refer to Accessory Relay in the Removal a...

Страница 1198: ...relays while the front control module contains the electronics con trolling the IPM and other functions This IPM con nects directly to the battery positive via a four pin connector The ground connecti...

Страница 1199: ...e until secured in mounting bracket An audible click may be heard 3 Install the battery in the vehicle Refer to the Battery section for the procedure 4 Install the battery thermal guard in the vehi cl...

Страница 1200: ...damaged Refer to Battery System for additional service information REMOVAL 1 Turn the ignition switch to the Off position 2 Unlatch and open the cover of the intelligent power module 3 Remove the IOD...

Страница 1201: ...battery voltage at the fused B circuit cavity of the power outlet wire harness connector If OK replace the faulty power outlet receptacle If not OK repair the open fused B circuit to the IPM fuse as r...

Страница 1202: ...CE GASKETS AND SEALERS 11 STANDARD PROCEDURE ENGINE GASKET SURFACE PREPARATION 11 STANDARD PROCEDURE MEASURING BEARING CLEARANCE USING PLASTIGAGE 12 REMOVAL ENGINE ASSEMBLY 12 INSTALLATION ENGINE ASSE...

Страница 1203: ...ALLATION 44 PISTON CONNECTING ROD DESCRIPTION 45 OPERATION 45 REMOVAL 45 INSTALLATION 46 PISTON RINGS STANDARD PROCEDURE PISTON RING FITTING 47 VIBRATION DAMPER REMOVAL 48 INSTALLATION 48 STRUCTURAL C...

Страница 1204: ...g 1 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING ENGINE DIAGNOSIS INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance The...

Страница 1205: ...ation 5 Incorrect spark plug gap 5 Set gap Refer to 8 ELECTRICAL IGNITION CONTROL SPECIFICATIONS 6 Contamination in fuel system 6 Clean system and replace fuel filter 7 Faulty fuel pump 7 Test fuel pu...

Страница 1206: ...essary 9 Faulty ignition coil s 9 Test and replace as necessary Refer to Appropriate Diagnostic Information ENGINE MISSES ON ACCELERATION 1 Dirty or incorrectly gapped spark plugs 1 Clean spark plugs...

Страница 1207: ...adjusters 7 Replace hydraulic lifters lash adjusters 8 Worn valve guides 8 Replace cylinder head assembly 9 Excessive runout of valve seats on valve faces 9 Grind valve seats and valves CONNECTING RO...

Страница 1208: ...vel 1 Check engine oil level 2 Faulty oil pressure sensor switch 2 Replace oil pressure sensor switch 3 Low oil pressure 3 Check oil pressure sensor switch and main bearing oil clearance 4 Clogged oil...

Страница 1209: ...ect the fresh air hose make up air at the cylinder head cover and plug or cap the nipple on the cover Remove the PCV valve hose from the cylinder head cover Cap or plug the PCV valve nipple on the cov...

Страница 1210: ...riskly 3 Remove all spark plugs from engine As spark plugs are being removed check electrodes for abnor mal firing indicators fouled hot oily etc Record cyl inder number of spark plug for future refer...

Страница 1211: ...e vehicle placed in service immediately STANDARD PROCEDURE REPAIR OF DAMAGED OR WORN THREADS Damaged or worn threads excluding spark plug and camshaft bearing cap attaching threads can be repaired Ess...

Страница 1212: ...a unique green in color anaerobic type gasket material that is specially made to seal the area between the bed plate and cylinder block without disturbing the bear ing clearance or alignment of these...

Страница 1213: ...stigage with the metric scale provided on the package Locate the band clos est to the same width This band shows the amount of clearance in thousandths of a millimeter Differ ences in readings between...

Страница 1214: ...ctors 11 Disconnect throttle body linkage 12 Disconnect engine wiring harness 13 Disconnect heater hoses from heater Fig 5 14 Discharge air conditioning system Refer to 24 HEATING AIR CONDITIONING PLU...

Страница 1215: ...be installed under vehicle Fig 8 32 Loosen cradle posts to allow movement for proper positioning Locate two rear posts right side of engine into the holes on the engine bedplate Locate the two front...

Страница 1216: ...ne Cradle Support Post Mounts 1 SPECIAL TOOL POSTS 6848 4 SPECIAL TOOL 6710 CRADLE 2 SPECIAL TOOL 6135 DOLLY 5 SPECIAL TOOL 6848 POST CONTACT ON PAN RAIL 3 SPECIAL TOOL POSTS 6848 RS ENGINE 2 4L 9 15...

Страница 1217: ...OLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 16 Install axle shafts Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT INSTALLA TION 17 Install accessory drive belt splash shield 18 Install front wheels...

Страница 1218: ...n Length 66 25 mm 2 608 in DESCRIPTION SPECIFICATION Piston Ring Groove Depth No 1 4 640 4 784 mm 0 182 0 188 in Piston Ring Groove Depth No 2 4 575 4 719 mm 0 180 0 185 in Piston Ring Groove Depth No...

Страница 1219: ...Camshaft Journal Diameter No 1 6 25 951 25 970 mm 1 021 1 022 in Bearing Clearance Diametrical 0 069 0 071 mm 0 0027 0 003 in End Play 0 05 0 17 mm 0 0019 0 0066 in DESCRIPTION SPECIFICATION Lift Zer...

Страница 1220: ...25 mm 0 010 in Exhaust 0 0736 0 094 mm 0 0029 0 0037 in Max Allowable 0 101 mm 0 004 in DESCRIPTION SPECIFICATION Service Limit 0 25 mm 0 010 in Valve Springs Free Length Approx 48 4 mm 1 905 in Nomi...

Страница 1221: ...Engine Mount Bracket Right Bolts 61 45 Engine Mounting Bolts Refer to 9 ENGINE ENGINE MOUNTING DESCRIPTION N m Ft Lbs In Lbs Exhaust Manifold to Cylinder Head Bolts 19 170 Exhaust Manifold Heat Shiel...

Страница 1222: ...er Removal Insert 6827A Dolly 6135 Cradle 6710A Post Kit Engine Cradle 6848 Camshaft Sprocket Holder 6847 Camshaft Seal Remover C 4679A Camshaft Seal Installer MD 998306 Crankshaft Damper Sprocket Ins...

Страница 1223: ...or MD998772A Valve Spring Compressor Adapter 6779 Indicator Cylinder Bore C 119 Connecting Rod Guides 8189 Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Remover Insert C 4685 C2 Front Crankshaf...

Страница 1224: ...Rear Crankshaft Oil Seal Installer 6926 Driver Handle C 4171 Balance Shaft Sprocket Installer 6052 Combustion Leak Tester C 3685 A Pressure Transducer CH7059 Cylinder Compression Pressure Adaptor 811...

Страница 1225: ...DESCRIPTION The cross flow designed aluminum cylinder head contains dual over head camshafts with four valves per cylinder Fig 13 The valves are arranged in two in line banks The intake valves face to...

Страница 1226: ...XCEED 138 kPa 20 psi Install Cooling System Tester 7700 or equivalent to pressure cap neck Start the engine and observe the tester s pressure gauge If gauge pulsates with every power stroke of a cylin...

Страница 1227: ...r scratch the alumi num head sealing surface Clean all engine oil passages INSPECTION 1 Cylinder head must be flat within 0 1 mm 0 004 in Fig 14 2 Inspect camshaft bearing journals for scoring 3 Remov...

Страница 1228: ...tion coil wiring connector 12 Install power steering pump reservoir and line support bracket to cylinder head 13 Raise vehicle and install the exhaust pipe to the manifold 14 Install accessory drive b...

Страница 1229: ...TALLATION 1 Shaft seal surface must be free of varnish dirt or nicks Polish with 400 grit paper if necessary 2 Install camshaft seals into cylinder head using Special Tool MD 998306 until flush with h...

Страница 1230: ...d camshaft for wear replace as necessary REMOVAL 1 Remove cylinder head cover Refer to 9 ENGINE CYLINDER HEAD CYLINDER HEAD COVER REMOVAL 2 Remove camshaft position sensor and camshaft target magnet R...

Страница 1231: ...ft lobes 2 Install all rocker arms in original positions if reused 3 Position camshafts on cylinder head bearing journals Install right and left camshaft bearing caps No 2 5 and right No 6 Tighten M6...

Страница 1232: ...ON Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping 3 Apply Mopart Engine RTV GEN II at the camshaft cap corners and at the top edges...

Страница 1233: ...HEAD COVER S REMOVAL 2 Remove camshafts Refer to 9 ENGINE CYL INDER HEAD CAMSHAFT S REMOVAL 3 Rotate crankshaft until piston is at TDC on compression 4 With air hose attached to adapter tool installe...

Страница 1234: ...998772 A with adapter 6779 to compress valve springs only enough to install locks Fig 33 Correct alignment of tool is necessary to avoid nick ing valve stems 3 Remove air hose and install spark plugs...

Страница 1235: ...d still leaves lash in the system 10 Faulty lash adjuster a Check lash adjusters for sponginess while installed in cylinder head Depress part of rocker arm over adjuster Normal adjusters should feel v...

Страница 1236: ...TION 1 Lubricate rocker arm with clean engine oil 2 Using Special Tools 8215A and 8436 slowly depress valve assembly until rocker arm can be installed on the hydraulic lifter and valve stem Fig 38 3 R...

Страница 1237: ...re and maintain the required lim its 2 Deglazing of the cylinder walls may be done using a cylinder surfacing hone recommended tool C 3501 or equivalent equipped with 280 grit stones if the cylinder b...

Страница 1238: ...lls should be checked for out of round and taper with Tool C119 or equivalent Fig 44 Refer to 9 ENGINE SPECIFICATIONS If the cylinder walls are badly scuffed or scored the cylinder block should be rep...

Страница 1239: ...cating probe perpendicular on nose of crankshaft Fig 47 2 Move crankshaft all the way to the rear of its travel 3 Zero the dial indicator 4 Move crankshaft all the way to the front and read the dial i...

Страница 1240: ...block dowel pins to prevent damage to the dowel pins and thrust bearing 17 Lift out crankshaft from cylinder block Do not damage the main bearings or journals when removing the crankshaft INSPECTION...

Страница 1241: ...furthest forward position Step 5 Install and tighten bolts 1 10 in sequence shown in Fig 52 to 41 N m 30 ft lbs Step 6 Remove wedge tool used to hold crank shaft 9 Tighten bolts 1 10 again to 41 N m...

Страница 1242: ...g service procedures are to be cleaned and oiled before installation Bearing shells are available in standard and the following undersized 0 025 mm 0 001 in and 0 250 mm 0 010 in Never install an unde...

Страница 1243: ...o 41 N m 30 ft lbs in sequence shown in Fig 56 CAUTION Do Not use a torque wrench for the fol lowing step 11 Turn bolts 1 10 an additional 1 4 turn in sequence shown in Fig 56 12 Install main bearing...

Страница 1244: ...R REMOVAL 1 Remove transaxle Refer to TRANSMISSION TRANSAXLE REMOVAL for procedure 2 Remove flex plate 3 Insert a 3 16 flat bladed screwdriver between the dust lip and the metal case of the crankshaft...

Страница 1245: ...en into the block past flush this may cause an oil leak 3 Drive the seal into the block using Special Tool 6926 2 and handle C 4171 Fig 63 until the tool bot toms out against the block Fig 64 Fig 61 R...

Страница 1246: ...er block Be sure to keep tops of pistons covered during this operation 2 Pistons have a directional stamping in the front half of the piston facing towards the front of engine Fig 65 3 Remove oil pan...

Страница 1247: ...guide rod over the crankshaft journal 6 Tap the piston down in cylinder bore using a hammer handle At the same time guide connecting rod into position on connecting rod journal NOTE The connecting ro...

Страница 1248: ...the piston Fig 72 CAUTION Install piston rings in the following order Oil ring expander Upper oil ring side rail Lower oil ring side rail No 2 Intermediate piston ring No 1 Upper piston ring 2 Instal...

Страница 1249: ...27 A Fig 75 INSTALLATION 1 Install crankshaft vibration damper using M12 1 75 x 150 mm bolt washer thrust bearing and nut from Special Tool 6792 Fig 76 2 Install crankshaft vibration damper bolt and t...

Страница 1250: ...40 ft lbs 2 Install engine front mount bracket and insula tor Refer to 9 ENGINE ENGINE MOUNTING FRONT MOUNT INSTALLATION 3 Lower vehicle ENGINE MOUNTING DESCRIPTION The engine mounting system consist...

Страница 1251: ...bolts 8 Remove the horizontal bolts from the mount to the transaxle Fig 81 or Fig 82 NOTE To remove mount additional lowering of transaxle may be required 9 Remove left mount INSTALLATION 1 Install l...

Страница 1252: ...ching bracket to transaxle Fig 85 7 Remove rear mount bracket INSTALLATION 1 Install rear mount bracket if removed Fig 85 2 Install the rear mount and bolts Fig 84 Tighten bolts to 54 N m 40 ft lbs 3...

Страница 1253: ...e bolts attaching the engine mount to the engine bracket Fig 86 9 Remove the right engine mount Fig 86 INSTALLATION 1 Position right engine mount and install frame rail to mount vertical bolts Fig 86...

Страница 1254: ...lubrication to the valve stems Cylinder bores and wrist pins are splash lubricated from directed slots on the connecting rod thrust collars DIAGNOSIS AND TESTING CHECKING ENGINE OIL PRESSURE 1 Discon...

Страница 1255: ...plug threads for stretching or other damage Replace drain plug and gasket if damaged 6 Remove oil filter Refer to 9 ENGINE LUBRI CATION OIL FILTER REMOVAL 7 Install and tighten drain plug in crankcas...

Страница 1256: ...vehicle and fill engine crankcase with proper oil to correct level OIL PRESSURE SWITCH REMOVAL 1 Raise vehicle 2 Position oil collecting container under pressure switch location 3 Disconnect oil pres...

Страница 1257: ...95 3 Remove pump rotors Fig 95 4 Wash all parts in a suitable solvent and inspect carefully for damage or wear Fig 91 Crankshaft Sprocket Removal 1 SPECIAL TOOL 6793 2 SPECIAL TOOL C 4685 C2 3 CRANKSH...

Страница 1258: ...ss and diameter of outer rotor If outer rotor thickness measures 9 40 mm 0 370 in or less Fig 98 or if the diameter is 79 95 mm 3 148 in or less replace outer rotor 4 If inner rotor measures 9 40 mm 0...

Страница 1259: ...g 93 CAUTION To align the front crankshaft seal MUST be out of pump or damage may result 5 Install new front crankshaft seal using Special Tool 6780 Fig 101 6 Install crankshaft key Fig 92 CAUTION The...

Страница 1260: ...one or more cylinders may not be functioning WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN...

Страница 1261: ...voir if equipped at upper intake manifold fittings 9 Disconnect throttle speed control if equipped and transaxle control 31TH equipped only cables from throttle lever and bracket Refer to 14 FUEL SYST...

Страница 1262: ...e tube to throttle body 13 Connect inlet air temperature sensor connec tor Fig 104 14 Connect negative cable to battery INTAKE MANIFOLD LOWER REMOVAL 1 Perform fuel system pressure release proce dure...

Страница 1263: ...and high tempera tures The manifold attaches to the cylinder head OPERATION The exhaust manifold collects the exhaust gasses exiting the combustion chambers Then it channels the exhaust gasses to the...

Страница 1264: ...ne Fig 115 INSTALLATION REAR COVER 1 Install timing belt rear cover and bolts Fig 115 CAUTION Do not use an impact wrench for tighten ing camshaft sprocket bolt Damage to the timing locating pin can o...

Страница 1265: ...oist 4 Remove right front wheel 5 Remove right inner splash shield 6 Remove accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE BELT TENSION ERS REMOVAL Fig 113 ENGINE FRONT MOUNT BRACKET 1 ENGIN...

Страница 1266: ...marks before removing timing belt 14 Before the removal of the timing belt rotate crankshaft until the TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket trailing edge of spr...

Страница 1267: ...a pre determined depth from the factory for correct tim ing belt tracking If removed use of Special Tool 6792 is required to set the sprocket to original installation depth An incorrectly installed s...

Страница 1268: ...CAUTION Ensure that the arrows on both camshaft sprockets are facing up 3 Install timing belt Starting at the crankshaft go around the water pump sprocket idler pulley camshaft sprockets and then aro...

Страница 1269: ...all crankshaft vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTALLATION 12 Install accessory drive belts Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 13 Install dri...

Страница 1270: ...5 4 Install timing belt idler pulley and torque mounting bolt to 61 N m 45 ft lbs 5 Install camshaft sprockets Use Special Tool 6847 to hold sprockets Fig 124 torque bolts to 101 N m 75 ft lbs 6 Insta...

Страница 1271: ...move chain and sprocket 6 Using two wide pry bars work the crankshaft sprocket back and forth until it is off the crankshaft shaft 7 Remove gear cover retaining stud double ended to also retain chain...

Страница 1272: ...Turn balance shafts until both shaft key ways are up parallel to vertical centerline of engine Install short hub drive gear on sprocket driven shaft and long hub gear on gear driven shaft After insta...

Страница 1273: ...chain is over the number 1 cyl inder timing mark on the balance shaft crankshaft sprocket Fig 135 8 Place balance shaft sprocket into the timing chain Fig 135 and align the timing mark on the sprocke...

Страница 1274: ...c Place a shim 1 mm 0 039 in thick x 70 mm 2 75 in long or between tensioner and chain Push tensioner and shim up against the chain Apply firm pressure 2 5 3 Kg 5 5 6 6 lbs directly behind the adjust...

Страница 1275: ...9 AIR CLEANER HOUSING REMOVAL 99 INSTALLATION 100 CYLINDER HEAD DESCRIPTION 100 OPERATION 100 DIAGNOSIS AND TESTING CYLINDER HEAD GASKET 100 REMOVAL CYLINDER HEAD 100 CLEANING 101 INSPECTION 101 INSTA...

Страница 1276: ...G ROD DESCRIPTION 126 OPERATION 126 STANDARD PROCEDURE STANDARD PROCEDURE FITTING CONNECTING RODS 127 STANDARD PROCEDURE FITTING PISTONS 127 REMOVAL 127 INSTALLATION 128 PISTON RINGS STANDARD PROCEDUR...

Страница 1277: ...URE STANDARD PROCEDURE VALVE TIMING VERIFICATION 155 STANDARD PROCEDURE MEASURING TIMING CHAIN WEAR 155 TIMING CHAIN COVER REMOVAL 155 INSTALLATION 156 TIMING CHAIN AND SPROCKETS REMOVAL REMOVAL TIMIN...

Страница 1278: ...r to 9 ENGINE DIAGNOSIS AND TESTING PERFORMANCE For fuel system diagnosis Refer to 14 FUEL SYSTEM FUEL DELIVERY DIAGNOSIS AND TESTING Additional tests and diagnostic procedures may be necessary for sp...

Страница 1279: ...n 5 Incorrect spark plug gap 5 Set gap Refer to 8 ELECTRICAL IGNITION CONTROL SPECIFICATIONS 6 Contamination in fuel system 6 Clean system and replace fuel filter 7 Faulty fuel pump 7 Test fuel pump a...

Страница 1280: ...y 9 Faulty ignition coil s 9 Test and replace as necessary Refer to Appropriate Diagnostic Information ENGINE MISSES ON ACCELERATION 1 Dirty or incorrectly gapped spark plugs 1 Clean spark plugs and s...

Страница 1281: ...sters 7 Replace hydraulic lifters lash adjusters 8 Worn valve guides 8 Replace cylinder head assembly 9 Excessive runout of valve seats on valve faces 9 Grind valve seats and valves CONNECTING ROD NOI...

Страница 1282: ...Check engine oil level 2 Faulty oil pressure sensor switch 2 Replace oil pressure sensor switch 3 Low oil pressure 3 Check oil pressure sensor switch and main bearing oil clearance 4 Clogged oil filt...

Страница 1283: ...the fresh air hose make up air at the cylinder head cover and plug or cap the nipple on the cover Remove the PCV valve hose from the cylinder head cover Cap or plug the PCV valve nipple on the cover A...

Страница 1284: ...y 3 Remove all spark plugs from engine As spark plugs are being removed check electrodes for abnor mal firing indicators fouled hot oily etc Record cyl inder number of spark plug for future reference...

Страница 1285: ...inches the other is a metric scale NOTE Plastigage is available in a variety of clear ance ranges Use the most appropriate range for the specifications you are checking 4 Install the proper crankshaft...

Страница 1286: ...All mounting holes must be circled For corner sealing a 3 17 or 6 35 mm 1 8 or 1 4 in drop is placed in the center of the gasket contact area Uncured sealant may be removed with a shop towel Component...

Страница 1287: ...R WORN THREADS Damaged or worn threads excluding spark plug and camshaft bearing cap attaching threads can be repaired Essentially this repair consists of drilling out worn or damaged threads tapping...

Страница 1288: ...ure ECT sensor and ignition coil electrical connectors 20 Disconnect the fuel injector electrical harness connector and disengage clip from support bracket 21 Disconnect camshaft and crankshaft positi...

Страница 1289: ...sconnect the engine block heater electrical connector if equipped 43 Remove the accessory belt splash shield 44 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 45 Di...

Страница 1290: ...st mounts until the engine is resting on posts Tighten all cradle post mounts to cradle frame This will keep mounts from moving when removing or installing engine and transmission 56 Lower vehicle so...

Страница 1291: ...nerator and wiring harness Refer to 8 ELECTRICAL CHARGING GENERATOR INSTALLATION 9 Raise vehicle 10 Attach wiring harness support clip to the engine oil dipstick tube 11 Connect oil pressure switch el...

Страница 1292: ...e harness clip to engine right side mount 41 Connect the brake booster and speed control vacuum hoses 42 Connect the vacuum hoses to the throttle body 43 Connect the EGR transducer electrical connec t...

Страница 1293: ...Taper Service Limits 0 051 mm 0 002 in Lifter Bore Diameter 22 980 23 010 mm 0 905 0 906 in Deck Surface Flatness Max 0 1 mm 0 004 in Pistons Piston Diameter 3 3L Measured 39 8 mm 1 567 in from pisto...

Страница 1294: ...Steel Rails 3 3L 0 435 0 490 mm 0 017 0 019 in 3 8L 0 435 0 510 mm DESCRIPTION SPECIFICATION 0 017 0 020 in Connecting Rod Bearing Clearance 0 019 0 065 mm 0 0008 0 0026 in Wear Limit 0 074 mm 0 003...

Страница 1295: ...Gasket Thickness Compressed 0 65 0 75 mm 0 025 0 029 in DESCRIPTION SPECIFICATION Valve Seat Angle 44 5 45 Valve Seat Runout Service Limits 0 0762 mm 0 003 in Valve Seat Width Intake Exhaust 1 50 2 00...

Страница 1296: ...SPECIFICATION 3 148 in Tip Clearance Between Rotors Max 0 20 mm 0 008 in Oil Pressure At Curb Idle Speed Minimum with engine at operating temerature 34 47 kPa 5 psi At 3000 rpm 205 551 kPa 30 80 psi O...

Страница 1297: ...Filter Adapter Bolts 28 250 Oil Gallery Plug 27 20 Oil Pan Bolts 12 105 Oil Pan Drain Plug 27 20 Oil Pressure Switch 23 200 Oil Pump Cover Plate Screws 12 105 Oil Pump Pick up Tube Bolt 28 250 Oil Dip...

Страница 1298: ...ft 8450 Crankshaft Damper Sprocket Installer 8452 Indicator Cylinder Bore C 119 Tester Valve Spring C 647 Compressor Valve Spring In vehicle 8453 Valve Spring Compressor Off vehicle C 3422 D RS ENGINE...

Страница 1299: ...Front Seal 6341A Installer Crankshaft Front Seal C 4992 Remover and Installer Crankshaft Main Bearing C 3059 Rear Crankshaft Oil Seal Installer 6926 Oil Pressure Gauge C 3292 Adapter 8406 Cooling Sys...

Страница 1300: ...clips AIR CLEANER HOUSING REMOVAL 1 Disconnect the negative battery cable 2 Disconnect the inlet air temperature sensor Fig 16 3 Remove the inlet hose to throttle body 4 Remove the bolt for air box a...

Страница 1301: ...LINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders follow the proce dures in Cylinder Compression Pressure Test Refer to 9 ENGINE DIAGNOSIS AND TE...

Страница 1302: ...omponents and multi layer steel cylinder head gaskets NOTE Multi Layer Steel MLS head gaskets require a scratch free sealing surface Remove all gasket material from cylinder head and block Refer to 9...

Страница 1303: ...ethod they should be exam ined BEFORE reuse If the threads are necked down the bolts must be replaced Fig 21 4 Necking can be checked by holding a scale or straight edge against the threads If all the...

Страница 1304: ...ocation Fig 23 NOTE Due to the tight packaging near the cylinder head covers which makes spill clean up difficult a spill during an engine oil change may be misinter preted as an oil leak When investi...

Страница 1305: ...er head cover Fig 24 8 Connect spark plug wires to spark plugs 9 Install wiper module Refer to 8 ELECTRI CAL WIPERS WASHERS WIPER MODULE INSTALLATION 10 Connect negative cable to battery Fig 24 P S Su...

Страница 1306: ...with four bead lock grooves The valve stem seals are made of Viton rubber OPERATION The two valves per cylinder are opened using hydraulic lifters push rods and rocker arms STANDARD PROCEDURE REFACIN...

Страница 1307: ...efacing the valve and seat Fig 32 If valves and or seats are reground measure the installed height of springs Fig 32 make sure measurements are taken from top of spring seat to the bottom surface of s...

Страница 1308: ...cylinder head 2 Install valve spring seat on head Fig 36 3 Install new seals on all valve stems and over valve guides Fig 36 Install valve springs and valve retainers Fig 36 4 Install the valve sprin...

Страница 1309: ...e engine until the piston in the cylinder bore requiring spring removal is at TDC 6 Install Special Tool 8453 to the cylinder head Fig 38 Tighten the attaching bolts to 23 N m 200 in lbs 7 Install a s...

Страница 1310: ...INSTALLATION INSTALLATION CYLINDER HEAD OFF 1 If removed install a new valve stem seal Refer to 9 ENGINE CYLINDER HEAD VALVE STEM SEALS INSTALLATION 2 Position valve spring and retainer on spring seat...

Страница 1311: ...and up motions on the valve stem on the opposing end OPERATION PUSHRODS The pushrod is a solid link between the hydraulic lifter and the rocker arm Also the pushrod supplies engine oil from the hydrau...

Страница 1312: ...the rocker arm and shaft assemblies on the pedestal mounts CAUTION Ensure all pushrods are properly located on the lifter and the rocker arm socket 2 Align each rocker arm socket with each push rod en...

Страница 1313: ...ER LENGTH 5 ROCKER ARM EXHAUST 2 SHAFT RETAINER SPACER 21 5 mm 0 84 in 6 WASHER 3 SHAFT RETAINER SPACER 37 5 mm 1 47 in 7 ROCKER ARM INTAKE LARGER OFFSET 4 SHAFT RETAINER SPACER 40 9 mm 1 61 in 8 ROCK...

Страница 1314: ...down fast enough to get a cross hatch pattern When hone marks intersect at 40 60 degrees the cross hatch angle is most satisfactory for proper seat ing of rings Fig 45 4 A controlled hone motor speed...

Страница 1315: ...earing journal and rear lobe Fig 48 The 3 3L engine application is as cast only The 3 8L engine applica tion the cast ring is machined off OPERATION The camshaft is driven by the crankshaft through a...

Страница 1316: ...hain cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 9 Install the cylinder heads Refer to 9 ENGINE CYLINDER HEAD INSTALLATION 10 Install the cylinder head covers Refer to...

Страница 1317: ...of taper present Record all readings taken Refer to Engine Specifications Refer to 9 ENGINE SPECIFICA TIONS Plastigage generally is accompanied by two scales One scale is in inches the other is a metr...

Страница 1318: ...nt engine on an engine stand 4 Remove the oil filter 5 Remove the oil pan and oil pick up tube Refer to 9 ENGINE LUBRICATION OIL PAN REMOVAL 6 Remove the timing chain cover Refer to 9 ENGINE VALVE TIM...

Страница 1319: ...CK CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE 4 Inspect main cap bolts for stretching Fig 55 Replace bolts that are stretched NOTE The main cap bolts should be examined before reuse Bolt stretch can...

Страница 1320: ...Upper main bearing halves of 1 3 and 4 are interchangeable Fig 56 CRANKSHAFT AND BLOCK 3 3L 1 MAIN BEARING CAP No 4 2 MAIN BEARING CAP No 3 3 MAIN BEARING CAP No 2 4 MAIN BEARING CAP BOLT QTY 2 PER CA...

Страница 1321: ...earing shell and the bearing cap on the adjacent bearings and tightening bolts to 14 20 N m 10 15 ft lbs When checking 1 main bearing shim 2 main bearing When checking 2 main bearing shim 1 3 main bea...

Страница 1322: ...RANKSHAFT MAIN BEARINGS 1 Remove the oil pan Refer to 9 ENGINE LU BRICATION OIL PAN REMOVAL 2 Identify main bearing caps before removal 3 Remove bearing caps one at a time Remove upper half of bearing...

Страница 1323: ...the holding tool 9 Install oil pan Refer to 9 ENGINE LUBRI CATION OIL PAN INSTALLATION 10 Fill engine crankcase with proper oil to cor rect level CRANKSHAFT OIL SEAL FRONT REMOVAL 1 Disconnect negati...

Страница 1324: ...f the seal Pry out seal CAUTION Do not permit the pry tool blade to con tact crankshaft seal surface Contact of the pry tool blade against crankshaft edge chamfer is permit ted INSTALLATION CAUTION If...

Страница 1325: ...BRI CATION OIL PAN INSTALLATION 3 Install oil seal Refer to 9 ENGINE ENGINE BLOCK CRANKSHAFT OIL SEAL REAR INSTALLATION FLEX PLATE REMOVAL 1 Remove the transaxle Refer to 21 TRANS MISSION TRANSAXLE AU...

Страница 1326: ...ters it causes them to become soft and allows valves to seat noisily Any leaks on intake side of pump through which air can be drawn will create the same lifter noise Check the lubrication system from...

Страница 1327: ...nal positions if reused 3 Install lifter aligning yokes Fig 73 4 Install yoke retainer and torque screws to 12 N m 105 in lbs Fig 73 5 Install the cylinder heads Refer to 9 ENGINE CYLINDER HEAD INSTAL...

Страница 1328: ...n and cylinder wall must be clean and dry Piston diameter should be measured 90 degrees to pis ton pin at size location shown in Fig 76 Cylinder bores should be measured halfway down the cylinder bore...

Страница 1329: ...s are butted and the rail gaps located as shown in Fig 80 3 Lubricate the piston and rings with clean engine oil Position a ring compressor over the piston and rings and tighten the compressor Fig 81...

Страница 1330: ...me time guide connecting rod into position on connecting rod journal 9 Install lower bearing shell and connecting rod cap Fig 81 Install nuts on cleaned and oiled rod bolts and tighten to 54 N m 40 ft...

Страница 1331: ...lean Insert the ring and push down with piston to ensure squareness in bore to approximately 12 mm 0 50 in from top of cylin der bore Check ring gap with a feeler gauge Fig 83 For clearance specificat...

Страница 1332: ...r b Upper oil ring side rail c Lower oil ring side rail d No 2 Intermediate piston ring e No 1 Upper piston ring 2 Install the side rail by placing one end between the piston ring groove and the expan...

Страница 1333: ...ing screw until damper releases from crankshaft 8 Remove the crankshaft vibration damper INSTALLATION 1 Install crankshaft vibration damper using the forcing screw nut and thrust bearing washer from S...

Страница 1334: ...insulator and front crossmember mounting bracket Fig 92 3 Remove six screws from air dam to allow access to the front mount screws 4 Remove the front engine mount screws and remove the insulator asse...

Страница 1335: ...NOTE To remove mount additional lowering of transaxle may be required 9 Remove left mount INSTALLATION 1 Install left mount on transaxle Fig 94 or Fig 95 2 Raise transaxle with jack until left mount i...

Страница 1336: ...LEFT MOUNT TO BRACKET 1 BOLT BRACKET TO FRAME RAIL 68 N m 50 ft lbs 2 BOLT MOUNT TO RAIL THRU 75 N m 55 ft lbs 3 BOLT LEFT MOUNT TO TRANSAXLE 54 N m 40 ft lbs 4 TRANSAXLE 5 MOUNT LEFT 6 BRACKET LEFT...

Страница 1337: ...ig 97 Tighten through bolt to 54 N m 40 ft lbs 4 Install the rear mount heat shield Fig 96 5 Lower vehicle on hoist Fig 97 REAR MOUNT 1 BOLT 54 N m 40 ft lbs 2 REAR MOUNT BRACKET 3 THRU BOLT 54 N m 40...

Страница 1338: ...an air tube to throttle body LUBRICATION DESCRIPTION The lubrication system is a full flow filtration pres sure feed type The oil pump is mounted in the tim ing chain cover and is driven by the cranks...

Страница 1339: ...ne off 2 Open hood remove oil fill cap 3 Hoist and support vehicle on safety stands Refer to Hoisting and Jacking Recommendations Refer to LUBRICATION MAINTENANCE HOIST ING STANDARD PROCEDURE 4 Place...

Страница 1340: ...ECK The best time to check engine oil level is after it has sat overnight or if the engine has been running allow the engine to be shut off for at least 5 minutes before checking oil level Checking th...

Страница 1341: ...r 4 Connect oil cooler inlet and outlet hoses Fig 103 5 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE COOLING SYSTEM FILLING OIL FILTER REMOVAL CAUTION When servicing the oil filter avoid...

Страница 1342: ...move engine oil dipstick 2 Raise vehicle on hoist and drain engine oil 3 Remove drive belt splash shield 4 Remove strut to transaxle attaching bolt Fig 106 Loosen strut to engine block attaching bolts...

Страница 1343: ...m 105 in lbs Fig 107 4 Install cover to transaxle case Fig 106 5 Install the strut bolt to transaxle housing Fig 106 Tighten all bending brace bolts 6 Install the drive belt splash shield 7 Lower vehi...

Страница 1344: ...nd diagnostic information Refer to Appropriate Wiring Diagnostic Information REMOVAL 1 Raise vehicle on hoist 2 Disconnect electrical connector from switch 3 Remove oil pressure switch Fig 110 INSTALL...

Страница 1345: ...place outer rotor 4 If inner rotor thickness measures 7 64 mm 0 301 in or less replace inner rotor Fig 114 5 Install outer rotor into chain case cover Press rotor to one side with fingers and measure...

Страница 1346: ...proximately 49 5 mm 1 95 inches it should test between 19 5 and 20 5 pounds when compressed to 34 mm 1 11 32 inches Replace spring that fails to meet specifications Fig 113 Measuring Outer Rotor Thick...

Страница 1347: ...ak the composite manifold can be salvaged The vacuum ports are designed to break at the shoulder if overloaded Additional material in the shoulder area provides sufficient stock to repair For more inf...

Страница 1348: ...ming this procedure avoid get ting the manifold material residue into the plenum chamber 1 File or sand the remaining port back until a flat surface is obtained plane normal to nipple port axis 2 Dril...

Страница 1349: ...ts and remove the manifold Fig 123 13 Cover the lower intake manifold with a suit able cover while the upper manifold is removed 14 Clean and inspect the upper intake manifold Refer to 9 ENGINE MANIFO...

Страница 1350: ...ig 123 Install and tighten bolts to 12 N m 105 in lbs following torque sequence in Fig 124 5 Connect the MAP sensor electrical connector 6 Connect the brake booster and LDP vacuum hose to intake manif...

Страница 1351: ...MANIFOLD INSPECTION Refer to 9 ENGINE MANIFOLDS INTAKE MANIFOLD CLEANING CLEANING 1 Discard gasket s 2 Clean all sealing surfaces INSPECTION Check for Damage and cracks of each section Clogged water p...

Страница 1352: ...DS INTAKE MANIFOLD INSTALLATION 10 Connect negative battery cable 11 Fill the cooling system Refer to 7 COOL ING STANDARD PROCEDURE Fig 126 ECT SENSOR HEATER SUPPLY 1 ENGINE COOLANT TEMPERATURE SENSOR...

Страница 1353: ...the heat shield attaching screws Fig 133 7 Remove the upper heat shield Fig 133 8 Raise vehicle on hoist and remove drive belt shield 9 Loosen the power steering pump support strut lower bolt Fig 131...

Страница 1354: ...taching bolts Tighten all bolts to 23 N m 200 in lbs 4 Position the power steering pump support strut and install upper bolt Fig 131 5 Install heat shield and attaching screws Fig 133 6 Install and co...

Страница 1355: ...er head mounting surface and exhaust crossover mounting surface with a straightedge and thickness gauge Fig 137 Manifold surface flatness limits should not exceed 1 0 mm 0 039 in INSTALLATION 1 Positi...

Страница 1356: ...to 9 ENGINE VALVE TIMING TIMING CHAIN COVER REMOVAL 1 Position a scale next to timing chain so that any movement of chain may be measured Fig 138 2 Position a torque wrench and socket on the camshaft...

Страница 1357: ...aces of chain case cover and cylinder block are clean and free from burrs Crankshaft oil seal must be removed to insure cor rect oil pump engagement NOTE DO NOT USE SEALER ON COVER GASKET 2 Position n...

Страница 1358: ...N m 21 ft lb lbs 11 Install idler pulley on engine mount bracket Fig 142 12 Install right side engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT INSTALLATION 13 Install camshaft position sens...

Страница 1359: ...sh shield and right front wheel 21 Fill crankcase with engine oil to proper level 22 Fill cooling system Refer to 7 COOLING STANDARD PROCEDURE 23 Connect negative cable to battery Fig 145 TIMING CHAIN...

Страница 1360: ...Position the sprocket on the crankshaft timing mark out with the timing slot aligned with the tim ing pin 2 Install sprocket using Special Tool 8452 Fig 148 Install sprocket until it is fully seats on...

Страница 1361: ...lbs 6 Rotate crankshaft 2 revolutions and check tim ing mark alignment Fig 146 If timing marks do not line up remove camshaft sprocket and realign 7 Install the timing chain cover Refer to 9 ENGINE VA...

Страница 1362: ...OVAL 27 INSTALLATION 27 ROCKER ARMS DESCRIPTION 27 OPERATION 27 REMOVAL 27 INSTALLATION 28 HYDRAULIC LIFTERS DESCRIPTION 29 REMOVAL 29 INSPECTION 30 INSTALLATION 30 ENGINE BLOCK DESCRIPTION 30 CRANKSH...

Страница 1363: ...TION 61 ENGINE 2 5L TURBO DIESEL DESCRIPTION DESCRIPTION 2 5L COMMON RAIL DIESEL ENGINE This 2 5 Liter 2500cc four cylinder common rail direct injection engine is an in line overhead valve diesel engi...

Страница 1364: ...ke tube assembly Fig 3 4 Remove coolant pressure tank pressure cap 5 Raise vehicle on hoist 6 Drain cooling system Refer to 7 COOLING ENGINE COOLANT STANDARD PROCEDURE 7 Remove lower splash shield 8 R...

Страница 1365: ...7 COOLING ENGINE COOLANT STANDARD PROCEDURE 16 Remove coolant pressure tank Fig 5 Fig 4 RESERVOIR AND HOSES 2 5L DIESEL 1 POWER STEERING FLUID RESERVOIR 2 RESERVOIR BRACKET 3 SUPPLY HOSE BRACKET 4 RE...

Страница 1366: ...r to 13 FRAME BUMPERS FRAME ENGINE CRADLE CROSSMEMBER REMOVAL 35 Remove both axle shaft assemblies Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT REMOVAL 36 Disconnect the clutch slave cylinder quick di...

Страница 1367: ...ngine cover retaining bolts 2 Remove engine cover from engine Fig 10 Fig 8 ENGINE COMPONENT LOCATIONS 1 FUEL INJECTOR RETURN LINE 2 FUEL INJECTOR SUPPLY LINE 3 OIL SEPARATOR 4 FUEL INJECTOR 5 CAMSHAFT...

Страница 1368: ...connectors Fig 8 23 Connect egr solenoid vacuum supply line to brake boost vacuum supply line 24 Connect brake booster vacuum supply line 25 Connect heater core return hose to coolant pipe 26 Connect...

Страница 1369: ...Clearance Between Journal and Bearing 0 045 0 080 mm Connecting Rod Journal Nominal 53 940 53 955 mm DESCRIPTION SPECIFICATION 0 25 53 690 53 705 mm Connecting Rod Bearing Nominal 53 977 54 016 mm 0 2...

Страница 1370: ...ameter 11 994 0 006 mm VALVES Intake Valve Opens 16 B T D C Closes 58 A B D C Exhaust Valve DESCRIPTION SPECIFICATION Opens 65 B B D C Closes 29 A T D C Face Angle Intake 45 25 55 35 Exhaust 45 25 45...

Страница 1371: ...ump Housing Nuts 24 4 18 212 Connecting Rod Bolts Refer to the Service Procedure Balance Shaft Bolts 32 4 24 Oil Jet Bolts 10 8 8 96 Oil Pan Bolts 11 8 8 96 Crankshaft Hub Bolt 304 225 Front Engine Co...

Страница 1372: ...Pump Nut 88 3 65 Engine Lift Hook Bolts 32 4 24 Thermostat Housing Bolts 27 5 21 Turbocharger Oil Feed Line Fitting 24 5 18 217 Exhaust Manifold Nuts 32 4 24 Exhaust Manifold Heatshield Bolts 27 5 21...

Страница 1373: ...AL TOOLS VM 1001 CYLINDER LINER PULLER VM 1005 TORQUE ANGLE GAUGE VM 1010 CYLINDER LINER PROTRUSION TOOL VM 1013 DIAL INDICATOR VM 1016 CYLINDER RETAINER 9a 12 ENGINE RG ENGINE 2 5L TURBO DIESEL Conti...

Страница 1374: ...LIGNMENT PIN VM 1052 INTAKE CAMSHAFT ALIGNMENT PIN VM 1053 EXHAUST CAMSHAFT ALIGNMENT PIN VM 1054 RELIEF VALVE REMOVER CENTRAL CARRIER PIN REMOVER INSTALLER VM 1055 CAMSHAFT INJECTION PUMP GEAR HOLDER...

Страница 1375: ...N VM 1059 OIL PRESSURE RELIEF VALVE INSTALLER VM 1060 OIL JET REMOVER INSTALLER VM 1061 FRONT OIL SEAL INSTALLER VM 1062 POWER STEERING PUMP INSTALLER VM 1063 FUEL INJECTOR REMOVER 9a 14 ENGINE RG ENG...

Страница 1376: ...ER VM 1065 PISTON RING COMPRESSOR VM 1066 CYLINDER HEAD COVER ALIGNMENT PINS VM 1068 90 DEGREES AFTER TDC ALIGNMENT PIN VM 1069 CRANKSHAFT REM INSTALL SLEEVE VM 1070 FLYWHEEL LOCKING TOOL RG ENGINE 9a...

Страница 1377: ...M 1073 CRANKSHAFT FRONT BEARING REMOVER INSTALLER VM 1074 TIMING BELT RETAINER VM 1075 FLYWHEEL ALIGNMENT PINS VM 1077 POWER STEERING BELT REMOVER VM 1078 POWER STEERING BELT INSTALLER 9a 16 ENGINE RG...

Страница 1378: ...angle 2 After refacing a margin of at least 4 52 4 49 mm 178 177 inch must remain Fig 12 If the margin is less than 4 49 mm 177 inch the valve must be replaced VALVE SEAT REFACING 1 Install a pilot o...

Страница 1379: ...ring the piston of cylinder no 1 exactly to top dead center 3 Zero the dial indicator on the cylinder block mating surface 4 Setup the dial indicator on the piston crown above the center of the piston...

Страница 1380: ...ne and remove right engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT REMOVAL CAUTION Before removing the cylinder head cover intake manifold or timing belt the engine must put at 90 after TD...

Страница 1381: ...nifold studs Fig 17 22 Remove cylinder head bolts Fig 16 TURBOCHARGER AND COOLANT PIPES 1 TURBOCHARGER OUTLET PIPE RETAINING BOLT 2 TURBOCHARGER OUTLET PIPE 3 ADAPTER HOSE 4 HEAT SHIELD 5 HOSE CLAMPS...

Страница 1382: ...t was removed can be used 1 Clean and inspect gasket mating surfaces 2 Position correct head gasket on engine block 3 Place cylinder head on engine block Fig 18 CAUTION New cylinder head bolts must be...

Страница 1383: ...ALLATION 20 Install accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 21 Install power steering belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS INSTALLATION 22 Insta...

Страница 1384: ...ial indicator The end play should be between 10 mm 30 mm NOTE If the camshaft endplay is not within speci fication measure thickness of the camshaft spacer Camshaft spacer thickness should be 2 8 02mm...

Страница 1385: ...BELTS REMOVAL 8 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 9 Remove generator Refer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL 10 Support engine and remove righ...

Страница 1386: ...ter assemblies from cylinder head Fig 25 27 Remove cylinder head cover intake manifold gasket from cylinder head INSTALLATION 1 Clean and inspect sealing surfaces 2 Install new gasket on cylinder head...

Страница 1387: ...tube retaining bolt at intake manifold Torque bolt to 27 5 N m 11 Connect oil separator outlet hose at separator 12 Install oil dipstick tube retaining bolt at intake manifold inlet Torque bolt to 10...

Страница 1388: ...and or piston damage during reassembly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 5 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL 6 Using VM 1055 rem...

Страница 1389: ...r equivlalent 4 Connect rocker arm s to lifter and reposition on valve s Fig 30 5 Install cylinder head cover intake manifold Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S INSTALLATION 6 Inst...

Страница 1390: ...ilure to do so could result in valve and or piston damage during reassembly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 6 Remove timing belt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND...

Страница 1391: ...ngine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT INSTALLATION 7 Install engine cover Refer to 9 ENGINE INSTALLATION 8 Install front wiper unit Refer to 8 ELECTRI CAL WIPERS WASHERS WIPER MODU...

Страница 1392: ...MING TIMING BELT CHAIN AND SPROCKETS REMOVAL 6 Remove timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL 7 Remove cylinder head cover intake manifold Refer to 9 E...

Страница 1393: ...de special tool VM 1069 on crankshaft Fig 38 20 Using special tool VM 1054 remove crank shaft support retainers Fig 39 21 Slide crankshaft out rear of engine block INSTALLATION NOTE Before installing...

Страница 1394: ...fold Refer to 9 ENGINE CYLINDER HEAD CYLIN DER HEAD COVER S INSTALLATION 16 Install timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 17 Install timing belt...

Страница 1395: ...eck with a dial indicator mounted on a special tool VM 1010 A All the measurements must be taken on high pressure pump side of engine block Zero dial gauge on block deck 3 Move dial gauge to cylinder...

Страница 1396: ...GINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL NOTE Crankshaft hub has LHD thread 10 Remove crankshaft hub 11 Remove front engine cover Refer to 9 ENGINE ENGINE BLOCK ENGINE COVER REMOVAL 12 Remo...

Страница 1397: ...t 12 mm 0 50 in from bottom of cylinder bore Fig 49 Check gap with feeler gauge Top compression ring gap 30 to 45mm 0118 to 0177 in Second compression ring gap 30 to 45mm 0118 to 0177 in Oil control r...

Страница 1398: ...ting rod is centered in cylinder bore NOTE Be careful not to nick or scratch crankshaft journals 9 After removal install bearing cap on the mat ing rod and mark pistons with matching cylinder number w...

Страница 1399: ...loosening connecting rod bolts tighten all bolts to 88N m 4 Check and record internal diameter of crank end of connecting rod NOTE When changing connecting rods all four must have the same weight and...

Страница 1400: ...ton The third is an oil control ring Ring gaps must be positioned before inserting piston into the liners as follows 3 Top ring gap must be positioned at the 3 posi tion looking at the piston crown fr...

Страница 1401: ...aces towards front of engine NOTE Be careful not to nick crankshaft journals 4 Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore Insert rod and piston into cyl...

Страница 1402: ...TIMING BELT CHAIN AND SPROCKETS REMOVAL 9 Remove timing belt inner cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S REMOVAL NOTE Crankshaft hub retaining bolt has LHD thread 10 Remove c...

Страница 1403: ...13 Install right engine mount Refer to 9 ENGINE ENGINE MOUNTING RIGHT MOUNT INSTALLATION 14 Install air cleaner housing 15 Connect negative battery cable VIBRATION DAMPER REMOVAL 1 Remove power steer...

Страница 1404: ...S REMOVAL NOTE Crankshaft hub has LHD thread 10 Remove crankshaft hub 11 Remove front engine cover Fig 63 INSTALLATION 1 Clean engine block and front engine cover seal ing surfaces 2 Apply a continous...

Страница 1405: ...ft and remove bearing halves from supports Fig 64 CRANKSHAFT FRONT MAIN BEARING 1 Using special tool VM 1073 push front main bearing out of front of engine block Fig 65 Fig 64 CRANKSHAFT ASSEMBLY 1 CR...

Страница 1406: ...oil hole in bearing lines up with oil gal lery in engine block Fig 68 3 Reassemble engine and install in vehicle Fig 66 CRANKSHAFT ASSEMBLY 1 CRANKSHAFT SUPPORT HALVE 2 MAIN BEARING HALVE 3 CRANKSHAFT...

Страница 1407: ...N 1 Clean oil pan and sealing surfaces Inspect oil pan and engine block 2 Install oil pan gasket and retaining bolts Fig 70 3 Be sure power steering line brackets are in proper location Fig 70 4 Torqu...

Страница 1408: ...OVAL 8 Remove crankshaft sprocket Fig 71 9 Remove oil pump retaining bolts and remove pump from engine block Fig 71 REMOVAL 1 Disconnect negative battery cable 2 Raise vehicle on hoist 3 Remove oil pa...

Страница 1409: ...N The oil pressure switch is located on the right side of the engine block The switch screws into the engines main oil gallery Fig 73 REMOVAL 1 Disconnect negative battery cable 2 Raise vehicle on hoi...

Страница 1410: ...ATION 1 Thoroughly clean all components and relief valve pocket in cylinder block 2 Lubricate all oil pressure relief valve compo nents with engine oil 3 Install oil pressure relief valve plunger spri...

Страница 1411: ...6 Remove oil cooler retaining bolt at engine block Fig 79 7 Remove oil cooler retaining stud and remove oil cooler from engine block Fig 79 INSTALLATION 1 Clean oil cooler and engine block sealing sur...

Страница 1412: ...style filter Fig 80 REMOVAL 1 Raise vehicle on hoist 2 Remove oil filter cap drain plug and drain oil from oil filter housing Fig 81 3 Remove oil filter cap with suitable oil filter wrench Fig 81 4 R...

Страница 1413: ...il jets Damage to oil jet nozzle could cause severe engine damage 1 Lubricate o ring on oil jet 2 Using special tool VM 1060 install oil jet in engine block Fig 83 3 Install oil jet retaining bolt Tor...

Страница 1414: ...7 Remove plug in cylinder head cover intake manifold and insert VM 1053 to lock exhaust cam shaft in position Fig 86 8 Remove generator Refer to 8 ELECTRICAL CHARGING GENERATOR REMOVAL Fig 84 CRANKSH...

Страница 1415: ...LATION 18 Connect negative battery cable BALANCE SHAFT DESCRIPTION The 2 5L Common Rail Diesel engine is equipped with two nodular cast iron balance shafts in a cast aluminum carrier The balance shaft...

Страница 1416: ...assembly can be installed 2 With balance shaft assembly on work bench Insert special tool VM 1056 into balance shaft assem bly Fig 91 This will ensure proper balance shaft and crankshaft timing after...

Страница 1417: ...fer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 6 Remove accessory drive belt Refer to 7 COOLING ACCESSORY DRIVE DRIVE BELTS REMOVAL 7 Remove vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRA...

Страница 1418: ...M FUEL DELIVERY FUEL INJEC TION PUMP INSTALLATION 5 Install camshaft sprockets Fig 93 Torque bolts to 108N m 6 Install timing belt idler pulleys Refer to 9 ENGINE VALVE TIMING TIMING BELT IDLER PULLEY...

Страница 1419: ...lt Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN AND SPROCKETS REMOVAL NOTE Idler pulley retaining bolts are LHD thread 10 Remove timing belt idler pulleys Fig 95 INSTALLATION 1 Install timing belt...

Страница 1420: ...r Refer to 9 ENGINE VALVE TIMING TMNG BELT CHAIN TENSIONER PULLEY ADJUSTMENTS 3 Install timing belt outer cover Refer to 9 ENGINE VALVE TIMING TIMING BELT CHAIN COVER S INSTALLATION 4 Install vibratio...

Страница 1421: ...embly Refer to 9 ENGINE VALVE TIMING STANDARD PROCEDURE 1 Disconnect negative battery cable 2 Remove engine cover Refer to 9 ENGINE REMOVAL 3 Remove air cleaner housing assembly 4 Support engine and r...

Страница 1422: ...MING BELT CHAIN COVER S INSTALLATION 7 Install vibration damper Refer to 9 ENGINE ENGINE BLOCK VIBRATION DAMPER INSTAL LATION 8 Install accessory drive belt Refer to 7 COOL ING ACCESSORY DRIVE DRIVE B...

Страница 1423: ......

Страница 1424: ...t system consists of a catalytic converter muffler and a resonator with connecting pipes in be tween Fig 1 The system is serviced in two sections the catalytic converter and pipe and the muffler and r...

Страница 1425: ...en clamps at leaking joints 2 Burned or rusted out muffler assembly or exhaust pipe 2 Replace muffler resonator tailpipe assembly or exhaust pipe with catalytic converter assembly 3 Burned or rusted o...

Страница 1426: ...for cracked joints broken welds and corrosion damage that would result in a leaking exhaust system Inspect the clamps support brackets and insulators for cracks and corrosion damage NOTE Slip joint b...

Страница 1427: ...ultaneously converts three exhaust emissions into harmless gases Specifically HC and CO emissions are con verted into water H2O and carbon dioxide CO2 Oxides of Nitrogen NOx are converted into elemen...

Страница 1428: ...to avoid ruining the catalyst core Do not allow engine to operate above 1200 RPM in neutral for extended periods over 5 minutes This condition may result in excessive exhaust system floor pan temperat...

Страница 1429: ...INSTALLA TION CROSS OVER PIPE 3 3 3 8L REMOVAL 1 Disconnect negative cable from battery 2 Remove the fasteners attaching the left bank manifold connection to cross over pipe Fig 6 3 Raise vehicle and...

Страница 1430: ...in lbs Fig 7 Fig 8 or Fig 9 3 Lower vehicle MUFFLER REMOVAL 1 Raise vehicle on a body contact type hoist NOTE To provide removal clearance between muf fler resonator pipe and rear axle parts the rear...

Страница 1431: ...ptable exhaust noise levels Provide proper exhaust system back pressure for maintaining emission and performance levels INSTALLATION 1 Install the muffler resonator assembly by guid ing resonator betw...

Страница 1432: ...l spot weld breaks Clean remaining spot weld from the pipe using a file or grinder until surface is smooth NOTE Maintain proper clamp orientation when replacing with new clamp 5 Tighten the band clamp...

Страница 1433: ......

Страница 1434: ...cked or loose joints 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 replacem...

Страница 1435: ...ession the air must pass through a charge air cooler to cool the incoming air and maintain power and efficiency Increasing air flow to the engine provides Improved engine performance Lower exhaust smo...

Страница 1436: ...as a guide in determining the amount of engine idle time required to sufficiently cool down the turbo charger before shut down depending upon the type of driving and the amount of cargo TURBOCHARGER...

Страница 1437: ...NT PIPES 1 TURBOCHARGER OUTLET PIPE RETAINING BOLT 2 TURBOCHARGER OUTLET PIPE 3 ADAPTER HOSE 4 HEAT SHIELD 5 HOSE CLAMPS 6 TURBOCHARGER INLET PIPE RETAINING BOLT 7 TURBOCHARGER INLET PIPE 8 ADAPTER HO...

Страница 1438: ...ield Fig 6 Torque bolts to 27 5N m 6 Install engine lift hook Fig 6 Torque bolts to 32 4N m 7 Install thermostat to upper radiator hose tube and turbocharger outlet tube Fig 5 8 Install engine in vehi...

Страница 1439: ...N 6 Install front wiper unit Refer to 8 ELECTRI CAL WIPERS WASHERS WIPER MODULE INSTALLATION Fig 8 EXHAUST MANIFOLD AND TURBOCHARGER 1 TURBOCHARGER OIL SUPPLY BANJO BOLT 2 COPPER WASHER 3 EXHAUST MANI...

Страница 1440: ...m of fas cia air dam to radiator closure panel 5 Remove front wheels 6 Remove front wheelhouse splash shields fasten ers as necessary to gain access to bolts attaching front fascia to fender Refer to...

Страница 1441: ...t from vehi cle INSTALLATION NOTE Check position of the arrows molded into the foam for correct orientation 1 Support front bumper reinforcement using a suitable lifting device and lift into position...

Страница 1442: ...een liftgate and fascia 5 Install the six screws attaching rear fascia to rear fascia brackets 6 Install the four plastic push pins attaching bot tom of rear fascia to fascia support 7 Lower vehicle 8...

Страница 1443: ...ick pry up the rear edge of the scuff pad to release tabs from the rear bumper fascia and pull scuff pad to release the forward tabs Fig 5 INSTALLATION 1 Verify that there are fifteen slots in the fas...

Страница 1444: ...Fig 6 CROSSMEMBER DIMENSIONS RS FRAME BUMPERS 13 5 FRAME Continued...

Страница 1445: ...Fig 7 ENGINE BOX TOP VIEW 13 6 FRAME BUMPERS RS FRAME Continued...

Страница 1446: ...Fig 8 ENGINE COMPARTMENT AND FRAME RAIL SIDE VIEW RS FRAME BUMPERS 13 7 FRAME Continued...

Страница 1447: ...Fig 9 FULL VEHICLE BOTTOM VIEW 13 8 FRAME BUMPERS RS FRAME Continued...

Страница 1448: ...cedure use only the thread inserts which are specified in the Mopar Parts Catalog for this repair procedure These thread inserts have been specifically devel oped for this application and use of other...

Страница 1449: ...hose coupling 9 Using a hose pinch off pliers C 4390 pinch power steering oil return hose off between the cross member coupling and the pump 10 Loosen hose clamp at the cradle crossmember coupling 11...

Страница 1450: ...REAR MOUNT Fig 13 CRADLE CROSSMEMBER MOUNT 1 CROSSMEMBER MOUNT 2 BRAKE HOSE MOUNT 3 STEERING TIE ROD 4 FRONT CROSSMEMBER 5 FRAME RAIL Fig 14 CRADLE CROSSMEMBER 1 ENGINE OIL PAN 2 TRANSAXLE 3 LOWER CO...

Страница 1451: ...shaft 18 Install steering column cover backing plate Refer to 23 BODY INSTRUMENT PANEL STEER ING COLUMN COVER BACKING PLATE INSTALLATION 19 Install steering column lower cover from instrument panel Re...

Страница 1452: ...EL SENDING UNIT SENSOR DESCRIPTION 4 OPERATION 4 REMOVAL 4 INSTALLATION 6 FUEL LINES DESCRIPTION FUEL LINES HOSES AND CLAMPS 6 STANDARD PROCEDURE HOSES AND CLAMP 6 FUEL PRESSURE REGULATOR OPERATION 7...

Страница 1453: ...the fuel pump relay The PCM requires only three inputs and a good ground to operate the fuel pump relay The three inputs are Ignition voltage Crankshaft Position CKP sensor Camshaft Position CMP sens...

Страница 1454: ...el Rail 3 3 3 8L 11 8 105 Fuel Tank Strap 54 40 Fuel Tank T Strap 28 2 250 Fuel Filter Bolt 4 5 40 SPECIAL TOOLS FUEL Pressure Gauge Assembly C 4799 B Fuel Pressure Test Adapter 6539 Spanner Wrench 68...

Страница 1455: ...ehicle 8 Connect the negative battery cable 9 Pressurize the fuel system with the DRBIIIt and check for leaks FUEL LEVEL SENDING UNIT SENSOR DESCRIPTION The fuel gauge level sending unit is attached t...

Страница 1456: ...n slightly 6 Slide level sensor wires through opening fuel pump module Fig 6 7 Slide level sensor out of installation channel in module Fig 3 Wire Terminal Locking Finger 1 LOCKING FINGER 2 WIRE TERMI...

Страница 1457: ...are of a special rolled edge construction This construction is used to prevent the edge of the clamp from cutting into the hose Only these rolled edge type clamps may be used in this system All other...

Страница 1458: ...3 Ensure both upper and lower O rings were removed with regulator INSTALLATION The fuel pressure regulator is part of the fuel pump module Remove the fuel pump module from the fuel tank to access the...

Страница 1459: ...y 400 34 kPa 58 5 psi FUEL PUMP ELECTRICAL CONTROL Voltage to operate the electric pump is supplied through the fuel pump relay For an electrical opera tional description of the fuel pump refer to fue...

Страница 1460: ...g from the chassis tube Refer to Fuel Hoses Clamps and Quick Connect Fittings in this Section Place a shop towel under the connections to absorb any fuel spilled from the fitting WARNING WRAP A SHOP T...

Страница 1461: ...The fuel tank is constructed of a plastic material Its main functions are for fuel storage and for place ment of the fuel pump module The tank is made from High density Polyethylene HDPE material If e...

Страница 1462: ...al connector has a retainer that locks it in place 11 Slide fuel pump module electrical connector lock to unlock Fig 17 12 Push down on connector retainer Fig 18 and pull connector off module 13 Lower...

Страница 1463: ...ctor to make sure of connection 9 Fill fuel tank replace cap and connect battery negative cable 10 Use the DRBIIIt scan tool to pressurize the fuel system Check for leaks FUEL TANK FILLER TUBE REMOVAL...

Страница 1464: ...NG STANDARD PROCEDURE QUICK CONNECT FITTINGS REMOVAL When disconnecting a quick connect fitting the retainer will remain on the fuel tube nipple WARNING RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTI...

Страница 1465: ...S UNDER A CON STANT PRESSURE EVEN WITH THE ENGINE OFF BEFORE SERVICING ANY FUEL SYSTEM HOSES FITTINGS OR LINES THE FUEL SYSTEM PRES SURE MUST BE RELEASED REFER TO THE FUEL PRESSURE RELEASE PROCEDURE I...

Страница 1466: ...on 2 Disconnect negative battery cable from battery or auxiliary jumper terminal 3 Clean fitting of any foreign material before dis assembly 4 To release fuel system component from quick connect fitti...

Страница 1467: ...AY DESCRIPTION 27 OPERATION 27 IDLE AIR CONTROL MOTOR DESCRIPTION 27 OPERATION 27 REMOVAL 28 INSTALLATION 28 INLET AIR TEMPERATURE SENSOR DESCRIPTION 28 OPERATION 28 MAP SENSOR DESCRIPTION 29 OPERATIO...

Страница 1468: ...ored dur ing OPEN LOOP modes except for heated oxygen sensor diagnostics they are checked for shorted con ditions at all times During CLOSED LOOP modes the PCM monitors the inputs from the upstream an...

Страница 1469: ...E WARM UP MODE This is an OPEN LOOP mode The following inputs are received by the PCM Manifold Absolute Pressure MAP Crankshaft position engine speed Engine coolant temperature Inlet Intake air temper...

Страница 1470: ...PCM senses a wide open throttle condi tion through the Throttle Position Sensor TPS it de energizes the A C compressor clutch relay This disables the air conditioning system and disables EGR if equipp...

Страница 1471: ...blem that would drive long term to 25 and short term to another 25 for a total change of 50 away from base pulse width calculation TYPICAL ADAPTIVE MEMORY FUEL CELLS Open Throttle Open Throttle Open T...

Страница 1472: ...R ALUMINUM MANIFOLD 11 9 105 THROTTLE CABLE BRACKET PLASTIC MANIFOLD 5 7 50 THROTTLE CABLE BRACKET ALUMINUM MANIFOLD 11 9 105 EGR TUBE PLASTIC MANIFOLD 5 7 50 EGR TUBE ALUMINUM MANIFOLD 11 9 105 THROT...

Страница 1473: ...al retainer and throttle cable from the upper end of the pedal lever Fig 2 3 Remove nuts from accelerator pedal attaching studs Remove assembly from vehicle Fig 3 Pressure Gauge Assembly C 4799 B Fuel...

Страница 1474: ...in the wide open position and install the throttle cable Fig 1 CRANKSHAFT POSITION SENSOR DESCRIPTION The 2 4L crankshaft sensor is located on the rear of the engine near the accessory drive belt Fig...

Страница 1475: ...haft position it begins energizing the injectors in sequence REMOVAL 1 Disconnect the negative battery cable 2 Raise vehicle and support 3 Disconnect the electrical connector Fig 8 4 Remove crankshaft...

Страница 1476: ...voltage to each injector through the ASD relay Injector operation is con trolled by a ground path provided for each injector by the PCM Injector on time pulse width is variable and is determined by th...

Страница 1477: ...the top slot of the injector The edge of the receiver cup will slide into the side slots of clip 3 Install injector top end into fuel rail receiver cap Be careful not to damage O ring during installa...

Страница 1478: ...dle speed through the idle air control motor to compensate for engine load coolant temperature or barometric pressure changes The throttle body has an air bypass passage that provides air for the engi...

Страница 1479: ...screws to 2 N m 17 in lbs torque 4 Connect electrical connector to idle air control motor 5 Connect negative cable to battery INLET AIR TEMPERATURE SENSOR DESCRIPTION The IAT Sensor is a Negative Temp...

Страница 1480: ...t above sea level because the air density changes with altitude It will also help to correct for varying weather conditions If a hurricane was coming through the pressure would be very very low or the...

Страница 1481: ...onding barometric pressure is for your area REMOVAL REMOVAL 2 4L 1 Disconnect the negative battery cable 2 Disconnect electrical connector and vacuum hose from MAP sensor Fig 18 3 Remove two screws ho...

Страница 1482: ...width accordingly During Open Loop operation the PCM ignores the O2 sensor input The PCM adjusts injector pulse width based on pre programmed fixed values and inputs from other sensors The Automatic S...

Страница 1483: ...ed the threads must be cleaned with an 18 mm X 1 5 6E tap If using the original sensor coat the threads with Loctite 771 64 anti seize compound or equivalent REMOVAL DOWNSTREAM 1 2 2 4 3 3 3 8L 1 Disc...

Страница 1484: ...ize compound to the threads of a new oxygen sensor 1 Install sensor and tighten to 27 N m 20 ft lbs 2 Connect the electrical connector 3 Lower vehicle 4 Install the negative battery cable THROTTLE BOD...

Страница 1485: ...e cable retainer and throttle cable from the upper end of the pedal shaft 4 Remove retainer clip from throttle cable and grommet at dash panel 5 From the engine compartment pull the throttle cable and...

Страница 1486: ...emove the electrical connector from the Inlet Air Temperature sensor 3 Remove the air cleaner box lid Remove hose from throttle body 4 Disconnect the electrical connector at TPS 5 Disconnect the elect...

Страница 1487: ......

Страница 1488: ...Water draining WARNING HIGH FUEL SYSTEM PRESSURE WARNING THE INJECTION PUMP SUPPLIES HIGH PRESSURE FUEL TO EACH INDIVIDUAL INJECTOR THROUGH HIGH PRESSURE LINES FUEL UNDER THIS AMOUNT OF PRESSURE CAN P...

Страница 1489: ...just behind the alternator Fig 1 3 Attach a hose of about 1 or 2 meters to this fit ting using an appropriate connector 4 Direct the end of the hose into an appropriate fuel container 5 Turn the igni...

Страница 1490: ...t 10 8 8 96 Boost Pressure Intake Air Temperature Sensor Bolts 5 4 48 Fuel Pump Nuts 27 5 21 Fuel Line Fittings at Pump 27 5 21 Fuel Pump Sprocket Nut 88 3 65 Fuel Injector Retaining Bolts 32 4 24 Hig...

Страница 1491: ...The fuel rail is common to all cylinders hence it s name common rail Even when large quantities of fuel are extracted the fuel rail maintains a constant inner pressure This ensures that the injection...

Страница 1492: ...e fuel heater and Water In Fuel WIF sensor OPERATION The fuel filter water separator protects the fuel injection pump by removing water and contaminants from the fuel The construction of the filter se...

Страница 1493: ...placement of high pressure fuel line is necessary High pressure fuel lines deliver fuel under extremely high pressure from the injection pump to the fuel injectors The lines expand and contract from t...

Страница 1494: ...nsfer pump is controlled by the Engine Control Module ECM The ECM turns the fuel transfer pump on for 30 seconds when the ignition ket is turned ON With the ignition ON and fuel tranfer pump run ning...

Страница 1495: ...ket as shown Fig 8 10 Install inner flange of special tool VM 1067 on injection pump sprocket as shown Fig 9 Secure flange to feet in injection pump sprocket with allen bolts supplied with tool 11 Scr...

Страница 1496: ...the accessory bracket into the injection pump sprocket 2 Install injection pump retaining nuts Fig 11 Torque nuts to 27 5N m 3 Unscrew injection pump holding plate part of VM 1067 from inner timing be...

Страница 1497: ...le WATER IN FUEL SENSOR DESCRIPTION The WIF sensor is located in the bowl assembly of the fuel filter water separator OPERATION The sensor sends an input to the Engine Control Module ECM when it sense...

Страница 1498: ...injectors for all four cyl inders These fuel injectors are used to spray fuel into the combustion chamber Fig 1 OPERATION The injector operation can be subdivided into four operating states with the...

Страница 1499: ...and the fuel is injected into the combustion chamber at a pressure almost equal to that in the fuel rail Fig 2 Injector closes end of injection As soon as the solenoid valve is no longer trig gered th...

Страница 1500: ...or pedal As the accelerator pedal is depressed and released the sensor provides a variable voltage sig nal to the engine control module This voltage signal is directly proportional to accelerator peda...

Страница 1501: ...o monitor air pressure within the intake manifold This sensor is also used to monitor the intake air temperature Fig 5 OPERATION When the intake manifold pressure is low high vacuum sensor voltage out...

Страница 1502: ...or retain ing screws and sensor Fig 6 INSTALLATION 1 Install intake air temperature sensor and retaining bolts Fig 6 Torque to 5 4 N m 2 Connect intake air temperature sensor 3 Install engine cover an...

Страница 1503: ...ure The change in resistance varies the signal voltage output to the ECM The diesel power relay supplies battery power the to MAF sensor Ground is provided by the ECM The MAF sensor signal is provided...

Страница 1504: ...f the helical pinion teeth with the rack teeth within the steering gear The lateral travel pushes and pulls the tie rods to change the direction of the vehicle s front wheels Power assist steering is...

Страница 1505: ...r steering system on the vehi cle 1 Check belt tension and adjust as necessary 2 Disconnect the power steering fluid pressure hose from the power steering pump Fig 3 Fig 4 3 Connect Adapter Fitting Sp...

Страница 1506: ...xtreme left until the stop in the steering gear is met Hold it there for 2 4 seconds then release it Now turn the steering wheel to the right until the right stop is met Hold it there for 2 4 seconds...

Страница 1507: ...er tie rod 2 Loose inner tie rod 2 Replace power steering gear CHIRP OR SQUEAL POWER STEERING PUMP 1 Loose power steering pump drive belt 1 Check and adjust power steering pump drive belt to specifica...

Страница 1508: ...nd the steer ing wheel is at the end of its travel Hiss is a very high frequency noise similar to that experienced while slowly closing a water tap The noise is present in every valve and results when...

Страница 1509: ...id reservoir to specified level and check for leaks 2 Tires not inflated to specified pressure 2 Inflate tires to the specified pressure 3 Lack of lubrication in front lower control arm ball joints 3...

Страница 1510: ...assembly 8 Binding shaft bearing in steering column 8 Replace the steering column 9 Excessive friction in steering column coupling 9 Replace steering column coupling 10 Excessive friction in power ste...

Страница 1511: ...sed low speed or stationary steer ing effort can be expected if the steering fluid is at a high temperature High fluid temperature usually results from high engine rpm due to trailer towing ascending...

Страница 1512: ...Size M14 183 N m 135 ft lbs Mounting Bolts Size M12 95 N m 70 ft lbs Tie Rod Steering Knuckle Nut 75 N m 55 ft lbs Tie Rod Jam Nut 75 N m 55 ft lbs Coupling Pinch Bolt 28 N m 250 in lbs Power Steerin...

Страница 1513: ...They are the key cylinder ignition switch lock cylinder housing multi function switch clockspring halo lamp speed control switches driver airbag trim shrouds steering wheel and steering column interm...

Страница 1514: ...Fig 2 Steering Column And Components Typical RS COLUMN 19 11 COLUMN Continued...

Страница 1515: ...Disconnect negative ground cable from the battery and isolate cable from battery terminal 3 Remove the lower shroud Refer to 19 STEERING COLUMN LOWER SHROUD REMOV AL 4 Remove the traction off switch...

Страница 1516: ...ING COLUMN KEY LOCK CYLINDER REMOVAL 25 Remove the BTSI INSTALLATION To service the steering wheel components or the airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVER AIRBAG REMOVAL Follow all WARN INGS...

Страница 1517: ...G WHEEL INSTALLATION 15 Install the vibration damper weight 16 Install the steering wheel retaining nut Tighten the nut to 61 N m 45 ft lbs 17 Install the airbag Refer to 8 ELECTRICAL RESTRAINTS DRIVE...

Страница 1518: ...re har ness connectors splices and grounds 1 Disconnect negative cable from battery 2 Remove steering column cover retaining screws Fig 8 3 Remove parking brake release cable from han dle Fig 9 4 Remo...

Страница 1519: ...ing on the end opposite the lock cylinder Fig 7 For ignition switch terminal and circuit identifica tion refer to the Wiring Diagrams section 1 Ensure the ignition switch is in the RUN posi tion and t...

Страница 1520: ...the key to the lock position unless the shifter is in the park posi tion On vehicles equipped with floor shift refer to the Transaxle for Automatic Transmission Shifter Ignition Interlock REMOVAL 1 D...

Страница 1521: ...el is mounted to the instrument panel using 2 screws one on each side of the column and retaining clips 7 Remove the 2 screws securing the steering col umn fixed shroud to the steering column Fig 21 t...

Страница 1522: ...cylinder straight out of the lock cyl inder housing 11 Remove the vehicle wiring harness connector from the key cylinder halo lamp Fig 25 12 Remove the key cylinder halo lamp from the lock cylinder ho...

Страница 1523: ...g holes 2 Install the self tapping lock cylinder housing mounting screws through the top of the column into the housing Fig 29 Tighten the two mounting screws to a torque of 11 N m 100 in lbs 3 Connec...

Страница 1524: ...ll the lower steering column shroud on the steering column Install and securely tighten the center screw attaching the lower shroud to the tilt head on the column Fig 20 16 Install the upper steering...

Страница 1525: ...EMOVAL 3 Remove the upper and lower shrouds Refer to 19 STEERING COLUMN LOWER SHROUD REMOVAL 4 Remove the cluster trim bezel Refer to 23 BODY INSTRUMENT PANEL CLUSTER BEZEL REMOVAL 5 Remove the fixed...

Страница 1526: ...etaining screws Tighten the screws to 11 N m 100 in lbs Fig 35 STEERING WHEEL REMOVAL NOTE Before proceeding Refer to 19 STEERING COLUMN WARNING 1 Rotate key cylinder to the lock position and remove k...

Страница 1527: ...than a half inch If bolts are threaded into the steering wheel more than a half inch they will contact and damage the clock spring 6 Remove the steering wheel from steering col umn shaft using a stee...

Страница 1528: ...damper on the steer ing wheel When damper is installed it must be posi tioned on the steering wheel as shown in Fig 39 3 Install the steering wheel retaining nut Tighten the steering wheel retaining...

Страница 1529: ...by an open center rotary type control valve which directs oil from the pump to either side of the integral rack piston upon demand Road feel is controlled by the diameter of a torsion bar which initia...

Страница 1530: ...tire assemblies 7 Remove front emissions vapor canister Refer to 25 EMISSIONS CONTROL EVAPORATIVE EMISSIONS VAPOR CANISTER REMOVAL 8 Remove a single hose at power steering cooler and allow fluid to dr...

Страница 1531: ...ion of the various sizes 14 Remove the bolts attaching the cradle cross member reinforcement to the front suspension cradle crossmember Fig 6 Remove the 2 bolts fastening the reinforcement and rear of...

Страница 1532: ...ehicle on the ground disconnect the steering column shaft coupler from the steering gear intermediate coupler Fig 2 6 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 7 Remo...

Страница 1533: ...steering gear 19 Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin Fig 9 Install Remover Installer Special Tool 6831A through the center of the rol...

Страница 1534: ...N CRADLE 4 REMOVER SPECIAL TOOL 6831A 5 STEERING GEAR 6 NUT 7 ROLL PIN 8 THREADED ROD Fig 10 RHD Gear Heat Shield And Hose Fittings 1 HEAT SHIELD 2 CRADLE CROSSMEMBER 3 RETURN HOSE FITTING 4 PRESSURE...

Страница 1535: ...n the cradle reinforce ment to suspension cradle mounting bolts is very important 7 Install the reinforcement on the front suspen sion cradle crossmember and install the bolts attach ing the reinforce...

Страница 1536: ...radle mounting bolt to a torque of 95 N m 70 ft lbs CAUTION Proper torque on the steering gear to suspension cradle mounting bolts is very impor tant 5 Install the heat shield on the steering gear Fig...

Страница 1537: ...t wheel toe Refer to 2 SUSPEN SION WHEEL ALIGNMENT STANDARD PROCE DURE SPECIAL TOOLS POWER STEERING GEAR OUTER TIE ROD REMOVAL 1 Loosen inner tie rod to outer tie rod jam nut Fig 14 2 Remove nut attac...

Страница 1538: ...ghten tie rod jam nut Fig 14 to 75 N m 55 ft lbs torque CAUTION During this procedure do not allow the steering gear boot to become twisted 5 Adjust the front toe setting on the vehicle Refer to 2 SUS...

Страница 1539: ...ON 3 3L 3 8L ENGINE 50 HOSE POWER STEERING SUPPLY REMOVAL REMOVAL 2 4L ENGINE 51 REMOVAL 3 3L 3 8L ENGINE 51 INSTALLATION INSTALLATION 2 4L ENGINE 51 INSTALLATION 3 3L 3 8L ENGINE 51 RESERVOIR POWER S...

Страница 1540: ...D WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS CAUTION CAUTION When the system is open cap all open ends of the hoses power steering pump fittings or power steering gear ports to p...

Страница 1541: ...sensor wiring harness from the vehicle wiring harness at the rear engine mount bracket NOTE The exhaust system needs to be removed from the engine to allow for an area to remove the power steering pu...

Страница 1542: ...oses 2 4L 1 POWER STEERING PUMP 2 RETURN HOSE HEAT SLEEVE COVERED 3 ROUTING CLAMPS 4 PRESSURE HOSE TUBE NUT 5 RETURN HOSE TUBE NUT 6 CRADLE CROSSMEMBER 7 POWER STEERING GEAR 8 PRESSURE HOSE Fig 6 Powe...

Страница 1543: ...iper module unit Refer to 8 ELECTRICAL WIPERS WASHERS WIPER MOD ULE REMOVAL 3 Raise the vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 4 Remove the drive belt splash shield 5 Re...

Страница 1544: ...ose from the pump Fig 12 9 Remove the bolt fastening the stamped bracket on the rear of the pump to the cast bracket Fig 13 10 Remove the three front mounting bolts through the pulley 11 Remove the pu...

Страница 1545: ...p once the pump is removed from the vehicle 1 Install the pulley with Installer C 4063 Fig 15 Do not use the tool adapters 2 Ensure that the tool and the pulley remain aligned with the pump shaft Prev...

Страница 1546: ...ve battery post 15 Perform the POWER STEERING PUMP INI TIAL OPERATION procedure to properly fill and bleed the power steering system Refer to 19 STEERING PUMP STANDARD PROCEDURE 16 Inspect for leaks I...

Страница 1547: ...POWER STEERING PUMP FLUID STANDARD PROCEDURE POWER STEERING FLUID LEVEL CHECKING WARNING FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS AND TO ENSURE ACCU RATE...

Страница 1548: ...luid reservoir 2 Raise vehicle Refer to LUBRICATION MAINTENANCE HOISTING STANDARD PROCE DURE 3 Remove the hose clamps at the cooler and remove the hoses from the cooler inlet and outlet tubes 4 Remove...

Страница 1549: ...luid 7 Disconnect pressure hose at power steering gear Fig 20 8 Remove pressure hose routing bracket bolt at engine Fig 21 Bolt can be accessed through hole in cradle crossmember Fig 22 9 Disconnect p...

Страница 1550: ...D PROCEDURE 12 Inspect system for leaks INSTALLATION 3 3L 3 8L ENGINE 1 Remove any used O rings from ends of power steering hose 2 Using a lint free towel wipe clean hose ends power steering pump pres...

Страница 1551: ...lbs torque 8 Route hose behind cradle crossmember and start hose end into gear port Do not tighten hose tube nut at this time 9 Attach hose to suspension cradle crossmember and steel reinforcement usi...

Страница 1552: ...crossmember reinforcement Fig 23 9 Remove bolts attaching routing clamps to front suspension cradle crossmember Fig 19 Remove return hose from clamps 10 Back out return hose tube nut at power steer i...

Страница 1553: ...SSIONS VAPOR CANISTER INSTALLATION 12 Lower vehicle 13 Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure Refer to 19 STEERING PUMP STAN DARD PROCEDURE...

Страница 1554: ...Fig 21 INSTALLATION INSTALLATION 2 4L ENGINE 1 Install and correctly route power steering fluid supply hose from remote fluid reservoir to power steering pump 2 Install fluid supply hose onto power st...

Страница 1555: ...ble from power steering fluid reservoir 3 Open retainer on side of reservoir and remove cables from retainer 4 Remove clamp attaching supply hose to power steering fluid reservoir Disconnect hose from...

Страница 1556: ...se clamp in installed past bead on fluid reservoir fitting 4 Install return hose onto reservoir Fig 21 Slide the hose clamp into position on fluid reservoir and attach it Be sure hose clamp in install...

Страница 1557: ......

Страница 1558: ...FT INNER SEAL REMOVAL 12 INSTALLATION 13 INPUT SHAFT COVER SEAL REMOVAL 13 INSTALLATION 14 INPUT SHAFT END SEAL REMOVAL 16 INSTALLATION 16 INPUT SHAFT SEAL REMOVAL 17 INSTALLATION 18 OUTER HALF SHAFT...

Страница 1559: ...Power Transfer Unit Components 21 2 POWER TRANSFER UNIT RS POWER TRANSFER UNIT Continued...

Страница 1560: ...T DIFFERENTIAL PINION 8 TAPERED ROLLER BEARING 25 LOCK NUT HEX FLANGE 42 PIN 9 SEAL RING 26 O RING 43 CASE DIFFERENTIAL 10 SEAL RING 27 RETAINER PLATE 44 TAPERED ROLLER BEARING CONE 11 HEX HEAD SCREW...

Страница 1561: ...vice Procedures If fluid is leaking from weep hole B Fig 5 the type of fluid leaking will determine which seal is leaking If the fluid leaking is red in color transmis sion fluid this indicates that t...

Страница 1562: ...URE PTU FLUID CHANGE NOTE PTU Fluid should be changed upon servic ing the unit or at the unit s regular scheduled inter val Refer to LUBRICATION MAINTENANCE MAINTENANCE SCHEDULES DESCRIPTION 1 Raise v...

Страница 1563: ...peller shaft front flange CAUTION Do not let propeller shaft to hang freely Damage to the shaft will occur 4 Remove propeller shaft assembly Fig 10 Refer to 3 DIFFERENTIAL DRIVELINE PRO PELLER SHAFT R...

Страница 1564: ...Fig 15 Record this measurement 5 Repeat steps Step 1 through Step 4using the new flange and the original shim Record this measurement 6 If measurements are not equal use a new shim that protrudes from...

Страница 1565: ...N m 180 in lbs Rear Cover 28 N m 250 in lbs Ring Gear 94 N m 70 ft lbs SPECIAL TOOLS SDP POWER TRANSFER UNIT 5049 a Seal Puller 5065 Bearing Installer 6514 Bearing Remover 6522 Bearing Remover 7794 a...

Страница 1566: ...he vehicle 3 Check and fill fluids as required END COVER BALL BEARING REMOVAL The end cover ball bearing can be removed and installed without removing the Power Transfer Unit from the vehicle When rep...

Страница 1567: ...all bearing Fig 20 into the housing 2 Install bearing retaining snap ring CAUTION When installing bearing retaining snap ring be sure to index the snap ring so that the snap ring does not cover bearin...

Страница 1568: ...STALLATION 1 Reinstall cover and tighten bolts to 28 N m 250 in lbs in the sequence shown in Fig 24 Retighten first bolt after all others are tight CAUTION When end cover is installed be careful not t...

Страница 1569: ...emove end cover bolts Fig 25 3 Tap on end cover ears to separate cover from case Fig 26 4 Drive seal out with a hammer and small chisel Fig 27 Fig 26 End Cover Removal 1 END COVER EARS 2 HAMMER 3 POWE...

Страница 1570: ...cover onto P T U case and install bolts Tighten bolts to 28 N m 250 in lbs in the sequence shown in Fig 29 Retighten first bolt after all other bolts are tight 5 Reinstall P T U assembly 6 Check and f...

Страница 1571: ...cover The differential bearing cup must be removed to service this seal 1 Clean and inspect seal area 2 Use special tool No MD998803 and install seal Fig 34 When installing seal the spring side of the...

Страница 1572: ...stall bolts Tighten bolts to 28 N m 250 in lbs in the sequence shown in Fig 37 Retighten first bolt after all others are tight CAUTION When end cover is installed be careful not to damage the P T U In...

Страница 1573: ...2 Remove input shaft from housing and stand on soft block of wood Install input shaft end seal with seal installer 5065 and handle C 4171 3 Lubricate seal lip after installing seal into input shaft 4...

Страница 1574: ...le to service this seal Refer to Power Trans fer Unit Removal in this section for procedures 1 Remove P T U end cover bolts Fig 42 2 Gently tap on end cover ears to separate cover from case Fig 43 3 R...

Страница 1575: ...led with the spring side facing towards the ring gear Drive the seal in until it bot toms against the case shoulder 3 Install input shaft 4 Install oil trough Fig 44 Oil Trough 1 OIL TROUGH 2 POWER TR...

Страница 1576: ...vehicle 3 Remove seal with a chisel and hammer Fig 48 INSTALLATION The outer half shaft seal is located on the outside of the end cover The P T U does not have to be removed to replace this seal 1 Cle...

Страница 1577: ...r O Ring Fig 53 INSTALLATION 1 To install reverse removal procedure Fig 52 Rear Cover Removal 1 POWER TRANSFER UNIT ASSEMBLY 2 REAR COVER 3 O RING Fig 51 Mark Rear Cover 1 REAR COVER 2 OUTPUT SHAFT 3...

Страница 1578: ...82 OPERATION 82 DISASSEMBLY 82 ASSEMBLY 84 CLUTCH REAR DESCRIPTION 86 OPERATION 86 DISASSEMBLY 87 ASSEMBLY 89 FINAL DRIVE DISASSEMBLY 91 ASSEMBLY 94 ADJUSTMENTS ADJUSTMENT DIFFERENTIAL BEARING 97 FLUI...

Страница 1579: ...al oil sump is common with the transaxle sump Separate filling of the differen tial is NOT necessary The torque converter is attached to the crankshaft through a flexible driving plate Cooling of the...

Страница 1580: ...NVERTER CLUTCH 2 TORQUE CONVERTER 3 OIL PUMP 4 FRONT CLUTCH 5 REAR CLUTCH 6 OVER RUNNING CLUTCH 7 PLANETARY GEARS 8 TRANSFER GEARS 9 SHAFT 10 GOVERNOR 11 DIFFERENTIAL RS 31TH AUTOMATIC TRANSAXLE 21 23...

Страница 1581: ...saxle problems should always begin with checking the easily accessible variables Fluid level and condition Gearshift cable adjustment Throttle valve cable adjustment After verifying or adjusting these...

Страница 1582: ...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 Rear Band Misad...

Страница 1583: ...se Misadjusted 2 Inspect adjust and reassemble linkage as needed Replace worn damaged parts 3 Filter Plugged 3 Remove and disassemble transmission Repair or replace failed components as needed Replace...

Страница 1584: ...gasket Replace pump assembly if needed NO REVERSE D RANGES OK 1 Gearshift Linkage Cable Misadjusted Damaged 1 Repair or replace linkage parts as needed 2 Rear Band Misadjusted Worn 2 Adjust band repl...

Страница 1585: ...ressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 5 Valve Body Malfunction 5 Sticking 1 2 2 3 shift valves governor plugs 3 4 solenoid 3 4 shi...

Страница 1586: ...Air pressure check clutch servo operation and repair as required 7 Band Linkage Binding 7 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level Low 1 Add fluid and check for leaks...

Страница 1587: ...required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan WHINE NOISE RELATED TO ENG...

Страница 1588: ...hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged Check for leaks past O ring seal on pump or past pump to case bolts pump housing porous oil coming out vent d...

Страница 1589: ...he actual cause of the problem may not be detected Practically any condition can be caused by leaking hydraulic circuits or sticking valves Therefore unless the condition is obvious the transaxle shou...

Страница 1590: ...n pressure readings to be taken 2 Operate engine at 1000 rpm for test 3 Move selector lever on transaxle one detent for ward from full rearward position This is selector 2 position Fig 1 Test Port Loc...

Страница 1591: ...ise 5 This tests pump output pressure regulation and condition of front clutch and rear servo hydraulic circuits 6 Move selector lever on transaxle to D position to check that low reverse pressure dro...

Страница 1592: ...wn the inside of the converter hous ing Fig 3 TORQUE CONVERTER LEAKAGE Possible sources of torque converter leakage are Torque converter weld leaks at the outside diam eter weld Fig 4 Torque converter...

Страница 1593: ...E SERVO REAR Direct air pressure into LOW REVERSE SERVO APPLY passage Operation of servo is indicated by a tightening of rear band Spring tension on servo pis ton should release the band If clutches a...

Страница 1594: ...el indicator tube bolt and tube indicator assembly Fig 6 Plug opening to prevent debris intrusion 3 Disconnect torque converter clutch solenoid TCC connector 4 Disconnect kickdown cable from lever and...

Страница 1595: ...Refer to 3 DIFFEREN TIAL DRIVELINE HALF SHAFT REMOVAL 11 Remove starter motor assembly Fig 10 Fig 9 Rear Mount Bracket 1 BOLT VERTICAL 2 BRACKET REAR MOUNT 3 BOLT HORIZONTAL Fig 10 Starter Motor Remov...

Страница 1596: ...mount thru bolt 18 Support engine with screw jack and wood block 19 Remove torque converter to drive plate bolts 20 Remove left wheel splash shield Fig 11 Front Mount and Bracket 1 BRACKET FRONT MOUNT...

Страница 1597: ...1 TRANSMISSION TRANSAXLE AUTOMATIC 31TH FINAL DRIVE DISASSEMBLY 1 Measure input shaft end play before disassembly using Tool 8266 and dial indicator C 3339 Fig 15 a Set up tools as shown in Fig 15 b M...

Страница 1598: ...itch 7 Remove park rod retainer e clip Fig 20 Fig 17 Transaxle Oil Pan 1 TRANSAXLE OIL PAN 2 OIL FILTER Fig 18 Oil Filter Screws 1 SCREWDRIVER HANDLE 2 SPECIAL TOOL L 4553 3 OIL FILTER SCREWS 2 4 OIL...

Страница 1599: ...and location of governor tubes Fig 21 Parking Rod 1 VALVE BODY 2 PARKING ROD Fig 22 Cooler Bypass Valve and Seal 1 TRANSFER PLATE 2 BYPASS VALVE 3 SEAL Fig 23 Valve Body Attaching Bolts 1 VALVE BODY...

Страница 1600: ...Fig 28 Fig 25 Loosen Low Reverse Band 1 LOW REVERSE BAND LEVER 2 ADJUSTING SCREW 3 STRUT 4 LOW REVERSE BAND 5 LOCK NUT 6 LEVER SHORT Fig 26 Low Reverse Servo Snap Ring 1 SNAP RING PLIERS Fig 27 Remove...

Страница 1601: ...e strut removal Fig 29 Accumulator Plate and Snap Ring 1 SNAP RING 2 ACCUMULATOR PLATE 3 88O RING Fig 30 Accumulator Spring and Piston 1 ACCUMULATOR SPRING 2 ACCUMULATOR PISTON 3 SEAL RINGS Fig 31 Kic...

Страница 1602: ...WN PISTON ROD GUIDE Fig 34 Kickdown Servo Rod Guide and Snap Ring 1 SNAP RING 2 ACCUMULATOR PLATE 3 RETURN SPRING 4 O RING 5 PISTON ROD GUIDE Fig 35 Kickdown Piston Return Spring and Piston 1 RETURN S...

Страница 1603: ...ot shaft Fig 39 26 Remove oil pump to transaxle case bolts Fig 40 Fig 37 Parking Sprag Rod Support 1 PARKING SPRAG ROD SUPPORT 2 BOLT 2 3 OUTPUT SHAFT GEAR Fig 38 Support and Bolts 1 BOLT 2 2 PARKING...

Страница 1604: ...2 with Adapters L 4437 1 PUMP 2 PULLERS TOOL C 3752 3 ADAPTERS TOOL L 4437 Fig 42 Oil Pump Removal 1 FRONT CLUTCH 2 OIL PUMP ASSEMBLY Fig 43 Oil Pump Gasket 1 SPLIT IN GASKET DIFFERENTIAL OIL FEED 2 P...

Страница 1605: ...embly 1 REAR CLUTCH ASSEMBLY 2 FRONT CLUTCH ASSEMBLY Fig 46 No 2 Thrust Washer and Rear Clutch 1 REAR CLUTCH ASSEMBLY 2 2 THRUST WASHER Fig 47 No 3 Thrust Washer 1 OUTPUT SHAFT 2 SUN GEAR DRIVING SHEL...

Страница 1606: ...t Planetary Gear Assembly 1 SUN GEAR 2 FRONT PLANETARY GEAR ASSEMBLY 3 6 THRUST WASHER Fig 50 Sun Gear Driving Shell 1 SUN GEAR DRIVING SHELL 2 REAR PLANETARY GEAR Fig 51 Sun Gear Driving Shell Compon...

Страница 1607: ...tary Gear Assembly 1 REAR PLANETARY GEAR ASSEMBLY Fig 54 No 10 Thrust Washer 1 OVERRUNNING CLUTCH CAM ASSEMBLY 2 10 THRUST WASHER Fig 55 Overrunning Clutch Cam Assembly 1 OUTPUT SHAFT 2 OVERRUNNING CL...

Страница 1608: ...NAL DRIVE ASSEMBLY NOTE This procedure does not include assembly of transfer system transfer shaft and output shaft components Refer to 21 TRANSMISSION TRANS AXLE AUTOMATIC 31TH TRANSFER SYSTEM INSTAL...

Страница 1609: ...ar planetary gear assembly Fig 63 8 Install 9 thrust washer Fig 64 Use petrola tum to secure Fig 61 Install Overrunning Clutch Rollers and Springs 1 TOOL L 4440 2 ROLLER 8 3 OVERRUNNING CLUTCH CAM ASS...

Страница 1610: ...ment is necessary Fig 65 Sun Gear Driving Shell 1 SUN GEAR DRIVING SHELL 2 REAR PLANETARY GEAR Fig 66 Front Planetary Gear Assembly 1 SUN GEAR 2 FRONT PLANETARY GEAR ASSEMBLY 3 6 THRUST WASHER Fig 67...

Страница 1611: ...nd Fig 71 Do not install strut or adjust at this time 17 Install oil pump gasket Fig 72 Fig 69 No 2 Thrust Washer and Rear Clutch 1 REAR CLUTCH ASSEMBLY 2 2 THRUST WASHER Fig 70 Front Clutch Assembly...

Страница 1612: ...Fig 75 22 Install rod support and bolts Fig 76 Torque bolts to 28 N m 250 in lbs Fig 77 Fig 73 Oil Pump Attaching Bolts 1 SEAL 2 PUMP ATTACHING BOLTS 7 3 PUMP HOUSING Fig 74 Measure Input Shaft End P...

Страница 1613: ...HAFT GEAR Fig 78 Controlled Load Kickdown Servo 1 KICKDOWN PISTON 2 O RING 3 SNAP RING 4 PISTON ROD GUIDE 5 SNAP RING 6 O RING 7 PISTON RETURN SPRING 8 PISTON ROD 9 SEAL RINGS Fig 79 Kickdown Piston R...

Страница 1614: ...84 and place snap ring into position for installation Fig 81 Kickdown Servo Snap Ring 1 SNAP RING 2 SNAP RING PLIERS 3 ACCUMULATOR PLATE 4 KICKDOWN LEVER 5 KICKDOWN PISTON ROD GUIDE Fig 82 Adjust Kic...

Страница 1615: ...ting nut 31 2 turns Torque lock nut to 14 N m 125 in lbs Fig 85 Accumulator Snap Ring 1 ACCUMULATOR PLATE SNAP RING 2 SNAP RING PLIERS 3 ACCUMULATOR PLATE Fig 86 Install Retainer Spring and Servo 1 SE...

Страница 1616: ...to 5 N m 40 in lbs 39 Install park rod into position and retain with e clip Fig 92 Fig 89 Valve Body and Governor Tubes 1 VALVE BODY ASSEMBLY 2 GOVERNOR TUBES Fig 90 Valve Body Attaching Bolts 1 VALVE...

Страница 1617: ...case and immediately install and torque oil pan to case bolts Fig 96 to 19 N m 165 in lbs torque Fig 93 Oil Filter and Gasket 1 OIL FILTER 2 GASKET 3 VALVE BODY Fig 94 Oil Filter Screws 1 SCREWDRIVER...

Страница 1618: ...ld 5 Install torque converter to drive plate bolts and torque to 88 N m 65 ft lbs 6 Install rear mount bracket to transaxle Fig 98 Install bolts by hand but do not tighten at this time 7 Align rear mo...

Страница 1619: ...nt and bracket Fig 101 Fig 99 Structural Collar 1 BOLT COLLAR TO OIL PAN 2 BOLT COLLAR TO TRANSAXLE 3 STRUCTURAL COLLAR 4 OIL PAN Fig 100 Starter Motor Removal Installation 1 STARTER MOTOR 2 BOLT 3 BO...

Страница 1620: ...cle on hoist 22 Torque rear mount bracket to transaxle case horizontal bolt Fig 98 to 102 N m 75 ft lbs 23 Torque rear mount thru bolt to 54 N m 40 ft lbs 24 Lower vehicle 25 Connect battery negative...

Страница 1621: ...SCHEMATICS AND DIAGRAMS 31TH TRANSAXLE HYDRAULIC SCHEMATICS Drive First Half Throttle 21 64 31TH AUTOMATIC TRANSAXLE RS 31TH AUTOMATIC TRANSAXLE Continued...

Страница 1622: ...Drive Second Half Throttle RS 31TH AUTOMATIC TRANSAXLE 21 65 31TH AUTOMATIC TRANSAXLE Continued...

Страница 1623: ...Drive Third Not Locked Up 21 66 31TH AUTOMATIC TRANSAXLE RS 31TH AUTOMATIC TRANSAXLE Continued...

Страница 1624: ...Drive Third Lock Up RS 31TH AUTOMATIC TRANSAXLE 21 67 31TH AUTOMATIC TRANSAXLE Continued...

Страница 1625: ...Drive Kickdown Part Throttle 21 68 31TH AUTOMATIC TRANSAXLE RS 31TH AUTOMATIC TRANSAXLE Continued...

Страница 1626: ...Second Manual Closed Throttle RS 31TH AUTOMATIC TRANSAXLE 21 69 31TH AUTOMATIC TRANSAXLE Continued...

Страница 1627: ...Low Manual Closed Throttle 21 70 31TH AUTOMATIC TRANSAXLE RS 31TH AUTOMATIC TRANSAXLE Continued...

Страница 1628: ...Reverse RS 31TH AUTOMATIC TRANSAXLE 21 71 31TH AUTOMATIC TRANSAXLE Continued...

Страница 1629: ...Standard Differential Assembly 0 7 1 4 N m 6 12 in lbs Output Shaft 0 0 3 N m 0 3 in lbs Transfer Shaft 0 051 0 254 mm 0 002 0 010 in end play Overall Drag At Output Hub 0 03 1 8 N m 3 16 in lbs CLUT...

Страница 1630: ...53 1 62 mm 0 060 0 064 in Output Shaft No 3 Select 1 96 2 03 mm 0 077 0 080 in Output Shaft No 3 Select 2 15 2 22 mm 0 085 0 087 in Output Shaft No 3 Select 2 34 2 41 mm 0 092 0 095 in Front Annulus...

Страница 1631: ...tor to Transaxle 54 40 Bolt Transaxle Case to Engine Block 95 70 Bolt Transfer Gear Cover to Case 19 165 Bolt Transfer Gear Strap 23 17 Bolt Valve Body to Case 12 105 Fitting Transaxle Oil Cooler to C...

Страница 1632: ...293 52 Puller Press C 293 PA Pressure Gauge High C 3293SP Dial Indicator C 3339 Spring Compressor C 3575 A Band Adjusting Adapter C 3705 Oil Pump Puller C 3752 Throttle Setting Gauge C 3763 Seal Pull...

Страница 1633: ...ller C 4193A Bearing Installer C 4637 Adapter C 4658 Torque Tool C 4995 Adapter C 4996 Remover Kit L 4406 Bearing Remover Cup L 4406 1 Bearing Remover Jaws L 4406 2 21 76 31TH AUTOMATIC TRANSAXLE RS 3...

Страница 1634: ...6 Bearing Installer L 4408 Bearing Installer L 4410 Bearing Installer L 4411 Installer Adapter L 4429 3 Gear Checking Plate L 4432 Gear Removing Plate L 4434 Bearing Puller L 4435 RS 31TH AUTOMATIC T...

Страница 1635: ...L 4437 Starter Nut L 4439 Transfer Shaft Remover Installer L 4512 Bearing Cup Remover L 4517 Special Jaw Set L 4518 Installer L 4520 End Play Socket Set 8266 Bearing Splitter P 334 21 78 31TH AUTOMATI...

Страница 1636: ...e kickdown servo As the line pressure reaches the accumulator the combination of spring pressure and line pressure forces the piston away from the accu mulator plate This causes a balanced pressure si...

Страница 1637: ...design the band does not completely encompass wrap the drum that it holds OPERATION The rear band holds the rear planet carrier sta tionary by being mounted around and applied to the low reverse drum...

Страница 1638: ...alant to the oil pan and install to case imme diately 8 Install oil pan to case bolts and torque to 19 N m 165 in lbs 9 Lower vehicle and refill transmission with Mopart ATF Plus 4 Type 9602 fluid Fig...

Страница 1639: ...into the clutch plates and pressure plate that are lugged to the clutch retainer The waved snap ring is used to cushion the application of the clutch pack In some transmissions the snap ring is select...

Страница 1640: ...sc Shown 1 FRONT CLUTCH RETAINER 2 CLUTCH PLATES 3 DRIVING DISCS Fig 117 Front Clutch Return Spring Snap Ring 1 COMPRESSOR TOOL C 3575 A 2 FRONT CLUTCH RETAINER 3 SNAP RING 4 SNAP RING PLIERS Fig 118...

Страница 1641: ...retainer Fig 119 Fig 120 Fig 119 Front Clutch Assembly 1 SNAP RING WAVE 5 SEAL 9 SPRING 2 REACTION PLATE 6 CLUTCH RETAINER 10 SNAP RING 3 CLUTCH DISC 7 SEAL 11 SPRING RETAINER 4 CLUTCH PLATE 8 PISTON...

Страница 1642: ...N SPRING RETAINER 4 SNAP RING 5 PISTON RETURN SPRING 6 FRONT CLUTCH RETAINER Fig 121 Front Clutch Return Spring Snap Ring 1 COMPRESSOR TOOL C 3575 A 2 FRONT CLUTCH RETAINER 3 SNAP RING 4 SNAP RING PLI...

Страница 1643: ...e applied between the clutch retainer and piston the piston moves away from the clutch retainer and compresses the clutch pack This action applies the clutch pack allowing torque to flow through the i...

Страница 1644: ...p Ring 1 SCREWDRIVER 2 SNAP RING 3 REAR CLUTCH ASSEMBLY Fig 127 Rear Clutch 4 Disc Shown 1 REAR CLUTCH RETAINER 2 CLUTCH PLATES 3 THICK STEEL PLATE 4 SNAP RING SELECTIVE 5 DRIVING DISCS 6 PRESSURE PLA...

Страница 1645: ...ig 129 Rear Clutch Piston and Piston Spring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 PISTON SPRING 4 WAVED SNAP RING 5 PISTON 6 PISTON SEALS Fig 130 Input Shaft Snap Ring 1 INPUT SHAFT 2 REAR CLUTCH RET...

Страница 1646: ...4 Fig 132 Fig 132 Rear Clutch Assembly 1 SNAP RING SELECT 6 CLUTCH RETAINER 11 SNAP RING WAVE 2 REACTION PLATE 7 INPUT SHAFT 12 SEAL 3 CLUTCH DISC 8 SNAP RING 13 SEAL 4 CLUTCH PLATE 9 PISTON 5 REACTIO...

Страница 1647: ...AP RING PLIERS 4 SNAP RING Fig 134 Input Shaft Snap Ring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 SNAP RING Fig 135 Rear Clutch Piston and Piston Spring 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 PISTON SPR...

Страница 1648: ...fferential bearing turning torque Refer to 21 TRANSMISSION TRANSAXLE AUTO MATIC 31TH BEARINGS ADJUSTMENTS 3 Remove adapter plate seal 4 Remove differential cover to transaxle case bolts Fig 140 Fig 13...

Страница 1649: ...plate out of assembly Clean surfaces of old adhesive prior to reassembly 11 Measure and record differential side gear end play using dial indicator C 3339 and Tool C 4995 as shown in Fig 144 and Fig 1...

Страница 1650: ...OTE POSITION 2 DIAL INDICATOR SET 3 DIFFERENTIAL ASSEMBLY Fig 146 Remove Differential Bearing Cone Extension Housing Side 1 SPECIAL TOOL C 293 2 SPECIAL TOOL C 293 36 3 SPECIAL TOOL C 293 3 Fig 147 Di...

Страница 1651: ...ool 5052 and driver handle C 4171 Fig 152 Install bearing cup into extension housing using Tool 6536 and driver handle C 4171 Fig 149 Remove Differential Bearing Cone 1 SPECIAL TOOL 5048 2 RING GEAR F...

Страница 1652: ...ng Cone Onto Differential 1 DIFFERENTIAL ASSEMBLY 2 DIFFERENTIAL BEARING Fig 154 Install Differential Bearing Cone 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL 6536 3 DIFFERENTIAL ASSEMBLY Fig 155 Checking Si...

Страница 1653: ...8 9 Install and torque bearing retainer bolts to 34 N m 25 ft lbs torque Fig 159 10 Install bearing retainer axle seal using Tool L 4520 inverted and driver handle C 4171 Fig 160 Fig 157 Differential...

Страница 1654: ...or differential teardown assembly or if any of the following parts are replaced Transaxle case Differential carrier Differential bearing retainer Extension housing Differential bearing cups and cones...

Страница 1655: ...tial Bearing Shim Chart Oil Baffle is not required when making shim selection e Install the proper shim under the bearing cup Make sure the oil baffle is installed properly in the bearing retainer bel...

Страница 1656: ...d so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze The red color is not permanent and is not an indicator of fluid condition As the vehicle is driven the...

Страница 1657: ...ransaxle oil pan This will ensure complete evacuation of the fluid in the pan 4 Follow the manufacturers recommended proce dure and evacuate the fluid from the transaxle 5 Remove the suction line from...

Страница 1658: ...el lower silencer Fig 170 5 Remove knee bolster Fig 171 6 Disconnect PRNDL cable from gear shift lever Fig 172 Fig 169 Gearshift Cable at Transaxle 1 MANUAL VALVE LEVER 2 GEAR SHIFT CABLE 3 UPPER MOUN...

Страница 1659: ...and secure grommet Fig 175 2 Install gear shift cable through column bracket Fig 176 until audible click is heard 3 Connect gear shift cable to gear shift lever Fig 176 Fig 173 Gearshift Cable at Colu...

Страница 1660: ...le end to transaxle man ual valve lever Fig 180 9 Adjust gearshift cable Refer to 21 TRANS MISSION TRANSAXLE AUTOMATIC 31TH GEAR SHIFT CABLE ADJUSTMENTS Fig 177 PRNDL Cable 1 PRNDL CABLE 2 GEAR SHIFT...

Страница 1661: ...selector in a forward driving range line pressure flows from the manual valve and down to the governor valve When the output shaft starts to rotate with vehicle motion the governor weight assembly wi...

Страница 1662: ...l pan As the clearance between the gear teeth in the crescent area decreases it forces pressurized fluid into the pump outlet and to the valve body STANDARD PROCEDURE OIL PUMP VOLUME CHECK Measuring t...

Страница 1663: ...o not need to be replaced unless cracked broken or severely worn 2 Visually inspect the pump and support compo nents Replace the pump assembly if the seal ring grooves or machined surfaces are worn sc...

Страница 1664: ...TCH The park neutral starting switch is the center ter minal of the 3 terminal switch It provides ground for the starter solenoid circuit through the selector lever in only Park P and Neutral N positi...

Страница 1665: ...Thrust Washer 1 SNAP RING 2 4 THRUST WASHER 3 SNAP RING 4 FRONT PLANETARY GEAR ASSEMBLY Fig 186 Annulus Gear Support Front Snap Ring 1 ANNULUS GEAR SUPPORT 2 FRONT SNAP RING 3 SCREWDRIVER 4 FRONT PLAN...

Страница 1666: ...ring Fig 192 Fig 189 Front Planetary Gear 1 FRONT PLANETARY GEAR ASSEMBLY Fig 190 Front Planetary Gear 1 FRONT PLANETARY GEAR ASSEMBLY Fig 191 Front Annulus Gear Support Snap Ring 1 FRONT ANNULUS GEA...

Страница 1667: ...aft support assembly from the transaxle case 1 To install a new seal place seal in opening of the pump housing lip side facing inward Using Tool C 4193 and Handle Tool C 4171 drive new seal into housi...

Страница 1668: ...by bleeding oil through a small orifice in the larger piston The release timing of the kickdown servo is very important to obtain a smooth but firm shift The release has to be very quick just as the...

Страница 1669: ...er visible Replace any servo component if doubt exists about condition Do not reuse suspect parts Fig 199 Kickdown Piston Return Spring and Piston 1 RETURN SPRING 2 KICKDOWN LEVER 3 PISTON ROD 4 KICKD...

Страница 1670: ...erse band OPERATION While in the de energized state no pressure applied the piston is held up in its bore by the pis ton spring The plug is held down in its bore in the piston by the plug spring When...

Страница 1671: ...spring if collapsed distorted or broken Replace the plug and piston if cracked bent or worn Discard the servo snap rings and use new ones at assembly Fig 204 Low Reverse Lever 1 LOW REVERSE LEVER Fig...

Страница 1672: ...solenoid is hardwired to and controlled by the Intelligent Power Module IPM Battery voltage is applied to one side of the solenoid with the ignition key is in either the OFF ON RUN or START positions...

Страница 1673: ...ion 1 Shifter CAN be shifted out of park with brake pedal applied 2 Turn key to the 9ON RUN9 position 2 Shifter CANNOT be shifted out of park 3 Turn key to the 9ON RUN9 position and depress the brake...

Страница 1674: ...ARK9 and try to remove the key 5 Key can be removed after returning to 9LOCK9 position 6 With the key removed try to shift out of 9PARK9 6 Shifter cannot be shifted out of 9PARK9 NOTE Any failure to m...

Страница 1675: ...gearshift lever is in PARK P and con nect solenoid connector Fig 219 3 Install steering column lower shroud 4 Install knee bolster Fig 220 Fig 217 Solenoid Retaining Screw 1 SOLENOID RETAINING SCREW...

Страница 1676: ...pplication of the torque converter clutch It is controlled by the Powertrain Control Module PCM which determines when conditions are acceptable for torque converter lock up REMOVAL 1 Remove valve body...

Страница 1677: ...cable 2 Disconnect cable core from throttle lever pin Fig 224 3 Disconnect cable retainer from throttle body bracket Fig 224 Fig 223 Torque Converter Clutch Solenoid and Regulator Control Valves 1 CO...

Страница 1678: ...dy bracket Fig 227 4 Connect cable core clip to throttle lever Fig 227 5 Adjust throttle valve cable Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 31TH THROTTLE VALVE CABLE ADJUST MENTS 6 Connect batte...

Страница 1679: ...ue converter Fig 229 is a hydraulic device that couples the engine crankshaft to the transmission The torque converter consists of an outer shell with an internal turbine a stator an overrunning clutc...

Страница 1680: ...f the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving member of the system Fig 230 Impeller 1 ENGINE FLEXPLATE 4 E...

Страница 1681: ...d through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 231 Tur...

Страница 1682: ...is lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impel ler and turbine were mec...

Страница 1683: ...s transferred into the turbine and the input shaft This causes both of them turbine and input shaft to rotate in a clockwise direction following the impeller As the fluid is leav ing the trailing edge...

Страница 1684: ...e clutch will engage at approximately 56 km h 35 mph with light throttle after the shift to third gear REMOVAL 1 Remove transmission and torque converter from vehicle Refer to 21 TRANSMISSION TRANS AX...

Страница 1685: ...E AUTO MATIC 31TH TRANSFER SYSTEM REMOVAL NOTE Transaxle geartrain must be removed to gain access to and service output shaft Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 31TH DISASSEMBLY 1 Using a su...

Страница 1686: ...ear and select shim Fig 244 Fig 240 Remove Strap From Stirrup and Gear 1 OUTPUT GEAR 2 STRAP Fig 241 Remove Stirrup From Gear 1 OUTPUT GEAR 2 STIRRUP Fig 242 Remove Output Shaft Retaining Nut and Wash...

Страница 1687: ...CONE 4 OUTPUT SHAFT GEAR 5 OUTPUT SHAFT Fig 245 Remove Output Shaft and Rear Annulus Gear Assembly 1 BEARING CUP 2 REAR ANNULUS GEAR 3 OUTPUT SHAFT Fig 246 Remove Output Shaft Gear Bearing Cone 1 SPEC...

Страница 1688: ...ress Fig 251 Fig 248 Remove Rear Planetary Annulus Gear Bearing Cone 1 SPECIAL TOOL L 4406 1 WITH ADAPTERS L 4406 2 2 REAR PLANETARY ANNULUS GEAR Fig 249 Remove Output Shaft Gear Bearing Cup 1 OUTPUT...

Страница 1689: ...e cups To determine proper shim thickness Refer to Output Shaft Bearing Adjustment Check output shaft bearing turning torque using an inch pound torque wrench If turning torque is 3 8 in lbs the prope...

Страница 1690: ...GREASE TO HOLD SHIMS IN POSITION 3 BEARING CONE 4 LUBRICATION HOLE 5 SELECT SHIMS Fig 257 Output Shaft and Select Shims in Position 1 BEARING CUP 2 SELECT SHIM 3 OUTPUT SHAFT ASSEMBLY Fig 258 Start O...

Страница 1691: ...ts of the output gear retaining nut 13 Rotate stirrup clockwise against flats of gear retaining nut Fig 263 Fig 260 Tighten Output Shaft Retaining Nut 1 OUTPUT SHAFT GEAR 2 SPECIAL TOOL L 4434 AND C 4...

Страница 1692: ...rans axle case measure output shaft end play 8 Once bearing end play has been determined refer to the output shaft bearing shim chart 9 The 12 65 mm 0 498 inch 13 15 mm 0 518 inch or 13 65 mm 0 537 in...

Страница 1693: ...34 14 49 570 50 020 13 15 1 29 14 44 568 55 022 13 15 1 24 14 39 566 60 024 13 15 1 19 14 34 564 65 026 13 15 1 14 14 29 562 70 028 13 15 1 09 14 24 560 75 030 13 15 1 04 14 19 558 80 032 13 15 99 14...

Страница 1694: ...Remove stirrup and retaining strap 6 Using Tool L 4434 Fig 267 remove transfer shaft gear retaining nut and washer Fig 268 Fig 265 Rear Cover Bolts 1 REAR COVER 2 REAR COVER BOLTS 10 Fig 266 Remove Re...

Страница 1695: ...er Shaft Gear using L 4407A 1 TRANSFER GEAR 2 TOOL L 4407A Fig 270 Remove Transfer Shaft Gear Bearing Cone 1 SPECIAL TOOL L 4406 1 2 TRANSFER SHAFT GEAR Fig 271 Governor Support Retainer 1 TRANSFER SH...

Страница 1696: ...BAND ANCHOR PIN 2 OUTPUT SHAFT GEAR Fig 274 Governor Assembly 1 TRANSFER SHAFT 2 OUTPUT SHAFT GEAR 3 GOVERNOR ASSEMBLY Fig 275 Transfer Shaft Bearing Snap Ring 1 SNAP RING PLIERS 2 SNAP RING 3 OUTPUT...

Страница 1697: ...ainer Assembly 1 OUTPUT SHAFT GEAR 2 O RING 3 SPECIAL TOOL L 4512 4 BEARING RETAINER ASSEMBLY 5 TRANSFER SHAFT Fig 278 Transfer Shaft and Bearing Retainer 1 O RING 2 TRANSFER SHAFT 3 BEARING CONE 4 TR...

Страница 1698: ...ft Bearing Cone 1 PRESS 2 SPECIAL TOOL L 4411 3 BEARING CONE 4 TRANSFER SHAFT Fig 281 Install Transfer Shaft Bearing Cup 1 PRESS 2 HANDLE C 4171 3 SPECIAL TOOL L 4520 4 TRANSFER SHAFT BEARING RETAINER...

Страница 1699: ...p Ring 1 SNAP RING PLIERS 2 SNAP RING 3 OUTPUT SHAFT GEAR 4 TRANSFER SHAFT Fig 286 Governor Assembly 1 TRANSFER SHAFT 2 OUTPUT SHAFT GEAR 3 GOVERNOR ASSEMBLY Fig 287 Low Reverse Band Anchor Pin 1 LOW...

Страница 1700: ...g Governor support 12 Install transfer shaft gear and select shim Fig 291 13 Install transfer shaft gear nut and washer Fig 292 Fig 289 Governor Support Retainer 1 TRANSFER SHAFT 2 OUTPUT SHAFT GEAR 3...

Страница 1701: ...Rubber Adhesive Sealant to transfer gear cover Fig 295 Immediately install to transaxle case 22 Install and torque transfer gear cover to case bolts Fig 296 to 19 N m 165 in lbs Fig 293 Tighten Trans...

Страница 1702: ...lined in Step 4 End play should be between 0 05 mm and 0 25 mm 0 002 to 0 010 inch NOTE If end play is too high install a 0 05 mm 0 002 inch thinner shim combination If end play is too low install a 0...

Страница 1703: ...Fig 297 7 Separate oil pan from case and drain fluid into suitable container Fig 298 8 Remove oil filter to valve body screws Fig 299 9 Remove oil filter and gasket Fig 300 Fig 297 Transaxle Oil Pan...

Страница 1704: ...se bolts Fig 304 Fig 301 Cooler Bypass Valve and Seal 1 TRANSFER PLATE 2 BYPASS VALVE 3 SEAL Fig 302 Parking Rod E Clip 1 VALVE BODY 2 SCREWDRIVER 3 E CLIP 4 PARKING ROD Fig 303 Parking Rod 1 VALVE BO...

Страница 1705: ...IDENTIFICATION 1 Remove detent spring to valve body screws and remove spring Fig 306 2 Remove valve body to separator plate screws Fig 307 Fig 308 Fig 305 Valve Body and Governor Tubes 1 VALVE BODY AS...

Страница 1706: ...parator Plate from Valve Body 1 SEPARATOR PLATE 2 TRANSFER PLATE 3 OIL SCREEN 4 VALVE BODY Fig 310 Steel Ball Locations 1 MANUAL VALVE 2 STEEL BALLS 8 3 STEEL BALLS Fig 311 Remove Throttle Shaft E Cli...

Страница 1707: ...alve Lever 1 THROTTLE VALVE LEVER ASSEMBLY 2 MANUAL VALVE LEVER ASSEMBLY 3 VALVE BODY Fig 314 Throttle Valve Lever Assembly 1 THROTTLE VALVE LEVER ASSEMBLY 2 MANUAL VALVE 3 VALVE BODY Fig 315 Manual V...

Страница 1708: ...ig 317 Pressure Regulators and Manual Controls 1 VALVE BODY 7 SPRING 2 LINE PRESSURE VALVE 8 KICKDOWN VALVE 3 SPRING 9 SPRING 4 ADJUSTING SCREW 10 MANUAL VALVE 5 SCREW 11 THROTTLE VALVE 6 GUIDE RS 31T...

Страница 1709: ...g 318 Fig 318 Governor Plugs 1 SHUTTLE VALVE SECONDARY SPRING 5 SCREW 4 2 SHUTTLE VALVE 6 END COVER 3 1 2 SHIFT VALVE GOVERNOR PLUG 7 2 3 SHIFT VALVE GOVERNOR PLUG 4 END COVER 8 E CLIP 21 152 31TH AUT...

Страница 1710: ...319 Torque Converter Clutch Solenoid and Regulator Control Valves 1 CONVERTER PRESSURE CONTROL VALVE 3 SCREW 3 5 REGULATOR VALVE THROTTLE PRESSURE PLUG 2 END COVER 4 REGULATOR VALVE THROTTLE PRESSURE...

Страница 1711: ...replaced CAUTION Many of the valve body valves and plugs are made of coated aluminum Aluminum compo nents can be identified by the dark color of the spe cial coating applied to the surface or by testi...

Страница 1712: ...ings The springs must be free of distortion warpage or broken coils 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 i...

Страница 1713: ...roper location of check balls Fig 326 Fig 323 Install Throttle Valve Lever Assembly 1 THROTTLE VALVE LEVER ASSEMBLY 2 MANUAL VALVE 3 VALVE BODY Fig 324 Install Manual Valve Lever 1 THROTTLE VALVE LEVE...

Страница 1714: ...327 Install Transfer Plate and Separator Plate to Valve Body 1 SEPARATOR PLATE 2 TRANSFER PLATE 3 OIL SCREEN 4 VALVE BODY Fig 328 Using Tool L 4553 on Valve Body Screw 1 SCREWDRIVER HANDLE 2 VALVE BO...

Страница 1715: ...stall park rod to valve body and install e clip Fig 334 Fig 335 Fig 331 Valve Body and Governor Tubes 1 VALVE BODY ASSEMBLY 2 GOVERNOR TUBES Fig 332 Valve Body Attaching Bolts 1 VALVE BODY 2 VALVE BOD...

Страница 1716: ...l pan Fig 338 and immediately install to case Fig 335 Parking Rod 1 VALVE BODY 2 PARKING ROD Fig 336 Oil Filter and Gasket 1 OIL FILTER 2 GASKET 3 VALVE BODY Fig 337 Oil Filter Screws 1 SCREWDRIVER HA...

Страница 1717: ...Insert gauge pin of Tool C 3763 between the throttle lever cam and kickdown valve 2 By pushing in on tool compress kickdown valve against its spring so throttle valve is com pletely bottomed inside t...

Страница 1718: ...NDITION CHECK 249 STANDARD PROCEDURE FLUID AND FILTER SERVICE 250 GEAR SHIFT CABLE REMOVAL 251 INSTALLATION 253 ADJUSTMENTS GEARSHIFT CABLE ADJUSTMENT 254 HOLDING CLUTCHES DESCRIPTION 255 OPERATION 25...

Страница 1719: ...ut clutches Two multiple disc holding clutches Four hydraulic accumulators Two planetary gear sets Hydraulic oil pump Valve body Solenoid Pressure switch assembly Integral differential assembly Contro...

Страница 1720: ...SPEED SENSOR 14 OIL PUMP 3 UNDERDRIVE CLUTCH 9 PLANETARY GEAR SET 15 TORQUE CONVERTER 4 OVERDRIVE CLUTCH 10 OUTPUT SHAFT GEAR 16 TORQUE CONVERTER CLUTCH 5 REVERSE CLUTCH 11 TRANSFER SHAFT 6 2 4 CLUTC...

Страница 1721: ...ive 0 69 1 Reverse 2 21 1 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING 41TE TRANSAXLE GENERAL DIAGNOSIS NOTE Before attempting any repair on a 41TE four speed automatic transaxle check for diagnostic t...

Страница 1722: ...ver A slipping clutch may also set a DTC and can be determined by operating the transaxle in all selector positions ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER Shift Lever Position INPUT CLUTCH...

Страница 1723: ...n either the solenoid assembly or TCM is at fault TEST THREE OVERDRIVE CLUTCH CHECK 3rd and 2nd Gear 1 Attach gauge to the overdrive clutch tap 2 Move selector lever to the OD position 3 Allow vehicle...

Страница 1724: ...a worn reaction shaft seal ring or a defective solenoid assembly is indi cated 5 If the underdrive clutch pressure is greater than 5 psi in Step 4 of Test Two A a defective sole noid assembly or TCM i...

Страница 1725: ...ston contacts the first separator plate Watch carefully for the piston to move forward The piston should return to its origi nal position after the air pressure is removed UNDERDRIVE CLUTCH Because th...

Страница 1726: ...d leaks at the outside diam eter weld Fig 8 Torque converter hub weld Fig 8 REMOVAL NOTE If transaxle assembly is being replaced or overhauled clutch and or seal replacement it is necessary to perform...

Страница 1727: ...lhousing 11 Reposition leak detection pump harness and hoses 12 Remove rear mount bracket to transaxle case bolts Fig 13 13 Remove transaxle upper bellhousing to block bolts 14 Raise vehicle on hoist...

Страница 1728: ...g 14 30 Remove remaining transaxle bellhousing to engine bolts 31 Remove transaxle assembly from vehicle DISASSEMBLY CAUTION If transaxle failure has occurred it is necessary to flush the transaxle oi...

Страница 1729: ...ROUGH 3 BOLT LEFT MOUNT TO TRANSAXLE 4 TRANSAXLE 5 MOUNT LEFT 6 BRACKET LEFT MOUNT Fig 15 Solenoid Pressure Switch Assembly and Gasket 1 SOLENOID PRESSURE SWITCH ASSEMBLY 2 GASKET Fig 16 Remove Oil Pa...

Страница 1730: ...ne application some accumulators will have two springs and others will have one spring The springs are color coded according to application and year When disassem bling mark accumulator spring locatio...

Страница 1731: ...CLUTCH ACCUMULATOR 3 SEAL RING 2 4 OVERDRIVE CLUTCH ACCUMULATOR Fig 23 Accumulator Underdrive 1 ACCUMULATOR PISTON UNDERDRIVE 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 24 Accumulator Overdrive 1 AC...

Страница 1732: ...If outside of this range a 4 thrust plate change is required Record indicator reading for reference upon reassembly Fig 26 Remove Low Reverse Accumulator Plug Cover 1 ADJUSTABLE PLIERS 2 PLUG Fig 27...

Страница 1733: ...g 31 18 Remove oil pump assembly Fig 32 Fig 33 Fig 33 Oil Pump Removed 1 OIL PUMP 2 GASKET Fig 30 Remove Pump Attaching Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 31 Install Tool C 3752 1 PULLERS...

Страница 1734: ...1 Remove 1 needle bearing Fig 36 22 Remove input clutch assembly Fig 37 Fig 34 Remove Oil Pump Gasket 1 PUMP GASKET Fig 35 Remove Bypass Valve 1 COOLER BYPASS VALVE Fig 36 Remove Caged Needle Bearing...

Страница 1735: ...the rear sun gear Fig 42 A small amount of petrolatum can be used to hold the bearing to the rear sun gear Fig 38 No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF PETRO...

Страница 1736: ...locking pliers and bolts to center the tool properly 28 Remove 2 4 clutch retainer Fig 44 29 Remove 2 4 clutch return spring Fig 45 Fig 42 Number 7 Bearing 1 7 NEEDLE BEARING 2 REAR SUN GEAR Fig 43 Re...

Страница 1737: ...ve 2 4 Clutch Pack 1 CLUTCH PLATE 4 2 CLUTCH DISC 4 Fig 47 Remove Tapered Snap Ring 1 LOW REVERSE CLUTCH REACTION PLATE 2 SCREWDRIVER 3 LOW REVERSE TAPERED SNAP RING TAPERED SIDE UP 4 OIL PAN FACE 5 L...

Страница 1738: ...late Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT SNAP RING 3 DO NOT SCRATCH CLUTCH PLATE Fig 51 Remove Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 52 Remove Rear Cover...

Страница 1739: ...Nut 1 TRANSFER SHAFT GEAR 2 OUTPUT GEAR 3 SPECIAL TOOL 6259 Fig 55 Transfer Shaft Gear Nut and Coned Washer 1 TRANSFER SHAFT 2 LOCK WASHER 3 NUT Fig 56 Remove Transfer Shaft Gear 1 SPECIAL TOOL L4407...

Страница 1740: ...ALIGN INDEXING TAB TO SLOT 2 BEARING CUP RETAINER Fig 59 Remove Transfer Gear Bearing Cone 1 WRENCHES 2 TOOL 5048 WITH JAWS TOOL 5048 4 AND BUTTON TOOL L 4539 2 3 TRANSFER SHAFT GEAR Fig 60 Remove Tra...

Страница 1741: ...emove output shaft stirrup strap bolts Fig 65 Fig 62 Remove Transfer Shaft 1 SPECIAL TOOL 5049 A 2 TRANSFER SHAFT 3 OUTPUT GEAR Fig 63 Bearing Cup Removed 1 BEARING CUP 2 BEARING CONE 3 TRANSFER SHAFT...

Страница 1742: ...ig 69 Fig 66 Remove Stirrup Strap 1 OUTPUT GEARBOLT 2 RETAINING STRAP 3 STIRRUP Fig 67 Remove Output Gear Bolt 1 OUTPUT GEAR 2 TOOL 6259 Fig 68 Output Gear Bolt and Washer 1 OUTPUT GEAR 2 BOLT 3 CONED...

Страница 1743: ...73 Fig 70 Output Gear and Select Shim 1 REAR CARRIER ASSEMBLY 2 SHIM SELECT 3 OUTPUT GEAR Fig 71 Remove Bearing Cone 1 TOOL 5048 WITH JAWS 5048 5 AND BUTTON L 4539 2 2 WRENCHES 3 OUTPUT GEAR Fig 72 Re...

Страница 1744: ...ing Compressor Tool 1 TOOL 6057 2 TOOL 5059 3 TOOL 5058 3 Fig 75 Compressor Tool in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 76 Rem...

Страница 1745: ...ig 81 Fig 78 Remove Anchor Shaft and Plug 1 GUIDE BRACKET ANCHOR SHAFT 2 PIVOT SHAFT 3 ANCHOR SHAFT PLUG Fig 79 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL F...

Страница 1746: ...Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 83 Remove Piston Retainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 84 Remove Piston...

Страница 1747: ...eing overhauled clutch and or seal replacement the TCM Quick Learn pro cedure must be performed Refer to 8 ELECTRI CAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Insta...

Страница 1748: ...tainer 1 LOW REVERSE CLUTCH PISTON RETAINER 2 GASKET Fig 90 Install Piston Retainer Attaching Screws 1 LOW REVERSE CLUTCH PISTON RETAINER 2 SCREWDRIVER 3 TORX LOC SCREWS Fig 91 Install Low Reverse Clu...

Страница 1749: ...g 96 Fig 93 Guide Bracket 1 GUIDE BRACKET 2 ANTIRATCHET SPRING MUST BE ASSEMBLED AS SHOWN 3 PAWL Fig 94 Pivot Shaft and Guide Bracket 1 ANTIRACHET SPRING 2 GUIDE BRACKET 3 PIVOT SHAFT 4 PAWL Fig 95 In...

Страница 1750: ...l in Use 1 LOW REVERSE CLUTCH RETURN SPRING 2 SNAP RING INSTALL AS SHOWN 3 TOOL 6057 4 TOOL 5059 5 TOOL 5058 3 Fig 98 Install Snap Ring 1 SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS AS SHOWN 2 SNA...

Страница 1751: ...ure output gear end play as shown in Fig 102 f Refer to the output gear bearing shim chart for the required shim to obtain proper bearing set ting g Use Tool 6259 to remove the output gear retaining b...

Страница 1752: ...4412813AB 0 25mm 0 010 in 4 22mm 0 166 in 4412825AB 0 74mm 0 029 in 3 74mm 0 147 in 4412813AB 0 28mm 0 011 in 4 18mm 0 165 in 4412824AB 0 76mm 0 030 in 3 70mm 0 146 in 4412812AB 0 30mm 0 012 in 4 14m...

Страница 1753: ...a 0 04 mm 0 0016 in thicker shim If the turning torque is too low install a 0 04 mm 0 0016 in thinner shim Repeat until the proper turning torque of 3 8 in lbs is obtained Fig 104 Install Output Gear...

Страница 1754: ...ue stirrup strap bolts to 23 N m 200 in lbs Fig 111 Fig 108 Install Stirrup 1 STIRRUP 2 OUTPUT GEAR RETAINING BOLT Fig 109 Install Strap Bolts 1 RETAINING STRAP 2 STIRRUP 3 RETAINING STRAP BOLTS Fig 1...

Страница 1755: ...n Strap Up Against Flats Of Bolts 1 RETAINING STRAP TABS 2 RETAINING STRAP 3 STIRRUP Fig 113 Install Transfer Shaft Bearing Cone 1 TOOL 6052 2 NEW BEARING CONE 3 TRANSFER SHAFT 4 ARBOR PRESS RAM Fig 1...

Страница 1756: ...ERS TOOL 6051 2 TRANSFER SHAFT BEARING SNAP RING 3 TRANSFER SHAFT Fig 117 Install Transfer Shaft Bearing Cup Into Retainer 1 ARBOR PRESS RAM 2 HANDLE C 4171 3 TOOL 6061 4 TRANSFER SHAFT BEARING CUP RE...

Страница 1757: ...4505588AB 0 76mm 0 030 in 3 94mm 0 155 in 4412818AB 0 08mm 0 003 in 4 62mm 0 182 in 4412835AB 0 79mm 0 031 in 3 90mm 0 154 in 4412817AB 0 10mm 0 004 in 4 58mm 0 180 in 4412834AB 0 81mm 0 032 in 3 90mm...

Страница 1758: ...in 4412806AB 0 53mm 0 021 in 4 18mm 0 165 in 4412824AB 1 24mm 0 049 in 3 46mm 0 136 in 4412806AB 0 56mm 0 022 in 4 14mm 0 163 in 4412823AB 1 27mm 0 050 in 3 42mm 0 135 in 4412805AB 0 58mm 0 023 in 4 1...

Страница 1759: ...epeat until 0 05 0 10 mm 0 002 0 004 in end play is obtained 36 Install a bead of Mopart ATF RTV MS GF41 to transfer gear cover Fig 123 37 Install transfer gear cover to case bolts and torque to 20 N...

Страница 1760: ...h flat side up Fig 128 Fig 125 Install Low Reverse Clutch Pack 1 CLUTCH PLATES 5 2 CLUTCH DISCS 5 Fig 126 Install Low Reverse Reaction Plate Snap Ring 1 SCREWDRIVER 2 LOW REVERSE REACTION PLATE FLAT S...

Страница 1761: ...fications LOW REVERSE REACTION PLATE CHART PART NUMBER THICKNESS 4799846AA 5 88 mm 0 232 in 4799847AA 6 14 mm 0 242 in 4799848AA 6 40 mm 0 252 in 4799849AA 6 66 mm 0 262 in 4799855AA 6 92 mm 0 273 in...

Страница 1762: ...2 4 Clutch Plate Pads 1 PILOT PADS 2 LUGS Fig 134 Proper Orientation of 2 4 Clutch Retainer and Spring 1 NOTE POSITION 2 RETURN SPRING 3 2 4 CLUTCH RETAINER Fig 135 2 4 Clutch Retainer 1 2 4 CLUTCH R...

Страница 1763: ...gear and 7 needle bearing Fig 139 NOTE The number seven needle bearing has three anti reversal tabs and is common with the number five and number two position The orientation should allow the bearing...

Страница 1764: ...speed sensor hole is not as shown in Fig 143 the input clutch assembly is not seated prop erly Fig 142 Select Thinnest No 4 Thrust Plate 1 OVERDRIVE SHAFT ASSEMBLY 2 4 THRUST PLATE SELECT 3 3 DABS OF...

Страница 1765: ...thrust plate chart to select the proper No 4 thrust plate NO 4 THRUST PLATE CHART PART NUMBER THICKNESS 4431665AB 1 60mm 0 063 in 3836237AB 1 73mm 0 068 in 4431666AB 1 80mm 0 071 in 3836238AB 1 96mm...

Страница 1766: ...g end towards rear of case Fig 148 56 Install oil pump gasket Fig 149 57 Install oil pump assembly Fig 150 Fig 147 Install Caged Needle Bearing 1 1 CAGED NEEDLE BEARING 2 NOTE TANGED SIDE OUT Fig 148...

Страница 1767: ...ing Fig 154 Fig 151 Install Pump to Case Bolts 1 PUMP ATTACHING BOLTS 2 PUMP HOUSING Fig 152 Install Low Reverse Accumulator 1 ACCUMULATOR PISTON 2 SEAL RINGS 3 RETURN SPRINGS 4 NOTE NOTCH Fig 153 Ins...

Страница 1768: ...tion Make sure park rod rollers are posi tioned within park guide bracket Fig 155 Accumulator Underdrive 1 ACCUMULATOR PISTON UNDERDRIVE 2 RETURN SPRINGS 3 SEAL RING 4 SEAL RING Fig 156 Accumulator Ov...

Страница 1769: ...165 in lbs 68 Install solenoid pressure switch assembly and gasket to case Fig 162 Fig 159 Install Valve Body to Case Bolts 1 VALVE BODY ATTACHING BOLTS 18 2 VALVE BODY Fig 160 Install Oil Filter 1 OI...

Страница 1770: ...le and torque bolts to 54 N m 40 ft lbs Fig 164 3 Raise engine transaxle assembly into position Install and torque upper mount to bracket thru bolt to 75 N m 55 ft lbs Fig 164 4 Remove transmission ja...

Страница 1771: ...r mount bracket to tran saxle vertical bolts Fig 165 to 102 N m 75 ft lbs 17 Install transaxle upper bellhousing to block bolts and torque to 95 N m 70 ft lbs 18 Install and connect crank position sen...

Страница 1772: ...eld 27 Connect battery cables 28 Fill transaxle with suitable amount of ATF 4 Automatic Transmission Fluid Type 9602 Refer to 21 TRANSMISSION TRANSAXLE AUTOMATIC 41TE FLUID STANDARD PROCEDURE Fig 167...

Страница 1773: ...SCHEMATICS AND DIAGRAMS 41TE TRANSAXLE HYDRAULIC SCHEMATICS Park Neutral Speed Under 8 MPH 21 216 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1774: ...Neutral Speed Over 8 MPH RS 41TE AUTOMATIC TRANSAXLE 21 217 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1775: ...Reverse 21 218 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1776: ...Reverse Block Shift to Reverse W Speed Over 8 mph RS 41TE AUTOMATIC TRANSAXLE 21 219 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1777: ...First Gear 21 220 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1778: ...Second Gear RS 41TE AUTOMATIC TRANSAXLE 21 221 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1779: ...Second Gear EMCC 21 222 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1780: ...Direct Gear RS 41TE AUTOMATIC TRANSAXLE 21 223 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1781: ...Direct Gear CC On 21 224 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1782: ...Overdrive RS 41TE AUTOMATIC TRANSAXLE 21 225 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1783: ...Overdrive EMCC 21 226 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1784: ...Overdrive CC On RS 41TE AUTOMATIC TRANSAXLE 21 227 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1785: ...004 in Overall Drag At Output Hub 0 3 1 9 N m 3 16 in lbs CLUTCH CLEARANCES DESCRIPTION METRIC STANDARD Low Rev Clutch Select Reaction Plate 0 89 1 47 mm 0 035 0 058 in Two Four Clutch No Selection 0...

Страница 1786: ...Gear Stirrup Strap 23 17 Bolt Oil Pump to Case 27 20 Bolt Reaction Support to Case 27 20 Bolt Solenoid Pressure Switch Assy to Case 12 110 Bolt Torque Converter to Driveplate 75 55 Bolt Transfer Gear...

Страница 1787: ...Puller C 637 Pressure Gauge High C 3293SP Dial Indicator C 3339 Oil Pump Puller C 3752 Seal Puller C 3981B Universal Handle C 4171 Seal Installer C 4193A Adapter C 4996 21 230 41TE AUTOMATIC TRANSAXLE...

Страница 1788: ...Puller L 4407A Bearing Installer L 4410 Gear Checking Plate L 4432 Bearing Puller L 4435 Differential Tool L 4436A Special Jaw Set L 4518 Installer L 4520 RS 41TE AUTOMATIC TRANSAXLE 21 231 41TE AUTOM...

Страница 1789: ...ton L 4539 2 Adapter L 4559 Adapter L 4559 2 Bearing Splitter P 334 Puller Set 5048 Remover Installer 5049 A Installer 5050A Installer 5052 21 232 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE...

Страница 1790: ...Compressor 5058A Compressor 5059 A Installer 5067 Pliers 6051 Installer 6052 Installer 6053 Button 6055 Plate 6056 RS 41TE AUTOMATIC TRANSAXLE 21 233 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1791: ...Disk 6057 Installer 6061 Remover 6062 A Holder 6259 Bolt 6260 Installer 6261 Tip 6268 Remover Installer 6301 21 234 41TE AUTOMATIC TRANSAXLE RS 41TE AUTOMATIC TRANSAXLE Continued...

Страница 1792: ...mover Installer 6302 Installer 6536 A Cooler Flusher 6906A Puller 7794 A End Play Socket Set 8266 Input Clutch Pressure Fixture 8391 RS 41TE AUTOMATIC TRANSAXLE 21 235 41TE AUTOMATIC TRANSAXLE Continu...

Страница 1793: ...nd retaining screws Fig 171 OPERATION The function of an accumulator is to cushion the application of a frictional clutch element When pres surized fluid is applied to a clutch circuit the appli catio...

Страница 1794: ...erdrive OFF 9Lockout9 depressed 2 8V 3 8V All switches open 3 8V 4 8V Voltage values 3V and 4 8V are considered INVALID and will result in a DTC Moving the switch up causes an upshift and mov ing the...

Страница 1795: ...applied the front sun gear assembly is driven FINAL DRIVE DISASSEMBLY NOTE The differential is serviced as an assembly Differential service is limited to bearing cups and cones Any other differential...

Страница 1796: ...Fig 178 Position Button and Collets Onto Differential and Bearing Ring Gear Side 1 SPECIAL TOOL L 4539 2 2 SPECIAL TOOL 5048 3 SPECIAL TOOL 5048 4 Fig 179 Position Tool 5048 Over Button and Collets at...

Страница 1797: ...retainers Fig 183 9 Separate ring gear from differential case Fig 184 Fig 181 Position Bearing Cup Remover Tool in Retainer 1 SPECIAL TOOL 6062A 2 DIFFERENTIAL BEARING RETAINER Fig 182 Remove Bearing...

Страница 1798: ...ig 188 Fig 185 Separating Differential Support with Screwdrivers 1 DIFFERENTIAL SUPPORT 2 DIFFERENTIAL CASE 3 SCREWDRIVER 4 RELIEF 2 180 APART Fig 186 Differential Support Removal 1 DIFFERENTIAL SUPPO...

Страница 1799: ...r Fig 192 18 Inspect all components for excessive wear Fig 189 Pinion Shaft Removal 1 PINION SHAFT Fig 190 Pinion Gear and Washer Removal 1 PINION GEAR 2 TABBED WASHER 3 LOCATING TAB 4 NOTCH Fig 191 S...

Страница 1800: ...2 Install side gear to differential case Fig 194 3 Install both pinion gears and washers to case while orientating washer tabs to notch in case Fig 195 4 Install pinion shaft Fig 196 Fig 193 Thrust Wa...

Страница 1801: ...199 8 Install differential ring gear to case Fig 200 Fig 197 Side Gear Installation 1 DIFFERENTIAL SIDE GEAR Fig 198 Side Gear Thrust Washer 1 SIDE GEAR THRUST WASHER Fig 199 Diff Support Installatio...

Страница 1802: ...Use MoparT Silicone Rubber Adhesive Seal ant or equivalent on retainer and extension hous ing adapter plate to seal to case 14 Install differential assembly into transaxle case Install differential be...

Страница 1803: ...orm all differential bearing preload mea surements with the transfer shaft and gear removed DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING EXISTING SHIM 1 Position the transaxle assembly vertically on...

Страница 1804: ...m 0 002 inch thicker shim Repeat until 5 18 inch pounds turning torque is obtained Oil Baffle is not required to be installed when making shim selection f Install the proper shim under the bearing cup...

Страница 1805: ...bearings are fully seated 7 Attach a dial indicator to the case and zero the dial Place the tip on the end of Special Tool L 4436 A 8 Place a large screwdriver to each side of the ring gear and lift C...

Страница 1806: ...t idle speed for at least one minute with the vehicle on level ground At normal operating temperature 82 C 180 F the fluid level is correct if it is in the HOT region on the oil level indicator Fig 21...

Страница 1807: ...rmal ATF 4 also has a unique odor that may change with age Consequently odor and color cannot be used to indicate the fluid condition or the need for a fluid change After the fluid has been checked se...

Страница 1808: ...e dipstick tube 6 Pour four quarts of Mopart ATF 4 Automatic Transmission Fluid Type 9602 through the dipstick opening 7 Start engine and allow to idle for at least one minute Then with parking and se...

Страница 1809: ...11 Disengage grommet from dash panel Fig 218 and remove gear shift cable from inside vehicle Fig 215 Instrument Panel Lower Silencer 1 INSTRUMENT PANEL LOWER SILENCER Fig 216 Knee Bolster 1 KNEE BOLS...

Страница 1810: ...cable to gear shift lever Fig 220 4 Install knee bolster Fig 221 5 Install instrument panel lower silencer Fig 222 Fig 219 Gearshift Cable Grommet at Dash Panel 1 CABLE GROMMET 2 DASH PANEL Fig 220 Ge...

Страница 1811: ...gine starts in both neutral N or park P gearshift cable is adjusted properly No adjustment is required 6 If engine does not start in either park P or neutral N perform adjustment procedure ADJUSTMENT...

Страница 1812: ...se LOW REVERSE CLUTCH The Low Reverse clutch is hydraulically applied in park reverse neutral and first gears by pressurized fluid against the Low Reverse clutch piston When the Low Reverse clutch is...

Страница 1813: ...Fig 227 Reverse Clutch Snap Ring 1 REACTION PLATE 2 SCREWDRIVER 3 REVERSE CLUTCH SNAP RING SELECT Fig 228 Pry Reverse Clutch Reaction Plate 1 REVERSE CLUTCH REACTION PLATE 2 SCREWDRIVER 3 SCREWDRIVER...

Страница 1814: ...ure Plate Snap Ring 1 OD REVERSE PRESSURE PLATE 2 SCREWDRIVER 3 OD REVERSE PRESSURE PLATE SNAP RING Fig 232 OD Reverse Pressure Plate 1 OD REVERSE PRESSURE PLATE STEP SIDE DOWN 2 STEP SIDE DOWN Fig 23...

Страница 1815: ...VE CLUTCH PLATE 2 OVERDRIVE SHAFT ASSEMBLY 3 OVERDRIVE CLUTCH DISC Fig 236 3 4 Thrust Washers 1 3 THRUST PLATE 3 TABS 2 OD SHAFT ASSEMBLY 3 4 THRUST PLATE 3 SLOTS Fig 237 Underdrive Shaft Assembly 1 3...

Страница 1816: ...lutch flat snap ring Fig 242 Fig 239 OD UD Reaction Plate Tapered Snap Ring 1 OVERDRIVE UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 SCREWDRIVER DO NOT SCRATCH REACTION PLATE Fig 240 OD UD R...

Страница 1817: ...245 19 Remove spring retainer Fig 245 20 Remove UD clutch piston Fig 246 Fig 243 Underdrive Clutch Pack 1 CLUTCH PLATE 2 ONE UD CLUTCH DISC 3 CLUTCH DISC Fig 244 UD Spring Retainer Snap Ring 1 SNAP RI...

Страница 1818: ...d Snap Ring 1 INPUT SHAFT 2 INPUT HUB SNAP RING TAPERED SIDE UP WITH TABS IN CAVITY 3 SNAP RING PLIERS Fig 248 Tap on Input Hub 1 INPUT SHAFT AND HUB ASSEMBLY 2 PLASTIC HAMMER Fig 249 Input Hub Remove...

Страница 1819: ...RAM COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING 2 SCREWDRIVER 3 SNAP RING 4 SPECIAL TOOL 6057 5 OD REVERSE PISTON 6 RETURN SPRING Fig 252 Snap Ring and Return Spring 1 OD REVERS...

Страница 1820: ...T 2 ARBOR PRESS RAM 3 INPUT SHAFT HUB ASSEMBLY Fig 256 Install Input Shaft Snap Ring 1 INPUT SHAFT 2 SCREWDRIVER DO NOT SCRATCH BEARING SURFACE 3 SNAP RING 4 O RINGS 5 SEALS Fig 257 Return Spring and...

Страница 1821: ...nstall OD Reverse Piston 1 PUSH DOWN TO INSTALL OVERDRIVE REVERSE PISTON 2 INPUT CLUTCHES RETAINER Fig 260 Install Input Shaft Hub Assembly 1 PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY ROTATE TO AL...

Страница 1822: ...installed Fig 266 Fig 263 Seal Compressor Special Tool 5067 1 PISTON RETURN SPRING 2 SPECIAL TOOL 5067 3 INPUT SHAFT CLUTCHES RETAINER ASSEMBLY Fig 264 UD Return Spring and Retainer 1 UNDERDRIVE SPRIN...

Страница 1823: ...tapered step side up Fig 267 UD Clutch Flat Snap Ring 1 UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 SCREWDRIVER Fig 268 Install Last UD Clutch Disc 1 ONE UNDERDRIVE CLUTCH DISC Fig 269 OD UD Re...

Страница 1824: ...cator Fig 274 When releasing pressure on clutch pack indica tor reading should advance 0 005 0 010 CAUTION Do not apply more than 30 psi 206 kPa to the underdrive clutch pack 18 Apply 30 psi 206 kPa t...

Страница 1825: ...tall the OD clutch pack four frictions three steels Fig 275 22 Install OD pressure plate waved snap ring Fig 276 23 Install the OD Reverse pressure plate with large step down towards OD clutch pack Fi...

Страница 1826: ...25 mm 0 042 0 128 in If not within specifications the clutch is not assembled properly There is no adjustment for the OD clutch clearance 28 Install reverse clutch pack two frictions one steel Fig 28...

Страница 1827: ...r Fig 285 When releasing pressure indicator should advance 0 005 0 010 as clutch pack relaxes Fig 282 Install Reverse Clutch Snap Ring 1 REVERSE CLUTCH SNAP RING SELECT 2 SCREWDRIVER 3 REVERSE CLUTCH...

Страница 1828: ...rive clutch must be removed 37 Install the 2 needle bearing Fig 286 38 Install the underdrive shaft assembly Fig 287 39 Install the 3 thrust washer to the underdrive shaft assembly Be sure five tabs a...

Страница 1829: ...tlet and to the valve body STANDARD PROCEDURE OIL PUMP VOLUME CHECK Measuring oil pump output volume will determine if sufficient flow to the transmission oil cooler exists and whether or not an inter...

Страница 1830: ...he transaxle it is necessary to inspect the oil pump for wear and damage 1 Remove the reaction shaft support bolts 2 Remove reaction shaft support from pump housing Fig 293 3 Remove the pump gears Fig...

Страница 1831: ...20 ft lbs torque PLANETARY GEARTRAIN DESCRIPTION The planetary geartrain is located between the input clutch assembly and the rear of the transaxle case The planetary geartrain consists of two sun gea...

Страница 1832: ...etic solenoid mounted to the steering column Fig 300 The solenoid s plunger consists of an integrated hook which operates the shift lever pawl part of shift lever assembly and a plunger return spring...

Страница 1833: ...de ener gizing the solenoid When the brake pedal is released the ground circuit is closed energizing the solenoid When the ignition key is in either the OFF ON RUN or START positions the BTSI solenoid...

Страница 1834: ...GNOSIS AND TESTING BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID For intended BTSI system operation refer to the following chart ACTION EXPECTED RESPONSE 1 Turn key to the 9OFF9 position 1 Shifter CAN b...

Страница 1835: ...r engages gearshift lever pawl pin Install and tighten screws Fig 309 2 Verify gearshift lever is in PARK P and con nect solenoid connector Fig 310 Fig 307 BTSI Solenoid Connector 1 BTSI SOLENOID 2 SO...

Страница 1836: ...o the LR CC 2 4 OD and UD friction elements The reverse clutch is controlled by line pressure from the manual valve in the valve body The solenoids are contained within the Solenoid Pressure Switch As...

Страница 1837: ...g point For example a switch may close at 18 psi and open at 17 psi The switches are continuously monitored by the TCM for the cor rect states open or closed in each gear as shown in the following cha...

Страница 1838: ...olenoid pressure switch 8 way connec tor and torque to 4 N m 35 in lbs 6 Install air cleaner assembly 7 Connect battery negative cable 8 If solenoid pressure switch assembly was replaced perform TCM Q...

Страница 1839: ...l and the engine speed signal to determine the following Torque converter clutch slippage Torque converter element speed ratio REMOVAL 1 Disconnect battery negative cable 2 If necessary disconnect and...

Страница 1840: ...ol Module TCM OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating As the rear planetary carrier park pawl lugs pass by the sensor coil Fig 324 an AC voltage...

Страница 1841: ...icle on hoist 3 Disconnect output speed sensor connector 4 Unscrew and remove output speed sensor Fig 325 5 Inspect speed sensor o ring Fig 326 and replace if necessary INSTALLATION 1 Verify o ring is...

Страница 1842: ...so provides reduced transmission fluid temperatures The con verter clutch engages in third gear The torque con verter hub drives the transmission oil fluid pump The torque converter is a sealed welded...

Страница 1843: ...f the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving member of the system Fig 328 Impeller 1 ENGINE FLEXPLATE 4 E...

Страница 1844: ...d through the center of the impeller and splined into the turbine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 329 Tur...

Страница 1845: ...is lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impel ler and turbine were mec...

Страница 1846: ...tor blades and is redirected into a helping direction before it enters the impeller This circula tion of oil from impeller to turbine turbine to stator and stator to impeller can produce a maximum tor...

Страница 1847: ...nverter hub and oil pump seal lip with transmission fluid 2 Place torque converter in position on transmis sion CAUTION Do not damage oil pump seal or bushing while inserting torque converter into the...

Страница 1848: ...pack pressure switches is checked After the relay is energized the TCM monitors the terminals to verify that the voltage is greater than 3 volts TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission...

Страница 1849: ...when a transmission overheat condition exists If the thermistor circuit fails the TCM will revert to calculated oil temperature usage CALCULATED TEMPERATURE A failure in the temperature sensor or circ...

Страница 1850: ...er clutch switch valve Converter clutch control valve Torque converter regulator valve Low Reverse switch valve In addition the valve body also contains the ther mal valve 2 3 4 check balls the 5 over...

Страница 1851: ...clutch piston both the con verter clutch control valve and the converter control valve move allowing pressure to be applied to the back side of the clutch T C REGULATOR VALVE The torque converter reg...

Страница 1852: ...345 Fig 346 CAUTION The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped Fig 343 Oil Filter 1 OIL FILTER 2 O RING Fig 344 Valve Body Attac...

Страница 1853: ...ist 5 Remove oil pan bolts Fig 347 6 Remove oil pan Fig 348 7 Remove oil filter Fig 349 8 Remove the valve body to transaxle case bolts Fig 350 NOTE To ease removal of the valve body turn the manual v...

Страница 1854: ...AL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Remove manual shaft seal Fig 353 2 Remove Transmission Range Sensor retaining screw Fig 354 Fig 351 Push Park Rod Rollers...

Страница 1855: ...aft Rooster Comb and Transmission Range Sensor 1 TRANSMISSION RANGE SENSOR 2 MANUAL SHAFT 3 ROOSTER COMB Fig 356 2 4 Accumulator Retaining Plate 1 2 4 ACCUMULATOR RETAINING PLATE 2 DETENT SPRING Fig 3...

Страница 1856: ...5 check valve Fig 361 10 Remove separator plate Fig 362 Fig 359 Remove Transfer Plate 1 TRANSFER PLATE Fig 360 Remove Oil Screen 1 OIL SCREEN Fig 361 Remove Overdrive Clutch 5 Check Valve 1 OVERDRIVE...

Страница 1857: ...64 Fig 363 Remove Thermal Valve 1 THERMAL VALVE Fig 364 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK LOCATION 5 LOW REVERSE SWITCH VALVE 6 T C LIMIT VA...

Страница 1858: ...s reconditioned the TCM Quick Learn Procedure must be performed Refer to 8 ELECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Install valves and springs as shown in...

Страница 1859: ...VE 3 L R SWITCH VALVE 7 SOLENOID SWITCH VALVE 4 CONVERTER CLUTCH CONTROL VALVE 8 REGULATOR VALVE Fig 369 Install Regulator Valve Spring Retainer using Tool 6302 1 TOOL 6302 2 RETAINER Fig 370 Install...

Страница 1860: ...n Fig 372 If necessary secure them with petrolatum or transmission assembly gel for assembly ease Fig 372 Ball Check Location 1 4 BALL CHECK LOCATION 2 2 BALL CHECK LOCATION 3 RETAINER 4 3 BALL CHECK...

Страница 1861: ...rator plate Fig 375 9 Install oil screen to separator plate Fig 376 Fig 373 Install Thermal Valve 1 THERMAL VALVE Fig 374 Install Separator Plate 1 SEPARATOR PLATE 2 VALVE BODY Fig 375 Install Overdri...

Страница 1862: ...in Fig 379 13 Torque 2 4 Accumulator retainer to 5 N m 45 in lbs Fig 380 Fig 377 Install Transfer Plate 1 TRANSFER PLATE Fig 378 Install Valve Body to Transfer Plate Screws 1 SCREW 24 2 TRANSFER PLATE...

Страница 1863: ...LECTRICAL ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE STANDARD PROCEDURE 1 Install valve body assembly to transaxle Fig 384 Install and torque valve body to transaxle case bolts Fig 385 to...

Страница 1864: ...ensor connector 6 Install manual valve lever to manual shaft 7 Install gearshift cable to manual valve lever 8 Connect battery negative cable 9 Fill transaxle with Mopart ATF 4 Transmis sion fluid Ref...

Страница 1865: ...INSTALLATION 371 GEARSHIFT KNOB REMOVAL 374 INSTALLATION 374 GEARSHIFT MECHANISM REMOVAL 375 INSTALLATION 377 INPUT SHAFT DESCRIPTION 380 DISASSEMBLY 380 ASSEMBLY 383 INTERMEDIATE SHAFT DESCRIPTION 3...

Страница 1866: ...SSEMBLY 4 4TH GEAR SPEED 12 5 R SHIFT FORK 20 EXTENSION HOUSING 5 5TH GEAR INPUT 13 5TH GEAR SPEED 21 INTERMEDIATE SHAFT BEARING CAGED ROLLER 6 REVERSE IDLER GEAR 14 3 4 CLUSTER GEAR 22 INTERMEDIATE S...

Страница 1867: ...ICATION NOTE Since transaxles use unique gear ratios for each of the two engine applications it is imperative that the transaxle is properly identified and the cor rect transaxle assembly number is us...

Страница 1868: ...and the input shaft turns Since no synchronizers are engaged on either the input or intermediate shafts power is not transmitted to the intermediate shaft and the differential does not turn Fig 3 Fig...

Страница 1869: ...irst speed gear freewheels until first gear is selected As the gearshift lever is moved to the first gear position the 1 2 fork moves the 1 2 synchronizer sleeve towards first gear on the inter mediat...

Страница 1870: ...cond speed gear freewheels until second gear is selected As the gearshift lever is moved to the second gear position the 1 2 fork moves the 1 2 synchronizer sleeve towards second gear on the intermedi...

Страница 1871: ...ut shaft third speed gear freewheels until third gear is selected As the gearshift lever is moved to the third gear position the 3 4 fork moves the 3 4 synchronizer sleeve towards third gear on the in...

Страница 1872: ...shaft fourth speed gear free wheels until fourth gear is selected As the gearshift lever is moved to the fourth gear position the 3 4 fork moves the 3 4 synchronizer sleeve towards fourth gear on the...

Страница 1873: ...ft fifth speed gear freewheels until fifth gear is selected As the gearshift lever is moved to the fifth gear position the 5 R fork moves the 5 R synchronizer sleeve towards the intermediate shaft fif...

Страница 1874: ...ar Because of this constant mesh the intermediate shaft reverse gear freewheels until reverse gear is selected As the gearshift lever is moved to the reverse gear position the 5 R fork moves the 5 R s...

Страница 1875: ...o causes gear disengagement Check for missing snap rings LOW LUBRICANT LEVEL Insufficient transaxle lubricant is usually the result of leaks or inaccurate fluid level check or refill method Leakage is...

Страница 1876: ...ctural collar 14 Remove modular clutch assembly to drive plate bolts 15 Position screw jack and wood block to engine oil pan 16 Remove transmission upper mount through bolt from left frame rail 17 Low...

Страница 1877: ...assembly clutch release components and engine drive plate REMOVAL 2 5L TD 1 Raise hood 2 Disconnect both battery cables 3 Remove battery thermal shield Fig 15 4 Remove battery hold down bolt clamp an...

Страница 1878: ...19 Remove cables and secure out of way 10 Remove three 3 right engine mount bracket to transaxle bolts Fig 20 Fig 17 Battery Tray 1 BATTERY TRAY Fig 18 Coolant Recovery Bottle Bracket 1 COOLANT RECOVE...

Страница 1879: ...ith screwdriver Fig 21 17 Remove engine left mount bracket Fig 22 18 Remove starter motor Fig 23 19 Disconnect back up lamp switch connector 20 Position screw jack and wood block to engine oil pan 21...

Страница 1880: ...nd flywheel DISASSEMBLY 1 Remove clutch release lever and bearing Fig 26 Inspect release lever pivot balls and replace if necessary Fig 27 Use slide hammer C 3752 and remover installer 6891 Fig 28 if...

Страница 1881: ...hift cover assembly Fig 30 Fig 27 Pivot Ball Orientation 1 PIVOT BALL 1 Fig 28 Pivot Ball Removal Installation 1 C 3752 SLIDE HAMMER 2 REMOVER INSTALLER 6891 3 PIVOT BALL Fig 29 Input Bearing Retainer...

Страница 1882: ...with bellhousing surface down 7 Remove backup lamp switch Fig 33 8 Remove end plate Fig 34 Fig 31 Extension Housing Seal 1 SCREWDRIVER 2 EXTENSION HOUSING 3 SEAL Fig 32 Extension Housing to Case Bolt...

Страница 1883: ...ase bolts 12 Fig 36 14 Remove end cover from transaxle Fig 37 15 Remove 3 4 shift rail bushing from end cover using slide hammer C 3752 and remover 6786 Fig 38 Fig 35 Input Bearing Snap Ring 1 SNAP RI...

Страница 1884: ...should be measured to ensure proper shim selection upon reassembly 22 Reinstall and torque extension housing and measure differential turning torque Refer to 21 TRANSMISSION TRANSAXLE MANUAL DIFFER E...

Страница 1885: ...earing race with puller 8472 Fig 44 29 Remove shift rail bushing from case with remover 6786 and slide hammer C 3752 Fig 45 Fig 42 Differential Shim Slinger Orientation 1 SLINGER 2 BEARING RACE 3 DIFF...

Страница 1886: ...ed with geartrain out of case 1 Install input shaft bearing using an arbor press and remover installer 8474 Fig 47 2 Install shift shaft bushing to case using installer 8475 Fig 48 Fig 46 Input Shaft...

Страница 1887: ...all bearing before assembling transaxle Refer to 21 TRANSMISSION TRANSAXLE MANUAL INPUT SHAFT DISASSEMBLY 4 Install assembled input and intermediate shafts to fixture 8487 Fig 50 Fig 49 Install Interm...

Страница 1888: ...artrain to case When installing geartrain to case use care not to damage bearing surfaces 7 Remove lifting bar 8489 from geartrain 8 Install shift 1 2 5 R rail as shown in Fig 52 9 Install reverse idl...

Страница 1889: ...washer Fig 56 13 Install wave washer Fig 57 Fig 54 Install Reverse Idler Gear Bearing 1 NEEDLE BEARING 2 REVERSE IDLER SHAFT Fig 55 Install Reverse Idler Gear 1 REVERSE IDLER GEAR Fig 56 Install Flat...

Страница 1890: ...ll to transaxle case Fig 61 While installing end cover be sure to guide oil trough into pocket Fig 62 Torque end cover to case bolts to 28 N m 250 in lbs Fig 63 Fig 58 Install Input Shaft Sealed Rolle...

Страница 1891: ...emove lifting bar 8489 22 Install a bead of Mopart Gear Lube RTV to end plate and immediately install to case Install and torque bolts to 28 N m 250 in lbs Fig 65 Fig 62 Oil Trough Pocket 1 OIL TROUGH...

Страница 1892: ...in bead of Mopart Gas ket Maker to differential cover and install to case Torque differential cover to case bolts to 54 N m 40 ft lbs 28 Install a 1 mm 0 04 in bead of Mopart Gas ket Maker to extensi...

Страница 1893: ...8 N m 250 in lbs 31 Install input shaft bearing retainer Fig 73 Torque bolts to 12 N m 105 in lbs Fig 70 Axle Seal Installation Extension Housing Side 1 EXTENSION HOUSING 2 SEAL 3 INSTALLER 8476 4 DRI...

Страница 1894: ...lever assembly into position by sliding bearing onto input bearing retainer and using moderate hand pressure to seat release lever to pivot ball Fig 77 A pop sound should be heard Verify proper engag...

Страница 1895: ...olts to 102 N m 75 ft lbs Install and torque bracket to engine bolts to 68 N m 50 ft lbs Torque through bolt and nut to 68 N m 50 ft lbs 10 Install clutch slave cylinder into position not ing orientat...

Страница 1896: ...mount bracket and secure with retaining clips 15 Connect battery cables 16 Check transaxle fluid and engine coolant lev els Adjust if necessary Refer to 21 TRANSMIS SION TRANSAXLE MANUAL FLUID STANDAR...

Страница 1897: ...Install and torque four 4 mount to transaxle bolts to 54 N m 40 ft lbs 4 Raise transaxle engine assembly into position and install upper mount through bolt Torque through bolt to 75 N m 55 ft lbs 5 R...

Страница 1898: ...e case cutout and hydraulic tube is vertical Connect quick connect connection until an audible click is heard Verify connection by pulling outward on connection 10 Install underbody splash panel 11 In...

Страница 1899: ...e sensor and install battery tray Fig 89 18 Install battery hold down clamp and nut Fig 90 Fig 87 Gearshift Cables at Transaxle 1 SELECTOR CABLE 2 CABLE RETAINER 3 CABLE RETAINER 4 CROSSOVER CABLE 5 M...

Страница 1900: ...nt mesh fully synchronized 5 speed with integral differential Lubrication Method Splash oil collected in case passage and oil trough and distributed to mainshafts via gravity Fluid Type ATF 4 Automati...

Страница 1901: ...mm 0 004 0 030 in Reverse 0 066 0 805 mm 0 003 0 0317 in DIFFERENTIAL DESCRIPTION METRIC STANDARD Differential Turning Torque 2 3 3 4 N m 20 30 in lbs Side Gear End Play each side 0 025 0 152 mm 0 001...

Страница 1902: ...850 TRANSAXLE Bearing Splitter P 334 Slide Hammer C 3752 Universal Handle C 4171 Torque Tool C 4995 Puller Set 5048 Disconnect Tool 6638A Remover 6786 RS T850 MANUAL TRANSAXLE 21 345 T850 MANUAL TRANS...

Страница 1903: ...ler 6891 Alignment Pins 8470 Installer 8471 Race Remover 8472 Bearing Installer 8473 Remover Installer 8474 Installer 8475 Installer 8476 Wrench 8478 21 346 T850 MANUAL TRANSAXLE RS T850 MANUAL TRANSA...

Страница 1904: ...Stake Tool 8479 Installer 8481 Bearing Installer 8482 Fixture 8483 Fixture 8487 Lifting Bar 8489 Thrust Buttons 8491 Wrench 8827 RS T850 MANUAL TRANSAXLE 21 347 T850 MANUAL TRANSAXLE Continued...

Страница 1905: ...lfshaft assemblies Refer to 3 DIFFERENTIAL DRIVELINE HALF SHAFT INSTALLATION 3 Check transaxle fluid level and adjust if neces sary Refer to 21 TRANSMISSION TRANSAXLE MANUAL FLUID STANDARD PROCEDURE 4...

Страница 1906: ...ntial case is supported in the transaxle by tapered roller bearings OPERATION The differential assembly is driven by the interme diate shaft via the ring gear The ring gear drives the differential cas...

Страница 1907: ...ocedure tools work for both sides 2 Remove ring gear to case bolts Fig 100 and remove ring gear Fig 97 Tool 8491 1 TOOL 8491 Fig 98 Puller 5048 1 5048 1 FORCING SCREW 2 5048 4 COLLETS 3 5048 6 SLEEVE...

Страница 1908: ...Fig 101 Separate Differential Case Halves 1 BOLT 3 2 DIFFERENTIAL CASE 3 DIFFERENTIAL SUPPORT Fig 102 Differential Support Plate 1 DIFFERENTIAL SUPPORT PLATE 2 DIFFERENTIAL CASE Fig 103 Side Gear Thr...

Страница 1909: ...e four pinion gears and thrust washers Fig 108 Fig 105 Long Pinion Shaft 1 PINION SHAFT LONG Fig 106 Short Pinion Shaft 2 1 PINION SHAFT SHORT 2 Fig 107 Pinion Shaft Retaining Ring 1 RETAINING RING Fi...

Страница 1910: ...Install differential side gear Fig 112 Fig 109 Differential Side Gear 1 DIFFERENTIAL SIDE GEAR Fig 110 Side Gear Thrust Washer 1 SIDE GEAR THRUST WASHER Fig 111 Side Gear Thrust Washer 1 SIDE GEAR TH...

Страница 1911: ...Install one 1 long pinion shaft Fig 116 7 Install differential side gear Fig 113 Pinion Gear and Thrust Washer 1 THRUST WASHER 4 2 PINION GEAR 4 Fig 114 Pinion Shaft Retaining Ring 1 RETAINING RING Fi...

Страница 1912: ...all remain ing ring gear to differential case bolts and torque to 95 N m 70 ft lbs Fig 121 13 Install tapered roller bearings using installer 8473 and an arbor press Fig 122 Insert button 8491 on oppo...

Страница 1913: ...40 ft lbs 3 Install extension housing and torque extension housing to case bolts to 28 N m 250 in lbs 4 Place transaxle on work bench so axle center line is parallel to the ground 5 Install turning to...

Страница 1914: ...354 4659256 0 94 0 0370 4659257 0 98 0 0386 4659258 1 02 0 0402 4659259 1 06 0 0418 4659260 1 10 0 0434 4659261 1 14 0 0449 4659262 1 18 0 0465 4659263 1 22 0 0481 4659264 1 26 0 0497 4659265 1 30 0 0...

Страница 1915: ...CEDURE FLUID LEVEL CHECK NOTE For proper fluid level check intervals Refer to LUBRICATION MAINTENANCE MAINTENANCE SCHEDULES DESCRIPTION The fluid required in this transaxle is Mopart ATF 4 Automatic T...

Страница 1916: ...tall drain plug and torque to 23 N m 17 ft lbs FLUID FILL 1 Remove transaxle fill plug Fig 128 2 Add 2 4 2 7L 2 5 2 9 qts of Mopart ATF 4 Automatic Transmission Fluid Type 9602 until fluid is within 1...

Страница 1917: ...1 Disconnect battery negative cable 2 Remove gearshift knob by pushing down and rotating 1 4 turn clock wise Fig 131 3 Remove gearshift boot from center console by disengaging at three 3 retaining cli...

Страница 1918: ...cable retainer clip Fig 136 Fig 133 Cup Holder Plugs 1 CUPHOLDER PLUG 2 Fig 134 Center Console Removal Installation LHD Shown RHD Typical 1 CENTER CONSOLE 2 SCREW 4 3 GEARSHIFT MECHANISM Fig 135 Cent...

Страница 1919: ...battery Fig 139 12 Remove battery tray Fig 140 Disconnect battery temperature sensor Fig 137 Crossover Cable at Gearshift Mechanism 1 GEARSHIFT MECHANISM 2 CROSSOVER CABLE Fig 138 Battery Thermal Shie...

Страница 1920: ...r cable into passenger compartment through floor pan hole Install remainder of cable into posi tion in engine compartment 2 Lower vehicle 3 Install crossover cable to mount bracket and secure with ret...

Страница 1921: ...tion Fig 145 8 Install battery hold down clamp and nut Fig 146 9 Install battery thermal shield Fig 147 Fig 144 Coolant Recovery Bottle Bracket 1 COOLANT RECOVERY BOTTLE BRACKET 2 NUT 3 MOUNT BRACKET...

Страница 1922: ...console assembly Fig 151 Install and torque center console to gearshift mecha nism screws to 5 N m 45 in lbs Fig 148 Crossover Cable at Gearshift Mechanism 1 GEARSHIFT MECHANISM 2 CROSSOVER CABLE Fig...

Страница 1923: ...ry negative cable ADJUSTMENTS ADJUSTMENT 1 Disconnect battery negative cable 2 Remove gearshift knob by pushing down and rotating 1 4 turn clock wise Fig 155 Fig 152 Cup Holder Plugs 1 CUPHOLDER PLUG...

Страница 1924: ...hift lever back and forth between 1 2 and 5 R planes Release lever allowing shifter spring to return lever to the neutral position in the 3 4 plane Place gearshift lever in the 3rd gear posi tion Fig...

Страница 1925: ...knob 1 4 turn clockwise push down and rotate 1 4 turn counter clockwise and release Secure boot to knob 15 Connect battery negative cable GEARSHIFT CABLE SELECTOR REMOVAL 1 Disconnect battery negative...

Страница 1926: ...hift mecha nism Fig 166 Fig 163 Center Console Removal Installation LHD Shown RHD Typical 1 CENTER CONSOLE 2 SCREW 4 3 GEARSHIFT MECHANISM Fig 164 Center Console Support Bracket 1 BRACKET 2 SCREW 3 GE...

Страница 1927: ...ove coolant recovery bottle from bracket 14 Remove coolant recovery bottle mounting bracket Fig 170 Fig 167 Battery Thermal Shield 1 BATTERY THERMAL SHIELD Fig 168 Battery and Hold Down Clamp 1 BATTER...

Страница 1928: ...in engine compartment 2 Lower vehicle 3 Install selector cable to mount bracket and secure with retainer clip Fig 172 4 Install cable to transaxle selector lever Fig 172 5 2 4L Gas models goto Step 10...

Страница 1929: ...mal shield Fig 176 10 Install selector cable to gearshift mechanism Fig 177 Install retainer clip Fig 178 Fig 174 Battery Tray 1 BATTERY TRAY Fig 175 Battery and Hold Down Clamp 1 BATTERY 2 HOLD DOWN...

Страница 1930: ...ism screws to 5 N m 45 in lbs 13 Install cupholder plugs Fig 181 Fig 178 Selector Cable Retainer Clip 1 RETAINER CLIP Fig 179 Center Console Support Bracket 1 BRACKET 2 SCREW 3 GEARSHIFT MECHANISM Fig...

Страница 1931: ...nob 2 Remove gearshift knob by pushing down and rotating 1 4 turn clockwise Fig 184 INSTALLATION 1 Install gearshift knob pattern 1 4 turn clock wise press down and rotate 1 4 turn counter clock wise...

Страница 1932: ...sole upon removal 5 Remove two 2 cupholder bottom plugs Fig 187 6 Remove four 4 center console to gearshift mechanism screws Remove console assembly Fig 188 Fig 185 Gearshift Knob Removal Installation...

Страница 1933: ...le retainer clip Fig 192 Fig 189 Center Console Support Bracket 1 BRACKET 2 SCREW 3 GEARSHIFT MECHANISM Fig 190 Crossover Cable Retainer Clip 1 RETAINER CLIP 2 CROSSOVER CABLE Fig 191 Crossover Cable...

Страница 1934: ...t mechanism Fig 196 Install retainer clip Fig 197 Fig 193 Selector Cable at Gearshift Mechanism 1 GEARSHIFT MECHANISM 2 SELECTOR CABLE Fig 194 Gearshift Mechanism Removal Installation RHD Shown LHD Ty...

Страница 1935: ...ift mechanism screws to 12 N m 108 in lbs Fig 197 Selector Cable Retainer Clip 1 RETAINER CLIP Fig 198 Crossover Cable at Gearshift Mechanism 1 GEARSHIFT MECHANISM 2 CROSSOVER CABLE Fig 199 Crossover...

Страница 1936: ...1 4 turn clockwise push down and rotate 1 4 turn counter clockwise and release Secure boot to knob 10 Connect battery negative cable Fig 201 Center Console Removal Installation LHD Shown RHD Typical...

Страница 1937: ...ing at the rear of the transaxle DISASSEMBLY NOTE When servicing the input shaft assembly all snap rings which are removed MUST be replaced with new snap rings upon reassembly The 5th gear nut must be...

Страница 1938: ...ear nut is staked to the shaft If neces sary grind stake area to ease removal but use care not to contact gear 5 Remove 5th gear nut with wrench 8478 Fig 208 Discard nut and use a new one upon assembl...

Страница 1939: ...emove 3 4 synchronizer Fig 212 11 Remove 3rd gear blocker ring Fig 213 Fig 210 4th Gear Blocker Ring 1 4th GEAR BLOCKER RING Fig 211 3 4 Synchro Snap Ring 1 SNAP RING 2 3 4 SYNCHRONIZER Fig 212 3 4 Sy...

Страница 1940: ...e replaced NOTE When installing 3 4 synchronizer hub to shaft make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub jour nal NOTE Refer to Fig 215 for input shaf...

Страница 1941: ...hub to shaft make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal 6 Install NEW 3 4 synchronizer snap ring Fig 219 Fig 216 3rd Gear Removal Installation...

Страница 1942: ...ut and torque to 200 N m 148 ft lbs using wrench 8478 Fig 223 Fig 220 4th Gear Blocker Ring 1 4th GEAR BLOCKER RING Fig 221 4th Gear Removal Installation 1 4th GEAR Fig 222 5th Gear Installation 1 ARB...

Страница 1943: ...rews and thumb screws Remove tool and visually inspect stake Fig 226 NOTE The input shaft sealed roller bearing and snap ring do not get installed until transaxle assem bly to facilitate installation...

Страница 1944: ...1 2 Synchronizer 5 R Synchronizer The intermediate shaft is supported by a caged roller bearing at the front of the transaxle and a sealed roller bearing at the rear of the transaxle Fig 227 Intermed...

Страница 1945: ...arbor press ram press reverse gear and inter mediate roller bearing off of shaft while holding remaining assembly with hand Fig 228 3 Remove reverse gear blocker ring 4 Remove reverse gear needle bea...

Страница 1946: ...ig 233 9 Remove 3 4 cluster gear snap ring Fig 234 Fig 231 5 R Synchronizer 1 5 R SYNCHRO ASSEMBLY Fig 232 5th Gear Blocker Ring 1 5th GEAR BLOCKER RING Fig 233 5th Gear 1 5th GEAR Fig 234 3 4 Cluster...

Страница 1947: ...e shaft from fixture and remove 3 4 cluster gear from shaft Fig 238 Fig 235 Fixture 8483 1 FIXTURE 8483 2 COLLAR 8483 3 Fig 236 Loading Intermediate Shaft 1 FIXTURE 8483 1 3 4 CLUSTER GEAR 2 COLLAR 84...

Страница 1948: ...ve 2nd Gear outer blocker ring Fig 242 Fig 239 2nd Gear Removal 1 2ND GEAR 2 INTERMEDIATE SHAFT Fig 240 2nd Gear Reactor Ring 1 2ND GEAR REACTOR RING Fig 241 2nd Gear Friction Cone 1 2ND GEAR FRICTION...

Страница 1949: ...45 20 Remove 1st gear friction cone Fig 246 Fig 243 1 2 Synchro Snap Ring 1 SNAP RING 2 1 2 SYNCHRO HUB Fig 244 1 2 Synchronizer 1 1 2 SYNCHRONIZER Fig 245 1st Gear Blocker Ring 1 1ST GEAR BLOCKER RIN...

Страница 1950: ...ve intermediate shaft roller bearing snap ring Fig 250 Fig 247 1st Gear Reactor Ring 1 1ST GEAR REACTOR RING Fig 248 1st Gear Removal 1 1ST GEAR Fig 249 1st Gear Needle Bearing 1 1ST GEAR NEEDLE BEARI...

Страница 1951: ...ler bearing is not re usable once removed It is necessary to install a new roller bearing upon re assembly Fig 251 Intermediate Shaft Roller Bearing Removal 1 ARBOR PRESS RAM 2 INTERMEDIATE SHAFT 3 RO...

Страница 1952: ...s intermediate shaft into NEW roller bear ing with arbor press Fig 253 Fig 252 Intermediate Shaft Assembly 1 INTERMEDIATE SHAFT 10 SNAP RING 2 ROLLER BEARING 11 SEALED ROLLER BEARING 3 SNAP RING 12 TH...

Страница 1953: ...blocker ring friction cone and reactor ring as shown in Fig 257 Fig 254 Intermediate Shaft Roller Bearing Snap Ring 1 SNAP RING Fig 255 1st Gear Needle Bearing 1 1ST GEAR NEEDLE BEARING Fig 256 1st Ge...

Страница 1954: ...ring tabs to gear slots Remove shaft assembly from fix ture 7 Install NEW 1 2 synchro snap ring Fig 259 8 Install 2nd gear blocker ring Fig 260 Fig 258 Install 1 2 Synchro to Intermediate Shaft 1 INTE...

Страница 1955: ...o intermediate shaft using cup 8481 Fig 264 Fig 261 2nd Gear Friction Cone 1 2ND GEAR FRICTION CONE Fig 262 2nd Gear Reactor Ring 1 2ND GEAR REACTOR RING Fig 263 2nd Gear 1 2ND GEAR 2 INTERMEDIATE SHA...

Страница 1956: ...onizer make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal Fig 265 3 4 Cluster Gear Snap Ring 1 SNAP RING Fig 266 5th Gear Installation 1 5th GEAR Fig...

Страница 1957: ...d roller bear ing and thrust washer using installer 8482 Fig 272 Fig 269 5 R Synchro Snap Ring 1 SNAP RING Fig 270 Reverse Gear Blocker Ring 1 REVERSE BLOCKER RING 2 5 R SYNCHRONIZER Fig 271 Reverse G...

Страница 1958: ...isms transaxle vent a main shift selector shaft and the 5 R blockout mechanism The shift cover is only ser viced as an assembly Fig 274 Shift Lever Identification 1 SHIFT COVER ASSEMBLY 2 VENT 3 CROSS...

Страница 1959: ...one style is used for the 5th Reverse and 3rd 4th applications Fig 277 and a dual cone style for the 1st 2nd gear appli cation Fig 278 DISASSEMBLY Place synchronizer in a clean shop towel and wrap Pre...

Страница 1960: ...ed sensor from transaxle CAUTION Carefully remove vehicle speed sensor so that sensor drive gear does not fall into trans axle Should sensor drive gear fall into the trans axle during sensor removal d...

Страница 1961: ......

Страница 1962: ...ND TESTING DIAGNOSIS AND TESTING TIRE NOISE 14 DIAGNOSIS AND TESTING TIRE VEHICLE LEAD 14 DIAGNOSIS AND TESTING TIRE WEAR PATTERNS 14 DIAGNOSIS AND TESTING TREAD WEAR INDICATORS 14 STANDARD PROCEDURE...

Страница 1963: ...continue with this diagnosis and testing procedure TIRE AND WHEEL RUNOUT MATCH MOUNTING 1 System Radial Runout This on the vehicle system check will measure the radial runout includ ing the hub wheel...

Страница 1964: ...rmed as follows a Dismount the tire from the wheel b Mount the wheel back on the wheel balancer c Measure radial runout of the wheel at the tire bead seat Fig 4 Runout should not exceed 0 254 mm 0 010...

Страница 1965: ...5 miles following the format described in Road Test If vibration persists and all components tested are within specification the tires may have an exces sive radial force condition Radial force variat...

Страница 1966: ...y spot causing imbalance Counter balance wheel directly opposite the heavy spot Determine weight required to counterbalance the area of imbalance Place half of this weight on the inner rim flange and...

Страница 1967: ...TER LINE OF SPINDLE 5 TIRE OR WHEEL TRAMP OR WHEEL HOP 3 ADD BALANCE WEIGHTS HERE Fig 9 Dynamic Unbalance Balance 1 CENTER LINE OF SPINDLE 3 CORRECTIVE WEIGHT LOCATION 2 ADD BALANCE WEIGHTS HERE 4 HEA...

Страница 1968: ...res are designed to improve traction on wet pave ment To obtain the full benefits of this design the tires must be installed so that they rotate in the cor rect direction This is indicated by arrows o...

Страница 1969: ...Fig 13 Tighten wheel mounting nuts to 135 N m 100 ft lbs 3 Lower the vehicle INSTALLATION TIRE AND WHEEL ASSEMBLY STEEL WHEEL NOTE Never use oil or grease on studs or wheel mounting nuts 1 Position t...

Страница 1970: ...r technology to monitor tire air pres sure levels Sensors mounted to each road wheel as part of the valve stem transmit tire pressure read ings to a receiver located in the overhead console These tran...

Страница 1971: ...r core in a tire pressure sensor in place of the original equipment style sensor cap and core CAUTION Do not attempt to install a tire pressure sensor in a steel wheel or aftermarket wheel Use tire pr...

Страница 1972: ...ure from entering the valve stem Retain this valve stem cap for reuse Do not substitute a regu lar valve stem cap in its place CAUTION The valve stem used on this vehicle is made of aluminum and the c...

Страница 1973: ...cedure on both the upper and lower tire beads b Rotating Tool Tire Changers Position the wheel on the changer so that the sensor valve stem is approximately 210 from the head of the changer in a clock...

Страница 1974: ...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 Tire type size load index and speed rating are enc...

Страница 1975: ...ence spare tire should be inflated to the pressure listed on its sidewall Do not exceed speeds of 80 km h 50 mph when the tempo rary spare tire is in use on the vehicle Refer to the Owner s Manual for...

Страница 1976: ...VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART RS TIRES WHEELS 22 15 TIRES Continued...

Страница 1977: ...quare inch psi 14 to 41 kPa during operation Do not reduce this normal pressure buildup Improper inflation can cause Uneven wear patterns Reduced tread life Reduced fuel economy Unsatisfactory ride Th...

Страница 1978: ...ten the 5 wheel nuts to a torque of 135 N m 100 ft lbs CLEANING TIRES Before delivery of a vehicle remove the protective coating on the tires with white sidewalls or raised white letters To remove the...

Страница 1979: ...THE SERVICE HISTORY OF THE WHEEL MAY HAVE INCLUDED SEVERE TREAT MENT OR VERY HIGH MILEAGE THE RIM COULD FAIL WITHOUT WARNING CLEANING ALUMINUM WHEEL CARE Chrome plated and painted aluminum wheels shou...

Страница 1980: ...e edges in line with the remaining installed wheel nuts and pull straight outward from the wheel This will pop the wheel cover retaining tabs over the two remaining wheel nuts removing the wheel cover...

Страница 1981: ...embly from the steering knuckle Fig 34 Hang the assembly out of the way using wire or a bungee cord Use care not to overextend the brake hose when doing this 5 Remove brake rotor from hub by pulling i...

Страница 1982: ...ION If a wheel attaching stud needs to be replaced in the hub and bearing assembly the studs MUST NOT be hammered out of the hub flange If a stud is removed by hammering it out of the bearing flange d...

Страница 1983: ...rum or disc brake rotor and caliper on the hub and bearing assembly 4 Install wheel and tire assembly on vehicle Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to h...

Страница 1984: ...AL INJURY CAN RESULT CAUTION When holes must be drilled or punched in an inner body panel verify depth of space to the outer body panel electrical wiring or other compo nents Damage to vehicle can res...

Страница 1985: ...of entry After leak point has been found repair the leak and water test to verify that the leak has stopped Locating the entry point of water that is leaking into a cavity between panels can be diffi...

Страница 1986: ...which include SMC ABS and Polycarbonates Semi Rigid Plastics Examples of semi rigid plastic use Interior Panels Under Hood Panels and other Body Trim Panels Flexible Plastics Examples of flexible pla...

Страница 1987: ...C POLYESTER RYNITE TRIM PBT PPO PBT PPO ALLOY GERMAX CLADDINGS PBTP POLYBUTYLENE THEREPTHALATE PBT PBTP POCAN VALOX WHEEL COVERS FENDERS GRILLES PBTP EEBC POLYBUTYLENE THEREPTHALATE EEBC ALLOY BEXLOY...

Страница 1988: ...DYLON PRAVEX INNER FENDER SPOILERS KICK PANELS PP EPDM PP EPDM ALLOY PP EPDM SPOILERS GRILLES PUR POLYURETHANE COLONELS PUR PU FASCIAS BUMPERS PUR PC PUR PC ALLOY TEXIN BUMPERS PVC POLYVINYL CHLORIDE...

Страница 1989: ...o dry before moving on with the repair PANEL REINFORCEMENT Structural repair procedures for rigid panels with large cracks and holes will require a reinforcement backing Reinforcements can be made wit...

Страница 1990: ...However a backer panel open fiberglass tape or matted material must be bonded from behind Fig 7 Fig 6 PANEL SURFACE PREPARATION If a body panel has been punctured cracked or crushed the damaged area...

Страница 1991: ...e cutout hole in the panel 2 Trim 3 mm 0 125 in from edges of pattern so patch will have a gap between connecting surfaces 3 Using the pattern as a guide cut the patch to size 4 Cut scrap pieces of pa...

Страница 1992: ...inder grind a 50 mm 2 in to 75 mm 3 in wide and 2 mm 0 080 in deep path across the gaps around the patch Fig 13 With compressed air blow dust from around patch 18 Apply adhesive backed nylon mesh dry...

Страница 1993: ...gun with a flat tip melt the material securing the components together Do not over heat the affected area dam age to the exterior of the trim panel may occur b If the heat staked material is broken o...

Страница 1994: ...pillar bolts 34 25 Front door hinge to door nuts and bolts 34 25 Front door latch striker bolts 28 21 Front quad seat cushion bolts 28 5 21 Front seat belt retractor bolts 38 28 Front seat riser to fl...

Страница 1995: ...nd wear When performing other under hood services the hood latch release mechanism and safety catch should be inspected cleaned and lubri cated During the winter season external door lock cylinders sh...

Страница 1996: ...ate Latch MOPART Multipurpose GREASE OR EQUIVALENT All Other Hood Mechanisms MOPART LOCK CYLINDER LUBRICANT OR EQUIVALENT Door Lock Cylinders Liftgate Lock Cylinder SPECIAL TOOLS BODY INDEX DESCRIPTIO...

Страница 1997: ...door frame 4 Remove applique from vehicle Fig 1 INSTALLATION 1 Position applique on vehicle 2 Hook rear edge of applique over rear edge of door frame and seat applique bottom edge on sheet metal 3 En...

Страница 1998: ...s attaching door check strap to A pillar Fig 4 7 Support door on suitable lifting device 8 Remove bolts attaching lower hinge to door end frame Fig 5 9 Steady door on lifting device and remove bolts a...

Страница 1999: ...8 Connect clips attaching door harness wire con nector to inner fender brace 9 Install front wheelhouse splash shield 10 Verify door operation and alignment Adjust as necessary DOOR GLASS REMOVAL 1 Re...

Страница 2000: ...THERSTRIP SEALS FRONT DOOR INNER BELT MOLDING INSTALLATION 10 Verify door glass operation and fit 11 Install watershield Refer to 23 BODY DOOR FRONT WATERSHIELD INSTALLATION FRAME CLOSEOUT MOLDING REM...

Страница 2001: ...necessary LATCH REMOVAL 1 Roll door glass up 2 Remove front door trim panel Refer to 23 BODY DOOR FRONT TRIM PANEL REMOVAL 3 Remove watershield as necessary to gain access to the outside door handle 4...

Страница 2002: ...4 Retrieve any shims found between latch striker and B pillar INSTALLATION 1 Position latch striker and any shims retrieved on vehicle 2 Loosely install screws attaching latch striker to B pillar 3 Al...

Страница 2003: ...Verify door latch operation 10 Install watershield and door trim panel TRIM PANEL REMOVAL 1 Remove the plug and remove screw attaching door pull cup to inner door panel 2 Remove switch bezel and disco...

Страница 2004: ...l 16 If equipped install screws to attach door assist handle to inner door panel 17 Connect wire connector into courtesy lamp 18 Install lamp in door trim 19 Install switch bezel WATERSHIELD REMOVAL 1...

Страница 2005: ...rough front access hole INSTALLATION 1 Insert front guide rail through front access hole 2 Insert rear guide rail through rear access hole 3 Place window regulator in position on inner door panel 4 Pl...

Страница 2006: ...or handle to door outer panel 10 Remove outside door handle from vehicle INSTALLATION If outside door handle replacement is necessary transfer lock cylinder from the original handle to the new one 1 P...

Страница 2007: ...LATION 35 UPPER HINGE REMOVAL 36 INSTALLATION 36 OUTSIDE HANDLE CABLE REMOVAL 36 INSTALLATION 37 INSIDE HANDLE CABLE REMOVAL 37 INSTALLATION 37 HOLD OPEN LATCH CABLE REMOVAL 38 INSTALLATION 38 CENTER...

Страница 2008: ...r to door inner panel Fig 1 3 Tighten screws attaching rear of stop bumper to door inner panel 4 Install door stop bumper bezel HOLD OPEN LATCH REMOVAL 1 Open sliding door 2 Remove sliding door sill p...

Страница 2009: ...nd perimeter of inner door panel CAUTION Replace the latch lock control if any of the metal clips on the latch lock control are bent or broken DO NOT attempt to repair the clips to retain the links 4...

Страница 2010: ...Install sliding door trim panel Refer to 23 BODY DOORS SLIDING TRIM PANEL INSTAL LATION CENTER STRIKER REMOVAL 1 Remove sliding door trim panel Refer to 23 BODY DOORS SLIDING TRIM PANEL REMOVAL 2 Remo...

Страница 2011: ...ocedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRI CAL section 1 Place roller arm into position Fig 7 2 Engage roller arm to lower channel 3 Install roller arm to sliding door 4 Install bolts...

Страница 2012: ...ice with a padded upper surface The door must be moveable with lifting device in place CAUTION Do not allow the center hinge roller to contact the quarter glass Glass can break 12 Slide door rearward...

Страница 2013: ...anism 2 On vehicles with left sliding doors check the fuel door blocker striker entry into latch Striker at this point must not affect alignment 3 Check C post and B post for door to aperture gaps and...

Страница 2014: ...t to position the sliding door into the correct location e Tighten center hinge bolts f Verify alignmen adjust as necessary 3 If the sliding door is low at the B post a Remove access plug in the slidi...

Страница 2015: ...arm on lower roller arm bracket to assist in making adjustments Fig 15 c Loosen bolts holding lower roller arm to lower roller arm bracket d Pivot lower roller arm toward center of vehi cle to decrea...

Страница 2016: ...e INSTALLATION 1 Place sliding door trim panel in position on vehicle 2 Align locating pins on backside of trim panel to mating holes in the inner door panel 3 Engage push in fasteners to hold trim to...

Страница 2017: ...N BELLCRANK REMOVAL 1 Remove stop bumper Refer to 23 BODY DOORS SLIDING STOP BUMPER REMOVAL 2 Remove sliding door trim panel Refer to 23 BODY DOORS SLIDING TRIM PANEL REMOVAL 3 Peel watershield away f...

Страница 2018: ...de door handle to outer door panel 3 Engage clip attaching linkage to outside door handle 4 Engage rigging cam to latch lock control mech anism 5 Move clip on latch lock control to bottom of slot and...

Страница 2019: ...TE For power sliding door procedures refer to POWER SLIDING DOOR SYSTEM in the ELECTRI CAL section 1 Disconnect and isolate the negative battery cable 2 Remove stop bumper Refer to 23 BODY DOORS SLIDI...

Страница 2020: ...AL 3 Peel watershield away from adhesive around perimeter of inner door panel 4 Remove the inside handle assembly from the side door Refer to 23 BODY DOORS SLIDING INSIDE LATCH HANDLE REMOVAL 5 Discon...

Страница 2021: ...3 BODY DOORS SLIDING HOLD OPEN LATCH REMOVAL 8 Disconnect the hold open latch cable from the hold open latch Gently pry cable sleeve retainer out of the handle bracket and then unhook swedged cable en...

Страница 2022: ...exterior handle electrical connector through the door and position handle 2 Install the two out screws and tighten to 20 N m 15 ft lbs 3 Install the two inner bolts and tighten to 40 N m 30 ft lbs 4 C...

Страница 2023: ...ftgate latch 4 Verify liftgate fit and operation Adjust as nec essary 5 Install liftgate trim panel LATCH STRIKER REMOVAL 1 Open liftgate 2 Mark outline of striker on sill to aid installa tion 3 Remov...

Страница 2024: ...ness into body wire harness 6 Install screws attaching wire connector to rear header 7 Connect rear window washer hose onto spray nozzle 8 Install liftgate upper frame molding 9 Verify liftgate alignm...

Страница 2025: ...vot 4 Remove bolt attaching end pivot to D pillar Fig 6 5 Remove bolt attaching prop assembly to lift gate 6 Remove prop assembly from vehicle INSTALLATION Ensure that the cylinder end is attached to...

Страница 2026: ...ate stop bumper REMOVAL LIFTGATE SIDE 1 Open liftgate 2 Remove liftgate stop bumper liftgate side attaching bolts Fig 10 3 Remove liftgate stop bumper INSTALLATION INSTALLATION 1 Place liftgate stop b...

Страница 2027: ...FENDER AIR EXHAUSTER DESCRIPTION 57 REMOVAL 57 INSTALLATION 58 ROOF JOINT MOLDING REMOVAL 58 INSTALLATION 58 SIDE VIEW MIRROR REMOVAL 58 INSTALLATION 58 SIDE VIEW MIRROR GLASS REMOVAL 59 INSTALLATION...

Страница 2028: ...ive tape to back of molding 2 Clean body surface with Mopart Super Kleen or equivalent Wipe surface dry with lint free cloth 3 Remove protective cover from tape on back of molding 4 Apply molding to b...

Страница 2029: ...NE TYPICAL 1 QUARTER PANEL 2 FRONT FENDER 3 POP RIVET 4 FENDER MOLDING 5 FRONT DOOR MOLDING 6 SLIDING DOOR MOLDING 7 GUIDE PINS 8 QUARTER PANEL MOLDING 9 LIFTGATE MOLDING 10 POP RIVET 23 46 EXTERIOR R...

Страница 2030: ...YPICAL 1 QUARTER PANEL 2 FRONT FENDER 3 POP RIVET 4 FENDER MOLDING 5 POP RIVET 6 FASCIA 7 FRONT DOOR MOLDING 8 SLIDING DOOR MOLDING 9 QUARTER PANEL MOLDING 10 FASCIA MOLDING 11 POP RIVET RS EXTERIOR 2...

Страница 2031: ...YPICAL 1 QUARTER PANEL 2 FRONT FENDER 3 POP RIVET 4 FENDER MOLDING 5 POP RIVET 6 FASCIA 7 FRONT DOOR MOLDING 8 SLIDING DOOR MOLDING 9 QUARTER PANEL MOLDING 10 FASCIA MOLDING 11 POP RIVET 23 48 EXTERIO...

Страница 2032: ...E MOLDINGS WITH APPLIQUE TYPICAL 1 FRONT ROCKER PANEL APPLIQUE 2 FRONT DOOR MOLDING 3 SLIDING DOOR MOLDING 4 REAR ROCKER PANEL APPLIQUE 5 LIFTGATE MOLDING 6 POP RIVET RS EXTERIOR 23 49 BODY SIDE MOLDI...

Страница 2033: ...by raising over opposite wiper pivot shaft and removing away from vehicle 10 Remove cowl cover from vehicle INSTALLATION 1 Reverse removal procedure 2 When installing cowl cover over wiper module mak...

Страница 2034: ...any reference points FRONT FENDER REMOVAL 1 Remove headlamp housing Refer to 8 ELEC TRICAL LAMPS LIGHTING EXTERIOR HEAD LAMP UNIT REMOVAL 2 Remove mud guard 3 Remove inner splash shield 4 Remove fende...

Страница 2035: ...eck in position 10 Install screws to hold fuel fill neck to fuel filler housing 11 Engage latch release link into clip on fuel fill blocker latch arm 12 Verify fuel fill blocker latch operation 13 Ins...

Страница 2036: ...ield patch covering access hole in C pillar 3 Disengage fuel filler lockout link from clip on fuel fill blocker latch arm Fig 12 4 Open fuel fill door 5 Remove screws holding fuel filler housing to fu...

Страница 2037: ...diator closure panel Fig 14 10 Lift crossmember upward and away from radiator closure panel 11 Remove crossmember from vehicle INSTALLATION 1 Place radiator closure panel crossmember in position on ve...

Страница 2038: ...hing splash shield to frame rail forward of suspension 3 Install push pin fasteners attaching splash shield to frame rail rearward of suspension 4 Install screws attaching wheelhouse splash shield to...

Страница 2039: ...o the unlock position Fig 18 Work from side to side sliding the crossbar assembly forward moving a little at a time to ensure it remains perpendicular to the side rails 3 Remove crossbar from vehicle...

Страница 2040: ...of the body REMOVAL SHORT WHEELBASE 1 Remove the rear fascia from the body Refer to 13 FRAMES BUMPERS BUMPERS REAR FAS CIA REMOVAL 2 Using a trim stick or another suitable wide flat bladed tool caref...

Страница 2041: ...F using a suit able heat lamp or heat gun 2 Pull stick on molding from painted surface 3 Remove adhesive tape residue from painted surface of vehicle Use a 3M Scotch Brite Molding Adhesive and Stripe...

Страница 2042: ...he moisture drain hole on the mirror glass holder assembly is facing downward 2 Align the mirror glass holder s attaching fin gers to the mirror motor housing NOTE Ensure that the protective rubber co...

Страница 2043: ...n lbs torque 4 Install pivot bolt to the body half of hood hinge Tighten bolts to 28 N m 21 ft lbs torque 5 Install Front Wiper Unit Refer to 8 ELEC TRICAL WIPERS WASHERS WIPER MODULE INSTALLATION for...

Страница 2044: ...emove hood latch from vehicle INSTALLATION 1 Position hood latch on vehicle 2 Connect hood release cable from hood latch 3 Position hood latch on crossmember 4 Align hood latch by placing latch over n...

Страница 2045: ...ommet cable insulator into hole in dash panel 6 Install hood release handle into instrument panel 7 Place cable in position on latch 8 Slide cable case end sideways into keyhole slot of hood latch 9 E...

Страница 2046: ...70 INSTALLATION 70 STEERING COLUMN COVER BACKING PLATE REMOVAL 70 INSTALLATION 71 OVER STEERING COLUMN COVER REMOVAL 71 INSTALLATION 71 CLUSTER BEZEL REMOVAL 1 Disconnect and isolate the battery negat...

Страница 2047: ...Open glove box 2 Push in on sides of glove box bin and lower door 3 Pivot glove box downward and disengage hinge hooks from instrument panel 4 Remove glove box INSTALLATION 1 Place glove box in posit...

Страница 2048: ...19 Disconnect the steering column wiring There are seven connectors and then unclip the harness from the column 20 Disconnect the Occupant Restraint Controller ORC harness connector 21 Remove the fou...

Страница 2049: ...K RIGHT LEFT REINFORCEMENT Fig 4 INSTRUMENT PANEL LEFT SILENCER 1 INSTRUMENT PANEL 2 INSTRUMENT PANEL LEFT SILENCER Fig 5 INSTRUMENT PANEL LOWER REINFORCEMENT 1 LOWER RIGHT REINFORCEMENT 2 STEERING WH...

Страница 2050: ...right side wire connectors to the HVAC behind the glove box area and the two antenna connectors behind the glove box hinge 9 Install the bolts attaching the instrument panel frame to the dash panel b...

Страница 2051: ...nsole to vehicle b Connect the auxiliary power outlet c Install the six retaining screws 33 Connect the battery negative cable INSTRUMENT PANEL CENTER BEZEL REMOVAL 1 Disconnect and isolate the batter...

Страница 2052: ...trument panel 4 Pull top cover rearward 5 Install A pillar trim LOWER CONSOLE REMOVAL 1 Remove screws attaching the lower console to floor bracket and instrument panel Fig 11 2 Slide lower console rea...

Страница 2053: ...nstall the cup holder and track 7 Install the lower console 8 Install the center bezel 9 Install the lower steering column cover 10 Install the right end cover LOWER STEERING COLUMN COVER REMOVAL 1 Re...

Страница 2054: ...fer to 23 BODY INSTRUMENT PANEL STEERING COLUMN OPENING COVER INSTALLATION OVER STEERING COLUMN COVER REMOVAL 1 Taking a firm grasp of the over steering col umn cover front edge give a quick upward pu...

Страница 2055: ...PILLAR TRIM PANEL REMOVAL 77 INSTALLATION 77 LIFTGATE SILL PLATE REMOVAL 77 INSTALLATION 77 QUARTER TRIM BOLSTER REMOVAL 77 INSTALLATION 77 RIGHT QUARTER TRIM PANEL REMOVAL 78 INSTALLATION 78 LEFT QU...

Страница 2056: ...ps 5 Install the assist handle if equipped Refer to 23 BODY INTERIOR ASSIST HANDLE INSTAL LATION ASSIST HANDLE REMOVAL 1 Using a trim stick C 4755 remove screw access covers from grab handle 2 Remove...

Страница 2057: ...elt through B pillar trim and web guide Fig 3 2 Place B pillar trim cover in position on vehicle 3 Engage hidden clips attaching trim cover to B pillar 4 Install shoulder belt bezel into trim cover 5...

Страница 2058: ...ers 10 Install lower B pillar trim covers 11 Install rear door sill plate 12 Install sliding door sill plates Refer to 23 BODY INTERIOR SLIDING DOOR SILL PLATE INSTALLATION 13 Install front cowl panel...

Страница 2059: ...dules 5 Remove A pillar trim covers 6 Remove B pillar upper trim covers 7 Remove C pillar upper trim covers 8 Remove D pillar trim covers 9 Remove liftgate opening header trim 10 If equipped remove ov...

Страница 2060: ...stall bolt attaching second row seat belt lower anchor to quarter on short wheel base vehicle Tighten all seat belt bolts to 39 N m 29 ft lbs 7 Install second row seat belt turning loop on long wheel...

Страница 2061: ...rea 9 Install second row seat belt anchor on long wheel base vehicle Tighten all seat belt bolts to 39 N m 29 ft lbs torque 10 Install first row seat belt anchor 11 Install D pillar trim panel 12 Inst...

Страница 2062: ...engage hidden clips holding trim to rear header Fig 10 2 Separate rear header trim from vehicle INSTALLATION 1 Place rear header trim in position on vehicle 2 Align guide pins on trim to holes in head...

Страница 2063: ...e 3 Connect speaker wire connector to speaker if equipped 4 Align locating pins on backside of trim panel to mating holes in D pillar 5 Engage hidden clips attaching trim to D pillar 6 Install screws...

Страница 2064: ...he sun visor verify label availability and ensure the label is installed 1 Place sun visor in position on vehicle 2 Connect illuminated vanity mirror wire connec tor into body harness 3 Place sun viso...

Страница 2065: ...Manual for proper procedures FLOOR CONSOLE TRAY BRACKET ASSEMBLY REMOVAL 1 Remove the floor carpet Refer to 23 BODY INTERIOR CARPETS AND FLOOR MATS REMOVAL 2 Disconnect the electrical connector 3 Rem...

Страница 2066: ...RED TINTED PEARLCOAT WEL STERLING BLUE SATIN GLOW YB2 LIGHT ALMOND PEARL METALLIC CLEARCOAT ZKJ STONE WHITE CLEARCOAT SW1 INTERIOR COLORS INTERIOR COLOR DAIMLERCHRYSLER COLOR CODE INTERIOR COLOR DAIM...

Страница 2067: ...od sur face finish The applicator brush should be wet enough to puddle fill the defect without running Do not stroke brush applicator on body surface Allow the filler primer to dry hard 4 Cover the fi...

Страница 2068: ...ATION 94 FRONT SEAT TRACK POWER ADJUSTER REMOVAL 94 INSTALLATION 94 FRONT SEAT TRACK MANUAL ADJUSTER REMOVAL 94 INSTALLATION 95 FRONT SEAT TRACK FRONT COVER REMOVAL 95 INSTALLATION 95 FRONT SEAT TRACK...

Страница 2069: ...Remove seat back cover 3 Remove screws attaching child restraint seat module hinges to seat back frame lower rail Fig 1 4 Return seat back to upright position 5 Disengage push in fasteners attaching u...

Страница 2070: ...interlock feature that will not allow the seat back to fold forward with the child seat open If the seat back hinges do not release at the same time the synchronizing cable must be adjusted 1 Remove s...

Страница 2071: ...estraint to top of travel 2 Depress lock button on side of sleeve at top of seat back Fig 9 3 Pull head restraint from top of seat back INSTALLATION 1 Place head restraint in position 2 Depress lock b...

Страница 2072: ...LE REMOVAL 1 Remove screw holding recliner handle to recliner spline shaft Fig 12 2 Remove recliner handle from spline shaft INSTALLATION 1 Place recliner handle in position on spline shaft 2 Install...

Страница 2073: ...retainer Refer to 23 BODY SEATS PLASTIC GRO CERY BAG RETAINER INSTALLATION FRONT SEAT REMOVAL 1 From under vehicle remove nuts attaching front seat risers to the floor 2 Remove seat and riser from flo...

Страница 2074: ...taching the recliner to the seat back frame Tighten nut to 12 N m 105 in lbs torque 4 Install both seat cushion side covers Refer to 23 BODY SEATS FRONT SEAT CUSHION SIDE COVER INSTALLATION 5 Install...

Страница 2075: ...ATION NOTE On vehicles equipped with seat side air bags the seat cover is NOT serviceable The seat back is serviced as an assembly only Refer to 23 BODY SEATS SEAT BACK INSTALLATION 1 Fit seat cover o...

Страница 2076: ...TION and Refer to 23 BODY SEATS QUAD BUCKET SEAT SIDE SHIELD NO CUP HOLDER INSTALLATION 9 Install seat cushion side covers Refer to 23 BODY SEATS FRONT SEAT CUSHION SIDE COVER INSTALLATION FRONT SEAT...

Страница 2077: ...ove nut attaching recliner to seat back frame 4 Remove bolts attaching seat back frame to seat track 5 Remove stud on seat back frame from recliner 6 Remove seat back 7 If power seat track is being re...

Страница 2078: ...SEAT CUSHION INSTAL LATION 7 Install seat in vehicle Refer to 23 BODY SEATS FRONT SEAT INSTALLATION FRONT SEAT TRACK FRONT COVER REMOVAL 1 Remove screws attaching front cover to seat track Fig 23 2 R...

Страница 2079: ...nd remove the hinge cover Fig 25 3 Remove the dump latch handle 4 Remove the three screws Fig 26 5 Depress the tab on the cup holder assembly Fig 27 6 Using a deep well socket or equivalent depress th...

Страница 2080: ...AT SIDE SHIELD NO CUP HOLDER REMOVAL 4 Remove the five bolts two nuts strut bushing and remove the riser from the seat Fig 30 INSTALLATION 1 Install the riser the strut bushing into the hole the five...

Страница 2081: ...hronizer cable if equipped Fig 31 5 Remove the seatback frame bolts and remove the seat back Fig 32 INSTALLATION 1 Install the seatback 2 Install the shoulder bolts attaching the seat back hinge to th...

Страница 2082: ...rd row bench seats install grocery bag holder Refer to 23 BODY SEATS PLASTIC GRO CERY BAG RETAINER INSTALLATION SEAT CUSHION COVER QUAD BUCKET 50 50 SPLIT BENCH REMOVAL BENCH SEAT 50 50 SPLIT 1 Remove...

Страница 2083: ...TION 6 Install seat into vehicle BENCH SEAT RISER 50 50 SPLIT REMOVAL 1 Remove the seat from the vehicle Refer to the Owners Manual for proper procedures 2 Unclip the seat cushion cover j strap Fig 35...

Страница 2084: ...nge cover to seat back hinge Tighten screws to 2 3 N m 20 in lbs torque 3 Place lower cover in position on hinge 4 Install screws attaching lower cover to seat back hinge Fig 37 Tighten screws to 2 3...

Страница 2085: ...m the recline mechanism by pulling the cable end toward the front of the seat Fig 39 3 Pull U shaped locking tab on self adjusting mehcanism to disengage auto adjust feature 4 Reattach self adjusting...

Страница 2086: ...e the bench seat back Refer to 23 BODY SEATS BENCH SEAT BACK REMOVAL 2 Remove the bench seatback panel Refer to 23 BODY SEATS BENCH SEATBACK PANEL REMOVAL 3 Disconnect the cover J straps 4 Remove the...

Страница 2087: ...ALLATION 3 PASS BENCH SEAT 1 Place retainer in position 2 Install the five attaching screws and tighten 2 N m 17 in lbs torque 50 50 SPLIT BENCH SEAT 1 Engage bottom hooks of the retainer and place in...

Страница 2088: ...bin track guide to seat riser Fig 45 Tighten screws to 81 N m 32 in lbs torque 3 Install under seat storage bin Refer to 23 BODY SEATS UNDER SEAT STORAGE BIN INSTALLATION UNDER SEAT STORAGE BIN LOCK...

Страница 2089: ...assembly 4 Remove frame and replace INSTALLATION 1 Trim the seat back frame 2 Install seat back assembly to cushion 3 Install attaching screw to lumbar handle The handle is to be installed between tw...

Страница 2090: ...BY THE ADHESIVE MANUFACTURER IF NOT STRUCTURAL INTEGRITY COULD BE COMPROMISED DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNI CAL DATA S...

Страница 2091: ...nt windshield The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening 1 Place replacement windshield into windshield opening and pos...

Страница 2092: ...LATION The temperature of the vehicle should be at least 21 C 70 F before removing the stationary quarter sliding door glass Butyl sealer becomes more pliable at high temperatures The stationary glass...

Страница 2093: ...d if available Fig 1 5 Remove rear window from vehicle REAR WINDOW REMOVAL INTERIOR METHOD 1 Remove rear window wiper arm if equipped 2 Remove screws attaching moldings to liftgate at the sides of the...

Страница 2094: ...m 1 in wide around perimeter of rear window Allow at least three min utes drying time 10 Apply Pinch weld Primer 19 mm 0 75 in wide around the rear window fence Allow at least three minutes drying tim...

Страница 2095: ...ped 7 Remove watershed as necessary to gain access to screw attaching front lower corner of glass run weatherstrip to inner door panel 8 Remove screw attaching glass run weatherstrip to inner door pan...

Страница 2096: ...Open front door 2 Using fork tool C 4829 remove push pin fas teners attaching front door weatherstrip to end frames and bottom of door Fig 2 3 Pull weatherstrip from retaining channel around window f...

Страница 2097: ...and check alignment FRONT DOOR INNER BELT MOLDING REMOVAL 1 Remove door trim panel 2 Peel upper corner seals away form inner belt molding to clear removal path 3 Pull inner belt molding upward to dis...

Страница 2098: ...OPENING DIMENSIONS 118 SEALER LOCATIONS SPECIFICATIONS BODY SEALING LOCATIONS 121 STUCTURAL ADHESIVE LOCATIONS SPECIFICATIONS STRUCTURAL ADHESIVE LOCATIONS 147 WELD LOCATIONS SPECIFICATIONS WELD LOCA...

Страница 2099: ...Fig 1 GAP FLUSH MEASUREMENTS 23 116 BODY STRUCTURE RS GAP AND FLUSH Continued...

Страница 2100: ...ING DOOR GLASS 5 0 2 0 PARALLEL WITHIN 2 0 1 0 UNDER FLUSH 2 0 CONSISTENT WITHIN 3 0 I FRONT DOOR TO SLIDING DOOR 5 0 2 0 PARALLEL WITHIN 2 0 2 0 CONSISTENT WITHIN 2 0 J SLIDING DOOR TO REAR APERTURE...

Страница 2101: ...OPENING DIMENSIONS SPECIFICATIONS BODY OPENING DIMENSIONS INDEX DESCRIPTION FIGURE WINDSHIELD OPENING 2 LIFTGATE OPENING 3 BODY SIDE OPENINGS 4 Fig 2 WINDSHIELD OPENING 23 118 BODY STRUCTURE RS...

Страница 2102: ...Fig 3 LIFTGATE OPENING RS BODY STRUCTURE 23 119 OPENING DIMENSIONS Continued...

Страница 2103: ...Fig 4 BODY SIDE OPENINGS 23 120 BODY STRUCTURE RS OPENING DIMENSIONS Continued...

Страница 2104: ...LEFT AND RIGHT SIDES 19 REAR WHEEL HOUSE FLOOR PAN LEFT AND RIGHT SIDES 20 REAR WHEELHOUSE TO FLOOR PAN LEFT AND RIGHT SIDES 21 UPPER SLIDING DOOR FLANGE LEFT AND RIGHT SIDES 22 UPPER LIFTGATE HINGE A...

Страница 2105: ...JOINT LEFT AND RIGHT SIDES 42 ROOF RAP JOINT LEFT AND RIGHT SIDES 43 DRAIN HOLE PATCHES 44 WHEELHOUSE VENT HOLE LEFT SIDE SHOWN RIGHT SIDE TYPICAL 45 FLOOR PAN HOLES LEFT AND RIDE SIDES 46 HOOD FRONT...

Страница 2106: ...Fig 5 METHODS OF APPLYING AUTO BODY SEALANT RS BODY STRUCTURE 23 123 SEALER LOCATIONS Continued...

Страница 2107: ...Fig 6 LOWER WINDSHIELD OPENING RIGHT AND LEFT SIDES Fig 7 COWL SIDE LEFT AND RIGHT SIDES 23 124 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2108: ...Fig 8 SIDE QUARTER WINDSHIELD OPENING LEFT AND RIGHT SIDES Fig 9 UPPER WINDSHIELD A PILLAR LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 125 SEALER LOCATIONS Continued...

Страница 2109: ...Fig 10 ROOF TRACK C PILLAR LEFT AND RIGHT SIDES Fig 11 SLIDING DOOR UPPER FLANGE SEAMS LEFT AND RIGHT SIDES 23 126 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2110: ...Fig 12 QUARTER PANEL EXTERIOR AREA LEFT AND RIGHT SIDES Fig 13 LOWER REAR EXTERIOR CORNER PANELS LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 127 SEALER LOCATIONS Continued...

Страница 2111: ...Fig 14 LOWER SILL LIFTGATE OPENING LEFT AND RIGHT SIDES Fig 15 C PILLAR CAN LEFT AND RIGHT SIDES 23 128 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2112: ...Fig 16 SHOCK TOWER AREA LEFT AND RIGHT SIDES Fig 17 OUTER SHOCK TOWER AREA LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 129 SEALER LOCATIONS Continued...

Страница 2113: ...Fig 18 CROSS MEMBER SUPPORT LEFT AND RIGHT SIDES Fig 19 A B PILLAR FLOOR PAN RISERS LEFT AND RIGHT SIDES 23 130 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2114: ...Fig 20 REAR WHEEL HOUSE FLOOR PAN LEFT AND RIGHT SIDES Fig 21 REAR WHEELHOUSE TO FLOOR PAN LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 131 SEALER LOCATIONS Continued...

Страница 2115: ...Fig 22 UPPER SLIDING DOOR FLANGE LEFT AND RIGHT SIDES Fig 23 UPPER LIFTGATE HINGE AREA LEFT AND RIGHT SIDES 23 132 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2116: ...Fig 24 REAR BRACKET SUPPORT REAR HANGER LEFT AND RIGHT SIDES Fig 25 LIFTGATE PANEL OPENING UNDERSIDE RS BODY STRUCTURE 23 133 SEALER LOCATIONS Continued...

Страница 2117: ...Fig 26 D PILLAR INSIDE SEAM LEFT AND RIGHT SIDES Fig 27 REAR TAIL LAMP AREA SEAMS LEFT AND RIGHT SIDES 23 134 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2118: ...Fig 28 UPPER LIFTGATE PANEL SILL LEFT AND RIGHT SIDES Fig 29 FRONT WHEELHOUSE SHOCK TOWER LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 135 SEALER LOCATIONS Continued...

Страница 2119: ...Fig 30 REAR QUARTER WHEELHOUSE LIP SEAT ANCHOR BOLT LEFT AND RIGHT SIDES Fig 31 TAILLAMP CAN LEFT AND RIGHT SIDES 23 136 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2120: ...Fig 32 B PILLAR AND SILL AREAS LEFT AND RIGHT SIDES Fig 33 FRONT FLOOR PAN RISER RS BODY STRUCTURE 23 137 SEALER LOCATIONS Continued...

Страница 2121: ...Fig 34 FLOOR PAN SEAMS LEFT AND RIGHT SIDES Fig 35 FLOOR PAN REAR WHEELHOUSE AREA LEFT AND RIGHT SIDES 23 138 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2122: ...Fig 36 FLOOR PAN SILL D PILLAR SEAMS LEFT AND RIGHT SIDES Fig 37 LEFT SIDE SEAT ANCHOR REINFORCEMENT SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 139 SEALER LOCATIONS Continued...

Страница 2123: ...Fig 38 UNDERBODY LEFT AND RIGHT SIDES Fig 39 ROOF TOP JOINT UPPER FRONT SLIDING DOOR LEFT AND RIGHT SIDES 23 140 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2124: ...Fig 40 ROOF TOP JOINT UPPER REAR SLIDING DOOR LEFT AND RIGHT SIDES Fig 41 ROOF TOP JOINT WINDSHIELD OPENING LEFT AND RIGHT SIDES RS BODY STRUCTURE 23 141 SEALER LOCATIONS Continued...

Страница 2125: ...Fig 42 LIFT GATE ROOF COACH JOINT LEFT AND RIGHT SIDES Fig 43 ROOF RAP JOINT LEFT AND RIGHT SIDES 23 142 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2126: ...Fig 44 DRAIN HOLE PATCHES Fig 45 WHEELHOUSE VENT HOLE LEFT SIDE SHOWN RIGHT SIDE TYPICAL RS BODY STRUCTURE 23 143 SEALER LOCATIONS Continued...

Страница 2127: ...Fig 46 FLOOR PAN HOLES LEFT AND RIDE SIDES Fig 47 HOOD FRONT HEM FLANGE SIDES 23 144 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2128: ...Fig 48 FRONT DOOR LOWER FLANGE Fig 49 LIFTGATE HEM FLANGE AND LATCH COVER SEAMS RS BODY STRUCTURE 23 145 SEALER LOCATIONS Continued...

Страница 2129: ...Fig 50 FRONT DOOR BELT DOOR BELT SEAMS FRONT Fig 51 FRONT DOOR BELT DOOR BELT SEAMS REAR 23 146 BODY STRUCTURE RS SEALER LOCATIONS Continued...

Страница 2130: ...WHEEL BASE ONLY 54 SUSPENSION HANGER REINFORCEMENTS LONG WHEEL BASE ONLY 55 FRONT HINGE PILLAR REINFORCEMENTS LONG WHEEL BASE ONLY 56 ROOF AND REAR QUARTER PANELS SHORT WHEEL BASE ONLY 57 FLOOR PAN S...

Страница 2131: ...Fig 52 UPPER COWL PLENUM UPPER AND LOWER DASH PANEL 23 148 BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS Continued...

Страница 2132: ...Fig 53 ROOF AND REAR QUARTER PANELS LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 149 STUCTURAL ADHESIVE LOCATIONS Continued...

Страница 2133: ...Fig 54 FLOOR PAN LONG WHEEL BASE ONLY 23 150 BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS Continued...

Страница 2134: ...Fig 55 SUSPENSION HANGER REINFORCEMENTS LONG WHEEL BASE ONLY Fig 56 FRONT HINGE PILLAR REINFORCEMENTS LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 151 STUCTURAL ADHESIVE LOCATIONS Continued...

Страница 2135: ...Fig 57 ROOF AND REAR QUARTER PANELS SHORT WHEEL BASE ONLY 23 152 BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS Continued...

Страница 2136: ...Fig 58 FLOOR PAN SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 153 STUCTURAL ADHESIVE LOCATIONS Continued...

Страница 2137: ...Fig 59 FRONT SIDE RAILS OUTER CROSS MEMBER BRACKETS Fig 60 OUTER ROOF PANEL UPPER WINDSHIELD FRAME 23 154 BODY STRUCTURE RS STUCTURAL ADHESIVE LOCATIONS Continued...

Страница 2138: ...Fig 61 COWL SIDE PANEL BODY SIDE APERTURE B PILLAR SLIDING DOOR TRACK SUPPORT RS BODY STRUCTURE 23 155 STUCTURAL ADHESIVE LOCATIONS Continued...

Страница 2139: ...MENTS 77 FLOOR PAN CROSS MEMBER REINFORCEMENTS 78 FRONT SEAT CROSS MEMBER 79 SEAT REINFORCEMENT CROSS MEMBERS SHORT WHEEL BASE 80 CENTER CONSOLE REINFORCEMENT SHORT WHEEL BASE 81 REAR SUSPENSION HANGE...

Страница 2140: ...114 INNER BODY SIDE SILL TO LOWER DASH PANEL 115 FRONT HINGE TAPPING PLATE 116 FRONT HINGE PILLAR 117 INNER WINDSHIELD FRAME 118 WINDSHIELD FRAME 119 FENDER BRACKET 120 INNER B PILLAR 121 STRIKER LATC...

Страница 2141: ...WHEEL BASE ONLY 156 UPPER WINDSHIELD FRAME ROOF PANEL LONG WHEEL BASE ONLY 157 ROOF BOWS INNER ROOF SIDE RAILS 158 OUTER ROOF PANEL LONG WHEEL BASE ONLY 159 INNER SIDE SILL SHORT WHEEL BASE ONLY 160...

Страница 2142: ...Fig 62 FRONT FENDER SHIELD RIGHT Fig 63 FRONT FENDER SHIELD LEFT RS BODY STRUCTURE 23 159 WELD LOCATIONS Continued...

Страница 2143: ...Fig 64 STRUT TOWER AND REINFORCEMENTS RIGHT 23 160 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2144: ...Fig 65 SUSPENSION RETAINERS AND REINFORCEMENTS RIGHT RS BODY STRUCTURE 23 161 WELD LOCATIONS Continued...

Страница 2145: ...Fig 66 STRUT TOWER AND REINFORCEMENTS LEFT 23 162 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2146: ...Fig 67 SUSPENSION RETAINERS AND REINFORCEMENTS LEFT RS BODY STRUCTURE 23 163 WELD LOCATIONS Continued...

Страница 2147: ...Fig 68 FLOOR PAN REINFORCEMENTS SIDE RAILS 23 164 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2148: ...Fig 69 REAR SUSPENSION BRACKETS RS BODY STRUCTURE 23 165 WELD LOCATIONS Continued...

Страница 2149: ...Fig 70 FLOOR PAN CROSS MEMBERS 23 166 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2150: ...Fig 71 SEAT REINFORCEMENTS LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 167 WELD LOCATIONS Continued...

Страница 2151: ...Fig 72 STRIKER REINFORCEMENTS LONG WHEEL BASE ONLY 23 168 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2152: ...Fig 73 FUEL TANK MOUNTING REAR SEAT AND SUSPENSION RS BODY STRUCTURE 23 169 WELD LOCATIONS Continued...

Страница 2153: ...Fig 74 REAR SUSPENSION HANGER BRACKETS LONG WHEEL BASE 23 170 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2154: ...Fig 75 FRONT SEAT CROSS MEMBER RS BODY STRUCTURE 23 171 WELD LOCATIONS Continued...

Страница 2155: ...Fig 76 FLOOR PAN SIDE RAIL REINFORCEMENT 23 172 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2156: ...Fig 77 SILL BULKHEAD REINFORCEMENTS RS BODY STRUCTURE 23 173 WELD LOCATIONS Continued...

Страница 2157: ...Fig 78 FLOOR PAN CROSS MEMBER REINFORCEMENTS 23 174 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2158: ...Fig 79 FRONT SEAT CROSS MEMBER RS BODY STRUCTURE 23 175 WELD LOCATIONS Continued...

Страница 2159: ...Fig 80 SEAT REINFORCEMENT CROSS MEMBERS SHORT WHEEL BASE 23 176 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2160: ...Fig 81 CENTER CONSOLE REINFORCEMENT SHORT WHEEL BASE RS BODY STRUCTURE 23 177 WELD LOCATIONS Continued...

Страница 2161: ...Fig 82 REAR SUSPENSION HANGER BRACKETS SHORT WHEEL BASE 23 178 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2162: ...Fig 83 LOWER LIFTGATE PANEL LATCH REINFORCEMENT RS BODY STRUCTURE 23 179 WELD LOCATIONS Continued...

Страница 2163: ...Fig 84 ENGINE MOUNTING PLATE AND TOW BRACKET 23 180 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2164: ...Fig 85 HEADLAMP MOUNTING PLATE RS BODY STRUCTURE 23 181 WELD LOCATIONS Continued...

Страница 2165: ...Fig 86 LOWER RADIATOR CROSS MEMBER BRACKETS 23 182 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2166: ...Fig 87 CROSS MEMBER EXTENSIONS RS BODY STRUCTURE 23 183 WELD LOCATIONS Continued...

Страница 2167: ...Fig 88 JACK MOUNTING BRACKET LONG WHEEL BASE SHOWN SHORT SIMILAR 23 184 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2168: ...Fig 89 FRONT SEAT CROSS MEMBER LONG WHEELBASE ONLY Fig 90 FRONT SEAT CROSS MEMBER ALL WHEEL DRIVE ONLY RS BODY STRUCTURE 23 185 WELD LOCATIONS Continued...

Страница 2169: ...Fig 91 FUEL TANK SUPPORT CROSS MEMBERS LONG WHEEL BASE ONLY 23 186 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2170: ...Fig 92 REAR SUPPORT AND TIRE STOWAGE CROSS MEMBERS LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 187 WELD LOCATIONS Continued...

Страница 2171: ...Fig 93 INNER SIDE SILLS LONG WHEEL BASE ONLY Fig 94 WHEELHOUSES SIDE SILLS SUSPENSION BRACKETS LONG WHEEL BASE ONLY 23 188 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2172: ...Fig 95 REAR SEAT REINFORCEMENTS SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 189 WELD LOCATIONS Continued...

Страница 2173: ...Fig 96 FUEL TANK SUPPORT AND TIRE STOWAGE SHORT WHEEL BASE ONLY 23 190 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2174: ...Fig 97 INNER SIDE SILLS SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 191 WELD LOCATIONS Continued...

Страница 2175: ...Fig 98 REAR SEAT REINFORCEMENTS SHORT WHEEL BASE ONLY 23 192 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2176: ...Fig 99 CENTER CONSOLE REINFORCEMENT SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 193 WELD LOCATIONS Continued...

Страница 2177: ...Fig 100 WHEELHOUSES SHORT WHEEL BASE ONLY Fig 101 FRONT SEAT CROSS MEMBER SHORT WHEELBASE ALL WHEEL DRIVE ONLY 23 194 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2178: ...Fig 102 FLOOR PAN SIDE RAIL LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 195 WELD LOCATIONS Continued...

Страница 2179: ...Fig 103 INNER BODY SIDE SILL REINFORCEMENTS Fig 104 TOE BOARD CROSS MEMBER 23 196 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2180: ...Fig 105 FRONT SIDE RAIL SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 197 WELD LOCATIONS Continued...

Страница 2181: ...Fig 106 DASH PANEL REINFORCEMENT 23 198 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2182: ...Fig 107 LOWER COWL PLENUM RS BODY STRUCTURE 23 199 WELD LOCATIONS Continued...

Страница 2183: ...Fig 108 UPPER COWL PLENUM SUPPORT 23 200 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2184: ...Fig 109 UPPER DASH PANEL RS BODY STRUCTURE 23 201 WELD LOCATIONS Continued...

Страница 2185: ...Fig 110 COWL SIDE PANELS Fig 111 INSTRUMENT PANEL ATTACHMENT TAPPING PLATES 23 202 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2186: ...Fig 112 INSTRUMENT PANEL DASH PANEL ACM MODULE AND ACCELERATOR PEDAL Fig 113 STRUT TOWER BRACKET AND COWL PLENUM RS BODY STRUCTURE 23 203 WELD LOCATIONS Continued...

Страница 2187: ...Fig 114 FRONT SIDE RAILS TO LOWER DASH PANEL 23 204 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2188: ...Fig 115 INNER BODY SIDE SILL TO LOWER DASH PANEL RS BODY STRUCTURE 23 205 WELD LOCATIONS Continued...

Страница 2189: ...Fig 116 FRONT HINGE TAPPING PLATE 23 206 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2190: ...Fig 117 FRONT HINGE PILLAR RS BODY STRUCTURE 23 207 WELD LOCATIONS Continued...

Страница 2191: ...Fig 118 INNER WINDSHIELD FRAME 23 208 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2192: ...Fig 119 WINDSHIELD FRAME RS BODY STRUCTURE 23 209 WELD LOCATIONS Continued...

Страница 2193: ...Fig 120 FENDER BRACKET 23 210 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2194: ...Fig 121 INNER B PILLAR RS BODY STRUCTURE 23 211 WELD LOCATIONS Continued...

Страница 2195: ...Fig 122 STRIKER LATCH AND TAPPING PLATES Fig 123 RIGHT REAR INNER QUARTER PANEL LONG WHEEL BASE ONLY 23 212 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2196: ...Fig 124 RIGHT REAR INNER QUARTER PANEL OUTER WHEELHOUSE LONG WHEEL BASE ONLY Fig 125 RIGHT REAR BODY SIDE APERTURE LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 213 WELD LOCATIONS Continued...

Страница 2197: ...Fig 126 STRIKER LATCH REINFORCEMENT LONG WHEEL BASE ONLY 23 214 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2198: ...Fig 127 BELT TAPPING PLATE LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 215 WELD LOCATIONS Continued...

Страница 2199: ...Fig 128 C PILLAR REINFORCEMENT LONG WHEEL BASE ONLY 23 216 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2200: ...Fig 129 OUTER WHEELHOUSE LONG WHEEL BASE ONLY Fig 130 C AND D PILLAR INNER REINFORCEMENTS LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 217 WELD LOCATIONS Continued...

Страница 2201: ...Fig 131 LEFT REAR INNER QUARTER PANEL LONG WHEEL BASE ONLY 23 218 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2202: ...Fig 132 OUTER WHEELHOUSE EXTENSION LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 219 WELD LOCATIONS Continued...

Страница 2203: ...Fig 133 TAIL LAMP LONG WHEEL BASE ONLY Fig 134 SLIDING DOOR LATCH LONG WHEEL BASE ONLY 23 220 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2204: ...Fig 135 ROOF BOW EXTENSION LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 221 WELD LOCATIONS Continued...

Страница 2205: ...Fig 136 RIGHT REAR INNER QUARTER PANEL SHORT WHEEL BASE ONLY 23 222 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2206: ...Fig 137 LATCH REINFORCEMENT AND OUTER WHEELHOUSE SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 223 WELD LOCATIONS Continued...

Страница 2207: ...Fig 138 D PILLAR REINFORCEMENT SHORT WHEEL BASE ONLY 23 224 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2208: ...Fig 139 OUTER WHEELHOUSE SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 225 WELD LOCATIONS Continued...

Страница 2209: ...Fig 140 LEFT REAR INNER QUARTER PANEL SHORT WHEEL BASE ONLY 23 226 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2210: ...Fig 141 LATCH REINFORCEMENT SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 227 WELD LOCATIONS Continued...

Страница 2211: ...Fig 142 D PILLAR REINFORCEMENT SHORT WHEEL BASE ONLY 23 228 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2212: ...Fig 143 OUTER WHEELHOUSE SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 229 WELD LOCATIONS Continued...

Страница 2213: ...Fig 144 BODY SIDE APERTURE RIGHT SIDE LONG WHEEL BASE ONLY 23 230 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2214: ...Fig 145 BODY SIDE APERTURE LEFT SIDE LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 231 WELD LOCATIONS Continued...

Страница 2215: ...Fig 146 BODY SIDE APERTURE RIGHT SIDE SHORT WHEEL BASE ONLY 23 232 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2216: ...Fig 147 BODY SIDE APERTURE LEFT SIDE SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 233 WELD LOCATIONS Continued...

Страница 2217: ...Fig 148 LOWER SLIDING DOOR TRACK 23 234 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2218: ...Fig 149 LIFTGATE UPPER FRAME Fig 150 UPPER WINDSHIELD FRAME RS BODY STRUCTURE 23 235 WELD LOCATIONS Continued...

Страница 2219: ...Fig 151 FRONT FENDER SHIELD BEAM 23 236 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2220: ...Fig 152 FRONT FENDER SHIELD BEAM COWL SIDE PANEL RS BODY STRUCTURE 23 237 WELD LOCATIONS Continued...

Страница 2221: ...Fig 153 HINGE PILLAR REINFORCEMENT 23 238 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2222: ...Fig 154 INNER SIDE SILL LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 239 WELD LOCATIONS Continued...

Страница 2223: ...Fig 155 INNER SIDE SILL OUTER SIDE SILL LONG WHEEL BASE ONLY 23 240 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2224: ...Fig 156 LOWER SLIDING DOOR TRACK REINFORCEMENT LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 241 WELD LOCATIONS Continued...

Страница 2225: ...Fig 157 UPPER WINDSHIELD FRAME ROOF PANEL LONG WHEEL BASE ONLY Fig 158 ROOF BOWS INNER ROOF SIDE RAILS 23 242 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2226: ...Fig 159 OUTER ROOF PANEL LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 243 WELD LOCATIONS Continued...

Страница 2227: ...Fig 160 INNER SIDE SILL SHORT WHEEL BASE ONLY 23 244 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2228: ...Fig 161 INNER SIDE OUTER SIDE SILLS SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 245 WELD LOCATIONS Continued...

Страница 2229: ...Fig 162 LOWER SLIDING DOOR TRACK SHORT WHEEL BASE ONLY 23 246 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2230: ...Fig 163 UPPER WINDSHIELD FRAME OUTER ROOF PANEL SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 247 WELD LOCATIONS Continued...

Страница 2231: ...Fig 164 REAR SUSPENSION HANGERS LONG WHEEL BASE SHOWN SHORT WHEEL BASE TYPICAL 23 248 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2232: ...Fig 165 FRONT LOWER LIFTGATE OPENING Fig 166 REAR JACKING REINFORCEMENT LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 249 WELD LOCATIONS Continued...

Страница 2233: ...Fig 167 INNER WHEELHOUSE LONG WHEEL BASE ONLY 23 250 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2234: ...Fig 168 SUSPENSION HANGER REINFORCEMENT LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 251 WELD LOCATIONS Continued...

Страница 2235: ...Fig 169 LOWER LIFTGATE OPENING PANEL LONG WHEEL BASE ONLY 23 252 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2236: ...Fig 170 ROOF BOWS UPPER LIFTGATE FRAME LONG WHEEL BASE ONLY RS BODY STRUCTURE 23 253 WELD LOCATIONS Continued...

Страница 2237: ...Fig 171 BODY SIDE APERTURE INNER QUARTER PANEL LONG WHEEL BASE ONLY 23 254 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2238: ...Fig 172 REAR JACKING REINFORCEMENT SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 255 WELD LOCATIONS Continued...

Страница 2239: ...Fig 173 INNER WHEELHOUSE INNER QUARTER PANEL SHORT WHEEL BASE ONLY 23 256 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2240: ...Fig 174 SUSPENSION HANGER REINFORCEMENT SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 257 WELD LOCATIONS Continued...

Страница 2241: ...Fig 175 LOWER LIFTGATE OPENING SHORT WHEEL BASE ONLY 23 258 BODY STRUCTURE RS WELD LOCATIONS Continued...

Страница 2242: ...Fig 176 ROOF PANEL ROOF RAIL SHORT WHEEL BASE ONLY RS BODY STRUCTURE 23 259 WELD LOCATIONS Continued...

Страница 2243: ......

Страница 2244: ...box provides easy access to the filter element The control panel and integral computer is located in the instrument panel The instrument panel mounted control and inte gral computer contains a power b...

Страница 2245: ...fold Absolute Pressure information from the PCM Coolant Temperature ATC computer moni tors Coolant temperature received from the PCM and converts it to degrees Fahrenheit Ambient Temperature ATC compu...

Страница 2246: ...des a vacuum flourescent digital dis play a rocker control for temperature and rotary con trols for adjustment of mode and fan speed control of the rear unit by intermediate seat passengers OPERATION...

Страница 2247: ...which controls the Rear Window Defogger and side view mirror if equipped circuitry The defogger function will be active for 10 minutes and can be turned off by a switch press The defogger will functio...

Страница 2248: ...lake icon and the DELAY text stop blinking before two minutes then the cool down test has been completed successfully If the two minutes expire without the evaporator tem perature reaching 20 F less t...

Страница 2249: ...FER TO THE APPLICABLE WARN INGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMB ING Check the coolant le...

Страница 2250: ...trol liquid line mounted input to Powertrain Control Module PCM PCM opens compressor clutch relay 29 4 psi High PSI Control pressure transducer liquid line mounted input to PCM PCM opens compressor cl...

Страница 2251: ...IS AND TESTING COMPRESSOR CLUTCH RELAY 22 REMOVAL 22 INSTALLATION 22 EVAPORATOR TEMPERATURE SENSOR DESCRIPTION 22 OPERATION 23 REMOVAL 23 INSTALLATION 23 INFRARED TEMPERATURE SENSOR DESCRIPTION 24 OPE...

Страница 2252: ...precautions to protect the center bezel from cosmetic damage 4 If the vehicle is equipped with the optional Automatic Temperature Control ATC system dis connect the infrared sensor jumper harness conn...

Страница 2253: ...air condition ing compressor clutch from engaging when ambient temperatures are below about 10 C 50 F due to the pressure temperature relationship of the refriger ant The Schrader type valve in the l...

Страница 2254: ...r the mode door and the recirculation air door Each actua tor is contained within an identical black molded plastic housing with an integral wire connector receptacle Two integral mounting tabs allow...

Страница 2255: ...formations of the heater air conditioner hous ing near the dash panel 5 Remove the heater core shield from the distri bution housing 6 Disconnect the HVAC wire harness connector for the blend door ac...

Страница 2256: ...er module ATC control The movable common feed contact point is held against the fixed normally closed contact point by spring pressure When the relay coil is energized an electromagnetic field is prod...

Страница 2257: ...rform further diagnosis of the relay circuits Refer to the appropriate diagnostic information If not OK replace the faulty relay REMOVAL 1 Disconnect and isolate the battery negative cable 2 Unlatch a...

Страница 2258: ...r motor ground path through fewer of the resistor wires increasing the blower motor speed When the blower motor switch is in the high est speed position the blower motor resistor wires are bypassed an...

Страница 2259: ...m the resistor connector receptacle 6 Remove the two screws that secure the blower motor resistor to the evaporator housing 7 Remove the blower motor resistor from the evaporator housing INSTALLATION...

Страница 2260: ...IN CONTROL MODULE DESCRIPTION PCM OPERATION STANDARD PROCEDURE STANDARD PROCEDURE COMPRESSOR CLUTCH AIR GAP If a new clutch plate and or clutch pulley are being used the air gap between the clutch pla...

Страница 2261: ...filter wrench or a strap wrench can be placed around the clutch plate to aid in bolt removal 9 Tap the clutch plate lightly with a plastic ham mer and remove the clutch plate and shim s from the compr...

Страница 2262: ...at the clutch coil pigtail wires are properly ori ented and routed so that they are not pinched between the compressor front cover and the clutch coil NOTE A new snap ring must be used to secure the c...

Страница 2263: ...r The lower screw at the rear of the compressor The lower screw at the front of the compressor The upper nut at the front of the compressor 12 On models with the 3 3L and 3 8L engines only engage the...

Страница 2264: ...dule IPM which is in the engine compartment near the battery See the fuse and relay layout map molded into the inner surface of the IPM cover for compressor clutch relay identification and location Th...

Страница 2265: ...OPEN 87A NORMALLY CLOSED REMOVAL 1 Disconnect and isolate the battery negative cable 2 Unlatch and remove the cover from the Intelli gent Power Module IPM 3 See the fuse and relay layout map molded i...

Страница 2266: ...to 8 ELECTRICAL WIPERS WASHERS WIPER MODULE REMOVAL 4 Remove the temperature sensor attaching screw from the expansion valve 5 Pull the evaporator temperature sensor away from the expansion valve far...

Страница 2267: ...e ATC system logic responds to the infrared sensor inputs by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the individ ually selected comf...

Страница 2268: ...UMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURTHER DIAG...

Страница 2269: ...system through a dedicated take out and connector of the instrument panel wire harness A second connector receptacle receives the pigtail wire connector from the blower motor The blower power module a...

Страница 2270: ...e heater A C housing unit on the bottom of the lower intake air housing The recirculation door actuator is mechanically con nected to the recirculation air door The recirculation door actuator is inte...

Страница 2271: ...air housing 5 Remove the recirculation door actuator from the lower intake air housing INSTALLATION WARNING ON VEHICLES EQUIPPED WITH AIR BAGS DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING...

Страница 2272: ...h to access the headliner wire harness connector on the back of the control 4 Disconnect the headliner wire harness connec tor for the rear heater A C control from the control connector receptacle 5 R...

Страница 2273: ...blend door actuator is interchangeable with the actuator for the mode door Each actuator is contained within an identical black molded plastic housing with an inte gral wire connector receptacle Two...

Страница 2274: ...f the rear heater A C unit housing away from the right quarter inner panel far enough to reach between the rear heater A C unit housing and the quarter inner panel to access the blend door actuator Fi...

Страница 2275: ...pade type terminals extend from the bottom of the base to connect the relay to the vehicle electrical sys tem and the ISO designation for each terminal is molded into the base adjacent to each termina...

Страница 2276: ...tion views for the various wire har ness connectors splices and grounds DIAGNOSIS AND TESTING BLOWER MOTOR RELAY The rear blower motor relay Fig 6 is located in the Intelligent Power Module IPM which...

Страница 2277: ...e is secured with two screws to the rear heater A C unit housing and is accessed for service by removing the right quarter and D pillar trim panels The blower motor resistor wires will get hot when in...

Страница 2278: ...to take this precaution can result in vehicle damage 1 Disconnect and isolate the battery negative cable 2 Remove the right quarter trim panel and right D pillar trim panel from the quarter inner pane...

Страница 2279: ...nfrared sensor cir cuit and will store a Diagnostic Trouble Code DTC for any problem it detects This DTC information can be retrieved and the infrared temperature sensor diagnosed using a DRBIIIt scan...

Страница 2280: ...ATER A C CONTROL CALIBRATION POWER MODULE DESCRIPTION A blower power module is used on this model when it is equipped with the optional Automatic Tempera ture Control ATC Fig 11 Models equipped with t...

Страница 2281: ...nector receptacle 5 Remove the two screws that secure the blower power module to the rear heater A C unit housing 6 Remove the blower power module from the rear heater A C unit housing INSTALLATION 1...

Страница 2282: ...ON CENTER BEZEL OUTLETS 43 INSTALLATION DEMISTER OUTLET 43 INSTALLATION FRONT DOOR REAR OUTLET 43 INSTALLATION INSTRUMENT PANEL OUTLET 43 BLOWER MOTOR DESCRIPTION 43 OPERATION 43 DIAGNOSIS AND TESTING...

Страница 2283: ...s the center of the vehicle 2 With the air filter Airflow arrow properly ori ented carefully slide the filter fully upward into the evaporator housing through the air filter opening 3 With the latch s...

Страница 2284: ...r the front floor carpet from an outlet nozzle on the bottom of the front heater A C unit distribution housing REMOVAL REMOVAL CENTER BEZEL OUTLETS The three outlets located near the top of the instru...

Страница 2285: ...flat bladed tool gently pry the outer perimeter of the instrument panel outlet away from the instrument panel top pad until the snap features on the outlet are released Fig 6 2 Remove the instrument...

Страница 2286: ...INSTALLATION 4 Reconnect the battery negative cable INSTALLATION INSTRUMENT PANEL OUTLET 1 Position the instrument panel outlet into the panel duct opening in the instrument panel top pad 2 Using han...

Страница 2287: ...C If OK go to Step 4 If not OK repair the open fused front blower motor relay output circuit to the IPM as required 4 Turn the ignition switch to the Off position Disconnect and isolate the battery ne...

Страница 2288: ...Fig 8 Blower Motor Noise Vibration Diagnosis RS DISTRIBUTION FRONT 24 45 BLOWER MOTOR Continued...

Страница 2289: ...AUTION A C PLUMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMB ING 1 Gently flex the recirculation air door far enough to position the blower motor and blower wheel i...

Страница 2290: ...negative cable 2 Remove the instrument panel from the vehicle Refer to 23 BODY INSTRUMENT PANEL IN STRUMENT PANEL ASSEMBLY REMOVAL 3 Place the instrument panel face down on a suitable work surface Be...

Страница 2291: ...the battery negative cable FLOOR DISTRIBUTION DUCTS REMOVAL 1 Roll back the carpet on the front floor from under the instrument panel toward the rear of the vehicle Refer to 23 BODY INTERIOR CARPETS A...

Страница 2292: ...the engine cooling system Refer to 7 COOLING STANDARD PROCEDURE COOLING SYSTEM DRAIN 3 Disconnect and isolate the battery negative cable 4 Disconnect the liquid line and suction line from the expansi...

Страница 2293: ...er to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM EVACUATE 11 Charge the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIG...

Страница 2294: ...side and two left side fully adjustable outlets along the roof rails distribute air from the rear A C distribution duct and the headliner ducts to the intermediate and rear seat occupants The headline...

Страница 2295: ...top of the rear heater A C unit housing 4 Reinstall the trim onto the right quarter inner panel and the right D pillar Refer to 23 BODY IN TERIOR RIGHT QUARTER TRIM PANEL INSTALLATION BLOWER MOTOR DE...

Страница 2296: ...wer is turned on Check for battery voltage at the fused rear blower motor relay output circuit cavity of the rear HVAC wire harness connector for the rear blower motor resistor MTC or the rear blower...

Страница 2297: ...Fig 4 Blower Motor Noise Vibration Diagnosis 24 54 DISTRIBUTION REAR RS BLOWER MOTOR Continued...

Страница 2298: ...er to 24 HEATING AIR CONDITIONING PLUMBING FRONT CAUTION A C PLUMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMB ING 1 Recover the refrigerant from the refrigerant sy...

Страница 2299: ...ear heater A C unit housing to the right quarter inner panel 22 Lift the rear heater A C unit housing up far enough for the lower mounting studs and the evapo rator extension lines to clear the mounti...

Страница 2300: ...all and tighten the three nuts that secure the rear heater A C unit mounting studs to the rear floor panel behind the right rear wheel housing Tighten the nuts to 9 N m 80 in lbs 15 Remove the tape or...

Страница 2301: ...rear heater distribution duct forward far enough to disengage it from the outlet on the front of the rear heater air conditioner unit housing 4 Remove the rear heater distribution duct from the vehic...

Страница 2302: ...INSTALLATION HEATER CORE EXTENSION TUBES 76 INSTALLATION HEATER CORE 77 HEATER HOSE REMOVAL 78 INSTALLATION 79 HEATER HOSES DIESEL SUPPLEMENTAL HEATER BUX REMOVAL 80 INSTALLATION 80 HEATER PIPES DIESE...

Страница 2303: ...E OF ETHYLENE GLYCOL BASED COOLANT PROPERLY CONTACT YOUR DEALER OR A LOCAL GOVERNMENT AGENCY FOR THE LOCATION OF AN APPROVED ETHYLENE GLY COL COLLECTION AND OR RECYCLING CENTER IN YOUR AREA WARNING A...

Страница 2304: ...phere any longer than necessary CAUTION Before connecting an open refrigerant fitting always install a new seal or gasket All fit tings with O rings need to be coated with refriger ant oil before inst...

Страница 2305: ...and closes when a minimum discharge pressure of 2756 kPa 400 psi is reached DIAGNOSIS AND TESTING COMPRESSOR NOISE DIAGNOSIS Excessive noise while the air conditioning compres sor is operating can be...

Страница 2306: ...port 9 Remove the seal from the discharge line fitting and discard 10 Install plugs in or tape over the opened dis charge line fitting and the compressor discharge port 11 Raise and support the vehic...

Страница 2307: ...e compressor The upper nut at the front of the compressor 4 On models with the 3 3L and 3 8L engines only engage the retainer on the engine wire harness com pressor clutch coil take out with the brack...

Страница 2308: ...als or shrouds must be properly reinstalled following radiator or condenser service REMOVAL WARNING REFER TO THE APPLICABLE WARN INGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERA...

Страница 2309: ...t system Use only refrigerant oil of the type recommended for the compressor in the vehi cle NOTE Be certain that each of the radiator and con denser air seals are reinstalled in their proper loca tio...

Страница 2310: ...refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROCE DURE REFRIGERANT SYSTEM CHARGE DISCHARGE LINE REMOVAL WARNING REFER TO THE APPLICABLE WARN INGS AND C...

Страница 2311: ...shield to the radiator closure panel crossmember Tighten the screws to 6 N m 53 in lbs 13 Evacuate the refrigerant system Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT REFRIGERANT STANDARD PROC...

Страница 2312: ...harness from the routing clips molded into the outside of the HVAC housing components 7 Remove the three screws from the dash panel side of the unit that secure the top of the distribution housing to...

Страница 2313: ...of the evaporator housing as a unit Be certain that the clam shell type rubber seal is fitted to the evaporator inlet and outlet tubes where they exit the evaporator housing 2 Position the upper half...

Страница 2314: ...18 Run the HVAC Control Actuator Calibration procedure Refer to 24 HEATING AIR CONDI TIONING DIAGNOSIS AND TESTING Refer to 24 HEATING AIR CONDITIONING DIAGNOSIS AND TESTING EXPANSION VALVE DESCRIPTI...

Страница 2315: ...emove all test equipment before returning the vehi cle to service REMOVAL WARNING REFER TO THE APPLICABLE WARN INGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION Refer to 24 H...

Страница 2316: ...erant oil and install it on the liquid line fitting 12 Reconnect the liquid line fitting to the filter drier outlet port on the top of the filter drier 13 Install and tighten the screw that secures th...

Страница 2317: ...that secure the heater core shield to the left end of the HVAC distribution housing Fig 15 6 Pull the heater core shield rearward far enough to disengage the two location tabs that position the front...

Страница 2318: ...r boot fasteners located around the base of the lower steering shaft from the dash panel so that it may be pushed aside 4 Remove the brake lamp switch from its mount ing bracket Refer to 8 ELECTRICAL...

Страница 2319: ...OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE DISCONNECT AND ISO LATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE AIRBAG SYS TEM CAPACITOR TO DISCHARGE BEFORE PER FORMING FURT...

Страница 2320: ...celerator pedal upward far enough for clearance slide the heater core into the distribution housing 2 Install and tighten the two screws that secure the heater core mounting plate to the distribution...

Страница 2321: ...MING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMB ING 1 Drain the engine cooling system Refer to 7 COOLING STANDARD PROCEDURE COOLING SYSTEM DRAIN 2...

Страница 2322: ...itioner All models use a combination of formed steel tubing and rubber hoses In most cases the rubber hose is secured to the steel tubing with a spring tension clamp WARNING REFER TO THE APPLICABLE WA...

Страница 2323: ...UX REMOVAL CAUTION Allow cooling system to cool completely before removing radiator cap or draining cooling system Injury could result is system is opened while system coolant is hot and under pressur...

Страница 2324: ...ATER CORE RETURN PIPE 3 A C LINES 4 A C EXPANSION VALVE 5 A C EXPANSION VALVE GROUND WIRE 6 CABIN HEATER RETURN PIPE 7 CABIN HEATER INTAKE PIPE 8 CABIN HEATER PIPES RETAINING NUT RS PLUMBING FRONT 24...

Страница 2325: ...h the optional rear air conditioner the rear section of the front air condi tioner liquid line also includes a liquid line hose and tube extension that connects the front liquid line to the liquid lin...

Страница 2326: ...he refrigerant from the refrigerant system Refer to 24 HEATING AIR CONDI TIONING PLUMBING FRONT REFRIGERANT STANDARD PROCEDURE REFRIGERANT RECOVERY 2 Disconnect and isolate the battery negative cable...

Страница 2327: ...line to the liquid line for the rear air condi tioner FRONT SECTION 1 Position the front section of the front liquid line into the engine compartment 2 Remove the tape or plugs from the liquid line f...

Страница 2328: ...o Step 23 17 Raise and support the vehicle 18 Remove the tape or plugs from the liquid line rear section extension fitting and the underbody liq uid line fitting 19 Lubricate a new rubber O ring seal...

Страница 2329: ...the filter drier mounting bracket to the studs Tighten the nuts to 10 N m 89 in lbs 3 Remove the tape or plugs from the liquid line rear section fitting for the filter drier and the filter drier outle...

Страница 2330: ...r refrigerant charge low include poor air conditioner performance fog emitted from the air conditioner outlets a hissing sound from the expansion valve evaporator area There are two different methods...

Страница 2331: ...hart reclaim 0 057 kilo gram 0 125 pound or 2 ounces of refrigerant from the system 6 Recheck the system charge level following each refrigerant adjustment Continue this process until the system readi...

Страница 2332: ...G PLUMBING FRONT CAUTION A C PLUMBING NOTE The proper amount of R 134a refrigerant for the refrigerant system in this model is Single or Dual Zone Front Unit Only 2 5L Die sel 0 91 kilograms 2 00 poun...

Страница 2333: ...5 Observe the liquid line discharge pressure and liquid line temperature Using the Charge Deter mination Chart Fig 34 determine whether the refrigerant system is operating within the Proper Charge Ra...

Страница 2334: ...valves on the manifold gauge set are opened the refrigerant in the system will escape through this hose STANDARD PROCEDURE REFRIGERANT SYSTEM CHARGE WARNING REFER TO THE APPLICABLE WARN INGS AND CAUT...

Страница 2335: ...NG OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING A C PLUMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT CAUTION A C PLUMBING If the refrigerant system has been op...

Страница 2336: ...G THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING A C PLUMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT CAUTION A C PLUMBING When an air conditioning...

Страница 2337: ...line fitting from the compressor suction port 7 Remove the seal from the suction line fitting and discard 8 Install plugs in or tape over the opened suc tion line fitting and the compressor suction p...

Страница 2338: ...stall and tighten the nut that secures the suction line fitting to the compressor Tighten the nut to 23 N m 17 ft lbs 11 Reconnect the drain tube to the wiper module drain on the right side of the eng...

Страница 2339: ...vice port CAUTION A valve core that is not fully seated in the A C service port can result in damage to the valve during refrigerant system evacuation and charge Such damage may result in a loss of sy...

Страница 2340: ...nt through the evaporator tubes The rear heater A C unit housing must be removed from the vehicle to access the evaporator for service The evaporator cannot be adjusted or repaired and if faulty or da...

Страница 2341: ...UMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING HEATER PLUMB ING 1 Remove the rear heater A C unit housing from the vehicle Refer to 24 HEATING AIR CONDI TIONING DISTRIBUTION RE...

Страница 2342: ...ING AIR CONDI TIONING DISTRIBUTION REAR REAR HEATER A C HOUSING INSTALLATION INSTALLATION EVAPORATOR LINE EXTENSION 1 Remove the tape or plugs from the evaporator line extension fittings and both expa...

Страница 2343: ...d read 965 to 1655 kPa 140 to 240 psi The suction low pressure gauge should read 140 kPa to 207 kPa 20 psi to 30 psi If OK go to Step 6 If not OK replace the faulty expansion valve WARNING PROTECT THE...

Страница 2344: ...er output air temperature by controlling how much of the air flowing through the rear heater A C unit housing is directed through the heater core STANDARD PROCEDURE HEATER CORE FILLING In its final in...

Страница 2345: ...C 70 F 1 Start the engine and allow it to idle until it warms up to normal operating temperature 2 Adjust the heater A C controls so that the front heater is turned Off the rear heater is set for ful...

Страница 2346: ...R HOSE REMOVAL REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PER FORMING THE FOLLOWING OPERATION Refer to 24 HEATING AIR CONDITIONING PLUMB ING FRONT WARNING HEATER PLUMBING 1 P...

Страница 2347: ...to 24 HEATING AIR CONDITIONING PLUMBING FRONT WARNING A C PLUMBING and Refer to 24 HEATING AIR CONDITIONING PLUMBING FRONT CAUTION A C PLUMBING 1 Recover the refrigerant from the refrigerant system R...

Страница 2348: ...clean refrigerant oil and install them on the suction line and liquid line fittings 4 Reconnect the liquid line and suction line fit tings to the expansion valve 5 Install and tighten the nut that se...

Страница 2349: ...nd straight heater hoses used on the rear heater A C unit can be ser viced in the vehicle Refer to Group 7 Cooling Sys tem for the heater hose service procedures OPERATION The rear heater and A C line...

Страница 2350: ...two rear retaining clamps behind rear wheel 5 Remove both compression fittings at front of A C lines Fig 9 6 Remove 1 bolt securing A C lines to block located at A C housing behind rear wheel and sepa...

Страница 2351: ...ant oil 2 Install A C line into rear block with nylon wedge 3 Install A C lines into five underbody brackets 4 Connect forward compression fittings 5 Install bolt at sealing block to rear A C hous ing...

Страница 2352: ...mounts of fuel to provide additional heat to the coolant Coolant is routed from the engine to the supplemental heater and then to the front heater core This provides additional heat to the passenger c...

Страница 2353: ...be inspected and components should be replaced as required Loss of fuel dripping Check heater system integration in vehicles fuel system Check fuel line connection for leakage If OK there is an intern...

Страница 2354: ...el line to pre vent fuel leakage while servicing dosing pump NOTE Utilize an approved fuel storage container to catch any residual fuel 3 Disconnect the electrical connector to the fuel pump by depres...

Страница 2355: ...laced 5 Install the cabin heater line Refer to 24 HEATING AIR CONDITIONING CABIN HEAT ER FUEL LINE INSTALLATION 6 Verify function of the heater REMOVAL 1 Elevate vehicle on a lift taking note of the h...

Страница 2356: ...eater activation during the first attempt to start the heater This will also set a Diagnostic Trouble Code DCT in the DCHA Control s memory do not per form the Dosing Pump Priming procedure if an atte...

Страница 2357: ...exhaust tube Removal of the rail tube assembly may aid in this service operation Refer to 24 HEATING AIR CONDITIONING CABIN HEATER EXHAUST TUBE REMOVAL 11 Remove seat hex nut at the heater mounting f...

Страница 2358: ...underside of the vehicle and install the two wiring harness retaining connectors 4 Plug the two connectors from the cabin heater harness to the cabin heater controller 5 Plug the connector to the cabi...

Страница 2359: ...air intake muffler and install and tighten the retaining clamp 4 Install the heater tubes to the lower heater connection and the lower EGR cooler connection and tighten the retaining clamps 5 Lower t...

Страница 2360: ...cles 80 warm up cycles for the Fuel System Monitor and the Misfire Monitor A warm up cycle can best be described by the following The engine must be running A rise of 40 F in engine temperature must o...

Страница 2361: ...d was carried out by monitoring specific input signals for expected changes For example when the PCM com mands the Idle Air Control IAC Motor to a specific position under certain operating conditions...

Страница 2362: ...e running or the MIL is illuminated for any of the following Misfire Monitor Front Oxygen Sensor and Heater Monitor MAP Sensor Vehicle Speed Sensor Engine Coolant Temperature Sensor Throttle Position...

Страница 2363: ...culated The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic converter The PCM calculates the A F mixture from the output of the O2S A low vol...

Страница 2364: ...Ethanel content learn is takeng place and the ethenal used once flag is set Suspend The Task Manager does not mature a catalyst fault if any of the following are present Oxygen Sensor Monitor Priorit...

Страница 2365: ...a DRBIIIt scan tool The following is a list of the system monitors EGR Monitor if equipped Misfire Monitor Fuel System Monitor Oxygen Sensor Monitor Oxygen Sensor Heater Monitor Catalyst Monitor Evap...

Страница 2366: ...ankshaft will vary more than normal FUEL SYSTEM MONITOR To comply with clean air regulations vehicles are equipped with catalytic converters These converters reduce the emission of hydrocarbons oxides...

Страница 2367: ...the pump is set so that the system will achieve an equalized pressure of about 7 5 water The cycle rate of pump strokes is quite rapid as the system begins to pump up to this pressure As the pressure...

Страница 2368: ...ld sooner than if the tank had to decay from a built up pressure The device itself has 3 wires Switch sense sole noid driver and ground It also includes a resistor to protect the switch from a short t...

Страница 2369: ...ontrol Mod ule PCM have two recognized states HIGH and LOW For this reason the PCM cannot recognize the difference between a selected switch position versus an open circuit a short circuit or a defect...

Страница 2370: ...rol system prevents the emis sion of fuel tank vapors into the atmosphere When fuel evaporates in the fuel tank the vapors pass through vent hoses or tubes to an activated carbon filled evaporative ca...

Страница 2371: ...3 55 Fig 1 ORVR System Schematic 1 FUEL CAP 2 RECIRCULATION TUBE 3 LIQUID SEPARATOR 4 PURGE SOLENOID 5 W LDP 6 BREATHER ELEMENT 7 W O LDP 8 CANISTER 9 ROLLOVER VALVE 10 FUEL TANK 11 CHECK VALVE 12 CON...

Страница 2372: ...rom solenoid 3 Remove solenoid from bracket INSTALLATION The solenoid attaches to a bracket near the radia tor on the passenger side of vehicle The solenoid will not operate unless it is installed cor...

Страница 2373: ...through the control valve to the vapor canister Vapor is absorbed in the canister until vapor flow in the lines stops either following shut off or by having the fuel level in the tank rise high enough...

Страница 2374: ...c 1 FUEL CAP 2 RECIRCULATION TUBE 3 LIQUID SEPARATOR 4 PURGE SOLENOID 5 W LDP 6 BREATHER ELEMENT 7 W O LDP 8 CANISTER 9 ROLLOVER VALVE 10 FUEL TANK 11 CHECK VALVE 12 CONTROL VALVE RS EVAPORATIVE EMISS...

Страница 2375: ...lure requires double failure plugged to LDP and atmosphere Leak detection pump failed closed Leak detection pump filter plugged On Board diagnostics evaporative system leak test just conducted Caniste...

Страница 2376: ...the top of the valve Fig 10 In this position there is minimal vapor flow through the valve During periods of moderate intake manifold vac uum the plunger is only pulled part way back from the inlet T...

Страница 2377: ...bes connect to the top of the canister It is a charcoal canister Fig 12 or Fig 13 OPERATION All vehicles use a maintenance free evaporative EVAP canister Fuel tank vapors vent into the can ister The c...

Страница 2378: ...remove canister INSTALLATION INSTALLATION 1 Install canister arrow heads into the rubber gromments Fig 14 2 Install bolt and tighten 3 Install hoses 4 Lower vehicle INSTALLATION REAR EVAP CANISTER 1 I...

Страница 2379: ...E DESCRIPTION N m Ft Lbs In Lbs EGR valve to cyl head 2 4L 22 200 25 EGR tube to EGR valve 2 4L 11 9 105 20 EGR tube to intake manifold 2 4L 11 9 105 20 EGR valve to adaptor 3 3 3 8L 22 200 25 EGR tub...

Страница 2380: ...ir box cover 9 Install the hose clamp at throttle body 10 Install the air box bolt 11 Connect the fresh air makeup hose on rear valve cover 12 Connect the negative battery cable INSTALLATION REAR TUBE...

Страница 2381: ...cause of low back pressure varies the strength of vacuum applied to the EGR valve Varying the strength of the vacuum changes the amount of EGR supplied to the engine This pro vides the correct amount...

Страница 2382: ...ing bolts 12 Remove the EGR valve INSTALLATION INSTALLATION 2 4L The EGR valve and Electrical EGR Transducer are serviced as an assembly Fig 1 1 Assemble EGR valve with new gasket onto the cylinder he...

Страница 2383: ...f the MIL is illuminated and a fault is stored from another monitor In these situations the Task Manager postpones monitors pending resolu tion of the original fault The Task Manager does not run the...

Страница 2384: ...trips the MIL is extinguished and the Task Manager automatically switches the trip counter to a warm up cycle counter DTCs are auto matically erased following 40 warm up cycles if the component does n...

Страница 2385: ...different Similar conditions Windows Fuel System and Misfire FUEL SYSTEM Fuel System Similar Conditions Window An indicator that Absolute MAP When Fuel Sys Fail and RPM When Fuel Sys Failed are all in...

Страница 2386: ...in accessing the Similar Conditions Window Adaptive Memory Factor The PCM utilizes both Short Term Compensation and Long Term Adap tive to calculate the Adaptive Memory Factor for total fuel correctio...

Страница 2387: ......

Страница 2388: ...onent resistance Output Device Current Flow The ECM senses whether the output devices are electrically connected If there is a problem with the circuit the ECM senses whether the circuit is open short...

Страница 2389: ...ORQUE SPECIFICATIONS DESCRIPTION N m Ft Lbs In Lbs EGR Cooler to EGR Bolts 32 4 24 EGR Cooler to Exhaust Manifold 27 5 21 EGR Valve Nuts 32 4 24 25a 2 EMISSIONS CONTROL 2 5L TURBO DIESEL RG EMISSIONS...

Страница 2390: ...he power brake boosterb and the heating and air conditioning system The pump is located internally in the front of the engine block and is driven by the crankshaft gear Vacuum lines and hoses connect...

Страница 2391: ...iper unit Refer to 8 ELEC TRICAL WIPERS WASHERS WIPER MODULE REMOVAL 3 Disconnect EGR valve vacuum line 4 Remove EGR cooler to EGR valve retaining bolts Fig 1 5 Remove EGR valve retaining nuts Fig 1 a...

Страница 2392: ...er and new gasket to EGR valve Fig 2 Torque bolts to 32 4N m 3 Install EGR valve cooler to exhaust manifold attaching bolt Fig 2 Torque bolt to 32 4N m 4 Connect EGR cooler coolant supply and return h...

Страница 2393: ...ut most likely will not identify the failed component directly Refer to the appropriate diagnos tic manual for more information on diagnosis of trou ble codes ACCESSING DIAGNOSTIC TROUBLE CODES A stor...

Страница 2394: ...ure Sensor Circuit MALF Signal Voltage Too Low P0195 Oil Temperature Sensor Circuit MALF Signal Voltage Too High Oil Temperature Sensor Circuit MALF Signal Voltage Too Low P0201 Cylinder 1 Injector Ci...

Страница 2395: ...P0500 Vehicle Speed Sensor Frequency Too High Vehicle Speed Sensor Frequency High Level Duration Vehicle Speed Sensor Plausibility Vehicle Speed Sensor Signal Voltage Too High P0514 Battery Temperatur...

Страница 2396: ...Off Too Late P0703 Brake Switch Signal Circuits Incorrect Can Message Brake Switch Signal Circuits Plausibility With Redundant Contact P1130 Fuel Rail Pressure Malfunction Small Leakage Detected Fuel...

Страница 2397: ...Access To EEPROM Failure P1696 EEPROM Communication Error EEPROM Communication Not Verified EEPROM Quanity Stop EEPROM Recovery Occured EEPROM Redundant Overrun Monitoring P1703 Brake Switch Signal CK...

Страница 2398: ..._____________________________________________ ______________________________________________________________________________________ ___________________________________________________________________...

Страница 2399: ...DaimlerChrysler Corporation Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills MI 48326 2757 8...

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