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Welcome to the

1997 Neon

(RHD & LHD)

Interactive Electronic Service Manual!

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tweddle litho: dom parts cdrom demo 09/96

page 4 <output:1248 ET 01/22/97>

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Страница 1: ...Welcome to the 1997 Neon RHD LHD Interactive Electronic Service Manual CLICK ON VEHICLE TO BEGIN tweddle litho dom parts cdrom demo 09 96 page 4 output 1248 ET 01 22 97 ...

Страница 2: ...ts scheduled maintenance to be performed when the vehicle is used for general trans portation Schedule B lists maintenance intervals for vehi cles that are operated under the conditions listed at the beginning of the Maintenance Schedule section Use the schedule that best describes your driving conditions Where time and mileage are listed follow the interval that occurs first PARTS AND LUBRICANT R...

Страница 3: ...ine for engine oil specifica tion GEAR LUBRICANTS SAE ratings also apply to multiple grade gear lubricants In addition API classification defines the lubricants usage LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI All approved products have the NLGI symbol Fig 3 on the label At the bottom NLGI symbol is the usage and quality identification letters Wheel bearin...

Страница 4: ...ded in this manual should be done to provide the best vehicle performance and reliability More frequent mainte nance may be needed for vehicles in severe operating conditions such as dusty areas and very short trip driving UNSCHEDULED INSPECTION At Each Stop For Fuel Check engine oil level add as required Check windshield washer solvent and add if required Once A Month Check tire pressure and look...

Страница 5: ... km or at 72 months Change engine oil Replace engine oil filter Check and replace if necessary the PCV valve Lubricate front suspension upper ball joints Inspect front brake pads and rear brake linings Adjust drive belt tension Replace air cleaner air cleaner element Replace spark plugs 97 500 Miles 156 000 km or at 78 months Change engine oil 105 000 Miles 168 000 km Change engine oil Replace eng...

Страница 6: ...s Replace drive belts Replace air cleaner element Replace ignition cables Replace spark plugs Change automatic transaxle fluid and filter Adjust the bands 63 000 Miles 101 000 km Change engine oil Inspect front brake pads and rear brake linings 66 000 Miles 106 000 km Change engine oil Replace engine oil filter 69 000 Miles 110 000 km Change engine oil 72 000 Miles 115 000 km Change engine oil Rep...

Страница 7: ...r Adjust drive belt tension Inspect and replace if necessary the air cleaner element Police taxi or delivery service usage and trailer towing require the more frequent transaxle service indicated with a in schedule B Perform these ser vices if the vehicle is usually operated under these conditions NOTE This maintenance is recommended by Chrysler to the owner but is not required to main tain the wa...

Страница 8: ...ause of starting problem on dis abled vehicle is severe damage to booster vehicle charging system can result 2 When using another vehicle as a booster source park the booster vehicle within cable reach Turn off all accessories set the parking brake place the automatic transmission in PARK or the manual transmission in NEUTRAL and turn the ignition OFF 3 On disabled vehicle place gear selector in p...

Страница 9: ...ved install lug nuts to retain brake drums or rotors A towed vehicle should be raised until lifted wheels are a minimum 100 mm 4 in from the ground Be sure there is adequate ground clearance at the oppo site end of the vehicle especially when towing over rough terrain or steep rises in the road If necessary remove the wheels from the lifted end of the vehicle and lower the vehicle closer to the gr...

Страница 10: ...mponents damage to vehicle can result Do not attempt to raise one entire side of the vehicle by placing a floor jack midway between the front and rear wheels This practice may result in permanent damage to the body FLOOR JACK When properly positioned a floor jack can be used to lift a PL vehicle Fig 3 Support the vehicle in the raised position with jack stands A floor jack must never be used on an...

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Страница 12: ...ndling and steering of the vehicle when it is in motion The method of checking a vehicle s front and rear wheel alignment will vary depending on the type and manufacturer of the equipment being used Instruc tions furnished by the manufacturer of the equip ment being used should always be followed to ensure accuracy of the alignment except alignment specifi cations recommended by Chrysler Corporati...

Страница 13: ...rrect front and rear wheel Toe specifications 4 Thrust Angle is defined as the average of the Toe settings on each rear wheel If this measurement is out of specification re adjust rear wheel Toe so that each wheel has 1 2 of the total Toe measure ment When re adjusting do not exceed the total Toe specification Fig 1 Alignment Camber Toe 2 2 SUSPENSION PL DESCRIPTION AND OPERATION Continued ...

Страница 14: ...oose Sway Bar Or Upper Strut Attachment 5 Tighten Sway Bar Or Upper Strut Attachment To Specified Torque Front End Whine With Vehicle Going Straight At A Constant Speed 1 Defective Wheel Bearing 1 Replace Wheel Bearing 2 Incorrect Wheel Alignment 2 Check And Reset Wheel Alignment 3 Worn Tires 3 Replace Tires Front End Growl Or Grinding With Vehicle Going Straight At A Constant Speed 1 Engine Mount...

Страница 15: ... 1 Low Tire Pressure 1 Inflate All Tires To Recommended Pressure 2 Lack Of Lubricant In Steering Gear 2 Replace Steering Gear 3 Low Power Steering Fluid Level 3 Fill Power Steering Fluid Reservoir To Correct Level 4 Loose Power Steering Pump Belt 4 Correctly Adjust Power Steering Pump Drive Belt 5 Lack Of Lubricant In Steering Ball Joints 5 Lubricate Or Replace Steering Ball Joints 6 Steering Gear...

Страница 16: ...g This must be done before using the Mopar Service Kit for setting camber to meet required specifi cation If a vehicles caster is not within manufacturers alignment specifications check for damaged suspen sion components or body parts This type of damage can cause component locations to move affecting vehicle alignment No adjustment can be made for the Caster setting on this vehicle CAUTION Do not...

Страница 17: ...to the pre ferred setting by pushing or pulling on the top of the front or rear tire When camber is correctly set tighten upper and lower strut clevis bracket bolts Again jounce front and rear of vehicle an equal amount of times and verify front and rear camber setting See Alignment Specifications in this group of the service manual for required specifications 11 When vehicle is at correct camber ...

Страница 18: ... at serrations and rotate tie rods Fig 7 to set the front wheel Toe to the pre ferred specification See Alignment Specifications in this group of the service manual for preferred speci fication 8 Tighten tie rod locknuts to 54 N m 40 ft lbs torque 9 Adjust steering gear to tie rod boots at tie rod 10 Remove steering wheel clamp Fig 4 Rear Lateral Link To Crossmember Attaching Bolts FUEL TANK REAR ...

Страница 19: ...PTABLE ALIGNMENT RANGE AT CURB HEIGHT PREFERRE SETTING CAMBER 75 to 0 25 0 25 TOTAL TOE Specified In Degrees See Note TOE OUT When Backed On Alignment Rack Is TOE In When Driving 0 3 in to 0 1 out 0 1 in THRUST ANGLE 0 10 to 0 10 Note Total Toe is the arithmetic sum of the left and right wheel Toe settings Positive is Toe in negative is Toe out Total Toe must be equally split between each front wh...

Страница 20: ...amage to rear suspension components will occur CAUTION At no time when servicing a vehicle can a sheet metal screw bolt or other metal fas tener be installed in the shock tower to take the place of an original plastic clip Also NO holes can be drilled into the front shock tower in the area shown in Fig 1 for the installation of any metal fasteners into the shock tower Because of the minimum cleara...

Страница 21: ...components A rubber isolated top mount an upper spring seat bearing assembly jounce bumper dust shield coil spring with plastic noise insulator and the strut dampener A cast lower control arm assembly Fig 2 is attached to the front suspension crossmember using 2 rubber isolator bushings and to the steering knuckle by means of a ball joint A sealed for life front hub and bearing assembly is attache...

Страница 22: ...Fig 2 Front Suspension Typical PL SUSPENSION 2 11 DESCRIPTION AND OPERATION Continued ...

Страница 23: ...ted to the front crossmember using a bolt through the center of the rubber pivot bushing Fig 4 The rear of the lower control arm is mounted to both the front crossmember and the frame rail of the vehicle using a thru bolt The thru bolt goes through both the crossmember and rear lower control arm bushing threading directly into the frame rail of the vehicle The lower control arms are inter con nect...

Страница 24: ...eg using a pinch bolt The ball joint used on this vehicle is replaceable and if found defective can be serviced as a separate component of the lower control arm assembly WHEEL MOUNTING STUDS If wheel attaching studs need to be replaced in the hub and bearing assembly the studs CAN NOT be hammered out of the hub flange If a stud is removed by hammering it out of the bearing flange damage to the hub...

Страница 25: ...lation sections in this group of the service manual BALL JOINT ASSEMBLY With the weight of the vehicle resting on the road wheels Grasp the grease fitting as shown in Fig 10 and with no mechanical assistance or added force attempt to move the grease fitting If the ball joint is worn the grease fitting will move easily If movement is noted replacement of the ball joint is recommended STABILIZER BAR...

Страница 26: ...s hydraulic hose routing bracket is combined with speed sensor cable routing bracket Fig 11 CAUTION The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal Remove nuts while holding bolts stationary in the steering knuckles 6 Remove the 2 bolts Fig 12 attaching the strut to the steering knuckle 7 Remove the 3 nuts attaching the upper mount of the s...

Страница 27: ... after loosening hub nut vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires 2 Loosen hub nut while vehicle is on the floor with the brakes applied Fig 15 The hub and driveshaft are splined together through the knuckle bearing and retained by the hub nut 3 Raise vehicle on jack stands or centered on a frame contact type hoist See Hoisting in the Lub...

Страница 28: ...kle 12 Separate ball joint stud from steering knuckle by prying down on lower control arm Fig 23 Note Use caution when separating ball joint stud Fig 17 Brake Caliper Removal DISC BRAKE CALIPER SLIDE THIS END OF CALI PER FROM UNDER STEER ING KNUCKLE ROTOR LIFT THIS END OF CALIPER AWAY FROM STEERING KNUCKLE FIRST Fig 18 Supporting Brake Caliper WIRE HANGER STEERING KNUCKLE BRAKE DISC DISC BRAKE CAL...

Страница 29: ...lled in the steering knuckle Installa tion of the new wheel bearing must be done before installing steering knuckle on vehicle Refer to Hub and Bearing Service in this section of the service manual for proper wheel bearing removal and installation procedure INSTALL 1 Install a new cartridge hub and bearing assem bly into the steering knuckle Refer to Hub And Bear ing Service in this section of the...

Страница 30: ...ring Fig 19 7 Install the disc brake caliper on the steering knuckle Caliper is installed by first sliding top of caliper under top abutment on steering knuckle Then installing bottom of caliper against bottom abutment of steering knuckle Fig 27 8 Install the disc brake caliper to steering knuckle attaching bolts Fig 16 Tighten the caliper attaching bolts to a torque of 31 N m 23 ft lbs 9 Clean al...

Страница 31: ... Fig 34 Then rotate stabilizer bar and attaching links away from lower control arms CAUTION Pulling steering knuckle out from vehi cle after releasing from ball joint can separate inner C V joint See Driveshafts 5 Using a pry bar separate steering knuckle from ball joint stud Fig 35 Use caution when separating ball joint stud from steering knuckle so ball joint seal does not get cut Fig 29 Torquin...

Страница 32: ...lamping bolt to 95 N m 70 ft lbs 4 Assemble stabilizer bar to lower control arm link assemblies and bushings as shown in Fig 37 5 Rotate stabilizer bar into position installing the stabilizer bar link assemblies into the lower con trol arms Then install the top stabilizer bar link bushings and nuts Fig 38 DO NOT TIGHTEN LINK ASSEMBLIES AT THIS TIME 6 Lower vehicle so suspension is supporting the t...

Страница 33: ...ont crossmember bushings require replacement at time of inspection install new bushings before installing stabilizer bar Bushings are replaced by opening slit on bushings and peeling them off stabilizer bar Install new bushings on sta bilizer bar by spreading bushing at slit and forcing them on stabilizer bar Bushings must be installed on stabilizer bar with slit in bushing facing front of vehicle...

Страница 34: ... from the vehicle Removal of the hub bearing from the steering knuckle MUST be done using an arbor press and the following procedure 2 Install Bearing Splitter Special Tool P334 on the steering knuckle and hub bearing assembly as shown in Fig 45 to support steering knuckle when pressing out hub 3 Position steering knuckle and hub and bearing in an arbor press supported by Bearing Splitter Spe cial...

Страница 35: ...lean dry shop towel CAUTION Do not use any type of solvent on the hub bearing when cleaning it CAUTION The hub bearing must be wiped as clean as possible Any remaining rust preventative on the bearing can effect the bonding action of the adhe sive to the bearing 2 Clean the rust preventative from the replace ment hub bearing using a clean dry shop towel CAUTION When applying adhesive to bore of st...

Страница 36: ...nt Procedure in the Service Procedures Sec tion in this group of the service manual CAUTION After the vehicle is aligned it can only be moved a short distance and then parked Do not move the vehicle any further until the adhesive has cured for a minimum of two hours Driving the vehi cle before the adhesive is allowed to cure properly will affect the retention of the bearing in the bore of the stee...

Страница 37: ... cast into front of steering knuckle Install Remover Spe cial Tool C 4150 on hub bearing flange and wheel stud Fig 56 Fig 52 Caliper Attaching Bolts DISC BRAKE CALIPER ASSEMBLY DRIVE SHAFT BRAKING DISC DISC BRAKE CALIPER ATTACHING BOLTS STEERING KNUCKLE LOWER CON TROL ARM Fig 53 Brake Caliper Removal DISC BRAKE CALI PER ASSEMBLY BRAKING DISC SLIDE THIS END OF CALIPER FROM UNDER STEERING KNUCKLE LI...

Страница 38: ...g 53 Tighten the attach ing bolts to a torque of 31 N m 23 ft lbs 6 Install front wheel and tire Install front wheel lug nuts and torque to 135 N m 7 100 ft lbs 8 Lower vehicle DISASSEMBLY AND ASSEMBLY McPHERSON STRUT DISASSEMBLY 1 Clamp the strut assembly in a vise with the strut in a vertical position When clamping the strut assembly in the vise do not clamp strut using the body of the strut onl...

Страница 39: ...r Fig 64 from the shaft of the strut assembly 8 Remove the coil spring from the strut assembly Fig 65 Mark left and right on the coil springs for their installation back on the correct side of the vehicle WARNING IF A REPLACEMENT COIL SPRING IS TO BE INSTALLED ON THE STRUT ASSEMBLY THE FIRST FULL TOP AND BOTTOM COIL OF THE SPRING MUST BE CAPTURED BY THE JAWS OF THE COIL SPRING COMPRESSOR 9 Inspect...

Страница 40: ...ng seat alignment notch with clevis bracket on strut assembly 6 Install strut mount on strut assembly Fig 62 and the strut mount retaining nut on the shaft of the strut assembly WARNING THE FOLLOWING 2 STEPS MUST BE COMPLETELY DONE BEFORE SPRING COMPRES SOR SPECIAL TOOL C 4838 IS RELEASED FROM THE COIL SPRING 7 Install Socket Strut Nut Special Tool L 4558A or L 4558 on the strut shaft retaining nu...

Страница 41: ...t assembly Fig 69 until ball joint is fully seated against bottom sur face of lower control arm Do not apply excessive pressure against ball joint and lower control arm 4 Install a NEW ball joint assembly sealing boot on ball joint assembly Install sealing boot as far as possible on ball joint assembly CAUTION Do not use an arbor press to install the sealing boot on the lower control arm ball join...

Страница 42: ...taller Cup Special Tool C 4212 F on Remover Installer Special Tool C 4212 F Fig 73 Then mount Bushing Installer Special Tool 6810 on screw portion of Remover Installer Special Tool C 4212 F Fig 73 2 Start front bushing into lower control arm by hand making sure it is square with its mount ing hole in the lower control arm Bushing is to be installed in lower control arm from the machined surface si...

Страница 43: ... an arbor press Do not attempt to use a different procedure from that below for the removal and replacement of rear lower control arm bushing 1 Remove the lower control arm assembly from the vehicle See Lower Control Arm in the Removal And Installation Section in this group of the service manual for the required removal procedure 2 Position lower control arm in an arbor press supported at rear bus...

Страница 44: ...NUCKLE Ball Joint Stud To Steering Knuckle Nut Bolt 95 N m 70 ft lbs Disc Brake Caliper Bolts 22 N m 16 ft lbs STEERING GEAR To Crossmember Attaching Bolts 68 N m 50 ft lbs Tie Rod End Adjusting Sleeve Nut 75 N m 55 ft lbs Tie Rod End To Steering Knuckle Nut 54 N m 40 ft lbs FRONT SUSPENSION CROSSMEMBER To Body Attaching Bolts 163 N m 120 ft lbs Lower Control Arm Pivot Bolt 163 N m 120 ft lbs STAB...

Страница 45: ... Strut Coil Spring C 4838 Press Remover Installer C 4212 F Remover Lower Control Arm Small Bushing And Ball Joint 6804 Installer Ball Joint 6758 Installer Lower Control Arm Small Bushing 6810 Adapter Ball Joint Remover Installer C 4212 3 Receiver Ball Joint 6756 2 34 SUSPENSION PL ...

Страница 46: ...uller Bearing P 334 Remover Ball Joint MB 990799 Remover Installer Lower Control Arm Bushing 6644 2 Installer Bearing 5052 Installer Adapter C 4698 2 Remover Lower Ball Joint C 4150A Fig 81 Installer Bearing Cup 6522 PL SUSPENSION 2 35 SPECIAL TOOLS Continued ...

Страница 47: ...LY 47 SPECIFICATIONS REAR SUSPENSION FASTENER TORQUE SPECIFICATIONS 50 SPECIAL TOOLS REAR SUSPENSION 50 GENERAL INFORMATION GENERAL INFORMATION CAUTION Only frame contact or wheel lift hoisting equipment can be used on vehicles having a fully independent rear suspension Vehicles with inde pendent rear suspension can not be hoisted using equipment designed to lift a vehicle by the rear axle If this...

Страница 48: ...Fig 1 Neon Fully Independent Rear Suspension PL SUSPENSION 2 37 DESCRIPTION AND OPERATION Continued ...

Страница 49: ...tion The split in the stabilizer bar to crossmember bushing must be positioned toward the rear of the vehicle when the stabilizer bar is installed on the vehicle KNUCKLE A forged rear knuckle bolts to each rear strut assembly The movement of the rear knuckle is con trolled laterally using two lateral arms attached to the knuckle The outboard ends of the two lateral arms are mounted forward and rea...

Страница 50: ...as bent or caused other damage to the tension strut If the tension strut is bent or damaged the tension strut will require replacement Do not attempt to repair or straighten a tension strut STABILIZER BAR AND BUSHINGS Inspect the stabilizer bar for damage or bending Inspect for broken or distorted stabilizer bar bush ings bushing retainers and worn or damaged stabi lizer bar to strut attaching lin...

Страница 51: ... the strut assembly fully remove the 4 strut mount attaching nuts 9 Remove strut assembly from knuckle by slid ing knuckle out of clevis bracket on strut assembly Then remove strut assembly from vehicle INSTALL 1 Position strut assembly back into vehicle with the 4 studs on strut mount assembly through holes in strut tower of vehicle Install the 4 strut mount to body attaching nuts Fig 7 onto moun...

Страница 52: ...ion in original posi tion If the coils springs require replacement Be sure that the springs needing replacement are replaced with springs meeting the correct load and spring rate for the vehicle NOTE During service procedures requiring removal or installation of a coil spring with Spring Compressor Special Tool C 4838 It is required that the first full top and bottom coil of the coil spring be cap...

Страница 53: ...vehicle to the ground 6 With suspension supporting the full weight of the vehicle securely tighten the stabilizer bar retainer to frame rail attaching bolts Fig 9 KNUCKLE REMOVE 1 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 2 Remove the re...

Страница 54: ... brake shoes and park brake cable as an assembly from knuckle CAUTION The knuckle to strut assembly attaching bolts are serrated and must not be turned during removal Loosen and remove nuts while holding bolts stationary in knuckle 9 Loosen but do not remove at this time the 2 strut assembly to knuckle attaching bolts Fig 17 Then remove the lateral links to knuckle attaching bolt Fig 17 Fig 13 Spe...

Страница 55: ...lateral link bolts 4 Install tension strut bushing tension strut retainer and nut on tension strut Fig 19 When installing tension strut retainers the retainers must be installed on tension strut with cupped side of retainer facing away from bushing and knuckle Fig 19 5 Position a large adjustable wrench on flat of tension strut to keep it from turning Fig 20 and then torque tension strut nut to 95...

Страница 56: ...d Refer to Front And Rear Toe Setting Procedure in the Wheel Alignment Check And Adjustment section in this group of the service man ual for the required Toe setting procedure LATERAL LINKS The rear suspension lateral links Fig 21 are only serviced as complete assemblies The isolator bush ings used in the lateral links are not serviced as sep arate components The rear lateral link assemblies are u...

Страница 57: ...e Fig 22 Small bushing sleeve must be installed on bolt in rear knuckle with large bushing sleeve at crossmember of vehicle 3 Install washer and nut onto lateral link attach ing bolt at rear knuckle Fig 22 Do not tighten the lateral link to rear knuckle attaching bolt at this time 4 Install Toe adjustment cam on long lateral link attaching bolt Install long lateral link attaching bolt and adjustme...

Страница 58: ...ive Coil spring Coil springs come in a standard rate of 120 lb in be sure spring is replaced with a spring of the same rate Dust shield Mount assembly Jounce Bumper Lower Spring Isolator Shaft Nut 1 Remove strut assembly requiring service from the vehicle Refer to Strut Assembly Removal in Ser vicing Rear Struts in this section of the service man ual 2 Position strut assembly in a vise Fig 25 Usin...

Страница 59: ...9 Remove the dust shield from the strut assem bly Fig 32 10 Remove the jounce bumper Fig 33 from the shaft of the strut assembly 11 Remove the coil spring lower isolator from the strut assembly spring seat Fig 34 12 Inspect all disassembled components for signs of abnormal wear or failure replacing any compo nents as required Inspect strut unit for signs of abnormal oil leakage and for loss of gas...

Страница 60: ...bs 10 Equally loosen the Spring Compressors Spe cial Tool C 4838 until spring is seated on upper strut mount and all tension is relieved from the spring compressors 11 Install the strut assembly back into the vehi cle Refer to Strut Assembly Removal in Servicing Rear Struts in this section of the service manual 12 Check and reset rear wheel TOE to specifica tions if required STABILIZER BAR BUSHING...

Страница 61: ...ut 34 N m 300 in lbs TENSION STRUT Shaft Nut 95 N m 70 ft lbs Bracket To Body Attaching Bolts 95 N m 70 ft lbs LATERAL LINK Attaching Nut 95 N m 70 ft lbs DISC BRAKE CALIPER To Adapter Mounting Bolt 22 N m 16 ft lbs Brake Hose To Caliper Mounting Bolt 45 N m 35 ft lbs Adapter To Knuckle Mounting Bolt 68 N m 50 ft lbs BRAKE HOSE Bracket Mounting Bolt 23 N m 17 ft lbs HUB AND BEARING To Knuckle Reta...

Страница 62: ... 1 Driveshafts used on both the right and left sides of the vehicle use a tuned rubber damper weight The damper weight applications vary by which side of the vehicle the driveshaft is located on and the transmis sion application of the vehicle When replacing a driveshaft be sure the replacement driveshaft has the same damper weight as the original Both driveshaft assemblies use the same type of in...

Страница 63: ... driveshaft inner and outer boots can be identified as shown in Fig 2 Driveshaft boot location on the driveshaft assemblies is determined by the number of convolutions on the driveshaft boot Refer to Fig 2 for the correct location of the sealing boots DIAGNOSIS AND TESTING DRIVESHAFT DIAGNOSIS VEHICLE INSPECTION 1 Check for grease in the vicinity of the inboard tripod joint and outboard C V joint ...

Страница 64: ...equired runout check ing procedure REMOVAL AND INSTALLATION FRONT DRIVESHAFTS CAUTION Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the C V joint Mishandling such as allowing the assemblies to dangle unsupported or pulling or pushing the ends can cut boots or dam age C V joints During removal and installation pro cedures always support both en...

Страница 65: ...d end stud with a 11 32 socket while loosen ing and removing nut 10 Remove the tie rod end stud from steering knuckle arm using Special Tool MB 990635 Fig 9 11 Remove nut and bolt Fig 10 retaining ball joint stud into steering knuckle NOTE Use caution when separating ball joint stud from steering knuckle so ball joint seal does not get damaged Fig 5 Front Disc Brake Caliper Assembly Bolts Fig 6 Br...

Страница 66: ... side gear If removing the left side inner tripod joint posi tion the punch in the groove of the inner tripod joint Fig 14 Strike the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear 16 Hold inner tripod joint and interconnecting shaft of driveshaft assembly Fig 15 Remove inner tripod joint from transaxle by pulling it straight out of transaxle side gear and t...

Страница 67: ...ig 16 5 Ensure that front of outer C V joint which fits into steering knuckle Fig 17 is free of debris and moisture before assembling into steering knuckle 6 Slide driveshaft back into front hub Install steering knuckle onto the ball joint stud Fig 18 7 Install a NEW steering knuckle to ball joint stud bolt and nut Fig 19 Tighten the nut and bolt to 95 N m 70 ft lbs 8 Install tie rod end into stee...

Страница 68: ...s 14 Install spring washer nut lock and cotter pin on outer C V joint stub axle Fig 24 15 Install front wheel and tire assembly Install front wheel lug nuts and tighten to 135 N m 100 ft lbs Fig 18 Driveshaft Installation Into Hub And Steering Knuckle HUB BEARING ASSEMBLY DRIVE SHAFT LOWER CONTROL ARM STEERING KNUCKLE BALL JOINT Fig 19 Tighten Steering Knuckle Clamp Bolt STEERING KNUCKLE BALL JOIN...

Страница 69: ...cing Driveshaft in this section for the required driveshaft removal pro cedure 2 Remove large boot clamp that retains inner tri pod joint sealing boot to tripod joint housing Fig 26 and discard Then remove small clamp that retains inner tripod joint sealing boot to interconnecting shaft and discard Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft CAUTION ...

Страница 70: ...8 ROLLER NEEDLE 10 CLAMP SEAL RETAINING 11 BUSHING TRILOBAL TRIPOT 12 SEAL DRIVE AXLE INBOARD 13 CLAMP SEAL RETAINING 14 SHAFT AXLE RH SHOWN LH SIMILAR 15 SEAL DRIVE AXLE OUTBOARD 16 CLAMP SEAL RETAINING 17 RING RACE RETAINING 18 BALL CHROME ALLOY 19 RACE C V JOINT INNER 20 CAGE C V JOINT 21 RACE C V JOINT OUTER PL DIFFERENTIAL AND DRIVELINE 3 9 DISASSEMBLY AND ASSEMBLY Continued ...

Страница 71: ...erconnecting shaft so the raised bead on the inside of the seal boot is in groove on interconnecting shaft Fig 30 Fig 26 Inner Tripod Joint Sealing Boot Clamps SMALL CLAMP LARGE CLAMP INNER TRIPOD JOINT SEALING BOOT INTERCON NECTING SHAFT Fig 27 Spider Assembly Joint Removal from Housing TRIPOD JOINT HOUSING SPIDER ASSEM BLY SEALING BOOT Fig 28 Spider Assembly Retaining Snap Ring INTERCONNECTING S...

Страница 72: ...6 Install inner tripod joint seal boot to intercon necting shaft clamp evenly on sealing boot 7 Clamp sealing boot onto interconnecting shaft using crimper Special Tool C 4975 A and the follow ing procedure Place crimping tool C 4975 A over bridge of clamp Fig 35 Tighten nut on crimping tool C 4975 A until jaws on tool are closed com pletely together face to face Fig 36 CAUTION Seal must not be di...

Страница 73: ... trim stick inserted between sealing boot and tripod joint housing position inner tripod joint on driveshaft until correct sealing boot edge to edge length is obtained for type of sealing boot material being used Fig 38 Fig 39 Then remove the trim stick 11 Clamp tripod joint sealing boot to tripod joint using required procedure for type of boot clamp application If seal boot uses crimp type boot c...

Страница 74: ...on for the required driveshaft removal and replacement procedure 1 Remove driveshaft assembly requiring boot replacement from vehicle See Servicing Driveshaft in Fig 39 Sealing Boot End to End Length with Silicone Boot 115 MILLIMETERS SILICONE SEALING BOOT CLAMP INNER TRIPOD JOINT Fig 40 Crimping Tool Installed on Sealing Boot Clamp TRIPOD JOINT HOUSING SPECIAL TOOL C 4975A SEALING BOOT CLAMP Fig ...

Страница 75: ...g boot 6 Slide failed sealing boot off interconnecting shaft 7 Thoroughly clean and inspect outer C V joint assembly and interconnecting joint for any signs of excessive wear If any parts show signs of exces sive wear the driveshaft assembly will require replacement Component parts of these drive shaft assemblies are not serviceable INSTALLATION 1 Slide new sealing boot to interconnecting shaft re...

Страница 76: ... nut on crimping tool C 4975 A until jaws on tool are closed com pletely together face to face Fig 51 CAUTION Seal must not be dimpled stretched or out of shape in any way If seal is NOT shaped cor rectly equalize pressure in seal and shape it by hand 8 Position outer C V joint sealing boot into its retaining groove on outer C V joint housing Install sealing boot to outer C V joint retaining clamp...

Страница 77: ... lbs Front Wheel Lug Nuts 135 N m 100 ft lbs Knuckle To Ball Joint Bolt 95 N m 70 ft lbs Tie Rod End To Knuckle 61 N m 45 ft lbs SPECIAL TOOLS DRIVESHAFT Fig 52 Crimping Tool Installed on Sealing Boot Clamp TRIPOD JOINT HOUSING SPECIAL TOOL C 4975A SEALING BOOT CLAMP Fig 53 Sealing Boot Retaining Clamp Installed JAWS OF SPECIAL TOOL C 4975A MUST BE CLOSED COMPLETELY TOGETHER HERE SEALING BOOT CLAM...

Страница 78: ...endix This system shares the base brake hardware with vehicles not equipped with ABS A vehicle equipped with ABS does however use a differ ent vacuum booster master cylinder and brake tubes Also included in the ABS system is a hydraulic con trol unit HCU four wheel speed sensors and an electronic controller CAB These components will be described in detail in the Bendix ABX 4 brake section in this ...

Страница 79: ...SHOES 31 REAR HUB BEARING 38 STOP LAMP SWITCH 56 VACUUM BOOSTER 42 WHEEL AND TIRE ASSEMBLY 25 DISASSEMBLY AND ASSEMBLY BRAKE FLUID LEVEL SWITCH 57 BRAKE FLUID RESERVOIR 56 FRONT AND REAR DISC BRAKE CALIPER 58 WHEEL CYLINDER REAR DRUM BRAKE 62 CLEANING AND INSPECTION CHASSIS TUBES AND HOSES 64 FRONT DISC BRAKES 63 REAR DISC BRAKES 63 REAR DRUM BRAKE WHEEL CYLINDER 64 REAR DRUM BRAKES 64 REAR WHEEL ...

Страница 80: ... opening and in a groove in the piston Fig 4 This prevents contamination in the bore area As front disc brake linings wear master cylinder reservoir brake fluid level will drop Fluid level should be checked after replacing linings Front disc brakes are equipped with an audible wear indicator Fig 2 on the outboard brake pad Fig 2 Front Disc Brake Caliper Exploded View CALIPER GUIDE PIN BOLT SLEEVE ...

Страница 81: ...l cylinder PARKING BRAKES All vehicles are equipped with a center mounted hand operated park brake lever This lever is an auto adjust type which continuously applies minimal tension to the parking brake cables to keep them in adjustment at all times Due to this feature the park brake cable system does not require adjustment Proper parking brake system adjustment is obtained by proper drum brake or...

Страница 82: ...lic Control Unit HCU Fig 10 Proportioning valves balance front to rear braking by controlling at a given ratio the increase in rear brake system hydraulic pressure above a preset level Fig 7 Park Brake Assembly With Rear Disc Brakes DISC BRAKE ADAPTER PARKING BRAKE BRAKE SHOES HUB BEARING ASSEM BLY BRAKING DISC STONE SHIELD PARKING BRAKE ACTU ATING STRUT Fig 8 Drum In Hat Rotor REAR BRAKING DISK R...

Страница 83: ... The ABS master cylinders are a two outlet design with the screw in proportion ing valves attached directly to the Hydraulic Control Unit HCU Fig 13 Vehicles equipped with rear drum brakes use a master cylinder with a 21 mm bore diameter while vehicles equipped with rear disc brake use a 7 8 bore master cylinder The brake system master cylinder assembly Fig 12 consists of the following components ...

Страница 84: ...her side This difference in pressure forces the output rod of the power booster Fig 17 out against the primary piston of the master cylinder As the pistons in the master cylinder move forward this creates the hydraulic pressure in the brake system Different engine options available for this vehicle require that different vacuum hose routings be used The power brake vacuum booster assembly mounts o...

Страница 85: ...SWITCH The stop lamp switch controls operation of the vehicles stop lamps Also if the vehicle is equipped with speed control the stop lamp switch will deacti vate speed control when the brake pedal is depressed The stop lamp switch controls operation of the right and left tail stop and turn signal lamp and CHMSL lamp by supplying battery current to these lamps The stop lamp switch controls the lam...

Страница 86: ...p Light On Without Brakes 3 All Brakes Drag 5 Rear Brakes Drag 2 NO NO Grabby Brakes O X Spongy Brake Pedal X NO Premature Rear Brake Lockup 4 NO NO O Excessive Pedal Effort 1 O Rough Engine Idle NO O Brake Chatter Rough NO NO X Surge During Braking NO NO X Noise During Braking NO NO X Rattle Or Clunking Noise NO NO X Pedal Pulsates During Braking NO NO X Pull To Right Or Left NO NO X No Not A Pos...

Страница 87: ...D RELEASE TURN FRONT WHEEL BY HAND OPEN BLEEDER SCREW AND TURN WHEEL AGAIN IF WHEEL TURNS HYDRAULIC PRESSURE WAS TRAPPED IN SYSTEM YES NO LOW ENGINE VACUUM SEE 6 CONTAMINATED FLUID SEALS SWOLLEN BINDING CALIPER PINS OR BUSHINGS REPLACE BUSH INGS BLOCKED OR PINCHED LINE OR HOSE OR BOOSTER VACUUM HOSE LINING TRANSFER ON FRONT ROTOR GLAZED LINING SAND ROTOR REPLACE LINING MASTER CYLINDER NOT RELEASIN...

Страница 88: ...FLUID LEVEL SWITCH AND MASTER CYLINDER FLOAT FOR PROPER OPERATION FLUID LEVEL LOW CHECK ENTIRE SYSTEM FOR LEAKS REPAIR OR REPLACE AS REQUIRED LIGHT OFF CHECK WARNING LIGHT CIRCUIT APPLY PARKING BRAKE IGNI TION IN RUN POSITION WARNING LIGHT ON OK PARKING BRAKE RELEASED LIGHT OFF CHECK WIRE CONNECTED TO WARNING SWITCH IN ENGINE COMPARTMENT WARNING LIGHT OFF NOT OK CHECK AND REPAIR ELEC TRICAL CIRCUI...

Страница 89: ...HAN 1 0 INCH Hg IN ONE MINUTE YES NO LEAK TEST BRAKES APPLIED BOOSTER IS DEFECTIVE AND SHOULD BE REPLACED NO YES APPLY LIGHT EFFORT APPROXIMATELY 15 POUNDS OF PEDAL FORCE TO THE BRAKE PEDAL AND HOLD STEADY IN THIS POSITION DO NOT MOVE THE PEDAL FROM THIS POSITION AS IT WILL AFFECT THE LEAKAGE READING IF VACUUM SUPPLY IS BELOW 12 INCHES REPLACE OR REPAIR VACUUM HOSE AND VACUUM FITTINGS ALSO TUNE OR...

Страница 90: ...ES PADS PINCHED LINES LEAKING SEALS PLUGGED BANJO BOLT REFER TO GROUP 2 SUS PENSION EXCESSIVE PEDAL TRAVEL DEFECTIVE AUTOMATIC ADJUSTER CHECK AIR IN BRAKE HYDRAULIC SYSTEM BLEED BRAKE HYDRAULIC SYSTEM LEAK IN BRAKE HYDRAULIC SYSTEM LOOK FOR WET AREAS AND REPAIR MASTER CYLINDER INTERNAL LEAK REPLACE MASTER CYLINDER EXCESSIVE PEDAL EFFORT INSPECT FRONT AND REAR BRAKES FOR FROZEN PIS TONS CONTAMINATE...

Страница 91: ...e not removed before installation of new brake pad assem blies Some discoloration or wear of the rotor surface is normal and does not require resurfacing when lin ings are replaced Excessive runout or wobble in a rotor can increase pedal travel due to piston knock back This will increase guide pin sleeve wear due to tendency of cal iper to follow rotor wobble Thickness variation in a rotor can als...

Страница 92: ...equal points with a micrometer at a radius approximately 25 mm 1 inch from edge of rotor Fig 23 If thickness measurements vary by more than 0 013 mm 0 0005 inch rotor should be removed and resurfaced or a new rotor installed If cracks or burned spots are evident rotor must be replaced Light scoring and or wear is acceptable If heavy scoring or warping is evident the rotor must be machined or repla...

Страница 93: ...r a premature rear wheel skid is the same for both rear wheel proportioning valves The pressure test fittings used for each proportioning valve though are different due to proportioning valve and brake tube nut thread sizes being unique for each rear wheel After road testing vehicle to deter mine which wheel skids first the proper test fittings required will have to be determined Then follow the p...

Страница 94: ...ning valve 10 Check rear wheel brake shoe linings for con tamination or for replacement brake shoes not meet ing OEM brake lining material specifications These conditions can also be a possible cause for a prema ture rear wheel skid 11 Install proportioning valve in master cylinder and hand tighten until proportioning is fully installed and O ring seal is seated into master cylin der Then torque p...

Страница 95: ...e test fitting Fig 31 Bleed air out of hose from pressure test fitting to pressure gauge at pressure gauge to remove all trapped air 9 With the aid of a helper apply pressure to the brake pedal until reading on proportioning valve inlet gauge is at the pressure shown on the following chart Then check the pressure reading on the pro portioning valve outlet gauge If proportioning valve outlet pressu...

Страница 96: ...ications Do not use petroleum based fluid because seal damage in the brake system will result If necessary add specified brake fluid bringing level to the FULL mark on the side of the master cylinder brake fluid reservoir Fig 32 BRAKE BLEEDING NOTE For bleeding the ABS hydraulic system see Bleeding ABX 4 Brake System in the Service Proce dures Section of the ABS Brake Section in this group of the ...

Страница 97: ...eeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydrau lic system Left rear wheel Right front wheel Right rear wheel Left front wheel 1 Attach a clear plastic hose to the bleeder screw starting at the right rear wheel and feed the hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose Fig 34 2 Pump the brake...

Страница 98: ...ire hydraulic system after replacing the master cylin der But the master cylinder must have been bled and filled upon installation BRAKE ROTOR MACHINING BRAKE ROTOR MACHINING PROCEDURES Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to ensure proper brake action If the rotor surface is deeply scored or warped or there is a complaint of brake rou...

Страница 99: ...ding and 0 013 mm 0 0005 inch thickness variation limits MUST BE MAINTAINED Extreme care in the operation of rotor turning equipment is required The use of a double straddle cutter Fig 39 that machines both sides of the rotor at the same time is highly recommended RESURFACNG BRAKE ROTOR This operation can be used when rotor surface is rusty has lining deposits or excessive lateral runout or thickn...

Страница 100: ...UIRED THE AUTO ADJUSTER MUST BE RELOADED AND LOCKED OUT 1 Remove screws attaching rear of center console assembly to console bracket Fig 43 or Fig 44 2 Remove the 2 screws located in cup holders Fig 45 attaching front of center console assembly to console bracket 3 Raise park brake hand lever assembly as high as it will go for required clearance to remove center console 4 Remove center console ass...

Страница 101: ... when repairing brake tubing to be sure the proper bending and flaring tools and procedures are used to avoid kinking Do not route the tubes against sharp edges moving components or into hot areas All tubes should be properly attached with recommended retaining clips Using Tubing Cutter Special Tool C 3478 A or equivalent cut off damaged seat or tubing Fig 49 Ream out any burrs or rough edges show...

Страница 102: ...tube routing clips REMOVAL AND INSTALLATION WHEEL AND TIRE ASSEMBLY To install the wheel and tire assembly first posi tion it properly on the mounting surface using the hub pilot as a guide Then progressively tighten the lug nuts in the proper sequence Fig 53 to half of the required torque Finally tighten the lug nuts in the proper sequence Fig 53 to 129 N m 95 ft lbs Never use oil or grease on st...

Страница 103: ...se Lubri cant or equivalent 3 If removed install the front rotor on the hub making sure it is squarely seated on face of hub CAUTION Use care when installing the caliper assembly onto the steering knuckle so the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses 4 Carefully position the brake caliper and brake shoes on the steering knuckle by first hooking th...

Страница 104: ...s of braking rotor and external surfaces of hub Handling of the braking rotor and caliper should be done in such a way as to avoid deformation of the rotor and scratching or nicking of the brake linings If inspection reveals that the square sectioned cal iper piston seal is worn or damaged it should be replaced immediately During removal and installation of a wheel and tire assembly use care not t...

Страница 105: ...found to be brit tle Refer to Guide Pin Bushing Service in Disc Brake Caliper Service in this section of the service manual INSTALL 1 Completely retract caliper piston back into pis ton bore of caliper This is required for caliper instal lation with new brake shoe assemblies 2 Lubricate both steering knuckle abutments with a liberal amount of Mopart Multipurpose Lubri cant or equivalent 3 Install ...

Страница 106: ...e caliper guide pin bolts 9 Install the wheel and tire assembly 10 Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs 11 Remove jackstands or lower hoist Before moving vehicle pump the brake pedal several times to insure the vehicle has a firm brake pedal 12 ...

Страница 107: ... lib eral amount of Mopart Multipurpose Lubricant or equivalent 3 If removed install the rear rotor on the hub making sure it is squarely seated on the face of the hub Fig 71 CAUTION Use care when installing caliper assembly onto adapter so the guide pin bushings and sleeves do not get damaged by the mounting bosses on adapter 4 Carefully lower caliper and brake shoe assem blies over braking disc ...

Страница 108: ...EATE BRAKELINING DUST BY SANDING BRAKE LININGS WHEN SERVICING A VEHICLE DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS USING ONLY SEALED AIRTIGHT BAGS OR CONTAINERS FOLLOW ALL RECOM MENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRA TION OSHA AND THE ENVIRONMENTAL PROTEC TION AGENCY EPA FOR HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS...

Страница 109: ...ke pad away from caliper pis ton until retaining clip is free from cavity in piston Fig 77 CALIPER INSPECTION Check caliper for piston seal leaks brake fluid in and around boot area and inboard lining and for any ruptures of the piston dust boot If boot is damaged or fluid leak is visible disassemble caliper and install a new seal and boot and piston if scored Refer to Caliper Disassembly And Re A...

Страница 110: ...nstall caliper assembly guide pin bolts into adapter and tighten Fig 72 Then torque both guide pin bolts to 22 N m 192 in lbs 9 Install the wheel and tire assembly 10 Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs 11 Remove jackstands or lower hoist Befor...

Страница 111: ...ps and pins attaching the leading and trailing brake shoes to the brake support plate Fig 83 8 Remove lower brake shoe to anchor plate return spring Fig 84 9 Remove the park brake lever pin to rear brake shoe retaining clip Fig 85 10 Remove the leading and trailing brake shoe upper return spring and automatic adjuster screw Fig 79 Rear Brake Drum Fig 80 Brake Drum Remove Install BRAKE SUPPORT PLAT...

Страница 112: ... overheated or are damaged replace Overheating indications are paint discolora tion or distorted end coils INSTALL 1 Lubricate the eight shoe contact areas on the support plate and anchor using Mopar Multi Purpose Lubricant or equivalent Fig 88 Fig 84 Brake Shoe To Anchor Plate Return Spring Fig 85 Park Brake Lever Pin To Brake Shoe Retaining Clip Fig 86 Remove Install Brake Shoes UPPER RETURN SPR...

Страница 113: ...dure in the service adjustments section of the service manual 13 Install the wheel and tire assembly 14 Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs 15 Road test vehicle The automatic adjuster will continue the brake adjustment during the road test of t...

Страница 114: ...e manual for the proper brake shoe assembly installation procedure 6 Install rear hub and bearing assembly on rear spindle Install a NEW hub and bearing assembly retaining nut Fig 91 Torque hub and bearing assembly retaining nut to 217 N m 160 ft lbs Install dust cap 7 Adjust brake shoes assemblies so as not to interfere with brake drum installation 8 Install brake drum Adjust and bleed service br...

Страница 115: ...to half specification Then repeat the tightening sequence to the full specified torque of 135 N m 100 ft lbs 7 Adjust the rear brakes See Rear Drum Brake Shoe Adjustment in the Adjustments section in this group of the service manual 8 Bleed the entire brake system See Bleeding Brake System in Service Adjustments section in this group of the service manual REAR HUB BEARING REMOVE 1 Raise vehicle on...

Страница 116: ...rakes install the rotor on the hub bearing 5 On disc brake equipped vehicles install the disc brake caliper on the adapter Install the 2 guide pin bolts Fig 100 mounting the disc brake caliper to the adapter Tighten the guide pin bolts to a torque of 22 N m 192 in lbs Refer To Rear Disc Brake Service in this group of the service manual for the required caliper installation procedure 6 Install rear...

Страница 117: ...ooster 6 Slide master cylinder assembly straight out of the power brake vacuum booster CAUTION On vehicles equipped with ABS the master cylinder is used to create the seal for hold ing vacuum in the power brake vacuum booster The vacuum seal in the front of the power brake vacuum booster Fig 105 MUST be replaced when ever the master cylinder is removed from the power brake vacuum booster 7 If vehi...

Страница 118: ...ports plug outlet ports and install fill cap on reservoir 5 Remove master cylinder from vise NOTE Note It is not necessary to bleed the entire hydraulic system after replacing the master cylin der But the master cylinder must have been bled and filled upon installation INSTALL CAUTION When replacing the master cylinder on a vehicle equipped with ABS a NEW vacuum seal MUST be installed in the power...

Страница 119: ... push rod on power brake vac uum booster with master cylinder push rod 4 Install the 2 master cylinder to power brake unit mounting nuts Fig 104 and torque to 28 N m 250 in lbs torque 5 Connect brake tubes to master cylinder pri mary and secondary ports Fig 102 and Fig 103 Torque all tube nuts to 17 N m 145 in lbs torque VACUUM BOOSTER REMOVE CAUTION On ABS equipped vehicles vacuum in power booste...

Страница 120: ... brake vacuum booster Fig 116 MUST be replaced when ever the master cylinder is removed from the power brake vacuum booster 7 If vehicle is equipped with ABS remove vac uum seal Fig 116 located in the front of the power brake vacuum booster Vacuum seal is removed by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vac uum seal Fig 116 and prying s...

Страница 121: ...e screwdriver Fig 118 enough to allow retaining clip tang to pass over the end of the brake pedal pin 11 Remove the 4 nuts attaching the power brake vacuum booster to the dash panel Fig 119 The nuts are accessible from under the instrument panel in the area of the steering column and brake pedal bracket 12 Slide power brake vacuum booster forward until mounting studs clear dash panel then tilt the...

Страница 122: ...e master cylinder push rod as indi cated in Fig 120 only using Mopar Dielectric Grease And No Substitutes Refer to the Mopar Chemicals Catalog to obtain the required lubricant 8 Install vacuum seal on master cylinder push rod as shown with notches on vacuum seal pointing toward master cylinder housing Fig 121 Then slide vacuum seal onto master push rod until seal is seated against master cylinder ...

Страница 123: ...aken when replacing brake tubing to be sure the proper bending and flaring tools and procedures are used to avoid kinking Do not route the tubes against sharp edges moving components or into hot areas All tubes should be properly attached with recommended retaining clips PROPORTIONING VALVE BASE BRAKES CAUTION Proportioning valves Fig 123 should never be disassembled There are two proportioning va...

Страница 124: ... bracket Fig 125 or Fig 126 2 Remove the 2 screws located in cup holders Fig 127 attaching front of center console assembly to console bracket 3 Raise park brake hand lever as high as it will go to get the required clearance to remove the center console 4 Remove center console assembly WARNING WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY OR CABLES IS REQUIRED THE AUTO ADJUSTER MUST BE RELOAD...

Страница 125: ...sm This will allow the park brake lever mechanism to correctly adjust the park brake cables 5 Connect electrical connector for brake warning lamp onto terminal on park brake lever assembly Fig 130 Fig 128 Locking Pin Installed In Park Brake Mechanism Fig 129 Park Brake Cables At Equalizer Fig 130 Brake Warning Lamp Connection To Park Brake Lever PARK BRAKE LEVER WARNING LAMP CONNECTOR WIRING HARNE...

Страница 126: ...ult in high efforts required to connect park brake cables to equalizer or park brake lever at rear wheel brakes For installation of the rear park brake cables fol low the procedure as listed below REMOVE 1 Remove screws attaching rear of center console assembly to floor pan of vehicle Fig 134 or Fig 135 2 Remove the 2 screws located in cup holders Fig 136 attaching front of center console to conso...

Страница 127: ... will compress tabs on park brake cable retainer allowing cable to be removed from console bracket From under carpet grasp park brake cable housing and pull cable straight out of console bracket 12 Raise vehicle on jackstands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehic...

Страница 128: ...e assembly 19 On vehicles equipped with rear disc brakes remove brake shoe assemblies Fig 148 from rear disc brake adapter Then remove parking brake actuating lever Fig 149 from the park brake cable Fig 141 Brake Drum Removal BRAKE DRUM WHEEL STUDS HUB BEARING ASSEMBLY BRAKE SUPPORT PLATE Fig 142 Rear Brake Rotor BRAKING DISC DISCSHIELD HUB DRUM IN HAT PARKING BRAKE Fig 143 Dust Cap Removal HUB BE...

Страница 129: ...Fig 147 Brake Adjustment Lever Actuating Spring BRAKE SHOE ADJUST MENT LEVER ADJUSTMENT LEVER ACTUATING SPRING PARK BRAKE CABLE Fig 148 Parking Brake Shoe Assemblies RETURN SPRING 2 PARK BRAKE SHOE HOLD DOWN CLIPS DISC BRAKE ADAPTER PARK BRAKE SHOE ASSEM BLIES STONE SHIELD ADJUSTER PARK BRAKE ACTUA TOR Fig 149 Parking Brake Actuator Lever PARK BRAKE CABLE DISC BRAKE ADAPTER PARK BRAKE SHOE ACTUATO...

Страница 130: ...ly on the rear spindle Then install A NEW rear hub bearing assembly retaining nut Torque hub bearing assembly retaining nut to 217 N m 160 ft lbs 7 Install hub bearing assembly dust cap using a soft faced hammer 8 On drum brake equipped vehicles install rear brake drum on hub bearing assembly On vehicles equipped with rear disc brakes install rotor on hub bearing assembly 9 On disc brake equipped ...

Страница 131: ... without dragging 20 Apply park brake to full engagement 21 Install center console assembly 22 Install the center console assembly attaching screws PARK BRAKE SHOES WITH REAR DISC BRAKES REMOVE 1 Remove rear disc brake caliper assembly from adapter and rotor See Disc Brake Shoe Removal 2 Remove rear rotor from rear hub 3 Remove dust cap from rear hub 4 Remove rear hub and bearing assembly retain i...

Страница 132: ...e shoe and hold down clip Fig 162 2 Install rear brake shoe and the upper brake shoe to shoe return spring Fig 161 3 Pull rear brake shoe over anchor block until properly located on adapter 4 Install the lower shoe to shoe return spring Fig 160 Fig 158 Rear Brake Shoe Hold Down Clip HOLD DOWN CLIP Fig 159 Park Brake Shoe Adjuster Assembly ADJUSTER Fig 160 Brake Shoe Lower Return Spring LOWER SPRIN...

Страница 133: ...ct the wiring harness connector to the stop lamp switch 3 Mount the stop lamp switch into the bracket using the following procedure Depress the brake pedal as far down as possible Then install switch in bracket by aligning index key on switch with slot at top of square hole in mounting bracket When switch is fully installed in bracket rotate switch clockwise approximately 30 to lock switch into br...

Страница 134: ...or from brake fluid reservoir level sensor Fig 165 2 Compress retaining tabs Fig 166 on end of brake fluid level switch 3 While compressing retaining tabs grasp oppo site end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir Fig 167 4 Correctly align the replacement level switch with its mounting hole in the brake fluid reservoir Push switch into fluid reservoir ...

Страница 135: ...ng the following procedure REMOVING CALIPER GUIDE PIN BUSHINGS 1 Remove caliper from brake rotor See Brake Shoe Removal Hang caliper assembly on a wire hook away from the brake rotor 2 Push out and then pull the steel sleeve from the inside of the bushing using your fingers as shown in Fig 168 3 Using your fingers collapse one side of the bushing Then pull on the opposite side to remove the bushin...

Страница 136: ...eeve and into the seal grove on sleeve Fig 174 Be sure other end of bushing did not come out of seal grove in sleeve 8 When the sleeve is seated properly into the bushing the sealed for life sleeve bushing can be Fig 171 Installing Caliper Guide Pin Bushing CALIPER BUSHING Fig 172 Bushing Correctly Installed In Caliper BUSHING CALIPER BE SURE BOTH BUSHING FLANGES ARE FULLY SEATED AROUND CALIPER BU...

Страница 137: ... the piston dust boot from the caliper and discard Fig 175 8 Using a soft tool such as a plastic trim stick work piston seal out of its groove in caliper piston bore Fig 176 Discard old seal Do not use a screw driver or other metal tool for this opera tion because of the possibility of scratching piston bore or burring edges of seal groove 9 Clean all parts using alcohol or a suitable sol vent and...

Страница 138: ...rs until properly seated NEVER USE AN OLD PISTON SEAL Be sure that fingers are clean and seal is not twisted or rolled Fig 178 3 Coat new piston boot with clean brake fluid leaving a generous amount inside boot 4 Position dust boot over piston after coating with brake fluid CAUTION Force must be applied to the piston uni formly to avoid cocking and binding of the piston in the bore of the caliper ...

Страница 139: ...nd spring Fig 181 Then using a soft tool such as a dowel rod press out the cup and piston that remain in the wheel cylinder 3 Wash wheel cylinder pistons and spring Fig 181 in clean brake fluid or alcohol DO NOT USE ANY PETROLEUM BASE SOLVENTS clean thor oughly and blow dry with compressed air Inspect cyl inder bore and piston for scoring and pitting Do not use a rag as lint from the rag will stic...

Страница 140: ...eness or damage to the piston dust boot If the boot is damaged or a fluid leak is visible disassemble cal iper assembly and install a new seal and boot and piston if scored Refer to Front Disc Brake Caliper in the Disassembly And Assembly Section in this group of the service manual Check the guide pin dust boots to determine if they are in good condition Replace if they are damaged dry or found to...

Страница 141: ...G ASSEMBLY The rear hub and bearing assembly is designed for the life of the vehicle and should require no mainte nance The following procedure may be used for eval uation of bearing condition With wheel and brake drum removed rotate flanged outer ring of hub Excessive roughness lat eral play or resistance to rotation may indicate dirt intrusion or bearing failure If the rear wheel bear ings exhib...

Страница 142: ...rake shoe drag 6 Repeat above adjustment at the other rear wheel Install adjusting hole rubber plugs Fig 184 in rear brake supports 7 Apply and release the park brake lever one time after wheel brake adjustment PARKING BRAKE ADJUSTMENT VEHICLE EQUIPPED REAR DRUM BRAKES Due to the auto adjust feature of the parking brake lever adjustment of the parking brake system on vehicles equipped with rear dr...

Страница 143: ... SAE 45 Inverted Flare BOOSTER Make Type Bendix Vacuum W W O ABS Mounting Studs M8 x 1 25 Type 230 mm Single Boost At 20 inches Of Manifold Vacuum 4690 All SCREW IN PROPORTIONING VALVE Material Aluminum Function Hydraulic Pressure Proportioning BRAKE PEDAL Pedal Ratio 3 28 BRAKE FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE BRAKE TUBES Tube Nuts To Fittings And Components Except HCU 17 N m 145...

Страница 144: ...CIAL TOOLS BASE BRAKE SYSTEM Adapters Brake Pressure Test 6805 Gauge Set C 4007 A Handle Universal C 4171 Installer Dust Boot C 4689 Dial Indicator C 3339 Tubes Master Cylinder Bleeding 6802 PL BRAKES 5 67 ...

Страница 145: ...K BRAKES CAB 83 FRONT WHEEL SPEED SENSOR 83 GENERAL SERVICE CAUTIONS 77 MASTER CYLINDER AND POWER BRAKE BOOSTER 81 PROPORTIONING VALVES 81 REAR WHEEL SPEED SENSOR 84 RELAY BOX 81 SPECIFICATIONS BRAKE FASTENER TORQUE SPECIFICATIONS 85 SPEED SENSOR TONE WHEEL RUNOUT 85 WHEEL SPEED SENSOR TO TONE WHEEL CLEARANCE 85 DESCRIPTION AND OPERATION ANTILOCK BRAKES OPERATION DESCRIPTION The purpose of the Ant...

Страница 146: ...when the tires ride on a film of water This results in the vehicles tires leaving the road surface rendering the vehicle virtually uncontrollable In addition extreme steering maneuvers at high speed or high speed cor nering beyond the limits of tire adhesion to the road surface may cause vehicle skidding independent of vehicle braking For this reason the ABS system is termed Antilock instead of An...

Страница 147: ...om wheel brakes of the vehicle to the sumps The Decay solenoids are spring loaded in the released build position during normal braking HYDRAULIC CONTROL UNIT SHUTTLE VALVES There are 4 Shuttle Valves one for each wheel The Shuttle Valve is a hydraulically actuated valve which shuttles when the decay solenoid and pump are energized This places an orifice restriction in the line between the pump and...

Страница 148: ...purpose of the system relay is to put the ABS system into a stand by mode for ABS operation The system relay is energized by the CAB shortly after the ignition switch is turned on When energized by the CAB the system relay turns off the ABS warning lamp and provides 12 volts to the CAB This voltage can then be used by the CAB to energize the decay solenoids during ABS braking When energized the sy...

Страница 149: ...n is dependent on accurate wheel speed signals The vehicle s wheels and tires must all be the same size and type to gen erate accurate signals Variations in wheel and tire size can produce inaccurate wheel speed signals CONTROLLER ANTILOCK BRAKE CAB The Antilock Brake Controller CAB is a micropro cessor based device which monitors the ABS system during normal braking and controls it when in an ABS...

Страница 150: ...the ABS warning lamp is on only the ABS function of the brake sys tem if affected The standard brake system and the ability to stop the car will not be affected when only the ABS warning lamp is on ABS BRAKING MODE HYDRAULIC CIRCUIT SOLENOID AND VALVE FUNCTION Through the following operation descriptions the function of the various hydraulic control valves in the ABS system will be described The f...

Страница 151: ...ting procedures and the DRB oper ators manual for its proper operational information when diagnosing this brake system DRB DIAGNOSTIC CONNECTOR On this vehicle the ABX 4 brake system DRB diagnostic connector is located under the steering col umn cover directly below the steering column Fig 9 The ABX 4 system uses the ISO 9141 K connector which is shared by other vehicle diagnostic systems such as ...

Страница 152: ...peration to resume during the ignition cycle in which a failure occurred if the failure conditions are no longer present The following conditions may result in inter mittent illumination of the ABS Warning Lamp All other failures will cause the lamp to remain on until the ignition switch is turned off Circuits involving these inputs to the CAB should be investigated if a complaint of intermittent ...

Страница 153: ... If the ABS Warning Lamp goes out shift into gear and drive the car to a speed of 5 mph to com plete the ABS start up cycle If at this time the ABS Warning Lamp goes on refer to the ABX 4 Diagnostic Manual 3 If the ABS Warning Lamp remains OUT drive the vehicle a short distance During this test drive be sure that the vehicle achieves at least 25 mph Brake to at least one complete stop and again ac...

Страница 154: ... connector Located under the steering col umn cover directly below the steering column Fig 11 3 Using the DRB check to make sure the CAB does not have any fault codes stored If it does remove them using the DRB WARNING WHEN BLEEDING THE BRAKE SYS TEM WEAR SAFETY GLASSES A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CON TAINER FILLED PART WAY WITH CLEAN BRAKE FL...

Страница 155: ...ake tubes from master cylinder housing Fig 13 Install plugs at brake tube outlets of master cylinder assembly 4 Clean area where master cylinder attaches to booster using a suitable brake cleaner CAUTION On ABS equipped vehicles vacuum in power booster must be pumped down before removing master cylinder to prevent the booster from sucking in any contamination This can be done simply by pumping the...

Страница 156: ...oles in frame rail Fig 18 2 Install and loosely tighten the bolt attaching the HCU mounting bracket to the top of the frame rail 3 Raise vehicle 4 Install the 2 bolts attaching the HCU mounting bracket to the side of the front frame rail Fig 18 Then torque both mounting bolts to 28 N m 200 in lbs 5 Lower vehicle 6 Torque bolt attaching HCU mounting bracket to top of frame rail to 20 N m 180 in lbs...

Страница 157: ...ompound Using any other type of grease or lubricant on the push rod will not provide adequate long term lubri cation of the push rod 12 Lubricate master cylinder push rod as indi cated in Fig 20 only using Mopar Dielectric Grease And No Substitutes Refer to the Mopar Chemicals Catalog to obtain the required lubricant 13 Install vacuum seal on master cylinder push rod as shown in Fig 21 with notche...

Страница 158: ...en until proportioning is fully installed and O ring seal is seated into HCU Then torque propor tioning valve to 40 N m 30 ft lbs 3 Install brake tube on proportioning valve Tighten tube nut to 17 N m 145 in lbs torque 4 Bleed the base brakes hydraulic system Refer to Bleeding Base Brake Hydraulic System in Service Procedures of the Base Brake Section MASTER CYLINDER AND POWER BRAKE BOOSTER If the...

Страница 159: ...to the HCU 5 Reconnect the 6 way connector onto the relay box 6 Install the HCU back in the vehicle See Hydraulic Control Unit in the Removal And Installa tion Section of the Antilock Brake System Section in this group of the service manual for the required HCU installation procedure 7 Connect the negative ground cable back on the negative post of the battery 8 Bleed the base brakes and the ABS br...

Страница 160: ...8 to 4 N m 38 in lbs 5 If a new CAB is being installed it must be initiallized prior to the vehicle being driven The CAB is initialized using the DRB Scan Tool and the initializing procedure described upon selecting Bendix ABX 4 Diagnostics New con trollers are programmed to flash the ABS warn ing lamp until initilized by the installing technician FRONT WHEEL SPEED SENSOR NOTE Proper installation ...

Страница 161: ... screw Fig 31 Torque the attaching screw to 7 N m 60 in lbs 4 Install the wheel and tire assembly on vehicle 5 Road test vehicle to ensure proper operation of the base and ABS systems REAR WHEEL SPEED SENSOR NOTE Proper installation of the Wheel Speed Sen sor Cables is critical to continued system opera tion Be sure that cables are installed routed and clipped properly Failure to install speed sen...

Страница 162: ...g 33 Install clip Fig 33 attach ing speed sensor cable connector to vehicle body 6 Install the tire and wheel assembly on vehicle 7 Road test vehicle to ensure proper operation of the base and ABS systems SPECIFICATIONS SPEED SENSOR TONE WHEEL RUNOUT The total indicator runout allowed for both the front and rear tone wheel measured using a dial indi cator is 0 25 mm 009 in WHEEL SPEED SENSOR TO TO...

Страница 163: ...PER Guide Pin Bolts 22 N m 192 in lbs Bleeder Screw 15 N m 125 in lbs ABS HYDRAULIC CONTROL UNIT To Mounting Bracket Bolts 28 N m 250 in lbs Bracket To Frame Rail Mounting Bolt Top 18 N m 160 in lbs Bracket To Frame Rail Mounting Bolts Side 22 N m 200 in lbs PARKING BRAKE Lever Mounting Nuts 28 N m 250 in lbs REAR HUB AND BEARING To Knuckle Retaining Nut 217 N m 160 ft lbs WHEEL Stud Lug Nut 109 1...

Страница 164: ...vehicles The Modular Clutch Service Package contains the following parts One modular clutch assembly One drive plate assembly One backing plate assembly Four drive plate to clutch bolts Eight drive plate to crankshaft bolts If only the clutch disc requires replacement obtain the clutch disc Replace the clutch disc using the information in the Removal And Installa tion section of this manual If the...

Страница 165: ...h is wired in series between the starter relay coil and the ignition switch The clutch pedal position switch is mounted to a bracket located behind the clutch pedal The switch is held in place by four plastic wing tabs The clutch pedal position switch IS NOT adjust able The pedal blade contacts the switch in the down position Fig 3 DIAGNOSIS AND TESTING CLUTCH PEDAL POSITION SWITCH CLUTCH PEDAL PO...

Страница 166: ...n from the floor If this condi tion is met then the problem is either the clutch or the self adjusting cable See Clutch Will Not Disen gage Properly If this condition is not met then the switch mounting tab on the brake bracket is bent and the brake bracket must be replaced If vehicle will not crank even with clutch pedal pressed to the floor refer to Service Diagnosis Clutch Pedal Position Switch...

Страница 167: ...transaxle input shaft seal Correct leak and replace w modular clutch assembly Too much grease applied to splines of disc and input shaft Apply lighter coating of grease to splines NO FAULT FOUND WITH CLUTCH COMPONENTS Problem actually related to suspension or driveline component Further diagnosis required Check engine transmission mounts suspension attaching parts and other driveline components as...

Страница 168: ...sh water entering housing Seal housing Inspect clutch assembly CLUTCH IS RUNNING PARTIALLY DISENGAGED Release bearing sticking or binding does not return to normal running position Verify that bearing is actually binding Then replace bearing and transmission front bearing retainer if sleeve surface is damaged Cable self adjuster mechanism sticking or binding causing high preload Verify that self a...

Страница 169: ...ENGAGE PROPERLY Disc bent distorted during transaxle installation Replace w modular clutch assembly Clutch cover diaphragm spring damaged during transaxle installation Replace w modular clutch assembly Release fork bent loose or damaged Replace fork if worn or damaged Clutch cable binding or routed incorrectly Check and correct cable routing Self adjuster in cable not functioning properly resultin...

Страница 170: ...s 7 Check clutch assembly for contamination dirt oil Replace clutch assembly if required 8 Check to see if the clutch disc hub splines are damaged Replace with new clutch assembly if nec essary 9 Check input shaft splines for damage Replace if necessary 10 Check for uneven wear on clutch fingers 11 Check for broken clutch cover diaphragm spring fingers Replace with new clutch assembly if necessary...

Страница 171: ...finishing installation ADJUSTER MECHANISM FUNCTION CHECK 1 With slight pressure pull the clutch release lever end of the cable to draw the cable taut Push the clutch cable housing toward the dash panel With less than 25 lbs of effort the cable housing should move 30 50mm This indicates proper adjuster mechanism function If the cable does not adjust determine if the mechanism is properly seated on ...

Страница 172: ...r ridges Replace parts as required 3 Clean the flywheel face with medium sandpa per 80 180 grade then wipe the surface with min eral spirits If the surface is severely scored heat checked cracked or warped replace the flywheel CAUTION Do not flat machine the flywheel face The surface profile is tapered 4 The heavy side of the flywheel is indicated by a daub of white paint near the outside diameter...

Страница 173: ...le support bracket 3 Remove the front transaxle support bracket 4 Remove modular clutch retaining bolts 5 Remove transaxle See Group 21 Manual Tran saxle for procedure 6 The transaxle and modular clutch come out as an assembly 7 Remove the modular clutch assembly from the transaxle input shaft Fig 9 Handle carefully to avoid contaminating the friction surfaces INSPECTION 1 Inspect for oil leakage ...

Страница 174: ... black GREASE CONTAMINATION Grease contamination is usually a product of over lubrication During clutch service apply only a small amount of grease to the input shaft splines Excess grease may be thrown off during operation contami nating the disc ROAD SPLASH WATER CONTAMINATION Road splash contamination is usually caused by driving the vehicle through deep water puddles Water can be forced into t...

Страница 175: ...g 12 SPECIFICATIONS TORQUE MODULAR CLUTCH DESCRIPTION TORQUE Drive Plate To Clutch Bolts 75 N m 55 ft lbs Drive Plate To Crankshaft Bolts 95 N m 70 ft lbs Clutch Pedal Pivot Shaft Nut 41 N m 30 ft lbs CONVENTIONAL CLUTCH DESCRIPTION TORQUE Clutch Cover Bolts 28 N m 250 in lbs Flywheel to Crankshaft Bolts 95 N m 70 ft lbs Clutch Pedal Pivot Shaft Nut 41 N m 30 ft lbs SPECIAL TOOLS CLUTCH Fig 10 Clu...

Страница 176: ... is a dia phragm type unit with a one piece diaphragm spring with multiple release fingers The pressure plate release fingers are preset during manufacture and are not adjustable A sleeve type release bearing is used to engage and disengage the clutch cover pressure plate The bear ing is prelubed during manufacture and is a sealed unit The release bearing is operated by a pivoting release fork in ...

Страница 177: ... continuity between the two ter minals in the connector on the switch harness There should be no continuity between the terminals when the switch is in its normal fully extended position When the switch is depressed more than 1 25 mm 0 050 the ohmmeter should show continuity zero ohms If ohmmeter readings do not fall within these ranges the switch is defective and must be replaced CLUTCH PEDAL POS...

Страница 178: ...ienced remove and inspect the clutch components If the problem is noise or hard shifting further diagnosis may be needed The transaxle or other driveline components may actually be at fault SERVICE DIAGNOSIS CLUTCH GRAB CHATTER CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC FACING COVERED WITH OIL OR GREASE Oil leak at engine rear main or transaxle input shaft seal Correct leak and replace w mod...

Страница 179: ...ter entering housing Seal housing Inspect clutch assembly CLUTCH IS RUNNING PARTIALLY DISENGAGED Release bearing sticking or binding does not return to normal running position Verify that bearing is actually binding Then replace bearing and transmission front bearing retainer if sleeve surface is damaged Hydraulic clutch mechanism sticking or binding causing high preload Verify that clutch slave c...

Страница 180: ...rted during transaxle installation Replace w modular clutch assembly Clutch cover diaphragm spring damaged during transaxle installation Replace w modular clutch assembly Release fork bent loose or damaged Replace fork if worn or damaged Clutch pedal binding or does not return Lubricate pedal bushings Check system for leaks and replace as needed Hydraulic clutch system has air in the lines Stroke ...

Страница 181: ...lutch assembly if necessary CLASH INTO REVERSE COMPLAINTS All Right Hand Drive NV T350 A 578 manual transaxles are equipped with a reverse brake It pre vents clash when shifting into reverse but only if the vehicle is not moving See Group 21 Transaxle for further diagnosis 1 Depress clutch pedal to floor and hold After three seconds shift to reverse If clash is present clutch has excessive spin ti...

Страница 182: ...er 1 4 turn clockwise 5 Slide remote reservoir into bracket at dash panel until locked in 6 From underneath dash panel ensure clutch master cylinder push rod is located between the pedal and locator bracket Snap clutch pedal pin into pushrod and slide cotter pin into bushing 7 Route hydraulic lines to retaining clips at frame rail 8 Raise vehicle 9 Connect upper clutch hydraulic line from mas ter ...

Страница 183: ...tion Fig 9 REMOVAL 1 Disconnect electrical harness to switch connec tor 2 Depress wing tabs on switch and push switch out of mounting bracket Then slide wires through slot in bracket INSTALLATION 1 Slide switch wires through slot in switch bracket 2 Line up switch tab with slot in switch bracket and push switch into position Do not pull on the switch wires to seat switch into bracket switch dam ag...

Страница 184: ...s pre lubricated and sealed and should not be immersed in oil or solvent 4 The bearing should turn smoothly when held in the hand under a light thrust load A light drag caused by the lubricant fill is normal If the bearing is noisy rough or dry replace the complete bearing assembly with a new bearing 5 Check the condition of the pivot stud spring clips on back side of clutch fork If the clips are ...

Страница 185: ...ndensation from steam vapors tend to accumu late on the internal clutch mechanism when the vehi cle is steam cleaned Facing of disc will absorb moisture and will bond to flywheel and or pressure plate if vehicle is allowed to stand for some time before use If this condition occurs it may require replacement of clutch assembly After cleaning drive the vehicle to its normal clutch operating tempera ...

Страница 186: ... is a dia phragm type unit with a one piece diaphragm spring with multiple release fingers The pressure plate release fingers are preset during manufacture and are not adjustable A sleeve type release bearing is used to engage and disengage the clutch cover pressure plate The bear ing is prelubed during manufacture and is a sealed unit The release bearing is operated by a pivoting release fork in ...

Страница 187: ... continuity between the two ter minals in the connector on the switch harness There should be no continuity between the terminals when the switch is in its normal fully extended position When the switch is depressed more than 1 25 mm 0 050 the ohmmeter should show continuity zero ohms If ohmmeter readings do not fall within these ranges the switch is defective and must be replaced CLUTCH PEDAL POS...

Страница 188: ...ienced remove and inspect the clutch components If the problem is noise or hard shifting further diagnosis may be needed The transaxle or other driveline components may actually be at fault SERVICE DIAGNOSIS CLUTCH GRAB CHATTER CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC FACING COVERED WITH OIL OR GREASE Oil leak at engine rear main or transaxle input shaft seal Correct leak and replace w mod...

Страница 189: ...ter entering housing Seal housing Inspect clutch assembly CLUTCH IS RUNNING PARTIALLY DISENGAGED Release bearing sticking or binding does not return to normal running position Verify that bearing is actually binding Then replace bearing and transmission front bearing retainer if sleeve surface is damaged Hydraulic clutch mechanism sticking or binding causing high preload Verify that clutch slave c...

Страница 190: ...rted during transaxle installation Replace w modular clutch assembly Clutch cover diaphragm spring damaged during transaxle installation Replace w modular clutch assembly Release fork bent loose or damaged Replace fork if worn or damaged Clutch pedal binding or does not return Lubricate pedal bushings Check system for leaks and replace as needed Hydraulic clutch system has air in the lines Stroke ...

Страница 191: ...lutch assembly if necessary CLASH INTO REVERSE COMPLAINTS All Right Hand Drive NV T350 A 578 manual transaxles are equipped with a reverse brake It pre vents clash when shifting into reverse but only if the vehicle is not moving See Group 21 Transaxle for further diagnosis 1 Depress clutch pedal to floor and hold After three seconds shift to reverse If clash is present clutch has excessive spin ti...

Страница 192: ...er 1 4 turn clockwise 5 Slide remote reservoir into bracket at dash panel until locked in 6 From underneath dash panel ensure clutch master cylinder push rod is located between the pedal and locator bracket Snap clutch pedal pin into pushrod and slide cotter pin into bushing 7 Route hydraulic lines to retaining clips at frame rail 8 Raise vehicle 9 Connect upper clutch hydraulic line from mas ter ...

Страница 193: ...tion Fig 9 REMOVAL 1 Disconnect electrical harness to switch connec tor 2 Depress wing tabs on switch and push switch out of mounting bracket Then slide wires through slot in bracket INSTALLATION 1 Slide switch wires through slot in switch bracket 2 Line up switch tab with slot in switch bracket and push switch into position Do not pull on the switch wires to seat switch into bracket switch dam ag...

Страница 194: ...s pre lubricated and sealed and should not be immersed in oil or solvent 4 The bearing should turn smoothly when held in the hand under a light thrust load A light drag caused by the lubricant fill is normal If the bearing is noisy rough or dry replace the complete bearing assembly with a new bearing 5 Check the condition of the pivot stud spring clips on back side of clutch fork If the clips are ...

Страница 195: ...ndensation from steam vapors tend to accumu late on the internal clutch mechanism when the vehi cle is steam cleaned Facing of disc will absorb moisture and will bond to flywheel and or pressure plate if vehicle is allowed to stand for some time before use If this condition occurs it may require replacement of clutch assembly After cleaning drive the vehicle to its normal clutch operating tempera ...

Страница 196: ...ERVICING COOLANT LEVEL 16 REMOVAL AND INSTALLATION ACCESSORY DRIVE BELTS 21 ENGINE BLOCK HEATER 21 ENGINE THERMOSTAT 18 RADIATOR DRAINCOCK 20 RADIATOR FANS AND MOTOR 20 RADIATOR 19 WATER PUMP INLET TUBE 18 WATER PUMP 17 CLEANING AND INSPECTION ACCESSORY DRIVE BELT INSPECTION 22 CHEMICAL CLEANING 23 CLEANING COOLING SYSTEM 23 COOLING SYSTEM CAP 22 RADIATOR FLUSHING 23 REVERSE FLUSHING 23 WATER PUMP...

Страница 197: ...tem provides space for expansion and contraction and a convenient safe method for checking and adjusting the coolant level and at atmo spheric pressure without removing the pressure cap It also provides some reserve coolant to compensate for minor leaks and evaporation or boiling losses All vehicles are equipped with this system Fig 3 See Coolant Level Check Service Procedures Deaeration and Press...

Страница 198: ...ith a pressure cap that releases pressure at some point within a range of 97 124 kPa 14 18 psi Fig 5 The system will operate at higher than atmo spheric pressure which raises the coolant boiling point allowing increased radiator cooling capacity AUTOMATIC TRANSMISSION OIL COOLER Oil coolers are internal oil to coolant type mounted in the radiator lower tank Fig 6 Rubber oil lines feed the oil cool...

Страница 199: ...as follows Pure Water 1 btu boils at 100 C 212 F and freezes at 0 C 32 F 100 Percent Glycol 7 btu can cause a hot engine and detonation and will raise the freeze point to 22 C 8 F 50 50 Glycol and Water 82 btu is the recom mended combination that provides a freeze point of 37 C 35 F The radiator water pump engine water jacket radiator pressure cap thermostat tempera ture gauge sending unit and hea...

Страница 200: ...HEN THE SYSTEM STOPS PUSHING OUT COOLANT AND STEAM AND THE PRESSURE DROPS CONTINUE SERVICE WARNING CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES WHEN REMOVING OR INSTALLING USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAM ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS CAUTION A number or letter is stamped into the tongue of constant tension clamps If ...

Страница 201: ...eater element continuity with an ohmmeter or 12 volt test light WATER PUMP The water pump body is made of aluminum with a steel impeller The water pump is bolted to the front of the block and driven by the timing belt The water pump is the heart of the cooling system pumping the coolant through the engine block cylinder head heater core and radiator NOTE The water pump on all models can be replace...

Страница 202: ... climbed vehicle being operated in slow moving traffic or engine idling during high ambient outside temperatures with air conditioning on High altitudes Could aggravate these conditions 1 This may be a temporary condition and repair is not necessary Turn off the air conditioning and drive the vehicle without any of the previous conditions Observe the temperature gauge the gauge should return to th...

Страница 203: ...r neck with some coolant removed engine warm and thermostat open Coolant should be observed flowing through filler neck If flow is not observed determine reason for lack of flow and repair as necessary 10 Radiator or A C condenser fins are dirty or clogged 10 Clean insects or debris 11 Radiator core is plugged or corroded 11 Replace or re core radiator 12 Fuel or ignition system problems 12 Refer ...

Страница 204: ...ter a few minutes of engine operation 6 Coolant level low in radiator air will build up in the cooling system causing the thermostat to open late 6 Check and correct coolant leaks Refer to Testing Cooling System for Leaks in this group 7 Cylinder head gasket leaking allowing exhaust gas to enter cooling system causing thermostat to open late 7 a Check for cylinder head gasket leaks with a commerci...

Страница 205: ...ernally blocked or plugged Check for blockage and repair as necessary ELECTRIC RADIATOR FAN RUNS ALL THE TIME 1 Fan relay powertrain control module PCM or engine coolant temperature sensor defective 1 Refer to appropriate Powertrain Diagnostic Procedures manual for operation of the DRB scan tool Repair as necessary 2 Check for low coolant level 2 Repair as necessary ELECTRIC RADIATOR FAN WILL NOT ...

Страница 206: ... to On Board Diagnostic in Group 25 and replace thermostat if necessary 2 Coolant level low 2 Refer to testing cooling system for leaks in this section Repair as necessary 3 Obstructions in heater hose fittings at engine 3 Remove heater hoses at both ends and check for obstructions Repair as necessary 4 Heater hose kinked 4 Locate kinked area and repair as necessary 5 Water pump is not pumping coo...

Страница 207: ...f necessary STEAM IS COMING FROM FRONT OF VEHICLE NEAR GRILL AREA WHEN WEATHER IS WET ENGINE IS WARMED UP AND RUNNING AND VEHICLE IS STATIONARY TEMPERATURE GAUGE IS IN NORMAL RANGE 1 During wet weather moisture snow ice or rain condensation on the radiator will evaporate when the thermostat opens This opening allows heated water into the radiator When the moisture contacts the hot radiator steam m...

Страница 208: ...rm mode of failure and normally only on high mileage vehicles The temperature gauge will indicate this Refer to diagnosis in this section ACCESSORY DRIVE BELT DIAGNOSIS Condition Possible Cause Correction INSUFFICIENT ACCESSORY OUTPUT DUE TO BELT SLIPPAGE a Belt too loose a Adjust belt tension b Belt excessively glazed or worn b Replace and tighten as specified BELT SQUEAL WHEN ACCELERATING ENGINE...

Страница 209: ...conditions The fan will not run during cranking until the engine starts no matter what the coolant tempera ture is Fan will run when the air conditioning clutch is engaged and low pressure cutout switch is closed Fan will run at vehicle speeds above about 40 mph only if coolant temperature reaches 110 C 230 F It will turn off when the temperature drops to 104 C 220 F At speeds below 40 mph the fan...

Страница 210: ...NG DOWN ROTATE IT COUNTER CLOCKWISE TO THE FIRST STOP ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN ON THE CAP AND REMOVE IT COMPLETELY SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL TO CHECK PRESSURE BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED PRESSURE TESTING COOLING SYSTEM PRESSU...

Страница 211: ...ling system is closed and designed to maintain coolant level to the top of the radiator When servicing requires a coolant level check in the radiator the engine must be off and not under pressure Drain several ounces of coolant from the radiator drain cock while observing the Coolant Recovery System CRS Tank Coolant level in the CRS tank should drop slightly Then remove the radi ator cap The radia...

Страница 212: ...and bracket assembly aside Power steering lines do not need to be disconnected 6 Remove right engine mount bracket 7 Remove timing belt Refer to Group 9 Engine for procedure 8 Remove inner timing belt cover 9 Remove water pump attaching screws to engine Fig 14 INSTALLATION 1 Install new O ring gasket in water pump body O ring groove Fig 15 Use small dabs of Mopar Sil icone Rubber Adhesive Sealant ...

Страница 213: ...stener to the intake manifold Tighten fas teners to 12 N m 105 in lbs 4 Connect lower radiator hose and heater hose to inlet tube 5 Install upper radiator hose 6 Fill cooling system Refer to procedure outlined in this section 7 Pressure system to 104 kPa 15 psi to check for leaks ENGINE THERMOSTAT REMOVAL 1 Drain cooling system to the thermostat level or below 2 Remove coolant recovery system CRS ...

Страница 214: ... be avoided 6 Remove upper radiator isolator bracket mount ing screws Disconnect the engine block heater wire if equipped 7 Remove the air conditioning condenser attach ing screws located at the front of the radiator if equipped Fig 22 Lean condenser forward it is not necessary to discharge the air conditioning system to remove radiator 8 Radiator can now be lifted free from engine compartment Car...

Страница 215: ...is unscrewed to the end of the threads pull the stem Fig 23 from the radiator tank INSTALLATION 1 Push the draincock assembly body into the tank opening 2 Tighten the draincock stem by turning clock wise to 2 0 2 7 N m 18 25 in lbs RADIATOR FANS AND MOTOR All models use a single speed electric motor driven cooling system fans The fan modules includes a motor fan blade and support shroud The module...

Страница 216: ...cooling system with coolant to the proper level vent air and inspect for leaks Pressurize sys tem with Radiator Pressure Tool before looking for leaks ACCESSORY DRIVE BELTS AIR CONDITIONING COMPRESSOR AND POWER STEERING PUMP 1 Loosen the power steering pump locking bolts A and B and pivot bolt C Fig 26 to remove and install belt and or adjust belt tension 2 Using a 1 2 breaker bar adjust belt tens...

Страница 217: ...eptable Cracks parallel are not Fig 28 NOTE Do not use any type of belt dressing or restorer on Poly V Belt and V Belt COOLING SYSTEM CAP Hold the cap in your hand right side up Fig 29 The vent valve at the bottom of the cap should open with a slight pull If the rubber gasket has swollen preventing the valve from opening replace the cap If any light can be seen between vent valve and the rubber ga...

Страница 218: ...LEANING One type of corrosion encountered with aluminum cylinder heads is aluminum hydroxide deposits Cor rosion products are carried to the radiator and depos ited when cooled off They appear as dark grey when wet and white when dry This corrosion can be removed with a two part cleaner oxalic acid and neutralizer available in auto parts outlets Follow manufacturers directions for use ADJUSTMENTS ...

Страница 219: ... Screws A C equipped 3 8 N m 34 in lbs Fan Motor to Shroud Retaining Screws Non A C equipped 2 3 N m 20 in lbs Radiator Cooling Module to Body Screws 7 2 N m 65 in lbs Thermostat Housing Engine Outlet Connector Screws 12 N m 105 in lbs Upper Radiator Crossmember Bolts 28 N m 250 in lbs Water Pump to Engine Block Mounting Bolts 12 N m 105 in lbs Water Pump Inlet Tube to Engine Block Mounting Screws...

Страница 220: ...lt into the battery cover The specific gravity indicates the battery s state of charge The OE bat tery is sealed and water cannot be added The battery is vented to release gases that are cre ated when the battery is being charged and dis charged The battery top posts and terminals should be cleaned when other under hood maintenance is performed When the electrolyte level is below the top of the pl...

Страница 221: ...e will rise Also the specific gravity of the electrolyte will rise bringing the green ball Fig 2 into view at approximately 75 percent state of charge DIAGNOSIS AND TESTING BATTERY BUILT IN TEST INDICATOR USING TEST INDICATOR The Test Indicator Fig 2 Fig 3 and Fig 4 measures the specific gravity of the electrolyte Spe cific Gravity SG of the electrolyte will show state of charge voltage The test i...

Страница 222: ...TEPS POSSIBLE CAUSE CORRECTION VISUAL INSPECTION Check for possible damage to battery and clean battery 1 Loose battery post Cracked battery cover or case Leaks or Any other physical 2 Battery OK 1 Replace Battery 2 Check state of charge Refer to Test Indicator TEST INDICATOR Check Charge Eye Color 1 GREEN 2 BLACK 3 CLEAR 1 Battery is charged Perform Battery 0pen Circuit Voltage Test 2 Perform Bat...

Страница 223: ...t or a fault in an elec tronic module Two fuses in the Power Distribution Center PDC feed the modules with ignition off draw Interior lamps fuse 10 Amp IOD PDC Fuel pump fuse 20 Amp in PDC 1 Remove interior lamp and fuel pump fuses By removing these fuses all ignition off draw from the vehicle electronics will be disconnected The test lamp should go out If test lamp goes out go to Step 2 If test l...

Страница 224: ...is a cur rent draw or short circuit in the A14 circuit Refer to Group 8W Wiring Diagrams BATTERY LOAD TEST A fully charged battery must have cranking capac ity to provide the starter motor and ignition system enough power to start the engine over a broad range of ambient temperatures A battery load test will ver ify the actual cranking capability of the battery WARNING IF BATTERY SHOWS SIGNS OF FR...

Страница 225: ...voltage reading of 12 4 volts or greater and will not pass the load test replace the battery because it is defective To test open circuit voltage perform the following operation 1 Remove both battery cables negative cable first Battery top cables and posts should be clean If green dot is not visible in indicator charge the bat tery Refer to Battery Charging Procedures 2 Connect a Volt Ammeter Load...

Страница 226: ...to operating instructions provided with battery charger being used CAUTION Charge battery until test indicator appears green Do not overcharge It may be necessary to jiggle the battery or vehicle to bring the green dot in the test indicator into view After the battery has been charged to 12 4 volts or greater perform a load test to determine cranking capacity Refer to Battery Load Test in this Gro...

Страница 227: ...Inspect battery case and cover for cracks leak age or damaged hold down ledge If battery is dam aged replace it 5 Inspect battery tray for damage caused by acid from battery If acid is present clean area with bak ing soda solution 6 Clean battery posts with a battery post clean ing tool Fig 16 7 Clean battery cable clamps with a battery ter minal cleaning tool Fig 17 Replace cables that are frayed...

Страница 228: ... is properly positioned on battery 3 Place thermoguard cover over the battery and snap it together with battery tray Fig 20 The bat tery tray pencil strut may have to be loosened on one end to install the thermoguard cover After the ther moguard cover is in place tighten pencil strut as necessary 4 Connect battery cable clamps to battery posts and making sure top of clamp is flush or below with to...

Страница 229: ...ALLATION For installation reverse above procedures Ensure that the lock tabs are properly seated in the radiator panel and to the bottom of battery tray Fig 22 Ensure that the tube opening is properly aligned with hole before pulling on strap SPECIFICATIONS BATTERY SPECIFICATIONS COLD CRANK RATING The current battery can deliver for 30 seconds and maintain a terminal voltage of 7 2 volts or greate...

Страница 230: ... and service procedures outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD RHD or Export if a special illustration or procedure is required BOSCH STARTER The Bosch is a permanent magnet starter motor A planetary gear train transmits power between starter motor and pinion shaft The fields have six perma nent magnets The starter system con...

Страница 231: ...Particu larly at starter terminals c Repeat test If engine still fails to crank prop erly trouble is within starter or starter mounted solenoid and replace starter STARTER RELAY WARNING CHECK TO ENSURE THAT THE TRANS MISSION IS IN THE PARK POSITION NEUTRAL WITH THE PARKING BRAKE APPLIED RELAY TEST The starter relay is located in the Power Distribu tion Center PDC in the engine compartment Refer to...

Страница 232: ...ion Switch refer to Group 21 Transaxle IGNITION SWITCH After testing starter solenoid and relay test igni tion switch and wiring Refer to Group 8D Ignition Systems or Group 8W Wiring Diagrams Check all wiring for opens or shorts and all connectors for being loose or corroded BATTERY Refer to Group 8A Battery for proper procedures ALL RELATED WIRING AND CONNECTORS Refer to Group 8W Wiring Diagrams ...

Страница 233: ...the ignition and fuel systems must be disabled 1 Connect a volt ampere tester to the battery ter minals Fig 7 Refer to the operating instructions provided with the tester being used 2 To disable the ignition and fuel systems dis connect the Automatic Shutdown Relay ASD The ASD relay is located in the Power Distribution Cen ter PDC Refer to the PDC cover for proper relay location The 2 5L Diesel En...

Страница 234: ...perform the following inspec tions Battery Visually inspect the battery for indi cations of physical damage and loose or corroded cable connections Determine the state of charge and cranking capacity of the battery Charge or replace the battery if required Refer to Group 8A Battery for more information Ignition Switch Visually inspect the ignition switch for indications of physical damage and loos...

Страница 235: ...ly STARTER ENGAGES FAILS TO TURN ENGINE 1 Battery discharged or faulty 2 Starting circuit wiring faulty 3 Starter assembly faulty 4 Engine seized 1 Refer to Group 8A Battery Charge or replace battery as necessary 2 Refer to the Feed Circuit Resistance Test and the Feed Circuit Test in this section Repair as necessary 3 If all other starting system components and circuits check OK replace starter a...

Страница 236: ...nnect push on solenoid connector 9 Position the starter vertically such that the pinion end faces downward 10 Remove the starter through the bottom of the vehicle Move aside A C plumbing as necessary INSTALLATION 1 Clean corrosion dirt from the cable and wire terminals before installing wiring to the solenoid 2 Connect the battery positive and generator out put wire to the starter solenoid post Fi...

Страница 237: ...on SPECIFICATIONS STARTER Engine should be up to operating temperature Extremely heavy oil or tight engine will increase starter amperage draw TORQUE DESCRIPTION TORQUE Starter Mounting Bolts 54 N m 40 ft lbs Starter Solenoid Battery Nut 10 N m 90 in lbs Fig 11 Wire Connection B POST GENERATOR OUTPUT WIRE PUSH ON SOLENOID CON NECTOR B BATTERY POSITIVE WIRE Manufacturer BOSCH Engine Application 2 0...

Страница 238: ...ed All OBD sensed systems are monitored by the PCM Each monitored circuit is assigned a Diagnos tic Trouble Code DTC The PCM will store a DTC in electronic memory for any failure it detects See the On Board Diagnostics Test in Group 8C Charging System for more information DESCRIPTION AND OPERATION CHARGING SYSTEM OPERATION The charging system consists of Generator Electronic Voltage Regulator EVR ...

Страница 239: ...warmer temperatures The sensor is located forward of the vehicle battery and is attached to the battery tray Fig 1 ELECTRONIC VOLTAGE REGULATOR The Electronic Voltage Regulator EVR is not a separate component It is actually a voltage regulat ing circuit located within the Powertrain Control Module PCM The EVR is not serviced separately If replacement is necessary the PCM must be replaced Operation...

Страница 240: ...y Replace battery if electrolyte level is low 4 Inspect generator mounting bolts for tightness Replace or tighten bolts if required Refer to the Gen erator Removal Installation section of this group for torque specifications 5 Inspect generator drive belt condition and ten sion Tighten or replace belt as required Refer to Belt Tension Specifications in Group 7 Cooling Sys tem 6 Inspect automatic b...

Страница 241: ...Charging System Schematic Typical 8C 4 CHARGING SYSTEM PL DIAGNOSIS AND TESTING Continued ...

Страница 242: ...OLTS YES CLEAN MOUNTING SUR FACES TIGHTEN FASTENERS TO SPECIFIED TORQUE NO CHECK ON BOARD DIAG NOSTIC TROUBLE CODES DTC PERFORM OUTPUT VOLT AGE TEST YES LOW OR NO CHARGING VOLTAGE OR DTC 41 OR 47 NO REFER TO VOLTAGE DROP TEST NO CHARGING SYSTEM AND GENERATOR IS OK CHARGING VOLTAGE ABOVE MAXIMUM OR DTC 41 OR 46 REFER TO LOAD TEST VOLTAGE YES REFER TO OVERCHARGE TEST PL CHARGING SYSTEM 8C 5 DIAGNOSI...

Страница 243: ...UT VOLTAGE TEST DISCONNECT FIELD TERMINAL MEASURE RESISTANCE FROM K20 CIRCUIT ON WIRING HAR NESS TO ENGINE GROUND YES IS RESISTANCE LESS THAN 1000 OHMS NO REPAIR SHORT TO GROUND MEASURE RESISTANCE FROM K20 TERMINAL ON GENERATOR TO ENGINE GROUND REPLACE GENERATOR YES IS RESISTANCE LESS THAN 1000 OHMS NO REPEAT OUTPUT VOLTAGE TEST 8C 6 CHARGING SYSTEM PL DIAGNOSIS AND TESTING Continued ...

Страница 244: ...erature 4 Shut engine off 5 Connect an engine tachometer 6 Fully engage the parking brake TEST 1 Start engine 2 Place heater blower in high position 3 Turn on headlamps and place in high beam position 4 Turn vehicle interior lamps on 5 Start engine Bring engine speed up to 2400 rpm and hold 6 Testing ground circuitry a Touch the negative lead of voltmeter directly to battery positive POST Fig 4 b ...

Страница 245: ...ating instructions supplied with tester When using a tester equipped with an inductive type clamp removal of wiring at the gener ator will not be necessary 7 Start the engine and allow it to reach operating temperature 8 Shut engine off 9 Turn off all electrical accessories and all vehicle lighting 10 Connect the volt amp tester leads to the bat tery Be sure the carbon pile rheostat control is in ...

Страница 246: ...EN NO CHECK FOR BLOWN FUSE LINK NO IF LESS THAN 5 OHMS IF GREATER THAN 5 OHMS MEASURE VOLTAGE AT K 20 TERMI NAL ON THE GENERATOR YES YES REPAIR WIRE DISCONNECT FIELD CONNECTOR REPLACE PCM REPLACE GENERATOR YES VOLTAGE AT K 20 LESS THAN 10 VOLTS REPEAT OUTPUT VOLTAGE TEST CHECK SHORT CIRCUIT IN WIRE REPAIR FUSE LINK AND WIRE SHORT REFER TO GROUP 8W WIRING DIA GRAMS YES SHORT CIRCUIT IN FEED WIRE NO...

Страница 247: ...ure they are operational A Diagnostic Trouble Code DTC is assigned to each input and output circuit monitored by the OBD system Some circuits are checked continuously and some are checked only under certain conditions If the OBD system senses that a monitored circuit is bad it will put a DTC into electronic memory The DTC will stay in electronic memory as long as the circuit continues to be bad Th...

Страница 248: ...llows 1 Lamp on for 2 seconds then turns off 2 Lamp flashes 4 times pauses and then flashes 1 time 3 Lamp pauses for 4 seconds flashes 4 times pauses then flashes 7 times 4 The two DTC s are 41 and 47 Any number of DTC s can be displayed as long as they are in mem ory The lamp will flash until all stored DTC s are displayed then it will flash a DTC 55 to indicate the test is complete ERASING DIAGN...

Страница 249: ...EMPERATURE SENSOR REMOVAL 1 Make sure ignition switch is in OFF position and all accessories are OFF 2 Remove battery negative cable first then the positive cable Fig 12 3 Remove battery thermoguard Fig 13 WARNING TO PROTECT THE HANDS FROM BAT TERY ACID A SUITABLE PAIR OF HEAVY DUTY RUBBER GLOVES NOT THE HOUSEHOLD TYPE SHOULD BE WORN WHEN REMOVING OR SERVIC ING A BATTERY SAFETY GLASSES ALSO SHOULD...

Страница 250: ... m 75 in lbs Battery Hold Down Clamp Bolt 9 N m 75 in lbs Generator Mounting Bolt 54 N m 40 ft lbs Generator Pivot Bolt 54 N m 40 ft lbs Fig 15 Battery Temperature Sensor Connector BATTERY TRAY BATTERY TEMPERATURE SENSOR AIR INLET TUBE TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS MELCO 4793190 83 AMPS 2 0L SOHC DOHC 75 AMPS PL CHARGING SYSTEM 8C 13 REMOVAL AND INSTALLATION Continued ...

Страница 251: ......

Страница 252: ...CHARGING SYSTEM CONTENTS page DIAGNOSIS AND TESTING CHARGING SYSTEM 2 PL CHARGING SYSTEM 8C 1 ...

Страница 253: ...DIAGNOSIS AND TESTING CHARGING SYSTEM INSPECTION Charging System Test 8C 2 CHARGING SYSTEM PL ...

Страница 254: ...CHARGING SYSTEM CONTENTS page DIAGNOSIS AND TESTING CHARGING SYSTEM 2 PL CHARGING SYSTEM 8C 1 ...

Страница 255: ...DIAGNOSIS AND TESTING CHARGING SYSTEM INSPECTION Charging System Test 8C 2 CHARGING SYSTEM PL ...

Страница 256: ...OHC 15 CRANKSHAFT POSITION SENSOR 15 IGNITION COIL 13 IGNITION INTERLOCK 17 IGNITION SWITCH 16 LOCK CYLINDER HOUSING 17 LOCK KEY CYLINDER 17 MAP IAT SENSOR DOHC 16 MAP IAT SENSOR SOHC 16 POWERTRAIN CONTROL MODULE PCM 12 SPARK PLUG CABLE SERVICE 12 SPARK PLUG SERVICE 12 SPARK PLUG TUBES 13 THROTTLE POSITION SENSOR 16 SPECIFICATIONS FIRING ORDER 2 0L 18 IGNITION COIL 18 SPARK PLUG CABLE RESISTANCE D...

Страница 257: ...als recommended in Group 0 Spark plugs that have low mileage may be cleaned and reused if not otherwise defective Refer to the Spark Plug Condition section of this group After cleaning file the center electrode flat with a small point file or jewelers file Adjust the gap between the electrodes Fig 2 to the dimensions specified in the chart at the end of this section Always tighten spark plugs to t...

Страница 258: ...he oxygen sensors A buss bar in the Power Distribution Center PDC supplies voltage to the solenoid side and contact side of the relay The ASD relay power circuit contains a 20 amp fuse between the buss bar in the PDC and the relay The fuse also protects the power circuit for the fuel pump relay and pump The fuse is located in the PDC Refer to Group 8W Wiring Diagrams for circuit information The PC...

Страница 259: ...nkshaft angle position In each group of timing reference notches the first notch represents 69 degrees before top dead center BTDC The sec ond notch represents 49 degrees BTDC The third notch represents 29 degrees The last notch in each set represents 9 degrees before top dead center BTDC The timing reference notches are machined at 20 increments From the voltage pulse width the PCM tells the diff...

Страница 260: ...or also acts as a thrust plate to control camshaft endplay on SOHC engines COMBINATION ENGINE COOLANT TEMPERATURE SENSOR The coolant temperature sensor provides an input voltage to the PCM and a separate input voltage to the temperature gauge on the instrument panel The PCM determines engine coolant temperature from the coolant temperature sensor As coolant tempera ture varies the coolant temperat...

Страница 261: ...constantly vibrates and sends an input voltage signal to the PCM while the engine operates As the intensity of the crystal s vibration increase the knock sensor output voltage also increases NOTE Over or under tightening effects knock sen sor performance possibly causing improper spark control MANIFOLD ABSOLUTE PRESSURE SENSOR MAP The PCM supplies 5 volts to the MAP sensor The MAP sensor function ...

Страница 262: ...eeds the Airbag Control Module ACM LOCK KEY CYLINDER The lock cylinder is inserted in the end of the housing opposite the ignition switch The ignition key rotates the cylinder to 5 different detents Fig 16 Accessory Off lock Unlock On Run Start IGNITION INTERLOCK All vehicles equipped with automatic transaxles have an interlock system The system prevents shift ing the vehicle out of Park unless th...

Страница 263: ...tance must be between ranges shown in chart in specifcation section in this group Replace any cable not within tolerance 2 Disconnect the electrical connector from the coil pack 3 Measure the primary resistance of each coil At the coil connect an ohmmeter between the B pin and the pin corresponding to the cylinders in ques tion Fig 18 Resistance on the primary side of each coil should be 0 45 0 65...

Страница 264: ...y in the On posi tion before cranking Wait for the test light to flash once then crank the engine 6 If the test light momentarily flashes during cranking the PCM is not receiving a crankshaft posi tion sensor signal 7 If the test light did not flash during cranking unplug the crankshaft position sensor connector Turn the ignition key to the off position Turn the key to the On position wait for the...

Страница 265: ...ntire tip of the spark plug with a rust colored deposit The rust color deposits can be misdiagnosed as being caused by coolant in the combustion chamber Spark plug performance is not affected by MMT depos its COLD FOULING CARBON FOULING Cold fouling is sometimes referred to as carbon foul ing because the deposits that cause cold fouling are basically carbon Fig 21 A dry black deposit on one or two...

Страница 266: ...tion cleaned and reused CHIPPED ELECTRODE INSULATOR A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap Under certain conditions severe detonation also can separate the insulator from the center electrode Fig 25 Spark plugs with chipped electrode insulators must be replaced PREIGNITION DAMAGE Excessive combustion chamber temp...

Страница 267: ...t 1 2 turn and pulling straight up in a steady motion 1 Remove the spark plug using a quality socket with a rubber or foam insert 2 Inspect the spark plug condition Refer to Spark Plug Condition in this section INSTALLATION 1 To avoid cross threading start the spark plug into the cylinder head by hand 2 Tighten spark plugs to 28 N m 20 ft lbs torque 3 Install spark plug insulators over spark plugs...

Страница 268: ...ack The coil pack towers are numbered with the cylinder identification Be sure the ignition cables snap onto the towers AUTOMATIC SHUTDOWN RELAY The relay is located in the Power Distribution Cen ter PDC Fig 31 The PDC is located next to the battery in the engine compartment For the location of the relay within the PDC refer to the PDC cover for location Check electrical terminals for corrosion an...

Страница 269: ...ft position sensor mounting screws Remove sensor 4 Loosen screw attaching target magnet to rear of camshaft Fig 35 INSTALLATION The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft Fig 36 1 Install target magnet in end of camshaft Tighten mounting screw to 3 N m 30 in lbs torque 2 Install camshaft position sensor Tighten sensor mounting screws to 9...

Страница 270: ...t level drops below sensor Refer to Group 7 Cooling System 2 Disconnect coolant sensor electrical connector 3 Remove coolant sensor INSTALLATION 1 Install coolant sensor Tighten sensor to 18 6 N m 165 in lbs torque 2 Attach electrical connector to sensor 3 Fill cooling system Refer to Group 7 Cooling System COMBINATION ENGINE COOLANT TEMPERATURE SENSOR DOHC The coolant sensor threads into the inta...

Страница 271: ...n Through the hole in the lower shroud depress lock cylinder retaining tab and remove key cylinder Fig 41 3 Remove upper and lower shrouds from steering column 4 Disconnect electrical connectors from ignition switch 5 Remove ignition switch mounting screw Fig 42 with a 10 Torxt bit 6 Depress retaining tabs Fig 43 and pull igni tion switch from steering column INSTALLATION 1 Ensure the ignition swi...

Страница 272: ...e end of the housing To align the socket with the lock cylinder ensure the socket is in the Run position Fig 46 3 Align the lock cylinder with the grooves in the housing Slide the lock cylinder into the housing until the tab sticks through the opening in the hous ing 4 Turn the key to the Off position Remove the key 5 Connect negative cable to battery IGNITION INTERLOCK Refer to Group 21 Transaxle...

Страница 273: ... 200 in lbs Ignition Coil Bracket Nuts 22 N m 200 in lbs Knock Sensor 10 N m 90 in lbs MAP IAT Sensor Plastic Manifold 2 N m 20 in lbs MAP IAT Sensor Aluminum Manifold 3 N m 30 in lbs Spark Plugs 28 N m 20 ft lbs SPARK PLUG CABLE RESISTANCE SOHC SPARK PLUG CABLE RESISTANCE DOHC SPARK PLUG IGNITION COIL IGNITION COIL CONNECTOR FRONT OF ENGINE FIRING ORDER 1 3 4 2 CABLE RESISTANCE 1 4 3500 ohms 4900...

Страница 274: ...Coil Polarity WEASTEC SILVER TOW ERS PL IGNITION SYSTEM 8D 19 SPECIFICATIONS Continued ...

Страница 275: ......

Страница 276: ... m 80 in lbs Coolant Temp Sensor 18 6 N m 165 in lbs Ignition Coil to Cyl Head 11 9 N m 105 in lbs Knock Sensor 10 N m 90 in lbs MAP IAT Sensor Plastic Manifold 2 N m 20 in lbs MAP IAT Sensor Aluminum Manifold 3 N m 30 in lbs Spark Plugs 28 N m 20 ft lbs Throttle Position Sensor 2 N m 20 in lbs IGNITION COIL Coil Manufacture Primary Resistance at 21 C 27 C 70 F 80 F Secondary Resistance at 21 C 27...

Страница 277: ......

Страница 278: ... m 80 in lbs Coolant Temp Sensor 18 6 N m 165 in lbs Ignition Coil to Cyl Head 11 9 N m 105 in lbs Knock Sensor 10 N m 90 in lbs MAP IAT Sensor Plastic Manifold 2 N m 20 in lbs MAP IAT Sensor Aluminum Manifold 3 N m 30 in lbs Spark Plugs 28 N m 20 ft lbs Throttle Position Sensor 2 N m 20 in lbs IGNITION COIL Coil Manufacture Primary Resistance at 21 C 27 C 70 F 80 F Secondary Resistance at 21 C 27...

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Страница 280: ...ONSOLE 9 FRONT FOG LAMP SWITCH EXPORT 9 GAUGE 10 GLOVE BOX DOOR BIN 10 GLOVE BOX SWITCH LAMP 10 HEADLAMP LEVELING SWITCH EXPORT 10 HEADLAMP SWITCH 10 HEATER A C CONTROL BLOWER SWITCH 11 HEATER A C CONTROL LAMP 11 HEATER A C CONTROL 11 HEATER CONTROL BLOWER SWITCH 11 IGNITION KEY LAMP 11 INSTRUMENT PANEL 12 LEFT TRIM PANEL 14 ODOMETER 14 RADIO 14 REAR WINDOW DEFOGGER AND OR FOG LAMP SWITCH 14 REAR ...

Страница 281: ...tronically drive the speedometer odometer and gauges Fig 1 and Fig 2 GAUGES All gauges in the electronic clusters are the analog type gauges When the ignition switch is moved to the OFF position the cluster drives each gauge to its lowest position WARNING AND INDICATOR LAMPS The instrument cluster has warning lamps and indicators for the following systems Airbag Anti lock Brakes ABS if equipped Br...

Страница 282: ...u minate replace the switch REAR EXPORT 1 Remove the fog lamp switch Refer to Rear Window Defogger and or Fog Lamp Switch Removal 2 Using two jumper wires connect Pin 2 and Pin 4 of the switch to battery voltage 3 Using a test lamp connect the test lamp to Pin 3 as shown in Fig 6 Refer to Group 8W Wiring Diagrams for fog lamp switch circuit 4 Push the fog lamp switch button The test lamp should il...

Страница 283: ...age reading should change as the switch is rotated to each position If the voltage does not vary replace switch If OK test the headlamp leveling motors and or circuit to the motors HEADLAMP SWITCH TEST 1 Remove the headlamp switch Refer to Head lamp Switch Removal 2 Use a ohmmeter and check continuity between the terminals of the switch as shown in the Head lamp Switch Test Fig 8 HEATER A C BLOWER...

Страница 284: ... wire at the connector checks good pull the con nector loose from the switch and with a jumper wire ground the connector to the engine With the ignition switch turned to the ON position check the warning lamp If the lamp still fails to light inspect for a burned out lamp or disconnected socket in the clus ter MULTIPLE GAUGE INOPERATIVE TEST Test speedometer tachometer and other gauges for malfunct...

Страница 285: ...unit Remove the cluster and check for an open or short in the sending unit wiring The sending unit will be less than 1080 ohms and greater than 50 ohms depend ing upon fuel level If the sending unit wiring is open or a short circuit repair as necessary c If the sending unit wiring is OK replace the gauge assembly If the condition persists replace the cluster printed circuit board FUEL GAUGE INCORR...

Страница 286: ...rint circuit board TEMPERATURE GAUGE 1 Disconnect the coolant temperature sensor Fig 15 2 Turn ignition switch ON The temperature gauge should be at its lowest position Turn ignition switch OFF 3 Ground temperature gauge sending unit con nector Pin 3 Refer to Group 8W wiring Diagrams Turn ignition switch ON The temperature gauge should be at its highest position After the seat belt lamp goes out t...

Страница 287: ...the bottom access hole and disconnect the cigar lighter receptacle wiring connectors 3 Unscrew the cigar lighter receptacle shell from the receptacle and remove from the base instrument panel INSTALLATION For installation reverse the above procedures CLUSTER CAUTION Cluster MUST be stored in a face up position or damage will occur to the gauge opera tion REMOVAL 1 Disconnect the battery to ensure ...

Страница 288: ...n 2 Remove the left trim panel as necessary to remove the end cap attaching screws 3 Remove the end cap Installation For installation reverse the above procedures FLOOR CONSOLE REMOVAL 1 Remove the MTX shifter knob only 2 Remove the attaching screws from each side of the cup holder a Non armrest console Remove the two screws from the rear of the console Fig 19 b Armrest console Remove the four scr...

Страница 289: ...tery negative cable and isolate it or remove fuse 12 prior to removing the switch or wires may short to ground 2 Open the glove box and push the glove box sides inward allowing the door bumpers to clear and the box to tip forward 3 Reach inside the opening and squeeze the lamp switch retainers until they are disengage 4 Pull the switch lamp rearward and remove it Replace the lamp To replace the sw...

Страница 290: ...ull the control rearward and disconnect the wiring connector 9 Using a screwdriver disengage the cable attachment clips INSTALLATION For installation reverse the above procedures HEATER A C CONTROL BLOWER SWITCH The switch is not serviced replace heater A C con trol Refer to the Heater A C Control Removal and Installation HEATER A C CONTROL LAMP REMOVAL 1 Remove the Heater A C Control Refer to the...

Страница 291: ...he straight ahead position This will prevent clockspring dam age when the steering wheel rotates freely 10 Disconnect the steering column at the bottom slap together joint 11 Disconnect the ATX shifter interlock cable at the shifter if equipped 12 Disconnect the instrument panel wiring as required 13 Remove the four attaching screws at the cen ter floor pan bracket Fig 24 14 Remove the four attach...

Страница 292: ...ANEL TOP COVER BEZEL PASSENGER AIRBAG MOD ULE RIGHT TRIM PANEL INSTRUMENT PANEL ASSEMBLY HVAC GLOVE BOX DOOR BIN RADIO ASH RECEIVER STEERING COLUMN COVER STEERING COLUMN COVER LINER CENTER BEZEL CLUSTER LEFT TRIM PANEL PL INSTRUMENT PANEL AND SYSTEMS 8E 13 REMOVAL AND INSTALLATION Continued ...

Страница 293: ...odometer to dial and gauge assembly When setting the dial gauge and or cluster assembly down it must be face up or the gauge operation will be damaged INSTALLATION For installation reverse the above procedures Carefully place the dial and gauge assembly on the cluster and ensure that the odometer connector is placed through the board Install with a slight rock ing motion to ensure the pins on gaug...

Страница 294: ... off the shifter shaft INSTALLATION For installation reverse the above procedures MTX SHIFTER REMOVAL 1 Pull the top part of the boot down until the two tabs at the bottom of the knob are exposed 2 Release the locking tabs from the pins on the shifter shaft 3 Pull up until the knob slides off the shifter shaft INSTALLATION For installation reverse the above procedures STEERING COLUMN COVER REMOVAL...

Страница 295: ...OVAL 1 Use care not to scratch the panel Lift up on the bottom outer areas of the cluster bezel and along the rearward edge of the top cover to disengage the clips Fig 29 2 Pull the top cover and cluster bezel rearward until the forward pins disengage from the instrument panel INSTALLATION For installation reverse the above procedures Position spring clips to instrument panel and push firmly until...

Страница 296: ...he socket from the lens Replace as necessary INSTALLATION For installation reverse the above procedures VEHICLE SPEED SENSOR REMOVAL 1 Remove the harness connector from the sensor and make sure the weather seal is on the harness connector 2 Remove the sensor retaining bolt 3 Pull the sensor and pinion gear assembly out of transaxle If necessary carefully pry it loose with a flat blade tool Fig 31 ...

Страница 297: ...8E 18 INSTRUMENT PANEL AND SYSTEMS PL REMOVAL AND INSTALLATION Continued ...

Страница 298: ...this rule have been clearly identified as LHD RHD or Export if a special illustration or procedure is required DESCRIPTION AND OPERATION INTERFERENCE ELIMINATION The radio utilizes a ground wire plugged on to a blade terminal and is bolted to the radio chassis Both connector and terminal should be securely attached The engine has two separate ground straps to suppress ignition noise which may inte...

Страница 299: ...ION SET VOLUME TO LISTEN ING LEVEL NO YES DO YOU HEAR AUDIO NOISE STATIC ONLY AM INOPERATIVE FM INOPERATIVE AM TAPE OK TAPE ONLY INOPERATIVE AM FM OK COMPACT DISC PLAYER CD INOPERATIVE AM FM OK RUN STATIC NOISE CHECK RUN ONLY AM INOPERATIVE ANTENNA SYSTEM CHECK EXCHANGE RADIO RUN TAPE SYSTEM CHECK RUN CD SYSTEM CHECK CHECK FUSE S IGNITION MEMORY FEED NO ARE ALL SPEAKERS DIS TORTED OR INOPERATIVE Y...

Страница 300: ...O ABOVE DIAGRAM FOR SPEAKER PLUS AND MINUS TERMINALS PLACE ONE LEAD OF THE OHMME TER TO PLUS TERMINAL AND THE OTHER LEAD TO GROUND SWITCH THE LEAD TO THE MINUS TERMI NAL TEST RESISTANCE BETWEEN THE SPEAKER PLUS AND MINUS TERMI NALS FOR A READING OF 3 TO 12 OHMS NO DOES ANY CIRCUIT SHOW RESISTANCE YES REPAIR AS NECESSARY CHECK SPEAKER CONNEC TOR FOR A LOOSE CONNECTIONS B BROKEN WIRES C CORROSION NO...

Страница 301: ...ISE CHECK THE FOL LOWING A ELECTRIC FUEL PUMP B IGNITION SYSTEM FAULTS C CHECK GROUND CONNECTIONS D CHECK ANTENNA MOUNTING NO IS THERE STATIC NOISE YES EXCHANGE RADIO CHECK ANTENNA CONNECTIONS REPAIR AS NECESSARY NO CONDITION OK YES USING A TEST ANTENNA CHECK RECEPTION EXCHANGE RADIO NO CONDI TION OK YES REPLACE OR REPAIR DEFECTIVE ANTENNA OR LEAD 8F 4 AUDIO SYSTEM PL DIAGNOSIS AND TESTING Continu...

Страница 302: ...HEAD CLEANER NO YES OBSTRUCTION FOUND IF NOT OK EXCHANGE UNIT TRY A KNOWN GOOD TAPE REPAIR AS NECESSARY NO YES PLAYS OK EXCHANGE UNIT ADVISE OWNER OF WORN OR DEFECTIVE TAPE NO YES PLAYS OK LOSS OF HIGH FREQUENCY CLEAN WITH WET HEAD CLEANER ADVISE OWNER OF WORN OR DEFECTIVE TAPE EXCHANGE UNIT NO EJECT Do Not Force Removal of Jammed Cassette EXCHANGE UNIT PL AUDIO SYSTEM 8F 5 DIAGNOSIS AND TESTING C...

Страница 303: ...TS OR MORE NO INSPECT CHARGING SYSTEM RETEST RADIO YES EXCHANGE UNIT IS CD SCRATCHED YES REPLACE DAM AGED CD NO IS CD DIRTY OR CONTAMINATED YES GENTLY CLEAN WITH A SOFT CLOTH FROM CENTER TO EDGE DO NOT SPRAY WITH ANY SOLVENTS OR CLEANERS USE CAUTION NO CD WILL SKIP AS A RESULT OF EXTREME BUMPS OR EXCESSIVE VIBRATION IF ALL OTHER POS SIBILITIES ARE ELIMINATED EXCHANGE UNIT NOTE THE CD PLAYER WILL O...

Страница 304: ...l megohms between the ground shell of the connector and radio end pin 3 Continuity should be observed between the ground shell of the connector and the mounting bracket Wiggle cable over its entire length to reveal intermittent short or open circuits dur ing step 1 2 and 3 REMOVAL AND INSTALLATION ANTENNA REMOVAL 1 Remove antenna mast by unscrewing mast from antenna body Fig 3 or Fig 4 2 Locate th...

Страница 305: ... bezel Fig 8 Refer to Group 8E Instrument Panel and Systems for removal procedures 2 Remove speaker retaining screws 3 Remove speaker and disconnect wire connector INSTALLATION For installation reverse the above procedures Fig 3 Antenna Mast Removal ANTENNA MAST ANTENNA ADAPTER Fig 4 Antenna Mast Removal Export ANTENNA MAST ANTENNA ADAPTER Fig 5 Antenna Mounting ANTENNA ADAPTER RIGHT FRONT FENDER ...

Страница 306: ... Pry out the seat belt trim bezel along the rear ward edge 3 Partially remove the shelf trim panel slipping it down to the seat back position 4 Remove four speaker retaining screws Fig 10 5 Remove speaker and disconnect wire connector INSTALLATION For installation reverse the above procedures Posi tion speakers so that the wire connectors are point ing to the drivers side of car Tighten the seat b...

Страница 307: ......

Страница 308: ...affected vehicle components have been constructed as mirror image of the LHD versions While most of the illustrations used in this group represent only the LHD version the diagnostic and service procedures outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD RHD or Export if a special illustration or procedure is required HORN SWITCH The h...

Страница 309: ...g voltmeter test voltage at a Circuit 62 and 66 test for battery voltage from fuse C to body ground b If voltage is incorrect repair as necessary Refer to Group 8W Wiring Diagrams 5 Check relay for 70 to 75 ohms resistance from terminal 85 to 86 Fig 4 If resistance not OK replace relay HORN SWITCH 1 Remove horn relay from the Power Distribution Center 2 Using ohmmeter connect one lead to ground an...

Страница 310: ... responsible or a defective horn switch allowed the horn to burn out is responsible If the fuse is OK test horn relay refer to Horn Relay Test If the relay is OK test horn refer to Horn Test CAUTION Continuous sounding of horn may cause horn relay to fail Should the horn sound continuously Unplug the horn relay from Power Distribution Center Refer to Horn Relay Test Refer to Group 8W wiring Disgra...

Страница 311: ...e connector repair as necessary 2 Replace Driver Airbag Module 3 Replace Driver Airbag Module Horn does not sound 1 Check fuse 23 in PDC 2 No Voltage at horn RELAY TERMINALS 62 66 and fuse is OK 3 Open circuit from terminal 65 of the horn relay to horn switch X3 circuit 4 Defective or damaged horn 5 Defective horn switch 1 Replace fuse if blown repair as necessary 2 No voltage repair PDC as necess...

Страница 312: ... not touch bumper reinforcement or the sound output may be altered HORN RELAY REMOVAL 1 Remove the Power Distribution Center cover and locate the horn relay 2 Remove the horn relay Fig 5 INSTALLATION For installation reverse the above procedures HORN SWITCHES The Horn Switch is part of the Driver Airbag Mod ule Refer to Driver Airbag Module Removal and Installation procedures in Group 8M Fig 7 Hor...

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Страница 314: ... SENSOR 11 GENERAL INFORMATION INTRODUCTION The speed control system is electronically con trolled and vacuum operated The electronic control is integrated into the powertrain control module which is located in the engine compartment The con trols are located on the steering wheel and consist of five switches The ON and OFF buttons are located on the left side of the airbag module The RESUME ACCEL...

Страница 315: ...fficient of friction between the road surface and tires is extremely low An rpm increase without a VSS signal increase indicates that the clutch has been disengaged Excessive engine rpm indicates that the trans mission may be in a low gear The VSS signal decreases at a rate of 10 mph per second indicates that the vehicle may have decelerated at an extremely high rate If the actual speed is not wit...

Страница 316: ...ear the transmission out put shaft The sensor is driven through the adapter by a speedometer pinion gear The VSS pulse signal to the speedometer odometer is monitored by the PCM speed control circuitry to determine vehicle speed and to maintain speed control set speed Refer to the appropriate Powertrain Diagnostic Procedures manual for diagnosis and testing of this component Refer to Group 14 Fuel...

Страница 317: ...tinuity of pin 1 to ground to test for intermittent short Wiggle wires while preforming test 4 If continuity to ground repair wiring 5 If no continuity to ground replace PCM SPEED CONTROL SLOWS DOWN BY ITSELF Test vehicle speed sensor refer to group 8E If sen sor fails replace sensor if it passes perform the fol lowing test 1 Perform the speed control switch test on the SET COAST switch if it fail...

Страница 318: ...or and pin 41 of the PCM 40 way connector Wiggle wires while preforming test If no continuity repair circuit 5 If continuity disconnect the servo connector Test continuity from pin 2 of connector and ground to test for intermittent short Wiggle wires while pre forming test If continuity repair circuit 6 If no continuity conduct the servo vacuum test If it fails replace servo 7 If it passes replace...

Страница 319: ...SUME ACCEL SET COAST CANCEL ON OFF VACUUM SOURCE VACUUM RESERVOIR VACUUM LINE S C CABLE T C CAM THROTTLE BODY BRAKE LAMP SWITCH SPEED CONTROL VACUUM SOLENOID V35 SPEED CNT VENT V36 SPEED CNT VAC K29 BRAKE SWITCH SIGNAL SPEED CNT MODE SELECT SIGNAL 8H 6 VEHICLE SPEED CONTROL SYSTEM PL DIAGNOSIS AND TESTING Continued ...

Страница 320: ...uum nipple and apply 10 15 inches of vacuum 6 If servo pulls cables replace servo 7 Ground Pin 1 on servo 8 Check that the throttle cable pulls in and holds as long as the vacuum pump is connected After one minute check if cable is still holding If cable does not hold replace the servo 9 Disconnect jumper from pin 3 Cable should return to rest position If not replace servo 10 Connect 4 way electri...

Страница 321: ...switch refer to Stop Switch Removal Installation in this section Discon nect connector from stop lamp switch Fig 8 Using an ohmmeter switch continuity may be checked as follows 2 With switch plunger released there should be continuity between Pin 5 and Pin 6 3 With switch plunger depressed there should be continuity Between Pin 1 and Pin 2 Between Pin 3 and Pin 4 4 If the above results are not obt...

Страница 322: ...lamp switch and ground When the pedal is depressed the meter should show open circuit If no continuity repair as necessary If OK go to step 8 10 Using an ohmmeter touch one lead to a ground and touch the other lead to pin 76 The meter should show no continuity when transmission is in DRIVE and continuity when in PARK or NEUTRAL If not test Neutral Start and Back Up switch using scan tool VACUUM SU...

Страница 323: ...seated in the hole rotate clockwise approximately 30 degrees to lock into place The switch will automatically adjust when the pedal is released Pull back on the pedal to assure correct adjustment SPEED CONTROL SERVO CABLE REMOVAL 1 Remove throttle control shield 2 Remove throttle clasp from the throttle body lever 3 Remove speed control cable from throttle lever by sliding clasp out hole used for ...

Страница 324: ... to 5 N m 44 in lbs 2 Install vacuum hoses 3 Lower vehicle VEHICLE SPEED SENSOR For Removal Installation refer to Vehicle Speed Sensor in Group 21 Transaxle Fig 13 Throttle Cable Attachment to Throttle Body Manual Transmission SPEED CONTROL CABLE THROTTLE CABLE THROTTLE LEVER Fig 14 Throttle Cable Attachment to Throttle Body Automatic Transmission SPEED CON TROL CABLE THROTTLE CABLE TRANSMISSION K...

Страница 325: ......

Страница 326: ...to the front of battery tray 7 Remove top two battery tray fasteners Loosen bottom two battery tray fasteners 8 Slide battery tray up disconnect speed control servo wiring and vacuum harness from servo Fig 1 9 Remove attaching nuts and remove speed con trol assembly from bottom of battery tray INSTALLATION 1 For installation reverse above procedures The servo wiring connector should point towards ...

Страница 327: ......

Страница 328: ...to the front of battery tray 7 Remove top two battery tray fasteners Loosen bottom two battery tray fasteners 8 Slide battery tray up disconnect speed control servo wiring and vacuum harness from servo Fig 1 9 Remove attaching nuts and remove speed con trol assembly from bottom of battery tray INSTALLATION 1 For installation reverse above procedures The servo wiring connector should point towards ...

Страница 329: ......

Страница 330: ... the switch returns to the OFF position as soon as the lever is released When the system is activated one of two indicator lamps mounted in the instrument cluster flashes in unison with the turn signal lamps indicating to the driver that the system is operating NOTE This group covers both Left Hand Drive LHD and Right Hand Drive RHD versions of this model Whenever required and feasible the RHD ver...

Страница 331: ...n feed wire to switch 4 faulty contact in switch 5 Open or grounded circuit in wiring to external lamps 1 Replace fuse 2 Replace flasher 3 Repair wiring harness Check connectors 4 Replace multi function switch 5 Repair wiring harness Indicator lamp illuminates brightly external lamp does not light 1 Open circuit in wire to external lamp 2 Burned out lamp 1 Repair wiring harness 2 Replace lamp Syst...

Страница 332: ...cable 2 Remove both upper and lower steering column shrouds 3 Remove multi function switch mounting screws Fig 4 INSTALLATION For installation reverse the above procedures Tighten multi function switch to column retain ing screws to 2 N m 17 in lbs torque Tighten steering column cover retaining screws to 2 N m 17 in lbs torque Fig 2 Turn Signal and Hazard Switch Continuity H RIGHT REAR I LEFT FRON...

Страница 333: ......

Страница 334: ... delay mode has a range of 1 to 15 seconds Pulse wipe is accomplished by momentarily moving the stalk lever into the WASH position while the wiper switch is in either OFF or DELAY position The wiper blades then sweep once or twice and return to the previous wiper switch mode OFF or DELAY The intermittent wiper function is integral to the wiper switch All electronics and relay are inside the switch...

Страница 335: ... the positive jumper wire to terminal 1 of the motor connector Connect the negative jumper wire to the motor ground strap a If motor does not run high or low speed go to Step 4 b If motor runs go to Step 5 4 Using an ohmmeter check for good ground at the motor ground strap If OK replace motor If not repair the ground circuit as necessary 5 Check terminal E of wiper switch connector for continuity ...

Страница 336: ...URNED OFF WIPERS STOP WHEREVER THEY ARE WITHOUT RETURNING TO PARK POSITION 1 Check at motor ground strap for a good ground 2 Turn ignition switch OFF Using an ohmmeter with the motor in the park position check for conti nuity between terminal 3 and ground strap If conti nuity replace wiper switch If no continuity repair wiring as necessary WIPERS DO NOT OPERATE WHEN WASHER MOTOR IS ENGAGED PULSE W...

Страница 337: ...ow high and intermittent position 2 Ensure park switch has clean ground Wiper blades slap against cowl screen or window moldings 1 Wiper arms are parked incorrectly 1 Park wiper arms Refer to Wiper Arm Adjustment Blades chatter 1 Foreign substance such as polish on glass or blades 2 Arms twisted blade at wrong angle on glass 3 Blade structure bent 4 Blade element has permanent set 1 Clean glass an...

Страница 338: ...ssembly from arm by pushing release tab under arm tip and slide blade away from arm tip Fig 6 and Fig 7 3 Gently place wiper arm tip on glass surface INSTALLATION For installation reverse above procedures WIPER BLADE ELEMENT REMOVAL 1 Lift wiper arm to raise blade off glass 2 Remove blade assembly from arm by pushing release tab under arm tip and slide blade away from arm tip Fig 6 and Fig 7 Gentl...

Страница 339: ...move wiper module refer above 2 Remove linkage from motor crank Insert screwdriver between crank and linkage then twist the screwdriver and lift straight up on linkage 3 Remove motor mounting screws and remove motor INSTALLATION For installation add unilube grease to socket and reverse the above procedures Tighten the motor mounting screws to 5 to 6 N m 45 to 55 in lbs torque Tighten drive link nu...

Страница 340: ...the wind shield If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper s the wiper blade is not roll ing over center If this condition exists refer to the Wiper Arm Alignment paragraph of this group ADJUSTMENTS WIPER ARM ADJUSTMENT 1 Cycle the wiper motor into the PARK position 2 Lift the wiper blade off the windshield and release it 3 T...

Страница 341: ...l operate the wipers and washer motor pump continuously until the washer button is released Releasing the button will stop the washer pump but the wipers will complete the current wipe cycle Followed by an average of two more wipe cycles 61 before the wipers park and the module turns off Whenever a windshield washer malfunction occurs first verify that the windshield washer wire harness is properl...

Страница 342: ... RESERVOIR REMOVAL 1 Remove filler neck Fig 5 2 Raise vehicle on hoist 3 Disconnect the wire connector from the reser voir pump Fig 6 4 Disconnect the washer hose at the pump and drain the reservoir 5 Remove fastener from reservoir 6 Remove the reservoir through fender opening INSTALLATION For installation reverse the above procedures Tighten the reservoir screw to 2 2 to 3 3 N m 20 to 29 in lbs t...

Страница 343: ...Gently pry pump away from reservoir and out of grommet Care must be taken not to puncture res ervoir Fig 7 5 Remover rubber grommet from reservoir and throw away INSTALLATION For installation reverse the above procedures Fig 6 Reservoir Removal SLIDE TAB TO FREE RESER VOIR ATTACHING SCREW Fig 7 Washer Pump 8K 10 WINDSHIELD WIPERS AND WASHERS PL REMOVAL AND INSTALLATION Continued ...

Страница 344: ...ower than indicated in the Bulb Application table at the end of this group Damage to lamp can result Do not use fuses circuit breakers or relays hav ing greater amperage value than indicated on the fuse panel or in the Owners Manual When it is necessary to remove components to ser vice another it should not be necessary to apply excessive force or bend a component to remove it Before damaging a tr...

Страница 345: ...ng all of the fuses and circuit breakers in the system Refer to Group 8W Wiring Diagrams Conventional and halogen headlamps are inter changeable It is recommended that they not be intermixed on a given vehicle 8L 2 LAMPS PL DIAGNOSIS AND TESTING Continued ...

Страница 346: ...GINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system refer to Group 8A 2 Poor headlamp circuit ground 2 Test voltage drop across Z1 ground refer to Group 8W 3 High resistance in headlamp circuit 3 Test amperage draw of headlamp circuit 4 Both headlamp bulbs defective 4 Replace both headlamp bulbs HEADLAMPS FLASH RANDOMLY 1 Poor headlamp circuit ground 1 Repair...

Страница 347: ...ces refer to Group 8W FOG LAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system refer to Group 8A 2 Poor fog lamp circuit ground 2 Test voltage drop across Z1 ground refer to Group 8W 3 High resistance in fog lamp circuit 3 Test amperage draw of fog lamp circuit 4 Both fog lamp bulbs defective 4 Replace both fog lamp bulbs FOG LAMPS FLASH R...

Страница 348: ...he line placement 4 Rock vehicle side to side three times to allow suspension to stabilize 5 Jounce front suspension three times by pushing downward on front bumper and releasing 6 Measure the distance from the center of head lamp lens to the floor Transfer measurement to the alignment screen with tape Use this line for up down adjustment reference 7 Measure distance from the centerline of the veh...

Страница 349: ...N TER LINE FLOOR TO CENTER OF HEADLAMP FRONT OF HEADLAMP 7 62 METERS 25 FT Fig 2 Lamp Alignment Screen CENTER LINE OF VEHICLE FLOOR TO CENTER FOG LAMP 4 INS FOG LAMP HOT SPOT FRONT OF FOG LAMP 7 62 METERS 25 FT CENTER LINE OF FOG LAMPS 8L 6 LAMPS PL SPECIAL TOOLS Continued ...

Страница 350: ...SPECIAL TOOLS SPECIAL TOOLS HEADLAMP ALIGNMENT Headlamp Aiming Kit C 4466 A PL LAMPS 8L 7 ...

Страница 351: ...ss of halogen bulbs with fingers or other possibly oily surface reduced bulb life will result Reverse the preceding operation FOG LAMP BULB REMOVAL 1 Remove fog lamp from behind fascia 2 Disengage wire connector from fog lamp bulb base 3 Remove bulb from lamp Fig 2 INSTALLATION CAUTION Do not touch the glass of halogen bulbs with fingers or other possibly oily surface reduced bulb life will result...

Страница 352: ...parate trunk lining from rear closure panel to gain access to back of tail lamp 3 Rotate and remove bulb socket from tail lamp through openings in rear closure panel Fig 6 4 Pull bulb from socket INSTALLATION 1 Push bulb into socket 2 Rotate and install bulb socket into tail lamp through openings in rear closure panel 3 Install trunk lining to rear closure panel 4 Close and secure trunk lid Fig 3 ...

Страница 353: ...Grasp bulb and pull from lamp socket INSTALLATION 1 Position bulb in socket and snap into place 2 Position lens on lamp and snap into place VISOR VANITY LAMP BULB REMOVAL 1 Lower visor 2 Insert a small flat bladed tool between the lamp lens and lamp 3 Carefully pry lens outward 4 Remove bulb from socket INSTALLATION 1 Position bulb in socket and snap into place 2 Position lens on lamp and snap int...

Страница 354: ...e to upper crossmember Fig 1 6 Disengage wire connector from headlamp and parking lamp sockets 7 Separate headlamp module from vehicle INSTALLATION Reverse the preceding operation FOG LAMP REMOVAL 1 Remove bolt holding fog lamp to radiator clo sure panel Fig 2 2 Separate fog lamp from radiator closure panel 3 Pull fog lamp through opening in fascia 4 Disengage wire connector from fog lamp bulb bas...

Страница 355: ... INSTALLATION Reverse the preceding operation TAIL STOP AND TURN SIGNAL LAMP REMOVAL 1 Release trunk latch and open trunk lid 2 Remove trunk trim panel from tail lamp area if equipped 3 Remove sockets and bulbs from lamp 4 Remove nuts holding tail lamp to rear closure panel Fig 6 5 Separate tail lamp from vehicle INSTALLATION Reverse the preceding operation Fig 3 Park and Turn Signal Lamp PARK AND...

Страница 356: ...pport and close hood DOME LAMP REMOVAL 1 Insert a trim stick between the headliner and dome lamp lens 2 Carefully pry downward on the four corners of the lamp lens 3 Separate lamp lens from lamp 4 Disengage wire connector and remove from vehicle INSTALLATION Reverse the removal procedure VISOR VANITY LAMP The visor vanity lamp is incorporated in the visor assembly Replace the visor if the lamp has...

Страница 357: ...t brace on the underside of the instrument panel Fig 1 REMOVAL 1 Remove screw attaching DRL module to I P support brace 2 Disengage wire connector 3 Separate module from vehicle INSTALLATION 1 Engage DRL module wire connector 2 Position module on I P support brace and install screw Fig 1 DRL Module INSTRU MENTPANEL CIGAR LIGHTER SUPPORT BRACKET DAYTIME RUNNING LAMP MODULE 8L 14 LAMPS PL ...

Страница 358: ...h fingers or other oily sur faces Bulb life will be reduced EXTERIOR LAMPS LAMP BULB Back up 3157 Center High Mounted Stop 921 Fog GE 881 Headlamp 9007 License Plate 168 Park Turn Signal 3157NA Tail Stop Turn Signal 3157 Front Side Marker 168 INTERIOR LAMPS Service procedures for most of the lamps in the instrument panel Instrument cluster and switches are located in Group 8E Instrument Panel and ...

Страница 359: ......

Страница 360: ...his vehicle is equipped with a remote headlamp leveling system This system allows the driver to adjust the vertical headlamp aim from the interior of the vehicle to compensate for passenger or cargo load A headlamp leveling switch is located in the instrument panel and controls the headlamp leveling motor and leveling cable found mounted to the upper radiator crossmember behind the headlamp module...

Страница 361: ...TER LAMP BULB 4 REMOVAL AND INSTALLATION HEADLAMP BULB REMOVAL 1 Release hood latch and open hood 2 Remove headlamp module from vehicle 3 Remove rubber seal boot Fig 1 4 Disengage retaining ring from headlamp Fig 2 5 Pull headlamp bulb from back of headlamp Fig 3 Fig 1 Rubber Boot Seal Fig 2 Headlamp Bulb Retaining Ring Fig 3 Headlamp Bulb 8L 2 LAMPS PL ...

Страница 362: ... into socket 2 Insert socket into back of headlamp 3 Rotate front turn signal socket clockwise one quarter turn 4 Install front turn signal lamp onto vehicle 5 Verify lamp operation CITYLIGHT LAMP BULB REMOVAL 1 Pull citylight lamp socket from rubber bushing in headlamp housing Fig 5 2 Rotate and pull bulb from socket Fig 6 INSTALLATION 1 Position citylight lamp bulb to lamp socket 2 Push and twis...

Страница 363: ... REPEATER LAMP BULB REMOVAL 1 Push lamp rearward 2 While pushing lamp pry forward edge of lamp away from car 3 Pull lamp from hole 4 Pull rubber boot away from lamp housing 5 Rotate and pull bulb from socket INSTALLATION 1 Align side repeater lamp bulb to socket 2 Push and twist bulb into socket 3 Push rubber boot over lamp housing 4 Position side repeater lamp assembly to hole in fender NOTE The ...

Страница 364: ...rom motor bracket 8 Separate leveling motor and bracket from vehicle 9 From between front fascia and headlamp mod ule remove bolt holding outboard end of module to fender 10 Remove bolts holding inboard end of module to radiator closure panel 11 Remove bolts holding top of module to upper crossmember Fig 1 12 Disengage wire connector from headlamp and parking lamp sockets 13 Separate headlamp modu...

Страница 365: ...ng motor arm 5 Install plastic locking cap to hold leveling cable into motor arm 6 Install bolts to hold headlamp leveling motor to upper radiator crossmember 7 Engage wire connector to headlamp leveling motor FOG LAMP REMOVAL 1 Remove nut holding fog lamp to radiator cross member Fig 4 2 Separate fog lamp from radiator crossmember 3 Pull fog lamp through opening in fascia 4 Disengage fog lamp wir...

Страница 366: ...1 Position Repeater Lamp Assembly in mounting hole NOTE The metal clip on the Repeater Lamp Assembly should be opposite from notch in fender hole 2 Compress metal clip by pushing Repeater Lamp Assembly rearward 3 While pushing Repeater Lamp Assembly rear ward push lamp into fender hole 4 Ensure that Repeater Lamp Assembly is firmly attatched to body PL LAMPS 8L 7 REMOVAL AND INSTALLATION Continued...

Страница 367: ...aminated with oil clean bulb with denatured alcohol or ammonia based sol vent SPECIFICATIONS EXTERIOR LAMPS LAMP BULB Back up P21W Center High Mounted Stop 921 Front Fog Lamp H 3 Headlamp H 4 License Plate W5W Front Turn Signal P21 5W Tail Stop P21 5W Rear Turn Signal P21W Rear Fog Lamp P21W Citylight T4W Side Repeater T4W INTERIOR LAMPS LAMP BULB ABS PC194 Airbag PC194 Ash Tray 161 Brake Warning ...

Страница 368: ...his vehicle is equipped with a remote headlamp leveling system This system allows the driver to adjust the vertical headlamp aim from the interior of the vehicle to compensate for passenger or cargo load A headlamp leveling switch is located in the instrument panel and controls the headlamp leveling motor and leveling cable found mounted to the upper radiator crossmember behind the headlamp module...

Страница 369: ...TER LAMP BULB 4 REMOVAL AND INSTALLATION HEADLAMP BULB REMOVAL 1 Release hood latch and open hood 2 Remove headlamp module from vehicle 3 Remove rubber seal boot Fig 1 4 Disengage retaining ring from headlamp Fig 2 5 Pull headlamp bulb from back of headlamp Fig 3 Fig 1 Rubber Boot Seal Fig 2 Headlamp Bulb Retaining Ring Fig 3 Headlamp Bulb 8L 2 LAMPS PL ...

Страница 370: ... into socket 2 Insert socket into back of headlamp 3 Rotate front turn signal socket clockwise one quarter turn 4 Install front turn signal lamp onto vehicle 5 Verify lamp operation CITYLIGHT LAMP BULB REMOVAL 1 Pull citylight lamp socket from rubber bushing in headlamp housing Fig 5 2 Rotate and pull bulb from socket Fig 6 INSTALLATION 1 Position citylight lamp bulb to lamp socket 2 Push and twis...

Страница 371: ... REPEATER LAMP BULB REMOVAL 1 Push lamp rearward 2 While pushing lamp pry forward edge of lamp away from car 3 Pull lamp from hole 4 Pull rubber boot away from lamp housing 5 Rotate and pull bulb from socket INSTALLATION 1 Align side repeater lamp bulb to socket 2 Push and twist bulb into socket 3 Push rubber boot over lamp housing 4 Position side repeater lamp assembly to hole in fender NOTE The ...

Страница 372: ...rom motor bracket 8 Separate leveling motor and bracket from vehicle 9 From between front fascia and headlamp mod ule remove bolt holding outboard end of module to fender 10 Remove bolts holding inboard end of module to radiator closure panel 11 Remove bolts holding top of module to upper crossmember Fig 1 12 Disengage wire connector from headlamp and parking lamp sockets 13 Separate headlamp modu...

Страница 373: ...ng motor arm 5 Install plastic locking cap to hold leveling cable into motor arm 6 Install bolts to hold headlamp leveling motor to upper radiator crossmember 7 Engage wire connector to headlamp leveling motor FOG LAMP REMOVAL 1 Remove nut holding fog lamp to radiator cross member Fig 4 2 Separate fog lamp from radiator crossmember 3 Pull fog lamp through opening in fascia 4 Disengage fog lamp wir...

Страница 374: ...1 Position Repeater Lamp Assembly in mounting hole NOTE The metal clip on the Repeater Lamp Assembly should be opposite from notch in fender hole 2 Compress metal clip by pushing Repeater Lamp Assembly rearward 3 While pushing Repeater Lamp Assembly rear ward push lamp into fender hole 4 Ensure that Repeater Lamp Assembly is firmly attatched to body PL LAMPS 8L 7 REMOVAL AND INSTALLATION Continued...

Страница 375: ...aminated with oil clean bulb with denatured alcohol or ammonia based sol vent SPECIFICATIONS EXTERIOR LAMPS LAMP BULB Back up P21W Center High Mounted Stop 921 Front Fog Lamp H 3 Headlamp H 4 License Plate W5W Front Turn Signal P21 5W Tail Stop P21 5W Rear Turn Signal P21W Rear Fog Lamp P21W Citylight T4W Side Repeater T4W INTERIOR LAMPS LAMP BULB ABS PC194 Airbag PC194 Ash Tray 161 Brake Warning ...

Страница 376: ... GLASSES RUBBER GLOVES AND LONG SLEEVES CLOTHING WHEN CLEANING POWDER RESIDUE FROM VEHICLE AFTER AIRBAG DEPLOYMENT SODIUM HYDROXIDE POWDER RESIDUE EMITTED FROM A DEPLOYED AIRBAG CAN CAUSE SKIN IRRITATION FLUSH AFFECTED AREA WITH COOL WATER IF IRRITATION IS EXPE RIENCED IF NASAL OR THROAT IRRITATION IS EXPERIENCED EXIT THE VEHICLE FOR FRESH AIR UNTIL THE IRRITATION CEASES IF IRRITATION CONTINUES SE...

Страница 377: ...SASSEMBLE THE DRIVER OR PASSENGER AIRBAG MODULE THERE ARE NO SERVICEABLE PARTS WITH IN THE MODULES The Driver Airbag Module located on the steering wheel is the most visible part of the system Fig 2 The airbag module contains a housing to which the cushion inflator and cover are attached to The driver side inflator assembly is mounted from the back of the module housing When supplied with the prop...

Страница 378: ...C outlets Multiple vacuum cleaning may to necessary to decontaminate the interior of the vehicle NOTE Dispose deployed airbag properly contact dealer or government agency for disposal recom mendations SERVICE OF DEPLOYED AIRBAG MODULE DRIVER AIRBAG After a Driver Airbag Module has been deployed Driver Airbag Module Clockspring assembly The component above must be replaced because they cannot be re...

Страница 379: ...OUND CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTALLATION PROCEDURE THIS WILL DISABLE THE AIRBAG SYSTEM FAILURE TO DISCONNECT BATTERY COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY ALLOW SYSTEM CAPACITOR TO DISCHARGE FOR 2 MINUTES BEFORE REMOVING ANY AIRBAG COMPONENTS CAUTION Failure to follow the parking brake ser vice procedures can result in dama...

Страница 380: ...10 Remove wiring harness electrical connector for brake warning light from park brake lever Fig 10 11 Remove the two nuts Fig 11 attaching park brake lever to console bracket Remove park brake lever mechanism from vehicle 12 Remove module mounting nuts and remove module Fig 12 13 Disconnect ACM 4 way and 13 way connectors Fig 13 14 Remove Airbag Control Module INSTALLATION 1 Connect both ACM conne...

Страница 381: ... lever mechanism to correctly adjust the park brake cables 8 Connect electrical connector for brake warning lamp onto terminal on park brake lever assembly Fig 17 9 Cycle park brake lever once to position park brake cables Then return the park brake lever its released position Check the rear wheels of the vehi cle They should rotate freely without dragging 10 Raise park brake lever to its fully en...

Страница 382: ...LY REMOVE FROM PARK BRAKE LEVER ASSEMBLY PARK BRAKE LEVER ASSEM BLY PARK BRAKE ASSEMBLY OUT PUT CABLE CONSOLE BRACKET Fig 17 Brake Warning Lamp Connection To Park Brake Lever PARK BRAKE MECH ANISM PARK BRAKE LEVER WARN ING LAMP CONNECTOR WIRING HARNESS CONNEC TOR Fig 18 Attaching Screws At Rear Of Center Console With Without Arm Rest CENTER CONSOLE ASSEMBLY PARK BRAKE HAND LEVER PAS SENGER SEAT AT...

Страница 383: ...aired and must be replaced if faulty 11 Rotate clockspring rotor a half turn 180 degrees to the left counter clockwise 12 Lock the clockspring rotor in the center posi tion as follows Insert a paper clip wire through the hole in the rotor at the 10 O clock position and bend to prevent it from falling out INSTALLATION 1 Confirm that The steering wheel position is a half turn 180 degrees to the righ...

Страница 384: ...e INSTALLATION For installation reverse the above procedures 1 Connect the squib wire to the module Make airbag connection by pressing straight in on the con nector The connector should be fully seated feel for positive snap to assure positive connection 2 Connect the horn wire 3 Install two bolts and tighten to 10 to 11 N m 90 to 100 in lbs torque 4 Install covers to the steering wheel armature o...

Страница 385: ...ck position after installing the connector Tighten trim screws to 2 N m 20 in lbs torque Tighten the module nuts to 22 to 34 N m 200 to 300 in lbs torque Do not con nect battery negative cable Refer to Diagnosis and Testing for Airbag System Test procedures STEERING WHEEL WARNING DISCONNECT AND ISOLATE THE BAT TERY NEGATIVE GROUND CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM COMPONENT REMOVAL OR INSTA...

Страница 386: ...hin the clockspring is not positioned properly with the steering wheel and the front wheels the clockspring may fail during use The following procedure MUST BE USED to center the clockspring if The clockspring is not known to be properly positioned The front wheels were moved The steering wheel was moved from the half turn 180 degrees to the right clockwise position WARNING DISCONNECT AND ISOLATE ...

Страница 387: ......

Страница 388: ...hicle components have been constructed as mirror image of the LHD versions While most of the illustrations used in this group represent only the LHD version the diagnostic and service procedures outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD RHD or Export if a special illustration or procedure is required REAR WINDOW DEFOGGER SWITCH ...

Страница 389: ...rial which when fired on glass becomes bonded to the glass and is highly resistant to abrasion It is possible however that a break may occur in an individual grid line resulting in no cur rent flow through the line To detect breaks in grid lines the following procedure is required 1 Turn ignition ON and turn control switch to ON The indicator light should come on 2 Using a DC voltmeter with 0 15 v...

Страница 390: ...h 6 To bench test relay a Using a jumper wire connect a 12 volt batter supply apply voltage to Pin 3 and 4 Ground Pin 2 b Follow the above procedures except Step 2 SERVICE PROCEDURES GRID LINE AND TERMINAL REPAIR WARNING REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER HARMFUL IF SWALLOWED AVOID CONTACT WITH SKIN AND EYES FOR SKIN WASH AFFECTED AREAS WITH SO...

Страница 391: ...fastened and to adjacent line 7 Apply a thin layer of conductive epoxy on ter minal and place terminal on desired location To pre vent terminal from moving while the epoxy is curing it must be wedged or clamped 8 Carefully remove masking tape from grid line CAUTION Do not allow the glass surface to exceed 204 C 400 F glass may fracture 9 Allow epoxy to cure 24 hours at room tempera ture or use hea...

Страница 392: ...D and Right Hand Drive RHD versions of this model Whenever required and feasible the RHD versions of affected vehicle components have been constructed as mirror image of the LHD versions While most of the illustrations used in this group represent only the LHD version the diagnostic and service procedures outlined can generally be applied to either version Exceptions to this rule have been clearly...

Страница 393: ...pen circuit 4 If test light comes on the wiring circuit between the battery and switch is functional REMOVAL AND INSTALLATION DOOR LOCK MOTOR REMOVAL 1 Remove door trim panel refer to Group 23 Body for removal procedures 2 Disconnect all door linkages at the latch lock assembly Fig 1 3 Disconnect motor wire connector 4 Remove latch lock assembly attaching screws and remove assembly INSTALLATION Fo...

Страница 394: ...itched to the RUN position The Remote Keyless Entry Module is capable of retaining the transmitter Vehicle Access Code VAC in memory even after vehicle power has been inter rupted DESCRIPTION AND OPERATION VEHICLE ACCESS CODE VAC PROGRAMMING The system allows locking and unlocking of vehicle door s by remote control using a hand held radio fre quency transmitter The ignition switch must be OFF bef...

Страница 395: ...HE TRANSMITTER BUT ALL OTHER DOORS WILL NOT UNLOCK 1 Using an analog voltmeter connect the meter to Pin 3 of the gray connector and to ground Fig 2 Press the unlock button twice within five seconds and check for a voltage pulse 2 If no voltage pulse is measured replace the receiver If voltage pulse is measured check the wir ing to the passenger door lock motors and repair as necessary ALL DOORS WI...

Страница 396: ...and the horn will sound to confirm programming Press the lock button on the second transmitter four times and the horn will sound to confirm programming 6 Disconnect the programming line from ground This returns the system to its normal operation mode 7 Replace any removed components Return pro gramming line chirpto its original position Check for system operation PANIC FUNCTION CANCELLATION Durin...

Страница 397: ...d are readily available at local retail stores The recommended battery is Duracell DL 2016 or equiva lent Battery life is about one to two years CAUTION Do not touch the battery terminals or handle the batteries any more than necessary Hands must be clean and dry RKE TRANSMITTER RANGE Normal operation range is up to about a distance of 7 meters 23 ft of the vehicle Range may be bet ter or worse de...

Страница 398: ...eceiver is programmed at the assembly plant with the vehicle access codes of the two transmitters that are shipped with the vehicle The immobilizer receiver also has a central pro cessing unit which contains the immobilizer system logic The programming in the immobilizer receiver allows the system to learn and retain transmitter vehicle access codes as well as to communicate with the Powertrain Co...

Страница 399: ...ore than five minutes after a battery disconnect or failure After any passive arm ing the system will have to be actively disarmed using one of the transmitters The power up mode logic also applies if the battery goes dead and battery jump starting is attempted The engine no run feature will prevent the engine from operating until the vehicle immobilizer system has been actively disarmed DIAGNOSIS...

Страница 400: ...m the immobilizer receiver to confirm the Unlock message has been received 2 Start the engine Each engine start must be followed by a minimum engine run duration of ten seconds 3 Allowing a cool down period between starts go back to Step 1 a total of twenty times After twenty cycles confirm that the vehicle immobilizer system is enabled by actively arming the receiver and attempt ing to start the ...

Страница 401: ......

Страница 402: ...ST The following wiring test determines whether or not voltage is continuous through the body harness to switch Remove switch for testing Connect a voltmeter positive lead to Pin 4 and negative lead to Pin 3 of the switch connector Fig 1 Turn ignition switch to the ON position Voltmeter should read battery volt age If OK go to Window Switch Test If not OK check the 30 amp circuit breaker behind th...

Страница 403: ...glass lift plate Remove the two attaching nuts and slide the window up and down by hand This check can not be made on a four door vehicle REMOVAL AND INSTALLATION WINDOW SWITCH REMOVAL 1 Using a flat tool insert tool in the slot on the bottom of the switch bezel Fig 4 2 Pry the bezel from the door trim panel 3 Disconnect wire connector from switch 4 Remove switch by releasing the tabs from bezel I...

Страница 404: ...ch test opera tion of motor 4 DOOR WINDOW MOTOR REMOVAL 1 Move the window so it is not in the full up or down position if possible 2 Remove door trim panel refer to Group 23 Body for removal procedures 3 Disconnect wiring connector from motor 4 Remove the three nuts attaching the window regulator motor housing to the door inner panel This will allow the motor housing to be moved to the lower door ...

Страница 405: ......

Страница 406: ... are disconnected when the vehicles are originally shipped from the factory Disconnecting this fuse will help prevent the battery from discharge during storage The fuse is located in Power Distri bution Center PDC refer to the cover for proper location This fuse is included in the power mirror circuity and should be checked if the mirrors are inoperative The RHD vehicle mirror circuitry is powered...

Страница 407: ...D 6 PINS 1 AND 7 PINS 2 AND 5 PINS 1 AND 8 PINS 2 AND 7 PINS 1 AND 6 Mirror Selector Knob in R Position MOVE LEVER CONTINUITY BETWEEN PINS 2 AND 4 PINS 1 AND 5 PINS 2 AND 6 PINS 1 AND 3 PINS 2 AND 5 PINS 1 AND 4 PINS 2 AND 3 PINS 1 AND 6 Fig 4 Power Fold Away Mirror Switch Test MIRROR SWITCH CONTINU ITY Mirror Selector Knob in L Position MOVE LEVER CONTINUITY BETWEEN PINS A 2 AND A 8 PINS A 1 AND ...

Страница 408: ... Power Fold Away Mirror refer to Fig 6 5 If test results are not obtained as shown in the Fig 5 check for open or shorted circuit Fig 7 or replace mirror assembly as necessary Fig 5 Mirror Test TERMINAL END VIEW Fig 6 Power Fold Away Mirror Test MIRROR SWITCH WIRING CONNECTORS MIRROR RELAY CONNEC TOR IN DOOR HARNESS MIRROR CONNECTOR IN DOOR S TERMINAL ENDS VIEWS PL POWER MIRRORS 8T 3 DIAGNOSIS AND...

Страница 409: ...MP POWER WINDOWS RIGHT FRONT DOOR SEPARATE EXTEND RETRACT R L R L UP RT DN LT RETRACT POWER MIRROR SWITCH RIGHT MIRROR C R CW DN RT R EXTEND PTC UP LT CCW RETRACT SHOWN IN EXTENDED POSI TION LT UP DN RT PTC CCW RETRACT CW EXTEND LEFT MIRROR C R R 1 PNL RIGHT CENTER SUP PORT EXTEND 8T 4 POWER MIRRORS PL ...

Страница 410: ... 8 2 Remove cartridge lamp and replace if neces sary INSTALLATION Install lens by setting lens into position and apply ing pressure until it is locked into position MIRROR SWITCH REMOVAL 1 Remove door trim panel refer to Group 23 Front Door Trim 2 Remove switch mounting screws from back side of trim panel and remove switch 3 Disconnect wire connector INSTALLATION For installation reverse the above...

Страница 411: ......

Страница 412: ... only the LHD version the diagnostic and service procedures outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD RHD or Export if a special illustration or procedure is required DIAGNOSIS AND TESTING FASTEN SEAT BELTS To test the fasten seat belts function turn the igni tion switch to the ON position with the driver s seat belt unbuckled a...

Страница 413: ...door and ensure the ignition key is in the OFF or ACC position Check for continuity to ground at Pin 5 of the J2 wire harness connector If ground OK replace cluster printed circuit board If no ground check key in switch or door switch wiring and repair as necessary CHIMES CONTINUE WHEN HEADLAMPS ARE TURNED OFF AND OR KEY IS REMOVED FROM IGNITION Check for ground at J2 5 If grounded the chime shoul...

Страница 414: ...s available in three ounce tubes Moisture in the air causes the Mopar Silicone Rubber Adhesive Sealant material to cure This material is normally used on flexible metal flanges It has a shelf life of one year and will not properly cure if over age Always inspect the package for the expiration date before use MOPAR GASKET MAKER Mopar Gasket Maker is an anaerobic type gasket material The material cu...

Страница 415: ...remove all rust and clean inside of cup plug hole in cylinder block or head Be sure to remove old sealer Lightly coat inside of cup plug hole with sealer Make certain the new plug is cleaned of all oil or grease Using proper drive plug drive plug into hole so that the sharp edge of the plug is at least 0 5 mm 0 020 inch inside the lead in chamfer Fig 1 It is in not necessary to wait for curing of ...

Страница 416: ...sed carefully the cylinder bore resizing hone C 823 equipped with 220 grit stones is the best tool for this job In addition to deglazing it will reduce taper and out of round as well as removing light scuffing scoring or scratches Usually a few strokes will clean up a bore and maintain the required lim its 2 Deglazing of the cylinder walls may be done using a cylinder surfacing hone Tool C 3501 eq...

Страница 417: ...oil 2 Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6 35 mm 1 4 in off center and away from the oil holes Fig 3 In addition suspected areas can be checked by placing the Plastigage in the suspected area Torque the bearing cap bolts of the bearing being checked to the proper specifications 3 Remove the bearing cap and compare the width of the flat...

Страница 418: ... to insure system is dry and clear of foreign material 2 Remove negative battery cable 3 Place a shop towel around the spark plugs when removing them from the engine This will catch any fluid that may possibly be in the cylinder under pressure 4 With all spark plugs removed rotate engine crankshaft using a breaker bar and socket 5 Identify the fluid in the cylinder s i e cool ant fuel oil or other...

Страница 419: ...ottles and the top of engine oil cans Fig 7 ENGINE OIL ADDITIVES In some instances such as infrequent operation short trip driving and during break in after a major overhaul addition of special materials containing anti rust and anti scuff additives are beneficial A suitable product for this purpose is MOPAR Engine Oil Supplement ENGINE OIL CHANGE Change engine oil at mileage and time intervals de...

Страница 420: ... the suspected leak has been found 4 Repair as required CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc tions Ensure the battery is completely charged and the engine starter motor is in good operating condition Otherwise the indicated compression pressures may not be valid for diagnosis purposes 1 Check engin...

Страница 421: ...ng to the tester manufacturer s instructions While testing listen for pressurized air escaping through the throttle body tailpipe and oil filler cap opening Check for bubbles in the radiator coolant All gauge pressure indications should be equal with no more than 25 leakage FOR EXAMPLE At 552 kPa 80 psi input pres sure a minimum of 414 kPa 60 psi should be main tained in the cylinder LASH ADJUSTER...

Страница 422: ...REA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine a more involved inspection is necessary The following steps should be followed to help pinpoint the source of the leak If the leakage occurs at the crankshaft rear oil seal area 1 Disconnect the battery 2 Raise the vehicle 3 Remove torque converter or clutch housing cover and inspec...

Страница 423: ...necessary refer to Group 8D Ignition System ENGINE LOSS OF POWER 1 Dirty or incorrectly gapped spark plugs 1 Clean plugs and set gap refer to Group 8D Ignition System 2 Dirt or water in fuel system 2 Clean system and replace fuel filter 3 Faulty fuel pump 3 Install new fuel pump 4 Incorrect valve timing 4 Correct valve timing 5 Blown cylinder head gasket 5 Install new cylinder head gasket 6 Low co...

Страница 424: ...rance 4 Measure bearings for correct clearance Repair as necessary 5 Excessive end play 5 Check thrust bearing for wear on flanges 6 Crankshaft journal out of round worn 6 Grind journals or replace crankshaft 7 Loose flywheel or torque converter 7 Tighten to correct torque OIL PRESSURE DROP 1 Low oil level 1 Check engine oil level 2 Faulty oil pressure sending unit 2 Install new sending unit 3 Low...

Страница 425: ... SPRINGS IN VEHICLE 23 VIBRATION DAMPER 40 DISASSEMBLY AND ASSEMBLY OIL PUMP 41 VALVE SERVICE WITH THE CYLINDER HEAD REMOVED 42 CLEANING AND INSPECTION CYLINDER BLOCK AND BORE 46 CYLINDER HEAD AND CAMSHAFT JOURNALS 44 OIL PUMP 45 SPECIFICATIONS ENGINE 2 0L SOHC 47 TORQUE CHART 2 0L SOHC 48 SPECIAL TOOLS ENGINE 2 0L SOHC 49 DESCRIPTION AND OPERATION ENGINE IDENTIFICATION The engine identification n...

Страница 426: ...isms are lubricated from a full length cylinder head oil gallery supplied from the crankcase main oil gallery PRESSURE LUBRICATION Oil drawn up through the pickup tube is pressur ized by the pump and routed through the full flow fil ter to the main oil gallery running the length of the cylinder block A cylinder head restrictor located in the block provides increased oil flow to the main oil galler...

Страница 427: ...HEAD SOHC It features a Single Over Head Camshaft four valves per cylinder cross flow design The valves are arranged in two inline banks with the two intake per cylinder facing toward the radiator The exhaust valves facing toward the dash panel Rocker arm shafts mount directly to the cylinder head It incorporates powder metal valve guides and seats The hollow rocker arm shafts supplies oil to the ...

Страница 428: ...nter line shown in Fig 3 Refer to Cylinder Bore and Speci fications Table Correct piston to bore clearance must be established in order to assure quiet and economi cal operation Chrysler engines use pistons designed specifically for each engine model Clearance and sizing locations vary with respect to engine model NOTE Pistons and cylinder bores should be mea sured at normal room temperature 21 C ...

Страница 429: ...ELER GAUGE Fig 6 Piston Ring Side Clearance FEELER GAUGE Ring Position Ring Gap Wear Limit Upper Ring 0 23 to 0 52 mm 0 009 to 0 020 in 0 8 mm 0 031 in Intermediate Ring 0 49 to 0 78 mm 0 019 to 0 031 in 1 0 mm 0 039 in Oil Control Ring 0 23 to 0 66 mm 0 009 to 0 026 in 1 0 mm 0 039 in Ring Position Groove Clearance Maximum Clearance Upper Ring 0 025 to 0 065 mm 0 0010 to 0 0026 in 0 10 mm 0 004 i...

Страница 430: ... for installation and tighten fasteners in this order a If engine mount bracket was removed tighten bolt 1 to 3 N m 20 in lbs and bolts 2 3 and 4 to 108 N m 80 ft lbs Fig 13 b If engine mount bracket was removed tighten bolts 5 and 1 to 54 N m 40 ft lbs c Tighten engine mount bracket to insulator assembly thru bolt to 54 N m 40 ft lbs d Tighten insulator assembly nuts to the lower radiator crossme...

Страница 431: ...k 4 Remove the thru bolt access hole cover Remove the thru bolt from the insulator assembly Fig 15 Remove insulator 5 Reverse removal procedure for installation Tighten engine mount to rail fasteners to 54 N m 40 ft lbs then tighten engine mount to engine bracket thru bolt to 108 N m 80 ft lbs POWER HOP DAMPER NOTE Power hop damper is used on manual trans mission vehicle only 1 Remove the thru bol...

Страница 432: ...h to allow engine dolly and cradle Special Tools 6135 and 6710 to be installed under vehicle 23 Loosen engine support posts to allow move ment for positioning onto engine locating holes and flange on the engine bedplate Lower vehicle and position cradle until the engine is resting on support posts Fig 18 Tighten mounts to cradle frame This will keep support posts from moving when removing or insta...

Страница 433: ...Connect engine and throttle body connections and harnesses Refer to Group 8 Electrical for procedure 17 Connect throttle body linkage Refer to Group 14 Fuel System for procedure 18 Install radiator and shroud assembly Install radiator hoses Fill cooling system Refer to Group 7 Cooling System for filling procedure 19 Install battery tray and battery Set Power train Control Module PCM into place 20 ...

Страница 434: ... pressed into the cylinder head cover to seal the end of the spark plug tubes If these seals show signs of hardness and or cracking they should be replaced CAMSHAFT NOTE TO REMOVE CAMSHAFT CYLINDER HEAD MUST BE REMOVED REMOVAL 1 Refer to Timing Belt Removal for timing belt and camshaft sprocket removal and installation 2 Remove the cylinder head cover 3 Mark rocker arm shaft assemblies for install...

Страница 435: ...ournals Install camshaft into the cylinder head carefully 2 Install cam sensor and tighten fasteners to 9 5 N m 85 in lbs 3 Install camshaft seal Camshaft must be installed before the camshaft seal is installed Refer to procedure outlined in this section 4 Install camshaft sprocket and tighten to 115 N m 85 ft lbs 5 Install timing belt Refer to procedure outlined in this section 6 Install rocker a...

Страница 436: ...oward the timing belt side of the engine Fig 27 Install the retainers in their original positions on the exhaust and intake shafts Fig 25 CAUTION When installing the intake rocker arm shaft assembly be sure that the plastic spacers do not interfere with the spark plug tubes If the spac ers do interfere rotate until they are at the proper angle To avoid damaging the spark plug tubes do not attempt ...

Страница 437: ...ng pump assembly and set aside 9 Disconnect coil pack wiring connector and remove coil pack and bracket from engine 10 Remove cylinder head cover 11 Remove cam sensor and fuel injectors wiring connectors 12 Remove intake manifold SOHC ONLY Removal procedure outline in Group 11 13 Remove timing belt and camshaft sprocket Refer to procedure outlined in this section 14 Remove rocker arm shaft assembl...

Страница 438: ...cedure outlined in this section for removal Cylinder Head and Valve Assembly ROCKER SHAFT RETAINING BOLT VALVE RETAINING LOCKS VALVE VALVE SPRING VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY ROCKER ARM SHAFT RETAINER SPACER INTAKE ROCKER ARM HYDRAULIC LASH ADJUSTER ASSEMBLY CAMSHAFT SPACER EXHAUST ROCKER ARM HY DRAULIC LASH ADJUSTER ASSEMBLY CAMSHAFT SEAL SPARK PLUG TUBE SEAL VALVE SPRING RETAINER RE...

Страница 439: ... Install crankshaft vibration damper Refer to procedure outlined in this section for installation 6 Install accessory drive belts Refer to Group 7 Cooling System Accessory Drive section for procedure 7 Raise vehicle on hoist and install right inner splash shield Fig 34 Cylinder Head Tightening Sequence Fig 35 Right Inner Splash Shield SIDESHIELD RIGHT FRAME RAIL PLUG SHIELD SCREW 3 Fig 36 Right En...

Страница 440: ... 4679 A Fig 39 CAUTION Do not nick shaft seal surface or seal bore 4 Shaft seal lip surface must be free of varnish dirt or nicks Polish with 400 grit paper if necessary INSTALLATION 1 Install camshaft seal flush with cylinder head using Special Tool MD 998306 Fig 40 2 Install camshaft sprocket retaining bolt Hold camshaft sprocket with Special Tool C 4687 1 Fig 38 and tighten bolt to 115 N m 85 f...

Страница 441: ...ts Refer to Group 7 Cooling System for procedure outlined in that section 2 Raise vehicle on a hoist and remove right inner splash shield Fig 43 Fig 41 Timing Belt System ACCESS PLUG CAMSHAFT BOLT AND WASHER CAMSHAFT SPROCKET REAR TIMING BELT COVER BRACKET WATER PUMP OIL PUMP BODY CRANKSHAFT SPROCKET TIMING BELT TENSIONER BOLT CRANKSHAFT DAMPER FRONT TIMING BELT COVER Fig 42 Camshaft Timing Marks ...

Страница 442: ...INE 1 When tensioner is removed from the engine it is necessary to compress the plunger into the ten sioner body 2 Place the tensioner into a vise equipped with soft jaws and slowly compress the plunger Fig 49 CAUTION Index the tensioner in the vise the same way it is installed on the engine This is to ensure proper pin orientation when tensioner is installed on the engine 3 When plunger is compre...

Страница 443: ...procket to TDC to take up belt slack Install tensioner to block but do not tighten fasteners 9 Using a torque wrench on the tensioner pulley apply 28 N m 250 in lbs of torque Fig 53 10 With torque being applied to the tensioner pulley move the tensioner up against the tensioner Fig 48 Remove Timing Belt TENSIONER PIVOT TIMING BELT TEN SIONER TENSIONER FASTENERS Fig 49 Compressing Timing Belt Tensi...

Страница 444: ...and Installation in this section 3 Remove front engine mount and bracket Refer to Engine Support Module Removal and Installation in this section 4 Remove transmission inspection cover 5 If equipped with air conditioning remove oil fil ter and adaptor Refer to Oil Filter Adapter Removal and Installation in this section 6 Remove oil pan 7 Clean oil pan and all gasket surfaces INSTALLATION 1 Apply Mo...

Страница 445: ...ith seal spring towards the inside of engine Install seal until flush with cover 3 Install crankshaft sprocket Fig 60 Using Special Tool 6792 NOTE Make sure the word front on the sprocket is facing you 4 Install timing belt and covers Refer to Timing Belt System in this section for installation 5 Install crankshaft damper Fig 61 Use thrust bearing washer and 12M 1 75 x 150 mm bolt from Special Too...

Страница 446: ...ou can read the words THIS SIDE OUT on seal Fig 63 Pilot tool should remain on crankshaft during instal lation of seal Ensure that the lip of the seal is facing towards the crankcase during installation CAUTION If the seal is driven 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 64 until the tool bot toms out aga...

Страница 447: ...per installation CRANKSHAFT MAIN JOURNALS INSPECTION The crankshaft journals should be checked for excessive wear taper and scoring Limits of taper or out of round on any crankshaft journals should be held to 025 mm 001 inch Journal grinding should not exceed 305 mm 012 inch under the standard journal diameter DO NOT grind thrust faces of Number 3 main bearing DO NOT nick crank pin or bearing fill...

Страница 448: ...y to seal the bedplate to cylinder block 3 Oil the bearings and journals and install crankshaft and O ring in cylinder block CAUTION Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine PISTON AND CONNECT ING ROD ASSEMBLY SEAL OIL PASSAGE O RING SEAL UPPER BEARING GROOVED THRUST BEARINGS NIPPLE OIL FILTER ADAPTER O RING CRANKSHAFT POSITION SEN SOR CPS BOLT MAIN...

Страница 449: ... shown in Fig 70 10 After the main bearing bedplate is installed check the crankshaft turning torque The turning torque should not exceed 5 6 N m 50 in lbs 11 Install oil pump If crankshaft end play is to be checked refer to service procedures in this section 12 Install crankshaft sprocket 13 Install oil filter adapter and filter Refer to procedure outlined in this section OIL FILTER ADAPTER REMOV...

Страница 450: ...tion 3 Remove Oil Pan Refer to Oil Pan Removal in this section 4 Remove Crankshaft Sprocket using Special Tool 6793 and insert C4685 C2 Fig 73 5 Remove oil pick up tube 6 Remove oil pump Fig 74 and front crank shaft seal Fig 74 Oil Pump and Tube O RING OIL FILTER ADAPTER OIL PAN GASKET OIL PAN OIL PICK UP TUBE DRAIN PLUG O RING OIL PUMP BODY FILTER O RING NIPPLE Fig 72 Engine Oil Filter OIL FILTER...

Страница 451: ...es with a reli able ridge reamer before removing pistons from cyl inder block Be sure to keep tops of pistons covered during this operation Mark piston with matching cylinder number Fig 78 2 Remove oil pan Scribe the cylinder number on the side of the rod and cap Fig 79 for identification 3 Pistons will have a stamping in the approxi mate location shown in Fig 78 These stamps will be either a dire...

Страница 452: ...cturers I D mark fac ing up to the top of the piston Fig 81 CAUTION Install piston rings in the following order a Oil ring expander b Upper oil ring side rail c Lower oil ring side rail d No 2 Intermediate piston ring e No 1 Upper piston ring f Install the side rail by placing one end between the piston ring groove and the expander Hold end firmly and press down the portion to be installed until s...

Страница 453: ...s on the center of the cylinder bore Insert rod and piston assembly into cylinder bore and 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 7 Install rod caps Install New bolts and tighten to 27 N m 20 ft lb Plus 1 4 turn VIBRATION DAMPER NOTE If a gap is found in the cra...

Страница 454: ...move the threaded plug and gasket from the oil pump Fig 89 CAUTION Oil pump pressure relief valve must be installed as shown in Fig 89 or serious damage may occur 3 Remove spring and relief valve Fig 89 4 Remove oil pump cover screws and lift off cover 5 Remove pump rotors 6 Wash all parts in a suitable solvent and inspect carefully for damage or wear Fig 90 Fig 87 Crankshaft Damper Removal SPECIA...

Страница 455: ... 1 Whenever valves have been removed for inspec tion reconditioning or replacement valve springs should be tested Special Tool C 647 As an example the compression length of the spring to be tested is 33 34 mm 1 5 16 inches Turn tool table until sur face is in line with the 33 34 mm 1 5 16 inch mark on the threaded stud and the zero mark on the front Place spring over stud on the table and lift com...

Страница 456: ... to the bottom edge of valve face raise valve seat with a 65 degrees stone Intake valve seat diameter is 33 mm 1 299 in Exhaust valve seat diameter is 28 mm 1 102 in 6 Valve seats which are worn or burned can be reworked provided that correct angle and seat width are maintained The intake valve seat must be ser viced when the valve seat width is 2 0 mm 0 079 in or greater The exhaust valve seat mu...

Страница 457: ...learance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed Specified dry lash is 1 17 mm 0 046 in for intake and 1 28 mm 0 050 in for exhaust After performing dry lash check refill adjuster with oil and allow 10 minutes for adjuster s to bleed down before rotating cam CLEANING AND INSPECTION CYLINDER HEAD ...

Страница 458: ...m 301 inch or less replace inner rotor Fig 103 5 Slide outer rotor into pump housing press to one side with fingers and measure clearance between rotor and housing Fig 104 If measurement is 0 39 mm 0 015 inch or more replace housing only if outer rotor is in specification 6 Install inner rotor into pump housing If clear ance between inner and outer rotors Fig 105 is 203 mm 008 inch or more replace...

Страница 459: ...lugs outlined in this section 3 Examine block and cylinder bores for cracks or fractures CYLINDER BORE INSPECTION The cylinder walls should be checked for out of round and taper with Tool C 119 Fig 107 The cyl inder bore out of round is 0 050 mm 002 inch maximum and cylinder bore taper is 0 051 mm 0 002 inch maximum If the cylinder walls are badly scuffed or scored the cylinder block should be reb...

Страница 460: ...de Clearance 0 13 0 38 mm 0 005 0 015 in Total Weight Less Bearing 543 grams 1 20 lbs Crankshaft Connecting Rod Journal Diameter 47 9924 48 0076 mm 1 8894 1 8900 in Out of Round Max 0 0035 mm 0 0001 in Taper Max 0 0038 mm 0 0001 in Main Bearing Diametrical Clearance No 1 5 0 022 0 062 mm 0 0008 0 0024 in End Play 0 09 0 24 mm 0 0035 0 0094 in Main Bearing Journals Diameter 51 9924 52 0076 mm 2 046...

Страница 461: ...Valve Springs Free Length Approx 44 4 mm 1 747 in Nominal Force Valve closed 91 N m 39 8 mm 67 ft lbs 1 57 in Nominal Force Valve open 239 N m 32 6 mm 176 lbs 1 28 in Installed Height 40 18 mm 1 580 in SERVICE AS AN ASSEMBLY WITH ROCKER ARM ALL READINGS IN CRANKSHAFT DEGREES AT 0 5 mm 0 019 in OF VALVE LIFT TORQUE CHART 2 0L SOHC DESCRIPTION TORQUE Camshaft Sensor Pick Up Bolts 9 6 N m 85 in lbs T...

Страница 462: ...mostat Housing Bolts 23 N m 200 in lbs Timing Belt Tensioner 31 N m 275 in lbs Timing Belt Tensioner Pivot Bracket Bolt 31 N m 275 in lbs Timing Belt Tensioner Pulley Bolt 68 N m 50 ft lbs Water Pump Mounting Bolts 12 N m 105 in lbs SPECIAL TOOLS ENGINE 2 0L SOHC Puller 1026 Crankshaft Damper Removal Insert 6827 A Camshaft Sprocket Remover Installer C 4687 Camshaft Sprocket Remover Installer Adapt...

Страница 463: ...r C 4685 C Valve Spring Compressor MD 998772 A Spring Compressor Adapter 6779 Valve Spring Compressor C 3575 A Cylinder Bore Indicator C 119 Front Crankshaft Seal Remover 6771 Front Crankshaft Seal Installer 6780 9 50 2 0L SOHC ENGINE PL SPECIAL TOOLS Continued ...

Страница 464: ...Sprocket Remover 6793 Crankshaft Sprocket Installer 6792 Rear Crankshaft Seal Guide and Installer 6926 1 and 6926 2 Pressure Gage C 32932 Valve Spring Tester C 647 PL 2 0L SOHC ENGINE 9 51 SPECIAL TOOLS Continued ...

Страница 465: ...D SEALS CYLINDER HEAD NOT REMOVED 63 VIBRATION DAMPER 66 DISASSEMBLY AND ASSEMBLY OIL PUMP 81 VALVE SERVICE WITH CYLINDER HEAD REMOVED 81 CLEANING AND INSPECTION CYLINDER BLOCK AND BORE 85 CYLINDER HEAD AND CAMSHAFT JOURNALS 84 OIL PUMP 84 SPECIFICATIONS ENGINE 2 0L DOHC 86 TORQUE CHART 2 0L DOHC 88 SPECIAL TOOLS ENGINE 2 0L DOHC 88 DESCRIPTION AND OPERATION ENGINE IDENTIFICATION NUMBER The engine...

Страница 466: ...cting rod journals CAMSHAFT HYDRAULIC LASH ADJUSTERS A vertical hole at the number five bulkhead routes pressurized oil through a restrictor up past a cylin der head bolt to an oil gallery running the length of the cylinder head The camshaft journals are par tially slotted to allow a predetermined amount of pressurized oil to pass into the bearing cap cavities with small holes directed to spray lu...

Страница 467: ...orts of the bank of two exhaust valves per cyl inder facing toward the dash panel Incorporates powder metal valve guides and seats Integral oil gal leys within the cylinder head supplies oil to the hydraulic lash adjusters camshaft and valve mecha nisms CAMSHAFTS The nodular iron camshafts have six bearing journals and 2 cam lobes per cylinder Flanges at the rear journals control camshaft end play...

Страница 468: ...d cylinder wall must be clean and dry Piston diameter should be measured 90 degrees to piston pin about 17 5 mm 11 16 inch from the bot tom of the skirt as shown in Fig 5 Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in Fig 4 Refer to Cylinder Bore and Piston Specifications Table Correct piston to bore clearance must be e...

Страница 469: ...nch for last step 5 Using a feeler gauge check connecting rod side clearance Fig 9 Refer to connecting rod specifica tions Fig 10 FITTING CRANKSHAFT BEARINGS Refer to Measuring Main Bearing Clearance in Standard Service Procedures Refer to Fig 11 for specifications CRANKSHAFT END PLAY DIAL INDICATOR METHOD 1 Mount a dial indicator to front of engine locat ing probe on nose of crankshaft Fig 12 2 M...

Страница 470: ...80 ft lbs Fig 14 b If engine mount bracket was removed tighten bolts 5 and 1 to 54 N m 40 ft lbs c Tighten engine mount bracket to insulator assembly thru bolt to 54 N m 40 ft lbs d Tighten insulator assembly nuts to the lower radiator crossmember torque to 54 N m 40 ft lbs Fig 10 Checking Connecting Rod Side Clearance CONNECTING ROD BEARING OIL CLEARANCE New Part 0 026 to 0 059 mm 0 001 to 0 0023...

Страница 471: ...e mounts by care fully supporting the engine and transmission assem bly with a floor jack 4 Remove the thru bolt access hole cover Remove the thru bolt from the insulator assembly Fig 16 Remove insulator 5 Reverse removal procedure for installation Tighten engine mount to rail fasteners to 54 N m 40 ft lbs then tighten engine mount to engine bracket thru bolt to 108 N m 80 ft lbs POWER HOP DAMPER ...

Страница 472: ...d reservoir Set them aside 20 Remove A C compressor 21 Remove ground straps to body 22 Raise vehicle enough to allow engine dolly and cradle Special Tools 6135 and 6710 to be installed under vehicle 23 Loosen engine support posts to allow move ment for positioning onto engine locating holes and flange on the engine bedplate Lower vehicle and position cradle until the engine is resting on support p...

Страница 473: ...to Group 6 Manual Transaxle Clutch 14 Automatic Transmission Connect shifter and kickdown linkage Refer to Group 21 Transaxle for procedures 15 Connect fuel line and heater hoses 16 Install ground straps Connect engine and throttle body connections and harnesses Refer to Group 8 Electrical for procedure 17 Connect throttle body linkage Refer to Group 14 Fuel System for procedure 18 Install radiato...

Страница 474: ...n this section 2 Remove timing belt sprockets and covers Refer to Timing Belt Service outlined in this section 3 Bearing caps are identified for location Remove the outside bearing caps first Fig 22 4 Loosen the camshaft bearing cap attaching fas teners in sequence shown in Fig 23 one camshaft at a time CAUTION Camshafts are not interchangeable The intake cam number 6 thrust bearing face spacing i...

Страница 475: ...ASSEMBLY REMOVAL 1 Remove valve cover using procedure outlined in this section 2 Remove timing belt sprockets and covers using procedure outlined in this section 3 Remove camshaft Refer to procedure previ ously outline this section 4 Remove cam follower assemblies from cylinder head Keep the cam followers in the order they have been removed from the head for reassembly Mark hydraulic lash adjuster...

Страница 476: ... in this section 2 Install valve spring and retainer Using Special Tool MD998772A compress valve springs only enough to install locks Correct alignment of tool is necessary to avoid nicking valve stems air pressure required piston at TDC 3 Remove air hose and install spark plugs 4 Install camshafts as previously outlined in this section 5 Install valve cover as previously outlined in this section ...

Страница 477: ...INDER HEAD HEAD GASKET VALVE VALVE GUIDE VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY VALVE SPRING VALVE SPRING RETAINER VALVE RETAINING LOCKS HYDRAULIC LASH ADJUSTER ROLLER FOLLOWER SPARK PLUG WELL GASKET CAMSHAFT OIL SEAL 9 64 2 0L DOHC ENGINE PL REMOVAL AND INSTALLATION Continued ...

Страница 478: ...l proce dure outlined in this section 14 Remove cylinder head bolts NOTE Remove all gasket material from cylinder head and block Be careful not to gouge or scratch the aluminum head sealing surface CYLINDER HEAD FLATNESS 1 Cylinder head must be flat within 0 1 mm 0 004 inch Fig 32 NOTE Inspect camshaft bearing journals for scor ing INSTALLATION 1 Before installing the bolts the threads should be o...

Страница 479: ...1 Install crankshaft damper using M12 1 75 x 150 mm bolt washer thrust bearing and nut from Special Tool 6792 Install crankshaft damper bolt and tighten to 142 N m 105 ft lbs Fig 88 2 Install accessory drive belts Refer to Group 7 Cooling System Accessory Drive section for proce dure 3 Raise vehicle on hoist and install right inner splash shield Fig 34 Weld Gap CRANKSHAFT DAMPER WELD GAP Fig 35 Ri...

Страница 480: ... fasteners remove cover Fig 40 INSTALLATION 1 Install front timing cover 2 Install engine mount bracket 3 Install Right engine mount Refer to procedure outlined in this section for installation 4 Remove jack from under engine 5 Install crankshaft vibration damper Refer to procedure outlined in this section for installation 6 Install accessory drive belts Refer to Group 7 Cooling System Accessory D...

Страница 481: ...re removing timing belt 1 Remove crankshaft damper bolt Remove damper procedure outlined in this section 2 Remove engine mount bracket and timing belt cover fasteners remove cover Fig 41 Typical Timing Belt System DOHC ACCESS PANEL CAMSHAFT SPROCK ETS REAR TIMING BELT COVER WATER PUMP OIL PUMP CRANKSHAFT SPROCKET TIMING BELT CRANKSHAFTDAMPER FRONT TIMING BELT COVER BRACKET TENSIONER Fig 42 Camshaf...

Страница 482: ... marks together by align ing notches on sprockets Fig 47 6 Rotate crankshaft 1 2 tooth counterclockwise from TDC Fig 48 7 Install timing belt in this direction Starting at the crankshaft go around the water pump sprocket idler pulley camshaft sprockets and then around the tensioner pulley Fig 49 8 Move crankshaft sprocket to TDC to take up belt slack Install tensioner to block but do not tighten f...

Страница 483: ...le Removal and Installation in this section 3 Remove front engine mount and bracket Refer to Engine Support Module Removal and Installation in this section 4 Remove transmission inspection cover 5 If equipped with air conditioning remove oil fil ter and adaptor Refer to Oil Filter Adapter Removal and Installation in this section 6 Remove oil pan 7 Clean oil pan and all gasket surfaces INSTALLATION...

Страница 484: ...aining bore Fig 54 CAUTION Do not nick shaft seal surface or seal bore 4 Shaft seal lip surface must be free of varnish dirt or nicks Polish with 400 grit paper if necessary INSTALLATION 1 Install camshaft seal into cylinder head using Special Tool MD 998713 until flush with the head Fig 55 2 Install camshaft sprockets and tighten attach ing bolts to 101 N m 75 ft lbs Fig 51 Oil Pan Sealing PLACE ...

Страница 485: ...ide of engine Install seal until flush with cover 3 Install crankshaft sprocket Fig 60 Using Special Tool 6792 NOTE Make sure the word front on the sprocket is facing you 4 Install timing belt and covers Refer to Timing Belt System in this section for installation 5 Install crankshaft damper Fig 61 Use thrust bearing washer and 12M 1 75 x 150 mm bolt from Special Tool 6792 Install crankshaft dampe...

Страница 486: ...ou can read the words THIS SIDE OUT on seal Fig 63 Pilot tool should remain on crankshaft during instal lation of seal Ensure that the lip of the seal is facing towards the crankcase during installation CAUTION If the seal is driven 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 64 until the tool bot toms out aga...

Страница 487: ...t Seal Special Tool 6926 2 SPECIAL TOOL 6926 1 PILOT SEAL SPECIAL TOOL 6792 2 INSTALLER Fig 65 Rear Crankshaft Seal Installation SPECIAL TOOL 6926 2 INSTALLER 9 74 2 0L DOHC ENGINE PL REMOVAL AND INSTALLATION Continued ...

Страница 488: ...er bearing shells in the crankcase have oil grooves All lower bearing shells installed in the bed plate main bearing cap are plain Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal Fig 67 NOTE The upper and lower main Bearing shells are Not interchangeable The lower shells have a revised tab to prevent improper installation CRANKSHAFT MAIN JOURNALS INS...

Страница 489: ...rings and bearing tabs seat in the block tab slots CAUTION Do Not get oil on the bedplate mating surface It will affect the sealer ability to seal the bedplate to cylinder block 3 Oil the bearings and journals and install crankshaft and O ring in cylinder block CAUTION Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine 4 Apply 1 5 to 2 0 mm 0 059 to 0 078 in ...

Страница 490: ...nst the seam at the base of the filter The seam joining the can to the base is reinforced by the base plate 1 Turn counterclockwise to remove 2 To install lubricate new filter gasket Check filter mounting surface The surface must be smooth flat and free of debris or old pieces of rubber Screw filter on until gasket contacts base Tighten to 21 N m 15 ft lbs OIL PUMP REMOVAL 1 Disconnect negative ba...

Страница 491: ...ck NOTE Front crankshaft seal MUST be out of pump to align or damage may result 5 Torque all oil pump attaching bolts to 28 N m 250 in lbs 6 Install new front crankshaft seal using Special Tool 6780 Fig 76 Fig 74 Oil Pump and Tube O RING OIL FILTER ADAPTER OIL PAN GASKET OIL PAN OIL PICK UP TUBE DRAIN PLUG O RING OIL PUMP BODY FILTER O RING NIPPLE Fig 75 Oil Pump Sealing APPLY GASKET MAKER TO OIL ...

Страница 492: ...on assemblies The weight designation stamps should face toward the timing belt side of the engine 4 Pistons and connecting rods must be removed from top of cylinder block Rotate crankshaft so that each connecting rod is centered in cylinder bore 5 Remove connecting rod cap bolts Do not use old bolts if reinstalling connecting rod Push each piston and rod assembly out of cylinder bore NOTE Be caref...

Страница 493: ...r tant for oil control PISTON AND ROD INSTALLATION 1 Before installing pistons and connecting rod assemblies into the bore be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap 2 Before installing the ring compressor make sure the oil ring expander ends are butted and the rail gaps located as shown in Fig 83 3 Immerse the piston head and rings in clean ...

Страница 494: ... for damage or wear Fig 90 VALVE SERVICE WITH CYLINDER HEAD REMOVED REMOVAL 1 With cylinder head removed compress valve springs using Special Tool MD 998735 or equivalent 2 Remove valve retaining locks valve spring retainers valve stem seals and valve springs 3 Before removing valves remove any burrs from valve stem lock grooves to prevent dam age to the valve guides Identify valves to insure inst...

Страница 495: ... be obtained 4 Measure the concentricity of valve seat and valve guide using a valve seat runout dial indicator Total runout should not exceed 0 051 mm 0 002 inch total indicator reading 5 Inspect the valve seat with Prussian blue to determine where the valve contacts the seat To do this coat valve seat LIGHTLY with Prussian blue then set valve in place Rotate the valve with light pressure If the ...

Страница 496: ...r the locks can become dislocated Check to make sure both locks are in their correct location after removing tool 4 Check the valve spring installed height B after refacing the valve and seat Fig 93 Make sure mea surements are taken from top of spring seat to the bottom surface of spring retainer If height is greater than 38 75 mm 1 525 in install a 7 620 mm 0 030 inch spacer under the valve sprin...

Страница 497: ...ear or damage Replace rocker arm hydraulic lash adjuster if worn or damaged If lobes show signs of pitting on the nose flank or base circle replace the camshaft CLEANING Remove all gasket material from cylinder head and block Be careful not to gouge or scratch the alumi num head sealing surface OIL PUMP 1 Clean all parts thoroughly Mating surface of the oil pump should be smooth Replace pump cover...

Страница 498: ...ure relief valve or other reasons for oil pressure loss CYLINDER BLOCK AND BORE 1 Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking 2 If new core plugs are installed Refer to Engine Core Plugs outlined in this section 3 Examine block and cylinder bores for cracks or fractures CYLINDER BORE INSPECTION The cylinder walls should be checked for out of round and tape...

Страница 499: ...oove Depth No 1 3 983 4 132 mm 0 157 0 163 in Piston Ring Groove Depth No 2 4 456 4 605 mm 0 175 0 181 in Piston Ring Groove Depth No 3 3 841 4 075 mm 0 151 0 160 in Piston Pins Clearance in Piston 0 008 0 020 mm 0 0003 0 0008 in In Rod Interference 0 018 0 043 mm 0 0007 0 0017 in Diameter 20 998 21 003 mm 0 8267 0 8269 in End Play None Length 74 75 75 25 mm 2 943 2 963 in Piston Rings Ring Gap To...

Страница 500: ...lve Opens BBDC 42 Exhaust Valve Duration 219 Valve Overlap 0 Cylinder Head Material Cast Aluminum Gasket Thickness Compressed 1 15 mm 0 045 in Valve Seat Angle 44 5 45 Runout Max 0 050 mm 0 002 in Width Finished Intake and Exhaust 0 9 1 3 mm 0 035 0 051 in Valve Guide Finished Diameter ID 5 975 6 000 mm 0 235 0 236 in Guide Bore Diameter Standard 11 0 11 02 mm 0 4330 0 4338 in Valves Head Diameter...

Страница 501: ...fold Bolts 28 N m 250 in lbs Oil Filter Adapter Fastener 80 N m 60 ft lbs Oil Filter 20 N m 15 ft lbs Oil Pan Bolts 12 N m 105 in lbs Drain Plug 34 N m 25 ft lbs Oil Pump Attaching Bolts 28 N m 250 in lbs Oil Pump Cover Fastener 12 N m 105 in lbs Oil Pump Pick up Tube Bolt 28 N m 250 in lbs Oil Pump Relief Valve Cap 55 N m 40 ft lbs Spark Plugs Plug 28 N m 20 ft lbs Thermostat Housing Bolts 23 N m...

Страница 502: ...per 6792 Installer Crankshaft Damper C 4685 C Valve Spring Compressor MD 998772 A Valve Spring Compressor C 3575 A Cylinder Bore Indicator C 119 Front Crankshaft Seal Remover 6771 Adapter Spring Compressor 6779 PL 2 0L DOHC ENGINE 9 89 SPECIAL TOOLS Continued ...

Страница 503: ...er 6780 Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Installer 6792 Rear Crankshaft Seal Guide and Installer 6926 1 and 6926 2 Pressure Gage C 32932 Valve Spring Tester C 647 9 90 2 0L DOHC ENGINE PL SPECIAL TOOLS Continued ...

Страница 504: ...NFORMATION EXHAUST SYSTEMS The exhaust system has an underfloor catalytic converter tail pipe and muffler Fig 1 EXHAUST BALL JOINT COUPLING An exhaust ball joint coupling Fig 2 is used to secure the exhaust pipe to the engine exhaust mani fold This flexible joint moves back and forth as the engine moves preventing breakage that could occur from the back and forth motion of a transverse mounted eng...

Страница 505: ... in the vicinity of the catalytic con verter Refer to Group 23 Body and Sheet Metal for ser vice procedures CAUTION Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield on cars if equipped Light over spray near the edges is permitted Appli cation of coating will greatly reduce the efficiency of the heat shields resulting in excessive floo...

Страница 506: ...e c a EGR Valve to Manifold Gasket a Tighten nuts or replace gasket b EGR Valve to EGR Tube Gasket b Tighten nuts or replace gasket c EGR Tube to Manifold Tube Nut c Tighten tube nut d Exhaust Flex Joint d a Spring height installed not correct a Check spring height both sides specification is 32 5 mm 1 28 inch look for source of spring height variation if out of specification b Exhaust sealing rin...

Страница 507: ...n removing exhaust pipe raise rear of vehicle to relieve body weight from rear suspension to provide clearance between pipe and lateral arms 6 Remove catalytic converter to exhaust manifold attaching bolts Fig 8 7 Clean ends of pipes and or muffler to assure mating of all parts Discard broken or worn insula tors rusted clamps supports and attaching parts NOTE When replacement is required on any co...

Страница 508: ...ICING FUEL SYSTEM COMPONENTS SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES NEVER SMOKE WHILE SERVICING THE VEHICLE 1 Disconnect negative cable from battery 2 Remove fuel filler cap 3 Remove the fresh air duct Fig 13 4 Remove the protective cap from the fuel pres sure test port on the fuel rail Fig 11 5 Place the open end of fuel pressure release hose tool number C 4799 1 int...

Страница 509: ...ect vacuum hoses from throttle body Fig 14 13 Disconnect Manifold Absolute Pressure Intake Air Temperature Sensor TMAP electrical connector Fig 15 Disconnect vapor and brake booster hoses 14 Disconnect knock sensor electrical connector Fig 16 and disconnect wiring harness from tab located on the intake manifold 15 Disconnect wiring at starter 16 Remove transmission to throttle body support bracket...

Страница 510: ...tor 8 Connect knock sensor connector and wiring at starter Connect wiring harness to intake manifold tab 9 Connect Idle Air Control IAC motor and Throttle Position Sensor TPS wiring connectors 10 Connect vacuum hoses to throttle body 11 Install accelerator kickdown and speed con trol cables to their bracket and connect them to the throttle lever Refer to Group 14 Fuel System Throt tle Body Install...

Страница 511: ...overing CAUTION Do not set fuel injectors on their tips damage may occur to the injectors 10 Remove accelerator kickdown and speed con trol cables from throttle lever and bracket Refer to Group 14 Fuel System Throttle Body Removal for procedures 11 Remove throttle body 12 Disconnect Idle Air Control IAC motor and Throttle Position Sensor TPS wiring connectors Fig 23 13 Disconnect vacuum hoses from...

Страница 512: ...jector holes and insure the holes are clean Install fuel rail assembly to intake manifold Tighten screws to 23 N m 200 in lbs 3 Connect PCV and brake booster hoses Fig 23 Idle Air Control IAC Motor and Throttle Position Sensor TPS Wiring Connectors Fig 24 Manifold Absolute Pressure Intake Air Temperature Sensor TMAP Electrical Connector FUEL INJECTORS FUEL RAIL TEST PORT MAP IAT SENSOR Fig 25 Knoc...

Страница 513: ...k for leaks CAUTION When using the ASD Fuel System Test the Auto Shutdown ASD relay will remain ener gized for 7 minutes or until the ignition switch is turned to the OFF position or Stop All Test is selected EXHAUST MANIFOLD REMOVAL 1 Remove air cleaner assembly and bracket 2 Remove exhaust manifold heat shield Fig 28 3 Disconnect upstream heated oxygen sensor con nector 4 Remove exhaust pipe fro...

Страница 514: ...CIFICATIONS TORQUE CHART EGR Tube Attaching Bolts 11 N m 95 in lbs Exhaust Manifold to Exhaust Pipe Nuts 27 N m 20 ft lbs Exhaust Manifold Mounting Bolts 23 N m 200 in lbs Intake Manifold Mounting Bolts SOHC 12 N m 105 in lbs Bolts DOHC 28 N m 250 in lbs Heat Shield Mounting Body Bolts 4 N m 35 in lbs Exhaust System Band Clamps Torca Fastener 75 N m 55 ft lbs Exhaust Manifold Heat Shield Bolts 23 ...

Страница 515: ......

Страница 516: ... fascia to bottom of bumper reinforcement 3 Install bolts holding fascia to bumper reinforce ment forward of radiator Fig 1 4 Install screws holding front fascia to inner wheelhouse 5 Install radiator grille refer to Group 23 Body for proper procedures FRONT BUMPER REINFORCEMENT REMOVAL 1 Remove front fascia 2 Support bumper reinforcement on a suitable lifting device 3 Remove nuts holding reinforc...

Страница 517: ...l REAR BUMPER REINFORCEMENT REMOVAL 1 Remove rear fascia 2 Support bumper reinforcement on a suitable lifting device 3 Remove nuts holding reinforcement to rear clo sure panel Fig 4 4 Separate bumper reinforcement from vehicle INSTALLATION Reverse the preceding operation Fig 2 Front Bumper Reinforcement RADIATOR CLOSURE PANEL FRONT BUMPER REIN FORCEMENT Fig 3 Rear Bumper Fascia Fig 4 Rear Bumper R...

Страница 518: ...lation of the crossmember is per formed verify that front suspension alignment is within specifications If camber caster settings and wheel stagger is not within specifications loosen and reposition crossmember to bring suspension within specifications Refer to Group 2 Front Suspension and Driveshaft for additional information REMOVAL 1 Hoist and support vehicle on safety stands 2 Using a suitable...

Страница 519: ...LPs Fig 2 11 Tighten bolts to hold suspension crossmember to frame rails and torque boxes 12 Insert ball joints into spindles 13 Install pinch bolts to hold front ball joints to spindles 14 Install front wheels on vehicle 15 Lower vehicle and verify front suspension alignment If camber caster settings and wheel stag ger is not within specifications loosen and reposition crossmember to bring suspen...

Страница 520: ...sted in metric mea surements All dimensions are from center to center of Principal Locating Point PLP or from center to center of PLP and fastener location Fig 3 Fig 4 Fig 5 Fig 6 Fig 7 and Fig 8 Fig 3 Engine Compartment Top View PT MM PT MM PL FRAME AND BUMPERS 13 5 ...

Страница 521: ...DGE OF FRONT SIDE RAIL REAR RAIL G LOWER EDGE OF FRONT SIDE RAIL REAR EXTENSION H WIDTH OF ENGINE COMPARTMENT FRONT PRINCIPLE LOCATING POINTS PLP I CENTER OF LOWER CROSSMEMBER TO ENGINE COMPARTMENT FRONT PLP J CENTER OF LOWER CROSSMEMBER K ENGINE COMPARTMENT FRONT PLP L ENGINE COMPARTMENT REAR PRINCIPLE LOCATING POINTS PLP M FRONT RAIL REAR EXTENSION REAR PLP 13 6 FRAME AND BUMPERS PL SPECIFICATIO...

Страница 522: ... CENTER OF REAR SUSPENSION CROSSMEMBER D REAR RAIL SECOND FORWARD PLP E FRONT OF REAR RAIL F WIDTH OF REAR RAIL FORWARD PRINCIPLE LOCATING POINTS PLP G FRONT LOWER SURFACE OF REAR RAIL H LOWER SURFACE OF SUSPENSION CROSSMEMBER I REAR LOWER SURFACE OF REAR RAIL PL FRAME AND BUMPERS 13 7 SPECIFICATIONS Continued ...

Страница 523: ...F RADIUS D CENTER PILLAR TO BODY SIDE APERTURE UPPER SEAM TO CENTER PILLAR TO BODY SIDE APERTURE LOWER SEAM E UPPER REAR CORNER CENTER OF RADIUS TO LOWER FRONT CORNER CENTER OF RADIUS F FRONT EDGE OF ROOF PANEL OF A PILLAR TO CEN TER OF FRONT DOOR LOWER FRONT CORNER G CENTER OF RADIUS AT BOTTOM TO CENTER OF RADIUS AT LOWER A PILLAR H I CENTER OF RADIUS AT TOP CORNER TO CEN TER OF RADIUS AT BOTTOM ...

Страница 524: ... BODY SIDE APERTURE LOWER SEAM C FRONT EDGE OF ROOF PANEL OF A PILLAR TO CENTER OF FRONT DOOR LOWER FRONT CORNER D CENTER OF RADIUS AT BOTTOM TO CENTER OF RADIUS AT LOWER A PIL LAR E COURTESY LAMP SWITCH HOLE TO FRONT LOWER BOTTOM HINGE BOLT HOLE F G CENTER OF RADIUS AT TOP CORNER TO CENTER OF RADIUS AT BOTTOM CORNER PL FRAME AND BUMPERS 13 9 SPECIFICATIONS Continued ...

Страница 525: ... CORNER TO CENTER OF RADIUS LOWER CORNER C LOWER EDGE OF BACK GLASS UPPER MOUNTING FLANGE OF REAR DECK OPENING WEATHERSTRIP FLANGE D E CENTER OF DECK OPENING FRONT CORNER RADIUS TO REAR TAIL PANEL DECK OPENING RADIUS F FRONT DECK OPENING WEATHER STRIP FLANGE TO DECK OPENING TAIL PANEL WEATHERSTRIP FLANGE G REAR EDGE OF DRAIN THROUGH JOINT H REAR CORNER OF BODY SIDE APERTURE THROUGH JOINT B S A COR...

Страница 526: ...INSTALLATION 1 Position front tow hook bracket to vehicle 2 Install bolts to hold front tow hook bracket to lower radiator crossmember 3 Lower vehicle REAR TOW HOOK BRACKET REMOVAL 1 Hoist and support vehicle Refer to Group 0 Lubrication and Maintenance for proper lifting pro cedure 2 Remove bolts holding rear tow hook bracket to rear frame rail Fig 2 3 Separate rear tow hook bracket from vehicle ...

Страница 527: ......

Страница 528: ...INSTALLATION 1 Position front tow hook bracket to vehicle 2 Install bolts to hold front tow hook bracket to lower radiator crossmember 3 Lower vehicle REAR TOW HOOK BRACKET REMOVAL 1 Hoist and support vehicle Refer to Group 0 Lubrication and Maintenance for proper lifting pro cedure 2 Remove bolts holding rear tow hook bracket to rear frame rail Fig 2 3 Separate rear tow hook bracket from vehicle ...

Страница 529: ......

Страница 530: ...tain detergents corrosion and stability additives are recommended Using gasolines that have these additives will help improve fuel economy reduce emissions and main tain vehicle performance Poor quality gasoline can cause problems such as hard starting stalling and stumble If you experi ence these problems try another brand of gasoline before considering service for the vehicle GASOLINE OXYGENATE ...

Страница 531: ...emissions and improve air quality Chrysler Corporation strongly supports the use of reformulated gasolines whenever available Although your vehicle was designed to provide optimum perfor mance and lowest emissions operating on high qual ity unleaded gasoline it will perform equally well and produce even lower emissions when operating on reformulated gasoline Materials Added to Fuel Indiscriminate ...

Страница 532: ...fuel tank accelerator pedal and throttle cable A fuel return system is used on all models all engines Fuel is returned through the fuel pump module and back into the fuel tank through the fuel filter fuel pressure regulator A separate fuel return line from the engine to the tank is no longer used with any engine The fuel tank assembly consists of the fuel tank filler tube fuel gauge sending unit e...

Страница 533: ...ll gas powered engines It is located on the top of the fuel pump module A separate frame mounted fuel filter is not used Fuel Pressure Regulator Operation The pres sure regulator is a mechanical device that is cali brated to maintain fuel system operating pressure of approximately 338 kPa 49 psi at the fuel injectors It contains a diaphragm calibrated springs and a fuel return valve The internal f...

Страница 534: ...ed by a similar unit if replacement is necessary WARNING REMOVE FILLER CAP TO RELIEVE TANK PRESSURE BEFORE REMOVING OR REPAIR ING FUEL SYSTEM COMPONENTS Fuel Tank Capacity NOTE Nominal refill capacities are shown A varia tion may be observed from vehicle due to manufac turing tolerance and refill procedure QUICK CONNECT FITTINGS Different types of quick connect fittings are used to attach various ...

Страница 535: ...he ignition switch is turned to the Off position 3 Place the ignition key in the ON position Using the DRB scan tool access ASD Fuel System Test The ASD Fuel System Test will activate the fuel pump and pressurize the system If the gauge reading equals 338 kPa 49 PSI further testing is not required If pressure is not cor rect record the pressure If fuel pressure is below specifications refer to the...

Страница 536: ...RAINER NOT RESTRICTED INCORRECTLY OPERATING FUEL FILTER REGULATOR OR FUEL PUMP REPLACE FUEL FILTER REG ULATOR FUEL PRESSURE ABOVE SPECIFICATIONS RESTRICTION IN CHASSIS FUEL SUP PLY LINE CHECK FOR KINKED OR PLUGGED FUEL SUPPLY LINE IF CHASSIS FUEL LINE IS NOT RESTRICTED REPLACE FILTER REGULA TOR PL FUEL SYSTEM 14 7 DIAGNOSIS AND TESTING Continued ...

Страница 537: ...ensor connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector Fig 10 Move the float lever to the positions shown in the resistance chart Fig 10 Record the resis tance at each point Replace the level sensor if the resistance is not within specifications FUEL INJECTORS For fuel injector diagnosis refer to the Fuel Injec tor Diagnosis charts For poor...

Страница 538: ...EFER TO WIRING DIA GRAMS FOR COLOR CODES AND PIN TERMINAL NUM BERS CIRCUITS OK YES TEST THE ENGINE CON TROL SYSTEM WITH THE DRB SCAN TOOL NO REPAIR OR REPLACE THE WIRING HARNESS AS NEC ESSARY YES CIRCUIT IS OK CHECK FOR FUEL DELIVERY AT SUS PECT INJECTOR BY REMOV ING THE INJECTOR FROM THE RAIL AND OBSERVING FOR FUEL AND OR RESTRICTIONS I THE RAIL OR INJECTOR FUEL INLET REFER TO FUEL INJECTOR REMOV...

Страница 539: ... on rear top of fuel tank Push a siphon hose into the drain port Fig 13 6 Drain fuel tank into holding tank or a properly labeled Gasoline safety container HOSES AND CLAMPS Inspect all hose connections clamps and quick con nect fittings for completeness and leaks Replace cracked scuffed or swelled hoses Replace hoses that rub against other vehicle components or show sign of wear Fuel injected vehi...

Страница 540: ...to the fuel tube the retainer locking ears and the fuel tube shoulder are visible in the windows If they are not visible the retainer was not properly installed Fig 14 Do not rely upon the audible click to confirm a secure connection CAUTION When using the ASD Fuel System Test the Auto Shutdown ASD Relay remains energized for either 7 minutes until the test is stopped or until the ignition switch ...

Страница 541: ...ompartment For the location of the relay within the PDC refer to the PDC cover for location Check electrical terminals for corrosion and repair as necessary FUEL PUMP RELAY The fuel pump relay is located in the PDC The inside top of the PDC cover has a label showing relay and fuse location FUEL PUMP MODULE REMOVAL WARNING RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS SERVICE...

Страница 542: ...ion 4 Depress locking spring tab on side of Fuel Reg ulator Fig 19 and rotate 90 counter clockwise and pull out NOTE Make sure that the upper and lower O rings are on the Filter Regulator assembly INSTALLATION Lightly lubricate the O rings with engine oil 1 Insert Filter Regulator into the opening in the fuel pump module align the two hold down tabs with the flange 2 While applying downward pressu...

Страница 543: ...ody lock over the locking tangs on the strainer 4 Install fuel pump module Refer to Fuel Pump Module Installation in this section FUEL LEVEL SENSOR REMOVAL Remove fuel pump module Refer to Fuel Pump Module in this section 1 Depress retaining tab and remove the fuel pump level sensor connector from the bottom of the fuel pump module electrical connector Fig 22 2 Pull off blue locking wedge Fig 23 3...

Страница 544: ...nstalled in the correct posi tion 5 Install locking wedge on connector 6 Push connector up into bottom of fuel pump module electrical connector 7 Install fuel pump module Refer to Fuel Pump Module in this section FUEL INJECTORS REMOVAL 1 Disconnect negative cable from battery 2 Release fuel system pressure Refer to Fuel System Pressure Release procedure in this section 3 Disconnect fuel supply tub...

Страница 545: ...in the Fuel Delivery Section of this Group FUEL TANK REMOVAL 1 Perform fuel system pressure release 2 Drain fuel tank Refer to Draining Fuel Tank in this section Fig 31 3 Raise vehicle on hoist WARNING WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE 4 Disconnect fuel pump module electrical connec tor Fig 32 5 Disconnect the fuel tube from Fuel Filter Reg ulator Refer to Quick Connect ...

Страница 546: ...ntil the ignition switch is turned to the Off posi tion 9 Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system Check for leaks FUEL FILLER NECK REMOVAL 1 Loosen fuel filler tube cap 2 Remove fuel filler neck screws Fig 34 3 Disconnect fuel fill vapor tube 4 Disconnect fuel filler tube from fuel tank Remove filler neck INSTALLATION 1 Reverse for installation FUEL FILLER TUBE ROL...

Страница 547: ...al shaft 3 From the engine compartment hold the throt tle body lever in the wide open position and install the throttle cable Install the throttle control shield THROTTLE CABLE MANUAL TRANSMISSION REMOVAL 1 Remove throttle control shield Fig 38 2 Working from the engine compartment remove the throttle cable from the throttle body lever Fig 39 and Fig 40 3 Compress the retaining tabs on the cable a...

Страница 548: ...throttle pedal up and remove the cable retainer and cable from upper end of pedal shaft Fig 36 and Fig 37 5 Remove retainer clip from throttle cable and grommet at the dash panel 6 From the engine compartment pull the throttle cable out of the dash panel grommet The grommet should remain in the dash panel INSTALLATION 1 From the engine compartment push the hous ing end fitting into the dash panel ...

Страница 549: ...FICATIONS TORQUE SPECIFICATION DESCRIPTION TORQUE Accelerator Pedal to Dash Nuts 12 N m 105 in lbs Fuel Pump Module Locknut 55 N m 40 ft lbs Fuel Tank Strap Bolts 23 N m 250 in lbs Fuel Rail Bolts 23 N m 195 in lbs Ignition Coil Mounting Bolts 11 N m 95 in lbs Intake Manifold Bolts 11 N m 95 in lbs Throttle Control Shield 5 6 N m 50 in lbs 14 20 FUEL SYSTEM PL REMOVAL AND INSTALLATION Continued ...

Страница 550: ...AP SENSOR PCM INPUT 31 PARK NEUTRAL POSITION SWITCH PCM INPUT 32 POWER DISTRIBUTION CENTER 25 POWER STEERING PRESSURE SWITCH PCM INPUT 31 POWERTRAIN CONTROL MODULE 25 RADIATOR FAN CONTROL MODULE PCM OUTPUT 36 SCI RECEIVE PCM INPUT 32 SCI RECEIVE PCM INPUT 37 SENSOR RETURN PCM INPUT 31 SPEED CONTROL PCM INPUT 31 SPEED CONTROL PCM INPUT 37 SYSTEM DIAGNOSIS 24 TACHOMETER PCM OUTPUT 37 THROTTLE POSITI...

Страница 551: ... determine how the PCM responds to the various input signals There are two different areas of operation OPEN LOOP and CLOSED LOOP During OPEN LOOP modes the PCM receives input signals and responds according to preset PCM programming Inputs from the upstream and down stream heated oxygen sensors are not monitored dur ing OPEN LOOP modes except for heated oxygen sensor diagnostics they are checked f...

Страница 552: ... between the two values it sets a MAP diagnostic trouble code into memory Once the ASD and fuel pump relays have been energized the PCM determines injector pulse width based on the following Battery voltage Engine coolant temperature Engine RPM Intake air temperature IAT Throttle position The number of engine revolutions since cranking was initiated During Start up the PCM maintains ignition tim i...

Страница 553: ...k The PCM may receive a closed throttle input from the Throttle Position Sensor TPS when it senses an abrupt decrease in manifold pressure This indicates a hard deceleration In response the PCM may momentarily turn off the injectors This helps improve fuel economy emissions and engine braking If decel fuel shutoff is detected downstream oxy gen sensor diagnostics is performed WIDE OPEN THROTTLE MO...

Страница 554: ... Link Connector Duty Cycle EVAP Canister Purge Solenoid EGR Solenoid Fuel Injectors Fuel Pump Relay Generator Field Idle Air Control Motor Ignition Coils Malfunction Indicator Check Engine Lamp Radiator Fan Relay Speed Control Solenoids Tachometer Torque Convertor Clutch Solenoid Based on inputs it receives the PCM adjusts fuel injector pulse width idle speed ignition spark advance ignition coil d...

Страница 555: ...ompressor discharge high side pressure through the air conditioning pressure transducer The transducer supplies an input to the PCM The PCM engages the A C compressor clutch if pressure is sufficient for A C system operation AUTOMATIC SHUTDOWN ASD SENSE PCM INPUT The ASD sense circuit informs the PCM when the ASD relay energizes A 12 volt signal at this input indicates to the PCM that the ASD has ...

Страница 556: ...get magnet passes underneath The sensor also acts as a thrust plate to control camshaft endplay CRANKSHAFT POSITION SENSOR PCM INPUT The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input The second crankshaft counter weight has two sets of four timing reference notches including a 60 degree signature notch Fig 7 From the crankshaf...

Страница 557: ...signature notch The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor the PCM knows cylin der number one is the next cylinder at TDC The crankshaft position sensor mounts to the engine block behind the alterna...

Страница 558: ...e By monitoring the oxygen content and converting it to electrical voltage the sensors act as a rich lean switch The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner Also it allows the system to remain i...

Страница 559: ...or input to the input from the upstream sensor the PCM cal culates catalytic convertor efficiency IGNITION CIRCUIT SENSE PCM INPUT The ignition circuit sense input tells the Power train Control Module PCM the ignition switch has energized the ignition circuit Refer to the wiring dia grams for circuit information INTAKE AIR TEMPERATURE SENSOR PCM INPUT The Intake Air Temperature IAT sensor measures...

Страница 560: ...ing switch is located on the power steering gear The switch Fig 16 provides an input to the PCM during periods of high pump load and low engine RPM such as during parking maneuvers When power steering pump pressure exceeds 2758 kPa 400 psi the switch is open The PCM increases idle air flow through the IAC motor to prevent engine stalling When pump pressure is low the switch is closed SENSOR RETURN...

Страница 561: ...rottle blade shaft The TPS is a variable resistor that provides the PCM with an input signal voltage The signal represents throttle blade position As the position of the throttle blade changes the resistance of the TPS changes The PCM supplies approximately 5 volts DC to the TPS The TPS output voltage input signal to the powertrain control module represents throttle blade position The TPS output v...

Страница 562: ...lay is located in the PDC The inside top of the PDC cover has a label showing relay and fuse location AUTOMATIC SHUTDOWN RELAY PCM OUTPUT The automatic shutdown ASD relay supplies bat tery voltage to the fuel injectors electronic ignition coil and the heating elements in the oxygen sensors A buss bar in the power distribution center PDC supplies voltage to the solenoid side and contact side of the...

Страница 563: ...LECTRIC EGR TRANSDUCER PCM OUTPUT The Electric EGR Transducer contains an electri cally operated solenoid and a back pressure con trolled vacuum transducer Fig 23 The PCM operates the solenoid based on inputs from the multi port fuel injection system The transducer and EGR valve are serviced as an assembly When the PCM energizes the solenoid vacuum does not reach the transducer Vacuum flows to the...

Страница 564: ...e ground paths on and off the PCM fine tunes injector pulse width Injector pulse width refers to the amount of time an injector operates The PCM determines injector synchronization from the camshaft position sensor and crankshaft position sensor inputs The PCM grounds the ASD and fuel pump relays after receiving the camshaft position sensor and crankshaft position sensor inputs The PCM energizes t...

Страница 565: ... PCM com pensates for the failure of certain components that send incorrect signals The PCM substitutes for the incorrect signals with inputs from other sensors If the PCM detects active engine misfire severe enough to cause catalyst damage it flashes the MIL At the same time the PCM also sets a Diagnostic Trouble Code DTC For signals that can trigger the MIL Check Engine Lamp refer to Group 25 On...

Страница 566: ... SCI Receive circuit TACHOMETER PCM OUTPUT The PCM operates the tachometer on the instru ment panel The PCM calculates engine RPM from the crankshaft position sensor input TORQUE CONVERTOR CLUTCH SOLENOID PCM OUTPUT Three speed automatic transaxles use a torque con verter clutch solenoid The PCM controls the engage ment of the torque converter clutch through the solenoid Fig 29 The torque converte...

Страница 567: ...e position sensor Fig 34 6 Check hose connections between the PCV valve vacuum port intake manifold and the oil sep arator Fig 35 Fig 32 Power Distribution Center POWER DISTRI BUTION CEN TER FUSES RELAYS Fig 33 Throttle Cable Automatic Transmission SPEED CON TROL CABLE THROTTLE CABLE TRANSMISSION KICKDOWNCABLE Fig 34 Idle Air Control Motor and Throttle Position Sensor Typical IDLE AIR CONTROL MOTO...

Страница 568: ...ctrical and hose connections at the duty cycle purge solenoid Fig 39 Fig 36 MAPIntake Air Temperature Sensor MAP AIR TEMPERATURE SENSOR PCV VACUUM NIPPLE INTAKE MANIFOLD Fig 37 Fuel Injectors FUEL SUP PLY LINE FUEL LINE QUICK CONNECTS IGNITION COIL FUEL RAIL FUEL INJEC TOR Fig 38 Ignition Coil and Spark Plugs Typical IGNITION COILS SPARK PLUG CABLE SPARK PLUG INSULATOR Fig 39 Duty Cycle Purge Sole...

Страница 569: ...tion sensor and engine coolant temperature sensor Fig 42 16 Check the electrical connector at the Elec tronic EGR Transducer Inspect the vacuum and back pressure hoses at the solenoid and transducer for leaks Fig 43 17 Inspect the electrical connections at the gen erator Fig 44 Check the generator belt for glazing or damage Fig 40 Starter Motor and Ground Strap STARTER MOTOR STARTER SOLENOID GROUN...

Страница 570: ...at the upstream and downstream heated oxygen sensors Fig 49 and Fig 50 Fig 45 Crankshaft Position Sensor CRANKSHAFT POSITION SENSOR OIL FILTER GENERATOR Fig 46 Vehicle Speed Sensor TRANSAXLE EXTENSION HOUSING VEHICLE SPEED SENSOR Fig 47 Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Fig 48 Park Neutral Switch and Torque Convertor Clutch Solenoid TORQUE CON VERTOR CLUTCH SOLE NOID AU...

Страница 571: ...e 1 Inspect the battery connections Clean corroded terminals Fig 31 2 Check the 2 PCM 40 way connector for stretched wires on pushed out terminals Fig 54 3 Open the Power Distribution Center PDC Check for blown fuses Ensure the relays and fuses are fully seated in the PDC Fig 55 A label on the underside of the PDC cover shows the locations of each relay and fuse Fig 51 Fuel Pump Module Electrical ...

Страница 572: ...fuel injector electrical connections Fig 60 Fig 56 Throttle Cable Automatic Transmission SPEED CON TROL CABLE THROTTLE CABLE TRANSMISSION KICKDOWNCABLE Fig 57 Idle Air Control Motor and Throttle Position Sensor Typical IDLE AIR CONTROL MOTOR THROTTLE POSITION SEN SOR Fig 58 PCV Valve PCV VALVE 1 SPARK PLUG BOOT Fig 59 MAP Intake Air Temperature Sensor FUEL RAIL INTAKE MANI FOLD MAP AIR TEM PERATUR...

Страница 573: ...ent Replace as necessary Check the air induction system for restrictions 14 Check the electrical connection at the knock sensor Fig 64 15 Check the electrical connections at the cam shaft position sensor Fig 65 and engine coolant temperature sensor Fig 66 Fig 61 Ignition Coil and Spark Plugs IGNITION COIL FAS TENERS ELECTRICAL CONNECTOR Fig 62 Duty Cycle Purge Solenoid DUTY CYCLE EVAP PURGE SOLENO...

Страница 574: ... the crank shaft position sensor Fig 69 19 Check the electrical connection at the vehicle speed sensor Fig 70 Fig 66 Engine Coolant Temperature Sensor FUEL RAIL COOLANT TEMPER ATURE SENSOR Fig 67 Electronic EGR Transducer EGR TRANSDUCER EGR VALVE SERVICE PORT CAM SENSOR Fig 68 Generator GENERATOR Fig 69 Crankshaft Position Sensor CRANKSHAFT POSITION SENSOR OIL FILTER GENERATOR Fig 70 Vehicle Speed...

Страница 575: ...l con nection at the fuel tank for corrosion or damage Fig 75 Check for pinched kinked or damaged fuel sup ply tube Fig 71 Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Fig 72 Park Neutral Switch and Torque Convertor Clutch Solenoid TORQUE CON VERTOR CLUTCH SOLE NOID AUTOMATIC TRANSAXLE HOUSING PARK NEUTRAL SWITCH Fig 73 Upstream Heated Oxygen Sensor OXYGEN SEN SORS EXHAUST MANIFOL...

Страница 576: ... 85 and 86 of the relay The resistance should be between 75 65 ohms 3 Connect the ohmmeter between relay terminals 30 and 87A of the relay The ohmmeter should show continuity between terminals 30 and 87A 4 Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show continuity at this time 5 Connect one end of a jumper wire 16 gauge or heavier to relay terminal ...

Страница 577: ...o terminals of the white wires in the heated oxygen sensor connector Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms IDLE AIR CONTROL IAC MOTOR TEST To preform a complete test of IAC motor and its circuitry refer to DRB scan tool and the appropriate Powertrain Diagnostics Procedures manual KNOCK SENSOR The knock sensor can be tested with a digital volt meter Sensor o...

Страница 578: ...utput terminal One of the other terminals is a 5 volt supply and the remaining ter minal is ground Connect the DVM between the center and sensor ground terminal Refer to Group 8W Wiring Dia grams for correct pinout With the ignition switch in the ON position check the output voltage at the center terminal wire of the connector Check the output voltage at idle and at Wide Open Throttle WOT At idle ...

Страница 579: ...ody from engine b While holding the throttle open spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner Only use Mopar Parts Cleaner to clean the throttle body c Using a soft scuff pad clean the top and bot tom of throttle body bore and the edges and mani fold side of the throttle blade The edges of the throttle blade and portions of the throttle ...

Страница 580: ...en position and install throttle cable clasp Fig 86 8 Install throttle cable cover Tighten bolt to 5 6 N m 50 ins lbs THROTTLE BODY AUTOMATIC TRANSMISSION REMOVAL 1 Remove throttle cable cover 2 Remove throttle body cables using the following procedures 3 Remove throttle cable from throttle body cam Fig 87 and Fig 88 4 Compress the retaining tabs on the cable and slide cable out of bracket Fig 88 ...

Страница 581: ...he engine compartment rotate the throttle lever forward to the wide open position and install throttle cable clasp Fig 88 8 If equipped with speed control rotate throttle lever forward to the wide open position and slide speed control cable connector onto nail head 9 Rotate throttle lever forward to the wide open position and slide kickdown cable connector onto nail head 10 Install throttle cable ...

Страница 582: ...on O rings or seals damage may result If assembly of component is difficult use water to aid assembly Use care when removing hoses to prevent damage to hose or hose nipple REMOVAL 1 Disconnect negative cable from battery 2 Remove electrical connector from idle air con trol motor and throttle position sensor 3 Remove the EVAP purge hose from the throttle body 4 Remove throttle body Refer to Throttl...

Страница 583: ...nector to sensor 4 Install air inlet duct wing nut and duct from intake manifold insure that the duct does not inter fer with ignition cables DUTY CYCLE EVAP PURGE SOLENOID VALVE The solenoid attaches to a bracket near the front engine mount Fig 98 The solenoid will not operate unless it is installed correctly REMOVAL 1 Disconnect electrical connector from solenoid 2 Disconnect vacuum tubes from s...

Страница 584: ...VAL 1 Raise and support vehicle 2 Unplug sensor connector 3 Remove sensor using an oxygen sensor crow foot wrench such as Snap On tool YA8875 or equiva lent Fig 100 4 After removing the sensor the exhaust mani fold threads must be cleaned with an 18 mm X 1 5 6E tap If reusing the original sensor coat the sensor threads with an anti seize compound such as Loctitet 771 64 or equivalent INSTALLATION ...

Страница 585: ...n sensor crow foot wrench such as Snap On tool YA8875 or equivalent Fig 102 Tighten the sensor to 28 N m 20 ft lbs torque 2 Connect sensor electrical harness from clips along body 3 Connect electrical connector from sensor 4 Lower vehicle AIR CLEANER ELEMENT Neon vehicles do not use a heated air inlet system The PCM adjusts fuel injector pulse width and igni tion timing to compensate for different...

Страница 586: ...ar of the cylinder head Fig 106 or Fig 107 REMOVAL 1 With the engine cold drain coolant until level drops below cylinder head Refer to Group 7 Cooling System 2 Disconnect coolant sensor electrical connector 3 Remove coolant sensor INSTALLATION 1 Install coolant sensor Tighten sensor to 18 N m 165 in lbs torque 2 Attach electrical connector to sensor 3 Fill cooling system Refer to Group 7 Cooling S...

Страница 587: ...l Information VECI label and the following specifications use specifica tions on VECI label The VECI label is located in the engine compartment TORQUE SPECIFICATIONS DESCRIPTION TORQUE Air Cleaner Wingnut 1 5 N m 15 in lbs Air Cleaner Mount Stud To Thrott Body 10 N m 90 in lbs Crankshaft Position Sensor Mounting Bolts 8 N m 70 in lbs Engine Coolant Temperature Sensor 18 N m 165 in lbs IAC Motor To...

Страница 588: ...SPECIAL TOOLS FUEL Extractor C 4334 Pressure Gauge Assembly C 4799 B Fuel Pressure Test Adapter 6539 Spanner Wrench 6856 Metering Orifice Fuel Line Tool Fuel Line Adapter PL FUEL SYSTEM 14 59 ...

Страница 589: ...Fuel Line Adapter 1 4 14 60 FUEL SYSTEM PL SPECIAL TOOLS Continued ...

Страница 590: ...e It is used to direct oil from the power steering pump to either side of the integral steering rack piston Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle As steering effort increases as in a turn the torsion bar twists causing relative rotary motion between the rotary valve body and valve spool This movement directs oil behind the integral rack piston ...

Страница 591: ...ired 4 Loose lower control arm to front suspension crossmember bolts 4 Tighten control arm mounting bolts to the specified torques 5 Loose strut assembly to body attaching bolts or nuts 5 Check upper strut mount to body attaching bolts or nuts for looseness If required tighten to the specified torques 6 Power steering fluid pressure hose touching the body of the vehicle 6 Adjust hose to proper pos...

Страница 592: ...nd replace O Ring as required 3 Low power steering fluid level 3 Fill power steering fluid reservoir to proper level and perform leakage diagnosis 4 Air leak between power steering fluid reservoir and power steering pump 4 Inspect and or replace power steering fluid reservoir as required SQUEAK OR RUBBING SOUND 1 Sound coming from steering column 1 Check for squeak in steering column Inspect for c...

Страница 593: ... 4 Lubricate tie rod ends if they are not a lubricated for life type If tie rod end is a lubricated for life type replace tie rod end 5 Loose power steering pump drive belt 5 Tighten the power steering pump drive belt to the specified tension See accessory drive in service manual 6 Faulty power steering pump flow control Verify cause using Power Steering Pump Test Procedure 6 Replace power steerin...

Страница 594: ...S MOMENTARY INCREASE IN EFFORT WHEN TURNING 1 Tires not properly inflated 1 Inflate tires to specified pressure 2 Low power steering fluid level 2 Add power steering fluid as required to power steering fluid reservoir to obtain proper level Perform leakage diagnosis on power steering system 3 Loose power steering pump drive belt 3 Adjust the power steering pump drive belt to the specified tension ...

Страница 595: ...ts 5 Mispositioned dash cover 5 Reposition dash cover To evaluate items 6 and 7 disconnect the intermediate shaft Turn the steering wheel and feel or listen for internal rubbing in steering column 6 Steering wheel rubbing 6 Adjust steering column shrouds to eliminate rubbing condition 7 Damaged mis positioned or un lubricated steering column coupler to dash seal 7 Determine condition which exists ...

Страница 596: ... universal joint broken isolator or loose fasteners 4 Free play in steering column 4 Check components of the steering system and repair or replace as required 5 Loose front suspension control arm ball joints 5 Check and or replace the ball joint or control arm as required 6 Loose steering knuckle to ball joint stud pinch bolt 6 Check pinch bolts and tighten if required to specified torque 7 Front ...

Страница 597: ...king 3 Check for dragging brakes Refer to the procedures in the Brake Group of this service manual 4 Unbalanced steering gear valve If this is the cause the steering efforts will be very light in direction of lead and heavier in the opposite direction 4 Replace steering gear STEERING WHEEL HAS FORE AND AFT LOOSENESS 1 Steering wheel to steering column shaft retaining nut not properly tightened and...

Страница 598: ...repair or replace the component as required Refer to Power Steering Pump and or Power Steering Gear in this group of the service manual for required procedures CONDITION POSSIBLE CAUSES CORRECTION AERATION AND OVERFLOW OF FLUID 1 Air leaks 1 Check for an air leak into the power steering system as described under Sucking Air Diagnosis and correct condition 2 Low fluid level 2 Extremely cold tempera...

Страница 599: ...cantly increased All vehicles equipped with power steering use a remote mounted reservoir for the power steering fluid The power steering fluid remote reservoir is mounted to the rear of the cylinder head on the pas senger side of the vehicle The service procedures for the TTA power steering pump are limited to the areas and components listed below No repair procedures are to be done on internal c...

Страница 600: ... safe level Under normal power steering pump operating con ditions pressure requirements of the pump are below maximum causing the pressure relief valve to remain closed DIAGNOSIS AND TESTING POWER STEERING SYSTEM TEST PROCEDURE The following procedure can be used to test the operation of the power steering system on the vehi cle This test will provide the flow rate of the power steering pump alon...

Страница 601: ...luid or equivalent DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID POWER STEERING PUMP INITIAL OPERATION CAUTION The fluid level should be checked with engine off to prevent injury from moving compo nents Use only MoparT Power Steering Fluid Do not use automatic transmission fluid Do not over fill Wipe filler cap clean then check the fluid level The dipstick should indicate FULL COLD when the ...

Страница 602: ...r steering pressure switch is used to improve the vehi cle s idle quality The pressure switch improves vehi cle idle quality by controlling engine idle speed when required The pressure switch functions by signaling the power train control module that the power steering system is putting additional load on the engine This type of condition exists when turning the front tires of the vehicle when the...

Страница 603: ...e MoparT Power Steering Fluid or equivalent 3 Fill power steering reservoir to correct fluid level 4 Connect negative cable back on negative post of battery 5 Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in sys tem Stop engine check fluid level and inspect sys tem for leaks See Checking Fluid Level POWER STEERING FLUID PRESSURE HOSE CAUTION Cap all o...

Страница 604: ...g Fig 13 4 Install a new O ring Fig 14 on power steering pressure hose banjo fitting bolt 5 Lubricate both O rings using fresh clean power steering fluid 6 Install banjo bolt into the power steering pres sure hose banjo fitting Fig 14 7 Attach power steering pressure hose to outlet fitting on power steering pump Fig 12 Do not tighten or torque pressure fitting Banjo bolt at this time Fig 9 Power S...

Страница 605: ...ring pressure hose bracket to generator shield 17 Start the engine and let run for a few seconds Then turn the engine off 18 Add fluid if necessary Repeat the above pro cedure until the fluid level remains constant after running the engine 19 Raise front wheels of vehicle off the ground 20 Start the engine Slowly turn the steering wheel right and left lightly contacting the wheel stops Then turn t...

Страница 606: ...top of the vehicles engine compartment CAUTION Care must be used when installing power steering fluid return hose on power steering fluid reservoir If excessive force is used when try ing to install hose on nipple of power steering fluid reservoir nipple can be broken off the reservoir 2 Install power steering return hose on power steering fluid reservoir fitting Install hose clamp on power steeri...

Страница 607: ...D EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING DO NOT START ENGINE WITH ANY LOOSE OR DIS CONNECTED HOSES DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST REMOVE CAUTION Care must be used when removing the power steering fluid supply hose from power steer ing fluid reservoir If excessive force is used when trying to remove hose from nipple on power steer ing fluid rese...

Страница 608: ...OSES OR ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST The power steering pump removal procedure and pump and bracket fastener locations are the same for both engine applications used for this vehicle The front power steering pump bracket must be removed as an assembly with the power steering pump and removed from the pump after removing the pulley from the power steering pump REMOVE 1 Remo...

Страница 609: ...ig 26 back on the engine using reverse of removal procedure 2 Slide front power steering pump bracket between bracket mounting bolt and front engine mount Fig 25 Be sure washer on bolt is between the head of the bolt and bracket and does not get trapped between bracket and engine mount 3 Install the 2 power steering pump to cast mounting bracket attaching bolts Fig 24 Do not tighten bolts at this ...

Страница 610: ... bracket Fig 21 While holding locating pin against power steering pump bracket torque pump end Banjo bolt to 34 N m 25 ft lbs CAUTION Do not use automatic transmission fluid in power steering system Only use MoparT Power Steering Fluid or equivalent 14 Fill power steering reservoir to correct fluid level 15 Connect negative cable back on negative post of battery 16 Start the engine and let run for...

Страница 611: ...rd the center of the vehicle CAUTION Care must be used when removing and installing power steering fluid hoses on the power steering fluid reservoir If excessive force is used when trying to remove or install hoses on nipples of power steering fluid reservoir nipples can be broken off the reservoir 6 Remove the power steering fluid return and supply hose from the power steering fluid reservoir Fig...

Страница 612: ... off 12 Add power steering fluid if necessary 13 Lower the vehicle and turn the steering wheel slowly from lock to lock 14 Stop the engine Check the fluid level and refill as required 15 If the fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure DISASSEMBLY AND ASSEMBLY POWER STEERING PUMP DRIVE PULLEY The power steering pump must be removed from the ...

Страница 613: ...ction in this group of the service manual for required procedure CAUTION Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley This will damage the pulley and the power steering pump 2 Mount the power steering pump in a vise using the power steering pump mounting bracket Fig 39 Mount Puller Special Tool C 4333 or C 4068 on power steering pump pulley Fig 39 Remov...

Страница 614: ...vice Procedures section in this group of the service manual for required procedure SPECIFICATIONS POWER STEERING PUMP FLOW SPECIFICATIONS Power Steering Pump Flow At 1500 RPM And Minimum Pressure 4 9 to 5 3 Liters Min 1 3 to 1 9 GPM Control Valve Pressure Relief 8240 to 8920 kPa 1195 to 1293 psi Fig 39 Pulley Removal From Power Steering Pump Shaft POWER STEERING PUMP POWER STEERING PUMP PULLEY SPE...

Страница 615: ...ember Attaching Bolt 23 N m 17 ft lbs Power Steering Pump Pressure Hose Banjo Bolt 34 N m 25 ft lbs Discharge Fitting 75 N m 55 ft lbs To Bracket Mounting Bolts 54 N m 40 ft lbs Brackets To Engine Mounting Bolts 54 N m 40 ft lbs SPECIAL TOOLS POWER STEERING PUMP Installer C 4063B Puller C 4333 P S System Analyzer 6815 19 26 STEERING PL SPECIFICATIONS Continued ...

Страница 616: ...ther side of the integral rack piston Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle This movement directs oil behind the integral rack piston which in turn builds up hydraulic pressure and assists in the turning effort The drive tangs on the pinion of the power steering pump mate loosely with a stub shaft This is to per mit manual steering control to b...

Страница 617: ... the hoses for restrictions and repair as necessary The initial pressure reading should be in the range of 345 552 kPa 50 80 psi The flow meter should read between 1 3 and 1 4 GPM CAUTION The following test procedure involves testing power steering pump maximum pressure output and flow control valve operation Do not leave valve closed for more than 5 seconds as the pump could be damaged 8 Close va...

Страница 618: ...m front suspension cross member Fig 5 Bobble strut does not need to be removed from transaxle assembly 5 Remove nuts attaching both outer tie rod ends to the steering knuckles Fig 6 Nuts are to be removed from tie rod ends using the following procedure hold tie rod end stud with an 11 32 socket while loosening and removing nut with wrench 6 Remove both tie rod end studs from the steer ing knuckles...

Страница 619: ...TION Before removing front suspension crossmember from the vehicle the location of the front suspension crossmember MUST be scribbed on body of vehicle per Fig 9 This must be done so crossmember can be relocated against body of vehicle in the same location when it is reinstalled If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assem bled NET BUILD fr...

Страница 620: ...ed steering gear assembly to the replacement steering gear if a new steering gear is being installed Fig 11 Marking Front Suspension Crossmember Location SCRIBBED LINE FOR LOCATION OF FRONT SUSPENSION CROSSMEMBER LOWER CON TROL ARM LOWER CONTROL ARM BUSHING MOUNTING BOLT FRONT SUSPENSION CROSSMEMBER AWL Fig 12 Supporting Front Suspension Crossmember STEERING GEAR SWAYBAR FRONT SUSPENSION CROSSMEMB...

Страница 621: ...gear tube nuts Fig 10 to 31 N m 275 in lbs 5 If vehicle is equipped with power steering install power steering pressure and return hose rout ing bracket and attaching screw on front suspension crossmember Fig 9 Torque hose routing bracket to crossmember attaching bolt Fig 9 to 23 N m 17 ft lbs 6 If the vehicle is equipped with power steering install vehicle wiring harness connector onto power stee...

Страница 622: ...e rods DISASSEMBLY AND ASSEMBLY OUTER TIE ROD END DISASSEMBLE 1 Loosen the inner tie rod to outer tie rod jam nut Fig 19 2 Remove the nut attaching the outer tie rod end to steering knuckle Fig 20 Nut is to be removed from tie rod end using the following procedure hold tie rod end stud with a 11 32 socket while loosening and removing nut with wrench 3 Remove the tie rod end stud from steering knuc...

Страница 623: ...tie rod if they became twisted during Toe adjustment SPECIFICATIONS STEERING GEAR FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE FRONT SUSPENSION CROSSMEMBER To Body Mounting Bolts 163 N m 120 ft lbs STEERING GEAR To Crossmember Mounting Bolts 68 N m 50 ft lbs OUTER TIE ROD To Steering Knuckle Nut 55 N m 40 ft lbs To Inner Tie Rod Jam Nut 61 N m 45 ft lbs POWER STEERING HOSE Tube Nuts 31 N m 27...

Страница 624: ...IFICATIONS 43 DESCRIPTION AND OPERATION STEERING COLUMN ASSEMBLY Both the standard non tilt and tilt steering col umns Fig 1 have been designed to be serviced only as complete assemblies if a component of the steer ing column is defective The only replaceable compo nents of the steering column assembly are the key cylinder ignition switch multi function switch clock spring trim shrouds and steerin...

Страница 625: ...Fig 1 Non Tilt And Tilt Steering Column Assemblies 19 36 STEERING PL DESCRIPTION AND OPERATION Continued ...

Страница 626: ...hicle is involved in a colli sion which deploys the air bag regardless of the extent of damage done to the vehicle 2 If a vehicle is involved in an impact of the vehi cles front suspension or under carriage which results in any type of damage to the front suspension cross member 3 Under any conditions which result in the steer ing column assembly or steering column shaft receiv ing a force great e...

Страница 627: ...NSITIVE COMPLEX ELECTRO MECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE REMOVE OR INSTALL THE AIR BAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGI NALLY USED FOR THE AIR BAG COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIF...

Страница 628: ...IVE MODULE THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF MODULE ACCIDENTLY DEPLOYS IF AIR BAG MOD ULE IS PLACED ON A BENCH OR OTHER SUR FACE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOYMENT Fig 6 Steering Column Cover ATTACHING SCREW FUSE ACCESS PANEL HEAD LAMP SWITCH STEERING COLUMN STEERING COLUMN COVER ATTACHING SCREWS Fig 7 Steer...

Страница 629: ...ving steering wheel from steering column 13 Remove steering wheel assembly from steer ing column shaft using Puller Special Tool C 3428 B or equivalent 14 Remove key lock cylinder from steering col umn Key lock cylinder is removed from steering col umn using the following procedure Place the key lock cylinder in the Run position Then through the hole in lower shroud Fig 14 depress lock cylinder re...

Страница 630: ...el 21 Remove routing clip Fig 18 holding wiring harness to jacket of steering column Then remove wiring harness connectors from the multi function switch and the windshield wiper switch Fig 18 Fig 14 Key Lock Cylinder Access Hole In Steering Column Shrouds Fig 15 Upper And Lower Steering Column Shrouds TILT LEVER LOWER STEERING COL UMN SHROUD STEERING COLUMN LOWER STEERING COL UMN SHROUD FASTEN ER...

Страница 631: ...n the 2 steering column upper mounting bracket nuts to a torque of 17 N m 150 in lbs 8 Tighten the steering column lower mounting bracket nuts 2 to a torque of 17 N m 150 in lbs 9 Assemble the steering column flex coupler to the intermediate steering coupler Fig 16 Install the steering coupler pinch bolt Torque the pinch bolt nut to 28 N m 250 in lbs Be sure to install upper to lower steering coup...

Страница 632: ...e to Negative post of the battery When reconnecting battery on a vehicle that has had the air bag module removed the following procedure should be used Remove forward console or cover as necessary Connect DRB II to ASDM diagnostic 6 way con nector located at right side of the ASDM module Turn ignition key to ON position Exit vehicle with the DRB II Install the latest version of the proper diagnost...

Страница 633: ......

Страница 634: ...emperature approximately 21 C to 27 C 70 F to 80 F In all pumps add fluid as necessary use only Mopar Power Steering Fluid or equivalent DO NOT USE ANY TYPE OF AUTOMATIC TRANSMIS SION FLUID REMOVAL AND INSTALLATION POWER STEERING PRESSURE SWITCH A power steering fluid pressure switch is used to improve the vehicle s idle quality The power steering fluid pressure switch improves vehicle idle qualit...

Страница 635: ...steering pressure switch CAUTION Do not use automatic transmission fluid in power steering system Only use MoparT Power Steering Fluid or equivalent 3 Fill power steering reservoir to correct fluid level 4 Connect negative cable back on negative post of battery 5 Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in sys tem Stop engine check fluid level an...

Страница 636: ...ings located at ends of power steering pressure hose and Banjo bolt INSTALL 1 Install power steering pressure hose in vehicle from top of engine compartment 2 Using a lint free towel wipe clean all open power steering hose ends and the power steering pump and steering gear ports 3 Install new O ring on end of power steering pressure hose banjo fitting Fig 7 Fig 4 Power Steering Pressure Hose Routi...

Страница 637: ...few seconds Then turn the engine off 17 Add fluid if necessary Repeat the above pro cedure until the fluid level remains constant after running the engine 18 Raise front wheels of vehicle off the ground 19 Start the engine Slowly turn the steering wheel right and left lightly contacting the wheel stops Then turn the engine off 20 Add power steering fluid if necessary 21 Lower the vehicle and turn ...

Страница 638: ...power steering return hose on steel tube at power steering gear Fig 9 Install hose clamp on power steering return hose at power steering gear Fig 9 Be sure hose clamp is installed on return hose past upset bead on steel tube at power gear 6 Lower vehicle 7 Add power steering fluid to the reservoir until the fluid level is at the full cold mark on the dipstick 8 Start the engine and let run for a f...

Страница 639: ...ring gear Fig 12 Be sure hose clamp is installed on return hose past upset bead on steel tube at power gear 5 Lower vehicle 6 Remove hose clamp attaching power steering fluid supply hose to power steering fluid reservoir Fig 13 Then remove power steering fluid supply hose from power steering fluid reservoir 7 Remove hose clamp attaching power steering fluid supply hose to power steering pump Fig 1...

Страница 640: ...e fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure 13 Check all hose connections for leaks POWER STEERING PUMP WARNING POWER STEERING OIL ENGINE COM PONENTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING DO NOT START ENGINE WITH ANY LOOSE OR DIS CONNECTED HOSES OR ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST The front m...

Страница 641: ...ey 13 Remove power steering pump and front mounting bracket as an assembly from the engine Fig 20 14 Transfer required parts from removed power steering pump to replacement power steering pump INSTALL 1 Install power steering pump and mounting bracket as an assembly Fig 20 back on the engine using reverse of removal procedure 2 Slide front power steering pump bracket between bracket mounting bolt ...

Страница 642: ... O rings using fresh clean power steering fluid 11 Install banjo bolt into the power steering pres sure hose banjo fitting 12 Attach power steering pressure hose on outlet fitting of the power steering pump Fig 16 13 Position locating pin on power steering pres sure hose banjo fitting so it is against power steering pump mounting bracket Fig 16 While holding locating pin against power steering pum...

Страница 643: ...id reservoir nipples can be broken off the reservoir 7 Remove the power steering fluid return and supply hose from the power steering fluid reservoir Fig 25 8 Remove the power steering fluid reservoir from the mounting bracket Reservoir is removed from bracket by lifting the reservoir straight up out of the bracket 9 If removal of the mounting bracket is required remove the bolts attaching it to t...

Страница 644: ...heck the fluid level and refill as required 12 If the fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure SPECIAL TOOLS POWER STEERING PUMP Installer C 4063B Puller C 4333 P S System Analyzer 6815 PL STEERING 19 11 REMOVAL AND INSTALLATION Continued ...

Страница 645: ...sted in the Mopar Parts Catalog that the correct replacement part for the vehicle being serviced is installed The power steering system used on this vehicle consists of these four major components Power Steering Gear Fig 1 Power Steering Pump Pres sure Hose and Return Hose Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack te...

Страница 646: ...aft Fig 2 2 Raise vehicle on jack stands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 3 Remove both front wheel and tire assemblies from the vehicle 4 Remove engine transaxle bobble dampener on vehicles so equipped from front suspension cross member Fig 3 Bobble strut...

Страница 647: ...le the location of the front suspension crossmember MUST be scribbed on body of vehicle per Fig 9 This must be done so crossmember can be relocated against body of vehicle in the same location when it is reinstalled If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assem bled NET BUILD front suspension alignment set tings will not be obtained This may...

Страница 648: ...n jack raise front sus pension crossmember and steering gear against body and frame rails of vehicle Start the 2 rear bolts into tapping plates attaching front suspension crossmem ber to body of vehicle Fig 9 Then install the 2 front bolts attaching front suspension crossmember to frame rails of vehicle Fig 9 Tighten the 4 mounting bolts until front suspension crossmember is against body of vehicl...

Страница 649: ...l and tire assemblies back on vehicle Tighten the wheel nuts to 135 N m 100 ft lbs torque 9 Lower vehicle 10 From interior of vehicle reconnect the steer ing gear coupler with the steering column shaft cou pler Install steering gear coupler retaining pinch bolt and torque to 28 N m 250 in lbs Be sure to install the upper to lower steering coupler retaining bolt retention pin Fig 2 CAUTION Do not u...

Страница 650: ...ody Mounting Bolts 163 N m 120 ft lbs STEERING GEAR To Crossmember Mounting Bolts 68 N m 50 ft lbs OUTER TIE ROD To Steering Knuckle Nut 55 N m 40 ft lbs To Inner Tie Rod Jam Nut 61 N m 45 ft lbs POWER STEERING HOSE Tube Nuts 31 N m 275 in lbs Routing Bracket At Crossmember 23 N m 17 ft lbs SPECIAL TOOLS POWER STEERING GEAR Fig 14 Outer Tie Rod End Jam Nut Remover Tie Rod End MB 990635 P S System ...

Страница 651: ...e components of the steering column assembly are the key cylinder ignition switch multi function switch clock spring trim shrouds and steering wheel These replaceable components of the steering column can be serviced without requiring removal of the steering column from the vehicle STEERING GEAR TO STEERING COLUMN COUPLING This vehicle uses a different design for the cou pling used to connect the ...

Страница 652: ...assembly or steering column shaft receiv ing a force great enough to move the steering column or shaft forward or rearward in a vehicle STEERING COUPLING INSPECTION PROCEDURE 1 Remove the pinch bolt safety pin from the steering column shaft coupling pinch bolt Fig 3 2 Loosen the coupling pinch bolt retaining nut and remove pinch bolt Fig 3 from steering coupler Pinch bolt nut is caged to coupler a...

Страница 653: ... FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGI NALLY USED FOR THE AIR BAG COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFI CALLY DESIGNED FOR THE AIR BAG SYSTEM THEY MUST NEVER BE REPLACED WITH ANY SUB STITUTES ANYTIME A NEW FASTENER IS NEEDED REP...

Страница 654: ...TIONS SHOULD BE OBSERVED AT NO TIME SHOULD ANY SOURCE OF ELECTRICITY BE PER MITTED NEAR THE INFLATOR ON THE BACK OF THE AIRBAG MODULE WHEN CARRYING A LIVE MODULE THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF AIRBAG ACCIDENTLY DEPLOYS IF AIRBAG MOD ULE IS PLACED ON A BENCH OR OTHER SUR FACE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOY...

Страница 655: ...ering column shaft when removing steering wheel from steering column 13 Remove steering wheel assembly from steer ing column shaft using Puller Snap On CJ2001P or an equivalent 14 Remove key lock cylinder from steering col umn Key lock cylinder is removed from steering col umn using the following procedure Place the key lock cylinder in the Run position Then through the hole in lower shroud Fig 15...

Страница 656: ...ng bracket through bolt Fig 18 19 Remove the 2 steering column assembly upper bat wing bracket to support bracket nuts Fig 19 20 Lower steering column assembly in the steer ing column access opening of the lower instrument panel Fig 15 Key Lock Cylinder Access Hole In Steering Column Shrouds Fig 16 Upper And Lower Steering Column Shrouds Fig 17 Steering Column Coupling Fig 18 Steering Column Lower...

Страница 657: ...shroud to lock housing attaching screws Fig 16 7 Be sure both breakaway capsules are still fully seated in the slots of the upper steering column mounting bracket Equally tighten both steering col umn mounting nuts until upper steering column mounting bracket is seated against support bracket Fig 19 Then tighten the 2 steering column upper mounting bracket nuts to a torque of 12 N m 105 in lbs 8 E...

Страница 658: ...ey lock cylinder is installed by positioning key cyl inder in the run position so retaining tab can be depressed and the pushing key cylinder into lock hos ing until retaining tab locks into key lock cylinder 19 Reconnect ground cable to Negative post of the battery When reconnecting battery on a vehicle that has had the air bag module removed the following procedure should be used Remove forward ...

Страница 659: ......

Страница 660: ...NS CIGAR LIGHTER 8W 41 1 8W 42 AIR CONDITIONING HEATER 8W 42 1 8W 43 AIRBAG SYSTEM 8W 43 1 8W 44 INTERIOR LIGHTING 8W 44 1 8W 47 AUDIO SYSTEMS 8W 47 1 8W 48 REAR WINDOW DEFOGGER 8W 48 1 8W 50 FRONT LIGHTING 8W 50 1 8W 51 REAR LIGHTING 8W 51 1 8W 52 TURN SIGNALS 8W 52 1 8W 53 WIPERS 8W 53 1 8W 60 POWER WINDOWS 8W 60 1 8W 61 POWER DOOR LOCKS 8W 61 1 8W 62 POWER MIRRORS 8W 62 1 8W 64 POWER SUNROOF 8W...

Страница 661: ......

Страница 662: ...tion with the doors closed and the key removed from the ignition If a component is part of several different circuits it is shown in the diagram for each For example the headlamp switch is the main part of the exterior lighting but it also affects the interior lighting and the chime warning system It is important to real ize that no attempt is made on the diagrams to represent components and wirin...

Страница 663: ...OCEDURE REQUIRES IT TO BE ON WARNING SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL WARNING OPERATE THE ENGINE ONLY IN A WELL VENTILATED AREA WARNING KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING ESPECIALLY THE FAN AND BELTS WARNING TO PREVENT SERIOUS BURNS AVOID CONTACT WITH HOT PARTS SUCH AS THE RA...

Страница 664: ...ponent connectors by name If a component has two or more connectors they will be identified as C1 C2 C3 etc This sections also provides terminal numbering cir cuit identification wire colors and functions All connectors are viewed from the terminal end unless otherwise specified To find the connector loca tion in the vehicle refer to section 8W 90 This sec tion uses the connector identification nu...

Страница 665: ...Fig 5 Symbol Identification 8W 01 4 8W 01 GENERAL INFORMATION PL DESCRIPTION AND OPERATION Continued ...

Страница 666: ...e front strut tower in the area shown in Fig 7 for the installation of any metal fasteners into the strut tower Because of the minimum clearance in this area Fig 7 installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring If a plastic clip is missing or is lost or broken during servicing a vehicle replace only with the equivalent part listed...

Страница 667: ...erminal push out Terminals in the wiring assembly are fully seated into the connector component and locked in position Dirt or corrosion on the terminals Any amount of corrosion or dirt could cause an intermittent prob lem Damaged connector component casing exposing the item to dirt and moisture Wire insulation that has rubbed through causing a short to ground Wiring broke inside of the insulation...

Страница 668: ... the item 4 The voltmeter will show the difference in volt age between the two points TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure The steps are listed and explained below Always check for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify ...

Страница 669: ...cles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal A service part is avail able if this fusible link requires replacement This service part has the eyelet that attaches to the starter motor If the fusible link requires replace ment this indicates a problem in the charging start ing system that needs to be corrected Replacement of ...

Страница 670: ...9 Connect connector to its mating half compo nent 10 Connect battery and test all affected systems CONNECTOR AND TERMINAL REPLACEMENT 1 Disconnect battery 2 Disconnect the connector that is to be repaired from its mating half component 3 Cut off the existing wire connector directly behind the insulator Remove six inches of tape from the harness 4 Stagger cut all wires on the harness side at 1 2 in...

Страница 671: ...e connector Fig 21 Fig 22 5 Cut the wire 6 inches from the back of the con nector 6 Remove 1 inch of insulation from the wire on the harness side 7 Select a wire from the terminal repair assem bly that best matches the color wire being repaired 8 Cut the repair wire to the proper length and remove 1 inch of insulation 9 Place a piece of heat shrink tubing over one side of the wire Make sure the tu...

Страница 672: ...low is correct If necessary refer to the appropriate wiring diagram for current flow 6 Solder the connection together using rosin core type solder only Do not use acid core solder 7 Tape the diode to the harness using electrical tape making sure the diode is completely sealed from the elements 8 Re connect the battery and test affected sys tems SPECIAL TOOLS WIRING TERMINAL Fig 23 Diode Identifica...

Страница 673: ......

Страница 674: ...witch 8W 10 21 Combination Flasher 8W 52 Controller Anti Lock Brake 8W 35 Crankshaft Position CKP Sensor 8W 30 Data Link Connector 8W 30 Diode 8W 15 42 Dome Lamp 8W 44 Component Page Door Ajar Switches 8W 44 Door Jamb Switches 8W 40 Door Lock Motors 8W 61 Door Lock Switches 8W 61 Door Speakers 8W 47 Driver Side Airbag 8W 43 Duty Cycle Evap Purge Solenoid 8W 30 EGR Transducer Solenoid 8W 30 Engine ...

Страница 675: ...ule 8W 30 PRNDL Lamp 8W 44 Pump Motor Driver 8W 35 Radiator Fan Motor 8W 42 Component Page Radio 8W 47 Rear Fog Lamp Switch 8W 51 Rear Window Defogger 8W 48 Rear Window Defogger Switch 8W 48 Repeater Lamps 8W 50 52 Seat Belt Warning Lamp 8W 40 Solid State Fan Relay 8W 42 Speakers 8W 47 Splice Information 8W 30 Stop Lamp Switch 8W 30 Sunroof Slide Switch 8W 64 Sunroof Vent Switch 8W 64 Switch Illum...

Страница 676: ...ORMATION INTRODUCTION This section provides an alphabetical listing of all the components covered in group 8W For information on system operation refer to the appropriate section of the wiring diagrams PL 8W 02 COMPONENT INDEX 8W 02 3 ...

Страница 677: ......

Страница 678: ...8 Fuse 14 FB 8W 10 12 Fuse 15 FB 8W 10 12 Fuse 16 FB 8W 10 12 Fuse 16 PDC 8W 10 4 11 Fuse 18 PDC 8W 10 4 9 Fuse 20 PDC 8W 10 4 9 Fuse 21 PDC 8W 10 4 10 Component Page Fuse 23 PDC 8W 10 4 10 Fuse 25 PDC 8W 10 4 9 Fuse Block 8W 10 6 12 G204 8W 10 5 Generator 8W 10 10 Glove Box Lamp And Switch 8W 10 8 Headlamp Switch 8W 10 6 Horn No 1 8W 10 9 Horn No 2 8W 10 9 Horn Relay 8W 10 9 Ignition Coil Pack 8W...

Страница 679: ...CHART FUSE NO AMPS CIRCUIT FUNCTION 2 40A A2 12PK BK FUSED B A3 12RD WT FUSED B A16 14GY 40A 3 FUSED B FUSED B 5 30A A4 14BK RD A20 12RD DG 30A 8 FUSED B A1 14RD 40A 10 FUSED B FUSED B 11 30A M1 18PK FUSED B 13 10A M1 18PK FUSED B A17 18RD BK FUSED B F61 18WT OR 20A 16 FUSED B 20 10A A14 16RD WT FUSED B 18 10A L9 18BK WT F32 18PK DB 20A 21 FUSED B F32 18PK DB 15A 23 FUSED B 15A 25 NOT USED F61 18W...

Страница 680: ... COMPRESSOR CLUTCH RELAY CONTROL GROUND Z1 18BK T41 18BR YL 31 M T 28 M T FUSED IGNITION START T141 14YL RD 40 25 3 FUSED B 41 A16 14GY FAN CONTROL RELAY CONTROL C27 18DB PK FAN CONTROL RELAY OUTPUT C25 14LG 38 C28 18DB OR 36 A C COMPRESSOR CLUTCH RELAY OUTPUT 35 C3 18DB BK FUSED B 32 A17 18RD BK PARK NEUTRAL POSITION SWITCH SENSE 31 A T A41 14YL 28 A T FUSED IGNITION START T40 14BR 30 ENGINE STAR...

Страница 681: ...22 15A FUSE 23 23 24 F32 18 PK DB IGNITION SWITCH TO TO S213 SOLID STATE FAN RELAY TO REAR WINDOW DEFOGGER SWITCH TO TO BOX RELAY ABS TO S203 A C COMPRESSOR CLUTCH RELAY TO IGNITION SWITCH TO TURN SIGNAL HAZARD SWITCH TO STOP LAMP VEHICLE SPEED CONTROL SWITCH TO FUEL PUMP ASD RELAYS IN PDC TO HORN RELAY IN PDC TO 15 16 16 FUSE 20A TO IN PDC RELAY LAMP FOG 8W 20 2 8W 10 5 8W 10 6 8W 10 7 8W 10 7 8W...

Страница 682: ... OFF 2 RUN 1 START SWITCH IGNITION A31 14 BK WT RUN ACC A31 ST RUN A21 A21 14 DB A22 12 BK OR RUN A22 10 A41 14 YL 1 G204 S202 Z1 22 BK Z1 20 BK 2 G9 22 GY BK 1 12 S208 G9 22 GY BK 3 0 2 1 3 0 2 1 ST A41 3 0 2 1 3 0 2 1 6 C2 CLUSTER INSTRUMENT BRAKE WARNING LAMP 8W 21 2 8W 21 2 8W 15 7 8W 15 7 8W 10 12 8W 10 12 8W 10 6 8W 70 3 8W 10 4 8W 10 12 8W 10 4 8W 40 5 PL RHD 8W 10 POWER DISTRIBUTION 8W 10 ...

Страница 683: ...LAMP 1 START 2 RUN 0 OFF 3 ACC IGNITION SWITCH 4 3 0 2 1 BATT A2 A22 12 BK OR S217 8 FUSE 10 28 25 5 10A FUSE 5 27 25A FUSE 7 26 10A FUSE 6 CIRCUIT BREAKER 30A 41 42 A22 12 BK OR BK OR 12 A22 FUSE BLOCK 8W 11 4 8W 11 6 8W 11 6 8W 11 2 8W 50 2 8W 10 4 8W 10 5 8W 10 5 8W 11 10 8W 11 8 8W 11 8 8W 11 8 8W 11 8 8W 11 2 8W 10 4 8W 10 6 8W 10 POWER DISTRIBUTION PL RHD 978W 1 PLR01005 ...

Страница 684: ... 8 FUSE 30A 10 FUSE 40A A4 14 BK RD 4 C102 A4 14 BK RD 4 SWITCH DEFOGGER WINDOW REAR 5 ABS RELAY BOX A20 12 RD DG 6 7 9 RELAY FAN STATE SOLID CENTER DISTRIBUTION POWER 8W 42 5 8W 48 2 8W 35 3 8W 42 5 8W 10 4 8W 10 4 PL RHD 8W 10 POWER DISTRIBUTION 8W 10 7 PLR01006 978W 1 ...

Страница 685: ...UMENT M1 22 PK M1 18 PK C MAP READING LAMPS M1 18 PK LAMPS VANITY VISOR LEFT RIGHT VISOR VANITY LAMPS PK 18 M1 S309 S203 1 1 3 C105 M1 22 PK CENTER DISTRIBUTION POWER C1 C2 14 SWITCH AND LAMP BOX GLOVE M1 20 PK M1 22 PK 8W 44 3 8W 44 2 8W 44 2 8W 47 2 8W 40 3 8W 44 4 8W 44 3 8W 44 3 8W 10 4 8W 44 4 8W 10 4 8W 10 8 8W 10 POWER DISTRIBUTION PL RHD 978W 1 PLR01007 ...

Страница 686: ... 10A 25 FUSE 15A L9 18 BK WT L9 22 BK WT 6 SWITCH HAZARD SIGNAL TURN F32 18 PK DB 6 15A FUSE 23 23 A X2 18 DG RD 63 66 62 RELAY HORN SWITCH LAMP STOP A S131 1 X2 18 DG RD X2 18 DG RD NO 2 HORN HORN NO 1 14 C103 17 19 24 26 8W 42 2 8W 42 2 8W 52 2 8W 10 4 8W 41 2 8W 30 12 8W 41 2 8W 41 2 8W 10 4 PL RHD 8W 10 POWER DISTRIBUTION 8W 10 9 PLR01008 978W 1 ...

Страница 687: ...18 DG OR POWERTRAIN CONTROL MODULE SENSOR OXYGEN HEATED UPSTREAM A142 18 DG OR A142 18 DG OR A142 18 DG OR A142 18 DG OR A142 18 DG OR DG OR 18 A142 DG OR 18 A142 A142 18 DG OR IGNITION COIL PACK SUPRESSOR NOISE S134 S121 S122 2 DG OR 18 A142 DG OR 14 A142 2 2 2 2 1 1 6 1 C2 58 FUEL INJECTOR NO 1 NO 2 INJECTOR FUEL FUEL INJECTOR NO 3 FUEL INJECTOR NO 4 CAPACITOR 8W 30 2 8W 30 10 8W 10 4 8W 30 10 8...

Страница 688: ...45 42 IN PDC RELAY LAMP FOG L39 18 LB WT 1 1 L39 18 LB WT L39 18 LB WT S115 LEFT FOG LAMP LAMP FOG RIGHT 2 SWITCH LAMP FOG REAR F61 18 WT OR 12 C103 F61 18 WT OR 8W 10 4 8W 50 6 8W 50 6 8W 50 6 8W 51 6 8W 10 4 PL RHD 8W 10 POWER DISTRIBUTION 8W 10 11 PLR01010 978W 1 ...

Страница 689: ...14 YL 2 1 SWITCH POSITION PEDAL CLUTCH T141 14 YL RD A41 14 YL 3 0 2 1 1 2 0 3 10 1 2 0 3 8 BK WT 14 A31 31 5A FUSE 11 32 10A FUSE 12 10 14 14 FUSE 20A 34 16 FUSE 10A 36 35 20A FUSE 15 FUSE BLOCK A41 14 YL BK 3 C241 1 C101 8W 21 2 8W 11 9 8W 11 2 8W 10 5 8W 10 5 8W 11 10 8W 11 9 8W 11 12 8W 11 12 8W 11 12 8W 11 2 8W 10 12 8W 10 POWER DISTRIBUTION PL RHD 978W 1 PLR01011 ...

Страница 690: ...RIPTION AND OPERATION This section covers the power distribution center and all circuits involved with it For additional infor mation on system operation refer to the appropriate wiring diagrams PL 8W 10 POWER DISTRIBUTION 8W 10 13 ...

Страница 691: ......

Страница 692: ... 11 13 Ignition Switch 8W 11 7 12 Instrument Cluster 8W 11 10 Instrument Cluster 8W 11 11 Intermittent Wipe Wash Switch 8W 11 12 Left Door Lock Switch 8W 11 6 Component Page Left Headlamp 8W 11 13 Left Headlamp Leveling Motor 8W 11 13 Left License Lamp 8W 11 4 Left Park Turn Signal Lamp 8W 11 5 Left Power Window Switch 8W 11 10 Left Tail Stop Lamp 8W 11 4 Master Power Window Switch 8W 11 10 Park N...

Страница 693: ...2 L55 20BK YL L32 20PK Z2 20BK LG L44 20VT RD L43 20VT L4 14VT WT F10 18YL RD A31 14BK WT F12 20DG WT E2 20OR A21 14DB L5 20BK F20 20WT A22 12BK OR F33 20PK RD F38 18RD A3 12RD WT F21 14TN A22 12BK OR F35 16RD YL F25 18TN LG C1 14DG F15 18DB WT G5 20DB WT G5 20DB WT X12 20RD WT F13 18DB L55 20BK YL F13 18DB RELAY LIGHTER RELAY COMBINATION GREY TOP OF FUSE BLOCK CIGAR F38 18RD F38 16RD F38 18RD F21...

Страница 694: ... 20OR F15 18DB WT F20 20WT 10A C1 14DG 25A 10A L5 20BK 10A F20 20WT 20A F35 16RD YL F33 20PK RD F38 16RD 15A A3 12RD WT A3 12RD WT A3 12RD WT A22 12BK OR A22 12BK OR A22 12BK OR A22 12BK OR E1 20TN A21 14DB A21 14DB A21 14DB A31 14BK WT A31 14BK WT A31 14BK WT L4 14VT WT L4 14VT WT G5 20DB WT CAVITY CIRCUIT FUNCTION CIGAR LIGHTER RELAY B B1 Z1 20BK GROUND B2 F38 16RD CIGAR LIGHTER FEED B2 F38 18RD...

Страница 695: ... 2 2 LEFT TAIL STOP LAMP L7 18 BK YL L7 20 BK YL S306 L7 20 BK YL 1 9 29 4A FUSE 9 E1 20 TN 9 2 1 0 FUSE BLOCK A 8W 11 5 TO C105 C2 SWITCH LAMP FOG FRONT L7 20 BK YL B5 RIGHT LICENSE LAMP LAMP LICENSE LEFT IN FB RELAY LIGHTER CIGAR 2 C340 C341 2 BLOCK FUSE 8W 10 6 8W 50 2 8W 47 2 8W 50 6 8W 51 5 8W 51 5 8W 41 3 8W 51 5 8W 51 5 8W 11 2 8W 11 2 8W 11 11 8W 11 4 8W 11 FUSE BLOCK PL RHD 978W 1 PLR0110...

Страница 696: ...S113 L7 18 BK YL 2 LAMP SIGNAL TURN PARK RIGHT LEFT PARK TURN SIGNAL LAMP 2 BK YL 18 L7 L7 20 BK YL 5 C105 L7 20 BK YL FROM C230 A 8W 11 4 8W 52 3 8W 52 3 PL RHD 8W 11 FUSE BLOCK 8W 11 5 PLR01104 978W 1 ...

Страница 697: ...TCH LOCK DOOR RIGHT LEFT DOOR LOCK SWITCH 3 C205 1 C231 1 F35 16 RD YL F35 18 RD YL RD YL 18 F35 RD YL 16 F35 RD YL 16 F35 24 23 10A FUSE 4 20A FUSE 3 NO CONNECTION 1 8W 10 6 8W 61 2 8W 61 2 8W 11 2 8W 11 6 8W 11 FUSE BLOCK PL RHD 978W 1 PLR01105 ...

Страница 698: ... 5 10A FUSE 5 27 25A FUSE 7 26 10A FUSE 6 BATT A2 3 ACC 0 OFF 2 RUN 1 START SWITCH IGNITION 4 CIRCUIT BREAKER 30A 41 42 A22 12 BK OR FUSE BLOCK 3 0 2 1 A22 12 BK OR 8W 10 5 8W 10 5 8W 11 2 PL RHD 8W 11 FUSE BLOCK 8W 11 7 PLR01106 978W 1 ...

Страница 699: ...DG 4 C206 C1 14 DG 1 MOTOR BLOWER HEATER A C F20 20 WT 3 C103 WT 20 F20 3 SWITCH POSITION NEUTRAL PARK B BACK UP M T A T F20 22 WT 3 SWITCH DEFOGGER WINDOW REAR F20 20 WT 2 C206 F20 22 WT 2 A C CYCLING SWITCH F20 22 WT S211 LAMP SWITCH 5 8W 43 2 8W 52 2 8W 42 3 8W 21 2 8W 48 2 8W 42 4 8W 51 2 8W 10 6 8W 11 2 8W 11 8 8W 11 FUSE BLOCK PL RHD 978W 1 PLR01107 ...

Страница 700: ...S126 ST RUN A21 60 BRAKE ANTI LOCK CONTROLLER F12 20 DG WT 1 ABS RELAY BOX F12 18 DG WT 2 SOLENOID PURGE EVAP CYCLE F12 20 DG WT 3 F12 20 DG WT 2 F12 18 DG WT DETECTOR LEAK CANISTER VAPOR 71 IN PDC RELAY CLUTCH COMPRESSOR A C F12 18 DG WT S109 DUTY A T SOLENOID CLUTCH CONVERTER TORQUE 10 C2 8W 43 2 8W 30 9 8W 30 9 8W 35 2 8W 30 9 8W 30 9 8W 42 2 8W 30 9 8W 35 2 8W 10 12 8W 11 2 PL RHD 8W 11 FUSE B...

Страница 701: ...41 RUN A22 F21 14 TN F21 14 TN G5 20 DB WT 4 SWITCH WINDOW POWER MASTER C231 7 TN 14 F21 TN 14 F21 3 SWITCH WINDOW POWER LEFT POWER MIRROR FUSE HOLDER 2 F21 14 TN CIRCUIT BREAKER 15A S138 7 C205 F21 14 TN 8W 40 6 8W 10 12 8W 10 6 8W 60 2 8W 60 2 8W 62 4 8W 62 4 8W 11 2 8W 11 10 8W 11 FUSE BLOCK PL RHD 978W 1 PLR01109 ...

Страница 702: ...NTROL SWITCH ASH RECEIVER LAMP RADIO 4 1 INSTRUMENT CLUSTER S210 HEADLAMP LEVELING SWITCH LAMP PRNDL 6 REAR FOG LAMP SWITCH E2 22 OR E2 22 OR E2 20 OR E2 22 OR E2 22 OR E2 22 OR E2 22 OR E2 22 OR E2 20 OR C2 8W 50 2 8W 11 4 8W 48 2 8W 42 3 8W 44 4 8W 47 2 8W 40 2 8W 50 4 8W 44 4 8W 51 6 8W 11 2 PL RHD 8W 11 FUSE BLOCK 8W 11 11 PLR01110 978W 1 ...

Страница 703: ... 3 3 F10 18 YL RD F10 18 YL RD F10 18 YL RD 5 C225 F10 18 YL RD S313 SUNROOF VENT SWITCH SWITCH SLIDE SUNROOF 8 SWITCH IGNITION BATT A1 14 A31 14 BK WT C2 3 0 2 1 1 START 2 RUN 0 OFF 3 ACC DB 18 F13 5 B3 DB 18 F13 IN FB RELAY LIGHTER CIGAR 8W 11 2 8W 47 2 8W 53 2 8W 53 3 8W 53 3 8W 64 2 8W 64 2 8W 10 5 8W 10 5 8W 41 3 8W 53 2 8W 11 12 8W 11 FUSE BLOCK PL RHD 978W 1 PLR01111 ...

Страница 704: ... L44 18 VT BK 2 1 0 3 2 1 SWITCH HORN OPTICAL DIMMER AND HEADLAMP 2 2 HEADLAMP LEFT RIGHT HEADLAMP 1 1 MOTOR LEVELING HEADLAMP LEFT RIGHT HEADLAMP LEVELING MOTOR S133 2 HEADLAMP LEVELING SWITCH L2 14 LG L43 20 VT L43 18 VT L43 22 VT L43 22 VT S221 4 L2 14 LG SWITCH LAMP FOG REAR 8W 50 2 8W 10 6 8W 50 2 8W 50 3 8W 50 3 8W 50 4 8W 50 4 8W 50 4 8W 51 6 8W 11 2 PL RHD 8W 11 FUSE BLOCK 8W 11 13 PLR0111...

Страница 705: ...ION AND OPERATION This section covers the fuse block and all circuits involved with it For additional information on sys tem operation please refer to the appropriate section of the wiring diagrams 8W 11 14 8W 11 FUSE FUSE BLOCK PL ...

Страница 706: ...eadlamp 8W 15 2 Left Headlamp Leveling Motor 8W 15 2 Left License Lamp 8W 15 8 Left Park Turn Signal Lamp 8W 15 2 Left Rear Fog Lamp 8W 15 8 Component Page Left Tail Stop Lamp 8W 15 8 Left Turn Signal Lamp 8W 15 8 Map Reading Lamps 8W 15 7 Master Power Window Switch 8W 15 6 Power Folding Mirror Relay 8W 15 6 Power Mirror Switch 8W 15 6 Power Steering Pressure Switch 8W 15 3 Power Sunroof Motor 8W ...

Страница 707: ...EADLAMP LEFT SWITCH LAMP WARNING BRAKE S107 S119 5 6 ABS HYDRAULIC MODULATOR B Z1 18 BK Z1 18 BK Z1 18 BK MOTOR PUMP WASHER WINDSHIELD 10 ABS RELAY BOX Z1 14 BK Z1 14 BK Z1 18 BK G101 S108 M T RELAY MOTOR STARTER ENGINE RELAY NO 2 HORN Z1 18 BK 3 Z1 22 BK MOTOR LEVELING HEADLAMP LEFT S127 8W 42 5 8W 42 5 8W 30 3 8W 30 3 8W 52 3 8W 50 3 8W 40 5 8W 35 4 8W 53 2 8W 53 3 8W 35 2 8W 35 3 8W 21 2 8W 41 ...

Страница 708: ...0 BK WT 2 SWITCH PRESSURE STEERING POWER Z12 22 BK TN 5 Z12 18 BK OR 2 Z12 20 BK TN SWITCH LAMP STOP Z12 22 BK TN Z12 22 BK TN Z12 18 BK TN G102 S104 4 5 CONTROLLER ANTI LOCK BRAKE LINK DATA CONNECTOR 8W 30 2 8W 30 4 8W 35 4 8W 30 12 8W 30 4 PL RHD 8W 15 GROUND DISTRIBUTION 8W 15 3 PLR01502 978W 1 ...

Страница 709: ... CLUTCH Z1 20 BK C3 18 DB BK 35 IN PDC RELAY CLUTCH COMPRESSOR A C C3 18 DB BK G103 Z1 20 BK Z1 18 BK 1 DIODE B 3 2 MOTOR LEVELING HEADLAMP RIGHT RIGHT REPEATER LAMP Z1 20 BK Z1 22 BK Z1 18 BK NO 1 HORN 8W 52 3 8W 50 3 8W 50 6 8W 50 6 8W 42 2 8W 42 2 8W 50 4 8W 50 3 8W 52 3 8W 41 2 8W 15 4 8W 15 GROUND DISTRIBUTION PL RHD 978W 1 PLR01503 ...

Страница 710: ... LG Z2 20 BK LG Z2 22 BK LG RADIO Z2 20 BK LG Z9 14 BK G201 NO CONNECTION Z0 8 BK G104 Z1 10 BK G105 BATTERY 71 POWERTRAIN CONTROL MODULE Z2 18 BK OR G106 10 AIRBAG CONTROL MODULE Z6 18 BK PK G202 C1 8W 53 3 8W 52 2 8W 48 2 8W 47 2 8W 20 2 8W 30 2 8W 43 2 PL RHD 8W 15 GROUND DISTRIBUTION 8W 15 5 PLR01504 978W 1 ...

Страница 711: ... HEATER A C Z8 18 BK VT 6 C225 Z8 18 BK VT 2 4 6 POWER SUNROOF MOTOR Z8 18 BK VT Z8 18 BK VT Z8 18 BK VT S314 Z8 14 BK VT Z8 14 BK VT 4 C205 Z8 14 BK VT G203 SWITCH VENT SUNROOF BK VT 18 Z8 6 RELAY MIRROR FOLDING POWER C1 SWITCH 8W 61 2 8W 62 2 8W 60 2 8W 64 2 8W 64 2 8W 62 4 8W 42 3 8W 15 6 8W 15 GROUND DISTRIBUTION PL RHD 978W 1 PLR01505 ...

Страница 712: ...202 Z1 20 BK Z1 22 BK Z1 22 BK G204 Z3 14 BK OR LAMPS READING MAP SWITCH AND LAMP BOX GLOVE Z1 20 BK POWER OUTLET Z3 20 BK OR 2 C203 SWITCH LAMP FOG REAR FRONT FOG LAMP SWITCH 3 BK 20 Z1 B1 CIGAR LIGHTER RELAY BK 20 Z1 3 HEADLAMP LEVELING SWITCH Z3 22BK OR 8W 44 4 8W 40 6 8W 44 4 8W 41 3 8W 50 2 8W 10 5 8W 44 4 8W 44 4 8W 51 6 8W 50 6 8W 41 3 8W 50 4 PL RHD 8W 15 GROUND DISTRIBUTION 8W 15 7 PLR015...

Страница 713: ... Z1 18 BK Z1 18 BK 3 C340 BK 20 Z1 1 Z1 20 BK NO CONNECTION LAMP FOG REAR LEFT LEFT TAIL STOP LAMP LAMP SIGNAL TURN LEFT LEFT BACK UP LAMP LEFT LICENSE LAMP LAMP LICENSE RIGHT 8W 51 7 8W 51 5 8W 52 4 8W 51 3 8W 51 5 8W 51 5 8W 15 8 8W 15 GROUND DISTRIBUTION PL RHD 978W 1 PLR01507 ...

Страница 714: ... DEFOGGER G301 1 2 MODULE PUMP FUEL G303 Z1 18 BK Z2 18 BK S307 BK 18 Z1 2 LAMP SIGNAL TURN RIGHT RIGHT REAR FOG LAMP 2 Z1 18 BK Z1 16 BK 3 C341 RIGHT TAIL STOP LAMP 8W 51 3 8W 48 2 8W 30 10 8W 52 4 8W 51 7 8W 51 5 PL RHD 8W 15 GROUND DISTRIBUTION 8W 15 9 PLR01508 978W 1 ...

Страница 715: ...t connect to those grounds and the components that connect those grounds For additional information on system operation refer to the appropriate section of the wiring diagrams For an illustration of the phys ical location of each ground refer to group 8W 90 8W 15 10 8W 15 GROUND DISTRIBUTION PL ...

Страница 716: ...Shut Down Relay 8W 20 2 Battery 8W 20 2 Capacitor 8W 20 2 Engine Starter Motor 8W 20 2 Fuse 21 PDC 8W 20 2 Fusible Link 8W 20 2 G104 8W 20 2 Component Page G105 8W 20 2 Generator 8W 20 2 Power Distribution Center 8W 20 2 Powertrain Control Module 8W 20 2 S122 8W 20 2 S125 8W 20 2 8W 20 2 8W 20 CHARGING SYSTEM PL ...

Страница 717: ...R DISTRIBUTION CENTER BATTERY A0 6 RD A0 8RD Z0 8 BK Z1 10 BK G104 G105 A142 18 DG OR 6 C161 A142 18 DG OR A142 18 DG OR S122 22 1 2 AUTOMATIC SHUT DOWN RELAY LINK FUSIBLE CAPACITOR 8W 30 11 8W 10 10 8W 10 4 8W 15 5 8W 15 5 8W 10 10 8W 21 2 8W 30 2 8W 20 2 8W 20 CHARGING SYSTEM PL RHD PL 8W 20 CHARGING SYSTEM 8W 20 3 GENERAL INFORMATION Continued ...

Страница 718: ...ut Down ASD relay The ground or voltage regulated side of the genera tor field is controlled by the K20 circuit which con nects to cavity 4 of the PCM connector When there is current present in the field and the rotor is turning the stator in the generator produces a B voltage that is supplied to the battery through the A11 and A0 circuits The A11 circuit is connected to the output terminal of the...

Страница 719: ......

Страница 720: ...ne Starter Motor 8W 21 2 Engine Starter Motor Relay 8W 21 2 Fuse 11 PDC 8W 21 2 Fusible Link 8W 21 2 G101 8W 21 2 Generator 8W 21 2 Component Page Ignition Switch 8W 21 2 Park Neutral Position Switch 8W 21 2 Power Distribution Center 8W 21 2 Powertrain Control Module 8W 21 2 S106 8W 21 2 S107 8W 21 2 S125 8W 21 2 S127 8W 21 2 8W 21 2 8W 21 STARTING SYSTEM PL ...

Страница 721: ...IBUTION POWER 1 2 A0 8 RD BATTERY 1 PULL IN 2 HOLD IN S125 BK GY 8 A11 BK 12 A11 GENERATOR SENSE SWITCH POSITION NEUTRAL PARK MODULE CONTROL POWERTRAIN S106 T41 18 BR YL T41 20 BR YL T41 20 BR YL 76 C1 PARK NEUTRAL POSITION SWITCH 2 1 C160 LINK FUSIBLE S107 3 0 2 1 8 C241 A41 14 YL BK 3 C241 Z1 18 BK S127 A41 14 YL BK 12 8W 10 5 8W 15 2 8W 10 5 8W 10 4 8W 10 5 8W 20 2 8W 20 2 8W 30 12 8W 15 2 M 8W...

Страница 722: ...relay is located in the PDC Check for a good ground at starter motor The left headlamp ground is the end point for the starter relay coil ground circuit and is located at the left side of the radiator closure panel STARTING SYSTEM AUTOMATIC TRANSMISSION The Power Distribution Center PDC supplies bat tery voltage to the engine starter motor solenoid through circuit T40 when the coil side of the eng...

Страница 723: ......

Страница 724: ...2 8W 30 2 4 12 G106 8W 30 2 G303 8W 30 10 Generator 8W 30 11 IAT MAP Sensor 8W 30 6 Idle Air Control Motor 8W 30 8 Ignition Coil Pack 8W 30 5 Immobilizer Engine Sensor 8W 30 13 Immobilizer Sensor 8W 30 3 8 13 Instrument Cluster 8W 30 7 8 10 11 Component Page Knock Sensor 8W 30 6 Noise Supressor 8W 30 5 Park Neutral Position Switch 8W 30 12 Power Distribution Center 8W 30 2 3 4 10 12 Power Steering...

Страница 725: ... S122 K51 18 DB YL 22 A142 18 DG OR A14 16 RD WT 16 MODULE CONTROL POWERTRAIN DATA LINK CONNECTOR OUTPUT RELAY ASD C2 6 47 C1 GROUND GROUND C1 50 71 C1 GROUND GROUND C2 10 G102 Z11 20 BK WT Z12 18 BK TN S104 Z12 18 BK TN 10 C160 Z12 18 BK TN Z12 20 BK TN BK OR 18 Z2 G106 8W 10 10 8W 10 4 8W 10 10 8W 30 4 8W 10 4 8W 15 3 8W 15 3 8W 15 5 8W 30 2 8W 30 FUEL IGNITION SYSTEM PL RHD 978W 1 PLR03001 ...

Страница 726: ...ENTER DISTRIBUTION POWER 21 20A FUSE 21 C161 POWERTRAIN CONTROL MODULE 30 C2 UPSTREAM HEATED OXYGEN SENSOR SIGNAL SIGNAL SENSOR OXYGEN HEATED DOWNSTREAM C1 51 Z1 18 BK C1 43 GROUND SENSOR MODULE CONTROL POWERTRAIN BK LB 20 K4 BK LB 18 K4 K4 20 BK LB S120 6 C2 ASD RELAY OUTPUT A142 18 DG OR S127 K4 20 BK LB 10 C161 2 1 SENSOR IMMOBILIZER BATTERY TEMPERATURE SENSOR K4 20 BK LB K4 18 BK LB 8W 70 2 8W...

Страница 727: ...51 MODULE CONTROL POWERTRAIN CONTROLLER ANTI LOCK BRAKE PK 20 D21 CONNECTOR LINK DATA S105 19 18 AIRBAG CONTROL MODULE 11 3 D1 20 VT BR 11 C101 12 D1 20 VT BR D2 20 WT BK D2 20 WT BK 16 22 RD WT 16 A14 72 BATT A0 CENTER DISTRIBUTION POWER 21 20A FUSE 21 A14 16 RD WT BUS CCD CCD BUS SCI TRANSMIT PAIR TWISTED 8W 15 3 8W 15 3 8W 35 3 8W 10 10 8W 43 2 8W 10 4 8W 10 4 8W 10 10 8W 30 4 8W 30 FUEL IGNITI...

Страница 728: ...3 17 C2 7 C2 16 C2 2 C2 3 C2 IGNITION COIL DRIVER K17 18 DB TN K19 18 BK GY K11 18 WT DB K12 18 TN K13 18 YL WT K14 18 LB BR FUEL INJECTOR NO 1 MODULE CONTROL POWERTRAIN NO 1 NO 2 INJECTOR FUEL NO 3 INJECTOR FUEL NO 4 INJECTOR FUEL DRIVER DRIVER NO 2 INJECTOR FUEL DRIVER NO 3 INJECTOR FUEL DRIVER NO 4 INJECTOR FUEL DRIVER COIL IGNITION 8W 10 10 PL RHD 8W 30 FUEL IGNITION SYSTEM 8W 30 5 PLR03004 97...

Страница 729: ...0 BK LB 24 C2 S110 K4 20 BK LB C2 37 C2 36 K21 18 BK RD K1 18 DG RD S120 K22 20 OR DB 35 C2 SENSOR GROUND KNOCK SENSOR SIGNAL IAT SENSOR SIGNAL MAP SENSOR SIGNAL 5V SUPPLY TPS SIGNAL K42 20 BK LG K42 20 DB LG 2 0L SOHC 2 0L DOHC MODULE CONTROL POWERTRAIN K6 20 VT WT K6 20 VT WT K6 20 VT WT 61 C1 9 C161 K6 18 VT WT S124 C 8W 30 3 8W 70 2 8W 30 6 8W 30 FUEL IGNITION SYSTEM PL RHD 978W 1 PLR03005 ...

Страница 730: ... 4 CLUSTER INSTRUMENT G20 22 VT YL G20 VT YL 20 7 C103 6 C160 A B C 20 VT YL G20 S120 C2 26 32 C2 C2 33 K44 20 TN YL SENSOR TEMPERATURE COOLANT ENGINE CRANKSHAFT POSITION SENSOR SIGNAL CAMSHAFT POSITION SENSOR SIGNAL ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K4 20 BK LB K4 20 BK RD SOHC DOHC DOHC SOHC TN BK 20 K2 TN DB 20 K2 CRANKSHAFT POSITION SENSOR SIGNAL MODULE CONTROL POWERTRAIN 2 1 BK LB 20 K...

Страница 731: ...LE NO 1 DRIVER MOTOR CONTROL AIR IDLE 5 C103 C1 10 CLUSTER INSTRUMENT G7 20 WT OR G7 22 WT OR G7 20 WT OR C1 66 VEHICLE SPEED SENSOR SIGNAL SENSOR GROUND 8V SUPPLY VEHICLE SPEED SENSOR SIGNAL K59 18 VT K59 20 VT K60 18 YL BK K60 20 YL BK K40 18 BR WT K40 20 BR WT K39 18 GY RD K39 20 GY RD MODULE CONTROL POWERTRAIN AIR CONTROL MOTOR NO 4 IDLE IDLE NO 2 MOTOR CONTROL AIR AIR CONTROL MOTOR NO 3 IDLE ...

Страница 732: ...2 18 DB WT F12 18 DB WT F12 18 DB WT POWERTRAIN CONTROL MODULE C2 20 40 C2 77 C1 79 C1 68 C1 C1 72 K35 20 GY YL K107 18 OR K106 18 WT LG K54 20 OR BK K52 20 PK BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL EGR SOLENOID CONTROL VAPOR CANISTER PUMP SWITCH DRIVER VAPOR CANISTER SOLENOID DRIVER DUTY CYCLE EVAP PURGE SOLENOID CONTROL S109 S126 10 ST RUN A21 FUSED IGN ST RUN 8W 11 9 8W 11 2 8W 11 9 8W 10 ...

Страница 733: ...TROL K31 18 BR 6 C105 A141 16 DG WT A141 18 DG WT SIGNAL SENSOR LEVEL FUEL 6 C230 G4 18 DB G4 20 DB 3 C160 G4 20 DB 7 C105 G4 20 DB Z1 18 BK Z2 18 BK 23 C2 MODULE CONTROL POWERTRAIN MODULE CONTROL POWERTRAIN FUEL PUMP RELAY 22 C2 10 FUEL GAUGE INSTRUMENT CLUSTER 71 G4 20 DB 8W 10 10 8W 10 4 8W 11 9 8W 11 2 8W 11 9 8W 15 9 8W 10 4 8W 10 12 8W 40 6 M 8W 30 10 8W 30 FUEL IGNITION SYSTEM PL RHD 978W 1...

Страница 734: ...RATOR K173 20 DG K173 20 LG C28 18 DB OR K20 18 DG C1 56 73 C1 8 C2 38 C2 18 C2 64 C1 4 C2 GENERATOR LAMP DRIVER TACHOMETER SIGNAL CHECK ENGINE LAMP DRIVER A C SWITCH SENSE RADIATOR FAN RELAY CONTROL A C COMPRESSOR CLUTCH RELAY CONTROL GENERATOR FIELD DRIVER MODULE CONTROL POWERTRAIN IN PDC RELAY CLUTCH COMPRESSOR A C 8W 40 3 8W 40 5 8W 40 6 8W 42 5 8W 42 5 8W 20 2 8W 42 2 PL RHD 8W 30 FUEL IGNITI...

Страница 735: ...5 K29 20 WT PK F32 18 PK DB SWITCH LAMP STOP CENTER DISTRIBUTION POWER Z12 20 BK TN Z12 20 BK TN G102 S104 WT TN 20 L50 WT TN 20 L50 NO CONNECTION SWITCH POSITION NEUTRAL PARK C1 C1 A T 1 2 C105 L50 22 WT TN L50 20 WT TN S101 13 CONTROLLER ANTI LOCK BRAKE L50 20 WT TN L50 22 WT TN NO CONNECTION A T M T A T 8W 11 8 8W 11 2 8W 10 4 8W 11 8 8W 21 2 8W 10 9 8W 10 4 8W 10 4 8W 15 3 8W 21 2 8W 35 4 8W 1...

Страница 736: ...MODULE CONTROL POWERTRAIN K7 20 OR K4 20 BK LB K4 20 BK LB S110 8V SUPPLY GROUND SENSOR S123 K7 20 OR K7 18 OR 5 C161 CAMSHAFT POSITION SENSOR VEHICLE SPEED SENSOR 1 1 CRANKSHAFT POSITION SENSOR 1 K7 20 OR K7 18 OR K7 20 OR 8W 30 3 8W 30 7 8W 30 8 8W 30 7 PL RHD 8W 30 FUEL IGNITION SYSTEM 8W 30 13 PLR03012 978W 1 ...

Страница 737: ...tects circuit F12 Circuit F15 feeds the Airbag Control Module ACM A 10 amp fuse in the fuse block cavity 9 pro tects circuit F15 BATTERY FEED Circuit A14 from the Power Distribution Center PDC supplies battery voltage to cavity 46 of the Powertrain Control Module PCM A 20 amp fuse in the PDC protects circuit A14 HELPFUL INFORMATION Circuit A14 connects to a bus bar in the PDC that the battery feed...

Страница 738: ...A14 and A142 The A142 circuit is spliced and supplies power to the generator fuel injectors PCM ignition coil and heated oxygen sensors HELPFUL INFORMATION Refer to group 14 Fuel System for additional information Check the 20 amp fuse located in the PDC FUEL PUMP MOTOR Circuit A14 is a bus bar in the Power Distribution Center PDC and connects to battery voltage The contact side of the fuel pump re...

Страница 739: ... sensor provides an input sig nal to the PCM The K24 circuit connects to cavity 32 of the PCM connector The PCM provides ground for the crankshaft position sensor signal circuit K24 through circuit K4 Circuit K4 connects to cavity 43 of the PCM connector HELPFUL INFORMATION Circuit K7 splices to supply 8 volts to the camshaft position sensor and vehicle speed sensor Circuit K4 splices to supply gr...

Страница 740: ...ifold Absolute Pressure MAP sensor Circuit K6 connects to cavity 61 of the PCM connector Circuit K1 delivers the MAP signal to the PCM Cir cuit K1 connects to cavity 36 of the PCM connector The PCM provides ground for the MAP sensor sig nal circuit K1 through circuit K4 Circuit K4 con nects to cavity 43 of the PCM connector HELPFUL INFORMATION Refer to Group 14 for MAP sensor operation Circuit K6 ...

Страница 741: ... cavity 13 of the PCM Circuit K12 is the ground circuit for Injector 2 Circuit K12 connects to cavity 17 of the PCM Circuit K13 is the ground circuit for Injector 3 Circuit K13 connects to cavity 7 of the PCM Circuit K14 is the ground circuit for Injector 4 Circuit K14 connects to cavity 16 of the PCM HELPFUL INFORMATION Circuit A142 splices to supply voltage to the fuel injectors ignition coil AS...

Страница 742: ... clutch relay and fuel pump relay In the START or RUN position the ignition switch connects circuit A1 from the fuse block and circuit A21 Circuit A1 connects to battery voltage and is protected by a 30 amp fuse in the PDC EGR TRANSDUCER EET SOLENOID Circuit F12 supplies battery voltage to the EET solenoid The Powertrain Control Module PCM switches ground path for the solenoid ON and OFF through c...

Страница 743: ......

Страница 744: ...nector 8W 35 3 Fuse 10 FB 8W 35 2 Fuse 10 PDC 8W 35 3 Fuse 25 PDC 8W 35 4 Fuse Block 8W 35 2 G101 8W 35 2 3 4 G102 8W 35 4 Component Page Instrument Cluster 8W 35 2 Left Front Wheel Speed Sensor 8W 35 5 Left Rear Wheel Speed Sensor 8W 35 5 Power Distribution Center 8W 35 3 4 Pump Motor Driver 8W 35 3 Right Front Wheel Speed Sensor 8W 35 5 Right Rear Wheel Speed Sensor 8W 35 5 S101 8W 35 4 S103 8W ...

Страница 745: ...TER INSTRUMENT G19 22 LG OR G19 20 LG BR 1 C103 ABS SYSTEM RELAY CONTROL G19 20 LG BR F12 20 DG WT 6 C101 S109 F12 20 DG WT B47 20 RD LB 60 B57 20 BR BK ABS SYSTEM RELAY LAMP WARNING ABS ABS PUMP MOTOR RELAY 4 57 CONTROL RELAY SYSTEM ABS DRIVER LAMP WARNING ABS 8W 11 9 8W 15 2 8W 15 2 8W 11 2 8W 40 5 8W 11 9 8W 10 12 8W 35 2 8W 35 ANTI LOCK BRAKES PL RHD 978W 1 PLR03501 ...

Страница 746: ...ROLLER ANTI LOCK BRAKE ABS PUMP MOTOR RELAY CONTROL SENSE MOTOR PUMP ABS SCI TRANSMIT G101 Z1 14 BK Z1 14 BK S108 D21 20 PK B116 20 GY B120 12 BR WT B120 16 BR WT S103 ABS PUMP MOTOR S210 ABS PUMP MOTOR RELAY DRIVER MOTOR PUMP 8W 10 7 8W 10 4 8W 10 4 8W 30 4 8W 15 2 8W 15 2 8W 11 11 PL RHD 8W 35 ANTI LOCK BRAKES 8W 35 3 PLR03502 978W 1 ...

Страница 747: ...UTPUT SWITCH LAMP STOP S108 5 GROUND 15A FUSE 25 POWER DISTRIBUTION CENTER 25 26 F32 18 PK DB 5 6 STOP LAMP SWITCH L50 20 WT TN S101 L50 20 WT TN Z1 18 BK Z1 18 BK Z1 14 BK G101 Z12 18 BK TN Z12 18 BK OR 13 B142 20 BR YL B146 20 BR LB B143 20 DG YL B148 20 DB LB 42 46 43 48 G102 S104 MODULATOR HYDRAULIC ABS BRAKE ANTI LOCK CONTROLLER BATT A0 4 2 3 1 8W 15 2 8W 10 9 8W 10 4 8W 30 12 8W 30 12 8W 15 ...

Страница 748: ...FT RIGHT FRONT WHEEL SPEED SENSOR RIGHT FRONT WHEEL SPEED SENSOR SENSOR SPEED WHEEL REAR RIGHT SENSOR SPEED WHEEL REAR RIGHT 8 9 3 4 6 7 1 2 B8 20 RD DB B9 20 RD 3 4 C108 B6 20 WT DB B7 20 WT B1 20 WT BK B2 20 DG WT 1 2 C108 B2 20 YL B1 20 YL DB B3 20 LG DB B4 20 LG 2 1 2 1 2 1 2 1 B3 20 LG DB B4 20 LG CONTROLLER ANTI LOCK BRAKE PAIR TWISTED TWISTED PAIR TWISTED PAIR PAIR TWISTED PL RHD 8W 35 ANTI...

Страница 749: ... a problem If a problem is detected the CAB grounds the G19 cir cuit and illuminates the lamp in the instrument clus ter Circuit G19 is also an output of the CAB to the ABS system relay contact side ABS SYSTEM RELAY The system relay is used for the operation of the ABS system Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake CAB Ground for the rela...

Страница 750: ...the CAB connector Circuit L50 is spliced in with the stop lamps and is used to provide the CAB with information on when the brakes are being applied DATA LINK CONNECTOR Circuit D21 is used for diagnostics of a fault with the ABS system It is spliced in with the Powertrain Control Module PCM circuits and used as an output from the Controller Anti Lock Brake CAB Circuit D21 connects to cavity 51 of ...

Страница 751: ......

Страница 752: ... 2 6 G101 8W 40 5 G204 8W 40 6 Headlamp Dimmer And Optical Horn Switch 8W 40 2 Headlamp Switch 8W 40 2 3 High Beam Indicator Lamp 8W 40 2 Instrument Cluster 8W 40 2 3 4 5 6 Key In Switch 8W 40 3 Component Page Left Front Door Jamb Switch 8W 40 3 Left Park Turn Signal Lamp 8W 40 4 Left Repeater Lamp 8W 40 4 Left Turn Indicator Lamp 8W 40 4 Low Oil Pressure Lamp 8W 40 6 Park Brake Switch 8W 40 5 Pow...

Страница 753: ... OR S210 C2 9 2 C1 3 S209 CLUSTER INSTRUMENT BATT F33 L3 14 RD OR L3 16 RD OR 2 1 0 CLUSTER ILLUMINATION LAMPS HIGH BEAM INDICATOR LAMP SWITCH HORN OPTICAL AND DIMMER HEADLAMP 8W 11 1 8W 11 2 8W 50 2 8W 11 11 8W 50 3 8W 11 4 8W 50 2 8W 40 2 8W 40 INSTRUMENT CLUSTER PL RHD 978W 1 PLR04001 ...

Страница 754: ...C103 G7 20 WT OR G7 18 WT OR 3 2 C160 VEHICLE SPEED SENSOR C2 5 HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD C1 10 C1 7 C1 6 VEHICLE SPEED SENSOR SIGNAL 0 1 2 6 5 1 2 KEY IN SWITCH LEFT FRONT DOOR JAMB SWITCH M1 22 PK POWER DISTRIBUTION CENTER INSTRUMENT CLUSTER G26 20 LB G26 20LB G16 20BK LB G16 20 BL LB 9 C230 BL LB 20 G16 C1 C1 SIGNAL SENSOR SPEED VEHICLE 8W 10 8 8W 10 8 8W 30 8 8W 30 11 8W 30 8 8W 50 2...

Страница 755: ...K LEFT LG 18 L61 S112 LG 20 L61 LG 22 L61 1 1 TN 18 L60 1 RIGHT PARK TURN SIGNAL LAMP S116 TN 18 L60 TN 22 L60 1 LEFT TURN INDICATOR LAMP LAMP INDICATOR TURN RIGHT L61 22 LG L60 22 TN 3 C101 9 C103 LEFT REPEATER LAMP LAMP REPEATER RIGHT 8W 52 3 8W 52 3 8W 52 3 8W 52 3 8W 52 3 8W 40 4 8W 40 INSTRUMENT CLUSTER PL RHD 978W 1 PLR04003 ...

Страница 756: ...GY BK SWITCH LAMP WARNING BRAKE BRAKE WARNING LAMP LAMP WARNING ANTI LOCK C2 7 9 C1 C1 56 GENERATOR G12 22 TN BK G12 20 TN BK 6 C103 9 R41 18 BK TN AIRBAG CONTROL MODULE AIRBAG WARNING LAMP POWERTRAIN CONTROL MODULE CHARGE INDICATOR LAMP LAMP WARNING AIRBAG SEAT BELT WARNING LAMP DRIVER LAMP C1 4 G10 20 LG RD NO CONNECTION S127 Z1 18 BK 8W 70 3 8W 15 2 8W 15 2 8W 35 2 8W 35 2 8W 43 3 8W 30 11 PL R...

Страница 757: ...MODULE FUEL PUMP MODULE SENSOR TEMPERATURE COOLANT ENGINE 3 G4 18 DB C160 9 C103 11 BK PK 20 G3 BK PK 22 G3 BK PK 20 G3 MODULE CONTROL POWERTRAIN 8 3 C2 CHECK ENGINE LAMP DRIVER C 6 C160 7 C103 4 C2 5A FUSE 11 SENSOR SIGNAL ENGINE COOLANT TEMPERATURE GAUGE LAMP ENGINE CHECK FUEL GAUGE LAMP PRESSURE OIL LOW FUEL TANK SENDING UNIT DB WT 20 G5 6 NO CONNECTION G4 20 DB 7 C105 C2 C2 8W 15 7 8W 11 2 8W ...

Страница 758: ... lifted OPEN during vehicle shipping to reduce battery draw SPEEDOMETER The speedometer and odometer receive their infor mation on the G7 circuit from the Vehicle Speed Sen sor VSS on manual and 3 spd automatic transmission applications The G7 circuit also pro vides a signal to the Powertrain Control Module PCM Logic internal to the instrument cluster adjusts the position of the gauge pointer to t...

Страница 759: ...o indicate to the opera tor that the key is in the ignition with the drivers door OPEN If the key is in the ignition and the driv ers door is OPEN a ground path is completed from the G26 circuit at the cluster through the CLOSED key in switch to the G16 circuit and terminating at the door ajar switch which is case grounded CHARGE INDICATOR LAMP The Charge Indicator lamp is used to alert the operat...

Страница 760: ...r through the switch to the left headlamp ground ANTI LOCK WARNING LAMP The Anti Lock warning lamp is used to alert the driver of a problem in the ABS system When the ABS controller determines a problem in the system it grounds the G19 circuit and illuminates the lamp HELPFUL INFORMATION Check the 5 amp fuse in cavity 11 of the fuse block Check the 4 amp fuse in cavity 12 of the fuse block Check t...

Страница 761: ......

Страница 762: ...1 3 Fuse 3 PDC 8W 41 3 Fuse 15 FB 8W 41 3 Fuse 23 PDC 8W 41 2 Fuse Block 8W 41 3 G101 8W 41 2 G103 8W 41 2 G204 8W 41 3 Horn No 1 8W 41 2 Component Page Horn No 2 8W 41 2 Horn Relay 8W 41 2 Left Horn Switch 8W 41 2 Power Distribution Center 8W 41 2 3 Right Horn Switch 8W 41 2 S108 8W 41 2 S111 8W 41 2 S117 8W 41 2 S131 8W 41 2 S202 8W 41 3 S206 8W 41 3 S213 8W 41 3 8W 41 2 8W 41 HORNS CIGAR LIGHTE...

Страница 763: ...RIGHT 5 C101 X3 20 BK RD B A BK 14 Z1 G101 S108 BK 14 Z1 S111 Z1 20 BK X2 18 DG RD 23 23 X3 18 BK RD DG RD 18 X2 BK 20 Z1 S117 Z1 14 BK G103 A B S131 X2 18 DG RD HORN NO 1 NO 2 HORN 8W 10 9 8W 10 4 8W 10 4 8W 15 2 8W 15 2 8W 15 2 8W 15 4 8W 15 2 8W 41 2 8W 41 HORN CIGAR LIGHTER POWER OUTLET PL RHD 978W 1 PLR04101 ...

Страница 764: ...R LIGHTER POWER OUTLET S202 Z1 20 BK 1 3 73 21 B1 B2 B5 B3 F38 18 RD CIGAR LIGHTER RELAY 5 35 RUN A22 15 FUSE 20A FUSE BLOCK F13 18 DB F13 18 DB S206 Z1 20 BK NOT USED F38 18 RD 8W 10 4 8W 10 6 8W 10 4 8W 10 6 8W 11 4 8W 11 2 8W 15 7 8W 15 7 8W 11 12 8W 10 6 8W 11 2 8W 11 12 PL RHD 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 3 PLR04102 978W 1 ...

Страница 765: ...h is located on the left side of the radiator closure panel HELPFUL INFORMATION Check the 15 amp fuse in the PDC Press the horn switch and listen for the horn relay to click A clicking relay indicates voltage is present up to the switch Check for a good ground at the left headlamp ground CIGAR LIGHTER The cigar lighter in this vehicle uses a cigar lighter relay and a cigar lighter element Power fo...

Страница 766: ...er Motor Resistor Block 8W 42 3 Diode 8W 42 2 Fuse 5 FB 8W 42 4 Fuse 5 PDC 8W 42 5 Fuse 7 FB 8W 42 3 Fuse 9 FB 8W 42 3 Fuse 10 FB 8W 42 2 Fuse 18 PDC 8W 42 2 Fuse Block 8W 42 2 3 4 Component Page G101 8W 42 5 G103 8W 42 2 G203 8W 42 3 Headlamp Switch 8W 42 3 Power Distribution Center 8W 42 2 5 Powertrain Control Module 8W 42 2 5 Radiator Fan Motor 8W 42 5 Rear Fog Lamp Switch 8W 42 3 S108 8W 42 5 ...

Страница 767: ...LUTCH COMPRESSOR A C C1 64 POWERTRAIN CONTROL MODULE S109 C28 18 DB OR A C COMPRESSOR CLUTCH RELAY CONTROL ST RUN A21 10A FUSE 18 17 BATT A0 1 2 A C COMPRESSOR CLUTCH RELAY DIODE C3 18DB BK 20BK Z1 8W 10 4 8W 11 9 8W 11 2 8W 15 4 8W 30 11 8W 11 9 8W 10 9 8W 10 12 8W 10 4 8W 42 2 8W 42 AIR CONDITIONING HEATER PL RHD 978W 1 PLR04201 ...

Страница 768: ...2 DB YL 1 C206 G203 Z8 14 BK VT S204 4A FUSE 9 5 27 29 25A FUSE 7 9 BLOCK FUSE 2 HEAD 1 PARK 0 OFF SWITCH HEADLAMP 1 BATT F33 E2 22 OR C1 14 DG C1 14 DG C7 14 BK TN C7 14 BK TN 4 C206 6 C206 RUN A22 FUSE BLOCK E1 20 TN 1 2 5 1 2 4 MODE SWITCH MODE SWITCH OUTPUT 4 3 2 1 5 2 1 0 MOTOR BLOWER HEATER A C A C CYCLING SWITCH C225 6 S314 TO Z8 18 BK VT E2 2O OR S210 6 SWITCH LAMP FOG REAR E2 22 OR SWITCH...

Страница 769: ...C206 2 MODE SWITCH OUTPUT A C CYCLING SWITCH OUTPUT C21 22 DB OR 3 C206 1 3 1 C206 S211 2 C101 C21 20 DB OR BLOCK FUSE C21 22 DB OR F20 22 WT 6 2 SWITCH PRESSURE LOW A C SWITCH CONTROL HEATER A C 8W 11 8 8W 11 8 8W 11 2 8W 42 5 8W 10 6 8W 42 3 8W 42 4 8W 42 AIR CONDITIONING HEATER PL RHD 978W 1 PLR04203 ...

Страница 770: ...LE MOTOR FAN RADIATOR 4 1 3 BR 18 C20 DB OR 22 C21 A C HIGH PRESSURE SWITCH A C LOW PRESSURE SWITCH C2 38 DB OR 20 C21 C206 3 2 1 2 1 C160 5 SENSE SWITCH A C BR OR 20 C20 DB WT 20 C22 DB OR 22 C21 1 2 A C CYCLING SWITCH RADIATOR FAN RELAY CONTROL A C CYCLING SWITCH OUTPUT 2 C101 8W 10 7 8W 10 4 8W 15 2 8W 15 2 8W 15 2 8W 30 11 8W 10 4 8W 42 4 M PL RHD 8W 42 AIR CONDITIONING HEATER 8W 42 5 PLR04204...

Страница 771: ...eates a magnetic field energizing the clutch Ground for the coil is provided at the right headlamp ground The connector at the A C compressor has a diode located in it This diode is used to control the induced voltage resulting from the magnetic field collapsing when the clutch is disengaged The diode provides a path for the voltage to protect other components and systems The A C compressor clutch...

Страница 772: ...located in cavity 10 of the fuse block for the A C compressor clutch relay Check the 10 amp fuse located in the PDC for the A C compressor clutch relay Check the 25 amp fuse located in cavity 7 of the fuse block for the blower motor Check the right headlamp ground located at the right fender side shield Check the left headlamp ground located on the left side of the radiator closure panel On vehicl...

Страница 773: ......

Страница 774: ...le 8W 43 2 3 4 Airbag Warning Lamp 8W 43 3 Data Link Connector 8W 43 2 Driver Side Airbag 8W 43 4 Fuse 12 FB 8W 43 2 Fuse Block 8W 43 2 Component Page G202 8W 43 2 Instrument Cluster 8W 43 3 Left Airbag Impact Sensor 8W 43 3 Passenger Side Airbag 8W 43 4 Right Airbag Impact Sensor 8W 43 3 8W 43 2 8W 43 AIRBAG SYSTEM PL ...

Страница 775: ...2 3 11 DATA LINK CONNECTOR 19 18 CCD BUS BUS CCD F25 18 TN GN F15 18 DB WT D1 20 VT BR D1 20 VT BR D2 20 WT BK D2 20 WT BK 11 C101 12 10 GROUND Z6 18 BK PK G202 RUN IGN FUSED PAIR TWISTED TWISTED PAIR 8W 11 9 8W 11 8 8W 11 2 8W 30 4 8W 15 5 8W 10 6 8W 10 12 8W 43 2 8W 43 AIRBAG SYSTEM PL RHD 978W 1 PLR04301 ...

Страница 776: ...T LEFT 1 3 LINE 1 LEFT IMPACT SENSOR AIRBAG WARNING LAMP DRIVER LINE 2 4 8 LINE 2 SENSOR IMPACT RIGHT LINE 1 7 9 AIRBAG CONTROL MODULE R47 18 DB LB R47 18 DB LB 15 16 7 8 C101 R49 18 LB R49 18 LB R46 18 BR LB R46 18 BR LB R48 18 TN R48 18 TN R41 18 BK TN SENSOR IMPACT LEFT RIGHT IMPACT SENSOR AIRBAG WARNING LAMP 8W 40 5 8W 40 5 PL RHD 8W 43 AIRBAG SYSTEM 8W 43 3 PLR04302 978W 1 ...

Страница 777: ...IB R51 18 VT YL R50 18 BR YL R42 18 BR YL R44 18 DG YL R43 18 BK LB R45 18 DG LB 12 11 5 6 2 1 2 1 3 4 2 1 SWITCH PRESSURE AIRBAG PASSENGER SENSE SQUIB AIRBAG PASSENGER LINE 2 SQUIB AIRBAG PASSENGER LINE 2 SENSE PASSENGER AIRBAG PRESSURE SWITCH SWITCH PRESSURE AIRBAG PASSENGER GROUND SQUIB AIRBAG DRIVER LINE 2 SQUIB AIRBAG DRIVER LINE 2 PAIR TWISTED PAIR TWISTED 8W 43 4 8W 43 AIRBAG SYSTEM PL RHD ...

Страница 778: ...t panel right center support AIRBAG IMPACT SENSOR The Airbag system uses a sensor internal to the Airbag Control Module ACM to detect impact For information regarding operation of this sensor refer to the appropriate group of the Service Manual AIRBAG SQUIB AIRBAG IGNITER DRIVERS SIDE AIRBAG Two circuits R43 and R45 connect the ACM to the drivers side airbag module squib igniter after pass ing thr...

Страница 779: ......

Страница 780: ...Door Ajar Switch 8W 44 2 Left Rear Door Ajar Switch 8W 44 2 Left Visor Vanity Lamps 8W 44 3 Map Reading Lamps 8W 44 2 4 Mercury Switch 8W 44 3 Power Distribution Center 8W 44 2 3 4 Component Page PRNDL Lamp 8W 44 4 Right Front Door Ajar Switch 8W 44 2 Right Rear Door Ajar Switch 8W 44 2 Right Visor Vanity Lamps 8W 44 3 S201 8W 44 4 S202 8W 44 2 S203 8W 44 2 3 4 S210 8W 44 4 S220 8W 44 2 4 S304 8W ...

Страница 781: ... M2 20 YL M4 22 GY BK M4 18 GY BK TRUNK SWITCH 3 C309 S220 1 NO CONNECTION M2 22 YL 3 SWITCH HEADLAMP M2 22 YL Z1 22 BK Z1 2O BK S202 G204 1 AND LAMP BOX GLOVE M1 22 PK M1 22 PK S203 DOME LAMP LAMP TRUNK M2 20 YL 12 C230 CENTER DISTRIBUTION POWER 13 14 SWITCH A M23 22 YL M2 22 YL MAP READING LAMPS 2 C225 8W 10 8 8W 10 4 8W 50 2 8W 15 7 8W 15 7 8W 10 8 8W 10 4 8W 44 4 8W 44 4 8W 44 2 8W 44 INTERIOR...

Страница 782: ...C103 M1 22 PK M1 22 PK 1 C225 M1 18 PK S203 SWITCH MERCURY LAMPS VANITY VISOR LEFT RIGHT VISOR VANITY LAMPS M1 18 PK M1 18 PK M1 18 PK UNDERHOOD LAMP S309 BATT A0 8W 10 8 8W 10 4 8W 10 8 8W 10 8 8W 10 4 PL RHD 8W 44 INTERIOR LIGHTING 8W 44 3 PLR04402 978W 1 ...

Страница 783: ...P PRNDL 2 1 OR 22 E2 E2 22 OR 1 2 Z3 20 BK OR E2 20 OR Z3 14 BK OR G204 LAMP RECEIVER ASH S210 S201 2 1 0 LAMPS READING MAP B Z3 18 BK OR Z3 20 BK OR 3 C225 S220 M2 22 YL M23 22 YL BK 2 C225 1 NO CONNECTION M2 22 YL M1 22 PK E2 22 OR 1 C203 Z3 20 BK OR 2 C203 M1 18 PK M1 18 PK 1 C225 S309 C A 8W 10 4 8W 10 8 8W 11 4 8W 11 2 8W 11 11 8W 50 2 8W 10 8 8W 15 7 8W 11 11 8W 15 7 8W 10 6 8W 10 4 8W 44 2 ...

Страница 784: ...s interior lamps It will also turn the lamps OFF after a spec ified period of time and works with the Remote Key less Entry RKE system for illuminated entry Cirucit M2 connects to the relay and supplied a ground path through the door ajar switches Circuit M1 is used to supply battery voltage to the relay This circuit is proteced by a 10 amp fuse located in cavity 13 of the Power Distribution Cente...

Страница 785: ... opened and completes a path to ground on the Z3 circuit The Z3 circuit is spliced in with the ash receiver lamp PRNDL lamp and the time delay relay The Z3 circuit terminates at the instrument panel left center support ASH RECEIVER LAMP The ash receiver lamp receives power on the E2 circuit from the 4 amp fuse located in the fuse block in cavity 12 The fuse receives power from the head lamp switch...

Страница 786: ...W 47 2 Fuse Block 8W 47 2 G201 8W 47 2 3 4 Headlamp Switch 8W 47 2 Left Front Door Speaker 8W 47 3 Component Page Left Instrument Panel Speaker 8W 47 3 Left Rear Speaker 8W 47 4 Power Distribution Center 8W 47 2 Radio 8W 47 2 3 4 Right Front Door Speaker 8W 47 3 Right Instrument Panel Speaker 8W 47 3 Right Rear Speaker 8W 47 4 S203 8W 47 2 S210 8W 47 2 8W 47 2 8W 47 AUDIO SYSTEMS PL ...

Страница 787: ... E2 20 OR S210 E2 22 OR X12 20 RD WT M1 18 PK M1 22 PK M1 22 PK S203 13 C103 6 C2 7 C2 5 C2 Z9 14 BK HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD 9 4 G201 4 C2 RADIO BLOCK FUSE FUSE BLOCK TN 20 E1 1 9 29 4A FUSE 9 POWER DISTRIBUTION CENTER 2 1 0 8W 11 11 8W 10 8 8W 50 2 8W 15 5 8W 10 12 8W 11 2 8W 11 2 8W 11 11 8W 11 4 8W 11 12 8W 10 8 8W 10 4 8W 10 6 8W 10 4 8W 47 2 8W 47 AUDIO SYSTEM PL RHD 978W 1 PLR047...

Страница 788: ...HT FRONT DOOR X53 22 DG X53 22 DG X55 22 BR RD X55 22 BR RD X54 22 VT X54 22 VT X56 22 DB RD X56 22 DB RD 15 16 C231 15 16 C205 Z9 14 BK 1 2 2 1 PREMIUM SPEAKER PANEL INSTRUMENT LEFT RIGHT INSTRUMENT PANEL SPEAKER PREMIUM GROUND X56 22 DB RD X54 22 VT X55 22 BR RD X53 22 DG G201 8W 15 5 PL RHD 8W 47 AUDIO SYSTEM 8W 47 3 PLR04702 978W 1 ...

Страница 789: ... RADIO LEFT REAR REAR LEFT RIGHT REAR RIGHT REAR X51 22 BR YL X51 22 BR YL X57 22 BR LB X57 22 BR LB X52 22 DB WT X52 22 DB WT X58 22 DB OR X58 22 DB OR 5 13 C230 7 15 C230 Z9 14 BK G201 ANTENNA INPUT ANTENNA 8W 15 5 8W 47 4 8W 47 AUDIO SYSTEM PL RHD 978W 1 PLR04703 ...

Страница 790: ... feeds the illumination lamp Circuit L7 feeds the park lamps of the radio Circuit F33 feeds circuit L7 A 4 amp fuse in cavity 12 of the fuse block pro tects circuit E2 A 15 amp fuse in cavity 2 of the fuse block protects circuits L7 and F33 SPEAKERS Circuit X53 feeds the speaker in the left front door Circuit X55 is the return from the speaker to the radio On the premium system the X53 and X55 cir...

Страница 791: ......

Страница 792: ... Fuse 8 PDC 8W 48 2 Fuse 9 FB 8W 48 2 Fuse Block 8W 48 2 G201 8W 48 2 G301 8W 48 2 Headlamp Switch 8W 48 2 Component Page Power Distribution Center 8W 48 2 Rear Window Defogger 8W 48 2 Rear Window Defogger Switch 8W 48 2 S205 8W 48 2 S210 8W 48 2 S211 8W 48 2 Switch Illumination 8W 48 2 8W 48 2 8W 48 REAR WINDOW DEFOGGER PL ...

Страница 793: ...WT F20 22 WT S210 S211 A4 14 BK RD A4 14 BK RD 4 C102 C15 14 BK WT C15 14 BK 16 C230 G301 Z1 14 BK G201 S205 Z2 22 BK LG Z2 20 BK LG DEFOGGER WINDOW REAR 0 OFF BATT F33 2 1 0 1 0 1 ON SWITCH ILLUMINATION 8W 10 7 8W 10 4 8W 11 2 8W 11 11 8W 11 8 8W 50 2 8W 11 11 8W 11 8 8W 15 5 8W 10 4 8W 11 4 8W 10 6 8W 48 2 8W 48 REAR WINDOW DEFOGGER PL RHD PL 8W 48 REAR WINDOW DEFOGGER 8W 48 3 DESCRIPTION AND OP...

Страница 794: ...age is passed through the grid the grid lines heat up and heat the rear window Grounding for the rear window defogger switch is provided on the Z2 circuit and terminates at the instrument panel right center support The grid uses the grounding point at the rear body in the right wheel house When the system is in operation a L E D located in the switch indicates to the operator the system is functio...

Страница 795: ......

Страница 796: ...witch 8W 50 2 4 5 6 Instrument Cluster 8W 50 3 Left Fog Lamp 8W 50 6 Left Headlamp 8W 50 3 4 6 Left Headlamp Leveling Motor 8W 50 4 Left License Lamp 8W 50 5 Left Park Turn Signal Lamp 8W 50 5 Power Distribution Center 8W 50 2 6 Component Page Radio 8W 50 5 Rear Fog Lamp Switch 8W 50 2 6 Right Fog Lamp 8W 50 6 Right Headlamp 8W 50 3 Right Headlamp Leveling Motor 8W 50 4 Right Park Turn Signal Lamp...

Страница 797: ...14 LG L20 14 LG WT TN 20 E1 1 S221 3 1 2 3 1 2 HORN OPTICAL AND DIMMER HEADLAMP SWITCH 1 HIGH 2 LOW 3 OPTICAL 2 4 FUSE BLOCK 9 4A FUSE 9 29 E2 20 OR 4 6 HEADLAMP LEVELING SWITCH E2 20 OR E2 22 OR S210 SWITCH LAMP FOG REAR A C HEATER CONTROL SWITCH 7 E2 22OR 9 3 1 8W 10 6 8W 10 4 8W 10 6 8W 10 4 8W 10 6 8W 11 4 8W 11 2 8W 11 12 8W 11 2 8W 11 11 8W 50 4 8W 11 11 8W 51 6 8W 42 3 8W 50 2 8W 50 FRONT L...

Страница 798: ...G101 3 G103 S117 Z1 18 BK 3 1 SWITCH HAZARD SIGNAL TURN 3 C1 TN 22 L60 L60 22 TN S207 L60 22 TN 16 C103 TN 22 L60 S116 L60 18 TN L60 18 TN 1 1 2 LAMP REPEATER RIGHT 3 LAMP SIGNAL TURN PARK RIGHT BK 18 Z1 Z1 18 BK S127 Z1 18 BK LEFT HEADLAMP 46 IN PDC RELAY LAMP FOG Z1 18 BK 1 L3 16 RD OR S114 L43 20VT 2 16 C103 L43 20 VT L43 18 VT S133 8W 50 2 8W 11 2 8W 11 12 8W 11 12 8W 40 2 8W 40 4 8W 15 2 8W 1...

Страница 799: ...DLAMP LEVELING MOTOR 3 1 2 BR YL 22 L13 VT 22 L43 L43 22 VT 2 S133 L43 18 VT G204 G101 S108 Z1 22 BK Z1 14 BK BK 14 Z1 BK 22 Z1 S117 G103 17 HEADLAMP LEFT LOW BEAM FEED 4 E2 20 OR S210 9 4A FUSE 9 29 BLOCK FUSE 1 3 HEAD 2 PARK 1 OFF SWITCH HEADLAMP BATT F33 E1 20 TN 8W 11 2 8W 50 2 8W 11 12 8W 15 7 8W 15 7 8W 15 2 8W 15 2 8W 15 4 8W 15 4 8W 50 3 8W 11 11 8W 11 11 8W 11 2 8W 50 2 8W 11 4 M M 8W 50 ...

Страница 800: ...0 1 SWITCH LAMP FOG FRONT L7 20BK YL BK YL 20 L7 S306 L7 20 BK YL 2 LEFT LICENSE LAMP L7 20BK YL 5 C105 L7 20 BK YL LAMP SIGNAL TURN PARK LEFT RIGHT PARK TURN SIGNAL LAMP 2 2 BK YL 20 L7 L7 20 BK YL S113 8W 10 6 8W 11 4 8W 11 2 8W 50 2 8W 47 2 8W 50 6 8W 11 4 8W 51 5 8W 52 3 8W 52 3 PL RHD 8W 50 FRONT LIGHTING 8W 50 5 PLR05004 978W 1 ...

Страница 801: ...P FOG REAR 15 WT OR 18 F61 WT OR 18 F61 CENTER DISTRIBUTION POWER 16 16 FUSE 20A BATT A0 12 C103 F61 18 WT OR 2 SWITCH LAMP FOG REAR 42 3 Z1 18 BK G101 Z1 18 BK S107 Z1 18 BK 43 7 L35 20 BR RD 3 Z3 22 BK OR 9 3 HEAD 2 PARK 1 OFF SWITCH HEADLAMP BATT F33 1 2 C230 L7 20BK YL L7 20BK YL S117 8W 50 3 8W 15 7 8W 15 7 8W 15 4 8W 51 6 8W 10 4 8W 10 11 8W 51 6 8W 15 2 8W 15 2 8W 50 2 8W 15 4 8W 11 4 8W 10...

Страница 802: ...he Z1 circuit grounding point is the left side of the radiator closure panel For the right front parking lamp turn signal side marker lamp and right headlamp the Z1 circuit grounding point is in the right fender side shield Circuit L7 also feeds the radio if equipped When the headlamp switch is in the PARK or ON position the dimmer circuit F33 also connects to circuit E1 Circuit E1 powers the ash ...

Страница 803: ...n the headlamp switch is in the ON position and the oper ator has selected LOW beam operation In addition circuit L43 is protected by a 10 amp fuse located in the fuse block and is the feed for the left LOW beam headlamp Ground for the switch is supplied on circuit Z1 When the operator moves the switch power is sup plied on circuit L13 from the switch to the headlamp leveling motors Ground for the...

Страница 804: ... Left Headlamp 8W 51 6 Left License Lamp 8W 51 5 Left Rear Fog Lamp 8W 51 7 Left Tail Stop Lamp 8W 51 5 Park Neutral Position Switch 8W 51 2 Power Distribution Center 8W 51 4 6 8 Powertrain Control Module 8W 51 2 Component Page Rear Fog Lamp Switch 8W 51 6 7 8 Right Back Up Lamp 8W 51 3 Right Fog Lamp 8W 51 6 Right License Lamp 8W 51 5 Right Rear Fog Lamp 8W 51 7 Right Tail Stop Lamp 8W 51 5 S101 ...

Страница 805: ...1 20 VT BK L1 18 VT BK 1 C105 SWITCH LAMP BACK UP BLOCK FUSE SWITCH POSITION NEUTRAL PARK C 8W 51 3 TO S301 BR YL 20 T41 2 T41 20 BR YL C1 76 PARK NEUTRAL POSITION SWITCH SENSE POWERTRAIN CONTROL MODULE S106 8W 11 8 8W 11 8 8W 10 6 8W 11 2 8W 30 12 8W 21 2 8W 51 2 8W 51 REAR LIGHTING PL RHD 978W 1 PLR05101 ...

Страница 806: ... BK S307 L1 18 VT BK S301 LAMP BACK UP RIGHT LAMP BACK UP LEFT VT BK 18 L1 L1 18 VT BK 1 C341 C 8W 51 2 FROM C105 Z1 16 BK 3 C341 Z1 18 BK Z1 18 BK 3 C340 S315 L1 18 VT BK 1 C340 8W 15 8 8W 15 8 8W 15 9 8W 15 9 8W 15 8 PL RHD 8W 51 REAR LIGHTING 8W 51 3 PLR05102 978W 1 ...

Страница 807: ...WT TN 2 C105 L50 20 WT TN B 8W 51 5 TO S316 BATT A3 22 15A FUSE 2 FUSE BLOCK 1 HEADLAMP SWITCH 1 OFF 2 PARK 3 HEAD 9 4 F33 20 PK RD A 8W 51 5 TO S306 L7 20 BK YL L7 20 BK YL 2 C230 M T A T 73 8W 10 9 8W 10 4 8W 30 12 8W 30 12 8W 11 4 8W 11 2 8W 10 4 8W 10 6 8W 50 2 8W 51 4 8W 51 REAR LIGHTING PL RHD 978W 1 PLR05103 3 2 1 ...

Страница 808: ...1 4 FROM C205 NO CONNECTION L50 20 WT TN S316 L50 18 WT TN L50 18 WT TN 5 C340 2 L7 18 BK YL L7 18 BK YL S308 BK 18 Z1 BK 18 Z1 G302 Z1 18 BK Z1 18 BK S315 3 C340 Z1 20 BK Z1 20 BK 2 1 3 1 2 3 LAMP STOP TAIL RIGHT LEFT TAIL STOP LAMP LEFT LICENSE LAMP LAMP LICENSE RIGHT Z1 18 BK 2 NO CONNECTION 8W 15 9 8W 15 9 8W 15 8 8W 15 8 PL RHD 8W 51 REAR LIGHTING 8W 51 5 PLR05104 978W 1 ...

Страница 809: ...P LEFT Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK S127 S107 G101 S115 2 1 1 2 L39 18 LB WT L39 18 LB WT L39 18 LB WT Z1 20 BK Z1 20 BK Z1 18 BK G103 2 5 L35 20 BR RD 7 SWITCH LAMP FOG REAR G204 Z3 20 BK OR Z3 14 BK OR S201 LOGIC LAMP FOG LEFT RIGHT FOG LAMP S117 17 8W 10 11 8W 10 4 8W 10 4 8W 50 6 8W 50 3 8W 15 2 8W 15 2 8W 15 4 8W 15 7 8W 15 7 8W 15 4 8W 51 6 8W 51 REAR LIGHTING PL RHD 978W 1 PLR05105 ...

Страница 810: ... WT L38 18 BR WT L38 18 BR WT 4 C340 4 C341 G301 G302 Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK S307 S315 S308 3 C340 C341 3 LAMP FOG REAR LEFT RIGHT REAR FOG LAMP S317 8W 51 6 8W 15 9 8W 15 8 8W 15 9 8W 15 8 8W 15 8 PL RHD 8W 51 REAR LIGHTING 8W 51 7 PLR05106 978W 1 ...

Страница 811: ...G S221 4 6 7 SWITCH CONTROL HEATER A C F33 20 PK RD 1 4 SWITCH HEADLAMP 9 FUSE 4A 29 9 FUSE BLOCK E1 20 TN E2 20 OR E2 20 OR S210 SWITCH LAMP FOG REAR SWITCH HEADLAMP 4 E2 20 OR 8W 10 6 8W 10 4 8W 10 4 8W 11 4 8W 11 2 8W 10 6 8W 10 6 8W 11 12 8W 42 3 8W 50 2 8W 11 11 8W 11 2 8W 11 11 8W 51 6 8W 50 2 8W 51 8 8W 51 REAR LIGHTING PL RHD 978W 1 PLR05107 ...

Страница 812: ...p and radio lamp A 4 amp fuse in cavity 12 of the fuse block protects circuit E1 FOG LAMPS REAR The rear fog lamps will operate only when the headlamp switch is in the ON position Circuit A3 from the Power Distribution Center sup plies PDC voltage to a bus bar in the fuse block Circuit F61 is one of four circuits that the bus bar feeds and is protected by a 20 amp fuse in cavity 4 Circuit F61 conn...

Страница 813: ...ower Distribution Center PDC to circuit A22 Circuit A22 feeds a bus bar in the fuse block A 40 amp fuse in the PDC protects the A2 and A22 circuits Circuit F20 is one of four circuits that connects to the fuse block bus bar fed by circuit A22 Circuit F20 supplies power to the back up lamp switch On 3 spd automatic transaxle vehicles the back up lamp switch is part of an assembly that includes the ...

Страница 814: ... Park Turn Signal Lamp 8W 52 3 Left Repeater Lamp 8W 52 3 Left Turn Signal Lamp 8W 52 4 Power Distribution Center 8W 52 2 Right Park Turn Signal Lamp 8W 52 3 Right Repeater Lamp 8W 52 3 Component Page Right Turn Signal Lamp 8W 52 4 S107 8W 52 3 S112 8W 52 3 S113 8W 52 3 S116 8W 52 3 S117 8W 52 3 S127 8W 52 3 S205 8W 52 2 S207 8W 52 3 S212 8W 52 3 S307 8W 52 4 S308 8W 52 4 S315 8W 52 4 Turn Signal ...

Страница 815: ...STRIBUTION CENTER BATT A0 L9 18 BK WT 14 C103 L5 20 BK 4 A3 A1 A2 L55 20 BK YL L32 20 PK INPUT OUTPUT GROUND IN FB FLASHER COMBINATION G201 S205 Z2 20 BK LG Z2 20 BK LG L9 22 BK WT 20 19 5 3 10 1 9 8W 11 8 8W 11 2 8W 10 9 8W 10 4 8W 15 5 8W 15 5 8W 10 4 8W 10 6 8W 52 2 8W 52 TURN SIGNALS PL RHD 978W 1 PLR05201 ...

Страница 816: ... YL Z1 18 BK Z1 18 BK Z1 18 BK Z1 18 BK S117 S107 G101 G103 Z1 18 BK Z1 18 BK Z1 18 BK S127 LEFT REPEATER LAMP LAMP SIGNAL TURN PARK LEFT RIGHT PARK TURN SIGNAL LAMP LAMP REPEATER RIGHT 1 2 3 1 2 3 2 RIGHT 1 LEFT SWITCH HAZARD SIGNAL TURN S113 S212 S207 8W 15 4 8W 15 2 8W 15 2 8W 15 4 8W 50 5 8W 40 4 8W 50 3 PL RHD 8W 52 TURN SIGNALS 8W 52 3 PLR05202 978W 1 ...

Страница 817: ...2 20 BR RD C230 L62 20 BR RD BK 16 Z1 S307 BK 18 Z1 G302 G301 2 1 1 2 L63 18 DG RD L62 18 BR RD 6 C340 6 C341 Z1 18 BK S315 3 C340 Z1 18 BK LAMP SIGNAL TURN LEFT RIGHT TURN SIGNAL LAMP C230 3 3 C341 Z1 18 BK 10 1 11 4 8W 15 8 8W 15 9 8W 15 8 8W 15 9 8W 15 8 8W 52 4 8W 52 TURN SIGNALS PL RHD 978W 1 PLR05203 ...

Страница 818: ...he instrument cluster GROUND CIRCUIT Circuit Z1 provides ground for all the turn signal lamps although the it has different grounding points for each turn signal circuit Circuit Z2 provides the ground path for the combination flashing unit HELPFUL INFORMATION For the left front turn signal hazard flasher lamp the Z1 circuit grounding point is the left side of the radiator closure panel For the rig...

Страница 819: ...ground ing points for each circuit Circuit Z2 provides the ground path for the combination flashing unit HELPFUL INFORMATION For the left front turn signal hazard flasher lamp the Z1 circuit grounding point is the left side of the radiator closure panel For the right front turn signal hazard flasher lamp the Z1 circuit grounding point is in the right fender side shield For the left rear turn signa...

Страница 820: ...nent Page Fuse 15 FB 8W 53 2 3 Fuse Block 8W 53 2 3 G101 8W 53 2 3 G201 8W 53 3 Intermittent Wipe Wash Switch 8W 53 3 S108 8W 53 2 3 Component Page S205 8W 53 3 S206 8W 53 2 3 Windshield Washer Pump Motor 8W 53 2 3 Wipe Wash Switch 8W 53 2 Wiper Motor 8W 53 2 3 8W 53 2 8W 53 WIPERS PL ...

Страница 821: ... YL V4 18 RD YL V3 18 BR WT V10 18 BR V10 18 BR 4 C101 A B Z1 18 BK Z1 14 BK G101 S108 S206 RUN ACC A31 0 1 2 2 1 0 1 4 4 DOWN WIPER MOTOR 1 UP 2 LOW 3 HIGH 1 3 2 HIGH 3 WASH WIPE WASH SWITCH 0 OFF 1 LOW M 4 14 8W 11 2 8W 11 12 8W 15 2 8W 15 2 8W 10 12 8W 11 12 8W 53 2 8W 53 WIPERS STANDARD PL RHD 978W 1 PLR05301 ...

Страница 822: ...ACC A31 3 2 1 2 4 4 DOWN WIPER MOTOR 1 UP 2 LOW 3 HIGH 1 3 M 4 BR WT 18 V3 DG YL 18 V5 F13 18 DB 14 3 2 1 0 0 1 2 3 0 1 2 3 RELAY CONTROL I WIPE LOGIC AND 1 2 4 6 5 3 4 5 6 6 WASH 4 MIN 5 MAX 0 OFF SWITCH WASH WIPE INTERMITTENT 2 LOW 1 DELAY 3 HIGH 8W 11 2 8W 11 12 8W 15 2 8W 15 2 8W 15 5 8W 15 5 8W 10 12 8W 11 12 PL RHD 8W 53 WIPERS INTERMITTENT 8W 53 3 PLR05302 978W 1 ...

Страница 823: ...W speed area of the switch V3 circuit and cycles the wipers The amount of delay between wiper cycles is dependent on switch position All relays and internal logic in the switch are not ser viceable and should be replaced as an assembly As the windshield wiper motor turns the park switch internal to the motor moves from its grounded position to the powered RUN position When the wiper switch is turn...

Страница 824: ...ION 3 Component Page Circuit Breaker 8W 60 2 Fuse Block 8W 60 2 G203 8W 60 2 Left Power Window Motor 8W 60 2 Left Power Window Switch 8W 60 2 Component Page Master Power Window Switch 8W 60 2 Right Power Window Motor 8W 60 2 S138 8W 60 2 S310 8W 60 2 8W 60 2 8W 60 POWER WINDOWS PL ...

Страница 825: ...K VT 4 C205 S310 G203 1 2 M Q11 14 LB Q21 14 VT MOTOR WINDOW POWER RIGHT M 2 1 LEFT POWER WINDOW MOTOR Q12 14 BR Q22 14 VT Q16 14 BR WT Q16 14 BR WT Q16 14 BR WT 13 13 Q26 14 VT WT Q26 14 VT WT Q26 14 VT WT 14 C205 14 F21 14 TN F21 14 7 C231 3 TN S138 F21 14 TN 8W 11 10 8W 11 2 8W 10 6 8W 15 6 8W 15 6 8W 11 10 8W 60 2 8W 60 POWER WINDOWS PL RHD PL 8W 60 POWER WINDOWS 8W 60 3 DESCRIPTION AND OPERAT...

Страница 826: ... is the ground MASTER WINDOW SWITCH RIGHT WINDOW OPERATION When the window switch is moved to the window DOWN position voltage is supplied on the F21 cir cuit through the CLOSED contacts in the switch to the Q26 circuit The Q26 circuit connects from the master switch to the right window switch A BUS bar internal to the right switch passes the voltage through the switch to circuit Q22 Circuit Q22 c...

Страница 827: ......

Страница 828: ...k 8W 61 2 G203 8W 61 2 4 Left Door Lock Switch 8W 61 2 4 Left Front Door Lock Motor 8W 61 3 Left Rear Door Lock Motor 8W 61 3 Right Door Lock Switch 8W 61 2 4 Component Page Right Front Door Lock Motor 8W 61 3 Right Rear Door Lock Motor 8W 61 3 S214 8W 61 2 S302 8W 61 3 S303 8W 61 3 S310 8W 61 2 4 8W 61 2 8W 61 POWER DOOR LOCKS PL ...

Страница 829: ... Z8 14 BK VT 4 C205 P34 18 PK BK F35 18 RD YL F35 16 RD YL 1 C205 2 LOCK LEFT DOOR LOCK SWITCH 1 UNLOCK 1 2 2 2 LOCK RIGHT DOOR LOCK SWITCH 1 UNLOCK S214 S310 TO C231 A 8W 61 3 B 8W 61 3 C231 TO OR BK 18 P33 BK VT 18 Z8 1 8W 11 6 8W 11 2 8W 10 6 8W 15 6 8W 11 6 8W 15 6 8W 61 2 8W 61 POWER DOOR LOCKS PL RHD 978W 1 PLR06101 ...

Страница 830: ...3 16 OR BK P33 16 OR BK 1 2 MOTOR LOCK DOOR REAR LEFT RIGHT REAR DOOR LOCK MOTOR 2 1 P34 18 PK BK 1 C324 2 C301 P34 18 PK BK P34 16 PK BK P34 16 PK BK 1 C325 P34 18 PK BK 2 C303 P34 16 PK BK S303 2 P33 18 OR BK 1 P33 16 OR BK P33 18 OR BK 2 P33 18 OR BK 1 P33 16 OR BK P33 16 OR BK S302 LEFT DOOR LOCK SWITCH FROM FROM SWITCH LOCK DOOR LEFT P34 18 PK BK P33 18 OR BK B 8W 61 2 A 8W 61 2 PK WT 16 P34 ...

Страница 831: ...6 16 PK VT 2 C231 P36 18 PK VT OR VT 18 P35 C231 3 OR VT 16 P35 C241 4 P35 16 OR VT P35 16 OR VT P35 18 OR VT 3 C205 9 C241 1 4 2 4 Z8 18 BK VT G203 Z8 14 BK VT Z8 14 BK VT 4 C205 2 2 LOCK RIGHT DOOR LOCK SWITCH 1 UNLOCK S310 BK VT 18 Z8 1 8W 15 6 8W 15 6 8W 61 4 8W 61 POWER DOOR LOCKS PL RHD 978W 1 PLR06103 ...

Страница 832: ...ar to the P34 circuit The P34 circuit then connects to the door motors on the unlock side Grounding for the UNLOCK function is provided by the P33 circuit The P33 circuit conects back to the right door switch LOCK side and passes through the internal bus bar to the P35 circuit The P35 circuit conects back to the left door switch and passes through the switch to the Z8 circuit The Z8 circuit goes t...

Страница 833: ......

Страница 834: ...onent Page Circuit Breaker 8W 62 2 4 G203 8W 62 2 G203 8W 62 4 Left Power Mirror 8W 62 2 3 4 Power Folding Mirror Relay 8W 62 2 3 4 Component Page Power Mirror Fuse Holder 8W 62 2 4 Power Mirror Switch 8W 62 2 3 4 Right Power Mirror 8W 62 2 3 4 S310 8W 62 2 4 8W 62 2 8W 62 POWER MIRRORS PL ...

Страница 835: ... VT S310 4 C205 5 4 4 3 6 3 4 LEFT POWER MIRROR RELAY MIRROR FOLDING POWER RIGHT POWER MIRROR P99 18 GY P99 18 GY P99 18 GY 4 C231 8 C205 P110 18 OR P95 18 DB WT P95 18 DB WT P95 18 DB WT 12 12 C231 11 C205 11 P93 18 YL BK P93 18 YL BK P93 18 YL BK P92 18 YL P94 18 WT YL P91 18 WT BK P91 18 WT BK 10 C205 F121 18 TN BK 8W 62 4 8W 15 6 8W 15 6 8W 62 3 8W 62 3 8W 62 4 8W 11 10 8W 62 2 8W 62 POWER MIR...

Страница 836: ...231 7 C1 C1 8 5 P95 18 DB WT P95 18 DB WT P95 18 DB WT P93 18 YL BK P93 18 YL BK P93 18 YL BK P99 18 GY P99 18 GY P99 18 GY 12 11 4 8 11 12 P99 18 GY P91 18 WT BK C1 4 3 C1 P92 18 YL P94 18 WT YL 6 6 6 RETRACT 4 LEFT 5 EXTEND 1 DOWN 2 UP 3 RIGHT 1 2 3 4 PTC 5 6 PTC 1 2 3 4 6 5 POWER POWER 3 RIGHT 2 UP 1 DOWN 5 EXTEND 4 LEFT 6 RETRACT MIRROR RIGHT 8W 62 4 8W 62 2 PL RHD 8W 62 POWER MIRRORS 8W 62 3 ...

Страница 837: ... POWER POWER MIRROR SWITCH 5 2 G203 P90 18 LG BK P90 18 LG BK P90 18 LG BK P90 18 LG BK F121 18 TN BK F121 18 TN BK P110 18 OR POWER FOLDING MIRROR RELAY Z8 18 BK VT Z8 14 BK VT Z8 18 BK VT S310 4 C205 Z8 18BK VT 8W 62 3 8W 62 3 8W 62 2 8W 15 6 8W 11 10 8W 15 6 8W 62 4 8W 62 POWER MIRRORS PL RHD 978W 1 PLR06203 ...

Страница 838: ...OSED con tacts in the mirror relay located in the right door When the left mirror DOWN movement is selected voltage is supplied through the switch to circuit P110 The P110 circuit connects from the switch to the power mirror relay located in the door coil side Power on the coil side causes the contacts in the relay to CLOSE con necting circuits F121 and P90 The P90 circuit then supplies power to t...

Страница 839: ......

Страница 840: ...ND OPERATION 3 Component Page A C Heater Control Switch 8W 64 2 Fuse 14 FB 8W 64 2 Fuse Block 8W 64 2 G203 8W 64 2 Power Sunroof Motor 8W 64 2 Component Page S313 8W 64 2 S314 8W 64 2 Sunroof Slide Switch 8W 64 2 Sunroof Vent Switch 8W 64 2 8W 64 2 8W 64 POWER SUNROOF PL ...

Страница 841: ... Z8 18 BK VT BLOCK FUSE Q45 18PK BK 1 2 2 CLOSE 1 OPEN SWITCH SLIDE SUNROOF SUNROOF VENT SWITCH 1 OPEN 2 CLOSE 2 1 1 2 3 4 Z8 18 BK VT CONTROL HEATER A C 1 Z8 18BK VT 4 VENT OPEN 3 VENT CLOSE 2 CLOSE 1 OPEN MOTOR SUNROOF POWER 14 F10 18 YL RD 5 C225 SWITCH 8W 11 12 8W 10 12 8W 11 2 8W 42 3 M 8W 64 2 8W 64 POWER SUNROOF PL RHD PL 8W 64 POWER SUNROOF 8W 64 3 DESCRIPTION AND OPERATION Continued ...

Страница 842: ...itch to circuit Q45 Circuit Q45 connects from the open close switch to the tilt switch The ground is passed through the switch to circuit Z8 and finally to ground When the operator selects the CLOSE function power and ground are reversed TILT OPEN CLOSE When the operator selects tilt OPEN circuit F10 is connected to circuit Q43 Circuit Q43 connects from the switch to the CLOSED vent limit switch i...

Страница 843: ......

Страница 844: ... 8W 11 9 8W 30 9 S127 8W 15 2 8W 21 2 8W 30 3 8W 40 5 8W 50 3 8W 51 6 8W 52 3 S129 8W 30 13 S131 8W 10 9 S131 8W 41 2 S133 8W 11 13 8W 50 4 S134 8W 10 10 8W 30 5 Component Page S138 8W 11 10 S201 8W 15 7 S202 8W 15 7 S203 8W 10 8 S204 8W 42 3 S205 8W 15 5 S206 8W 11 12 S207 8W 40 4 8W 50 3 S208 8W 70 3 S209 8W 50 3 S210 8W 11 11 S211 8W 11 8 S212 8W 40 4 S213 8W 10 6 S214 8W 11 6 S217 8W 10 6 8W 1...

Страница 845: ...SOR KNOCK BATTERY TEMPERATURE SENSOR SENSOR TEMPERATURE COOLANT ENGINE THROTTLE POSITION SENSOR 1 2 2 A A 1 K4 20 BK LB K4 20 BK LB K4 20 BK LB K4 20 BK LB K4 20 BK LB K4 20 BK LB 10 C161 K4 20 BK RD K4 20 BK LB 2 0L SOHC DOHC 2 0L S120 K4 20 BK LB S110 SENSOR IAT MAP 8W 30 3 8W 30 7 8W 30 3 8W 30 8 8W 30 7 8W 30 6 8W 30 7 8W 30 7 8W 30 6 8W 30 3 8W 30 6 8W 70 2 8W 70 SPLICE INFORMATION PL RHD 978...

Страница 846: ...N SWITCH LAMP WARNING BRAKE INSTRUMENT CLUSTER PARK BRAKE SWITCH S208 G9 20 GY BK G9 20 GY BK G9 22 GY BK G9 22 GY BK G9 22 GY BK 2 C103 8W 10 5 8W 40 5 8W 40 5 8W 40 5 PL RHD 8W 70 SPLICE INFORMATION 8W 70 3 PLR07002 978W 1 ...

Страница 847: ......

Страница 848: ... 8W 80 15 Duty Cycle Evap Purge Solenoid 8W 80 15 EGR Transducer solenoid 8W 80 15 Engine Coolant Temperature Sensor ECT 8W 80 15 Engine Oil Pressure Switch 8W 80 16 Front Fog Lamp Switch 8W 80 16 Fuel Injector No 1 8W 80 16 Fuel Injector No 2 8W 80 16 Fuel Injector No 3 8W 80 16 Fuel Injector No 4 8W 80 16 Fuel Pump Module 8W 80 17 Generator 8W 80 17 Glove Box Lamp and Switch 8W 80 17 Headlamp Di...

Страница 849: ... 8W 80 25 Power Mirror Switch C2 8W 80 26 Power Steering Pressure Switch 8W 80 26 Power Sunroof Motor 8W 80 26 Powertrain Control Module C1 8W 80 26 Powertrain Control Module C2 8W 80 27 PRNDL Lamp 8W 80 28 Radiator Fan Motor 8W 80 28 Radio C1 8W 80 28 Radio C2 8W 80 29 Rear Fog Lamp Switch 8W 80 29 Rear Window Defogger Switch 8W 80 29 Right Airbag Impact Sensor 8W 80 29 Right Back Up Lamp 8W 80 2...

Страница 850: ...33 Right Turn Signal Lamp 8W 80 33 Solid State Fan Relay 8W 80 33 Stop Lamp Switch 8W 80 33 Component Page Sunroof Slide Switch 8W 80 34 Sunroof Vent Switch 8W 80 34 Throttle Position Sensor TPS 8W 80 34 Torque Convertor Clutch TCC Solenoid ATX 8W 80 34 Trunk Lamp 8W 80 34 Turn Signal Hazard Switch 8W 80 35 Upstream Heated Oxygen Sensor 8W 80 35 Vapor Canister Leak Detector 8W 80 35 Vehicle Speed ...

Страница 851: ...IGH BLOWER MOTOR DRIVER 3 C6 14LB M2 BLOWER MOTOR DRIVER 4 C5 14LG M1 BLOWER MOTOR DRIVER 5 C4 14TN LOW BLOWER MOTOR DRIVER 6 C2 22DB YL MODE SWITCH OUTPUT 7 E2 22OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL 7 E2 22OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL WITH A C A C HEATER CONTROL SWITCH CAV CIRCUIT FUNCTION 1 C20 20BR OR A C SWITCH SENSE 2 C22 20DB WT LOW PRESSURE SWITCH OUTPUT BLACK 2 1 A C HIGH...

Страница 852: ... BR ABS WARNING LAMP DRIVER 8 9 B47 20RD LB ABS SYSTEM RELAY OUTPUT 10 Z1 14BK GROUND DARK GRAY ABS HYDRAULIC MODULATOR 3 1 6 4 ABS RELAY BOX 5 1 10 6 CAV CIRCUIT FUNCTION 1 R45 18DG LB DRIVER AIRBAG SQUIB LINE 2 2 R43 18BK LB DRIVER AIRBAG SQUIB LINE 1 3 R47 18DB LB LEFT IMPACT SENSOR LINE 1 4 R49 18LB LEFT IMPACT SENSOR LINE 2 5 R42 18BK YL PASSENGER AIRBAG SQUIB LINE 1 6 R44 18DG YL PASSENGER A...

Страница 853: ...TCH OUTPUT RUN A B A B CAV CIRCUIT FUNCTION 1 K4 18BK LB SENSOR GROUND 2 G31 18VT LG AMBIENT TEMPERATURE SENSOR SIGNAL 2 1 5 4 3 CAV CIRCUIT FUNCTION 1 C5 14LG M1 BLOWER MOTOR DRIVER 2 C6 14LB M2 BLOWER MOTOR DRIVER 3 4 C7 14BK TN HIGH BLOWER MOTOR DRIVER 5 C4 14TN LOW BLOWER MOTOR DRIVER BLOWER MOTOR RESISTOR BLOCK 3 2 5 4 1 BLACK CAV CIRCUIT FUNCTION 1 G9 20GY BK RED BRAKE WARNING LAMP DRIVER 2 ...

Страница 854: ...R 3 L61 22LG 4 V10 18BR 5 X3 20BK RD 6 F12 20DG WT 7 R46 18BR LB 8 R48 18TN 9 L35 20BR RD 10 L13 20BR YL 11 D1 20VT BR 12 D2 20WT BK 13 14 L3 14RD OR 15 R47 18DB LB 16 R49 18LB BROWN BROWN 7 16 1 8 16 7 8 1 CAV CIRCUIT 1 G19 20LG BR G19 20LG BR 2 G9 20GY BK 3 F20 20WT 4 G6 20GY 5 G7 20WT OR G7 20WT OR 6 G12 20TN BK 7 G20 20VT YL 8 G21 20GY LB 9 L60 22TN 10 11 G3 20BK PK 12 F61 18WT OR 13 M1 18PK M...

Страница 855: ...T40 14BR 2 G7 20WT OR 3 G4 20DB 4 K141 20TN WT 5 C20 20BR OR 6 G20 20VT YL 7 F12 20DG WT 8 9 G3 20BK PK 10 Z12 20BK TN 11 12 13 K173 20DG 14 CAV CIRCUIT 1 T40 14BR 2 G7 18WT OR 3 G4 20DB 4 K141 20TN WT 5 C20 18BR 6 G20 20VT YL 7 F12 18DB WT 8 9 G3 20BK PK 10 Z12 18BK TN 11 12 13 K173 20LG 14 5 1 10 6 BLACK BLACK CAV CIRCUIT 1 Z1 20BK 2 K39 20GY RD 3 K40 20BR WT 4 K59 20VT 5 K7 20OR 6 A142 18DG OR ...

Страница 856: ...8PK BK 7 F21 14TN 8 P99 18GY P99 18GY 9 P90 18LG BK P90 18LG BK 10 P91 18WT BK P91 18WT BK 11 P93 18YL BK 12 P95 18DB WT 13 Q16 14BR WT 14 Q26 14VT WT 15 X54 22VT 16 X56 22DB RD C205 C205 CAV CIRCUIT 1 C2 22DB YL 2 F20 22WT 3 C21 22DB OR 4 C1 14DG 5 6 C7 14BK TN CAV CIRCUIT 1 C2 22DB YL 2 F20 22WT 3 C21 22DB OR 4 C1 14DG 5 6 C7 14BK TN BLUE 6 4 3 1 4 6 1 3 BLUE C206 C206 CAV CIRCUIT 1 E2 22OR 2 Z3...

Страница 857: ...3 P35 16OR VT 4 P99 18GY 5 P33 16OR BK 6 P34 16PK BK 7 F21 14TN 8 9 P90 18LG BK 10 P91 18WT BK 11 P93 18YL BK 12 P95 18DB WT 13 Q16 14BR WT 14 Q26 14VT WT 15 X53 22DG X53 22DG 16 X55 22BR RD X55 22BR RD CAV CIRCUIT 1 2 L7 20BK YL L7 20BK YL 3 L62 20BR RD 4 L63 20DG RD 5 X51 22BR YL 6 G4 20DB 7 X52 22DB WT 8 L38 18BR WT 9 G16 20BK LB 10 P33 16OR BK P33 16OR BK 11 P34 16PK BK P34 16PK BK 12 M2 22YL ...

Страница 858: ...301 C301 C303 C303 CAV CIRCUIT 1 2 3 M4 18GY BK CAV CIRCUIT 1 L50 20WT TN 2 Z1 20BK 3 M4 22GY BK BLACK BLACK 1 3 C309 C309 BLACK 1 2 CAV CIRCUIT 1 P34 18PK BK 2 P33 18OR BK CAV CIRCUIT 1 P34 18PK BK 2 P33 18OR BK 2 1 BLACK C315 C315 BLACK BLACK 1 2 CAV CIRCUIT 1 P34 18PK BK 2 P33 18OR BK CAV CIRCUIT 1 P34 18PK BK 2 P33 18OR BK BLACK BLACK 1 2 CAV CIRCUIT 1 P34 18PK BK 2 P33 18OR BK CAV CIRCUIT 1 P...

Страница 859: ...K 1 2 BLACK BLACK CAV CIRCUIT 1 P34 18PK BK 2 P33 18OR BK CAV CIRCUIT 1 P34 18PK BK 2 P33 18OR BK 1 2 2 1 C325 C325 CAMSHAFT POSITION SENSOR 3 1 BLACK CAV CIRCUIT 1 L1 18VT BK 2 L7 18BK YL 3 Z1 18BK 4 L38 18BR WT 5 L50 18WT TN 6 L63 18DG RD CAV CIRCUIT 1 L1 18VT BK 2 L7 18BK YL 3 Z1 18BK 4 L38 18BR WT 5 L5018WT TN 6 L63 18DG RD C340 C340 CAV CIRCUIT 1 L1 18VT BK 2 L7 18BK YL 3 Z1 16BK 4 L38 18BR W...

Страница 860: ...RD LEFT FRONT WHEEL SPEED SENSOR 10 11 12 13 L50 20WT TN STOP LAMP SWITCH OUTPUT 14 15 G19 20LG BR ABS WARNING LAMP DRIVER 16 B116 20GY ABS PUMP MOTOR RELAY CONTROL 17 18 19 20 B120 16BR WT ABS PUMP MOTOR RELAY OUTPUT 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 B142 20BR YL LEFT FRONT DUMP SOLENOID CONTROL 43 B143 20DG YL RIGHT FRONT DUMP SOLENOID CONTROL 44 45 46 B146 20BR L...

Страница 861: ... SUPPLY 2 K4 20BK LB SENSOR GROUND 3 K24 20GY BK CRANKSHAFT POSITION SENSOR SIGNAL CRANKSHAFT POSITION CKP SENSOR CAV CIRCUIT FUNCTION 1 2 3 D1 20VT BR CCD BUS 4 Z12 22BK TN GROUND 5 Z12 22BK TN GROUND 6 D20 20LG SCI RECEIVE 7 D21 20PK SCI TRANSMIT 8 9 10 11 D2 20WT BK CCD BUS 12 13 14 15 16 A14 16RD WT FUSED B BLACK DATA LINK CONNECTOR 1 8 9 16 CAV CIRCUIT FUNCTION 1 M1 22PK FUSED B 2 3 M2 20YL D...

Страница 862: ...L 2 F12 20DG WT FUSED IGNITION SWITCH OUTPUT RUN START BLACK 2 1 DUTY CYCLE EVAP PURGE SOLENOID CAV CIRCUIT FUNCTION A K4 20BK LB SENSOR GROUND A K4 20BK RD SENSOR GROUND B K2 20TN DB ENGINE COOLANT TEMPERATURE SENSOR SIGNAL B K2 20TN BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL C G20 20VT YL ENGINE COOLANT TEMPERATURE GAUGE SIGNAL BLACK ENGINE COOLANT TEMPERATURE ECT SENSOR B A C B A C 2 0L SOHC E...

Страница 863: ... FRONT FOG LAMP SWITCH CAV CIRCUIT FUNCTION 1 K11 18WT DB INJECTOR NO 1 DRIVER 2 A142 18DG OR AUTOMATIC SHUTDOWN RELAY OUTPUT FUEL INJECTOR NO 1 CAV CIRCUIT FUNCTION 1 K12 18TN INJECTOR NO 2 DRIVER 2 A142 18DG OR AUTOMATIC SHUTDOWN RELAY OUTPUT FUEL INJECTOR NO 2 BLACK 2 1 BLACK 2 1 CAV CIRCUIT FUNCTION 1 K13 18YL WT INJECTOR NO 3 DRIVER 2 A142 18DG OR AUTOMATIC SHUTDOWN RELAY OUTPUT FUEL INJECTOR...

Страница 864: ...4LG HEADLAMP SWITCH OUTPUT 3 L3 14RD OR DIMMER SWITCH HIGH BEAM OUTPUT 4 L20 14LG WT FUSED B BLACK HEADLAMP SWITCH 1 2 9 7 3 4 5 6 8 CAV CIRCUIT FUNCTION 1 E1 20TN PANEL LAMPS DIMMER SWITCH SIGNAL 2 L2 14LG HEADLAMP SWITCH OUTPUT 3 M2 22YL TIME OUT RELAY 4 F33 20PK RD FUSED B 5 G26 20LB KEY IN IGNITION SWITCH SENSE G26 20LB KEY IN IGNITION SWITCH SENSE 6 G16 20BK LB LEFT FRONT DOOR JAMB SWITCH SEN...

Страница 865: ...ENSOR SIGNAL C K6 18VT WT 5 VOLT SUPPLY D K1 18DG RD MAP SENSOR SIGNAL BLACK A D IAT MAP SENSOR CAV CIRCUIT FUNCTION 1 K59 18VT IDLE AIR CONTROL MOTOR NO 4 DRIVER 2 K40 18BR WT IDLE AIR CONTROL MOTOR NO 1 DRIVER 3 K60 18YL BK IDLE AIR CONTROL MOTOR NO 2 DRIVER 4 K39 18GY RD IDLE AIR CONTROL MOTOR NO 3 DRIVER IDLE AIR CONTROL IAC MOTOR CAV CIRCUIT FUNCTION 1 K17 18DB TN IGNITION COIL NO 2 DRIVER 2 ...

Страница 866: ...ENSOR IMMOBILIZER SENSOR CAV CIRCUIT FUNCTION 1 2 L3 16RD OR DIMMER SWITCH HIGH BEAM OUTPUT 3 L60 22TN RIGHT TURN SIGNAL 4 G10 20LG RD SEAT BELT SWITCH SENSE 5 G5 20DB WT FUSED IGNITION SWITCH OUTPUT RUN START 6 M1 22PK FUSED B 7 G21 22GY LB TACHOMETER SIGNAL 8 Z3 16BK OR GROUND 9 R41 18BK TN AIRBAG WARNING LAMP DRIVER 10 G7 22WT OR VEHICLE SPEED SENSOR SIGNAL BLACK 5 1 10 6 INSTRUMENT CLUSTER C1 ...

Страница 867: ...MITTENT WIPERS 2 1 KNOCK SENSOR CAV CIRCUIT FUNCTION 1 R47 18DB LB LEFT IMPACT SENSOR LINE 1 2 R49 18LB LEFT IMPACT SENSOR LINE 2 BLACK 2 1 LEFT AIRBAG IMPACT SENSOR LEFT BACK UP LAMP CAV CIRCUIT FUNCTION 1 L1 18VT BK BACK UP LAMP SENSE 2 Z1 18BK GROUND CAV CIRCUIT FUNCTION 1 Z2 22BK LG GROUND 2 V5 18DG YL WIPER RELAY COMMON 3 V10 18BR WINDSHIELD WASHER RELAY OUTPUT 4 V3 18BR WT WIPER SWITCH LOW S...

Страница 868: ... SWITCH 1 2 3 4 5 CAV CIRCUIT FUNCTION 1 Q22 14VT LEFT FRONT DOWN 2 Q12 14BR LEFT FRONT UP LEFT DOOR WINDOW MOTOR BLACK 2 1 LEFT FOG LAMP CAV CIRCUIT FUNCTION 1 L39 20LB WT FRONT FOG LAMPS SWITCH OUTPUT 2 Z1 20BK GROUND BLACK LEFT FRONT DOOR LOCK MOTOR CAV CIRCUIT FUNCTION 1 P34 18PK BK DOOR UNLOCK DRIVER 2 P33 18OR BK DOOR LOCK DRIVER 2 1 CAV CIRCUIT FUNCTION 1 X55 22BR RD LEFT FRONT SPEAKER 2 X5...

Страница 869: ...P CAV CIRCUIT FUNCTION 1 X53 22DG LEFT FRONT SPEAKER 2 X55 22BR RD LEFT FRONT SPEAKER BLACK 1 2 LEFT INSTRUMENT PANEL SPEAKER PREMIUM CAV CIRCUIT FUNCTION 1 L61 18LG LEFT TURN SIGNAL 2 L7 18BK YL PARK LAMP SWITCH OUTPUT 3 Z1 18BK GROUND LEFT PARK TURN SIGNAL LAMP CAV CIRCUIT FUNCTION 1 L43 22VT LEFT HEADLAMP FEED 2 L13 22BR YL HEADLAMP LEVELING SIGNAL FROM SWITCH 3 Z1 22BK GROUND LEFT HEADLAMP LEV...

Страница 870: ... 18OR BK DOOR LOCK DRIVER 2 1 CAV CIRCUIT FUNCTION 1 X51 22BR YL LEFT REAR SPEAKER 2 X57 22BR LB LEFT REAR SPEAKER BLACK CAV CIRCUIT FUNCTION 1 B3 20LG DB LEFT REAR WHEEL SPEED SENSOR 2 B4 20LG LEFT REAR WHEEL SPEED SENSOR 2 1 LEFT REAR WHEEL SPEED SENSOR BLACK LEFT REAR SPEAKER 1 2 CAV CIRCUIT FUNCTION 1 Q12 14BR LEFT FRONT UP 2 Q26 14VT WT MASTER SWITCH LEFT FRONT DOWN 3 F21 14TN FUSED IGNITION ...

Страница 871: ...PUT RUN START 5 Q26 14VT WT MASTER SWITCH LEFT FRONT DOWN 6 Q16 14BR WT MASTER SWITCH LEFT FRONT UP NATURAL 1 3 5 2 4 6 MASTER POWER WINDOW SWITCH CAV CIRCUIT FUNCTION 1 L61 18LG LEFT TURN SIGNAL 2 Z1 18BK GROUND LEFT REPEATER LAMP CAV CIRCUIT FUNCTION 1 L63 18DG RD LEFT TURN SIGNAL LAMP FEED 2 Z1 18BK GROUND LEFT TURN SIGNAL LAMP CAV CIRCUIT FUNCTION A M23 22YL BK TIME OUT RELAY B Z3 18BK OR GROU...

Страница 872: ... RELAY OUTPUT 3 4 P110 18OR RELAY COIL FEED 5 Z8 18BK VT GROUND 6 Z8 18BK VT GROUND 6 Z8 18BK VT GROUND 7 8 P90 18LG BK POWER MIRRORS 9 POWER FOLDING MIRROR RELAY CAV CIRCUIT FUNCTION 1 F121 18TN BK POWER FOLDING MIRROR FEED 1 F121 18TN BK POWER MIRROR SWITCH FEED 2 F21 14TN FUSED IGNITION SWITCH OUTPUT RUN POWER MIRROR FUSE HOLDER 1 4 5 8 POWER MIRROR SWITCH C1 CAV CIRCUIT FUNCTION 1 Z8 18BK VT G...

Страница 873: ... 1 POWER STEERING PRESSURE SWITCH CAV CIRCUIT FUNCTION 41 42 43 K4 20BK LB SENSOR GROUND 44 K7 20OR 8 VOLT SUPPLY 45 K10 20WT POWER STEERING PRESSURE SWITCH SENSE 46 A14 18RD WT FUSED B 47 Z11 20BK WT GROUND 48 K40 20BR WT IDLE AIR CONTROL MOTOR NO 3 DRIVER 49 K60 20YL BK IDLE AIR CONTROL MOTOR NO 2 DRIVER 50 Z12 20BK TN GROUND 51 K141 20TN WT DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL 52 G31 18VT LG ...

Страница 874: ...9 79 K54 20OR BK TORQUE CONVERTOR CLUTCH SOLENOID CONTROL 80 CONTINUED 2 0L SOHC ENGINE 2 0L DOHC ENGINE MTX ATX CAV CIRCUIT FUNCTION 1 2 K19 18BK GY IGNITION COIL NO 1 3 DRIVER 3 K17 18DB TN IGNITION COIL NO 2 4 DRIVER 4 K20 18DG GENERATOR FIELD DRIVER 5 V32 20YL RD SPEED CONTROL FEED 6 A142 18DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT 7 K13 18YL WT INJECTOR NO 3 DRIVER 8 G3 20BK PK CHECK ENGINE LAMP...

Страница 875: ...G RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL 37 K21 18BK RD INTAKE AIR TEMPERATURE SENSOR SIGNAL 38 C20 18BR A C SWITCH SENSE 39 40 K35 20GY YL EXHAUST GAS RECIRCULATION SOLENOID CONTROL CONTINUED CAV CIRCUIT FUNCTION 1 E2 22OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL 2 Z3 20BK OR GROUND BLACK 1 2 PRNDL LAMP CAV CIRCUIT FUNCTION 1 C25 14LG RADIATOR FAN RELAY OUTPUT 2 Z1 14BK GROUND RADIATOR FAN MOT...

Страница 876: ... OUTPUT RUN 4 A4 14BK RD FUSED B 5 C15 14BK WT REAR WINDOW DEFOGGER RELAY OUTPUT BLACK 5 1 REAR WINDOW DEFOGGER SWITCH CAV CIRCUIT FUNCTION 1 R46 18BR LB RIGHT IMPACT SENSOR LINE 1 2 R48 18TN RIGHT IMPACT SENSOR LINE 2 BLACK 2 1 RIGHT AIRBAG IMPACT SENSOR RIGHT BACK UP LAMP CAV CIRCUIT FUNCTION 1 L1 18VT BK BACK UP LAMP SENSE 2 Z1 18BK GROUND RADIO C2 GRAY 7 1 CAV CIRCUIT FUNCTION 1 2 F61 18WT OR ...

Страница 877: ... OUTPUT CAV CIRCUIT FUNCTION 1 Q21 14VT RIGHT FRONT DOWN 2 Q11 14LB RIGHT FRONT UP BLACK RIGHT DOOR WINDOW MOTOR 2 1 CAV CIRCUIT FUNCTION 1 L39 18LB WT FRONT FOG LAMPS SWITCH OUTPUT 2 Z1 20BK GROUND RIGHT FOG LAMP CAV CIRCUIT FUNCTION 1 X56 22DB RD RIGHT FRONT SPEAKER 2 X54 22VT RIGHT FRONT SPEAKER 1 2 BLACK RIGHT FRONT DOOR SPEAKER BLACK CAV CIRCUIT FUNCTION 1 P34 18PK BK DOOR UNLOCK DRIVER 2 P33...

Страница 878: ... CIRCUIT FUNCTION 1 X54 22VT RIGHT FRONT SPEAKER 2 X56 22DB RD RIGHT FRONT SPEAKER RIGHT INSTRUMENT PANEL SPEAKER PREMIUM BLACK 1 2 CAV CIRCUIT FUNCTION 1 L60 18TN RIGHT TURN SIGNAL 2 L7 18BK YL PARK LAMP SWITCH OUTPUT 3 Z1 18BK GROUND RIGHT PARK TURN SIGNAL LAMP CAV CIRCUIT FUNCTION 1 L43 22VT RIGHT HEADLAMP FEED 2 L13 22BR YL HEADLAMP LEVELING SIGNAL FROM SWITCH 3 Z1 22BK GROUND RIGHT HEADLAMP L...

Страница 879: ...IZONTAL SUPPLY BLACK RIGHT REAR DOOR LOCK MOTOR CAV CIRCUIT FUNCTION 1 P34 18PK BK DOOR UNLOCK DRIVER 2 P33 18OR BK DOOR LOCK DRIVER 2 1 RIGHT REAR FOG LAMP CAV CIRCUIT FUNCTION 1 L38 18BR WT REAR FOG LAMP FEED 2 Z1 18BK GROUND CAV CIRCUIT FUNCTION 1 X52 22DB WT RIGHT REAR SPEAKER 2 X58 22DB OR RIGHT REAR SPEAKER CAV CIRCUIT FUNCTION 1 B1 20WT BK RIGHT REAR WHEEL SPEED SENSOR 2 B2 20DG WT RIGHT RE...

Страница 880: ...D 2 K173 20DG RADIATOR FAN RELAY CONTROL 3 C25 14LG ENGINE FAN FEED 4 A16 14GY RADIATOR FAN RELAY FEED SOLID STATE FAN RELAY CAV CIRCUIT FUNCTION 1 L60 18TN RIGHT TURN SIGNAL 2 Z1 18BK GROUND RIGHT REPEATER LAMP CAV CIRCUIT FUNCTION 1 L50 18WT TN TAIL STOP 2 L7 18BK YL TAIL STOP 3 Z1 18BK GROUND RIGHT TAIL STOP LAMP CAV CIRCUIT FUNCTION 1 L63 18DG RD RIGHT TURN SIGNAL LAMP FEED 2 Z1 18BK GROUND RI...

Страница 881: ...EN CLOSE LIMIT 3 F10 18YL RD FUSED IGNITION SWITCH OUTPUT RUN ACC 4 Q45 18PK BK POWER SUNROOF VENT CLOSE 5 Q41 18WT POWER SUNROOF OPEN WHITE WHITE CAV CIRCUIT FUNCTION 1 K4 20BK LB SENSOR GROUND 2 K22 20OR DB THROTTLE POSITION SENSOR SIGNAL 3 K6 20VT WT 5 VOLT SUPPLY THROTTLE POSITION TPS SENSOR BLACK 3 1 CAV CIRCUIT FUNCTION 1 M1 22PK FUSED B M1 22PK FUSED B 2 M4 22GY BK TRUNK LAMP SWITCH OUTPUT ...

Страница 882: ...ACK TURN SIGNAL HAZARD SWITCH 6 1 11 7 CAV CIRCUIT FUNCTION 1 2 F12 18DG WT FUSED IGNITION SWITCH OUTPUT RUN START 3 K106 18WT LG VAPOR CANISTER SOLENOID DRIVER 4 K107 18OR VAPOR CANISTER PUMP SWITCH DRIVER BLACK VAPOR CANISTER LEAK DETECTOR 4 1 CAV CIRCUIT FUNCTION 1 K7 18OR 8 VOLT SUPPLY 2 K4 18BK LB SENSOR GROUND 3 G7 18WT OR VEHICLE SPEED SENSOR SIGNAL VEHICLE SPEED SENSOR BLACK 3 1 CAV CIRCUI...

Страница 883: ...PER SWITCH HIGH SPEED OUTPUT 2 V3 18BR WT WIPER SWITCH LOW SPEED OUTPUT 3 V5 18DG YL WIPER RELAY COMMON 4 F13 18DB FUSED IGNITION SWITCH OUTPUT RUN ACC WIPER MOTOR CAV CIRCUIT FUNCTION A V10 18BR WASHER PUMP CONTROL SWITCH OUTPUT B Z1 18BK GROUND BLACK WINDSHIELD WASHER PUMP MOTOR A B BLACK 1 4 ...

Страница 884: ...r BK Bottom of Battery Tray 6 Blower Motor Resistor Block NAT Left Side Cowl Top N S Brake Warning Lamp Switch BK Right Frame Rail N S C101 BR Top of I P 13 C102 BK Top of I P 13 C103 BL Top of I P 13 C105 BL Right Kick Panel N S C108 BK Left Lower Cowl N S C160 LT GY Left Fender Side Shield 5 Connector Name Number Color Location Fig C161 BK Left Fender Side Shield 5 C203 BK Left Side of I P N S C...

Страница 885: ...witch GN Rear of Switch 10 Knock Sensor GY Front of Engine 8 Connector Name Number Color Location Fig Left Airbag Impact Sensor GY Left Side of Radiator Closure Panel 1 Left Back Up Lamp GY At Lamp 20 Left Door Lock Switch WT At Switch 12 Left Door Window Motor BK At Motor 12 Left Fog Lamp BK Rear of Lamp 4 Left Front Door Lock Motor BK At Motor 12 Left Front Door Speaker BK At Speaker 12 Left Fro...

Страница 886: ...of Lamp 4 Right Headlamp Leveling Motor BK Rear of Right Headlamp 4 Right Instrument Panel Speaker BK At Speaker N S Connector Name Number Color Location Fig Right License Lamp NAT At Lamp 18 Right Park Turn Signal Lamp NAT At Lamp 4 RIght Power Mirror BK At Mirror 12 Right Rear Door Lock Motor BK Rear of Door 15 Right Rear Fog Lamp NAT At Lamp N S Right Rear Speaker BK At Speaker 16 Right Rear Wh...

Страница 887: ...Fig 1 Airbag Impact Sensors Fig 2 Brake Support Bracket Connections 8W 90 4 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 888: ...8W 90 4 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 889: ...Fig 3 Transmission Connections PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 5 DESCRIPTION AND OPERATION Continued ...

Страница 890: ...Fig 4 Engine Compartment Connections Right Side 8W 90 6 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 891: ...Fig 5 Engine Compartment Connections Left Side PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 7 DESCRIPTION AND OPERATION Continued ...

Страница 892: ...Fig 6 Engine Compartment Connections 8W 90 8 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 893: ...Fig 7 Engine Connections PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 9 DESCRIPTION AND OPERATION Continued ...

Страница 894: ...Fig 8 Engine Connections 8W 90 10 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 895: ...Fig 11 Console Connections Fig 12 Door Connections Front PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued ...

Страница 896: ...Fig 9 Visor Vanity Connections Fig 10 Steering Column Connections PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued ...

Страница 897: ...8W 90 12 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 898: ...Fig 15 Door Connections Rear Fig 16 Body Connections Left Side PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 13 DESCRIPTION AND OPERATION Continued ...

Страница 899: ...Fig 13 Left Side Instrument Panel Connections 8W 90 14 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 900: ...Fig 19 Fuel Tank Connections Fig 20 Rear Lighting Connections PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued ...

Страница 901: ...Fig 14 Right Side Instrument Panel Connections 8W 90 14 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 902: ...PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued ...

Страница 903: ...Fig 17 Trunk Connections Fig 18 Decklid Rear Bumper Connections 8W 90 16 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 904: ...PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 17 DESCRIPTION AND OPERATION Continued ...

Страница 905: ......

Страница 906: ...GR Sol 3 S123 Near HD LP and Dash Connector 3 S124 Between Cam Sensor and Coil T O s 3 S125 Near Starter 3 S126 Near PCM T O 1 S127 Near Ignition Coil 3 S128 Near A C Compressor Clutch T O N S S129 In PCM T O 1 S201 Near T O for Center Console N S S202 Near T O for PAB 5 S203 Near T O for HVAC 5 Spllice Location Fig S204 Near HVAC Connector 5 S205 Near Center Stack T O 5 S206 Near Center Stack T O...

Страница 907: ...Fig 1 Engine Compartment Splices 8W 95 2 8W 95 SPLICE LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 908: ...Fig 2 Engine Compartment Splices PL 8W 95 SPLICE LOCATIONS 8W 95 3 DESCRIPTION AND OPERATION Continued ...

Страница 909: ...Fig 3 Engine Splices 8W 95 4 8W 95 SPLICE LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 910: ...Fig 4 Instrument Panel Splices Right Side PL 8W 95 SPLICE LOCATIONS 8W 95 5 DESCRIPTION AND OPERATION Continued ...

Страница 911: ...Fig 5 Instrument Panel Splices Left Side 8W 95 6 8W 95 SPLICE LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 912: ...Fig 6 Body Splices Left Side PL 8W 95 SPLICE LOCATIONS 8W 95 7 DESCRIPTION AND OPERATION Continued ...

Страница 913: ...Fig 7 Body Splices Right Side 8W 95 8 8W 95 SPLICE LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 914: ...Fig 8 Door Splices PL 8W 95 SPLICE LOCATIONS 8W 95 9 DESCRIPTION AND OPERATION Continued ...

Страница 915: ......

Страница 916: ...NS CIGAR LIGHTER 8W 41 1 8W 42 AIR CONDITIONING HEATER 8W 42 1 8W 43 AIRBAG SYSTEM 8W 43 1 8W 44 INTERIOR LIGHTING 8W 44 1 8W 47 AUDIO SYSTEMS 8W 47 1 8W 48 REAR WINDOW DEFOGGER 8W 48 1 8W 50 FRONT LIGHTING 8W 50 1 8W 51 REAR LIGHTING 8W 51 1 8W 52 TURN SIGNALS 8W 52 1 8W 53 WIPERS 8W 53 1 8W 60 POWER WINDOWS 8W 60 1 8W 61 POWER DOOR LOCKS 8W 61 1 8W 62 POWER MIRRORS 8W 62 1 8W 64 POWER SUNROOF 8W...

Страница 917: ......

Страница 918: ...tion with the doors closed and the key removed from the ignition If a component is part of several different circuits it is shown in the diagram for each For example the headlamp switch is the main part of the exterior lighting but it also affects the interior lighting and the chime warning system It is important to real ize that no attempt is made on the diagrams to represent components and wirin...

Страница 919: ...OCEDURE REQUIRES IT TO BE ON WARNING SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL WARNING OPERATE THE ENGINE ONLY IN A WELL VENTILATED AREA WARNING KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING ESPECIALLY THE FAN AND BELTS WARNING TO PREVENT SERIOUS BURNS AVOID CONTACT WITH HOT PARTS SUCH AS THE RA...

Страница 920: ...ponent connectors by name If a component has two or more connectors they will be identified as C1 C2 C3 etc This sections also provides terminal numbering cir cuit identification wire colors and functions All connectors are viewed from the terminal end unless otherwise specified To find the connector loca tion in the vehicle refer to section 8W 90 This sec tion uses the connector identification nu...

Страница 921: ...Fig 5 Symbol Identification 8W 01 4 8W 01 GENERAL INFORMATION PL DESCRIPTION AND OPERATION Continued ...

Страница 922: ...e front strut tower in the area shown in Fig 7 for the installation of any metal fasteners into the strut tower Because of the minimum clearance in this area Fig 7 installation of metal fasteners could damage the coil spring coating and lead to a corrosion failure of the spring If a plastic clip is missing or is lost or broken during servicing a vehicle replace only with the equivalent part listed...

Страница 923: ...erminal push out Terminals in the wiring assembly are fully seated into the connector component and locked in position Dirt or corrosion on the terminals Any amount of corrosion or dirt could cause an intermittent prob lem Damaged connector component casing exposing the item to dirt and moisture Wire insulation that has rubbed through causing a short to ground Wiring broke inside of the insulation...

Страница 924: ... the item 4 The voltmeter will show the difference in volt age between the two points TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure The steps are listed and explained below Always check for non factory items added to the vehicle before doing any diagnosis If the vehicle is equipped with these items disconnect them to verify ...

Страница 925: ...cles there is a fusible link placed between the output terminal of the generator and the engine starter motor terminal A service part is avail able if this fusible link requires replacement This service part has the eyelet that attaches to the starter motor If the fusible link requires replace ment this indicates a problem in the charging start ing system that needs to be corrected Replacement of ...

Страница 926: ...9 Connect connector to its mating half compo nent 10 Connect battery and test all affected systems CONNECTOR AND TERMINAL REPLACEMENT 1 Disconnect battery 2 Disconnect the connector that is to be repaired from its mating half component 3 Cut off the existing wire connector directly behind the insulator Remove six inches of tape from the harness 4 Stagger cut all wires on the harness side at 1 2 in...

Страница 927: ...e connector Fig 21 Fig 22 5 Cut the wire 6 inches from the back of the con nector 6 Remove 1 inch of insulation from the wire on the harness side 7 Select a wire from the terminal repair assem bly that best matches the color wire being repaired 8 Cut the repair wire to the proper length and remove 1 inch of insulation 9 Place a piece of heat shrink tubing over one side of the wire Make sure the tu...

Страница 928: ...low is correct If necessary refer to the appropriate wiring diagram for current flow 6 Solder the connection together using rosin core type solder only Do not use acid core solder 7 Tape the diode to the harness using electrical tape making sure the diode is completely sealed from the elements 8 Re connect the battery and test affected sys tems SPECIAL TOOLS WIRING TERMINAL Probing Tool Package 68...

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Страница 930: ...nkshaft Position CKP Sensor 8W 30 Data Link Connector 8W 30 Diode No 1 8W 11 44 Diode No 2 8W 15 42 Dome Lamp 8W 44 Door Ajar Switches 8W 44 Door Jamb Switches 8W 40 Component Page Door Lock Motors 8W 61 Door Lock Switches 8W 61 Door Speakers 8W 47 Driver Side Airbag 8W 43 Duty Cycle Evap Purge Solenoid 8W 30 EGR Transducer Solenoid 8W 30 Engine Coolant Temperature ECT Sensor 8W 30 Engine Coolant ...

Страница 931: ...r 8W 42 Radio 8W 47 Rear Fog Lamp Switch 8W 51 Rear Window Defogger 8W 48 Rear Window Defogger Switch 8W 48 Component Page Repeater Lamps 8W 50 52 Seat Belt Warning Lamp 8W 40 Solid State Fan Relay 8W 42 Speakers 8W 47 Splice Information 8W 30 Stop Lamp Switch 8W 30 Sunroof Slide Switch 8W 64 Sunroof Vent Switch 8W 64 Switch Illumination 8W 48 Tail Stop Lamps 8W 51 Throttle Position TP Sensor 8W 3...

Страница 932: ...ORMATION INTRODUCTION This section provides an alphabetical listing of all the components covered in group 8W For information on system operation refer to the appropriate section of the wiring diagrams PL 8W 02 COMPONENT INDEX 8W 02 3 ...

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Страница 934: ...15 FB 8W 10 12 Fuse 16 FB 8W 10 12 Fuse 16 PDC 8W 10 4 11 Fuse 18 PDC 8W 10 4 9 Fuse 20 PDC 8W 10 4 9 Fuse 21 PDC 8W 10 4 10 Fuse 23 PDC 8W 10 4 10 Fuse 25 PDC 8W 10 4 9 Component Page Fuse Block 8W 10 6 12 G204 8W 10 5 Generator 8W 10 10 Glove Box Lamp And Switch 8W 10 8 Headlamp Switch 8W 10 6 Horn No 1 8W 10 9 Horn No 2 8W 10 9 Horn Relay 8W 10 9 Ignition Coil Pack 8W 10 10 Ignition Switch 8W 1...

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Страница 946: ...RIPTION AND OPERATION This section covers the power distribution center and all circuits involved with it For additional infor mation on system operation refer to the appropriate wiring diagrams PL 8W 10 POWER DISTRIBUTION 8W 10 13 ...

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Страница 948: ... 8W 11 4 11 13 Ignition Switch 8W 11 7 12 Instrument Cluster 8W 11 10 11 14 Intermittent Wipe Wash Switch 8W 11 12 Left Door Lock Switch 8W 11 6 Left Front Door Ajar Switch 8W 11 14 Component Page Left Headlamp 8W 11 13 Left Headlamp Leveling Motor 8W 11 13 Left License Lamp 8W 11 4 Left Park Turn Signal Lamp 8W 11 5 Left Tail Stop Lamp 8W 11 4 Map Reading Lamps 8W 11 14 Master Power Window Switch...

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Страница 962: ...ION AND OPERATION This section covers the fuse block and all circuits involved with it For additional information on sys tem operation please refer to the appropriate section of the wiring diagrams PL 8W 11 FUSE FUSE BLOCK 8W 11 15 ...

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Страница 964: ... 15 7 Left Fog Lamp 8W 15 4 Left Headlamp 8W 15 2 Left Headlamp Leveling Motor 8W 15 2 Left License Lamp 8W 15 8 Left Park Turn Signal Lamp 8W 15 2 Component Page Left Rear Fog Lamp 8W 15 8 Left Tail Stop Lamp 8W 15 8 Left Turn Signal Lamp 8W 15 8 Map Reading Lamps 8W 15 7 Master Power Window Switch 8W 15 6 Power Mirror Switch 8W 15 6 Power Steering Pressure Switch 8W 15 3 Power Sunroof Motor 8W 1...

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Страница 973: ...t connect to those grounds and the components that connect those grounds For additional information on system operation refer to the appropriate section of the wiring diagrams For an illustration of the phys ical location of each ground refer to group 8W 90 8W 15 10 8W 15 GROUND DISTRIBUTION PL ...

Страница 974: ...Shut Down Relay 8W 20 2 Battery 8W 20 2 Capacitor 8W 20 2 Engine Starter Motor 8W 20 2 Fuse 21 PDC 8W 20 2 Fusible Link 8W 20 2 G104 8W 20 2 Component Page G105 8W 20 2 Generator 8W 20 2 Power Distribution Center 8W 20 2 Powertrain Control Module 8W 20 2 S122 8W 20 2 S125 8W 20 2 PL 8W 20 CHARGING SYSTEM 8W 20 1 ...

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Страница 976: ...ut Down ASD relay The ground or voltage regulated side of the genera tor field is controlled by the K20 circuit which con nects to cavity 4 of the PCM connector When there is current present in the field and the rotor is turning the stator in the generator produces a B voltage that is supplied to the battery through the A11 and A0 circuits The A11 circuit is connected to the output terminal of the...

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Страница 978: ...ne Starter Motor 8W 21 2 Engine Starter Motor Relay 8W 21 2 Fuse 11 PDC 8W 21 2 Fusible Link 8W 21 2 G101 8W 21 2 Generator 8W 21 2 Component Page Ignition Switch 8W 21 2 Park Neutral Position Switch 8W 21 2 Power Distribution Center 8W 21 2 Powertrain Control Module 8W 21 2 S106 8W 21 2 S107 8W 21 2 S125 8W 21 2 S127 8W 21 2 PL 8W 21 STARTING SYSTEM 8W 21 1 ...

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Страница 980: ...relay is located in the PDC Check for a good ground at starter motor The left headlamp ground is the end point for the starter relay coil ground circuit and is located at the left side of the radiator closure panel STARTING SYSTEM AUTOMATIC TRANSMISSION The Power Distribution Center PDC supplies bat tery voltage to the engine starter motor solenoid through circuit T40 when the coil side of the eng...

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Страница 982: ... 4 12 G106 8W 30 2 G303 8W 30 10 Generator 8W 30 11 IAT MAP Sensor 8W 30 6 Idle Air Control Motor 8W 30 8 Ignition Coil Pack 8W 30 5 Immobilizer Engine Sensor 8W 30 13 Immobilizer Sensor 8W 30 3 8 13 Instrument Cluster 8W 30 7 8 10 11 Knock Sensor 8W 30 6 Component Page Noise Supressor 8W 30 5 Park Neutral Position Switch 8W 30 12 Power Distribution Center 8W 30 2 3 4 10 12 Power Steering Pressure...

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Страница 995: ...tects circuit F12 Circuit F15 feeds the Airbag Control Module ACM A 10 amp fuse in the fuse block cavity 9 pro tects circuit F15 BATTERY FEED Circuit A14 from the Power Distribution Center PDC supplies battery voltage to cavity 46 of the Powertrain Control Module PCM A 20 amp fuse in the PDC protects circuit A14 HELPFUL INFORMATION Circuit A14 connects to a bus bar in the PDC that the battery feed...

Страница 996: ...A14 and A142 The A142 circuit is spliced and supplies power to the generator fuel injectors PCM ignition coil and heated oxygen sensors HELPFUL INFORMATION Refer to group 14 Fuel System for additional information Check the 20 amp fuse located in the PDC FUEL PUMP MOTOR Circuit A14 is a bus bar in the Power Distribution Center PDC and connects to battery voltage The contact side of the fuel pump re...

Страница 997: ...ity 44 of the PCM connector Circuit K24 from the sensor provides an input sig nal to the PCM The K24 circuit connects to cavity 32 of the PCM connector The PCM provides ground for the crankshaft posi tion sensor signal circuit K24 through circuit K4 Circuit K4 connects to cavity 43 of the PCM connec tor HELPFUL INFORMATION Circuit K7 splices to supply 8 volts to the camshaft position sensor and ve...

Страница 998: ...e speed sensor MANIFOLD ABSOLUTE PRESSURE SENSOR From the Powertrain Control Module PCM cir cuit K6 supplies 5 volts to the Manifold Absolute Pressure MAP sensor Circuit K6 connects to cavity 61 of the PCM connector Circuit K1 delivers the MAP signal to the PCM Circuit K1 connects to cavity 36 of the PCM connec tor The PCM provides ground for the MAP sensor sig nal circuit K1 through circuit K4 Ci...

Страница 999: ...jectors The PCM controls the ground circuit of each injector Circuit K11 is the ground circuit for Injector 1 Circuit K11 connects to cavity 13 of the PCM Circuit K12 is the ground circuit for Injector 2 Circuit K12 connects to cavity 17 of the PCM Circuit K13 is the ground circuit for Injector 3 Circuit K13 connects to cavity 7 of the PCM Circuit K14 is the ground circuit for Injector 4 Circuit K...

Страница 1000: ... also connects to a bus bar in the PDC that supplies volt age to the coil side of radiator fan relay A C clutch relay and fuel pump relay In the RUN or START position the ignition switch connects circuit A1 from the fuse block and circuit A21 Circuit A1 connects to battery voltage and is protected by a 30 amp fuse in the PDC DUTY CYCLE EVAP PURGE SOLENOID Circuit F12 supplies battery voltage to th...

Страница 1001: ...cuit G4 provides an input to the Powertrain Control Module PCM indicating fuel tank level This circuit connects to cavity 23 of the PCM connec tor The G4 circuit is also used for the fuel gauge located in the instrument cluster For operation of the fuel gauge refer to section 8W 40 PARK NEUTRAL POSITION SWITCH INPUT 3 SPD TRANSMISSION On vehicles equipped with the 3 spd automatic transmission the ...

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Страница 1003: ...nector 8W 35 3 Fuse 10 FB 8W 35 2 Fuse 10 PDC 8W 35 3 Fuse 25 PDC 8W 35 4 Fuse Block 8W 35 2 G101 8W 35 2 3 4 G102 8W 35 4 Component Page Instrument Cluster 8W 35 2 Left Front Wheel Speed Sensor 8W 35 5 Left Rear Wheel Speed Sensor 8W 35 5 Power Distribution Center 8W 35 3 4 Pump Motor Driver 8W 35 3 Right Front Wheel Speed Sensor 8W 35 5 Right Rear Wheel Speed Sensor 8W 35 5 S101 8W 35 4 S103 8W ...

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Страница 1008: ... a problem If a problem is detected the CAB grounds the G19 cir cuit and illuminates the lamp in the instrument clus ter Circuit G19 is also an output of the CAB to the ABS system relay contact side ABS SYSTEM RELAY The system relay is used for the operation of the ABS system Power for the relay is supplied on the B57 circuit from cavity 57 of the Controller Anti Lock Brake CAB Ground for the rela...

Страница 1009: ...the CAB connector Circuit L50 is spliced in with the stop lamps and is used to provide the CAB with information on when the brakes are being applied DATA LINK CONNECTOR Circuit D21 is used for diagnostics of a fault with the ABS system It is spliced in with the Powertrain Control Module PCM circuits and used as an output from the Controller Anti Lock Brake CAB Circuit D21 connects to cavity 51 of ...

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Страница 1011: ...0 2 6 G101 8W 40 5 G204 8W 40 6 Headlamp Dimmer And Optical Horn Switch 8W 40 2 Headlamp Switch 8W 40 2 3 High Beam Indicator Lamp 8W 40 2 Instrument Cluster 8W 40 2 3 4 5 6 Key In Switch 8W 40 3 Component Page Left Front Door Jamb Switch 8W 40 3 Left Park Turn Signal Lamp 8W 40 4 Left Repeater Lamp 8W 40 4 Left Turn Indicator Lamp 8W 40 4 Low Oil Pressure Lamp 8W 40 6 Park Brake Switch 8W 40 5 Po...

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Страница 1017: ...o power the underhood lamp and the interior lamps The fuse is also lifted OPEN during vehicle shipping to reduce battery draw SPEEDOMETER The speedometer and odometer receive their infor mation on the G7 circuit from the Vehicle Speed Sen sor VSS on manual and 3 spd automatic transmission applications The G7 circuit also pro vides a signal to the Powertrain Control Module PCM Logic internal to the...

Страница 1018: ...c driven by the instrument cluster When the instrument cluster determines a low fuel condition based on an input from the fuel tank gauge level sending unit circuit G4 it illuminates the lamp HEADLAMP ON CHIME The headlamp ON chime is used to indicate to the operator that the headlamps or parking lamps are ON when the drivers door is OPEN If the lamps are ON and the drivers door is opened a ground...

Страница 1019: ...lly OPEN switch is CLOSED This switch is case grounded The other switch used is the brake warning lamp switch This switch is normally OPEN When the brake system pressure is below a predetermined level the switch CLOSES and completes a path to ground from the G9 circuit at the cluster through the switch to the left headlamp ground ANTI LOCK WARNING LAMP The Anti Lock warning lamp is used to alert t...

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Страница 1021: ... 41 3 Fuse 3 PDC 8W 41 3 Fuse 23 PDC 8W 41 2 Fuse Block 8W 41 3 G101 8W 41 2 G103 8W 41 2 G204 8W 41 3 Horn No 1 8W 41 2 Horn No 2 8W 41 2 Component Page Horn Relay 8W 41 2 Left Horn Switch 8W 41 2 Power Distribution Center 8W 41 2 3 Right Horn Switch 8W 41 2 S108 8W 41 2 S111 8W 41 2 S117 8W 41 2 S131 8W 41 2 S202 8W 41 3 S213 8W 41 3 PL 8W 41 HORNS CIGAR LIGHTER 8W 41 1 ...

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Страница 1024: ...h is located on the left side of the radiator closure panel HELPFUL INFORMATION Check the 15 amp fuse in the PDC Press the horn switch and listen for the horn relay to click A clicking relay indicates voltage is present up to the switch Check for a good ground at the left headlamp ground CIGAR LIGHTER The cigar lighter in this vehicle uses a cigar lighter relay and a cigar lighter element Power fo...

Страница 1025: ...Motor Resistor Block 8W 42 3 Diode No 2 8W 42 2 Fuse 5 PDC 8W 42 5 Fuse 7 FB 8W 42 3 Fuse 8 FB 8W 42 4 Fuse 10 FB 8W 42 2 Fuse 12 FB 8W 42 3 Fuse 18 PDC 8W 42 2 Fuse Block 8W 42 2 3 4 Component Page G101 8W 42 5 G103 8W 42 2 G203 8W 42 3 Headlamp Switch 8W 42 3 Power Distribution Center 8W 42 2 5 Powertrain Control Module 8W 42 2 5 Radiator Fan Motor 8W 42 5 Rear Fog Lamp Switch 8W 42 3 S108 8W 42...

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Страница 1030: ...eates a magnetic field energizing the clutch Ground for the coil is provided at the right headlamp ground The connector at the A C compressor has a diode located in it This diode is used to control the induced voltage resulting from the magnetic field collapsing when the clutch is disengaged The diode provides a path for the voltage to protect other components and systems The A C compressor clutch...

Страница 1031: ...located in cavity 10 of the fuse block for the A C compressor clutch relay Check the 10 amp fuse located in the PDC for the A C compressor clutch relay Check the 25 amp fuse located in cavity 7 of the fuse block for the blower motor Check the right headlamp ground located at the right fender side shield Check the left headlamp ground located on the left side of the radiator closure panel On vehicl...

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Страница 1033: ...le 8W 43 2 3 4 Airbag Warning Lamp 8W 43 3 Data Link Connector 8W 43 2 Driver Side Airbag 8W 43 4 Fuse 12 FB 8W 43 2 Fuse Block 8W 43 2 Component Page G202 8W 43 2 Instrument Cluster 8W 43 3 Left Airbag Impact Sensor 8W 43 3 Passenger Side Airbag 8W 43 4 Right Airbag Impact Sensor 8W 43 3 PL 8W 43 AIRBAG SYSTEM 8W 43 1 ...

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Страница 1037: ...t panel right center support AIRBAG IMPACT SENSOR The Airbag system uses a sensor internal to the Airbag Control Module ACM to detect impact For information regarding operation of this sensor refer to the appropriate group of the Service Manual AIRBAG SQUIB AIRBAG IGNITER DRIVERS SIDE AIRBAG Two circuits R43 and R45 connect the ACM to the drivers side airbag module squib igniter after pass ing thr...

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Страница 1039: ... Switch 8W 44 3 Left Rear Door Ajar Switch 8W 44 3 Left Visor Vanity Lamps 8W 44 3 Map Reading Lamps 8W 44 2 Mercury Switch 8W 44 3 Power Distribution Center 8W 44 2 3 4 Component Page PRNDL Lamp 8W 44 4 Right Front Door Ajar Switch 8W 44 3 Right Rear Door Ajar Switch 8W 44 3 Right Visor Vanity Lamps 8W 44 3 S201 8W 44 2 4 S202 8W 44 2 S203 8W 44 2 3 4 S210 8W 44 4 S220 8W 44 2 4 S304 8W 44 3 S309...

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Страница 1043: ...s interior lamps It will also turn the lamps OFF after a spec ified period of time and works with the Remote Key less Entry RKE system for illuminated entry Cirucit M2 connects to the relay and supplied a ground path through the door ajar switches Circuit M1 is used to supply battery voltage to the relay This circuit is proteced by a 10 amp fuse located in cavity 13 of the Power Distribution Cente...

Страница 1044: ... opened and completes a path to ground on the Z3 circuit The Z3 circuit is spliced in with the ash receiver lamp PRNDL lamp and the time delay relay The Z3 circuit terminates at the instrument panel left center support ASH RECEIVER LAMP The ash receiver lamp receives power on the E2 circuit from the 4 amp fuse located in the fuse block in cavity 12 The fuse receives power from the head lamp switch...

Страница 1045: ...8W 47 2 Fuse Block 8W 47 2 G201 8W 47 2 3 4 Headlamp Switch 8W 47 2 Left Front Door Speaker 8W 47 3 Left Instrument Panel Speaker 8W 47 3 Component Page Left Rear Speaker 8W 47 4 Power Distribution Center 8W 47 2 Radio 8W 47 2 3 4 Right Front Door Speaker 8W 47 3 Right Instrument Panel Speaker 8W 47 3 Right Rear Speaker 8W 47 4 S203 8W 47 2 S210 8W 47 2 PL 8W 47 AUDIO SYSTEMS 8W 47 1 ...

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Страница 1049: ... feeds the illumination lamp Circuit L7 feeds the park lamps of the radio Circuit F33 feeds circuit L7 A 4 amp fuse in cavity 12 of the fuse block pro tects circuit E2 A 15 amp fuse in cavity 2 of the fuse block protects circuits L7 and F33 SPEAKERS Circuit X53 feeds the speaker in the left front door Circuit X55 is the return from the speaker to the radio On the premium system the X53 and X55 cir...

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Страница 1051: ... Fuse 8 PDC 8W 48 2 Fuse 12 FB 8W 48 2 Fuse Block 8W 48 2 G201 8W 48 2 G301 8W 48 2 Headlamp Switch 8W 48 2 Power Distribution Center 8W 48 2 Component Page Rear Window Defogger 8W 48 2 Rear Window Defogger Switch 8W 48 2 S205 8W 48 2 S210 8W 48 2 S211 8W 48 2 Switch Illumination 8W 48 2 PL 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

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Страница 1053: ...age is passed through the grid the grid lines heat up and heat the rear window Grounding for the rear window defogger switch is provided on the Z2 circuit and terminates at the instrument panel right center support The grid uses the grounding point at the rear body in the right wheel house When the system is in operation a L E D located in the switch indicates to the operator the system is functio...

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Страница 1055: ...witch 8W 50 2 4 5 6 Instrument Cluster 8W 50 3 Left Fog Lamp 8W 50 6 Left Headlamp 8W 50 3 4 6 Left Headlamp Leveling Motor 8W 50 4 Left License Lamp 8W 50 5 Left Park Turn Signal Lamp 8W 50 5 Power Distribution Center 8W 50 2 6 Component Page Radio 8W 50 5 Rear Fog Lamp Switch 8W 50 2 6 Right Fog Lamp 8W 50 6 Right Headlamp 8W 50 3 Right Headlamp Leveling Motor 8W 50 4 Right Park Turn Signal Lamp...

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Страница 1061: ...he Z1 circuit grounding point is the left side of the radiator closure panel For the right front parking lamp turn signal side marker lamp and right headlamp the Z1 circuit grounding point is in the right fender side shield Circuit L7 also feeds the radio if equipped When the headlamp switch is in the PARK or ON position the dimmer circuit F33 also connects to circuit E1 Circuit E1 powers the ash ...

Страница 1062: ...n the headlamp switch is in the ON position and the oper ator has selected LOW beam operation In addition circuit L43 is protected by a 10 amp fuse located in the fuse block and is the feed for the left LOW beam headlamp Ground for the switch is supplied on circuit Z1 When the operator moves the switch power is sup plied on circuit L13 from the switch to the headlamp leveling motors Ground for the...

Страница 1063: ...6 Left Headlamp 8W 51 6 Left License Lamp 8W 51 5 Left Rear Fog Lamp 8W 51 7 Left Tail Stop Lamp 8W 51 5 Park Neutral Position Switch 8W 51 2 Power Distribution Center 8W 51 4 6 8 Powertrain Control Module 8W 51 2 Rear Fog Lamp Switch 8W 51 6 7 8 Component Page Right Back Up Lamp 8W 51 3 Right Fog Lamp 8W 51 6 Right License Lamp 8W 51 5 Right Rear Fog Lamp 8W 51 7 Right Tail Stop Lamp 8W 51 5 S101...

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Страница 1071: ...p and radio lamp A 4 amp fuse in cavity 12 of the fuse block protects circuit E1 FOG LAMPS REAR The rear fog lamps will operate only when the headlamp switch is in the ON position Circuit A3 from the Power Distribution Center sup plies PDC voltage to a bus bar in the fuse block Circuit F61 is one of four circuits that the bus bar feeds and is protected by a 20 amp fuse in cavity 4 Circuit F61 conn...

Страница 1072: ...ower Distribution Center PDC to circuit A22 Circuit A22 feeds a bus bar in the fuse block A 40 amp fuse in the PDC protects the A2 and A22 circuits Circuit F20 is one of four circuits that connects to the fuse block bus bar fed by circuit A22 Circuit F20 supplies power to the back up lamp switch On 3 spd automatic transaxle vehicles the back up lamp switch is part of an assembly that includes the ...

Страница 1073: ... Park Turn Signal Lamp 8W 52 3 Left Repeater Lamp 8W 52 3 Left Turn Signal Lamp 8W 52 4 Power Distribution Center 8W 52 2 Right Park Turn Signal Lamp 8W 52 3 Right Repeater Lamp 8W 52 3 Component Page Right Turn Signal Lamp 8W 52 4 S107 8W 52 3 S112 8W 52 3 S113 8W 52 3 S116 8W 52 3 S117 8W 52 3 S127 8W 52 3 S205 8W 52 2 S207 8W 52 3 S212 8W 52 3 S307 8W 52 4 S308 8W 52 4 S315 8W 52 4 Turn Signal ...

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Страница 1077: ...he instrument cluster GROUND CIRCUIT Circuit Z1 provides ground for all the turn signal lamps although the it has different grounding points for each turn signal circuit Circuit Z2 provides the ground path for the combination flashing unit HELPFUL INFORMATION For the left front turn signal hazard flasher lamp the Z1 circuit grounding point is the left side of the radiator closure panel For the rig...

Страница 1078: ...ground ing points for each circuit Circuit Z2 provides the ground path for the combination flashing unit HELPFUL INFORMATION For the left front turn signal hazard flasher lamp the Z1 circuit grounding point is the left side of the radiator closure panel For the right front turn signal hazard flasher lamp the Z1 circuit grounding point is in the right fender side shield For the left rear turn signa...

Страница 1079: ...nent Page Fuse 15 FB 8W 53 2 3 Fuse Block 8W 53 2 3 G101 8W 53 2 3 G201 8W 53 3 Intermittent Wipe Wash Switch 8W 53 3 S108 8W 53 2 3 Component Page S205 8W 53 3 S206 8W 53 2 3 Windshield Washer Pump Motor 8W 53 2 3 Wipe Wash Switch 8W 53 2 Wiper Motor 8W 53 2 3 PL 8W 53 WIPERS 8W 53 1 ...

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Страница 1082: ...W speed area of the switch V3 circuit and cycles the wipers The amount of delay between wiper cycles is dependent on switch position All relays and internal logic in the switch are not ser viceable and should be replaced as an assembly As the windshield wiper motor turns the park switch internal to the motor moves from its grounded position to the powered RUN position When the wiper switch is turn...

Страница 1083: ...OPERATION 3 Component Page Circuit Breaker 8W 60 2 Fuse Block 8W 60 2 G203 8W 60 2 Left Power Window Motor 8W 60 2 Master Power Window Switch 8W 60 2 Component Page Right Power Window Motor 8W 60 2 Right Power Window Switch 8W 60 2 S310 8W 60 2 PL 8W 60 POWER WINDOWS 8W 60 1 ...

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Страница 1085: ... is the ground MASTER WINDOW SWITCH RIGHT WINDOW OPERATION When the window switch is moved to the window DOWN position voltage is supplied on the F21 cir cuit through the CLOSED contacts in the switch to the Q26 circuit The Q26 circuit connects from the master switch to the right window switch A BUS bar internal to the right switch passes the voltage through the switch to circuit Q22 Circuit Q22 c...

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Страница 1087: ...k 8W 61 2 G203 8W 61 2 4 Left Door Lock Switch 8W 61 2 4 Left Front Door Lock Motor 8W 61 3 Left Rear Door Lock Motor 8W 61 3 Right Door Lock Switch 8W 61 2 4 Component Page Right Front Door Lock Motor 8W 61 3 Right Rear Door Lock Motor 8W 61 3 S214 8W 61 2 S302 8W 61 3 S303 8W 61 3 S310 8W 61 2 4 PL 8W 61 POWER DOOR LOCKS 8W 61 1 ...

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Страница 1091: ... point RIGHT DOOR SWITCH OPERATION LOCK When the switch is moved to the LOCK position voltage is supplied to the P33 circuit and then to the door lock motors The ground path is provided on the P34 circuit back to the right door switch The ground is passed through the switch internal bus bar to the P36 circuit The P36 circuit connects to the left door switch and through to the Z8 circuit The Z8 cir...

Страница 1092: ...35 and P35 Circuit P35 connects from the module to the passangers and drivers door switch lock side Power is passed through the bus bar in the pas sangers switch to circuit P33 This circuit connects to the LOCK side of the motors Ground for the motors is supplied on circuit P34 through a bus bar in the right switch to circuit P36 The P36 circuit connects from the switch to the UNLOCK ALL relay in ...

Страница 1093: ...TION AND OPERATION 3 Component Page Fuse 13 PDC 8W 62 2 G203 8W 62 2 Left Power Mirror Motor 8W 62 2 Power Distribution Center 8W 62 2 Component Page Right Power Mirror Motor 8W 62 2 Right Power Switch 8W 62 2 S203 8W 62 2 S310 8W 62 2 PL 8W 62 POWER MIRRORS 8W 62 1 ...

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Страница 1095: ...nects from the switch to its grounding point on the right instrument panel center support If right door mirror movement LEFT is selected voltage is supplied through the P94 circuit and the ground is passed through circuit P91 When left mir ror RIGHT movement is selected the power and ground are reversed When the switch is moved to the LEFT position and mirror movement UP is selected voltage is sup...

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Страница 1097: ...ND OPERATION 3 Component Page A C Heater Control Switch 8W 64 2 Fuse 14 FB 8W 64 2 Fuse Block 8W 64 2 G203 8W 64 2 Power Sunroof Motor 8W 64 2 Component Page S313 8W 64 2 S314 8W 64 2 Sunroof Slide Switch 8W 64 2 Sunroof Vent Switch 8W 64 2 PL 8W 64 POWER SUNROOF 8W 64 1 ...

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Страница 1099: ...itch to circuit Q45 Circuit Q45 connects from the open close switch to the tilt switch The ground is passed through the switch to circuit Z8 and finally to ground When the operator selects the CLOSE function power and ground are reversed TILT OPEN CLOSE When the operator selects tilt OPEN circuit F10 is connected to circuit Q43 Circuit Q43 connects from the switch to the CLOSED vent limit switch i...

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Страница 1101: ... 2 S126 8W 11 9 8W 30 9 S127 8W 15 2 8W 21 2 8W 30 3 8W 40 5 8W 50 3 8W 51 6 8W 52 3 S129 8W 30 13 S131 8W 10 9 S131 8W 41 2 S133 8W 11 13 8W 50 4 S134 8W 10 10 8W 30 5 Component Page S201 8W 15 7 S202 8W 15 7 S203 8W 10 8 S204 8W 42 3 S205 8W 15 5 S206 8W 11 12 S207 8W 40 4 8W 50 3 S208 8W 70 3 S209 8W 50 3 S210 8W 11 11 S211 8W 11 8 S212 8W 40 4 S213 8W 10 6 S214 8W 11 6 S217 8W 10 6 8W 11 7 S22...

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Страница 1105: ... 12 Clockspring 8W 80 12 Clutch Pedal Position Switch MTX 8W 80 12 Controller Anti Lock Brake 8W 80 13 Crankshaft Position Sensor 8W 80 14 Data Link Connector 8W 80 14 Dome Lamp 8W 80 14 Downstream Heated Oxygen Sensor 8W 80 15 Driver Side Airbag 8W 80 15 Duty Cycle Evap Purge Solenoid 8W 80 15 EGR Transducer solenoid 8W 80 15 Engine Coolant Temperature Sensor ECT 8W 80 15 Engine Oil Pressure Swit...

Страница 1106: ...Motor 8W 80 23 Left Rear Door Lock Motor 8W 80 23 Left Rear Fog Lamp 8W 80 23 Component Page Left Rear Speaker 8W 80 24 Left Rear Wheel Speed Sensor 8W 80 24 Left Repeater Lamp 8W 80 24 Left Tail Stop Lamp 8W 80 24 Left Turn Signal Lamp 8W 80 24 Map Reading Lamps 8W 80 24 Master Power Window Switch 8W 80 25 Park Neutral Position Switch ATX 8W 80 25 Passenger Side Airbag 8W 80 25 Power Mirror Switc...

Страница 1107: ...Right Rear Door Lock Motor 8W 80 32 Right Rear Fog Lamp 8W 80 33 Right Rear Speaker 8W 80 33 Right Rear Wheel Speed Sensor 8W 80 33 Component Page Right Repeater Lamp 8W 80 33 Right Tail Stop Lamp 8W 80 33 Right Turn Signal Lamp 8W 80 34 Solid State Fan Relay 8W 80 34 Stop Lamp Switch 8W 80 34 Sunroof Slide Switch 8W 80 34 Sunroof Vent Switch 8W 80 34 Throttle Position Sensor TPS 8W 80 35 Torque C...

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Страница 1141: ... Transmission 4 Battery Temp Sensor BK Front Lower of Battery Tray 7 Blower Motor Resistor Block NAT RT Side Cowl Panel 10 Brake Warning Lamp Switch BK LT Frame Rail 6 C101 BR Top Center of I P 15 C102 BK Top Center of I P 15 C103 BL Top Center of I P 15 C105 BK LT Kick Panel N S C108 BK Rear of ABS Hydraulic Unit 3 Connector Name Number Color Location Fig C160 LT GY Near PDC 6 C161 BK Near PDC 6 ...

Страница 1142: ...immer Optical Horn Switch BK Rear of Switch 12 Headlamp Switch BK Bottom of Switch 14 Heater Blower Motor BK RT Side of HVAC Housing N S Horn BK LT Inner Fender 7 Idle Air Control Motor BK On Throttle Body 9 Ignition Coil Pack BK Top of Valve Cover 8 Ignition Switch BK Rear of Switch 12 Ignition Switch Lamp BK At Lamp N S Instrument Cluster C1 BK LT Side of Cluster 17 Instrument Cluster C2 BK RT S...

Страница 1143: ...k Up Lamp GY At Lamp 24 RIght Door Lock Switch WT At Switch 18 Connector Name Number Color Location Fig Right Door Power Window Switch WT At Switch 18 Right Door Window Lift Motor BK At Motor 18 RIght Fog Lamp BK At Lamp 5 Right Front Door Speaker BK At Speaker 18 Right Front Power Door Lock Motor GY At Motor 18 Right Front Side Marker Lamp BK At Lamp 5 Right Front Wheel Speed Sensor GY RT Fender ...

Страница 1144: ...Fig 1 Airbag Impact Sensors Fig 2 Brake Support Bracket Connections 8W 90 4 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1145: ...of Clockspring 12 Vehicle Speed Sensor BK Rear of Transmisison 4 Washer Fluid Level Switch BK Bottom of Reservior N S Connector Name Number Color Location Fig Wiper Washer Switch NAT Rear of Switch 12 WIndshield Washer Pump Motor BK Bottom of Reservior 7 Windshield Wiper Motor BK Center of Cowl Panel 10 PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 5 DESCRIPTION AND OPERATION Continued ...

Страница 1146: ...Fig 3 ABS Connections 8W 90 6 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1147: ...Fig 4 Transmission Connections PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 7 DESCRIPTION AND OPERATION Continued ...

Страница 1148: ...Fig 5 Engine Compartment Connections Right Side 8W 90 8 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1149: ...Fig 6 Engine Compartment Connections Left Side PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 9 DESCRIPTION AND OPERATION Continued ...

Страница 1150: ...Fig 7 Engine Compartment Connections Left Side 8W 90 10 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1151: ...Fig 8 Engine Connections PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued ...

Страница 1152: ...Fig 10 Cowl Panel Connections Fig 11 Visor Vanity Connections 8W 90 12 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1153: ...Fig 12 Steering Column Connections Fig 13 Console Connections PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 13 DESCRIPTION AND OPERATION Continued ...

Страница 1154: ...Fig 9 Engine Connections 8W 90 14 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1155: ...Fig 14 Instrument Panel Connections Left Side PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued ...

Страница 1156: ...Fig 15 Instrument Panel Connections Center Stack 8W 90 16 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1157: ...Fig 16 Instrument Panel Connections Right Side PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 17 DESCRIPTION AND OPERATION Continued ...

Страница 1158: ...Fig 17 Instrument Panel Connections Left Side 8W 90 18 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1159: ...Fig 18 Door Connections Front Fig 19 Door Connections Rear PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 19 DESCRIPTION AND OPERATION Continued ...

Страница 1160: ...Fig 20 Body Connections Left Rear Fig 21 Trunk Connections 8W 90 20 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1161: ...Fig 22 Decklid Rear Bumper Connections Fig 23 Fuel Tank Connections PL 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 21 DESCRIPTION AND OPERATION Continued ...

Страница 1162: ...Fig 24 Rear Lighting Connections 8W 90 22 8W 90 CONNECTOR GROUND LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1163: ...T O for EGR Sol 3 S123 Near HD LP and Dash Connector 3 S124 Between Cam Sensor and Coil T O s 3 S125 Near Starter 3 S126 Near PCM T O 1 S127 Near Ignition Coil 3 S201 Near T O for Center Console 5 S202 Near T O for PAB 4 S203 Near T O for HVAC 4 S204 Near HVAC Connector 4 S205 Near Center Stack T O 4 Splice Location Fig S206 Near Center Stack T O 4 S207 Top Center of I P 5 S208 Top Center of I P 5...

Страница 1164: ...Fig 1 Engine Compartment Splices 8W 95 2 8W 95 SPLICE LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1165: ...Fig 2 Engine Compartment Splices PL 8W 95 SPLICE LOCATIONS 8W 95 3 DESCRIPTION AND OPERATION Continued ...

Страница 1166: ...Fig 3 Engine Splices 8W 95 4 8W 95 SPLICE LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1167: ...Fig 4 Instrument Panel Splices PL 8W 95 SPLICE LOCATIONS 8W 95 5 DESCRIPTION AND OPERATION Continued ...

Страница 1168: ...Fig 5 Instrument Panel Splices 8W 95 6 8W 95 SPLICE LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1169: ...Fig 6 Body Splices Left Side PL 8W 95 SPLICE LOCATIONS 8W 95 7 DESCRIPTION AND OPERATION Continued ...

Страница 1170: ...Fig 7 Body Splices Right Side 8W 95 8 8W 95 SPLICE LOCATIONS PL DESCRIPTION AND OPERATION Continued ...

Страница 1171: ...Fig 8 Door and Windshield Header Splices PL 8W 95 SPLICE LOCATIONS 8W 95 9 DESCRIPTION AND OPERATION Continued ...

Страница 1172: ...s available in three ounce tubes Moisture in the air causes the Mopar Silicone Rubber Adhesive Sealant material to cure This material is normally used on flexible metal flanges It has a shelf life of one year and will not properly cure if over age Always inspect the package for the expiration date before use MOPAR GASKET MAKER Mopar Gasket Maker is an anaerobic type gasket material The material cu...

Страница 1173: ...remove all rust and clean inside of cup plug hole in cylinder block or head Be sure to remove old sealer Lightly coat inside of cup plug hole with sealer Make certain the new plug is cleaned of all oil or grease Using proper drive plug drive plug into hole so that the sharp edge of the plug is at least 0 5 mm 0 020 inch inside the lead in chamfer Fig 1 It is in not necessary to wait for curing of ...

Страница 1174: ...sed carefully the cylinder bore resizing hone C 823 equipped with 220 grit stones is the best tool for this job In addition to deglazing it will reduce taper and out of round as well as removing light scuffing scoring or scratches Usually a few strokes will clean up a bore and maintain the required lim its 2 Deglazing of the cylinder walls may be done using a cylinder surfacing hone Tool C 3501 eq...

Страница 1175: ...oil 2 Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6 35 mm 1 4 in off center and away from the oil holes Fig 3 In addition suspected areas can be checked by placing the Plastigage in the suspected area Torque the bearing cap bolts of the bearing being checked to the proper specifications 3 Remove the bearing cap and compare the width of the flat...

Страница 1176: ... to insure system is dry and clear of foreign material 2 Remove negative battery cable 3 Place a shop towel around the spark plugs when removing them from the engine This will catch any fluid that may possibly be in the cylinder under pressure 4 With all spark plugs removed rotate engine crankshaft using a breaker bar and socket 5 Identify the fluid in the cylinder s i e cool ant fuel oil or other...

Страница 1177: ...ottles and the top of engine oil cans Fig 7 ENGINE OIL ADDITIVES In some instances such as infrequent operation short trip driving and during break in after a major overhaul addition of special materials containing anti rust and anti scuff additives are beneficial A suitable product for this purpose is MOPAR Engine Oil Supplement ENGINE OIL CHANGE Change engine oil at mileage and time intervals de...

Страница 1178: ... the suspected leak has been found 4 Repair as required CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunc tions Ensure the battery is completely charged and the engine starter motor is in good operating condition Otherwise the indicated compression pressures may not be valid for diagnosis purposes 1 Check engin...

Страница 1179: ...ng to the tester manufacturer s instructions While testing listen for pressurized air escaping through the throttle body tailpipe and oil filler cap opening Check for bubbles in the radiator coolant All gauge pressure indications should be equal with no more than 25 leakage FOR EXAMPLE At 552 kPa 80 psi input pres sure a minimum of 414 kPa 60 psi should be main tained in the cylinder LASH ADJUSTER...

Страница 1180: ...REA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine a more involved inspection is necessary The following steps should be followed to help pinpoint the source of the leak If the leakage occurs at the crankshaft rear oil seal area 1 Disconnect the battery 2 Raise the vehicle 3 Remove torque converter or clutch housing cover and inspec...

Страница 1181: ...necessary refer to Group 8D Ignition System ENGINE LOSS OF POWER 1 Dirty or incorrectly gapped spark plugs 1 Clean plugs and set gap refer to Group 8D Ignition System 2 Dirt or water in fuel system 2 Clean system and replace fuel filter 3 Faulty fuel pump 3 Install new fuel pump 4 Incorrect valve timing 4 Correct valve timing 5 Blown cylinder head gasket 5 Install new cylinder head gasket 6 Low co...

Страница 1182: ...rance 4 Measure bearings for correct clearance Repair as necessary 5 Excessive end play 5 Check thrust bearing for wear on flanges 6 Crankshaft journal out of round worn 6 Grind journals or replace crankshaft 7 Loose flywheel or torque converter 7 Tighten to correct torque OIL PRESSURE DROP 1 Low oil level 1 Check engine oil level 2 Faulty oil pressure sending unit 2 Install new sending unit 3 Low...

Страница 1183: ... SPRINGS IN VEHICLE 23 VIBRATION DAMPER 40 DISASSEMBLY AND ASSEMBLY OIL PUMP 41 VALVE SERVICE WITH THE CYLINDER HEAD REMOVED 42 CLEANING AND INSPECTION CYLINDER BLOCK AND BORE 46 CYLINDER HEAD AND CAMSHAFT JOURNALS 44 OIL PUMP 45 SPECIFICATIONS ENGINE 2 0L SOHC 47 TORQUE CHART 2 0L SOHC 48 SPECIAL TOOLS ENGINE 2 0L SOHC 49 DESCRIPTION AND OPERATION ENGINE IDENTIFICATION The engine identification n...

Страница 1184: ...isms are lubricated from a full length cylinder head oil gallery supplied from the crankcase main oil gallery PRESSURE LUBRICATION Oil drawn up through the pickup tube is pressur ized by the pump and routed through the full flow fil ter to the main oil gallery running the length of the cylinder block A cylinder head restrictor located in the block provides increased oil flow to the main oil galler...

Страница 1185: ...HEAD SOHC It features a Single Over Head Camshaft four valves per cylinder cross flow design The valves are arranged in two inline banks with the two intake per cylinder facing toward the radiator The exhaust valves facing toward the dash panel Rocker arm shafts mount directly to the cylinder head It incorporates powder metal valve guides and seats The hollow rocker arm shafts supplies oil to the ...

Страница 1186: ...nter line shown in Fig 3 Refer to Cylinder Bore and Speci fications Table Correct piston to bore clearance must be established in order to assure quiet and economi cal operation Chrysler engines use pistons designed specifically for each engine model Clearance and sizing locations vary with respect to engine model NOTE Pistons and cylinder bores should be mea sured at normal room temperature 21 C ...

Страница 1187: ...ELER GAUGE Fig 6 Piston Ring Side Clearance FEELER GAUGE Ring Position Ring Gap Wear Limit Upper Ring 0 23 to 0 52 mm 0 009 to 0 020 in 0 8 mm 0 031 in Intermediate Ring 0 49 to 0 78 mm 0 019 to 0 031 in 1 0 mm 0 039 in Oil Control Ring 0 23 to 0 66 mm 0 009 to 0 026 in 1 0 mm 0 039 in Ring Position Groove Clearance Maximum Clearance Upper Ring 0 025 to 0 065 mm 0 0010 to 0 0026 in 0 10 mm 0 004 i...

Страница 1188: ... for installation and tighten fasteners in this order a If engine mount bracket was removed tighten bolt 1 to 3 N m 20 in lbs and bolts 2 3 and 4 to 108 N m 80 ft lbs Fig 13 b If engine mount bracket was removed tighten bolts 5 and 1 to 54 N m 40 ft lbs c Tighten engine mount bracket to insulator assembly thru bolt to 54 N m 40 ft lbs d Tighten insulator assembly nuts to the lower radiator crossme...

Страница 1189: ...k 4 Remove the thru bolt access hole cover Remove the thru bolt from the insulator assembly Fig 15 Remove insulator 5 Reverse removal procedure for installation Tighten engine mount to rail fasteners to 54 N m 40 ft lbs then tighten engine mount to engine bracket thru bolt to 108 N m 80 ft lbs POWER HOP DAMPER NOTE Power hop damper is used on manual trans mission vehicle only 1 Remove the thru bol...

Страница 1190: ...h to allow engine dolly and cradle Special Tools 6135 and 6710 to be installed under vehicle 23 Loosen engine support posts to allow move ment for positioning onto engine locating holes and flange on the engine bedplate Lower vehicle and position cradle until the engine is resting on support posts Fig 18 Tighten mounts to cradle frame This will keep support posts from moving when removing or insta...

Страница 1191: ...Connect engine and throttle body connections and harnesses Refer to Group 8 Electrical for procedure 17 Connect throttle body linkage Refer to Group 14 Fuel System for procedure 18 Install radiator and shroud assembly Install radiator hoses Fill cooling system Refer to Group 7 Cooling System for filling procedure 19 Install battery tray and battery Set Power train Control Module PCM into place 20 ...

Страница 1192: ... pressed into the cylinder head cover to seal the end of the spark plug tubes If these seals show signs of hardness and or cracking they should be replaced CAMSHAFT NOTE TO REMOVE CAMSHAFT CYLINDER HEAD MUST BE REMOVED REMOVAL 1 Refer to Timing Belt Removal for timing belt and camshaft sprocket removal and installation 2 Remove the cylinder head cover 3 Mark rocker arm shaft assemblies for install...

Страница 1193: ...ournals Install camshaft into the cylinder head carefully 2 Install cam sensor and tighten fasteners to 9 5 N m 85 in lbs 3 Install camshaft seal Camshaft must be installed before the camshaft seal is installed Refer to procedure outlined in this section 4 Install camshaft sprocket and tighten to 115 N m 85 ft lbs 5 Install timing belt Refer to procedure outlined in this section 6 Install rocker a...

Страница 1194: ...oward the timing belt side of the engine Fig 27 Install the retainers in their original positions on the exhaust and intake shafts Fig 25 CAUTION When installing the intake rocker arm shaft assembly be sure that the plastic spacers do not interfere with the spark plug tubes If the spac ers do interfere rotate until they are at the proper angle To avoid damaging the spark plug tubes do not attempt ...

Страница 1195: ...ng pump assembly and set aside 9 Disconnect coil pack wiring connector and remove coil pack and bracket from engine 10 Remove cylinder head cover 11 Remove cam sensor and fuel injectors wiring connectors 12 Remove intake manifold SOHC ONLY Removal procedure outline in Group 11 13 Remove timing belt and camshaft sprocket Refer to procedure outlined in this section 14 Remove rocker arm shaft assembl...

Страница 1196: ...cedure outlined in this section for removal Cylinder Head and Valve Assembly ROCKER SHAFT RETAINING BOLT VALVE RETAINING LOCKS VALVE VALVE SPRING VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY ROCKER ARM SHAFT RETAINER SPACER INTAKE ROCKER ARM HYDRAULIC LASH ADJUSTER ASSEMBLY CAMSHAFT SPACER EXHAUST ROCKER ARM HY DRAULIC LASH ADJUSTER ASSEMBLY CAMSHAFT SEAL SPARK PLUG TUBE SEAL VALVE SPRING RETAINER RE...

Страница 1197: ... Install crankshaft vibration damper Refer to procedure outlined in this section for installation 6 Install accessory drive belts Refer to Group 7 Cooling System Accessory Drive section for procedure 7 Raise vehicle on hoist and install right inner splash shield Fig 34 Cylinder Head Tightening Sequence Fig 35 Right Inner Splash Shield SIDESHIELD RIGHT FRAME RAIL PLUG SHIELD SCREW 3 Fig 36 Right En...

Страница 1198: ... 4679 A Fig 39 CAUTION Do not nick shaft seal surface or seal bore 4 Shaft seal lip surface must be free of varnish dirt or nicks Polish with 400 grit paper if necessary INSTALLATION 1 Install camshaft seal flush with cylinder head using Special Tool MD 998306 Fig 40 2 Install camshaft sprocket retaining bolt Hold camshaft sprocket with Special Tool C 4687 1 Fig 38 and tighten bolt to 115 N m 85 f...

Страница 1199: ...ts Refer to Group 7 Cooling System for procedure outlined in that section 2 Raise vehicle on a hoist and remove right inner splash shield Fig 43 Fig 41 Timing Belt System ACCESS PLUG CAMSHAFT BOLT AND WASHER CAMSHAFT SPROCKET REAR TIMING BELT COVER BRACKET WATER PUMP OIL PUMP BODY CRANKSHAFT SPROCKET TIMING BELT TENSIONER BOLT CRANKSHAFT DAMPER FRONT TIMING BELT COVER Fig 42 Camshaft Timing Marks ...

Страница 1200: ...INE 1 When tensioner is removed from the engine it is necessary to compress the plunger into the ten sioner body 2 Place the tensioner into a vise equipped with soft jaws and slowly compress the plunger Fig 49 CAUTION Index the tensioner in the vise the same way it is installed on the engine This is to ensure proper pin orientation when tensioner is installed on the engine 3 When plunger is compre...

Страница 1201: ...procket to TDC to take up belt slack Install tensioner to block but do not tighten fasteners 9 Using a torque wrench on the tensioner pulley apply 28 N m 250 in lbs of torque Fig 53 10 With torque being applied to the tensioner pulley move the tensioner up against the tensioner Fig 48 Remove Timing Belt TENSIONER PIVOT TIMING BELT TEN SIONER TENSIONER FASTENERS Fig 49 Compressing Timing Belt Tensi...

Страница 1202: ...and Installation in this section 3 Remove front engine mount and bracket Refer to Engine Support Module Removal and Installation in this section 4 Remove transmission inspection cover 5 If equipped with air conditioning remove oil fil ter and adaptor Refer to Oil Filter Adapter Removal and Installation in this section 6 Remove oil pan 7 Clean oil pan and all gasket surfaces INSTALLATION 1 Apply Mo...

Страница 1203: ...ith seal spring towards the inside of engine Install seal until flush with cover 3 Install crankshaft sprocket Fig 60 Using Special Tool 6792 NOTE Make sure the word front on the sprocket is facing you 4 Install timing belt and covers Refer to Timing Belt System in this section for installation 5 Install crankshaft damper Fig 61 Use thrust bearing washer and 12M 1 75 x 150 mm bolt from Special Too...

Страница 1204: ...ou can read the words THIS SIDE OUT on seal Fig 63 Pilot tool should remain on crankshaft during instal lation of seal Ensure that the lip of the seal is facing towards the crankcase during installation CAUTION If the seal is driven 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 64 until the tool bot toms out aga...

Страница 1205: ...per installation CRANKSHAFT MAIN JOURNALS INSPECTION The crankshaft journals should be checked for excessive wear taper and scoring Limits of taper or out of round on any crankshaft journals should be held to 025 mm 001 inch Journal grinding should not exceed 305 mm 012 inch under the standard journal diameter DO NOT grind thrust faces of Number 3 main bearing DO NOT nick crank pin or bearing fill...

Страница 1206: ...y to seal the bedplate to cylinder block 3 Oil the bearings and journals and install crankshaft and O ring in cylinder block CAUTION Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine PISTON AND CONNECT ING ROD ASSEMBLY SEAL OIL PASSAGE O RING SEAL UPPER BEARING GROOVED THRUST BEARINGS NIPPLE OIL FILTER ADAPTER O RING CRANKSHAFT POSITION SEN SOR CPS BOLT MAIN...

Страница 1207: ... shown in Fig 70 10 After the main bearing bedplate is installed check the crankshaft turning torque The turning torque should not exceed 5 6 N m 50 in lbs 11 Install oil pump If crankshaft end play is to be checked refer to service procedures in this section 12 Install crankshaft sprocket 13 Install oil filter adapter and filter Refer to procedure outlined in this section OIL FILTER ADAPTER REMOV...

Страница 1208: ...tion 3 Remove Oil Pan Refer to Oil Pan Removal in this section 4 Remove Crankshaft Sprocket using Special Tool 6793 and insert C4685 C2 Fig 73 5 Remove oil pick up tube 6 Remove oil pump Fig 74 and front crank shaft seal Fig 74 Oil Pump and Tube O RING OIL FILTER ADAPTER OIL PAN GASKET OIL PAN OIL PICK UP TUBE DRAIN PLUG O RING OIL PUMP BODY FILTER O RING NIPPLE Fig 72 Engine Oil Filter OIL FILTER...

Страница 1209: ...es with a reli able ridge reamer before removing pistons from cyl inder block Be sure to keep tops of pistons covered during this operation Mark piston with matching cylinder number Fig 78 2 Remove oil pan Scribe the cylinder number on the side of the rod and cap Fig 79 for identification 3 Pistons will have a stamping in the approxi mate location shown in Fig 78 These stamps will be either a dire...

Страница 1210: ...cturers I D mark fac ing up to the top of the piston Fig 81 CAUTION Install piston rings in the following order a Oil ring expander b Upper oil ring side rail c Lower oil ring side rail d No 2 Intermediate piston ring e No 1 Upper piston ring f Install the side rail by placing one end between the piston ring groove and the expander Hold end firmly and press down the portion to be installed until s...

Страница 1211: ...s on the center of the cylinder bore Insert rod and piston assembly into cylinder bore and 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 7 Install rod caps Install New bolts and tighten to 27 N m 20 ft lb Plus 1 4 turn VIBRATION DAMPER NOTE If a gap is found in the cra...

Страница 1212: ...move the threaded plug and gasket from the oil pump Fig 89 CAUTION Oil pump pressure relief valve must be installed as shown in Fig 89 or serious damage may occur 3 Remove spring and relief valve Fig 89 4 Remove oil pump cover screws and lift off cover 5 Remove pump rotors 6 Wash all parts in a suitable solvent and inspect carefully for damage or wear Fig 90 Fig 87 Crankshaft Damper Removal SPECIA...

Страница 1213: ... 1 Whenever valves have been removed for inspec tion reconditioning or replacement valve springs should be tested Special Tool C 647 As an example the compression length of the spring to be tested is 33 34 mm 1 5 16 inches Turn tool table until sur face is in line with the 33 34 mm 1 5 16 inch mark on the threaded stud and the zero mark on the front Place spring over stud on the table and lift com...

Страница 1214: ... to the bottom edge of valve face raise valve seat with a 65 degrees stone Intake valve seat diameter is 33 mm 1 299 in Exhaust valve seat diameter is 28 mm 1 102 in 6 Valve seats which are worn or burned can be reworked provided that correct angle and seat width are maintained The intake valve seat must be ser viced when the valve seat width is 2 0 mm 0 079 in or greater The exhaust valve seat mu...

Страница 1215: ...learance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed Specified dry lash is 1 17 mm 0 046 in for intake and 1 28 mm 0 050 in for exhaust After performing dry lash check refill adjuster with oil and allow 10 minutes for adjuster s to bleed down before rotating cam CLEANING AND INSPECTION CYLINDER HEAD ...

Страница 1216: ...m 301 inch or less replace inner rotor Fig 103 5 Slide outer rotor into pump housing press to one side with fingers and measure clearance between rotor and housing Fig 104 If measurement is 0 39 mm 0 015 inch or more replace housing only if outer rotor is in specification 6 Install inner rotor into pump housing If clear ance between inner and outer rotors Fig 105 is 203 mm 008 inch or more replace...

Страница 1217: ...lugs outlined in this section 3 Examine block and cylinder bores for cracks or fractures CYLINDER BORE INSPECTION The cylinder walls should be checked for out of round and taper with Tool C 119 Fig 107 The cyl inder bore out of round is 0 050 mm 002 inch maximum and cylinder bore taper is 0 051 mm 0 002 inch maximum If the cylinder walls are badly scuffed or scored the cylinder block should be reb...

Страница 1218: ...de Clearance 0 13 0 38 mm 0 005 0 015 in Total Weight Less Bearing 543 grams 1 20 lbs Crankshaft Connecting Rod Journal Diameter 47 9924 48 0076 mm 1 8894 1 8900 in Out of Round Max 0 0035 mm 0 0001 in Taper Max 0 0038 mm 0 0001 in Main Bearing Diametrical Clearance No 1 5 0 022 0 062 mm 0 0008 0 0024 in End Play 0 09 0 24 mm 0 0035 0 0094 in Main Bearing Journals Diameter 51 9924 52 0076 mm 2 046...

Страница 1219: ...Valve Springs Free Length Approx 44 4 mm 1 747 in Nominal Force Valve closed 91 N m 39 8 mm 67 ft lbs 1 57 in Nominal Force Valve open 239 N m 32 6 mm 176 lbs 1 28 in Installed Height 40 18 mm 1 580 in SERVICE AS AN ASSEMBLY WITH ROCKER ARM ALL READINGS IN CRANKSHAFT DEGREES AT 0 5 mm 0 019 in OF VALVE LIFT TORQUE CHART 2 0L SOHC DESCRIPTION TORQUE Camshaft Sensor Pick Up Bolts 9 6 N m 85 in lbs T...

Страница 1220: ...mostat Housing Bolts 23 N m 200 in lbs Timing Belt Tensioner 31 N m 275 in lbs Timing Belt Tensioner Pivot Bracket Bolt 31 N m 275 in lbs Timing Belt Tensioner Pulley Bolt 68 N m 50 ft lbs Water Pump Mounting Bolts 12 N m 105 in lbs SPECIAL TOOLS ENGINE 2 0L SOHC Puller 1026 Crankshaft Damper Removal Insert 6827 A Camshaft Sprocket Remover Installer C 4687 Camshaft Sprocket Remover Installer Adapt...

Страница 1221: ...r C 4685 C Valve Spring Compressor MD 998772 A Spring Compressor Adapter 6779 Valve Spring Compressor C 3575 A Cylinder Bore Indicator C 119 Front Crankshaft Seal Remover 6771 Front Crankshaft Seal Installer 6780 9 50 2 0L SOHC ENGINE PL SPECIAL TOOLS Continued ...

Страница 1222: ...Sprocket Remover 6793 Crankshaft Sprocket Installer 6792 Rear Crankshaft Seal Guide and Installer 6926 1 and 6926 2 Pressure Gage C 32932 Valve Spring Tester C 647 PL 2 0L SOHC ENGINE 9 51 SPECIAL TOOLS Continued ...

Страница 1223: ...D SEALS CYLINDER HEAD NOT REMOVED 63 VIBRATION DAMPER 66 DISASSEMBLY AND ASSEMBLY OIL PUMP 81 VALVE SERVICE WITH CYLINDER HEAD REMOVED 81 CLEANING AND INSPECTION CYLINDER BLOCK AND BORE 85 CYLINDER HEAD AND CAMSHAFT JOURNALS 84 OIL PUMP 84 SPECIFICATIONS ENGINE 2 0L DOHC 86 TORQUE CHART 2 0L DOHC 88 SPECIAL TOOLS ENGINE 2 0L DOHC 88 DESCRIPTION AND OPERATION ENGINE IDENTIFICATION NUMBER The engine...

Страница 1224: ...cting rod journals CAMSHAFT HYDRAULIC LASH ADJUSTERS A vertical hole at the number five bulkhead routes pressurized oil through a restrictor up past a cylin der head bolt to an oil gallery running the length of the cylinder head The camshaft journals are par tially slotted to allow a predetermined amount of pressurized oil to pass into the bearing cap cavities with small holes directed to spray lu...

Страница 1225: ...orts of the bank of two exhaust valves per cyl inder facing toward the dash panel Incorporates powder metal valve guides and seats Integral oil gal leys within the cylinder head supplies oil to the hydraulic lash adjusters camshaft and valve mecha nisms CAMSHAFTS The nodular iron camshafts have six bearing journals and 2 cam lobes per cylinder Flanges at the rear journals control camshaft end play...

Страница 1226: ...d cylinder wall must be clean and dry Piston diameter should be measured 90 degrees to piston pin about 17 5 mm 11 16 inch from the bot tom of the skirt as shown in Fig 5 Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in Fig 4 Refer to Cylinder Bore and Piston Specifications Table Correct piston to bore clearance must be e...

Страница 1227: ...nch for last step 5 Using a feeler gauge check connecting rod side clearance Fig 9 Refer to connecting rod specifica tions Fig 10 FITTING CRANKSHAFT BEARINGS Refer to Measuring Main Bearing Clearance in Standard Service Procedures Refer to Fig 11 for specifications CRANKSHAFT END PLAY DIAL INDICATOR METHOD 1 Mount a dial indicator to front of engine locat ing probe on nose of crankshaft Fig 12 2 M...

Страница 1228: ...80 ft lbs Fig 14 b If engine mount bracket was removed tighten bolts 5 and 1 to 54 N m 40 ft lbs c Tighten engine mount bracket to insulator assembly thru bolt to 54 N m 40 ft lbs d Tighten insulator assembly nuts to the lower radiator crossmember torque to 54 N m 40 ft lbs Fig 10 Checking Connecting Rod Side Clearance CONNECTING ROD BEARING OIL CLEARANCE New Part 0 026 to 0 059 mm 0 001 to 0 0023...

Страница 1229: ...e mounts by care fully supporting the engine and transmission assem bly with a floor jack 4 Remove the thru bolt access hole cover Remove the thru bolt from the insulator assembly Fig 16 Remove insulator 5 Reverse removal procedure for installation Tighten engine mount to rail fasteners to 54 N m 40 ft lbs then tighten engine mount to engine bracket thru bolt to 108 N m 80 ft lbs POWER HOP DAMPER ...

Страница 1230: ...d reservoir Set them aside 20 Remove A C compressor 21 Remove ground straps to body 22 Raise vehicle enough to allow engine dolly and cradle Special Tools 6135 and 6710 to be installed under vehicle 23 Loosen engine support posts to allow move ment for positioning onto engine locating holes and flange on the engine bedplate Lower vehicle and position cradle until the engine is resting on support p...

Страница 1231: ...to Group 6 Manual Transaxle Clutch 14 Automatic Transmission Connect shifter and kickdown linkage Refer to Group 21 Transaxle for procedures 15 Connect fuel line and heater hoses 16 Install ground straps Connect engine and throttle body connections and harnesses Refer to Group 8 Electrical for procedure 17 Connect throttle body linkage Refer to Group 14 Fuel System for procedure 18 Install radiato...

Страница 1232: ...n this section 2 Remove timing belt sprockets and covers Refer to Timing Belt Service outlined in this section 3 Bearing caps are identified for location Remove the outside bearing caps first Fig 22 4 Loosen the camshaft bearing cap attaching fas teners in sequence shown in Fig 23 one camshaft at a time CAUTION Camshafts are not interchangeable The intake cam number 6 thrust bearing face spacing i...

Страница 1233: ...ASSEMBLY REMOVAL 1 Remove valve cover using procedure outlined in this section 2 Remove timing belt sprockets and covers using procedure outlined in this section 3 Remove camshaft Refer to procedure previ ously outline this section 4 Remove cam follower assemblies from cylinder head Keep the cam followers in the order they have been removed from the head for reassembly Mark hydraulic lash adjuster...

Страница 1234: ... in this section 2 Install valve spring and retainer Using Special Tool MD998772A compress valve springs only enough to install locks Correct alignment of tool is necessary to avoid nicking valve stems air pressure required piston at TDC 3 Remove air hose and install spark plugs 4 Install camshafts as previously outlined in this section 5 Install valve cover as previously outlined in this section ...

Страница 1235: ...INDER HEAD HEAD GASKET VALVE VALVE GUIDE VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY VALVE SPRING VALVE SPRING RETAINER VALVE RETAINING LOCKS HYDRAULIC LASH ADJUSTER ROLLER FOLLOWER SPARK PLUG WELL GASKET CAMSHAFT OIL SEAL 9 64 2 0L DOHC ENGINE PL REMOVAL AND INSTALLATION Continued ...

Страница 1236: ...l proce dure outlined in this section 14 Remove cylinder head bolts NOTE Remove all gasket material from cylinder head and block Be careful not to gouge or scratch the aluminum head sealing surface CYLINDER HEAD FLATNESS 1 Cylinder head must be flat within 0 1 mm 0 004 inch Fig 32 NOTE Inspect camshaft bearing journals for scor ing INSTALLATION 1 Before installing the bolts the threads should be o...

Страница 1237: ...1 Install crankshaft damper using M12 1 75 x 150 mm bolt washer thrust bearing and nut from Special Tool 6792 Install crankshaft damper bolt and tighten to 142 N m 105 ft lbs Fig 88 2 Install accessory drive belts Refer to Group 7 Cooling System Accessory Drive section for proce dure 3 Raise vehicle on hoist and install right inner splash shield Fig 34 Weld Gap CRANKSHAFT DAMPER WELD GAP Fig 35 Ri...

Страница 1238: ... fasteners remove cover Fig 40 INSTALLATION 1 Install front timing cover 2 Install engine mount bracket 3 Install Right engine mount Refer to procedure outlined in this section for installation 4 Remove jack from under engine 5 Install crankshaft vibration damper Refer to procedure outlined in this section for installation 6 Install accessory drive belts Refer to Group 7 Cooling System Accessory D...

Страница 1239: ...re removing timing belt 1 Remove crankshaft damper bolt Remove damper procedure outlined in this section 2 Remove engine mount bracket and timing belt cover fasteners remove cover Fig 41 Typical Timing Belt System DOHC ACCESS PANEL CAMSHAFT SPROCK ETS REAR TIMING BELT COVER WATER PUMP OIL PUMP CRANKSHAFT SPROCKET TIMING BELT CRANKSHAFTDAMPER FRONT TIMING BELT COVER BRACKET TENSIONER Fig 42 Camshaf...

Страница 1240: ... marks together by align ing notches on sprockets Fig 47 6 Rotate crankshaft 1 2 tooth counterclockwise from TDC Fig 48 7 Install timing belt in this direction Starting at the crankshaft go around the water pump sprocket idler pulley camshaft sprockets and then around the tensioner pulley Fig 49 8 Move crankshaft sprocket to TDC to take up belt slack Install tensioner to block but do not tighten f...

Страница 1241: ...le Removal and Installation in this section 3 Remove front engine mount and bracket Refer to Engine Support Module Removal and Installation in this section 4 Remove transmission inspection cover 5 If equipped with air conditioning remove oil fil ter and adaptor Refer to Oil Filter Adapter Removal and Installation in this section 6 Remove oil pan 7 Clean oil pan and all gasket surfaces INSTALLATION...

Страница 1242: ...aining bore Fig 54 CAUTION Do not nick shaft seal surface or seal bore 4 Shaft seal lip surface must be free of varnish dirt or nicks Polish with 400 grit paper if necessary INSTALLATION 1 Install camshaft seal into cylinder head using Special Tool MD 998713 until flush with the head Fig 55 2 Install camshaft sprockets and tighten attach ing bolts to 101 N m 75 ft lbs Fig 51 Oil Pan Sealing PLACE ...

Страница 1243: ...ide of engine Install seal until flush with cover 3 Install crankshaft sprocket Fig 60 Using Special Tool 6792 NOTE Make sure the word front on the sprocket is facing you 4 Install timing belt and covers Refer to Timing Belt System in this section for installation 5 Install crankshaft damper Fig 61 Use thrust bearing washer and 12M 1 75 x 150 mm bolt from Special Tool 6792 Install crankshaft dampe...

Страница 1244: ...ou can read the words THIS SIDE OUT on seal Fig 63 Pilot tool should remain on crankshaft during instal lation of seal Ensure that the lip of the seal is facing towards the crankcase during installation CAUTION If the seal is driven 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 64 until the tool bot toms out aga...

Страница 1245: ...t Seal Special Tool 6926 2 SPECIAL TOOL 6926 1 PILOT SEAL SPECIAL TOOL 6792 2 INSTALLER Fig 65 Rear Crankshaft Seal Installation SPECIAL TOOL 6926 2 INSTALLER 9 74 2 0L DOHC ENGINE PL REMOVAL AND INSTALLATION Continued ...

Страница 1246: ...er bearing shells in the crankcase have oil grooves All lower bearing shells installed in the bed plate main bearing cap are plain Crankshaft end play is controlled by a flanged bearing on the number three main bearing journal Fig 67 NOTE The upper and lower main Bearing shells are Not interchangeable The lower shells have a revised tab to prevent improper installation CRANKSHAFT MAIN JOURNALS INS...

Страница 1247: ...rings and bearing tabs seat in the block tab slots CAUTION Do Not get oil on the bedplate mating surface It will affect the sealer ability to seal the bedplate to cylinder block 3 Oil the bearings and journals and install crankshaft and O ring in cylinder block CAUTION Use only the specified anaerobic sealer on the bedplate or damage may occur to the engine 4 Apply 1 5 to 2 0 mm 0 059 to 0 078 in ...

Страница 1248: ...nst the seam at the base of the filter The seam joining the can to the base is reinforced by the base plate 1 Turn counterclockwise to remove 2 To install lubricate new filter gasket Check filter mounting surface The surface must be smooth flat and free of debris or old pieces of rubber Screw filter on until gasket contacts base Tighten to 21 N m 15 ft lbs OIL PUMP REMOVAL 1 Disconnect negative ba...

Страница 1249: ...ck NOTE Front crankshaft seal MUST be out of pump to align or damage may result 5 Torque all oil pump attaching bolts to 28 N m 250 in lbs 6 Install new front crankshaft seal using Special Tool 6780 Fig 76 Fig 74 Oil Pump and Tube O RING OIL FILTER ADAPTER OIL PAN GASKET OIL PAN OIL PICK UP TUBE DRAIN PLUG O RING OIL PUMP BODY FILTER O RING NIPPLE Fig 75 Oil Pump Sealing APPLY GASKET MAKER TO OIL ...

Страница 1250: ...on assemblies The weight designation stamps should face toward the timing belt side of the engine 4 Pistons and connecting rods must be removed from top of cylinder block Rotate crankshaft so that each connecting rod is centered in cylinder bore 5 Remove connecting rod cap bolts Do not use old bolts if reinstalling connecting rod Push each piston and rod assembly out of cylinder bore NOTE Be caref...

Страница 1251: ...r tant for oil control PISTON AND ROD INSTALLATION 1 Before installing pistons and connecting rod assemblies into the bore be sure that compression ring gaps are staggered so that neither is in line with oil ring rail gap 2 Before installing the ring compressor make sure the oil ring expander ends are butted and the rail gaps located as shown in Fig 83 3 Immerse the piston head and rings in clean ...

Страница 1252: ... for damage or wear Fig 90 VALVE SERVICE WITH CYLINDER HEAD REMOVED REMOVAL 1 With cylinder head removed compress valve springs using Special Tool MD 998735 or equivalent 2 Remove valve retaining locks valve spring retainers valve stem seals and valve springs 3 Before removing valves remove any burrs from valve stem lock grooves to prevent dam age to the valve guides Identify valves to insure inst...

Страница 1253: ... be obtained 4 Measure the concentricity of valve seat and valve guide using a valve seat runout dial indicator Total runout should not exceed 0 051 mm 0 002 inch total indicator reading 5 Inspect the valve seat with Prussian blue to determine where the valve contacts the seat To do this coat valve seat LIGHTLY with Prussian blue then set valve in place Rotate the valve with light pressure If the ...

Страница 1254: ...r the locks can become dislocated Check to make sure both locks are in their correct location after removing tool 4 Check the valve spring installed height B after refacing the valve and seat Fig 93 Make sure mea surements are taken from top of spring seat to the bottom surface of spring retainer If height is greater than 38 75 mm 1 525 in install a 7 620 mm 0 030 inch spacer under the valve sprin...

Страница 1255: ...ear or damage Replace rocker arm hydraulic lash adjuster if worn or damaged If lobes show signs of pitting on the nose flank or base circle replace the camshaft CLEANING Remove all gasket material from cylinder head and block Be careful not to gouge or scratch the alumi num head sealing surface OIL PUMP 1 Clean all parts thoroughly Mating surface of the oil pump should be smooth Replace pump cover...

Страница 1256: ...ure relief valve or other reasons for oil pressure loss CYLINDER BLOCK AND BORE 1 Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking 2 If new core plugs are installed Refer to Engine Core Plugs outlined in this section 3 Examine block and cylinder bores for cracks or fractures CYLINDER BORE INSPECTION The cylinder walls should be checked for out of round and tape...

Страница 1257: ...oove Depth No 1 3 983 4 132 mm 0 157 0 163 in Piston Ring Groove Depth No 2 4 456 4 605 mm 0 175 0 181 in Piston Ring Groove Depth No 3 3 841 4 075 mm 0 151 0 160 in Piston Pins Clearance in Piston 0 008 0 020 mm 0 0003 0 0008 in In Rod Interference 0 018 0 043 mm 0 0007 0 0017 in Diameter 20 998 21 003 mm 0 8267 0 8269 in End Play None Length 74 75 75 25 mm 2 943 2 963 in Piston Rings Ring Gap To...

Страница 1258: ...lve Opens BBDC 42 Exhaust Valve Duration 219 Valve Overlap 0 Cylinder Head Material Cast Aluminum Gasket Thickness Compressed 1 15 mm 0 045 in Valve Seat Angle 44 5 45 Runout Max 0 050 mm 0 002 in Width Finished Intake and Exhaust 0 9 1 3 mm 0 035 0 051 in Valve Guide Finished Diameter ID 5 975 6 000 mm 0 235 0 236 in Guide Bore Diameter Standard 11 0 11 02 mm 0 4330 0 4338 in Valves Head Diameter...

Страница 1259: ...fold Bolts 28 N m 250 in lbs Oil Filter Adapter Fastener 80 N m 60 ft lbs Oil Filter 20 N m 15 ft lbs Oil Pan Bolts 12 N m 105 in lbs Drain Plug 34 N m 25 ft lbs Oil Pump Attaching Bolts 28 N m 250 in lbs Oil Pump Cover Fastener 12 N m 105 in lbs Oil Pump Pick up Tube Bolt 28 N m 250 in lbs Oil Pump Relief Valve Cap 55 N m 40 ft lbs Spark Plugs Plug 28 N m 20 ft lbs Thermostat Housing Bolts 23 N m...

Страница 1260: ...per 6792 Installer Crankshaft Damper C 4685 C Valve Spring Compressor MD 998772 A Valve Spring Compressor C 3575 A Cylinder Bore Indicator C 119 Front Crankshaft Seal Remover 6771 Adapter Spring Compressor 6779 PL 2 0L DOHC ENGINE 9 89 SPECIAL TOOLS Continued ...

Страница 1261: ...er 6780 Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Installer 6792 Rear Crankshaft Seal Guide and Installer 6926 1 and 6926 2 Pressure Gage C 32932 Valve Spring Tester C 647 9 90 2 0L DOHC ENGINE PL SPECIAL TOOLS Continued ...

Страница 1262: ...NFORMATION EXHAUST SYSTEMS The exhaust system has an underfloor catalytic converter tail pipe and muffler Fig 1 EXHAUST BALL JOINT COUPLING An exhaust ball joint coupling Fig 2 is used to secure the exhaust pipe to the engine exhaust mani fold This flexible joint moves back and forth as the engine moves preventing breakage that could occur from the back and forth motion of a transverse mounted eng...

Страница 1263: ... in the vicinity of the catalytic con verter Refer to Group 23 Body and Sheet Metal for ser vice procedures CAUTION Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shield on cars if equipped Light over spray near the edges is permitted Appli cation of coating will greatly reduce the efficiency of the heat shields resulting in excessive floo...

Страница 1264: ...e c a EGR Valve to Manifold Gasket a Tighten nuts or replace gasket b EGR Valve to EGR Tube Gasket b Tighten nuts or replace gasket c EGR Tube to Manifold Tube Nut c Tighten tube nut d Exhaust Flex Joint d a Spring height installed not correct a Check spring height both sides specification is 32 5 mm 1 28 inch look for source of spring height variation if out of specification b Exhaust sealing rin...

Страница 1265: ...n removing exhaust pipe raise rear of vehicle to relieve body weight from rear suspension to provide clearance between pipe and lateral arms 6 Remove catalytic converter to exhaust manifold attaching bolts Fig 8 7 Clean ends of pipes and or muffler to assure mating of all parts Discard broken or worn insula tors rusted clamps supports and attaching parts NOTE When replacement is required on any co...

Страница 1266: ...ICING FUEL SYSTEM COMPONENTS SERVICE VEHICLES IN WELL VENTILATED AREAS AND AVOID IGNITION SOURCES NEVER SMOKE WHILE SERVICING THE VEHICLE 1 Disconnect negative cable from battery 2 Remove fuel filler cap 3 Remove the fresh air duct Fig 13 4 Remove the protective cap from the fuel pres sure test port on the fuel rail Fig 11 5 Place the open end of fuel pressure release hose tool number C 4799 1 int...

Страница 1267: ...ect vacuum hoses from throttle body Fig 14 13 Disconnect Manifold Absolute Pressure Intake Air Temperature Sensor TMAP electrical connector Fig 15 Disconnect vapor and brake booster hoses 14 Disconnect knock sensor electrical connector Fig 16 and disconnect wiring harness from tab located on the intake manifold 15 Disconnect wiring at starter 16 Remove transmission to throttle body support bracket...

Страница 1268: ...tor 8 Connect knock sensor connector and wiring at starter Connect wiring harness to intake manifold tab 9 Connect Idle Air Control IAC motor and Throttle Position Sensor TPS wiring connectors 10 Connect vacuum hoses to throttle body 11 Install accelerator kickdown and speed con trol cables to their bracket and connect them to the throttle lever Refer to Group 14 Fuel System Throt tle Body Install...

Страница 1269: ...overing CAUTION Do not set fuel injectors on their tips damage may occur to the injectors 10 Remove accelerator kickdown and speed con trol cables from throttle lever and bracket Refer to Group 14 Fuel System Throttle Body Removal for procedures 11 Remove throttle body 12 Disconnect Idle Air Control IAC motor and Throttle Position Sensor TPS wiring connectors Fig 23 13 Disconnect vacuum hoses from...

Страница 1270: ...jector holes and insure the holes are clean Install fuel rail assembly to intake manifold Tighten screws to 23 N m 200 in lbs 3 Connect PCV and brake booster hoses Fig 23 Idle Air Control IAC Motor and Throttle Position Sensor TPS Wiring Connectors Fig 24 Manifold Absolute Pressure Intake Air Temperature Sensor TMAP Electrical Connector FUEL INJECTORS FUEL RAIL TEST PORT MAP IAT SENSOR Fig 25 Knoc...

Страница 1271: ...k for leaks CAUTION When using the ASD Fuel System Test the Auto Shutdown ASD relay will remain ener gized for 7 minutes or until the ignition switch is turned to the OFF position or Stop All Test is selected EXHAUST MANIFOLD REMOVAL 1 Remove air cleaner assembly and bracket 2 Remove exhaust manifold heat shield Fig 28 3 Disconnect upstream heated oxygen sensor con nector 4 Remove exhaust pipe fro...

Страница 1272: ...CIFICATIONS TORQUE CHART EGR Tube Attaching Bolts 11 N m 95 in lbs Exhaust Manifold to Exhaust Pipe Nuts 27 N m 20 ft lbs Exhaust Manifold Mounting Bolts 23 N m 200 in lbs Intake Manifold Mounting Bolts SOHC 12 N m 105 in lbs Bolts DOHC 28 N m 250 in lbs Heat Shield Mounting Body Bolts 4 N m 35 in lbs Exhaust System Band Clamps Torca Fastener 75 N m 55 ft lbs Exhaust Manifold Heat Shield Bolts 23 ...

Страница 1273: ......

Страница 1274: ... fascia to bottom of bumper reinforcement 3 Install bolts holding fascia to bumper reinforce ment forward of radiator Fig 1 4 Install screws holding front fascia to inner wheelhouse 5 Install radiator grille refer to Group 23 Body for proper procedures FRONT BUMPER REINFORCEMENT REMOVAL 1 Remove front fascia 2 Support bumper reinforcement on a suitable lifting device 3 Remove nuts holding reinforc...

Страница 1275: ...l REAR BUMPER REINFORCEMENT REMOVAL 1 Remove rear fascia 2 Support bumper reinforcement on a suitable lifting device 3 Remove nuts holding reinforcement to rear clo sure panel Fig 4 4 Separate bumper reinforcement from vehicle INSTALLATION Reverse the preceding operation Fig 2 Front Bumper Reinforcement RADIATOR CLOSURE PANEL FRONT BUMPER REIN FORCEMENT Fig 3 Rear Bumper Fascia Fig 4 Rear Bumper R...

Страница 1276: ...lation of the crossmember is per formed verify that front suspension alignment is within specifications If camber caster settings and wheel stagger is not within specifications loosen and reposition crossmember to bring suspension within specifications Refer to Group 2 Front Suspension and Driveshaft for additional information REMOVAL 1 Hoist and support vehicle on safety stands 2 Using a suitable...

Страница 1277: ...LPs Fig 2 11 Tighten bolts to hold suspension crossmember to frame rails and torque boxes 12 Insert ball joints into spindles 13 Install pinch bolts to hold front ball joints to spindles 14 Install front wheels on vehicle 15 Lower vehicle and verify front suspension alignment If camber caster settings and wheel stag ger is not within specifications loosen and reposition crossmember to bring suspen...

Страница 1278: ...sted in metric mea surements All dimensions are from center to center of Principal Locating Point PLP or from center to center of PLP and fastener location Fig 3 Fig 4 Fig 5 Fig 6 Fig 7 and Fig 8 Fig 3 Engine Compartment Top View PT MM PT MM PL FRAME AND BUMPERS 13 5 ...

Страница 1279: ...DGE OF FRONT SIDE RAIL REAR RAIL G LOWER EDGE OF FRONT SIDE RAIL REAR EXTENSION H WIDTH OF ENGINE COMPARTMENT FRONT PRINCIPLE LOCATING POINTS PLP I CENTER OF LOWER CROSSMEMBER TO ENGINE COMPARTMENT FRONT PLP J CENTER OF LOWER CROSSMEMBER K ENGINE COMPARTMENT FRONT PLP L ENGINE COMPARTMENT REAR PRINCIPLE LOCATING POINTS PLP M FRONT RAIL REAR EXTENSION REAR PLP 13 6 FRAME AND BUMPERS PL SPECIFICATIO...

Страница 1280: ... CENTER OF REAR SUSPENSION CROSSMEMBER D REAR RAIL SECOND FORWARD PLP E FRONT OF REAR RAIL F WIDTH OF REAR RAIL FORWARD PRINCIPLE LOCATING POINTS PLP G FRONT LOWER SURFACE OF REAR RAIL H LOWER SURFACE OF SUSPENSION CROSSMEMBER I REAR LOWER SURFACE OF REAR RAIL PL FRAME AND BUMPERS 13 7 SPECIFICATIONS Continued ...

Страница 1281: ...F RADIUS D CENTER PILLAR TO BODY SIDE APERTURE UPPER SEAM TO CENTER PILLAR TO BODY SIDE APERTURE LOWER SEAM E UPPER REAR CORNER CENTER OF RADIUS TO LOWER FRONT CORNER CENTER OF RADIUS F FRONT EDGE OF ROOF PANEL OF A PILLAR TO CEN TER OF FRONT DOOR LOWER FRONT CORNER G CENTER OF RADIUS AT BOTTOM TO CENTER OF RADIUS AT LOWER A PILLAR H I CENTER OF RADIUS AT TOP CORNER TO CEN TER OF RADIUS AT BOTTOM ...

Страница 1282: ... BODY SIDE APERTURE LOWER SEAM C FRONT EDGE OF ROOF PANEL OF A PILLAR TO CENTER OF FRONT DOOR LOWER FRONT CORNER D CENTER OF RADIUS AT BOTTOM TO CENTER OF RADIUS AT LOWER A PIL LAR E COURTESY LAMP SWITCH HOLE TO FRONT LOWER BOTTOM HINGE BOLT HOLE F G CENTER OF RADIUS AT TOP CORNER TO CENTER OF RADIUS AT BOTTOM CORNER PL FRAME AND BUMPERS 13 9 SPECIFICATIONS Continued ...

Страница 1283: ... CORNER TO CENTER OF RADIUS LOWER CORNER C LOWER EDGE OF BACK GLASS UPPER MOUNTING FLANGE OF REAR DECK OPENING WEATHERSTRIP FLANGE D E CENTER OF DECK OPENING FRONT CORNER RADIUS TO REAR TAIL PANEL DECK OPENING RADIUS F FRONT DECK OPENING WEATHER STRIP FLANGE TO DECK OPENING TAIL PANEL WEATHERSTRIP FLANGE G REAR EDGE OF DRAIN THROUGH JOINT H REAR CORNER OF BODY SIDE APERTURE THROUGH JOINT B S A COR...

Страница 1284: ...INSTALLATION 1 Position front tow hook bracket to vehicle 2 Install bolts to hold front tow hook bracket to lower radiator crossmember 3 Lower vehicle REAR TOW HOOK BRACKET REMOVAL 1 Hoist and support vehicle Refer to Group 0 Lubrication and Maintenance for proper lifting pro cedure 2 Remove bolts holding rear tow hook bracket to rear frame rail Fig 2 3 Separate rear tow hook bracket from vehicle ...

Страница 1285: ......

Страница 1286: ...INSTALLATION 1 Position front tow hook bracket to vehicle 2 Install bolts to hold front tow hook bracket to lower radiator crossmember 3 Lower vehicle REAR TOW HOOK BRACKET REMOVAL 1 Hoist and support vehicle Refer to Group 0 Lubrication and Maintenance for proper lifting pro cedure 2 Remove bolts holding rear tow hook bracket to rear frame rail Fig 2 3 Separate rear tow hook bracket from vehicle ...

Страница 1287: ......

Страница 1288: ...tain detergents corrosion and stability additives are recommended Using gasolines that have these additives will help improve fuel economy reduce emissions and main tain vehicle performance Poor quality gasoline can cause problems such as hard starting stalling and stumble If you experi ence these problems try another brand of gasoline before considering service for the vehicle GASOLINE OXYGENATE ...

Страница 1289: ...emissions and improve air quality Chrysler Corporation strongly supports the use of reformulated gasolines whenever available Although your vehicle was designed to provide optimum perfor mance and lowest emissions operating on high qual ity unleaded gasoline it will perform equally well and produce even lower emissions when operating on reformulated gasoline Materials Added to Fuel Indiscriminate ...

Страница 1290: ...fuel tank accelerator pedal and throttle cable A fuel return system is used on all models all engines Fuel is returned through the fuel pump module and back into the fuel tank through the fuel filter fuel pressure regulator A separate fuel return line from the engine to the tank is no longer used with any engine The fuel tank assembly consists of the fuel tank filler tube fuel gauge sending unit e...

Страница 1291: ...ll gas powered engines It is located on the top of the fuel pump module A separate frame mounted fuel filter is not used Fuel Pressure Regulator Operation The pres sure regulator is a mechanical device that is cali brated to maintain fuel system operating pressure of approximately 338 kPa 49 psi at the fuel injectors It contains a diaphragm calibrated springs and a fuel return valve The internal f...

Страница 1292: ...ed by a similar unit if replacement is necessary WARNING REMOVE FILLER CAP TO RELIEVE TANK PRESSURE BEFORE REMOVING OR REPAIR ING FUEL SYSTEM COMPONENTS Fuel Tank Capacity NOTE Nominal refill capacities are shown A varia tion may be observed from vehicle due to manufac turing tolerance and refill procedure QUICK CONNECT FITTINGS Different types of quick connect fittings are used to attach various ...

Страница 1293: ...he ignition switch is turned to the Off position 3 Place the ignition key in the ON position Using the DRB scan tool access ASD Fuel System Test The ASD Fuel System Test will activate the fuel pump and pressurize the system If the gauge reading equals 338 kPa 49 PSI further testing is not required If pressure is not cor rect record the pressure If fuel pressure is below specifications refer to the...

Страница 1294: ...RAINER NOT RESTRICTED INCORRECTLY OPERATING FUEL FILTER REGULATOR OR FUEL PUMP REPLACE FUEL FILTER REG ULATOR FUEL PRESSURE ABOVE SPECIFICATIONS RESTRICTION IN CHASSIS FUEL SUP PLY LINE CHECK FOR KINKED OR PLUGGED FUEL SUPPLY LINE IF CHASSIS FUEL LINE IS NOT RESTRICTED REPLACE FILTER REGULA TOR PL FUEL SYSTEM 14 7 DIAGNOSIS AND TESTING Continued ...

Страница 1295: ...ensor connect an ohmmeter across the sensor signal and sensor ground terminals of the fuel pump module connector Fig 10 Move the float lever to the positions shown in the resistance chart Fig 10 Record the resis tance at each point Replace the level sensor if the resistance is not within specifications FUEL INJECTORS For fuel injector diagnosis refer to the Fuel Injec tor Diagnosis charts For poor...

Страница 1296: ...EFER TO WIRING DIA GRAMS FOR COLOR CODES AND PIN TERMINAL NUM BERS CIRCUITS OK YES TEST THE ENGINE CON TROL SYSTEM WITH THE DRB SCAN TOOL NO REPAIR OR REPLACE THE WIRING HARNESS AS NEC ESSARY YES CIRCUIT IS OK CHECK FOR FUEL DELIVERY AT SUS PECT INJECTOR BY REMOV ING THE INJECTOR FROM THE RAIL AND OBSERVING FOR FUEL AND OR RESTRICTIONS I THE RAIL OR INJECTOR FUEL INLET REFER TO FUEL INJECTOR REMOV...

Страница 1297: ... on rear top of fuel tank Push a siphon hose into the drain port Fig 13 6 Drain fuel tank into holding tank or a properly labeled Gasoline safety container HOSES AND CLAMPS Inspect all hose connections clamps and quick con nect fittings for completeness and leaks Replace cracked scuffed or swelled hoses Replace hoses that rub against other vehicle components or show sign of wear Fuel injected vehi...

Страница 1298: ...to the fuel tube the retainer locking ears and the fuel tube shoulder are visible in the windows If they are not visible the retainer was not properly installed Fig 14 Do not rely upon the audible click to confirm a secure connection CAUTION When using the ASD Fuel System Test the Auto Shutdown ASD Relay remains energized for either 7 minutes until the test is stopped or until the ignition switch ...

Страница 1299: ...ompartment For the location of the relay within the PDC refer to the PDC cover for location Check electrical terminals for corrosion and repair as necessary FUEL PUMP RELAY The fuel pump relay is located in the PDC The inside top of the PDC cover has a label showing relay and fuse location FUEL PUMP MODULE REMOVAL WARNING RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS SERVICE...

Страница 1300: ...ion 4 Depress locking spring tab on side of Fuel Reg ulator Fig 19 and rotate 90 counter clockwise and pull out NOTE Make sure that the upper and lower O rings are on the Filter Regulator assembly INSTALLATION Lightly lubricate the O rings with engine oil 1 Insert Filter Regulator into the opening in the fuel pump module align the two hold down tabs with the flange 2 While applying downward pressu...

Страница 1301: ...ody lock over the locking tangs on the strainer 4 Install fuel pump module Refer to Fuel Pump Module Installation in this section FUEL LEVEL SENSOR REMOVAL Remove fuel pump module Refer to Fuel Pump Module in this section 1 Depress retaining tab and remove the fuel pump level sensor connector from the bottom of the fuel pump module electrical connector Fig 22 2 Pull off blue locking wedge Fig 23 3...

Страница 1302: ...nstalled in the correct posi tion 5 Install locking wedge on connector 6 Push connector up into bottom of fuel pump module electrical connector 7 Install fuel pump module Refer to Fuel Pump Module in this section FUEL INJECTORS REMOVAL 1 Disconnect negative cable from battery 2 Release fuel system pressure Refer to Fuel System Pressure Release procedure in this section 3 Disconnect fuel supply tub...

Страница 1303: ...in the Fuel Delivery Section of this Group FUEL TANK REMOVAL 1 Perform fuel system pressure release 2 Drain fuel tank Refer to Draining Fuel Tank in this section Fig 31 3 Raise vehicle on hoist WARNING WRAP SHOP TOWELS AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE 4 Disconnect fuel pump module electrical connec tor Fig 32 5 Disconnect the fuel tube from Fuel Filter Reg ulator Refer to Quick Connect ...

Страница 1304: ...ntil the ignition switch is turned to the Off posi tion 9 Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system Check for leaks FUEL FILLER NECK REMOVAL 1 Loosen fuel filler tube cap 2 Remove fuel filler neck screws Fig 34 3 Disconnect fuel fill vapor tube 4 Disconnect fuel filler tube from fuel tank Remove filler neck INSTALLATION 1 Reverse for installation FUEL FILLER TUBE ROL...

Страница 1305: ...al shaft 3 From the engine compartment hold the throt tle body lever in the wide open position and install the throttle cable Install the throttle control shield THROTTLE CABLE MANUAL TRANSMISSION REMOVAL 1 Remove throttle control shield Fig 38 2 Working from the engine compartment remove the throttle cable from the throttle body lever Fig 39 and Fig 40 3 Compress the retaining tabs on the cable a...

Страница 1306: ...throttle pedal up and remove the cable retainer and cable from upper end of pedal shaft Fig 36 and Fig 37 5 Remove retainer clip from throttle cable and grommet at the dash panel 6 From the engine compartment pull the throttle cable out of the dash panel grommet The grommet should remain in the dash panel INSTALLATION 1 From the engine compartment push the hous ing end fitting into the dash panel ...

Страница 1307: ...FICATIONS TORQUE SPECIFICATION DESCRIPTION TORQUE Accelerator Pedal to Dash Nuts 12 N m 105 in lbs Fuel Pump Module Locknut 55 N m 40 ft lbs Fuel Tank Strap Bolts 23 N m 250 in lbs Fuel Rail Bolts 23 N m 195 in lbs Ignition Coil Mounting Bolts 11 N m 95 in lbs Intake Manifold Bolts 11 N m 95 in lbs Throttle Control Shield 5 6 N m 50 in lbs 14 20 FUEL SYSTEM PL REMOVAL AND INSTALLATION Continued ...

Страница 1308: ...AP SENSOR PCM INPUT 31 PARK NEUTRAL POSITION SWITCH PCM INPUT 32 POWER DISTRIBUTION CENTER 25 POWER STEERING PRESSURE SWITCH PCM INPUT 31 POWERTRAIN CONTROL MODULE 25 RADIATOR FAN CONTROL MODULE PCM OUTPUT 36 SCI RECEIVE PCM INPUT 32 SCI RECEIVE PCM INPUT 37 SENSOR RETURN PCM INPUT 31 SPEED CONTROL PCM INPUT 31 SPEED CONTROL PCM INPUT 37 SYSTEM DIAGNOSIS 24 TACHOMETER PCM OUTPUT 37 THROTTLE POSITI...

Страница 1309: ... determine how the PCM responds to the various input signals There are two different areas of operation OPEN LOOP and CLOSED LOOP During OPEN LOOP modes the PCM receives input signals and responds according to preset PCM programming Inputs from the upstream and down stream heated oxygen sensors are not monitored dur ing OPEN LOOP modes except for heated oxygen sensor diagnostics they are checked f...

Страница 1310: ... between the two values it sets a MAP diagnostic trouble code into memory Once the ASD and fuel pump relays have been energized the PCM determines injector pulse width based on the following Battery voltage Engine coolant temperature Engine RPM Intake air temperature IAT Throttle position The number of engine revolutions since cranking was initiated During Start up the PCM maintains ignition tim i...

Страница 1311: ...k The PCM may receive a closed throttle input from the Throttle Position Sensor TPS when it senses an abrupt decrease in manifold pressure This indicates a hard deceleration In response the PCM may momentarily turn off the injectors This helps improve fuel economy emissions and engine braking If decel fuel shutoff is detected downstream oxy gen sensor diagnostics is performed WIDE OPEN THROTTLE MO...

Страница 1312: ... Link Connector Duty Cycle EVAP Canister Purge Solenoid EGR Solenoid Fuel Injectors Fuel Pump Relay Generator Field Idle Air Control Motor Ignition Coils Malfunction Indicator Check Engine Lamp Radiator Fan Relay Speed Control Solenoids Tachometer Torque Convertor Clutch Solenoid Based on inputs it receives the PCM adjusts fuel injector pulse width idle speed ignition spark advance ignition coil d...

Страница 1313: ...ompressor discharge high side pressure through the air conditioning pressure transducer The transducer supplies an input to the PCM The PCM engages the A C compressor clutch if pressure is sufficient for A C system operation AUTOMATIC SHUTDOWN ASD SENSE PCM INPUT The ASD sense circuit informs the PCM when the ASD relay energizes A 12 volt signal at this input indicates to the PCM that the ASD has ...

Страница 1314: ...get magnet passes underneath The sensor also acts as a thrust plate to control camshaft endplay CRANKSHAFT POSITION SENSOR PCM INPUT The PCM determines what cylinder to fire from the crankshaft position sensor input and the camshaft position sensor input The second crankshaft counter weight has two sets of four timing reference notches including a 60 degree signature notch Fig 7 From the crankshaf...

Страница 1315: ...signature notch The 60 degree signature notch produces a longer pulse width than the smaller timing reference notches If the camshaft position sensor input switches from high to low when the 60 degree signature notch passes under the crankshaft position sensor the PCM knows cylin der number one is the next cylinder at TDC The crankshaft position sensor mounts to the engine block behind the alterna...

Страница 1316: ...e By monitoring the oxygen content and converting it to electrical voltage the sensors act as a rich lean switch The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner Also it allows the system to remain i...

Страница 1317: ...or input to the input from the upstream sensor the PCM cal culates catalytic convertor efficiency IGNITION CIRCUIT SENSE PCM INPUT The ignition circuit sense input tells the Power train Control Module PCM the ignition switch has energized the ignition circuit Refer to the wiring dia grams for circuit information INTAKE AIR TEMPERATURE SENSOR PCM INPUT The Intake Air Temperature IAT sensor measures...

Страница 1318: ...ing switch is located on the power steering gear The switch Fig 16 provides an input to the PCM during periods of high pump load and low engine RPM such as during parking maneuvers When power steering pump pressure exceeds 2758 kPa 400 psi the switch is open The PCM increases idle air flow through the IAC motor to prevent engine stalling When pump pressure is low the switch is closed SENSOR RETURN...

Страница 1319: ...rottle blade shaft The TPS is a variable resistor that provides the PCM with an input signal voltage The signal represents throttle blade position As the position of the throttle blade changes the resistance of the TPS changes The PCM supplies approximately 5 volts DC to the TPS The TPS output voltage input signal to the powertrain control module represents throttle blade position The TPS output v...

Страница 1320: ...lay is located in the PDC The inside top of the PDC cover has a label showing relay and fuse location AUTOMATIC SHUTDOWN RELAY PCM OUTPUT The automatic shutdown ASD relay supplies bat tery voltage to the fuel injectors electronic ignition coil and the heating elements in the oxygen sensors A buss bar in the power distribution center PDC supplies voltage to the solenoid side and contact side of the...

Страница 1321: ...LECTRIC EGR TRANSDUCER PCM OUTPUT The Electric EGR Transducer contains an electri cally operated solenoid and a back pressure con trolled vacuum transducer Fig 23 The PCM operates the solenoid based on inputs from the multi port fuel injection system The transducer and EGR valve are serviced as an assembly When the PCM energizes the solenoid vacuum does not reach the transducer Vacuum flows to the...

Страница 1322: ...e ground paths on and off the PCM fine tunes injector pulse width Injector pulse width refers to the amount of time an injector operates The PCM determines injector synchronization from the camshaft position sensor and crankshaft position sensor inputs The PCM grounds the ASD and fuel pump relays after receiving the camshaft position sensor and crankshaft position sensor inputs The PCM energizes t...

Страница 1323: ... PCM com pensates for the failure of certain components that send incorrect signals The PCM substitutes for the incorrect signals with inputs from other sensors If the PCM detects active engine misfire severe enough to cause catalyst damage it flashes the MIL At the same time the PCM also sets a Diagnostic Trouble Code DTC For signals that can trigger the MIL Check Engine Lamp refer to Group 25 On...

Страница 1324: ... SCI Receive circuit TACHOMETER PCM OUTPUT The PCM operates the tachometer on the instru ment panel The PCM calculates engine RPM from the crankshaft position sensor input TORQUE CONVERTOR CLUTCH SOLENOID PCM OUTPUT Three speed automatic transaxles use a torque con verter clutch solenoid The PCM controls the engage ment of the torque converter clutch through the solenoid Fig 29 The torque converte...

Страница 1325: ...e position sensor Fig 34 6 Check hose connections between the PCV valve vacuum port intake manifold and the oil sep arator Fig 35 Fig 32 Power Distribution Center POWER DISTRI BUTION CEN TER FUSES RELAYS Fig 33 Throttle Cable Automatic Transmission SPEED CON TROL CABLE THROTTLE CABLE TRANSMISSION KICKDOWNCABLE Fig 34 Idle Air Control Motor and Throttle Position Sensor Typical IDLE AIR CONTROL MOTO...

Страница 1326: ...ctrical and hose connections at the duty cycle purge solenoid Fig 39 Fig 36 MAPIntake Air Temperature Sensor MAP AIR TEMPERATURE SENSOR PCV VACUUM NIPPLE INTAKE MANIFOLD Fig 37 Fuel Injectors FUEL SUP PLY LINE FUEL LINE QUICK CONNECTS IGNITION COIL FUEL RAIL FUEL INJEC TOR Fig 38 Ignition Coil and Spark Plugs Typical IGNITION COILS SPARK PLUG CABLE SPARK PLUG INSULATOR Fig 39 Duty Cycle Purge Sole...

Страница 1327: ...tion sensor and engine coolant temperature sensor Fig 42 16 Check the electrical connector at the Elec tronic EGR Transducer Inspect the vacuum and back pressure hoses at the solenoid and transducer for leaks Fig 43 17 Inspect the electrical connections at the gen erator Fig 44 Check the generator belt for glazing or damage Fig 40 Starter Motor and Ground Strap STARTER MOTOR STARTER SOLENOID GROUN...

Страница 1328: ...at the upstream and downstream heated oxygen sensors Fig 49 and Fig 50 Fig 45 Crankshaft Position Sensor CRANKSHAFT POSITION SENSOR OIL FILTER GENERATOR Fig 46 Vehicle Speed Sensor TRANSAXLE EXTENSION HOUSING VEHICLE SPEED SENSOR Fig 47 Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Fig 48 Park Neutral Switch and Torque Convertor Clutch Solenoid TORQUE CON VERTOR CLUTCH SOLE NOID AU...

Страница 1329: ...e 1 Inspect the battery connections Clean corroded terminals Fig 31 2 Check the 2 PCM 40 way connector for stretched wires on pushed out terminals Fig 54 3 Open the Power Distribution Center PDC Check for blown fuses Ensure the relays and fuses are fully seated in the PDC Fig 55 A label on the underside of the PDC cover shows the locations of each relay and fuse Fig 51 Fuel Pump Module Electrical ...

Страница 1330: ...fuel injector electrical connections Fig 60 Fig 56 Throttle Cable Automatic Transmission SPEED CON TROL CABLE THROTTLE CABLE TRANSMISSION KICKDOWNCABLE Fig 57 Idle Air Control Motor and Throttle Position Sensor Typical IDLE AIR CONTROL MOTOR THROTTLE POSITION SEN SOR Fig 58 PCV Valve PCV VALVE 1 SPARK PLUG BOOT Fig 59 MAP Intake Air Temperature Sensor FUEL RAIL INTAKE MANI FOLD MAP AIR TEM PERATUR...

Страница 1331: ...ent Replace as necessary Check the air induction system for restrictions 14 Check the electrical connection at the knock sensor Fig 64 15 Check the electrical connections at the cam shaft position sensor Fig 65 and engine coolant temperature sensor Fig 66 Fig 61 Ignition Coil and Spark Plugs IGNITION COIL FAS TENERS ELECTRICAL CONNECTOR Fig 62 Duty Cycle Purge Solenoid DUTY CYCLE EVAP PURGE SOLENO...

Страница 1332: ... the crank shaft position sensor Fig 69 19 Check the electrical connection at the vehicle speed sensor Fig 70 Fig 66 Engine Coolant Temperature Sensor FUEL RAIL COOLANT TEMPER ATURE SENSOR Fig 67 Electronic EGR Transducer EGR TRANSDUCER EGR VALVE SERVICE PORT CAM SENSOR Fig 68 Generator GENERATOR Fig 69 Crankshaft Position Sensor CRANKSHAFT POSITION SENSOR OIL FILTER GENERATOR Fig 70 Vehicle Speed...

Страница 1333: ...l con nection at the fuel tank for corrosion or damage Fig 75 Check for pinched kinked or damaged fuel sup ply tube Fig 71 Power Steering Pressure Switch POWER STEERING PRESSURE SWITCH Fig 72 Park Neutral Switch and Torque Convertor Clutch Solenoid TORQUE CON VERTOR CLUTCH SOLE NOID AUTOMATIC TRANSAXLE HOUSING PARK NEUTRAL SWITCH Fig 73 Upstream Heated Oxygen Sensor OXYGEN SEN SORS EXHAUST MANIFOL...

Страница 1334: ... 85 and 86 of the relay The resistance should be between 75 65 ohms 3 Connect the ohmmeter between relay terminals 30 and 87A of the relay The ohmmeter should show continuity between terminals 30 and 87A 4 Connect the ohmmeter between relay terminals 87 and 30 of the relay The ohmmeter should not show continuity at this time 5 Connect one end of a jumper wire 16 gauge or heavier to relay terminal ...

Страница 1335: ...o terminals of the white wires in the heated oxygen sensor connector Replace the heated oxygen sensor if the resistance is not between 4 and 7 ohms IDLE AIR CONTROL IAC MOTOR TEST To preform a complete test of IAC motor and its circuitry refer to DRB scan tool and the appropriate Powertrain Diagnostics Procedures manual KNOCK SENSOR The knock sensor can be tested with a digital volt meter Sensor o...

Страница 1336: ...utput terminal One of the other terminals is a 5 volt supply and the remaining ter minal is ground Connect the DVM between the center and sensor ground terminal Refer to Group 8W Wiring Dia grams for correct pinout With the ignition switch in the ON position check the output voltage at the center terminal wire of the connector Check the output voltage at idle and at Wide Open Throttle WOT At idle ...

Страница 1337: ...ody from engine b While holding the throttle open spray the entire throttle body bore and the manifold side of the throttle plate with Mopar Parts Cleaner Only use Mopar Parts Cleaner to clean the throttle body c Using a soft scuff pad clean the top and bot tom of throttle body bore and the edges and mani fold side of the throttle blade The edges of the throttle blade and portions of the throttle ...

Страница 1338: ...en position and install throttle cable clasp Fig 86 8 Install throttle cable cover Tighten bolt to 5 6 N m 50 ins lbs THROTTLE BODY AUTOMATIC TRANSMISSION REMOVAL 1 Remove throttle cable cover 2 Remove throttle body cables using the following procedures 3 Remove throttle cable from throttle body cam Fig 87 and Fig 88 4 Compress the retaining tabs on the cable and slide cable out of bracket Fig 88 ...

Страница 1339: ...he engine compartment rotate the throttle lever forward to the wide open position and install throttle cable clasp Fig 88 8 If equipped with speed control rotate throttle lever forward to the wide open position and slide speed control cable connector onto nail head 9 Rotate throttle lever forward to the wide open position and slide kickdown cable connector onto nail head 10 Install throttle cable ...

Страница 1340: ...on O rings or seals damage may result If assembly of component is difficult use water to aid assembly Use care when removing hoses to prevent damage to hose or hose nipple REMOVAL 1 Disconnect negative cable from battery 2 Remove electrical connector from idle air con trol motor and throttle position sensor 3 Remove the EVAP purge hose from the throttle body 4 Remove throttle body Refer to Throttl...

Страница 1341: ...nector to sensor 4 Install air inlet duct wing nut and duct from intake manifold insure that the duct does not inter fer with ignition cables DUTY CYCLE EVAP PURGE SOLENOID VALVE The solenoid attaches to a bracket near the front engine mount Fig 98 The solenoid will not operate unless it is installed correctly REMOVAL 1 Disconnect electrical connector from solenoid 2 Disconnect vacuum tubes from s...

Страница 1342: ...VAL 1 Raise and support vehicle 2 Unplug sensor connector 3 Remove sensor using an oxygen sensor crow foot wrench such as Snap On tool YA8875 or equiva lent Fig 100 4 After removing the sensor the exhaust mani fold threads must be cleaned with an 18 mm X 1 5 6E tap If reusing the original sensor coat the sensor threads with an anti seize compound such as Loctitet 771 64 or equivalent INSTALLATION ...

Страница 1343: ...n sensor crow foot wrench such as Snap On tool YA8875 or equivalent Fig 102 Tighten the sensor to 28 N m 20 ft lbs torque 2 Connect sensor electrical harness from clips along body 3 Connect electrical connector from sensor 4 Lower vehicle AIR CLEANER ELEMENT Neon vehicles do not use a heated air inlet system The PCM adjusts fuel injector pulse width and igni tion timing to compensate for different...

Страница 1344: ...ar of the cylinder head Fig 106 or Fig 107 REMOVAL 1 With the engine cold drain coolant until level drops below cylinder head Refer to Group 7 Cooling System 2 Disconnect coolant sensor electrical connector 3 Remove coolant sensor INSTALLATION 1 Install coolant sensor Tighten sensor to 18 N m 165 in lbs torque 2 Attach electrical connector to sensor 3 Fill cooling system Refer to Group 7 Cooling S...

Страница 1345: ...l Information VECI label and the following specifications use specifica tions on VECI label The VECI label is located in the engine compartment TORQUE SPECIFICATIONS DESCRIPTION TORQUE Air Cleaner Wingnut 1 5 N m 15 in lbs Air Cleaner Mount Stud To Thrott Body 10 N m 90 in lbs Crankshaft Position Sensor Mounting Bolts 8 N m 70 in lbs Engine Coolant Temperature Sensor 18 N m 165 in lbs IAC Motor To...

Страница 1346: ...SPECIAL TOOLS FUEL Extractor C 4334 Pressure Gauge Assembly C 4799 B Fuel Pressure Test Adapter 6539 Spanner Wrench 6856 Metering Orifice Fuel Line Tool Fuel Line Adapter PL FUEL SYSTEM 14 59 ...

Страница 1347: ...Fuel Line Adapter 1 4 14 60 FUEL SYSTEM PL SPECIAL TOOLS Continued ...

Страница 1348: ...e It is used to direct oil from the power steering pump to either side of the integral steering rack piston Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle As steering effort increases as in a turn the torsion bar twists causing relative rotary motion between the rotary valve body and valve spool This movement directs oil behind the integral rack piston ...

Страница 1349: ...ired 4 Loose lower control arm to front suspension crossmember bolts 4 Tighten control arm mounting bolts to the specified torques 5 Loose strut assembly to body attaching bolts or nuts 5 Check upper strut mount to body attaching bolts or nuts for looseness If required tighten to the specified torques 6 Power steering fluid pressure hose touching the body of the vehicle 6 Adjust hose to proper pos...

Страница 1350: ...nd replace O Ring as required 3 Low power steering fluid level 3 Fill power steering fluid reservoir to proper level and perform leakage diagnosis 4 Air leak between power steering fluid reservoir and power steering pump 4 Inspect and or replace power steering fluid reservoir as required SQUEAK OR RUBBING SOUND 1 Sound coming from steering column 1 Check for squeak in steering column Inspect for c...

Страница 1351: ... 4 Lubricate tie rod ends if they are not a lubricated for life type If tie rod end is a lubricated for life type replace tie rod end 5 Loose power steering pump drive belt 5 Tighten the power steering pump drive belt to the specified tension See accessory drive in service manual 6 Faulty power steering pump flow control Verify cause using Power Steering Pump Test Procedure 6 Replace power steerin...

Страница 1352: ...S MOMENTARY INCREASE IN EFFORT WHEN TURNING 1 Tires not properly inflated 1 Inflate tires to specified pressure 2 Low power steering fluid level 2 Add power steering fluid as required to power steering fluid reservoir to obtain proper level Perform leakage diagnosis on power steering system 3 Loose power steering pump drive belt 3 Adjust the power steering pump drive belt to the specified tension ...

Страница 1353: ...ts 5 Mispositioned dash cover 5 Reposition dash cover To evaluate items 6 and 7 disconnect the intermediate shaft Turn the steering wheel and feel or listen for internal rubbing in steering column 6 Steering wheel rubbing 6 Adjust steering column shrouds to eliminate rubbing condition 7 Damaged mis positioned or un lubricated steering column coupler to dash seal 7 Determine condition which exists ...

Страница 1354: ... universal joint broken isolator or loose fasteners 4 Free play in steering column 4 Check components of the steering system and repair or replace as required 5 Loose front suspension control arm ball joints 5 Check and or replace the ball joint or control arm as required 6 Loose steering knuckle to ball joint stud pinch bolt 6 Check pinch bolts and tighten if required to specified torque 7 Front ...

Страница 1355: ...king 3 Check for dragging brakes Refer to the procedures in the Brake Group of this service manual 4 Unbalanced steering gear valve If this is the cause the steering efforts will be very light in direction of lead and heavier in the opposite direction 4 Replace steering gear STEERING WHEEL HAS FORE AND AFT LOOSENESS 1 Steering wheel to steering column shaft retaining nut not properly tightened and...

Страница 1356: ...repair or replace the component as required Refer to Power Steering Pump and or Power Steering Gear in this group of the service manual for required procedures CONDITION POSSIBLE CAUSES CORRECTION AERATION AND OVERFLOW OF FLUID 1 Air leaks 1 Check for an air leak into the power steering system as described under Sucking Air Diagnosis and correct condition 2 Low fluid level 2 Extremely cold tempera...

Страница 1357: ...cantly increased All vehicles equipped with power steering use a remote mounted reservoir for the power steering fluid The power steering fluid remote reservoir is mounted to the rear of the cylinder head on the pas senger side of the vehicle The service procedures for the TTA power steering pump are limited to the areas and components listed below No repair procedures are to be done on internal c...

Страница 1358: ... safe level Under normal power steering pump operating con ditions pressure requirements of the pump are below maximum causing the pressure relief valve to remain closed DIAGNOSIS AND TESTING POWER STEERING SYSTEM TEST PROCEDURE The following procedure can be used to test the operation of the power steering system on the vehi cle This test will provide the flow rate of the power steering pump alon...

Страница 1359: ...luid or equivalent DO NOT USE ANY TYPE OF AUTOMATIC TRANSMISSION FLUID POWER STEERING PUMP INITIAL OPERATION CAUTION The fluid level should be checked with engine off to prevent injury from moving compo nents Use only MoparT Power Steering Fluid Do not use automatic transmission fluid Do not over fill Wipe filler cap clean then check the fluid level The dipstick should indicate FULL COLD when the ...

Страница 1360: ...r steering pressure switch is used to improve the vehi cle s idle quality The pressure switch improves vehi cle idle quality by controlling engine idle speed when required The pressure switch functions by signaling the power train control module that the power steering system is putting additional load on the engine This type of condition exists when turning the front tires of the vehicle when the...

Страница 1361: ...e MoparT Power Steering Fluid or equivalent 3 Fill power steering reservoir to correct fluid level 4 Connect negative cable back on negative post of battery 5 Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in sys tem Stop engine check fluid level and inspect sys tem for leaks See Checking Fluid Level POWER STEERING FLUID PRESSURE HOSE CAUTION Cap all o...

Страница 1362: ...g Fig 13 4 Install a new O ring Fig 14 on power steering pressure hose banjo fitting bolt 5 Lubricate both O rings using fresh clean power steering fluid 6 Install banjo bolt into the power steering pres sure hose banjo fitting Fig 14 7 Attach power steering pressure hose to outlet fitting on power steering pump Fig 12 Do not tighten or torque pressure fitting Banjo bolt at this time Fig 9 Power S...

Страница 1363: ...ring pressure hose bracket to generator shield 17 Start the engine and let run for a few seconds Then turn the engine off 18 Add fluid if necessary Repeat the above pro cedure until the fluid level remains constant after running the engine 19 Raise front wheels of vehicle off the ground 20 Start the engine Slowly turn the steering wheel right and left lightly contacting the wheel stops Then turn t...

Страница 1364: ...top of the vehicles engine compartment CAUTION Care must be used when installing power steering fluid return hose on power steering fluid reservoir If excessive force is used when try ing to install hose on nipple of power steering fluid reservoir nipple can be broken off the reservoir 2 Install power steering return hose on power steering fluid reservoir fitting Install hose clamp on power steeri...

Страница 1365: ...D EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING DO NOT START ENGINE WITH ANY LOOSE OR DIS CONNECTED HOSES DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST REMOVE CAUTION Care must be used when removing the power steering fluid supply hose from power steer ing fluid reservoir If excessive force is used when trying to remove hose from nipple on power steer ing fluid rese...

Страница 1366: ...OSES OR ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST The power steering pump removal procedure and pump and bracket fastener locations are the same for both engine applications used for this vehicle The front power steering pump bracket must be removed as an assembly with the power steering pump and removed from the pump after removing the pulley from the power steering pump REMOVE 1 Remo...

Страница 1367: ...ig 26 back on the engine using reverse of removal procedure 2 Slide front power steering pump bracket between bracket mounting bolt and front engine mount Fig 25 Be sure washer on bolt is between the head of the bolt and bracket and does not get trapped between bracket and engine mount 3 Install the 2 power steering pump to cast mounting bracket attaching bolts Fig 24 Do not tighten bolts at this ...

Страница 1368: ... bracket Fig 21 While holding locating pin against power steering pump bracket torque pump end Banjo bolt to 34 N m 25 ft lbs CAUTION Do not use automatic transmission fluid in power steering system Only use MoparT Power Steering Fluid or equivalent 14 Fill power steering reservoir to correct fluid level 15 Connect negative cable back on negative post of battery 16 Start the engine and let run for...

Страница 1369: ...rd the center of the vehicle CAUTION Care must be used when removing and installing power steering fluid hoses on the power steering fluid reservoir If excessive force is used when trying to remove or install hoses on nipples of power steering fluid reservoir nipples can be broken off the reservoir 6 Remove the power steering fluid return and supply hose from the power steering fluid reservoir Fig...

Страница 1370: ... off 12 Add power steering fluid if necessary 13 Lower the vehicle and turn the steering wheel slowly from lock to lock 14 Stop the engine Check the fluid level and refill as required 15 If the fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure DISASSEMBLY AND ASSEMBLY POWER STEERING PUMP DRIVE PULLEY The power steering pump must be removed from the ...

Страница 1371: ...ction in this group of the service manual for required procedure CAUTION Do not hammer on power steering pump pulley or shaft to remove power steering pump pulley This will damage the pulley and the power steering pump 2 Mount the power steering pump in a vise using the power steering pump mounting bracket Fig 39 Mount Puller Special Tool C 4333 or C 4068 on power steering pump pulley Fig 39 Remov...

Страница 1372: ...vice Procedures section in this group of the service manual for required procedure SPECIFICATIONS POWER STEERING PUMP FLOW SPECIFICATIONS Power Steering Pump Flow At 1500 RPM And Minimum Pressure 4 9 to 5 3 Liters Min 1 3 to 1 9 GPM Control Valve Pressure Relief 8240 to 8920 kPa 1195 to 1293 psi Fig 39 Pulley Removal From Power Steering Pump Shaft POWER STEERING PUMP POWER STEERING PUMP PULLEY SPE...

Страница 1373: ...ember Attaching Bolt 23 N m 17 ft lbs Power Steering Pump Pressure Hose Banjo Bolt 34 N m 25 ft lbs Discharge Fitting 75 N m 55 ft lbs To Bracket Mounting Bolts 54 N m 40 ft lbs Brackets To Engine Mounting Bolts 54 N m 40 ft lbs SPECIAL TOOLS POWER STEERING PUMP Installer C 4063B Puller C 4333 P S System Analyzer 6815 19 26 STEERING PL SPECIFICATIONS Continued ...

Страница 1374: ...ther side of the integral rack piston Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle This movement directs oil behind the integral rack piston which in turn builds up hydraulic pressure and assists in the turning effort The drive tangs on the pinion of the power steering pump mate loosely with a stub shaft This is to per mit manual steering control to b...

Страница 1375: ... the hoses for restrictions and repair as necessary The initial pressure reading should be in the range of 345 552 kPa 50 80 psi The flow meter should read between 1 3 and 1 4 GPM CAUTION The following test procedure involves testing power steering pump maximum pressure output and flow control valve operation Do not leave valve closed for more than 5 seconds as the pump could be damaged 8 Close va...

Страница 1376: ...m front suspension cross member Fig 5 Bobble strut does not need to be removed from transaxle assembly 5 Remove nuts attaching both outer tie rod ends to the steering knuckles Fig 6 Nuts are to be removed from tie rod ends using the following procedure hold tie rod end stud with an 11 32 socket while loosening and removing nut with wrench 6 Remove both tie rod end studs from the steer ing knuckles...

Страница 1377: ...TION Before removing front suspension crossmember from the vehicle the location of the front suspension crossmember MUST be scribbed on body of vehicle per Fig 9 This must be done so crossmember can be relocated against body of vehicle in the same location when it is reinstalled If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assem bled NET BUILD fr...

Страница 1378: ...ed steering gear assembly to the replacement steering gear if a new steering gear is being installed Fig 11 Marking Front Suspension Crossmember Location SCRIBBED LINE FOR LOCATION OF FRONT SUSPENSION CROSSMEMBER LOWER CON TROL ARM LOWER CONTROL ARM BUSHING MOUNTING BOLT FRONT SUSPENSION CROSSMEMBER AWL Fig 12 Supporting Front Suspension Crossmember STEERING GEAR SWAYBAR FRONT SUSPENSION CROSSMEMB...

Страница 1379: ...gear tube nuts Fig 10 to 31 N m 275 in lbs 5 If vehicle is equipped with power steering install power steering pressure and return hose rout ing bracket and attaching screw on front suspension crossmember Fig 9 Torque hose routing bracket to crossmember attaching bolt Fig 9 to 23 N m 17 ft lbs 6 If the vehicle is equipped with power steering install vehicle wiring harness connector onto power stee...

Страница 1380: ...e rods DISASSEMBLY AND ASSEMBLY OUTER TIE ROD END DISASSEMBLE 1 Loosen the inner tie rod to outer tie rod jam nut Fig 19 2 Remove the nut attaching the outer tie rod end to steering knuckle Fig 20 Nut is to be removed from tie rod end using the following procedure hold tie rod end stud with a 11 32 socket while loosening and removing nut with wrench 3 Remove the tie rod end stud from steering knuc...

Страница 1381: ...tie rod if they became twisted during Toe adjustment SPECIFICATIONS STEERING GEAR FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE FRONT SUSPENSION CROSSMEMBER To Body Mounting Bolts 163 N m 120 ft lbs STEERING GEAR To Crossmember Mounting Bolts 68 N m 50 ft lbs OUTER TIE ROD To Steering Knuckle Nut 55 N m 40 ft lbs To Inner Tie Rod Jam Nut 61 N m 45 ft lbs POWER STEERING HOSE Tube Nuts 31 N m 27...

Страница 1382: ...IFICATIONS 43 DESCRIPTION AND OPERATION STEERING COLUMN ASSEMBLY Both the standard non tilt and tilt steering col umns Fig 1 have been designed to be serviced only as complete assemblies if a component of the steer ing column is defective The only replaceable compo nents of the steering column assembly are the key cylinder ignition switch multi function switch clock spring trim shrouds and steerin...

Страница 1383: ...Fig 1 Non Tilt And Tilt Steering Column Assemblies 19 36 STEERING PL DESCRIPTION AND OPERATION Continued ...

Страница 1384: ...hicle is involved in a colli sion which deploys the air bag regardless of the extent of damage done to the vehicle 2 If a vehicle is involved in an impact of the vehi cles front suspension or under carriage which results in any type of damage to the front suspension cross member 3 Under any conditions which result in the steer ing column assembly or steering column shaft receiv ing a force great e...

Страница 1385: ...NSITIVE COMPLEX ELECTRO MECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE REMOVE OR INSTALL THE AIR BAG SYSTEM COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGI NALLY USED FOR THE AIR BAG COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIF...

Страница 1386: ...IVE MODULE THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF MODULE ACCIDENTLY DEPLOYS IF AIR BAG MOD ULE IS PLACED ON A BENCH OR OTHER SUR FACE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOYMENT Fig 6 Steering Column Cover ATTACHING SCREW FUSE ACCESS PANEL HEAD LAMP SWITCH STEERING COLUMN STEERING COLUMN COVER ATTACHING SCREWS Fig 7 Steer...

Страница 1387: ...ving steering wheel from steering column 13 Remove steering wheel assembly from steer ing column shaft using Puller Special Tool C 3428 B or equivalent 14 Remove key lock cylinder from steering col umn Key lock cylinder is removed from steering col umn using the following procedure Place the key lock cylinder in the Run position Then through the hole in lower shroud Fig 14 depress lock cylinder re...

Страница 1388: ...el 21 Remove routing clip Fig 18 holding wiring harness to jacket of steering column Then remove wiring harness connectors from the multi function switch and the windshield wiper switch Fig 18 Fig 14 Key Lock Cylinder Access Hole In Steering Column Shrouds Fig 15 Upper And Lower Steering Column Shrouds TILT LEVER LOWER STEERING COL UMN SHROUD STEERING COLUMN LOWER STEERING COL UMN SHROUD FASTEN ER...

Страница 1389: ...n the 2 steering column upper mounting bracket nuts to a torque of 17 N m 150 in lbs 8 Tighten the steering column lower mounting bracket nuts 2 to a torque of 17 N m 150 in lbs 9 Assemble the steering column flex coupler to the intermediate steering coupler Fig 16 Install the steering coupler pinch bolt Torque the pinch bolt nut to 28 N m 250 in lbs Be sure to install upper to lower steering coup...

Страница 1390: ...e to Negative post of the battery When reconnecting battery on a vehicle that has had the air bag module removed the following procedure should be used Remove forward console or cover as necessary Connect DRB II to ASDM diagnostic 6 way con nector located at right side of the ASDM module Turn ignition key to ON position Exit vehicle with the DRB II Install the latest version of the proper diagnost...

Страница 1391: ......

Страница 1392: ...emperature approximately 21 C to 27 C 70 F to 80 F In all pumps add fluid as necessary use only Mopar Power Steering Fluid or equivalent DO NOT USE ANY TYPE OF AUTOMATIC TRANSMIS SION FLUID REMOVAL AND INSTALLATION POWER STEERING PRESSURE SWITCH A power steering fluid pressure switch is used to improve the vehicle s idle quality The power steering fluid pressure switch improves vehicle idle qualit...

Страница 1393: ...steering pressure switch CAUTION Do not use automatic transmission fluid in power steering system Only use MoparT Power Steering Fluid or equivalent 3 Fill power steering reservoir to correct fluid level 4 Connect negative cable back on negative post of battery 5 Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in sys tem Stop engine check fluid level an...

Страница 1394: ...ings located at ends of power steering pressure hose and Banjo bolt INSTALL 1 Install power steering pressure hose in vehicle from top of engine compartment 2 Using a lint free towel wipe clean all open power steering hose ends and the power steering pump and steering gear ports 3 Install new O ring on end of power steering pressure hose banjo fitting Fig 7 Fig 4 Power Steering Pressure Hose Routi...

Страница 1395: ...few seconds Then turn the engine off 17 Add fluid if necessary Repeat the above pro cedure until the fluid level remains constant after running the engine 18 Raise front wheels of vehicle off the ground 19 Start the engine Slowly turn the steering wheel right and left lightly contacting the wheel stops Then turn the engine off 20 Add power steering fluid if necessary 21 Lower the vehicle and turn ...

Страница 1396: ...power steering return hose on steel tube at power steering gear Fig 9 Install hose clamp on power steering return hose at power steering gear Fig 9 Be sure hose clamp is installed on return hose past upset bead on steel tube at power gear 6 Lower vehicle 7 Add power steering fluid to the reservoir until the fluid level is at the full cold mark on the dipstick 8 Start the engine and let run for a f...

Страница 1397: ...ring gear Fig 12 Be sure hose clamp is installed on return hose past upset bead on steel tube at power gear 5 Lower vehicle 6 Remove hose clamp attaching power steering fluid supply hose to power steering fluid reservoir Fig 13 Then remove power steering fluid supply hose from power steering fluid reservoir 7 Remove hose clamp attaching power steering fluid supply hose to power steering pump Fig 1...

Страница 1398: ...e fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure 13 Check all hose connections for leaks POWER STEERING PUMP WARNING POWER STEERING OIL ENGINE COM PONENTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING DO NOT START ENGINE WITH ANY LOOSE OR DIS CONNECTED HOSES OR ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST The front m...

Страница 1399: ...ey 13 Remove power steering pump and front mounting bracket as an assembly from the engine Fig 20 14 Transfer required parts from removed power steering pump to replacement power steering pump INSTALL 1 Install power steering pump and mounting bracket as an assembly Fig 20 back on the engine using reverse of removal procedure 2 Slide front power steering pump bracket between bracket mounting bolt ...

Страница 1400: ... O rings using fresh clean power steering fluid 11 Install banjo bolt into the power steering pres sure hose banjo fitting 12 Attach power steering pressure hose on outlet fitting of the power steering pump Fig 16 13 Position locating pin on power steering pres sure hose banjo fitting so it is against power steering pump mounting bracket Fig 16 While holding locating pin against power steering pum...

Страница 1401: ...id reservoir nipples can be broken off the reservoir 7 Remove the power steering fluid return and supply hose from the power steering fluid reservoir Fig 25 8 Remove the power steering fluid reservoir from the mounting bracket Reservoir is removed from bracket by lifting the reservoir straight up out of the bracket 9 If removal of the mounting bracket is required remove the bolts attaching it to t...

Страница 1402: ...heck the fluid level and refill as required 12 If the fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure SPECIAL TOOLS POWER STEERING PUMP Installer C 4063B Puller C 4333 P S System Analyzer 6815 PL STEERING 19 11 REMOVAL AND INSTALLATION Continued ...

Страница 1403: ...sted in the Mopar Parts Catalog that the correct replacement part for the vehicle being serviced is installed The power steering system used on this vehicle consists of these four major components Power Steering Gear Fig 1 Power Steering Pump Pres sure Hose and Return Hose Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack te...

Страница 1404: ...aft Fig 2 2 Raise vehicle on jack stands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 3 Remove both front wheel and tire assemblies from the vehicle 4 Remove engine transaxle bobble dampener on vehicles so equipped from front suspension cross member Fig 3 Bobble strut...

Страница 1405: ...le the location of the front suspension crossmember MUST be scribbed on body of vehicle per Fig 9 This must be done so crossmember can be relocated against body of vehicle in the same location when it is reinstalled If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assem bled NET BUILD front suspension alignment set tings will not be obtained This may...

Страница 1406: ...n jack raise front sus pension crossmember and steering gear against body and frame rails of vehicle Start the 2 rear bolts into tapping plates attaching front suspension crossmem ber to body of vehicle Fig 9 Then install the 2 front bolts attaching front suspension crossmember to frame rails of vehicle Fig 9 Tighten the 4 mounting bolts until front suspension crossmember is against body of vehicl...

Страница 1407: ...l and tire assemblies back on vehicle Tighten the wheel nuts to 135 N m 100 ft lbs torque 9 Lower vehicle 10 From interior of vehicle reconnect the steer ing gear coupler with the steering column shaft cou pler Install steering gear coupler retaining pinch bolt and torque to 28 N m 250 in lbs Be sure to install the upper to lower steering coupler retaining bolt retention pin Fig 2 CAUTION Do not u...

Страница 1408: ...ody Mounting Bolts 163 N m 120 ft lbs STEERING GEAR To Crossmember Mounting Bolts 68 N m 50 ft lbs OUTER TIE ROD To Steering Knuckle Nut 55 N m 40 ft lbs To Inner Tie Rod Jam Nut 61 N m 45 ft lbs POWER STEERING HOSE Tube Nuts 31 N m 275 in lbs Routing Bracket At Crossmember 23 N m 17 ft lbs SPECIAL TOOLS POWER STEERING GEAR Fig 14 Outer Tie Rod End Jam Nut Remover Tie Rod End MB 990635 P S System ...

Страница 1409: ...e components of the steering column assembly are the key cylinder ignition switch multi function switch clock spring trim shrouds and steering wheel These replaceable components of the steering column can be serviced without requiring removal of the steering column from the vehicle STEERING GEAR TO STEERING COLUMN COUPLING This vehicle uses a different design for the cou pling used to connect the ...

Страница 1410: ...assembly or steering column shaft receiv ing a force great enough to move the steering column or shaft forward or rearward in a vehicle STEERING COUPLING INSPECTION PROCEDURE 1 Remove the pinch bolt safety pin from the steering column shaft coupling pinch bolt Fig 3 2 Loosen the coupling pinch bolt retaining nut and remove pinch bolt Fig 3 from steering coupler Pinch bolt nut is caged to coupler a...

Страница 1411: ... FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGI NALLY USED FOR THE AIR BAG COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFI CALLY DESIGNED FOR THE AIR BAG SYSTEM THEY MUST NEVER BE REPLACED WITH ANY SUB STITUTES ANYTIME A NEW FASTENER IS NEEDED REP...

Страница 1412: ...TIONS SHOULD BE OBSERVED AT NO TIME SHOULD ANY SOURCE OF ELECTRICITY BE PER MITTED NEAR THE INFLATOR ON THE BACK OF THE AIRBAG MODULE WHEN CARRYING A LIVE MODULE THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF AIRBAG ACCIDENTLY DEPLOYS IF AIRBAG MOD ULE IS PLACED ON A BENCH OR OTHER SUR FACE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOY...

Страница 1413: ...ering column shaft when removing steering wheel from steering column 13 Remove steering wheel assembly from steer ing column shaft using Puller Snap On CJ2001P or an equivalent 14 Remove key lock cylinder from steering col umn Key lock cylinder is removed from steering col umn using the following procedure Place the key lock cylinder in the Run position Then through the hole in lower shroud Fig 15...

Страница 1414: ...ng bracket through bolt Fig 18 19 Remove the 2 steering column assembly upper bat wing bracket to support bracket nuts Fig 19 20 Lower steering column assembly in the steer ing column access opening of the lower instrument panel Fig 15 Key Lock Cylinder Access Hole In Steering Column Shrouds Fig 16 Upper And Lower Steering Column Shrouds Fig 17 Steering Column Coupling Fig 18 Steering Column Lower...

Страница 1415: ...shroud to lock housing attaching screws Fig 16 7 Be sure both breakaway capsules are still fully seated in the slots of the upper steering column mounting bracket Equally tighten both steering col umn mounting nuts until upper steering column mounting bracket is seated against support bracket Fig 19 Then tighten the 2 steering column upper mounting bracket nuts to a torque of 12 N m 105 in lbs 8 E...

Страница 1416: ...ey lock cylinder is installed by positioning key cyl inder in the run position so retaining tab can be depressed and the pushing key cylinder into lock hos ing until retaining tab locks into key lock cylinder 19 Reconnect ground cable to Negative post of the battery When reconnecting battery on a vehicle that has had the air bag module removed the following procedure should be used Remove forward ...

Страница 1417: ......

Страница 1418: ...emperature approximately 21 C to 27 C 70 F to 80 F In all pumps add fluid as necessary use only Mopar Power Steering Fluid or equivalent DO NOT USE ANY TYPE OF AUTOMATIC TRANSMIS SION FLUID REMOVAL AND INSTALLATION POWER STEERING PRESSURE SWITCH A power steering fluid pressure switch is used to improve the vehicle s idle quality The power steering fluid pressure switch improves vehicle idle qualit...

Страница 1419: ...steering pressure switch CAUTION Do not use automatic transmission fluid in power steering system Only use MoparT Power Steering Fluid or equivalent 3 Fill power steering reservoir to correct fluid level 4 Connect negative cable back on negative post of battery 5 Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in sys tem Stop engine check fluid level an...

Страница 1420: ...ings located at ends of power steering pressure hose and Banjo bolt INSTALL 1 Install power steering pressure hose in vehicle from top of engine compartment 2 Using a lint free towel wipe clean all open power steering hose ends and the power steering pump and steering gear ports 3 Install new O ring on end of power steering pressure hose banjo fitting Fig 7 Fig 4 Power Steering Pressure Hose Routi...

Страница 1421: ...few seconds Then turn the engine off 17 Add fluid if necessary Repeat the above pro cedure until the fluid level remains constant after running the engine 18 Raise front wheels of vehicle off the ground 19 Start the engine Slowly turn the steering wheel right and left lightly contacting the wheel stops Then turn the engine off 20 Add power steering fluid if necessary 21 Lower the vehicle and turn ...

Страница 1422: ...power steering return hose on steel tube at power steering gear Fig 9 Install hose clamp on power steering return hose at power steering gear Fig 9 Be sure hose clamp is installed on return hose past upset bead on steel tube at power gear 6 Lower vehicle 7 Add power steering fluid to the reservoir until the fluid level is at the full cold mark on the dipstick 8 Start the engine and let run for a f...

Страница 1423: ...ring gear Fig 12 Be sure hose clamp is installed on return hose past upset bead on steel tube at power gear 5 Lower vehicle 6 Remove hose clamp attaching power steering fluid supply hose to power steering fluid reservoir Fig 13 Then remove power steering fluid supply hose from power steering fluid reservoir 7 Remove hose clamp attaching power steering fluid supply hose to power steering pump Fig 1...

Страница 1424: ...e fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure 13 Check all hose connections for leaks POWER STEERING PUMP WARNING POWER STEERING OIL ENGINE COM PONENTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING DO NOT START ENGINE WITH ANY LOOSE OR DIS CONNECTED HOSES OR ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST The front m...

Страница 1425: ...ey 13 Remove power steering pump and front mounting bracket as an assembly from the engine Fig 20 14 Transfer required parts from removed power steering pump to replacement power steering pump INSTALL 1 Install power steering pump and mounting bracket as an assembly Fig 20 back on the engine using reverse of removal procedure 2 Slide front power steering pump bracket between bracket mounting bolt ...

Страница 1426: ... O rings using fresh clean power steering fluid 11 Install banjo bolt into the power steering pres sure hose banjo fitting 12 Attach power steering pressure hose on outlet fitting of the power steering pump Fig 16 13 Position locating pin on power steering pres sure hose banjo fitting so it is against power steering pump mounting bracket Fig 16 While holding locating pin against power steering pum...

Страница 1427: ...id reservoir nipples can be broken off the reservoir 7 Remove the power steering fluid return and supply hose from the power steering fluid reservoir Fig 25 8 Remove the power steering fluid reservoir from the mounting bracket Reservoir is removed from bracket by lifting the reservoir straight up out of the bracket 9 If removal of the mounting bracket is required remove the bolts attaching it to t...

Страница 1428: ...heck the fluid level and refill as required 12 If the fluid is extremely foamy allow the vehi cle to stand a few minutes and repeat the above pro cedure SPECIAL TOOLS POWER STEERING PUMP Installer C 4063B Puller C 4333 P S System Analyzer 6815 PL STEERING 19 11 REMOVAL AND INSTALLATION Continued ...

Страница 1429: ...sted in the Mopar Parts Catalog that the correct replacement part for the vehicle being serviced is installed The power steering system used on this vehicle consists of these four major components Power Steering Gear Fig 1 Power Steering Pump Pres sure Hose and Return Hose Turning of the steering wheel is converted into linear travel through the meshing of the helical pinion teeth with the rack te...

Страница 1430: ...aft Fig 2 2 Raise vehicle on jack stands or centered on a frame contact type hoist See Hoisting in the Lubri cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle 3 Remove both front wheel and tire assemblies from the vehicle 4 Remove engine transaxle bobble dampener on vehicles so equipped from front suspension cross member Fig 3 Bobble strut...

Страница 1431: ...le the location of the front suspension crossmember MUST be scribbed on body of vehicle per Fig 9 This must be done so crossmember can be relocated against body of vehicle in the same location when it is reinstalled If location of front suspension crossmember to body of vehicle is not maintained when vehicle is assem bled NET BUILD front suspension alignment set tings will not be obtained This may...

Страница 1432: ...n jack raise front sus pension crossmember and steering gear against body and frame rails of vehicle Start the 2 rear bolts into tapping plates attaching front suspension crossmem ber to body of vehicle Fig 9 Then install the 2 front bolts attaching front suspension crossmember to frame rails of vehicle Fig 9 Tighten the 4 mounting bolts until front suspension crossmember is against body of vehicl...

Страница 1433: ...l and tire assemblies back on vehicle Tighten the wheel nuts to 135 N m 100 ft lbs torque 9 Lower vehicle 10 From interior of vehicle reconnect the steer ing gear coupler with the steering column shaft cou pler Install steering gear coupler retaining pinch bolt and torque to 28 N m 250 in lbs Be sure to install the upper to lower steering coupler retaining bolt retention pin Fig 2 CAUTION Do not u...

Страница 1434: ...ody Mounting Bolts 163 N m 120 ft lbs STEERING GEAR To Crossmember Mounting Bolts 68 N m 50 ft lbs OUTER TIE ROD To Steering Knuckle Nut 55 N m 40 ft lbs To Inner Tie Rod Jam Nut 61 N m 45 ft lbs POWER STEERING HOSE Tube Nuts 31 N m 275 in lbs Routing Bracket At Crossmember 23 N m 17 ft lbs SPECIAL TOOLS POWER STEERING GEAR Fig 14 Outer Tie Rod End Jam Nut Remover Tie Rod End MB 990635 P S System ...

Страница 1435: ...e components of the steering column assembly are the key cylinder ignition switch multi function switch clock spring trim shrouds and steering wheel These replaceable components of the steering column can be serviced without requiring removal of the steering column from the vehicle STEERING GEAR TO STEERING COLUMN COUPLING This vehicle uses a different design for the cou pling used to connect the ...

Страница 1436: ...assembly or steering column shaft receiv ing a force great enough to move the steering column or shaft forward or rearward in a vehicle STEERING COUPLING INSPECTION PROCEDURE 1 Remove the pinch bolt safety pin from the steering column shaft coupling pinch bolt Fig 3 2 Loosen the coupling pinch bolt retaining nut and remove pinch bolt Fig 3 from steering coupler Pinch bolt nut is caged to coupler a...

Страница 1437: ... FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGI NALLY USED FOR THE AIR BAG COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFI CALLY DESIGNED FOR THE AIR BAG SYSTEM THEY MUST NEVER BE REPLACED WITH ANY SUB STITUTES ANYTIME A NEW FASTENER IS NEEDED REP...

Страница 1438: ...TIONS SHOULD BE OBSERVED AT NO TIME SHOULD ANY SOURCE OF ELECTRICITY BE PER MITTED NEAR THE INFLATOR ON THE BACK OF THE AIRBAG MODULE WHEN CARRYING A LIVE MODULE THE TRIM COVER SHOULD BE POINTED AWAY FROM THE BODY TO MINIMIZE INJURY IF AIRBAG ACCIDENTLY DEPLOYS IF AIRBAG MOD ULE IS PLACED ON A BENCH OR OTHER SUR FACE PLASTIC COVER SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN CASE OF ACCIDENTAL DEPLOY...

Страница 1439: ...ering column shaft when removing steering wheel from steering column 13 Remove steering wheel assembly from steer ing column shaft using Puller Snap On CJ2001P or an equivalent 14 Remove key lock cylinder from steering col umn Key lock cylinder is removed from steering col umn using the following procedure Place the key lock cylinder in the Run position Then through the hole in lower shroud Fig 15...

Страница 1440: ...ng bracket through bolt Fig 18 19 Remove the 2 steering column assembly upper bat wing bracket to support bracket nuts Fig 19 20 Lower steering column assembly in the steer ing column access opening of the lower instrument panel Fig 15 Key Lock Cylinder Access Hole In Steering Column Shrouds Fig 16 Upper And Lower Steering Column Shrouds Fig 17 Steering Column Coupling Fig 18 Steering Column Lower...

Страница 1441: ...shroud to lock housing attaching screws Fig 16 7 Be sure both breakaway capsules are still fully seated in the slots of the upper steering column mounting bracket Equally tighten both steering col umn mounting nuts until upper steering column mounting bracket is seated against support bracket Fig 19 Then tighten the 2 steering column upper mounting bracket nuts to a torque of 12 N m 105 in lbs 8 E...

Страница 1442: ...ey lock cylinder is installed by positioning key cyl inder in the run position so retaining tab can be depressed and the pushing key cylinder into lock hos ing until retaining tab locks into key lock cylinder 19 Reconnect ground cable to Negative post of the battery When reconnecting battery on a vehicle that has had the air bag module removed the following procedure should be used Remove forward ...

Страница 1443: ......

Страница 1444: ...URES FLUID DRAIN AND FILL 4 REMOVAL AND INSTALLATION AXLE SEALS 9 BACK UP LAMP SWITCH 8 CROSSOVER LEVER 8 GEARSHIFT BOOT 5 GEARSHIFT CABLES 5 GEARSHIFT KNOB 5 GEARSHIFT MECHANISM REPLACEMENT 7 SELECTOR LEVER 8 SHIFT SHAFT SEALS 9 TRANSAXLE 9 VEHICLE SPEED SENSOR DRIVE GEAR 8 DISASSEMBLY AND ASSEMBLY DIFFERENTIAL 25 INPUT SHAFT 21 OUTPUT SHAFT 25 SHIFT RAILS OVERHAUL 28 SYNCHRONIZER 28 TRANSAXLE CA...

Страница 1445: ...arious final drive gear ratios in different vehicle applications Therefore it is necessary that the correct transaxle assembly number is used when ordering service parts The last eight digits of the Vehicle Identification Number V I N are stamped on the case below the back up lamp switch NOTE There are four different versions of this transaxle There are no external differences between the models R...

Страница 1446: ...shows which transax les are available with the reverse input shaft brake This brake allows easier shifting into reverse and helps eliminate reverse gear clash GEARSHIFT PATTERN The NV T350 A 578 transaxle shift pattern is a modified H pattern Fig 4 Overdrive fifth and reverse gears are in line and outboard of the first through fourth gear positions ENGINE 2 0 SOHC 2 0 DOHC U S ONLY 2 0 SOHC or DOH...

Страница 1447: ... by mis aligned or damaged shift components or worn teeth on the drive gears or synchronizer components Incor rect assembly also causes gear disengagement LOW LUBRICANT LEVEL Insufficient transaxle lubricant is usually the result of leaks or inaccurate fluid level check or refill method Leakage is evident by the presence of oil around the leak point If leakage is not evident the condition is proba...

Страница 1448: ... boot from the gearshift mechanism INSTALLATION 1 For installation reverse removal procedure Install new plastic retaining clips GEARSHIFT CABLES Use this procedure if either of the shift cables require replacement REMOVAL 1 Disconnect Power Distribution Center from battery tray and set aside 2 Remove air cleaner inlet horn 3 Remove battery and battery tray 4 Disconnect gear shift cable ends from ...

Страница 1449: ...g bushings 11 Lift vehicle on hoist Remove self tapping screw securing grommet plate to underbody heat shield and floor pan Fig 14 12 Detach cables from cable support clip in tun nel above exhaust catalyst 13 Remove shift cable assembly from vehicle INSTALLATION CAUTION Gearshift cable bushings must not be lubricated or the bushings will swell and split 1 To install reverse removal procedure After...

Страница 1450: ...case and per form functional check by shifting transaxle into all gears 6 Reinstall center shift console Blouse boot out around console Seat boot lip on top of console GEARSHIFT MECHANISM REPLACEMENT REMOVAL 1 Remove shifter knob 2 Remove console assembly Refer to Group 23 Body for procedure 3 Remove shifter boot 4 Remove gearshift cables 5 Remove the parking brake mechanism Refer to Group 5 Brake...

Страница 1451: ...h 3 Unscrew switch from transaxle INSTALLATION 1 To install reverse removal procedure Teflon tape or equivalent must be used on switch threads CAUTION Do not overtighten switch 2 Confirm back up lamps are functioning prop erly following installation CROSSOVER LEVER REMOVAL 1 Remove crossover cable Refer to Gearshift Cable removal 2 Using a pin punch remove the crossover roll pin from lever 3 Pull ...

Страница 1452: ...s REMOVAL 1 Using a pick tool pry up on the shift shaft seal and remove seal from bore INSTALLATION 1 Position new shift shaft seal in bore 2 Install shift shaft seal into bore using an appropriate size deep well socket TRANSAXLE NOTE The transaxle can be removed from the vehicle without having to remove the engine All transaxle components are serviced with the transaxle out of the vehicle with th...

Страница 1453: ... upper bellhousing bolts 12 Install engine bridge fixture and support engine 13 Lift vehicle on hoist and remove front wheels 14 Drain fluid from transaxle 15 Remove both front driveshafts Refer to Group 2 Suspension for procedure CAUTION When reinstalling driveshafts new drive shaft retaining clips must be used Do not reuse old clips Failure to use new clips may result in disen gagement of inner ...

Страница 1454: ...e 2 After installing transaxle fill transaxle to bot tom of fill plug hole vehicle level on hoist Fill tran saxle with Mopart type M S 9417 Manual Transaxle Fluid before lowering vehicle to floor 3 Verify that vehicle s back up lights and speed ometer are functioning properly Crossover cable adjustment procedure is required after installing transaxle in car to ensure proper shifter adjustment Road...

Страница 1455: ...shaft shift pin out of the slot in the blocker assembly Turn selector shaft up and out of the way Fig 40 11 Remove transaxle end cover Fig 41 Fig 42 12 Remove two snap rings retaining the output shaft and the input shaft to the bearings Fig 43 13 Using bench fixture and shims provided Mill er tools 6785 6785 1 and 6785 2 turn transaxle over Install transaxle onto bench fixture Fig 44 Fig 30 Case B...

Страница 1456: ...LER SHAFT REVERSE IDLE SHAFT BOLT Fig 36 Reverse Idler Gear Removal INPUT SHAFT CASE REVERSE IDLE GEAR SHAFT REVERSE IDLE GEAR Fig 37 Screws Retaining Reverse Fork Bracket Fig 38 Remove Reverse Fork Bracket REVERSE FORK BRACKET REVERSE CAM BLOCKOUT SHIFT BLOCKER ASSEMBLY Fig 39 Remove Selector Shaft Spacer SHIFT BLOCKER ASSEMBLY SELECTOR SHAFT SPACER PLASTIC SNAP RING PLIERS Fig 40 Selector Shaft ...

Страница 1457: ... out of case Fig 46 Fig 41 Transaxle Cover Removal TRAN SAXLE CASE END COVER Fig 42 End Cover END COVER CASE Fig 43 Snap Rings Retaining Bearings SNAP RING PLIERS SNAP RINGS Fig 44 Bench Fixture SHIMS TRANSAXLE 6785 BENCH FIXTURE Fig 45 Bearing Fixture BEARING FIXTURE TRANSAXLE CASE Fig 46 Pressing Gears Out of Case PRESS RAM TRAN SAXLE CASE BENCH FIX TURE BEARING FIXTURE 21 14 TRANSAXLE PL DISASS...

Страница 1458: ...e Fig 54 20 Remove the 1 2 shift fork from the output shaft Fig 55 21 Remove input and output shaft assemblies from bench fixture Fig 56 CAUTION The output shaft assembly is serviced as an assembly Do not try to repair any component on the output shaft If the 1 2 synchronizer or gear fails it is necessary to replace the complete output shaft assembly Fig 47 Transaxle Case Removal TRANSAXLE CASE BE...

Страница 1459: ...reverse brake blocking ring Fig 62 7 Install reverse brake friction cone Fig 63 8 Install reverse brake shim Fig 64 Apply petroleum jelly to shim to hold in place 9 Install gear case half over bench fixture Fig 65 Line up shift finger over 3 4 lug 10 Line up reverse brake friction cone lugs to the slots in the gear case Fig 66 Verify reverse brake shim is in position Fig 52 Reverse Brake Needle Be...

Страница 1460: ...ply Mopart RTV sealant to end cover outer edge and around bolt holes Install end cover onto Fig 57 Bench Fixture BENCH FIXTURE GEARTRAIN Fig 58 Shift Rail Installation 6785 BENCH FIXTURE 1 2 SHIFT FORK Fig 59 Shift Blocker Installation 6785 BENCH FIXTURE SHIFT BLOCKER ASSEMBLY Fig 60 Reverse Brake Race Installation Fig 61 Reverse Brake Needle Bearing Fig 62 Reverse Brake Blocking Ring Installation...

Страница 1461: ...Fig 70 Fig 63 Reverse Brake Friction Cone Installation Fig 64 Reverse Brake Shim REVERSE BRAKESHIM REVERSE BRAKE FRICTION CONE Fig 65 Gear Case Half TRANSAXLE CASE BENCH FIXTURE GEARTRAIN Fig 66 Friction Cone Lugs CASE FRICTION CONE LUGS INPUT SHAFT Fig 67 Installing Input and Output Bearings SPECIAL TOOL C 4992 1 INPUT AND OUTPUT BEARINGS Fig 68 Snap Rings Retaining Bearings 21 18 TRANSAXLE PL DI...

Страница 1462: ... for proper shims Improperly seated bearing cups and cones are subject to low mileage failure 2 Bearing cups and cones should be replaced if they show signs of pitting or heat distress If distress is seen on either the cup or bearing rollers both cup and cone must be replaced 3 Bearing preload and drag torque specifications must be maintained to avoid premature bearing fail ures Used original bear...

Страница 1463: ...r of times This will settle the bearings Zero the dial indicator To obtain end play readings apply a medium load in an upward direction while rolling differential assembly back and forth Fig 76 Record end play 7 The shim required for proper bearing preload is the total of end play plus constant preload of 0 18mm 0 007 in Never combine shims to obtain the required preload 8 Remove case bolts Remove...

Страница 1464: ...aced The input shaft incorporates the 3rd 4th and 5th speed gears and synchronizers on the assembly Fig 78 1 Install bearing splitter behind 5th speed gear Remove snap ring at 5th synchronizer hub on input shaft Fig 79 2 Remove synchronizer and gear using shop press Fig 80 3 Remove caged needle bearing Fig 81 4 Remove 4 5 gears split thrust washer ring Fig 82 5 Remove split thrust washer Fig 83 6 ...

Страница 1465: ...onizer and 3rd gear Fig 88 Fig 81 Caged Needle Bearing Removal Fig 82 Split Thrust Washer Ring Removal Fig 83 Split Thrust Washer Removal INPUT SHAFT SPLIT THRUST WASHER Fig 84 Split Thrust Washer Separation Pin Fig 85 4th Gear Removal Fig 86 Caged Needle Bearing Removal INPUT SHAFT CAGED NEEDLE BEARING 21 22 TRANSAXLE PL DISASSEMBLY AND ASSEMBLY Continued ...

Страница 1466: ...the U facing upward 4 Install 3 4 synchronizer snap ring into slot on input shaft 5 Install blocking ring into 3 4 synchronizer Install 4th gear caged needle bearing 6 Install 4th gear onto input shaft 7 Install 4 5 split thrust washer separation pin Fig 91 8 Install split thrust washer onto input shaft Fig 92 9 Install split thrust washer retaining ring Fig 93 10 Install 5th gear caged needle bea...

Страница 1467: ...ST WASHER Fig 93 Retaining Ring Installation SPLIT THRUST WASHER RINGINPUT SHAFT Fig 94 Caged Needle Bearing Installation INPUT SHAFT CAGED NEEDLE BEARING Fig 95 5th Speed Gear Installation Fig 96 5th Gear Synchronizer Snap Ring Installation SNAP RING SNAP RING PLI ERS INPUT SHAFT BEARING SPLITTER 21 24 TRANSAXLE PL DISASSEMBLY AND ASSEMBLY Continued ...

Страница 1468: ...e output shaft assembly must be replaced The output shaft incorporates the 1st and 2nd gears and synchronizers on the assembly Fig 97 DIFFERENTIAL Shim thickness need be determined only if any of the following parts are replaced Transaxle gear case Clutch bellhousing case Differential case Differential bearings Refer to Bearing Adjustment Procedure in the Adjustments section at the end of this sec...

Страница 1469: ...ioned down ward when installing onto differential assembly Fig 100 Remove Differential Bearing Cone SPECIAL TOOL C 293 SPECIAL TOOL ADAPTER C 293 45 USE 4 PIECES DIFFERENTIAL ASSEMBLY DIFFERENTIAL BEARING CONE SPECIAL TOOL C 4996 NOTE POSITION Fig 101 Install Differential Bearing Cone ARBOR PRESS RAM SPECIAL TOOL HANDLE C 4171 SPECIAL TOOL L 4410 DIFFEREN TIAL ASSEMBLY BEARING CONE Fig 102 Remove ...

Страница 1470: ...g in differential Fig 111 4 Remove differential gears Fig 112 INSTALLATION 1 Assemble the differential side gears pinion gears and pinion gears with the pinion gear washers 2 Install pinion shaft retaining pin Fig 113 Fig 105 Speedometer Drive Gear SPEEDOMETER DRIVE GEAR DIFFERENTIAL ASSEMBLY Fig 106 Press Gear onto Diferential STEEL STOCK PRESS RAM SPECIAL TOOL L 4440 DIFFERENTIAL ASSEMBLY SPEEDO...

Страница 1471: ... position Fig 119 6 Line up stop ring tang over the keys in the hub Fig 120 Install stop rings Center the keys and balls by pushing on both stop rings SHIFT RAILS OVERHAUL 1 Remove shift rails from the geartrain 2 To service the 5 R shift rail remove the C clip retaining the reverse shift lever arm Remove the 5th shift fork roll pin and remove the 5th shift fork Remove the shift lug roll pin and r...

Страница 1472: ...dentical end to end Install bearing with larger diameter cage ring facing out 1 Remove caged roller bearing from output bear ing race Fig 123 2 Remove screws at output bearing retainer strap Fig 124 3 Install tool 6787 and slide hammer Fig 125 Tighten tool to output bearing race Fig 112 Differential Gears DIFFERENTIAL ASSEMBLY PINION SHAFT SPEEDOMETER DRIVE GEAR SIDE GEARS PINION SHAFT RETAIN ING ...

Страница 1473: ... C 4996 NOTE POSI TION DIAL INDICATOR SET DIFFERENTIAL ASSEMBLY SIDE GEAR MOVE SIDE GEAR UP AND DOWN Fig 116 Checking Side Gear End Play Typical SPECIAL TOOL C 4996 NOTE POSITION DIAL INDICATOR SET DIFFERENTIAL ASSEMBLY MOVE SIDE GEAR UP AND DOWN Fig 117 Synchronizer Assembly SLEEVE BALL KEY SPRING HUB Fig 118 Synchronizer Balls INPUT SHAFT HUB KEY BALL Fig 119 Synchronizer Sleeve SLEEVE INPUT SHA...

Страница 1474: ...tool 6342 over input bearing on the gear case side of the transaxle clutch housing Fig 121 Axle Shaft Seal Removal Fig 122 Axle Seal Installation TOOL C 4171 TOOL 6709 AXLE SEAL Fig 123 Output Roller Bearing INPUT BEARING OUTPUT BEARING LARGER DIAMETER CAGE RING Fig 124 Output Bearing Strap BEARING RETAINER OUTPUT BEARING RACE Fig 125 Output Bearing Race Removal C 3752 SPECIAL TOOL 6787 OUTPUT SHA...

Страница 1475: ...bore until it is fully seated Fig 130 Fig 126 Output Bearing Race Installation TOOLC 4171 TOOLC 4628 OUTPUT BEAR ING RACE Fig 127 Input Bearing And Sleeve DIFFERENTIAL BEARING OUTPUT BEAR ING INPUT BEAR ING BEARING RETAINER Fig 128 Input Bearing Removal SPECIAL TOOL 6342 BELLHOUSING HALF INPUT BEARING AND SLEEVE Fig 129 Input Bearing Tool SPECIAL TOOL C 4680 1 SPECIAL TOOL 4894 BELLHOUSING HALF Fi...

Страница 1476: ...bore until flush with the chamfer in the case SHIFT SHAFT SEALS It is not necessary to remove the shift shafts from the transaxle to service the shift shaft seals REMOVAL 1 Using a pick tool pry up on the shift shaft seal and remove seal from bore INSTALLATION 1 Position new shift shaft seal in bore 2 Install shift shaft seal into bore using an appropriate size deep well socket SHIFT SELECTOR SHAF...

Страница 1477: ...cement bushing over selector shaft bore 2 Using an appropriate size deep well socket install bushing in selector shaft bore Fig 136 SHIFT CROSSOVER SHAFT BUSHING REMOVAL 1 Install slide hammer 3752 through the cross over bushing 2 Thread nut and washer onto slide hammer 3 Using the slide hammer remove the crossover shaft bushing Fig 137 INSTALLATION 1 Position the replacement crossover shaft bush ...

Страница 1478: ... the friction material is burned flaking off or worn Check the condition of the synchro keys and springs Replace these parts if worn cracked or distorted SYNCHRONIZER CLEAN Do not attempt to clean the blocking rings in sol vent The friction material will become contaminated Place synchronizer components in a suitable holder and clean with solvent Air dry INSPECT Proper inspection of components inv...

Страница 1479: ... shim from clutch bellhousing case 2 Press in new bearing cup into bellhousing case or use a cup that has been ground down on the outer edge for ease of measurement 3 Press in new bearing cup into gear case side 4 Oil differential bearings with Mopart type M S 9417 Manual Transaxle Fluid Install differential assembly in transaxle gear case Install clutch bell housing over gear case Install and tor...

Страница 1480: ...put Bearing Race Ret Strap 11 N m 96 in lbs Power Hop Damper Bkt to Trans 54 N m 40 ft lbs Power Hop Damper to Frame Bkt 54 N m 40 ft lbs Power Hop Damper to Trans Bkt 54 N m 40 ft lbs Reverse Fork Bracket 11 N m 96 in lbs Reverse Idler Shaft Bolt 26 N m 19 ft lbs DESCRIPTION TORQUE Shift Cable Bracket to Transaxle 28 N m 250 in lbs Transaxle Case Bolts 29 N m 21 ft lbs Transaxle to Engine Bolt 95...

Страница 1481: ...OOLS NV T350 A 578 MANUAL TRANSAXLE Adapter Blocks C 293 45 Puller Press C 293 PA Dial Indicator C 3339 Sleeve C 3717 Slide Hammer C 3752 Universal Handle C 4171 Bearing Installer C 4628 Seal Remover C 4680 21 38 TRANSAXLE PL ...

Страница 1482: ...Seal Installer C 4992 Torque Tool C 4995 Adapter C 4996 Installer L 4410 Special Jaw Set L 4518 Bearing Splitter 1130 Driver 6342 Seal Installer 6709 PL TRANSAXLE 21 39 SPECIAL TOOLS Continued ...

Страница 1483: ...Bearing Remover 6768 Bench Fixture 6785 Remover 6786 Remover 6787 21 40 TRANSAXLE PL SPECIAL TOOLS Continued ...

Страница 1484: ...HIFT MECHANISM 59 INTERLOCK MECHANISM 64 PARK NEUTRAL STARTING AND BACK UP LAMP SWITCH 65 PUMP OIL SEAL 68 SHIFTER IGNITION INTERLOCK CABLE 61 THROTTLE PRESSURE CABLE 60 TRANSAXLE 65 VEHICLE SPEED SENSOR PINION GEAR 64 DISASSEMBLY AND ASSEMBLY ACCUMULATOR RECONDITION 83 DIFFERENTIAL REPAIR 95 FRONT CLUTCH RECONDITION 79 FRONT PLANETARY AND ANNULUS GEAR RECONDITION 82 KICKDOWN SERVO CONTROLLED LOAD...

Страница 1485: ...ng shell The driving shell is splined to the sun gear and front clutch retainer The hydraulic system consists of an oil pump and a single valve body which con tains all of the valves except the governor valves The transaxle sump and differential sump are both vented through the dipstick Output torque from the main center line is delivered through helical gears to the transfer shaft This gear set i...

Страница 1486: ...d pressure to the valve body in conjunction with vehicle speed to control upshift and downshift The throttle valve transmits regulated pressure to the transaxle dependent on throttle position to con trol upshift and downshift FLOW CONTROL VALVES The manual valve provides the different transaxle drive ranges selected by the vehicle operator The 1 2 shift valve automatically shifts the tran saxle fr...

Страница 1487: ...eaning or assembling the governor be sure the governor valves move freely in the bores of the governor body DIAGNOSIS AND TESTING 31TH TRANSAXLE DIAGNOSIS AND TESTS Automatic transaxle malfunctions can be caused by four general conditions 1 Poor engine performance 2 Improper adjustments 3 Hydraulic malfunctions 4 Mechanical malfunctions Diagnosis of these problems should always begin by checking t...

Страница 1488: ...er operation of good units Road testing can usually diagnose slip ping units although the actual cause of the problem may not be detected Practically any condition can be caused by leaking hydraulic circuits or sticking valves CONDITION POSSIBLE CAUSES CORRECTION HARSH ENGAGEMENT FROM NEUTRAL TO DRIVE Engine idle speed too high Check engine curb idle speed Correct as necessary Valve body malfuncti...

Страница 1489: ...uid 12 Engine idle speed too low 12 Set up engine to specs 13 Worn reaction shaft support seal rings 13 Inspect and replace reaction shaft support seal rings 14 Worn or faulty front clutch 14 Replace discs and seal at front clutch RUNAWAY UPSHIFT 1 Hydraulic pressures too low 1 Check fluid pressure at ports 2 Valve body malfunction 2 Inspect valve body and repair 3 Low fluid level 3 Fill trans to ...

Страница 1490: ...ecs 3 2 KICKDOWN RUNAWAY 1 Hydraulic pressure too low 1 Check fluid pressure at ports 2 Valve body malfunction 2 Inspect valve body and repair 3 Low fluid level 3 Fill trans to level 4 Aerated fluid 4 Replace trans fluid 5 Incorrect throttle linkage adjustment 5 Adjust throttle linkage 6 Kickdown band out of adjustment 6 Adjust kickdown band 7 Governor support seal rings worn 7 Replace governor su...

Страница 1491: ...epair kickdown band servo or linkage 13 Worn front clutch 13 Replace discs and seals at front clutch 14 Engine performance 14 Set up engine to specs SLIPS IN FORWARD DRIVE POSITIONS 1 Hydraulic pressure too low 1 Check fluid pressure at ports 2 Valve body malfunction 2 Inspect valve body and repair 3 Low fluid level 3 Fill trans to level 4 Incorrect gearshift linkage adjustment 4 Adjust gearshift ...

Страница 1492: ...aft support seal rings 11 Worn front clutch 11 Replace discs and seals at front clutch SLIPS IN ALL POSITIONS 1 Hydraulic pressure too low 1 Check fluid pressure at ports 2 Valve body malfunction 2 Inspect valve body and repair 3 Low fluid level 3 Fill trans to level 4 Oil filter clogged 4 Replace oil filter 5 Faulty oil pump 5 Replace oil pump 6 Worn input shaft seal rings 6 Replace input shaft s...

Страница 1493: ...reverse band and linkage 5 Incorrect gearshift linkage adjustment 5 Adjust gearshift linkage 6 Worn reaction shaft support seal rings 6 Replace reaction shaft support seal rings 7 Worn front clutch 7 Replace discs and seals at front clutch 8 Worn rear clutch 8 Replace discs and seals at rear clutch 9 Planetary gear sets broken or seized 9 Replace planetary gear sets DRIVES IN NEUTRAL 1 Valve body ...

Страница 1494: ... HARD TO FILL OIL BLOWS OUT FILLER HOLE 1 Oil filter clogged 1 Replace oil filter 2 Aerated fluid 2 Replace trans fluid 3 High fluid level 3 Adjust fluid level to specs TRANSAXLE OVERHEATS 1 Stuck cooler flow switch valve 1 Replace switch valve behind oil pump housing 2 Engine idle speed too high 2 Adjust engine idle to specs 3 Hydraulic pressures too low 3 Check fluid pressure at ports 4 Low flui...

Страница 1495: ...n reaction shaft support seal rings 4 Replace reaction shaft support seal rings 5 Governor malfunction 5 Inspect and repair governor 6 Kickdown band servo or linkage malfunction 6 Inspect and repair kickdown band servo or linkage 7 Worn front clutch 7 Replace discs and seals at front clutch 8 Engine performance 8 Set up engine to specs NO TORQUE CONVERTER CLUTCH APPLICATION 1 Stuck cooler flow swi...

Страница 1496: ...ump output pressure regulation and condition of rear clutch and rear servo hydraulic circuits TEST TWO SELECTOR IN 2 1 Attach one gauge to line pressure port and tee another gauge into lower cooler line fitting This will allow lubrication 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 se...

Страница 1497: ...ottle lever clockwise Pressure should gradually increase to 260 to 300 psi as lever is moved counterclockwise 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 drops to zero 7 This tests for leakage into rear servo due to case porosity which can cause rever...

Страница 1498: ...at front clutch is operating Hold air pressure on for a few seconds and inspect system for excessive oil leaks REAR CLUTCH Apply air pressure to rear clutch apply passage and listen for a dull thud which indicates that rear clutch is operating Also inspect for excessive oil leaks If a dull thud cannot be heard in the clutches place finger tips on clutch housing and again apply air pressure Movemen...

Страница 1499: ... pan should be cleaned with a clean dry cloth NOTE If the transaxle is disassembled for any rea son the fluid and filter should be changed and the band s adjusted FLUID DRAIN AND REFILL 1 Raise vehicle on a hoist See Group 0 Lubrica tion Place a drain container with a large opening under transaxle oil pan 2 Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain th...

Страница 1500: ...ushing solvents are petroleum based solutions gen erally used to clean automatic transmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906 3 Verify pump power switch is turned OFF Con nect red alligator clip to positive battery post Connect black alligator clip to a good ground 4 Disconnect the cooler lines at t...

Страница 1501: ...T CABLE REMOVAL 1 Disconnect both battery cables 2 Pull up and remove the power distribution cen ter 3 Remove the battery thermoguard 4 Remove the battery and battery holddown from the battery tray 5 Remove the battery tray and cruise control servo if equipped 6 Remove the screw from the cable bracket at the transaxle Fig 7 7 Squeeze the three metal tabs in and remove the cable from the bracket 8 ...

Страница 1502: ...ALLATION 1 To install gearshift cable reverse removal pro cedure 2 Adjust gearshift cable using the adjustment procedure in this Group GEARSHIFT MECHANISM REMOVAL 1 Disconnect battery negative cable and isolate 2 Remove console assembly Refer to Group 23 Body 3 Remove the gearshift knob set screw and knob Fig 13 Fig 9 Gearshift Bezel Fig 10 Gearshift Cable Fig 11 Cable Mounting CABLE MOUNTING NUTS...

Страница 1503: ...URE CABLE REMOVAL 1 Unsnap the throttle pressure cable end at the throttle control lever at transaxle Fig 17 2 Squeeze the retaining tabs inward at the mounting bracket Fig 18 Remove the cable from the bracket 3 Unsnap the cable end from the throttle linkage cam Squeeze the tabs inward at the bracket Fig 19 Remove the cable from the vehicle INSTALLATION 1 To install cable reverse removal procedure...

Страница 1504: ...m of operation by moving the transaxle throttle lever forward counterclockwise Then slowly release it to confirm it will return fully rearward clockwise No lubrication is required for any component of the throttle cable system SHIFTER IGNITION INTERLOCK CABLE REMOVAL 1 Disconnect and isolate the battery negative cable from the vehicle battery 2 Remove console assembly Refer to Group 23 Body 3 Remo...

Страница 1505: ...and START positions This will disengage the cylinder from the column Fig 24 14 Pull out the key cylinder 15 Remove the three lower to upper shroud attaching screws through the bottom of the lower shroud Fig 25 16 Separate the upper and lower shrouds 17 Grasp the interlock cable clip and connector Remove the cable from the interlock housing Fig 26 18 Unclip the cable from the retaining clip located...

Страница 1506: ...beginning of this section 9 Install console assembly Refer to Group 23 Body 10 Install screws retaining the gearshift indica tor bezel and install bezel and indicator lamp 11 Install the gearshift knob set screw and knob 12 Install two screws at the upper area of the column liner and lower left corner 13 Snap the clips in at the lower column cover Install the three screws along the bottom of the l...

Страница 1507: ... in the adjuster 13 Snap down the interlock adjuster lock onto the cable and remove the shim 14 After adjusting the interlock system perform the Interlock System Operation Check in the Adjust ments section of this group INTERLOCK MECHANISM REMOVAL 1 Remove the lower column covers ignition switch and shrouds Refer to Interlock Cable Replacement 2 Grasp the interlock cable and connector firmly Remov...

Страница 1508: ...f the three terminal switch 4 To test switch remove wiring connector from switch and test for continuity between the two out side pins 5 Continuity should exist only with transaxle in REVERSE position 6 No continuity should exist from either pin to the case TRANSAXLE REMOVAL NOTE The transaxle can be removed from the vehicle without having to remove the engine The transaxle and torque converter mu...

Страница 1509: ...fts new drive shaft retaining clips must be used Do not reuse old clips Failure to use new clips may result in disen gagement of inner constant velocity joint 14 Remove transaxle to rear lateral bending strut from engine and transaxle Fig 37 15 Remove front engine bracket through bolt Remove front engine bracket bolts Fig 38 16 Remove lower starter bolt Fig 39 17 Remove lower dust shield screw Fig...

Страница 1510: ...saxle mount from transaxle 22 Remove rear engine bolt at transaxle 23 Carefully work transaxle and torque converter assembly rearward off engine block dowels Disen gage converter hub from end of crankshaft Attach a small C clamp to edge of bellhousing This will Fig 37 Bracket Removal Fig 38 Front Engine Bracket FRONT ENGINE MOUNT BOLTS Fig 39 Starter Bolts Fig 40 Rotate Engine ROTATE ENGINE CLOCKW...

Страница 1511: ...r Tool C 3981 B into seal Fig 44 then tighten screw portion of tool to with draw the seal INSTALLATION 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 housing until tool bottoms Fig 45 DISASSEMBLY AND ASSEMBLY TRANSAXLE Prior to removing any transaxle parts plug all openings and clean the unit pre...

Страница 1512: ...er seated against end of input shaft Fig 54 Move input shaft in and out to obtain end play reading End play specifications are 0 19 to 1 50 mm 0 008 to 0 060 inch Record indicator reading for reference when reas sembling the transaxle CAUTION The input shaft for torque converter without a clutch has two seal rings The input shaft for torque converter with a clutch has three seal rings Fig 46 Trans...

Страница 1513: ... 53 Valve Body and Governor Tubes VALVE BODY ASSEMBLY GOVERNORTUBES Fig 54 Measure Input Shaft End Play PUMP OIL SEAL REACTION SHAFT USE A STEEL BALL DIAL INDICATOR INPUT SHAFT Fig 55 Loosen Lock Nut and Tighten Kickdown Band Adjusting Screw KICKDOWN BAND ADJUSTING SCREW Fig 56 Pump Attaching Bolts SEAL PUMP ATTACHING BOLTS 7 PUMP HOUSING 21 70 TRANSAXLE PL DISASSEMBLY AND ASSEMBLY Continued ...

Страница 1514: ...LIT IN GASKET DIFFER ENTIAL OIL FEED PUMP GAS KET PUMP GASKET DIFFEREN TIAL OIL FEED CUTOUT Fig 60 Loosen Kickdown Band Adjusting Screw KICKDOWN BAND ADJUSTING SCREW Fig 61 Kickdown Band and Strut FRONT CLUTCH KICKDOWN BAND OIL RETURN AND FEED HOLE TO DIF FERENTIAL Fig 62 Front Clutch Assembly REAR CLUTCH ASSEMBLY FRONT CLUTCH ASSEMBLY PL TRANSAXLE 21 71 DISASSEMBLY AND ASSEMBLY Continued ...

Страница 1515: ...netary Gear Snap Ring FRONT PLANETARY GEAR SNAP RING SNAP RING PLIERS FRONT PLANETARY GEAR ASSEMBLY Fig 66 Front Planetary Gear Assembly SUN GEAR FRONT PLANETARY GEAR ASSEMBLY 6 THRUST WASHER Fig 67 Sun Gear Driving Shell SUN GEAR DRIVING SHELL REAR PLANETARY GEAR Fig 68 Sun Gear Driving Shell Components 8 THRUST WASHER STEEL 7 SPACER STEEL SUN GEAR SUN GEAR DRIVING SHELL SNAP RING 21 72 TRANSAXLE...

Страница 1516: ...EMBLY 10 THRUST WASHER Fig 72 Overrunning Clutch Cam Assembly OUTPUT SHAFT OVERRUNNING CLUTCH CAM ASSEMBLY Fig 73 Overrunning Clutch Rollers and Spring LOW REVERSE BAND OVERRUNNING CLUTCH ROLLERS 8 OVERRUNNING CLUTCH SPRINGS 8 Fig 74 Loosen or Adjust Low Reverse Band LOW REVERSE BAND LEVER ADJUSTING SCREW STRUT LOW REVERSE BAND LOCK NUT LEVER SHORT PL TRANSAXLE 21 73 DISASSEMBLY AND ASSEMBLY Conti...

Страница 1517: ...PRINGS AS THEY ARE REMOVED FOR REASSEMBLY IDENTIFICATION Fig 75 Low Reverse Band and Strut 11 THRUST WASHER LOW REVERSE BAND STRUT Fig 76 No 11 Thrust Washer 11 THRUST WASHER OUTPUT SHAFT Fig 77 Install Overrunning Clutch Rollers and Springs TOOL L 4440 ROLLER 8 OVERRUNNING CLUTCH CAM ASSEMBLY SPRING 8 Fig 78 Detent Spring Attaching Screw and Spring SPECIAL TOOL L 4553 DETENT SPRING SCREW SCREWDRI...

Страница 1518: ...L VALVE STEEL BALLS 8 STEEL BALLS Fig 83 Remove or Install Throttle Shaft E Clip MANUAL VALVE LEVER ASSEMBLY THROTTLE VALVE LEVER ASSEMBLY SCREWDRIVER E CLIP Fig 84 Throttle Shaft E Clip Washer and Seal MANUAL VALVE LEVER ASSEMBLY OIL SEAL E CLIP THROTTLE VALVE LEVER ASSEMBLY WASHER Fig 85 Manual Valve Lever Assembly THROTTLE VALVE LEVER ASSEMBLY MANUAL VALVE LEVER ASSEM BLY VALVE BODY PL TRANSAXL...

Страница 1519: ... ADJUSTING SCREW BRACKET VALVE BODY SCREWS Fig 89 Pressure Regulators and Manual Controls VALVE BODY LINE PRESSURE VALVE SPRING ADJUSTING SCREW SCREW SPRING GUIDE KICKDOWN VALVE SPRING MANUAL VALVE THROTTLE VALVE Fig 86 Throttle Valve Lever Assembly THROTTLE VALVE LEVER ASSEMBLY MANUAL VALVE VALVE BODY 21 76 TRANSAXLE PL DISASSEMBLY AND ASSEMBLY Continued ...

Страница 1520: ... COVER SCREW 4 END COVER 2 3 SHIFT VALVE GOVER NOR PLUG E CLIP Fig 91 Pressure Regulator Valve Plugs CONVERTER PRESSURE CONTROL VALVE REGULATOR VALVE THROT TLE PRESSURE PLUG END COVER SCREW 3 REGULATOR VALVE THROTTLE PRESSURE PLUG SPRING SWITCH VALVE PL TRANSAXLE 21 77 DISASSEMBLY AND ASSEMBLY Continued ...

Страница 1521: ...ING SHUTTLE VALVE PLUG SCREWS BY PASS VALVE SPRING 1 2 SHIFT VALVE SPRING 1 2 SHIFT VALVE BY PASS VALVE TORQUE CON VERTER CLUTCH SOLENOID VALVE BODY SPRING GUIDES 2 Fig 93 Reaction Shaft Support Bolts REACTION SHAFT SUPPORT BOLTS 6 OIL PUMP HOUSING Fig 94 Reaction Shaft Support REACTION SHAFT SUP PORT PUMP HOUSING OUTER GEAR INNER GEAR 21 78 TRANSAXLE PL DISASSEMBLY AND ASSEMBLY Continued ...

Страница 1522: ...OCKET Fig 96 Measuring Pump Clearance Gear to Pocket INNER GEAR FEELER GAUGE OUTER GEAR PUMP HOUSING Fig 97 Front Clutch Waved Snap Ring WAVED SNAP RING SCREW DRIVER FRONT CLUTCH ASSEMBLY Fig 98 Thick Steel Plate and Waved Snap Ring WAVED SNAP RING THICK STEEL PLATE FRONT CLUTCH RETAINER Fig 99 Front Clutch 4 Disc Shown FRONT CLUTCH RETAINER CLUTCH PLATES DRIVING DISCS PL TRANSAXLE 21 79 DISASSEMB...

Страница 1523: ...atches light scratches will not interfere with sealing of the seals Inspect Neoprene seal rings for deterioration wear and hardness Inspect piston spring and waved snap ring for distor tion or breakage Inspect Teflon and or cast iron seal rings on input shaft for wear Do not remove rings unless conditions warrant Inspect rear clutch to front clutch No 2 thrust washer for wear Washer thickness shou...

Страница 1524: ... Fig 106 Rear Clutch Piston and Piston Spring REAR CLUTCH RETAINER PISTON SPRING WAVED SNAP RING PISTON PISTONSEALS INPUT SHAFT Fig 107 Remove or Install Input Shaft Snap Ring REAR CLUTCH RETAINER SNAP RING PLIERS SNAP RING INPUT SHAFT Fig 108 Input Shaft Snap Ring INPUT SHAFT REAR CLUTCH RETAINER SNAP RING Fig 109 Measuring Rear Clutch Plate Clearance REAR CLUTCH ASSEMBLY FEELER GAUGE SELECTIVE S...

Страница 1525: ...anetary Gear FRONT PLANETARY GEAR ASSEMBLY Fig 112 Annulus Gear Support Front Snap Ring ANNULUS GEAR SUPPORT FRONT SNAP RING SCREWDRIVER FRONT PLANE TARY ANNULUS GEAR Fig 113 Front Annulus Gear Support and Snap Ring FRONT ANNULUS GEAR FRONT SNAP RING FRONT ANNULUS GEAR SUPPORT REAR SNAP RING Fig 114 Front Annulus Gear Support Snap Ring FRONT ANNULUS GEAR REAR SNAP RING Fig 115 Low Reverse Lever LO...

Страница 1526: ...IERS Fig 117 Remove Retainer Spring and Servo SERVO PISTON SPRING AND RETAINER Fig 119 Accumulator Snap Ring ACCUMULATOR PLATE SNAP RING SNAP RING PLIERS ACCUMULATOR PLATE Fig 120 Accumulator Plate and Snap Ring SNAP RING ACCUMULATOR PLATE 88O RING Fig 121 Accumulator Spring and Piston ACCUMULATOR SPRING ACCUMULATOR PISTON SEAL RINGS PL TRANSAXLE 21 83 DISASSEMBLY AND ASSEMBLY Continued ...

Страница 1527: ... transfer shaft The strap is used to hold the stirrup to the transfer gear and prevent the stirrup retain ing bolts from backing out Fig 122 Kickdown Servo Snap Ring SNAP RING SNAP RING PLIERS ACCUMULATOR PLATE KICKDOWN LEVER KICKDOWN PISTON ROD GUIDE Fig 123 Kickdown Servo Rod Guide and Snap Ring SNAP RING ACCUMULATOR PLATE RETURN SPRING O RING PISTON ROD GUIDE Fig 124 Kickdown Piston Return Spri...

Страница 1528: ... or Install Rear Cover OUTPUT SHAFT GEAR USE MOPAR SILICONE RUB BER ADHESIVE SEALER REAR COVER TRANSFER SHAFT GEAR Fig 128 Remove Transfer Shaft Gear Retaining Nut TRANSFER SHAFT GEAR SCREW 2 OUTPUT SHAFT GEAR SPECIAL TOOL L 4434 Fig 129 Transfer Shaft Gear Nut and Washer Fig 130 Remove Transfer Shaft Gear Fig 131 Transfer Shaft Gear and Select Shim TRANSFER SHAFT GEAR OUTPUT SHAFT GEAR SHIM SELEC...

Страница 1529: ...ort Retainer TRANSFER SHAFT OUTPUT SHAFT GEAR BEARING CUP GOVERNOR SUP PORT RETAINER Fig 135 Remove Governor Support Retainer Bearing Cup PRESS HANDLE C 4171 WITH SPE CIAL TOOL L 4517 GOVERNOR SUPPORT RETAINER Fig 136 Install Governor Support Retainer Bearing Cup PRESS HANDLE C 4171 SPECIAL TOOL L 4520 GOVERNOR SUPPORT RETAINER BEARING CUP Fig 137 Low Reverse Band Anchor Pin LOW REVERSE BAND ANCHO...

Страница 1530: ...sembly SPECIAL TOOL L 4512 SPECIAL TOOL L 4437 SPECIAL TOOL C 3752 Fig 141 Remove or Install Transfer Shaft and Bearing Retainer Assembly Using Tool L 4512 OUTPUT SHAFT GEAR O RING SPECIAL TOOL L 4512 BEARING RETAINER ASSEM BLY TRANSFER SHAFT Fig 142 Transfer Shaft and Bearing Retainer O RING TRANSFER SHAFT BEARING CONE TRANSFER SHAFT BEARING RETAINER Fig 143 Remove Transfer Shaft Bearing Cone TOO...

Страница 1531: ...roper shim thickness Fig 144 Install Transfer Shaft Bearing Cone PRESS SPECIAL TOOL L 4411 BEARING CONE TRANSFER SHAFT Fig 145 Remove Transfer Shaft Bearing Cup SPECIAL TOOL L 4518 TRANSFER SHAFT BEAR ING RETAINER 88O RING BEARING CUP Fig 146 Install Transfer Shaft Bearing Cup PRESS HANDLE C 4171 SPECIAL TOOL L 4520 TRANSFER SHAFT BEARING RETAINER O RING Fig 147 Tighten Transfer Shaft Gear Retaini...

Страница 1532: ...r retaining nut 5 Tighten retaining bolts to 23 N m 200 in lbs 6 Bend tabs of strap up against flats of retain ing bolts ASSEMBLY To install transfer shaft reverse the above proce dure PARKING PAWL DISASSEMBLY Fig 148 Checking Transfer Shaft End Play SPECIAL TOOL L 4432 AND C 4658 TRANSFER SHAFT GEAR STEEL BALL USE GREASE TO HOLD IN PLACE DIAL INDICA TOR SCREW 2 Fig 149 Parking Sprag Rod Support P...

Страница 1533: ...e output gear and prevent the stirrup retaining bolts from backing out REMOVAL 1 Using a punch bend tabs on strap flat against output gear Fig 153 2 Remove bolts holding retaining strap to stirrup Fig 154 3 Remove strap from output gear and stirrup Fig 155 4 Remove stirrup from output gear Fig 156 Fig 157 Fig 152 Stirrup and Retaining Strap Assembly STRAP RETAINING BOLTS 2 OUTPUT GEAR STIRRUP Fig ...

Страница 1534: ...t Gear SPECIAL BOLTS L 4407 6 OUTPUT SHAFT GEAR SPECIAL TOOL L 4407 Fig 160 Output Shaft Gear and Select Shim BEARING CUP SHIM SELECT BEARING CONE OUTPUT SHAFT GEAR OUTPUT SHAFT Fig 161 Remove Output Shaft Gear Bearing Cone SPECIAL TOOL L 4406 1 WITH ADAPTERS L 4406 2 OUTPUT SHAFT GEAR Fig 162 Remove Output Shaft and Rear Annulus Gear Assembly BEARING CUP REAR ANNULUS GEAR OUTPUT SHAFT PL TRANSAXL...

Страница 1535: ...ft Gear Bearing Cup OUTPUT SHAFT GEAR BEARING CUP SPECIAL TOOL L 4518 Fig 166 Remove Rear Planetary Annulus Gear Bearing Cup REAR PLANETARY ANNULUS GEAR BEARING CUP SPECIAL TOOL L 4518 Fig 167 Install Output Shaft Gear Bearing Cone PRESS HANDLE C 4171 SPECIAL TOOL L 4408 OUTPUT SHAFT GEAR BEARING CONE Fig 168 Install Rear Planetary Annulus Gear Bearing Cone ARBOR PRESS RAM SPECIAL TOOL C 4637 REAR...

Страница 1536: ...tput shaft bearing turning torque using an inch pound torque wrench If turning torque is 3 to 8 inch pounds the proper shim has been installed Fig 169 Install Output Shaft into Rear Planetary Annulus Gear Fig 170 Install Output Shaft Gear Bearing Cup Fig 171 Install Rear Planetary Annulus Gear Bearing Cup SPECIAL TOOL L 4429 3 Fig 172 Install Output Shaft Assembly Fig 173 Output Shaft and Select S...

Страница 1537: ...wise against the flats of the output gear retaining nut Fig 179 Fig 175 Holding Output Shaft Gear OUTPUT SHAFT SCREW 2 SPECIAL TOOL L 4434 AND C 4658 WASHER NUT Fig 176 Tighten Output Shaft Retaining Nut to 271 N m 200 ft lbs OUTPUT SHAFT GEAR SPECIAL TOOL L 4434 AND C 4658 SCREW 2 Fig 177 Checking Output Shaft End Play SPECIAL TOOL L 4432 AND C 4658 SCREW 2 OUTPUT SHAFT GEAR STEEL BALL GREASE IN ...

Страница 1538: ...AP OUTPUT GEAR STIRRUP Fig 181 Remove Extension Seal EXTENSION HOUSING SMALL CHISEL HAMMER OIL SEAL Fig 182 Install New Seal into Extension SPECIAL TOOL L 4520 INVERTED HANDLE C 4171 HAMMER EXTENSION HOUS ING Fig 183 Differential Cover Bolts DIFFERENTIAL COVER DIFFERENTIAL COVER BOLT Fig 184 Remove or Install Differential Cover GOVERNOR PRESSURE PLUG DIFFERENTIAL COVER 1 8 INCH BEAD OF R T V SEALA...

Страница 1539: ...al SPECIAL TOOL L 4520 SPECIAL TOOL C 4171 Fig 187 Differential Bearing Retainer Bolts DIFFERENTIAL BEARING RETAINER DIFFERENTIAL BEARING RETAINER BOLTS 6 Fig 188 Remove or Install Bearing Retainer GOVERNOR PRESSURE PLUG DIFFERENTIAL BEARING RETAINER SPECIAL TOOL L 4435 Fig 189 Differential Bearing Retainer Typical DIFFERENTIAL BEARING CUP DIFFERENTIAL DIFFERENTIAL BEARING RETAINER Fig 190 Extensi...

Страница 1540: ...2 Differential and Extension EXTENSION HOUSING O RING DIFFERENTIAL ASSEMBLY Fig 193 Remove Differential Bearing Cone Extension Housing Side SPECIAL TOOL C 293 SPECIAL TOOL C 293 36 SPECIAL TOOL C 293 3 Fig 194 Position Bearing Cone Onto Differential Fig 195 Install Differential Bearing Cone Fig 196 Position Button and Collets Onto Differential and Bearing Ring Gear Side SPECIAL TOOL L 4539 2 SPECI...

Страница 1541: ...N Side gear end play must be BETWEEN 0 001 to 0 013 inch Fig 197 Position Tool 5048 Over Button and Collets at Differential Bearing SPECIAL TO0L 5048 DIFFERENTIAL SPECIAL TOOL 5048 4 Fig 198 Remove Differential Bearing Cone SPECIAL TOOL 5048 RING GEAR Fig 199 Checking Side Gear End Play SPECIAL TOOL C 4996 NOTE POSI TION DIAL INDICATOR SET DIFFERENTIAL ASSEMBLY SIDE GEAR MOVE SIDE GEAR UP AND DOWN...

Страница 1542: ... shaft it should be replaced Do not attempt to straighten bent levers Inspect all mating surfaces for burrs nicks and scratches Minor blemishes may be removed with cro cus cloth using only a very light pressure Using a straightedge inspect all mating surfaces for warpage or distortion Slight distortion may be corrected using a surface plate Be sure all metering holes in steel plate are open Using ...

Страница 1543: ...up until it seats against the plastic housing NOTE If the collar will not rotate to the fully detented lock position rotate the collar back to its initial unlocked position Position the ATX in the gated PARK position Apply a slight load to the shift lever fore or aft in vehicle while simultaneously rotating the collar upward to the LOCK position The collar must seat against the plastic housing to ...

Страница 1544: ...l and remove bezel and indicator lamp Fig 208 5 Reinstall the gearshift knob 6 Place shifter in PARK 7 Turn ignition switch to the LOCK or ACCES SORY position If cable has lost its adjustment man ually position cable to get key into LOCK or ACCESSORY position Grasp slug on interlock cable with needle nose pliers and pull back on cable This will allow the ignition switch to be turned to the LOCK or...

Страница 1545: ...throttle lever cam touching tool and throttle valve bottomed Be sure adjustment is made with spring fully com pressed and valve bottomed in the valve body BEARING ADJUSTMENT PROCEDURES 1 Take extreme care when removing and install ing bearing cups and cones Use only an arbor press for installation as a hammer may not properly align the bearing cup or cone Burrs or nicks on the bearing seat will gi...

Страница 1546: ...FERENTIAL BEARING 1 Position the transaxle assembly vertically on the support stand differential bearing retainer side up 2 Install Tool L 4436A into the differential and onto the pinion mate shaft 3 Rotate the differential at least one full revolu tion to ensure the tapered roller bearings are fully seated 4 Using Tool L 4436A and an inch pound torque wrench check the turning torque of the differ...

Страница 1547: ...lbs To measure bearing end play a Attach tool L 4432 to the transfer gear b Mount a steel ball with grease into the end of the transfer shaft c Push and pull the gear while rotating back and forth to insure seating of the bearing rollers d Using a dial indicator measure transfer shaft end play e Refer to the Transfer Bearing Shim Chart for the required shim combination to obtain the proper bearing...

Страница 1548: ...TRANSFER BEARING SHIM CHART End Play with 2 29 mm and 1 39 mm gauging shims installed Required Shim Com bination Total Thickness mm inch mm mm inch PL TRANSAXLE 21 105 SCHEMATICS AND DIAGRAMS Continued ...

Страница 1549: ...SCHEMATICS AND DIAGRAMS 31TH TRANSAXLE HYDRAULIC SCHEMATIC 31TH TRANSAXLE HYDRAULIC SCHEMATIC 21 106 TRANSAXLE PL ...

Страница 1550: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC PL TRANSAXLE 21 107 SCHEMATICS AND DIAGRAMS Continued ...

Страница 1551: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC 21 108 TRANSAXLE PL SCHEMATICS AND DIAGRAMS Continued ...

Страница 1552: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC PL TRANSAXLE 21 109 SCHEMATICS AND DIAGRAMS Continued ...

Страница 1553: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC 21 110 TRANSAXLE PL SCHEMATICS AND DIAGRAMS Continued ...

Страница 1554: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC PL TRANSAXLE 21 111 SCHEMATICS AND DIAGRAMS Continued ...

Страница 1555: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC 21 112 TRANSAXLE PL SCHEMATICS AND DIAGRAMS Continued ...

Страница 1556: ...31TH TRANSAXLE HYDRAULIC SCHEMATIC PL TRANSAXLE 21 113 SCHEMATICS AND DIAGRAMS Continued ...

Страница 1557: ...ter Inch Front Clutch Non Adjustable Measured from Reaction Plate to Farthest Wave 4 Disc 1 27 2 79 050 110 Rear Clutch 4 Disc Adjustable 4 Disc 71 1 10 028 043 Selective Snap Rings 5 1 22 1 27 048 050 1 52 1 57 060 062 1 73 1 78 068 070 1 88 1 93 074 076 2 21 2 26 087 089 Band Adjustment Kickdown Backed off from 8 N m 72 in lbs 2 1 4 Turns Low Reverse Backed off from 5 N m 41 in lbs 3 1 2 Turns T...

Страница 1558: ...CONVERSION CHART INCHES TO MILLIMETERS inches All values in this table are exact millimeters inches PL TRANSAXLE 21 115 SPECIFICATIONS Continued ...

Страница 1559: ...trap Bolts 23 N m 17 ft lbs Output Shaft Nut 271 N m 200 ft lbs Park Neutral Switch 34 N m 25 ft lbs Pressure Check Plug 5 N m 45 in lbs Pump To Case Bolts 31 N m 275 in lbs Reaction Shaft Assembly Bolt 28 N m 250 in lbs Rear Cover To Case Screw 19 N m 165 in lbs Reverse Band Adj Lock Nut 14 N m 125 in lbs Reverse Band Shaft Plug 7 N m 60 in lbs Ring Gear Screw 95 N m 70 ft lbs Speedo To Ext Hous ...

Страница 1560: ...637 Pressure Gauge Low C 3292 Pressure Gauge High C 3293SP Dial Indicator C 3339 Spring Compressor C 3575 A Band Adjusting Adapter Oil Pump Puller C 3752 Seal Puller C 3981B PL TRANSAXLE 21 117 SPECIAL TOOLS Continued ...

Страница 1561: ...rsal Handle C 4171 Seal Installer 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 21 118 TRANSAXLE PL SPECIAL TOOLS Continued ...

Страница 1562: ...er Jaws L 4406 2 Adapter L 4406 3 Gear Puller L 4407A Puller L 4407 6 Bearing Installer L 4408 Bearing Installer L 4410 Bearing Installer L 4411 Installer Adapter L 4429 3 PL TRANSAXLE 21 119 SPECIAL TOOLS Continued ...

Страница 1563: ...r Removing Plate L 4434 Bearing Puller L 4435 Differential Tool L 4436A Housing Remover Adapter L 4437 Starter Nut L 4439 Transfer Shaft Remover Installer L 4512 Bearing Cup Remover L 4517 21 120 TRANSAXLE PL SPECIAL TOOLS Continued ...

Страница 1564: ...L 4518 Installer L 4520 Bearing Splitter P 334 Bearing Cone Remover 5048 Bearing Installer 5052 Bearing Cup Remover 6062 A Bearing Installer 6536 A Cooling System Tester 7700 PL TRANSAXLE 21 121 SPECIAL TOOLS Continued ...

Страница 1565: ...Seal Remover 7794 a 21 122 TRANSAXLE PL SPECIAL TOOLS Continued ...

Страница 1566: ...les have a torque capacity of 184 N m The gear ratios of each transaxle are shown in the following chart ENGINE 2 0 SOHC and DOHC 2 0 SOHC RIGHT HAND DRIVE ONLY GEAR 1st 3 54 3 54 2nd 2 13 2 13 3rd 1 36 1 36 4th 1 03 1 03 5th 0 72 0 72 FINAL DRIVE 3 55 3 55 REVERSE BRAKE NO NO CLUTCH RELEASE SYSTEM CABLE HYDRAULIC PL TRANSAXLE 21 1 ...

Страница 1567: ......

Страница 1568: ...les have a torque capacity of 184 N m The gear ratios of each transaxle are shown in the following chart ENGINE 2 0 SOHC and DOHC 2 0 SOHC RIGHT HAND DRIVE ONLY GEAR 1st 3 54 3 54 2nd 2 13 2 13 3rd 1 36 1 36 4th 1 03 1 03 5th 0 72 0 72 FINAL DRIVE 3 55 3 55 REVERSE BRAKE NO NO CLUTCH RELEASE SYSTEM CABLE HYDRAULIC PL TRANSAXLE 21 1 ...

Страница 1569: ......

Страница 1570: ...horten the life of any tire are Rapid acceleration Severe application of brakes High speed driving Taking turns at excessive speeds Striking curbs and other obstacles Radial ply tires are more prone to irregular tread wear It is important to follow the tire rotation inter val shown in the section on Tire Rotation This will help to achieve a greater tread life potential TIRE IDENTIFICATION Tire typ...

Страница 1571: ... SPARE TIRE TEMPORARY The temporary spare tire is designed for emer gency use only The original tire should be repaired and reinstalled at the first opportunity or a new tire purchased Do not exceed speeds of 50 MPH Refer to Owner s Manual for complete details TIRE INFLATION PRESSURES Under inflation causes rapid shoulder wear tire flexing and can result in tire failure Fig 2 Over inflation causes...

Страница 1572: ...eed tires must be used Consult tire manufacturer for correct inflation pressure recommendations REPLACEMENT TIRES The original equipment tires provide a proper bal ance of many characteristics such as Ride Noise Handling Durability Tread life Traction Rolling resistance Speed capability It is recommend that tires equivalent to the origi nal equipment tires be used when replacement is needed Failur...

Страница 1573: ...vehicle over a smooth road at varying speeds Note the effect of acceleration and decelera tion on noise level Differential and exhaust noises will change in intensity as speed varies while tire noise will usually remain constant LEAD CORRECTION CHART Use the following chart to diagnose a vehicle that has a complaint of a drift or lead condition The use of the chart will held to determine if the le...

Страница 1574: ...TO PREFERRED SPECIFICATIONS CAR LEADS OPPOSITE DIRECTION PROBABLE CAUSE TIRES SWITCH RIGHT FRONT TO RIGHT REAR ROAD TEST ROAD TEST OK CAR STILL LEADS ADJUST FRONT CAMBER TO COMPENSATE LEAD CORRECTED REPLACE RIGHT REAR TIRE CAR STILL LEADS REPLACE LEFT FRONT TIRE ROAD TEST OK CAR STILL LEADS CONTACT APPROPRIATE TIRE MANUFACTURER NOTE VERIFY THAT LEAD IS NOT RELATED TO STEER ING WHEEL NOT CENTERED S...

Страница 1575: ...ta tion is maintained Refer to Owner s Manual for rotation schedule REPAIRING TIRE LEAKS For proper repairing a radial tire must be removed from the wheel Repairs should only be made if the defect or puncture is in the tread area Fig 7 The tire should be replaced if the puncture is located in the sidewall Deflate tire completely before dismounting tire from the wheel Use lubrication such as a mild...

Страница 1576: ...l and Tire Runout If the high spot is NOT within 102 mm 4 0 in of either high spot draw an arrow on the tread from second high spot to first Break down the tire and remount it 90 degrees on rim in that direction Fig 10 This procedure will normally reduce the runout to an acceptable amount CLEANING AND INSPECTION CLEANING OF TIRES Remove protective coating on tires before delivery of vehicle The co...

Страница 1577: ...enger car tire or T for temporary use tire 185 Nominal width of tire in millimeters 70 Tire height to width ratio R Radial ply tire or D for bias ply tire 14 Nominal rim diameter in inches Do not install smaller than minimum size tires shown on the tire inflation placard on the vehicle 22 8 TIRES AND WHEELS PL ...

Страница 1578: ...y or of a substitute design All aluminum wheels use wheel nuts with an enlarged nose This enlarged nose is necessary to ensure proper retention of the wheels Vehicles that are equipped with bolt on wheel cov ers use large nose wheel nuts The wheel nuts used on a vehicle equipped with bolt on wheel covers are externally threaded so that the wheel covers can be attached to the wheel nuts Before inst...

Страница 1579: ...Runout should always be measured off the vehicle and on a suitable balance machine Radial run out is the difference between the high and low points on the outer edge of the tire or wheel Lateral run out is the total side to side wobble of the tire or wheel Radial run out of more than 1 5 mm 060 inch measured at the center line of the tread may cause the vehicle to shake Lateral run out of more tha...

Страница 1580: ...be noticed mostly when driving over 90 km h 55 mph on a smooth road It is recommended that a two plane dynamic bal ancer be used when a wheel and tire assembly require balancing Static should be used only when a two plane balancer is not available Off vehicle tire and wheel balancing is recom mended to be used on this vehicle NOTE If on vehicle equipment is being used to bal ance the tire wheel as...

Страница 1581: ... nuts Fig 10 attaching the wheel cover to the wheel nuts 2 Grasp the wheel cover and pull straight out ward from the wheel This will remove the wheel cover from the wheel Fig 8 Static Unbalance Balance HEAVYSPOT OF SPINDLE ADD BALANCE WEIGHTS HERE CORRECTIVE WEIGHT LOCATION TIRE OR WHEEL TRAMP OR WHEEL HOP Fig 9 Dynamic Unbalance Balance OF SPINDLE ADD BALANCE WEIGHTS HERE PER DIRECTION OF DYNAMIC...

Страница 1582: ...n the proper sequence Fig 11 Then tighten wheel nuts in the proper sequence to a torque of 135 N m 100 ft lbs Never use oil or grease on studs or nuts STEEL WHEEL REMOVE CAUTION When removing the wheel cover do not attempt pry the wheel cover off the wheel This can result in damage to the wheel cover The wheel cover is removed by un threading the wheel cover retaining nuts and pulling it off the w...

Страница 1583: ...nt just prior to this occur ring To avoid rattling of the wheel cover be sure all five retaining nuts are correctly tightened WHEEL COVER RETAINING NUT If a retaining nut for the lock on wheel is damaged it can be replaced as a separate part of the wheel cover Use the following procedure for replacing a wheel cover retaining nut REMOVE 1 If required remove the wheel cover from the wheel Refer to W...

Страница 1584: ...ng flange Fig 15 2 Push on hex of retaining nut forcing the retain ing nut flange past the 2 small retaining tabs in wheel cover SPECIFICATIONS WHEEL SPECIFICATIONS Wheel Mounting Stud Size M12 x 1 5 mm Mounting Stud Lug Nut Hex Size 19 mm Mounting Lug Nut Tightening Torque 4 and 5 Stud Wheels 109 150 N m 80 to 110 ft lbs PL TIRES AND WHEELS 22 15 REMOVAL AND INSTALLATION Continued ...

Страница 1585: ......

Страница 1586: ... system can result Do not use abrasive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning sol vents on painted or upholstered surfaces Damage to finish or color can result Do not hammer or pound on plastic trim panel when servicing interior trim Plastic panels can break Chrysler Corporation uses many different types of push in fasteners ...

Страница 1587: ... clear coat for durability PAINTED SURFACE TOUCHUP When a painted metal surface has been scratched or chipped it should be touched up as soon as possi ble to avoid corrosion For best results use Mopart Scratch Filler Primer Touch Up Paints and Clear Top Coat Refer to Introduction group of this manual for Body Code Plate information TOUCHUP PROCEDURE 1 Scrape loose paint and corrosion from inside s...

Страница 1588: ...de Satin Glow SQM 18885 26094 B9620 51534 CHA96 SQM Lapis Blue Clear Coat RC4 4935 24098 B9531 50218 CHA95 RC4 Brilliant Blue Pearl Coat PCH 4784 24073 B9452 48538 CHA94 PCH Light Iris Pearl Coat PC5 4788 24078 B9455 48782 CHA94 PC5 Black Clear Coat DX8 9700 15214 99 35858 CHA85 DX8 90 5950 Bright White Clear Coat GW7 4037 18238 B8833 37298 CHA88 GW Herberts Standox and Spies Hecker use the Chrysl...

Страница 1589: ...ndshield to the fence is difficult to cut or clean from any surface If the moldings are set in urethane it would also be unlikely they could be salvaged Before removing the windshield check the availability of the windshield and moldings from the parts supplier REMOVAL AND INSTALLATION WINDSHIELD The urethane adhesive holding the windshield to the opening pinch weld fence can be cut using a sharp ...

Страница 1590: ...uitable work surface with two padded wood 10 cm by 10 cm by 50 cm 4 in by 4 in by 20 in blocks placed par allel 75 cm 2 5 ft apart Fig 4 WARNING DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER POOR ADHESION CAN RESULT 6 Clean inside of windshield with ammonia based glass cleaner and lint free cloth 7 Apply molding to perimeter of windshield 8 Apply ...

Страница 1591: ...ass opening in quarter panel 2 If original quarter glass is reused clean old butyl from around glass 3 Prime perimeter of quarter glass fence in quar ter panel opening with black out primer Fig 3 Center Windshield and Mark at Support Spacers A PILLAR WINDSHIELD MARKS SUPPORT SPACER COWL Fig 4 Work Surface Set up and Molding Installation WINDSHIELD AND MOULD INGS URETHANE BEAD AROUND GLASS 7mm 3 in...

Страница 1592: ...esult REAR WINDOW REMOVAL 1 Remove rear window moldings 2 Remove upper quarter trim panel 3 Disengage wire connectors from rear window defogger WARNING WEAR EYE AND HAND PROTECTION WHEN HANDLING SAFETY GLASS PERSONAL INJURY CAN RESULT CAUTION Do not damage body or trim finish when cutting out glass or applying fence primer 4 Cut the urethane around the perimeter of the rear window glass Refer to W...

Страница 1593: ... and into the openings in the floor pan cross member 4 Install and tighten front inboard bolt holding seat track to floor crossmember 5 Install and tighten front outboard bolt holding seat track to floor crossmember 6 Move seat to forward position 7 Install and tighten bolts holding rear of seat track to floor NOTE The torque specification for all front seat retaining bolts is 55 N M 40 ft lbs REA...

Страница 1594: ... seat back frame to trunk closure panel through access holes in child seat mod ule Fig 4 4 Remove bolts holding bottom of rear seat back and seat belts to floor 5 Lift seat back upward to disengage retainer hooks from trunk closure panel 6 Separate rear seat back from vehicle INSTALLATION 1 Move child restraint seat back into position in vehicle 2 Push seat back downward to engage hooks into trunk...

Страница 1595: ... from seat back INSTALLATION 1 Place child seat module in position on seat back 2 Install screws to hold bottom of child seat mod ule to seat back frame CAUTION Do not capture seat belt webbing between module and seat back frame when install ing upper screws 3 Install screws to hold top of child seat module to seat back frame from behind shoulder belts 4 Engage push in fasteners to hold upper bols...

Страница 1596: ...s attaching sunroof module to vehicle roof and support braces 3 With the aid of a helper separate sunroof mod ule from roof 4 Remove sunroof module from vehicle INSTALLATION 1 With the aid of a helper position sunroof mod ule in vehicle 2 Install fasteners holding sunroof module to vehicle roof 3 Tighten all fasteners starting from the front and working rearward and then the motor bracket 4 Adjust...

Страница 1597: ... Binding cable or linkage Faulty circuit ground Faulty power circuit to sunroof drive motor Faulty sunroof drive motor Faulty sunroof motor connector Audible whine when switch is depressed sunroof does not operate Faulty motor drive clutch Binding linkage Faulty sunroof motor connections Sunroof opens but does not close Binding linkage Faulty circuit Faulty switch Sunroof vents but does not open B...

Страница 1598: ...y to disengage wind deflector 13 from assembly INSTALLATION 1 Engage wind deflector 13 into guide 5 and mechanism 9 assembly 2 Position assembly onto module and install screws holding assembly to sunroof module 3 Engage drive cable to mechanism 4 Install front locator 7 or 8 It may ease installation to move sunroof mechanism slightly rear ward 5 Install sunroof glass panel Refer to procedure found...

Страница 1599: ...umber Component Name 1 Drive Tube Locator 8 Locator R H 2 Drive Tube L H 9 Mechanism 3 Drive Tube R H 10 Drive Motor 4 Glass Reinforcment Panel 11 Sunshade 5 Guide 12 Tray Assembly 6 Sunshade Guide 13 Wind Deflector 7 Locator L H 23 14 BODY PL REMOVAL AND INSTALLATION Continued ...

Страница 1600: ...that the corners are flush to 6 1 0 mm off the top surface of the roof panel c Tighten all glass attachment screws VENT HEIGHT 1 Cycle the sunroof module to vent position using the drive motor 2 Check glass height in tilt using the appropriate measuring tool 3 If the vent height is greater than 35 mm using switch slowly set to correct height 4 After setting correct height remove drive motor 5 With...

Страница 1601: ... CABLE 19 HOOD 19 LOCK BUTTON BELL CRANK 22 LOWER QUARTER TRIM 4 DOOR 39 PARCEL SHELF TRIM 39 QUARTER TRIM PANEL 2 DOOR 38 REAR DOOR GLASS 34 REAR DOOR INNER BELT WEATHERSTRIP 34 REAR DOOR INTERLOCK LATCH STRIKER 36 REAR DOOR LATCH STRIKER 35 REAR DOOR LATCH 35 REAR DOOR LOCK BELL CRANK 35 REAR DOOR OUTER BELT WEATHERSTRIP 35 REAR DOOR TRIM 33 REAR DOOR WINDOW REGULATOR 34 REAR SEAT BELT BUCKLE 41...

Страница 1602: ...t turns hoist the right side of the vehi cle For hoisting recommendations refer to Group 0 Lubrication and Maintenance General Information section WATER LEAK DETECTION To detect a water leak point of entry do a water test and watch for water tracks or droplets forming on the inside of the vehicle If necessary remove inte rior trim covers or panels to gain visual access to the leak area If the hose...

Страница 1603: ...te section of this group for proper proce dures ROAD TESTING WIND NOISE 1 Drive the vehicle to verify the general location of the wind noise 2 Apply 50 mm 2 in masking tape in 150 mm 6 in lengths along weatherstrips weld seams or moldings After each length is applied drive the vehi cle If noise goes away after a piece of tape is applied remove tape locate and repair defect POSSIBLE CAUSE OF WIND N...

Страница 1604: ...te the hood from the vehicle INSTALLATION 1 Place hood in position on vehicle With assis tance from a helper at the opposite side of the vehicle to support the hood install bottom bolts to hold hood to hinge finger tight 2 Install top bolts to hold hood to hinge finger tight 3 Position bolts at marks and tighten bolts The hood should be aligned to 4 mm 0 160 in gap to the front fenders and flush a...

Страница 1605: ...age hidden clips holding trim panel to door from around perimeter of trim panel Fig 7 8 Tilt trim panel outward to clear locator pins on backside of trim panel 9 Disengage trim panel from retainer channel on inner belt weatherstrip at the top of the door by lift ing and gently jiggling 10 Move trim panel away from door and disen gage clip holding door latch linkage to back of inside door handle 11...

Страница 1606: ...ass 3 Remove window regulator crank if so equipped Fig 8 4 Remove screw from inside arm rest pull cup Fig 9 5 Pull and hold inside latch release handle away from door trim 6 Remove screw from behind inside latch release handle Fig 9 7 Disengage push in fasteners holding trim to door panel around perimeter of trim panel 8 Tilt trim panel outward to clear locator pins on backside of trim panel 9 Dis...

Страница 1607: ...ge to lock but ton bell crank 5 Peel water shield away from adhesive around perimeter of inner door panel Fig 10 INSTALLATION 1 Insure that enough adhesive remains to securely retain the watershield Replace as necessary 2 Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages 3 Engage clip holding lock linkage to lock button bell crank ...

Страница 1608: ...ravel to access glass attachment bolts 5 Remove bolts holding regulator lift channel to door glass Fig 15 6 Remove bolts holding rear guide plate to door glass Fig 14 7 Separate rear guide plate from door glass 8 Lift door glass upward and out of opening at top of door Fig 16 9 Remove front guide plate from door glass Fig 12 Front Door Inner Belt Weatherstrip START THIS END FIRST INNER BELT WEATHE...

Страница 1609: ...therstrip 6 Install door trim panel and water shield WINDOW REGULATOR 2 DOOR NOTE Power and manual door glass regulators are serviced using the same procedures For power window motor service procedures refer to Group 8S Power Windows REMOVAL 1 Remove door trim panel and water shield 2 Disconnect wire connector to power window motor if so equipped 3 Remove nuts holding regulator lift channel to doo...

Страница 1610: ... are serviced using the same procedures For power window motor service procedures refer to Group 8S Power Windows REMOVAL 1 Remove door trim panel and water shield 2 Remove door glass 3 Disconnect wire connector to power window motor if so equipped 4 Remove nuts holding top of regulator to inner door panel 5 Remove nuts holding bottom of regulator to door panel Fig 22 and Fig 23 6 Loosen bolts hol...

Страница 1611: ...holding bottom of guide bar to door panel while holding jack screws Fig 24 6 Remove front vertical guide bar through speaker hole in inner door panel Fig 25 INSTALLATION Reverse the preceding operation Verify door glass alignment adjust if necessary REAR VERTICAL GUIDE BAR REMOVAL 1 Remove door trim panel and water shield 2 Remove nut holding top of rear guide bar to inner door panel 3 Using a Sna...

Страница 1612: ... handle retainer to outer door panel Fig 28 5 Separate retainer from back of door handle 6 Separate door handle from vehicle INSTALLATION 1 Position door handle into door and install retainer at back of handle 2 Install nut holding door handle retainer to outer door panel 3 Connect lock and latch rods to door latch 4 Install door trim panel and water shield DOOR LOCK CYLINDER REMOVAL 1 Remove door...

Страница 1613: ...ON Reverse the preceding operation SIDE VIEW MIRROR REMOVAL 1 Remove side view mirror cover 2 Remove door trim panel 3 Remove water shield if equipped with power mirror 4 Disengage wire connector from power mirror motor if equipped 5 Remove bolts holding mirror to stanchion Fig 32 6 Separate mirror from vehicle INSTALLATION 1 Position side view mirror on vehicle and install nuts attaching mirror t...

Страница 1614: ...N Reverse the preceding operation Using a Snap on flare nut socket FRXM10 and hex wrench adjust the jack screw at bottom of stanchion to achieve proper alignment FRONT DOOR OUTER BELT WEATHERSTRIP REMOVAL 1 Open door glass 2 Pull upward at rear end of outer belt weather strip 3 Separate outer belt weatherstrip from vehicle Fig 34 Fig 32 Side View Mirror DOOR GLASS MIRROR STANCHION DOOR Fig 33 Side...

Страница 1615: ...to door hinge 4 Install new clip holding hinge pin in upper hinge 5 Install new clip holding pin in lower hinge 6 Install bolts holding door check strap to hinge pillar 7 Engage wire connector at hinge pillar if neces sary DOOR HINGE The procedure for replacing the front and rear door hinges are the same Refer to the following procedure when servicing either hinge NOTE If both hinges on one door a...

Страница 1616: ...MOVAL 1 Using a fork type prying tool disengage push in fasteners holding weatherstrip to door Fig 38 2 Separate weatherstrip from door INSTALLATION Reverse the preceding operation ROOF RAIL WEATHERSTRIP REMOVAL 1 Using a fork tool C 4829 Disengage push in fasteners holding bottom of weatherstrip to B pillar 2 Disengage push in fasteners holding bottom of weatherstrip to A pillar Fig 39 3 Pull roo...

Страница 1617: ...ttom of applique to B pillar 3 Separate applique from body side molding tape on back of applique Fig 42 4 Disengage push in fastener holding top of applique to B pillar 5 Separate applique from vehicle INSTALLATION Reverse the preceding operation Carefully remove adhesive residue from back of applique and B pillar Install new body side molding adhesive tape on back of applique B PILLAR APPLIQUE 4 ...

Страница 1618: ...ling 8 Tilt top of trim panel away from door and dis engage clip holding latch rod to handle 9 Separate latch rod from handle 10 Separate trim panel from door INSTALLATION 1 Replace any damaged or missing push in fas teners from around perimeter of door trim panel 2 Place trim panel in position on door 3 Insert latch rod into handle and engage clip 4 Engage trim panel into retainer channel at top ...

Страница 1619: ...ough opening in top of door and into position in the window regulator 2 Install nuts holding door glass to window reg ulator lift plate 3 Raise glass and tighten window inner belt sta bilizer 4 Install inner door belt weatherstrip water shield and door trim panel 5 Operate window and check for interference Adjust glass as necessary REAR DOOR WINDOW REGULATOR REMOVAL 1 Remove door trim panel and wa...

Страница 1620: ...h to door end frame 2 Engage wire connector to power door lock motor if so equipped 3 Connect lock and latch rods to door latch 4 Install watershield and door trim panel REAR DOOR LOCK BELL CRANK REMOVAL 1 Remove door trim panel and water shield 2 Disengage clips holding lock rods to bell crank 3 Separate lock rods from bell crank 4 Rotate bell crank to align retaining tabs to slots in door panel ...

Страница 1621: ...bracket 7 Snap out side attachment covers if equipped Fig 53 8 Remove side attachment bolts holding rear of console to floor bracket if equipped 9 Remove shift lever knob if vehicle is equipped with a manual transmission 10 Lift console upward over gear selector and park brake handle 11 Separate console from vehicle INSTALLATION 1 Move floor console into position in vehicle 2 Install screws holdin...

Страница 1622: ...e paint dot position 4 Install door sill trim panel A PILLAR TRIM REMOVAL 1 Remove instrument panel top cover 2 Disengage clips holding trim to A pillar 3 Separate A pillar trim from vehicle Fig 56 INSTALLATION 1 Position A pillar trim panel to A pillar 2 Align locating pins on backside of trim panel to mating holes in A pillar 3 Push clips on trim panel into slots in A pillar 4 Install instrument...

Страница 1623: ...t cushion and back 2 Slide lower seat belt anchor cover up the web bing to expose the belt 3 Remove bolt holding lower seat belt anchor to floor 4 Separate seat belt from floor 5 Remove screw holding coat hook to top of quar ter trim panel 6 Disengage hidden clips holding quarter trim panel to inner quarter panel Fig 59 7 Separate trim from quarter panel 8 Feed seat belt webbing through access hol...

Страница 1624: ... 1 Position lower quarter trim panel to vehicle 2 Install seat belt to slot in trim panel 3 Align locating pins on backside of trim panel to mating holes in inner quarter panel 4 Press clips on trim panel into slots in inner quarter panel 5 Install rear seat back and cushion 6 Install upper quarter trim panel PARCEL SHELF TRIM REMOVAL 1 Remove upper quarter trim from one side of vehicle 2 Remove r...

Страница 1625: ... m 29 ft lbs FRONT SEAT BELT BUCKLE REMOVAL 1 Move front seat to the forward position 2 Remove bolt holding seat belt buckle to seat 3 Separate seat belt buckle from seat INSTALLATION Reverse the preceding operation FRONT SEAT BELT RETRACTOR REMOVAL 1 Remove B pillar trim 2 Remove bolt holding seat belt retractor to B pillar Fig 65 3 Separate seat belt retractor from vehicle INSTALLATION Reverse t...

Страница 1626: ...l Fig 67 6 Push seat belt bezel and buckle stab through access hole in parcel shelf 7 From in luggage compartment separate rear seat belt retractor from vehicle INSTALLATION Reverse the preceding operation CARPET REMOVAL 1 Remove front seats 2 Remove rear seat cushion 3 Remove bolts holding front seat belt lower anchors to floor Fig 68 4 Remove door sill trim covers 5 Remove cowl trim covers 6 Rem...

Страница 1627: ...ch pod retainer to roof 11 Remove push in fastener at rear of headlin ing 12 Disengage dome lamp wire connector at rear of headlining 13 Remove push in fastener holding wiring to C pillar 14 Remove headlining through door opening Fig 70 INSTALLATION 1 Position headlining in vehicle 2 Install sun visor hooks 3 Install coat hooks if vehicle is a 4 door 4 Install push in fastener at rear of headlinin...

Страница 1628: ...a helper install bolts to hold bot tom of hinge to trunk lid 3 Install bolts to hold top of hinge to trunk lid 4 Align trunk lid to achieve equal spacing on all sides and flush across gaps 5 Verify trunk lid operation and sealing 6 Connect wire connector and release cable on latch 7 Install clips to hold wire harness and cable to trunk lid TRUNK LID LIFT SPRINGS REMOVAL WARNING USE EYE AND HAND PR...

Страница 1629: ... Remove bolts holding trunk latch to trunk lid Fig 76 3 Separate trunk latch from trunk lid 4 Disconnect remote trunk latch release cable form trunk latch 5 Disengage trunk ajar switch connector from latch 6 Separate latch from vehicle INSTALLATION 1 Position latch in vehicle and engage trunk ajar switch connector to latch 2 Connect remote trunk latch release cable to trunk latch 3 Install bolts h...

Страница 1630: ...section lays over the outer sections TRUNK TRIM PANEL Removal 1 Remove fasteners holding trunk trim panel to vehicle Fig 79 2 Remove trunk trim panel from vehicle Installation 1 Position panel to deck lid over the stricker 2 Install push in fasteners 3 Position and tuck the upper flange into existing trim panel on both sides 4 Push the corners in place under seal 5 Seat the lower edges of the carp...

Страница 1631: ...he roof seam trough and position molding so both ends are covered by the glass moldings If the molding will not lay flat on the bottom of the trough trim the ends of the molding until proper fit achieved 6 Using a suitable marking pencil mark an index line across the RAP molding and the adjacent surfaces 7 Remove the RAP molding from the roof seam trough 8 Apply a 5 mm 0 2 in bead of urethane adhe...

Страница 1632: ... as necessary to gain access to adjusters 3 Using a Snap ont flare nut socket FRXM10 loosen the lower jack screw jamb nuts 4 Close door and raise glass 5 Using a suitable allen wrench rotate jack screws to achieve proper in out positioning at the top edge of the glass 6 Adjust glass so that a piece of paper can be pulled between the glass and weatherstrip with some tension 7 Tighten all fasteners ...

Страница 1633: ...linkage 3 Lift upward on outside door handle and release it 4 Tighten socket head screw on latch 5 Verify latch operation REAR DOOR GLASS ADJUSTMENT UP STOP ADJUSTMENTS 1 Remove door trim panel 2 Remove water shield as necessary to gain access to adjusters 3 Using a Snap ont flare nut socket FRXM10 loosen up stop eccentric jamb nut Fig 89 4 Using a suitable hex wrench rotate up stop eccentric to a...

Страница 1634: ...ted cleaned and lubricated During the winter season external door lock cylinders should be lubricated to assure proper operation when exposed to water and ice Prior to the application of any lubricant the parts concerned should be wiped clean to remove dust and grit If necessary a suitable solvent can be used to clean the item to be lubricated After lubricating a component any excess oil or grease...

Страница 1635: ...Latches Liftgate Prop Pivots Ash Receiver Fuel Filler Door Remote Control Latch Mecha nism Parking Brake Mechanism Sliding Seat Tracks Trunk Latch MOPART MULTI PURPOSE GREASE OR EQUIVALENT All Other Hood Mechanisms MOPART LOCK CYLINDER LUBRICANT OR EQUIVALENT Door Lock Cylinders Trunk Lock Cylinder SPECIAL TOOLS BODY REMOVER MOLDINGS C 4829 STICK TRIM C4755 23 50 BODY PL SPECIFICATIONS Continued ...

Страница 1636: ...RATOR PROBE 22 EVAPORATOR 22 EXPANSION VALVE 23 HEATER CORE 24 HEATER HOSES 24 HIGH PRESSURE CUT OUT SWITCH 24 HIGH PRESSURE RELIEF VALVE 24 LIQUID LINE 25 LOW PRESSURE CUT OFF SWITCH 25 MODE CONTROL CABLE 25 RECIRCULATION CONTROL CABLE RHD 26 RECIRCULATION DOOR ACTUATOR 26 SUCTION LINE 26 TEMPERATURE CONTROL CABLE 26 UNIT HOUSING 28 DISASSEMBLY AND ASSEMBLY AIR DISTRIBUTION MODULE RECONDITION 29 ...

Страница 1637: ... TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH AS A RESULT ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL FREEZE ALWAYS PROTECT SKIN OR DELI CATE OBJECTS FROM DIRECT CONTACT WITH REFRIGERANT R 134a SERVICE EQUIPMENT OR VEHICLE A C SYSTEM SHOULD NOT BE PRES SURE TESTED OR LEAK TESTED WITH COM PRESSED AIR SOME MIXTURES OF AIR and R 134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES ...

Страница 1638: ...viceable parts on the suction line other than the rubber O rings and expansion valve gasket If the line is found to be leaking or is dam aged it must be replaced as an assembly A C SERVICE PORT VALVE CORES The A C service port valve cores are serviceable Fig 5 and Fig 6 BLOWER MOTOR RESISTOR The blower motor resistor is located in the cowl at the base of the windshield There are two different resi...

Страница 1639: ... compartment It is normal to see con densate drainage below the vehicle If the tube is damaged it should be replaced ENGINE COOLING SYSTEM REQUIREMENTS To maintain ample temperature levels from the heating A C system the cooling system must be in proper working order Refer to Group 0 Lubrication and Maintenance or Group 7 Cooling System of this manual The use of a bug screen is not recommended Any...

Страница 1640: ...clean and dry HIGH PRESSURE CUT OUT SWITCH The high pressure cut out switch is located in the compressor manifold Fig 8 It turns off the com pressor if the system pressure exceeds 3240 kPa 470 psi LOW PRESSURE CUT OFF SWITCH The Low Pressure Cut Off Switch Fig 9 monitors the refrigerant gas pressure on the suction side of the system The low pressure cut off switch is located on the expansion valve...

Страница 1641: ...vaporator condenser and filter drier will retain a significant amount of oil refer to the Refrigerant Oil Capacities chart When a compo nent is replaced the specified amount of refrigerant oil must be added When the compressor is replaced the amount of oil that is retained in the rest of the system must be drained from the replacement com pressor When a line or component has ruptured and oil has e...

Страница 1642: ...dle speeds or battery voltage high speed CAUTION Stay clear of the blower motor and resis tor block Hot Do not operate the blower motor with the resistor block removed from the heater A C housing Refer to the Blower Motor Vibration Noise chart Fig 12 for diagnosis COMPRESSOR NOISE DIAGNOSIS Excessive noise while the A C is being used can be caused by loose mounts loose clutch or high operat ing pr...

Страница 1643: ...ED OR STALLED TEST VOLTAGE AT BOTH ENDS OF FUSE REPLACE FUSE REPLACE MOTOR VOLTAGE PRESENT NO VOLTAGE TEST CONTINUITY FUSELINK TO IGN SWITCH TO FUSE BLOCK REPAIR OPEN CIRCUIT OR BAD CONNECTION TEST BLOWER SWITCH REPLACE CONTROL NO CONTINUITY REPLACE MOTOR TEST MOTOR CONTINUITY CHECK INST PANEL GROUND CONNECTION TEST FOR BODY GROUND AT MOTOR REPAIR GROUND CIRCUIT SEE WIRING DIAGRAMS CHECK FOR BAD C...

Страница 1644: ... PRESENT NOISE GONE PROBLEM NOT IN BLOWER SYSTEM CHECK BLOWER SCROLL AREA FOREIGN MATERIAL IN FAN OR SCROLL FAN RUBBING HOUSING YES REMOVE FOREIGN MATE RIAL NO REPLACE MOTOR YES ADJUST TO CORRECT RE CHECK RE CHECK RE CHECK NOISE STILL PRESENT REPLACE MOTOR RE CHECK NOISE GONE VIBRATION CHECK MOTOR MOUNTING MOUNTING OK LOOSE TIGHTEN RE CHECK OK VIBRATION STILL PRESENT REPLACE MOTOR WHEEL RE CHECK P...

Страница 1645: ... should stabilize at 103 to 241 kPa 15 to 35 psi If not replace expansion valve 9 When expansion valve test is complete test A C overall performance Refer to the Heater and A C Performance Test in this section Remove all test equipment before returning vehicle to use EVAPORATOR PROBE TEST The work area and vehicle must be between 16 C 60 F and 32 C 90 F when testing the switch 1 Disconnect the thr...

Страница 1646: ...y and return ports at cooling system connections refer to Group 7 Cooling System 4 Plugged heater core 5 Air locked heater core 6 If coolant flow is verified and outlet tempera ture is insufficient a mechanical problem may exist POSSIBLE LOCATION OR CAUSE OF INSUFFICIENT HEAT 1 Obstructed cowl air intake 2 Obstructed heater system outlets 3 Blend air door not functioning properly TEMPERATURE CONTR...

Страница 1647: ...d to use the gauges or reclaim re cycle equipment 1 Use a manifold gauge and check the liquid line pressure 2 Attach a clamp on thermocouple P S E 66 324 0014 or 80PK 1A or equivalent to the liquid line near the filter drier 3 The vehicle must be in the following modes Automatic transaxle in park or manual tran saxle in neutral Engine at idle A C controls set to outside air Panel mode A C ON full ...

Страница 1648: ...connected to this side of the check valve vacuum should flow through the valve without restriction If not OK replace the faulty valve CONDITION POSSIBLE CAUSES CORRECTION NO FORCED AIR IN HEAT POSITION 1 Vacuum line pinched or leaking 1 Locate and repair vacuum leak or pinched line 2 Faulty heat defroster or mode door 2 Test actuators and door operation Repair as necessary 3 Faulty selector switch...

Страница 1649: ... in Hg If not there is a leak in the Actuator Feed line 9 If there is no leak in the Supply line Control or the Actuator Feed line the leak must be in the Actuator itself Connect the Vacuum hose from the Vacuum Test Gauge directly to the Actuator to verify the leak The Actuator vacuum port is accessible behind and above the Glove Box LOCATING PINCHED VACUUM LINES The operation of the Circulation d...

Страница 1650: ...efer to capacities Refer to the instructions provided with the equipment being used 3 Verify engine is shut off Open the suction and discharge valves Open the charge valve to allow the refrigerant to flow into the system When the trans fer of refrigerant has stopped close the suction and discharge valve 4 If all of the charge did not transfer from the dispensing device put vehicle controls into th...

Страница 1651: ...formance Never add any other type of refrigerant to a system designed to use R 134a refrigerant System failure will occur The high pressure service port is located on the ffilter drier The low pressure service port is located on the suction line near the strut tower When servicing a system it is required that an air conditioning charging recovery recycling machine be used Fig 19 Contact an automot...

Страница 1652: ...s fully charged with R 134a This is accomplished by performing a system Charge Level Check or Fill If while performing this test A C liquid line pressure is less than 345 kPa 50 psi proceed to Empty Refrigerant System Leak Test If liquid line pressure is greater than 345 kPa 50 psi proceed to low refrigerant level leak test If the refrigerant system is empty or low in refrigerant charge a leak at ...

Страница 1653: ...t fully seated can lead to damage to the valve during evacuation and charge This can result in system refrigerant dis charge while uncoupling the charge adapters 2 Install valve core into port 3 Evacuate and charge the A C system 4 Install the valve caps BLOWER MOTOR AND WHEEL ASSEMBLY The blower motor is located on the bottom right side of the unit housing The blower motor can be removed from the...

Страница 1654: ...if removing the com pressor clutch coil assembly engine cylinder head or alternator WARNING REFRIGERANT PRESSURES REMAIN HIGH EVEN THOUGH THE ENGINE MAY BE TURNED OFF DO NOT TWIST OR KINK THE REFRIGERANT LINES WHEN REMOVING A FULLY CHARGED COMPRESSOR SAFETY GLASSES MUST BE WORN 1 Disconnect battery negative cable 2 Loosen and remove drive belts refer to Group 7 Engine Cooling 3 Using a R 134a refr...

Страница 1655: ... or excessive leak age of grease Replace bearing as required INSTALLATION 1 Align pin in back of field coil with hole in com pressor end housing and position field coil into place Make sure that lead wires are properly routed and fasten the coil wire bracket ground retaining screw NOTE The bevel side of the snap ring must be out ward 2 Install field coil retaining snap ring with Snap Ring Pliers P...

Страница 1656: ... procedure set the system to the A C mode engine rpm at 1500 2000 and high blower speed This procedure burnishing will seat the opposing friction surfaces and provide a higher clutch torque capability CONDENSATION DRAIN TUBE REMOVAL 1 Raise vehicle 2 Locate rubber drain tube on right side of dash panel Fig 28 3 Squeeze clamp and remove drain tube INSTALLATION To install reverse the preceding opera...

Страница 1657: ...ng does not separate and is only one unit 1 Remove the clips and screws that hold the Unit Housing to the Evaporator Blower Module Then sep arate the two units 2 Remove the evaporator to dash panel foam seal Fig 30 3 Disconnect fin sensing switch from harness 4 Remove upper to lower case retaining clips and screws 5 Separate the case halves Fig 31 6 Lift the evaporator out of the module Fig 32 ASS...

Страница 1658: ...et on the evaporator sealing plate 2 Carefully hold the expansion valve to the evap orator sealing plate so not to scratch the sealing sur face Install two screws and tighten to 11 6 3 N m 100 6 30 in lbs 3 Remove and replace the aluminum gasket on the refrigerant line sealing plate assembly 4 Carefully hold the refrigerant line sealing plate assembly to the expansion valve Install bolt and tighte...

Страница 1659: ...parate relief valve from the vehicle Fig 35 INSTALLATION For installation reverse the above procedures using a new O ring seal Evacuate and charge the refrigerant system HEATER CORE Refer to Air Distribution Recondition of this section for heater core removal procedure HEATER HOSES CAUTION When removing hoses from heater core inlet or outlet nipples DO NOT exert excess pres sure The heater core ma...

Страница 1660: ...procedures Evacuate and charge the system MODE CONTROL CABLE The Mode Control Cable can be removed and installed without having to remove the instrument panel from the vehicle REMOVAL 1 Remove instrument panel upper cowl panel 2 Remove right side upper instrument panel bezel Fig 38 3 Remove center vent duct Fig 39 4 Remove upper defrost duct Fig 40 5 Remove inner defrost duct Fig 41 6 Disconnect c...

Страница 1661: ...ect actuator from recirc door link 5 Remove recirculation door actuator from vehicle INSTALLATION For installation reverse the above procedures SUCTION LINE WARNING THE REFRIGERANT MUST BE RECOV ERED BEFORE SERVICING ANY PART OF THE REFRIGERANT SYSTEMS REMOVAL 1 Using a R 134a refrigerant recovery machine remove the refrigerant from A C system 2 Remove retaining bolt at expansion valve Fig 43 3 Re...

Страница 1662: ...anel Defrost Duct UPPER DEFROSTER DUCT RETAINING TAB LOWER DEFROSTER DUCT DUCT SEAL TABS FOR ATTACHMENT TO HEATER A C HOUSING UPPER HEATER A C UNIT PL HEATING AND AIR CONDITIONING 24 27 REMOVAL AND INSTALLATION Continued ...

Страница 1663: ... from evaporator Place a piece of tape over open evaporator fitting to pre vent moisture and or dirt from entering the evapora tor 6 Remove rubber drain tube extension from con densation drain tube 7 Remove three retaining nuts located in the engine compartment on the dash panel Fig 44 8 Remove the right side retaining screw Fig 45 9 Remove remaining nut located on dash panel stud 10 Disconnect th...

Страница 1664: ...ts Fig 46 2 Remove the panel opening foam seal demister opening foam seal and heater core tube foam seals from unit 3 Remove the retaining clips and screws that hold the upper and lower housings together Fig 47 4 Place the unit in the upside down position Then separate the two halves of the module Fig 48 Fig 45 Retaining Screws RIGHT SIDE RETAINING SCREW EVAPORATOR PROBE GROMMET SCREW BOSSES DASH ...

Страница 1665: ...Heat Defrost link pivot screw Fig 54 11 Lift the Heat Defrost link and the door as an assembly Then separate the link from the door ASSEMBLE To reassemble reverse the above procedures Fig 49 Heater Core Removal HEATER CORE CASE Fig 50 Temperature Door Removal TEMPERATURE DOOR MODE DOOR DEFROST DOOR Fig 51 Mode Door Removal Fig 52 Cam Screw Removal CAM SCREW HEAT DEFROST DOOR CAM MODE DOOR LEVER Fi...

Страница 1666: ...e recirc knob completely counterclock wise 4 While holding the knob in the counterclockwise position pull on the black casing of the recirc cable This will take up any free play in the cable and index the recirc door to the recirc knob TEMPERATURE CONTROL CABLE 1 Attach cable to actuator arm on temperature door and clip black casing against the stop 2 Attach other end of cable to instrument panel ...

Страница 1667: ......

Страница 1668: ...ge of engine RPM engine temperature and or input voltage to the PCM The PCM might not store a DTC for a monitored circuit even though a malfunction has occurred This may happen because one of the DTC criteria for the circuit has not been met For example assume the diagnostic trouble code criteria requires the PCM to monitor the circuit only when the engine operates between 750 and 2000 RPM Suppose...

Страница 1669: ...t internally recognize The PCM attempts to activate these outputs and allow an observer to verify proper operation Most of the tests provide an audible or visual indication of device operation click of relay contacts fuel spray etc Except for intermittent conditions if a device functions properly during testing assume the device its associated wiring and driver circuit work cor rectly DIAGNOSTIC T...

Страница 1670: ...oltage sense input below target charging during engine operation Also no significant change detected in battery voltage during active test of generator output circuit 06 46 Charging System Voltage Too High Battery voltage sense input above target charging voltage during engine operation 0A 42 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the auto shutdown relay circu...

Страница 1671: ...rich or lean condition detected from the oxygen sensor 21 17 Engine Is Cold Too Long Engine did not reach operating temperature within acceptable limits 23 15 P0500 No Vehicle Speed Sensor Signal No vehicle speed sensor signal detected during road load conditions 24 14 P0107 MAP Sensor Voltage Too Low MAP sensor input below minimum acceptable voltage or 25 P0108 MAP Sensor Voltage Too High MAP sen...

Страница 1672: ...ications PCM Internal fault condition detected 52 77 S C Power Relay Ckt 65 42 Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel pump relay control circuit 66 21 P0133 Right Bank Upstream O2S Slow Response Oxygen sensor response slower than minimum required switching frequency or 67 P0135 Right Rear or just Upstream O2S Heater Failure Upstream oxygen sensor heating ...

Страница 1673: ... Not Reached Actual idle speed does not equal target idle speed 91 25 P1299 Vacuum Leak Found IAC Fully Seated MAP sensor signal does not correlate to throttle position sensor signal Possible vacuum leak 92 71 P1496 5 Volt Supply Output Too Low 5 volt output from regulator does not meet minimum requirement 94 37 P0740 Torq Conv Clu No RPM Drop At Lockup Relationship between engine speed and vehicl...

Страница 1674: ... monitors that check fuel emission engine and ignition perfor mance These monitors use information from various sensor circuits to indicate the overall operation of the fuel engine ignition and emission systems and thus the emissions performance of the vehicle The fuel engine ignition and emission systems monitors do not indicate a specific component prob lem They do indicate that there is an impl...

Страница 1675: ...r by iso lating the effect of the heater element on the O2S output voltage from the other effects DTC 32 HEX 2E EGR MONITOR The Powertrain Control Module PCM performs an on board diagnostic check of the EGR system The EGR system consists of two main components a vacuum solenoid and a vacuum operated valve with a back pressure transducer The EGR monitor is used to test whether the EGR system is ope...

Страница 1676: ...fficiency deteriorates and exhaust emissions increase to over the legal limit the MIL check engine lamp will be illuminated DTC 31 HEX A0 A1 B7 and B8 LEAK DETECTION PUMP MONITOR The leak detection assembly incorporates two pri mary functions it must detect a leak in the evapora tive system and seal the evaporative system so the leak detection test can be run The primary components within the asse...

Страница 1677: ...st important that after a repair has been made all DTC s be erased and the repair veri fied COMPONENT MONITORS There are several components that will affect vehi cle emissions if they malfunction If one of these com ponents malfunctions the Malfunction Indicator Lamp Check Engine will illuminate Some of the component monitors are checking for proper operation of the part Electrically operated comp...

Страница 1678: ... trouble code and cause a high idle condition PCM SYSTEM GROUND The PCM cannot determine a poor system ground However one or more diagnostic trouble codes may be generated as a result of this condition The mod ule should be mounted to the body at all times also during diagnostic PCM CONNECTOR ENGAGEMENT The PCM may not be able to determine spread or damaged connector pins However it might store di...

Страница 1679: ...el tank vent valve hoses should the vehicle rollover All vehicles pass a 360 rollover The pressure relief valve opens at a certain pressure When fuel tank pressure increases above the calibrated pressure the valve opens to release fuel tank vapors pressure The charcoal filled evaporative canister stores the vapors For pressure relief rollover valve service refer to the Fuel Tank section of Group 1...

Страница 1680: ...t the full travel posi tion The vent seal will remain closed while the pump is cycling This is due to the operation of the 3 port solenoid which prevents the diaphragm assem bly from reaching full travel After the brief initial ization period the solenoid is de energized allowing atmospheric pressure to enter the pump cavity This permits the spring to drive the diaphragm which forces air out of th...

Страница 1681: ...rs from flowing through the valve Fig 7 When the engine is at idle or cruising high mani fold vacuum is present At these times manifold vac uum is able to completely compress the spring and pull the plunger to the top of the valve Fig 8 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...

Страница 1682: ...FORMING ANY TEST OR ADJUSTMENT WITH THE ENGINE OPERATING With the engine idling remove the PCV valve from its attaching point If the valve is operating properly a hissing noise will be heard and a strong vacuum felt when placing a finger over the valve inlet Fig 10 With the engine off shake the valve The valve should rattle when shaken Replace the valve if it does not operate properly Do not attem...

Страница 1683: ...ENGINE VACUUM SCHEMATIC SOHC 25 16 EMISSION CONTROL SYSTEMS PL DIAGNOSIS AND TESTING Continued ...

Страница 1684: ...ENGINE VACUUM SCHEMATIC DOHC PL EMISSION CONTROL SYSTEMS 25 17 DIAGNOSIS AND TESTING Continued ...

Страница 1685: ... Install pump to bracket and tighten bolts to 1 2 N m 10 6 in lbs 2 Install pump and bracket assembly to body and tighten bolts to 10 N m 90 in lbs 3 Install EVAP canister to bracket and tighten nutts to 5 6 N m 50 in lbs 4 Install electrical connetor to pump and push locking tab to lock 5 Before installing hoses to LDP make sure they are not cracked or split If a hose leaks it will cause the Chec...

Страница 1686: ...tube EGR valve Electronic EGR Transducer EET Connecting hoses The electronic EGR transducer contains an electri cally operated solenoid and a back pressure trans ducer Fig 2 The Powertrain Control Module PCM operates the solenoid The PCM determines when to energize the solenoid Exhaust system back pressure controls the transducer When the PCM energizes the solenoid vacuum does not reach the transd...

Страница 1687: ... APPLY PARKING BRAKE AND OR BLOCK WHEELS BEFORE TESTING THE EGR SYS TEM 1 Check the condition of all EGR system hoses and tubes for leaks cracks kinks and hardening of rubber hoses Repair and correct these conditions before performing any tests 2 Be sure the hoses at both the EGR valve and EGR valve control are connected to the proper fit tings Fig 3 3 Be sure the electrical connector is firmly co...

Страница 1688: ...If the valve shows evidence of heavy carbon build up near the base replace it EGR VALVE LEAKAGE TEST This is not to be used as a complete test of the EGR system If the engine will not idle dies out on idle or idle is rough or slow the poppet valve Fig 3 at the base of the EGR valve may be leaking in the closed posi tion 1 The engine should be off for the following test 2 Disconnect the rubber hose...

Страница 1689: ...ecessary before proceeding to next step 11 Reconnect the rubber hose to the vacuum inlet fitting Fig 3 on the EGR valve 12 Disconnect the rubber hose at the vacuum outlet fitting Fig 3 on the EGR valve 13 Connect a vacuum gauge to this fitting 14 Disconnect the electrical connector Fig 3 at the valve control This will simulate an open circuit no ground from the PCM at the valve 15 Start the engine...

Страница 1690: ...ws to 22 N m 200 in lbs torque 5 Install air inlet duct 6 Connect vacuum supply tube to solenoid 7 Attach electrical connector to solenoid 8 Install EGR transducer onto air inlet duct EGR TUBE The EGR tube attaches to the intake manifold ple num below the throttle body and EGR valve REMOVAL 1 Remove screws attaching EGR tube to intake manifold Fig 6 2 Remove EGR tube to EGR valve screws 3 Remove E...

Страница 1691: ......

Страница 1692: ...A Pillar The VIN consists of 17 charac ters in a combination of letters and numbers that provide specific information about the vehicle Fig 1 Refer to VIN Code Decoding Chart To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden tification Number The check digit is used by the manufacturer and governmen...

Страница 1693: ...N Refer to Vehicle Identification Number VIN paragraph for proper breakdown of VIN code BODY CODE EMBOSS LINE 2 DIGITS 1 3 Paint Code Refer to Group 23 Body for paint information DIGITS 4 7 Trim Code Refer to Parts Catalog for more information DIGITS 5 10 Open DIGITS 11 14 Vehicle Order Number VIN CODE DECODING POSITION INTERPRETATION CODE DESCRIPTION 1 Country of Origin 1 United states 3 Mexico 2...

Страница 1694: ...39 6 in 36 5 in 42 5 in 35 1 in 52 0 in 54 7 in 50 3 in 53 9 in EXTERIOR DIMENSIONS CAR BODY STYLE WHEEL BASE FRONT TRACK REAR TRACK OVERALL LENGTH OVERALL WIDTH OVERALL HEIGHT MM IN MM IN MM IN MM IN MM IN MM IN PL PL 42 2642 104 1458 57 4 1458 57 4 4364 171 8 1708 67 2 1395 54 9 PL PL 22 2642 104 1458 57 4 1458 57 4 4364 171 8 1711 67 4 1395 54 9 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS HIGH BE...

Страница 1695: ... line marks on the top of each bolt head The actual bolt strength grade corresponds to the number of line marks plus 2 The most commonly used metric bolt strength classes are 9 8 and 12 9 The metric strength class identification number is imprinted on the head of the bolt The higher the class number the greater the bolt strength Some metric nuts are imprinted with a single digit strength class on ...

Страница 1696: ...FASTENER IDENTIFICATION PL INTRODUCTION 5 GENERAL INFORMATION Continued ...

Страница 1697: ...rk Hexagon flange bolt w washer hexagon bolt No mark Grooved Hexagon head bolt Two protruding lines Hexagon flange bolt w washer hexagon bolt Two protruding lines Welded bolt Hexagon head bolt Three protrud ing lines Hexagon head bolt Four protruding lines 6 INTRODUCTION PL GENERAL INFORMATION Continued ...

Страница 1698: ...ND EQUIVALENT VALUES Multiply By To Get Multiply By To Get in lbs x 0 11298 Newton Meters N m N m x 8 851 in lbs ft lbs x 1 3558 Newton Meters N m N m x 0 7376 ft lbs Inches Hg 60 F x 3 377 Kilopascals kPa kPa x 0 2961 Inches Hg psi x 6 895 Kilopascals kPa kPa x 0 145 psi Inches x 25 4 Millimeters mm mm x 0 03937 Inches Feet x 0 3048 Meters M M x 3 281 Feet Yards x 0 9144 Meters M M x 1 0936 Yards...

Страница 1699: ...88 11 8 104 4433 15 8 139 8478 24 212 4270 40 4 5193 80 9 0386 120 13 5580 160 18 0773 200 22 5966 4 35 4045 8 70 8090 12 106 2135 16 141 6180 25 221 2781 ft lbs to N m N m to ft lbs ft lb N m ft lb N m ft lb N m ft lb N m ft lb N m N m ft lb N m ft lb N m ft lb N m ft lb N m ft lb 1 1 3558 21 28 4722 41 55 5885 61 82 7049 81 109 8212 1 7376 21 15 9888 41 30 2400 61 44 9913 81 59 7425 2 2 7116 22 ...

Страница 1700: ...69 02717 89 03504 10 2 540 30 7 620 50 12 700 70 17 780 90 22 860 10 00394 30 01181 50 01969 70 02756 90 03543 11 2 794 31 7 874 51 12 954 71 18 034 91 23 114 11 00433 31 01220 51 02008 71 02795 91 03583 12 3 048 32 8 128 52 13 208 72 18 288 92 23 368 12 00472 32 01260 52 02047 72 02835 92 03622 13 3 302 33 8 382 53 13 462 73 18 542 93 23 622 13 00512 33 01299 53 02087 73 02874 93 03661 14 3 556 3...

Страница 1701: ... 25 59 600 43 65 670 48 14 1 5 91 930 67 100 1 050 76 16 1 5 140 1 400 101 6 1 8 80 69 in lbf 9 90 78 in lbf 8 1 25 19 195 14 21 210 15 6T 10 1 25 39 400 29 44 440 32 12 1 25 71 730 53 80 810 59 14 1 5 110 1 100 80 125 1 250 90 16 1 5 170 1 750 127 6 1 10 5 110 8 12 120 9 8 1 25 25 260 19 28 290 21 7T 10 1 25 52 530 38 58 590 43 12 1 25 95 970 70 105 1 050 76 14 1 5 145 1 500 108 165 1 700 123 16 ...

Страница 1702: ...hicle Refer to the VIN Decoding Information Table to interpret VIN code VIN CHECK DIGIT To protect the consumer from theft and possible fraud the manufacturer is required to include a check Digit at the ninth position of the VIN The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation The formula to use the check digit...

Страница 1703: ...ERPRETATION CODE DESCRIPTION 1 Country of origin 1 United States 2 Make C Chrysler 3 Vehicle Type 3 Passenger Car 4 Passenger Safety E Active Restraints Driver and Passenger Airbags 5 Car Line S Neon 6 Series M DD5 5 Speed Manual Transmission A 3 Speed Automatic Transmission 7 Body Style 7 4 Door Pillared Hardtop 8 Engine C 2 0L 4 Cyl 16V SOHC 9 Check Digit See explanation in this section 10 Model...

Страница 1704: ...hicle Refer to the VIN Decoding Information Table to interpret VIN code VIN CHECK DIGIT To protect the consumer from theft and possible fraud the manufacturer is required to include a check Digit at the ninth position of the VIN The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documentation The formula to use the check digit...

Страница 1705: ...ERPRETATION CODE DESCRIPTION 1 Country of origin 1 United States 2 Make C Chrysler 3 Vehicle Type 3 Passenger Car 4 Passenger Safety E Active Restraints Driver and Passenger Airbags 5 Car Line S Neon 6 Series M DD5 5 Speed Manual Transmission A 3 Speed Automatic Transmission 7 Body Style 7 4 Door Pillared Hardtop 8 Engine C 2 0L 4 Cyl 16V SOHC 9 Check Digit See explanation in this section 10 Model...

Страница 1706: ... Vehicle Speed Control System 8J Turn Signal and Flashers 8K Windshield Wipers and Washers 8L Lamps 8M Restraint System 8N Electrically Heated Systems 8P Power Door Locks 8S Power Windows 8T Power Mirrors 8U Chime Warning Reminder System 8W Wiring Diagrams 9 Engines 11 Exhaust System and Intake Manifold 13 Frame and Bumpers 14 Fuel System 19 Steering 21 Transaxle 22 Tires and Wheels 23 Body 24 Hea...

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