Dodge R1500 1999 Скачать руководство пользователя страница 374

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Removal (AX15 & NV1500)

1) Shift gear selector into 1st or 3rd gear. Raise and

support vehicle. Disconnect necessary exhaust system components.

Remove "Y" pipe and position remaining pipes for working clearance.

Support transmission adjustable jackstand. Disconnect rear cushion and

mounting bracket from transmission or transfer case.

2) Remove rear crossmember. If transmission will be

disassembled for repair, drain transmission fluid. Disconnect

transmission shift linkage, speedometer cable, transfer case vacuum

lines and clutch hydraulic lines. Lower transmission/transfer case

assembly no more than 3" (76 mm). Reaching around transmission case,

unseat and lift shift lever dust boot. Press shift lever retainer

downward, turn retainer counterclockwise, and lift lever and retainer

out of shift tower.

3) Mark front and rear drive shaft and "U" joint for

reassembly reference. Disconnect and remove both drive shafts. Remove

crankshaft position sensor (AX15). Disconnect transmission/transfer

case assembly vent hoses. Remove slave cylinder from clutch housing.

Remove wire harness from clips on transmission case and transfer case.

4) Support transmission/transfer case assembly with

transmission jack. Secure assembly to jack with safety chains.

Reposition adjustable jackstand under engine. Remove clutch housing

brace rod. Remove clutch housing nuts and bolts. Remove

transmission/transfer case assembly.

Installation

To install, reverse removal procedure. Apply high-temperature

grease to release fork, lever, pivot ball stud and pilot bushing

located in end of crankshaft. Fill transmission with appropriate

fluid, if necessary. Tighten all nuts and bolts to specification. See

TORQUE SPECIFICATIONS table.

Removal (NV 3500)

1) Disconnect negative battery cable. Shift transmission to

Neutral. Open console lid and remove bolts attaching console to floor

pan. Lift cup holder bin and remove bolt attaching console to floor

pan. Lift rear of console and pull console rearward to separate from

shift bezel. Remove console from vehicle. Remove screws attaching

shift boot to floor pan and slide boot upward on lever extension.

2) Remove shift lever extension. Raise and support vehicle.

On 4WD models, remove skid plate, if equipped. Mark drive shaft and

axle yoke for alignment reference. Remove drive shaft. Remove exhaust

"Y" pipe. On 4WD models, disconnect and lower remaining exhaust pipes

for clearance as necessary. Disconnect speed sensor harness connector

and back-up light harness connector.

3) Support engine using adjustable jackstand. If transmission

is to be disassembled for repair, drain lubricant from transmission.

On 4WD models, disconnect transfer case shift linkage at transfer case

range lever and remove shift lever from transmission. Remove

bolts/nuts attaching transmission to rear mount.

4) Support transmission with a transmission jack. Secure

transmission with safety chains. Remove rear crossmember. On 4WD

models, support transfer case with transmission jack and secure

transfer case to jack with safety chains. Remove transfer case

attaching nuts and move transfer case rearward until input gear clears

transmission output shaft.

5) Lower transfer case assembly and remove it from under

vehicle. On 4WD models, remove clutch slave cylinder splash shield, if

equipped. Remove clutch slave cylinder and move aside for working

clearance. Remove starter. Remove transmission splash shield. Remove

transmission harness wires from clips on transmission shift cover.

6) Lower transmission slightly. Remove shift tower and lever

assembly. Remove transmission-to-engine attaching bolts. Slide

Содержание R1500 1999

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 783: ...cification Refer to OEM recommended service procedures POWER STEERING PRESSURE SENSORS POWER STEERING PRESSURE SENSOR INSPECTION Condition Code Procedure Attaching hardware missing C Require replaceme...

Страница 784: ...r Require repair or replacement 3 Inoperative includes intermittent operation or out of OEM specification Some components may be serviceable check for accepted cleaning procedure POWERTRAIN CONTROL MO...

Страница 785: ...quire repair or replacement of affected component s 2 Determine cause and correct prior to repair or replacement of part 3 Determine source of contamination such as engine coolant fuel metal particles...

Страница 786: ...TOR FAN CLUTCH INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or replacement of hardware Attaching hardware missing C Require replacement of hardware Attaching hardware...

Страница 787: ...l restrictions not affecting performance 2 Suggest repair or replacement Leaking A Require repair or replacement Threads damaged A Require repair or replacement Threads stripped threads missing A Requ...

Страница 788: ...ent Inoperative B 3 Require repair or replacement Further inspection required Leaking A Require repair or replacement Missing C Require replacement Resistance out of specification B Require repair or...

Страница 789: ...or Barometric Pressure Sensor BARO Camshaft Position Sensor CMP Clutch Pedal Position Switch CPP Cooling Fan Motor Sensors and Switches Crankshaft Position Sensor CKP Electronic Transmission Feedback...

Страница 790: ...ooling system performance A Require repair or replacement Cracked affecting cooling system performance A Require repair or replacement Loose affecting cooling system performance A Require repair Loose...

Страница 791: ...ring noisy A Require replacement Bearing worn A Require replacement Boost pressure incorrect A 1 Require repair or replacement Clearance out of specification B Require repair or replacement Leaking A...

Страница 792: ...t Terminal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require re...

Страница 793: ...Threads stripped threads missing A Require replacement Wire lead conductors exposed B Require repair or replacement Wire lead corroded A Require repair or replacement Wire lead open A Require repair...

Страница 794: ...ement 1 Inoperative includes intermittent operation or out of OEM specification THROTTLE BODIES THROTTLE BODY INSPECTION Condition Code Procedure Connector broken A Require repair or replacement Conne...

Страница 795: ...g procedure THROTTLE CABLES See THROTTLE LINKAGES AND CABLES THROTTLE LINKAGES AND CABLES THROTTLE LINKAGE AND CABLE INSPECTION Condition Code Procedure Attaching hardware broken A Require repair or r...

Страница 796: ...ing hardware threads damaged A Require repair or replacement of hardware Attaching hardware threads stripped threads missing A Require repair or replacement of hardware Connector broken A Require repa...

Страница 797: ...re threads damaged A Require repair or replacement of hardware Attaching hardware threads stripped threads missing A Require repair or replacement of hardware Connector broken A Require repair or repl...

Страница 798: ...re Attaching hardware not functioning A Require repair or replacement of hardware Bent A Require replacement Cracked A Require replacement Key damaged A Require replacement Loose A Require repair or r...

Страница 799: ...g A Require replacement Body dented A 1 Further inspection required Body punctured A Require replacement Bushing deteriorated affecting performance A Require replacement Bushing deteriorated not affec...

Страница 800: ...inal burned affecting performance A 1 Require repair or replacement Terminal burned not affecting performance 2 Suggest repair or replacement Terminal corroded affecting performance A Require repair o...

Страница 801: ...hing hardware not functioning A Require repair or replacement of hardware Boost pressure incorrect A 1 Require repair or replacement Leaking A Require repair or replacement Noisy 2 Suggest repair or r...

Страница 802: ...placement Resistance out of specification B Require repair or replacement Restricted affecting performance A Require repair or replacement Terminal broken A Require repair or replacement Terminal burn...

Страница 803: ...placement Connector missing C Require replacement Contaminated A 2 Require repair or replacement Inoperative B 3 Require repair or replacement Further inspection required Leaking A Require repair or r...

Страница 804: ...ng A Require repair or replacement Connector melted A 1 Require repair or replacement Connector missing C Require replacement Contaminated A 2 Require repair or replacement Inoperative B 3 Require rep...

Страница 805: ...air or replacement of hardware Connector broken A Require repair or replacement Connector Weatherpack type leaking A Require repair or replacement Connector melted A 1 Require repair or replacement Co...

Страница 806: ...re Boost pressure incorrect A 1 Require repair or replacement Further inspection required Leaking A Require repair or replacement 1 Incorrect boost pressure includes intermittent operation or out of O...

Страница 807: ...f part 2 Check fan motor controls Inoperative includes intermittent operation or out of OEM specification WATER PUMPS NON ELECTRIC WATER PUMP NON ELECTRIC INSPECTION Condition Code Procedure Attaching...

Страница 808: ...conduit melted 2 1 Suggest repair or replacement Protective shield conduit missing 2 Suggest repair or replacement Resistance voltage drop out of specification A Require repair or replacement Routed...

Страница 809: ...torists the information and encouragement to take greater responsibility for their vehicles through proper manufacturer recommended maintenance We encourage participating service and repair shops incl...

Страница 810: ...outreach with your support both the automotive repair industry and your customers will reap the benefits Please visit MAP at our Internet site www motorist org or contact us at 1444 I Street NW Suite...

Страница 811: ...have not failed In this case replacement may be suggested to satisfy the customer s wishes In this case replacement of the shocks or struts may not be sold as a requirement A customer of course has t...

Страница 812: ...cle Be sure to review and adhere to EPA policy on removing and replacing catalytic converters Where state or local laws are stricter they take precedence over these guidelines NOTE Some exhaust system...

Страница 813: ...s cracked B Require repair or replacement Internal rattle except pellet type 2 1 Further inspection required Mounting brackets that are part of converter broken A Require repair or replacement Obvious...

Страница 814: ...replacement Clamp loose A Require repair or replacement Clamp missing C Require replacement Corroded affecting structural integrity 1 Suggest replacement Incorrect type i e flange ball socket etc B Re...

Страница 815: ...t Missing C Require replacement MANIFOLDS CAST AND TUBE TYPE MANIFOLD CAST AND TUBE TYPE INSPECTION Condition Code Procedure Air injection tube in manifold broken A Require repair or replacement of in...

Страница 816: ...stud Stud missing C Require replacement of stud Stud threads damaged A Require repair or replacement of stud Stud threads stripped threads missing A Require replacement of stud 1 Stove may not be avai...

Страница 817: ...re replacement Sound quality unsatisfactory 2 Suggest replacement to address customer need and or request Split exhaust leaking A Require replacement Weak due to corrosion but no leaks present 1 Sugge...

Страница 818: ...must be within specifications at all points If no defects are found check gear tooth contact pattern GEAR TOOTH CONTACT PATTERN NOTE Drive pattern should be well centered on ring gear teeth Coast patt...

Страница 819: ...ith no change in backlash moving pinion further from ring gear moves drive pattern toward heel and top of tooth and moves coast pattern toward toe and top of tooth 2 With no change in backlash moving...

Страница 820: ...rust and scale Follow manufacturer s instructions in the use of cleaner If considerable rust and scale has to be removed cooling system should be flushed Clean radiator air passages with compressed ai...

Страница 821: ...n a 50 50 mixture of coolant and water See Fig 1 Do not allow thermostat or thermometer to touch bottom of container Heat water until thermostat just begins to open 2 Read temperature on thermometer T...

Страница 822: ...f pressure drops inspect for external leaks If no leaks are apparent detach tester and run engine until normal operating temperature is reached Reattach tester and observe If pressure builds up immedi...

Страница 823: ...r Switch Fan speed is controlled with a rotary blower motor switch There are 4 different fan speed settings one low speed 2 medium speeds and one high speed Mode Control Knob A rotary mode switch is u...

Страница 824: ...em Check serpentine drive belt tension Check radiator and radiator fan operation Ensure that accessory vacuum supply line is connected at power brake booster Dakota or engine vacuum source except Dako...

Страница 825: ...d Durango fuse No 12 40 amp on Ram Pickup If battery voltage exists go to next step If battery voltage does not exist check for open in Red wire between battery and underhood power distribution center...

Страница 826: ...ep 2 If continuity exists go to next step If continuity does not exist repair open in Black wire between heater control panel and ground connector located at lower right of steering column 3 Place hea...

Страница 827: ...ck for an open in circuit between heater control panel connector and blower motor relay Fig 3 Identifying Heater Control Panel C1 Connector Terminals Courtesy of Chrysler Corp Fig 4 Identifying Heater...

Страница 828: ...T HEATER OUTPUT 1 Start engine Allow engine to reach normal operating temperature With engine at idle set controls to maximum heat floor and high blower positions Using a thermometer check air tempera...

Страница 829: ...nect blower motor cooling tube Remove blower motor electrical connector from retainer Disconnect electrical connector 2 Remove blower motor and fan assembly mounting bolts Remove blower motor and fan...

Страница 830: ...Fig 5 Identifying Heater Assembly Components Ram Pickup Courtesy of Chrysler Corp...

Страница 831: ...stall reverse removal procedure Removal Installation Ram Pickup Blower motor resistor is located under glove box attached to blower motor housing See Fig 5 Disconnect negative battery cable Remove blo...

Страница 832: ...gative battery cable Drain cooling system In engine compartment remove coolant hoses from heater core tubes Plug all openings Remove coolant overflow bottle Remove instrument panel See INSTRUMENT PANE...

Страница 833: ...equipped set tilt steering column in lowest position 2 On all models carefully pry bezel away from instrument panel to disengage clips Unplug connectors from cigarette lighter and auxiliary power out...

Страница 834: ...ster Bezel Ram Pickup Courtesy of Chrysler Corp CAUTION Use care when removing or installing instrument cluster bezel so as not to damage trip odometer reset button If trip odometer reset button is da...

Страница 835: ...from parking brake linkage rod located at back of parking brake release handle Remove rod end from parking brake handle Remove instrument panel center support bracket Unplug vacuum harness connector...

Страница 836: ...vehicle 6 From driver s side of instrument panel disengage parking brake release linkage rod from parking brake mechanism Disconnect instrument panel wiring harness from parking brake mechanism Disco...

Страница 837: ...tioned as indicated See Fig 10 Measurements must be made with cable end bottomed against flag retainer on heater control panel end of cable housing 2 Measure distance between center of self adjusting...

Страница 838: ...t to remove fastener from cowl side panel 3 Lift cowl plenum cover enough to access windshield washer nozzle and vacuum plumbing Disconnect vacuum supply hose from vacuum reservoir Remove cowl plenum...

Страница 839: ...Fig 11 Heater System Vacuum Circuits Dakota Courtesy of Chrysler Corp...

Страница 840: ...Fig 12 Heater System Vacuum Circuits Durango Courtesy of Chrysler Corp...

Страница 841: ...Fig 13 Heater System Vacuum Circuits Ram Pickup Courtesy of Chrysler Corp...

Страница 842: ...Fig 14 Heater System Vacuum Circuits Ram Van Wagon Courtesy of Chrysler Corp WIRING DIAGRAMS...

Страница 843: ...Fig 15 Heater System Wiring Diagram Dakota...

Страница 844: ...Fig 16 Heater System Wiring Diagram Durango...

Страница 845: ...Fig 17 Heater System Wiring Diagram Ram Pickup...

Страница 846: ...Fig 18 Heater System Wiring Diagram Ram Van Wagon...

Страница 847: ...veral pages Today the majority of these diagrams follow a much improved format which permits space for internal switch details Wiring diagrams are drawn in a top down format The diagrams are drawn wit...

Страница 848: ...wiring symbol are used in these diagrams The illustration below will help clarify any symbols that are not easily understood at a glance Most components are labeled Motor Switch or Relay in addition t...

Страница 849: ...LOCATIONS TABLE Component Wiring Diagram ABS Electronic Control Unit Anti Lock Brakes Data Link Connectors ABS Hydraulic Unit Anti Lock Brakes Acceleration Sensor Anti Lock Brakes Accessory Delay Rela...

Страница 850: ...Sensor Air Bag Air Bag Restraint System Distributor Engine Performance Door Lock Actuators Power Door Locks Remote Keyless Entry Door Lock Relay s Power Door Locks Electrochromic Mirror Power Mirrors...

Страница 851: ...tia Fuel Shutoff Switch Engine Performance Inhibit Relay Starters Instrument Cluster Analog Instrument Panels Intake Air Temperature IAT Sensor Engine Performance Interior Lights Illumination Interior...

Страница 852: ...an Motor s Electric Cooling Fans Radiator Fan Relay s Engine Performance Electric Cooling Fans Rainsense Module Wiper Washer Systems Raise Relay Power Convertible Top Remote Anti Theft Personality RAP...

Страница 853: ...Twilight Sentinel Switch Headlight Systems Daytime Running Lights Vapor Canister Leak Detection Pump Engine Performance Vehicle Control Module VCM Engine Performance Vehicle Dynamic Module Electronic...

Страница 854: ...e is not sufficient to open oil pressure sending unit switch Oil pressure warning light bulb test occurs with ignition switch in RUN position All instrument clusters include these analog gauges Coolan...

Страница 855: ...age between ground and both sides of fuse No 17 10 amp in junction block If battery voltage exists on both sides go to next step If battery voltage exists on one side only repair short circuit and rep...

Страница 856: ...go to next step If all gauges and CCD bus controlled indicator lights are inoperative go to step 5 2 Check fuse No 12 15 amp in junction block If fuse is okay go to next step If any fuse is blown repa...

Страница 857: ...circuit between instrument cluster connector C2 terminal No 7 Black wire and ground See WIRING DIAGRAMS 9 Turn ignition off and disconnect negative battery cable Remove instrument cluster See INSTRUME...

Страница 858: ...e needle should stop at 3 calibration points then return to relaxed position If any gauge does not perform as specified remove instrument cluster See INSTRUMENT CLUSTER under REMOVAL INSTALLATION Insp...

Страница 859: ...block 3 Turn ignition off Disconnect negative battery cable Disconnect 4WD switch connector 4WD switch connector is located at right side of front axle Check continuity between 4WD switch connector B...

Страница 860: ...NOPERATIVE RAM PICKUP DIESEL 1 Remove and inspect fuse No 17 10 amp in junction block Junction block is located at left end cover of instrument panel If fuse is okay go to next step If fuse is blown l...

Страница 861: ...t 2 minutes before servicing instrument cluster See appropriate AIR BAG RESTRAINT SYSTEMS article CAUTION When battery is disconnected vehicle computer and memory systems may lose memory data Driveabi...

Страница 862: ...r Remove shift indicator Remove instrument cluster To install reverse removal procedure Fig 3 Removing Instrument Cluster Bezel Ram Pickup Courtesy of Chrysler Corp Removal Installation Ram Van Ram Wa...

Страница 863: ...ve left underdash cover and knee bolster reinforcement Remove 2 CTM retaining screws at right side of underdash opening See Fig 5 2 Slide CTM down into opening far enough to gain access to connectors...

Страница 864: ...r Corp SHIFT INDICATOR Removal Installation Ram Pickup 1 Remove instrument cluster See INSTRUMENT CLUSTER Remove shift indicator from back of instrument cluster Place gear selector in PARK position Re...

Страница 865: ...cover has 4 retaining clips on upper half and will require prying or lifting with flat bladed tool to remove Remove steering column opening cover 2 Remove park brake release handle and data Link Conn...

Страница 866: ...rews and bezel To install switch reverse removal procedure Removal Installation Ram Van Ram Wagon 1 Disconnect negative battery cable Turn ignition switch to UNLOCK position and shift gear selector to...

Страница 867: ...WIRING DIAGRAMS Fig 9 Analog Instrument Panel Wiring Diagram Ram Pickup 1 Of 2...

Страница 868: ...Fig 10 Analog Instrument Panel Wiring Diagram Ram Pickup 2 Of 2...

Страница 869: ...Fig 11 Analog Instrument Panel Wiring Diagram Ram Van Ram Wagon...

Страница 870: ...ERVICE DIESEL SCHEDULED SERVICES NORMAL SERVICE DIESEL R2500 SCHEDULED SERVICES NORMAL SERVICE GAS SCHEDULED SERVICES SEVERE SERVICE GAS SCHEDULED SERVICES NORMAL SERVICE GAS MD SCHEDULED SERVICES SEV...

Страница 871: ...icle Weight H 6001 7000 Lbs J 7001 8000 Lbs K 8001 9000 Lbs L 9001 10000 Lbs M 10001 14000 Lbs W Hydraulic Brakes 5 Truck Line C Ram Chassis Ram Pick Up 4x2 F Ram Chassis Ram Pick Up 4x4 6 Series 1 15...

Страница 872: ...ice is recommended at mileage intervals based on vehicle operation Normal Service and Severe Service schedules are based on the following primary operating conditions Normal Service Driven More Than 1...

Страница 873: ...Fig 1 Service Point Locations Typical V6 and V8 Engines Courtesy of Chrysler Corp Fig 2 Service Point Locations 8 0L V10 Engine Courtesy of Chrysler Corp...

Страница 874: ...Fig 3 Service Point Locations 5 9L Turbo Diesel Courtesy of Chrysler Corp ADDITIONAL SERVICE INFORMATION DIESEL MODELS...

Страница 875: ...Fig 4 Engine Service Locations 5 9L Engine Diesel Courtesy of Chrysler Corp NOTE For more information regarding 5 9L Diesel engine service refer to the E THEORY OPERATION 5 9L DIESEL article...

Страница 876: ...to the F BASIC TESTING 5 9L DIESEL article in the ENGINE PERFORMANCE section NOTE DO NOT remove the air filter housing to inspect air filter element When disc in Filter Minder is in the RED zone the...

Страница 877: ...more information regarding 5 9L Diesel engine service refer to the 5 9L V8 TURBO DIESEL VIN D article in the ENGINE MECHANICAL section When a diesel vehicle runs out of fuel air is pulled into the fue...

Страница 878: ...30 times 3 Start engine using normal procedure 4 Engine may run rough until air is forced from lines CAUTION If this procedure fails to start vehicle more involved procedures may be required Fig 7 Val...

Страница 879: ...the ENGINE MECHANICAL section Fig 8 Valve Adjustment Step 1 of 2 Diesel Courtesy of Chrysler Corp NOTE For more information regarding 5 9L Diesel engine service refer to the 5 9L V8 TURBO DIESEL VIN...

Страница 880: ...y of Chrysler Corp NOTE For more information regarding 5 9L Diesel engine service refer to the 5 9L V8 TURBO DIESEL VIN D article in the ENGINE MECHANICAL section Fig 10 Water Separator Diesel Courtes...

Страница 881: ...ilter until clear fuel is visible Drain fuel into a container and follow proper disposal procedures CAUTION DO NOT drain fuel water separator when engine is running or hot Allow engine to cool before...

Страница 882: ...Fig 12 CNG Fuel Rail Service Points Courtesy of Chrysler Corp...

Страница 883: ...Fig 13 CNG Fuel Tank Components Courtesy of Chrysler Corp...

Страница 884: ...Fig 14 Manual Shutoff Valve Location Courtesy of Chrysler Corp...

Страница 885: ...Fig 15 CNG Fuel Filter Courtesy of Chrysler Corp IDENTIFICATION LABEL LOCATIONS Fig 16 Identification Label Locations Courtesy of Chrysler Corp...

Страница 886: ...Fig 17 CNG Identification Label Locations Courtesy of Chrysler Corp Fig 18 Tank Test Date Label Location Courtesy of Chrysler Corp LUBRICATION SPECIFICATIONS DIESEL...

Страница 887: ...ansmission Fluid Transfer Case All ATF 2 Type 7176 Fluid Or DEXRON III ATF Manual All 75W 90 Synthc API GL4 Transmission Fluid Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Wheel Bearin...

Страница 888: ...k 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant Automatic 46RE Dry Fill 17 Qts 16L Transmission Fluid 47RE Dry Fill 17 Qts 16L Manual NV4500 4 Qts 3 8L Transmission Fluid Rear Axle DANA 70 Model 267...

Страница 889: ...Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Automatic All ATF 2 Type 7176 Transmission Fluid Transfer Case All ATF 2 Type 7176 Fluid Or DEXRON III ATF Manual NV 4500 75W 90 Synth...

Страница 890: ...3 9L Drained W New Filter 4 Qts 3 8L 5 2L Drained W New Filter 5 Qts 4 7L 5 9L Drained W New Filter 5 Qts 4 7L 3 9L Drained 3 5 Qts 3 3L 5 2L Drained 4 5 Qts 4 2L 5 9L Drained 4 5 Qts 4 2L Engine 3 9L...

Страница 891: ...culated levels Always use dipstick if available to measure level WHEEL TIRE SPECIFICATIONS TIRE REPLACEMENT The tires on your new vehicle provide a balance of many characteristics They should be inspe...

Страница 892: ...ction of the system Use only plain water when cleaning the horn pad Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system WARNING To avoid injury fr...

Страница 893: ...be caused by a restriction therefore adding refrigerant can cause a dangerous pressure rise ANTI LOCK BRAKE SYSTEM CAUTION The anti lock brake system contains electronic equipment that can be suscept...

Страница 894: ...e use of an incorrect amperage rating fuse may result in a dangerous electrical system overload BRAKE PAD WEAR INDICATOR Indicator will cause a squealing or scraping noise warning that brake pads need...

Страница 895: ...G Many solid state electrical components can be damaged by static electricity ESD Some will display a warning label but many will not Discharge personal static electricity by touching a metal ground p...

Страница 896: ...15 These tires are too large for sufficient body clearance with chains or other traction devices Tire chains are not allowed on 4x2 vehicles equipped with P235 70R15 tires or 4x4 vehicles equipped wit...

Страница 897: ...Fig 19 Interior Fuse Panel Courtesy of Chrysler Corp Fuse Circuit Breaker Identification...

Страница 898: ...wertrain Control Module PCM Ignition Module High Pressure Fuel Shut Off Solenoid Relay CNG Models Only EGR Solenoid CNG Models Only 10 Not Used Vehicle Speed Control 11 10 Amp Red Buzzer Overhead Cons...

Страница 899: ...uto Transmission Relay D Anti Lock Brake System Relay E Auto Shutdown Relay F Air Conditioning Clutch Relay G Horn Relay H Fuel System Relay J ABS Warning Light Relay K Fog Lamp 2 Relay L Fog Lamp 1 R...

Страница 900: ...meter is slightly longer than a yard about 40 inches An aspirin tablet is about one centimeter across 4 inches A millimeter is about the thickness of a dime VOLUME Cubic meters and centimeters are us...

Страница 901: ...ascals Thoroughly confused Try the examples below Atmospheric pressure at sea level is about 14 7 psi Atmospheric pressure at sea level is about 1 bar Atmospheric pressure at sea level is about 1 kg c...

Страница 902: ...88 4 763 13 64 203 5 159 7 32 219 5 556 15 64 234 5 953 1 4 250 6 350 17 64 266 6 747 9 32 281 7 144 19 64 297 7 541 5 16 313 7 938 21 64 328 8 334 11 32 344 8 731 23 64 359 9 128 3 8 375 9 525 25 64...

Страница 903: ...7 20 241 13 16 813 20 638 53 64 828 21 034 27 32 844 21 431 55 64 859 21 828 7 8 875 22 225 57 64 891 22 622 29 32 906 23 019 59 64 922 23 416 15 16 938 23 813 61 64 953 24 209 31 32 969 24 606 63 64...

Страница 904: ...er turns off mirror heater after about 10 minutes COMPONENT TESTS AUTOMATIC DAY NIGHT INSIDE MIRROR 1 Turn ignition switch to ON position with transmission in Neutral or Park Place mirror switch in ON...

Страница 905: ...yager Disconnect harness connector from mirror and headlight switch Using 2 jumper wires connect one jumper to a 12 volt source and the other jumper wire to a good ground Connect other end of jumper w...

Страница 906: ...irror Operation Mirror Operation To Pin Pin Right Left Switch Connector 1 12 6 N A Up 7 6 N A Left 6 12 N A Down 6 7 N A Right 13 1 Up N A 8 1 Left N A 1 13 Down N A 1 8 Right N A 5 11 2 2 1 Use illus...

Страница 907: ...ON table check for open or shorted circuit or replace mirror assembly as necessary See Fig 3 POWER MIRROR MOTOR TEST DAKOTA DURANGO RAM PICKUP RAM VAN RAM WAGON Apply 12 Volts Ground Mirror To Pin Pin...

Страница 908: ...R Right Up 9 13 1 11 9 12 Down 9 1 13 11 12 11 Left 9 8 1 11 9 7 Right 9 1 8 11 7 11 Illumination N A 5 11 Dakota Durango Ram Pickup Ram Van Ram Wagon Remove switch and disconnect wiring connector Se...

Страница 909: ...enever rear window defogger is on Caravan Town Country Voyager 1 Mirror should be warm to touch with rear window defogger activated If mirror is not warm to touch check fuse No 12 10 amp in junction b...

Страница 910: ...CAUTION When battery is disconnected vehicle computer and memory systems may lose memory data Driveability problems may exist until computer systems have completed a relearn cycle See COMPUTER RELEAR...

Страница 911: ...ob Remove power window lock switch assembly by inserting a screwdriver in notch at forward end of switch housing to release locking tabs Pull switch assembly forward and out from door panel Remove tri...

Страница 912: ...WIRING DIAGRAMS Fig 5 Power Mirror System Wiring Diagram Caravan Town Country Voyager...

Страница 913: ...Fig 6 Power Mirror System Wiring Diagram Dakota...

Страница 914: ...Fig 7 Power Mirror System Wiring Diagram Durango...

Страница 915: ...Fig 8 Power Mirror System Wiring Diagram Ram Pickup...

Страница 916: ...Fig 9 Power Mirror System Wiring Diagram Ram Van Ram Wagon...

Страница 917: ...N CAUTION Always turn ignition off when connecting or disconnecting battery cables battery chargers or jumper cables DO NOT turn test switch to OFF position which causes current to run through ammeter...

Страница 918: ...ircuits powered up 5 Select low amp scale Switch lead to the correct meter position Turn test switch to OFF position and compare results to normal current draw See the GENERAL MOTORS PARASITIC LOAD TA...

Страница 919: ...1 0 Voltage Regulator 1 4 2 0 INTERMITTENT PARASITIC LOAD PROBLEMS Intermittent parasitic lad can occur because of a memory device that does not power down with ignition off With an intermittent paras...

Страница 920: ...Fig 2 Diode Check Solenoid Test General Motors Courtesy of General Motors Corp QUAD DRIVER TEST GENERAL MOTORS...

Страница 921: ...Fig 3 Quad Driver Test General Motors Courtesy of General Motors Corp...

Страница 922: ...ion procedures are covered in this article If component removal and installation is primarily an unbolt and bolt on procedure only a torque specification may be furnished COMPUTERIZED ENGINE CONTROLS...

Страница 923: ...ntercooler if damaged CAUTION DO NOT use caustic cleaners to clean intercooler or intercooler may be damaged 2 If intercooler cleaning is required flush intercooler with a non caustic solvent in the o...

Страница 924: ...ger with your finger as sharp edges may exist 3 Pour 3 ozs 60 cc of clean engine oil into turbocharger oil supply line fitting on turbocharger while using soft object to rotate turbine wheel in turboc...

Страница 925: ...Tighten CKP bolt to specification See TORQUE SPECIFICATIONS INTAKE MANIFOLD AIR TEMPERATURE SENSOR Removal Installation 1 Disconnect electrical connector from intake manifold air temperature sensor S...

Страница 926: ...NOTE APPS is replaced as assembly including lever brackets and sensor Removal 1 Disconnect negative battery cables Remove cable cover Using finger pressure only disconnect end of speed control servo...

Страница 927: ...battery See Fig 5 Disconnect negative battery cables 2 Note location of wiring on intake manifold air heater relays for installation reference Disconnect electrical connectors at intake manifold air...

Страница 928: ...ner ring disconnect fitting See Fig 6 Determine type of disconnect fitting used and use proper procedure for proper disconnect fitting Fig 6 Identifying Fuel Line Disconnect Fitting Courtesy of Chrysl...

Страница 929: ...ent that may be replaced is the plastic retainer If plastic retainer must be removed from fuel system component carefully release the plastic retainer from the fuel system component using 2 screwdrive...

Страница 930: ...fuel lines Allow 2 minute intervals between starter operations 3 To bleed air from fuel injection pump ensure parking brake is applied and transmission is in Neutral as engine may start when operating...

Страница 931: ...sing NEW O ring install WIF sensor on canister if removed Tighten WIF sensor to specification See TORQUE SPECIFICATIONS 2 Install drain valve on canister if removed Tighten drain valve to canister bol...

Страница 932: ...uel tank module lock nut from fuel tank Remove fuel tank module and gasket from fuel tank Inspect in tank fuel filter for damage Installation 1 Using NEW gasket install fuel tank module in fuel tank I...

Страница 933: ...manifold air heater assembly If removing injector at cylinder No 5 remove engine lifting bracket Ensure area around fuel injector and high pressure fuel line is clean Disconnect high pressure fuel li...

Страница 934: ...ion See TORQUE SPECIFICATIONS Bleed high pressure fuel lines See FUEL LINE BLEEDING under FUEL SYSTEM FUEL INJECTION PUMP CAUTION High pressure fuel lines must be clamped securely and routed so they d...

Страница 935: ...ve them before engine start 4 Using gear puller separate injection pump gear from injection pump shaft See Fig 11 DO NOT pull fuel injection pump drive gear too far forward or timing gear cover may be...

Страница 936: ...t Mounting Bolts Courtesy of Chrysler Corp Fig 11 Removing Fuel Injection Pump Drive Gear Courtesy of Chrysler Corp NOTE Before installing fuel injection pump ensure shaft on fuel injection pump is pr...

Страница 937: ...e gear to shaft mating surfaces are clean and free of oil to provide proper seating of fuel injection pump drive gear on shaft of fuel injection pump 2 Pump gear keyway has an arrow and 3 digit number...

Страница 938: ...from fuel system See FUEL LINE BLEEDING FUEL TANK ROLLOVER VALVE Removal 1 Fuel tank rollover valve is pressed into rubber grommet on top of fuel tank module See Fig 7 Manufacturer recommends removing...

Страница 939: ...not contact each other or any other components DO NOT weld or substitute high pressure fuel lines High pressure lines are same length and proper high pressure fuel line must be installed in specified...

Страница 940: ...Remove 4 air intake housing bolts Remove air intake housing from top of intake manifold air heater elements See Fig 13 2 Remove heater element assembly from intake manifold Clean old gasket from air i...

Страница 941: ...4 Intake Manifold Air Heater Housing Bolt 18 24 Intake Manifold Air Temperature Sensor 20 27 Intake Manifold Cover Bolt 1 18 24 Oil Fill Plug 21 29 Overflow Valve To Fuel Injection Pump 24 33 Park Neu...

Страница 942: ...Module PCM the correct vehicle mileage and Vehicle Identification Number VIN must be programmed into the PCM to prevent Diagnostic Trouble Codes DTCs from being set in the Anti Lock Brake System ABS...

Страница 943: ...Fig 2 Locating PCM Ram Pickup Courtesy of Chrysler Corp Fig 3 Locating PCM Ram Van Ram Wagon Courtesy of Chrysler Corp PCM PROGRAMMING...

Страница 944: ...ssary ENGINE SENSORS SWITCHES BATTERY TEMPERATURE SENSOR Removal Installation Battery temperature sensor is snapped into center of battery tray directly below the battery Remove battery Disconnect ele...

Страница 945: ...er on brake switch must be pulled outward to fully extended position and then pushed inward 4 detent positions to ensure proper brake switch adjustment Installation 1 Pull plunger on brake switch outw...

Страница 946: ...de of generator and contains a Tan Black wire and a Black Light Blue wire in the electrical connector 2 Remove air cleaner if necessary for access to engine coolant temperature sensor On models equipp...

Страница 947: ...oling system FUEL LEVEL SENSOR Removal Installation See FUEL LEVEL SENSOR under FUEL SYSTEM INTAKE AIR TEMPERATURE IAT SENSOR NOTE Intake air temperature sensor may also be referred to as intake manif...

Страница 948: ...AT Sensor Dakota 3 9L 5 2L 5 9L Durango Ram Pickup 3 9L 5 2L 5 9L Ram Van Ram Wagon Courtesy of Chrysler Corp Fig 6 Locating Intake Air Temperature IAT Sensor Ram Pickup 8 0L Courtesy of Chrysler Corp...

Страница 949: ...ntake manifold Rubber seal gasket is part of the MAP sensor and is not serviceable Inspect rubber seal gasket for damage Replace MAP sensor with rubber seal gasket if gasket is defective 3 To install...

Страница 950: ...ressure MAP Sensor Dakota 3 9L 5 2L 5 9L Durango Ram Pickup 3 9L 5 2L 5 9L Ram Van Ram Wagon Courtesy of Chrysler Corp Fig 9 Locating Manifold Absolute Pressure MAP Sensor Ram Pickup 8 0L Courtesy of...

Страница 951: ...er s Side Rear Corner Of Cylinder Block Below Distributor 1 Contains a Gray Yellow wire and a Black Light Blue wire in the electrical connector 2 Contains a Gray Orange wire and a Black Light Blue wir...

Страница 952: ...QUE SPECIFICATIONS Install electrical connector Add Mopar Plus 7176 ATF as necessary POWER STEERING PRESSURE SWITCH Removal Installation Dakota 2 5L 1 Power steering pressure switch is located in pres...

Страница 953: ...retaining bolts for TP sensor to specification See TORQUE SPECIFICATIONS 4 Operate throttle lever on throttle body to ensure no binding exists in TP sensor Install electrical connector and air inlet d...

Страница 954: ...TRANSMISSION OVERDRIVE SWITCH NOTE Transmission overdrive switch may also be referred to as overdrive override switch OD switch or overdrive off switch Removal Installation A T Models Transmission ove...

Страница 955: ...ated on throttle body and contains a 4 pin electrical connector On Ram Van and Ram Wagon remove engine cover 2 On all models remove air inlet duct or air cleaner assembly for access to IAC motor Disco...

Страница 956: ...ION GOVERNOR PRESSURE SOLENOID NOTE Transmission governor pressure solenoid may also be referred to as governor pressure solenoid Removal Installation A T Models Transmission governor pressure solenoi...

Страница 957: ...nect camshaft position sensor electrical wiring harness Lift camshaft position sensor from distributor housing 4 To install reverse removal procedure Ensure tab on bottom of camshaft position sensor e...

Страница 958: ...sensor is installed camshaft sprocket may have to be rotated to allow high machined area on camshaft sprocket to be aligned with camshaft position sensor mounting hole opening on timing chain cover D...

Страница 959: ...any of the original rib material is still present See Fig 16 The rib material was used to position the camshaft position sensor at the correct installation depth when the sensor was originally install...

Страница 960: ...reinstalling camshaft position sensor to obtain the correct camshaft position sensor installation depth 8 Remove camshaft position sensor from timing chain cover Remove paper spacer from camshaft end...

Страница 961: ...ocating Rib Material On Camshaft Position Sensor Ram Pickup 8 0L Courtesy of Chrysler Corp Fig 17 Placing Scribe Line On Timing Chain Cover Ram Pickup 8 0L Courtesy of Chrysler Corp CRANKSHAFT POSITIO...

Страница 962: ...al procedure Tighten crankshaft position sensor retaining bolts and wheel lug nuts to specification See TORQUE SPECIFICATIONS Removal Installation Ram Pickup 3 9L 5 2L 5 9L Ram Van Ram Wagon 1 Cranksh...

Страница 963: ...l and tighten crankshaft position sensor retaining bolt to specification See TORQUE SPECIFICATIONS 3 To install remaining components reverse removal procedure Ensure NEW plastic tie is installed throu...

Страница 964: ...rical connector for distributor 2 Remove spark plug from cylinder No 1 at timing chain end of engine Rotate crankshaft clockwise viewed from front of engine until cylinder No 1 is at Top Dead Center T...

Страница 965: ...ment pin is used to temporarily lock distributor rotor in correct position for cylinder No 1 Plastic alignment pin must be removed after installing distributor Fig 21 Locating Plastic Alignment Pin Da...

Страница 966: ...amshaft position sensor from distributor See Fig 13 Rotate distributor shaft and install a 3 16 4 76 mm diameter drift through proper alignment hole in plastic ring and into access hole in bottom of d...

Страница 967: ...5 2L 5 9L Ram Van Ram Wagon 1 Disconnect negative battery cable On Ram Van and Ram Wagon remove engine cover On all models remove air cleaner assembly Remove distributor cap Disconnect electrical con...

Страница 968: ...YNCHRONIZATION under FUEL SYSTEM in ON VEHICLE ADJUSTMENTS article IGNITION COIL Removal Installation Dakota 2 5L Ignition coil is located on side of engine near distributor Service procedure is prima...

Страница 969: ...e or electrical components 1 Remove fuel cap from fuel tank Note location of spring loaded flapper valve inside fuel tank filler tube assembly Flapper valve is located just below the fuel cap area on...

Страница 970: ...esidual fuel pressure may exist 9 Diagnostic Trouble Code DTCs may have been stored in Powertrain Control Module PCM due to the removal of fuel pump relay Using scan tool clear DTCs from PCM See appro...

Страница 971: ...onnect fitting 3 Inspect components for damage If disconnect fitting is damaged entire assembly must be replaced The only component that may be replaced is the plastic retainer If plastic retainer mus...

Страница 972: ...l line fitting Perform STEP 2 See Fig 25 Pull fuel line fitting with fuel line from fuel rail 4 Inspect fuel line fitting components for damage If fuel line fitting components are damaged entire fuel...

Страница 973: ...all fuel line fitting on fuel rail 5 Rotate latch clip downward so it snaps into position Ensure latch clip is fully snapped into position If latch clip will not snap into position check for improper...

Страница 974: ...ilter fuel pressure regulator Installation 1 Install plastic fuel line with NEW retaining clamp on fuel filter fuel pressure regulator Rotate fuel filter fuel pressure regulator in plastic fuel line u...

Страница 975: ...Fig 27 Locating Fuel Pump Module Components Dakota Courtesy of Chrysler Corp Fig 28 Locating Fuel Pump Module Components Durango Courtesy of Chrysler Corp...

Страница 976: ...Fig 29 Locating Fuel Pump Module Components Ram Pickup Courtesy of Chrysler Corp Fig 30 Locating Fuel Pump Module Components Ram Van Ram Wagon Courtesy of Chrysler Corp FUEL LEVEL SENSOR...

Страница 977: ...erence Remove wires for fuel level sensor from electrical connector for fuel pump and fuel level sensor 5 Note location of notch and locking tab at end of fuel level sensor See Fig 31 Carefully push l...

Страница 978: ...ure area around fuel pump module is clean Using Fuel Pump Module Lock Nut Spanner Wrench 6856 remove fuel pump module lock nut See Fig 32 Remove fuel pump module with rubber gasket from fuel tank CAUT...

Страница 979: ...el Pump Module Lock Nut Dakota Ram Pickup Ram Van Ram Wagon Courtesy of Chrysler Corp Fig 33 Positioning Fuel Pump Module In Fuel Tank Dakota Courtesy of Chrysler Corp Removal Durango 1 Fuel pump modu...

Страница 980: ...TION When fuel pump module is removed from fuel tank rubber gasket must be replaced DO NOT reuse rubber gasket Installation 1 Ensure sealing area on fuel tank is clean Using NEW rubber gasket install...

Страница 981: ...ce while tightening fuel pump module lock nut to specification See TORQUE SPECIFICATIONS Reinstall fuel tank using proper procedure Removal Ram Van Ram Wagon 1 Fuel pump module is located on top of fu...

Страница 982: ...2 Disconnect fuel line from fuel rail See FUEL LINE AT FUEL RAIL Connect Fuel Hose 6541 6539 6631 or 6923 for proper engine application at fuel line fitting on fuel rail Place remaining end of fuel h...

Страница 983: ...l to body screw See Fig 36 Remove the 3 bezel to body screws at the outer circumference of the plastic bezel DO NOT remove fuel tank filler tube assembly to bezel screws Fig 36 Locating Plastic Bezel...

Страница 984: ...fuel tank as far as possible See Fig 37 Ensure disconnect fitting is fully pressed onto fuel tank fitting before attempting to push release sleeve into disconnect fitting 11 Push release sleeve upwar...

Страница 985: ...container 3 Connect scan tool to Data Link Connector DLC DLC is a 16 pin connector attached to bottom of driver s side of the instrument panel just to the right of the brake pedal Using scan tool manu...

Страница 986: ...ghtly rotate fuel tank so vent hose and filler hose on fuel tank are above the fuel level in the fuel tank to prevent fuel leakage when hoses are disconnected Vent hose and filler hose attach to fitti...

Страница 987: ...6 If fuel tank was previously drained go to next step If fuel tank was not previously drained siphon fuel from fuel tank into an approved gasoline container by installing siphon hose in small vent ho...

Страница 988: ...es at throttle body Remove control cable mounting bracket from intake manifold for access to fuel rail 4 Remove fuel rail bolts Ensure area around injectors and intake manifold is clean Using rocking...

Страница 989: ...Ensure all injectors are fully seated 4 Tighten fuel rail bolts and throttle body bolts to specification See TORQUE SPECIFICATIONS Install fuel line on fuel rail using proper procedure See FUEL LINE A...

Страница 990: ...all injectors are fully seated 4 Tighten fuel rail bolts to specification See TORQUE SPECIFICATIONS Using NEW gasket install upper intake manifold with all bolts loosely installed Tighten upper intake...

Страница 991: ...specification See TORQUE SPECIFICATIONS Removal Installation Ram Pickup 1 Two EVAP canisters are used EVAP canisters are located on mounting bracket attached to outside of passenger s side frame rail...

Страница 992: ...n center Unsnap power distribution center from battery tray Carefully position power distribution center aside 5 Remove battery tray Disconnect electrical connector and vacuum hoses at EVAP leak detec...

Страница 993: ...emoval Ram Van Ram Wagon 1 EVAP leak detection pump and EVAP leak detection pump filter must be replaced as an assembly EVAP leak detection pump and EVAP leak detection pump filter are located on moun...

Страница 994: ...AP Leak Detection Pump Filter EVAP Purge Solenoid Ram Pickup Courtesy of chrusler corp Fig 42 Locating EVAP Leak Detection Pump EVAP Leak Detection Pump Filter EVAP Purge Solenoid Ram Van Ram Wagon Co...

Страница 995: ...P purge solenoid is located at driver s side of engine compartment near brake booster See Fig 44 2 On all models disconnect electrical connector and vacuum hoses at EVAP purge solenoid Use care not to...

Страница 996: ...41 2 On Ram Van and Ram Wagon EVAP purge solenoid is located at driver s side of engine compartment near the wheelwell See Fig 42 3 On all models disconnect electrical connector and vacuum hoses at E...

Страница 997: ...9L 17 23 Throttle Body Nut 8 0L 16 22 Upper Intake Manifold Bolt 8 0L 6 16 22 Upstream Oxygen Sensor 22 30 Wheel Lug Nut Dakota Durango 100 136 INCH Lbs N m Air Cleaner Housing To Throttle Body Nut D...

Страница 998: ...CH lbs 8 0 N m 4 Tighten bolts to 100 INCH lbs 11 3 N m 5 Tighten retaining nuts to 60 INCH lbs 6 8 N m 6 Tighten bolts to specification in sequence See 39 7 On ignition coil using only bolts tighten...

Страница 999: ...ing Severe conditions are NOT taken into account Frequent short driving less than 5 Miles 8 Km Frequent driving in dusty conditions Frequent trailer towing Extensive idling More than 50 of your drivin...

Страница 1000: ...ne oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity...

Страница 1001: ...er Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACIT...

Страница 1002: ...n With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Mult...

Страница 1003: ...age Automatic Transmission Bands Clean Fuel Strainer Adjust Valve Lash Clearance REPLACE Engine Oil Engine Oil Filter Fuel Filter Automatic Transmission Fluid Filter LUBRICATION SPECIFICATIONS Materia...

Страница 1004: ...cation 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant Automatic 46RE Dry Fill 17 Qts 16L Transmission Fluid 47RE Dry Fill 17...

Страница 1005: ...Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition...

Страница 1006: ...W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Et...

Страница 1007: ...evel Hoses Clamps SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above...

Страница 1008: ...ulated levels Always use dipstick if available to measure level 48 000 MILE 77 000 KM 48 MONTH NORMAL SERVICE 48 000 MILE 77 000 KM 48 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed INSP...

Страница 1009: ...lti Mileage Linkage Lubricant Lubricant Automatic All ATF 2 Type 7176 Transmission Fluid Wheel Bearing All High Temperature Multi Grease Purporse EP Grease 1 SAE 10W 30 engine oil is preferred Use onl...

Страница 1010: ...1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50...

Страница 1011: ...ERVICE Rotate Tires Lubricate Steering Linkage Clean Fuel Strainer REPLACE Engine Oil Engine Oil Filter Engine Coolant Fuel Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oi...

Страница 1012: ...ipstick if available to measure level 66 000 MILE 106 000 KM 66 MONTH NORMAL SERVICE 66 000 MILE 106 000 KM 66 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake...

Страница 1013: ...fication 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick...

Страница 1014: ...0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethyle...

Страница 1015: ...NORMAL SERVICE 78 000 MILE 125 000 KM 78 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Rotate Tires Lubricat...

Страница 1016: ...10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 84 000 MILE 134...

Страница 1017: ...ar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Up...

Страница 1018: ...Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API...

Страница 1019: ...gine Oil Filter Automatic Transmission Fluid Filter Fuel Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C...

Страница 1020: ...ned 26 Qts 24 5L Coolant Automatic 46RE Dry Fill 17 Qts 16L Transmission Fluid 47RE Dry Fill 17 Qts 16L 1 Capacities are recommended or calculated levels Always use dipstick if available to measure le...

Страница 1021: ...10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9...

Страница 1022: ...Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Milea...

Страница 1023: ...RICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C...

Страница 1024: ...SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Front Wheel Bearings 4x2 SERVICE Rotate Tires Lubricate Steering Linkage Automatic...

Страница 1025: ...S Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant Automatic 46RE Dry Fill 17 Qts 16L Transmission...

Страница 1026: ...Axle SAE 80W 90 Lubricant GL 5 Gear Lube Power All Mopar Power Steering Steering Fluid Or Equivalant Fluid 3 Petroleum Based Clutch All Multipurpose Grease Linkage NLGI Grade 2 E P Lubricant A C All...

Страница 1027: ...xle Model 267 2WD 7 Pts 3 3L Limited Slip Differential Model 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Front Axle Model 248 7 6 Pts 3 6L Lubricant Transfer Case NV241...

Страница 1028: ...ck fluid levels of coolant reservoir brake master cylinder power steering transmission Add fluids as required Once a month check all lights and all other electrical items for correct operation Once a...

Страница 1029: ...re based on normal vehicle usage ONLY The following Severe conditions are NOT taken into account Frequent short driving less than 5 Miles 8 Km Frequent driving in dusty conditions Frequent trailer tow...

Страница 1030: ...approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 3 9L Drained W New Filter 4 Qts 3 8L 5 2L Drained W New Filter 5 Qts 4 7L 5 9L Drained W New Filter 5 Qts...

Страница 1031: ...eage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 3 9L Drained W New Filt...

Страница 1032: ...ICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 5...

Страница 1033: ...ure level 30 000 MILE 48 000 KM 24 MONTH NORMAL SERVICE 30 000 MILE 48 000 KM 24 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Ho...

Страница 1034: ...Drained W New Filter 5 Qts 4 7L 3 9L Drained 3 5 Qts 3 3L 5 2L Drained 4 5 Qts 4 2L 5 9L Drained 4 5 Qts 4 2L Engine 3 9L Drained 20 Qts 19L Coolant 5 2L Drained 20 Qts 19L 5 9L Drained 20 Qts 19L 1 C...

Страница 1035: ...er Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Automatic All ATF 2 Type 7176 Transmission Fluid Transfer Case All ATF 2 Type 7176 Fluid Or DEXRON...

Страница 1036: ...jor Service Was Performed INSPECT Exhaust System Brake Hoses Front Wheel Bearing 4x2 Brake Linings SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter Engine Coolant L...

Страница 1037: ...L 5 9L Drained 4 5 Qts 4 2L Engine 3 9L Drained 20 Qts 19L Coolant 5 2L Drained 20 Qts 19L 5 9L Drained 20 Qts 19L 1 Capacities are recommended or calculated levels Always use dipstick if available to...

Страница 1038: ...il with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 3 9L Drained W New Filter 4 Qts 3 8L 5 2L Drained W New Filter 5 Qts 4 7L 5 9L Drained W New Filter 5 Qts 4 7L 3 9L...

Страница 1039: ...perature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubri...

Страница 1040: ...el Hoses Clamps Front Wheel Bearings 4x2 Brake Linings SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil 1 1 If mileage is less than 7 500 miles 12 000 KM yearly replace the oil filte...

Страница 1041: ...rained 4 5 Qts 4 2L 5 9L Drained 4 5 Qts 4 2L Engine 3 9L Drained 20 Qts 19L Coolant 5 2L Drained 20 Qts 19L 5 9L Drained 20 Qts 19L 1 Capacities are recommended or calculated levels Always use dipsti...

Страница 1042: ...smission Fluid Transfer Case All ATF 2 Type 7176 Fluid Or DEXRON III ATF 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specificat...

Страница 1043: ...cate Steering Linkage REPLACE Engine Oil 1 1 If mileage is less than 7 500 miles 12 000 KM yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification...

Страница 1044: ...ained 20 Qts 19L 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 90 000 MILE 144 000 KM 72 MONTH NORMAL SERVICE 90 000 MILE 144 000 KM 72 MONTH NORM...

Страница 1045: ...only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 3 9L Drained W New Filter 4 Qts 3 8L 5 2L Drained W New Filter 5 Qts 4 7L 5 9L Drained W New Filt...

Страница 1046: ...F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is...

Страница 1047: ...LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0...

Страница 1048: ...MONTH NORMAL SERVICE 112 500 MILE 180 000 KM 90 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Front Wheel Bearings...

Страница 1049: ...C LB 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 3 9L Drained W New Filter 4 Qts 3 8L 5 2L Drained W...

Страница 1050: ...r Spark Plugs Ignition Cables LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SA...

Страница 1051: ...ial Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of C...

Страница 1052: ...Modifier 3 Never add gear oil automatic transmission fluid or hydroboost power steering fluid FLUID CAPACITIES FLUID CAPACITIES TABLE Item Condition Specification 1 Engine Oil 3 9L Drained W New Filte...

Страница 1053: ...er Power Drained 2 7 Pts 1 3L Steering Fluid A C Charge Capacity 32 Oz 9Kg Refrigerant Refrigerant A C System Capacity 7 75 Oz 230ML Oil Fuel Tank 119 139 Wheelbase Vehicles 26 Gal 98L All Others 35 G...

Страница 1054: ...efined as any one of the following conditions Frequent short driving less than 5 Miles 8 16 Km Frequent driving in dusty conditions Frequent trailer towing Extensive idling More than 50 of your drivin...

Страница 1055: ...Dodge trucks Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine...

Страница 1056: ...All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specificati...

Страница 1057: ...ke Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID C...

Страница 1058: ...40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater...

Страница 1059: ...Rear Axle DANA 70 Model 267 2WD 7 Pts 3 3L Lubricant DANA 70 Model 267 4WD 7 8 Pts 3 6L DANA 80 Model 286 2WD 6 8 Pts 3 2L DANA 80 Model 286 4WD 10 1 Pts 4 8L Rear Axle Model 267 2WD 7 Pts 3 3L Limit...

Страница 1060: ...Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approve...

Страница 1061: ...SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled W...

Страница 1062: ...ial Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Tha...

Страница 1063: ...0 MILE 38 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Front Wheel Bearings 4x2 Fan Hub Damper Water Pump Wee...

Страница 1064: ...7176 Transmission Fluid Rear Axle All Mopar Hypoid Lubricant Lubricant SAE 80W 90 2 GL 5 Gear Lube 4x4 Front All Mopar Hypoid Lubricant Axle SAE 80W 90 Lubricant GL 5 Gear Lube Wheel Bearing All High...

Страница 1065: ...ays use dipstick if available to measure level 27 000 MILE 43 000 KM SEVERE DUTY SERVICE 27 000 MILE 43 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake...

Страница 1066: ...Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick if available to m...

Страница 1067: ...eering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine O...

Страница 1068: ...ater Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with...

Страница 1069: ...Case Fluid Fuel Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30...

Страница 1070: ...ty Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant Automatic 46RE Dry Fill 17 Qts 16L Transmission Fluid 47RE Dry Fill 17 Qts 16L Rear Axle DANA 70...

Страница 1071: ...er 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine...

Страница 1072: ...Tires Lubricate Steering Linkage Clean Fuel Strainer REPLACE Engine Oil Engine Oil Filter Fuel Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above...

Страница 1073: ...easure level 45 000 MILE 72 000 KM SEVERE DUTY SERVICE 45 000 MILE 72 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses C...

Страница 1074: ...Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 48 00...

Страница 1075: ...0 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Automatic All ATF 2 Type 7176 Transmission Flui...

Страница 1076: ...Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Rear Axle Model 248 2WD 6 3 Pts 3L Limited Slip Differential Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Mode...

Страница 1077: ...0 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks...

Страница 1078: ...Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture...

Страница 1079: ...ine Oil Filter LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18...

Страница 1080: ...VICE 60 000 MILE 96 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Water Pump Weep Hole For Brockage Brake Lini...

Страница 1081: ...80W 90 2 GL 5 Gear Lube 4x4 Front All Mopar Hypoid Lubricant Axle SAE 80W 90 Lubricant GL 5 Gear Lube 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol 2 Axles with...

Страница 1082: ...Always use dipstick if available to measure level 63 000 MILE 101 000 KM SEVERE DUTY SERVICE 63 000 MILE 101 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System B...

Страница 1083: ...tem Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels...

Страница 1084: ...3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Eng...

Страница 1085: ...lled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil...

Страница 1086: ...Automatic Transmission Fluid Filter Rear Axle Fluid Front Axle Fluid 4x4 Transfer Case Fluid LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE...

Страница 1087: ...n Modifier such as Mopar Gear Oil Additive Friction Modifier FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine...

Страница 1088: ...VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter LUBRICATION SPECIFI...

Страница 1089: ...Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 78 000 MILE 130 000 KM SEVERE DUTY SERVICE 78 000 MILE 130 000 KM SEVERE DUTY SERV...

Страница 1090: ...ly API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Engine Drained 26 Qts 24 5...

Страница 1091: ...ng All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil C...

Страница 1092: ...40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater...

Страница 1093: ...nsmission Fluid 47RE Dry Fill 17 Qts 16L Rear Axle 9 1 4 Drained 4 8 Pts 2 3L Fluid Model 248 2WD 6 3 Pts 3L Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Model 286 2W...

Страница 1094: ...ure Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering Al...

Страница 1095: ...BRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 10 F SAE 15W 40 1 12 C To Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1...

Страница 1096: ...ERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter LUBRICATION...

Страница 1097: ...ned 26 Qts 24 5L Coolant 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 96 000 MILE 160 000 KM SEVERE DUTY SERVICE 96 000 MILE 160 000 KM SEVERE DU...

Страница 1098: ...Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Wheel Bearing All High Temperature Multi Grease Purporse EP Grease Automatic All ATF 2 Type 7176 Transmission Fluid Rear A...

Страница 1099: ...mited Slip Differential Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Front Axle Model 216 6 8 Pts 3 6L Lubrican...

Страница 1100: ...rake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID...

Страница 1101: ...ith Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi M...

Страница 1102: ...Over 30 F 1 C Ambient Temperature Less Than SAE 10W 30 0 F 18 C To Over 30 F 1 C Ambient Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engi...

Страница 1103: ...SPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Brake Linings Drive Belts Water Pump Weep Hole For Blockage SERVICE Rotate Tires Lubricate Steering Linkage Automatic Transmission Ba...

Страница 1104: ...ATF Rear Axle All Mopar Hypoid Lubricant Lubricant SAE 80W 90 2 GL 5 Gear Lube 4x4 Front All Mopar Hypoid Lubricant Axle SAE 80W 90 Lubricant GL 5 Gear Lube 1 SAE 10W 30 engine oil is preferred Use on...

Страница 1105: ...8 Pts 3 6L Lubricant Model 248 7 6 Pts 3 6L Transfer Case NV241 5 Pts 2 7L Fluid NV241 HD 6 5 Pts 3 5L NV241 HD W PTO 9 Pts 4 9L 1 Capacities are recommended or calculated levels Always use dipstick...

Страница 1106: ...Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe...

Страница 1107: ...ater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferr...

Страница 1108: ...Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mo...

Страница 1109: ...ands Clean Fuel Strainer REPLACE Engine Oil Engine Oil Filter Automatic Transmission Fluid Filter Rear Axle Fluid Front Axle Fluid 4x4 Fuel Filter LUBRICATION SPECIFICATIONS Material Condition Specifi...

Страница 1110: ...ction Modifier such as Mopar Gear Oil Additive Friction Modifier FLUID CAPACITIES Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7 5L Eng...

Страница 1111: ...Temperature Less Than With Block Heater 10 F 23 C Up To 0 F 18 C SAE 10W 30 Without Block Heater SAE 5W 30 Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Aut...

Страница 1112: ...ission fluid or hydroboost power steering fluid FLUID CAPACITIES FLUID CAPACITIES TABLE Item Condition Specification 1 Engine Oil Capacity Upper Safe Mark 10 Qts 9 5L Capacity Lower Safe Mark 8 Qts 7...

Страница 1113: ...f available to measure level MISCELLANEOUS NOTES Once a month check tire pressure and look for unusual wear or damage Once a month inspect battery and clean and tighten terminals as required Once a mo...

Страница 1114: ...aintenance services in this article are based on Severe Duty vehicle usage ONLY Severe Duty vehicle usage is defined as any one of the following conditions Frequent short driving less than 5 Miles 8 1...

Страница 1115: ...ileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engi...

Страница 1116: ...All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use only API approved oil with Starburst Symbol FLUID CAPACITIE...

Страница 1117: ...re Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred for use in all Dodge trucks Use on...

Страница 1118: ...Yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Tem...

Страница 1119: ...ry Fill 17 26 Pts 8 12 3L Transmission Fluid 47RE Dry Fill 17 33 Pts 8 15 6L Rear Axle 9 1 4 Drained 4 8 Pts 2 3L Fluid Model 248 2WD 6 3 Pts 3L Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Mod...

Страница 1120: ...TION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engi...

Страница 1121: ...ne Oil Filter 1 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000 miles 9 600 Km Yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Con...

Страница 1122: ...t Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter 1 1 8 0L Change...

Страница 1123: ...Drained 20 Qts 19L Coolant 8 0L Drained 24 Qts 22 7L 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 24 000 MILE 38 000 KM SEVERE DUTY SERVICE 24 0...

Страница 1124: ...Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Automatic All ATF 2 Type 7176 Transmission Fluid Rear Axle All Mopar Hypoid Lubricant Lubricant SAE 80W 90 2 GL 5 Gea...

Страница 1125: ...le Model 248 2WD 6 3 Pts 3L Limited Slip Differential Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Front Axle M...

Страница 1126: ...stilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FL...

Страница 1127: ...30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mo...

Страница 1128: ...eage is less than 6 000 miles 9 600 Km Yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30...

Страница 1129: ...VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps Brake Linings Engine Air Cleaner Air Pump Filters SERVICE Lubricate Steering Linkage Autom...

Страница 1130: ...opar Hypoid Lubricant Axle SAE 80W 90 Lubricant GL 5 Gear Lube 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol 2 Axles with Limited Slip Differentials require the...

Страница 1131: ...8L Front Axle Model 216 6 8 Pts 3 6L Lubricant Model 248 7 6 Pts 3 6L 1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 39 000 MILE 62 000 KM SEVERE D...

Страница 1132: ...oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New Filter 5 Qts 4 7L 8 0L Drained W New Filter 5 Qts 4 7L 5...

Страница 1133: ...Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES...

Страница 1134: ...8 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage...

Страница 1135: ...e Coolant Engine Air Cleaner Air Pump Filters Automatic Transmission Fluid Filter Rear Axle Fluid Front Axle Fluid 4x4 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000 m...

Страница 1136: ...f a 5 Friction Modifier such as Mopar Gear Oil Additive Friction Modifier FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New Filter 5 Qts 4 7L 8 0L Drained W New Filter 5 Qt...

Страница 1137: ...haust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter 1 1 8 0L Change oil filter at every oil change 5 9L If m...

Страница 1138: ...ted levels Always use dipstick if available to measure level 54 000 MILE 86 000 KM SEVERE DUTY SERVICE 54 000 MILE 86 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust...

Страница 1139: ...ine Oil 5 9L Drained W New Filter 5 Qts 4 7L 8 0L Drained W New Filter 5 Qts 4 7L 5 9L Drained 4 5 Qts 4 2L Engine 5 9L Drained 20 Qts 19L Coolant 8 0L Drained 24 Qts 22 7L 1 Capacities are recommende...

Страница 1140: ...ge Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New Filter...

Страница 1141: ...mileage is less than 6 000 miles 9 600 Km Yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W...

Страница 1142: ...9L Drained 20 Qts 19L Coolant 8 0L Drained 24 Qts 22 7L Automatic 47RE Dry Fill 17 33 Pts 8 15 6L Transmission Fluid Rear Axle 9 1 4 Drained 4 8 Pts 2 3L Fluid Model 248 2WD 6 3 Pts 3L Model 248 4WD 7...

Страница 1143: ...ly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperat...

Страница 1144: ...oolant Level Hoses Clamps SERVICE Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter 1 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000 miles 9 600 Km Yearl...

Страница 1145: ...E 110 000 KM SEVERE DUTY SERVICE 69 000 MILE 110 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level Hoses Clamps SERVICE Rotate...

Страница 1146: ...5 Qts 4 7L 5 9L Drained 4 5 Qts 4 2L Engine 5 9L Drained 20 Qts 19L Coolant 8 0L Drained 24 Qts 22 7L 1 Capacities are recommended or calculated levels Always use dipstick if available to measure lev...

Страница 1147: ...C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Automatic All ATF 2 Type 7176 Tr...

Страница 1148: ...3 2L Model 286 4WD 10 1 Pts 4 8L Rear Axle Model 248 2WD 6 3 Pts 3L Limited Slip Differential Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L...

Страница 1149: ...F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Link...

Страница 1150: ...oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C...

Страница 1151: ...SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter 1 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000 miles 9 600 Km Yearly replace th...

Страница 1152: ...M 82 MONTH NORMAL SERVICE 82 500 MILE 132 000 KM 82 MONTH NORMAL SERVICE VERIFY Last Major Service Was Performed REPLACE Oxygen Sensor 5 9L Only 1 1 Requires service reminder indicator light If so equ...

Страница 1153: ...5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant Automatic All ATF...

Страница 1154: ...del 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Rear Axle Model 248 2WD 6 3 Pts 3L Limited Slip Differential Model 248 4WD 7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 2...

Страница 1155: ...ent Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubrican...

Страница 1156: ...Km Yearly replace the oil filter at every oil change LUBRICATION SPECIFICATIONS Material Condition Specification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient T...

Страница 1157: ...ngine Coolant Level Hoses Clamps SERVICE Rotate Tires Lubricate Steering Linkage REPLACE Engine Oil Engine Oil Filter 1 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000...

Страница 1158: ...1 Capacities are recommended or calculated levels Always use dipstick if available to measure level 96 000 MILE 154 000 KM SEVERE DUTY SERVICE 96 000 MILE 154 000 KM SEVERE DUTY SERVICE VERIFY Last Ma...

Страница 1159: ...age Lubricant Lubricant Wheel Bearing All High Temperature Multi Grease Purporse EP Grease Automatic All ATF 2 Type 7176 Transmission Fluid Rear Axle All Mopar Hypoid Lubricant Lubricant SAE 80W 90 2...

Страница 1160: ...7 3 Pts 3 4L Model 267 2WD 7 Pts 3 3L Model 267 4WD 7 8 Pts 3 6L Model 286 2WD 6 8 Pts 3 2L Model 286 4WD 10 1 Pts 4 8L Front Axle Model 216 6 8 Pts 3 6L Lubricant Model 248 7 6 Pts 3 6L 1 Capacities...

Страница 1161: ...ke Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Spe...

Страница 1162: ...0 C Engine All 50 50 Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use onl...

Страница 1163: ...pecification Engine Oil Ambient Temperature Above 0 F SAE 10W 30 1 18 C To Over 100 F 38 C Ambient Temperature Less Than SAE 5W 30 20 F 29 C Up To 32 F 0 C Engine All 50 50 Mixture Of Coolant Distille...

Страница 1164: ...Automatic Transmission Bands REPLACE Engine Oil Engine Oil Filter Automatic Transmission Fluid Filter Transfer Case Fluid Rear Axle Fluid Front Axle Fluid 4x4 Engine Coolant 1 8 0L Change oil filter...

Страница 1165: ...th Limited Slip Differentials require the use of a 5 Friction Modifier such as Mopar Gear Oil Additive Friction Modifier FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New F...

Страница 1166: ...to measure level 111 000 MILE 185 000 KM SEVERE DUTY SERVICE 111 000 MILE 185 000 KM SEVERE DUTY SERVICE VERIFY Last Major Service Was Performed INSPECT Exhaust System Brake Hoses Engine Coolant Level...

Страница 1167: ...ed W New Filter 5 Qts 4 7L 8 0L Drained W New Filter 5 Qts 4 7L 5 9L Drained 4 5 Qts 4 2L Engine 5 9L Drained 20 Qts 19L Coolant 8 0L Drained 24 Qts 22 7L 1 Capacities are recommended or calculated le...

Страница 1168: ...Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst Symbol FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New Filter 5 Qts 4 7...

Страница 1169: ...olant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Steering All Mopar Multi Mileage Linkage Lubricant Lubricant 1 SAE 10W 30 engine oil is preferred Use only API approved oil with Starburst S...

Страница 1170: ...uid 4x4 Spark Plugs Ignition Cables PCV Valve 5 9L EGR Valve 5 9L Distributor Cap Rotor 5 9L 1 8 0L Change oil filter at every oil change 5 9L If mileage is less than 6 000 miles 9 600 Km Yearly repla...

Страница 1171: ...ive Friction Modifier FLUID CAPACITIES Item Condition Specification 1 Engine Oil 5 9L Drained W New Filter 5 Qts 4 7L 8 0L Drained W New Filter 5 Qts 4 7L 5 9L Drained 4 5 Qts 4 2L Engine 5 9L Drained...

Страница 1172: ...Mixture Of Coolant Distilled Water Ethylene Glycol Brake Fluid All DOT 3 Automatic All ATF 2 Type 7176 Transmission Fluid Transfer Case All ATF 2 Type 7176 Fluid Or DEXRON III ATF Manual NV 4500 All...

Страница 1173: ...ar Oil Additive Friction Modifier 3 Never add gear oil automatic transmission fluid or hydroboost power steering fluid FLUID CAPACITIES FLUID CAPACITIES TABLE Item Condition Specification 1 Engine Oil...

Страница 1174: ...t Refrigerant A C System Capacity 7 75 Oz 230ML Oil Fuel Tank 119 139 Wheelbase Vehicles 26 Gal 98L All Others 35 Gal 132L 1 Capacities are recommended or calculated levels Always use dipstick if avai...

Страница 1175: ...roup 34 500 60 3 3L Group 34 500 60 3 8L Std Battery Group 34 600 66 Opt Battery Group 34 685 72 Dakota Durango Std Battery Group 27 600 66 Opt Battery Group 27 750 75 Ram Pickup 3 9L 5 2L 5 9L Gasoli...

Страница 1176: ...line filler door 3 Quantity includes heater and coolant recovery tank Add 2 qts 1 9L if equipped with rear heater 4 Add this amount of fluid Start engine and shift transaxle through all gears and back...

Страница 1177: ...type of transmission used before servicing The AX 15 uses a flywheel housing bolted to the front of the transmission The NV 3500 uses a flywheel housing which is an integral part of the transmission h...

Страница 1178: ...entified by model number stamped on identification tag on rear of transfer case just above filler plug FLUID CAPACITIES RAM PICKUP Application 1 Quantity Crankcase Includes Filter 2 3 9L 4 0 Qts 3 8L...

Страница 1179: ...of transmission used before servicing The NV 3500 uses a flywheel housing which is an integral part of the transmission housing The NV 4500 uses a flywheel housing which is bolted to the front of the...

Страница 1180: ...temperature Adjust fluid level to MAX mark on dipstick Approximate drain and refill capacity is 4 0 qts 3 8L 4 Quantity may vary by type of oil cooler and oil cooler lines 5 Use only Mopar power stee...

Страница 1181: ...vere service Severe service is described as use of ethanol fuel frequent short trip operation of less than 5 miles long periods of engine idling trailer towing police taxi local delivery service or op...

Страница 1182: ...ck Front Wheel Bearings Normal Service 18 22 500 Severe Service 2 21 000 1 Different interval may be required for normal and severe service Severe service is described as long periods of engine idling...

Страница 1183: ...and severe service Severe service is described as long periods of engine idling frequent short trip operation of less than 5 miles trailer towing off highway operation snow removal operation or opera...

Страница 1184: ...described as long periods of engine idling frequent short trip operation of less than 5 miles trailer towing off highway operation snow removal operation or operating in dusty or excessively hot condi...

Страница 1185: ...or operating in dusty or excessively hot conditions 3 Monthly interval is not available from manufacturer 4 Inspect air filter every 15 000 miles and replace as necessary Replace at 30 000 miles unle...

Страница 1186: ...o 2500 and 3500 Federal models with 8 0L engine and all 3500 models with 5 9L gasoline engine 2 Different interval may be required for normal and severe service Severe service is described as long per...

Страница 1187: ...requent short trip operation of less than 5 miles trailer towing off highway operation snow removal operation or operating in dusty or excessively hot conditions 2 Service interval is not available fr...

Страница 1188: ...om manufacturer 3 Inspect air filter every 15 000 miles and replace as necessary Replace at 30 000 miles unless previously replaced during inspection 4 Replace coolant at 45 000 miles or 36 months whi...

Страница 1189: ...at ignition coil to prevent engine from starting Check engine compression with all spark plugs removed and throttle wide open COMPRESSION SPECIFICATIONS Application Specification Compression Ratio Car...

Страница 1190: ...c lifters No adjustments are required 5 9L Diesel Ram Pickup Valve adjustment is recommended every 150 months or 150 000 miles during normal service every 135 000 miles during severe service Severe se...

Страница 1191: ...ation is not available from manufacturer HIGH TENSION WIRE RESISTANCE HIGH TENSION WIRE RESISTANCE Application Ohms Caravan 1 2 4L Cylinder No 1 Or 4 4200 Cylinder No 2 Or 3 3200 3 0L Cylinder No 1 14...

Страница 1192: ...ms per one inch or 3000 12 000 ohms per 12 inches SPARK PLUGS SPARK PLUG TYPE 1 Application Champion No Caravan 2 4L RC12YC5 3 0L RN11YC4 3 3L 3 8L RN14PMP5 Dakota 2 5L RC12ECC 3 9L 5 2L 5 9L RC12LC4...

Страница 1193: ...y 048 053 1 22 1 35 20 27 Voyager 2 4L 048 053 1 22 1 35 20 27 3 0L 039 044 1 00 1 12 20 27 3 3L 048 053 1 22 1 35 20 27 1 Check spark plug gap specification on underhood vehicle emission control labe...

Страница 1194: ...Fig 2 Firing Order Distributor Rotation 2 5L 4 Cyl Dakota...

Страница 1195: ...Fig 3 Firing Order Distributor Rotation 3 0L V6 Caravan Voyager Fig 4 Firing Order 3 3L 3 8L V6 Caravan Town Country Voyager...

Страница 1196: ...Fig 5 Firing Order Distributor Rotation 3 9L V6 Dakota Durango Ram Pickup Ram Van Ram Wagon...

Страница 1197: ...Fig 6 Firing Order Distributor Rotation 5 2L 5 9L Gasoline V8 Dakota Durango Ram Pickup Ram Van Ram Wagon Fig 7 Firing Order 5 9L Diesel 6 Cyl Ram Pickup...

Страница 1198: ...NOT attempt to adjust ignition timing NOTE On Dakota 3 9L 5 2L and 5 9L Durango Ram Pickup 3 9L 5 2L and 5 9L gasoline Ram Van and Ram Wagon the distributor can be checked for proper location See FUEL...

Страница 1199: ...th engine off ignition on and using scan tool to activate fuel pump 3 Information is not available from manufacturer FUEL INJECTION PUMP FUEL TRANSFER PUMP DIESEL NOTE For fuel injection pump timing s...

Страница 1200: ...Miles Or Less 3 560 910 More Than 1000 Miles 3 610 910 3 3L 3 8L 2 1000 Miles Or Less 3 525 875 More Than 1000 Miles 3 575 875 Dakota 2 5L 500 900 3 9L 5 2L 5 9L 1 500 900 Durango 1 500 900 Ram Pickup...

Страница 1201: ...8 0L 1 2 At Idle 35 90 At Full Throttle Less Than 4 50 5 9L Diesel 3 Ram Van Ram Wagon 1 2 At Idle 35 90 At Full Throttle Less Than 4 50 1 Measure voltage at center terminal on throttle position senso...

Страница 1202: ...moves forward and backward TROUBLE SHOOTING NOTE Before any testing is attempted the battery should be fully charged and all connections and terminals cleaned and tightened to ensure proper continuity...

Страница 1203: ...and retest system 3 Remove power seat switch See POWER SEAT SWITCH under REMOVAL INSTALLATION Check for battery voltage at power supply Red wire on Ram Van and Ram Wagon Red Light Blue wire on Ram Pi...

Страница 1204: ...B E B K B L Vertical Up A E A M B N B J Vertical Down A J A N B M B E Horizontal Forward B K A L Horizontal Aft B L A K Front Tilt Up B N A M Front Tilt Down A N B M Rear Tilt Up A E B J Rear Tilt Dow...

Страница 1205: ...under seat Remove 4 nuts attaching seat frame to floor pan The rear nuts are accessed by lifting up the seat riser rear shield Remove seat from vehicle To install reverse removal procedure Tighten se...

Страница 1206: ...nector and disconnect connector Remove 2 screws holding switch to shield Remove switch from shield To install reverse removal procedure Removal Installation Ram Van Ram Wagon Remove seat adjuster and...

Страница 1207: ...Fig 3 Power Seat System Wiring Diagram Ram Pickup...

Страница 1208: ...Fig 4 Power Seat System Wiring Diagram Ram Van Ram Wagon...

Страница 1209: ...using Starter has serviceable gear and clutch assembly only If starter solenoid fails entire starter motor must be replaced All models use a starter relay in starter circuit between the battery and st...

Страница 1210: ...KING TEST NOTE Ensure engine is at normal operating temperature High viscosity oil extreme cold temperatures or tight engine will increase amperage draw 1 Using a battery load tester connect positive...

Страница 1211: ...starter solenoid or replace positive battery cable SOLENOID CIRCUIT TEST NOTE Perform SOLENOID CIRCUIT TEST before testing starter relay and starter relay circuit Ensure A T is in Park position or M...

Страница 1212: ...Fig 1 Identifying Starter Relay Terminals Except Concorde Dakota Durango Intrepid LHS Ram Van Ram Wagon 300M Courtesy of Chrysler Corp...

Страница 1213: ...Fig 2 Identifying Starter Relay Terminals Concorde Dakota Durango Intrepid LHS Ram Van Ram Wagon 300M Courtesy of Chrysler Corp...

Страница 1214: ...switch See CLUTCH POSITION SWITCH TEST If battery voltage is not present repair wiring between ignition switch and starter relay socket as necessary 6 On M T models connect voltmeter negative lead to...

Страница 1215: ...ITCH TEST NOTE For ignition switch testing procedures see appropriate STEERING COLUMN SWITCHES article in ACCESSORIES EQUIPMENT BENCH TESTING SOLENOID TEST 1 With starter removed from vehicle remove s...

Страница 1216: ...Gasoline Engines 125 250 Amps Ram Van Ram Wagon 125 250 Amps No Load Test At 11 Volts Maximum Amps Caravan Town Country Voyager 73 Amps Dakota Durango 2 5L 90 Amps 3 9L 5 2L 5 9L 73 Amps Ram Pickup Ga...

Страница 1217: ...n Ft Lbs N m Starter Mounting Bolts Nuts All Except Dakota Durango Ram Pickup Ram Van Ram Wagon 40 54 Dakota Durango 2 5L 33 45 3 9L 5 2L 5 9L 50 68 Ram Pickup Diesel Engines 32 43 Gasoline Engines 50...

Страница 1218: ...Fig 3 Starting System Wiring Diagram Breeze Cirrus Stratus...

Страница 1219: ...Fig 4 Starting System Wiring Diagram Caravan Town Country Voyager...

Страница 1220: ...Fig 5 Starting System Wiring Diagram Concorde Intrepid LHS 300M...

Страница 1221: ...Fig 6 Starting System Wiring Diagram Dakota...

Страница 1222: ...Fig 7 Starting System Wiring Diagram Durango...

Страница 1223: ...Fig 8 Starting System Wiring Diagram Neon...

Страница 1224: ...Fig 9 Starting System Wiring Diagram Ram Pickup...

Страница 1225: ...Fig 10 Starting System Wiring Diagram Ram Van Ram Wagon...

Страница 1226: ...Fig 11 Starting System Wiring Diagram Sebring Convertible...

Страница 1227: ...ounting bracket bolts must be carefully torqued to ensure proper sensor operation Never apply power to ABRS if a sensor is not rigidly attached to vehicle To avoid accidental air bag deployment while...

Страница 1228: ...screws Disconnect horn wires Remove horn switch 3 Remove steering wheel retaining nut Reference mark steering wheel and steering shaft Using puller remove steering wheel To install reverse removal pro...

Страница 1229: ...ig 1 Exploded View Of Steering Column Typical Courtesy of Chrysler Corp OVERHAUL NOTE Steering column is not serviceable except for trim switches and steering wheel If service is required replace colu...

Страница 1230: ...ndshield wash systems use a common switch assembly multifunction switch mounted within upper steering column housing Ignition switch and lock cylinder are incorporated into an assembly attached to sid...

Страница 1231: ...ire to turn signal switch Faulty switch connections Open or grounded circuit in wiring to external lights Turn Signal Inoperative One Side Faulty external bulb Poor ground at external light Open circu...

Страница 1232: ...Corp IGNITION SWITCH NOTE For ignition switch circuit identification see IGNITION SWITCH CIRCUIT FUNCTIONS table Remove ignition switch See IGNITION SWITCH under REMOVAL INSTALLATION Check continuity...

Страница 1233: ...of Chrysler Corp MULTIFUNCTION SWITCH Turn Signal Hazard Warning Switch Disconnect negative battery cable Remove multifunction switch See MULTIFUNCTION SWITCH under REMOVAL INSTALLATION Check continui...

Страница 1234: ...relay from Power Distribution Center PDC Measure voltage between ground and horn relay terminals No 30 and 86 in PDC See Fig 4 If battery voltage exists at both terminals go to next step If battery v...

Страница 1235: ...If continuity exists go to next step If continuity does not exist check for proper installation of steering column mounting nuts 2 Disable air bag system and remove driver s air bag module See appropr...

Страница 1236: ...er fuse is blown repair short circuit and replace fuse 5 Check for battery voltage at hazard warning fuse in PDC Turn ignition on Check for battery voltage at turn signal fuse in junction block If bat...

Страница 1237: ...Dakota and Durango is not provided by manufacturer Removal Installation Disconnect negative battery cable Remove 4 air bag nuts from back of steering wheel Pull air bag module back far enough to disc...

Страница 1238: ...rk lock dowel and park lock slider linkage See Fig 6 Slide park lock slider linkage forward completely then back 25 6 mm Apply a light coating of grease to column lock flag 4 Carefully install ignitio...

Страница 1239: ...cylinder turn lock cylinder to RUN position so retaining pin can be depressed Install lock cylinder in ignition switch aligning slot until retaining pin engages Turn key to OFF or LOCK position Pull...

Страница 1240: ...cable On tilt columns remove tilt lever On all models remove upper and lower steering column covers Remove tamper proof Torx screws Pull switch away from column and loosen connector screw screw remai...

Страница 1241: ...Lbs N m Air Bag Retaining Nuts 90 97 9 11 Ignition Switch Mounting Screw 22 30 2 5 3 5 Multifunction Switch Connector Screw 17 2 Multifunction Switch Mounting Screw 17 2 Steering Column Cover Screw 1...

Страница 1242: ...Fig 10 Horn System Wiring Diagram Durango...

Страница 1243: ...Fig 11 Horn System Wiring Diagram Ram Pickup...

Страница 1244: ...onents with solvent and dry with compressed air Inspect all parts for burrs chips wear flat spots or cracks Replace all damaged or worn parts INSTALLATION NOTE When aligning upper ball joint nut to in...

Страница 1245: ...en lug nuts to specification TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application 1 Ft Lbs N m ABS Sensor Bolt 15 11 Brake Caliper Bolt 38 52 Drag Link Nut 65 88 Hub To Steering Knuckle Bolt 125 16...

Страница 1246: ...d rack piston See Fig 1 When worm shaft is turned the rack piston moves and piston teeth mesh with sector shaft teeth turning pitman arm which turns steering linkage The steering linkage consists of p...

Страница 1247: ...pen shutoff valve on test gauge With a thermometer in fluid reservoir start engine and warm fluid to 150 170 F 66 77 C Turning wheels from stop to stop will aid in warming fluid DO NOT hold wheels aga...

Страница 1248: ...auge and connect pressure hose LUBRICATION CAPACITY CAPACITY Models Pts L Dakota 4WD 2 5 1 2 Ram Pickup Ram Van Wagon 2 7 1 3 FLUID TYPE CAUTION DO NOT use Automatic Transmission Fluid ATF Use Mopar P...

Страница 1249: ...djustments 1 Remove steering gear from vehicle See STEERING GEAR under REMOVAL INSTALLATION Ensure steering gear is empty of hydraulic fluid Rotate steering from stop to stop several times to drain fl...

Страница 1250: ...stub shaft and count turns required to go from stop to stop Turn stub shaft back 1 2 number of turns to center steering gear Fig 4 Adjusting Over Center Preload Courtesy of Chrysler Corp 2 Rotate sect...

Страница 1251: ...G under LUBRICATION VACUUM POWER STEERING PUMP DIESEL Removal 1 Disconnect negative battery cable Place drip pan under vacuum power steering pump Disconnect and cap power brake booster hose at vacuum...

Страница 1252: ...ical connector Install oil feed line to vacuum pump and tighten to 60 INCH lbs 7 N m To complete installation reverse removal procedure Fill and bleed system See HYDRAULIC SYSTEM BLEEDING under LUBRIC...

Страница 1253: ...e removing parts Remove 2 studs and fitting from back of pump See Fig 7 2 Rock reservoir by hand or tap with soft face mallet to remove Remove O ring from housing and reservoir Remove flow control val...

Страница 1254: ...N m Tighten nuts and bolts to specification See TORQUE SPECIFICATIONS Add power steering fluid DO NOT use ATF Bleed hydraulic system See HYDRAULIC SYSTEM BLEEDING under LUBRICATION Fig 7 Exploded View...

Страница 1255: ...vehicle Place wheels in straight ahead position Disconnect steering linkage center link from pitman arm Disconnect stabilizer bar if necessary 2 Place reference mark on pitman arm and sector shaft Re...

Страница 1256: ...t 3 minutes DO NOT turn wheels during this time Rotate wheels both directions and check for leaks Refill pump reservoir CENTER LINK Removal Installation Separate tie rods idler arm steering and drag l...

Страница 1257: ...Removal Remove cotter pin and nut from tie rod end Using Tie Rod End Puller C 3894 A remove tie rod end from steering knuckle or center link Loosen lock nut or clamp bolt Remove tie rod end Note numb...

Страница 1258: ...ing Studs 35 47 Pitman Arm Nut 1 185 251 Sector Shaft Adjuster Screw Lock Nut 20 27 Dakota 4WD Ram Van Wagon 20 27 Ram Pickup 43 58 Steering Gear Housing To Frame Bolt Dakota 4WD 65 88 Ram Pickup 140...

Страница 1259: ...SION MODULES AIR RIDE SUSPENSION RELAYS COMPRESSOR AIR RIDE SUSPENSION SWITCHES ON OFF AIR RIDE SUSPENSION TORSION SPRINGS COUNTER BALANCING AIR RIDE SUSPENSION TUBING AIR RIDE SUSPENSION WARNING LAMP...

Страница 1260: ...o the customer according to industry standards Given that the industry did not have such standards the Motorist Assurance Program successfully promulgated industry inspection communication standards i...

Страница 1261: ...ts of this inspection must be explained to the customer and documented on an inspection form The condition of the vehicle and its components will indicate what services part replacements may be Requir...

Страница 1262: ...s that required or suggested repair or replacement is recommended the customer must be informed of the generally acceptable repair replacement options whether or not performed by the shop When present...

Страница 1263: ...hicles with height or load sensing proportioning valve equipped braking systems unless these components are original equipment AIR RIDE SUSPENSION NOTE Depending on the air suspension design there are...

Страница 1264: ...replacement AIR RIDE SUSPENSION AIR SPRINGS AIR RIDE SUSPENSION AIR SPRING INSPECTION Condition Code Procedure Attaching hardware broken A Require replacement of broken part Attaching hardware incorre...

Страница 1265: ...re repair or replacement Does not build pressure A 1 Further inspection required Excessive run time B 2 Further inspection required Inoperative A Require replacement Leaking A Require repair or replac...

Страница 1266: ...nsor failure AIR RIDE SUSPENSION MODULES AIR RIDE SUSPENSION MODULE INSPECTION Condition Code Procedure Attaching hardware loose A Require repair or replacement of loose part Attaching hardware missin...

Страница 1267: ...ing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attaching hardware threads stripped threads missing A Require replacement of part with stripped...

Страница 1268: ...quire replacement Fusible link blown A Require replacement Open A Require repair or replacement Poor ground A Require repair or replacement Routed incorrectly B Require rerouting according to vehicle...

Страница 1269: ...ed part if available otherwise replace ball joint Attaching hardware incorrect A Require replacement of incorrect part if available otherwise replace ball joint Attaching hardware loose A Require repa...

Страница 1270: ...ill accelerate wear 5 If the greaseable ball joint still will not take grease after replacing the grease fitting suggest replacement of ball joint 6 Check for bent stud or damaged taper hole 7 Check f...

Страница 1271: ...placement Surface cracking weather checked No service suggested or required 1 If noise isolated to bushing suggest repair or replacement CAUTION Use only approved lubricant on rubber bushings Petroleu...

Страница 1272: ...ire repair or replacement Threads stripped threads missing A 7 Require replacement Wear exceeds manufacturer s specifications B Require replacement 1 If greaseable grease joint If problem persists or...

Страница 1273: ...ds missing A Require replacement CONTROL ARMS CONTROL ARM INSPECTION Condition Code Procedure Attaching hardware bent B Require repair or replacement of bent part if available otherwise replace contro...

Страница 1274: ...DRAG LINK INSPECTION Condition Code Procedure Attaching hardware incorrect A Require replacement of incorrect part if available otherwise replace drag link Attaching hardware loose A Require repair o...

Страница 1275: ...e joint and will accelerate wear 4 Torn grease boot will allow contaminants to enter the joint and will accelerate wear 5 Missing grease seal will allow contaminants to enter the joint and will accele...

Страница 1276: ...acement of missing part if available otherwise replace idler arm Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace idler ar...

Страница 1277: ...to enter joint and will accelerate wear 6 If manufacturer s procedures and specifications exist use those procedures and specifications otherwise use an approved inspection method such as the dry par...

Страница 1278: ...of missing part if available otherwise replace king pin Looseness exceeds manufacturer s specifications B Require replacement of worn parts Seized A Require replacement Threads damaged A Require repai...

Страница 1279: ...es missing A Require replacement Stud bent B 8 Require replacement Stud broken A 8 Require replacement Stud loose in taper hole A 8 Require repair or replacement Taper hole elongated A 9 Require repla...

Страница 1280: ...ir or replacement of the following components may be required if performed as part of a power steering pump overhaul or rebuild service to meet a minimum rebuild standard POWER STEERING HYDRAULIC PUMP...

Страница 1281: ...f cap Reservoir cap missing C Require replacement of cap Seized A Require replacement Threads damaged A Require repair or replacement Threads stripped threads missing A Require replacement 1 Determine...

Страница 1282: ...ng hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace relay rod Attaching hardware threads stripped threads missing A Require replacem...

Страница 1283: ...S You are not required to replace shocks or struts in axle sets However when replacing a shock or strut due to the conditions that follow you may suggest replacement of the other shock or strut on the...

Страница 1284: ...wise replace shock or strut Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace shock or strut Attaching hardware threads str...

Страница 1285: ...e replacement Noise 2 5 Further inspection required Piston rod bent A Require replacement Piston rod broken A Require replacement Piston rod has surface defect 2 Suggest replacement Piston rod threads...

Страница 1286: ...r or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attachin...

Страница 1287: ...Broken all springs except secondary leave s on multi leaf springs A Require replacement Coil clash 1 Require ride height check Coil spring insulator deteriorated 2 Suggest replacement of insulator Co...

Страница 1288: ...STEEL POWER STEERING LINES CAUTION When replacing steel power steering lines be sure to use a replacement product that meets or exceeds OEM design specifications STEEL POWER STEERING LINE INSPECTION C...

Страница 1289: ...t with damaged threads Attaching hardware threads stripped threads missing A Require replacement of part with stripped threads Bent B Require replacement Broken A Require replacement Taper hole elonga...

Страница 1290: ...pped threads if available otherwise replace steering damper Binding A Require replacement Damper body dented A 1 Further inspection required Damper body punctured A Require replacement Damping none A...

Страница 1291: ...or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attaching...

Страница 1292: ...sary to determine the extent of the system failure the suggestion may be made to rebuild or replace the power steering pump Repair or replacement of the following components may be required if perform...

Страница 1293: ...replacement of coupler Fluid contaminated B 1 Require flushing and refilling of the system Gasket leaking A Require repair or replacement Hard steering on cold start up 1 2 Suggest repair or replaceme...

Страница 1294: ...of incorrect part Attaching hardware loose A Require repair or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require...

Страница 1295: ...replacement Split 1 Suggest replacement STRUT RODS STRUT ROD INSPECTION Condition Code Procedure Adjusting nut seized A 1 Require repair or replacement Attaching hardware bent B Require repair or repl...

Страница 1296: ...y the bearing should be replaced if it is available separately otherwise replace the bearing plate assembly STRUT UPPER BEARING PLATE ASSEMBLY INSPECTION Condition Code Procedure Attaching hardware br...

Страница 1297: ...t if available otherwise replace link Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace link Attaching hardware threads str...

Страница 1298: ...WAY BAR INSPECTION Condition Code Procedure Attaching hardware broken A Require replacement of broken part if available otherwise replace sway bar Attaching hardware corroded affecting structural inte...

Страница 1299: ...cement of sleeve or tie rod end Adjusting sleeve clamps out of position B Require repair Adjusting sleeve corroded affecting structural integrity A Require replacement of sleeve or tie rod end Adjusti...

Страница 1300: ...oint and will accelerate wear 5 Torn grease boot will allow contaminants to enter joint and will accelerate wear 6 If greaseable tie rod end will not take grease after replacing the grease fitting sug...

Страница 1301: ...ripped threads missing A 7 Require replacement Wear exceeds manufacturer s specifications B Require replacement 1 Cracked grease boot will allow contaminants to enter joint and will accelerate wear 2...

Страница 1302: ...LS NOTE When replacing or repacking wheel bearings grease seal replacement is required You are not required to replace these components in axle sets Determine the need to replace based upon the indivi...

Страница 1303: ...on component replacement or correction kits may be required Errors in set back and steering axis inclination SAI are often attributable to failed or damaged components and must be corrected prior to p...

Страница 1304: ...d dismount or mount tires Explosions of tire and wheel assembly can result from improper mounting possibly causing serious injury or death WARNING Consult the vehicle owner s manual or vehicle placard...

Страница 1305: ...ull or lead caused by tire A Require repair or replacement Radial and bias or bias belted ply tires on same axle B Require repair or replacement Radials are on the front and not on the rear B 2 Requir...

Страница 1306: ...in tubeless tire Recommendation for repair or replacement should be based upon condition of tires and or wheel listed in these guidelines VALVE STEMS VALVE STEM INSPECTION Condition Code Procedure Be...

Страница 1307: ...g to mount a tire of one diameter on a wheel of a different diameter or flange type may result in serious injury or death If the wheel identification stamp is not legible or cannot be found do not use...

Страница 1308: ...re replacement Run out beyond OEM specs B Require replacement Stud holes elongated A 2 Require replacement Welded or brazed repair 2 Suggest replacement Welds leaking A Require replacement Wheel cente...

Страница 1309: ...rol arms steering knuckles coil springs and shock absorbers See Fig 1 Upper control arms are mounted to frame side rails Lower control arms are mounted to crossmember Steering knuckles are mounted bet...

Страница 1310: ...int stud Using Ball Joint Breaker C 4150A separate ball joint from steering knuckle 3 Remove lower shock bolt from suspension arm Lower jack and suspension arm until spring tension is relieved Remove...

Страница 1311: ...e Remove link rod retaining nut at each end of stabilizer bar Remove outer retainers and rubber bushings from link rods Remove stabilizer bar clamps from frame rails Remove stabilizer bar from vehicle...

Страница 1312: ...remaining components reverse removal procedure TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft Lbs N m Ball Joint Nuts Lower Light Duty 95 129 Heavy Duty 110 149 Upper 60 81 Lower Control A...

Страница 1313: ...o the frame with 3 studs on a ring The shock is mounted at bottom of axle below the spring seat See Fig 1 A track bar is used and is attached to a frame rail bracket with a ball stud The track bar is...

Страница 1314: ...IONS table LOWER CONTROL ARM Removal Installation 1 Raise and support vehicle Scribe alignment marks on cam adjusters and suspension arm for installation reference Remove lower control arm nut cam and...

Страница 1315: ...Fig 2 Removing Front Shock Absorber Assembly Courtesy of Chrysler Corp STABILIZER BAR...

Страница 1316: ...emoving Stabilizer Bar Assembly Courtesy of Chrysler Corp STEERING KNUCKLE Removal Installation 1 Raise and support vehicle Remove wheel and tire assembly Remove tie rod or drag link end from steering...

Страница 1317: ...val Installation 1 Raise and support vehicle Remove wheel Remove caliper and rotor Remove ABS sensor if equipped Remove cotter pin and axle hub nut 2 Remove wheel bearing and hub assembly hub to knuck...

Страница 1318: ...on Ft Lbs N m Anti Rattle Springs Clips 15 20 Axle Nut 175 237 Ball Joint Nut Model 44 Lower 80 108 Upper 75 102 Model 60 Lower 140 160 190 217 Upper 70 95 Cam Adjustment Nut 170 230 Control Arm Lower...

Страница 1319: ...NSION MODULES AIR RIDE SUSPENSION RELAYS COMPRESSOR AIR RIDE SUSPENSION SWITCHES ON OFF AIR RIDE SUSPENSION TORSION SPRINGS COUNTER BALANCING AIR RIDE SUSPENSION TUBING AIR RIDE SUSPENSION WARNING LAM...

Страница 1320: ...o the customer according to industry standards Given that the industry did not have such standards the Motorist Assurance Program successfully promulgated industry inspection communication standards i...

Страница 1321: ...ts of this inspection must be explained to the customer and documented on an inspection form The condition of the vehicle and its components will indicate what services part replacements may be Requir...

Страница 1322: ...s that required or suggested repair or replacement is recommended the customer must be informed of the generally acceptable repair replacement options whether or not performed by the shop When present...

Страница 1323: ...hicles with height or load sensing proportioning valve equipped braking systems unless these components are original equipment AIR RIDE SUSPENSION NOTE Depending on the air suspension design there are...

Страница 1324: ...replacement AIR RIDE SUSPENSION AIR SPRINGS AIR RIDE SUSPENSION AIR SPRING INSPECTION Condition Code Procedure Attaching hardware broken A Require replacement of broken part Attaching hardware incorre...

Страница 1325: ...re repair or replacement Does not build pressure A 1 Further inspection required Excessive run time B 2 Further inspection required Inoperative A Require replacement Leaking A Require repair or replac...

Страница 1326: ...nsor failure AIR RIDE SUSPENSION MODULES AIR RIDE SUSPENSION MODULE INSPECTION Condition Code Procedure Attaching hardware loose A Require repair or replacement of loose part Attaching hardware missin...

Страница 1327: ...ing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attaching hardware threads stripped threads missing A Require replacement of part with stripped...

Страница 1328: ...quire replacement Fusible link blown A Require replacement Open A Require repair or replacement Poor ground A Require repair or replacement Routed incorrectly B Require rerouting according to vehicle...

Страница 1329: ...ed part if available otherwise replace ball joint Attaching hardware incorrect A Require replacement of incorrect part if available otherwise replace ball joint Attaching hardware loose A Require repa...

Страница 1330: ...ill accelerate wear 5 If the greaseable ball joint still will not take grease after replacing the grease fitting suggest replacement of ball joint 6 Check for bent stud or damaged taper hole 7 Check f...

Страница 1331: ...placement Surface cracking weather checked No service suggested or required 1 If noise isolated to bushing suggest repair or replacement CAUTION Use only approved lubricant on rubber bushings Petroleu...

Страница 1332: ...ire repair or replacement Threads stripped threads missing A 7 Require replacement Wear exceeds manufacturer s specifications B Require replacement 1 If greaseable grease joint If problem persists or...

Страница 1333: ...ds missing A Require replacement CONTROL ARMS CONTROL ARM INSPECTION Condition Code Procedure Attaching hardware bent B Require repair or replacement of bent part if available otherwise replace contro...

Страница 1334: ...DRAG LINK INSPECTION Condition Code Procedure Attaching hardware incorrect A Require replacement of incorrect part if available otherwise replace drag link Attaching hardware loose A Require repair o...

Страница 1335: ...e joint and will accelerate wear 4 Torn grease boot will allow contaminants to enter the joint and will accelerate wear 5 Missing grease seal will allow contaminants to enter the joint and will accele...

Страница 1336: ...acement of missing part if available otherwise replace idler arm Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace idler ar...

Страница 1337: ...to enter joint and will accelerate wear 6 If manufacturer s procedures and specifications exist use those procedures and specifications otherwise use an approved inspection method such as the dry par...

Страница 1338: ...of missing part if available otherwise replace king pin Looseness exceeds manufacturer s specifications B Require replacement of worn parts Seized A Require replacement Threads damaged A Require repai...

Страница 1339: ...es missing A Require replacement Stud bent B 8 Require replacement Stud broken A 8 Require replacement Stud loose in taper hole A 8 Require repair or replacement Taper hole elongated A 9 Require repla...

Страница 1340: ...ir or replacement of the following components may be required if performed as part of a power steering pump overhaul or rebuild service to meet a minimum rebuild standard POWER STEERING HYDRAULIC PUMP...

Страница 1341: ...f cap Reservoir cap missing C Require replacement of cap Seized A Require replacement Threads damaged A Require repair or replacement Threads stripped threads missing A Require replacement 1 Determine...

Страница 1342: ...ng hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace relay rod Attaching hardware threads stripped threads missing A Require replacem...

Страница 1343: ...S You are not required to replace shocks or struts in axle sets However when replacing a shock or strut due to the conditions that follow you may suggest replacement of the other shock or strut on the...

Страница 1344: ...wise replace shock or strut Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace shock or strut Attaching hardware threads str...

Страница 1345: ...e replacement Noise 2 5 Further inspection required Piston rod bent A Require replacement Piston rod broken A Require replacement Piston rod has surface defect 2 Suggest replacement Piston rod threads...

Страница 1346: ...r or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attachin...

Страница 1347: ...Broken all springs except secondary leave s on multi leaf springs A Require replacement Coil clash 1 Require ride height check Coil spring insulator deteriorated 2 Suggest replacement of insulator Co...

Страница 1348: ...STEEL POWER STEERING LINES CAUTION When replacing steel power steering lines be sure to use a replacement product that meets or exceeds OEM design specifications STEEL POWER STEERING LINE INSPECTION C...

Страница 1349: ...t with damaged threads Attaching hardware threads stripped threads missing A Require replacement of part with stripped threads Bent B Require replacement Broken A Require replacement Taper hole elonga...

Страница 1350: ...pped threads if available otherwise replace steering damper Binding A Require replacement Damper body dented A 1 Further inspection required Damper body punctured A Require replacement Damping none A...

Страница 1351: ...or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require repair or replacement of part with damaged threads Attaching...

Страница 1352: ...sary to determine the extent of the system failure the suggestion may be made to rebuild or replace the power steering pump Repair or replacement of the following components may be required if perform...

Страница 1353: ...replacement of coupler Fluid contaminated B 1 Require flushing and refilling of the system Gasket leaking A Require repair or replacement Hard steering on cold start up 1 2 Suggest repair or replaceme...

Страница 1354: ...of incorrect part Attaching hardware loose A Require repair or replacement of loose part Attaching hardware missing C Require replacement of missing part Attaching hardware threads damaged A Require...

Страница 1355: ...replacement Split 1 Suggest replacement STRUT RODS STRUT ROD INSPECTION Condition Code Procedure Adjusting nut seized A 1 Require repair or replacement Attaching hardware bent B Require repair or repl...

Страница 1356: ...y the bearing should be replaced if it is available separately otherwise replace the bearing plate assembly STRUT UPPER BEARING PLATE ASSEMBLY INSPECTION Condition Code Procedure Attaching hardware br...

Страница 1357: ...t if available otherwise replace link Attaching hardware threads damaged A Require repair or replacement of part with damaged threads if available otherwise replace link Attaching hardware threads str...

Страница 1358: ...WAY BAR INSPECTION Condition Code Procedure Attaching hardware broken A Require replacement of broken part if available otherwise replace sway bar Attaching hardware corroded affecting structural inte...

Страница 1359: ...cement of sleeve or tie rod end Adjusting sleeve clamps out of position B Require repair Adjusting sleeve corroded affecting structural integrity A Require replacement of sleeve or tie rod end Adjusti...

Страница 1360: ...oint and will accelerate wear 5 Torn grease boot will allow contaminants to enter joint and will accelerate wear 6 If greaseable tie rod end will not take grease after replacing the grease fitting sug...

Страница 1361: ...ripped threads missing A 7 Require replacement Wear exceeds manufacturer s specifications B Require replacement 1 Cracked grease boot will allow contaminants to enter joint and will accelerate wear 2...

Страница 1362: ...LS NOTE When replacing or repacking wheel bearings grease seal replacement is required You are not required to replace these components in axle sets Determine the need to replace based upon the indivi...

Страница 1363: ...on component replacement or correction kits may be required Errors in set back and steering axis inclination SAI are often attributable to failed or damaged components and must be corrected prior to p...

Страница 1364: ...d dismount or mount tires Explosions of tire and wheel assembly can result from improper mounting possibly causing serious injury or death WARNING Consult the vehicle owner s manual or vehicle placard...

Страница 1365: ...ull or lead caused by tire A Require repair or replacement Radial and bias or bias belted ply tires on same axle B Require repair or replacement Radials are on the front and not on the rear B 2 Requir...

Страница 1366: ...in tubeless tire Recommendation for repair or replacement should be based upon condition of tires and or wheel listed in these guidelines VALVE STEMS VALVE STEM INSPECTION Condition Code Procedure Be...

Страница 1367: ...g to mount a tire of one diameter on a wheel of a different diameter or flange type may result in serious injury or death If the wheel identification stamp is not legible or cannot be found do not use...

Страница 1368: ...re replacement Run out beyond OEM specs B Require replacement Stud holes elongated A 2 Require replacement Welded or brazed repair 2 Suggest replacement Welds leaking A Require replacement Wheel cente...

Страница 1369: ...ght questions are asked at write up Making the Worksheets a Part of Your Normal Routine The following information contains ideas that may be helpful in forming habits that promote daily use of the Sym...

Страница 1370: ...GE NOTE Have the service adviser fill out this form with the customer whenever possible Fig 1 Entire Vehicle Symptom Check List For Customer FULL VERSION ALL ON FOUR PAGES NOTE Have the service advise...

Страница 1371: ...customer whenever possible Fig 2 Symptom Check List Page 1...

Страница 1372: ...Fig 3 Symptom Check List Page 2...

Страница 1373: ...Fig 4 Symptom Check List Page 3...

Страница 1374: ...Fig 5 Symptom Check List Page 4 INDIVIDUAL SYSTEM BASED CHECK LISTS NOTE Have the service adviser fill out these forms with the customer whenever possible...

Страница 1375: ...Fig 6 Engine Driveability Automatic Transmission...

Страница 1376: ...Fig 7 Brakes Steering Suspension Fig 8 Air Conditioning Heater Ventilation...

Страница 1377: ...Fig 9 Electrical Radio Tape CD Player...

Страница 1378: ...Fig 10 Manual Transmission Clutch...

Страница 1379: ...Fig 11 Squeak Rattle Noise Conditions Fig 12 Water Leak Wind Noise...

Страница 1380: ...manifold air heater system perform procedures in SELF DIAGNOSTICS JEEP TRUCKS RWD VANS article INTERCOOLER Cleaning and inspection procedures for intercooler is the only information available from man...

Страница 1381: ...a Diagnostic Trouble Code DTC will be stored in Powertrain Control Module PCM See SELF DIAGNOSTICS JEEP TRUCKS RWD VANS article Crankshaft Position Sensor If problem exists in crankshaft position sen...

Страница 1382: ...brake pedal Disconnect electrical connector from brake switch Pull plunger on brake switch fully outward See Fig 2 2 Using ohmmeter check for continuity between terminals No 5 and 6 on brake switch S...

Страница 1383: ...ls No 85 and 86 on relay Resistance should be 70 80 ohms If resistance is within specification go to next step If resistance is not within specification replace relay 3 Using ohmmeter ensure continuit...

Страница 1384: ...tery voltage to relay trigger wire terminals small wire terminals at base of intake manifold air heater relay See Fig 4 Polarity is not important 4 Intake manifold air heater relay should click and oh...

Страница 1385: ...power distribution center at driver s side front corner of engine compartment near battery If problem exists in transmission relay or wiring circuit a Diagnostic Trouble Code DTC will be stored in Pow...

Страница 1386: ...Transmission Torque Converter Clutch Solenoid A T Models See TRANSMISSION under MISCELLANEOUS CONTROLS Fig 5 Locating Fuel System Components Courtesy of Chrysler Corp FUEL SYSTEM...

Страница 1387: ...ing information is available from manufacturer Fuel Heater 1 Malfunctioning fuel heater may cause excessive wax build up in fuel filter water separator during cold ambient temperatures Wax build up ma...

Страница 1388: ...metal fuel line at engine Remove clip from metal line Snap clip into fuel supply hose Install Rubber Adapter Hose 6631 into ends of disconnected fuel supply line 2 Install transducer from PEP module...

Страница 1389: ...ents are made by Engine Control Module ECM If a DTC has been stored indicating an ENGINE SYNC ERROR or STATIC TIMING ERROR remove plastic access cover injection pump nut and washer 2 Locate keyway beh...

Страница 1390: ...article 3 To check for defective fuel injector start and idle engine Loosen high pressure fuel line nut at fuel injector and listen for a decrease in engine speed Tighten high pressure fuel line nut...

Страница 1391: ...ransmission speed sensor is located on overdrive case at rear of transmission Transmission speed sensor contains a 2 pin connector with a Dark Blue Black wire and a Light Green Black wire If problem e...

Страница 1392: ...hmmeter to isolate wiring harness shorts or opens COMPUTERIZED ENGINE CONTROLS POWERTRAIN CONTROL MODULE PCM PCM power and ground circuits may be checked by performing TEST NS 1 in SELF DIAGNOSTICS JE...

Страница 1393: ...VANS article SOLENOIDS Evaporative EVAP Purge Solenoid See appropriate DTC P0443 EVAP PURGE SOLENOID CIRCUIT test in SELF DIAGNOSTICS JEEP TRUCKS RWD VANS article Leak Detection Pump LDP Solenoid See...

Страница 1394: ...ticle Torque Converter Clutch TCC Relay See appropriate DTC P0743 TORQUE CONVERTER CLUTCH SOLENOID TRANSMISSION RELAY CIRCUIT test in SELF DIAGNOSTICS JEEP TRUCKS RWD VANS article Transmission Governo...

Страница 1395: ...filter Repair air filter if plugged If air filter is okay test is complete CRANKCASE VENTILATION CCV 8 0L 1 CCV system does NOT use a PCV valve System consists of a fixed orifice Gray color that is c...

Страница 1396: ...4 If paper is held against opening performance is okay If paper is not held against opening replace PCV valve and retest If performance does not improve inspect system for restrictions and clean as ne...

Страница 1397: ...SYSTEM WIRING DIAGRAMS 1999 Dodge Pickup R1500 1999 System Wiring Diagrams Dodge Pickup R1500 AIR CONDITIONING Heater Circuit...

Страница 1398: ...Manual A C Circuit ANTI LOCK BRAKES...

Страница 1399: ...Anti lock Brake Circuits ANTI THEFT...

Страница 1400: ...Anti theft Circuit BODY COMPUTER...

Страница 1401: ...Central Timer Module Circuit...

Страница 1402: ...Integrated Central Electronics Module Circuit COMPUTER DATA LINES...

Страница 1403: ...Computer Data Lines CRUISE CONTROL...

Страница 1404: ...Cruise Control Circuit ENGINE PERFORMANCE...

Страница 1405: ...3 9L 3 9L Engine Performance Circuits 1 of 3...

Страница 1406: ...3 9L Engine Performance Circuits 2 of 3...

Страница 1407: ...3 9L Engine Performance Circuits 3 of 3 5 2L...

Страница 1408: ...5 2L Engine Performance Circuits 1 of 3...

Страница 1409: ...5 2L Engine Performance Circuits 2 of 3...

Страница 1410: ...5 2L Engine Performance Circuits 3 of 3 5 9L...

Страница 1411: ...5 9L Engine Performance Circuits 1 of 3...

Страница 1412: ...5 9L Engine Performance Circuits 2 of 3...

Страница 1413: ...5 9L Engine Performance Circuits 3 of 3 EXTERIOR LIGHTS...

Страница 1414: ...Back up Lamps Circuit...

Страница 1415: ...Exterior Lamps Trailer connector Circuit 1 of 2...

Страница 1416: ...Exterior Lamps Trailer connector Circuit 2 of 2 GROUND DISTRIBUTION...

Страница 1417: ...Ground Distribution Circuit 1 of 3...

Страница 1418: ...Ground Distribution Circuit 2 of 3...

Страница 1419: ...Ground Distribution Circuit 3 of 3 HEADLIGHTS...

Страница 1420: ...Headlight Circuit W DRL W Quad Headlights...

Страница 1421: ...Headlight Circuit W DRL W O Quad Headlights...

Страница 1422: ...Headlight Circuit W O DRL W Quad Headlights...

Страница 1423: ...Headlight Circuit W O DRL W O Quad Headlights HORN...

Страница 1424: ...Horn Circuit INSTRUMENT CLUSTER...

Страница 1425: ...Instrument Cluster Circuit 1 of 2...

Страница 1426: ...Instrument Cluster Circuit 2 of 2...

Страница 1427: ...Overhead Console Circuit INTERIOR LIGHTS...

Страница 1428: ...Courtesy Lamps Circuit...

Страница 1429: ...Instrument Illumination Circuit PASSIVE RESTRAINTS...

Страница 1430: ...Passive Restraint Circuit POWER DISTRIBUTION...

Страница 1431: ...Power Distribution Circuit 1 of 3...

Страница 1432: ...Power Distribution Circuit 2 of 3...

Страница 1433: ...Power Distribution Circuit 3 of 3 POWER DOOR LOCKS...

Страница 1434: ...Power Door Lock Circuit W Keyless Entry...

Страница 1435: ...Power Door Lock Circuit W O Keyless Entry POWER MIRRORS...

Страница 1436: ...Power Mirror Circuit POWER SEATS...

Страница 1437: ...Power Seat Circuits POWER WINDOWS...

Страница 1438: ...Power Window Circuit RADIO...

Страница 1439: ...Radio Circuits Premium Radio...

Страница 1440: ...Radio Circuits Standard STARTING CHARGING...

Страница 1441: ...Charging Circuit...

Страница 1442: ...Starting Circuit SUPPLEMENTAL RESTRAINTS...

Страница 1443: ...Supplemental Restraint Circuit TRANSMISSION...

Страница 1444: ...3 9L 3 9L A T Circuit 1 of 2...

Страница 1445: ...3 9L A T Circuit 2 of 2 5 2L...

Страница 1446: ...5 2L A T Circuit 1 of 2...

Страница 1447: ...5 2L A T Circuit 2 of 2 5 9L...

Страница 1448: ...5 9L A T Circuit 1 of 2...

Страница 1449: ...5 9L A T Circuit 2 of 2 WARNING SYSTEMS...

Страница 1450: ...Warning System Circuits WIPER WASHER...

Страница 1451: ...Wiper Washer Circuit...

Страница 1452: ...ocedures should also be used if an intermittent soft FTC was present but no problem is found during self diagnostic testing NOTE For specific testing procedures see SELF DIAGNOSTICS JEEP TRUCKS RWD VA...

Страница 1453: ...lead to PCM setting a Diagnostic Trouble Code FTC which may help in diagnosis If problem vehicle does not produce DTCs monitor voltage or resistance values using a Digital Volt Ohmmeter DVOM while at...

Страница 1454: ...d lead to a specific component system test or adjustment Use intermittent test procedures to locate driveability problems that do not occur when the vehicle is being tested These problems may cause a...

Страница 1455: ...inimum idle airflow Check Idle Air Control IAC motor operation HESITATION OR STUMBLE Check the following Check secondary ignition system Check PCM power and ground circuits Check engine vacuum Check f...

Страница 1456: ...ure Check Engine Coolant Temperature ECT sensor calibration Check Throttle Position TP sensor calibration Check Manifold Absolute Pressure MAP calibration Check minimum idle airflow Check oxygen senso...

Страница 1457: ...en sensor heater Check Idle Air Control IAC motor operation Check engine mechanical condition Check evaporative system Check EGR system Check Intake Air Temperature IAT motor operation Check Park Neut...

Страница 1458: ...r bend wiring harness Spray component with water Remove apply vacuum source Monitor circuit component voltage or resistance while simulating intermittent If engine is running monitor for DTCs Use test...

Страница 1459: ...les or systems with which you are not completely familiar AIR INDUCTION SYSTEM INTERCOOLER NOTE Intercooler may also be referred to as a charge air cooler Intercooler is a heat exchanger used to reduc...

Страница 1460: ...ler and then into intake manifold where the air is distributed into each cylinder Supplying increased airflow provides improved engine performance lower exhaust smoke density altitude compensation and...

Страница 1461: ...tesy of Chrysler Corp ENGINE CONTROL MODULE ECM Engine Control Module ECM uses input signals from various switches and sensors to control output devices in order to achieve optimum engine performance...

Страница 1462: ...peed control adaptive memory Camshaft Position Sensor CMP Camshaft Position CMP sensor is a hall effect sensor 0 5 volts switched located below injection pump in rear face of timing gear cover Sensor...

Страница 1463: ...set Other sensor is an integral part of fuel heater See FUEL HEATER Intake Manifold Air Temperature IAT Sensor Intake manifold air temperature sensor is a variable thermistor sensor located on top of...

Страница 1464: ...ion has been requested Once A C operation has been requested an A C request signal is delivered to ECM from A C high pressure switch and A C low pressure switch The A C request signal indicates evapor...

Страница 1465: ...cate engine speed and crankshaft position ECM uses CKP signal along with other input signals for controlling injector firing sequence and timing Sensor is located below fuel transfer pump on side of e...

Страница 1466: ...sion near shift linkage Transmission Governor Pressure Sensor A T Models Transmission governor pressure sensor delivers input signal to Powertrain Control Module PCM to indicate transmission governor...

Страница 1467: ...ater In Fuel WIF Sensor Fuel Injection Pump Relay The Engine Control Module ECM energizes the fuel injection pump and integral Fuel Pump Control Module FPCM through the relay When ignition is turned o...

Страница 1468: ...r relays are energized by Engine Control Module ECM based on input signals from intake manifold air temperature sensor engine speed sensor and vehicle speed Fig 5 Locating Intake Manifold Air Heater C...

Страница 1469: ...n goes off as a bulb and wiring circuit test each time ignition switch is turned to the ON position If Engine Control Module ECM receives an incorrect signal or receives no signal from certain sensors...

Страница 1470: ...M OUTPUT SIGNALS A C Clutch Relay The Engine Control Module ECM controls A C compressor operation by controlling ground circuit for A C clutch relay ECM de energizes A C clutch relay if engine coolant...

Страница 1471: ...mission overdrive indicator light will be turned on Transmission overdrive indicator light is located on instrument panel just below the speedometer Tachometer Engine Control Module ECM delivers outpu...

Страница 1472: ...ne type pump supplies low fuel pressure from fuel tank through fuel heater fuel filter water separator to fuel injection pump Fuel transfer pump contains internal check valves to prevent fuel from ble...

Страница 1473: ...perate fuel heater is provided from ignition switch through fuel heater relay and to fuel heater Fuel heater and fuel heater relay are not controlled by Engine Control Module ECM EMISSION SYSTEMS INTA...

Страница 1474: ...on the MIL to warn the driver that a malfunction exists in the electronic system MISCELLANEOUS CONTROLS TRANSMISSION Transmission Overdrive Solenoid A T Models Engine Control Module ECM operates tran...

Страница 1475: ...Distributorless Ignition System DIS or distributor on models without DIS Crankshaft Position CKP sensor Engine Coolant Temperature ECT sensor Intake Air Temperature IAT sensor logic circuits Manifold...

Страница 1476: ...in idle speed at a preprogrammed RPM when brakes are applied If PCM receives an input signal from brake switch when speed control system is on PCM will turn speed control system off Camshaft Position...

Страница 1477: ...acts like a rich lean air fuel ratio switch by monitoring oxygen content in exhaust gas This information is used by PCM to adjust air fuel ratio by adjusting injector pulse width HO2S produces low vo...

Страница 1478: ...ill not shift into overdrive or will downshift if already in overdrive Transmission Temperature Sensor A T Models Transmission temperature sensor monitors transmission fluid temperature and sends an i...

Страница 1479: ...ator See GENERATOR under MISCELLANEOUS CONTROLS Idle Air Control IAC Motor See IDLE SPEED under FUEL SYSTEM Ignition Coil See IGNITION SYSTEM In Tank Fuel Pump See FUEL DELIVERY under FUEL SYSTEM Limp...

Страница 1480: ...D RELAY FUEL PUMP RELAY under MISCELLANEOUS CONTROLS Fuel Pressure Regulator Fuel pressure regulator is a mechanical device used to maintain a constant pressure across fuel injector tip Spring and rub...

Страница 1481: ...fuel pressure regulator fuel pump reservoir a separate in tank fuel filter pressure relief rollover valve fuel gauge sending unit and fuel supply line See Fig 3 Fig 3 Identifying Fuel Pump Module Com...

Страница 1482: ...is is an open loop mode PCM pre positions IAC motor based on ECT sensor input PCM determines atmospheric pressure from MAP sensor and determines basic fuel strategy PCM modifies fuel strategy accordin...

Страница 1483: ...re it reduces injector pulse width to lean air fuel mixture Under certain RPM and closed throttle position conditions HO2S signals are ignored and PCM cuts off fuel injection until idle speed is reach...

Страница 1484: ...gine revolution may be required for PCM to determine crankshaft position during cranking Molded ignition coils are used Each coil fires 2 paired spark plugs at the same time One cylinder is on compres...

Страница 1485: ...case Ventilation CCV system is used on some engines see CRANKCASE VENTILATION CCV SYSTEM SELF DIAGNOSTIC SYSTEM The PCM monitors several different circuits of engine control system If a problem is sen...

Страница 1486: ...s HO2S Heating Element When ignition switch is turned to RUN position PCM energizes ASD relay and electric fuel pump relay which powers these components If PCM does not receive a CMP and CKP sensor s...

Страница 1487: ...ist of 3 buttons OFF ON RESUME ACCEL and SET DECEL Speed control servo is controlled by PCM System will operate at 35 85 MPH TACHOMETER PCM provides signal to drive tachometer TORQUE CONVERTER CLUTCH...

Страница 1488: ...l connector for crankshaft position sensor On 2 5L crankshaft position sensor is mounted on driver s side of transmission housing See Fig 1 On 3 9L 5 2L and 5 9L crankshaft position sensor is mounted...

Страница 1489: ...n cylinder block 10 Install C clamp on edge of transmission housing to hold torque converter in place Lower transmission and remove transmission from vehicle Fig 1 Locating Crankshaft Position Sensor...

Страница 1490: ...n and engine 2 Ensure area around transmission oil cooler lines fitting are clean Disengage retainer on quick disconnect cooler line fitting Pull cooler line from transmission oil cooler Remove starte...

Страница 1491: ...il cooler line to ensure oil cooler line is locked in place Fill transmission with Mopar ATF Plus Type 7176 RAM VAN WAGON Removal 1 Disconnect negative battery cable Raise and support vehicle Remove e...

Страница 1492: ...50 241 0 mm 3 Bolt Lug Torque Converter 46 11 7 9 50 241 0 mm 4 Bolt Lug Torque Converter 52 13 2 10 00 254 0 mm 4 Bolt Lug Torque Converter 52 13 2 10 75 273 0 mm 4 Bolt Lug Torque Converter 44 11 2...

Страница 1493: ...olt Large Bolt 35 65 47 88 Small Bolt 20 40 27 54 INCH Lbs N m Crankshaft Position Sensor Bolt 70 7 9 1 Bolt torque is determined by diameter of torque converter and number of torque converter bolt lu...

Страница 1494: ...ignation Dakota Durango 3 9L 42RE 5 2L 44RE 5 9L 46RE Ram Pickup 3 9L 42RE 46RE 5 2L 5 9L Gasoline 46RE 5 9L Diesel 8 0L 47RE Ram Van Wagon 3 9L 32RH 5 2L 36RH 5 2L 5 9L 46RE TRANSFER CASE APPLICATION...

Страница 1495: ...transmission fluid adjust bands and replace transmission filter at specified interval See TRANSMISSION SERVICING INTERVALS table Severe service conditions are conditions such as long periods of engine...

Страница 1496: ...See TRANSFER CASE SERVICING INTERVALS table Severe service conditions are conditions such as long periods of engine idling trailer towing off highway operation snow removal or operating in dusty or ex...

Страница 1497: ...from rear of transfer case Fluid level should even with bottom of transfer case fill plug hole on rear of transfer case Add appropriate type of transfer case fluid if necessary See RECOMMENDED FLUID...

Страница 1498: ...6RE 2 1 5 1 4 3 11 4 11 6 10 8 11 0 1 Approximate quantity listed 2 Add fluid until fluid level is at MIN arrow mark on dipstick Start engine and allow engine to idle With brakes applied shift transmi...

Страница 1499: ...luid to drain from transfer case 2 Reinstall transfer case drain plug Tighten transfer case drain plug to specification See TORQUE SPECIFICATIONS Remove transfer case fill plug from rear of transfer c...

Страница 1500: ...Hold kickdown band adjusting screw in this position and tighten kickdown band adjusting screw lock nut to specification See TORQUE SPECIFICATIONS KICKDOWN BAND ADJUSTMENT Application Back Off Adjusti...

Страница 1501: ...TMENT table Hold low reverse band adjusting screw and tighten low reverse band adjusting screw lock nut to specification See TORQUE SPECIFICATIONS LOW REVERSE BAND ADJUSTMENT Application Back Off Adju...

Страница 1502: ...cept Park or Neutral shift cable may be improperly adjusted or park neutral position switch may be defective Ram Van Wagon 1 Raise and support vehicle Ensure shift lever is in Park Unsnap shift cable...

Страница 1503: ...arts in any other gears except Park and Neutral shift linkage adjustment is incorrect or park neutral position switch is defective Fig 7 Identifying Typical Shift Linkage Components Courtesy of Chrysl...

Страница 1504: ...swivel lubricate shift rod as necessary 2 Ensure shift lever on transfer case is still in 4L position Ensure pin on end of adjusting swivel is centered in hole on shift arm Tighten lock bolt With all...

Страница 1505: ...ransfer case is still in 2H position Tighten lock bolt With all wheels off floor start engine and shift transfer case through all ranges to ensure proper operation TORQUE SPECIFICATIONS TORQUE SPECIFI...

Страница 1506: ...5 9L NV231HD Or 1 NV242HD Ram Pickup 1500 NV231HD 2500 3500 NV241 Or NV241HD 1 NV242HD is used on automatic transmission only IDENTIFICATION TRANSMISSION AX 15 identification numbers are located on b...

Страница 1507: ...nsmissions fluid level should even with bottom of fill plug hole on side of transmission Add appropriate type of transmission fluid if necessary See RECOMMENDED FLUID Install and tighten transaxle fil...

Страница 1508: ...ated on passenger s side of transmission On NV3500 transmission drain plug is located on bottom of transmission housing at center of transmission housing 2 On all transmissions install and tighten tra...

Страница 1509: ...e drain plug is located on rear of transfer case at driver s side corner of transfer case Allow fluid to drain from transfer case 2 Reinstall transfer case drain plug Tighten transfer case drain plug...

Страница 1510: ...lock bolt at adjusting swivel on shift rod See Fig 1 Ensure shift rod slides freely in adjusting swivel If shift rod fails to slide freely in adjusting swivel lubricate shift rod as necessary 3 Ensure...

Страница 1511: ...PTO Cover Bolt Ram Pickup 30 40 Transfer Case Drain Plug Fill Plug 40 54 Dakota 15 25 20 25 Ram Pickup 30 40 40 54 Transmission Drain Plug Fill Plug Dakota AX 15 33 44 NV1500 25 34 NV3500 14 20 19 27...

Страница 1512: ...ES article This will assist in identifying improperly routed vacuum hoses which may cause driveability and or computer indicated malfunctions VACUUM DIAGRAMS NOTE References to California models apply...

Страница 1513: ...Fig 2 Vacuum Hose Diagram Caravan Voyager 2 4L Except Calif Courtesy of Chrysler Corp Fig 3 Vacuum Hose Diagram Caravan Town Country Voyager 3 3L 3 8L Calif Courtesy of Chrysler Corp...

Страница 1514: ...Fig 4 Vacuum Hose Diagram Caravan Town Country Voyager 3 3L 3 8L Except Calif Courtesy of Chrysler Corp Fig 5 Vacuum Hose Diagram Dakota 2 5L Calif Courtesy of Chrysler Corp...

Страница 1515: ...Fig 6 Vacuum Hose Diagram Dakota 2 5L Except Calif Courtesy of Chrysler Corp Fig 7 Vacuum Hose Diagram Dakota 3 9L 5 2L Calif Courtesy of Chrysler Corp...

Страница 1516: ...Fig 8 Vacuum Hose Diagram Dakota 5 9L Calif Courtesy of Chrysler Corp Fig 9 Vacuum Hose Diagram Dakota 3 9L 5 2L Except Calif Courtesy of Chrysler Corp...

Страница 1517: ...Fig 10 Vacuum Hose Diagram Dakota 5 9L Except Calif Courtesy of Chrysler Corp Fig 11 Vacuum Hose Diagram Durango 3 9L 5 2L Calif Courtesy of Chrysler Corp...

Страница 1518: ...Fig 12 Vacuum Hose Diagram Durango 5 9L Calif Courtesy of Chrysler Corp Fig 13 Vacuum Hose Diagram Durango 3 9L 5 2L Except Calif Courtesy of Chrysler Corp...

Страница 1519: ...Fig 14 Vacuum Hose Diagram Durango 5 9L Except Calif Courtesy of Chrysler Corp Fig 15 Vacuum Hose Diagram Ram Pickup 3 9L 5 2L Light Duty Courtesy of Chrysler Corp...

Страница 1520: ...Fig 16 Vacuum Hose Diagram Ram Pickup 5 9L Light Duty Courtesy of Chrysler Corp Fig 17 Vacuum Hose Diagram Ram Pickup 3 9L 5 2L Medium Duty Calif Courtesy of Chrysler Corp...

Страница 1521: ...Fig 18 Vacuum Hose Diagram Ram Pickup 5 9L Medium Duty Calif Courtesy of Chrysler Corp Fig 19 Vacuum Hose Diagram Ram Pickup 8 0L Medium Duty Courtesy of Chrysler Corp...

Страница 1522: ...Fig 20 Vacuum Hose Diagram Ram Van Ram Wagon 3 9L Calif Courtesy of Chrysler Corp Fig 21 Vacuum Hose Diagram Ram Van Ram Wagon 3 9L Except Calif Courtesy of Chrysler Corp...

Страница 1523: ...Fig 22 Vacuum Hose Diagram Ram Van Ram Wagon 5 2L Calif Courtesy of Chrysler Corp Fig 23 Vacuum Hose Diagram Ram Van Ram Wagon 5 2L Except Calif Courtesy of Chrysler Corp...

Страница 1524: ...Fig 24 Vacuum Hose Diagram Ram Van Ram Wagon 5 2L CNG Courtesy of Chrysler Corp Fig 25 Vacuum Hose Diagram Ram Van Ram Wagon 5 9L Calif Courtesy of Chrysler Corp...

Страница 1525: ...Fig 26 Vacuum Hose Diagram Ram Van Ram Wagon 5 9L Except Calif Courtesy of Chrysler Corp...

Страница 1526: ...RT TO BATTERY BUS SHORT TO GROUND BUS BUS OPEN BUS OPEN OR BUS OPEN NOTE For connector terminal identification and wiring diagrams see BODY CONTROL COMPUTER INTRODUCTION article Perform VERIFICATION T...

Страница 1527: ...not display BUS BUS SHORTED TOGETHER replace compass mini trip computer If scan tool displays BUS BUS SHORTED TOGETHER go to next step 5 Turn ignition off Disconnect radio connector Turn ignition on I...

Страница 1528: ...repair open Black Light Green wire If resistance is more than 5 ohms go to next step 8 Measure resistance between ground and instrument cluster connector C1 terminal No 5 Black wire If resistance is...

Страница 1529: ...al No 3 White Black wire Measure resistance between ground and instrument cluster connector C1 terminal No 10 Violet Brown wire If resistance is less than 5 ohms go to next step If resistance is 5 ohm...

Страница 1530: ...ms or more repair open Light Green Yellow wire Replace fuse No 19 6 Using external voltmeter measure voltage between ground and voltage input side of fuse No 19 socket If voltage is 10 volts or less r...

Страница 1531: ...t Green wire If resistance is 5 ohms or less go to next step 7 Turn ignition on Using scan tool perform CCD Bus test Connect jumper wire between ground and CTM 18 pin connector terminal No 16 Violet B...

Страница 1532: ...BODY CONTROL COMPUTER INTRODUCTION article Perform VERIFICATION TEST VER 1 after each repair CAUTION Always turn ignition off prior to disconnecting any module connector 1 Remove and inspect fuse No...

Страница 1533: ...sure voltage between ground and radio Gray terminal No 6 Red White wire If voltage is 10 volts or less repair open Red White wire If voltage is more than 10 volts go to next step 6 Inspect ground stra...

Страница 1534: ...urn ignition off prior to disconnecting any module connector 1 Turn ignition off Disconnect Powertrain Control Module PCM PCM is mounted in right side of firewall Turn ignition on If scan tool does no...

Страница 1535: ...fter each repair CAUTION Always turn ignition off prior to disconnecting any module connector 1 Turn ignition off Disconnect Powertrain Control Module PCM PCM is mounted in right side of firewall Turn...

Страница 1536: ...displays BUS SHORT TO GROUND go to next step 2 Turn ignition off Disconnect anti lock brake controller module Controller module is mounted to top of ABS hydraulic unit Turn ignition on If scan tool do...

Страница 1537: ...t connectors Turn ignition on engine off Using scan tool erase all fault messages Turn ignition off Wait 10 seconds Turn ignition on engine off Operate system that is malfunctioning If system does not...

Страница 1538: ...oad coverage is because there are only a few basic ways to operate a solenoid type injector By understanding the fundamental principles you will understand all the major points of injector patterns yo...

Страница 1539: ...noid light designed for full voltage Circuits with current controlled injector drivers e g Peak and Hold Basically this type of driver allows a quick burst of voltage current to flow and then throttl...

Страница 1540: ...ecause it is unimportant if the flashing light is dim or bright It is only important that it flashes In any cases of doubt regarding the use of a noid light a lab scope will overcome all inherent weak...

Страница 1541: ...he injector is not on This is especially true with current controlled driver circuits The Fluke 88 among others fall into this category Outside of using a Fluke 87 or equivalent in the 1 mS min max mo...

Страница 1542: ...his is an approach of last resort it does provide benefits We will discuss the strengths and weaknesses in a moment but first we will look at how a duty cycle meter and dwell meter work How A Duty Cyc...

Страница 1543: ...onds With exactly one crankshaft rotation in 100 milliseconds we know that the injector fires exactly one time 4 Determine the ratio of injector on time vs off time in the fixed time period then figur...

Страница 1544: ...f control the current flow through the injector would cause the solenoid coil to overheat and result in a damaged injector VOLTAGE CONTROLLED CIRCUIT SATURATED SWITCH The voltage controlled driver ins...

Страница 1545: ...tage controlled driver because as the name implies it has to limit current flow in addition to its ON OFF switching function Recall this driver typically requires injector circuits with a total leg re...

Страница 1546: ...ance injector This will cause injector damage from solenoid coil overheating THE TWO WAYS INJECTOR CIRCUITS ARE WIRED Like other circuits injector circuits can be wired in one of two fundamental direc...

Страница 1547: ...eak driver Alert readers will catch that this is exactly opposite of the current controlled type drivers explained in the next section because they bend upwards at this point How come the difference B...

Страница 1548: ...ctor If you see more than one hump it is because of a distorted pintle or seat This faulty condition is known as pintle float It is important to realize that it takes a good digital storage oscillosco...

Страница 1549: ...indication of a resistance problem on the ground circuit that needs repaired You might miss this fault if you do not use the negative battery post for your Lab Scope hook up so it is HIGHLY recommende...

Страница 1550: ...he final turn off of the driver This spike should be like the spike on top of point D Point G shows a slight hump This is actually the mechanical injector pintle closing Recall that moving an iron cor...

Страница 1551: ...t flow of 2 amps See Fig 4 Note that if just one injector has a resistance problem and partially shorts the entire parallel bank that it belongs to will draw more current This can damage the injector...

Страница 1552: ...Fig 5 Injector Bank w Excessive Current Flow Current Pattern Fig 6 Single Injector w Normal Current Flow Current Pattern Fig 7 Single Injector w Excessive Current Flow Current Pattern...

Страница 1553: ...e total resistance of this parallel circuit drops to 4 1 ohms Fourteen volts divided by four ohms would pull a maximum of 3 4 amps on this bank of injectors However as we discussed in EXAMPLE 1 above...

Страница 1554: ...jector set point occurred at 400 milliamps and current peaked at 750 milliamps This is a good specification for this engine The next waveform pattern in Fig 11 shows an abnormality with another inject...

Страница 1555: ...illiamps and the actual opening of the injector set point is just below 600 milliamps This is offered as a comparison against the Ford pattern listed above as they are both Ford SEFI injectors but wit...

Страница 1556: ...aveform is from a Ford 5 0L V8 CFI VIN F See Fig 14 The pattern which is set on a 250 milliamps scale indicates a 1 25 amp peak draw and a hold at 350 milliamps Fig 14 Single Injector w Normal Current...

Страница 1557: ...of intermittent computer shutdown Using a current waveform pattern is the most accurate method of pinpointing this problem Fig 15 Single Injector w Normal Current Flow Current Pattern Fig 16 Single In...

Страница 1558: ...LES EXAMPLE 1 VOLTAGE CONTROLLED DRIVER These two known good waveform patterns are from a Ford 4 6L V8 VIN W Fig 18 illustrates the 64 volt inductive kick on this engine indicating no clamping is occu...

Страница 1559: ...Fig 18 Injector Bank Known Good Voltage Pattern...

Страница 1560: ...9 Injector Bank Known Good Voltage Pattern EXAMPLE 2 VOLTAGE CONTROLLED DRIVER The known good waveform pattern in Fig 20 is from a GM 3 8L V6 PFI VIN 3 It was taken during hot idle closed loop and no...

Страница 1561: ...20 Injector Bank Known Good Voltage Pattern EXAMPLE 3 VOLTAGE CONTROLLED DRIVER This known good waveform pattern Fig 21 is from a GM 5 0L V8 TPI VIN F It was taken during hot idle closed loop and no l...

Страница 1562: ...is type injector drive on their TBI equipped engines See Fig 22 for a known good pattern Instead of the ground side controlling the injector Chrysler permanently grounds out the injector and switches...

Страница 1563: ...o known good waveform patterns are from a Chrysler 3 0L V6 VIN 3 The first waveform Fig 23 is a dual trace pattern that illustrates how Chrysler uses the rising edge of the engine speed signal to trig...

Страница 1564: ...Fig 23 Injector Bank Known Good Voltage Pattern...

Страница 1565: ...ge Pattern EXAMPLE 6 CURRENT CONTROLLED DRIVER This known good pattern from a Ford 3 0L V6 PFI VIN U illustrates that a zener diode inside the computer is used to clamp the injector s inductive kick t...

Страница 1566: ...Fig 25 Injector Bank Known Good Voltage Pattern EXAMPLE 7 CURRENT CONTROLLED DRIVER This known good waveform from a Ford 5 0L V8 CFI VIN F was taken during hot idle closed loop and no load See Fig 26...

Страница 1567: ...RRENT CONTROLLED DRIVER These two known good waveform patterns are from a GM 2 0L In Line 4 VIN 1 Fig 27 illustrates the 78 volt inductive spike that indicates a zener diode is not used The second wav...

Страница 1568: ...Fig 27 Single Injector Known Good Voltage Pattern...

Страница 1569: ...Fig 28 Single Injector Known Good Voltage Pattern...

Страница 1570: ...move if present Riding height between left side and right side of vehicle should vary less than 0 5 12 7 mm Information on riding height between front and rear is not available from manufacturer See R...

Страница 1571: ...way between front and rear wheels as permanent body damage could occur DO NOT place jack under an axle tube aluminum differential steering linkage engine or transmission oil pan fuel tank or front sus...

Страница 1572: ...Corp CAUTION Never place jack under any part of vehicle underbody DO NOT attempt to raise one entire side of vehicle by placing a jack midway between front and rear wheels as permanent body damage cou...

Страница 1573: ...ount See Fig 3 2 On 4WD models raise front end by placing floor jack under as shown See Fig 3 or 4 To raise rear end place floor jack under rear axle next to leaf spring mount Support vehicle with jac...

Страница 1574: ...Fig 4 Identifying Hoisting Jacking Locations Durango Courtesy of Chrysler Corp Ram Van Wagon To raise front end place floor jack under center of front...

Страница 1575: ...ot See Fig 5 To raise rear end place floor jack under rear axle next to leaf spring U bolt mount Fig 5 Identifying Hoisting Jacking Locations Ram Van Wagon Courtesy of Chrysler Corp RIDING HEIGHT SPEC...

Страница 1576: ...p type drive hoists If using swiveling arm hoist ensure lifting arms pads or ramps are positioned evenly on frame rails and adequate clearance is maintained for transfer case 4WD models or skid plate...

Страница 1577: ...TE Moving rear of control arm changes caster significantly Moving front of control arm changes camber significantly Fig 7 Adjusting Camber Caster Dakota Durango Ram Pickup With Independent Front Suspe...

Страница 1578: ...ter cam on lower control arm See WHEEL ALIGNMENT SPECIFICATIONS table See Fig 8 Fig 8 Adjusting Caster Ram Pickup With Link Coil Suspension Courtesy of Chrysler Corp Ram Van Wagon 1 Use Adjuster Tool...

Страница 1579: ...control arm See WHEEL ALIGNMENT SPECIFICATIONS table Tighten pivot retaining bolts See TORQUE SPECIFICATIONS table Fig 9 Camber Caster Angle Adjustment Tool Courtesy of Chrysler Corp FRONT WHEEL TOE A...

Страница 1580: ...t steering gear to tie rod boots at tie rod Remove steering wheel clamp See Fig 10 Ram Van Wagon 4WD Models Center steering wheel and hold with steering wheel clamp Loosen tie rod adjustment sleeve cl...

Страница 1581: ...ures are provided by the manufacturer TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Ft Lbs N m Axle Bracket Eccentric Cam Nut Ram Pickup 95 130 Pivot Bar To Frame Bolts Dakota Durango Ram Pi...

Страница 1582: ...ont 0 15 0 25 To 0 55 Rear 0 0 25 To 0 25 Caster 2 1 4 0 4 To 2 4 Toe In 3 Front 0 05 1 5 0 05 To 0 15 1 5 To 4 Rear 0 0 0 2 To 0 2 5 To 5 Toe In 2 Front 0 1 0 1 To 0 3 Rear 0 0 4 To 0 4 1998 2WD AWD...

Страница 1583: ...To 1 4WD Short Bed 5 5 2WD Long Bed 0 5 0 To 1 4WD Long Bed 5 5 Ram 2500 HD 2WD Long Bed 0 5 0 To 1 4WD Long Bed 5 5 2WD Club Cab Club Cab Short Bed 0 5 0 To 1 4WD Club Cab Quad Cab Short Bed 5 5 2WD...

Страница 1584: ...n 3 All Models 0 05 1 5 0 To 0 1 0 To 2 5 Toe In 2 All Models 0 1 0 To 0 2 Ram Van Wagon Camber 2 0 0 6 To 0 6 Caster 2 2 5 1 5 To 3 5 Toe In 3 0 0 0 12 To 0 12 3 To 3 Toe In 2 0 25 To 0 25 1 Specific...

Страница 1585: ...of same construction and tread style equal in tread wear and overall diameter Verify that radial and axial runout is not excessive Inflation should be at manufacturer s specifications Steering linkage...

Страница 1586: ...caster and toe in using this sequence Follow instructions of the alignment equipment manufacturer CAUTION Do not attempt to correct alignment by straightening parts Damaged parts must be replaced Fig...

Страница 1587: ...from side of vehicle See Fig 4 2 When axis is tilted backward from vertical caster is positive This creates a trailing action on front wheels When axis is tilted forward caster is negative causing a l...

Страница 1588: ...tered position Face of tie rod end must be parallel with machined surface of steering rod end to prevent binding 3 When tightening clamps make certain that clamp bolts are positioned so there will be...

Страница 1589: ...vel and camber should be properly adjusted See Fig 6 2 If camber cannot be brought within limits and steering axis inclination is correct steering knuckle is bent If camber and steering axis inclinati...

Страница 1590: ...hes mounted in driver s door panel NOTE Power window circuits on Caravan Town Country and Voyager use Positive Temperature Coefficient PTC devices The PTC is a specified amperage solid state resettabl...

Страница 1591: ...is okay 3 If voltmeter indicates battery voltage at one terminal only replace faulty circuit breaker If voltmeter indicates no voltage at either terminal check for an open or shorted circuit to circu...

Страница 1592: ...indow glass tracks and regulator for sticking binding or improper adjustment Repair as necessary and recheck system operation POWER WINDOW SWITCH 1 Remove window switch from door trim panel See POWER...

Страница 1593: ...sler Corp Fig 3 Identifying Driver s Passenger s Power Window Switch Terminals Dakota Ram Pickup Courtesy of Chrysler Corp Fig 4 Identifying Passenger s Power Window Switch Terminals Durango Courtesy...

Страница 1594: ...indow Switch Terminals Ram Van Ram Wagon Courtesy of Chrysler Corp Fig 6 Identifying Passenger s Power Window Switch Terminals Ram Van Ram Wagon Courtesy of Chrysler Corp DRIVER S WINDOW SWITCH CONTIN...

Страница 1595: ...Off 1 3 2 3 3 4 3 6 Up Left 3 4 5 6 Right 1 5 2 3 Down Left 3 6 4 5 Right 1 3 2 5 Light 3 5 DRIVER S WINDOW SWITCH CONTINUITY DURANGO Switch Position Continuity Between Terminals Off 2 5 3 5 5 6 5 11...

Страница 1596: ...1 4 3 11 Light 8 11 PASSENGER S WINDOW SWITCH CONTINUITY DURANGO Switch Position Continuity Between Terminals Off 2 5 3 6 Up 2 5 3 4 Down 3 6 4 5 PASSENGER S WINDOW SWITCH CONTINUITY RAM VAN RAM WAGON...

Страница 1597: ...ble Remove driver s front power window switch See POWER WINDOW SWITCH under REMOVAL INSTALLATION 3 Check for continuity between ground and terminal No 5 Black wire at driver s power window switch wiri...

Страница 1598: ...or wire connector terminals of inoperative power window If continuity exists in all circuits power window switch and switch circuits are okay Check power window motor See POWER WINDOW MOTOR under COMP...

Страница 1599: ...e faulty power window switch as necessary If switch is okay go to next step 5 Using an ohmmeter check continuity of each circuit between inoperative power window switch wiring harness connector and co...

Страница 1600: ...k gently pry around perimeter of D pillar trim panel and separate trim panel from inner quarter panel Disconnect rear speaker connector if equipped 3 On short wheelbase models pass seat belt through s...

Страница 1601: ...ith aid of an assistant lower window glass 1 2 inches Drum will rotate when glass is lowered 5 Install cover plate onto window motor Connect window motor connector Remove tape holding window in place...

Страница 1602: ...w regulator to inner door panel Remove remaining window regulator mounting bolts Remove window regulator and motor assembly through access hole in inner door panel To install reverse removal procedure...

Страница 1603: ...connector Remove watershield Remove inner and outer belt weatherstrip from door 2 Lower glass enough to expose window glass to regulator bolts Loosen window glass to regulator bolts Loosen bolts at fr...

Страница 1604: ...To complete installation reverse removal procedure Fig 10 Removing Power Vent Motor Caravan Town Country Voyager Courtesy of Chrysler Corp POWER WINDOW SWITCH Removal Installation Caravan Town Countr...

Страница 1605: ...kup Disconnect negative battery cable Using a trim stick gently pry upper edge of switch bezel to release retainer securing bezel to door trim panel Pull switch and bezel away from door trim panel and...

Страница 1606: ...Fig 11 Power Window System Wiring Diagram Caravan Town Country Voyager...

Страница 1607: ...Fig 12 Power Window System Wiring Diagram Dakota...

Страница 1608: ...Fig 13 Power Window System Wiring Diagram Durango...

Страница 1609: ...Fig 14 Power Window System Wiring Diagram Ram Pickup...

Страница 1610: ...Fig 15 Power Window System Wiring Diagram Ram Van Ram Wagon...

Страница 1611: ...anel outboard of glove box CTM switches an intermittent wiper relay located in Power Distribution Center PDC On high line models CTM is connected to Chrysler Collision Detection CCD data bus network t...

Страница 1612: ...TTENT WIPER RELAY 1 Remove relay See INTERMITTENT WIPER RELAY under REMOVAL INSTALLATION Check continuity between relay terminals No 30 and 87A Continuity should exist Check continuity between relay t...

Страница 1613: ...ith air bag restraint systems See appropriate AIR BAG RESTRAINT SYSTEMS article before servicing steering wheel or column Use extreme caution to avoid personal injury and vehicle damage NOTE If proble...

Страница 1614: ...ct negative battery cable Turn ignition on While depressing washer switch check voltage at washer pump harness connector Brown wire terminal If battery voltage exists replace pump If battery voltage d...

Страница 1615: ...or terminal No 12 White Dark Blue wire See Fig 3 If continuity does not exist repair open in White Dark Blue wire If continuity exists go to next step 6 Check continuity between multifunction switch h...

Страница 1616: ...es equipped with air bag restraint systems see appropriate AIR BAG RESTRAINT SYSTEMS article before servicing steering wheel or column Use extreme caution to avoid personal injury and vehicle damage C...

Страница 1617: ...ove wiper linkage and motor module To install reverse removal procedure Align wiper arms See WIPER BLADES under ADJUSTMENTS WIPER WASHER SWITCH NOTE Wiper washer switch is part of multifunction steeri...

Страница 1618: ...voir being careful not to puncture reservoir Remove and discard grommet To install reverse removal procedure Use a NEW rubber grommet TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application INCH Lbs N...

Страница 1619: ...Fig 5 Wiper Washer System Wiring Diagram Ram Pickup...

Страница 1620: ...L WIRING DIAGRAMS 1999 Dodge Pickup R1500 1999 ENGINE PERFORMANCE Wiring Diagrams CHRY All Models WIRING DIAGRAMS AVENGER SEBRING COUPE Fig 1 PCM Wiring Diagram Avenger Sebring Coupe 2 0L 1 Of 3...

Страница 1621: ...Fig 2 PCM Wiring Diagram Avenger Sebring Coupe 2 0L 2 Of 3...

Страница 1622: ...Fig 3 PCM Wiring Diagram Avenger Sebring Coupe 2 0L 3 Of 3...

Страница 1623: ...Fig 4 PCM Wiring Diagram Avenger Sebring Coupe 2 5L 1 Of 3...

Страница 1624: ...Fig 5 PCM Wiring Diagram Avenger Sebring Coupe 2 5L 2 Of 3...

Страница 1625: ...Fig 6 PCM Wiring Diagram Avenger Sebring Coupe 2 5L 3 Of 3 BREEZE STRATUS...

Страница 1626: ...Fig 7 PCM Wiring Diagram Breeze Stratus 2 0L 2 4L 1 Of 3...

Страница 1627: ...Fig 8 PCM Wiring Diagram Breeze Stratus 2 0L 2 4L 2 Of 3...

Страница 1628: ...Fig 9 PCM Wiring Diagram Breeze Stratus 2 0L 2 4L 3 Of 3 CARAVAN TOWN COUNTRY VOYAGER...

Страница 1629: ...Fig 10 PCM Wiring Diagram Caravan Voyager 2 4L 1 Of 3...

Страница 1630: ...Fig 11 PCM Wiring Diagram Caravan Voyager 2 4L 2 Of 3...

Страница 1631: ...Fig 12 PCM Wiring Diagram Caravan Voyager 2 4L 3 Of 3...

Страница 1632: ...Fig 13 PCM Wiring Diagram Caravan Voyager 3 0L 1 Of 3...

Страница 1633: ...Fig 14 PCM Wiring Diagram Caravan Voyager 3 0L 2 Of 3...

Страница 1634: ...Fig 15 PCM Wiring Diagram Caravan Voyager 3 0L 3 Of 3...

Страница 1635: ...Fig 16 PCM Wiring Diagram Caravan Town Country Voyager 3 3L 3 3L Flex Fuel 3 8L 1 Of 3...

Страница 1636: ...Fig 17 PCM Wiring Diagram Caravan Town Country Voyager 3 3L 3 3L Flex Fuel 3 8L 2 Of 3...

Страница 1637: ...Fig 18 PCM Wiring Diagram Caravan Town Country Voyager 3 3L 3 3L Flex Fuel 3 8L 3 Of 3 CIRRUS STRATUS...

Страница 1638: ...Fig 19 PCM Wiring Diagram Cirrus Stratus 2 5L 1 Of 3...

Страница 1639: ...Fig 20 PCM Wiring Diagram Cirrus Stratus 2 5L 2 Of 3...

Страница 1640: ...Fig 21 PCM Wiring Diagram Cirrus Stratus 2 5L 3 Of 3 CONCORDE INTREPID LHS 300M...

Страница 1641: ...Fig 22 PCM Wiring Diagram Concorde Intrepid 2 7L 1 Of 3...

Страница 1642: ...Fig 23 PCM Wiring Diagram Concorde Intrepid 2 7L 2 Of 3...

Страница 1643: ...Fig 24 PCM Wiring Diagram Concorde Intrepid 2 7L 3 Of 3...

Страница 1644: ...Fig 25 PCM Wiring Diagram Concorde Intrepid 3 2L LHS 300M 3 5L 1 Of 3...

Страница 1645: ...Fig 26 PCM Wiring Diagram Concorde Intrepid 3 2L LHS 300M 3 5L 2 Of 3...

Страница 1646: ...Fig 27 PCM Wiring Diagram Concorde Intrepid 3 2L LHS 300M 3 5L 3 Of 3 DAKOTA...

Страница 1647: ...Fig 28 PCM Wiring Diagram Dakota 2 5L 1 Of 3...

Страница 1648: ...Fig 29 PCM Wiring Diagram Dakota 2 5L 2 Of 3...

Страница 1649: ...Fig 30 PCM Wiring Diagram Dakota 2 5L 3 Of 3...

Страница 1650: ...Fig 31 PCM Wiring Diagram Dakota 3 9L 5 2L 1 Of 3...

Страница 1651: ...Fig 32 PCM Wiring Diagram Dakota 3 9L 5 2L 2 Of 3...

Страница 1652: ...Fig 33 PCM Wiring Diagram Dakota 3 9L 5 2L 3 Of 3...

Страница 1653: ...Fig 34 PCM Wiring Diagram Dakota 5 9L 1 Of 3...

Страница 1654: ...Fig 35 PCM Wiring Diagram Dakota 5 9L 2 Of 3...

Страница 1655: ...Fig 36 PCM Wiring Diagram Dakota 5 9L 3 Of 3 DURANGO...

Страница 1656: ...Fig 37 PCM Wiring Diagram Durango 3 9L 5 2L 5 9L 1 Of 3...

Страница 1657: ...Fig 38 PCM Wiring Diagram Durango 3 9L 5 2L 5 9L 2 Of 3...

Страница 1658: ...Fig 39 PCM Wiring Diagram Durango 3 9L 5 2L 5 9L 3 Of 3 NEON...

Страница 1659: ...Fig 40 PCM Wiring Diagram Neon 2 0L 1 Of 3...

Страница 1660: ...Fig 41 PCM Wiring Diagram Neon 2 0L 2 Of 3...

Страница 1661: ...Fig 42 PCM Wiring Diagram Neon 2 0L 3 Of 3 RAM PICKUP...

Страница 1662: ...Fig 43 PCM Wiring Diagram Ram Pickup 3 9L 5 2L 5 9L 1 Of 3...

Страница 1663: ...Fig 44 PCM Wiring Diagram Ram Pickup 3 9L 5 2L 5 9L 2 Of 3...

Страница 1664: ...Fig 45 PCM Wiring Diagram Ram Pickup 3 9L 5 2L 5 9L 3 Of 3...

Страница 1665: ...Fig 46 PCM Wiring Diagram Ram Pickup 2500 3500 8 0L 1 Of 3...

Страница 1666: ...Fig 47 PCM Wiring Diagram Ram Pickup 2500 3500 8 0L 2 Of 3...

Страница 1667: ...Fig 48 PCM Wiring Diagram Ram Pickup 2500 3500 8 0L 3 Of 3...

Страница 1668: ...Fig 49 PCM Wiring Diagram Ram Pickup 2500 3500 5 9L 24 Valve Diesel 1 Of 3...

Страница 1669: ...Fig 50 PCM Wiring Diagram Ram Pickup 2500 3500 5 9L 24 Valve Diesel 2 Of 3...

Страница 1670: ...Fig 51 PCM Wiring Diagram Ram Pickup 2500 3500 5 9L 24 Valve Diesel 3 Of 3 RAM VAN RAM WAGON...

Страница 1671: ...Fig 52 PCM Wiring Diagram Ram Van Ram Wagon 1500 3 9L 1 Of 3...

Страница 1672: ...Fig 53 PCM Wiring Diagram Ram Van Ram Wagon 1500 3 9L 2 Of 3...

Страница 1673: ...Fig 54 PCM Wiring Diagram Ram Van Ram Wagon 1500 3 9L 3 Of 3...

Страница 1674: ...Fig 55 PCM Wiring Diagram Ram Van Ram Wagon 5 2L Gasoline 5 9L 1 Of 3...

Страница 1675: ...Fig 56 PCM Wiring Diagram Ram Van Ram Wagon 5 2L Gasoline 5 9L 2 Of 3...

Страница 1676: ...Fig 57 PCM Wiring Diagram Ram Van Ram Wagon 5 2L Gasoline 5 9L 3 Of 3...

Страница 1677: ...Fig 58 PCM Wiring Diagram Ram Van Ram Wagon 5 2L CNG 1 Of 3...

Страница 1678: ...Fig 59 PCM Wiring Diagram Ram Van Ram Wagon 5 2L CNG 2 Of 3...

Страница 1679: ...Fig 60 PCM Wiring Diagram Ram Van Ram Wagon 5 2L CNG 3 Of 3 SEBRING CONVERTIBLE...

Страница 1680: ...Fig 61 PCM Wiring Diagram Sebring Convertible 2 4L 1 Of 4...

Страница 1681: ...Fig 62 PCM Wiring Diagram Sebring Convertible 2 4L 2 Of 4...

Страница 1682: ...Fig 63 PCM Wiring Diagram Sebring Convertible 2 4L 3 Of 4...

Страница 1683: ...Fig 64 PCM Wiring Diagram Sebring Convertible 2 4L 4 Of 4...

Страница 1684: ...Fig 65 PCM Wiring Diagram Sebring Convertible 2 5L 1 Of 4...

Страница 1685: ...Fig 66 PCM Wiring Diagram Sebring Convertible 2 5L 2 Of 4...

Страница 1686: ...Fig 67 PCM Wiring Diagram Sebring Convertible 2 5L 3 Of 4...

Страница 1687: ...Fig 68 PCM Wiring Diagram Sebring Convertible 2 5L 4 Of 4...

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