Jeep Wrangler 1999 Скачать руководство пользователя

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Fig.

Body

iring

Splices—RHD

8W - 95 - 16

8W - 95 SPLICE LOCATIONS

DESCRIPTION AND OPERATION (Continued)

Содержание Wrangler 1999

Страница 1: ...HOFRPH WR WKH UDQJOHU OHFWURQLF 6HUYLFH 0DQXDO OLFN 2Q 7KH RJR 7R HJLQ...

Страница 2: ...Turn Signal and Hazard Warning Systems 8K Wiper and Washer Systems 8L Lamps 8La Lamps 8M Passive Restraint Systems 8N Electrically Heated System 8O Power Distribution System 8Q Vehicle Theft Security...

Страница 3: ...Certification Label Frame rail To protect the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden tification Number...

Страница 4: ...e plate is attached to the floor pan under the drivers seat Fig 2 Disengage the snaps attaching the carpet to the floor pan to read the information There are seven lines of information on the body cod...

Страница 5: ...gine Code EPE 2 5 L 4 cyl MPI Gasoline ERH 4 0L 6 cyl MPI Gasoline BODY CODE PLATE LINE 1 DIGITS 1 2 AND 3 Transmission Codes DDQ AX5 5 speed Manual DDO AX15 5 speed Manual DGD 30RH 3 speed Automatic...

Страница 6: ...is imprinted on the head of the bolt The higher the class number the greater the bolt strength Some metric nuts are imprinted with a single digit strength class on the nut face Refer to the Fastener I...

Страница 7: ...FASTENER IDENTIFICATION TJ INTRODUCTION 5 GENERAL INFORMATION Continued...

Страница 8: ...FASTENER STRENGTH 6 INTRODUCTION TJ GENERAL INFORMATION Continued...

Страница 9: ...n one hundred one thousand and one million Fig 6 The following chart will assist in converting metric units to equivalent English and SAE units or vice versa Refer to the Conversion Chart to convert t...

Страница 10: ...METRIC CONVERSION 8 INTRODUCTION TJ GENERAL INFORMATION Continued...

Страница 11: ...rque Charts appear at the end of many Groups Refer to the Standard Torque Specifi cations Chart for torque references not listed in the individual torque charts TORQUE SPECIFICATIONS TJ INTRODUCTION 9...

Страница 12: ...the consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden tification Number The check digit is used by the manufacture...

Страница 13: ...e plate is attached to the floor pan under the drivers seat Fig 2 Disengage the snaps attaching the carpet to the floor pan to read the information There are seven lines of information on the body cod...

Страница 14: ...oup 23 Body for color codes DIGIT 9 Open Space DIGITS 10 THROUGH 13 Secondary Paint DIGIT 14 Open Space DIGITS 15 THROUGH 18 Interior Trim Code DIGIT 19 Open Space DIGITS 20 21 AND 22 Engine Code EPE...

Страница 15: ...ls illustrated in the following International Control and Display Symbols chart are used to identify various instrument controls The symbols correspond to the controls and displays that are located on...

Страница 16: ...ant and fluid inspection and fill locations Fig 1 CLASSIFICATION OF LUBRICANTS Only lubricants bearing designations defined by the following organization should be used to service a Chrysler Corporati...

Страница 17: ...tional 71 9 L 19 0 gal ENGINE OIL 2 5L 3 8 L 4 0 qts 4 0L 5 7 L 6 0 qts COOLING SYSTEM 2 5L 8 5 L 9 0 qts 4 0L 9 9 L 10 5 qts AUTOMATIC TRANSMISSION Dry fill capacity 32RH 8 1 L 17 1pts 30RH 6 6 L 14...

Страница 18: ...n At Each Oil Change Inspect exhaust system Inspect brake hoses Rotate the tires at each oil change interval shown on Schedule A 7 500 miles or every other interval shown on Schedule B 6 000 miles Che...

Страница 19: ...ing linkage Flush and replace engine coolant if it has been 30 000 miles 48 000 km or 24 months since last change Lubricate steering and suspension ball joints Drain and refill manual transmission flu...

Страница 20: ...Change engine oil Replace engine oil filter Lubricate steering linkage Drain and refill automatic transmission fluid Drain and refill front and rear axles Inspect brake linings Lubricate steering and...

Страница 21: ...gine oil Replace engine oil filter Lubricate steering linkage Drain and refill automatic transmission fluid Drain and refill front and rear axles Inspect brake linings Lubricate steering and suspensio...

Страница 22: ...if it has been 30 000 miles 48 000 km since last change Lubricate steering linkage 114 000 Miles 182 000 km Change engine oil Replace engine oil filter Lubricate steering linkage Lubricate steering a...

Страница 23: ...uel fumes or leakage correct if necessary Frozen battery Yellow or bright color test indicator if equipped Low battery fluid level CAUTION If the cause of starting problem on dis abled vehicle is seve...

Страница 24: ...ns or other motorists Do not attach tow chains T hooks J hooks or a tow sling to a bumper steering linkage drive shafts or a non reinforced frame hole GROUND CLEARANCE CAUTION If vehicle is towed with...

Страница 25: ...el RECREATIONAL TOWING Refer to the Owners Manual for towing procedures EMERGENCY TOW HOOKS WARNING REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS THE TOW STRAPS CHAINS...

Страница 26: ...st chassis hoist A ramp type drive on hoist NOTE When a frame contact type hoist is used verify that the lifting pads are positioned properly WARNING THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE...

Страница 27: ...utward provides positive camber Incorrect camber will cause wear on the inside or outside edge of the tire The angle is not adjustable damaged component s must be replaced to correct the camber angle...

Страница 28: ...Fig 1 Wheel Alignment Measurements 2 2 SUSPENSION TJ DESCRIPTION AND OPERATION Continued...

Страница 29: ...icle to specifications 5 Leaking steering dampener 5 Replace steering dampener VEHICLE INSTABILITY 1 Loose or worn wheel bearings 1 Adjust or replace wheel bearings 2 Loose or worn steering or suspens...

Страница 30: ...nability During the road test turn the vehicle to both the left and right If the steering wheel returns to the center position unassisted the caster angle is correct However if steering wheel does not...

Страница 31: ...setting does not change during clamp tightening 5 Verify the right toe specifications and turn off the engine SPECIFICATIONS ALIGNMENT SPECIFICATIONS NOTE Alignment specifications are in degrees ADJU...

Страница 32: ...to isolate road noise The suspen sion arms are bolted to the frame and axle through the rubber bushings The lower suspension arms can be uses to adjust caster and pinion angle by install a cam bolt se...

Страница 33: ...ner and grommet on the upper stud Insert the shock absorber through the shock bracket hole 2 Install the lower bolts and nuts Tighten nuts to 28 N m 250 in lbs 3 Install the upper grommet and retainer...

Страница 34: ...bolt and new nut finger tighten in the axle and align the reference marks 4 If equipped with ABS brakes install sensor wire to the inboard side of the arm with new clips 5 Lower the vehicle 6 Tighten...

Страница 35: ...90635 2 Remove front bumper valence refer to Group 23 Body for procedure 3 Remove stabilizer retainer bolts Fig 6 and remove retainers 4 Remove stabilizer bar 5 Remove lower link nuts and bolts and re...

Страница 36: ...the brake caliper rotor and ABS wheel speed sensor refer to Group 5 Brakes 4 Remove the cotter pin nut retainer and axle hub nut Fig 8 5 Remove the hub bearing mounting bolts from the back of the stee...

Страница 37: ...kes for procedure 6 Install wheel and tire assembly use new lug nut on stud or studs that were replaced 7 Remove support and lower vehicle SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Shock Absorber...

Страница 38: ...SPECIAL TOOLS FRONT SUSPENSION Remover Installer Suspension Bushing 7932 Nut Long 7603 Bolt Special 7604 Remover C 4150A 2 12 SUSPENSION TJ...

Страница 39: ...is and mounts to the rear axle Links are connected from the bar to frame brackets The bar is isolated by rubber bushings Track Bar The track bar is used to control rear axle lateral movement The track...

Страница 40: ...rom the upper mount seat and remove the spring INSTALLATION NOTE Springs can be install with either end up 1 Position the coil spring on the axle pad isolator 2 Raise the axle into position until the...

Страница 41: ...5 N m 55 ft lbs 6 Tighten the upper suspension arm axle bracket nut to 75 N m 55 ft lbs STABILIZER BAR REMOVAL 1 Raise and support the vehicle 2 Remove the stabilizer bar link bolts from the frame mou...

Страница 42: ...ove supports and lower the vehicle 4 Tighten the track bar nut bolt at both ends to 100 N m 74 ft lbs SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Shock Absorber Upper Bolts 31 N m 23 ft lbs Lower N...

Страница 43: ...on and axle It must also be capable of changing length while transmitting torque The axle rides sus pended by springs in a floating motion The propeller shaft must be able to change operating angles w...

Страница 44: ...le measure ments or checking the phasing of two piece shafts consider each shaft separately Ideally the driveline system should have Angles that are equal or opposite within 1 degree of each other Hav...

Страница 45: ...to drop or hang from any propeller shaft joint during removal Attach the propeller shaft to the vehicle underside with wire to prevent damage to the joints DIAGNOSIS AND TESTING VIBRATION Tires that a...

Страница 46: ...sive axle yoke deflection 11 Inspect and replace yoke if necessary 12 Excessive transfer case runout 12 Inspect and repair as necessary Universal Joint Noise 1 Loose U joint clamp screws 1 Install new...

Страница 47: ...weld areas to ensure that the effects of the weld process will not enter into the measurements 4 Refer to Runout Specifications chart 5 If the propeller shaft runout is out of specifica tion remove t...

Страница 48: ...the vehi cle 3 Place Inclinometer on yoke bearing A parallel to the shaft Fig 9 Center bubble in sight glass and record measurement This measurement will give you the transmis sion or Output Yoke Ang...

Страница 49: ...Fig 11 Rear Input Angle Measurement B Fig 12 Universal Joint Angle Example TJ DIFFERENTIAL AND DRIVELINE 3 7 SERVICE PROCEDURES Continued...

Страница 50: ...er case yoke 2 Place front universal joint into the axle pinion yoke 3 Align mark on the rear link yoke and universal joint to the mark on the transfer case yoke Fig 14 4 Loosely install bolts to hold...

Страница 51: ...1 Remove the propeller shaft 2 Using a soft drift tap the outside of the bear ing cap assembly to loosen snap ring 3 Remove snap rings from both sides of yoke Fig 18 4 Set the yoke in an arbor press o...

Страница 52: ...ap with the yoke bore Fig 22 Keep the needle bearings upright in the bearing assembly A needle bearing lying at the bottom of the cap will prevent proper assembly 4 Press the bearing cap into the yoke...

Страница 53: ...ve grease fittings that interfere with removal 6 Grasp the protruding bearing by vise jaws Tap the link yoke with a mallet and drift to dislodge the bearing cap from the yoke Fig 25 7 Flip assembly an...

Страница 54: ...sembly A needle bearing lying at the bottom of the cap will prevent proper assembly 4 Press the bearing cap into the yoke bore enough to install a snap ring Fig 29 5 Install a snap ring 6 Flip the pro...

Страница 55: ...r it should snap over center in both directions when correctly assembled Fig 36 14 Install the propeller shaft CLEANING AND INSPECTION SINGLE AND DOUBLE CARDAN JOINT 1 Clean all the universal joint yo...

Страница 56: ...re ferred caster angle A cam kit is available to be installed in the rear axle lower suspension arms in order to provide adjustablity of the pinion angle Follow the proce dures supplied with the kit i...

Страница 57: ...apor ization and internal expansion The axles are equipped with semi floating axle shafts meaning that loads are supported by the hub bearings The axle shafts are retained by nuts at the hub bearings...

Страница 58: ...en turning corners the outside wheel must travel a greater distance than the inside wheel to complete a turn The difference must be compensated for to prevent the tires from scuffing and skidding thro...

Страница 59: ...earings are loaded Road test the vehicle Turn the vehicle sharply to the left and to the right This will load the bearings and change the noise level Where axle bearing damage is slight the noise is u...

Страница 60: ...FRONT AXLES DIAGNOSIS 3 18 DIFFERENTIAL AND DRIVELINE TJ DIAGNOSIS AND TESTING Continued...

Страница 61: ...CONTINUED TJ DIFFERENTIAL AND DRIVELINE 3 19 DIAGNOSIS AND TESTING Continued...

Страница 62: ...ess from the vehicle wiring harness if necessary 7 Disconnect the vent hose from the axle shaft tube 8 Mark the propeller shaft and yoke for installa tion alignment reference 9 Remove propeller shaft...

Страница 63: ...ment AXLE SHAFT CARDAN U JOINT Single cardan U joint components are not service able If defective they must be replaced as a unit If the bearings seals spider or bearing caps are dam aged or worn repl...

Страница 64: ...e 8 Using Holder 6958 to hold the pinion yoke remove the pinion nut and washer 9 Use Remover C 452 and Wrench C 3281 to remove the pinion yoke Fig 6 10 Use a suitable pry tool or a slide hammer mounte...

Страница 65: ...tallation reference 5 Remove the propeller shaft from the yoke 6 Rotate the pinion gear three or four times 7 Measure the amount of torque necessary to rotate the pinion gear with a in lbs dial type t...

Страница 66: ...apsible spacer from pinion shaft INSTALLATION 1 Install a new collapsible preload spacer on pin ion shaft Fig 13 2 If pinion gear was removed install pinion gear in housing 3 Install pinion front bear...

Страница 67: ...sembly and axle shafts if necessary 12 Align marks made previously on yoke and propeller shaft and install propeller shaft 13 Install brake rotors and calipers Refer to Group 5 Brakes for proper proce...

Страница 68: ...axle shaft into the housing and differential side gears Avoid damaging the axle shaft oil seals in the axle housing 4 Install the hub bearing if necessary 5 Install the hub to knuckle bolts and tight...

Страница 69: ...llow fluid to drain 4 Remove hub bearings and axle shafts 5 Note the installation reference letters stamped on the bearing caps and housing machined sealing surface Fig 24 6 Loosen the differential be...

Страница 70: ...Fig 22 Upper Ball Stud Remove Install Fig 23 Lower Ball Stud Remove Install 3 28 DIFFERENTIAL AND DRIVELINE TJ REMOVAL AND INSTALLATION Continued...

Страница 71: ...he case in the housing Measure the distance with the dial indicator Fig 27 4 Remove the dial indicator 5 Install differential case in the housing Ensure that the differential bearing cups remain in po...

Страница 72: ...nge Refer to the Differential Bearing Preload and Gear Backlash pro cedures in this section to determine the proper shim selection 1 Install differential side bearing shims onto dif ferential case hub...

Страница 73: ...ble vise with soft metal jaw protectors Fig 34 3 Remove bolts holding ring gear to differential case 4 Using a soft hammer drive ring gear from dif ferential case Fig 34 INSTALLATION CAUTION Do not re...

Страница 74: ...inion shaft Fig 37 6 Remove the pinion gear and collapsible spacer from housing Fig 38 Catch the pinion with your hand to prevent it from falling and being damaged 7 Remove the front pinion bearing cu...

Страница 75: ...NSTALLATION NOTE Pinion depth shims are placed between the rear pinion bearing cup and axle housing to achieve proper ring and pinion gear mesh If the factory installed ring and pinion gears are reuse...

Страница 76: ...he lip of pinion seal Install seal with Installer C 3972 A and Handle C 4171 Fig 45 6 Install the rear pinion bearing and oil slinger if equipped on the pinion gear with Installer W 262 and a shop pre...

Страница 77: ...6 8 N m 5 ft lb increments until the rotating torque is achieved Measure the rotating torque frequently to avoid over crushing the collapsible spacer Fig 50 12 Check bearing rotating torque with an in...

Страница 78: ...ll pin holes in shaft and the differential case 4 Install the roll pin to hold the pinion mate shaft in the differential case Fig 53 5 Install the ring gear 6 Lubricate all differential components wit...

Страница 79: ...ut any raised edges Raised metal on shoulders of cup bores should be removed with a hand stone Wear and damage to pinion gear mate shaft pinion gears side gears and thrust washers Replace as a matched...

Страница 80: ...3339 into Scooter Block D 115 2 and secure set screw 6 Place Scooter Block Dial Indicator in position in axle housing so dial probe and scooter block are flush against the rearward surface of the pini...

Страница 81: ...easurement determines the thickness of the shim used on the ring gear side of the differential case Subtract the gear backlash shim thickness from the total overall shim thickness and select that amou...

Страница 82: ...blow type mallet seat the differ ential dummy bearings to each side of the axle hous ing Fig 63 and Fig 64 8 Thread guide stud C 3288 B into rear cover bolt hole below ring gear Fig 65 9 Attach a dial...

Страница 83: ...s D 348 in axle housing without shims install bear ing caps and tighten bolts snug 19 Seat ring gear side dummy bearing Fig 64 20 Position the dial indicator plunger on a flat surface between the ring...

Страница 84: ...hold ring gear upward while not allowing the pinion gear to rotate 37 Zero dial indicator face to pointer 38 Push and hold ring gear downward while not allowing the pinion gear to rotate Dial indicato...

Страница 85: ...to increase the turning resistance of the pinion gear This will provide a more distinct contact pattern 3 Using a boxed end wrench on a ring gear bolt Rotate the differential case one complete revolut...

Страница 86: ...Fig 72 Gear Tooth Contact Patterns 3 44 DIFFERENTIAL AND DRIVELINE TJ ADJUSTMENTS Continued...

Страница 87: ...Rotating Torque Original Bearings 1 2 N m 10 20 in lbs New Bearings 1 5 4 N m 15 35 in lbs 181 FBI AXLE DESCRIPTION TORQUE Fill Hole Plug 34 N m 25 ft lbs Diff Cover Bolt 41 N m 30 ft lbs Bearing Cap...

Страница 88: ...Dial Indicator C 3339 Driver C 3716 A Handle C 4171 Installer D 146 Remover D 149 Installer W 162 D Cup 8109 Remover Installer 6289 3 46 DIFFERENTIAL AND DRIVELINE TJ SPECIAL TOOLS Continued...

Страница 89: ...nstaller 6761 Installer 6752 Installer Discs 8110 Turnbuckle 6797 Tool Set Pinion Depth 6774 Gauge Block 6733 Spanner 6958 Installer C 3972 A TJ DIFFERENTIAL AND DRIVELINE 3 47 SPECIAL TOOLS Continued...

Страница 90: ...Spreader W 129 B Adapter Kit 6987 Pilot Stud C 3288 B Remover C 4345 Installer D 130 Installer W 262 3 48 DIFFERENTIAL AND DRIVELINE TJ SPECIAL TOOLS Continued...

Страница 91: ...tion and internal expansion The axles are equipped with semi floating axle shafts meaning that loads are supported by the axle shaft and bearings The axle shafts are retained by C clips in the differe...

Страница 92: ...ve with the pinion mate shaft but do not rotate around it Fig 2 When turning corners the outside wheel must travel a greater distance than the inside wheel to complete a turn The difference must be co...

Страница 93: ...The noise can also occur during a specific type of driving condition These conditions are acceleration deceleration coast or constant load When road testing accelerate the vehicle to the speed range...

Страница 94: ...ct the helper to shift the transmission into gear Listen for the noise a mechanics stethoscope is helpful in isolating the source of a noise TRAC LOK DIFFERENTIAL NOISE The most common problem is a ch...

Страница 95: ...DIAGNOSIS CHART TJ DIFFERENTIAL AND DRIVELINE 3 53 DIAGNOSIS AND TESTING Continued...

Страница 96: ...DIAGNOSIS CHART CONTINUED 3 54 DIFFERENTIAL AND DRIVELINE TJ DIAGNOSIS AND TESTING Continued...

Страница 97: ...lt in lubricant foaming and overheating 10 Install the fill hole plug and lower the vehicle 11 Trac lok differential equipped vehicles should be road tested by making 10 to 12 slow figure eight turns...

Страница 98: ...to Lubricant Specifications in this section for lubricant requirements 14 Remove lifting device from axle and lower the vehicle 15 Tighten lower suspension arm bolts to 177 N m 130 ft lbs torque 16 T...

Страница 99: ...orque is reached prior to reaching the required rotating torque the collapsible spacer may have been dam aged Replace the collapsible spacer 7 Align the installation reference marks on the propeller s...

Страница 100: ...on gear three or four times 7 Measure the amount of torque necessary to rotate the pinion gear with a in lbs dial type torque wrench Record the torque reading for instal lation reference 8 Remove diff...

Страница 101: ...pacer is defective and must be replaced 10 Slowly tighten the nut in 6 8 N m 5 ft lbs increments until the rotating torque is achieved Measure the rotating torque frequently to avoid over crushing the...

Страница 102: ...le shaft through seal bearing and engage it into side gear splines NOTE Use care to prevent shaft splines from dam aging axle shaft seal lip Also exercise care not to damage the wheel speed sensor on...

Страница 103: ...etters stamped on the bearing caps and housing machined sealing surface Fig 23 6 Loosen the differential bearing cap bolts 7 Position Spreader W 129 B utilizing some items from Adapter set 6987 with t...

Страница 104: ...shim requirements may change Refer to the Differ ential Bearing Preload and Gear Backlash proce dures in this section to determine the proper shim selection 1 Position Spreader W 129 B utilizing some...

Страница 105: ...Fig 29 7 Loosely install differential bearing cap bolts 8 Remove axle housing spreader 9 Tighten the bearing cap bolts to 77 N m 57 ft lbs torque 10 Install the axle shafts DIFFERENTIAL SIDE BEARINGS...

Страница 106: ...in a matched set Do not replace the pinion gear without replacing the ring gear REMOVAL 1 Remove differential from the axle housing 2 Mark pinion yoke and propeller shaft for installation alignment 3...

Страница 107: ...aring cup 2 Install the pinion rear bearing cup with Installer D 146 and Driver Handle C 4171 Fig 40 Ensure cup is correctly seated 3 Apply Mopart Door Ease or equivalent stick lubricant to outside su...

Страница 108: ...ger if equipped on the pinion gear with Installer W 262 Fig 43 9 Install a new collapsible preload spacer on pin ion shaft and install pinion gear in housing Fig 44 10 Install pinion gear in housing 1...

Страница 109: ...ly tighten the nut in 6 8 N m 5 ft lbs increments until the rotating torque is achieved Measure the rotating torque frequently to avoid over crushing the collapsible spacer Fig 47 16 Check bearing rot...

Страница 110: ...r lubri cant Refer to the Lubricant Specifications section of this group for the gear lubricant requirements 4 Install the fill hole plug DISASSEMBLY AND ASSEMBLY STANDARD DIFFERENTIAL DISASSEMBLY 1 R...

Страница 111: ...Side Gear Holding Tool 6965 Fig 52 3 Remove ring gear if necessary Ring gear removal is necessary only if the ring gear is to be replaced The Trac lok differential can be serviced with the ring gear...

Страница 112: ...from differential case 15 Remove Forcing Screw C 6960 4 Step Plate C 6960 3 and Threaded Adapter C 6960 1 16 Remove top side gear clutch pack retainer and clutch pack Keep plates in correct order dur...

Страница 113: ...1 into top side gear 8 Insert Forcing Screw C 6960 4 9 Tighten forcing screw tool to slightly compress clutch discs 10 Place pinion gears in position in side gears and verify that the pinion mate shaf...

Страница 114: ...ifferential installation If replacement gears and thrust washers were installed it is not necessary to measure the gear backlash Correct fit is due to close machining tolerances during manufacture 17...

Страница 115: ...ssed air Inspect clutch pack plates for wear scoring or damage Replace both clutch packs if any one component in either pack is damaged Inspect side and pinion gears Replace any gear that is worn crac...

Страница 116: ...rt PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion cups and pin ion bearings installed in housing Take measure ments with a Pinion Gauge Set Pinion Block 6735 Arbor Discs 67...

Страница 117: ...sign on the variance number For exam ple if the depth variance is 2 add 0 002 in to the dial indicator reading 10 Remove the pinion depth gauge components from the axle housing DIFFERENTIAL BEARING P...

Страница 118: ...ear side of the axle housing 12 Record dial indicator reading 13 Add the dial indicator reading to the starting point shim thickness to determine total shim thick ness to achieve zero differential end...

Страница 119: ...to the other Fig 74 37 Verify differential case and ring gear runout by measuring ring to pinion gear backlash at several locations around the ring gear Readings should not vary more than 0 05 mm 0 00...

Страница 120: ...Fig 75 Gear Tooth Contact Patterns 3 78 DIFFERENTIAL AND DRIVELINE TJ ADJUSTMENTS Continued...

Страница 121: ...008 in Pinion Std Depth 92 08 mm 3 625 in Pinion Bearing Preload Original Bearings 1 2 N m 10 20 in lbs Pinion Bearing Preload New Bearings 1 5 4 N m 15 35 in lbs Maximum Carrier Spread 0 51 mm 0 020...

Страница 122: ...Wrench C 3281 Installer C 3972 A Spanner 6958 Installer Screw 8112 Cup 8109 Handle C 4171 Driver C 3716 A Installer D 130 3 80 DIFFERENTIAL AND DRIVELINE TJ SPECIAL TOOLS Continued...

Страница 123: ...Installer D 146 Remover C 4345 Remover D 149 Installer W 262 Installer 6436 Installer 6437 Disc Axle Arbor 6732 Gauge Block 6735 TJ DIFFERENTIAL AND DRIVELINE 3 81 SPECIAL TOOLS Continued...

Страница 124: ...n Depth 6774 Trac lok Tool Set 6960 Holder 6965 Starting Point Shim 8107 Spreader W 129 B Adapter Kit 6987 Guide Pin C 3288 B Bearing Remover Tool Set 6310 3 82 DIFFERENTIAL AND DRIVELINE TJ SPECIAL T...

Страница 125: ...Hub Puller 6790 Dial Indicator C 3339 TJ DIFFERENTIAL AND DRIVELINE 3 83 SPECIAL TOOLS Continued...

Страница 126: ...n and internal expansion The axles are equipped with semi floating axle shafts The vehicle weight is supported by the axle shaft and bearings The axle shafts are retained by plates bolted to the end f...

Страница 127: ...pin ion gears do not rotate on the pinion mate shaft This occurs because input torque applied to the gears is divided and distributed equally between the two side gears As a result the pinion gears re...

Страница 128: ...SE Axle gear noise can be caused by insufficient lubri cant incorrect backlash tooth contact or worn dam aged gears Gear noise usually happens at a specific speed range The range is 30 to 40 mph or ab...

Страница 129: ...ter mined with the assistance of a helper Raise the vehi cle on a hoist with the wheels free to rotate Instruct the helper to shift the transmission into gear Listen for the noise a mechanics stethosc...

Страница 130: ...DIAGNOSIS CHART 3 88 DIFFERENTIAL AND DRIVELINE TJ DIAGNOSIS AND TESTING Continued...

Страница 131: ...DIAGNOSIS CHART CONTINUED TJ DIFFERENTIAL AND DRIVELINE 3 89 DIAGNOSIS AND TESTING Continued...

Страница 132: ...lt in lubricant foaming and overheating 10 Install the fill hole plug and lower the vehicle 11 Trac lok differential equipped vehicles should be road tested by making 10 to 12 slow figure eight turns...

Страница 133: ...er to Lubricant Specifications in this section for lubricant requirements 14 Remove lifting device from axle and lower the vehicle 15 Tighten lower suspension arm bolts to 177 N m 130 ft lbs torque 16...

Страница 134: ...nt require ments 9 Install the brake drums Refer to Group 5 Brakes for proper procedures 10 Install wheel and tire assemblies 11 Lower the vehicle AXLE SHAFT REMOVAL 1 Hoist and support vehicle on saf...

Страница 135: ...r Press press unit bearing from axle shaft Fig 14 6 Slide seal from axle 7 Slide retaining plate from axle shaft INSTALLATION 1 Using a suitable straight edge verify flatness of axle shaft retaining p...

Страница 136: ...ad the indicator plunger against the opposite side of the housing Fig 19 and zero the indicator 7 Spread the housing enough to remove the case from the housing Measure the distance with the dial indic...

Страница 137: ...d or damaged 4 Remove the dial indicator 5 Install differential in housing 6 Install case in the housing Tap the differential case with a rawhide or rubber mallet to ensure the bearings are fully seat...

Страница 138: ...a matched set Do not replace the ring gear without replacing the pinion gear REMOVAL 1 Remove differential from axle housing 2 Place differential case in a suitable vise with soft metal jaw protector...

Страница 139: ...yoke remove the pinion nut and washer Fig 27 5 Using Remover C 452 and Holder C 3281 remove the pinion yoke from pinion shaft Fig 28 6 Remove the pinion gear and preload shims from housing Fig 29 Cat...

Страница 140: ...bearing cup bore in the axle housing 2 Apply Mopart Door Ease or equivalent stick lubricant to outside surface of rear pinion bearing cup Install the bearing cup with Installer D 145 and Handle C 417...

Страница 141: ...r loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload rotating torque 11 Check bearing preload torque with an inch pound torque wrench Fig 40 The...

Страница 142: ...pack Decreasing the shim pack thick ness 0 025 mm 0 001 in will increase the rotating torque approximately 0 9 N m 8 in lbs 15 Install differential assembly FINAL ASSEMBLY 1 Scrape the residual sealan...

Страница 143: ...ion gear mate shaft 3 Rotate the differential side gears and remove the pinion mate gears and thrust washers Fig 43 4 Remove the differential side gears and thrust washers ASSEMBLY 1 Install the diffe...

Страница 144: ...ear removal is necessary only if the ring gear is to be replaced The Trac Lok differential can be serviced with the ring gear installed 4 Remove the pinion gear mate shaft lock screw Fig 46 Fig 43 Pin...

Страница 145: ...from behind the pinion gears Fig 51 11 Insert Turning Bar C 4487 4 in case Fig 52 12 Loosen the Forcing Screw C 4487 2 in small increments until the clutch pack tension is relieved and the differenti...

Страница 146: ...ase Fig 55 Be sure clutch pack retaining clips remain in position and are seated in the case pockets 4 Position the differential case on Side Gear Holding Tool 6963 A 5 Install lubricated Step Plate C...

Страница 147: ...Correct fit is due to close machining tolerances during manufacture 17 Lubricate all differential components with hypoid gear lubricant CLEANING AND INSPECTION AXLE COMPONENTS Wash differential compon...

Страница 148: ...er is the amount in thousandths of an inch the depth varies from the standard depth setting of a pinion etched with a 0 The standard setting from the center line of the ring gear to the back face of t...

Страница 149: ...housing through pinion bearing cups Fig 60 3 Install front pinion bearing and Cone 6740 hand tight 4 Place Arbor Disc 6732 on Arbor D 115 3 in posi tion in axle housing side bearing cradles Fig 61 In...

Страница 150: ...n gear depth variance number etched in the face of the pinion gear Fig 57 10 Remove the pinion depth gauge components from the axle housing DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH Differential...

Страница 151: ...Fig 68 9 Attach a dial indicator C 3339 to Guide Stud C 3288 B Position the dial indicator plunger on a flat surface between the ring gear bolt heads Fig 68 10 Push and hold differential case to pinio...

Страница 152: ...ial indicator plunger on a flat surface between the ring gear bolt heads Fig 68 22 Push and hold differential case toward pinion gear Fig 71 23 Zero dial indicator face to pointer Fig 71 24 Push and h...

Страница 153: ...to the other Fig 74 40 Verify differential case and ring gear runout by measuring ring to pinion gear backlash at several locations around the ring gear Readings should not vary more than 0 05 mm 0 00...

Страница 154: ...Fig 75 Gear Tooth Contact Patterns 3 112 DIFFERENTIAL AND DRIVELINE TJ ADJUSTMENTS Continued...

Страница 155: ...klash 0 13 0 20 mm 0 005 0 008 in Pinion Depth 109 52 mm 4 312 in Brg Preload Pinion New 2 26 4 52 N m 20 40 in lbs Brg Preload Pinion Original 1 3 N m 10 20 in lbs 216 RBI TORQUE DESCRIPTION TORQUE P...

Страница 156: ...andle C 4171 Installer D 156 Pilot C 3288 B Dial Indicator C 3339 Trac lok Tool Set C 4487 Installer C 3972 A Installer D 144 Installer D 145 3 114 DIFFERENTIAL AND DRIVELINE TJ SPECIAL TOOLS Continue...

Страница 157: ...Remover D 147 Remover D 148 Spreader W 129 B Installer W 162 D Cup 8109 Splitter 1130 Installer W 262 Pinion Depth Set 6730 TJ DIFFERENTIAL AND DRIVELINE 3 115 SPECIAL TOOLS Continued...

Страница 158: ...Adapter 6790 Adapter Set 6956 Holder 6958 Holder 6963 A Adapter Set 6987 Slide Hammer 7420 Adapter 7420 8 Installer 7913 A 3 116 DIFFERENTIAL AND DRIVELINE TJ SPECIAL TOOLS Continued...

Страница 159: ...H 8 SERVICE PROCEDURES BASE BRAKE BLEEDING 12 BRAKE DRUM MACHINING 13 BRAKE FLUID LEVEL 11 BRAKE TUBE FLARING 13 DISC ROTOR MACHINING 13 MASTER CYLINDER BLEEDING 11 REMOVAL AND INSTALLATION BRAKE PEDA...

Страница 160: ...containing mineral oil to clean the system components These fluids damage rubber cups and seals Use only fresh brake fluid or Mopar brake cleaner to clean or flush brake system components These are t...

Страница 161: ...e is through a filter and inlet valve at the rear of the housing Fig 1 The chamber areas forward of the booster dia phragms are exposed to vacuum from the intake manifold The chamber areas to the rear...

Страница 162: ...the caliper piston and within the caliper bore will be equal Fig 2 Fluid pressure applied to the piston is transmitted directly to the inboard brake shoe This forces the shoe lining against the inner...

Страница 163: ...ualizer which is the connecting point for the rear cables Fig 5 The rear cables are connected to the actuating lever on each secondary brake shoe The levers are attached to the brake shoes by a pin ei...

Страница 164: ...note if vehicle was being operated with parking brake partially applied 5 Check brake pedal operation Verify that pedal does not bind and has adequate free play If pedal lacks free play check pedal an...

Страница 165: ...requently misdiagnosed pull condi tion is where direction of pull changes after a few stops The cause is a combination of brake drag fol lowed by fade at one of the brake units As the dragging brake o...

Страница 166: ...e stop lamp circuit SWITCH CONTINUITY TEST 1 Check continuity between terminal pins 1 and 2 as follows a Push in switch plunger completely b Attach test leads to pins 1 and 2 and note ohmmeter reading...

Страница 167: ...ps more than one inch HG 33 millibars within 15 seconds booster diaphragm or check valve is faulty POWER BOOSTER CHECK VALVE TEST 1 Disconnect vacuum hose from check valve 2 Remove check valve and val...

Страница 168: ...n ROTOR THICKNESS VARIATION Variations in rotor thickness will cause pedal pul sation noise and shudder Measure rotor thickness at 6 to 12 points around the rotor face Fig 10 Position the micrometer a...

Страница 169: ...ever the vehicle is in for service Inspect the hoses for surface cracking scuffing or worn spots Replace any brake hose immediately if the fabric casing of the hose is exposed due to cracks or abrasio...

Страница 170: ...uring bleed operations An empty cylinder will allow additional air to be drawn into the system Check the cylinder fluid level frequently and add fluid as needed Bleed only one brake component at a tim...

Страница 171: ...Be sure the drum is securely mounted in the lathe before machining operations A damper strap should always be used around the drum to reduce vibration and avoid chatter marks The maximum allowable dia...

Страница 172: ...ess brake pedal downward to fully applied position 3 Rotate switch approximately 30 in counter clockwise direction to unlock switch retainer Then pull switch rearward and out of bracket 4 Disconnect s...

Страница 173: ...aft 3 Install new pivot pin C clip 4 Position pedal support and install support bolts and tighten to 28 N m 21 ft lbs 5 Slid the booster master cylinder assembly into place install mounting nuts and t...

Страница 174: ...and tighten mounting nuts to 24 N m 18 ft lbs NOTE Use only original or factory replacement nuts 4 Install combination valve onto brake booster studs and tighten mounting nuts to 24 N m 18 ft lbs 5 I...

Страница 175: ...per Fig 24 Do not allow clamp screw to bear directly on outboard shoe retainer spring Use wood or metal spacer between shoe and clamp screw 5 Remove brake hose mounting bolt and discard washers Fig 25...

Страница 176: ...6 Install wheel and tire assemblies 7 Remove supports and lower vehicle 8 Verify firm pedal before moving vehicle DISC BRAKE SHOES REMOVAL 1 Raise and support vehicle 2 Remove wheel and tire assembly...

Страница 177: ...BRAKE ROTOR REMOVAL 1 Remove wheel and tire assemble 2 Remove caliper 3 Remove retainers securing rotor to hub studs Fig 33 4 Remove rotor from hub 5 If rotor shield requires service remove front hub...

Страница 178: ...secure lever 6 Remove wheel cylinder clamps 7 Attach parking brake cable to lever 8 Install brake shoes on support plate Secure shoes with new hold down springs pins and retain ers 9 Install parking b...

Страница 179: ...onnect parking brake switch wiring con nectors Fig 37 7 Remove screws attaching parking brake lever to mount Fig 38 8 Disengage front cable from parking brake lever and remove lever assembly from vehi...

Страница 180: ...zer and install equalizer nuts 7 Adjust parking brakes DISASSEMBLY AND ASSEMBLY MASTER CYLINDER RESERVOIR REMOVAL 1 Remove reservoir cap and empty fluid into drain container 2 Remove pins that retain...

Страница 181: ...s Place this piece in the out board shoe side of the caliper in front of the piston This will cushion and protect caliper piston during removal Fig 46 4 Remove caliper piston with short bursts of low...

Страница 182: ...l groove with finger Fig 52 5 Install new dust boot on caliper piston and seat boot in piston groove Fig 53 6 Press piston into caliper bore by hand use a turn and push motion to work piston into seal...

Страница 183: ...bore and against piston Be sure lip of piston cup is facing inward toward spring and expander and flat side is against piston 3 Install spring and expander followed by remaining piston cup and piston...

Страница 184: ...t rust and scale from the brake shoe contact pads on the sup port plate with fine sandpaper INSPECTION As a general rule riveted brake shoes should be replaced when worn to within 0 78 mm 1 32 in of t...

Страница 185: ...brake cables operate freely and are not binding or seized Replace faulty cables before proceeding 6 Reinstall brake drums and wheel tire assem blies after brake shoe adjustment is complete 7 Lower veh...

Страница 186: ...heel move tool handle upward until slight drag can be felt when wheel is rotated 7 Push and hold adjuster lever away from star wheel with thin screwdriver 8 Back off adjuster screw star wheel until br...

Страница 187: ...ax Thickness Variation 0 013 mm 0 0005 in Min Thickness 22 7 mm 0 8937 in Brake Drum Size 228 6 x 63 5 mm 9 x 2 5 in Brake Booster Type Tandem Diaphragm TORQUE CHART DESCRIPTION TORQUE Brake Pedal Sup...

Страница 188: ...exhibits a fault during ini tialization the CAB illuminates the amber warning light and registers a fault code in the microprocessor memory NORMAL BRAKING During normal braking the master cylinder po...

Страница 189: ...an ABS brake system During antilock braking solenoid valve pressure modulation occurs in three stages pressure increase pressure hold and pressure decrease The valves are all contained in the valve b...

Страница 190: ...required COMBINATION VALVE The combination valve contains a pressure differ ential valve and switch and a rear brake proportion ing valve The valve is not repairable and must be replaced as an assembl...

Страница 191: ...ystem For additional informa tion refer to the Antilock Brake section in Group 8W For test procedures refer to the Chassis Diag nostic Manual SERVICE PROCEDURES BLEEDING ABS BRAKE SYSTEM ABS system bl...

Страница 192: ...re removal 5 Remove bolt attaching sensor to steering knuckle and remove sensor Fig 8 INSTALLATION 1 If original sensor will be installed wipe all traces of old spacer material off sensor pickup face...

Страница 193: ...t air gap will be established as tone ring rotates and peels spacer off sensor face 7 Secure the rear sensor wires to the retainer clips Verify that wire is clear of rotating components 8 Connect sens...

Страница 194: ...he mercury switch inside the accelera tion switch will not function properly if the switch is installed incorrectly Verify that the switch locat ing arrow is pointing to the front of the vehicle Fig 1...

Страница 195: ...Unit Bracket to HCU Bolts 6 5 N m 57 in lbs Body Bracket Bolts 16 24 N m 142 212 in lbs HCU to Body Bracket Bolts 9 13 N m 80 115 in lbs Brake Lines 15 18 N m 130 160 in lbs Controller Anitlock Brake...

Страница 196: ...PONENTS The hydraulic linkage consists of a clutch master cylinder with integral reservoir a clutch slave cylin der and an interconnecting fluid line The clutch master cylinder push rod is connected t...

Страница 197: ...ragm spring As additional force is applied the bearing presses the diaphragm spring fingers inward on the ful crums This action moves the pressure plate rearward relieving clamp force on the disc The...

Страница 198: ...Fig 2 Clutch Components And Inspection TJ CLUTCH 6 3 DIAGNOSIS AND TESTING Continued...

Страница 199: ...fere with proper clutch release Clean the crankshaft flange before mounting the flywheel Dirt and grease on the flange surface may cock the flywheel causing excessive runout Use new bolts when remount...

Страница 200: ...DIAGNOSTIC CHART TJ CLUTCH 6 5 DIAGNOSIS AND TESTING Continued...

Страница 201: ...DIAGNOSTIC CHART 6 6 CLUTCH TJ DIAGNOSIS AND TESTING Continued...

Страница 202: ...DIAGNOSTIC CHART CONTINUED TJ CLUTCH 6 7 DIAGNOSIS AND TESTING Continued...

Страница 203: ...DIAGNOSTIC CHART CONTINUED 6 8 CLUTCH TJ DIAGNOSIS AND TESTING Continued...

Страница 204: ...ndicator ring To avoid contaminating the hydraulic fluid during inspection wipe reservoir and cover clean before removing the cap FLYWHEEL Inspect the flywheel whenever the clutch disc cover and housi...

Страница 205: ...bly on a workbench and let it cool in normal shop air CAUTION Do not use water or compressed air to cool the flywheel The rapid cooling produced by water or compressed air can distort or crack the gea...

Страница 206: ...elease fork and fork pivot Be sure pivot is secure and in good condition Be sure fork is not distorted or worn Replace release fork retainer spring if bent or damaged INSTALLATION 1 Lubricate cranksha...

Страница 207: ...kage components cannot be overhauled or serviced separately The cylinders and connecting line are sealed units Also note that removal installation pro cedures for right and left hand drive models are...

Страница 208: ...for access Refer to Group 8E Instrument Panel for procedure 2 Disconnect clutch pedal position switch wires 3 Disengage captured bushing lock tabs attach ing clutch master cylinder actuator to pedal p...

Страница 209: ...lutch housing 3 8 37 N m 27 ft lbs Bolt clutch housing 7 16 58 N m 43 ft lbs Bolt clutch housing trans 38 N m 28 ft lbs Bolt dust shield M8 8 N m 72 in lbs Bolt dust shield lower 50 N m 37 ft lbs Bolt...

Страница 210: ...ACCESSORY DRIVE BELT 27 AUTOMATIC TRANSMISSION OIL COOLER 21 BLOCK HEATER 25 COOLANT RESERVE OVERFLOW BOTTLE 21 RADIATOR 25 THERMOSTAT 24 VISCOUS FAN 26 VISCOUS FAN DRIVE 27 WATER PUMP 21 CLEANING AND...

Страница 211: ...during engine operation The coolant carries heat to the radiator and heater core Here it is transferred to the ambient air pass ing through the radiator and heater core fins The coolant also removes...

Страница 212: ...uid or transmission fluid may enter the cooling system Both cooling system and transmission should be drained and inspected if the internal radiator mounted transmission cooler is leaking These models...

Страница 213: ...F 50 50 Ethylene Glycol and Water Is the recom mended mixture it provides protection against freez ing to 37 C 34 F The antifreeze concentration must always be a minimum of 44 percent year round in al...

Страница 214: ...to and from the radia tor intake manifold and heater core Radiator lower hoses are spring reinforced to pre vent collapse from water pump suction at moderate and high engine speeds WARNING CONSTANT T...

Страница 215: ...of the fan to a predetermined maximum level at higher engine speeds A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit a typical viscous unit is shown in...

Страница 216: ...ouble Code DTC can be set If an open or shorted condition has developed in the relay circuit controlling the electric radiator fan a Diagnostic Trouble Code DTC can be set If the problem is sensed in...

Страница 217: ...eizure 3 Replace faulty component or bearing 4 Belt glazed or hardened from heat and excessive slippage 4 Replace belt LONGITUDAL BELT CRACKING 1 Belt has mistracked from pulley groove 1 Replace belt...

Страница 218: ...VERHEATING Establish what driving conditions caused the com plaint Abnormal loads on the cooling system such as the following may be the cause PROLONGED IDLE VERY HIGH AMBIENT TEMPERATURE SLIGHT TAIL...

Страница 219: ...ing for procedures TEMPERATURE GAUGE READS HIGH OR ENGINE COOLANT WARNING LAMP ILLUMINATES COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM COOLING SYSTEM 1 Trailer is being towed a steep hill is being...

Страница 220: ...verflow tank and tank hoses for blockage Repair as necessary 8 Freeze point of antifreeze not correct Mixture may be too rich 8 Check antifreeze Refer to Coolant section of this group Adjust antifreez...

Страница 221: ...essary Gauge reading should return to normal range after vehicle is driven 4 Gauge reading high after restarting a warmed up hot engine 4 A normal condition No correction is necessary The gauge should...

Страница 222: ...NG 1 Vacuum created in cooling system on engine cool down is not being relieved through coolant reserve overflow system 1 a Radiator cap relief valve stuck Refer to Radiator Cap in this group Replace...

Страница 223: ...missing or damaged air seals and repair as necessary INADEQUATE HEATER PERFORMANCE THERMOSTAT FAILED IN OPEN POSITION 1 Has a diagnostic trouble code DTC been set 1 Refer to group 25 Emission Control...

Страница 224: ...using the DRB scan tool Replace thermostat if necessary STEAM IS COMING FROM FRONT OF VEHICLE NEAR GRILL AREA WHEN WEATHER IS WET ENGINE IS WARMED UP AND RUNNING AND VEHICLE IS STATIONARY TEMPERATURE...

Страница 225: ...from the stop tabs Wipe the inner part of the filler neck and examine the lower inside sealing seat for nicks cracks paint dirt and solder residue Inspect the reserve overflow tank tube for internal o...

Страница 226: ...CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE SERIOUS BURNS FROM COOLANT CAN OCCUR Drain sufficient coolant to allow for thermostat removal Refer t...

Страница 227: ...an drive unit CAUTION Engines equipped with serpentine drive belts have reverse rotating fans and viscous fan drives They are marked with the word REVERSE to designate their usage Installation of the...

Страница 228: ...filler neck for white deposits that indicate a leaking cap COOLANT LOW LEVEL AERATION If the coolant level in radiator drops below top of radiator core tubes air will enter cooling system Low coolant...

Страница 229: ...by removing drain plug at left rear side of block Fig 15 COOLING SYSTEM REFILLING 1 Tighten the radiator draincock and the cylinder block drain plug s 2 Fill system using a 50 50 mixture of water and...

Страница 230: ...ct for sludge Inspect for a dirty or plugged inlet filter If none of these condi tions are found the transmission and torque con verter may require reconditioning Refer to Group 21 for automatic trans...

Страница 231: ...ter hose fit ting must be removed Note position of fitting before removal INSTALLATION 1 If pump is being replaced install the heater hose fitting to the pump Use a sealant on the fitting such as Mopa...

Страница 232: ...stem with coolant and check for leaks Refer to Refilling Cooling System in this group 10 Connect battery cable to battery 11 Start and warm the engine Check for leaks Fig 19 Power Steering Pump Attach...

Страница 233: ...heater hose at thermostat housing 3 Disconnect wiring connector at engine coolant temperature sensor 4 Remove thermostat housing mounting bolts thermostat housing gasket and thermostat Fig 23 Discard...

Страница 234: ...and bottom of radia tor on certain models only Fig 25 To prevent pos sible overheating these seals must be installed to their original positions INSTALLATION 1 Position the radiator Install and tighte...

Страница 235: ...block heater Route cord away from moving parts linkages and exhaust sys tem components Secure cord in place with tie straps VISCOUS FAN REMOVAL 1 Loosen but do not remove at this time the four fan hub...

Страница 236: ...er to Cooling System Fan for removal and installation procedures of the viscous drive unit Viscous Fan Drive Fluid Pump Out Require ment After installing a new viscous fan drive bring the engine speed...

Страница 237: ...e end of this group for Drive Belt Tension specifica tions 3 Tighten idler pulley bolt and re check belt ten sion Adjust if necessary CLEANING AND INSPECTION RADIATOR PRESSURE CAP Visually inspect the...

Страница 238: ...coolant loss and engine overheating Ordinary worm gear type hose clamps when equipped can be removed with a straight screw driver or a hex socket To prevent damage to hoses or clamps the hose clamps...

Страница 239: ...ts 8 N m 72 in lbs Thermostat Housing Bolts 20 N m 15 ft lbs Transmission Cooler Lines Fittings at Radiator 16 N m 140 in lbs Pressure Fitting at Trans 20 N m 180 in lbs Viscous Fan Drive to Water Pum...

Страница 240: ...SPECIAL TOOLS COOLING Hose Clamp Pliers 6094 Belt Tension Gauge C 4162 Cooling System Pressure Tester 7700 A Quick Disconnect Tool 6935 TJ COOLING SYSTEM 7 31...

Страница 241: ...glass of the indicator will reveal the battery condition Refer to Built In Test Indicator in the Diagnosis and Testing section of this group for more information This group covers only the battery di...

Страница 242: ...charges deposited on the plates and the voltage potential of the battery cells For a battery to remain useful it must be able to produce high amperage current over an extended period A battery must al...

Страница 243: ...hese systems to make it easier to locate the information you are seeking within this Service Manual However when attempt ing to diagnose any of these systems it is important that you keep their interd...

Страница 244: ...temperature corrected specific gravity of the battery electrolyte is less than 1 235 The battery open circuit voltage is less than 12 4 volts A battery that will not accept a charge is faulty and mus...

Страница 245: ...erminal connections if required 4 Determine the battery state of charge Refer to Built In Test Indicator Hydrometer Test or Open Circuit Voltage Test in the Diagnosis and Testing section of this group...

Страница 246: ...m in the Diagnosis and Testing section of Group 8C Charging System for more information Repair the charging system if required 8 Inspect the vehicle for aftermarket electrical equipment which might ca...

Страница 247: ...sted Refer to Load Test in the Diagnosis and Testing section of this group for more information Black or Dark indicates 0 to 75 state of charge The battery is inadequately charged and must be charged...

Страница 248: ...y battery failure To read the hydrometer correctly hold it with the top surface of the electrolyte at eye level Fig 4 Hydrometer floats are generally calibrated to indi cate the specific gravity corre...

Страница 249: ...letely charge the battery Refer to Battery Charging in the Ser vice Procedures section of this group for the proper battery charging procedures 1 Before measuring the open circuit voltage the surface...

Страница 250: ...c tions provided by the manufacturer of the tester you are using Check the open circuit voltage no load of the battery Refer to Open Circuit Voltage Test in the Diagnosis and Testing section of this g...

Страница 251: ...L CAPS The following operation will require a voltmeter accurate to 1 10 0 10 volt Before performing the tests be certain the following procedures are accom plished The battery is fully charged Refer...

Страница 252: ...nition switch in the Off position and all non ignition controlled circuits in proper working order The twenty five milliamperes are needed to enable the memory functions for the Powertrain Con trol Mo...

Страница 253: ...om the generator If the amperage reading now becomes very low or nonexistent refer to Charging System in the Diagnosis and Testing section of Group 8C Charging System to diagnose the condition After t...

Страница 254: ...completely discharged battery Unless this proce dure is properly followed a good battery may be needlessly replaced 1 Measure the voltage at the battery posts with a voltmeter accurate to 1 10 0 10 v...

Страница 255: ...minal clamps for corrosion and damage Remove any corrosion using a wire brush or a post and terminal cleaning tool and a sodium bicarbonate baking soda and warm water cleaning solution Fig 16 Replace...

Страница 256: ...id film Fig 19 Rinse the battery with clean water Ensure that the cleaning solution does not enter the battery cells through the vent holes If the battery is being replaced refer to Battery Ratings an...

Страница 257: ...Then connect and tighten the bat tery negative cable terminal clamp Tighten both bat tery cable terminal clamp bolts to 6 2 N m 55 in lbs 5 Apply a thin coating of petroleum jelly or chas sis grease t...

Страница 258: ...Classifications and Ratings Part Number BCI Group Size Classification Cold Cranking Amperage Reserve Capacity Ampere Hours Load Test Amperage 56027960 34 500 110 Minutes 60 250 56041003 34 600 120 Mi...

Страница 259: ...the proper section of Group 8D Ignition System for complete service information for the igni tion switch Refer to Clutch Pedal Position Switch in the proper section of Group 6 Clutch for complete ser...

Страница 260: ...onverter drive plate As the solenoid plunger reaches the end of its travel the solenoid contact disc completes the high amperage starter feed circuit and energizes the sole noid plunger hold in coil C...

Страница 261: ...electromagnetic coil a resistor or diode and three two fixed and one mov able electrical contacts The movable common feed relay contact is held against one of the fixed contacts normally closed by spr...

Страница 262: ...y 2 Starting circuit wiring faulty 3 Starter motor faulty 4 Engine seized 1 Refer to Battery in the Diagnosis and Testing section of Group 8A Battery Charge or replace the battery if required 2 Refer...

Страница 263: ...r relay for indications of physical damage and loose or corroded wire harness connections Starter Motor Visually inspect the starter motor for indications of physical damage and loose or corroded wire...

Страница 264: ...n that the following procedures are accomplished Battery is fully charged and load tested Refer to Battery in the Diagnosis and Testing section of Group 8A Battery for the procedures Fully engage the...

Страница 265: ...ws Starter Relay Refer to Starter Relay in the Diagnosis and Testing section of this group for the procedures Starter Solenoid Refer to Starter Motor in the Diagnosis and Testing section of this group...

Страница 266: ...rmed with the starter motor removed from the vehicle Refer to Starting System in the Specifications section of this group for the starter motor specifications CAUTION The 2 5L engine uses a permanent...

Страница 267: ...eplace the faulty starter motor assembly 4 Check for continuity between the solenoid ter minal and the solenoid case Fig 10 There should be continuity If not OK replace the faulty starter motor assemb...

Страница 268: ...in the relay On vehicles with a manual transmission it is grounded at all times On vehicles with an automatic transmission it is grounded through the park neutral position switch only when the gearsh...

Страница 269: ...ut that secures the battery cable harness connector eyelet to the solenoid battery terminal stud Tighten the nut to 10 N m 90 in lbs Always support the starter motor during this process do not let the...

Страница 270: ...9 Reconnect the battery negative cable STARTER RELAY REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the cover from the Power Distribution Center PDC Fig 15 3 See the fuse and re...

Страница 271: ...er of Brushes 4 Drive Type Planetary Gear Reduction Free Running Test Voltage 11 2 Volts Free Running Test Maximum Amperage Draw 90 Amperes Free Running Test Minimum Speed 2 5L 2600 rpm 4 0L 2500 rpm...

Страница 272: ...ature data along with data from monitored line voltage is used by the PCM to vary the battery charging rate This is done by cycling the ground path to control the strength of the rotor mag netic field...

Страница 273: ...not register properly an undercharged or overcharged battery condi tion occurs Remember that an undercharged battery is often caused by accessories being left on with the engine not running a faulty...

Страница 274: ...generator Fig 3 Disconnect terminal from genera tor 6 Disconnect field wire connector at rear of gen erator by pushing on connector tab 7 Remove generator from vehicle INSTALLATION 1 Position generato...

Страница 275: ...sor into top of battery tray 2 Connect pigtail harness 3 Install battery Refer to Group 8A Battery for procedures Fig 2 Generator Remove Install Fig 3 Generator Connectors Typical Fig 4 Battery Temper...

Страница 276: ...4 0L 88 TORQUE CHART Description Torque Generator Upper Mounting Bolt Nut 2 5L 4 0L Engine 55 N m 41 ft lbs Generator Lower Mounting Bolt 2 5L 4 0L Engine 55 N m 41 ft lbs Battery Terminal Nut 8 5 N m...

Страница 277: ...TIONS ENGINE FIRING ORDER 2 5L 4 CYLINDER ENGINE 19 ENGINE FIRING ORDER 4 0L 6 CYLINDER ENGINE 19 IGNITION COIL RESISTANCE 20 IGNITION TIMING 19 SPARK PLUG CABLE RESISTANCE 20 SPARK PLUGS 20 TORQUE CH...

Страница 278: ...resistor type spark plugs Remove the spark plugs and examine them for burned elec trodes and fouled cracked or broken porcelain insu lators Keep plugs arranged in the order in which they were removed...

Страница 279: ...ur notches at its outer edge On 4 0L 6 cylinder engines there are three sets of notches Fig 7 or Fig 8 On 2 5L 4 cylinder engines there are two sets of notches Fig 6 The notches cause a pulse to be ge...

Страница 280: ...agnetic field causes the voltage to switch high resulting in a sync signal of approxi mately 5 volts When the trailing edge of the pulse ring shutter leaves the sync signal generator the following occ...

Страница 281: ...SD RELAY TEST To perform a complete test of this relay and its cir cuitry refer to the DRB scan tool Also refer to the appropriate Powertrain Diagnostics Procedures man ual To test the relay only refe...

Страница 282: ...R ROTOR Visually inspect the rotor Fig 13 for cracks evi dence of corrosion or the effects of arcing on the metal tip Also check for evidence of mechanical interference with the cap Some charring is n...

Страница 283: ...ector connected for this test 9 If voltage is still not present perform vehicle test using the DRB scan tool 10 If voltage is present at cavity A 17 but not at the supply wire a Check continuity betwe...

Страница 284: ...nd terminal at ignition coil end of cable If resistance is not within specifications as found in the Spark Plug Cable Resistance chart remove the cable from the distributor cap Connect the ohmmeter to...

Страница 285: ...p and go driving When the engine is suddenly subjected to a high torque load deposits partially liq uefy and bridge the gap between electrodes Fig 17 This short circuits the electrodes Spark plugs wit...

Страница 286: ...of the center electrodes porcelain insulator SPARK PLUG OVERHEATING Overheating is indicated by a white or gray center electrode insulator that also appears blistered Fig 21 The increase in electrode...

Страница 287: ...ed torque Over tightening can cause distortion This may result in a change in the spark plug gap or a cracked por celain insulator When replacing the spark plug and ignition coil cables route the cabl...

Страница 288: ...sing at the left rear side of the engine block Fig 26 Fig 27 or Fig 28 On 2 5L 4 cylinder and 4 0L 6 cylinder engines with manual transmissions the sensor is attached with two bolts On 2 5L engines wi...

Страница 289: ...N05252229 5 Used Sensors Clean bottom of sensor and install spacer PN05252229 6 Install sensor into transmission bellhousing hole 7 Push sensor against flywheel drive plate With sensor pushed against...

Страница 290: ...3 Remove distributor cap from distributor 2 screws Do not remove cables from cap Do not remove rotor 4 Disconnect distributor wiring harness from main engine harness 5 Remove cylinder number 1 spark...

Страница 291: ...slightly before counterclock wise of 11 o clock position Fig 34 If not place a flat blade screwdriver into oil pump gear and rotate it into proper position 3 Factory replacement distributors are equip...

Страница 292: ...0L 6 Cylinder Engine Pre position distributor into engine while holding centerline of base slot in 1 o clock position Fig 36 Continue to engage distrib utor into engine The rotor and distributor will...

Страница 293: ...butor cap Tighten distributor cap holddown screws to 3 N m 26 in lbs torque 17 If removed install spark plug cables to dis tributor cap For proper firing order refer to Specifi cations section at the...

Страница 294: ...R INSTALLATION 1 If equipped with an automatic transmission place shifter in PARK position 2 Position key cylinder into steering column as it would normally be in the ON position 3 Press key cylinder...

Страница 295: ...procedures The ignition interlock device within the steering column is not serviceable If service is nec essary the steering column must be replaced Refer to Group 19 Steering for procedures SPECIFIC...

Страница 296: ...0 13 300 Ohms TORQUE CHART DESCRIPTION TORQUE Crankshaft Position Sensor Bolts With Manual Transmission 19 N m 14 ft lbs Crankshaft Position Sensor Nuts 2 5L With Automatic Transmission 19 N m 14 ft l...

Страница 297: ...the instrument panel components and systems This group is responsible for covering service infor mation for the vehicle instrument panel systems However complete service information coverage for all o...

Страница 298: ...g section of this group The instrument cluster circuitry also integrates a chime tone generator and a timer circuit These items replace the chime or buzzer module and the separate timer circuit for th...

Страница 299: ...next to the ash receiver A plastic cap snaps into the power outlet base when the power out let is not in use A cigar lighter that fits into the power outlet is a dealer installed option The cigar lig...

Страница 300: ...COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY PRELIMINARY DIAGNOSIS 1 If...

Страница 301: ...mp bulb is not faulty and that the bulb holder is properly installed on the instrument cluster electronic circuit board before considering instrument cluster replacement If the bulb and bulb holder ch...

Страница 302: ...Fig 1 Instrument Cluster Actuator Test 8E 6 INSTRUMENT PANEL SYSTEMS TJ DIAGNOSIS AND TESTING Continued...

Страница 303: ...the fuseblock module If OK go to Step 3 If not OK repair the open fused ignition switch output run start circuit to the igni tion switch as required 3 Turn the ignition switch to the Off position Disc...

Страница 304: ...uired FOUR WHEEL DRIVE INDICATOR LAMP The diagnosis found here addresses an inoperative four wheel drive indicator lamp condition If the problem being diagnosed is related to lamp accuracy be certain...

Страница 305: ...r left turn signal circuit cavity of the instrument cluster wire harness connector connector A left or connector B right There should be a switching on and off bat tery voltage signal If OK replace th...

Страница 306: ...cumference of the cigar lighter power outlet receptacle shell and a good ground there should be continuity If OK go to Step 2 If not OK go to Step 3 2 Turn the ignition switch to the On position Check...

Страница 307: ...the Removal and Installa tion section of this group for the procedures 3 Remove the four screws that secure the knee blocker to the instrument panel Fig 4 4 Remove the knee blocker from the instrumen...

Страница 308: ...ument panel 4 Install and tighten the spanner nut that secures the headlamp switch to the instrument panel mounting bracket Tighten the nut to 2 7 N m 24 in lbs 5 Install the knee blocker onto the ins...

Страница 309: ...panel Fig 7 5 Remove the three screws that secure the upper mounting flange of the cluster bezel to the instru ment panel Fig 8 6 Remove the cluster bezel from the instrument panel INSTALLATION 1 Posi...

Страница 310: ...auges and the instrument cluster electronic cir cuit board Following are the service procedures for the instrument cluster components WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSI...

Страница 311: ...ove the cluster lens from the cluster hous ing Refer to Instrument Cluster Components Cluster Lens in the Removal and Installation sec tion of this group for the procedures 4 Work around the perimeter...

Страница 312: ...2 Press firmly and evenly on the cluster lens to install it onto the cluster housing 3 Work around the perimeter of the cluster hous ing to be certain that each of the latches that secure the cluster...

Страница 313: ...r bezel 4 Remove the one screw from the back of the ash receiver housing that secures the lower portion of the center bezel to the instrument panel Fig 12 5 Remove the two screws that secure the top o...

Страница 314: ...nt panel wire harness connectors to the connector receptacles the accessory switches and the cigar lighter power outlet on the back of the accessory switch bezel 3 Position the accessory switch bezel...

Страница 315: ...nel 5 Remove the glove box from the instrument panel INSTALLATION 1 Position the glove box to the instrument panel 2 Engage the hinge hook formations on the lower edge of the glove box door with the h...

Страница 316: ...e glove box lock cylinder 5 Insert a small screwdriver into the retaining tumbler release slot and depress the retaining tum bler Fig 17 6 Pull the lock cylinder out of the glove box latch handle by u...

Страница 317: ...f this group for the procedures 3 Remove the two screws that secure the latch striker to the grab handle bezel at the top of the instrument panel glove box opening Fig 18 4 Remove the latch striker fr...

Страница 318: ...t panel Refer to Instrument Panel Grab Handle in the Removal and Installation section of this group for the procedures 5 Reconnect the battery negative cable INSTRUMENT PANEL ASSEMBLY WARNING ON VEHIC...

Страница 319: ...dash panel studs in the vehicle 2 Install and tighten the four nuts that secure the top of the instrument panel to the studs on the top of the dash panel Tighten the nuts to 12 N m 105 in lbs 3 Insta...

Страница 320: ...emove the radio from the instrument panel Refer to Radio in the Removal and Installation sec tion of Group 8F Audio Systems for the procedures 7 Remove the heater A C control from the instru ment pane...

Страница 321: ...and Installation section of Group 8F Audio Systems for the procedures 10 Install the grab handle bezel onto the instru ment panel Refer to Instrument Panel Grab Han dle Bezel in the Removal and Insta...

Страница 322: ......

Страница 323: ...AL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY REMOVAL 1 Using a flat blade screwdriver or similar tool between the headlamp leveling switch and the steer ing column cover Fig 1 Gently pry the hea...

Страница 324: ...ry the instrument panel top cover up and away from the instrument panel to release the snap clip retainers Fig 3 2 Remove the instrument panel top cover from the vehicle 3 Remove the ash receiver from...

Страница 325: ...LLATION 1 Install the rear foglamp switch to the accessory switch bezel 2 Connect the rear foglamp switch electrical con nector to the switch 3 Install the screws attaching the accessory switch bezel...

Страница 326: ...e battery current when the ignition switch is in the Off position including the clock and radio station preset memory functions The fuse is removed to prevent battery discharge during vehicle storage...

Страница 327: ...ers These internal suppression devices are only serviced as part of the radio receiver External suppression devices that are used on this vehicle to control RFI or EMI noise include the fol lowing Rad...

Страница 328: ...off draw fuse Replace fuse if required 2 Check for loose or corroded radio connector Repair if required 3 Check for battery voltage at radio connector Repair wiring if required 4 Check for continuity...

Страница 329: ...nd system Do not allow any speaker lead to short to ground as damage to the radio may result 1 Turn the ignition switch to the On position Turn the radio on Adjust the balance and fader con trols to c...

Страница 330: ...2 Test 2 checks the antenna for an open circuit as follows 1 Unplug the antenna coaxial cable connector from the radio chassis 2 Connect one ohmmeter test lead to the tip of the antenna mast Connect...

Страница 331: ...ay from the factory installed vehicle wire harnesses whenever possible The antenna and cable must be carefully matched to ensure a low Standing Wave Ratio SWR Fleet vehicles are available with an extr...

Страница 332: ...secure the out board end of the speaker bezel to the instrument panel Fig 5 3 Using a trim stick or another suitable wide flat bladed tool gently pry at the top and bottom edges of the speaker bezel t...

Страница 333: ...ard top from the vehicle Refer to Hard Top in Group 23 Body for the procedures 3 If the vehicle is equipped with the standard soft top lower the soft top Refer to Folding Down the Fabric Top in the Ow...

Страница 334: ...o unsnap it from the antenna body base 7 Remove the three screws that secure the antenna body base to the right outer cowl side panel 8 From the outside of the vehicle pull the antenna body base and c...

Страница 335: ...ner of the engine cylinder head Tighten the nut to 5 6 N m 50 in lbs 4 Install and tighten the screw that secures the engine to body ground strap eyelet to the dash panel Tighten the screw to 48 5 N m...

Страница 336: ...on the features use and operation of the horn system HORN DESCRIPTION The dual electromagnetic diaphragm type horns are standard equipment on this model Each horn is secured with a bracket to the left...

Страница 337: ...pen fixed contact When the electromagnetic coil is de energized spring pressure returns the movable contact to the normally closed position The resistor or diode is con nected in parallel with the ele...

Страница 338: ...required 2 The relay normally closed terminal 87A is connected to terminal 30 in the de energized position but is not used for this application Go to Step 3 3 The relay normally open terminal 87 is co...

Страница 339: ...iagrams 1 Disconnect the wire harness connectors from the horn connector receptacles Measure the resis tance between the ground circuit cavity of the horns wire harness connectors and a good ground Th...

Страница 340: ...nits from the left front inner fender shield INSTALLATION 1 Position the horn and mounting bracket units onto the left front inner fender shield 2 Install and tighten the screw that secures the horn a...

Страница 341: ...the PCM will duty cycle the vent solenoid with the vacuum sole noid still de activated to close the throttle to return to target speed SPEED CONTROL SWITCHES Two separate speed control switch modules...

Страница 342: ...ould be corrected before proceeding Refer to Group 8E Instrument Panel and Gauges for speedometer diag nosis If a road test verifies a system problem and the speedometer operates properly check for A...

Страница 343: ...t 4 way electrical connector at servo 3 Turn speed control switch to ON position 4 Check for battery voltage at pin 3 of wiring harness 4 way connector Fig 1 This is the 12 volt feed from the stoplamp...

Страница 344: ...lbs 5 Connect vacuum line at servo 6 Connect electrical connector at servo 7 Connect servo cable to throttle body Refer to Servo Cable Removal Installation in this group 8 Connect negative battery cab...

Страница 345: ...nd push cable out of cable locking plate 4 Unclip cable from cable guide at valve cover Fig 6 5 Disconnect servo cable at servo Refer to Speed Control Servo Removal Installation INSTALLATION 1 Attach...

Страница 346: ...1 Position reservoir to vehicle and install mount ing screw 2 Tighten screw to 1 2 N m 10 in lbs torque 3 Connect vacuum line to reservoir 4 Install battery and battery tray Refer to Group 8A Battery...

Страница 347: ...is activated When the turn signal system is activated the circuitry of the turn signal switch and the combination flasher will cause the selected right or left turn signal indicator lamp front park t...

Страница 348: ...signal and hazard warning switches cannot be repaired If these switches or any other circuit or component of the multi function switch unit is faulty or damaged the entire multi function switch unit...

Страница 349: ...ns The combination flasher should never be substituted for an ISO relay or replaced with an ISO relay or else component and vehicle damage may occur Because of the active electronic elements within th...

Страница 350: ...Contents of Group 8W Wiring Diagrams WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COM...

Страница 351: ...ERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable Disconnect the instrument...

Страница 352: ...tion section of Group 8E Instrument Panel Systems for the procedures 7 Reconnect the battery negative cable TURN SIGNAL SWITCH AND HAZARD WARNING SWITCH WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFE...

Страница 353: ...s a unit 3 Reconnect the two instrument panel wire har ness connectors to the multi function switch connec tor receptacles 4 Position the multi function switch onto its mounts on the left side of the...

Страница 354: ...s will operate only when the ignition switch is in the Accessory or On positions A fuse located in the fuseblock module protects the cir cuitry of either windshield wiper system Refer to the owner s m...

Страница 355: ...to the center of the linkage and pivot module bracket The wiper pivots are secured to the ends of the module bracket The driver side wiper pivot crank arm and the wiper motor crank arm each have ball...

Страница 356: ...st be replaced WASHER RESERVOIR A single washer fluid reservoir is used for both the front and rear washer systems The washer fluid res ervoir is secured to the inner fender shield over the left front...

Страница 357: ...hex nut The rear washer nozzle cannot be adjusted The nozzle check valve and hose fittings cannot be repaired and if faulty or damaged they must be replaced DIAGNOSIS AND TESTING WIPER SYSTEM FRONT Fo...

Страница 358: ...AL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Check the fuse in the fuseblock module If OK go to Step 2 If not OK repair the shorted circuit or component as required and replace the faulty fuse...

Страница 359: ...If OK replace the faulty switch If not OK repair the open circuit as required REAR The diagnosis found here addresses an inoperative rear washer pump If the washer pump operates but no washer fluid is...

Страница 360: ...asher system wire harness circuits as required REAR Perform the diagnosis for the rear wiper system and or washer system as described in this group before testing the rear wiper and washer switch For...

Страница 361: ...otor output shaft end of the arm Fig 6 3 To install the wiper blade on the wiper arm slide the blade retainer into the U shaped formation on the tip of the wiper arm until the release tab snaps into i...

Страница 362: ...tor in this group for the service procedures WIPER MOTOR FRONT 1 Disconnect and isolate the battery negative cable 2 Remove the wiper arms from the wiper pivots See Wiper Arm in this group for the pro...

Страница 363: ...e nut 8 From the inside of the liftglass gently pull the rear wiper motor away from the liftglass until the output shaft clears the hole in the liftglass 9 Move the motor towards the right side of the...

Страница 364: ...a unit and move it out of the way If the vehicle is equipped with the optional tilt steering column lifting gently upward on the tilt release lever will provide additional clearance to ease multi func...

Страница 365: ...procedures to install Be certain that both of the switch snap clip retainers in the receptacle on the back of the accessory switch bezel are fully engaged Tighten the mounting screws to 2 2 N m 20 in...

Страница 366: ...r nozzle nipple 5 While holding the nozzle securely from the out side of the liftglass remove the plastic nut that secures the threaded nozzle nipple from the inside of the liftglass 6 Push the nozzle...

Страница 367: ...S PER SONAL INJURY CAN RESULT CAUTION Do not touch the glass of halogen bulbs with fingers or other possibly oily surface reduced bulb life will result Do not use bulbs with higher candle power than i...

Страница 368: ...r to Group 8A ABOVE IDLE 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations refer to Group 8W 3 High resistance in headlamp circuit 3 Test amperage draw of headlamp c...

Страница 369: ...DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system Refer to Group 8A 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locat...

Страница 370: ...module 2 Parking brake engaged 3 Parking brake circuit shorted to ground 4 Headlamp circuit shorted to ground 5 Defective DRL module 1 Secure connector on DRL module 2 Disengage parking brake 3 Check...

Страница 371: ...ssary tape a line on the floor 7 62 meters 25 ft away from and parallel to the wall 3 Measure from the floor up 1 27 meters 5 ft and tape a line on the wall at the centerline of the vehicle Sight alon...

Страница 372: ...the upper outboard up down adjustment screw Fig 2 until the headlamp beam pattern on screen wall is similar to the pattern depicted in Fig 1 NOTE When using a headlamp aiming screen Adjust the headla...

Страница 373: ...and straight ahead Fig 3 1 Loosen the nut attaching the fog lamp to the mounting bracket Fig 4 2 Move the fog lamp to adjust beam height 3 Tighten the nut attaching the fog lamp to the mounting bracke...

Страница 374: ...Position the bulb element in the reflector 3 Engage the bulb retainer 4 Position the reflector in the lamp housing 5 Install the screws that attach the reflector to the lamp housing FRONT PARK TURN S...

Страница 375: ...otate the bulb socket one third turn counter clockwise and separate from lamp housing 3 Pull the bulb straight out of the socket INSTALLATION 1 Install the bulb 2 Position the lens on the CHMSL and in...

Страница 376: ...t and press into place 2 Position lamp lens on lamp housing and press into place CARGO AREA DOME LAMP BULB REMOVAL 1 Remove the dome cargo lamp lens by squeezing it at the lens at the top and bottom F...

Страница 377: ...ess connec tor and remove the bulb from the bucket Fig 3 INSTALLATION 1 Connect the wire harness connector and posi tion the bulb in the bucket 2 Position retaining ring on the headlamp bulb and insta...

Страница 378: ...the vehicle remove the push in fastener attaching the bottom rear edge of the rear wheelhouse splash shield to the body 2 Pull the rear of the wheelhouse splash shield away from the body and reach upw...

Страница 379: ...g over and firmly press onto base to snap into place 6 Connect the wire harness connector to the lamp DOME LAMP SOUND BAR DOME LAMP REMOVAL 1 Insert a small flat blade between the lamp housing and lam...

Страница 380: ...nect the lamp wire connector 2 Position the lamp in the hardtop 3 Install the screws that attach the lamp to the hardtop 4 Install the bulb 5 Position the lens on the lamp housing and press into place...

Страница 381: ...L module receives a vehicle moving signal from the vehicle speed sensor This provides a constant headlamps on condition as long as the vehicle is moving The lamps are illuminated at less than 50 perce...

Страница 382: ...arker 168 or W3W Headlamp Sealed Beam H6024 Park Turn Signal 3157 Tail Stop 1157 INTERIOR LAMPS CAUTION Do not use bulbs that have a higher can dle power than the bulb listed in the Bulb Applica tion...

Страница 383: ...Do not touch the glass of halogen bulbs with fingers or other possibly oily surfaces reduced bulb life can result Do not use bulbs with higher candle power than indicated in the Bulb Application Tabl...

Страница 384: ...oded terminals or splices in circuit 2 Inspect and repair all connectors and splices Refer to Group 8W HEADLAMPS ARE DIM WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repa...

Страница 385: ...WITH ENGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system Refer to Group 8A 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations...

Страница 386: ...up 8W Wiring 3 Defective motor 3 Replace motor BOTH MOTORS DO NOT OPERATE 1 No voltage at headlamp leveling switch 1 Repair circuit or replace fuse Refer to Group 8W Wiring 2 No voltage at both motors...

Страница 387: ...es and open hood 2 Disconnect the headlamp wire harness connec tors 3 Remove the headlamp bezel retaining screws and bezel Fig 1 4 Remove the headlamp retaining ring screws and retaining ring Fig 2 5...

Страница 388: ...b from housing Installation 1 Perform the removal procedure in reverse order TAIL LAMP BULB REMOVAL 1 Remove the tail lamp lense retaining screws Fig 8 2 Separate the tail lamp lense from the tail lam...

Страница 389: ...and lense 2 Remove the bulb from the socket INSTALLATION 1 Perform the removal procedure in reverse order CENTER HIGH MOUNTED STOP LAMP CHMSL BULB REMOVAL 1 Remove the screws attaching the center high...

Страница 390: ...moval procedure in reverse order HEADLAMP LEVELING MOTOR REMOVAL 1 Remove the headlamp bezel attaching screws and bezel Fig 3 2 Disconnect the headlamp and headlamp level ing motor electrical connecto...

Страница 391: ...mp housing attaching bolts Fig 7 3 Separate the lamp housing from the body 4 Disconnect the tail lamp electrical connector and remove tail lamp housing INSTALLATION 1 Perform the removal procedure in...

Страница 392: ...pull the wire harness terminal ends from the contact buttons Fig 8 5 Route wire harness through tailgate and sepa rate CHMSL from vehicle INSTALLATION 1 Perform the removal procedure in reverse order...

Страница 393: ...adlamp H 4 License Plate W5W Front Turn Signal P27 7W Tail Stop P21 5W Rear Turn Signal P21W Rear Fog Lamp P21W Citylight T4W Side Repeater W5W INTERIOR LAMPS Service procedures for most of the lamps...

Страница 394: ...lockspring Driver and passenger side airbag modules including the airbag inflators Driver and passenger side knee blockers Passenger side airbag on off switch Wire harness and connections This group p...

Страница 395: ...US AND EXTREMELY FLAMMABLE CONTACT WITH ACID WATER OR HEAVY METALS MAY PRO DUCE HARMFUL AND IRRITATING GASES SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE OR COMBUSTIBLE COMPOUNDS THE PASSENG...

Страница 396: ...with the proper electrical signal Fol lowing an airbag deployment the airbag cushion quickly deflates by venting this gas through the porous fabric material used on each end panel of the airbag cushio...

Страница 397: ...citor stores enough electrical energy to deploy the airbags for up to one second following a battery disconnect or failure during an impact The purpose of the capacitor is to provide airbag system pro...

Страница 398: ...per mitted near the inflator on the back of an airbag module When carrying a non deployed airbag mod ule the trim cover or airbag side of the module should be pointed away from the body to minimize in...

Страница 399: ...OR FRESH AIR UNTIL THE IRRITATION CEASES IF IRRITATION CONTINUES SEE A PHYSI CIAN Begin the cleanup by removing the airbag modules from the vehicle Refer to Driver Side Airbag Mod ule and Passenger Si...

Страница 400: ...kspring wire harness to disengage the connector from the airbag mod ule connector receptacle 6 Remove the driver side airbag module from the steering wheel 7 If the driver side airbag has been deploye...

Страница 401: ...OPER PRECAUTIONS OR TO FOLLOW THE PROPER PROCEDURES COULD RESULT IN ACCI DENTAL INCOMPLETE OR IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE OCCUPANT INJU RIES REMOVAL 1 Disconnect and isolate the battery ne...

Страница 402: ...g 8 Driver Side Airbag Trim Cover Retainers Remove Install w Speed Control Fig 9 Driver Side Airbag Trim Cover Remove Install w o Speed Control Fig 10 Driver Side Airbag Trim Cover Remove Install w Sp...

Страница 403: ...driver side airbag module onto the steering wheel Refer to Driver Side Airbag Mod ule in the Removal and Installation section of this group for the procedures PASSENGER SIDE AIRBAG MODULE The followin...

Страница 404: ...e harness and that the connector is fully engaged and latched 4 Do not reconnect the battery negative cable at this time Refer to Airbag System in the Diagnosis and Testing section of this group for t...

Страница 405: ...tighten the two screws that secure the passenger side airbag door bracket to the instru ment panel armature Tighten the screws to 12 N m 105 in lbs 4 Install and tighten the five screws that secure th...

Страница 406: ...urther service 2 Remove the passenger side airbag on off switch from the bezel Refer to Passenger Side Airbag On Off Switch in the Removal and Installation sec tion of this group for the procedures 3...

Страница 407: ...AL INJURY NEVER STRIKE OR KICK THE AIRBAG CON TROL MODULE AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION IF AN AIR BAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE THE MODULE MU...

Страница 408: ...ative cable at this time Refer to Airbag System in the Diagnosis and Testing section of this group for the proper pro cedures CLOCKSPRING The clockspring cannot be repaired It must be replaced if faul...

Страница 409: ...oud Fig 20 9 If the vehicle is equipped with a standard non tilt steering column loosen the two upper steering column mounting nuts If the vehicle is equipped with the optional tilt steering column mo...

Страница 410: ...ing column shroud to the upper shroud Tighten the screws to 2 N m 18 in lbs 7 Install the steering column opening cover onto the instrument panel Refer to Steering Column Opening Cover in the Removal...

Страница 411: ...your other hand to rotate the clockspring rotor clockwise to the end of its travel Do not apply excessive torque 5 From the end of the clockwise travel rotate the rotor about two and one half turns co...

Страница 412: ...ame ignition cycle the defogger system will auto matically turn off after about five minutes The defogger system will automatically shut off if the ignition switch is turned to the Off position or it...

Страница 413: ...be adjusted or repaired and if faulty or damaged the instrument cluster assembly must be replaced DEFOGGER RELAY The rear window defogger relay is a International Standards Organization ISO type relay...

Страница 414: ...x volts indicates a line is good A reading of zero volts indicates a break in the grid line between midpoint C and the left side bus bar A reading of ten to fourteen volts indicates a break between mi...

Страница 415: ...ties of the rear glass heating grid and defogger switch connec tors at all times If OK go to Step 4 If not OK repair the open circuit s as required 4 The coil battery terminal 86 is connected to the e...

Страница 416: ...grid lines bus bars terminals or pigtail wires can be accomplished using a Mopar Rear Window Defogger Repair Kit Part Number 4267922 or equivalent WARNING MATERIALS CONTAINED IN THE REPAIR KIT MAY CAU...

Страница 417: ...sory switch bezel out from the instrument panel far enough to access the wire har ness connectors 5 Unplug the wire harness connectors from the rear of the accessory switches and the cigar lighter pow...

Страница 418: ...r s manual in the vehicle glove box for more information on the features use and operation of all of the power distribution system components POWER DISTRIBUTION CENTER DESCRIPTION All of the electrica...

Страница 419: ...ule housing is faulty or damaged the entire fuseblock module and cross body harness unit must be replaced REMOVAL AND INSTALLATION POWER DISTRIBUTION CENTER The Power Distribution Center PDC is servic...

Страница 420: ...the battery positive cable take out and the engine wire harness take out onto the PDC stud Tighten the nut to 8 4 N m 75 in lbs 7 Engage the tabs on the lower edge of the ter minal stud cover in the...

Страница 421: ...n the retainer locations 6 Remove the two screws that secure the fuse block module to the bracket on the dash panel Fig 6 7 Remove the fuseblock module and the cross body wire harness from the dash pa...

Страница 422: ...ehicle The SKIS will recognize no more than eight valid Sentry Key transponders at any one time The SKIS performs a self test each time the igni tion switch is turned to the On position and will store...

Страница 423: ...rument cluster to flash the SKIS indicator lamp The SKIM can also send messages to the instrument cluster to flash the lamp and to gen erate a single audible chime tone These functions serve as an ind...

Страница 424: ...Diagnostic Proce dures manual DIAGNOSIS AND TESTING SENTRY KEY IMMOBILIZER SYSTEM WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING...

Страница 425: ...the ignition switch to the Off position replace the valid Sentry Key with a blank Sentry Key transponder and turn the ignition switch back to the On position 6 About ten seconds after the completion...

Страница 426: ...ket Pull downward on the connector end of the SKIM mounting bracket to release this clip from the steering column jacket 9 Rotate the SKIM and its mounting bracket downwards and then to the side away...

Страница 427: ...circuitry monitors hard wired switch inputs as well as message inputs received from other vehicle electronic modules on the Chrysler Collision Detection CCD data bus network The instrument cluster us...

Страница 428: ...POSSIBLE PERSONAL INJURY 1 Rotate the headlamp switch knob counterclock wise to ensure that the dome lamps are not switched off Open the driver door and note whether the inte rior lamps light They sh...

Страница 429: ...mb switch sense circuit cavity of the headlamp switch wire harness connector and a good ground There should be no continuity with the driver door closed and continuity with the driver door open If OK...

Страница 430: ...8E Instrument Panel Sys tems If not OK repair the open circuit as required REMOVAL AND INSTALLATION CHIME WARNING SYSTEM SWITCHES Service procedures for the various hard wired switches used in the chi...

Страница 431: ...8W 50 1 FUEL IGNITION SYSTEMS 8W 30 1 FUSE FUSE BLOCK 8W 11 1 GENERAL INFORMATION 8W 01 1 GROUND DISTRIBUTION 8W 15 1 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 INSTRUMENT CLUSTER 8W 40 1 INTERIOR LIGHTI...

Страница 432: ...use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle it is impor tant to understand all of their features and charac teristics Diagrams are arranged such that the power B side of th...

Страница 433: ...The System shown here is an EXAMPLE ONLY It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION 8W 01 2 8W 01 GENERAL INFORMATION TJ DESCRIPTION AND OPERATION Continued...

Страница 434: ...The System shown here is an EXAMPLE ONLY It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION TJ 8W 01 GENERAL INFORMATION 8W 01 3 DESCRIPTION AND OPERATION Continued...

Страница 435: ...BROWN WT DB DARK BLUE WT DG DARK GREEN WT GY GRAY BK LB LIGHT BLUE BK LG LIGHT GREEN BK OR ORANGE BK PK PINK BK or WT RD RED WT TN TAN WT VT VIOLET WT WT WHITE BK YL YELLOW BK WITH TRACER CIRCUIT IDEN...

Страница 436: ...throughout the wir ing diagrams These symbols are consistent with those being used around the world GROUP TOPIC 8W 01 thru 8W 09 General Information and Diagram Overview 8W 10 thru 8W 19 Main Sources...

Страница 437: ...Wiring Diagram Symbols 8W 01 6 8W 01 GENERAL INFORMATION TJ DESCRIPTION AND OPERATION Continued...

Страница 438: ...ground location illustrations The illustrations contain the connector name or number ground number and component identification Connector ground location charts in Section 8W 90 reference the illustr...

Страница 439: ...ce 2 Avoid touching electrical terminals of the part unless instructed to do so by a written procedure 3 When using a voltmeter be sure to connect the ground lead first 4 Do not remove the part from i...

Страница 440: ...hat has rubbed through causing a short to ground Some or all of the wiring strands broken inside of the insulation covering Wiring broken inside of the insulation TROUBLESHOOTING TESTS Before beginnin...

Страница 441: ...ted symptoms Do this by per forming operational checks on components that are in the same circuit Refer to the wiring diagrams 3 Analyze the symptoms Use the wiring dia grams to determine what the cir...

Страница 442: ...Insert the probe end of special tool 6934 into the back of the connector cavity Fig 13 5 Grasp the wire and tool 6934 and slowly remove the wire and terminal from the connector 6 Repair or replace the...

Страница 443: ...r cavities For additional connector pin out identification refer to the wiring diagrams 8 Insert the connector locking wedge into the repaired connector if required 9 Connect connector to its mating h...

Страница 444: ...13 for each wire 15 Re tape the wire harness starting 1 1 2 inches behind the connector and 2 inches past the repair 16 Re connect the repaired connector 17 Connect the battery and test all affected...

Страница 445: ...ect the battery 2 Locate the diode in the harness and remove the protective covering 3 Remove the diode from the harness pay atten tion to the current flow direction Fig 22 4 Remove the insulation fro...

Страница 446: ...SPECIAL TOOLS WIRING TERMINAL Terminal Pick 6680 Probing Tool Package 6807 Terminal Removing Tool 6932 Terminal Removing Tool 6934 TJ 8W 01 GENERAL INFORMATION 8W 01 15...

Страница 447: ...tor Relay 8W 21 Fog Lamps 8W 50 Fog Lamp Illumination 8W 51 Fog Lamp Indicator 8W 51 Fog Lamp Relays 8W 50 Front Fog Lamp Switch 8W 50 Fuel Injectors 8W 30 Fuel Pump Module 8W 30 Component Page Fuel P...

Страница 448: ...40 Splice Information 8W 70 Tachometer 8W 40 Tail Stop Turn Signal Lamps 8W 51 52 Component Page Tail Stop Lamps 8W 51 Throttle Position Sensor 8W 30 Torque Converter Clutch Solenoid 8W 30 31 Transfe...

Страница 449: ...10 9 Fuse 11 PDC 8W 10 6 13 Fuse 12 FB 8W 10 9 Fuse 13 FB 8W 10 9 Fuse 13 PDC 8W 10 7 17 Fuse 14 FB 8W 10 9 Component Page Fuse 14 PDC 8W 10 7 17 Fuse 15 FB 8W 10 9 Fuse 15 PDC 8W 10 7 14 Fuse 16 PDC...

Страница 450: ...0A 40A 17 24 11 3 9 2 30A 30A 16 23 10 2 8 1 40A 20A 15 22 9 M1 FUSES POWER DISTRIBUTION CENTER RELAY HORN RELAY PUMP FUEL ENGINE STARTER MOTOR RELAY RELAY CLUTCH COMPRESSOR A C RELAY DOWN SHUT AUTOMA...

Страница 451: ...16 17 20A 18 19 20 10A A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD L9 16BK WT M1 20PK WT 21 10A B47 14RD LB 40A A4 12BK PK A142 14DG PK 20A A0 6RD A0 6R...

Страница 452: ...AY CONTROL CIRCUIT CAVITY FUNCTION C1 C2 C3 C4 C6 C7 C8 C9 C5 FUSED B A10 12RD DG Z1 14BK GROUND B47 14RD LB ABS SYSTEM RELAY OUTPUT B116 20GY ABS PUMP MOTOR RELAY CONTROL B120 12BR WT ABS PUMP MOTOR...

Страница 453: ...RTER MOTOR RELAY OUTPUT T41 20BR LB FUSED IGNITION SWITCH OUTPUT ST T40 12BR PARK NEUTRAL POSITION SWITCH SENSE T141 14YL RD A2 12PK BK FUSED B D13 D12 D11 D10 FUNCTION CAVITY CIRCUIT D14 B20 REAR WIN...

Страница 454: ...FUSE 6 RD WT 14 A14 20A FUSE 9 TO AUTOMATIC SHUT BK WT 16 L9 DOWN RELAY 1 8 9 2 10 3 11 4 12 5 22 15 16 23 A14 14 RD WT TO SWITCH HAZARD SIGNAL TURN TO POWERTRAIN CONTROL MODULE S332 TO A2 12 PK BK C...

Страница 455: ...8 CENTER DISTRIBUTION POWER TO ABS PUMP MOTOR RELAY IN PDC IN PDC RELAY PUMP FUEL TO TO REAR WINDOW DEFOGGER RELAY IN PDC A C COMPRESSOR CLUTCH RELAY IN PDC TO TO IN PDC RELAY HORN HORN RELAY IN PDC T...

Страница 456: ...TION SWITCH 1 START 2 RUN 3 LOCK 0 OFF 4 ACC 20A FUSE 20 20 A41 14 YL C104 NOT USED CLUTCH PEDAL POSITION SWITCH CONNECTOR S331 RELAY MOTOR STARTER ENGINE A2 12 PK BK IN PDC T40 12 BR A2 12 PK BK 6 12...

Страница 457: ...11 10 FUSE 10A FUSE BLOCK 10A FUSE 9 9 A2 12 PK BK BATT A2 13 FUSE 10A 20A FUSE 14 15 FUSE 10A 13 2 RELAY ACCESSORY LIGHTER CIGAR S307 1 START 2 RUN 3 LOCK 0 OFF 4 ACC G9 C322 C322 9 LHD RHD A31 14 BK...

Страница 458: ...GHTER CIGAR WT PK 12 F22 3 10 11 4 1 1 FUSE 20A BLOCK FUSE 20A FUSE 2 F30 12 RD PK F1 C106 A6 12 RD BK F7 C106 20A FUSE 19 18 FUSE 15A 19 18 F30 12 RD PK S332 F30 12 RD PK 21 22 39 38 8W 10 6 8W 10 2...

Страница 459: ...S107 F142 20 OR DG 1 C103 3 C180 2 PUMP DETECTION LEAK LEAK DETECTION OTHER OXYGEN SENSOR 1 1 UPSTREAM 1 F142 18 OR DG S124 F142 18 OR DG F142 18 OR DG 1 DOWNSTREAM 1 2 SENSOR OXYGEN OR DG 20 F142 A20...

Страница 460: ...2 18 DG LG DG LG 18 F42 DG LG 18 F42 FUEL INJECTOR NO 3 NO 4 INJECTOR FUEL 4 0L NO 5 INJECTOR FUEL FUEL INJECTOR NO 6 4 0L NO 1 INJECTOR FUEL FUEL INJECTOR NO 2 B 8W 10 11 FROM C104 F42 18 DG LG 8W 30...

Страница 461: ...HAZARD SWITCH 30A FUSE 10 23 16 RD WT 14 A3 A3 14 RD WT SWITCH HEADLAMP 8 17 24 11 FUSE 40A A111 12 RD LB F12 C106 A12 C202 RD LB 12 A111 RD LB 12 A111 4 C170 C108 D11 8 UNIT HVAC 8W 10 6 8W 10 2 8W 5...

Страница 462: ...DULE FUEL PUMP S320 C15 12 BK WT 10A FUSE 17 17 FUSE BLOCK C15 14 BK WT HARD TOP DEFOGGER WINDOW REAR H1 C323 1 C323 RHD LHD 7 C103 A4 12 BK PK A61 18 DG BK IN PDC RELAY DEFOGGER WINDOW REAR IN PDC RE...

Страница 463: ...PK WT 20 M1 LAMP BAR SOUND DOME 1 PK WT 20 M1 M1 20 PK WT 2 SPEAKER SYSTEM SYSTEM 4 SPEAKER M1 20 PK WT LAMP DOME C326 8 3 C325 S313 M1 20 PK WT PK WT 20 M1 16 9 INSTRUMENT CLUSTER C2 M1 20 PK WT B7...

Страница 464: ...1 18 VT A17 20 RD GY 1 B15 1 LOW NOTE HORN HORN NOTE HIGH 1 S115 EXCEPT BUILT UP EXPORT BUILT UP EXPORT X2 18 WT RD X2 18 WT RD A6 A5 25 FUSE 20A D6 C108 3 5 NO 1 RELAY LAMP FOG F61 18 WT OR F61 18 WT...

Страница 465: ...A13 B48 20 RD YL 1 C2 5 S110 1 B120 12 BR WT B47 14 RD LB B47 14 RD LB A ABS DIODE S146 B48 20 RD YL A20 14 RD DB B47 14 RD LB A10 12 RD DG PDC RELAY SYSTEM ABS PDC RELAY MOTOR PUMP ABS ABS PUMP MOTO...

Страница 466: ...8W 11 8 Fuse 10 FB 8W 11 8 Fuse 11 FB 8W 11 8 Fuse 12 FB 8W 11 8 Fuse 13 FB 8W 11 9 Component Page Fuse 14 FB 8W 11 9 Fuse 15 FB 8W 11 9 Fuse 16 FB 8W 11 10 Fuse 17 FB 8W 11 9 Fuse 18 FB 8W 11 10 Fus...

Страница 467: ...7 FUSE 17 13 FUSE 13 33 14 FUSE 14 34 15 FUSE 15 35 36 16 FUSE 16 9 FUSE 9 29 10 FUSE 10 30 11 FUSE 11 31 32 12 FUSE 12 5 FUSE 5 25 6 FUSE 6 26 7 FUSE 7 27 28 8 FUSE 8 1 FUSE 1 21 2 FUSE 2 22 3 FUSE 3...

Страница 468: ...0YL BK A21 14DB A31 14BK DG F14 18LG YL L5 20BK GY V6 18PK BK 10A X12 20PK 10A A22 12BK OR 20A 10A F20 20VT WT 20A 2 10A 10A T141 14YL RD F24 20RD DG F15 20DB E2 20OR Z1 20BK M23 20YL BK A41 14YL G5 2...

Страница 469: ...T CLUSTER 3 C2 E2 20 OR S206 OR 20 E2 OR 20 E2 OR 20 E2 OR 20 E2 E2 20 OR E2 20 OR BUILT UP SWITCH LAMP FOG REAR HARD TOP SWITCH DEFOGGER WINDOW REAR HARD TOP SWITCH WASHER WIPER REAR 1 EXPORT EXCEPT...

Страница 470: ...0 M23 NO 1 RELAY LAMP FOG 2 NO 2 RELAY LAMP FOG Z1 20 BK Z1 20 BK Z1 20 BK Z1 16 BK RHD LHD 3 EXPORT BUILT UP RELAY LAMP FOG REAR Z1 20 BK UP EXPORT EXCEPT BUILT EXCEPT BUILT UP EXPORT 1 1 2 8W 11 2 8...

Страница 471: ...23 18 BR PK 1 REAR WIPER MOTOR 4 C326 C204 C6 WASHER WIPER REAR 5 SWITCH BR PK 18 V23 NOT USED RHD LHD H4 C323 4 C323 SOFT TOP USED NOT C323 4 BR PK 18 V23 LHD RHD G10 C322 10 C322 LHD RHD V23 18 BR P...

Страница 472: ...OSITION B BACK UP LAMP SWITCH F20 20 VT WT C1 5 BRAKE ANTI LOCK CONTROLLER F20 20 VT WT VT WT 20 F20 ABS SYSTEM RELAY S108 IN PDC F24 20 RD DG 5 9 B8 F20 20 VT WT VT WT 20 F20 D4 IN PDC RELAY DEFOGGER...

Страница 473: ...Y PUMP FUEL A10 C202 G5 20 DB WT G5 20 DB WT 3 F15 20 DB 9 C103 F12 20 RD LG 5 MODULE LAMP RUNNING DAYTIME F12 20 RD LG SOLENOID INTERLOCK SHIFT BRAKE 13 18 F12 20 RD LG 12 FUSE 10A 32 20 F15 DB F15 D...

Страница 474: ...OGGER WINDOW REAR A5 C202 F81 20 DB RD F9 C106 ST A41 T141 14 YL RD D11 IN PDC RELAY MOTOR STARTER ENGINE T141 14 YL RD 1 M T A T SWITCH POSITION PEDAL CLUTCH T141 14 YL RD CLUTCH PEDAL POSITION SWITC...

Страница 475: ...HARNESS IN FB T O FB T O HARNESS IN TAPED TO POWER AUXILIARY SWITCHED S330 C9 C204 L22 20 LG DG L22 20 LG DG D13 C108 9 C110 1 MOTOR LEVELING HEADLAMP LEFT RIGHT HEADLAMP LEVELING MOTOR 1 S151 2 L22 2...

Страница 476: ...nstrument Cluster 8W 15 7 8 Left City Lamp 8W 15 3 Left Fog Lamp 8W 15 3 Left Front Park Turn Signal Lamp 8W 15 3 Left Front Turn Signal Lamp 8W 15 3 Left Headlamp 8W 15 3 Left Headlamp Leveling Motor...

Страница 477: ...3 C2 C2 14 Z22 16 BK PK S109 4 8 MODULE LAMP RUNNING DAYTIME IN PDC RELAY MOTOR PUMP ABS IN PDC RELAY SYSTEM ABS Z1 18 BK BK 18 Z1 ABS PUMP MOTOR Z1 18 BK SERVO CONTROL SPEED VEHICLE BASE OTHER Z1 12...

Страница 478: ...UILT LAMP CITY LEFT UP EXPORT BUILT MOTOR LEVELING HEADLAMP LEFT 3 FRONT FOG LAMPS EXCEPT BUILT UP EXPORT EXCEPT Z1 18 BK FRONT FOG LAMPS BUILT UP EXPORT UP EXPORT BUILT LAMP REPEATER LEFT LAMP SIGNAL...

Страница 479: ...103 BK 6 Z0 GENERATOR G104 BK 18 Z1 3 LAMPS FRONT FOG LAMP SIGNAL TURN PARK FRONT RIGHT RIGHT FRONT PARK TURN SIGNAL LAMP EXCEPT FRONT FOG LAMPS 8W 50 2 8W 50 7 8W 20 2 8W 50 4 8W 52 3 8W 50 4 8W 52 3...

Страница 480: ...20 BK Z1 18 BK S150 BK 6 Z0 GENERATOR G104 LAMP CITY RIGHT MOTOR LEVELING HEADLAMP RIGHT G103 Z1 18 BK LAMP REPEATER RIGHT LAMP SIGNAL TURN FRONT RIGHT 8W 50 2 8W 20 2 8W 50 4 8W 50 5 8W 52 3 8W 52 3...

Страница 481: ...Z1 BK 18 Z1 Z1 20 BK BK 20 Z1 Z1 20 BK M T A T S132 Z1 14 BK BK TN 10 Z12 G105 2 2 B Z1 20 BK 1 C154 3 C154 1 C154 Z1 20 BK 4 Z12 20 BK LB C1 A6 T41 20 BR LB MODULE CONTROL POWERTRAIN D11 D13 IN PDC...

Страница 482: ...ITCH LAMP FOG FRONT Z1 20 BK SWITCH LEVELING HEADLAMP TOP HARD SWITCH DEFOGGER WINDOW REAR 4 HARD TOP SWITCH WASHER WIPER REAR EXPORT BUILT UP SWITCH LAMP FOG REAR BUILT UP EXPORT BUILT UP EXCEPT EXPO...

Страница 483: ...K LG 18 Z2 C1 9 G201 G200 SWITCH LAMP FOG REAR SWITCH HEADLAMP TOP HARD SWITCH DEFOGGER WINDOW REAR HARD TOP SWITCH WASHER WIPER REAR HEADLAMP LEVELING SWITCH 4 EXPORT BUILT UP G202 C2 BK WT 20 Z11 CO...

Страница 484: ...CH COMBINATION FLASHER PRNDL LAMP SWITCH LAMP BRAKE 2 5 RELAY ACCESSORY LIGHTER CIGAR G300 Z1 20 BK Z1 20 BK 3 Z1 20 BK UP EXPORT EXCEPT BUILT NO 1 RELAY LAMP FOG FOG LAMP RELAY NO 2 EXCEPT BUILT UP E...

Страница 485: ...IGNITION SWITCH COMBINATION FLASHER PRNDL LAMP SWITCH LAMP BRAKE RELAY ACCESSORY LIGHTER CIGAR G300 3 Z1 20 BK RELAY LAMP FOG REAR 5 2 Z1 20 BK BK 20 Z1 Z1 20 BK 2 WINDSHIELD WIPER SWITCH BK 20 Z1 MO...

Страница 486: ...LAMP DEFOGGER WINDOW REAR HARD TOP PUMP WASHER REAR MOTOR WIPER REAR S400 HARD TOP S316 BUILT UP EXPORT BUILT UP EXCEPT LHD EXPORT G5 C322 Z1 12 BK BK 12 Z1 5 C322 RHD LHD Z1 12 BK 6 C331 AIRBAG PASSE...

Страница 487: ...Motor 8W 20 2 Fuse 6 PDC 8W 20 2 Fuse 12 FB 8W 20 2 Fuse Block 8W 20 2 Fusible Link 8W 20 2 Component Page G104 8W 20 2 G106 8W 20 2 G107 8W 20 2 Generator 8W 20 2 Power Distribution Center 8W 20 2 Po...

Страница 488: ...TIC SHUT DOWN RELAY IN PDC 6 FUSE 30A 12 5 POWER DISTRIBUTION CENTER A14 14 RD WT S131 DB 20 F15 BLOCK FUSE 10A FUSE 12 ST RUN A21 32 F4 C106 F15 20 DB A2 C1 F15 18 DB DB 20 F15 Z0 6 BK Z0 4 BK LHD RH...

Страница 489: ...ctor 8W 21 2 Engine Starter Motor 8W 21 2 Engine Starter Motor Relay 8W 21 2 Fuse 2 PDC 8W 21 2 Fuse 20 FB 8W 21 2 Component Page Fuse Block 8W 21 2 G105 8W 21 2 Ignition Switch 8W 21 2 Manual Transmi...

Страница 490: ...H POSITION NEUTRAL PARK BK C154 3 20 Z1 1 C154 S132 Z1 20 BK Z1 14 BK C154 3 MANUAL TRANSMISSION JUMPER 2 HOLD IN 1 PULL IN A T 20A FUSE 20 FUSE BLOCK 40 20 F9 C106 T141 14YL RD CLUTCH PEDAL POSITION...

Страница 491: ...8W 30 11 Fuse 12 FB 8W 30 2 3 14 Fuse 18 PDC 8W 30 4 5 6 Fuse 19 PDC 8W 30 3 Fuse 20 PDC 8W 30 13 Fuse 27 PDC 8W 30 9 11 Component Page Fuse Block 8W 30 2 3 11 14 G100 8W 30 16 G105 8W 30 2 3 9 12 13...

Страница 492: ...BLOCK FUSE 10A FUSE 12 ST RUN A21 32 F4 C106 F15 20 DB A2 C1 F15 18 DB DB 20 F15 RD WT 14 A14 S130 BK TN 10 Z12 G105 A14 14 RD WT A14 14 RD WT 3 C103 13 3 F15 20 DB 7 C104 FUSED IGNITION SWITCH OUTPU...

Страница 493: ...DULE PUMP FUEL SIGNAL SENSOR LEVEL FUEL C3 C26 DB LG 18 K226 3 18 A4 C1 SENSOR GROUND 4 K226 20 DB LG S133 BR YL 20 K167 K167 BR YL C3 C1 B10 IN PDC RELAY CLUTCH COMPRESSOR A C K31 18 BR C13 18 DB OR...

Страница 494: ...SUPPLY 5V 5V SUPPLY A17 20 2 B1 A142 14 DG PK B2 DG LG 18 F42 S128 F42 18 DG LG F42 18 DG LG CENTER DISTRIBUTION POWER AUTOMATIC SHUT DOWN RELAY BATT A14 S127 20 BR YL K167 18 BR YL K167 20 BR YL K167...

Страница 495: ...1 2 1 2 20A FUSE 18 A19 A20 A142 14 DG PK F42 18 DG LG 18 18 18 S101 FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR S128 18 4 C104 11 RHD LHD F42 DG LG F42 DG LG F42 DG LG F42 DG LG F42 DG L...

Страница 496: ...18 18 18 18 20A FUSE 18 A20 A19 S101 FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR FUEL INJECTOR INJECTOR FUEL FUEL INJECTOR 4 C104 DG LG F42 DG LG F42 DG LG F42 DG LG F42 DG LG F42 DG LG F42 DG LG F42 D...

Страница 497: ...SENSOR PRESSURE ABSOLUTE MANIFOLD SIGNAL SENSOR TEMPERATURE COOLANT ENGINE K167 20 BR YL BR YL 20 K167 INTAKE AIR TEMPERATURE SENSOR 2 1 SIGNAL SENSOR TEMPERATURE AIR INTAKE 2 3 K167 20 BR YL SENSOR...

Страница 498: ...URE COOLANT ENGINE S129 K7 20 OR SIGNAL SENSOR PRESSURE ABSOLUTE MANIFOLD SIGNAL SENSOR TEMPERATURE COOLANT ENGINE K167 20 BR YL BR YL 20 K167 INTAKE AIR TEMPERATURE SENSOR 2 1 SIGNAL SENSOR TEMPERATU...

Страница 499: ...TOMATIC SHUT DOWN RELAY BATT A14 18 K167 BR YL BR YL 20 K167 S132 G105 Z1 14 BK S124 OR DG 1 4 2 3 2 3 1 4 F142 18 OR DG 10A FUSE 27 A142 14 DG PK A2 A1 F142 20 OR DG S101 S127 1 C103 K167 20 BR YL F1...

Страница 500: ...NSOR POSITION THROTTLE BATTERY TEMPERATURE SENSOR SIGNAL VEHICLE SPEED SENSOR SIGNAL BR YL 20 K167 G7 20 WT OR S135 WT OR 20 G7 BR YL 20 K167 S127 K167 20 BR YL 7 G7 20 WT OR MODULE LAMP RUNNING DAYTI...

Страница 501: ...DG K105 18 WT OR K105 20 WT OR K106 20 WT DG FUSED AUTOMATIC OUTPUT LEAK DETECTION PUMP CONTROL SOLENOID PUMP BUILT UP EXCEPT PUMP DETECTION LEAK EXPORT DETECTION LEAK RELAY SHUT DOWN SOLENOID CONTRO...

Страница 502: ...BR Z1 1 20 BK 2 POWER STEERING PRESSURE SWITCH 2 5L C22 18 DB WT C22 C3 A C SENSE SWITCH 2 DB WT 20 C22 1 2 2 C90 20 LG C104 1 SELECT INPUT A C C3 C23 LG 18 C90 LG 20 C90 C3 A A C HEATER CONTROL C90 2...

Страница 503: ...103 B8 B10 B7 C203 E9 C107 C204 C4 Z12 20 BK TN BK TN 20 Z12 A6 C202 E6 11 BK LB 20 Z12 BK LB 20 Z12 BK LB 20 Z12 BK TN Z12 Z12 BK TN 10 G105 C203 D20 20 LG D21 20 PK BRAKE ANTI LOCK CONTROLLER M1 20...

Страница 504: ...SED BATT A6 GROUND CCD BUS PAIR TWISTED TWISTED PAIR ST RUN A21 2 32 F15 20 DB F34 20 TN BK Z1 20 BK D1 20 VT BR D2 20 WT BK D2 20 WT BK D1 20 VT BR D2 20 WT BK PAIR TWISTED 4 CONNECTOR LINK DATA Z12...

Страница 505: ...BR YL B15 RELAY HORN CENTER DISTRIBUTION POWER E7 C107 X3 20 RD YL X3 20 RD YL SENSOR GROUND MODULE CONTROL POWERTRAIN 2 C2 2 BATTERY TEMPERATURE SENSOR D10 C108 K167 20 BR YL RHD LHD BR YL 18 K167 D3...

Страница 506: ...CONTROL SPEED ON OFF CONTROL SPEED SENSE SWITCH BRAKE 3 1 BRAKE LAMP SWITCH MODULE CONTROL POWERTRAIN V32 20 YL RD Z1 18 BK CONTROL CONTROL SENSE SWITCH BK 12 Z1 RHD LHD Z1 16 BK Z1 20 BK Z1 20 BK SO...

Страница 507: ...Cigar Lighter Accessory Relay 8W 31 2 Fuse 10 FB 8W 31 2 Fuse 11 FB 8W 31 2 Fuse Block 8W 31 2 Component Page G105 8W 31 2 G300 8W 31 2 Instrument Cluster 8W 31 2 Powertrain Control Module 8W 31 2 To...

Страница 508: ...STRUMENT INDICATOR 4WD BK RD 20 G107 5 C170 13 C103 B A G107 20 BK RD 5 RELAY ACCESSORY LIGHTER CIGAR A10 C202 G300 G105 S132 Z1 20 BK Z1 16 BK Z1 20 BK Z1 14 BK G5 20 DB WT G5 20 DB WT G5 20DB WT MOD...

Страница 509: ...2 FB 8W 35 5 Fuse 7 FB 8W 35 2 3 Fuse 10 FB 8W 35 3 Fuse 13 PDC 8W 35 2 Fuse 14 PDC 8W 35 2 Component Page Fuse 21 PDC 8W 35 2 Fuse Block 8W 35 2 3 5 G Switch 8W 35 5 G100 8W 35 2 G101 8W 35 3 Hydraul...

Страница 510: ...14 RD LB S114 S110 Z1 12 BK S106 G100 Z1 12 BK F20 20 VT WT TO UNIT CONTROL HYDRAULIC B47 14 RD LB HYDRAULIC CONTROL UNIT TO B47 14 RD LB OUTPUT C2 3 ABS PUMP MOTOR RELAY B120 16 BR WT S112 B120 12 BR...

Страница 511: ...4 C2 8 2 C1 1 ABS WARNING INDICATOR DRIVER B14 C203 D2 C108 G19 20 LG OR B A ABS DIODE 5 C2 B48 20 RD YL S146 A 8W 35 2 TO CENTER DISTRIBUTION POWER F20 20 VT WT G5 20 DB WT ABS MAIN RELAY GROUND GRO...

Страница 512: ...LEFT FRONT INLET VALVE VALVE OUTLET FRONT RIGHT 6 C2 CONTROL CONTROL C2 15 RIGHT FRONT INLET VALVE 2 10 7 4 9 3 1 8 UNIT CONTROL HYDRAULIC B251 20 WT BK DG OR 20 B254 DG BK 20 B243 WT LG 20 B245 DG WT...

Страница 513: ...3 2 1 C1 2 G SWITCH TEST SIGNAL B43 20 PK OR YL VT 20 B41 SENSE NO 1 G SWITCH 6 C1 C1 7 G SWITCH NO 2 SENSE B42 20 TN WT TRANSMIT SCI 3 C1 PK 20 D21 E14 C107 B10 C203 7 DATA LINK CONNECTOR C3 C27 MOD...

Страница 514: ...B1 18 YL DB B2 18 YL B2 18 YL B1 18 YL DB 3 C104 4 C104 6 7 B3 18 LG DB B4 18 LG B7 18 WT B6 18 WT DB BRAKE ANTI LOCK CONTROLLER LEFT FRONT WHEEL SPEED SENSOR SENSOR SPEED WHEEL FRONT LEFT SENSOR SPEE...

Страница 515: ...W 40 5 G201 8W 40 2 3 4 5 6 7 8 9 G300 8W 40 6 7 G302 8W 40 4 Headlamp Dimmer Switch 8W 40 9 Component Page Headlamp Switch 8W 40 7 8 High Beam Indicator 8W 40 9 Ignition Switch 8W 40 6 Instrument Clu...

Страница 516: ...2 DB WT 20 G5 C202 A10 8 C2 G5 20 DB WT M1 20 PK WT HARD TOP TOP SOFT PK WT 20 M1 TO BAR SOUND DOME LAMP G5 20 DB WT 9 C1 Z2 18 BK LG SOLENOID INTERLOCK SHIFT BRAKE DOME LAMP AND SOUND BAR DOME LAMP T...

Страница 517: ...Z2 18 BK LG GROUND FUSED B CCD BUS BUS CCD C1 2 1 C1 C203 B12 B11 D1 VT BR 20 WT BK 20 D2 S302 S303 D4 D5 C108 D2 18 WT BK 18 VT BR D1 C3 C30 C28 C3 POWERTRAIN CONTROL MODULE CCD BUS BUS CCD TWISTED...

Страница 518: ...B11 B12 C203 1 2 CCD BUS BUS CCD B FUSED GROUND BK LG 18 Z2 CLUSTER INSTRUMENT 6 C2 BATT M1 TWISTED PAIR D2 20 WT BK ST RUN G5 TRIP ODOMETER RESET SWITCH TRIP RESET S302 S303 C1 9 Z2 18 BK LG 3 11 DAT...

Страница 519: ...ELT WARNING DRIVER INDICATOR M T DRIVER INDICATOR UPSHIFT M T INDICATOR UPSHIFT 4WD INDICATOR S303 S302 B G107 20 BK RD G105 S132 Z1 20 BK Z1 14 BK 9 C1 Z2 18 BK LG 3 11 DATA LINK CONNECTOR PAIR TWIST...

Страница 520: ...9 20 LG OR NOT USED OTHERS ABS G19 20 LG OR D2 C108 B DIODE ABS CONTROLLER ANTI LOCK BRAKE 1 C1 G19 20 LG OR 1 START 2 RUN 3 LOCK 0 OFF 4 ACC 9 C1 Z2 18 BK LG G99 20 GY WT G99 20 GY WT RHD LHD C322 G9...

Страница 521: ...5 B3 C203 1 2 KEY IN SWITCH G26 20 LB G16 20 BK LB 3 1 SWITCH AJAR DOOR DRIVER M23 20 YL BK PASSENGER DOOR AJAR SWITCH 1 M23 20 YL BK 2 HEAD 1 PARK 0 OFF G26 20LB 9 C1 Z2 18 BK LG 3 11 DATA LINK CONN...

Страница 522: ...ER ILLUMINATION LAMPS 1 3 4 5 10A FUSE 3 E1 18 TN A3 C202 3 23 BLOCK FUSE A4 C202 S206 E2 20 OR 5 MIN 2 HEAD 3 DOME 1 PARK 0 HEAD 4 MAX 9 C1 Z2 18 BK LG HARD TOP SWITCH DEFOGGER WINDOW REAR E2 20 OR 1...

Страница 523: ...R INSTRUMENT BK LG 18 Z2 C2 6 G201 9 C1 Z2 18 BK LG DRL OTHER 4 1 MODULE LAMP RUNNING DAYTIME L3 16 RD OR G34 18 RD GY L3 16 RD OR 1 EXPORT FOG LAMP RELAY NO 2 EXCEPT BUILT UP G34 16 RD GY HIGH BEAM I...

Страница 524: ...1 2 Clockspring 8W 41 3 Fuse 5 PDC 8W 41 2 Fuse 17 PDC 8W 41 3 Fuse 19 FB 8W 41 2 Fuse Block 8W 41 2 G102 8W 41 3 Component Page G200 8W 41 2 G300 8W 41 2 High Note Horn 8W 41 3 Horn Relay 8W 41 3 Hor...

Страница 525: ...3 LOCK 0 OFF 4 ACC 2 BRAKE LAMP SWITCH Z1 20 BK S332 20A FUSE 19 BLOCK FUSE RHD LHD S304 39 19 F38 16 LB SWITCH AUXILIARY POWER TAPED TO HARNESS IN FB T O Z1 20 BK F30 12 RD PK F22 12 WT PK GROUND A3...

Страница 526: ...C110 6 2 HIGH NOTE HORN 1 1 CLOCKSPRING LOW NOTE HORN IN PDC RELAY HORN F31 18 VT F31 18 VT C2 EXCEPT BUILT UP EXPORT BUILT UP EXPORT S115 X2 18 WT RD X2 18 WT RD X2 18 WT RD S117 G102 Z1 18 BK Z1 18...

Страница 527: ...W 42 4 Blend Door Actuator 8W 42 2 3 Blower Motor 8W 42 2 3 Blower Motor Relay 8W 42 2 3 Fuse 7 FB 8W 42 4 Fuse 8 FB 8W 42 2 3 Component Page Fuse 11 PDC 8W 42 2 3 Fuse 16 PDC 8W 42 4 Fuse Block 8W 42...

Страница 528: ...5 16 LG LB C6 14 LB C7 12 BR TN 3 2 1 0 4 E C1 C3 B C1 12 DG 8 LOW 6 M2 7 M1 0 OFF 5 HIGH 1 VENT 2 HEAT 4 DEFROST 3 MIX CONTROL HEATER A C C2 3 C2 3 C C3 2 C2 OR 20 E2 S206 FROM C2 5 4 C2 C36 20 DB RD...

Страница 529: ...C3 B C1 12 DG 8 M2 6 DEFROST 7 HIGH 0 OFF 5 MIX 1 MAX 2 NORM 4 HEAT 3 VENT CONTROL HEATER A C C2 3 C2 1 C C3 2 C2 OR 20 E2 S206 FROM C2 5 4 C2 C36 20 DB RD G200 Z1 20 BK BK 20 Z1 G200 G203 Z11 20 BK W...

Страница 530: ...20 DB BK C13 18 DB OR 2 C104 C22 18 DB WT C22 20 DB WT S103 C3 A C90 18 LG C90 20 LG C104 1 C90 20 LG RUN A22 6 C170 14 C103 A C LOW PRESSURE SWITCH A17 20 RD GY A C COMPRESSOR CLUTCH RELAY IN PDC 0 6...

Страница 531: ...k Solenoid 8W 43 3 Clockspring 8W 43 2 Data Link Connector 8W 43 3 Driver Airbag Squib 8W 43 2 Fuse 5 FB 8W 43 2 Component Page Fuse 9 FB 8W 43 2 Fuse 10 FB 8W 43 3 Fuse Block 8W 43 2 3 G301 8W 43 2 I...

Страница 532: ...CH MODULE CONTROL AIRBAG 10A FUSE 5 9 FUSE 10A A B 6 5 PASSENGER AIRBAG TWISTED PAIR DG LB 18 R45 1 2 R43 18 BK LB ST RUN A21 29 17 20 25 DB YL 18 F23 RUN A22 BLOCK FUSE F14 18 LG YL G301 2 C1 1 C1 CL...

Страница 533: ...WT G5 20 DB WT D2 20 WT BK D1 20 VT BR PAIR TWISTED 3 C1 C1 11 D1 20 VT BR D2 20 WT BK DATA LINK CONNECTOR SOLENOID INTERLOCK SHIFT BRAKE TWISTED PAIR BUS CCD BUS CCD 19 VT BR 18 D1 WT BK 18 D2 18 S3...

Страница 534: ...8W 44 4 5 Headlamp Switch 8W 44 4 5 6 Instrument Cluster 8W 44 4 6 Component Page Key In Switch 8W 44 4 Left Courtesy Lamp 8W 44 4 Mercury Switch 8W 44 3 Passenger Door Ajar Switch 8W 44 4 Power Dist...

Страница 535: ...2 20 YL NOT USED C323 H3 M2 20 YL H3 C323 HARD TOP SOFT TOP 4 SPEAKER SYSTEM LHD 2 SPEAKERSYSTEM 2 SPEAKER SYSTEM 4 SPEAKER SYSTEM A 8W 44 4 TO S301 M2 20 YL TO S204 M1 20 PK WT M1 20 PK WT M1 20 PK W...

Страница 536: ...LAMP UNDERHOOD 1 2 MERCURY SWITCH M1 20 PK WT G100 BK 12 Z1 G100 S106 BK 18 Z1 Z1 18 BK OTHER BASE B 8W 44 2 FROM C108 8W 15 2 8W 15 2 8W 15 2 TJ 8W 44 INTERIOR LIGHTING 8W 44 3 TJI04403 J998W 5...

Страница 537: ...10A FUSE 20 BATT A0 A16 A15 POWER DISTRIBUTION CENTER PK WT 20 M1 C108 12 B7 C203 S204 M1 20 PK WT LAMP UNDERHOOD 2 M1 20 PK WT M1 20 PK WT TO BAR SOUND PK WT 20 M1 HARD TOP TOP SOFT DOME LAMP 1 DOME...

Страница 538: ...C2 C2 BK 16 Z1 5 MIN 2 HEAD 3 DOME 1 PARK 0 OFF 4 MAX E2 20 OR E2 20 OR HARD TOP SWITCH DEFOGGER WINDOW REAR HARD TOP SWITCH WASHER WIPER REAR EXPORT BUILT UP SWITCH LAMP FOG REAR BK 20 Z1 4 1 EXPORT...

Страница 539: ...E BLOCK 23 3 A3 TN 18 E1 3 FUSE 10A 5 4 3 1 BATT F34 2 1 0 SWITCH HEADLAMP C2 C2 C1 5 MIN 2 HEAD 3 DOME 1 PARK 0 OFF 4 MAX E2 20 OR E2 20 OR PRNDL LAMP TO E2 20 OR 8W 47 2 8W 40 8 8W 11 4 8W 11 2 8W 1...

Страница 540: ...47 2 Headlamp Switch 8W 47 2 Left Front Speaker 8W 47 3 Left Rear Speaker 8W 47 3 Component Page Power Distribution Center 8W 47 2 Radio 8W 47 2 3 Radio Antenna 8W 47 2 Right Front Speaker 8W 47 3 Rig...

Страница 541: ...3 3 BATT F34 23 5 C1 S206 A4 C202 C202 A3 E1 18 TN E1 18 TN E2 20 OR E2 20 OR S204 B7 C203 M1 20 PK WT M1 20 PK WT TOP SOFT TOP HARD SOUND BAR DOME LAMP TO M1 20 PK WT 1 HEAD 2 PARK 0 OFF B6 C203 L7 1...

Страница 542: ...1 2 1 2 X55 18 BR RD X53 18 DG X56 18 DB X54 18 VT C13 C204 C14 C11 C12 X57 18 BR LB X57 18 BR LB X51 18 BR YL X51 18 BR YL X58 18 DB PK X58 18 DB PK X52 18 DB WT X52 18 DB WT 2 1 5 6 C325 DB WT 20 X5...

Страница 543: ...Block 8W 48 2 G200 8W 48 2 G302 8W 48 2 Illumination Lamp 8W 48 2 Component Page Indicator Lamp 8W 48 2 Instrument Cluster 8W 48 2 Power Distribution Center 8W 48 2 Rear Window Defogger 8W 48 2 Rear...

Страница 544: ...20 BK Z1 16 BK ILLUMINATION LAMP HARD TOP LAMP INDICATOR FROM S206 E2 20 OR A5 C202 1 C326 C15 12 GY C80 20 DB LG C81 20 LB WT 10A FUSE 17 FUSE BLOCK S320 F81 20 DB RD HARD TOP TOP HARD 37 17 2 C170 R...

Страница 545: ...Leveling Switch 8W 50 5 Headlamp Switch 8W 50 2 3 4 5 6 8 Component Page Instrument Cluster 8W 50 2 3 4 6 8 Key In Switch 8W 50 3 Left City Lamp 8W 50 4 Left Fog Lamp 8W 50 7 Left Front Park Turn Sign...

Страница 546: ...TCH 1 LOW 2 HIGH 3 FLASH E1 18 TN 4 1 MODULE LAMP RUNNING DAYTIME G34 18 RD GY DRL OTHER MODULE LAMP RUNNING DAYTIME C202 L3 16 RD OR L3 16 RD OR L4 16 VT WT E1 18 TN L2 16 LG 1 EXPORT BUILT UP EXCEPT...

Страница 547: ...6 20 BK LB KEY IN IGNITION SWITCH SENSE 1 SWITCH KEY IN G16 20 BK LB DRIVER DOOR AJAR SWITCH SENSE SENSE SWITCH AJAR DOOR DRIVER LHD RHD G200 S207 FROM S202 Z1 16 BK Z1 16 BK Z1 16 BK Z1 16 BK M2 20 Y...

Страница 548: ...BUILT UP LAMP CITY LEFT RIGHT CITY LAMP BUILT UP 2 1 L7 18 BK YL L7 18 BK YL Z1 18 BK Z1 20 BK G103 EXPORT BUILT UP EXCEPT NO 2 RELAY LAMP FOG LAMP UP EXPORT SIGNAL LAMP UP EXPORT EXCEPT BUILT EXPORT...

Страница 549: ...VELING HEADLAMP LEFT HEADLAMP LEVELING MOTOR MOTOR LEVELING HEADLAMP RIGHT 5 2 4 L22 20 LG DG L22 20 LG DG C108 D13 C9 C204 L22 20 LG DG L22 20 LG DG S330 36 16 10A FUSE 16 L2 16 LG BLOCK FUSE L22 20L...

Страница 550: ...5 CLUSTER INSTRUMENT G34 16 RD GY G34 16 RD GY G34 16 RD GY D7 C108 B6 C203 L7 18 BK YL L7 18 BK YL 3 L3 16 RD OR S105 E4 C107 L3 16 RD OR L3 14 RD OR 2 1 0 4 5 0 OFF 1 PARK 2 HEAD 3 DOME 4 MAX 5 MIN...

Страница 551: ...20A FUSE 25 A5 BATT A6 B13 C203 SWITCH LAMP FOG FRONT 3 1 4 2 A 8W 50 6 C 8W 50 6 B 8W 50 6 Z1 20 BK Z1 16 BK G200 S207 FOG LAMP RELAY NO 2 FROM FROM C202 S206 E2 20 OR FROM C204 L95 18 DG YL D6 C108...

Страница 552: ...G34 16 RD GY G34 16RD GY DAYTIME RUNNING LAMP MODULE C2 G100 S106 S119 S104 S105 POWERTRAIN CONTROL MODULE Z1 18 BK DIMMER SWITCH HIGH BEAM OUTPUT HIGH BEAM INDICATOR DRIVER VEHICLE SPEED SENSOR SIGN...

Страница 553: ...7 8 Fuse Block 8W 51 2 3 4 6 7 8 G200 8W 51 7 8 G300 8W 51 6 7 8 Component Page G302 8W 51 4 7 8 Headlamp Dimmer Switch 8W 51 7 8 Headlamp Switch 8W 51 2 3 7 8 Left License Lamp 8W 51 7 8 Left Rear L...

Страница 554: ...D L62 18 BR RD B6 C203 E1 C107 G1 C322 L7 18 BK YL L7 18 BK YL LAMP LAMP A T M T S108 S310 L63 18 DG RD 0 OFF SWITCH HEADLAMP 1 PARK 2 HEAD L1 20 VT BK F20 20 VT WT LEFT TURN SIGNAL RIGHT TURN SIGNAL...

Страница 555: ...0 L63 18 DG RD 0 OFF SWITCH HEADLAMP 1 PARK 2 HEAD L1 20 VT BK F20 20 VT WT LEFT TURN SIGNAL RIGHT TURN SIGNAL L7 18 BK YL L7 18 BK YL 2 4 1 2 4 1 L1 20 VT BK L1 20 VT BK LHD RHD 1 C322 G1 C322 G2 C32...

Страница 556: ...BLY BUILT UP EXPORT EXCEPT BUILT UP EXPORT EXCEPT BUILT UP EXPORT BUILT UP EXPORT RHD 8 C1 7 C322 G7 C322 C322 G7 A 8W 51 5 TURN SIGNAL HAZARD SWITCH TO BRAKE LAMP SWITCH 3 3 L50 18 WT TN G5 C322 5 C3...

Страница 557: ...PORT BUILT UP LHD RHD DG RD 18 L63 USED NOT 4 EXPORT BUILT UP EXCEPT EXPORT BUILT UP LHD RHD ASSEMBLY LAMP REAR RIGHT LAMP SIGNAL TURN TAIL STOP TURN SIGNAL LAMP LEFT REAR LAMP ASSEMBLY L63 18 DG RD 2...

Страница 558: ...SWITCH LAMP BRAKE BRAKE LAMP SWITCH OUTPUT OUTPUT SWITCH LAMP BRAKE EXPORT BUILT UP EXCEPT EXPORT BUILT UP EXPORT BUILT UP BUILT UP EXCEPT LHD EXPORT C322 G7 C322 WT TN 18 L50 2 SWITCH HAZARD SIGNAL...

Страница 559: ...REAR L38 20BR WT Z1 20 BK E2 20 OR 4 MIN 2 HEAD 3 MAX 1 PARK 0 OFF L7 18 BK YL L7 18 BK YL L38 18 BR WT L7 18 BK YL G8 C322 BLOCK FUSE 24 Z1 20BK S304 Z1 16 BK 2 16 FUSE 10A 16 36 L22 20 LG DG L22 20...

Страница 560: ...0 OR 4 MIN 2 HEAD 3 MAX 1 PARK 0 OFF L7 18 BK YL L7 18 BK YL L38 18 BR WT L7 18 BK YL 8 C322 BLOCK FUSE 24 Z1 20BK 2 16 FUSE 10A 16 36 L22 20 LG DG L22 20 LG DG S330 L22 20 LG DG L38 20 BR WT TO S118...

Страница 561: ...Turn Signal Lamp 8W 52 3 Left Rear Lamp Assembly 8W 52 2 Component Page Left Repeater Lamp 8W 52 3 Left Side Marker Lamp 8W 52 3 Power Distribution Center 8W 52 2 Right Front Park Turn Signal Lamp 8W...

Страница 562: ...Y LAMP REAR RIGHT LAMP SIGNAL TURN STOP TAIL 3 BR RD 18 L62 3 NORMAL 4 HAZARD 2 RIGHT 1 LEFT Z1 16 BK 1 2 DG RD 18 L63 ASSEMBLY LAMP REAR LEFT LAMP SIGNAL TURN STOP TAIL TURN SIGNAL LAMP RIGHT REAR LA...

Страница 563: ...41 S122 G102 S117 L61 18 GY BUILT UP EXPORT EXCEPT BUILT UP EXPORT BUILT UP EXPORT UP EXPORT BUILT EXCEPT S142 S141 Z1 18 BK Z1 18 BK S125 S122 OTHER FRONT FOG LAMPS OTHER FRONT FOG LAMPS LAMP REPEATE...

Страница 564: ...W 53 4 G300 8W 53 2 3 G302 8W 53 4 Headlamp Switch 8W 53 4 Component Page Internal Delay Relay 8W 53 3 PRNDL Lamp 8W 53 4 Rear Washer Pump 8W 53 4 Rear Wiper Motor 8W 53 4 Rear Wiper Washer Switch 8W...

Страница 565: ...18 V3 V4 18 RD YL 3 BR 18 V10 3 E8 C107 A B PUMP WASHER WINDSHIELD V10 18 BR Z1 18 BK S304 G300 Z1 16 BK BK 16 Z1 G102 S117 BK 18 Z1 C110 8 V10 18 BR 0 3 LOW 4 HIGH 2 RUN 1 PARK 0 OFF 1 LOW 3 WASH 2...

Страница 566: ...WIPER MOTOR 1 5 2 4 6 V5 18 DG YL BR WT 18 V3 V4 18 RD YL 4 BR 18 V10 3 E8 C107 A B PUMP WASHER WINDSHIELD Z1 18 BK S304 G300 Z1 16 BK BK 16 Z1 G102 S117 BK 18 Z1 0 5 MIN 4 WASH 2 LOW 3 HIGH 1 DELAY 0...

Страница 567: ...2 3 23 BLOCK FUSE A4 C202 S206 26 RUN A22 20A FUSE 6 BLOCK FUSE BR PK 18 V23 5 C326 S401 V21 18 BR PK 5 MIN 2 HEAD 3 DOME 1 PARK 0 OFF 4 MAX 2 RUN 1 PARK 2 WASH 1 WIPE 0 OFF E2 20 OR H5 C323 5 C323 H4...

Страница 568: ...S131 8W 11 8 S132 8W 15 6 S133 8W 70 3 S134 8W 15 6 S135 8W 30 10 S136 8W 10 6 S138 8W 50 5 Component Page S141 8W 50 4 S142 8W 50 4 S143 8W 50 4 S144 8W 50 4 S146 8W 10 17 S147 8W 70 3 S150 8W 15 5 S...

Страница 569: ...YL L7 18 BK YL L7 18 BK YL L7 18 BK YL L7 18 BK YL 1 LAMP CITY LEFT 1 RIGHT CITY LAMP BUILT UP S143 S144 EXPORT EXPORT BUILT UP EXPORT BUILT UP EXPORT EXCEPT BUILT UP EXPORT 1 C322 RHD LHD EXPORT EXCE...

Страница 570: ...POSITION CAMSHAFT 2 VEHICLE SPEED SENSOR K167 20 BR YL 8 C103 K167 20 BR YL MODULE PUMP FUEL 4 BR YL 20 K167 3 3 UPSTREAM 1 1 SENSOR OXYGEN K167 20 BR YL 3 3 CLOCKSPRING OTHER K167 20 BR YL S147 K167...

Страница 571: ...5 C104 T41 20 BR LB BR LB 20 T41 M T A T 2 BR LB 20 T41 3 C154 Z1 20 BK T41 20 BR LB 1 C154 Z1 20 BK Z1 14 BK S132 G105 C154 3 T41 20 BR LB SWITCH POSITION NEUTRAL PARK MODULE CONTROL POWERTRAIN B31...

Страница 572: ...11 C204 8W 80 11 Component Page C322 8W 80 12 C323 8W 80 12 13 C325 8W 80 13 C326 8W 80 13 C329 8W 80 14 C330 8W 80 14 C331 8W 80 14 Camshaft Position Sensor 8W 80 14 Cigar Lighter Accessory Relay 8W...

Страница 573: ...8W 80 25 Component Page Left Fog Lamp 8W 80 25 Left Front Park Turn Signal Lamp 8W 80 25 Left Front Speaker 8W 80 25 Left Front Turn Signal Lamp 8W 80 26 Left Front Wheel Speed Sensor 8W 80 26 Left He...

Страница 574: ...eadlamp Leveling Motor 8W 80 36 Right License Lamp 8W 80 36 Component Page Right Rear Lamp Assemby 8W 80 36 Right Rear Speaker 8W 80 36 Right Rear Wheel Speed Sensor 8W 80 37 Right Repeater Lamp 8W 80...

Страница 575: ...END DOOR FEEDBACK SIGNAL FUSED PANEL LAMPS DIMMER SWITCH SIGNAL GROUND CAV 1 2 3 4 5 C36 20DB RD F24 20RD DG E2 20OR Z1 20BK 1 5 A C HIGH PRESSURE SWITCH A C HEATER CONTROL C1 A C HEATER CONTROL C3 A...

Страница 576: ...D1 18VT BR F23 18DB YL CIRCUIT FUNCTION ABS MAIN RELAY OUTPUT ABS WARNING INDICATOR DRIVER CAV A B B48 20RD YL G19 20LG OR BLACK B A CIRCUIT FUNCTION ABS PUMP MOTOR RELAY OUTPUT GROUND CAV 1 2 B120 1...

Страница 577: ...20DB BK G107 20BK RD G7 20WT OR Z12 20BK LB Z12 20BK TN F12 20RD LG K167 20BR YL A141 18DG WT K226 20DB LG B7 18WT B6 18WT DB A14 14RD WT K72 18DG OR F142 18OR DG 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CAV...

Страница 578: ...10 F11 F12 F30 12RD PK L1 20VT BK F20 20VT WT A1 14RD A2 12PK BK A6 12RD BK C15 12BK WT T141 14YL RD T141 14YL RD F12 20RD LG G9 20GY BK G9 20GY BK A111 12RD LB C106 ABS RHD RHD GREY GREY C104 C104 8...

Страница 579: ...D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 V32 18YL RD G19 20LG OR K167 20BR YL D1 18VT BR D2 18WT BK F61 18WT OR L3 16RD OR L20 16LG WT V37 18RD LG L9 16BK WT M1 20PK WT M1 20PK WT L22 20LG DG K29 1...

Страница 580: ...L60 18TN L61 18GY L3 16RD OR L4 16VT WT X2 18WT RD V10 18BR L22 20LG DG K52 18PK BK F12 20RD LG L39 18LB L13 20BR YL BLACK 1 8 7 14 BLACK 7 14 1 8 C110 BUILT UP EXPORT FRONT FOG LAMPS A T M T L22 20LG...

Страница 581: ...A5 A6 A8 A9 A10 A11 A12 F24 20RD DG L20 16LG WT L20 14LG WT E1 18TN E2 20OR F81 20DB RD Z12 20BK LB L2 14LG L2 16LG F38 16LB G5 20DB WT F34 18TN BK F34 20TN BK A111 12RD LB C202 CIRCUIT CAV 1 2 3 K105...

Страница 582: ...BR WT G19 20LG OR GREEN B7 B14 B1 B8 GREEN B1 B8 B7 B14 C203 CIRCUIT CAV C1 C2 C3 C4 C5 C6 C8 C9 C10 C11 C12 C13 C14 L95 18DG YL V13 18BR LG G10 20LG RD Z12 20BK TN V23 18BR PK M2 20YL L38 20BR WT L22...

Страница 583: ...ACK V23 18BR PK G9 20GY BK L38 20BR WT L50 18WT TN G10 20LG RD Z1 12BK L63 18DG RD L1 20VT BK L62 18BR RD L7 18BK YL 10 9 8 7 6 5 4 3 2 1 CAV CIRCUIT V23 18BR PK G9 20GY BK L38 20BR WT L50 18WT TN G10...

Страница 584: ...M2 20YL M1 20PK WT X51 18BR YL X57 18BR LB 6 5 4 3 2 1 CAV CIRCUIT X52 18DB WT X58 18DB PK M2 20YL M1 20PK WT X51 18BR YL X57 18BR LB 6 5 4 3 2 1 CAV CIRCUIT 10 1 6 5 BLACK 10 5 6 1 6 1 BLACK M2 18YL...

Страница 585: ...20PK WT X51 20BR YL X57 20BR LB 6 5 4 3 2 1 CAV CIRCUIT X52 18DB WT X58 18DB PK M2 20YL M1 20PK WT X51 18BR YL X57 18BR LB 6 5 4 3 2 1 CAV CIRCUIT 10 1 6 5 BLACK 10 5 6 1 6 1 BLACK M2 20YL M1 20PK WT...

Страница 586: ...FUSED B IGNITION SWITCH OUTPUT RUN ACC CIGAR LIGHTER ACCESSORY RELAY OUTPUT GROUND CAV 1 2 3 4 5 F30 12RD PK A31 14BK DG F22 12WT PK Z1 20BK Z1 20BK BLACK CIGAR LIGHTER ACCESSORY RELAY 2 5 1 4 2 CIRC...

Страница 587: ...IGHT FRONT OUTLET VALVE CONTROL ABS PUMP MOTOR RELAY CONTROL LEFT FRONT OUTLET VALVE CONTROL LEFT FRONT WHEEL SPEED SENSOR LEFT FRONT WHEEL SPEED SENSOR ABS MAIN RELAY CONTROL REAR OUTLET VALVE CONTRO...

Страница 588: ...NCTION DIMMER SWITCH HIGH BEAM OUTPUT HIGH BEAM INDICATOR DRIVER FUSED IGNITION SWITCH OUTPUT ST RUN FUSED B OPTICAL HORN FEED VEHICLE SPEED SENSOR SIGNAL GROUND DIMMER SWITCH LOW BEAM OUTPUT CAV 1 2...

Страница 589: ...UTY CYCLE EVAP PURGE SOLENOID ENGINE COOLANT TEMPERATURE SENSOR AJAR SWITCH DRIVER DOOR 3 2 1 NATURAL G16 20BK LB M2 20YL M23 20YL BK 3 2 1 CAV DRIVER DOOR AJAR SWITCH SENSE COURTESY LAMPS DRIVER DOOR...

Страница 590: ...SWITCH 5 RELAY NO 1 FOG LAMP 5 4 3 2 1 BLACK L39 18LB F61 18WT OR Z1 20BK L35 18BR WT 5 4 3 2 1 CAV FOG LAMP RELAY NO 1 OUTPUT FUSED B GROUND FOG LAMP SWITCH OUTPUT FUNCTION CIRCUIT 2 5L FUEL INJECTO...

Страница 591: ...5L FUEL INJECTOR NO 3 F42 18DG LG AUTOMATIC SHUT DOWN RELAY OUTPUT 1 2 BLACK FUNCTION K13 18YL WT 2 1 CAV FUEL INJECTOR NO 3 DRIVER CIRCUIT CIRCUIT FUEL INJECTOR NO 3 DRIVER CAV 1 2 K13 18YL WT FUNCT...

Страница 592: ...CUIT K15 18PK BK 2 1 CAV FUEL INJECTOR NO 5 DRIVER FUNCTION CIRCUIT GENERATOR G SWITCH MODULE FUEL PUMP 2 1 BLACK K20 18DG K72 18DG OR 2 1 CAV GENERATOR FIELD DRIVER VOLTAGE REGULATOR SIGNAL FUNCTION...

Страница 593: ...20YL F34 18TN BK G26 20LB G16 20BK LB L20 16LG WT A3 14RD WT L7 18BK YL CIRCUIT FUNCTION HORN RELAY OUTPUT GROUND CAV 1 2 X2 18WT RD Z1 18BK 9 8 7 6 5 4 3 2 1 BLACK 1 2 BLACK HEADLAMP LEVELING SWITCH...

Страница 594: ...21 14DB A41 14YL GRAY 1 5 6 10 CIRCUIT FUNCTION AUTOMATIC SHUT DOWN RELAY OUTPUT IGNITION COIL NO 1 DRIVER CAV 1 2 F42 18DG LG K19 18GY GRAY 1 2 BLACK 4 1 IDLE AIR CONTROL MOTOR IGNITION COIL IGNITION...

Страница 595: ...18BK RD K167 20BR YL GRAY 1 2 INSTRUMENT CLUSTER C2 INTAKE AIR TEMPERATURE SENSOR CLUSTER C1 INSTRUMENT HARD TOP 10 6 5 1 GREEN G10 20LG RD Z2 18BK LG G26 20LB L60 18TN G107 20BK RD C80 20DB LG C81 20...

Страница 596: ...COURTESY LAMP LEFT FOG LAMP LEFT FRONT SPEAKER LEFT CITY LAMP BUILT UP EXPORT EXPORT EXCEPT BUILT UP TURN SIGNAL LAMP LEFT FRONT PARK 3 1 Z1 18BK L7 18BK YL L61 18GY 3 2 1 CAV GROUND HEADLAMP SWITCH...

Страница 597: ...UIT FUNCTION HEADLAMP SWITCH OUTPUT GROUND CAV 1 2 L7 18BK YL Z1 20BK BLACK GRAY 3 1 1 2 LEFT HEADLAMP LEFT HEADLAMP LEVELING MOTOR LEFT LICENSE LAMP BUILT UP EXPORT CIRCUIT FUNCTION LEFT FRONT WHEEL...

Страница 598: ...V 1 2 L61 18GY Z1 18BK CIRCUIT FUNCTION HEADLAMP SWITCH OUTPUT LEFT TURN SIGNAL CAV 1 2 L7 18BK YL L61 18GY 3 4 1 2 1 2 GRAY 1 2 GRAY LEFT REAR LAMP ASSEMBLY LEFT REAR WHEEL SPEED SENSOR LEFT SIDE MAR...

Страница 599: ...42 18BK YL YELLOW B A 3 1 MANIFOLD ABSOLUTE PRESSURE SENSOR PARK NEUTRAL POSITION SWITCH A T PASSENGER AIRBAG 1 1 UPSTREAM OXYGEN SENSOR 1 2 3 4 GRAY K41 18BK DG K167 20BR YL Z1 18BK F142 18OR DG 4 3...

Страница 600: ...4 18LG YL Z6 20BK PK GRAY YELLOW 4 1 PASSENGER AIRBAG ON OFF SWITCH C2 PASSENGER AIRBAG ON OFF SWITCH C1 CIRCUIT FUNCTION DOOR AJAR SWITCH OUTPUT COURTESY LAMPS DRIVER CAV 1 2 M23 20YL BK M2 20YL BLAC...

Страница 601: ...MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL OXYGEN SENSOR 1 2 SIGNAL OXYGEN SENSOR 1 1 SIGNAL THROTTLE POSITION SENSOR SIGNAL FUSED B IDLE AIR CONTROL NO 4 DRIVER IDLE AIR CONTROL NO 1 DRIVER CAMSHAFT PO...

Страница 602: ...19 B18 B17 B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 CAV 5V SUPPLY VEHICLE SPEED SENSOR SIGNAL ENGINE OIL PRESSURE SENSOR SIGNAL FUEL INJECTOR NO 4 DRIVER FUEL INJECTOR NO 2 DRIVER FUEL I...

Страница 603: ...C15 C14 C13 C12 C11 C10 C9 C8 C7 C6 C5 C4 C3 C2 C1 CAV SPEED CONTROL SWITCH SIGNAL CCD BUS SCI RECEIVE CCD BUS SCI TRANSMIT ISO 9141K FUEL LEVEL SENSOR SIGNAL VOLTAGE REGULATOR SIGNAL BRAKE SWITCH SE...

Страница 604: ...ACK 1 7 GRAY CIRCUIT FUNCTION REAR FOG LAMP FEED GROUND CAV 1 2 L38 18BR WT Z1 20BK CIRCUIT FUNCTION GROUND REAR FOG LAMP RELAY CONTROL REAR FOG LAMP FEED FUSED PANEL LAMPS DIMMER SWITCH SIGNAL CAV 1...

Страница 605: ...ION SWITCH OUTPUT RUN GROUND REAR WIPER MOTOR CONTROL CAV 1 2 3 V23 18BR PK Z1 16BK V13 18BK LG 1 3 BLACK REAR WASHER PUMP HARD TOP REAR WINDOW DEFOGGER SWITCH HARD TOP REAR WIPER MOTOR HARD TOP WASHE...

Страница 606: ...PEAKER CAV 1 2 X54 18VT X56 18DB RIGHT COURTESY LAMP RIGHT FOG LAMP RIGHT FRONT SPEAKER BLACK BUILT UP EXPORT LAMP RIGHT CITY BUILT UP EXPORT SIGNAL LAMP RIGHT FRONT TURN BLACK 1 3 Z1 18BK L60 18TN 3...

Страница 607: ...AV 1 2 L7 18BK YL Z1 20BK 2 1 GRAY RIGHT HEADLAMP LEVELING MOTOR RIGHT REAR LAMP ASSEMBLY RIGHT LICENSE LAMP CIRCUIT FUNCTION RIGHT FRONT WHEEL SPEED SENSOR RIGHT FRONT WHEEL SPEED SENSOR CAV 1 2 B6 1...

Страница 608: ...BUILT UP EXPORT CIRCUIT FUNCTION RIGHT REAR WHEEL SPEED SENSOR RIGHT REAR WHEEL SPEED SENSOR CAV 1 2 B1 18YL DB B2 18YL 1 2 BLACK RIGHT REAR WHEEL SPEED SENSOR MODULE IMMOBILIZER SENTRY KEY CIRCUIT FU...

Страница 609: ...COMBINATION FLASHER INPUT CAV 1 2 3 4 5 6 7 8 9 10 11 L60 18TN L50 18WT TN L62 18BR RD L32 16PK L5 20BK GY L9 16BK WT L63 18DG RD L61 18GY L55 16RD WT BLACK 1 6 7 11 TORQUE CONVERTOR CLUTCH SOLENOID...

Страница 610: ...V10 18BR V3 18BR WT V6 18PK BK V4 18RD YL NATURAL 1 6 CIRCUIT FUNCTION 5V SUPPLY SENSOR GROUND VEHICLE SPEED SENSOR SIGNAL CAV 1 2 3 K6 20VT OR K167 20BR YL G7 20WT OR BLACK 1 3 CIRCUIT FUNCTION WASH...

Страница 611: ...Module YL Front of Floor Pan Tunnel 15 16 19 Back up Lamp Switch M T BK Right Side of Transmission 14 Battery Temperature Sensor BK Under Battery Tray 3 4 Brake Lamp Switch GY Top of Brake Pedal Brack...

Страница 612: ...Lock Brake C2 GY Near Grommet Rear Left Side of Dash Panel 2 19 Crankshaft Position Sensor BK At Rear of Intake Manifold 9 10 13 Connector Name Number Color Location Fig Data Link Connector LHD BK Bot...

Страница 613: ...O for Controller Anti Lock Brake 19 Generator BK Rear of Generator 12 Headlamp Dimmer Switch BK At Steering Column Part of Multifunction Switch 20 Headlamp Leveling Switch Built Up Export BK Right Sid...

Страница 614: ...t Up Export BK Left Front Fender Side Shield 5 Manifold Absolute Pressure Sensor BK Side of Throttle Body 9 10 Oxygen Sensor 1 1 Upstream GY On Front Exhaust Pipe 9 10 Oxygen Sensor 1 2 Downstream BK...

Страница 615: ...Motor 1 Connector Name Number Color Location Fig Right License Lamp Built Up Export GY At Lamp 24 25 Right Rear Lamp Assembly BK At Lamp 24 25 Right Rear Speaker Sound Bar BK At Sound Bar N S Right R...

Страница 616: ...ump BK Under Washer Fluid Reservoir 5 Windshield Wiper Motor BK Center of Cowl Panel 7 8 Connector Name Number Color Location Fig Windshield Wiper Switch NAT At Steering Column 20 8W 90 6 8W 90 CONNEC...

Страница 617: ...Fig 1 Front End Wiring Connectors TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 7 DESCRIPTION AND OPERATION Continued...

Страница 618: ...Fig 2 Engine Compartment Connectors Rear LHD 8W 90 8 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 619: ...Fig 3 Engine Compartment Connectors Rear RHD TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 9 DESCRIPTION AND OPERATION Continued...

Страница 620: ...Fig 4 Engine Compartment Connectors LHD 8W 90 10 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 621: ...Fig 5 Engine Compartment Connectors Front Side TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued...

Страница 622: ...Fig 6 ABS Hydraulic Control Unit Fig 7 Windshield Wiper Motor LHD 8W 90 12 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 623: ...Fig 8 Windshield Wiper Motor RHD TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 13 DESCRIPTION AND OPERATION Continued...

Страница 624: ...Fig 9 Engine Harness Connectors 2 5L Engine 8W 90 14 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 625: ...Fig 10 Engine Harness Connectors 4 0L Engine TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued...

Страница 626: ...Fig 11 Engine and Automatic Transmission Connectors 8W 90 16 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 627: ...Fig 12 Engine Grounds TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 17 DESCRIPTION AND OPERATION Continued...

Страница 628: ...Fig 13 Crankshaft Position Sensor and Right Front Wheel Speed Sensor 8W 90 18 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 629: ...Fig 14 Transmission and Transfer Case Connectors TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 19 DESCRIPTION AND OPERATION Continued...

Страница 630: ...Fig 15 Dash Panel Connectors LHD 8W 90 20 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 631: ...Fig 16 Dash Panel Connectors RHD TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 21 DESCRIPTION AND OPERATION Continued...

Страница 632: ...Fig 17 Instrument Panel Wiring Connectors LHD 8W 90 22 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 633: ...Fig 18 Instrument Panel Wiring Connectors RHD TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 23 DESCRIPTION AND OPERATION Continued...

Страница 634: ...Fig 19 Airbag Control Module and Controller Antilock Brakes LHD 8W 90 24 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 635: ...Fig 20 Steering Column Connectors TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 25 DESCRIPTION AND OPERATION Continued...

Страница 636: ...Fig 21 Instrument Panel Connectors Right Side LHD 8W 90 26 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 637: ...Fig 22 Body Connectors LHD TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 27 DESCRIPTION AND OPERATION Continued...

Страница 638: ...Fig 23 Rear Body Wiring Connectors RHD 8W 90 28 8W 90 CONNECTOR GROUND LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 639: ...Fig 24 Rear Under Body Wiring Connectors LHD Fig 25 Rear Under Body Wiring Connectors RHD TJ 8W 90 CONNECTOR GROUND LOCATIONS 8W 90 29 DESCRIPTION AND OPERATION Continued...

Страница 640: ...3 and C104 2 S110 Near T O for C103 and C104 2 S112 Near Controller Antilock Brake 2 S114 Near ABS Pump Motor T O 2 S115 Except Built Up Export Near T O for Duty Cycle Evap Purge Solenoid 1 S116 Excep...

Страница 641: ...urn Signal Lamp N S Splice Number Location Fig S144 Near T O for Right Front Park Turn Signal Lamp N S S146 Near T O for Powertrain Control Module 2 S147 LHD Near T O for Powertrain Control Module 2 S...

Страница 642: ...HD In T O for Fuse Block 8 S330 RHD Near Passenger Airbag On Off Switch 9 Splice Number Location Fig S331 Near T O for Airbag Control Module 8 9 S332 Near T O for Cigar Lighter Accessory Relay 8 9 S33...

Страница 643: ...Fig 1 Engine Compartment Splices Front 8W 95 4 8W 95 SPLICE LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 644: ...Fig 2 Engine Compartment Splices Rear LHD TJ 8W 95 SPLICE LOCATIONS 8W 95 5 DESCRIPTION AND OPERATION Continued...

Страница 645: ...Fig 3 Engine Compartment Splices Rear RHD 8W 95 6 8W 95 SPLICE LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 646: ...Fig 4 Engine Wiring Splices LHD TJ 8W 95 SPLICE LOCATIONS 8W 95 7 DESCRIPTION AND OPERATION Continued...

Страница 647: ...Fig 5 Engine Wiring Splices RHD 8W 95 8 8W 95 SPLICE LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 648: ...Fig 6 Engine Wiring Splices LHD TJ 8W 95 SPLICE LOCATIONS 8W 95 9 DESCRIPTION AND OPERATION Continued...

Страница 649: ...Fig 7 Engine Wiring Splices RHD 8W 95 10 8W 95 SPLICE LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 650: ...Fig 8 Dash Panel Wiring Splices LHD TJ 8W 95 SPLICE LOCATIONS 8W 95 11 DESCRIPTION AND OPERATION Continued...

Страница 651: ...Fig 9 Dash Panel Wiring Splices RHD 8W 95 12 8W 95 SPLICE LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 652: ...Fig 10 Instrument Panel Wiring Splices LHD TJ 8W 95 SPLICE LOCATIONS 8W 95 13 DESCRIPTION AND OPERATION Continued...

Страница 653: ...Fig 11 Instrument Panel Wiring Splices RHD 8W 95 14 8W 95 SPLICE LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 654: ...Fig 12 Body Wiring Splices LHD TJ 8W 95 SPLICE LOCATIONS 8W 95 15 DESCRIPTION AND OPERATION Continued...

Страница 655: ...Fig 13 Body Wiring Splices RHD 8W 95 16 8W 95 SPLICE LOCATIONS TJ DESCRIPTION AND OPERATION Continued...

Страница 656: ...al is normally used on flexible metal flanges It has a shelf life of a year and will not properly cure if over aged Always inspect the package for the expi ration date before use MOPAR GASKET MAKER Mo...

Страница 657: ...and Maintenance Group 0 9 Inspect crankcase ventilation system as out lined in Group 0 Lubrication and Maintenance For emission controls see Group 25 Emission Controls for service procedures 10 Road t...

Страница 658: ...Plastigage approximately 6 35 mm 1 4 inch off cen ter and away from the oil holes In addition suspect areas can be checked by placing the Plastigage in that area Tighten the bearing cap bolts of the b...

Страница 659: ...propriate procedures for cleaning inspec tion and torque tightening HYDROSTATIC LOCK When an engine is suspected of hydrostatic lock regardless of what caused the problem follow the steps below 1 Perf...

Страница 660: ...t engine oil level approximately every 800 kilometers 500 miles Unless the engine has exhibited loss of oil pressure run the engine for about five minutes before checking oil level Checking engine oil...

Страница 661: ...pan under the oil filter 2 Using a suitable oil filter wrench loosen filter 3 Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss Fig 8 4 When filter separates...

Страница 662: ...is HYDRAULIC TAPPETS LEAK DOWN TEST After cleaning and inspection test each tappet for specified leak down rate tolerance to ensure zero lash operation Fig 1 Swing the weighted arm of the hydraulic va...

Страница 663: ...overheating and loss of coolant CYLINDER TO CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders follow the proce dures outlined in Cylinder Comp...

Страница 664: ...s thoroughly mixed as indicated with a bright yellow color under a black light 3 Using a black light inspect the entire engine for fluorescent dye particularly at the suspected area of oil leak If the...

Страница 665: ...done until dis assembled ENGINE OIL PRESSURE 1 Disconnect connector and remove oil pressure sending unit 2 Install Oil Pressure Line and Gauge Tool C 3292 or equivalent Start engine and record pres s...

Страница 666: ...idle speed too low 2 Check Idle Air Control circuit Refer to Group 14 Fuel System 3 Worn or incorrectly gapped spark plugs 3 Replace or clean and re gap spark plugs Refer to group 8D Ignition System 4...

Страница 667: ...oil pressure 2 Check engine oil level If ok Perform oil pressure test Refer to this group for engine oil pressure test specifications 3 Thin or diluted oil 3 Change oil to correct viscosity Refer to t...

Страница 668: ...d or cracked 9 Install new oil pump OIL LEAKS 1 Misaligned or deteriorated gaskets 1 Replace gasket 2 Loose fastener broken or porous metal part 2 Tighten repair or replace the part 3 Front or rear cr...

Страница 669: ...KER ARMS AND PUSH RODS 50 SPECIFICATIONS 2 5L ENGINE 51 2 5L TORQUE SPECIFICATIONS 53 SPECIAL TOOLS 2 5L ENGINE 54 DESCRIPTION AND OPERATION ENGINE DESCRIPTION The 2 5 liter 150 CID four cylinder engi...

Страница 670: ...ept number 4 main bear ing journal to the connecting rod journals Each con necting rod bearing cap has a small squirt hole oil passes through the squirt hole and is thrown off as the rod rotates This...

Страница 671: ...Oil Lubrication System 2 5L Engine 9 16 2 5L ENGINE TJ DESCRIPTION AND OPERATION Continued...

Страница 672: ...AUGE METHOD 1 To correctly select the proper size piston a cyl inder bore gauge capable of reading in 0 003 mm 0001 in INCREMENTS is required If a bore gauge is not available do not use an inside micr...

Страница 673: ...g 0 042 to 0 084 mm 0 0017 to 0 0033 in Second Compression Ring 0 042 to 0 084 mm 0 0017 to 0 0033 in Oil Control Ring 0 06 to 0 21 mm 0 0024 to 0 0083 in 4 Place ring in the cylinder bore and push do...

Страница 674: ...Orientation Position the gaps on the piston as shown Fig 12 Oil spacer Gap on center line of piston skirt Oil rails gap 180 apart on centerline of piston pin bore No 2 Compression ring Gap 180 from to...

Страница 675: ...ds must face the camshaft The arrow on the piston crown should point to the front of the engine Fig 16 Verify that the oil squirt holes in the rods face the camshaft and that the arrows on the pistons...

Страница 676: ...er Upper Insert Size Lower Insert Size Yellow 53 2257 53 2079 mm Yellow Standard Yellow Standard 2 0955 2 0948 in Orange 53 2079 53 1901 mm Yellow Standard Blue Undersize 2 0948 2 0941 in 0 025 mm 0 0...

Страница 677: ...n Bearing Fitting Chart The bearing color code appears on the edge of the insert The size is not stamped on bearing inserts used for engine production The main bearing journal size diameter is identi...

Страница 678: ...m 0 002 inch undersize bearing insert and a 0 0254 mm 0 001 inch undersize insert would reduce the origi nal clearance an additional 0 0127 mm 0 0005 inch The clearance would then be 0 0381 mm 0 0015...

Страница 679: ...m 0 010 in Red Undersize 0 254 mm 0 010 in 2 4901 2 4896 in 0 254 mm 0 010 in Undersize CRANKSHAFT JOURNAL 5 ONLY CORRESPONDING CRANKSHAFT BEARING INSERT Color Code Diameter Upper Insert Size Lower In...

Страница 680: ...e through bolt nut to 69 N m 51 ft lbs torque 4 Remove the engine support 5 Lower the vehicle 6 Connect negative cable to battery ENGINE MOUNT REAR A resilient rubber cushion supports the transmis sio...

Страница 681: ...e nuts Fig 24 Fig 25 Tighten the nuts to 28 N m 21 ft lbs torque 2 Install the skid plate bolts to the sill and tighten to 75 N m 55 ft lbs torque 3 Remove the transmission support 4 Lower the vehicle...

Страница 682: ...uel supply line at the fuel rail Refer to Group 14 Quick Connect Fittings for correct procedure 29 If equipped with power steering a Disconnect the hoses from the fittings at the steering gear b Drain...

Страница 683: ...r 18 Lower the vehicle 19 If equipped with power steering a Remove the protective caps b Connect the hoses to the fittings at the steer ing gear Tighten the nut to 52 N m 38 ft lbs torque c Fill the p...

Страница 684: ...y negative cable 2 Raise the vehicle 3 Disconnect the exhaust pipe from the engine exhaust manifold 4 Lower the vehicle 5 Remove the intake manifold Refer to proce dure in this section 6 Remove fasten...

Страница 685: ...Disconnect the crankcase ventilation CCV vacuum hose and manifold absolute pressure MAP sensor vacuum hose connector at the intake mani fold 11 Disconnect HVAC supply vacuum hose from intake manifold...

Страница 686: ...engine and check for leaks CYLINDER HEAD COVER A cured gasket is part of the engine cylinder head cover REMOVAL 1 Disconnect negative cable from battery 2 Disconnect the Crankcase Ventilation CCV vacu...

Страница 687: ...ressing the valve spring 1 Remove the engine cylinder head cover Refer to procedure in this section 2 Remove cap screws bridge and pivot assem blies and rocker arms for access to each valve spring to...

Страница 688: ...the hoses at the engine thermostat housing DO NOT waste reus able coolant If the solution is clean and is being drained only to service the engine or cooling system drain the coolant into a clean con...

Страница 689: ...te oversize valve stems Remove all carbon buildup and reface the valves 1 Fabricate two engine cylinder head alignment dowels from used head bolts Fig 37 Use the long est head bolt Cut the head of the...

Страница 690: ...ling System for the proper procedure 21 Install the air cleaner and ducting 22 Connect the hoses to the thermostat housing and fill the cooling system to the specified level refer to Group 7 Cooling S...

Страница 691: ...ver installed 1 Disconnect negative cable from battery 2 Remove the serpentine drive belt 3 Remove the vibration damper 4 Remove the radiator shroud 5 Carefully remove the oil seal Make sure seal bore...

Страница 692: ...oil pan gasket and the cylinder block 5 Insert Timing Case Cover Alignment and Seal Installation Tool 6139 in the crankshaft opening in the cover Fig 44 6 Install the timing case cover to cylinder bl...

Страница 693: ...ar Silicone Rubber Adhesive Sealant to the keyway in the crankshaft and insert the key With the key in the crankshaft keyway install the crankshaft camshaft sprockets and timing chain Ensure the timin...

Страница 694: ...5 If the camshaft appears to have been rubbing against the timing case cover examine the oil pres sure relief holes in the rear cam journal The oil pressure relief holes must be free of debris 6 Lubr...

Страница 695: ...he crankshaft vibration damper 9 Remove the timing case cover Clean the gasket material from the cover 10 Rotate crankshaft until the crankshaft sprocket timing mark is closest to and on the center li...

Страница 696: ...s within four steel shelled babbitt lined bearings that are pressed into the cyl inder block and then line reamed The camshaft bearing bores and bearing diameters are not the same size They are steppe...

Страница 697: ...a Attach a magnetic base dial indicator to the cylinder block at either the front or rear of the engine b Position the dial indicator rod so that it is parallel to the center line of the crankshaft c...

Страница 698: ...amper 7 Place a piece of wood 2 x 2 between the jack stand and the engine vibration damper 8 Remove the engine mount through bolts 9 Using the jack stand raise the engine until adequate clearance is o...

Страница 699: ...asteners Fig 61 Tighten these fasteners to 15 N m 132 in lbs torque 8 Remove the dowels Install the remaining 1 4 inch oil pan fasteners and tighten to 9 5 N m 84 in lbs 9 Lower the engine until it is...

Страница 700: ...hin the pump body a replacement tube and strainer assembly must be installed to assure an airtight seal INSTALLATION 1 Install the oil pump on the cylinder block using a replacement gasket Tighten the...

Страница 701: ...ek or counterweight toward the flange rear end of the crankshaft The color codes used to indi cate journal sizes are listed in the Connecting Rod Bearing Fitting Chart 10 When required upper and lower...

Страница 702: ...and compress the valve spring with Valve Spring Compressor Tool MD 998772A 6 Install the valve locks and release the tool 7 Tap the valve spring from side to side with a hammer to ensure that the spri...

Страница 703: ...the valve guide VALVE STEM TO GUIDE CLEARANCE MEASUREMENT Valve stem to guide clearance may be measured by either of the following two methods PREFERRED METHOD 1 Remove the valve from the head 2 Clea...

Страница 704: ...ing chain bumper 8 Remove the oil slinger from crankshaft 9 Remove the camshaft retaining bolt and remove the sprockets and chain as an assembly 10 Remove the camshaft 11 Remove the oil pan and gasket...

Страница 705: ...h tappet body Inspect each tappet base for concave wear with a straightedge positioned across the base If the base is concave the corresponding lobe on the camshaft is also worn Replace the camshaft a...

Страница 706: ...of round condition exceeds these maximum limits the cylinder must be bored and then honed to accept an oversize piston A slight amount of taper always exists in the cylinder bore after the engine has...

Страница 707: ...Tappet Bore Diameter 23 000 to 23 025 mm 0 9055 to 0 9065 in Flatness 0 03 mm per 25 mm 0 001 in per 1 in Flatness 0 05 mm per 152 mm 0 002 in per 6 in Flatness Max 0 20 mm for total length 0 008 in...

Страница 708: ...n Ring Side Clearance Compression Rings 0 042 to 0 084 mm 0 0017 to 0 0033 in Ring Side Clearance Oil Control Ring 0 06 to 0 21 mm 0 0024 to 0 0083 in Piston Ring Groove Height Compression Rings 1 530...

Страница 709: ...justing Bolt 24 N m 18 ft lbs Pivot Bolt Nut 38 N m 28 ft lbs Mounting Bracket to Engine Bolts 38 N m 28 ft lbs Mounting Head Bolts 45 N m 33 ft lbs Main Bearing Cap Bolts 108 N m 80 ft lbs Oil Filter...

Страница 710: ...Fig 78 Vibration Damper Removal Tool 7697 Fig 79 Timing Case Cover Alignment and Seal Tool 6139 TJ 2 5L ENGINE 9 55 SPECIAL TOOLS Continued...

Страница 711: ...IONS 4 0L ENGINE SPECIFICATIONS 93 4 0L TORQUE SPECIFICATIONS 95 SPECIAL TOOLS 4 0L ENGINE 96 DESCRIPTION AND OPERATION ENGINE DESCRIPTION The 4 0 Liter 242 CID six cylinder engine is an In line light...

Страница 712: ...r ing journal to the connecting rod journals Each con necting rod bearing cap has a small squirt hole oil passes through the squirt hole and is thrown off as the rod rotates This oil throwoff lubricat...

Страница 713: ...Oil Lubrication System 4 0L Engine 9 58 4 0L ENGINE TJ DESCRIPTION AND OPERATION Continued...

Страница 714: ...GAGE METHOD 1 To correctly select the proper size piston a cyl inder bore gauge capable of reading in 0 003 mm 0001 in INCREMENTS is required If a bore gauge is not available do not use an inside micr...

Страница 715: ...g 0 042 to 0 084 mm 0 0017 to 0 0033 in Second Compression Ring 0 042 to 0 084 mm 0 0017 to 0 0033 in Oil Control Ring 0 06 to 0 21 mm 0 0024 to 0 0083 in 4 Place ring in the cylinder bore and push do...

Страница 716: ...Orientation Position the gaps on the piston as shown Fig 12 Oil spacer Gap on center line of piston skirt Oil rails gap 180 apart on centerline of piston pin bore No 2 Compression ring Gap 180 from to...

Страница 717: ...the camshaft The arrow on the piston crown should point to the front of the engine Fig 16 Verify that the oil squirt holes in the rods face the camshaft and that the arrows on the pistons face the fro...

Страница 718: ...Standard Blue Undersize 2 0948 2 0941 in 0 0178 mm 0 0007 in 0 025 mm 0 001 in Undersize Blue 53 1901 53 1724 mm Blue Undersize Blue Undersize 2 0941 2 0934 in 0 0356 mm 0 0014 in 0 025 mm 0 001 in 0...

Страница 719: ...izes may be used as a pair A standard size insert is sometimes used in combination with a 0 025 mm 0 001 inch undersize insert to reduce the clear ance by 0 013 mm 0 0005 inch Never use a pair of bear...

Страница 720: ...earing insert and a 0 0254 mm 0 001 inch undersize insert would reduce the original clearance an additional 0 0127 mm 0 0005 inch The clearance would then be 0 0381 mm 0 0015 inch CAUTION Never use a...

Страница 721: ...he journal with a micrometer Measure at two locations 90 apart at each end of the journal The maximum allowable taper and out of round is 0 013 mm 0 0005 inch Compare the measured diameter with the jo...

Страница 722: ...254 mm 0 010 in Red Undersize 0 254 mm 0 010 in 2 4901 2 4896 in 0 254 mm 0 010 in Undersize Crankshaft Journal 7 Only Corresponding Bearing Insert Color Code Diameter Upper Insert Size Lower Insert...

Страница 723: ...ove the engine support 5 Lower the vehicle 6 Connect negative cable to battery ENGINE MOUNT REAR A resilient rubber cushion supports the transmis sion at the rear between the transmission extension ho...

Страница 724: ...rque 2 Install the skid plate bolts to the sill and tighten to 75 N m 55 ft lbs torque 3 Remove the transmission support 4 Lower the vehicle 5 Connect negative cable to battery ENGINE ASSEMBLY REMOVAL...

Страница 725: ...fuel supply line at the fuel rail Refer to Group 14 Quick Connect Fittings for correct procedure 29 If equipped with power steering a Disconnect the hoses from the fittings at the steering gear b Drai...

Страница 726: ...ighten the bolts to 45 N m 33 ft lbs 12 Install the oil filter 13 Lower the vehicle 14 If equipped with power steering a Remove the protective caps b Connect the hoses to the fittings at the steer ing...

Страница 727: ...r cable speed control cable if equipped and the transmission line pres sure cable if equipped Remove these cables from the bracket 4 Disconnect the following electrical connectors Map Sensor Idle Air...

Страница 728: ...Connect air inlet hose to the throttle body and air cleaner housing 16 Raise vehicle on hoist 17 Using a new seal connect the exhaust pipe to the engine exhaust manifold Tighten the bolts to 31 N m 2...

Страница 729: ...lignment of the rocker arm to valve tip area 3 Remove the capscrews at each bridge and pivot assembly Fig 34 Alternately loosen the capscrews one turn at a time to avoid damaging the bridges 4 Remove...

Страница 730: ...AUTION Install oil seals carefully to prevent dam age from the sharp edges of the valve spring lock grove 1 Lightly push the valve seal over the valve stem and valve guide boss Be sure the seal is com...

Страница 731: ...o the cyl inder bores INSTALLATION The engine cylinder head gasket is a composition gasket The gasket is to be installed DRY DO NOT use a gasket sealing compound on the gasket If the engine cylinder h...

Страница 732: ...r the proper procedure 17 Install the air cleaner and ducting 18 Install the engine cylinder head cover 19 Connect the hoses to the engine thermostat housing and fill the cooling system to the specifi...

Страница 733: ...ft and insert the key With the key in position align the keyway on the vibration damper hub with the crankshaft key and tap the damper onto the crankshaft 2 Install the vibration damper retaining bolt...

Страница 734: ...1 Install the engine fan and hub assembly and shroud 12 Install the serpentine drive belt and tighten to obtain the specified tension 13 Connect negative cable to battery TIMING CHAIN AND SPROCKETS RE...

Страница 735: ...an drain it into a clean container for reuse 3 Remove the radiator or radiator and condenser if equipped with A C refer to Group 7 Cooling Sys tem for the proper procedure 4 Remove the distributor cap...

Страница 736: ...n wires Refer to Distributor in the Component Removal In stallation section of Group 8D Ignition Systems 21 Install the serpentine drive belt and tighten to the specified tension refer to Group 7 Cool...

Страница 737: ...ust be clean and free of debris CAUTION Make sure outside diameter of number 1 bearing is clean Make sure that the bearing is properly installed in the engine block align the oil hole in the bearing w...

Страница 738: ...at are attached to the oil pan studs 14 Remove the oil pan bolts and studs Carefully slide the oil pan and gasket to the rear If equipped with an oil level sensor take care not to damage the sensor IN...

Страница 739: ...l pump removal or replacement will not affect the distributor timing because the distributor drive gear remains in mesh with the camshaft gear REMOVAL 1 Drain the engine oil 2 Remove the oil pan 3 Rem...

Страница 740: ...l the main bearing upper inserts 3 Install the lower bearing inserts into the main bearing caps 4 Install the main bearing cap s and lower insert s 5 Tighten the bolts of caps 1 2 4 5 6 and 7 to 54 N...

Страница 741: ...lug Tighten the plug to 34 N m 25 ft lbs torque 14 Lower the vehicle 15 Install the spark plugs Tighten the plugs to 37 N m 27 ft lbs torque 16 Fill the oil pan with engine oil to the full mark on the...

Страница 742: ...not stamped on inserts used for production of engines 8 The rod journal is identified during the engine production by a color coded paint mark on the adja cent cheek or counterweight toward the flang...

Страница 743: ...lip of the seal 10 Install the rear main bearing cap DO NOT strike the cap more than twice for proper engage ment 11 Tighten all main bearing bolts to 108 N m 80 ft lbs torque 12 Install the main bea...

Страница 744: ...emoved from the block REMOVAL 1 Remove the engine cylinder head from the cyl inder block 2 Use Valve Spring Compressor Tool MD 998772A and compress each valve spring 3 Remove the valve locks retainers...

Страница 745: ...G 1 Use a valve refacing machine to reface the intake and exhaust valves to the specified angle 2 After refacing a margin of at least 0 787 mm 0 031 inch must remain Fig 64 If the margin is less than...

Страница 746: ...ore diam eter with specifications 7 95 7 97 mm or 0 313 0 314 inch If the measurement differs from specification by more than 0 076 mm 0 003 inch ream the guide bore to accommodate an oversize valve s...

Страница 747: ...G AND INSPECTION CYLINDER HEAD CLEANING Thoroughly clean the engine cylinder head and cylin der block mating surfaces Clean the intake and engine exhaust manifold and engine cylinder head mating sur f...

Страница 748: ...bove 6 Determine out of roundness by comparing the difference between each measurement 7 If cylinder bore taper does not exceed 0 025 mm 0 001 inch and out of roundness does not exceed 0 025 mm 0 001...

Страница 749: ...ter 23 000 to 23 025 mm 0 9055 to 0 9065 in Flatness 0 03 mm per 25 mm 0 001 in per 1 in Camshaft Flatness 0 05 mm per 152 mm 0 002 in per 6 in Flatness Max 0 20 mm max for total length 0 008 in max f...

Страница 750: ...to 0 21 mm 0 0024 to 0 0083 in Piston Ring Groove Height Compression Rings 1 530 to 1 555 mm 0 0602 to 0 0612 in Piston Ring Groove Height Oil Control Ring 4 035 to 4 060 mm 0 1589 to 0 1598 in Camsha...

Страница 751: ...o Crankshaft Bolts 143 N m 105 ft lbs Front Cover to Block Bolts 1 4 20 7 N m 60 in lbs Bolts 5 16 18 22 N m 192 in lbs Fuel Rail Bolts Stud 12 N m 108 in lbs Generator Fixed Bolt 24 N m 18 ft lbs Thr...

Страница 752: ...Timing Case Cover Alignment and Seal installation Tool 6139 Vibration Damper Removal Tool 7697 Hydraulic Valve Tappet Removal Installation Tool C 4129 A TJ 4 0L ENGINE 9 97 SPECIAL TOOLS Continued...

Страница 753: ...original equip ment parts or their equivalent This will assure proper alignment and provide acceptable exhaust noise levels CAUTION Avoid application of rust prevention compounds or undercoating mate...

Страница 754: ...Fig 1 Exhaust System 2 5L Engine Fig 2 Exhaust System 4 0L Engine 11 2 EXHAUST SYSTEM TJ GENERAL INFORMATION Continued...

Страница 755: ...IS COOLED SPECIAL CARE SHOULD BE TAKEN WHEN WORKING NEAR THE CATALYTIC CON VERTER THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME WARNING IF TORCH...

Страница 756: ...CATALYTIC CON VERTER THE TEMPERATURE OF THE CONVERTER RISES TO A HIGH LEVEL AFTER A SHORT PERIOD OF ENGINE OPERATION TIME WARNING IF TORCHES ARE USED WHEN WORK ING ON THE EXHAUST SYSTEM DO NOT ALLOW T...

Страница 757: ...re that the exhaust tailpipe has sufficient clearance from the floor pan 4 Tighten the nut on the muffler to catalytic con verter clamp to 48 N m 35 ft lbs torque 5 Insert rods into isolators 6 Lower...

Страница 758: ...bolts that attach the tow hook to the bumper Fig 1 2 Separate the tow hook from the bumper INSTALLATION 1 Position the tow hook on the bumper 2 Install the torx bolts that attach the tow hook to the...

Страница 759: ...per INSTALLATION 1 Position the extension on the bumper 2 Install the screws attaching the bumper exten sion to the bumper REAR BUMPER REMOVAL 1 Remove the bolt attaching the bumper to frame rail Fig...

Страница 760: ...me provides a station for the engine The vehicle body is attached to the frame with holddowns Fig 1 The torque specification for the holddown bolts are Radiator to frame tighten to 47 N m 35 ft lbs to...

Страница 761: ...d frame Welding the joints around riveted cross members and frame side rails is not recommended A straightening repair process should be limited to frame members that are not severely damaged The repl...

Страница 762: ...SE AND TRANSMIS SION ARE SUPPORTED BY THE TRANSFER CASE SKID PLATE BEFORE REMOVING THE TRANSFER CASE SKID PLATE ENSURE THAT THE TRANSMIS SION IS PROPERLY SUPPORTED 1 Raise and support the vehicle 2 Pl...

Страница 763: ...7 4 Separate the fuel tank strap from the skid plate 5 Support the fuel tank and remove the skid plate from the vehicle INSTALLATION 1 Attach the skid plate to the fuel tank strap 2 Position and supp...

Страница 764: ...SPECIFICATIONS FRAME DIMENSIONS FRAME SIDE VIEW TJ FRAME AND BUMPERS 13 7...

Страница 765: ...FRAME TOP VIEW 13 8 FRAME AND BUMPERS TJ SPECIFICATIONS Continued...

Страница 766: ...el Tank Strap Nuts 5 N m 40 in lbs Main Floor holdown Bolt 47 N m 35 ft lbs Radiator Holdown Bolt 47 N m 35 ft lbs Rear Bumper Bolt 67 N m 50 ft lbs Rear Bumper Nut 67 N m 50 ft lbs Rear Floor holdown...

Страница 767: ...E EYE REMOVAL 1 Remove the emergency toe eye cover 2 Remove the emergency toe eye attaching bolts Fig 1 INSTALLATION 1 Perform the removal procedure in reverse order FRONT BUMPER EXTENSIONS REMOVAL 1...

Страница 768: ...reverse order REAR LICENSE PLATE BRACKET REMOVAL 1 Remove the rear license plate bracket attach ing screws Fig 4 2 Disconnect the license plate lamp electrical connectors INSTALLATION 1 Perform the re...

Страница 769: ...TANK FILLER TUBE CAP 21 THROTTLE CABLE 21 SPECIFICATIONS FUEL SYSTEM PRESSURE 22 FUEL TANK CAPACITY 22 TORQUE CHART 22 DESCRIPTION AND OPERATION FUEL REQUIREMENTS OPERATION Your engine is designed to...

Страница 770: ...This may cause the Check Engine or Service Engine Soon light to illuminate Illumination of either light while operating on high sulfur gasoline does not necessarily mean your emis sion control system...

Страница 771: ...Control Systems Both fuel filters at bottom of fuel pump module and within fuel pressure regulator are designed for extended service They do not require normal sched uled maintenance Filters should o...

Страница 772: ...e frame mounted fuel filter is not used with any engine Fuel Pressure Regulator Operation The pres sure regulator is a mechanical device that is not con trolled by engine vacuum or the Powertrain Cont...

Страница 773: ...ugh the ASD relay When the engine is operating voltage is supplied by the charging sys tem The PCM determines injector pulse width based on various inputs FUEL RAIL FUEL DAMPER 2 5L ENGINE The fuel ra...

Страница 774: ...SSURE TEST PORT Use this test in conjunction with the Fuel Pump Capacity Test Fuel Pressure Leak Down Test and Fuel Pump Amperage Test found elsewhere in this group Check Valve Operation The electric...

Страница 775: ...iced separately on certain applications Refer to Fuel Filter Fuel Pressure Regulator Removal In stallation for additional information c If both fuel pressure and capacity are low replace fuel pump mod...

Страница 776: ...Replace the fuel pump module assembly The filter regulator may be replaced separately on certain applications Refer to Fuel Filter Fuel Pressure Reg ulator Removal Installation for additional informa...

Страница 777: ...elays may be used Type 1 type 2 and type 3 13 If equipped with type 1 relay Fig 11 attach test leads from LCS adapter into PDC relay cavities number 30 and 87 For location of these cav ities refer to...

Страница 778: ...fuel fill tube and press on flap to relieve any tank pressure 3 Remove Fuel Pump relay from Power Distribu tion Center PDC For location of relay refer to label on underside of PDC cover 4 Start and ru...

Страница 779: ...ittings are used to attach various fuel system components These are a single tab type a two tab type a plastic retainer ring type or a latch clip type Certain fittings may require the use of a special...

Страница 780: ...IS UNDER A CON STANT PRESSURE EVEN WITH THE ENGINE OFF BEFORE SERVICING ANY FUEL SYSTEM HOSES FITTINGS OR LINES THE FUEL SYSTEM PRES SURE MUST BE RELEASED REFER TO THE FUEL PRESSURE RELEASE PROCEDURE...

Страница 781: ...owards compo nent being serviced while firmly pushing plastic retainer ring into fitting Fig 19 With plastic ring depressed pull fitting from component The plastic retainer ring must be pressed square...

Страница 782: ...ne onto fuel rail until a click is felt 11 Install latch clip snaps into position If latch clip will not fit this indicates fuel line is not properly installed to fuel rail Recheck fuel line connectio...

Страница 783: ...filter regulator Refer to Quick Connect Fittings in this group for procedures 10 Install fuel tank Refer to Fuel Tank Removal Installation FUEL PUMP MODULE Fuel tank removal will be necessary for fue...

Страница 784: ...emove fuel pump module Refer to Fuel Pump Module Removal Installation 3 Remove filter by prying from bottom of module with 2 screwdrivers Filter is snapped to module 4 Clean bottom of pump module INST...

Страница 785: ...System for procedures 9 Disconnect automatic transmission cable at throttle body if equipped 10 Remove cable routing bracket Fig 30 at intake manifold 11 Remove nut securing crankshaft position sen s...

Страница 786: ...throttle body if equipped 10 Remove cable routing bracket Fig 31 at intake manifold 11 Remove nut securing crankshaft position sen sor pigtail harness to fuel rail mounting stud Remove clamp and harn...

Страница 787: ...r engine application Position opposite end of this hose tool to an approved gasoline draining station Activate fuel pump and drain tank until empty If electric fuel pump is not operating tank must be...

Страница 788: ...2 mm between bottom of nut to end of strap stud Fig 36 Do not over tighten nuts 2 Install two protective caps to tank strap studs 3 Connect fuel filler hoses at tank Tighten hose clamps 4 Raise skid p...

Страница 789: ...ator pedal mounting bracket nuts 3 Remove accelerator pedal assembly INSTALLATION 1 Place accelerator pedal assembly over mount ing studs protruding from floor pan Tighten mount ing nuts to 8 5 N m 75...

Страница 790: ...arting engine operate accelerator pedal to check for any binding SPECIFICATIONS FUEL TANK CAPACITY Models Liters U S Gallons All 57L 15 All 72L 19 Nominal refill capacities are shown A variation may b...

Страница 791: ...SE PCM INPUT 30 LEAK DETECTION PUMP PCM OUTPUT 34 MALFUNCTION INDICATOR LAMP ECM PCM OUTPUT 34 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR PCM INPUT 31 OIL PRESSURE SENSOR PCM INPUT 31 OXYGEN SENSOR O2S PCM...

Страница 792: ...l economy combined with low emission engine performance The fuel injection system has the following modes of operation Ignition switch ON Engine start up crank Engine warm up Idle Cruise Acceleration...

Страница 793: ...met at the high and low pres sure A C switches Refer to Group 24 Heating and Air Conditioning for additional information When engine has reached operating tempera ture the PCM will begin monitoring O...

Страница 794: ...nly Vehicle speed sensor If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions the PCM will ignore the oxygen sensor input signal The PCM will enter a fuel cut o...

Страница 795: ...Speed control multiplexed single wire input Throttle position sensor Vehicle speed sensor NOTE Powertrain Control Module PCM Outputs A C clutch relay Auto Shutdown ASD relay CCD bus circuits for spee...

Страница 796: ...control of the Idle Air Con trol IAC motor The brake switch input is also used to disable vent and vacuum solenoid output signals to the speed control servo FIVE VOLT SENSOR SUPPLY PRIMARY Supplies t...

Страница 797: ...the exhaust gas in the exhaust manifold When a large amount of oxygen is present caused by a lean air fuel mixture the sen sors produces a low voltage When there is a lesser amount present rich air fu...

Страница 798: ...sensors may look exactly alike but are not interchangeable IGNITION CIRCUIT SENSE PCM INPUT The ignition circuit sense input tells the Power train Control Module PCM the ignition switch has energized...

Страница 799: ...used only on vehicles equipped with a 2 5L engine and power steering The switch Fig 9 provides an input to the Powertrain Control Module PCM This input is provided during periods of high pump load an...

Страница 800: ...rrent engine operating conditions In response to engine operating conditions the PCM will adjust fuel injector pulse width and ignition timing VEHICLE SPEED AND DISTANCE SENSOR PCM INPUT The vehicle s...

Страница 801: ...GE SOLENOID VALVE PCM OUTPUT Refer to Group 25 Emission Control System for information FUEL INJECTORS PCM OUTPUT Six individual fuel injectors are used with the 4 0L 6 cylinder engine Four individual...

Страница 802: ...is screw All idle speed functions are controlled by the PCM IGNITION COIL PCM OUTPUT System voltage from the Automatic Shutdown ASD relay is supplied to the ignition coil positive terminal The Powertr...

Страница 803: ...ontrol Module PCM Fig 15 2 Inspect battery cable connections Be sure that they are clean and tight 3 Inspect fuel pump relay and ASD relay connec tions Inspect starter motor relay connections Inspect...

Страница 804: ...is firmly connected to fit ting on intake manifold Also check connection to brake vacuum booster 13 Inspect air cleaner inlet and air cleaner ele ment for dirt or restrictions 14 Inspect radiator gri...

Страница 805: ...nspect for exhaust system restrictions such as pinched exhaust pipes collapsed muffler or plugged catalytic convertor 24 If equipped with automatic transmission ver ify that electrical harness is firm...

Страница 806: ...tage is not supplied to the rest of the circuit Ter minal 87A is the center terminal on the relay When the PCM energizes the ASD and fuel pump relays terminal 87 connects to terminal 30 This is the On...

Страница 807: ...the harness wires are not damaged by the test meter probes 2 Test MAP sensor output voltage at MAP sensor connector between terminals A and B Fig 30 With ignition switch ON and engine OFF output volta...

Страница 808: ...tance of sensor with a high input impedance digital volt ohmmeter Refer to SENSOR RESISTANCE OHMS COOLANT TEMPERA TURE SENSOR INTAKE AIR TEMPERATURE SENSOR chart The resistance as measured across sens...

Страница 809: ...idle speed through the Idle Air Control IAC motor This is done to prevent the engine from stalling under the increased load When steering pump pressure exceeds 3275 kPa 6 690 kPa 475 psi 6 100 psi th...

Страница 810: ...lowly opened from idle to WOT THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE The following test procedure has been developed to check throttle body calibrations for correct idle condi tions The proced...

Страница 811: ...k condition of relay terminals and PDC connector terminals for damage or corrosion Repair if necessary before installing relay 4 Check for pin height pin height should be the same for all terminals wi...

Страница 812: ...ake manifold gasket INSTALLATION 1 Clean mating surfaces of throttle body and intake manifold 2 Install new throttle body to intake manifold gasket 3 Install throttle body to intake manifold 4 Install...

Страница 813: ...ABSOLUTE PRESSURE MAP SENSOR The MAP sensor is mounted to the side of the throttle body Fig 41 or Fig 42 An L shaped rub ber fitting is used to connect the MAP sensor to throttle body Fig 46 REMOVAL 1...

Страница 814: ...7 Use the DRB scan tool to reprogram new PCM with vehicles original Identification Number VIN and original vehicle mileage POWER STEERING PRESSURE SWITCH 2 5L ENGINE This switch is not used with 4 0L...

Страница 815: ...nti seize compound to aid in removal DO NOT add any additional anti seize compound to the threads of a new oxygen sensor 1 Install O2S sensor Tighten to 30 N m 22 ft lbs torque 2 Connect O2S sensor wi...

Страница 816: ...t housing INSTALLATION 1 Apply sealant to sensor threads new replace ment sensors will have sealant already applied 2 Install coolant temperature sensor into thermo stat housing Tighten to 11 N m 8 ft...

Страница 817: ...pter 3 Tighten sensor mounting bolt to 2 2 N m 20 in lbs torque 4 Connect electrical connector to sensor SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Accelerator Pedal Bracket Mounting Nuts 8 5 N m...

Страница 818: ...Wrench 6856 Adapters Fuel Pressure Test 6539 and or 6631 Fitting Air Metering 6714 O2S Oxygen Sensor Remover Installer C 4907 Test Kit Fuel Pressure 5069 Test Kit Fuel Pressure C 4799 B Fuel Line Remo...

Страница 819: ...l to your engine However continued heavy spark knock at high speeds can cause damage and should be reported to your dealer immediately Engine damage resulting from operating with a heavy spark knock m...

Страница 820: ...0L engine is mounted to the pump body Fig 1 The 2 5L engine has a remote pump reservoir mounted to the fan shroud Fig 2 The steering gear used is a recirculating ball type gear The gear acts as a roll...

Страница 821: ...r 2 Replace steering gear RATTLE OR CLUNK 1 Gear mounting bolts loose 1 Tighten bolts to specification 2 Loose or damaged suspension components 2 Inspect and repair suspension 3 Loose or damaged steer...

Страница 822: ...lubricate steering and suspension compnents 5 Low pump pressure 5 Pressure test and repair as necessary 6 Internal gear leak 6 Pressure and flow test and repair as necessary STEERING WHEEL DOES NOT WA...

Страница 823: ...letely 8 Start engine and let idle long enough to circu late power steering fluid through flow pressure test gauge 9 Shut off the engine and check the fluid level add fluid as necessary Start engine a...

Страница 824: ...tops for more than 2 to 4 seconds at a time because pump damage will result PUMP SPECIFICATIONS ENGINE RELIEF PRESSURE 6 50 FLOW RATE GPM 2 5L 9653 kPa 1400 psi 1500 RPM 2 4 2 8 GPM 4 0L 9653 kPa 1400...

Страница 825: ...mp shaft has a pressed on drive pul ley that is belt driven by the crankshaft pulley The power steering pump is a constant flow rate and dis placement vane type pump The pump internal parts operate su...

Страница 826: ...look ing allow the vehicle to stand a few minutes and repeat the procedure CAUTION Do not run a vehicle with foamy fluid for an extended period This may cause pump damage REMOVAL AND INSTALLATION POW...

Страница 827: ...p Initial Operation DISASSEMBLY AND ASSEMBLY PUMP PULLEY DISASSEMBLY 1 Remove pump assembly 2 Remove pulley from pump with Puller C 4333 Fig 4 Fig 2 Pump Mounting Fig 3 Pump Reservoir 2 5L Fig 4 Pulle...

Страница 828: ...oir from pump body Remove and discard O ring seal ASSEMBLY 1 Lubricate new O ring Seal with Mopar Power Steering Fluid or equivalent 2 Install O ring seal in housing 3 Install reservoir onto housing 4...

Страница 829: ...Power Steering Pump Bracket to Pump 28 N m 21 ft lbs Bracket to Engine 47 N m 35 ft lbs Flow Control Valve 75 N m 55 ft lbs Pressure Line 28 N m 21 ft lbs SPECIAL TOOLS POWER STEERING PUMP Analyzer Se...

Страница 830: ...tio recircu lating ball type gear Fig 1 The ratio is 15 1 on cen ter reducing to 13 1 at the end of travel The gear acts as a rolling thread between the worm shaft and rack piston The worm shaft is su...

Страница 831: ...Fig 1 Recirculating Ball Type Gear 19 12 STEERING TJ DESCRIPTION AND OPERATION Continued...

Страница 832: ...ll power steering hoses tubes to steering gear and tighten to 28 N m 21 ft lbs 2 Install steering gear on the frame rail and tighten bolts to 95 N m 70 ft lbs 3 Align the column coupler shaft to steer...

Страница 833: ...g 6 3 Rotate the stub shaft with a 12 point socket from stop to stop and count the number of turns 4 Center the stub shaft by rotating it from the stop 1 2 of the total amount of turns 5 Remove side c...

Страница 834: ...nstall side cover bolts and tighten to 60 N m 44 ft lbs 13 Perform over center rotation torque adjust ment SPOOL VALVE DISASSEMBLY 1 Remove lock nut Fig 9 2 Remove adjuster nut with Spanner Wrench C 4...

Страница 835: ...oul der 4 Install O rings and teflon rings over the O rings on valve body 5 Install O ring into the back of the stub shaft cap Fig 16 6 Install stub shaft and valve assembly in the housing Line up wor...

Страница 836: ...pis ton onto the tool and hold the rack piston balls in place 7 Remove the rack piston and tool together from housing 8 Remove tool from rack piston 9 Remove rack piston balls 10 Remove clamp bolts c...

Страница 837: ...than the silver balls 4 Lubricate and install rack piston balls through return guide hole while turning worm shaft COUN TERCLOCKWISE Fig 22 5 Install remaining balls in guide using grease to hold the...

Страница 838: ...ise to perform adjustments WORM THRUST BEARING PRELOAD 1 Mount the gear carefully into a vise CAUTION Do not overtighten the vise on the gear case This may affect the adjustment 2 Remove adjuster plug...

Страница 839: ...al torque in this range Fig 29 This is the Over Cen ter Rotating Torque NOTE The stub shaft must rotate smoothly without sticking or binding 4 Rotate the stud shaft between 90 and 180 to the left of c...

Страница 840: ...Type Recirculating Ball Gear Ratio 15 to 13 1 Worm Shaft Bearing Preload 0 45 1 13 N m 4 10 in lbs Pitman Shaft Over Center Drag New Gear under 400 miles 0 45 0 90 N m 4 8 in lbs Worm Shaft Preload U...

Страница 841: ...or cor rosion If these conditions exist replace the tie rod A replacement seal can be installed if lubricant is in good condition Otherwise a complete replacement ball stud end should be installed CA...

Страница 842: ...ment sleeve and tie rod end Position clamp bolts Fig 2 2 Position the drag link at the steering linkage Install the drag link to the steering knuckle nut Do the same for the tie rod and pitman arm 3 T...

Страница 843: ...Studs 74 N m 55 ft lbs Clamp 49 N m 36 ft lbs Tie Rod Ends Ball Studs 74 N m 55 ft lbs Clamp 27 N m 20 ft lbs Tie Rod Ball Stud 88 N m 65 ft lbs Steering Damper Frame 74 N m 55 ft lbs Drag Link 74 N m...

Страница 844: ...OR THE AIRBAG COMPONENTS HAVE SPECIAL COAT INGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES ANYTIME A NEW FASTENER IS NEEDED REPLACE WITH THE C...

Страница 845: ...Remove clock spring Fig 7 switches SKIM if equipped and ignition key cylinder refer to Group 8 Electrical for service procedures INSTALLATION 1 Install upper column mounting bracket on non tilt column...

Страница 846: ...wheel and tighten nut to 54 N m 40 ft lbs NOTE If equipped with cruise control connect clock spring harness to cruise switch harness on the steering wheel 14 Install airbag refer to Group 8M Restrain...

Страница 847: ...nsmission with fifth gear being the overdrive range An adapter housing is used to attach the transmission to the transfer case on 4 wheel drive applications A stan dard style extension housing is used...

Страница 848: ...lica tions TRANSMISSION ASSEMBLY INFORMATION Lubricate the transmission components with Mopart 75W 90 GL 3 gear lubricant during assem bly Use petroleum jelly to lubricate seal lips and or hold parts...

Страница 849: ...dations will ensure an accurate check and avoid an underfill or overfill condition Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition HARD SHI...

Страница 850: ...ller shaft and rear axle yokes for installation alignment Fig 5 7 Mark front propeller shaft axle and transfer case yokes for installation alignment if equipped 8 Remove propeller shaft s 9 Unclip wir...

Страница 851: ...bolts 26 Pull transmission jack rearward until input shaft clears clutch Then slide transmission out from under vehicle 27 Remove clutch release bearing release fork and retainer clip 28 Remove clutc...

Страница 852: ...shaft 25 Align marks on rear propeller shaft and rear axle yokes Fig 10 26 Install and tighten propeller shaft U joint clamp bolts to 19 N m 170 in lbs torque 27 Align marks on front propeller shaft a...

Страница 853: ...that the seal is located 0 6 0 5 mm 0 6 0 02 in to the face of the extension housing Fig 13 3 Install propeller shaft Refer to Group 3 Differ ential and Driveline for proper procedures 4 Check and add...

Страница 854: ...ve bolts holding shift tower to transmis sion case 6 Remove shift tower from transmission case Fig 16 7 Remove shift tower gasket from shift tower or transmission case Fig 17 8 Remove detent ball plug...

Страница 855: ...18 On 4x2 transmissions a Remove speedometer gear retaining snap ring from output shaft b Remove speedometer gear from output shaft and remove speedometer gear lock ball from output shaft Fig 18 Clutc...

Страница 856: ...tainer to the transmission case 20 Remove the bearing retainer from transmis sion case Fig 29 Fig 22 Shift Arm Retainer Bolt Removal Fig 23 Shift Arm Rstrictor Pins Fig 24 Removing Shift Lever Shaft P...

Страница 857: ...transmission case intermediate plate and adapter extension hous ing 2 Apply a 1 8 to 3 16 inch wide bead of Threeb ondt Liquid Gasket TB1281 P N 83504038 as shown making sure to keep sealer bead to in...

Страница 858: ...N m 12 ft lbs 7 On 4x2 transmissions a Install speedometer drive gear locating snap ring Fig 37 b Install speedometer gear lock ball in output shaft and install speedometer gear onto output shaft c I...

Страница 859: ...hifter arm shaft in hole in back of adapter or extension housing Align shift arm and shifter arm shaft and insert shifter arm shaft through the shifter arm and into the forward portion of the adapter...

Страница 860: ...m 20 ft lbs Fig 43 16 Install shift detent ball in detent opening of case Fig 44 17 Install detent spring in case Fig 45 Fig 40 Install Shifter Arm Shaft Fig 41 Install Shift Arm Retainer Bolt Fig 42...

Страница 861: ...3 ft lbs torque 23 Install new metal o ring onto the backup lamp switch 24 Install backup lamp switch Fig 48 Tighten switch to 44 N m 32 5 ft lbs torque 25 Install new seal in adapter extension housin...

Страница 862: ...ail Fig 51 4 Remove fifth gear blocker ring from counter shaft assembly with Puller L 4407 Fig 52 5 Remove fifth gear synchro ring Fig 53 6 Remove the countershaft fifth gear assembly from countershaf...

Страница 863: ...re to retrieve the pin and compression spring from the reverse idler shaft 11 Remove bolts holding output shaft rear bear ing retainer to the intermediate plate and remove retainer Fig 58 12 Remove bo...

Страница 864: ...removed by moving the countershaft rearward and downward Fig 62 17 Remove the mainshaft by moving the main shaft forward until the mainshaft rear bearing is clear of the intermediate plate and then r...

Страница 865: ...e vise rotate the plate 180 and reinstall the plate in the vise using the same bolt and washer mounting set up CAUTION The interlock balls and pins are different sizes and shapes Be sure to correctly...

Страница 866: ...t rail and reverse shift fork and arm assembly from intermediate plate Fig 70 28 Remove interlock pin from reverse shift rail Fig 71 29 Remove reverse elongated check ball Fig 72 Fig 66 Remove Lock Ba...

Страница 867: ...Also verify that all shift rail components are in their neutral position when installing the check balls and interlock pins 1 Install the 3 4 shift rail into the intermediate plate 2 Install the 1 2...

Страница 868: ...all the reverse check ball into the interme diate plate Fig 78 7 Install the interlock pin into the reverse shift rail Fig 79 Fig 75 Shift Rail Components Fig 76 Install 1 2 Check Ball Fig 77 Install...

Страница 869: ...Install the fifth gear interlock ball and check ball Fig 83 13 Install fifth gear shift rail Fig 84 14 Remove the intermediate plate from the vise rotate the plate 180 and reinstall the plate in the...

Страница 870: ...of countershaft with inner race of counter shaft rear bearing 23 Raise countershaft upward until gears mesh with the mating gears on the mainshaft 24 Using a suitable rubber mallet tap on the input sh...

Страница 871: ...is a small relief cut above one of the main longitudinal slots Be sure that the pin is aligned with the proper slot the opposite slot has an oil drain hole which the pin will drop into The assembly w...

Страница 872: ...w bolt to hold fifth gear shift fork to the fifth gear shift rail Fig 95 48 Measure countershaft fifth gear thrust clear ance 49 Select a snap ring so that the thrust clearance is 0 10 0 30 mm 0 004 0...

Страница 873: ...earing rollers from the input shaft and the output shaft 4 Remove the fourth gear synchronizer ring from the input shaft Fig 98 5 Remove the select fit snap ring holding the input shaft bearing onto t...

Страница 874: ...ear snap ring with two screwdrivers Fig 102 4 Using Bearing Splitter P 334 or suitable press plates positioned under first gear press fifth gear rear bearing first gear and first gear bearing inner ra...

Страница 875: ...r bearing from the output shaft or second gear 10 Remove select fit snap ring holding the 3 4 synchronizer onto the output shaft Fig 106 11 Using Bearing Splitter P 334 or suitable press plates positi...

Страница 876: ...haft flange 5 Install third gear synchronizer ring to third gear 6 Position the 3 4 synchronizer onto the output shaft 7 Using Adapter 6747 1A and a shop press press the 3 4 synchronizer onto the outp...

Страница 877: ...aft Fig 111 18 Install first gear needle bearing onto output shaft Fig 112 19 Install first gear onto output shaft and over bearing 20 Install first gear bearing inner race onto out put shaft and insi...

Страница 878: ...rse idler gear synchronizer ring from the reverse idler gear hub race Fig 118 ASSEMBLY 1 Install the reverse idler gear synchronizer ring onto the reverse idler gear hub race Apply a film of 75W 90 GL...

Страница 879: ...e housing and intermediate plate with solvent and dry with compressed air Replace the case if cracked porous or if any of the bearing and gear bores are damaged Inspect the threads in the case housing...

Страница 880: ...aged Inspect the bearing surfaces and replace shaft if any surface shows damage or wear Check condition of the countershaft front bearing Replace the bearing if worn noisy or damaged GEAR AND SYNCHRON...

Страница 881: ...r Shaft Clamp 16 23 N m 140 200 in lbs Bolts Rear Mount to Transmission 33 60 N m 24 44 ft lbs Nut Rear Mount Clevis 54 75 N m 40 55 ft lbs Nuts Rear Mount to Crossmember 33 49 N m 24 36 ft lbs Pins R...

Страница 882: ...r Set C 3995 A Installer Extension Housing Seal C 4171 Handle Universal Tool 8211 Installer Seal 8212 Installer Seal 8208 Installer Seal P 334 Splitter Bearing 8109 Cup Installer L 4507 Tube Driver 21...

Страница 883: ...6747 1A Adapter Fixture MD 998805 Installer Seal TJ TRANSMISSION AND TRANSFER CASE 21 37 SPECIAL TOOLS Continued...

Страница 884: ...PONENTS 70 SPECIFICATIONS TORQUE 72 SPECIAL TOOLS AX15 73 GENERAL INFORMATION AX15 MANUAL TRANSMISSION The AX15 is a 5 speed synchromesh manual transmission Fifth gear is an overdrive range with a rat...

Страница 885: ...case Fig 3 The drain plug is located on the passenger side of the transmission case near the bottom Fig 4 Approximate dry fill lubricant capacity is 3 10 liters 3 27 qts for 4 wheel drive applica tio...

Страница 886: ...ations will ensure an accurate check and avoid an underfill or overfill condition Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition HARD SHIF...

Страница 887: ...ller shaft and rear axle yokes for installation alignment Fig 6 7 Mark front propeller shaft axle and transfer case yokes for installation alignment if equipped 8 Remove propeller shaft s 9 Unclip wir...

Страница 888: ...olts 26 Pull transmission jack rearward until input shaft clears clutch Then slide transmission out from under vehicle 27 Remove clutch release bearing release fork and retainer clip 28 Remove clutch...

Страница 889: ...ke to trans mission or transfer case if equipped output shaft 25 Align marks on rear propeller shaft and rear axle yokes Fig 11 26 Install and tighten propeller shaft U joint clamp bolts to 19 N m 170...

Страница 890: ...al Installer 8212 install new extension housing seal so that the seal is located 0 6 0 5 mm 0 6 0 02 in to the face of the extension housing Fig 14 3 Install propeller shaft Refer to Group 3 Differ en...

Страница 891: ...essary 5 Remove bolts holding shift tower to transmis sion case 6 Remove shift tower from transmission case Fig 17 7 Remove shift tower gasket from shift tower or transmission case Fig 18 8 Remove rev...

Страница 892: ...sion housing by tapping it loose with plastic mallet Fig 28 17 Remove adapter extension housing Fig 29 Fig 19 Clutch Housing Fig 20 Remove Detent Ball Plug Fig 21 Remove Detent Spring Fig 22 Remove De...

Страница 893: ...Shift Arm Rstrictor Pins Fig 25 Removing Shift Lever Shaft Plug Fig 26 Remove Shifter Shaft Fig 27 Adapter Extension Housing Bolts TJ TRANSMISSION AND TRANSFER CASE 21 47 DISASSEMBLY AND ASSEMBLY Con...

Страница 894: ...Fig 32 22 Remove cluster gear bearing snap ring Fig 33 23 Separate intermediate plate and transfer case by tapping them loose with plastic mallet Fig 34 24 Separate the intermediate plate from the tra...

Страница 895: ...bearing retainer sealing surface 6 Install the front bearing retainer Fig 39 and tighten bolts to 17 N m 12 ft lbs 7 On 4x2 transmissions a Install speedometer drive gear locating snap ring Fig 40 b...

Страница 896: ...sion housing Align shift arm and shifter arm shaft and insert shifter arm shaft through the shifter arm and into the forward portion of the adapter extension housing Fig 43 12 Rotate the shifter arm s...

Страница 897: ...46 16 Install shift detent ball in detent opening Fig 47 Fig 43 Install Shifter Arm Shaft Fig 44 Install Shift Arm Retainer Bolt Fig 45 Shifter Arm Shaft Plug Installation Fig 46 Install Shifter Rest...

Страница 898: ...on bolt heads 2 Measure thrust clearance between countershaft fifth gear and thrust ring with feeler gauge Clear ance should be 0 10 to 0 40 mm 0 003 to 0 019 in If clearance exceeds limits gear and o...

Страница 899: ...ise Fig 52 Remove Fifth Gear Snap ring Fig 53 Remove Fifth Gear Shift Fork Retainer Bolt Fig 54 Remove Fifth Gear Shift Fork Fig 55 Remove Reverse Shift Head Assembly TJ TRANSMISSION AND TRANSFER CASE...

Страница 900: ...ins used in various places in the transmission Whenever a pin or ball is removed it should be identified in such a way that it can be reinstalled in the same location from which it was removed Fig 56...

Страница 901: ...e Fig 65 18 Then remove lock ball and spring from plug holes with pencil magnet Fig 66 19 Remove the fifth gear shift rail Fig 67 20 Retrieve the fifth gear shift rail lock ball from the intermediate...

Страница 902: ...and the intermediate plate Fig 71 24 Remove the 3 4 shift rail interlock plug from the intermediate plate with a small magnet Fig 72 25 Remove the 3 4 shift fork Fig 73 26 Remove the 1 2 shift rail fr...

Страница 903: ...ng holding the reverse shift rail into the intermediate plate using two equally sized screwdrivers Fig 77 31 Remove the reverse shift rail and fork from the intermediate plate Fig 78 Fig 69 Remove Shi...

Страница 904: ...haft with a suitable rubber mallet This will release the countershaft from the counter shaft rear bearing and the mainshaft rear bearing from the intermediate plate The mainshaft will release from the...

Страница 905: ...mainshaft into the intermediate plate 3 Tap the mainshaft assembly rear bearing into the intermediate plate with a suitable rubber mallet 4 Install the countershaft thru the countershaft rear bearing...

Страница 906: ...mponents with petroleum jelly during assembly Petroleum jelly will hold com ponents in position during installation 10 Install interlock pin in reverse shift rail Fig 82 11 Install the reverse shift r...

Страница 907: ...the shift forks to the shift rails Fig 90 20 Install c rings to 1 2 and 3 4 shift rails Fig 91 Fig 86 Install 1 2 Shift Rail Interlock Pin Fig 87 Install 1 2 Shift Rail Fig 88 Install 3 4 Shift Rail I...

Страница 908: ...lts to hold retainer to interme diate plate Fig 93 26 Install the fifth gear thrust ring lock ball into the countershaft Fig 95 27 Install fifth gear thrust ring onto countershaft and over lock ball F...

Страница 909: ...assem bly Fig 101 36 Move reverse shift rail forward as far as pos sible and install fifth gear shift fork onto synchro nizer sleeve Fig 102 37 Install new bolt to hold fifth gear shift fork to shift...

Страница 910: ...bearing on end of countershaft Be sure the snap ring groove in bearing is facing forward 3 Using Special Tool 8109 and a shop press press bearing onto countershaft 4 Select the thickest snap ring that...

Страница 911: ...input shaft Be sure that the snap ring groove in the bearing is facing forward 2 Using Driver 6052 drive bearing onto input shaft 3 Select the thickest snap ring that will fit into the snap ring groo...

Страница 912: ...necessary 2 Measure and note thrust clearance of output shaft gears Fig 112 First gear clearance should be 0 10 0 40 mm 0 004 0 0197 in Second and third gear clearance should be 0 10 0 30 mm 0 003 0 0...

Страница 913: ...ing Splitter P 334 or suitable press plates positioned under second gear press 1 2 syn chronizer reverse gear and second gear from output shaft Fig 115 11 Remove second gear needle roller bearing from...

Страница 914: ...synchronizer onto the output shaft 8 Select the thickest snap ring that will fit into the snap ring groove of the output shaft Fig 119 9 Install snap ring to hold 3 4 synchronizer onto output shaft 10...

Страница 915: ...asher locating pin into the output shaft 23 Install the first gear thrust washer onto the output shaft Rotate the thrust washer until the washer locating pin aligns with the notch in the washer 24 Pos...

Страница 916: ...s with clean dry shop towels only Never use compressed air on the bearings This could cause severe damage to the bearing roller and race surfaces If output shaft flange thickness is within specifica t...

Страница 917: ...Replace the countershaft if any teeth are worn or damaged Inspect the bearing surfaces and replace shaft if any surface shows damage or wear Check condition of the countershaft front bearing Replace t...

Страница 918: ...ft lbs Nut Rear Mount Clevis 54 75 N m 40 55 ft lbs Nuts Rear Mount to Crossmember 33 49 N m 24 36 ft lbs Pins Restrictor 27 4 N m 20 ft lbs Bolts Reverse Shift Arm Bracket 18 N m 13 ft lbs Screw Shif...

Страница 919: ...C 3339 Dial Indicator Set C 4171 Handle Universal Tool 8209 Installer Seal 8212 Installer Seal 8208 Installer Seal L 4407A Puller Gear P 334 Splitter Bearing 8109 Cup Installer TJ TRANSMISSION AND TR...

Страница 920: ...6052 Tube Driver 6761 Adapter Installer MD 998805 Tube Driver L 4507 Tube Driver 21 74 TRANSMISSION AND TRANSFER CASE TJ SPECIAL TOOLS Continued...

Страница 921: ...CEDURE 95 REMOVAL AND INSTALLATION BRAKE TRANSMISSION SHIFT INTERLOCK 102 EXTENSION HOUSING 100 GEARSHIFT CABLE 102 GOVERNOR AND PARK GEAR 104 OUTPUT SHAFT REAR BEARING 104 PARK LOCK 105 PARK NEUTRAL...

Страница 922: ...ry causes 1 A result of restricted fluid flow through the main and or auxiliary cooler This condition is usu ally the result of a faulty or improperly installed drainback valve a damaged main cooler o...

Страница 923: ...Fig 1 30 32 RH Automatic Transmission TJ TRANSMISSION AND TRANSFER CASE 21 77 GENERAL INFORMATION Continued...

Страница 924: ...shift indicator is located on the console next to the gear shift The shift posi tions are Park P Reverse R Neutral N Drive D Manual Second 2 Manual Low 1 Manual low 1 range provides first gear only O...

Страница 925: ...ird gear is con trolled by sensor inputs to the powertrain control module Inputs that determine clutch engagement are coolant temperature vehicle speed and throttle position The torque converter clutc...

Страница 926: ...k up or move forward VEHICLE IS DRIVEABLE 1 Check for transmission fault codes using DRB scan tool 2 Check fluid level and condition 3 Adjust throttle and gearshift linkage if com plaint was based on...

Страница 927: ...ward force on center of shift handle Transmission shall not be able to shift from neutral to reverse THROTTLE VALVE CABLE Transmission throttle valve cable adjustment is extremely important to proper...

Страница 928: ...895 kPa governor pressure to 300 psi 2068 kPa at the rear servo pressure port in reverse An accurate tachometer and two test gauges are required for the pressure test Test Gauge C 3292 has a 100 psi...

Страница 929: ...on 4 Read pressures on both gauges as transmission throttle lever is moved from full forward to full rear ward position 5 Line pressure should be 54 60 psi 372 414 kPa with throttle lever forward and...

Страница 930: ...ted Stall Speed Low Low stall speed with a properly tuned engine indi cate a torque converter overrunning clutch problem The condition should be confirmed by road testing A stall speed 250 350 rpm bel...

Страница 931: ...d the true source of the leak Some suspected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter housing or excess fluid spilled during...

Страница 932: ...nverter clutch fault condi tions The hydraulic flow charts in the Schematics and Diagrams section of this group outline fluid flow and hydraulic circuitry Circuit operation is provided for neutral thi...

Страница 933: ...on and repair as necessary 10 Governor Valve Stuck 10 Remove and inspect governor components Replace worn or damaged parts 11 Regulator Valve Stuck 11 Clean 12 Cooler Plugged 12 Flush transmission coo...

Страница 934: ...l may be necessary Perform lube flow test Flush oil Replace cooler as necessary 5 Oil Pump Damaged 5 Perform pressure test to confirm low pressure Replace pump body assembly if necessary 6 Valve Body...

Страница 935: ...olts defective gasket Replace pump assembly if needed NO REVERSE D RANGES OK 1 Gearshift Linkage Cable Misadjusted Damaged 1 Repair or replace linkage parts as needed 2 Park Sprag Sticking 2 Inspect a...

Страница 936: ...aulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 5 Valve Body Malfunction 5 Sticking 1 2 2 3 shift valves or governor plugs STUCK IN L...

Страница 937: ...r pressure check clutch servo operation and repair as required 7 Band Linkage Binding 7 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level Low 1 Add fluid and check for leaks 2...

Страница 938: ...ernally 4 Check for leakage between passages in case 5 Servo Band or Linkage Malfunction 5 Air pressure check servo operation and repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clut...

Страница 939: ...Leaks Damaged 3 Replace O ring seal Inspect tube for cracks in tube 4 Pressure Port Plug Loose Loose Damaged 4 Tighten to correct torque Replace plug or reseal if leak persists 5 Pan Gasket Leaks 5 Ti...

Страница 940: ...t overfill CAUTION Do not overfill the transmission Overfill ing may cause leakage out the pump vent which can be mistaken for a pump seal leak Overfilling will also cause fluid aeration and foaming a...

Страница 941: ...evel is equal on both sides of the dipstick If one side is noticably higher than the other the dipstick has picked up some oil from the dipstick tube Allow the oil to drain down the dipstick tube and...

Страница 942: ...ransmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906 3 Verify pump power switch is turned OFF Con nect red al...

Страница 943: ...ill also be necessary to remove bolt attaching transfer case vent tube to converter hous ing 11 Mark torque converter and drive plate for assembly alignment Note that bolt holes in crank shaft flange...

Страница 944: ...or tilt transmission to align converter housing with engine block dowels 12 Rotate converter so alignment marks scribed on converter are aligned with mark on driveplate 13 Carefully work transmission...

Страница 945: ...ter from the transmission 3 Pull the torque converter forward until the cen ter hub clears the oil pump seal 4 Separate the torque converter from the trans mission INSTALLATION Check converter hub and...

Страница 946: ...over out put shaft Fig 21 4 Guide park shaft into park sprag and push extension housing forward until rod passes through opening behind sprag It may be necessary to use a wire to hold sprag to the sid...

Страница 947: ...n pinion gear 10 Install speedometer adapter clamp and retain ing screw Tighten clamp screw to 10 12 N m 90 110 in lbs torque 11 Connect wires to vehicle speed sensor 12 Lower vehicle and top off tran...

Страница 948: ...ument Panel and Gauges for proper procedure 2 Remove lower steering column shroud Refer to Group 19 Steering for proper procedure 3 Remove tie strap near the solenoid retaining the brake transmission...

Страница 949: ...dy forward to disengage park rod 10 Push manual lever shaft and solenoid case connector out of transmission case 11 Lower valve body rotate it away from case pull park lock rod out of sprag and remove...

Страница 950: ...ll speedometer pinion gear adapter and speed sensor 16 Lower vehicle 17 Fill transmission with Mopart ATF Plus 3 Type 7176 fluid 18 Adjust gearshift and throttle cable if neces sary OUTPUT SHAFT REAR...

Страница 951: ...31 7 Install extension housing and gasket on trans mission Tighten housing bolts to 32 N m 24 ft lbs 8 Install rear transmission mount and skid plate 9 Install speed sensor and speedometer compo nents...

Страница 952: ...ght from outer weight 6 Position intermediate weight on suitable size socket Fig 37 7 Push inner weight downward with nut driver Then remove inner weight snap ring with Miller Plier Tool 6823 Fig 37 8...

Страница 953: ...for reference as they are removed Do not allow them to become inter mixed 1 Remove screws attaching adjusting screw bracket to valve body and transfer plate Hold bracket firmly against spring force w...

Страница 954: ...main in place and not fall out when transfer plate is removed 16 Remove screws attaching transfer plate to valve body Fig 48 17 Remove transfer plate and separator plate from valve body Fig 48 Note po...

Страница 955: ...valve end plate Fig 51 22 Remove shuttle valve E clip and remove sec ondary spring and spring guides from end of valve Fig 52 Fig 45 Converter Clutch Solenoid Fig 46 Clutch Module And Connecting Tube...

Страница 956: ...Inspec tion section of this group for proper procedure CAUTION Do not force valves or plugs into place during reassembly If the valve body bores valves and plugs are free of distortion or burrs the v...

Страница 957: ...ing and shuttle valve into valve body Fig 53 Verify valve components slide freely 15 Install 1 2 and 2 3 shift valve governor plugs into valve body Fig 53 Verify valve components slide freely 16 Place...

Страница 958: ...mponents slide freely 30 Insert spring and fail safe valve into converter clutch valve module Fig 60 Verify valve compo nents slide freely 31 Place cover plate in position on converter clutch valve mo...

Страница 959: ...ve in manual valve Fig 67 44 Install seal washer and E clip to retain man ual shaft to valve body Fig 66 45 Install switch valve and spring pressure reg ulator valve and spring kickdown valve and spri...

Страница 960: ...ension housing 8 Remove fluid pan 9 Remove park neutral position switch and seal Fig 70 10 Remove valve body 11 Remove accumulator spring and piston Fig 71 NOTE The 32RH is equipped with an additional...

Страница 961: ...queeze front band together and remove band strut Fig 74 18 Remove front and rear clutch units as an assembly Grasp input shaft hold clutch units together and remove them from case Fig 75 19 Lift front...

Страница 962: ...train with both hands during removal Do not allow machined sur faces on output shaft to become nicked or scratched 26 Loosen rear band adjusting screw 4 5 turns Fig 80 27 Remove snap ring that secures...

Страница 963: ...double wrap band that does not require a link bar a Remove low reverse drum and overrunning clutch as assembly Slide drum and clutch through rear band and out of case Fig 84 Set drum and clutch assemb...

Страница 964: ...ng a 1 4 inch drive extension remove front band reaction pin access plug Fig 87 b Remove front band reaction pin with pencil magnet Pin is accessible from converter housing side of case Fig 88 c Remov...

Страница 965: ...ols and remove rear servo spring and piston ASSEMBLY 1 Install rear servo piston spring and spring retainer Compress rear servo spring and retainer with Compressor Tool C 3422 B Fig 92 or a large C cl...

Страница 966: ...e closest to the pan sealing face The awl should be next to the wide space area at the back of transmission case 11 Insert low reverse drum and overrunning clutch into front of transmission case and i...

Страница 967: ...99 Use petroleum jelly to hold thrust plate in place 27 Check rear clutch thrust washer Use addi tional petroleum jelly to hold washer in place if nec essary 28 Coat output shaft thrust washer with pe...

Страница 968: ...tainer Verify that front rear clutches are still seated before continuing 36 Verify that reaction shaft support hub seal rings are hooked together Fig 106 37 Coat front clutch thrust washer with petro...

Страница 969: ...y hand Then install two or three pump bolts to hold pump in place 42 Remove pilot stud tools and install remaining oil pump bolts Tighten bolts alternately in diagonal pattern to 20 N m 15 ft lbs 43 M...

Страница 970: ...spring assembly from the overrunning clutch race ASSEMBLY 1 Assemble clutch rollers and springs in retainer if necessary Fig 112 2 Install overrunning clutch roller spring and retainer assembly in clu...

Страница 971: ...e plug and spring from servo piston Fig 117 2 Remove and discard servo piston seal ring ASSEMBLY 1 Lubricate piston and guide seals with petro leum jelly Lubricate other servo parts with Mopart ATF Pl...

Страница 972: ...h and ham mer 7 Remove front clutch thrust washer from sup port hub Fig 122 OIL PUMP BUSHING REPLACEMENT 1 Remove pump bushing with Tool Handle C 4171 and Bushing Remover SP 3551 from Tool Set C 3887...

Страница 973: ...l Bushing Installer SP 5325 bottoms 9 Clean reaction shaft support thoroughly after installing bushing ASSEMBLY 1 Lubricate gear bore in pump housing with transmission fluid 2 Lubricate pump gears wit...

Страница 974: ...bolts to required torque as follows a Reverse pump assembly and install it in transmission case Position pump so bolts are fac ing out and are accessible b Secure pump assembly in case with 2 or 3 bo...

Страница 975: ...hub Discard both seals as they are not reus able ASSEMBLY 1 Soak clutch discs in transmission fluid while assembling other clutch parts 2 Install new seals on piston and in hub of retainer Be sure lip...

Страница 976: ...uge bar across the clutch drum with the dial indicator pointer on the pressure plate Fig 136 b Using two small screw drivers lift the pres sure plate and compress the waved snap ring This will assure...

Страница 977: ...nsmission fluid Then press input shaft into retainer Use a suitably sized press tool to support retainer as close to input shaft as possible 4 Install input shaft snap ring Fig 138 5 Invert retainer a...

Страница 978: ...Fig 137 13 Install top pressure plate 14 Install selective snap ring Be sure snap ring is fully seated in retainer groove 15 Using a suitable gauge bar and dial indicator measure clutch pack clearance...

Страница 979: ...remove driving shell rear plane tary and rear annulus from output shaft Fig 148 8 Remove front planetary rear thrust washer from driving shell 9 Remove tabbed thrust washers from rear plan etary gear...

Страница 980: ...n sun gear Fig 153 Note that driving shell thrust plates are interchangeable Use either plate on sun gear and at front rear of shell 9 Hold sun gear in place and install thrust plate over sun gear at...

Страница 981: ...e enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated 16 Assemble front annulus gear and support if necessary Be sure support snap ring is seated 17 Install fron...

Страница 982: ...ents to move forward for accurate end play check 23 Check planetary geartrain end play with feeler gauge Fig 164 Gauge goes between shoulder on output shaft and end of rear annulus support 24 Geartrai...

Страница 983: ...place the filter if damaged Inspect the park gear for chipped or worn gear teeth or damaged ring grooves Replace the gear if damaged Check the teeth on the park gear for wear or dam age Replace the ge...

Страница 984: ...tion plug spring clip only enough to remove and install it Do not distort the clip during removal or installation Fig 165 Governor Weights Fig 166 Governor Components 21 138 TRANSMISSION AND TRANSFER...

Страница 985: ...ipe off valve body components Lint from these materials will adhere to the valve body components Lint will interfere with valve operation and may clog filters and fluid passages Inspect the throttle a...

Страница 986: ...to view the bore interiors Replace the valve body if any bores are distorted or scored Inspect all of the valve body springs The springs must be free of distortion warpage or broken coils Trial fit e...

Страница 987: ...NG CLUTCH LOW REVERSE DRUM OVERDRIVE PISTON RETAINER Clean the overrunning clutch assembly clutch cam low reverse drum and overdrive piston retainer in solvent Dry them with compressed air after clean...

Страница 988: ...0075 in Measure clearance with an appropriate feeler gauge FRONT CLUTCH Clean and inspect the front clutch components Replace the clutch discs if warped worn scored burned or charred or if the facing...

Страница 989: ...Be sure the oil passages are open and clear Replace the shaft if scored pitted or damaged Inspect the sun gear and driving shell If either component is worn or damaged remove the sun gear rear retain...

Страница 990: ...sition f Return transmission to the PARK position without applying the brake 8 Move shift lever back to PARK and check igni tion switch operation You should be able to turn switch to LOCK position and...

Страница 991: ...fully closed position Then be sure lever on throttle body is at curb idle position 5 Insert a small screwdriver under edge of retaining clip and remove retaining clip 6 Center cable end on attachment...

Страница 992: ...s shift quality and timing As a result both adjustments must be performed properly and in the correct sequence Adjust line pressure first and throttle pressure last LINE PRESSURE ADJUSTMENT Measure di...

Страница 993: ...top screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool NOTE The kickdown valve spring must be fully compressed and the kickdown valve completely botto...

Страница 994: ...HYDRAULIC FLOW IN PARK NEUTRAL 21 148 TRANSMISSION AND TRANSFER CASE TJ SCHEMATICS AND DIAGRAMS Continued...

Страница 995: ...HYDRAULIC FLOW IN D FIRST GEAR TJ TRANSMISSION AND TRANSFER CASE 21 149 SCHEMATICS AND DIAGRAMS Continued...

Страница 996: ...HYDRAULIC FLOW IN D SECOND GEAR 21 150 TRANSMISSION AND TRANSFER CASE TJ SCHEMATICS AND DIAGRAMS Continued...

Страница 997: ...HYDRAULIC FLOW IN D THIRD GEAR TJ TRANSMISSION AND TRANSFER CASE 21 151 SCHEMATICS AND DIAGRAMS Continued...

Страница 998: ...HYDRAULIC FLOW IN D THIRD GEAR CONVERTER CLUTCH APPLIED 21 152 TRANSMISSION AND TRANSFER CASE TJ SCHEMATICS AND DIAGRAMS Continued...

Страница 999: ...HYDRAULIC FLOW AT PART THROTTLE 3 2 KICKDOWN TJ TRANSMISSION AND TRANSFER CASE 21 153 SCHEMATICS AND DIAGRAMS Continued...

Страница 1000: ...HYDRAULIC FLOW AT FULL THROTTLE 3 2 KICKDOWN 21 154 TRANSMISSION AND TRANSFER CASE TJ SCHEMATICS AND DIAGRAMS Continued...

Страница 1001: ...HYDRAULIC FLOW IN MANUAL SECOND TJ TRANSMISSION AND TRANSFER CASE 21 155 SCHEMATICS AND DIAGRAMS Continued...

Страница 1002: ...HYDRAULIC FLOW IN MANUAL LOW 21 156 TRANSMISSION AND TRANSFER CASE TJ SCHEMATICS AND DIAGRAMS Continued...

Страница 1003: ...HYDRAULIC FLOW IN REVERSE TJ TRANSMISSION AND TRANSFER CASE 21 157 SCHEMATICS AND DIAGRAMS Continued...

Страница 1004: ...HYDRAULIC FLOW IN MANUAL FIRST GEAR 1 21 158 TRANSMISSION AND TRANSFER CASE TJ SCHEMATICS AND DIAGRAMS Continued...

Страница 1005: ...HYDRAULIC FLOW IN MANUAL SECOND GEAR 2 TJ TRANSMISSION AND TRANSFER CASE 21 159 SCHEMATICS AND DIAGRAMS Continued...

Страница 1006: ...ns 30RH Rear Band adjustment from 41 in lbs Back off 7 turns Recommended fluid MoparT ATF Plus 3 Type 7176 THRUST WASHER SPACER SNAP RING DIMENSIONS COMPONENT METRIC INCH Front clutch thrust washer re...

Страница 1007: ...N TORQUE Bolt torque convertor 31 N m 23 ft lbs Bolt nut crossmember 68 N m 50 ft lbs Bolt driveplate to crankshaft 75 N m 55 ft lbs Plug front band reaction 17 N m 13 ft lbs Locknut front band adj 34...

Страница 1008: ...e C 3292 Pressure Gauge C 3293SP Dial Indicator C 3339 Spring Compressor C 3422 B Fixture Engine Support C 3487 A Spring Compressor C 3575 A Spring Compressor C 3863 A 21 162 TRANSMISSION AND TRANSFER...

Страница 1009: ...pair Stand C 3750 B Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 Seal Installer C 3860 A Bushing Remover Installer C 3887 J Cup Remover SP 3633 Remover Bushing SP 5301 TJ TRANSMISSION AND...

Страница 1010: ...staller Bushing SP 5302 Remover Bushing SP 3550 Remover Bushing SP 3629 Installer Bushing SP 5511 Snap ring Plier C 3915 Seal Remover C 3985 B Bushing Remover 6957 21 164 TRANSMISSION AND TRANSFER CAS...

Страница 1011: ...Flusher Oil Cooler 6906 Installer C 3995 A Universal Handle C 4171 Remover Installer C 4470 Nut Bushing Remover SP 1191 TJ TRANSMISSION AND TRANSFER CASE 21 165 SPECIAL TOOLS Continued...

Страница 1012: ...izer mechanism for shifting The geartrain is mounted in two aluminum case halves attached with bolts The mainshaft front and rear bearings are mounted in aluminum retainer housings bolted to the case...

Страница 1013: ...r case components binding worn or damaged 5 Repair or replace components as necessary Transfer case noisy in all drive modes 1 Insufficient or incorrect lubricant 1 Drain and refill transfer case with...

Страница 1014: ...ller shafts Refer to Group 3 Differential and Driveline for proper proce dures and specifications 9 Fill transfer case with correct fluid Check transmission fluid level Correct as necessary 10 Install...

Страница 1015: ...apter Fig 4 if necessary 3 Lubricate sensor and adapter O rings with transmission fluid 4 Install vehicle speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 N m 15 27 in lbs tor...

Страница 1016: ...tapping seal into bore until installer tool seats against case DISASSEMBLY AND ASSEMBLY NV231 TRANSFER CASE DISASSEMBLY Position transfer case on shallow drain pan Remove drain plug and drain lubrican...

Страница 1017: ...rear case half Fig 12 11 Remove snap ring holding oil pump in position on output shaft 12 Disengage oil pickup tube from oil pump and remove oil pump assembly Remove oil pump by tilt ing the edge of...

Страница 1018: ...ol is positioned on yoke and not on slinger as slinger will be damaged 4 Remove seal washer from front output shaft Discard washer as it should not be reused 5 Remove nut and washer that attach range...

Страница 1019: ...tube from rear case Fig 20 6 Remove mode fork spring Fig 21 7 Pull front output shaft upward and out of front output shaft bearing Fig 22 8 Remove front output shaft and chain SHIFT FORKS AND MAINSHA...

Страница 1020: ...MAINSHAFT DISASSEMBLY 1 Remove mode hub retaining ring with heavy duty snap ring pliers Fig 28 2 Slide mode hub off mainshaft Fig 29 3 Slide drive sprocket off mainshaft Fig 30 INPUT GEAR AND LOW RAN...

Страница 1021: ...duty snap ring pliers Fig 33 5 Place front case in horizontal position Then remove input gear and low range gear as an assem bly Fig 34 Tap gear out of bearing with plastic mallet if necessary Fig 28...

Страница 1022: ...automatic transmission fluid or petroleum jelly where indicated during assembly BEARING AND SEAL INSTALLATION CAUTION The bearing bores in various transfer case components contain oil feed holes Make...

Страница 1023: ...case groove Be sure ring is fully seated before proceeding 6 Install new front output seal in front case with Installer Tool 8143 as follows a Place new seal on tool Garter spring on seal goes toward...

Страница 1024: ...s gear opening in the case Fig 49 10 Install locating ring on new bearing 11 Position case so forward end is facing upward 12 Using Remover C 4210 and Handle C 4171 drive input shaft bearing into case...

Страница 1025: ...andle C 4171 Fig 52 15 Remove front bearing retainer seal with suit able pry tool 16 Install new front bearing retainer seal with Installer 7884 Fig 53 Fig 48 Output Shaft Rear Bearing Installation De...

Страница 1026: ...put gear is fully seated 4 Install remaining thrust washer in low range gear and on top of input gear Be sure washer tabs are properly aligned in gear notches 5 Install retainer on input gear and inst...

Страница 1027: ...rive sprocket onto mainshaft 3 Slide mode hub onto mainshaft 4 Install mode hub retaining ring Verify that the retaining ring is fully seated in mainshaft groove SHIFT FORKS AND MAINSHAFT INSTALLATION...

Страница 1028: ...goes through range fork and into case bore Also be sure sleeve is aligned and seated on mainshaft hub 10 Rotate sector to Neutral position 11 Install new O ring on detent plug Fig 67 12 Lubricate det...

Страница 1029: ...e 3 Install new pickup tube O ring in oil pump Fig 71 4 Insert oil pickup tube in oil pump inlet 5 Position assembled oil pump and pickup tube in rear case Be sure pickup screen is securely seated in...

Страница 1030: ...front output shaft Fig 76 4 Lubricate yoke hub with transmission fluid and install yoke on front shaft 5 Install new seal washer on front shaft 6 Install yoke and new yoke nut on front output shaft F...

Страница 1031: ...feed passages in the case halves retainers gears and shafts The oil pickup screen can be cleaned with solvent Shake excess solvent from the screen after cleaning and allow it to air dry Do not use com...

Страница 1032: ...if the pads are worn or damaged Check both of the sleeves for wear or damage especially on the interior teeth Replace the sleeves if wear or damage is evident REAR RETAINER BEARING SEAL SLINGER BOOT I...

Страница 1033: ...FRONT RETAINER Inspect the cases and retainer for wear and dam age Clean the sealing surfaces with a scraper and 3M all purpose cleaner This will ensure proper sealer adhesion at assembly Replace the...

Страница 1034: ...Fig 84 Rear Retainer Components Fig 85 Seal Contact Surface Of Yoke Slinger Fig 86 Low Range Annulus Gear 21 188 TRANSMISSION AND TRANSFER CASE TJ ADJUSTMENTS Continued...

Страница 1035: ...ft lbs Bolt Case Half 27 34 N m 20 25 ft lbs Nut Front Yoke 122 176 N m 90 130 ft lbs Nut Range Lever 27 34 N m 20 25 ft lbs Bolt Rear Retainer 35 46 N m 26 34 ft lbs Nuts Mounting 29 40 N m 22 30 ft...

Страница 1036: ...5 A Installer Seal 8143 Handle Universal C 4171 Installer Seal C 4210 Installer Bearing 5064 Installer Bearing 5065 Installer Bushing 5066 Installer Bearing 8128 21 190 TRANSMISSION AND TRANSFER CASE...

Страница 1037: ...Remover L 4454 Cup 8148 Installer Seal 7884 Installer Pump Housing Seal 7888 TJ TRANSMISSION AND TRANSFER CASE 21 191 SPECIAL TOOLS Continued...

Страница 1038: ...w of the driving habits which will shorten the life of any tire are Rapid acceleration Severe brake applications High speed driving Excessive speeds on turns Striking curbs and other obstacles Radial...

Страница 1039: ...emer gency use only The original tire should be repaired or replaced at the first opportunity and reinstall Do not exceed speeds of 50 MPH Refer to Owner s Man ual for complete details TIRE INFLATION...

Страница 1040: ...quipment tires provide a proper bal ance of many characteristics such as Ride Noise Handling Durability Tread life Traction Rolling resistance Speed capability It is recommend that tires equivalent to...

Страница 1041: ...at the factory Match mounting is a technique used to reduce runout in the wheel tire assembly This means that the high spot of the tire is aligned with the low spot on the wheel rim The high spot on t...

Страница 1042: ...S For proper repairing a radial tire must be removed from the wheel Repairs should only be made if the defect or puncture is in the tread area Fig 11 The tire should be replaced if the puncture is loc...

Страница 1043: ...applying warm water and let it soak for a few minutes Then scrub the coating away with a soft bristle brush Steam cleaning may also be used to remove the coating NOTE DO NOT use gasoline mineral oil...

Страница 1044: ...acement studs or nuts with a different design or lesser quality DIAGNOSIS AND TESTING WHEEL INSPECTION Inspect wheels for Excessive run out Dents or cracks Damaged wheel lug nut holes Air Leaks from a...

Страница 1045: ...runout Fig 4 STEEL WHEELS Radial runout 0 040 in Lat eral runout 0 045 in maximum ALUMINUM WHEELS Radial runout 0 030 in Lateral runout 0 035 in maximum 3 If point of greatest wheel lateral runout is...

Страница 1046: ...le Replacement with used wheels is not recommended Their service history may have included severe treat ment TIRE AND WHEEL BALANCE It is recommended that a two plane service dynamic balancer be used...

Страница 1047: ...on the inner rim flange and the other half on the outer rim flange Fig 6 For dynamic balancing the balancing equipment is designed to locate the amount of weight to be applied to both the inner and o...

Страница 1048: ...stem can result Do not use abrasive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning sol vents on painted or upholstered surfaces Damage...

Страница 1049: ...ian CAUTION Do not remove clear coat finish more than 5 mils if equipped Use a paint thickness gauge to verify paint thickness Base coat paint must retain clear coat for durability PAINTED SURFACE TOU...

Страница 1050: ...4468 CHA98 VB3 HMR9B Gun Metal Pearl Coat TQ7 5248 B9735 52952 CHA97 TQ7 ERA9B Black Clear Coat DX8 9700 99 34858 90 5950 CHA85 DX8 TC60B Stone White Clear Coat SW1 83542 B9622 51539 CHA96 SW1 8KY5B H...

Страница 1051: ...Apply the hardener resin mixture to both sides of the fiberglass cloth 10 Place the fiberglass cloth over the repair sur face area Next place the aluminum foil over the cloth Use a plastic spreader t...

Страница 1052: ...WITH GLASS CAUTION Protect all painted and trimmed surfaces from coming in contact with urethane or primers Be careful not to damage painted surfaces when removing moldings or cutting urethane around...

Страница 1053: ...are vis ible 9 Apply Glass Primer 25 mm 1 in wide around perimeter of windshield Allow at least three minutes drying time 10 Apply Pinchweld primer 15 mm 75 in wide around the windshield fence Allow...

Страница 1054: ...the window glass with naphtha or a similar product 8 Apply molding to perimeter of quarter glass The butt weld of the molding should be centered at the bottom edge of the quarter glass 9 Apply Glass...

Страница 1055: ...separate the seatback from the seat cushion INSTALLATION 1 Position the seatback on the seat cushion while routing the recliner handle through the cushion cover opening 2 Passenger seat and driver dum...

Страница 1056: ...t bracket 7 Install seat BUCKET SEAT CUSHION COVER REMOVAL 1 Remove seat 2 Remove seatback 3 Disengage inboard J strap 4 Disengage front J strap 5 Roll cover up to access hog rings 6 Disengage inboard...

Страница 1057: ...corners 6 Install the seatback 7 Install rear seat REAR SEAT CUSHION COVER REMOVAL 1 Remove rear seat 2 Remove the seatback 3 Disengage the J straps at the rear cushion cor ners 4 Disengage the seat...

Страница 1058: ...26 HALF DOOR OUTSIDE HANDLE 26 HALF DOOR TRIM PANEL 25 HALF DOOR WEATHERSTRIP 27 HALF DOOR WINDOW 28 HARD TOP 28 HARD TOP AIR EXHAUSTER 29 HARD SOFT TOP LATCH 30 HOOD 12 HOOD HINGE 13 HOOD SAFETY LATC...

Страница 1059: ...mber valence cover 3 Remove the radiator overflow bottle 4 Remove the bolts that attach the radiator and shroud from the grille panel 5 If A C equipped a Evacuate the system b Disconnect the high and...

Страница 1060: ...4 Using a wax pencil mark the position of the hinge on the hood for installation alignment refer ence 5 Remove the screws attaching the hinge to the hood Fig 2 6 Separate the hinge from the hood INSTA...

Страница 1061: ...igned or dam aged seals may allow water to enter the HEVAC 1 Position the cowl screen and grille on the cowl 2 Install the screws that attach the grille and screen to the cowl WINDSHIELD FRAME REMOVAL...

Страница 1062: ...R FRAME WEATHERSTRIP REMOVAL The lower windshield frame weatherstrip can be removed with the frame tilted forward to the full hor izontal position 1 Mark the position of the wiper arms and remove the...

Страница 1063: ...e of masking tape above or below the decal as a reference mark 3 Start at one end of the decal and apply heat with a heat gun Slowly peel the decal from the panel by pulling it back Do not pull the de...

Страница 1064: ...the battery temperature sensor con nector 10 Disengage the vacuum line at the reservoir under the battery tray reinforcement bracket 11 Disengage the headlamp wire connector 12 Route the fog lamp if...

Страница 1065: ...BS Hydraulic Control Unit HCU to the support tray 7 Secure the HCU 8 Remove the HCU tray 9 Disengage the front end lighting wire harness retainers on the fender 10 Disengage the headlamp wire connecto...

Страница 1066: ...the bolts 11 Install EVAP canister 12 Install horns 13 Engage horn wire connectors 14 Install the windshield washer reservoir 15 Connect the negative terminal on the battery BODY SIDE MOLDING REMOVAL...

Страница 1067: ...upward and separate the trim panel from the door INSTALLATION 1 Position the trim panel on the door 2 Press the push in fasteners attaching trim panel to door into place 3 Install the screws attaching...

Страница 1068: ...ces sary FULL DOOR OUTSIDE RELEASE HANDLE REMOVAL 1 Remove the door trim panel 2 Position the window in the full upward posi tion 3 Remove the grab handle support bracket Fig 20 4 Peel back the waterd...

Страница 1069: ...Disconnect the lock cylinder to latch rod Fig 23 4 Disconnect the lock knob to latch rod 5 Disconnect the outside handle to latch rod 6 Remove the screws attaching the latch to the door Fig 24 7 Lower...

Страница 1070: ...or glass run channel from the door sail 3 Roll glass fully downward 4 Remove the door sail panel Fig 27 and Fig 28 5 Roll glass 1 4 upward to access regulator arm guide 6 Remove the screws that attach...

Страница 1071: ...e the door glass 4 Grasp the glass run channel weatherstrip in the door Fig 30 and pull from the channel INSTALLATION Applying a small amount of lubricant to the weath erstrip may ease the installatio...

Страница 1072: ...the upper and lower weatherstrip channels ensuring that the weather strip is completely engaged to the weatherstrip chan nels FULL DOOR WINDOW REGULATOR REMOVAL 1 Remove door trim panel 2 Remove door...

Страница 1073: ...door hinge are the same as the full door hinge Refer to Full Door Hinge Removal Installation procedures in this group HALF DOOR OUTSIDE HANDLE REMOVAL 1 Remove trim panel 2 Disconnect the outside han...

Страница 1074: ...ck knob to latch rod 7 Connect the lock cylinder to latch rod Fig 36 8 Install trim panel HALF DOOR LATCH STRIKER REMOVAL 1 Remove the screws attaching the striker to the body 2 Separate the striker a...

Страница 1075: ...trip in the weatherstrip channel ensuring that the weatherstrip is fully engaged in the weatherstrip channel 5 Install window retaining sleeve 6 Install trim panel HALF DOOR WINDOW REMOVAL 1 Open the...

Страница 1076: ...hard top disengage one edge of exhauster from hard top 2 Separate the air exhauster from the hard top INSTALLATION 1 Position the air exhauster on the hard top 2 Press air exhauster into opening in h...

Страница 1077: ...ric to the front roof bow and fold back fabric 5 Separate the soft top fabric from the frame INSTALLATION 1 Position the soft top fabric on the frame 2 Install the screws attaching the soft top fabric...

Страница 1078: ...HE RETRACTOR IS INOPERATIVE FRONT SHOULDER LAP BELT AND RETRACTOR REMOVAL 1 Move front seat to the full forward position 2 Remove the bolt attaching the retractor to the sport bar Fig 51 3 Using a sma...

Страница 1079: ...RETRACTOR AND BUCKLE REPLACE THE BELT OR BUCKLE THAT IS EITHER CUT FRAYED TORN OR DAMAGED REPLACE THE BELT IF THE RETRACTOR IS INOPERATIVE SEAT LAP BELT AND RETRACTOR REMOVAL 1 Move the rear seat to...

Страница 1080: ...holes 2 Install the anchor bolt Tighten the bolt to 43 N m 32 ft lbs torque 3 Move the rear seat back to the latch position BUCKET SEAT REMOVAL 1 Disengage seat belt electrical connector Fig 58 2 Remo...

Страница 1081: ...e console upward and shift transmission to L 2nd gear for man trans 9 Remove console through the passenger door INSTALLATION 1 Position and align the console in the vehicle 2 Install the bolts attachi...

Страница 1082: ...r from the console cover INSTALLATION 1 Insert the assembled lock in the console cover hole and position the retainer on the lock and install the screw SHIFT BOOT REMOVAL 1 Using a trim stick pry the...

Страница 1083: ...h the pivot brackets 2 Install the hitch pins on the seat frame pivot pins 3 Move the seat back to the latch position and engage the strikers with the latch brackets ADD A TRUNK REMOVAL 1 Release latc...

Страница 1084: ...trunk 3 Return the rear seat to the full rearward posi tion SPORT BAR REMOVAL 1 Remove hard top and or soft top 2 Remove the door opening frames 3 Remove the sunvisors 4 Remove the A pillar weatherstr...

Страница 1085: ...to 40 N m 30 ft lbs torque 8 Return seat back to upright position 9 Install the bolts attaching the sport bar to the cargo floor panel and install the center carpet Tighten the bolts to 40 N m 30 ft l...

Страница 1086: ...th saturated with isopropyl rubbing alcohol Finally clean the glass with a paper towel dampened with alcohol 3 Sand the surface on the support bracket with fine grit sandpaper Wipe the bracket surface...

Страница 1087: ...frame 2 Install the screws that attach the sunvisor arm support brackets to the frame Tighten the screws securely WHEELHOUSE SPLASH SHIELD REMOVAL 1 Remove the plastic push pins that attach the splash...

Страница 1088: ...DISASSEMBLE OR REPAIR THE SUP PORT RODS 3 Open the tailgate and liftgate 4 Remove support rod cylinders 5 Remove the bolts attaching the liftgate hinge to the hardtop Fig 76 6 Separate the liftgate gl...

Страница 1089: ...liftgate glass SPARE TIRE CARRIER REMOVAL 1 Remove the spare tire from the wheel bracket Fig 78 2 Remove the bolts that attach the tire bracket to the tailgate Fig 79 3 Disconnect CHMSL 4 Remove the...

Страница 1090: ...e body and tailgate Fig 82 3 Separate the hinge from the tailgate INSTALLATION 1 Prepare and paint the replacement hinge to match the body paint color 2 Lubricate the hinge with spray lubricant 3 Alig...

Страница 1091: ...AL 1 Remove the striker from the bracket with a Torx bit 2 Remove the shim washers from the bracket 3 Remove the screws attaching the striker bracket to the body INSTALLATION 1 Position the striker br...

Страница 1092: ...JUSTMENTS HOOD ADJUSTMENT The hood hinge screw holes are oversized to facili tate hood adjustment movement 1 Loosen the screws 2 Move the hood in the direction s required for correct alignment 3 Tight...

Страница 1093: ...LB 2 EP 2 Tailgate Hinge As Required Multi Purpose Grease NLGI GC LB 2 EP 2 Liftgate Support Arms As Required Engine Oil Tailgate Latches As Required White Spray Lubricant 3 Tailgate Release Handle A...

Страница 1094: ...WELD LOCATIONS DASH COWL AND PLENUM TJ BODY 23 47 SPECIFICATIONS Continued...

Страница 1095: ...DASH COWL AND PLENUM 23 48 BODY TJ SPECIFICATIONS Continued...

Страница 1096: ...DASH COWL AND PLENUM TJ BODY 23 49 SPECIFICATIONS Continued...

Страница 1097: ...DASH COWL AND PLENUM 23 50 BODY TJ SPECIFICATIONS Continued...

Страница 1098: ...DASH COWL AND PLENUM TJ BODY 23 51 SPECIFICATIONS Continued...

Страница 1099: ...DASH COWL AND PLENUM SUPPORTS AND REINFORCEMENTS 23 52 BODY TJ SPECIFICATIONS Continued...

Страница 1100: ...DASH COWL AND PLENUM SUPPORTS AND REINFORCEMENTS TJ BODY 23 53 SPECIFICATIONS Continued...

Страница 1101: ...DASH COWL AND PLENUM SUPPORTS AND REINFORCEMENTS 23 54 BODY TJ SPECIFICATIONS Continued...

Страница 1102: ...DASH COWL AND PLENUM SUPPORTS AND REINFORCEMENTS TJ BODY 23 55 SPECIFICATIONS Continued...

Страница 1103: ...FRONT FLOOR STRAINER REINFORCEMENT AND COWL SIDE LOWER 23 56 BODY TJ SPECIFICATIONS Continued...

Страница 1104: ...FRONT FLOOR STRAINER REINFORCEMENT AND COWL SIDE LOWER TJ BODY 23 57 SPECIFICATIONS Continued...

Страница 1105: ...FRONT FLOOR STRAINER REINFORCEMENT AND COWL SIDE LOWER 23 58 BODY TJ SPECIFICATIONS Continued...

Страница 1106: ...FRONT FLOOR STRAINER REINFORCEMENT AND COWL SIDE LOWER TJ BODY 23 59 SPECIFICATIONS Continued...

Страница 1107: ...SIDE APERTURE 23 60 BODY TJ SPECIFICATIONS Continued...

Страница 1108: ...SIDE APERTURE TJ BODY 23 61 SPECIFICATIONS Continued...

Страница 1109: ...SIDE APERTURE 23 62 BODY TJ SPECIFICATIONS Continued...

Страница 1110: ...SIDE APERTURE TJ BODY 23 63 SPECIFICATIONS Continued...

Страница 1111: ...SIDE APERTURE 23 64 BODY TJ SPECIFICATIONS Continued...

Страница 1112: ...WHEELHOUSE TJ BODY 23 65 SPECIFICATIONS Continued...

Страница 1113: ...WHEELHOUSE 23 66 BODY TJ SPECIFICATIONS Continued...

Страница 1114: ...WHEELHOUSE TJ BODY 23 67 SPECIFICATIONS Continued...

Страница 1115: ...REAR FLOOR PAN AND REINFORCEMENTS 23 68 BODY TJ SPECIFICATIONS Continued...

Страница 1116: ...REAR FLOOR PAN AND REINFORCEMENTS TJ BODY 23 69 SPECIFICATIONS Continued...

Страница 1117: ...REAR FLOOR PAN AND REINFORCEMENTS 23 70 BODY TJ SPECIFICATIONS Continued...

Страница 1118: ...DOOR OUTER PANELS TJ BODY 23 71 SPECIFICATIONS Continued...

Страница 1119: ...DOOR OUTER PANELS 23 72 BODY TJ SPECIFICATIONS Continued...

Страница 1120: ...SEALER LOCATIONS APPLICATION METHODS TJ BODY 23 73 SPECIFICATIONS Continued...

Страница 1121: ...COWL AND PLENUM 23 74 BODY TJ SPECIFICATIONS Continued...

Страница 1122: ...COWL TOP END AND PLENUM TJ BODY 23 75 SPECIFICATIONS Continued...

Страница 1123: ...COWL AND WINDSHIELD OUTER PANEL INNER WHEELHOUSE 23 76 BODY TJ SPECIFICATIONS Continued...

Страница 1124: ...REAR FLOOR RISER AND OUTER BODY SEAMS REAR CORNER PANEL TJ BODY 23 77 SPECIFICATIONS Continued...

Страница 1125: ...HALF DOOR FULL DOOR 23 78 BODY TJ SPECIFICATIONS Continued...

Страница 1126: ...OR OPENING A Center of radius at bottom front to center of radius at top rear B Center of door lower rear corner to center of top of windshield frame C Center of door lower rear corner to top of cowl...

Страница 1127: ...QUARTER WINDOW OPENING 23 80 BODY TJ SPECIFICATIONS Continued...

Страница 1128: ...ENGINE COMPARTMENT TJ BODY 23 81 SPECIFICATIONS Continued...

Страница 1129: ...FTGATE OPENING A Center of liftgate opening to floor B Center of radius upper corner to center of body and floor corner C Liftgate opening distance D Tailgate opening distance 23 82 BODY TJ SPECIFICAT...

Страница 1130: ...Front retractor bolt 47 N m 35 ft lbs Rear retractor bolt 47 N m 35 ft lbs Rear turning loop bolt 47 N m 35 ft lbs Rear belt anchor bolt 47 N m 35 ft lbs Rearview mirror setscrew 1 N m 9 in lbs Rear b...

Страница 1131: ...ER MOTOR RESISTOR 19 BLOWER MOTOR SWITCH 19 COMPRESSOR 19 COMPRESSOR CLUTCH COIL 20 COMPRESSOR CLUTCH RELAY 20 HEATER PERFORMANCE 13 HIGH PRESSURE CUT OFF SWITCH 21 LOW PRESSURE CYCLING CLUTCH SWITCH...

Страница 1132: ...of the output air tem perature of the system The mode control knob on the heater only or heat er A C control panel is used to direct the conditioned air to the selected system outlets Both mode contro...

Страница 1133: ...over the refrigerant before opening any fit ting or connection Open the fittings with caution even after the system has been discharged Never open or loosen a connection before recovering the refriger...

Страница 1134: ...d one side of the connection stationary while loosening or tightening the other side of the connec tion with a second wrench The refrigerant must be recovered completely from the system before opening...

Страница 1135: ...ulty or damaged they must be replaced The blower motor and blower wheel are ser viced only as a unit BLOWER MOTOR RELAY The blower motor relay is a International Stan dards Organization ISO type relay...

Страница 1136: ...gnetic coil unit and the hub bearing and pulley assembly are each retained on the nose of the compressor front housing with snap rings The clutch plate is keyed to the compressor shaft and secured wit...

Страница 1137: ...ed orifice tube has a nylon mesh filter screen which filters the refrigerant and helps to reduce the potential for blockage of the metering orifice by refrigerant system contaminants Fig 4 The outlet...

Страница 1138: ...air flow The low pressure cycling clutch switch contacts are open when the suction pressure is approximately 141 kPa 20 5 psi or lower The switch contacts will close when the suction pressure rises t...

Страница 1139: ...f protection In addition some models have a plastic ring that is used at the factory as a visual indicator to confirm that these couplers are connected After the coupler is connected the plastic indic...

Страница 1140: ...rt is located on the refrigerant line manifold near the discharge port of the compressor The low pressure service port is located on the liquid line at the rear of the engine compartment near the evap...

Страница 1141: ...the air entering the vehicle adds to the comfort of the passengers Although an owner may expect too much from their air conditioning system on humid days A perfor mance test is the best way to determ...

Страница 1142: ...group Test the refrigerant system for leaks Repair evacuate and charge the refrigerant system if required 2 Check the fuses in the Power Distribution Center and the fuseblock module Repair the shorte...

Страница 1143: ...ressure is too low 1 Accessory drive belt slipping 2 Fixed orifice tube not installed 3 Faulty compressor 1 Refer to Group 7 Cooling System for more information Inspect the accessory drive belt condit...

Страница 1144: ...A C mode control switch operation will determine if the vacuum and mechanical controls are functioning However it is possible that a vacuum control system that operates perfectly at engine idle high e...

Страница 1145: ...acuum line colors refer to the Vacuum Circuits chart Fig 10 or Fig 11 4 Disconnect and plug the vacuum line from the component fitting actuator valve switch or reser voir on the other end of the leaki...

Страница 1146: ...Fig 10 Vacuum Circuits Heater Only 24 16 HEATING AND AIR CONDITIONING TJ DIAGNOSIS AND TESTING Continued...

Страница 1147: ...Fig 11 Vacuum Circuits Heater A C TJ HEATING AND AIR CONDITIONING 24 17 DIAGNOSIS AND TESTING Continued...

Страница 1148: ...n terminals 30 and 87 and no continuity between terminals 87A and 30 If OK see the Relay Circuit Test procedure in this group If not OK replace the faulty relay RELAY CIRCUIT TEST 1 The relay common f...

Страница 1149: ...Off position Disconnect and isolate the battery negative cable Remove the heater A C control from the instrument panel but do not unplug the wire harness connec tors Connect the battery negative cable...

Страница 1150: ...8W 42 Air Conditioning Heater in Group 8W Wir ing Diagrams The battery must be fully charged before performing the following tests Refer to Group 8A Battery for more information 1 Connect an ammeter 0...

Страница 1151: ...ect refrigerant charge See Refrigerant Sys tem Charge in the Service Procedures section of this group for more information For circuit descriptions and diagrams refer to 8W 42 Air Conditioning Heater...

Страница 1152: ...l outlet Set the blower motor switch to the lowest speed position and the mode control switch in the recirculation mode SYSTEM LOW 1 Position the vehicle in a wind free work area This will aid in dete...

Страница 1153: ...ant system The accumulator evaporator condenser and compressor will each retain a significant amount of the needed refrigerant oil It is important to have the correct amount of oil in the refrigerant...

Страница 1154: ...le half of the cou pler fitting CAUTION Use only the specified O rings as they are made of a special material for the R 134a sys tem The use of any other O rings may allow the connection to leak inter...

Страница 1155: ...ant Recovery in this group for the procedures 3 Unplug the wire harness connector from the high pressure cut off switch 4 Remove the bolt that secures the discharge line support bracket to the compres...

Страница 1156: ...r to the mounting bracket Fig 17 7 Remove the compressor from the mounting bracket Fig 18 INSTALLATION NOTE If a replacement compressor is being installed be certain to check the refrigerant oil level...

Страница 1157: ...ve the external front housing snap ring with snap ring pliers Fig 21 10 Install the lip of the rotor puller Special Tool C 6141 1 into the snap ring groove exposed in the previous step and install the...

Страница 1158: ...Align the rotor assembly squarely on the front compressor housing hub 4 Install the pulley bearing assembly with the installer Special Tool C 6871 Fig 26 Thread the installer on the shaft then turn t...

Страница 1159: ...imately twenty times five seconds on then five seconds off During this procedure set the heater A C control to the Recirculation Mode the blower motor switch in the highest speed position and the engi...

Страница 1160: ...line fittings 6 Remove the liquid line from the plastic clip that secures it to the right inner fender shield 7 Remove the liquid line from the vehicle INSTALLATION 1 Remove the tape or plugs from th...

Страница 1161: ...ATION 1 Lubricate a new O ring seal with clean refrig erant oil and install it on the accumulator fitting Use only the specified O rings as they are made of a special material for the R 134a system Us...

Страница 1162: ...es of refrigerant oil to the refrigerant system Use only refrigerant oil of the type recommended for the compressor in the vehi cle CONDENSER WARNING REVIEW THE WARNINGS AND CAU TIONS IN THE FRONT OF...

Страница 1163: ...e bottom of the grille panel Tighten the screws to 2 2 N m 20 in lbs 7 Install the lower condenser air seal to the bot tom of the grille panel and the passenger side frame rail with three retainers 8...

Страница 1164: ...nplug the blower motor wire harness connec tor Fig 37 4 Remove the three screws that secure the blower motor and wheel assembly to the heater A C housing 5 Rotate and tilt the blower motor unit as nee...

Страница 1165: ...NSTALLATION 1 Plug the three wire harness connectors into the back of the heater A C control 2 Position the heater A C control in the instru ment panel and secure it with four screws Tighten the screw...

Страница 1166: ...necessary remove the intermediate shaft from the blend air door pivot shaft INSTALLATION 1 Reverse the removal procedures for installa tion 2 Install and tighten the screws that secures the blend air...

Страница 1167: ...TION 1 Position the slotted upper kick cover mounting tabs under the heads of the two loosened heater A C housing screws Tighten the screws to 2 2 N m 20 in lbs 2 Install the two screws that secure th...

Страница 1168: ...r A C housing actuator mount Fig 46 Gently pry the actuator latch while pulling firmly outwards on the actuator to remove the actuator from the mount 5 Rotate and tilt the vacuum actuator as required...

Страница 1169: ...a trim stick or another suitable wide flat bladed tool into the latch hole on the heater A C housing actuator mount Fig 46 Gently pry the actuator latch while pulling firmly outwards on the actuator t...

Страница 1170: ...MBLY 1 Remove the heater A C housing from the vehi cle and place it on a work bench 2 Unplug the vacuum harness connectors from the floor door actuator and if the unit is so equipped the recirculation...

Страница 1171: ...the heater A C housing to the plenum bracket on the passenger compartment side of the dash panel Tighten the screw to 3 4 N m 30 in lbs 3 Install the floor duct to the bottom of the heat er A C housi...

Страница 1172: ...aft from the outside of the upper half of the heater A C housing 4 Reach inside the upper half of the heater A C housing and carefully flex the panel defrost door Fig 53 enough so that the door pivot...

Страница 1173: ...or upwards Fig 55 4 Guide the recirculation air door lever through the air intake grille of the heater A C housing while removing the door from the housing 5 Reverse the removal procedures to install...

Страница 1174: ...HICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PR...

Страница 1175: ...floor duct from the bottom of the heater A C housing See Floor Duct in this group for the procedures 4 Remove the one screw that secures the heater A C housing to the plenum bracket on the passenger c...

Страница 1176: ...ut voltage to the PCM The PCM might not store a DTC for a monitored circuit even though a malfunction has occurred This may happen because one of the DTC criteria for the circuit has not been met For...

Страница 1177: ...tch circuit to the PCM functions properly Connect the DRB scan tool to the data link connector and access the state display screen Then access either State Display Inputs and Outputs or State Display...

Страница 1178: ...erature sensor input above the maximum acceptable voltage P0121 M TPS Voltage Does Not Agree With MAP TPS signal does not correlate to MAP sensor signal P0121 M Accelerator Position Sensor APPS Signal...

Страница 1179: ...P0153 M 2 1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required switching frequency P0154 M 2 1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the o...

Страница 1180: ...rly to the control signal P0205 M Injector 5 Control Circuit Injector 5 output driver stage does not respond properly to the control signal P0206 M Injector 6 Control Circuit Injector 6 output driver...

Страница 1181: ...LINDER 5 MISFIRE Misfire detected in cylinder 5 P0306 M CYLINDER 6 MISFIRE Misfire detected in cylinder 6 P0307 M CYLINDER 7 MISFIRE Misfire detected in cylinder 7 P0308 M CYLINDER 8 MISFIRE Misfire d...

Страница 1182: ...ge input below the minimum acceptable voltage P0388 Crankshaft Position Sensor Supply Voltage Too High CKP sensor voltage input above the maximum acceptable voltage P0401 EGR System Failure Required c...

Страница 1183: ...P0524 Oil Pressure Too Low Engine oil pressure is low Engine power derated P0545 A C Clutch Relay Circuit Problem detected in air conditioning clutch relay control circuit P0551 Power Steering Switch...

Страница 1184: ...auto trans only P0740 M Torq Con Clu No RPM Drop at Lockup Relationship between engine and vehicle speeds indicated failure of torque convertor clutch lock up system TCC PTU solenoid P0743 M Torque Co...

Страница 1185: ...nitor test Also see SCI DTC 68 was P0139 P1198 Radiator Temperature Sensor Volts Too High Radiator coolant temperature sensor input above the maximum acceptable voltage P1199 Radiator Temperature Sens...

Страница 1186: ...Position Sensor signal Possible vacuum leak P1388 Auto Shutdown Relay Control Circuit An open or shorted condition detected in the ASD or CNG shutoff relay control ckt P1388 Auto Shutdown Relay Contro...

Страница 1187: ...ed condition detected in the control circuit of the high speed radiator fan control relay P1490 Low Speed Fan CTRL Relay Circuit An open or shorted condition detected in control circuit of the low spe...

Страница 1188: ...ntrol module P1682 G Charging System Voltage Too Low Battery voltage sense input below target charging voltage during engine operation and no significant change in voltage detected during active test...

Страница 1189: ...nd PCM P1719 Skip Shift Solenoid Circuit An open or shorted condition detected in the transmission 2 3 gear lock out solenoid control circuit P1740 TCC or OD Sol Perf A rationality error has been dete...

Страница 1190: ...dicate that there is an implied prob lem within one of the systems and that a specific problem must be diagnosed If any of these monitors detect a problem affecting vehicle emissions the Malfunction I...

Страница 1191: ...briefly energized This initializes the pump by drawing air into the pump cavity and also closes the vent seal During non test conditions the vent seal is held open by the pump diaphragm assembly which...

Страница 1192: ...xygen storage capacity of a catalyst its effi ciency can be indirectly calculated The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic con ver...

Страница 1193: ...with the malfunction present Components without an associated limp in will take two trips to illumi nate the MIL Refer to the Diagnostic Trouble Codes Description Charts in this section and the approp...

Страница 1194: ...aged connector pins However it might store diagnostic trouble codes as a result of spread connec tor pins HIGH AND LOW LIMITS OPERATION The PCM compares input signal voltages from each input device wi...

Страница 1195: ...p LDP will be used as part of the evaporative system for OBD II requirements Also refer to Leak Detection Pump NOTE The evaporative system uses specially man ufactured lines hoses If replacement becom...

Страница 1196: ...om reaching full travel After the brief initialization period the solenoid is de energized allowing atmo spheric pressure to enter the pump cavity This per mits the spring to drive the diaphragm which...

Страница 1197: ...ront of cylinder head cover on 4 0L engines It is connected to rear of cover on 2 5L engines Fig 3 Evaporative System Monitor Schematic Typical Fig 4 CCV System 2 5L Engine Fig 5 CCV System 4 0L Engin...

Страница 1198: ...ench languages These labels are per manently attached and cannot be removed without defacing information and destroying label DIAGNOSIS AND TESTING VACUUM SCHEMATICS A vacuum schematic for emission re...

Страница 1199: ...d on the top of the fuel tank Fig 9 The valves are not serviceable If replacement is necessary the fuel tank must be replaced Refer to the Fuel Tank section of Group 14 Fuel Systems for removal and in...

Страница 1200: ...firmly connected Check the vapor vacuum lines at the LDP LDP filter and EVAP canister purge solenoid for damage or leaks If a leak is present a Diagnostic Trouble Code DTC may be set 6 Connect electri...

Страница 1201: ...ion Certain criteria must be met before the PCM stores a DTC in memory The criteria may be a spe cific range of engine RPM engine temperature and or input voltage to the PCM The PCM might not store a...

Страница 1202: ...e engine misfire or fuel sys tem tests The PCM performs these tests while the engine is operating within 6 375 RPM of and within 10 of the load of the operating condition at which the malfunction was...

Страница 1203: ...Purge Solenoid Circuit An open or shorted condition detected in the duty cycle purge solenoid circuit 13 P0203 Injector 3 Control Circuit Injector 3 output driver does not respond properly to the con...

Страница 1204: ...PCM Failure SPI Communications PCM Internal fault condition detected 45 P0205 Injector 5 Control Circuit Injector 5 output driver does not respond properly to the control signal or 46 P0206 Injector 6...

Страница 1205: ...on systems monitors do not indicate a specific component prob lem They do indicate that there is an implied prob lem within one of the systems and that a specific problem must be diagnosed If any of t...

Страница 1206: ...The PCM is programmed to maintain the optimum air fuel ratio of 14 7 to 1 This is done by making short term corrections in the fuel injector pulse width based on the O2S sensor output The programmed...

Страница 1207: ...ing properly An effective catalyst will have fewer downstream switches than it has upstream switches i e a ratio closer to zero For a totally ineffective catalyst this ratio will be one to one indicat...

Страница 1208: ...used as part of the evaporative system This pump is used as part of OBD II requirements Refer to Leak Detection Pump in this group for additional information NOTE The evaporative system uses speciall...

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