Chrysler neon 1997 Service Manual
  1. Manuals
  2. Brands
  3. Chrysler Manuals
  4. Automobile
  5. neon 1997
  6. Service manual

Chrysler neon 1997 Service Manual

Hide thumbs
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
591
592
593
594
595
596
597
598
599
600
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
616
617
618
619
620
621
622
623
624
625
626
627
628
629
630
631
632
633
634
635
636
637
638
639
640
641
642
643
644
645
646
647
648
649
650
651
652
653
654
655
656
657
658
659
660
661
662
663
664
665
666
667
668
669
670
671
672
673
674
675
676
677
678
679
680
681
682
683
684
685
686
687
688
689
690
691
692
693
694
695
696
697
698
699
700
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
717
718
719
720
721
722
723
724
725
726
727
728
729
730
731
732
733
734
735
736
737
738
739
740
741
742
743
744
745
746
747
748
749
750
751
752
753
754
755
756
757
758
759
760
761
762
763
764
765
766
767
768
769
770
771
772
773
774
775
776
777
778
779
780
781
782
783
784
785
786
787
788
789
790
791
792
793
794
795
796
797
798
799
800
801
802
803
804
805
806
807
808
809
810
811
812
813
814
815
816
817
818
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
836
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
853
854
855
856
857
858
859
860
861
862
863
864
865
866
867
868
869
870
871
872
873
874
875
876
877
878
879
880
881
882
883
884
885
886
887
888
889
890
891
892
893
894
895
896
897
898
899
900
901
902
903
904
905
906
907
908
909
910
911
912
913
914
915
916
917
918
919
920
921
922
923
924
925
926
927
928
929
930
931
932
933
934
935
936
937
938
939
940
941
942
943
944
945
946
947
948
949
950
951
952
953
954
955
956
957
958
959
960
961
962
963
964
965
966
967
968
969
970
971
972
973
974
975
976
977
978
979
980
981
982
983
984
985
986
987
988
989
990
Table of Contents

Advertisement

Quick Links

Welcome to the
1997 Neon
(RHD & LHD)
Interactive Electronic Service Manual!
CLICK ON VEHICLE TO BEGIN
tweddle litho: dom parts cdrom demo 09/96
page 4 <output:1248 ET 01/22/97>

Advertisement

Table of Contents
loading

Related Manuals for Chrysler neon 1997

Summary of Contents for Chrysler neon 1997

  • Page 1 Welcome to the 1997 Neon (RHD & LHD) Interactive Electronic Service Manual! CLICK ON VEHICLE TO BEGIN tweddle litho: dom parts cdrom demo 09/96 page 4 <output:1248 ET 01/22/97>...

  • Page 2: Lubrication And Maintenance

    Fig. 1 International Symbols interval that occurs first. PARTS AND LUBRICANT RECOMMENDATIONS When service is required, Chrysler Corporation recommends that only Mopar brand parts, lubri- cants and chemicals be used. Mopar provides the best engineered products for servicing Chrysler Cor- poration vehicles.
  • Page 3 TION CHASSIS WHEEL BEARINGS by the NLGI. All approved products have the NLGI organization should be used to service a Chrysler Corporation vehicle. symbol (Fig. 3) on the label. At the bottom NLGI • Society of Automotive Engineers (SAE) symbol is the usage and quality identification letters.

  • Page 4: Maintenance Schedules

    LUBRICATION AND MAINTENANCE 0 - 3 MAINTENANCE SCHEDULES INDEX page page GENERAL INFORMATION SCHEDULE—B ......4 INTRODUCTION .
  • Page 5 0 - 4 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) • Replace air cleaner element. • Replace spark plugs. • Replace spark plugs. 97,500 Miles (156 000 km) or at 78 months • Change engine oil. 37,500 Miles (60 000 km) or at 30 months •...
  • Page 6 LUBRICATION AND MAINTENANCE 0 - 5 GENERAL INFORMATION (Continued) • Lubricate front suspension upper ball joints. • Replace spark plugs. • Adjust drive belt tension. • Change automatic transaxle fluid and filter. • Replace air cleaner element. Adjust the bands.* •...
  • Page 7 • Inspect front brake pads and rear brake linings. NOTE: **This maintenance is recommended by Chrysler to the owner but is not required to main- 102,000 Miles (163 000km) • Change engine oil. tain the warranty on the PCV valve.
  • Page 8 BATTERY NEGATIVE CABLE BATTERY POSITIVE CABLE NEGATIVE JUMPER CABLE POSITIVE JUMPER CABLE ENGINE GROUND TEST INDICATOR BATTERY LUBRICATION AND MAINTENANCE 0 - 7 JUMP STARTING, TOWING AND HOISTING INDEX page page SERVICE PROCEDURES JUMP STARTING PROCEDURE ... . . 7 HOISTING RECOMMENDATIONS .
  • Page 9 Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers. TOWING—FRONT WHEEL LIFT Chrysler Corporation recommends that a vehicle be towed with the front end lifted, whenever possible. RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams TOWING—REAR WHEEL LIFT...
  • Page 10 LUBRICATION AND MAINTENANCE 0 - 9 SERVICE PROCEDURES (Continued) not more than 25 km (15 miles). The gear selector must be in the neutral position. HOISTING RECOMMENDATIONS Refer to Owner’s Manual provided with vehicle for proper emergency jacking procedures. WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHI- CLE.
  • Page 12 CURB HEIGHT ......8 DESCRIPTION AND OPERATION cations recommended Chrysler Corporation MUST ALWAYS be used. WHEEL ALIGNMENT GENERAL INFORMATION...
  • Page 13 2 - 2 SUSPENSION DESCRIPTION AND OPERATION (Continued) (3) Toe is measured in degrees or inches and is (4) Thrust Angle is defined as the average of the the distance that the front edges of the tires are Toe settings on each rear wheel. If this measurement closer (or farther apart) than the rear edges (Fig.

  • Page 14: Required

    SUSPENSION 2 - 3 DIAGNOSIS AND TESTING SUSPENSION AND STEERING DIAGNOSIS CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Front End Whine On Turns 1. Defective Wheel Bearing 1. Replace Wheel Bearing 2. Incorrect Wheel Alignment 2. Check And Reset Wheel Alignment 3. Worn Tires 3.

  • Page 15: Wheel Alignment

    2 - 4 SUSPENSION DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Road Wander 1. Incorrect Tire Pressure 1. Inflate Tires To Rcommended Pressure 2. Incorrect Front Or Rear Wheel 2. Check And Reset Front Wheel 3. Worn Wheel Bearings 3.

  • Page 16: Wheel Alignment

    SUSPENSION 2 - 5 DIAGNOSIS AND TESTING (Continued) compartment and trunk of the vehicle are vacant If a vehicles caster is not within manufacturers with the exception of the spare tire. People, luggage, alignment specifications, check for damaged suspen- and any other appreciable weight will adversely sion components or body parts.
  • Page 17 KNUCKLE STRUT ASSEMBLY CLEVIS STRUT REMOVE AND REPLACE BRACKET BRACKET LOOSEN CLEVIS THIS BOLT BOLT THIS STRUT CLEVIS BRACKET TO STEERING CLEVIS KNUCKLE ATTACHING BOLTS STEERING KNUCKLE BRACKET KNUCKLE ATTACHING BOLTS 2 - 6 SUSPENSION SERVICE PROCEDURES (Continued) CAUTION: The Mopar Service Kit for allowing (4) Loosen lower bolt attaching strut clevis bracket adjustment of front and rear camber are different to steering knuckle or rear knuckle ONLY enough to...
  • Page 18 REAR REAR LATERAL LINKS REAR LATERAL LINKS ADJUSTMENT CAMS LATERAL NUTS LINK REAR CROSSMEMBER ATTACHING BOLT NUTS LATERAL LINKS ADJUSTMENT CAMS FUEL TANK SUSPENSION 2 - 7 SERVICE PROCEDURES (Continued) Fig. 4 Rear Lateral Link To Crossmember Attaching Fig. 6 Torquing Rear Lateral Link Attaching Bolts Bolts Fig.
  • Page 19 2 - 8 SUSPENSION SPECIFICATIONS VEHICLE ALIGNMENT SPECIFICATIONS AT CURB HEIGHT ACCEPTABLE ALIGNMENT FRONT WHEEL ALIGNMENT PREFERRE SETTING RANGE AT CURB HEIGHT CAMBER ....-0.4°...

  • Page 20: Front Suspension

    NO SHEET METAL SCREWS, BOLTS, METAL FASTENERS ARE TO BE INSTALLED INTO SHOCK TOWER ALSO, NO HOLES ARE TO BE DRILLED INTO SHOCK TOWER SHOCK TOWER THIS THIS OTHER AREA. AREA. SAME COIL SPRING SUSPENSION 2 - 9 FRONT SUSPENSION INDEX page page...
  • Page 21 2 - 10 SUSPENSION DESCRIPTION AND OPERATION (Continued) bracket and steering knuckle (Fig. 2). The top of the dust shield, coil spring with plastic noise insulator strut is mounted directly to the strut tower of the and the strut dampener. vehicle by the strut mount assembly’s 3 studs and A cast lower control arm assembly (Fig.
  • Page 22 SUSPENSION 2 - 11 DESCRIPTION AND OPERATION (Continued)
  • Page 23 FRONT BRAKE WHEEL MOUNTING STUDS STEERING KNUCKLE STRUT CALIPER FRONT HUB ATTACH- MENTS ABUT- MENT REAR ISOLATOR BUSHING FRONT ISOLATOR BUSHING LOWER CONTROL ARM BALL JOINT BOOT SEAL BALL JOINT 2 - 12 SUSPENSION DESCRIPTION AND OPERATION (Continued) McPHERSON STRUT ASSEMBLY through both the crossmember and rear lower control arm bushing, threading directly into the frame rail of The front strut and suspension of the vehicle is...
  • Page 24 STEERING KNUCKLE BEARING RETAINING SNAP RING UNIT 1 TYPE CAR- TRIDGE BEARING BALL SEAL BOOT JOINT GREASE FITTING BALL JOINT ASSEMBLY BALL JOINT STUD SUSPENSION 2 - 13 DESCRIPTION AND OPERATION (Continued) FRONT WHEEL HUB BEARING serviced as a separate component of the lower control arm assembly.
  • Page 25 STEERING COIL SPRING KNUCKLE STRUT DUST BOOT ASSEMBLY 2 - 14 SUSPENSION DIAGNOSIS AND TESTING (Continued) distortion. Do not attempt to repair or straighten a broken or bent lower control arm. The serviceable components of the lower control arm are: the ball joint assembly, ball joint assembly grease seal and control arm bushings.
  • Page 26 HYDRAULIC BRAKE ATTACHING B OLTS STRUT BRAKE HOSE AND SPEED ROUTING BRACKET SPEED SENSOR CABLE DAMPER STRUT DAMPER SENSOR HOSE BRAKE BRACKET WITHOUT ANTI- ATTACHING SCREW HOSE ROUTING BRACKET BRAKE BRACKET WITH ANTI-LOCK HOSE HOSE LOCK BRAKES ROUTING ROUTING BRAKES ATTACHING BRAKE HOSE STRUT...
  • Page 27 DISC BRAKE CALIPER STEERING KNUCKLE ASSEMBLY DRIVE SHAFT BRAKING DISC LOWER TROL ARM CON- DISC BRAKE CALIPER STRUT MOUNTING BOLTS ASSEMBLY UPPER STRUTMOUNT FRONT H UB SPRING WASHER COTTER PIN NUT LOCK ATTACHING BOLTS SHOCK HUB NUT TOWER 2 - 16 SUSPENSION REMOVAL AND INSTALLATION (Continued) CAUTION:...
  • Page 28 SLIDE THIS END OF CALI- PER FROM UNDER STEER- LIFT THIS END OF CALIPER AWAY WIRE HANGER DISC BRAKE CALIPER DISC BRAKE CALIPER FROM KNUCKLE FIRST ING KNUCKLE ASSEMBLY STEERING ROTOR BRAKE HYDRAULIC HOSE STEERING KNUCKLE BRAKE DISC WHEEL DISC SAFETY CHAIN SPECIAL TOOL STEERING KNUCKLE...
  • Page 29 BALL JOINT STEERING KNUCKLE PRY BAR LOWER CONTROL STEERING KNUCKLE CLAMPING NUT AND BOLTLOWER CONTROL ARM DRIVE SHAFT BALL BALL JOINT SEAL JOINT STUD ATTACHING B OLTS DRIVE SHAFT STEERING KNUCKLE HUB/BEARING ASSEMBLY BALL JOINT LOWER STRUT STEERING CONTROL ASSEMBLY KNUCKLE 2 - 18 SUSPENSION...
  • Page 30 SLIDE TOP OF BRAKE CALI- MENT STEERING KNUCKLE BRAKE DISC BRAKE CALIPER UNDER KNUCKLE AS SHOWN BRAKING DISC ABUTMENT STEERING ABUT- SUSPENSION 2 - 19 REMOVAL AND INSTALLATION (Continued) CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation.
  • Page 31 SPRING BRAKING DISC WASHER NUT LOCK TORQUE WRENCH “PULL” COTTER PIN COTTER PIN THROUGH NUT LOCK “WRAP” TIGHT HUB NUT 2 - 20 SUSPENSION REMOVAL AND INSTALLATION (Continued) (2) Remove the steering knuckle to ball joint ball stud, clamping nut and bolt (Fig. 32). Fig.
  • Page 32 FRONT BOLT CROSSMEMBER SUSPENSION SWAY BAR RETAINERS BOLT FRONT LOWER CONTROL ARM LOWER CONTROL ARM ATTACHING BOLT SWAY BAR SWAY RETAINER REAR ARM ATTACHING BOLT LOWER CONTROL SWAY BAR FRONT SUSPENSION CROSSMEMBER SUSPENSION 2 - 21 REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 33 2 - 22 SUSPENSION REMOVAL AND INSTALLATION (Continued) retainers, stabilizer bar, and bushings from front crossmember. Fig. 40 Front Stabilizer Bar Bushing Retainers INSTALL Fig. 38 Installed Stabilizer Bar To Lower Control (1) If inspection determines replacement of stabi- Arm Attaching Link lizer bar to lower control arm attachment link bush- ings is required, replace bushings before installing (8) Torque the 2 stabilizer bar bushing retainer, to...
  • Page 34 SWAY BAR BUSHINGS BOLT SWAY BAR SLEEVE LOWER CONTROL SLIT FRONT SUSPENSION SLIT IN BUSHING MUST FACE FRONT OF SWAY BAR FRONT OF VEHICLE SLIT SWAY BAR LINK AND SWAY BAR LINK TO LOWER CON- CROSSMEMBER VEHICLE BUSHINGS TROL ARM MOUNTING HOLE SUSPENSION 2 - 23 REMOVAL AND INSTALLATION (Continued)
  • Page 35 SCREWDRIVER SPECIAL TOOL MB-990799 PRESS BLOCKS ARBOR PRESS SNAP RING HUB BEAR- STEERING KNUCKLE STEERING KNUCKLE PRESS BLOCKS ARBOR PRESS SPECIAL TOOL 6644–2 BEARING RACE SPECIAL TOOL P334 2 - 24 SUSPENSION REMOVAL AND INSTALLATION (Continued) (5) Remove Bearing Splitter, Special Tool P334 (8) Install Bearing Splitter, Special Tool P334 on from the steering knuckle.
  • Page 36 SUSPENSION 2 - 25 REMOVAL AND INSTALLATION (Continued) hub bearing into the steering knuckle until it is fully bottomed in the bore of the steering knuckle. Fig. 51 Pressing Hub Into Hub Bearing section in this group of the service manual for the required steering knuckle installation procedure.
  • Page 37 DISC BRAKE CALIPER DISC STEERING KNUCKLE PER ASSEMBLY BRAKE ASSEMBLY CALI- BRAKING DISC DRIVE SHAFT SLIDE THIS END OF CALIPER FROM BRAKING DISC UNDER STEERING KNUCKLE LOWER TROL ARM CON- WHEEL DISC WIRE HANGER DISC BRAKE CALIPER SPECIAL TOOL C-4150A STEERING KNUCKLE STEERING KNUCKLE BRAKE...
  • Page 38 DISC BRAKE CALIPER STEERING KNUCKLE ABUTMENT ASSEMBLY BRAKE BRAKING DISC SLIDE TOP OF BRAKE CALI- STEERING KNUCKLE WHEEL LUG NUT HUB/BEARING WASHERS STRUT BRACKET CLEVIS STRUT ASSEMBLY VISE PER UNDER TOP ABUT- MENT OF STEERING KNUCKLE AS SHOWN SUSPENSION 2 - 27 REMOVAL AND INSTALLATION (Continued) (8) Tighten Special Tool C-4150, pushing the wheel (5) Install the disc brake caliper to steering...
  • Page 39 SPECIAL TOOL L-4558A STRUT ASSEMBLY STRUT MOUNT SPECIAL TOOL C-4838 10 MM SOCKET SPECIAL TOOL C-4838 STRUT ASSEMBLY COIL SPRING 2 - 28 SUSPENSION COIL SPRING SPECIAL TOOL C-4838 UPPER STRUT MOUNT UPPER SPRING SEAT PIVOT BEARING UPPER SPRING SEAT DUST BOOT DISASSEMBLY AND ASSEMBLY (Continued) WARNING:...
  • Page 40 JOUNCE BUMPER STRUT SHAFT COIL SPRING SUSPENSION 2 - 29 DISASSEMBLY AND ASSEMBLY (Continued) † Mount for cracks and distortion and retaining studs for any sign of damage. † Severe deterioration of rubber isolator, † Binding strut assembly pivot bearing. If pivot bearing is replaced it is to be installed with the white DUST SHIELD STRUT...
  • Page 41 LOWER CONTROL ARM ARBOR PRESS SPECIAL TOOL 6758 SPECIAL TOOL 6804 BALL JOINT BALL LOWER CONTROL ARM ASSEMBLY JOINT SCREWDRIVER BALL JOINT STUD SEAL BOOT LOWER CONTROL ARM SPECIAL TOOL 6804 SPECIAL TOOL 6758 ARBOR PRESS BALL JOINT 2 - 30 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) Special Tool 6804 on the bottom of the ball joint...
  • Page 42 SPECIAL C-4212–F TOOL SPECIAL TOOL 6758 SPECIAL TOOL 6804 VISE BUSHING IS TO BE INSTALLED IN CON- TROL ARM WITH FLANGE ON BUSHING INSTALLED MACHINED SURFACE ON CONTROL SPECIAL SPECIAL TOOL 6758 SPECIAL TOOL C-4212–F C-4212–F BUSHING FLANGE TOOL AGAINST SPECIAL TOOL 6810 LOWER CONTROL ARM ARM AS SHOWN...
  • Page 43 TOOL IS TO BE FLAT AGAINST THIS SURFACE OF LOWER CONTROL ARM TO INSTALL BUSHING TO CORRECT POSITION SPECIAL TOOL C-4212–F SPECIAL TOOL 6810 SPECIAL TOOL 6810 SPECIAL TOOL C-4212–3 BUSHING LOWER CONTROL ARM LOWER CONTROL ARM SPECIAL C-4212–3 TOOL SUPPORTPLATE ARBOR PRESS LOWER CONTROL ARM...
  • Page 44 ARROW ON REAR BUSHING IS TO BE POSITIONED AS INDICATED WHEN INSTALL- ING BUSHING IN LOWER LOWER ARBOR PRESS RAM SPECIAL CONTROL ARM BUSHING LOWER CONTROL ARM COMPRESSION STRUT CONTROL TOOL 6760 CONTROL ARM SINGLE VOID SPECIAL TOOL 6756 REAR BUSHING REAR CONTROL ARM BUSHING MUST BE FLUSH WITH CONTROL ARM AT THIS LOCATION FOR...
  • Page 45 2 - 34 SUSPENSION SPECIAL TOOLS FRONT SUSPENSION Installer Ball Joint 6758 Socket/Holder Front Strut Nut L-4558A Installer Lower Control Arm Small Bushing 6810 Compressor Strut Coil Spring C-4838 Adapter Ball Joint Remover/Installer C-4212-3 Press Remover/Installer C-4212-F Receiver Ball Joint 6756 Remover Lower Control Arm Small Bushing And Ball Joint 6804...
  • Page 46 SUSPENSION 2 - 35 SPECIAL TOOLS (Continued) Installer Ball Joint 6760 Installer Bearing 5052 Remover Tie Rod End MB-990635 Installer Adapter C-4698-2 Puller Bearing P-334 Remover Lower Ball Joint C-4150A Remover Ball Joint MB-990799 Fig. 81 Installer Bearing Cup 6522 Remover/Installer Lower Control Arm Bushing 6644-2...

  • Page 47: Rear Suspension

    2 - 36 SUSPENSION REAR SUSPENSION INDEX page page GENERAL INFORMATION SERVICE PROCEDURES GENERAL INFORMATION ....36 REAR WHEEL ALIGNMENT ....39 DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION COIL SPRING...
  • Page 48 SUSPENSION 2 - 37 DESCRIPTION AND OPERATION (Continued)
  • Page 49 LOWER SPRING ISOLATOR DUST BOOT STRUT ASSEMBLY COIL SPRING 2 - 38 SUSPENSION DESCRIPTION AND OPERATION (Continued) STRUT ASSEMBLY LATERAL LINKS AND TENSION STRUTS The rear strut assemblies support the weight of The lateral arms and tension strut have rubber the vehicle using coil springs positioned around the isolator bushings at each end.
  • Page 50 DUST B OOT STRUT RESERVOIR FLUID STRUT SHAFT INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID LEAKAGE SUSPENSION 2 - 39 DIAGNOSIS AND TESTING (Continued) (4) Lift dust boot and inspect strut assembly for and or the retainers will be required. The bushings evidence of fluid running from the upper end of fluid and retainers are serviceable as separate components reservoir.
  • Page 51 STRUT ASSEM- KNUCKLE STRUT ASSEMBLY CLEVIS BRACKET STRUT BRACKET BRACKET HYDRAULIC CLEVIS KNUCKLE ATTACHING BOLT FLEX HOSE BRACKET ATTACHING BOLTS DUST SHIELD STRUT MOUNT ATTACHING NUTS STRUT STRUT TOWER TOWER REAR STRUT 2 - 40 SUSPENSION REMOVAL AND INSTALLATION (Continued) (7) Remove carpet (if required) from top of strut tower.
  • Page 52 SPECIAL TOOL C-4838 NOTE POSITION OF SPRING REMOVED FROM VEHICLE STRUT SWAY BAR TOP AND BOTTOM COIL OF SWAY ATTACHING LINK SPRING STRUT LEFT SIDE SUSPENSION 2 - 41 REMOVAL AND INSTALLATION (Continued) (2) Install dust shield into hole on top of strut tower (Fig.
  • Page 53 SWAY RETAINER FRAME RAIL SLIT IN SWAY BAR BUSHINGS MUST BE IN THIS DIRECTION WHEN BUSHINGS ARE INSTALLED ON SWAY BAR SWAY SWAY BAR BUSHINGS SWAY BAR BOLT FRAME R AIL SWAY RETAINER FLEX HOSE CALIPER ASSEMBLY STRUT WIRE HANGER 2 - 42 SUSPENSION REMOVAL AND INSTALLATION (Continued)
  • Page 54 BRACKET PARK BRAKE BRAKE BRAKE SHOES DISC BRAKE SUPPORT SUPPORT MOUNTING BOLTS PLATE BRAKE MOUNTING BOLTS SHOES BRAKE PLATE ADAPTER KNUCKLE DISC WHEEL ADAPTER KNUCKLE BRAKE INDER CYL- SUSPENSION 2 - 43 REMOVAL AND INSTALLATION (Continued) Fig. 13 Speed Sensor Head Attachment To Disc Fig.
  • Page 55 TENSION S TRUT FRONT LATERAL ARM ADJUSTABLE WRENCH FLAT BUSHING RETAINER REAR LATERAL ARM KNUCKLE TENSION FRONT TENSION STRUT TENSION STRUT TENSION RETAINER STRUT BUSHING STRUT ADJUSTABLE WRENCH FLAT KNUCKLE KNUCKLE TENSION REAR STRUT BUSHING NUT RETAINER STRUT TENSION TORQUE WRENCH 2 - 44 SUSPENSION...
  • Page 56 TENSION STRUT KNUCKLE FRONT LATERAL LINKS REAR LATERAL LINKS REAR CROSSMEMBER TENSION S TRUT KNUCKLE SUSPENSION 2 - 45 REMOVAL AND INSTALLATION (Continued) CAUTION: The hub/bearing retaining nut must be Adjustment section in this group of the service man- tightened to but must not exceed its required ual for the required Toe setting procedure.
  • Page 57 2 - 46 SUSPENSION REMOVAL AND INSTALLATION (Continued) (1) Install washer on short lateral link attaching bolt. Then install short lateral link attaching bolt, into lateral link having the same size bushing sleeves. Then install lateral link, bolt and washer onto knuckle as an assembly, with head of bolt facing to front of vehicle (Fig.
  • Page 58 STRUT ASSEM- COIL SPRING STRUT CLEVIS BRACKET SPECIAL TOOL C-4838 UPPER MOUNT STRUT STRUT ASSEM- VISE SUSPENSION 2 - 47 REMOVAL AND INSTALLATION (Continued) (9) With suspension supporting total weight of vehicle, and lateral links at correct curb height, torque both lateral link attaching bolts to 95 N·m (70 ft.
  • Page 59 2 - 48 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) BREAKER BAR (4) Install Strut Rod Socket, Special Tool, L-4558A SPECIAL TOOL C-4838 SOCKET SPECIAL L-4558A TOOL UPPER STRUT MOUNT or L-4558 on strut shaft nut (Fig. 27). Inserted a 10 mm socket through special tool and onto end of strut WASHER UPPER STRUT MOUNT shaft (Fig.
  • Page 60 DUST SHIELD STRUT SLIT IN SWAY BAR BUSHINGS MUST BE IN THIS DIRECTION WHEN BUSHINGS ARE INSTALLED ON SWAY BAR SWAY SWAY BAR BUSHINGS STRUT SHAFT JOUNCE STRUT BUMPER LOWER SPRING ISOLATOR STRUT STRUT SHAFT LOWER SPRING SEAT SUSPENSION 2 - 49 DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (1) Install the original or a new isolator on lower...
  • Page 61 2 - 50 SUSPENSION SPECIFICATIONS SPECIAL TOOLS REAR SUSPENSION FASTENER TORQUE REAR SUSPENSION SPECIFICATIONS DESCRIPTION TORQUE STRUT ASSEMBLY: To Body Attaching Nuts ..34 N·m (300 in. lbs.) Clevis Bracket To Knuckle Nut/Bolt ....95 N·m (70 ft. lbs.) Strut Assembly Shaft Nut .

  • Page 62: Table Of Contents

    STUB AXLE INTERCONNECTING SHAFT OUTER C/V JOINT LEFT DRIVESHAFT OUTER C/V JOINT BOOT INNER TRIPOD JOINT BOOT TUNED INNER TRIPOD JOINT RUBBER DAMPER WEIGHT INNER TRIPOD JOINT INTERCONNECTING SHAFT INNER TRIPOD JOINT BOOT RIGHT DRIVESHAFT OUTER C/V JOINT BOOT OUTER C/V JOINT STUB AXLE DIFFERENTIAL AND DRIVELINE 3 - 1...

  • Page 63: General Information

    LEFT RIGHT SIDE MANUAL TRAN- LEFT SIDE MANUAL TRAN- TRANSAXLE DRIVESHAFT INNER SIDE SAXLE DRIVESHAFT SAXLE DRIVESHAFT RIGHT TRANSAXLE DRIVESHAFT TRIPOD AUTOMATIC JOINT SIDE AUTOMATIC INNTER TRIPOD JOINT SEALING INTERCONNECTING SHAFT BOOT SEALING BOOT MANUAL TRANSAXLE INTERCONNECT- INTERCONNECTING SHAFT TUNED DAMPER WEIGHT TUNED DAMPER WEIGHT AUTOMATIC...

  • Page 64: Removal And Installation Front Driveshafts

    DIFFERENTIAL AND DRIVELINE 3 - 3 DIAGNOSIS AND TESTING (Continued) NOISE AND/OR VIBRATION IN TURNS REMOVAL A clicking noise and/or a vibration in turns could CAUTION: The driveshaft, when installed, acts as a be caused by one of the following conditions. bolt and secures the front hub/bearing assembly.
  • Page 65 WIRE HANGER DISC BRAKE CALIPER DISC BRAKE CALI- ASSEMBLY STEERING (STORED) ASSEMBLY KNUCKLE BRAKING DISC BRAKE HYDRAULIC HOSE STEERING KNUCKLE BRAKE DISC 3 - 4 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (5) Remove front disc brake caliper assembly to steering knuckle bolts (Fig.
  • Page 66 BALL JOINT STEERING KNUCKLE PRY BAR LOWER CONTROL STEERING KNUCKLE CLAMPING NUT AND BOLTLOWER CONTROL ARM DRIVE SHAFT BALL BALL JOINT SEAL JOINT STUD DRIVE SHAFT STEERING KNUCKLE HUB/BEARING ASSEMBLY BALL JOINT PUNCH TRANSAXLE RIGHT INNER TRI- LOWER POD JOINT CONTROL DIFFERENTIAL AND DRIVELINE 3 - 5...
  • Page 67 SPLINE OILSEAL FRONT CROSSMEMBER SNAP RING SUSPENSION DRIVESHAFT INNER TRIPOD NOTCH INTERCON- NECTING S HAFT JOINT DRIFT INNER TRANSAXLE TRANSAXLE TRIPOD JOINT 3 - 6 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) fully seated. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand.
  • Page 68 BALL JOINT STEERING KNUCKLE DRIVE SHAFT STEERING KNUCKLE HUB/BEARING CLAMPING NUT AND BOLTLOWER CONTROL ARM ASSEMBLY BALL JOINT DRIVE SHAFT LOWER CONTROL DIFFERENTIAL AND DRIVELINE 3 - 7 REMOVAL AND INSTALLATION (Continued) DISC BRAKE CALIPER STEERING KNUCKLE ASSEMBLY DRIVE SHAFT BRAKING DISC LOWER TROL ARM...

  • Page 69: Disassembly And Assembly Driveshaft Recondition

    HUB AND BEAR- STUB NUT LOCK AXLE WASHER “PULL” COTTER PIN THROUGH HUB NUT “WRAP” TIGHT 3 - 8 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) See (Fig. 25) for the exploded view of the front driveshaft components. INNER TRIPOD JOINT SEAL BOOT REMOVAL To remove sealing boot from driveshaft for replace- ment, the driveshaft assembly must be removed from...
  • Page 70 2. — HOUSING ASM, RETAINER & 3. — RING, SPACER 4. — SPIDER, TRIPOT JOINT 5. — RING, RETAINING 6. — RETAINER, BALL & ROLLER 7. — BALL, TRIPOT JOINT 8. — ROLLER, NEEDLE 10. — CLAMP, SEAL RETAINING 11. — BUSHING, TRILOBAL TRIPOT 12.
  • Page 71 RETAINING SNAP RING INTERCONNECTING SMALL SEALING SEALING BOOT CLAMP BOOT SHAFT INTERCON- NECTING SHAFT LARGE CLAMP TRIPOD SPIDER HOUSING INNER SPIDER JOINT ASSEM- TRIPOD JOINT ASSEM- SPIDER ASSEM- INTERCONNECTING SHAFT SEALING BOOT INTERCONNECTING SHAFT RAISED BEAD IN THIS AREA ASSEMBLY WHEN REMOVING SPIDER SEALING BOOT GROOVE...
  • Page 72 BRASS INTERCONNECTING DRIFT SHAFT CHAMFER SPIDER ASSEMBLY DO NOT HIT BEARINGS WHEN INSTALLING THE INTERCONNECTING SHAFT SPIDER ASSEMBLY SPIDER ASSEM- RETAINING SNAP RING INTERCONNECTING SEALING BOOT SHAFT TRIPOD SPIDER HOUSING SPIDER JOINT ASSEM- ASSEM- DIFFERENTIAL AND DRIVELINE 3 - 11 DISASSEMBLY AND ASSEMBLY (Continued) (2) Install spider assembly onto interconnecting shaft with chamfer on spider assembly toward inter-...
  • Page 73 SEALINGBOOT CLAMP CLAMP JAWS OF SPECIAL TOOL C-4975A CLOSED INTERCON- NECTING SHAFT INTERCONNECTING TOGETHER HERE SPECIAL TOOL C-4975A COMPLETELY MUST SHAFT INNER INNER TRIPOD JOINT SEAL- TRIPOD JOINT TRIM STICK ING BOOT SEALING BOOT CLAMP MILLIME- TERS INNER HYTREL JOINT HOUSING SEALING TRIPOD BOOT...

  • Page 74: Outer C/V Joint Seal Boot

    SPECIAL TOOL C-4975A TRIPOD HOUS- SEALING BOOT INNER CLAMP CLAMP TRIPOD JOINT CLAMP 115 MILLIMETERS JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY SILICONE SEALING TRIPOD TOGETHER SEALING BOOT HOUSING SPECIAL TOOL C -4975A HERE JOINT BOOT INNER JOINT HOUSING CLAMP TRIPOD TOP BANK OF CLAMP MUST BE...
  • Page 75 SMALL INTERCONNECTING CLAMP SHAFT SEALING BOOT CIRCLIP (OUTER END OF SHAFT) LARGE CLAMP OUTER C/V JOINT HOUSING WEAR SLEEVE SNAP RING PLIERS SEALING BOOT INTERCONNECTING SHAFT INTERCONNECTING RAISED BEAD IN THIS AREA CIRCLIP SHAFT SEALING BOOT GROOVE SOFT HAMMER (TAP HOUS- ING) 3 - 14 DIFFERENTIAL AND DRIVELINE...
  • Page 76 OUTER C/V JOINT ASSEM- OUTER C/V JOINT SOFT FACED HAMMER STUB AXLE CROSS INTERCONNECTING SHAFT SEALINGBOOT CLAMP CLAMP JAWS OF SPECIAL TOOL C-4975A CLOSED INTERCON- NECTING SHAFT INTERCONNECTING TOGETHER HERE SPECIAL TOOL C-4975A COMPLETELY MUST SHAFT SEALING BOOT DIFFERENTIAL AND DRIVELINE 3 - 15 DISASSEMBLY AND ASSEMBLY (Continued) (2) Align splines on interconnecting shaft with...

  • Page 77: Specifications

    SPECIAL TOOL C-4975A TRIPOD HOUS- SEALING BOOT CLAMP CLAMP JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TRIPOD TOGETHER SEALING BOOT HOUSING SPECIAL TOOL C -4975A HERE JOINT 3 - 16 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) tool C- 4975-A until jaws on tool are closed com- this section for the required driveshaft installation pletely together, face to face (Fig.
  • Page 78 BRAKES 5 - 1 BRAKES CONTENTS page page ANTILOCK BRAKE SYSTEM–BENDIX ABX-4 . . 68 GENERAL INFORMATION ....1 BASE BRAKE SYSTEM ....2 GENERAL INFORMATION INDEX page...
  • Page 79 5 - 2 BRAKES BASE BRAKE SYSTEM INDEX page page DESCRIPTION AND OPERATION PARK BRAKE SHOES WITH REAR DISC CHASSIS TUBES AND HOSES ... . . 6 BRAKES ......54 FRONT DISC BRAKES .
  • Page 80 CALIPER ASSEMBLY STEERING KNUCKLE BRAKE PADS AND LININGS BRAKE ROTOR DRIVING HUB CALIPER GUIDE PIN CALIPER GUIDE PIN BOLT BOLT SLEEVE SLEEVE BLEEDER SCREW BUSHING BRAKE SHOE BUSHING CALIPER FRONT BRAKE STEERING KNUCKLE CALIPER ASSEMBLY DISC HOSE FLEX BRAKE WEAR PISTON SEAL BRAKE SHOE CATOR...
  • Page 81 PISTON BRAKE PISTON SURE OFF PRES- SEAL CALIPER HOUSING CYLINDER BORE DUST BOOT PISTON SEAL BRAKE PRESSURE BRAKE SHOE TO ANCHOR AUTOMATIC ADJUSTER PARKING RETURNSPRING HOLD FRONT BRAKE ANCHOR PLATE CALIPER ASSEMBLY RETURN SPRING AND SPRING REAR BRAKE SHOE DOWN BRAKE CLIP SHOE...
  • Page 82 DISC BRAKING REAR STONE SHIELD ADAPTER BRAKE DISK ROTOR BRAKING DISC PARKING PARKING BRAKE ACTU- BRAKE SHOES H UB/BEARING ATING STRUT BRAKE ASSEM- PROPORTIONING FRONT HYDRAULIC PROPORTIONING HYDRAULIC LINES HYDRAULIC CONTROL UNIT VALVES VALVES BRAKE BRAKE LINES MASTER MASTER MASTER CYLINDER ANTI-LOCK HYDRAULIC REAR BRAKE HYDRAULIC CYLINDER...
  • Page 83 TO REAR BRAKE LINE COLORED CATION BAND IDENTIFI- O-RING SEAL TO MASTER CYLINDER OR HYDRAULIC CONTROL UNIT PROPORTIONING FRONT HYDRAULIC PROPORTIONING HYDRAULIC LINES HYDRAULIC CONTROL UNIT VALVES VALVES BRAKE BRAKE LINES MASTER MASTER MASTER CYLINDER ANTI-LOCK HYDRAULIC REAR BRAKE HYDRAULIC CYLINDER FLUID RESERVOIR CYLINDER...
  • Page 84 PROPORTIONING MASTER CYLINDER PROPOR- TIONINGVALVES SECONDARY VALVES BRAKE TUBE PRIMARY BRAKE TUBE MASTER MASTER CYLINDER PRI- ONDARY OUTPUT PORTS MARY OUTPUT PORTS CYLINDER MASTER ANTILOCK BRAKES CYLINDER H.C.U. SEC- MASTER CYLINDER MOUNT- MASTER CYLINDER PUSH VACUUM CHECK VALVE ING STUDS PART POWER BRAKE...
  • Page 85 MASTER MOUNTING STUDS (2) OUTPUT ROD VACUUM CHECK VALVE CYLINDER POWER BRAKE BOOSTER POWER BOOSTER ASSEM- MASTER MOUNTING STUDS (4) POWER BRAKE BOOSTER DASH MASTER CYLINDER CYLINDER FLUID RESERVOIR BRAKE LEVEL SENSOR PANEL INPUT ROD ASSEMBLY BRAKE FLUID 5 - 8 BRAKES DESCRIPTION AND OPERATION (Continued) As the fluid drops below the minimum level, the...
  • Page 86 BRAKES 5 - 9 DIAGNOSIS AND TESTING BRAKE SYSTEM BASIC DIAGNOSIS GUIDE CHART 1 CHART 2 CHART 3 CHART 4 CHART 5 SYMPTOM MISC. WARNING POWER BRAKE WHEEL COND. LIGHT BRAKES NOISE BRAKES Brake Warning Light On Excessive Pedal Travel Pedal Goes To The Floor Stop Light On Without Brakes All Brakes Drag...
  • Page 87 CHECK OBSTRUCTION OF BRAKE INSPECT FOR AND COR- RECT STOP VERIFY THAT BRAKE PEDAL IS RETURNING FULLY TO APPLY RELEASE, WHEEL BY BLEEDER TURN WHEEL TURNS, HYDRAULIC PRESSURE WAS TRAPPED LOW ENGINE VACUUM SEE CONTAMINATED BINDING CALIPER PINS OR BUSHINGS REPLACE BUSH- BLOCKED OR PINCHED LINE LINING FRONT...
  • Page 88 CHECK FLUID LEVEL SWITCH AND MASTER CYLINDER FLOAT FOR REMOVE DER RESERVOIR CAP — CHECK FLUID LEVEL PROPER OPERATION MASTER FLUID LEVEL OK LIGHT CHECK BRAKE IS FULLY RELEASED CYLIN- “ON” THAT MALFUNCTION INDICATING PARKING REPAIR OR REPLACE AS CHECK FLUID LEVEL LOW ENTIRE CHECK WARNING LIGHT IGNITION...
  • Page 89 IF VACUUM SUPPLY IS BELOW 12 INCHES — REPLACE OR REPAIR VACUUM HOSE AND VACUUM FITTINGS. ALSO TUNE OR REPAIR IF PEDAL DOES NOT DROP, CONNECT VACUUM GAUGE TO SPEED CONTROL VACUUM PORT ON POWER UNIT. WITH ENGINE ENGINE OFF. DEPRESS AND RELEASE BRAKE PEDAL SEVERAL DEPRESS PEDAL AND HOLD WITH LIGHT EFFORT OF 15 TO 25 IF POWER UNIT IS OPERATING, PEDAL WILL FALL SLIGHTLY AND THEN HOLD.

  • Page 90: Brake Noise

    HIGH LOW SPEED, LIGHT PEDAL REPLACE BRAKE PADS PITCH SQUEAK AT DISC BRAKES FRONT BROKEN OR MISS- RATTLE SPRING OR CLIP ANTI-RATTLE CLUNKING PINS LOOSE SCRAPING (METAL TO AND REAR REPLACE WORN OUT INSPECT FERENCE OR FOREIGN DETERMINE NOISE LOCA- OBJECTS METAL) LININGS...
  • Page 91 5 - 14 BRAKES DIAGNOSIS AND TESTING (Continued) DRUM BRAKE AUTOMATIC ADJUSTER the rotor. (The hub and rotor runouts are separable). To measure runout on the vehicle, remove the wheel Place the vehicle on a hoist with a helper in the and reinstall the lug nuts tightening the rotor to the driver’s seat to apply the brakes.
  • Page 92 BRAKES 5 - 15 DIAGNOSIS AND TESTING (Continued) outer diameter. Care must be taken to position stem If runout is not within specifications. Install a new outside the stud circle but inside the chamfer on the rotor or reface rotor, being careful to remove as little hub rim (Fig.
  • Page 93 PROPORTIONING VALVE TO MASTER CYLINDER OR HCU BRAKE PROPORTIONING VALVE FITTINGS FITTING TUBE SPECIAL TOOL C-4007–A SPECIAL TOOL 6805 PROPORTIONING VALVE TO MASTER CYLINDER OR HCU FITTING LEFT REAR BRAKE PROPOR- AIR INLET CLEANER TIONING VALVE MASTER CYLINDER RIGHT REAR BRAKE PROPOR- RIGHT LEFT FRONT BRAKE FRONT...
  • Page 94 SPECIAL TOOL 6805-3 OR PROPORTIONING VALVE SPECIAL TOOL 6805-1 6805-4 OR 6805-2 MASTER CYL- I NDER PROPOR- TIONING VALVE SPECIAL C-4007-A PRESSURE TEST FIT- TOOL TINGS BLEED AIR FROM GAUGE HOSES HERE BRAKES 5 - 17 DIAGNOSIS AND TESTING (Continued) (4) Install Pressure Test Fitting, Special Tool 6805-1 or 6805-2 (Fig.
  • Page 95 SPECIAL TOOL 6805-3 PROPORTIONING OR 6805-4 SPECIAL TOOL 6805-1 VALVE OR 6805-2HCU BLEED AIR FROM BOTH PRES- SPECIAL C-4007-A SURE GAUGES HERE TOOL MASTER CYLINDER 5 - 18 BRAKES DIAGNOSIS AND TESTING (Continued) The test procedure is the same for both rear wheel (8) Install Pressure Gauge,...
  • Page 96 BRAKES 5 - 19 DIAGNOSIS AND TESTING (Continued) BRAKE PROPORTIONING VALVE APPLICATIONS AND PRESSURE SPECIFICATIONS SALES BRAKE SYSTEM SPLIT INLET OUTLET SLOPE IDENTIFICATION CODE TYPE POINT PRESSURE PRESSURE 14” Disc/Drum 400 psi 0.43 Black Band 1000 psi 600-700 psi 14” Disc/Disc 400 psi 0.34 Bar Code Band...
  • Page 97 CALIPER ASSEMBLY FLEX HOSE BRAKE BLEEDER SCREW CALIPER GUIDE PIN BOLTS (2) 5 - 20 BRAKES SERVICE PROCEDURES (Continued) Fig. 33 Trapped Air in Brake Line adequate removal of all trapped air from the hydrau- Fig. 35 Open Bleeder Screw at Least One Full Turn lic system.
  • Page 98 MASTER CYLINDER FLUID RESERVOIR SPECIAL TOOL 6802 MASTER CYLINDER MASTER FLUID RESERVOIR CYLINDER SPECIAL TOOL 6802 MASTER CYLINDER WOODEN BRAKE FLUID RESERVOIR DOWEL MASTER CYLINDER SPECIAL TOOL 6802 BRAKES 5 - 21 SERVICE PROCEDURES (Continued) MASTER CYLINDER BLEEDING (1) Clamp the master cylinder in a vise. Attach Bleeding Tubes, Special Tool 6802 to the master cyl- inder (Fig.
  • Page 99 BRAKING DISC GRINDER ROTOR MINIMUM NESS MARKING ROTOR THICK- 5 - 22 BRAKES SERVICE PROCEDURES (Continued) Fig. 41 Minimum Brake Rotor Thickness Markings (Typical) REFACING BRAKE ROTOR Refacing of the rotor is not required each time the brake pads are replaced. Fig.
  • Page 100 CENTER CENTER CENTER CON- ATTACHING SCREWS SOLE LINER SOLE CON- ASSEMBLY CONSOLE CENTER ATTACHING SCREWS CONSOLE ATTACHING SCREWS ARMREST PARK WITH HAND LEVER CENTER BRAKE PAS- SENGER SEAT CONSOLE RADIO BRAKES 5 - 23 SERVICE PROCEDURES (Continued) BRAKE DRUM MACHINING Measure drum runout and diameter.
  • Page 101 5 - 24 BRAKES CONSOLE BRACKET PARK BRAKE ASSEMBLY PARK BRAKE LEVER ASSEM- GRASP PIN WITH PLIERS OUTPUT CABLE AND QUICKLY REMOVE SERVICE PROCEDURES (Continued) FROM PARK BRAKE LEVER ASSEMBLY (6) Grasp park brake lever output cable by hand mechanism. This will allow the park brake lever and pull upward (Fig.
  • Page 102 INVERTED TUBE NUT FLARE TUBE INVERTED DOUBLE FLARE SEAT BE SURE ALL BURRS ARE REMOVED FROM INSIDE OF TUBING HYDRAULIC BRAKE TUBING LINE BE SURE END OF TUBING IS SQUARE BEFORE FLARING TUBE DOUBLE INVERTED-STYLE FLARE BRAKES 5 - 25 SERVICE PROCEDURES (Continued) tinue to screw down until tool is firmly seated in tub- ing.
  • Page 103 CALIPER ASSEMBLY GUIDE STEERING DISC BRAKE CALI- PER ASSEMBLY KNUCKLE PIN BOLTS BRAKING DISC DRIVESHAFT LOWER CONTROL SLIDE THIS END OF CALI- PER FROM UNDER STEER- LIFT THIS END OF CALIPER AWAY WIRE HANGER DISC BRAKE CALIPER DISC BRAKE CALIPER FROM KNUCKLE FIRST ING KNUCKLE...
  • Page 104 SLIDE TOP OF BRAKE CALI- MENT STEERING KNUCKLE BRAKE DISC BRAKE CALIPER UNDER KNUCKLE AS SHOWN BRAKING DISC ABUTMENT STEERING ABUT- BRAKES 5 - 27 REMOVAL AND INSTALLATION (Continued) If inspection reveals that the square sectioned cal- iper piston seal is worn or damaged, it should be replaced immediately.
  • Page 105 WHEEL DISC WIRE HANGER DISC BRAKE CALIPER STEERING KNUCKLE BRAKE MOUNTING ASSEMBLY (STORED) CALIPER ROTOR STUD HOLE BRAKE HYDRAULIC HOSE STEERING KNUCKLE BRAKE DISC CALIPER INBOARD ASSEMBLY BRAKE SHOE SCREWDRIVER STEERING KNUCKLE PISTON HANGER WIRE HANGER WIRE OUTBOARD HUB/BEARING BRAKE PAD RETAINING CLIP ASSEMBLY BRAKE...
  • Page 106 BRAKES 5 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 64 Front Brake Shoe Identification Fig. 66 Installing Outboard Brake Shoe BRAKE SHOE PISTON CALIPER ASSEMBLY (5) Install the new inboard brake shoe into the cal- iper piston by firmly pressing into piston bore with thumbs (Fig.
  • Page 107 CALIPER GUIDE PIN BRAKING DISC BOLTS LOWER ADAPTER ABUTMENT MACHINED CALIPER ADAPTER DISC BRAKE CALIPER FLEX HOSE CALIPER ASSEMBLY BRAKING DISC STRUT DRUM-IN-HAT DISCSHIELD WIRE HANGER PARKING BRAKE CALIPER 5 - 30 BRAKES REMOVAL AND INSTALLATION (Continued) (3) Remove the 2 caliper assembly to adapter guide pin bolts (Fig.
  • Page 108 BRAKES 5 - 31 REMOVAL AND INSTALLATION (Continued) removal procedure (Fig. 69). Make sure that the cal- If inspection reveals that the square sectioned cal- iper guide pin bolts, bushings and sleeves are clear of iper piston seal is worn or damaged, it should be the adapter bosses.
  • Page 109 FLEX HOSE CALIPER ASSEMBLY BRAKING DISC STRUT DRUM-IN-HAT DISCSHIELD WIRE HANGER PARKING BRAKE CALIPER FINGERS RETAINING CLIP 5 - 32 BRAKES REMOVAL AND INSTALLATION (Continued) (5) Support caliper assembly firmly from rear strut (7) Remove outboard brake pad from caliper by to prevent weight of caliper from damaging the flex- prying brake pad retaining clip over raised area on ible brake hose (Fig.
  • Page 110 BRAKES 5 - 33 REMOVAL AND INSTALLATION (Continued) cedures in Disc Brake Caliper Service in this section times to insure the vehicle has a firm brake of the service manual. pedal. . Check the caliper dust boot and caliper pin bush- (12) Road test the vehicle and make several stops ings to determine if they are in good condition.
  • Page 111 5 - 34 BRAKES REMOVAL AND INSTALLATION (Continued) REAR BRAKE SHOES REMOVE (1) Raise vehicle on jackstands or centered on a hoist. See Hoisting in the Lubrication and Mainte- nance section of this manual. (2) Remove the rear wheel and tire assemblies from the vehicle.
  • Page 112 BRAKES 5 - 35 REMOVAL AND INSTALLATION (Continued) CLEANING AND INSPECTION Clean metal portion of brake shoes. Check to see if shoes are bent. Lining should show contact across entire width and from heel to toe, otherwise replace. Shoes with lack of contact at toe or heel may be improperly ground.
  • Page 113 PARK BRAKE LEVER BRAKE SHOE ASSEMBLY PARK BRAKE LEVER RETAINING CLIP SCREWDRIVER HUB/BEARING ASSEMBLY HUB/BEARING ASSEMBLY RETAINING NUT DUST CAP SPINDLE 5 - 36 BRAKES REMOVAL AND INSTALLATION (Continued) (2) Assemble front and rear brake shoe assembly, REAR BRAKE SHOE SUPPORT PLATE automatic adjuster screw and upper return spring before installation on brake support plate.
  • Page 114 BRAKES 5 - 37 REMOVAL AND INSTALLATION (Continued) (5) Remove the rear brake shoes from the brake (9) Remove the 4 brake support plate to knuckle support plate. Refer to Rear Brake Shoes in the attaching bolt and washer assemblies. Separate Removal And Installation Section in this group of the BRAKE SUPPORT...
  • Page 115 WHEEL BRAKE SUPPORT O-RING CYLIN- WHEEL CYLINDER ASSEM- PLATE WHEEL ATTACHING BOLTS CYLINDER REAR BRAKE FLEX HOSE SUPPORT PLATE TUBE HUB/BEARING ASSEMBLY BRAKE SUPPORT PLATE WHEEL STUDS BRAKE DRUM 5 - 38 BRAKES REMOVAL AND INSTALLATION (Continued) (6) Disconnect the rear brake flex hose from the (4) Install rear brake shoe assemblies on the brake wheel cylinder (Fig.
  • Page 116 BRAKING DISC DRUM-IN-HAT DISCSHIELD PARKING BRAKE HUB/BEARING ASSEMBLY RETAINING NUT SPINDLE BRAKES 5 - 39 HUB/BEARING ASSEMBLY DUST CAP REMOVAL AND INSTALLATION (Continued) CALIPER GUIDE PIN BOLTS DISC BRAKE CALIPER Fig. 99 Hub/Bearing Assembly Retaining Nut (1) Position hub/bearing assembly on rear spindle. (2) Install a new hub nut (Fig.
  • Page 117 MASTER CYLINDER PROPOR- TIONINGVALVES SECONDARY BRAKE TUBE PRIMARY BRAKE TUBE ANTILOCK BRAKES H.C.U. 5 - 40 BRAKES REMOVAL AND INSTALLATION (Continued) MASTER CYLINDER BRAKE VACUUM BRAKE FLUID RESERVOIR BOOSTER MASTER CYL- I NDER MOUNTING NUTS (2) REMOVE CAUTION: On ABS equipped vehicles, vacuum in power booster must be pumped down before removing master cylinder to prevent booster from sucking in any contamination.
  • Page 118 BRAKES 5 - 41 REMOVAL AND INSTALLATION (Continued) brake vacuum booster. Vacuum seal is removed by carefully inserting a small screw driver between the push rod of the power brake vacuum booster and vac- POWER BRAKE VAC- UUM BOOSTER PUSH SCREWDRIVER TO REMOVE LIP SEAL INSERT...
  • Page 119 NOTCHES SEAL MUST BE POINTING TOWARD ANTILOCK BRAKES MASTER LUBRICATING SURFACE OF ROD IN PUSH ROD VACUUM SEAL CYLINDER WHEN MASTER THIS AREA BRAKE FLUID RESER- INSTALLED ENTIRE SEAL VACUUM CYLIN- VOIR MASTER CYLINDER HOUSING PUSH ROD VACUUM SEAL IS TO BE SEATED AGAINST MASTER CYLINDER HOUS- VACUUM SEAL ING AS SHOWN...
  • Page 120 POWER BRAKE BOOSTER MASTER MASTER CYLINDER CYLINDER FLUID RESERVOIR BRAKE LEVEL SENSOR BRAKE FLUID ANTILOCK BRAKES PROPOR- TIONINGVALVES SECONDARY H.C.U. BRAKE TUBE PRIMARY BRAKE TUBE MASTER CYL- I NDER BRAKE FLUID RES- PRIMARY SECONDARY BRAKE TUBES MASTER MOUNTING NUTS ERVOIR BRAKE TUBES CYLINDER...
  • Page 121 POWER BRAKE VAC- UUM BOOSTER PUSH SCREWDRIVER TO REMOVE LIP SEAL INSERT HERE POWER VACUUM BOOSTER BRAKE SCREW- LIP SEAL DRIVER BRAKE PEDAL BRAKE P EDAL POWER BOOSTER SCREWDRIVER INPUT ROD MOUNTING BRAKE NUTS RETAINING CLIP BRAKE PEDAL PIN VACUUM HOSES CHECK VALVE POWER...
  • Page 122 LUBRICATING SURFACE OF ROD IN PUSH ROD THIS AREA BRAKE FLUID RESER- ENTIRE VOIR ANTILOCK BRAKES MASTER CYLINDER MASTER CYLINDER HOUS- VACUUM SEAL IS TO BE SEATED AGAINST MASTER CYLINDER HOUS- VACUUM S EAL VACUUM SEAL PUSH ROD ING AS SHOWN NOTCHES NOTCHES ON VACUUM SEAL MUST CYLINDER...
  • Page 123 5 - 46 BRAKES REMOVAL AND INSTALLATION (Continued) (10) Install the 2 master cylinder mounting nuts (Fig. 115) and torque to 28 N·m (250 in. lbs.) torque. (11) Connect brake tubes to master cylinder pri- mary and secondary ports (Fig. 113) and (Fig. 114). Torque all tube nuts to 17 N·m (145 in.
  • Page 124 BRAKES 5 - 47 REMOVAL AND INSTALLATION (Continued) INSTALL (1) Wet O-ring seal on new proportioning valve using clean fresh brake fluid. (2) Install proportioning valve in master cylinder and hand tighten until proportioning valve and O-ring seal is fully seated in master cylinder. Torque proportioning valve to 40 N·m (30 ft.
  • Page 125 5 - 48 BRAKES REMOVAL AND INSTALLATION (Continued) (9) Remove the 2 nuts (Fig. 131) attaching the park brake lever to the console bracket. Remove park brake lever mechanism from vehicle. Fig. 128 Locking Pin Installed In Park Brake Mechanism Fig.
  • Page 126 RELEASE BUTTON PARK ASSEMBLY OUTPUT CABLE HANDLE CLOCK SPRING BRAKE LEVER PARK BRAKE CABLE EQUALIZER OUTPUT CENTER CENTER CON- ATTACHING SCREWS SOLE LINER ASSEMBLY CONSOLE CENTER CONSOLE ATTACHING SCREWS ARMREST PARK WITH HAND LEVER CENTER BRAKE PAS- SENGER SEAT CONSOLE BRAKES 5 - 49 REMOVAL AND INSTALLATION (Continued)
  • Page 127 5 - 50 BRAKES REMOVAL AND INSTALLATION (Continued) WARNING: WHEN REPAIRS TO THE PARK BRAKE HAND LEVER ASSEMBLY CABLES REQUIRED, THE AUTO ADJUSTER MUST RELOADED AND LOCKED OUT. (5) Lower park brake lever handle. (6) Grasp park lever output cable by hand and pull rearward (Fig.
  • Page 128 WHEEL MOUNTING STUDS REAR SPINDLE HUB/BEARING HUB/BEARING ASSEMBLY BRAKE SUPPORT PLATE BRAKING DISC WHEEL STUDS BRAKE DRUM DRUM-IN-HAT DISCSHIELD PARKING BRAKE HUB/BEARING HUB/BEARING ASSEMBLY ASSEMBLY DUST CAP RETAINING NUT SPINDLE BRAKES 5 - 51 REMOVAL AND INSTALLATION (Continued) adapter, and then remove rotor (Fig. 142) from hub/ bearing assembly.
  • Page 129 BRAKE ADJUSTER PARK BRAKE CABLE SHOE STONE SHIELD ASSEM- BLIES RETURN SPRING PARK BRAKE SHOE ASSEM- PARK BRAKE ACTUAT- BRAKE SHOE ADJUST- ADJUSTMENT ING LEVER ACTUATING SPRING MENT LEVER BLIES PARK BRAKE SHOE HOLD-DOWN CLIPS LEVER DISC ADAPTER BRAKE PARK BRAKE CABLE PARK ACTUATOR LEVER BRAKE...
  • Page 130 PARK BRAKE CABLE SCREW DRIVER ROUTING BRACKET RETAINER FUEL FILTER PARK BRAKE CABLE TENSION STRUT DISC FRAME RAIL ADAPTER BRAKE FUEL TANK SEALING GROM- PARK BRAKE CABLE FLOOR PAN STONE SHIELD PARK BRAKE CABLE BRAKES 5 - 53 REMOVAL AND INSTALLATION (Continued) (21) On vehicles equipped with rear disc brakes, remove park brake cable (Fig.
  • Page 131 CALIPER GUIDE PIN VEHICLE CARPETING BOLTS FLOOR PAN SEAL VEHICLE WIRING HARNESS DISC BRAKE CALIPER GROM- 5 - 54 BRAKES REMOVAL AND INSTALLATION (Continued) CONSOLE BRACKET PARK BRAKE ASSEMBLY PARK BRAKE LEVER ASSEM- GRASP PIN WITH PLIERS OUTPUT CABLE AND QUICKLY REMOVE FROM PARK BRAKE...
  • Page 132 HOLD DOWN CLIP UPPER SPRING REAR BRAKE PARK- SHOE LOWER SPRING HOLDDOWN CLIP BRAKES 5 - 55 ADJUSTER REMOVAL AND INSTALLATION (Continued) Fig. 158 Rear Brake Shoe Hold-Down Clip Fig. 160 Brake Shoe Lower Return Spring (8) Remove adjuster assembly from the parking brake shoe assemblies (Fig.
  • Page 133 HOLD DOWN CLIP FRONT SHOE ASSEMBLY BRAKE STRIKER BRAKE LIGHT SWITCH BRAKE PEDAL SWITCH BRACKET 5 - 56 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 163 Stop Lamp Switch (1) Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until it has ratcheted out to its fully extended position.
  • Page 134 MASTER CYLIN- FLUID MASTER FLUID RESER- BRAKE RESER- VOIR BRAKE CYLIN- VOIR POWER BRAKE FLUID LEVEL SWITCH RETAINING BOOSTER MASTER CYLINDER MASTER TABS MASTER CYLINDER CYLINDER BRAKE FLUID RESERVOIR BRAKE LEVEL SWITCH LEVEL SENSOR MASTER CYL- I NDER BRAKE FLUID FLUID BRAKES 5 - 57...
  • Page 135 SLEEVE CALIPER BUSHING CALIPER CALIPER GUIDE PIN BUSHING BUSHING 5 - 58 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) (5) Install the wiring harness connector onto the (3) Using your fingers, collapse one side of the brake fluid level switch. bushing. Then pull on the opposite side to remove the bushing from the brake caliper housing (Fig.
  • Page 136 BE SURE BOTH BUSHING FLANGES ARE FULLY SEATED AROUND CALIPER BUSH- CALIPER ING BORES. BUSHING CALIPER BUSHING CALIPER CALIPER BE SURE THE BUSHING IS FULLY SEATING IN SEAL GROOVE OF SLEEVE AS SHOWN. BUSHINGSLEEVE BUSHING SLEEVE BRAKES 5 - 59 DISASSEMBLY AND ASSEMBLY (Continued) Fig.
  • Page 137 CALIPER PISTON SEAL PLASTIC TRIM STICK PISTON SEAL GROOVE SCREW DRIVER CALIPER BOOT 5 - 60 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) held between your fingers and easily slid back and forth without the bushing unseating from the sleeve groove. CALIPER DISASSEMBLY WARNING: UNDER NO CONDITION SHOULD AIR PRESSURE EVER BE USED TO REMOVE A PISTON...
  • Page 138 CALIPER CALIPERBORE SPECIAL C-4095 TOOL BRAKES 5 - 61 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 178 Installing New Piston Seal In Caliper CAUTION: Force must be applied to the piston uni- formly to avoid cocking and binding of the piston in the bore of the caliper.
  • Page 139 CALIPER PUSH-ON BOOT SPECIAL C-4171 TOOL PISTON CYLINDER SPECIAL HAMMER C-4689 TOOL BLEEDER SCREW EXPANDERS SPRING PISTON PUSH-ON BOOT 5 - 62 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) (11) Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly banjo bolt to 33 N·m (24 ft.
  • Page 140 BRAKES 5 - 63 DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLE is damaged, or a fluid leak is visible, disassemble cal- Before assembling the pistons and new cups in the iper assembly and install a new seal and boot, and wheel cylinders, dip them in clean brake fluid. If the piston if scored.
  • Page 141 5 - 64 BRAKES CLEANING AND INSPECTION (Continued) REAR DRUM BRAKES contact with moving or hot components of the vehi- cle. Rear brake shoe lining should show contact across entire width of the lining and also from the heel to REAR WHEEL HUB AND BEARING ASSEMBLY the toe of the lining, otherwise replace.
  • Page 142 BRAKES 5 - 65 ADJUSTMENTS (Continued) BRAKE HOLE PLUG ADJUSTING REAR STRUT REAR BRAKE SUPPORT PLATE Fig. 185 Brake Drum Adjustment With Tool C-3784 Fig. 183 Stop Light Switch Location In Vehicle (5) Insert a thin screwdriver or piece of welding REAR DRUM BRAKE SHOE ADJUSTMENT rod into brake adjusting hole (Fig.
  • Page 143 5 - 66 BRAKES SPECIFICATIONS (Continued) only Mopar brake fluid or an equivalent from a BRAKE FASTENER TORQUE SPECIFICATIONS tightly sealed container. DESCRIPTION TORQUE CAUTION: Never use reclaimed brake fluid or fluid BRAKE TUBES: from an container which has been left open. An Tube Nuts To Fittings And open container will absorb moisture from the air Components Except HCU.
  • Page 144 BRAKES 5 - 67 SPECIAL TOOLS BASE BRAKE SYSTEM Installer, Dust Boot C-4689 Adapters, Brake Pressure Test 6805 Dial Indicator C-3339 Gauge Set C-4007-A Tubes, Master Cylinder Bleeding 6802 Handle, Universal C-4171...
  • Page 145 5 - 68 BRAKES ANTILOCK BRAKE SYSTEM–BENDIX ABX-4 INDEX page page DESCRIPTION AND OPERATION DIAGNOSTIC TESTER (DRB) ....74 ABS BRAKING MODE HYDRAULIC CIRCUIT DIAGNOSTIC TROUBLE CODE SOLENOID AND VALVE FUNCTION .
  • Page 146 BRAKES 5 - 69 DESCRIPTION AND OPERATION (Continued) ABS OPERATION AND VEHICLE PERFORMANCE vehicles tires leaving the road surface rendering the vehicle virtually uncontrollable. In addition, extreme This ABS System represents the current state-of- steering maneuvers at high speed or high speed cor- the-art in vehicle braking systems and offers the nering beyond the limits of tire adhesion to the road driver increased safety and control during braking.
  • Page 147 SECONDARY PROPOR- TIONINGVALVES ANTILOCK BRAKES BRAKE TUBE H.C.U. MASTER CYLINDER PRIMARY BRAKE TUBE 5 - 70 BRAKES MASTER MASTER PRIMARY OUTLET CYLINDER CYLINDER ONDARY OUTLET SEC- HYDRAULIC POWER ABX-4 MASTER CYL- UNIT (HCU) BOOSTER CONTROL BRAKE INDER DESCRIPTION AND OPERATION (Continued) MASTER CYLINDER AND POWER BRAKE BOOSTER The Bendix ABX-4 ABS System uses a modified master cylinder and power brake booster assembly...
  • Page 148 SYSTEM RELAY AND PUMP/ MOTOR RELAY BOX SYSTEM RELAY AND PUMP/MO- TOR RELAY BOX 10 WAY CON- NECTOR 6-WAY NECTOR CON- TO REAR BRAKE LINE COLORED CATION BAND IDENTIFI- O-RING SEAL TO MASTER CYLINDER OR HYDRAULIC CONTROL UNIT BRAKES 5 - 71 DESCRIPTION AND OPERATION (Continued) HYDRAULIC CONTROL UNIT PUMP MOTOR SYSTEM RELAY OPERATION...
  • Page 149 5 - 72 BRAKES DESCRIPTION AND OPERATION (Continued) WHEEL SPEED SENSORS One Wheel Speed Sensor (WSS) is located at each wheel (Fig. 5), (Fig. 6) and (Fig. 7), and sends a small AC signal to the control module (CAB). This signal is generated by magnetic induction created when a toothed sensor ring (tone wheel) (Fig.
  • Page 150 BRAKES 5 - 73 DESCRIPTION AND OPERATION (Continued) ABS WARNING LAMP FUNCTION AND LOCATION The ABS system uses an Amber ABS Warning Lamp, located in the instrument cluster. The purpose of the warning lamp is discussed in detail below. The ABS warning lamp will turn on when the CAB detects a condition which results in a shutdown of ABS function.
  • Page 151 5 - 74 BRAKES DESCRIPTION AND OPERATION (Continued) passes through the de-energized decay solenoid and to the wheel brakes to restore braking pressure. DIAGNOSIS AND TESTING ABS GENERAL DIAGNOSTICS INFORMATION This section contains information necessary to diagnose and test the Bendix ABX-4 Brake System. Specifically, this section should be used to help diag- nose conditions which result in any of the following: •...
  • Page 152 BRAKES 5 - 75 DIAGNOSIS AND TESTING (Continued) erased automatically is the (CAB) fault. A (CAB) (8) Low system voltage. If Low System Voltage is fault can only be erased by the technician using the detected by the CAB, the CAB will turn on the ABS DRB diagnostic tester.
  • Page 153 5 - 76 BRAKES DIAGNOSIS AND TESTING (Continued) a malfunction has occurred with one of the propor- Warning Lamp goes on refer to the ABX-4 Diagnostic tioning valves. Manual. One proportioning valve controls the right rear (3) If the ABS Warning Lamp remains OUT, drive brake, and the other proportioning valve controls the the vehicle a short distance.
  • Page 154 BRAKES 5 - 77 SERVICE PROCEDURES (Continued) ABS system, particularly the HCU, should only be bled when the HCU is replaced or removed from the vehicle, or if there is reason to believe the HCU has ingested air. Under most circumstances that would require brake bleeding, only the base brake system needs to be bled.
  • Page 155 POWER BRAKE BOOSTER MASTER MASTER CYLINDER CYLINDER FLUID RESERVOIR BRAKE LEVEL SENSOR BRAKE FLUID MASTER CYLINDER PROPOR- TIONINGVALVES SECONDARY BRAKE TUBE PRIMARY BRAKE TUBE ANTILOCK BRAKES H.C.U. 5 - 78 BRAKES REMOVAL AND INSTALLATION (Continued) CAUTION: Brake fluid will damage painted sur- faces.
  • Page 156 BRAKES 5 - 79 10-WAY NECTOR CON- RELAY BOX POWER VACUUM BOOSTER 6-WAY NECTOR BRAKE CON- REMOVAL AND INSTALLATION (Continued) (7) Disconnect the 6 way connector from the HCU wiring harness and 10 way connector from the relay box located on the HCU (Fig. 15). Fig.
  • Page 157 5 - 80 BRAKES REMOVAL AND INSTALLATION (Continued) (8) Install primary and secondary brake tubes Grease—And No Substitutes. Refer to the Mopar (Fig. 16) from the master cylinder onto the HCU, Chemicals Catalog to obtain the required lubricant. with tube nuts only hand tightened. (9) Install vehicle wiring harness connectors onto the 10 way, and 6 way connectors, located on the relay box of the HCU (Fig.
  • Page 158 BRAKES 5 - 81 REMOVAL AND INSTALLATION (Continued) Fig. 22 Vacuum Seal Positioned For Installing Fig. 23 Rear Wheel Proportioning Valve Location On Master Cylinder (15) Install the 2 master cylinder to power brake (2) Install proportioning valve in HCU and hand unit mounting nuts (Fig.
  • Page 159 PULL RELAY BOX IN THIS DIRECTION RELAY BOX MOUNT- HCU RELAY BOX RELAY BOX CONNECTOR ING SCREWS RELAY BOX PUMP MOTOR MOUNT- ING SCREWS DO NOT 6-WAY PUMP MOTOR CONNECTOR NESS CONNECTOR WIRING REMOVE PUMP M OTOR AND SEAL HAR- PUMP MOTOR 5 - 82...
  • Page 160 DIAGNOSTIC LEFT PANEL CONNECTOR INSTRUMENT MOUNTING BRACKET RETAININGBOLT 60-WAY CONTROLLER ANTILOCK 60–WAY BRAKES NECTOR NECTOR CON- CON- MOUNTING STUDS (2) MOUNTING NUTS CAB BRACKET BRAKES 5 - 83 REMOVAL AND INSTALLATION (Continued) CONTROLLER ANTILOCK BRAKES (CAB) The CAB is mounted under the instrument panel on the drivers side kick panel of the vehicle (Fig.
  • Page 161 WHEEL FRONT SION CROSSMEM- TIE ROD END SUSPEN- BOLT STEERING KNUCKLE BER ROUTING CLIP FLOOR PAN VEHICLE WIRING HAR- ROTOR NESS SPEED SENSOR CABLE (LEFT FRONT WHEEL SPEED SENSOR TONE WHEEL DRIVESHAFT FRONT SHOWN) STEERING GEAR GROM- STRUT METS SPEED SENSOR CABLE SPEED...
  • Page 162 BRAKE EXHAUST PIPE BRAKE CHASSIS SPEED LINE SPEED SENSOR CABLE HOSE FLEX BOLT SENSOR HEAD VEHICLE FRAME SPEED CLIP SENSOR CABLE VEHICLE WIRING HARNESS BOLT REAR SPEED SENSOR CABLE ROUTING STRUT BRACKET BRAKES 5 - 85 REMOVAL AND INSTALLATION (Continued) (3) Unplug speed sensor cable connector from vehi- INSTALL cle wiring harness (Fig.
  • Page 163 5 - 86 BRAKES SPECIFICATIONS (Continued) DESCRIPTION TORQUE REAR WHEEL CYLINDER: To Support Plate Mounting Bolts ... 13 N·m (115 in. lbs.) Bleeder Screw ....10 N·m (80 in. lbs.) BRAKE SUPPORT PLATE: To Axle Mounting Bolts .
  • Page 164 CLUTCH 6 - 1 CLUTCH CONTENTS page page GENERAL INFORMATION CLUTCH CABLE ......7 CLUTCH COMPONENTS ....1 CLUTCH PEDAL POSITION SWITCH .

  • Page 165: General Information

    CLUTCH PEDAL PIVOT PIN SPRING CLIP BUSHINGS CLUTCH PEDAL BRAKE PEDAL PIVOT PIN PEDAL BRACKET BRAKE PEDAL BUSHINGS DASH PANEL CLUTCH PEDAL TION SWITCH SELF ADJUSTING MECHA- POSI- CLUTCH CABLE NISM TRANSAXLE LEFT STRUT TOWER PRELOAD SPRING CLIP BRACKET MOUNT CLUTCH CABLE CLUTCH PEDAL 6 - 2...
  • Page 166 CLUTCH 6 - 3 DIAGNOSIS AND TESTING (Continued) CLUTCH PEDAL POSITION Slowly depress the clutch pedal and feel for any SWITCH–MECHANICAL TEST vehicle motion when the starter is energized. If there With the park brake set and the vehicle IN NEU- is no motion, the switch is working properly.
  • Page 167 6 - 4 CLUTCH DIAGNOSIS AND TESTING (Continued) CLUTCH DIAGNOSIS Drive the vehicle at normal speeds during road test. Shift the transaxle through all gear ranges and Problem diagnosis will generally require a road observe clutch action. If chatter, grab, slip, or test to determine the type of fault.
  • Page 168 CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—CLUTCH SLIPS CONDITION POSSIBLE CAUSES CORRECTION DISC FACING WORN OUT Normal wear. Replace w/modular clutch assembly. Driver frequently rides (slips) clutch, Replace w/modular clutch assembly results in rapid wear overheating. Insufficient clutch cover diaphragm Replace w/modular clutch assembly spring tension CLUTCH DISC FACING...
  • Page 169 6 - 6 CLUTCH DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—IMPROPER CLUTCH RELEASE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC BINDS ON INPUT Clutch disc hub splines damaged Clean, smooth, and lubricate disc SHAFT SPLINES during installation and shaft splines. Replace w/modular clutch assembly and/or input shaft if splines are severely damaged.

  • Page 170: Clash-Into-Reverse Complaints

    CLUTCH 6 - 7 DIAGNOSIS AND TESTING (Continued) DRIVE PLATE MISALIGNMENT CLASH–INTO–REVERSE COMPLAINTS Common causes of misalignment are: Certain NV T350 (A-578) manual transaxles are • Heat warping equipped with a reverse brake. It prevents clash • Mounting drive plate on a dirty crankshaft when shifting into reverse, but only if the vehicle is flange not moving.
  • Page 171 6 - 8 CLUTCH REMOVAL AND INSTALLATION (Continued) (4) Guide cable through slot in transaxle and dis- ADJUSTER MECHANISM FUNCTION CHECK connect cable from release lever. (1) With slight pressure, pull the clutch release (5) Disconnect clutch cable up-stop/spacer with lever end of the cable to draw the cable taut.
  • Page 172 FLYWHEEL DOWELS (3) PRESSURE PLATE CLUTCH 6 - 9 REMOVAL AND INSTALLATION (Continued) switch wires to seat switch into bracket, switch dam- hands onto the clutch disc facing may cause clutch age may occur. chatter. (3) Attach switch wiring harness to vehicle wiring (5) Remove the clutch pressure plate and cover harness.

  • Page 173: Release Bearing And Fork

    DOWEL PINS ENGINE CLUTCH DISC FLYWHEEL CLUTCH COVER SPECIAL TOOL TRANSAXLE ENGINE UPPER COVER UPPER COVER CASE DRIVE PLATE BOLT DRIVE PLATE CLUTCH BOLT CRANKSHAFT CLUTCH ASSEMBLY PLATE BOLT DRIVE PLATE BOLT BACKING DRIVE PLATE TRANSAXLE 6 - 10 CLUTCH REMOVAL AND INSTALLATION (Continued) from discoloration, burned areas, cracks, grooves, or (5) Remove transaxle.

  • Page 174: Cleaning And Inspection

    CLUTCH 6 - 11 REMOVAL AND INSTALLATION (Continued) two hands in the pivot stud socket area. Pull with GREASE CONTAMINATION even pressure and the lever will pop off the pivot- Grease contamination is usually a product of over- –stud. Do not use a screwdriver or pry bar to pop off lubrication.

  • Page 175: Clutch Pedal Position Switch

    DASH PANEL SELF ADJUSTING MECHA- EGR TUBE NISM TRANSAXLE LEFT STRUT TOWER PRELOAD SPRING CLUTCH CABLE BELLHOUSING BRACKET MOUNT CLUTCH CABLE CLUTCH PEDAL TION SWITCH POSI- CLUTCH CABLE CLIP CLUTCH PEDAL 6 - 12 CLUTCH ADJUSTMENTS (Continued) Fig. 10 Clutch Cable Routing Fig.
  • Page 176 CLUTCH 6 - 1 CLUTCH CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION CLUTCH COMPONENTS ....1 CLUTCH ASSEMBLY ..... 8 CLUTCH DISC AND COVER APPLICATION .

  • Page 177: Description And Operation

    6 - 2 CLUTCH DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING HYDRAULIC CLUTCH SYSTEM CLUTCH PEDAL POSITION SWITCH The hydraulic clutch linkage consists of a clutch CLUTCH PEDAL POSITION master cylinder, remote hydraulic fluid reservoir, SWITCH–ELECTRICAL TEST lower clutch slave cylinder, damper, and hydraulic Disconnect clutch pedal position switch harness lines.
  • Page 178 CLUTCH 6 - 3 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS–CLUTCH PEDAL POSITION SWITCH CONDITION POSSIBLE CAUSES CORRECTION ENGINE WON’T CRANK WHEN Switch does not have continuity Defective switch. Replace switch. CLUTCH PEDAL IS PRESSED TO when plunger is depressed 1.25 mm THE FLOOR Switch plunger is not depressed Floor mat interferes with clutch pedal...
  • Page 179 6 - 4 CLUTCH DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—CLUTCH SLIPS CONDITION POSSIBLE CAUSES CORRECTION DISC FACING WORN OUT Normal wear. Replace w/modular clutch assembly. Driver frequently rides (slips) clutch, Replace w/modular clutch assembly results in rapid wear and overheating. Insufficient clutch cover diaphragm Replace w/modular clutch assembly spring tension...
  • Page 180 CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—IMPROPER CLUTCH RELEASE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC BINDS ON INPUT Clutch disc hub splines damaged Clean, smooth, and lubricate disc SHAFT SPLINES during installation and shaft splines. Replace w/modular clutch assembly and/or input shaft if splines are severely damaged.

  • Page 181: Clash-Into-Reverse Complaints

    6 - 6 CLUTCH DIAGNOSIS AND TESTING (Continued) DRIVE PLATE MISALIGNMENT vehicle is not moving. See Group 21, Transaxle for further diagnosis. Common causes of misalignment are: • Heat warping (1) Depress clutch pedal to floor and hold. After • Mounting drive plate on a dirty crankshaft three seconds, shift to reverse.
  • Page 182 CLUTCH 6 - 7 REMOVAL AND INSTALLATION (Continued) (9) Remove cylinder from dash panel. INSTALLATION NOTE: Verify that the reservoir cap is on securely. This is necessary to avoid undue spillage during installation. (1) Position clutch master cylinder to dash panel approximately 45°...

  • Page 183: Clutch Pedal Position Switch

    6 - 8 CLUTCH REMOVAL AND INSTALLATION (Continued) HYDRAULIC SLAVE CYLINDER CLUTCH PEDAL POSITION SWITCH The clutch pedal position switch is mounted to a REMOVAL bracket located behind the clutch pedal. The switch (1) Raise vehicle on hoist. is held in place by four plastic wing tabs. (2) Separate hydraulic line at quick-disconnect The clutch pedal position switch IS NOT adjust- using Special Tool 6638.

  • Page 184: Release Bearing And Fork

    CLUTCH 6 - 9 REMOVAL AND INSTALLATION (Continued) (5) Remove transaxle. See Group 21, Manual Tran- two hands in the pivot stud socket area. Pull with saxle, for procedure. even pressure and the lever will pop off the pivot- (6) The transaxle and modular clutch come out as –stud.

  • Page 185: Cleaning Precautions

    6 - 10 CLUTCH CLEANING AND INSPECTION (Continued) GREASE CONTAMINATION ADJUSTMENTS Grease contamination is usually a product of over- lubrication. During clutch service, apply only a small CLUTCH PEDAL POSITION SWITCH amount of grease to the input shaft splines. Excess The clutch pedal position switch is mounted to a grease may be thrown off during operation, contami- bracket located behind the clutch pedal.
  • Page 186 CLUTCH 6 - 1 CLUTCH CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION CLUTCH COMPONENTS ....1 CLUTCH ASSEMBLY ..... 8 CLUTCH DISC AND COVER APPLICATION .

  • Page 187: Description And Operation

    6 - 2 CLUTCH DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING HYDRAULIC CLUTCH SYSTEM CLUTCH PEDAL POSITION SWITCH The hydraulic clutch linkage consists of a clutch CLUTCH PEDAL POSITION master cylinder, remote hydraulic fluid reservoir, SWITCH–ELECTRICAL TEST lower clutch slave cylinder, damper, and hydraulic Disconnect clutch pedal position switch harness lines.
  • Page 188 CLUTCH 6 - 3 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS–CLUTCH PEDAL POSITION SWITCH CONDITION POSSIBLE CAUSES CORRECTION ENGINE WON’T CRANK WHEN Switch does not have continuity Defective switch. Replace switch. CLUTCH PEDAL IS PRESSED TO when plunger is depressed 1.25 mm THE FLOOR Switch plunger is not depressed Floor mat interferes with clutch pedal...
  • Page 189 6 - 4 CLUTCH DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—CLUTCH SLIPS CONDITION POSSIBLE CAUSES CORRECTION DISC FACING WORN OUT Normal wear. Replace w/modular clutch assembly. Driver frequently rides (slips) clutch, Replace w/modular clutch assembly results in rapid wear and overheating. Insufficient clutch cover diaphragm Replace w/modular clutch assembly spring tension...
  • Page 190 CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—IMPROPER CLUTCH RELEASE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC BINDS ON INPUT Clutch disc hub splines damaged Clean, smooth, and lubricate disc SHAFT SPLINES during installation and shaft splines. Replace w/modular clutch assembly and/or input shaft if splines are severely damaged.

  • Page 191: Clash-Into-Reverse Complaints

    6 - 6 CLUTCH DIAGNOSIS AND TESTING (Continued) DRIVE PLATE MISALIGNMENT vehicle is not moving. See Group 21, Transaxle for further diagnosis. Common causes of misalignment are: • Heat warping (1) Depress clutch pedal to floor and hold. After • Mounting drive plate on a dirty crankshaft three seconds, shift to reverse.
  • Page 192 CLUTCH 6 - 7 REMOVAL AND INSTALLATION (Continued) (9) Remove cylinder from dash panel. INSTALLATION NOTE: Verify that the reservoir cap is on securely. This is necessary to avoid undue spillage during installation. (1) Position clutch master cylinder to dash panel approximately 45°...

  • Page 193: Clutch Pedal Position Switch

    6 - 8 CLUTCH REMOVAL AND INSTALLATION (Continued) HYDRAULIC SLAVE CYLINDER CLUTCH PEDAL POSITION SWITCH The clutch pedal position switch is mounted to a REMOVAL bracket located behind the clutch pedal. The switch (1) Raise vehicle on hoist. is held in place by four plastic wing tabs. (2) Separate hydraulic line at quick-disconnect The clutch pedal position switch IS NOT adjust- using Special Tool 6638.

  • Page 194: Release Bearing And Fork

    CLUTCH 6 - 9 REMOVAL AND INSTALLATION (Continued) (5) Remove transaxle. See Group 21, Manual Tran- two hands in the pivot stud socket area. Pull with saxle, for procedure. even pressure and the lever will pop off the pivot- (6) The transaxle and modular clutch come out as –stud.

  • Page 195: Cleaning Precautions

    6 - 10 CLUTCH CLEANING AND INSPECTION (Continued) GREASE CONTAMINATION ADJUSTMENTS Grease contamination is usually a product of over- lubrication. During clutch service, apply only a small CLUTCH PEDAL POSITION SWITCH amount of grease to the input shaft splines. Excess The clutch pedal position switch is mounted to a grease may be thrown off during operation, contami- bracket located behind the clutch pedal.
  • Page 196 COOLING 7 - 1 COOLING CONTENTS page page GENERAL INFORMATION WATER PUMP DIAGNOSIS ....14 ACCESSORY DRIVE BELTS ....2 SERVICE PROCEDURES AUTOMATIC TRANSMISSION OIL COOLER .

  • Page 197: General Information

    GENERATOR CONDITIONING PRESSOR COM- POWER STEERING PUMP RADIATOR COOLANT RECOV- HEAT UP SYSTEM TANK THERMOSTAT HEATER COOLDOWN HOUSING PRESSURE CAP WATER PUMP ENGINE 7 - 2 COOLING GENERAL INFORMATION (Continued) Fig. 1 Cooling System Operation Coolant flow circuit for the 2.0L engine is shown in trapped air.

  • Page 198: Automatic Transmission Oil Cooler

    COOLING 7 - 3 GENERAL INFORMATION (Continued) ENGINE THERMOSTAT The engine thermostat is located on the front of the engine (radiator side) in the thermostat housing/ engine outlet connector. The thermostat has an air bleed (vent) located in the flange and a O-ring for sealing incorporate on it.

  • Page 199: Coolant Performance

    TRANSMISSION MANUAL WITH AIR CONDITIONING COOLER NIPPLES TRANSMISSION DRAIN COCK AIR DOORS FAN MODULES MOUNTING FAS- AUTOMATIC TENERS TRANSMISSION FAN MODULE MOUNTING FAS- TENERS DRAIN COCK DRAIN COCK FAN MODULE MOUNTING FAS- WITHOUT AIR CONDITIONING TENERS LOWER MOUNTING ISOLATORS WITH AIR CONDITIONING 7 - 4 COOLING DESCRIPTION AND OPERATION (Continued)

  • Page 200: Cooling System Pressure Cap

    COOLING 7 - 5 HOSE CLAMP TOOL 6094 HOSE CLAMP VACUUM VENT VALVE (SHOWN IN SEAL- CROSS-SECTIONAL VIEW ING POSITION) TOP VIEW PRESSURE RATING PRESSURE VALVE FILLER NECK SEAL DESCRIPTION AND OPERATION (Continued) contaminated, drain, flush, and replace with fresh ON VEHICLE.

  • Page 201: Water Pump

    7 - 6 COOLING DESCRIPTION AND OPERATION (Continued) must be secured in its retainer clips, and not WATER PUMP positioned so it could contact linkages or The water pump body is made of aluminum with a exhaust manifolds and become damaged. steel impeller.

  • Page 202: Diagnosis And Testing

    COOLING 7 - 7 DIAGNOSIS AND TESTING COOLING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to On Board Diagnostic in (DTC) number 17 been set Group 25. Replace thermostat if indicating a stuck open engine necessary.
  • Page 203 7 - 8 COOLING DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 7. Coolant level low in radiator but 7. (a) Check condition of radiator HIGH OR ENGINE COOLANT not in coolant overflow/reserve cap and cap seals.
  • Page 204 COOLING 7 - 9 DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION TEMPERAUTRE GAUGE READING 1. The gauge may cycle up and 1. A normal condition. No correction IS INCONSISTENT (FLUCTUATES, down. This is due to the cycling of is necessary.
  • Page 205 7 - 10 COOLING DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as GROUND WITHOUT PRESSURE system hoses, water pump or necessary.
  • Page 206 COOLING 7 - 11 DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR CONDITIONER 1. Radiator and/or air conditioning 1. Remove restriction and/or clean PERFORMANCE (COOLING condenser is restricted, obstructed as necessary. SYSTEM SUSPECTED) or dirty. 2.
  • Page 207 7 - 12 COOLING DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION HEAT ODOR - CONT. 2. Is temperature gauge reading 2. Refer to the previous above the normal range? Temperature Gauge Reads High in these Diagnosis Charts. Repair as necessary.

  • Page 208: Accessory Drive Belt Diagnosis

    COOLING 7 - 13 DIAGNOSIS AND TESTING (Continued) ENGINE THERMOSTAT TESTING check engine light will not be lit by an open too soon condition. If it has failed open, code 17 will be set. Do The thermostat is operated by a wax filled con- not change a thermostat for lack of heater perfor- tainer (pellet) which is sealed so that when heated to mance or temperature gage position, unless code 17...

  • Page 209: Cooling System Flow Check

    7 - 14 COOLING DIAGNOSIS AND TESTING (Continued) WATER PUMP DIAGNOSIS to 104°C (220°F). At speeds below 40 mph the fan switches on at 102°C (215°F) and off at 93°C (200°F). A quick flow test to tell whether or not the pump is •...

  • Page 210: Low Coolant Level Aeration

    COOLING 7 - 15 DIAGNOSIS AND TESTING (Continued) If the needle on the dial does not fluctuate, race the engine a few times. If an abnormal amount of coolant or steam is emitted from the tail pipe, it may indicate a faulty head gasket, cracked engine block, or cracked cylinder head.

  • Page 211: Temperature Gauge Indication

    ENGINE COOLANT RECOV- (CRS) HOSE SYSTEM PRESSURE CAP COOLANT RECOVERY SYSTEM (CRS) TANK 7 - 16 COOLING DIAGNOSIS AND TESTING (Continued) Fig. 11 Pressure Testing Radiator Cap DEAERATION Air can only be removed from the system by gath- ering under the pressure cap. On the next heat up it will be pushed past the pressure cap into the CRS tank by thermal expansion of the coolant.

  • Page 212: Removal And Installation

    DRAIN COCK VALVE DRAIN HOLE FASCIA PANEL CYLINDER BLOCK PUMP BODY COOLING 7 - 17 SERVICE PROCEDURES (Continued) (1) Shut engine off and turn draincock counter- (7) Remove timing belt. Refer to Group 9, Engine clockwise to open (Fig. 13). for procedure.

  • Page 213: Engine Thermostat

    7 - 18 COOLING REMOVAL AND INSTALLATION (Continued) WATER PUMP INLET TUBE The inlet tube connects the water pump to the radiator and heater core. This tube is sealed by a O-ring and held in place by fasteners to the block. REMOVAL CAUTION: Do not use any sharp tools to remove hoses from inlet tube.
  • Page 214 COOLANT RECOVERY LOCATION THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR HOSE MOUNTING BOLTS COOLING 7 - 19 REMOVAL AND INSTALLATION (Continued) Fig. 20 Radiator Mounting Fig. 19 Thermostat/Engine Outlet Connector—DOHC RADIATOR REMOVAL WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.

  • Page 215: Radiator Fans And Motor

    7 - 20 COOLING REMOVAL AND INSTALLATION (Continued) tighten to 5.4 N·m (50 in. lbs.). Then seat the assem- REMOVAL FAN MODULE bly lower rubber isolators into the mounting holes (1) Disconnect fan motor leads from module. provided in the lower crossmember. (2) Remove fan module fasteners from radiator (3) Tighten radiator isolator mounting bracket (Fig.
  • Page 216 BOLT BOLT P/S SQUARE OPENING ADJUST PIVOT BRACKET PIVOT BOLT COOLING 7 - 21 REMOVAL AND INSTALLATION (Continued) INSTALLATION FAN MODULE (1) Install module to radiator. Torque shroud to radiator fasteners to 7.5 N·m (65 in. lbs.). (2) Connect fan motor lead. For wiring diagrams of fan motor systems Refer to 8W Wiring Dia- grams .

  • Page 217: Water Pump

    NORMAL NOT NORMAL CRACKS BELT OK CRACKS RELACE BELT 7 - 22 COOLING Fig. 27 Generator Adjustment CLEANING AND INSPECTION WATER PUMP Replace water pump body assembly if it has any of VACUUM VENT VALVE (SHOWN IN SEAL- CROSS-SECTIONAL VIEW ING POSITION) TOP VIEW PRESSURE RATING PRESSURE VALVE...

  • Page 218: Chemical Cleaning

    COOLING 7 - 23 CLEANING AND INSPECTION (Continued) CLEANING COOLING SYSTEM ADJUSTMENTS Drain cooling system (see: Draining Cooling Sys- PROPER BELT TENSION tem ) and refill with clean water (see: Refilling Cooling System ). Run engine with radiator cap Satisfactory performance of the belt driven accesso- installed until upper radiator hose is hot.

  • Page 219: Specifications

    7 - 24 COOLING SPECIFICATIONS SPECIAL TOOLS COOLING SYSTEM CAPACITY COOLING 7.00 LITERS 7.40 QTS. CAPACITY, Includes Heater and Coolant Reserve System TORQUE DESCRIPTION TORQUE A/C Condenser to Radiator ..7.2 N·m (65 in. lbs.) Fan Module to Radiator ..7.2 N·m (65 in. lbs.) Fan Motor to Shroud Accessory Drive Belt Tension Gauge C-4162 Retaining Screws (A/C equipped) .
  • Page 220 BATTERY 8A - 1 BATTERY CONTENTS page page GENERAL INFORMATION CHARGING COMPLETELY DISCHARGED INTRODUCTION ......1 BATTERY ......7 DESCRIPTION AND OPERATION VISUAL INSPECTION .

  • Page 221: Description And Operation

    8A - 2 BATTERY DESCRIPTION AND OPERATION (Continued) CHARGING TIME REQUIRED WARNING: NEVER EXCEED 20 AMPS WHEN CHARGING A COLD -1°C (30°F) BATTERY. PER- SONAL INJURY MAY RESULT. The time required to charge a battery will vary depending upon the following factors. SIZE OF BATTERY A completely discharged large heavy-duty battery may require more recharging time than a completely...
  • Page 222 SIGHT PLASTIC TUBE GREENBALL GLASS BATTERY TOP BATTERY 8A - 3 DIAGNOSIS AND TESTING (Continued) A clear color dot shows electrolyte level in battery is below the test indicator (Fig. 2). Water cannot be added to a maintenance free battery. The battery must be replaced.

  • Page 223: Battery Ignition Off Draw (Iod)

    NEGATIVE BATTERY NEGATIVE TERMINAL 12 VOLT TEST LIGHT POST 8A - 4 BATTERY DIAGNOSIS AND TESTING (Continued) BATTERY BATTERY TERMINAL PULLER ABNORMAL BATTERY DISCHARGING • Corroded battery posts, cables or terminals. • Loose or worn generator drive belt. • Electrical loads that exceed the output of the charging system due to equipment or accessories installed after delivery.

  • Page 224: Battery Load Test

    INDUCTION AMPMETER POSITIVE CLAMP CLAMP NEGATIVE CLAMP BATTERY 8A - 5 DIAGNOSIS AND TESTING (Continued) • Interior lamps fuse (10 Amp) BATTERY LOAD TEST A fully charged battery must have cranking capac- ity, to provide the starter motor and ignition system enough power to start the engine over a broad range of ambient temperatures.

  • Page 225: Battery Open Circuit Voltage Test

    8A - 6 BATTERY DIAGNOSIS AND TESTING (Continued) (3) Allow the battery to stabilize for 2 minutes, has open circuit voltage reading of 12.4 volts or and then verify open circuit voltage. greater, and will not pass the load test, replace the (4) Rotate the load control knob on the tester to battery because it is defective.

  • Page 226: Service Procedures

    BATTERY 8A - 7 SERVICE PROCEDURES After the battery has been charged to 12.4 volts or greater, perform a load test to determine cranking BATTERY CHARGING capacity. Refer to Battery Load Test in this Group. If the battery passes the load test, the battery is OK to A battery is considered fully charged when it will use.

  • Page 227: Visual Inspection

    WARM WATER AND BAKING CLEANING BRUSH TEST INDICATOR SODA SOLUTION BATTERY BATTERY CABLE CLEANING BATTERY TEST INDICATOR TOOL MX75 TEST INDICA- BATTERY POST BATTERY BATTERY CABLE CLEANER CABLE 8A - 8 BATTERY SERVICE PROCEDURES (Continued) able during charging time, the battery may be good, and charging should be completed in the normal manner.

  • Page 228: Removal And Installation

    BATTERY TRAY INTAKE DUCT BATTERY 8A - 9 REMOVAL AND INSTALLATION BATTERY HOLD DOWN CLAMP BATTERY THERMO- GUARDCOVER REMOVAL (1) Make sure ignition switch is in OFF position and all accessories are OFF. (2) Remove battery negative cable then the posi- tive cable (Fig.

  • Page 229: Fresh Air Inlet Tube Removal

    NEGATIVE BATTERY POST BATTERY INDICATOR TEST NEGATIVE CABLE 8A - 10 BATTERY REMOVAL AND INSTALLATION (Continued) Fig. 21 Remove and Install Battery Cables FRESH AIR INLET TUBE REMOVAL REMOVAL (1) Ensure that the ignition switch and all acces- Fig. 22 Air Inlet Tube Pull Strap sories are OFF SPECIFICATIONS (2) Remove battery negative cable first then the...

  • Page 230: Note: This Group Covers Both Left-Hand Drive

    PARK/NEUTRAL IGNITION SWITCH NEGATIVE SWITCH (AUTO. TRANS. ONLY) CABLE POSITIVE CLUTCH SWITCH (MAN. TRANSMISSION BATTERY BATTERY POSITION CABLE SOLENOID TERMINAL PEDAL RELAY THIS CIRCUIT GROUNDED AT ALL TIMES (MAN. TRANS. ONLY) FEED IGNITION POSITION ONLY) FEED GROUND CIRCUIT STARTER SOLE- STARTER RELAY STARTER...
  • Page 231 RELAY CAVITIES RELAY TERMINALS 8B - 2 STARTING DIAGNOSIS AND TESTING STARTER RELAY WARNING: CHECK TO ENSURE THAT THE TRANS- CONTROL CIRCUIT TEST MISSION IS IN THE PARK POSITION/NEUTRAL The starter control circuit has: WITH THE PARKING BRAKE APPLIED • Starter solenoid •...

  • Page 232: Feed Circuit Resistance Test

    STARTING 8B - 3 DIAGNOSIS AND TESTING (Continued) continuity between the cavity for relay terminal 87 The following operation will require a voltmeter, and the starter solenoid terminal at all times. If OK, accurate to 1/10 of a volt. go to Step 4. If not OK, repair the open circuit to the CAUTION: Ignition system also must be disabled starter solenoid as required.

  • Page 233: Feed Circuit Test

    VOLTMETER VOLTMETER VOLTMETER 8B - 4 STARTING DIAGNOSIS AND TESTING (Continued) Fig. 4 Test Starter Motor Ground Fig. 3 Test Ground Circuit Resistance (3) Connect positive voltmeter lead to the starter motor housing and the negative lead to the battery negative terminal (Fig.

  • Page 234: Starting System Test

    POSITIVE CLAMP INDUCTION NEGATIVE CLAMP AMMETER CLAMP STARTING 8B - 5 DIAGNOSIS AND TESTING (Continued) STARTING SYSTEM TEST For circuit descriptions and diagrams, refer to 8W-21, Starting System in Group 8W, Wiring Dia- grams. WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP...
  • Page 235 8B - 6 STARTING DIAGNOSIS AND TESTING (Continued) STARTING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS TO ENGAGE. 1. Battery discharged or faulty. 1. Refer to Group 8A, Battery. 2. Starting circuit wiring faulty. Charge or replace battery, if required. 3.

  • Page 236: Removal And Installation

    TRANSAXLE HOUSING GROUND CABLE FRONT ENGINE MOUNTING BRACKET STARTING 8B - 7 REMOVAL AND INSTALLATION SAFETY SWITCHES NEGATIVE BATTERY POST BATTERY INDICATOR TEST NEGATIVE CABLE For Removal and Installation of the: • Clutch Position Switch, refer to Group 6, Clutch. •...

  • Page 237: Starter Relay

    PUSH ON SOLENOID CON- B+ BATTERY POSITIVE WIRE GENERATOR OUTPUT WIRE B+ POST NECTOR 8B - 8 STARTING REMOVAL AND INSTALLATION (Continued) SPECIFICATIONS STARTER Manufacturer BOSCH Engine Application 2.0L OHC - DOHC Power rating 0 .95 Kw Voltage 12 VOLTS No.
  • Page 238 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CONTENTS page page GENERAL INFORMATION CHARGING SYSTEM ..... 2 OVERVIEW ......1 CURRENT OUTPUT TEST .

  • Page 239: Description And Operation

    INLET TUBE BATTERY TRAY BATTERY TEMPERATURE SENSOR 8C - 2 CHARGING SYSTEM DESCRIPTION AND OPERATION (Continued) the proper voltage depending on battery tempera- ture. All vehicles are equipped with On-Board Diagnos- tics (OBD). All OBD-sensed systems, including the EVR (field control) circuitry, are monitored by the PCM.
  • Page 240 CHARGING SYSTEM 8C - 3 DIAGNOSIS AND TESTING (Continued) The following procedures may be used to correct a erator Removal/Installation section of this group for problem diagnosed as a charging system fault. torque specifications. (5) Inspect generator drive belt condition and ten- INSPECTION sion.
  • Page 241 8C - 4 CHARGING SYSTEM DIAGNOSIS AND TESTING (Continued)
  • Page 242 CHECK TION. CHARGE BATTERY IF CHECK DRIVE BELT. REFER SYSTEM FOR ACCESSORY CHARGING SYSTEM RESIS- IS GROUND PATH VOLTAGE CLEAN TIGHTEN CHECK ON BOARD DIAG- NOSTIC TROUBLE CODES PERFORM OUTPUT VOLT- VOLTAGE OR DTC 41 OR REFER TO VOLTAGE DROP CHARGING CHARGING ABOVE MAXIMUM OR DTC...
  • Page 243 REPEAT OUTPUT VOLTAGE TEST REPAIR PINS DISCONNECT BOTH 40 WAY CONNEC- TORS ON POWERTRAIN CONTROL MOD- ULE — INSPECT FOR DAMAGE OR REPAIR DAMAGED PIN OR PINS ON POWER- TRAIN MODULE? TO GROUND SHORT DISCONNECT FIELD TERMINAL. MEASURE RESISTANCE FROM K20 CIRCUIT ON WIRING HAR- CORROSION.

  • Page 244: Charging System Resistance Tests

    CASE GROUND OHMMETER TO POWERTRAIN CONTROL FEED WIRE HARNESS CON- B+ TERMINAL NECTOR MODULE VOLTMETER CHARGING SYSTEM 8C - 7 DIAGNOSIS AND TESTING (Continued) CHARGING SYSTEM RESISTANCE TESTS These tests will show the amount of voltage drop across the generator output wire from the generator output (B+) terminal to the battery positive post.

  • Page 245: Current Output Test

    8C - 8 CHARGING SYSTEM DIAGNOSIS AND TESTING (Continued) performed at each (- ground) connection in this cir- (7) Start the engine and allow it to reach operating cuit to locate the excessive resistance. temperature. (7) Testing (+ positive) circuitry: (8) Shut engine off.
  • Page 246 REPEAT OUTPUT VOLT- REPEAT OUTPUT VOLT- REPAIR FUSE LINK AND WIRE SHORT. REFER TO GROUP REPEAT CONNEC- TIONS GOOD? VOLTAGE TEST WIRING WIRE BROKEN? REPAIR WIRE GRAMS. OUTPUT AGE TEST AGE TEST DIA- DISCONNECT CHECK SHORT CIRCUIT REPEAT CHECK TIONS STARTER, CHECK WIRING FOR BROKEN WIRE...

  • Page 247: On-Board Diagnostic System Test

    BATTERY ENGINE WIRING HARNESS SENSOR HARNESS BATTERY TRAY TEMPERATURE SENSOR 8C - 10 CHARGING SYSTEM DIAGNOSIS AND TESTING (Continued) BATTERY TEMPERATURE SENSOR (4) At room temperature of 25° C (75–80° F), an ohmmeter reading of 9,000 (9K) to 11,000 (11K) ohms To perform a complete test of this sensor and its should be observed.

  • Page 248: Removal And Installation

    CHARGING SYSTEM 8C - 11 DIAGNOSIS AND TESTING (Continued) symptom, not as the cause for the problem. In some (3) Raise vehicle with front wheels turned fully to cases, because of the design of the diagnostic test the right. procedure, a DTC can be the reason for another DTC to be set.

  • Page 249: Battery Temperature Sensor

    FIELD CONNECTION B+ TERMINAL PIVOT ROTATION TAB W/ANTI- ADJUSTMENT BOLT SPILL SHIELD BATTERY BATTERY INLET PULL STRAP HOLD DOWN CLAMP TUBE CAUTION DANGER BATTERY TEMPERA- TURE SENSOR BATTERY TERMINAL BATTERY PULLER BATTERY TRAY THERMO- GUARDCOVER 8C - 12 CHARGING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig.

  • Page 250: Specifications

    INLET TUBE BATTERY TRAY BATTERY TEMPERATURE SENSOR CHARGING SYSTEM 8C - 13 REMOVAL AND INSTALLATION (Continued) (5) Disconnect sensor wire connector (Fig. 15). INSTALLATION For installation reverse above procedures. Fig. 15 Battery Temperature Sensor Connector SPECIFICATIONS GENERATOR RATINGS TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS...
  • Page 252 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CONTENTS page DIAGNOSIS AND TESTING CHARGING SYSTEM ..... 2...
  • Page 253 8C - 2 CHARGING SYSTEM DIAGNOSIS AND TESTING CHARGING SYSTEM INSPECTION Charging System Test...
  • Page 254 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CONTENTS page DIAGNOSIS AND TESTING CHARGING SYSTEM ..... 2...
  • Page 255 8C - 2 CHARGING SYSTEM DIAGNOSIS AND TESTING CHARGING SYSTEM INSPECTION Charging System Test...
  • Page 256 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page GENERAL INFORMATION TESTING FOR SPARK AT COIL—2.0/2.4L ..7 INTRODUCTION ......1 THROTTLE POSITION SENSOR .

  • Page 257: Description And Operation

    8D - 2 IGNITION SYSTEM POWER DISTRI- BUTION CEN- 40–WAY CONNECTOR BATTERY SPARK PLUG GAUGE DESCRIPTION AND OPERATION (Continued) The 2.0L engines use a fixed ignition timing sys- that a problem exists in the corresponding cylinder. tem. The distributorless electronic ignition system is Replace spark plugs at the intervals recommended in referred to as the Direct Ignition System (DIS).

  • Page 258: Description And Operation

    SPARK INSULATOR PLUG IGNITION COILS IGNITION SYSTEM 8D - 3 SPARK INSULATOR PLUG SPARK PLUG CABLE IGNITION COILS BATTERY SPEED CONTROL SERVO POWER DISTRIBUTION CEN- DESCRIPTION AND OPERATION (Continued) #1 cable must be routed under the PCV hose and clipped to the #2 cable. ELECTRONIC IGNITION COILS WARNING: THE DIRECT IGNITION SYSTEM GEN-...
  • Page 259 CRANKSHAFT GENERATOR OIL FILTER POSITION SENSOR 8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 6 Timing Reference Notches weight has machined into it two sets of four timing notches and the 60 degree signature notch. The 60 reference notches including a 60 degree signature degree signature notch produces a longer pulse-width notch (Fig.
  • Page 260 CAMSHAFT POSITION SEN- CAMSHAFT POSITION SEN- REAR OF CYLINDER HEAD CAMSHAFT POSITION SEN- CAM MAGNET/TARGET TARGET MAGNET IGNITION SYSTEM 8D - 5 DESCRIPTION AND OPERATION (Continued) Fig. 8 Camshaft Position Sensor—SOHC Fig. 10 Target Magnet —Typical Fig. 9 Camshaft Position Sensor—DOHC attaches to the rear of the camshaft and indexes to the correct position.

  • Page 261: Intake Air Temperature Sensor

    8D - 6 IGNITION SYSTEM MAP/AIR PCV VACUUM NIPPLE INTAKE MANIFOLD TEMPERATURE SENSOR DESCRIPTION AND OPERATION (Continued) ENGINE TEMPERATURE CAMSHAFT POSITION COOLANT SENSOR SENSOR COOLANT TEMPER- ATURE SENSOR FUEL RAIL When the engine is cold, the PCM will demand and Intake Air Temperature (IAT) functions into one slightly richer air-fuel mixtures and higher idle sensor (Fig.

  • Page 262: Lock Key Cylinder

    INTAKE MANI- FOLD MAP/AIR PERATURE SENSOR TEM- FUEL RAIL IGNITION SYSTEM 8D - 7 ACCESSORY UNLOCK ON/RUN START DESCRIPTION AND OPERATION (Continued) • On/Run • Start Fig. 15 MAP/IAT sensor—DOHC THROTTLE POSITION SENSOR (TPS) Fig. 16 Ignition Lock Cylinder Detents The TPS mounts to the side of the throttle body.

  • Page 263: Check Coil Test

    8D - 8 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) GOOD GROUND ENGINE SPARK PLUG CABLE BOOT CHECK SPARKPLUG SPARK HERE BATTERY VOLTAGE CYLINDERS 2 & 3 CYLINDERS 1 & 4 CHECK SECONDARY RESIS- TANCE ACROSS COIL TOW- NOTE: New isolated engine valve cover may not (3) Measure the primary resistance of each coil.

  • Page 264: Engine Coolant Temperature Sensor

    IGNITION COILS CYLINDERS 1 & 4 BATTERY VOLTAGE CYLINDERS 2 & 3 IGNITION SYSTEM 8D - 9 DIAGNOSIS AND TESTING (Continued) ual. Refer to the wiring diagrams section for circuit priate Powertrain Diagnostics Procedure Manual. information. Refer to the wiring diagrams section for circuit The Powertrain Control Module (PCM) supplies 8 information.
  • Page 265 NORMAL DEPOSITS BLACK COLD (CARBON) FOULING 8D - 10 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) terminals is a 5 volt supply and the remaining ter- Spark plug performance is not affected by MMT depos- minal is ground. its. Connect the DVM between the center and sensor COLD FOULING (CARBON FOULING) ground terminal.
  • Page 266 GROUND ELECTRODE CENTER ELECTRODE DEPOSITS GROUND CENTER ELEC- ELECTRODE TRODE GROUND ELECTRODE COV- ERED WITH WHITE OR YEL- LOW DEPOSITS CENTER ELECTRODE CHIPPED INSULATOR IGNITION SYSTEM 8D - 11 DIAGNOSIS AND TESTING (Continued) HIGH SPEED MISS When replacing spark plugs because of a high speed miss condition;...

  • Page 267: Removal And Installation

    BLISTERED GRAY COLORED INSULATOR GROUND ELECTRODE STARTING TO DISSOLVE WHITE CENTER ELECTRODE DISSOLVED POWER DISTRI- BUTION CEN- 40–WAY CONNECTOR BATTERY 8D - 12 IGNITION SYSTEM Fig. 26 Preignition Damage Fig. 28 Powertrain Control Module (4) Connect positive cable to battery. (5) Connect negative cable to battery.

  • Page 268: Automatic Shutdown Relay

    IGNITION SYSTEM 8D - 13 REMOVAL AND INSTALLATION (Continued) INSTALLATION Install spark plug insulators over spark plugs. Ensure the top of the spark plug insulator covers the upper end of the spark plug tube.The connect the other end to coil pack. On SOHC engines, be sure that dual plastic clip holds #1,#2 cables off of valve cover and that PCV hose plastic clip holds #3 cable away from metal PCV clamp and edge of air duct.

  • Page 269: Camshaft Position Sensor-Dohc

    CAMSHAFT POSITION SEN- REAR OF CYLINDER HEAD REAR OF CYLINDER HEAD TARGET MAGNET MOUNTING BOLT CAMSHAFT POSITION SEN- MOUNTINGBOLT TARGET MAGNET 8D - 14 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 34 Camshaft Position Sensor Location—DOHC Fig. 32 Camshaft Position Sensor Location—SOHC (2) Disconnect electrical connector from camshaft position sensor.

  • Page 270: Combination Engine Coolant Temperature Sensor-Dohc

    IGNITION SYSTEM 8D - 15 REMOVAL AND INSTALLATION (Continued) Fig. 38 Engine Coolant Temperature Sensor Fig. 36 Target Magnet Installation REMOVAL CRANKSHAFT POSITION SENSOR (1) With the engine cold, drain the cooling system The crankshaft position sensor mounts to the until coolant level drops below sensor.

  • Page 271: Lock Cylinder Housing

    8D - 16 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) REMOVAL (1) With the engine cold, drain coolant until level drops below cylinder head. Refer to Group 7, Cooling System. (2) Disconnect coolant sensor electrical connector. (3) Remove coolant sensor. INSTALLATION (1) Install coolant sensor.
  • Page 272 IGNITION SWITCH DEPRESS RETAININGTABS IGNITION SYSTEM 8D - 17 REMOVAL AND INSTALLATION (Continued) Fig. 45 Ignition Lock Cylinder Detentes Fig. 43 Removing Ignition Switch (2) The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position (Fig.

  • Page 273: Specifications

    FIRING ORDER 1–3–4–2 IGNITION COIL FRONT OF ENGINE CONNECTOR 8D - 18 IGNITION SYSTEM SPECIFICATIONS TORQUE SPECIFICATION VECI LABEL DESCRIPTION TORQUE If anything differs between the specifications found Camshaft Position Sensor Screw . 9 N·m (80 in. lbs.) on the Vehicle Emission Control Information (VECI) SOHC Cam Magnet/Target .
  • Page 274 WEASTEC (SILVER TOW- ERS) IGNITION SYSTEM 8D - 19 SPECIFICATIONS (Continued) Coil Polarity...
  • Page 276 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page SPECIFICATIONS TORQUE SPECIFICATION ....1 IGNITION COIL ......1 SPECIFICATIONS TORQUE SPECIFICATION DESCRIPTION...
  • Page 278 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page SPECIFICATIONS TORQUE SPECIFICATION ....1 IGNITION COIL ......1 SPECIFICATIONS TORQUE SPECIFICATION DESCRIPTION...
  • Page 280 INSTRUMENT PANEL AND SYSTEMS 8E - 1 INSTRUMENT PANEL AND SYSTEMS CONTENTS page page GENERAL INFORMATION DOME LENS/LAMP ..... . 9 INTRODUCTION .

  • Page 281: Description And Operation

    8E - 2 INSTRUMENT PANEL AND SYSTEMS GENERAL INFORMATION (Continued) NOTE: This group covers both Left-Hand Drive (LHD) and Right-Hand Drive (RHD) versions of this model. Whenever required and feasible, the RHD versions of affected vehicle components have been constructed as mirror-image of the LHD versions. While most of the illustrations used in this group represent only the LHD version, the diagnostic and service procedures outlined can generally be...

  • Page 282: Fog Lamp Switch Test Export

    INSTRUMENT PANEL AND SYSTEMS 8E - 3 DIAGNOSIS AND TESTING (Continued) FOG LAMP SWITCH TEST (3) Push the fog lamp switch button. The LED indicator on the front of the switch should illuminate. (1) Remove the fog lamp switch. Refer to the Rear Check Pin L35 with a test lamp for battery voltage.

  • Page 283: Headlamp Switch Test

    OFF’ POSITION PARK’ POSITION ON’ POSITION 8E - 4 INSTRUMENT PANEL AND SYSTEMS DIAGNOSIS AND TESTING (Continued) (2) If the L.E.D. is not illuminated, using a voltme- (2) Use a ohmmeter, and check continuity between ter, connect B+ lead to Pin 4 of the Wire harness con- the terminals of the switch as shown in the Head- nector.

  • Page 284: Instrument Panel And Components

    CONNECTOR TERMINAL FUNCTION 1 — Lighting 2 — A/C Compressor Clutch 3 — Low Blower 4 — M1 Blower 5 — M2 Blower 6 — High Blower 7 — Ground CONNECTOR TERMINAL FUNCTION 1 — Lighting 2 — Not used for Heater 3 —...
  • Page 285 VIEWED FROM TERMINAL 8E - 6 INSTRUMENT PANEL AND SYSTEMS DIAGNOSIS AND TESTING (Continued) Check for battery voltage at Pin J1-6 of the connec- INDIVIDUAL GAUGE INOPERATIVE tor. If no voltage, repair as necessary. (3) Check Pin J1-8 of the connector for continuity FUEL GAUGE to ground.

  • Page 286: Seat Belt Reminder System Test

    INSTRUMENT PANEL AND SYSTEMS 8E - 7 DIAGNOSIS AND TESTING (Continued) tions, the point where the lamp illuminates, may (b) If not OK, and the high temperature chime vary from 1/16 to 3/16 mark on the fuel gauge. There sounds but the gauge shows cold, replace the gauge is a built in time delay before the lamp illuminates.

  • Page 287: Removal And Installation Ash Receiver Retainer And Lamp

    ILLUM AIR BAG HAZARD ILLUM BRAKE BATT ILLUM (OPT) ILLUM ILLUM (OPT) CHK ENG LOW FUEL 8E - 8 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (2) Reach underneath instrument panel through the bottom access hole and disconnect the ASH RECEIVER RETAINER AND LAMP cigar lighter receptacle wiring connectors.

  • Page 288: Cluster Printed Circuit Board

    ODOMETER CONNECTION RETAINING SCREWS INSTRUMENT PANEL AND SYSTEMS 8E - 9 REMOVAL AND INSTALLATION (Continued) CLUSTER PRINTED CIRCUIT BOARD REMOVAL (1) Remove the cluster, refer to Cluster Removal. (2) Remove the attaching screws and rear cover (Fig. 17). The bottom screws attaching lens to hous- ing can be accessed without removing foam pad.

  • Page 289: Gauge

    8E - 10 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) GLOVE BOX SWITCH/LAMP REMOVAL (1) Disconnect battery negative cable and isolate it or remove fuse 12 prior to removing the switch, or wires may short to ground. (2) Open the glove box and push the glove box sides inward allowing the door bumpers to clear and the box to tip forward.

  • Page 290: Heater A/C Control Blower Switch

    INSTRUMENT PANEL AND SYSTEMS 8E - 11 REMOVAL AND INSTALLATION (Continued) (5) Remove the switch knob by depressing the release button on the bottom on the switch and pull- ing out knob from switch. (6) Snap headlamp switch bezel out of mounting plate to gain access to the mounting plate retaining nut.

  • Page 291: Instrument Panel

    8E - 12 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTRUMENT PANEL (10) Disconnect the steering column at the bottom slap together joint. (11) Disconnect the ATX shifter interlock cable at REMOVAL the shifter, if equipped. CAUTION: Disconnect battery negative cable, in (12) Disconnect the instrument panel wiring as engine compartment, before servicing instrument required.
  • Page 292 REAR WINDOW DEFOGGER & FOGLAMP SWITCH MOD- PASSENGER AIRBAG MOD- INSTRUMENT COVER & BEZEL PANEL LEFT TRIM PANEL INSTRUMENT RIGHT TRIM PANEL ASSEMBLY RADIO PANEL HVAC ASH RECEIVER STEERING COLUMN COVER STEERING COLUMN COVER GLOVE BOX DOOR & BIN CLUSTER CENTER BEZEL LINER INSTRUMENT PANEL AND SYSTEMS...

  • Page 293: Left Trim Panel

    8E - 14 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Remove the screws attaching PC board cover to cluster. (5) Disconnect the odometer connector from the printed circuit board. (6) Remove the screws attaching lens, dial and gauge assembly to the housing. The bottom screws attaching lens to the housing can be accessed without removing the foam pad.

  • Page 294: Rear Window Defogger And/Or Rear Fog Lamp Switch Export

    7 — FRONT FOG LAMP SW. REAR WINDOW DEFOGGER REAR FOG LAMP SWITCH 6 — 1/PANEL ILLUM FEED 3 — REAR FOG LAMPS 4 — HEADLAMP FEED ON” INDICATOR LED 2 — BATTERY 5 — GROUND SWITCH BEZEL INPUT INSTRUMENT PANEL AND SYSTEMS 8E - 15 REMOVAL AND INSTALLATION (Continued) (3) Remove the six attaching screws across the for-...

  • Page 295: Steering Column Shrouds

    STEERING STEERING COLUMN COVER COVER LINER COLUMN LEFT TRIM PANEL ACCESS HOLE FOR KEY CYLINDER REMOVAL UPPER COVER SHROUD LOWER COVER SHROUD RIGHT TRIM PANEL STEERING COLUMN INSTRUMENT PANEL COVER CLUSTER BEZEL 8E - 16 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig.

  • Page 296: Trunk Lamp/Lens

    SENSOR SENSOR RETAINING BOLT CONNECTOR VEHICLE SPEED SENSOR TRANSAXLE EXTENSION SENSOR RETAINING BOLT TRANSAXLE EXTENSION VEHICLE SPEED SENSOR SPEEDOMETER PINION INSTRUMENT PANEL AND SYSTEMS 8E - 17 REMOVAL AND INSTALLATION (Continued) (2) Remove the attaching screw from each of the two forward cup holders of the floor console.
  • Page 297 8E - 18 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued)

  • Page 298: Audio System

    AUDIO SYSTEM 8F - 1 AUDIO SYSTEM CONTENTS page page GENERAL INFORMATION TESTING ......7 INTRODUCTION .
  • Page 299 FM INOPERATIVE AM-TAPE TAPE COMPACT (CD) INOPERATIVE AM-FM RUN ONLY AM INOPERATIVE CHECK FUSE(S) IGNITION ARE ALL SPEAKERS DIS- ONE CHANNEL (LEFT OR CHECK FOR SHORT CIR- CUIT IN SPEAKERS IN THE CHECK IF SPEAKER IS DAMAGED, RUN TAPE SYSTEM CHECK TORTED OR INOPERATIVE? RUN STATIC NOISE CHECK ANTENNA SYSTEM CHECK...
  • Page 300 USING CHECK FOR SHORT TO GROUND. REFER TO ABOVE DIAGRAM FOR SPEAKER PLUS AND MINUS TERMINALS. PLACE ONE LEAD OF THE OHMME- TER TO PLUS TERMINAL AND THE OTHER LEAD TO GROUND. LEAD TO THE MINUS TERMI- TEST BETWEEN PLUS AND MINUS TERMI- NALS FOR A READING OF 3 DOES ANY CIRCUIT SHOW CHECK SPEAKER CONNEC-...
  • Page 301 START ENGINE. WITH ENGINE RUNNING, IF THERE IS STATIC/NOISE, CHECK THE FOL- (C) CHECK GROUND CONNECTIONS (D) CHECK ANTENNA MOUNTING (B) IGNITION SYSTEM FAULTS (A) ELECTRIC FUEL PUMP REPAIR NECESSARY LOWING: CHECK USE DIRECT FEED FROM BAT- TERY. CHECK FOR NOISE WITH THE IGNITION IN ACCESSORY POSITION, WITH ALL ELECTRI- CONDITION...
  • Page 302 IF NOT OK, EXCHANGE UNIT ADVISE OWNER OF WORN LOSS OF HIGH FREQUENCY. CLEAN WITH WET HEAD ADVISE OWNER OF WORN Do Not Force Removal of TRY A KNOWN GOOD TAPE REPAIR AS NECESSARY OBSTRUCTION FOUND? OR DEFECTIVE TAPE OR DEFECTIVE TAPE Jammed Cassette EXCHANGE UNIT EXCHANGE UNIT...
  • Page 303 IS CD IN UNIT? EJECT INSPECT CD INOPERA- SKIP AS A RESULT OF EXTREME BUMPS OR EXCESSIVE SCRATCHED? VIBRATION SCRATCHES WILL TIVE EXCHANGE UNIT GENTLY CLEAN WITH A S OFT CLOTH FROM CENTER EDGE. SPRAY WITH SOLVENTS CLEANERS. CAUTION. & WILL EJECT? DAMAGE/DIRTY/DEFECTIVE...
  • Page 304 RADIO END PIN TEST POINT DISCONNECT TEST POINTS TEST POINT MAST AUDIO SYSTEM 8F - 7 RADIO LEAD IN TIP OF MAST CONNECTORS ANTENNA BODY PLUG DIAGNOSIS AND TESTING (Continued) TESTING bracket. Wiggle cable over its entire length to reveal intermittent short or open circuits dur- The antenna has a short cable which connects into ing step 1, 2 and 3.
  • Page 305 MOUNTINGSCREW ANTENNA BASE & ANTENNA ANTENNA MAST ADAPTER ANTENNA ADAPTER BRACKET ANTENNA MAST ANTENNA ADAPTER ACCESS HOLE AND RIGHT PLUG FENDER FRONT 8F - 8 AUDIO SYSTEM REMOVAL AND INSTALLATION (Continued) (5) Connect the antenna cable to the cable lead. (2) Remove two mounting screws on the radio and pull out of instrument panel (Fig.
  • Page 306 SPEAKERS AUDIO SYSTEM 8F - 9 REMOVAL AND INSTALLATION (Continued) Fig. 8 Instrument Panel Speakers Fig. 9 Front Door Speaker FRONT DOOR SPEAKER INSTALLATION For installation reverse the above procedures. Posi- REMOVAL tion speakers so that the wire connectors are point- (1) Remove door trim panel, refer to Group 23, ing to the drivers side of car.
  • Page 308 FUSE HORN RELAY HORN SWITCH HORN CLOCK SPRING AIRBAG MODULE HORN SWITCH HEAD LAMP GROUND HORNS 8G - 1 HORNS CONTENTS page page DESCRIPTION AND OPERATION SYSTEM TEST ......3 INTRODUCTION .

  • Page 309: Horn Switch

    + POSITIVE - NEGATIVE FUEL PUMP AUTO- RADI- ATOR FAN HORN RELAY VIEWED MATIC SHUT DOWN FROM TERMINAL ENGINE STARTER RELAY HORN TACT HORN FUSE MALLY OPEN CON- NOR- NOT USED COM- PRESSOR CLUTCH 8G - 2 HORNS DIAGNOSIS AND TESTING (5) Check relay for 70 to 75 ohms resistance from terminal 85 to 86 (Fig.

  • Page 310: System Test

    OHMMETER GROUND B+ WIRE HORNS 8G - 3 DIAGNOSIS AND TESTING (Continued) SYSTEM TEST Refer to Horn System Test below. If the horn does not sound, check horn fuse located in the Power Dis- tribution Center. If the fuse is blown, replace with the correct fuse.
  • Page 311 8G - 4 HORNS REMOVAL AND INSTALLATION (Continued) HORN SYSTEM TEST CONDITION POSSIBLE CAUSE CORRECTION Horn sounds continuously. (1) Faulty horn relay. (1) Refer to horn relay test. NOTE: Immediately unplug horn (2) Horn control circuit to relay (2) Check terminal 65 in PDC for relay in the Power Distribution shorted to ground.

  • Page 312: Removal And Installation

    HORNS 8G - 5 REMOVAL AND INSTALLATION HORN REMOVAL Disconnect connector and remove horn attaching nuts from the bumper support bracket (Fig. 7). INSTALLATION For installation, reverse the above procedures. Insure that the horn projector does not touch bumper reinforcement or the sound output may be altered. HORN RELAY REMOVAL (1) Remove the Power Distribution Center cover...
  • Page 314 ACCEL SPEED SWITCHES CONTROL COAST CANCEL VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM CONTENTS page page GENERAL INFORMATION ROAD TEST ......3 INTRODUCTION .

  • Page 315: Description And Operation

    THROTTLE BODY THROTTLE BODY AUTOMATIC VIEW IN DIRECTION SPEED OF ARROW Z THROTTLE KICKDOWN CONTROL CABLE CABLE VIEW IN DIRECTION OF CONTROL CABLE ARROW Z SPEED THROTTLE CONTROLCABLE TROL CABLE CON- 8H - 2 VEHICLE SPEED CONTROL SYSTEM SPEED CONTROL SWITCHES There are two separate switch pods that operate speed control...

  • Page 316: Stop Lamp Switch

    VEHICLE SPEED CONTROL SYSTEM 8H - 3 DESCRIPTION AND OPERATION (Continued) existing recorded target speed, depress and hold the to the speedometer/odometer is monitored by the SET/COAST switch until the desired speed is PCM speed control circuitry to determine vehicle reached.
  • Page 317 DATA LINK CONNECTOR 8H - 4 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) If a scan tool is not available, use the following procedure: (1) With key inserted in ignition switch, cycle switch to ON position three times. On third cycle, leave switch in ON position.
  • Page 318 VEHICLE SPEED CONTROL SYSTEM 8H - 5 DIAGNOSIS AND TESTING (Continued) (2) If the switch passes, conduct the vacuum sup- (5) If continuity, disconnect the servo connector. ply test. Test continuity from pin 2 of connector and ground to (3) If it passes, conduct the servo vacuum test. If it test for intermittent short.
  • Page 319 SPEED CONTROL VACUUM K29 BRAKE SWITCH SIGNAL SPEED CNT MODE SELECT POWERTRAIN V35 SPEED CNT VENT BRAKE LAMP SWITCH VACUUM RESERVOIR V36 SPEED CNT VAC VACUUM SOURCE THROTTLE BODY VACUUM LINE S/C CABLE SOLENOID CONTROL T/C CAM MODULE SIGNAL PARK/NEUTRAL SWITCH SPEED RESUME/ACCEL SENSOR...

  • Page 320: Servo Vacuum Test

    VEHICLE SPEED CONTROL SYSTEM 8H - 7 DIAGNOSIS AND TESTING (Continued) OVERSHOOT/UNDERSHOOT ON SPEED CONTROL If the operator repeatedly presses and releases the set button with their foot off of the accelerator (a “lift foot set” to begin speed control operation), the vehicle may accelerate and exceed the desired set speed by up to 5 MPH (8 km/h) and then decelerate to less than the desired set speed before finally achieving...

  • Page 321: Stop Lamp Switch Test

    8H - 8 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) contact closes to ground through a 6,650 ohm resis- tor. The 5-volt signal then passes through a higher resistance than that of the SET/COAST switch, caus- ing the voltage to be approximately 3.30 to 4.14 volts. When the OFF switch is depressed, the contacts close directly to ground, causing the 5-volt signal to drop to 0 volts.

  • Page 322: Vacuum Supply Test

    VEHICLE SPEED CONTROL SYSTEM 8H - 9 DIAGNOSIS AND TESTING (Continued) VACUUM SUPPLY TEST (1) Disconnect vacuum hose at the servo and install a vacuum gauge in the hose (Fig. 11). Fig. 10 PCM 40—Way Connectors (d) Reconnect the BLACK connector (with pins 1–40) to PCM.

  • Page 323: Speed Control Servo Cable

    THROTTLE MOUNTING SCREW MOUNTING TAB CONTROL SHIELD 8H - 10 VEHICLE SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) SPEED CONTROL SWITCH (5) Disconnect electrical connector from servo. (6) Disconnect vacuum hose from servo The speed control switches are mounted in the (7) Remove 2 nuts retaining bracket to servo.

  • Page 324: Vacuum Reservoir

    SPEED TROL CABLE CON- SPEED THROTTLE LEVER CONTROL CABLE THROTTLE CABLE TRANSMISSION KICKDOWN CABLE THROTTLE CABLE CABLE TABS CLASP VEHICLE SPEED CONTROL SYSTEM 8H - 11 REMOVAL AND INSTALLATION (Continued) POWERTRAIN CONTROL MODULE For Removal/Installation refer to Powertrain Con- trol Module in Group 14, Fuel Injection System. VACUUM RESERVOIR REMOVAL (1) Raise and support vehicle.
  • Page 326 VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM CONTENTS page REMOVAL AND INSTALLATION SPEED CONTROL SERVO ....1 REMOVAL AND INSTALLATION SPEED CONTROL SERVO REMOVAL (1) Disconnect battery.
  • Page 328 VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM CONTENTS page REMOVAL AND INSTALLATION SPEED CONTROL SERVO ....1 REMOVAL AND INSTALLATION SPEED CONTROL SERVO REMOVAL (1) Disconnect battery.
  • Page 330 TIME DELAY RELAY COMBO FLASHER TURN SIGNAL AND FLASHERS 8J - 1 TURN SIGNAL AND FLASHERS CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 MULTI-FUNCTION SWITCH .
  • Page 331 8J - 2 TURN SIGNAL AND FLASHERS DIAGNOSIS AND TESTING MULTI-FUNCTION SWITCH The multi-function switch contains electrical cir- cuitry for turn signal, hazard warning, headlamp beam select, headlamp optical horn. This integrated switch assembly is mounted to the left hand side of the steering column.
  • Page 332 J — RIGHT FRONT H — RIGHT REAR I — LEFT FRONT K — LEFT REAR TURN SIGNAL AND FLASHERS 8J - 3 DIAGNOSIS AND TESTING (Continued) To test the switch, first disconnect the negative battery cable, then remove the upper and lower col- umn shrouds to gain access to the switch connector.

  • Page 334: Windshield Wipers And Washers

    WINDSHIELD WIPERS AND WASHERS 8K - 1 WINDSHIELD WIPERS AND WASHERS CONTENTS page page WINDSHIELD WASHER SYSTEM ... . 8 WINDSHIELD WIPERS ....1 WINDSHIELD WIPERS INDEX page...

  • Page 335: Description And Operation

    FUSE 15 WIPER TIME DELAY RELAY COMBO FLASHER HI LO PARK FUNCTION IGNITION FEED 8K - 2 WINDSHIELD WIPERS AND WASHERS DESCRIPTION AND OPERATION (Continued) remove the accumulation of salt and road film. The positive terminal and terminal 2 of the motor connec- wiper blades, arms, and windshield should be tor.

  • Page 336: Wiper Motor

    + BATTERY — TERMINAL 4 AMMETER WINDSHIELD WIPERS AND WASHERS 8K - 3 DIAGNOSIS AND TESTING (Continued) (2) Using an ohmmeter, check the high and low circuits for a short to ground. Refer to Group 8W, Wiring Diagrams. (3) Check to see if wiper linkage or pivots are binding or caught.
  • Page 337 8K - 4 WINDSHIELD WIPERS AND WASHERS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Wiper blades do not park properly. (1) Wiper arms improperly parked. (1) Remove wiper arms and repark. (2) Wiper arms are loose on pivot Refer to Wiper Arm Removal and shaft.

  • Page 338: Wiper Switch

    INTERMITTENT SWITCH PINS WIPER WINDSHIELD WIPERS AND WASHERS 8K - 5 DIAGNOSIS AND TESTING (Continued) WIPER SWITCH To test the switch, first disconnect the switch wires from the body wiring in the steering column. Using an ohmmeter, test for continuity between the termi- nals of the switch, as indicated in the following con- tinuity chart (Fig.

  • Page 339: Wiper Linkage

    8K - 6 WINDSHIELD WIPERS AND WASHERS REMOVAL AND INSTALLATION (Continued) WIPER LINKAGE WIPER MOTOR REMOVAL REMOVAL (1) Remove wiper module refer above (Fig. 9). (1) Remove wiper module refer above. (2) Disconnect wiper arm linkage, by insert screw- (2) Remove linkage from motor crank. Insert driver between ball cap and linkage, then twist the screwdriver between crank and linkage then twist screwdriver and lift straight up on linkage.

  • Page 340: Cleaning And Inspection

    TURN SIGNAL LEVER WINDSHIELD WASHER SWITCH WIPER/ LEVER WINDSHIELD WIPERS AND WASHERS 8K - 7 shield. If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not roll- ing over center.

  • Page 341: Windshield Washer System

    NOZZLE HOOD NOZZLE ADJUST WITH A PIN TARGET 8K - 8 WINDSHIELD WIPERS AND WASHERS WINDSHIELD WASHER SYSTEM INDEX page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION WASHER NOZZLE ..... . . 8 WASHER NOZZLE .
  • Page 342 WASHER RESERVOIR WASHER PUMP FILLER NECK WINDSHIELD WIPERS AND WASHERS 8K - 9 FILLER NECK Fig. 3 Windshield Washer Test WASHER RESERVOIR REMOVAL (1) Remove filler neck (Fig. 5). (2) Raise vehicle on hoist. (3) Disconnect the wire connector from the reser- voir pump (Fig.
  • Page 343 SLIDE TAB TO FREE RESER- ATTACHING SCREW VOIR 8K - 10 WINDSHIELD WIPERS AND WASHERS REMOVAL AND INSTALLATION (Continued) (3) Disconnect the washer hose at the pump and drain the reservoir. (4) Gently pry pump away from reservoir and out of grommet.
  • Page 344 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... 15 LAMP DIAGNOSIS ..... . . 1 HEADLAMP ALIGNMENT .
  • Page 345 8L - 2 LAMPS DIAGNOSIS AND TESTING (Continued) HEADLAMP DIAGNOSIS Always begin any diagnosis by testing all of the fuses and circuit breakers in the system. Refer to Group 8W, Wiring Diagrams. Conventional and halogen headlamps are inter- changeable. It is recommended that they not be intermixed on a given vehicle.
  • Page 346 LAMPS 8L - 3 DIAGNOSIS AND TESTING (Continued) HEADLAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM WITH 1. Loose or corroded battery 1. Clean and secure battery cable ENGINE IDLING OR IGNITION cables. clamps and posts. TURNED OFF. 2. Loose or worn generator drive 2.
  • Page 347 8L - 4 LAMPS DIAGNOSIS AND TESTING (Continued) FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM WITH 1. Loose or corroded battery 1. Clean and secure battery cable ENGINE IDLING OR IGNITION cables. clamps and posts. TURNED OFF. 2.

  • Page 348: Headlamp Alignment

    LAMPS 8L - 5 HEADLAMP ALIGNMENT INDEX page page GENERAL INFORMATION HEADLAMP ADJUSTMENT USING ALIGNMENT HEADLAMP ALIGNMENT ....5 SCREEN ......5 SERVICE PROCEDURES SPECIAL TOOLS HEADLAMP ALIGNMENT PREPARATION .
  • Page 349 VEHICLE CENTER LINE 7.62 METERS (25 FT.) HEADLAMP FRONT OF HEADLAMP TER LINE CEN- FLOOR CENTER HEADLAMP 8L - 6 LAMPS SPECIAL TOOLS (Continued) CENTER LINE LAMPS 7.62 METERS (25 FT.) CENTER LINE OF VEHICLE FOG LAMP HOT SPOT FLOOR TO CENTER FOG FRONT OF FOG LAMP LAMP 4 INS.
  • Page 350 LAMPS 8L - 7 SPECIAL TOOLS SPECIAL TOOLS—HEADLAMP ALIGNMENT Headlamp Aiming Kit C-4466–A...
  • Page 351 RADIATOR SURE PANEL CLO- HEADLAMP HEADLAMPBULB RETAINING R ING 8L - 8 LAMPS BULB FOG LAMP LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION PARK AND TURN SIGNAL LAMP BULB ..8 CENTER HIGH MOUNTED STOP LAMP BULB . . 9 REAR CARGO LAMP BULB .
  • Page 352 PARK AND TURN SIGNAL LAMP BULB SIDE MARKER LAMP SOCKET FRONT BUMPER FASCIA BULB SOCKET REAR CLOSURE SOCKET PANEL CENTER BULB HIGH STOP LAMP MOUNTED TAIL LAMP BULB SOCKET LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) Fig. 3 Park and Turn Signal Lamp Bulb Fig.
  • Page 353 LICENSE PLATE LAMP BULB 8L - 10 LAMPS REMOVAL AND INSTALLATION (Continued) LICENSE PLATE LAMP BULB DOME LAMP BULB REMOVAL REMOVAL (1) Remove screws holding license plate lamp to (1) Insert a trim stick between the headliner and rear bumper (Fig. 7). dome lamp lens.
  • Page 354 HEADLAMP FRONT BUMPER FAS- MOD- UPPER CROSSMEMBER BULB FOG LAMP LAMPS 8L - 11 LAMP SERVICE INDEX page page REMOVAL AND INSTALLATION LICENSE PLATE LAMP ....13 CENTER HIGH MOUNTED STOP LAMP PARK AND TURN SIGNAL LAMP .
  • Page 355 PARK AND TURN FRONT BUMPER FASCIA SIGNAL LAMP SIDE MARKER LAMP SOCKET BULB BULB SOCKET TAIL LAMP QUARTERPANEL BEZEL SOCKET BULB CENTER MOUNTED REAR CLO- SUREPANEL TRUNK LID STOP LAMP HIGH 8L - 12 LAMPS REMOVAL AND INSTALLATION (Continued) (5) Separate CHMSL bezel from trunk lid. Fig.
  • Page 356 LICENSE PLATE LAMP BULB LAMPS 8L - 13 REMOVAL AND INSTALLATION (Continued) LICENSE PLATE LAMP (5) Separate lamp from vehicle. INSTALLATION REMOVAL (1) Position lamp on hood and install screw. (1) Remove screws holding license plate lamp to (2) Route lamp wire through hood silencer pad and rear bumper fascia (Fig.
  • Page 357 INSTRU- MENTPANEL DAYTIME SUPPORT BRACKET RUNNING CIGAR LIGHTER MODULE LAMP 8L - 14 LAMPS LAMP SYSTEMS INDEX page REMOVAL AND INSTALLATION DAYTIME RUNNING LAMP (CANADA) ..14 REMOVAL AND INSTALLATION REMOVAL (1) Remove screw attaching DRL module to I/P DAYTIME RUNNING LAMP (CANADA) support brace.
  • Page 358 LAMPS 8L - 15 BULB APPLICATION INDEX page page SPECIFICATIONS GENERAL INFORMATION ....15 EXTERIOR LAMPS ..... 15 INTERIOR LAMPS .
  • Page 360 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... . 8 LAMP DIAGNOSIS ..... . . 1 LAMP BULB SERVICE .
  • Page 361 8L - 2 LAMPS LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION FRONT TURN SIGNAL LAMP BULB ..3 CITYLIGHT LAMP BULB ....3 HEADLAMP BULB .
  • Page 362 LAMPS 8L - 3 REMOVAL AND INSTALLATION (Continued) INSTALLATION CITYLIGHT LAMP BULB CAUTION: Do not touch the glass of halogen bulbs REMOVAL with fingers of other possibly oily surface. Reduced (1) Pull citylight lamp socket from rubber bushing bulb life will result. in headlamp housing (Fig.
  • Page 363 8L - 4 LAMPS REMOVAL AND INSTALLATION (Continued) (4) Disconnect Bulb Power and Ground Leads from INSTALLATION harness and bulb base. (Fig. 8). CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. (1) Align locator tabs and insert new bulb into fog lamp housing.
  • Page 364 LAMPS 8L - 5 LAMP SERVICE INDEX page page GENERAL INFORMATION REMOVAL AND INSTALLATION HEADLAMP DIMMER SWITCH ....5 FOG LAMP ......6 HEADLAMP SWITCH .
  • Page 365 8L - 6 LAMPS REMOVAL AND INSTALLATION (Continued) HEADLAMP LEVELING MOTOR INSTALLATION (1) Position headlamp leveling motor to vehicle. (2) Insert leveling motor through hole in leveling REMOVAL (1) Disengage wire connector from headlamp level- motor bracket. ing motor. (3) Rotate leveling motor one quarter turn clock- (2) Remove bolts holding headlamp leveling motor wise.
  • Page 366 LAMPS 8L - 7 REMOVAL AND INSTALLATION (Continued) SIDE REPEATER LAMP NOTE: The metal clip on the Repeater Lamp Assembly should be opposite from notch in fender REMOVAL hole. (1) Push Repeater Lamp Assembly Rearward (2) Compress metal clip by pushing Repeater (2) While pushing Repeater Lamp Assembly rear- Lamp Assembly rearward.
  • Page 367 8L - 8 LAMPS BULB APPLICATION INDEX page page GENERAL INFORMATION SPECIFICATIONS INTRODUCTION ......8 EXTERIOR LAMPS .
  • Page 368 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... . 8 LAMP DIAGNOSIS ..... . . 1 LAMP BULB SERVICE .
  • Page 369 8L - 2 LAMPS LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION FRONT TURN SIGNAL LAMP BULB ..3 CITYLIGHT LAMP BULB ....3 HEADLAMP BULB .
  • Page 370 LAMPS 8L - 3 REMOVAL AND INSTALLATION (Continued) INSTALLATION CITYLIGHT LAMP BULB CAUTION: Do not touch the glass of halogen bulbs REMOVAL with fingers of other possibly oily surface. Reduced (1) Pull citylight lamp socket from rubber bushing bulb life will result. in headlamp housing (Fig.
  • Page 371 8L - 4 LAMPS REMOVAL AND INSTALLATION (Continued) (4) Disconnect Bulb Power and Ground Leads from INSTALLATION harness and bulb base. (Fig. 8). CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. (1) Align locator tabs and insert new bulb into fog lamp housing.
  • Page 372 LAMPS 8L - 5 LAMP SERVICE INDEX page page GENERAL INFORMATION REMOVAL AND INSTALLATION HEADLAMP DIMMER SWITCH ....5 FOG LAMP ......6 HEADLAMP SWITCH .
  • Page 373 8L - 6 LAMPS REMOVAL AND INSTALLATION (Continued) HEADLAMP LEVELING MOTOR INSTALLATION (1) Position headlamp leveling motor to vehicle. (2) Insert leveling motor through hole in leveling REMOVAL (1) Disengage wire connector from headlamp level- motor bracket. ing motor. (3) Rotate leveling motor one quarter turn clock- (2) Remove bolts holding headlamp leveling motor wise.
  • Page 374 LAMPS 8L - 7 REMOVAL AND INSTALLATION (Continued) SIDE REPEATER LAMP NOTE: The metal clip on the Repeater Lamp Assembly should be opposite from notch in fender REMOVAL hole. (1) Push Repeater Lamp Assembly Rearward (2) Compress metal clip by pushing Repeater (2) While pushing Repeater Lamp Assembly rear- Lamp Assembly rearward.
  • Page 375 8L - 8 LAMPS BULB APPLICATION INDEX page page GENERAL INFORMATION SPECIFICATIONS INTRODUCTION ......8 EXTERIOR LAMPS .
  • Page 376 DLING AN UNDEPLOYED AIRBAG MODULE, THE If the Driver/Passenger Airbag Module is defective TRIM SIDE OF THE AIRBAG SHOULD BE POINTING and not deployed, refer to Chrysler Corporation cur- AWAY FROM THE BODY TO MINIMIZE POSSIBILITY rent return list for proper handling procedures.

  • Page 377: Description And Operation

    DATA LINK CONNECTOR AIRBAG CONTROL MODULE PASSENGER AIRBAG MOD- DRIVER AIRBAG MODULE 8M - 2 RESTRAINT SYSTEM DESCRIPTION AND OPERATION The airbag module contains a housing to which the cushion, inflator and cover are attached to. AIRBAG CONTROL MODULE The driver side inflator assembly is mounted from the back of the module housing.

  • Page 378: Diagnosis And Testing

    RESTRAINT SYSTEM 8M - 3 DIAGNOSIS AND TESTING AIRBAG SYSTEM TEST (1) Connect scan tool (DRB) to Data Link connec- tor, located at right side of the steering column and at the lower edge of the lower instrument panel. (2) Turn the ignition key to ON position. Exit vehi- cle with scan tool.

  • Page 379: Maintenance Inspection

    CENTER CENTER CON- PAS- SENGER SOLE LINER SEAT ASSEMBLY CONSOLE CENTER CONSOLE ATTACHING SCREWS ARMREST PARK WITH HAND LEVER CENTER BRAKE ATTACHING SCREWS CONSOLE 8M - 4 RESTRAINT SYSTEM SERVICE PROCEDURES (Continued) bag face down on a solid surface, the airbag will (4) Remove the two screws located in cup holders propel into the air if accidentally deployment occurs.
  • Page 380 CENTER SOLE CON- RADIO ATTACHING SCREWS PARK BRAKE LEVER PARK BRAKE LEVER PARK BRAKE PARK BRAKE WIRING HARNESS CONNEC- OUTPUT CABLE OUTPUT CABLE LEVER LEVER PULL UPWARD ON CABLE PULL UPWARD ON CABLE PARK BRAKE LEVER WARN- ING LAMP CONNECTOR PARK PARK ASSEMBLY...
  • Page 381 CONSOLE BRACKET PARK LEVER ASSEM- BRAKE PARK ATTACHING NUTS BRAKE LEVER PARK BRAKE LEVER AIRBAG CONTROL MODULE MOUNTING NUTS AIRBAG CONTROL MOD- 8M - 6 RESTRAINT SYSTEM REMOVAL AND INSTALLATION (Continued) CAUTION: USE SUPPLIED SCREWS ONLY (2) Position ACM (arrow pointing forward) in the console floor bracket, attach the nuts and tighten to 11 to 14 N·m (105 to 125 in.
  • Page 382 PARK REAR PARK ASSEMBLY OUT- DRILL BIT PARK ASSEMBLY PUT CABLE PARK OUTPUT CABLE BRAKE BRAKE CABLES EQUALIZER BRAKE BRAKE PARK BRAKE ASSEMBLY OUTPUT PARK BRAKE ASSEMBLY OUT- PARK BRAKE CABLE EQUALIZER OUTPUT CABLE PUT CABLE ASSEMBLY CENTER WIRING HARNESS CONNEC- CENTER CON- PAS- SENGER...

  • Page 383: Clockspring

    CENTER SOLE CON- RADIO ATTACHING SCREWS COLUMN LATCH NECTOR CON- HORN WIRE NECTOR CON- SQUIB WIRE SPEED TROL WIRES CON- 8M - 8 RESTRAINT SYSTEM REMOVAL AND INSTALLATION (Continued) wiring harness at the base of the clockspring (Fig. 21). (10) Unlatch and remove clockspring assembly from steering shaft.

  • Page 384: Driver Airbag Module

    AIRBAG SQUIB WIRE AIRBAG MODULE HORN WIRE SPEED CONTROL CONNEC- TORS RESTRAINT SYSTEM 8M - 9 REMOVAL AND INSTALLATION (Continued) speed control leads through the larger slot. Ensure (4) Install covers to the steering wheel armature leads do not get pinched under the steering wheel. or connect the wire connectors to the speed control (5) Route speed control wires under and behind switches and install switches.

  • Page 385: Steering Wheel

    RED LOCKING TAB PRESS LOCK LOCK TOP COVER UNLOCK ATTACHING SCREWS PASSENGER AIRBAG MOD- RIGHT TRIM BEZEL 8M - 10 RESTRAINT SYSTEM REMOVAL AND INSTALLATION (Continued) DEPLOYED MODULE REMOVAL When removing a deployed module, rubber gloves, eye protection, and a long-sleeved shirt should be worn, as there may be deposits on the surface which could irritate the skin and eyes.

  • Page 386: Clockspring Centering Procedure

    RESTRAINT SYSTEM 8M - 11 REMOVAL AND INSTALLATION (Continued) (3) Remove the speed control switches and discon- ADJUSTMENTS nect the wire connectors or covers. (4) Remove the Driver Airbag Module attaching CLOCKSPRING CENTERING PROCEDURE bolts from the back of steering wheel. If the rotating tape within the clockspring is not (5) Lift module and disconnect the airbag and horn positioned properly with the steering wheel and the...

  • Page 388: Electrically Heated Systems

    REAR WINDOW DEFOGGER ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION GRID LINES ......2 INTRODUCTION .
  • Page 389 GROUND “B’’ PARCEL SHELF MID-POINT “C’’ REAR C.H.M.S.L. TRIM COVER DEFOGGER WINDOW PICK-UP LEADS VIEW FROM INSIDE VEHI- VOLTAGE FEED “A’’ VOLTMETER POWER TO IGNITION SWITCH HEADLAMP SWITCH CONNEC- FUSE TO BATTERY TOR POINT A REAR WINDOW GRID LINE MIDPOINT (TYPI- STRUCTURE CAL)
  • Page 390 “ON” INDICATOR LED BEZEL 1 - SYMBOL LAMP 2 - GROUND 3 - IGNITION 4 - BATTERY 5 - TO BACK GLASS REAR WINDOW DEFOGGER REAR FOG LAMP SWITCH “ON” INDICATOR LED 5 - TO BACK GLASS 1 - SYMBOL LAMP 4 - BATTERY 2 - GROUND 3 - IGNITION...
  • Page 391 8N - 4 ELECTRICALLY HEATED SYSTEMS SERVICE PROCEDURES (Continued) (2) Follow instructions in repair kit for preparing vent terminal from moving while the epoxy is curing, damaged area. it must be wedged or clamped. (3) Remove package separator clamp and mix plas- (8) Carefully remove masking tape from grid line.
  • Page 392 POWER DOOR LOCKS 8P - 1 POWER DOOR LOCKS CONTENTS page page POWER DOOR LOCKS ....1 REMOTE KEYLESS ENTRY ....3 POWER DOOR LOCKS INDEX page...
  • Page 393 VIEW + TO LOCK DIRECTION ARROW Z 8P - 2 POWER DOOR LOCKS DIAGNOSIS AND TESTING (Continued) WIRING The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. (1) Remove left side switch from door trim panel. (2) Carefully separate multiple terminal block on wiring harness from switch body.

  • Page 394: Remote Keyless Entry

    BATTERIES POWER DOOR LOCKS 8P - 3 REMOTE KEYLESS ENTRY INDEX page page GENERAL INFORMATION PANIC FUNCTION CANCELLATION ..5 INTRODUCTION ......3 PROGRAM REMOTE KEYLESS ENTRY DESCRIPTION AND OPERATION MODULE...
  • Page 395 BLACK GRAY 8P - 4 POWER DOOR LOCKS DIAGNOSIS AND TESTING (Continued) REMOTE KEYLESS ENTRY GENERAL CHECKS the unlock button once and check for a voltage pulse BEFORE OTHER CHECKS. (Fig. 2). (1) Check if door locks operate properly. If not OK, (2) If no voltage pulse is measured, replace the repair as necessary.
  • Page 396 POWER DOOR LOCKS 8P - 5 DIAGNOSIS AND TESTING (Continued) (3) Connect the meter to Pin 5 of the black connec- (6) Disconnect the programming line from ground. tor and to ground to test head lamps out put. Press This returns the system to its normal operation the panic button and check for a voltage pulse (Fig.
  • Page 397 8P - 6 POWER DOOR LOCKS REMOVAL AND INSTALLATION REMOTE KEYLESS ENTRY MODULE REMOVAL (1) Remove the right trim panel, refer to Group 8E, Instrument Panel and Systems for proper removal procedures. (2) Disconnect wire connector from RKE module. (3) Remove screws holding RKE module to instru- ment panel assembly (Fig.

  • Page 398: Immobilizer System

    The system will be activated after turning the igni- the Powertrain Control Module (PCM) and/or the tion switch to the OFF position and using one of the DRB scan tool on the Chrysler Collision Detection following methods. (CCD) data bus network.
  • Page 399 DRB scan tool for the procedures. Each transmitter operates on two Duracell DL2016 The vehicle immobilizer system and the Chrysler (or equivalent) batteries. Typical battery life is from Collision Detection (CCD) data bus network should one to two years.
  • Page 400 IMMOBILIZER SYSTEM 8Q - 3 SERVICE PROCEDURES (Continued) (3) Disconnect and isolate the battery negative The same immobilizer system enable logic will cable. Unplug the wire harness connector at the apply anytime the PCM is replaced with a new unit. immobilizer receiver.

  • Page 402: Power Windows

    POWER WINDOWS 8S - 1 POWER WINDOWS CONTENTS page page GENERAL INFORMATION WIRING TEST ......1 NATURAL WHITE INTRODUCTION...
  • Page 403 8S - 2 POWER WINDOWS DIAGNOSIS AND TESTING (Continued) (5) If window moved completely up or down, the test leads should be reversed one more time to com- plete a full window travel inspection. (6) If window does not move, check to make sure that it is free.
  • Page 404 MOTOR MOUNTING SCREWS CLAMP REGULATOR SECTOR GEAR POWER WINDOWS 8S - 3 REMOVAL AND INSTALLATION (Continued) WARNING: FAILURE TO CLAMP THE SECTOR 4 DOOR WINDOW MOTOR GEAR TO THE MOUNTING PLATE WHEN REMOV- ING THE MOTOR CAN RESULT IN INJURY. REMOVAL CABLE DRUM MOTOR...

  • Page 406: Power Mirrors

    POWER MIRRORS 8T - 1 POWER MIRRORS CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION INTRODUCTION ......1 INSIDE MIRROR/READING LAMPS DIAGNOSIS AND TESTING ASSEMBLY .

  • Page 407: Front Door Trim

    Mirror Selector Knob in “R” Position Mirror Selector Knob in “L” Position MIRROR SWITCH CONTINUITY CONTINUITY BETWEEN CONTINUITY BETWEEN PINS 2 AND 4 PINS 2 AND 8 MIRROR SWITCH CONTINU- Mirror Selector Knob in “L” Mirror Selector Knob in “R” CONTINUITY BETWEEN CONTINUITY BETWEEN Mirror Folding Position...
  • Page 408 MIRROR MIRROR RELAY CONNEC- MIRROR TOR IN DOOR HARNESS TERMINAL ENDS VIEWS SWITCH CONNECTOR CONNECTORS DOOR(S) WIRING POWER MIRRORS 8T - 3 DIAGNOSIS AND TESTING (Continued) (3) Disconnect wire connector. (4) Using two jumper wires, one connected to a 12 volt source, and 2 the other connected to a good body ground.
  • Page 409 SHOWN IN EXTENDED POSI- 1/PNL RIGHT CENTER SUP- POWER MIRROR SWITCH RIGHT FRONT DOOR POWER WINDOWS IGNITION SWITCH CIRCUIT BRAKE CIRCUIT BRAKE RIGHT MIRROR C R LEFT MIRROR C R R SEPARATE RETRACT R L R L RETRACT RETRACT RETRACT (30 AMP) (15 AMP) EXTEND...
  • Page 410 POWER MIRRORS 8T - 5 REMOVAL AND INSTALLATION INSIDE MIRROR/READING LAMPS ASSEMBLY REMOVAL (1) Disconnect wiring connector. (2) Loosen mirror set screw (Fig. 8). (3) Lift mirror from mounting button. INSTALLATION For installation, reverse the above procedure. Ensure the mirror is fully locked into place. INSIDE MIRROR/READING LAMPS BULB/LENS REMOVAL (1) Using a small thin blade tool, pry at the center...
  • Page 412 CHIME WARNING/REMINDER SYSTEM 8U - 1 CHIME WARNING/REMINDER SYSTEM CONTENTS page page GENERAL INFORMATION KEY LEFT IN IGNITION SWITCH ... . 1 INTRODUCTION ......1 REMOVAL AND INSTALLATION DIAGNOSIS AND TESTING CHIME .
  • Page 413 VIEWED FROM TERMINAL END 8U - 2 CHIME WARNING/REMINDER SYSTEM DIAGNOSIS AND TESTING (Continued) (2) Using voltmeter, check for battery feed at Pin 6 of the J1 wire harness connector. Check for NO igni- tion feed at Pin 5 of the J1 wire harness connector. If OK, go to Step 3.
  • Page 414 ENGINE 9 - 1 ENGINE CONTENTS page page 2.0L DOHC ENGINE ..... 52 ENGINE DIAGNOSIS ..... . 7 2.0L SOHC ENGINE .
  • Page 415 CYLINDER CUP PLUG BLOCK DRIFT SECOND REMOVE PLUG FIRST STRIKE HERE WITH HAMMER WITH PLIERS 9 - 2 ENGINE GENERAL INFORMATION (Continued) assure gasket rails are flat. Flatten rails with a ham- mer on a heavy steel plate if required. Gasket sur- faces must be free of oil and dirt.
  • Page 416 CROSS-HATCH PATTERN ENGINE 9 - 3 GENERAL INFORMATION (Continued) Insert compression gage adaptor into the #1 tory surface. Inspect cylinder walls after each 20 spark plug hole in cylinder head. Crank engine until strokes, using a light honing oil. Do not use engine maximum pressure is reached on gage.
  • Page 417 PLASTIGAGE 9 - 4 ENGINE GENERAL INFORMATION (Continued) Fig. 4 Clearance Measurement Fig. 3 Plastigage Placed in Lower Shell ALTERNATIVE METHOD NOTE: The total clearance of the main bearings The weight of the crankshaft can be supported by a can only be determined by removing the weight of jack under the counterweight adjacent to the bearing the crankshaft.
  • Page 418 ENGINE LEVEL STICK DIP- ENGINE 9 - 5 GENERAL INFORMATION (Continued) the oil hole (Fig. 3). In addition, suspect areas can be (5) Identify the fluid in the cylinder(s) (i.e., cool- checked by placing plastigage in the suspect area. ant, fuel, oil or other). (4) Assemble the rod cap with Plastigage in place.

  • Page 419: Maintenance Schedules

    ANTICIPATED TURE RANGE NEXT OIL CHANGE TEMPERA- BEFORE 9 - 6 ENGINE GENERAL INFORMATION (Continued) ENGINE OIL SPECIFICATION CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certi- fied or an oil that conforms to the API Service Grade SH or SH/CD.
  • Page 420 ENGINE 9 - 7 ENGINE DIAGNOSIS INDEX page page DIAGNOSIS AND TESTING GENERAL INFORMATION ....7 CYLINDER COMBUSTION PRESSURE INSPECTION (ENGINE OIL LEAKS IN LEAKAGE TEST .
  • Page 421 9 - 8 ENGINE DIAGNOSIS AND TESTING (Continued) cause of low compression unless some malfunc- Perform the test procedures on each cylinder tion is present. according to the tester manufacturer’s instructions. (11) Clean or replace spark plugs as necessary While testing, listen for pressurized air escaping and adjust gap as specified in Group 8, Electrical.
  • Page 422 ENGINE 9 - 9 DIAGNOSIS AND TESTING (Continued) (3) Using a black light, inspect the entire engine If the leakage occurs at the crankshaft rear oil seal for fluorescent dye, particularly at the suspected area area: of oil leak. If the oil leak is found and identified, (1) Disconnect the battery.
  • Page 423 9 - 10 ENGINE DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT 1. Weak battery. 1. Test battery specific gravity. Charge or START replace as necessary. 2. Corroded or loose battery connections. 2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals.
  • Page 424 ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in crankcase. 1. Check for correct oil level (refer to Group 0, Lubrication and Maintenance). 2. Thin or diluted oil. 2.
  • Page 425 ENGINE IDENTIFI- CATION LOCATION 9 - 12 2.0L SOHC ENGINE 2.0L SOHC ENGINE INDEX page page DESCRIPTION AND OPERATION OIL PUMP ......37 ENGINE COMPONENTS .
  • Page 426 OIL FILTER ADAPTER OIL PICK-UP TUBE OIL PAN GASKET OIL PUMP BODY DRAIN PLUG OIL PAN O-RING O-RING O-RING NIPPLE FILTER 2.0L SOHC ENGINE 9 - 13 DESCRIPTION AND OPERATION (Continued) Engine Lubrication Components ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION Refer to Group 0, Lubrication and Maintenance for recommended oil to be used in various engine appli- cation.
  • Page 427 9 - 14 2.0L SOHC ENGINE DESCRIPTION AND OPERATION (Continued) route oil from main bearing journals to connecting directly to the cylinder head. It incorporates powder rod journals. metal valve guides and seats. The hollow rocker arm shafts supplies oil to the hydraulic lash adjusters, CAMSHAFT/HYDRAULIC LASH ADJUSTERS camshaft and valve mechanisms.
  • Page 428 Refer to Cylinder Bore and Piston Specifications Table. Fig. 4 Piston Measurements Chrysler engines use pistons designed specifically for each engine model. Clearance and sizing locations vary with respect to engine model. NOTE: Pistons and cylinder bores should be mea- sured at normal room temperature, 21°C (70°F).
  • Page 429 FEELER GAUGE FEELER GAUGE 9 - 16 2.0L SOHC ENGINE SERVICE PROCEDURES (Continued) CAUTION: Do not rotate crankshaft or the Plasti- gage may be smeared. Fig. 8 Checking Connecting Rod Bearing Clearance Fig. 5 Piston Ring Gap NOTE: The rod bearing bolts should not be reused. (2) Before installing the NEW bolts the threads should be oiled with clean engine oil.
  • Page 430 2.0L SOHC ENGINE 9 - 17 SERVICE PROCEDURES (Continued) CONNECTING ROD BEARING OIL CLEARANCE New Part: 0.026 to 0.059 mm (0.001 to 0.0023 in.) Wear Limit: 0.075 mm (0.003 in.) CONNECTING ROD SIDE CLEARANCE New Part: 0.13 to 0.38 mm (0.005 to 0.015 in.) Wear Limit: 0.40 mm...
  • Page 431 FRONT FRONT MOUNT INSULATOR ENGINE THROUGH BOLT MASS DAMPER BRACKET MOUNT 9 - 18 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) ENGINE FRAME SOCKET MOUNT TO RAIL TENER (2) FAS- ENGINE MOUNT TO ENGINE BRACKET THRU-BOLT ENGINE BRACKET Fig. 13 Engine Mounting—Front Fig.
  • Page 432 FRONT MANUAL TRANSMISSION POWER HOP DAMPER THROUGH BOLT CROSSMEMBER SUSPENSION GROMMET GROMMET WHEELHOUSE SPLASH SHIELD PUSH-IN FASTENER NUT-SNAP FENDER ACCESSORY BELT SPLASH SHIELD PUSH-IN FAS- TENER FASCIA DRIVE 2.0L SOHC ENGINE 9 - 19 REMOVAL AND INSTALLATION (Continued) Fig. 16 Power Hop Damper Fig.
  • Page 433 PLACE FRONT SUP- PORT ENGINE FLANGE UNDER BLOCK PLACE REAR SUP- PORT LOCATING HOLE IN SPECIAL 6135 AND 6710 POST BEDPLATE TOOLS INTO 9 - 20 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) (15) Connect fuel line and heater hoses. (16) Install ground straps.
  • Page 434 SPARK PLUG TUBE SPARK INSULATOR PLUG SPARK PLUG CABLE LOCKING PLIERS IGNITION COILS CYLINDER HEAD COVER SPARK PLUG TUBE SEAL 2.0L SOHC ENGINE 9 - 21 REMOVAL AND INSTALLATION (Continued) SPARK PLUG TUBE SEALS The spark plug tube seals are located in the cylin- der head cover (Fig.
  • Page 435 ROCKER SHAFT RETAINERS EXHAUST ROCKER ARM SHAFT EXHAUST INTAKE ROCKER ASSEMBLY PLASTIC SHAFT ROCKER SPACERS ASSEMBLY INTAKE ROCKER ARM SHAFT 9 - 22 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) NOTE: Check oil feed holes for blockage. (6) Install rocker arm assemblies in correct order Inspect cylinder head journals for wear, Refer to as removed.
  • Page 436 INTAKE ROCKER ARM ROLLER EXHAUST ROCKER ARM HYDRAULIC LASH ADJUSTERS EXHAUST ROCKER ARM SHAFT NOTCHES FACING UP AND TOWARD THE TIMING BELT SIDE OF THE ENGINE INTAKE ROCKER ARM SHAFT 2.0L SOHC ENGINE 9 - 23 REMOVAL AND INSTALLATION (Continued) (5) Slide the rocker arms and spacers off the shaft.
  • Page 437 AIR HOSE VALVE SPRING COMPRES- SPECIAL MD-998772A TOOL VALVE SEAL TOOL VALVE STEM ADAPTER 6779 VALVE RETAINER SPRING VALVE RETAINING LOCKS VALVE VALVE SPRING SEAT VALVESPRING SEAL ASSEMBLY 9 - 24 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 31 Valve Spring Assembly Fig.
  • Page 438 EXHAUST ROCKER ARM/HY- DRAULIC LASH ADJUSTER RETAINER SPACER ASSEMBLY CAMSHAFT SEAL SPARK VALVE RETAINING LOCKS PLUG TUBE SEAL VALVE SPRING RETAINER INTAKE ROCKER ARM/HYDRAULIC CAMSHAFT LASH ADJUSTER ASSEMBLY FEELER VALVE GAUGE SPRING SEAT ASSEMBLY SPACER SEAL AND VALVE SPRING VALVE VALVE ROCKER RETAINER SPACER...
  • Page 439 SIDESHIELD SCREW(3) RIGHT FRAME SHIELD PLUG RAIL ACCESS PLUG ENGINE MOUNT BRACKET TO FASTENERS ENGINE FASTENERS INDICATES CLIP LOCATION RETAINING 9 - 26 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 34 Cylinder Head Tightening Sequence Fig. 36 Right Engine Mount Bracket Fig.
  • Page 440 12.7 MM (1/2 IN.) 50.8 MM (2 IN.) GRIND 2.0L SOHC ENGINE 9 - 27 SPECIAL C-4679–A TOOL REMOVAL AND INSTALLATION (Continued) CAMSHAFT OIL SEAL (4) Shaft seal lip surface must be free of varnish, SPECIAL TOOL MD 998306 dirt or nicks. Polish with 400 grit paper if necessary. REMOVAL CAUTION: Do Not Rotate the camshaft or crank-...
  • Page 441 FRONT TIMING BELT CRANKSHAFT TIMING MARK SPROCKET ACCESS PLUG COVER DAMPER BOLT CAMSHAFT BOLT WASHER ARROW TIMING BELT REAR COVER CAMSHAFT SPROCKET SIDESHIELD CRANKSHAFT SPROCKET TENSIONER REAR TIMING BELT COVER SCREW(3) OIL PUMP BODY BRACKET WATER PUMP RIGHT FRAME SHIELD PLUG RAIL 9 - 28...
  • Page 442 2.0L SOHC ENGINE 9 - 29 REMOVAL AND INSTALLATION (Continued) (3) Remove crankshaft damper bolt. Remove damper using the large side of Special Tool 1026 and insert 6827-A (Fig. 44). BACKING TENSIONER PULLEY PIVOT TENSIONER (DO NOT TIGHTEN, LOOSEN PULLEY FASTENER PLATE PIVOT OR REMOVE)
  • Page 443 TIMING BELT TEN- TENSIONER PIVOT SIONER TENSIONER FASTENERS T.D.C. MARK TIMING MARK SPROCKET TDCMARK T.D.C. REFER- ENCE MARK 1/2 NOTCH LOCATION ARROW REAR COVER 9 - 30 2.0L SOHC ENGINE LOCKING PIN TENSIONER BENCH VISE (WITH SOFT JAWS) REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 444 CAMSHAFT T.D.C. REMOVE CLEAR- CRANKSHAFT T.D.C. SIONER UP TO MOVE TEN- ANCE INSTALL WRENCH HERE TORQUE 2.0L SOHC ENGINE 9 - 31 REMOVAL AND INSTALLATION (Continued) Fig. 54 Crankshaft Damper—Installation (3) Remove front engine mount and bracket. Refer to Engine Support Module Removal and Installation in this section.
  • Page 445 9 - 32 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) FRONT CRANKSHAFT OIL SEAL REMOVAL (1) Using Special Tool 1026 and Insert 6827–A, remove crankshaft damper (Fig. 56). PROTECTOR INSTALLER SPECIAL TOOL 6780–1 SEAL Fig. 58 Front Crankshaft Oil Seal—Removal (2) Place seal into opening with seal spring towards the inside of engine.
  • Page 446 M12 — 1.75 WASHER BEARING FROM SPECIAL TOOL 6792 150 MM BOLT, TOOL 6792 SPECIAL THRUST REAR CRANKSHAFT SCREW- DRIVER SEAL ENGINE BLOCK REAR CRANKSHAFT SEAL ENGINE BLOCK CRANK- REAR SHAFT SHAFT SCREW- METAL CASE DUST LIP PRY IN THIS DIRECTION CRANK- DRIVER...
  • Page 447 SPECIAL 6792–2 INSTALLER SPECIAL TOOL 6926–1 PILOT SPECIAL TOOL 6926–2 INSTALLER TOOL SEAL 9 - 34 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) CRANKSHAFT REMOVAL (1) Remove oil filter and adapter from bedplate. (2) Remove oil pan. (3) Remove crankshaft sprocket and oil pump both procedures outlined in this section.
  • Page 448 MAIN BED PLATE ASSEMBLY CRANKSHAFT POSITION CONNECTING BEARING SOR (CPS) INDICATES DOWEL LOCA- SEN- BEARINGS CAP/ PISTON AND CONNECT- ING ROD ASSEMBLY TION O-RING BOLT SEAL NIPPLE OIL FILTER ADAPTER THRUST BEARINGS FRONT OF ENGINE UPPER (GROOVED) FRONT BEARING SEAL OIL GROOVES OIL HOLES LOWER...
  • Page 449 O-RING LUBRICATION GROOVES OIL HOLES INDICATES DOWEL LOCA- TION FRONT OF ENGINE 9 - 36 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 70 Main Bearing Caps/Bedplate Torque Fig. 68 Installing Main Bearing Upper Shell Sequence (4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of (10) After the main bearing bedplate is installed, Mopar Torque Cure Gasket Maker to cylinder block check the crankshaft turning torque.
  • Page 450 OIL FILTER LOCATE WRENCH BAND AT OIL FILTER ADAPTER OIL PICK-UP TUBE OIL PAN GASKET OIL PUMP BODY BASE OF FILTER DRAIN PLUG OIL PAN O-RING O-RING O-RING NIPPLE FILTER OIL FILTER WRENCH 2.0L SOHC ENGINE 9 - 37 REMOVAL AND INSTALLATION (Continued) (1) Turn counterclockwise to remove.
  • Page 451 9 - 38 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Make sure all surfaces are clean and free of oil and dirt. (2) Apply Mopar Gasket Maker to oil pump as shown in (Fig. 75). Install oil ring into oil pump body discharge passage.
  • Page 452 SPACER EXPANDER NO. 2 PISTON RING NO. 1 PISTON RING OIL RING SIDE RAIL END SIDE RAIL 2.0L SOHC ENGINE 9 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 79 Identify Connecting Rod to Cylinder (4) Pistons and connecting rods must be removed from top of cylinder block.
  • Page 453 CRANKSHAFT DAMPER WELD GAP NO. 2 RING GAP AND SPACER GAP OF LOWER SIDE RAIL EXPANDER FRONT OF ENGINE NO. 1 RING GAP GAP OF UPPER SIDE RAIL 9 - 40 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) on the thrust direction. Staggering ring gap is impor- rod and piston assembly into cylinder bore and guide tant for oil control.
  • Page 454 SPECIAL M12 — 1.75 WASHER BEARING SPECIAL TOOL 1026 TOOL FROM 150 MM BOLT, INSERT 6827–A TOOL 6792 SPECIAL THRUST 2.0L SOHC ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) (3) Remove crankshaft damper bolt. Remove DISASSEMBLY AND ASSEMBLY damper using the large side of Special Tool 1026 and OUTERROTOR INNER ROTOR RELIEF V ALVE RETAINER CAP...
  • Page 455 MIDDLE BOTTOM CUT AWAY VIEW OF VALVE SUREMENT GUIDE LOCA- TIONS MEA- 9 - 42 2.0L SOHC ENGINE DISASSEMBLY AND ASSEMBLY (Continued) VALVE SERVICE WITH THE CYLINDER HEAD REMOVED REMOVAL (1) With cylinder head removed, compress valve springs using Special Tool C-3422–B or equivalent. (2) Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs.
  • Page 456 VALVE MARGIN VALVE FACE 2.0L SOHC ENGINE 9 - 43 DISASSEMBLY AND ASSEMBLY (Continued) Verify springs are not distorted with a steel Total runout should not exceed. 0.051 mm (0.002 square and surface plate, check springs from both inch.) (total indicator reading). ends.
  • Page 457 9 - 44 2.0L SOHC ENGINE DISASSEMBLY AND ASSEMBLY (Continued) in.) spacer under the valve spring seat to bring spring height back within specification. (5) Install rocker shafts previously described in this section. (6) Checking dry lash. Dry lash is the amount of clearance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed.
  • Page 458 2.0L SOHC ENGINE 9 - 45 CLEANING AND INSPECTION (Continued) OIL PUMP (1) Clean all parts thoroughly. Mating surface of the oil pump should be smooth. Replace pump cover if scratched or grooved. (2) Lay a straightedge across the pump cover sur- face (Fig.
  • Page 459 FEELER STRAIGHT EDGE GAUGE FRONT MIDDLE OF BORE SIZING PISTON 9 - 46 2.0L SOHC ENGINE CLEANING AND INSPECTION (Continued) (7) Place a straightedge across the face of the specified clearances may be maintained. Refer to pump housing, between bolt holes. If a feeler gauge Honing Cylinder Bores outlined in the Stan- of .102 mm (.004 inch) or more can be inserted dard Service Procedures for specification and...
  • Page 460 2.0L SOHC ENGINE 9 - 47 SPECIFICATIONS Side Clearance ....0.13 - 0.38 mm (0.005 - 0.015 in.) ENGINE 2.0L SOHC Total Weight (Less Bearing) ... 543 grams (1.20 lbs.) Cylinder Block Crankshaft...
  • Page 461 9 - 48 2.0L SOHC ENGINE SPECIFICATIONS (Continued) Valve Timing Exhaust Valve Valve Springs Closes (ATDC) ......5.4° Free Length (Approx.) .
  • Page 462 2.0L SOHC ENGINE 9 - 49 SPECIFICATIONS (Continued) DESCRIPTION ....TORQUE Oil Pump Cover Fastener . . . 12 N·m (105 in. lbs.) Oil Pump Pick-up Tube Bolt .
  • Page 463 9 - 50 2.0L SOHC ENGINE SPECIAL TOOLS (Continued) Crankshaft Damper Installer 6792 Valve Spring Compressor C-3575-A Crankshaft Damper Installer C-4685-C Cylinder Bore Indicator C-119 Valve Spring Compressor MD-998772-A Front Crankshaft Seal Remover 6771 Spring Compressor Adapter 6779 Front Crankshaft Seal Installer 6780...
  • Page 464 2.0L SOHC ENGINE 9 - 51 SPECIAL TOOLS (Continued) Crankshaft Sprocket Remover 6793 Valve Spring Tester C-647 Crankshaft Sprocket Installer 6792 Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Pressure Gage C-32932...
  • Page 465 ENGINE IDENTIFICATION LOCATION 9 - 52 2.0L DOHC ENGINE 2.0L DOHC ENGINE INDEX page page DESCRIPTION AND OPERATION OIL FILTER ......77 ENGINE COMPONENTS .
  • Page 466 OIL FILTER ADAPTER OIL PICK-UP TUBE OIL PAN GASKET OIL PUMP BODY DRAIN PLUG OIL PAN O-RING O-RING O-RING NIPPLE FILTER RESTRICTOR 2.0L DOHC ENGINE 9 - 53 DESCRIPTION AND OPERATION (Continued) ENGINE LUBRICATION SYSTEM Fig. 2 Engine Lubrication Components PRESSURE LUBRICATION Oil drawn up through the pickup tube is pressur- ized by the pump and routed through the full flow fil-...
  • Page 467 9 - 54 2.0L DOHC ENGINE DESCRIPTION AND OPERATION (Continued) SPLASH LUBRICATION the intake camshaft at the rear of cylinder head. A Oil returning to the pan from pressurized compo- hydrodynamic oil seal is used for oil control at the nents supplies lubrication to the valve stems.
  • Page 468 Fig. 5 Piston Measurements Chrysler engines use pistons designed specifically for each engine model. Clearance and sizing locations vary with respect to engine model. NOTE: Pistons and cylinder bores should be mea- sured at normal room temperature, 21°C (70°F).
  • Page 469 FEELER GAUGE FEELER GAUGE 9 - 56 2.0L DOHC ENGINE SERVICE PROCEDURES (Continued) FITTING PISTON RINGS Ring Position Ring Gap Wear Limit (1) Wipe cylinder bore clean. Insert ring and push Upper Ring 0.23 to 0.52 mm 0.8 mm down with piston to ensure it is square in bore. The (0.009 to 0.020 in.) (0.031 in.) ring gap measurement must be made with the ring...
  • Page 470 2.0L DOHC ENGINE 9 - 57 SERVICE PROCEDURES (Continued) Fig. 10 Checking Connecting Rod Side Clearance Fig. 13 Checking Crankshaft End Play— Dial Indicator CONNECTING ROD BEARING OIL CLEARANCE (3) Zero the dial indicator. New Part: 0.026 to 0.059 mm (4) Move crankshaft all the way to the front and (0.001 to 0.0023 in.) read the dial indicator.
  • Page 471 AUTOMATIC TRANSMISSION MANUAL TRANSMISSION LEFT MOUNT 9 - 58 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) e. Install mass damper and tighten to 54 N·m (40 ft. lbs.) Fig. 15 Engine Mounting—Left ft. lbs.), then tighten engine mount to engine bracket Fig.
  • Page 472 2.0L DOHC ENGINE 9 - 59 REMOVAL AND INSTALLATION (Continued) Fig. 17 Power Hop Damper Fig. 18 Right Inner Splash Shield ENGINE ASSEMBLY (18) Lower vehicle. Remove air cleaner assembly. (19) Remove power steering pump and reservoir, REMOVAL Set them aside. (1) Perform fuel pressure release procedure.
  • Page 473 9 - 60 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) (15) Connect fuel line and heater hoses. (16) Install ground straps. Connect engine and throttle body connections and harnesses. Refer to Group 8, Electrical for procedure. (17) Connect throttle body linkage. Refer to Group 14, Fuel System for procedure.
  • Page 474 2.0L DOHC ENGINE 9 - 61 REMOVAL AND INSTALLATION (Continued) COVER INSTALLATION CAUTION: Camshafts are not interchangeable. The intake cam number 6 thrust bearing face spacing is NOTE: Before installation, clean cylinder head and wider. cover mating surfaces. Make certain the rails are flat.
  • Page 475 9 - 62 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: Check camshaft for binding in cylinder head. Inspect camshaft bearing journals for dam- age. If camshafts are binding, also check the cylin- der head bearing surface for damage, and check the camshaft bearing oil feed holes in the cylinder head for clogging.
  • Page 476 AIR HOSE VALVE SPRING COMPRES- SOR MD 998772A VALVE RETAINER SPRING VALVE SEAL TOOL VALVE STEM VALVE RETAINING LOCKS VALVE VALVE SPRING SEAT VALVESPRING SEAL ASSEMBLY 2.0L DOHC ENGINE 9 - 63 REMOVAL AND INSTALLATION (Continued) (5) Remove valve spring. (6) Remove valve stem seal by using a valve stem seal tool (Fig.
  • Page 477 VALVE RETAINING LOCKS HYDRAULIC VALVE SPRING RETAINER VALVE GUIDE VALVE SPRING SEAT ASSEMBLY SEAL AND VALVE SPRING ADJUSTER ROLLER FOLLOWER LASH VALVE VALVE SPARK PLUG WELL GASKET OIL FILL CAP CAMSHAFT OIL SEAL CAMSHAFT BEARING CAPS CYLINDER HEAD COVER PLUG GASKET CYLINDER HEAD HEAD GASKET...
  • Page 478 2.0L DOHC ENGINE 9 - 65 REMOVAL AND INSTALLATION (Continued) REMOVAL CYLINDER HEAD FLATNESS FEELER GAUGE STRAIGHT EDGE (1) Perform fuel system pressure release procedure (1) Cylinder head must be flat within 0.1 mm before attempting any repairs. Refer to Group 14, (0.004 inch) (Fig.
  • Page 479 SIDESHIELD CRANKSHAFT DAMPER SCREW(3) WELD GAP RIGHT FRAME SHIELD PLUG RAIL SPECIAL M12 — 1.75 WASHER BEARING SPECIAL TOOL 1026 TOOL FROM 150 MM BOLT, INSERT 6827–A TOOL 6792 SPECIAL THRUST 9 - 66 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) (3) Reverse removal procedure, for rest of installa- (3) Remove crankshaft...
  • Page 480 SIDESHIELD SCREW(3) RIGHT FRAME SHIELD PLUG RAIL SPECIAL CHANNEL SPECIAL TOOL 1026 FASTENERS RETAINER TOOL INSERT 6827–A FRONT TIMING BELT COVER FASTEN- TIMING INSPECTION COVER ENGINE MOUNT BRACKET TENER BELT FAS- 2.0L DOHC ENGINE 9 - 67 REMOVAL AND INSTALLATION (Continued) TIMING BELT COVER REMOVAL CAUTION:...
  • Page 481 FRONT CRANKSHAFTDAMPER ACCESS PANEL TIMING COVER BELT CAMSHAFT SPROCK- TIMING BELT CRANKSHAFT SPROCKET BRACKET TENSIONER REAR TIMING BELT COVER WATER PUMP OIL PUMP CAMSHAFT TIMING MARKS SHOULD LINE UP 9 - 68 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) TIMING BELT CHANNEL FASTENERS RETAINER...
  • Page 482 BACKING TENSIONER PULLEY PIVOT TENSIONER (DO NOT TIGHTEN, LOOSEN LOCKING PIN PULLEY FASTENER PLATE PIVOT OR REMOVE) BRACKET SIONER PULLEY BOLT TEN- TENSIONER BENCH VISE (WITH SOFT JAWS) TDCMARK ALIGN CAMSHAFT SPROCKET TIMING MARKS TOGETHER CENTERLINE 2.0L DOHC ENGINE 9 - 69 REMOVAL AND INSTALLATION (Continued) (3) Align camshaft timing marks.
  • Page 483 T.D.C. MARK T.D.C. REFER- ENCE MARK 1/2 NOTCH LOCATION 9 - 70 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) LOCKING INSTALLED INTO TEN- MOVE TENSIONER UP SIONER CAMSHAFTS TDC INSTALL TORQUE WRENCH CRANKSHAFT TDC HERE Fig. 48 Adjusting Crankshaft Sprocket for Timing Fig.
  • Page 484 TDCMARK PLACE A 1/8 INCH BEAD OF SEALER AT THE PARTING LINE OF THE OIL PUMP TO ENGINE BLOCK ADAPTER CAMSHAFT SEAL SPECIAL TOOL C-4687–1 SPECIAL TOOL C-4687 MD998713 PRY BAR 2.0L DOHC ENGINE 9 - 71 REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 485 SPECIAL TOOL6771 9 - 72 2.0L DOHC ENGINE PROTECTOR INSTALLER SPECIAL TOOL 6780–1 REMOVAL AND INSTALLATION (Continued) SEAL FRONT CRANKSHAFT OIL SEAL SPECIAL SPECIAL TOOL 1026 TOOL SPECIAL TOOL 6793 INSERT 6827–A REMOVAL (1) Using Special Tool 1026 and Insert 6827–A, remove crankshaft damper (Fig.
  • Page 486 M12 — 1.75 WASHER BEARING FROM SPECIAL TOOL 6792 150 MM BOLT, TOOL 6792 SPECIAL THRUST REAR CRANKSHAFT SCREW- DRIVER SEAL ENGINE BLOCK SPECIAL TOOL 6926–1 PILOT REAR CRANKSHAFT SEAL ENGINE BLOCK CRANK- REAR SHAFT SHAFT SCREW- METAL CASE DUST LIP PRY IN THIS DIRECTION CRANK-...
  • Page 487 SPECIAL 6792–2 INSTALLER SPECIAL TOOL 6926–1 PILOT TOOL SPECIAL TOOL 6926–2 INSTALLER SEAL 9 - 74 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 64 Crankshaft Seal Special Tool 6926-2 Fig. 65 Rear Crankshaft Seal—Installation...
  • Page 488 MAIN BED PLATE ASSEMBLY CRANKSHAFT POSITION CONNECTING BEARING SOR (CPS) SEN- BEARINGS CAP/ PISTON AND CONNECT- ING ROD ASSEMBLY O-RING BOLT SEAL NIPPLE OIL FILTER ADAPTER THRUST BEARINGS UPPER (GROOVED) BEARING SEAL PASSAGE O-RING INDICATES DOWEL LOCA- TION FRONT OF ENGINE 2.0L DOHC ENGINE 9 - 75 REMOVAL AND INSTALLATION (Continued)
  • Page 489 FRONT OIL GROOVES OIL HOLES LOWER UPPER BEARINGS BEARINGS O-RING LUBRICATION GROOVES OIL HOLES 9 - 76 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 67 Main Bearing Identification Fig. 68 Installing Main Bearing Upper Shell held to .025 mm (.001 inch). Journal grinding should CAUTION: Use only the specified anaerobic sealer not exceed .305 mm (.012 inch) under the standard on the bedplate or damage may occur to the...
  • Page 490 O-RING INDICATES DOWEL LOCA- TION ADAPTER FRONT OF ENGINE FILTER LOCATING ROLL 2.0L DOHC ENGINE 9 - 77 REMOVAL AND INSTALLATION (Continued) against the seam at the base of the filter. The seam, joining the can to the base is reinforced by the base plate.
  • Page 491 APPLY MAKER PUMP OIL FILTER ADAPTER OIL PICK-UP TUBE GASKET FLANGE OIL PAN GASKET OIL PUMP BODY BODY DRAIN PLUG OIL PAN O-RING O-RING O-RING NIPPLE FILTER O-RING 9 - 78 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 74 Oil Pump and Tube PROTECTOR INSTALLER SPECIAL...
  • Page 492 2.0L DOHC ENGINE 9 - 79 REMOVAL AND INSTALLATION (Continued) (7) Install crankshaft sprocket, using Special Tool 6792 (Fig. 77). Fig. 79 Identify Connecting Rod to Cylinder tion assemblies. The weight designation stamps should face toward the timing belt side of the engine. (4) Pistons and connecting rods must be removed from top of cylinder block.
  • Page 493 SPACER EXPANDER NO. 2 PISTON RING NO. 1 PISTON RING OIL RING SIDE RAIL END SIDE RAIL NO. 2 RING GAP AND SPACER GAP OF LOWER SIDE RAIL EXPANDER FRONT OF ENGINE NO. 1 RING GAP GAP OF UPPER SIDE RAIL 9 - 80 2.0L DOHC ENGINE REMOVAL AND INSTALLATION (Continued)
  • Page 494 RELIEF V ALVE RETAINER CAP SPRING GASKET OIL PUMP BODY MIDDLE BOTTOM OUTERROTOR INNER ROTOR OIL PUMP COVER CUT AWAY VIEW OF VALVE SUREMENT GUIDE PUMP BODY LOCA- TIONS MEA- 2.0L DOHC ENGINE 9 - 81 REMOVAL AND INSTALLATION (Continued) should face toward the front of the engine for DOHC engine (Fig.
  • Page 495 VALVE GUIDE 13.25 — 13.75 mm (.521 — .541 in.) SPRING SEAT VALVE TESTER SPRING TORQUE WRENCH 9 - 82 2.0L DOHC ENGINE DISASSEMBLY AND ASSEMBLY (Continued) CHECK VALVE GUIDE HEIGTH Fig. 89 Testing Valve Spring Valve Guide Heigth (4) Measure the concentricity of valve seat and valve guide using a valve seat runout dial indicator.
  • Page 496 2.0L DOHC ENGINE 9 - 83 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 93 Checking Spring Installed Height and Valve Tip Height Dimensions (2) Install new valve stem seals on all valves using a valve stem seal tool (Fig. 94). The valve stem seals should be pushed firmly and squarely over valve guide.
  • Page 497 9 - 84 2.0L DOHC ENGINE DISASSEMBLY AND ASSEMBLY (Continued) (5) Install cam followers and camshaft as previ- OIL PUMP ously described in this section. (1) Clean all parts thoroughly. Mating surface of (6) Checking dry lash. Dry lash is the amount of the oil pump should be smooth.
  • Page 498 INNER OUTER ROTOR FEELER GAUGE ROTOR FEELER GAUGE OUTER ROTOR FEELER STRAIGHT EDGE GAUGE 2.0L DOHC ENGINE 9 - 85 CLEANING AND INSPECTION (Continued) (7) Place a straightedge across the face of the pump housing, between bolt holes. If a feeler gauge of .102 mm (.004 inch) or more can be inserted between rotors and the straightedge, replace pump assembly (Fig.
  • Page 499 FRONT MIDDLE OF BORE SIZING PISTON 9 - 86 2.0L DOHC ENGINE CLEANING AND INSPECTION (Continued) specified clearances may be maintained. Refer to SPECIFICATIONS Honing Cylinder Bores outlined in the Stan- ENGINE 2.0L DOHC dard Service Procedures for specification and procedures.
  • Page 500 2.0L DOHC ENGINE 9 - 87 SPECIFICATIONS (Continued) Connecting Rod Cylinder Head Bearing Clearance ... 0.026 - 0.059 mm Material ....Cast Aluminum (0.001 - 0.0023 in.) Gasket Thickness Piston Pin Bore Diameter .
  • Page 501 9 - 88 2.0L DOHC ENGINE SPECIFICATIONS (Continued) TORQUE CHART 2.0L DOHC SPECIAL TOOLS ENGINE 2.0L DOHC DESCRIPTION ....TORQUE Camshaft Sensor Pick-Up Bolts .
  • Page 502 2.0L DOHC ENGINE 9 - 89 SPECIAL TOOLS (Continued) Camshaft Seal Installer MD-998713 Adapter Spring Compressor 6779 Installer Crankshaft Damper 6792 Front Crankshaft Seal Remover 6771 Installer Crankshaft Damper C-4685-C Valve Spring Compressor C-3575-A Valve Spring Compressor MD-998772-A Cylinder Bore Indicator C-119...
  • Page 503 9 - 90 2.0L DOHC ENGINE SPECIAL TOOLS (Continued) Front Crankshaft Seal Installer 6780 Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Crankshaft Sprocket Remover 6793 Pressure Gage C-32932 Crankshaft Sprocket Installer 6792 Valve Spring Tester C-647...
  • Page 504 EXHAUST BALL JOINT COUPLING There is no regularly scheduled maintenance on An exhaust ball joint coupling (Fig. 2) is used to any Chrysler catalytic converter (Fig. 3). If damaged, secure the exhaust pipe to the engine exhaust mani- the converter must be replaced.
  • Page 505 CATALYTIC EXHAUST MANI- NUT 28 N·m (250 in. lbs.) SHOULDER FOLD VERTER SPRING CON- BOLT INSULATOR BRACKETS OVAL MUFFLER HEAT SHIELD EXHAUST PIPE SHOULDERBOLT SPRING NUT SEAL RING HEAT SHIELD SCREWS UNDER BODY 11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD GENERAL INFORMATION (Continued) result in excessive exhaust system/floor pan temper- atures because of no air movement under the vehicle.

  • Page 506: Exhaust Manifold

    EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3 DESCRIPTION AND OPERATION This long branch fan design enhances low and midrange torque. INTAKE MANIFOLD SOHC EXHAUST MANIFOLD The intake manifold is a molded plastic composi- The exhaust manifold is made of nodular cast iron tion, attached to the cylinder head with ten fasten- for strength and high temperatures.

  • Page 507: Removal And Installation

    11 - 4 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION EXHAUST PIPE AND MUFFLER REMOVAL (1) Raise vehicle on hoist and apply penetrating oil to band clamp fastener of component being removed (Fig. 5). HEATED HEAT SHIELD SENSOR EXHAUST PIPE WIRE OXY- CATALYTIC...
  • Page 508 UNDER TORQUE SPECI- CATALYTIC BODY FICATION SHIELD 37 mm (1.45 in.) HEAT VERTER CON- EXHAUST PIPE TOEBOARD FLOOR PANEL CONVERTER MOUNTED 23 mm (.91 in.) CLAMP SIZE CROSS MEMBER HEAT SHIELD EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5 REMOVAL AND INSTALLATION (Continued) INSTALLATION INTAKE MANIFOLD—SINGLE OVERHEAD CAM When assembling exhaust system do not tighten...
  • Page 509 MAP/AIR THROTTLE POSITION SENSOR PCV VACUUM NIPPLE INTAKE MANIFOLD TEMPERATURE SENSOR STARTER MOTOR KNOCK SEN- IDLE AIR CON- TROL MOTOR 11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (Continued) (6) Perform fuel system pressure release procedure before attempting any repairs. (7) Disconnect the fuel supply line quick connect at the fuel tube assembly.

  • Page 510: Intake Manifold-Dual Overhead Cam Engine (Dohc)

    INTAKE WATER INLET SUPPORT EGR TUBE TO INTAKE MANIFOLD FASTENERS MANIFOLD TUBE FASTENERS VALVE EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7 REMOVAL AND INSTALLATION (Continued) (18) Remove EGR tube bolts at the valve and at (4) Connect PCV and brake booster hoses. the intake manifold (Fig.
  • Page 511 11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (Continued) (3) Remove fresh air inlet duct (Fig. 21). Remove wing nut on intake. (4) Remove the protective cap from the fuel pres- sure test port on the fuel rail (Fig. 19). Fig.

  • Page 512: Engine (Sohc)

    EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9 REMOVAL AND INSTALLATION (Continued) EGR TUBE TO INTAKE FOLD FASTEN- MANI- TUBE FASTENERS VALVE FUEL INJECTORS MAP/IAT SENSOR TEST PORT FUEL RAIL Fig. 25 Knock Sensor Electrical Fig. 23 Idle Air Control (IAC) Motor and Throttle Position Sensor (TPS) Wiring Connectors Fig.

  • Page 513: Cleaning And Inspection

    11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (Continued) (4) Inspect quick connect fittings for damage, replace if necessary Refer to Group 14, Fuel System for procedure. Lube tube with clean 30w engine oil, Connect fuel supply hose to fuel rail assembly. Check connection by pulling on connector to insure it locked into position.

  • Page 514: Specifications

    THROTTLE BODY MANIFOLD GASKET CAPTIVE O-RING GASKET INJECTOR RAIL MOUNTS EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11 CLEANING AND INSPECTION (Continued) (3) Inspect manifolds for cracks or distortion. Replace manifold if necessary. SPECIFICATIONS TORQUE CHART EGR Tube Attaching Bolts ....11 N·m (95 in. lbs.) Exhaust Manifold to Exhaust Pipe Nuts .
  • Page 516 FRONT FASCIA BUMPER REIN- FORCE- MENT RADIATOR CLOSURE PANEL FENDER FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS CONTENTS page page BUMPERS ......1 FRAMES .
  • Page 517 RADIATOR CLOSURE PANEL FRONT BUMPER REIN- FORCEMENT 13 - 2 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) REAR CLOSURE REAR BUMPER PANEL FORCEMENT REIN- LUGGAGE COMPART- MENT Fig. 2 Front Bumper Reinforcement Fig. 3 Rear Bumper Fascia (4) Remove bolts holding fascia bracket to lower (4) Separate bumper reinforcement from vehicle.
  • Page 518 LOWER CON- TROL ARM STABILIZER BAR FRONT MOUNT SUSPENSION MEMBER CROSS- REAR MOUNT FRAME AND BUMPERS 13 - 3 FRAMES INDEX page page REMOVAL AND INSTALLATION TORQUE SPECIFICATIONS ....10 FRONT SUSPENSION CROSSMEMBER .
  • Page 519 LOWER CONTROL ARM REAR BOLT HOLE PLP HOLE TORQUE BOX LOWER CONTROL ARM REAR TORQUE BOX BOLT 13 - 4 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) (3) Place steering gear in position on crossmember. (11) Tighten bolts to hold suspension crossmember (4) Install bolts to hold steering gear to crossmem- to frame rails and torque boxes.
  • Page 520 FRAME AND BUMPERS 13 - 5 SPECIFICATIONS STRUCTURAL DIMENSIONS Structural dimensions are listed in metric mea- surements. All dimensions are from center to center of Principal Locating Point (PLP), or from center to center of PLP and fastener location (Fig. 3), (Fig. 4), (Fig.
  • Page 521 H. WIDTH OF ENGINE COMPARTMENT FRONT PRINCIPLE LOCATING POINTS (PLP) I. CENTER OF LOWER CROSSMEMBER TO ENGINE COMPARTMENT FRONT PLP J. CENTER OF LOWER CROSSMEMBER K. ENGINE COMPARTMENT FRONT PLP L. ENGINE COMPARTMENT REAR PRINCIPLE LOCATING POINTS (PLP) M. FRONT RAIL REAR EXTENSION REAR PLP A.
  • Page 522 A. WIDTH OF REAR PLP B. REAR RAIL REAR PRINCIPLE LOCATING POINTS C. CENTER OF REAR SUSPENSION CROSSMEMBER D. REAR RAIL SECOND FORWARD PLP E. FRONT OF REAR RAIL F. WIDTH OF REAR RAIL FORWARD PRINCIPLE LOCATING POINTS (PLP) G. FRONT LOWER SURFACE OF REAR RAIL H.
  • Page 523 A. REAR DOOR HINGE MOUNTING HOLE TO SHELF PANEL TO QUARTER PANEL JOINT. B. UPPER FRONT CORNER CENTER OF RADIUS TO LOWER REAR CORNER CENTER OF RADIUS. C. UPPER REAR CORNER CENTER OF RADIUS TO LOWER FRONT CORNER CENTER OF RADIUS. D.
  • Page 524 A. UPPER REAR CORNER CENTER OF RADIUS TO LOWER FRONT CORNER CENTER OF RADIUS. B. REAR PILLAR TO BODY SIDE APER- TURE UPPER SEAM TO BODY SIDE APERTURE LOWER SEAM. D. CENTER OF RADIUS AT BOTTOM TO CENTER OF RADIUS AT LOWER A-PIL- LAR.
  • Page 525 B/S/A CORNER TO CORNER A. & B. CENTER OF RADIUS UPPER CORNER TO CENTER OF RADIUS LOWER CORNER. C. LOWER EDGE OF BACK GLASS UPPER MOUNTING FLANGE OF REAR DECK OPENING WEATHERSTRIP FLANGE. D. & E. CENTER OF DECK OPENING FRONT CORNER RADIUS TO REAR TAIL PANEL DECK OPENING RADIUS.
  • Page 526 FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS CONTENTS page FRAME ....... . 1 FRAME INDEX page...
  • Page 528 FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS CONTENTS page FRAME ....... . 1 FRAME INDEX page...

  • Page 530: Introduction

    FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page page FUEL DELIVERY SYSTEM ....3 GENERAL INFORMATION ....1 FUEL INJECTION SYSTEM .
  • Page 531 Problems that are the result of using methanol/ mance and lowest emissions operating on high qual- gasoline blends are not the responsibility of Chrysler ity unleaded gasoline, it will perform equally well Corporation and may not be covered by the vehicle and produce even lower emissions when operating on warranty.
  • Page 532 FUEL FILTER/PRESSURE REGULATOR FUEL RESERVOIR INLET STRAINER FUEL LEVEL SENSOR FLOAT FUEL SYSTEM 14 - 3 FUEL DELIVERY SYSTEM INDEX page page DESCRIPTION AND OPERATION HOSES AND CLAMPS ....10 ELECTRIC FUEL PUMP .
  • Page 533 RUBBER LOCKING TAB INTERNAL FUEL FILTER CALIBRATED SPRINGS MODULE GROM- PUMP FUEL INLET O-RINGS EXCESS FUEL FLOW TO FUEL INJEC- FUEL FUEL FILTER/FUEL SURE REGULATOR BACK TANK TORS PRES- 14 - 4 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) ELECTRIC FUEL PUMP Fuel is supplied to the filter/regulator by the elec- tric fuel pump through an opening tube at the bot- The electric fuel pump is located in and is part of...
  • Page 534 FUEL RAIL FUEL INJECTOR TOP (FUEL ENTRY) TEST PORT NOZZLE FUEL INJEC- TORS INTAKE MANI- FUEL RAIL FOLD FUEL SYSTEM 14 - 5 DESCRIPTION AND OPERATION (Continued) longer mounted to the fuel rail on any engine. It is now located on the fuel tank mounted fuel pump module.
  • Page 535 RETAINER “EAR” CASING WINDOW WINDOW RETAINER TAB O RINGS NIPPLE FUEL SPARK INSULATOR INJEC- TORS PLUG IGNITION COILS FUEL PRESSURE GAUGE C-4799-B TEST PORT ELECTRICAL CON- NECTOR FUEL RAIL FUEL RAIL TEST PORT SPARK FUEL RAIL PLUG CABLE 14 - 6 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig.
  • Page 536 IF CHASSIS FUEL LINE IS REPLACE REPLACE INLET STRAINER FILTER/REGULA- RESTRICTED. RESTRICTED INCORRECTLY FILTER/REGULATOR OR FUEL PUMP REPLACE FUEL FILTER/REG- NOT RESTRICTED OPERATING ULATOR FUEL CHECK FOR RESTRICTED FUEL PUMP FUEL PRESSURE BELOW SPECIFICA- FUEL PRESSURE ABOVE SPECIFICATIONS RESTRICTION IN CHASSIS FUEL SUP- INLET STRAINER TIONS PLY LINE.
  • Page 537 14 - 8 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) FUEL LEVEL SENSOR This procedure tests the resistance of the level sen- sor itself. It does not test the level sensor circuit. Refer to Group 8W - Wiring Diagrams for circuit identification.
  • Page 538 CHECK POWER FEED AND GROUND BETWEEN PCM AND THE INJECTOR REFER GRAMS FOR COLOR CODES AND PIN TERMINAL NUM- TEST THE ENGINE CON- TROL SYSTEM WITH THE REPAIR OR REPLACE THE WIRING HARNESS AS NEC- CIRCUIT IS OK. CHECK FOR FUEL DELIVERY AT SUS- PECT INJECTOR BY REMOV- ING THE INJECTOR FROM...
  • Page 539 14 - 10 FUEL SYSTEM SERVICE PROCEDURES DRAINING FUEL TANK FUEL SYSTEM PRESSURE RELEASE PROCEDURE WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL SYSTEM COMPONENTS. WARNING: RELEASE FUEL SYSTEM PRESSURE SERVICE VEHICLES IN WELL VENTILATED AREAS BEFORE SERVICING FUEL SYSTEM COMPONENTS. AND AVOID IGNITION SOURCES.
  • Page 540 FUEL SYSTEM 14 - 11 SERVICE PROCEDURES (Continued) QUICK-CONNECT FITTINGS CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized REMOVAL for either 7 minutes, until the test is stopped, or When disconnecting a quick-connect fitting, the until the ignition switch is turned to the Off posi- retainer will remain on the fuel tube nipple.
  • Page 541 BATTERY POSITIVE BATTERY GROUND AIR CLEANER 14 - 12 FUEL SYSTEM SERVICE PROCEDURES (Continued) (2) Perform the fuel pressure release procedure. Refer to the Fuel Pressure Release Procedure in this section. (3) Clean the fitting of any foreign material before disassembly.
  • Page 542 LOCKNUT LOCKNUT SPECIAL TOOL 6856 FUEL FILTER/PRESSURE REGULATOR FUEL FILTER/PRESSURE REGULATOR FUEL SPRING TABLOCATING SLOT LINE FUEL SYSTEM 14 - 13 REMOVAL AND INSTALLATION (Continued) (2) Raise vehicle on hoist. (3) Disconnect fuel supply line at the Filter/Regu- lator nipple (refer to Quick Connect Fittings in this section).
  • Page 543 INLET STRAINER TABS ELECTRICAL CONNECTOR RETAINING TAB WIRE MINAL TER- BLUE LOCKING WEDGE LOCKING FINGER ELECTRICAL CONNECTOR TANK SEAL 14 - 14 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) FUEL PUMP INLET STRAINER REMOVAL (1) Remove fuel pump module. Refer to Fuel Pump Module Removal in this section.
  • Page 544 CHANNEL FOR LEVEL SEN- REAR VIEW OF LEVEL SEN- WIRE CHANNEL FOR LEVEL SEN- MINAL TER- LOCKING WRAP FINGER LEVEL SENSOR FUEL LEVEL SEN- WIRES GROOVE FUEL LINE QUICK CONNECTS FUEL INJECTOR IGNITION C OIL FUEL SUP- FUEL RAIL PLY LINE FUEL SYSTEM 14 - 15 REMOVAL AND INSTALLATION (Continued)
  • Page 545 14 - 16 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) RETAINER FUEL INJECTOR TOP (FUEL ENTRY) FUEL INJECTOR NOZZLE HEAT SHIELD FUEL PUMP MOD- FUEL DRAIN TANK FUEL RAIL (5) Remove fuel rail mounting screws. FUEL TANK (6) Lift rail off of intake manifold. Cover the fuel FUEL LINE ELECTRICAL CON-...
  • Page 546 FUEL FILL VAPOR VAPOR TUBE TO TANK TUBE FUEL FILLER TUBE VAPOR TUBE TO CANISTER FUEL TANK DRAIN QUARTER PANEL FUEL FILLER NECK FUEL SYSTEM 14 - 17 REMOVAL AND INSTALLATION (Continued) FUEL FILLERTUBE ROLLOVER VALVE VAPOR TUBE TO EVAP CAN- ISTER Fig.
  • Page 547 DASHPANEL CABLE ASSEM- GROMMET GROMMET CABLE ASSEM- RETAINER CLIP DASH PANEL SEAL PEDAL AND BRACKET CABLE RETAINER GROMMET CABLE SHAFT THROTTLE MOUNTING SCREW MOUNTING TAB CONTROL SHIELD 14 - 18 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (3) Attach vapor tube to valve. (4) Working from the engine compartment, remove (4) Install fuel filler tube cap.
  • Page 548 SPEED THROTTLE LEVER CONTROL CABLE THROTTLE CABLE SPEED TROL CABLE CON- CABLE CLASP THROTTLE CABLE TRANSMISSION KICKDOWN CABLE TABS FUEL SYSTEM 14 - 19 REMOVAL AND INSTALLATION (Continued) CABLE TABS CLASP Fig. 39 Throttle Cable Attachment to Throttle Body Fig. 41 Throttle Body Cables Attachment to Throttle Body Fig.
  • Page 549 14 - 20 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (5) From the engine compartment, rotate the SPECIFICATIONS throttle lever forward to the wide open position and install cable clasp (Fig. 42). TORQUE SPECIFICATION (6) Install throttle ontrol shield (Fig. 38). Tighten to 5.6 N·m (50 in.

  • Page 550: Introduction

    FUEL SYSTEM 14 - 21 FUEL INJECTION SYSTEM INDEX page page GENERAL INFORMATION POWER STEERING PRESSURE SWITCH— INTRODUCTION ..... . . 22 PCM INPUT .
  • Page 551 14 - 22 FUEL SYSTEM SPECIFICATIONS (Continued) THROTTLE BODY—MANUAL SPECIFICATIONS TRANSMISSION ..... . 50 TORQUE SPECIFICATIONS ....58 THROTTLE POSITION SENSOR (TPS) .
  • Page 552 FUEL SYSTEM 14 - 23 GENERAL INFORMATION (Continued) • The PCM monitors the engine coolant tempera- During Start-up the PCM maintains ignition tim- ture sensor and throttle position sensor input. The ing at 9° BTDC. PCM determines basic fuel injector pulse width from ENGINE WARM-UP MODE this input.
  • Page 553 14 - 24 FUEL SYSTEM GENERAL INFORMATION (Continued) The PCM performs several diagnostic routines. The PCM may receive a closed throttle input from They include: the Throttle Position Sensor (TPS) when it senses an • Oxygen sensor monitor abrupt decrease in manifold pressure. This indicates •...
  • Page 554 FUEL SYSTEM 14 - 25 DESCRIPTION AND OPERATION (Continued) • Engine Coolant Temperature Sensor POWER DISTRIBUTION CENTER • Fuel Level Sensor The power distribution center (PDC) is located next POWER DISTRI- BUTION POWER DISTRI- BUTION CEN- CEN- RELAYS SPEED TROL SERVO CON- WINDSHIELD WASHER...
  • Page 555 14 - 26 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) • Transmission gear selection (park/neutral AUTOMATIC SHUTDOWN (ASD) SENSE—PCM switch) INPUT The PCM also adjusts engine idle speed through The ASD sense circuit informs the PCM when the the idle air control motor based on the following ASD relay energizes.
  • Page 556 FUEL SYSTEM 14 - 27 DESCRIPTION AND OPERATION (Continued) CAMSHAFT POSITION SENSOR—PCM INPUT The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor (Fig. 3) or (Fig. 4) and crankshaft position sensor. From the two inputs, the PCM determines crankshaft position.
  • Page 557 MACHINED NOTCHES CRANKSHAFT CRANKSHAFT GENERATOR OIL FILTER POSITION SENSOR POSITION SENSOR 14 - 28 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 7 Timing Reference Notches voltage switches from low (metal) to high (notch) then back to low. If available, an oscilloscope can display the square wave patterns of each voltage pulses.
  • Page 558 ENGINE TEMPERATURE CAMSHAFT POSITION COOLANT SENSOR SENSOR COOLANT TEMPER- ATURE SENSOR FUEL RAIL FUEL SYSTEM 14 - 29 DESCRIPTION AND OPERATION (Continued) SOHC less efficient catalyst. To monitor catalytic convertor The coolant sensor threads into the rear of the cyl- deterioration, the fuel injection system uses two inder head, next to the camshaft position sensor (Fig.
  • Page 559 EXHAUST MANIFOLD OXYGEN SORS SEN- DOWNSTREAM OXYGEN CATALYTIC CON- SENSOR VERTOR 14 - 30 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner.
  • Page 560 STARTER MOTOR KNOCK SEN- FUEL SYSTEM 14 - 31 DESCRIPTION AND OPERATION (Continued) KNOCK SENSOR—PCM INPUT POWER STEERING PRESSURE SWITCH—PCM The knock sensor threads into the side of the cyl- INPUT inder block in front of the starter (Fig. 15). When the A pressure sensing switch is located on the power POWER PRESSURE SWITCH...
  • Page 561 PARK/NEUTRAL TRANSAXLE HOUSING SWITCH 14 - 32 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) SCI RECEIVE—PCM INPUT THROTTLE POSITION SEN- IDLE AIR CONTROL Along with inputs from other sensors, the PCM IDLE CONTROL MOTOR THROTTLE SHIELD MOTOR PURGE HOSE THROTTLE POSITION SEN- uses the TPS input to determine current engine oper- SCI Receive is the serial data communication ating conditions.
  • Page 562 VEHICLE SPEED SENSOR TRANSAXLE EXTENSION TRANSAXLE SPEED SENSOR RETAINING BOLT SPEED SENSOR HOUSING FUEL SYSTEM 14 - 33 DESCRIPTION AND OPERATION (Continued) VEHICLE SPEED SENSOR—PCM INPUT The vehicle speed sensor is located in the transmis- sion extension housing (Fig. 20) and (Fig. 21). The sensor input is used by the PCM to determine vehicle speed and distance traveled.
  • Page 563 DUTY PURGE CYCLE SOLENOID VALVE EVAP ENGINE MOUNT 14 - 34 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) FUEL PUMP RELAY—PCM OUTPUT The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Cen- ter (PDC) supplies voltage to the solenoid side and contact side of the relay.
  • Page 564 IDLE CONTROL MOTOR EGR TRANSDUCER SERVICE PORT CAM SENSOR EGR VALVE FRESH AIR OPENING DATA LINK CONNECTOR FUEL SYSTEM 14 - 35 DESCRIPTION AND OPERATION (Continued) Fig. 25 Data Link Connector FUEL INJECTORS—PCM OUTPUT The 2.0L engine uses electrically operated top feed Fig.
  • Page 565 14 - 36 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) IGNITION COIL—PCM OUTPUT MALFUNCTION INDICATOR (CHECK ENGINE) The coil assembly consists of 2 coils molded LAMP—PCM OUTPUT together. The coil assembly is mounted over the valve The PCM supplies the malfunction indicator (check cover (Fig.
  • Page 566 AUTOMATIC TRANSAXLE TORQUE VERTOR CLUTCH SOLE- HOUSING BATTERY CON- NOID POWER TRIBUTION CENTER DIS- PARK/NEUTRAL SWITCH WINDSHIELD WASHER SPEED CONTROL BOTTLE SERVO FLUID FUEL SYSTEM 14 - 37 DESCRIPTION AND OPERATION (Continued) conditioning pressure drops approximately 40 psi, the pressure switch opens and the fan turns off. The PWM relay is located on the left front inner frame just behind the radiator.
  • Page 567 SPEED TROL CABLE POWER DISTRI- BUTION CON- CEN- RELAYS THROTTLE CABLE TRANSMISSION KICKDOWN CABLE FUSES 14 - 38 FUEL SYSTEM IDLE AIR CONTROL MOTOR DIAGNOSIS AND TESTING (Continued) (3) Open the Power Distribution Center (PDC). (5) Check the electrical connections at the idle air PCV VALVE CONNECTION CONNECTION TO INTAKE...
  • Page 568 MAP/AIR PCV VACUUM NIPPLE INTAKE MANIFOLD TEMPERATURE SENSOR IGNITION COIL FUEL RAIL FUEL QUICK- CONNECTS LINE FUEL SUP- FUEL INJEC- PLY LINE FUEL SYSTEM 14 - 39 SPARK INSULATOR PLUG SPARK PLUG CABLE IGNITION COILS DIAGNOSIS AND TESTING (Continued) (7) Inspect the electrical connections at the MAP (9) Inspect the ignition coil electrical connector.
  • Page 569 14 - 40 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (11) Check the electrical connection to the radiator GROUND STRAP STARTER SOLENOID STARTER MOTOR fan. (12) Inspect for corrosion on the electrical connec- tions at the starter motor solenoid. Check the ground cable connection below the starter motor (Fig.
  • Page 570 CRANKSHAFT VEHICLE SPEED SENSOR GENERATOR OIL FILTER POWER POSITION SENSOR PRESSURE SWITCH STEERING AUTOMATIC TRANSAXLE TORQUE VERTOR CLUTCH SOLE- HOUSING CON- NOID EXHAUST MANIFOLD OXYGEN PARK/NEUTRAL SWITCH SORS SEN- TRANSAXLE EXTENSION HOUSING FUEL SYSTEM 14 - 41 DIAGNOSIS AND TESTING (Continued) (18) Inspect the electrical connector at the crank- (21) On vehicles with automatic transaxles, check shaft position sensor (Fig.
  • Page 571 INLET TUBE BATTERY TRAY BATTERY TEMPERATURE SENSOR FUEL LINE BATTERY POWER TRIBUTION CENTER DIS- WINDSHIELD WASHER SPEED CONTROL BOTTLE SERVO FLUID ELECTRICAL CON- NECTOR 14 - 42 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (23) Inspect the fuel pump module electrical connec- tion at the fuel tank for corrosion or damage (Fig.
  • Page 572 IDLE AIR CONTROL SPEED TROL CABLE MOTOR CON- THROTTLE CABLE TRANSMISSION THROTTLE POSITION SEN- KICKDOWN CABLE INTAKE MANI- FOLD PCV VALVE IGNITION COIL FUEL RAIL FUEL QUICK- CONNECTS LINE MAP/AIR PERATURE #1 SPARK PLUG SENSOR TEM- BOOT FUEL SUP- FUEL RAIL FUEL INJEC- PLY LINE FUEL SYSTEM...
  • Page 573 STARTER MOTOR KNOCK DUTY PURGE CYCLE SOLENOID VALVE EVAP ENGINE MOUNT ELECTRICAL CONNECTOR GROUND STRAP STARTER SOLENOID IGNITION COIL FAS- STARTER TENERS MOTOR 14 - 44 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (9) Inspect the ignition coil electrical connector. Ensure the spark plug insulators are firmly seated over the spark plugs (Fig.
  • Page 574 EGR TRANSDUCER SERVICE PORT CAM SENSOR EGR VALVE COOLANT TEMPER- ATURE SENSOR CRANKSHAFT VEHICLE SPEED SENSOR GENERATOR OIL FILTER POSITION SENSOR GENERATOR FUEL RAIL TRANSAXLE EXTENSION HOUSING FUEL SYSTEM 14 - 45 DIAGNOSIS AND TESTING (Continued) Fig. 68 Generator Fig. 66 Engine Coolant Temperature Sensor (16) Check the electrical connector at the Elec- tronic EGR Transducer.
  • Page 575 AUTOMATIC TRANSAXLE TORQUE VERTOR CLUTCH SOLE- HOUSING CON- NOID POWER PRESSURE SWITCH STEERING PARK/NEUTRAL SWITCH DOWNSTREAM OXYGEN CATALYTIC CON- SENSOR VERTOR EXHAUST MANIFOLD OXYGEN SORS SEN- FUEL LINE ELECTRICAL CON- NECTOR 14 - 46 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (20) Check the electrical connection at the power steering pressure switch on the power steering gear housing (Fig.
  • Page 576 INLET TUBE BATTERY TRAY BATTERY TEMPERATURE SENSOR FUEL SYSTEM 14 - 47 DIAGNOSIS AND TESTING (Continued) • The Powertrain Control Module (PCM) grounds (24) Inspect the connections to the speed control servo, if equipped (Fig. 54). Refer to Group 8H, Vehi- the coil side of the relay through terminal number cle Speed Control.
  • Page 577 14 - 48 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) ENGINE COOLANT TEMPERATURE SENSOR (1) With the key off, disconnect wire harness con- nector from coolant temperature sensor (Fig. 78) or (Fig. 79). Fig. 80 Engine Coolant Temperature Sensor greater than 1 ohm, repair the wire harness as nec- essary.
  • Page 578 MAP OUTPUT VOLTAGE VOLTAGE SUPPLY IAT OUTPUT VOLTAGE SENSOR GROUND THROTTLEBODY INTAKE MANI- FOLD PCV VALVE CONNECTION INTAKE MANIFOLD PURGE HOSE FUEL SYSTEM 14 - 49 DIAGNOSIS AND TESTING (Continued) The voltage should drop to 1.5 to 2.1 volts with a hot, Wide-Open-Throttle (WOT).
  • Page 579 PURGE SPECIAL TOOL #6457 NIP- 14 - 50 FUEL SYSTEM SPEED THROTTLE LEVER CONTROL CABLE THROTTLE CABLE DIAGNOSIS AND TESTING (Continued) (4) Use a piece of hose to attach Air Metering Ori- (b) While holding the throttle open, spray the fice 6457 (0.125 in.
  • Page 580 SPEED TROL CABLE CON- CABLE CLASP THROTTLE CABLE TRANSMISSION KICKDOWN CABLE TABS CABLE TABS CLASP FUEL SYSTEM 14 - 51 REMOVAL AND INSTALLATION (Continued) (2) Remove throttle body cables using the following procedures. (3) Remove throttle cable from throttle body cam (Fig.
  • Page 581 SPEED CONTROL CABLE TRANSMISSION DOWN CABLE PUSH KICK- PUSH INTAKE MANIFOLD THROTTLE POSITION SENSOR IDLE AIR CON- RE-USABLE TROL MOTOR GASKET 14 - 52 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 91 Re-Usable Throttle Body Gasket Fig. 89 Transmission Kickdown Cable Connector (6) Install throttle body cables using the following procedures.
  • Page 582 FUEL SYSTEM 14 - 53 REMOVAL AND INSTALLATION (Continued) (2) Disconnect electrical connector from idle air (2) Remove electrical connector from idle air con- control motor and throttle position sensor. trol motor and throttle position sensor. (3) Remove throttle body. Refer to Throttle Body in (3) Remove the EVAP purge hose from the throttle this section.
  • Page 583 14 - 54 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (2) Disconnect the electrical connector from the (1) Insert sensor into intake manifold while mak- MAP/IAT sensor. ing sure not to damage O-ring seal. (3) Remove sensor mounting screws. (2) Tighten mounting screws to 2 N·m (20 in. lbs) (4) Remove sensor.
  • Page 584 POWER DISTRI- BUTION DUTY PURGE CYCLE CEN- SOLENOID VALVE EVAP SPEED TROL SERVO CON- WINDSHIELD WASHER BATTERY ENGINE MOUNT BOTTLE FLUID FUEL SYSTEM 14 - 55 REMOVAL AND INSTALLATION (Continued) (3) Install PDC by pushing down into brackets. (4) Install washer bottle neck. (5) Connect positive cable to battery.
  • Page 585 DOWNSTREAM HEATED OXYGEN SENSOR CATALYTIC CONVERTOR 14 - 56 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) DOWNSTREAM HEATED OXYGEN SENSOR The downstream heated oxygen sensor threads into the exhaust outlet pipe behind the catalytic convertor (Fig. 101). REMOVAL (1) Raise vehicle. (2) Disconnect electrical connector from sensor.
  • Page 586 AIR CLEANER FUEL SYSTEM 14 - 57 REMOVAL AND INSTALLATION (Continued) (2) Unfasten clasps on top of air cleaner housing. INSTALLATION Rotate front of housing forward then lift front away (1) Install coolant sensor. Tighten sensor to 18 ENGINE TEMPERATURE CAMSHAFT POSITION COOLANT...
  • Page 587 TRANSAXLE SPEED SENSOR RETAINING BOLT SPEED SENSOR 14 - 58 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) VEHICLE SPEED SENSOR KNOCK SENSOR The vehicle speed sensor is located in the transmis- For removal/installation procedures refer to Group sion extension housing (Fig. 108). 8D- Ignition System, Service Procedures.
  • Page 588 FUEL SYSTEM 14 - 59 SPECIAL TOOLS FUEL Spanner Wrench 6856 Extractor C–4334 Metering Orifice Pressure Gauge Assembly C–4799–B Fuel Line Tool Fuel Pressure Test Adapter 6539 Fuel Line Adapter...
  • Page 589 14 - 60 FUEL SYSTEM SPECIAL TOOLS (Continued) Fuel Line Adapter 1/4...
  • Page 590 STEERING 19 - 1 STEERING CONTENTS page page GENERAL INFORMATION ....1 STEERING COLUMN ..... 35 POWER STEERING PUMP .
  • Page 591 19 - 2 STEERING DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Objectionable Hiss Or Whistle 1. Damaged or mispositioned 1. Check for proper seal between steering column coupler to dash steering column coupler and dash panel seal. seal. 2. Noisy valve in power steering 2.
  • Page 592 STEERING 19 - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Power steering pump growl results from the development of high pressure fluid flow. Normally this noise should not be high enough to be objectionable. Abnormal situations, such as a low oil level causing aeration or hose touching the vehicle body, can create a noise level that could bring complaints.
  • Page 593 19 - 4 STEERING DIAGNOSIS AND TESTING (Continued) BINDING STICKING SEIZED CONDITION POSSIBLE CAUSES CORRECTION CATCHES, STICKS IN CERTAIN 1. Low power steering fluid level. 1. Fill power steering fluid reservoir POSITIONS OR IS DIFFICULT TO to specified level and perform TURN.
  • Page 594 STEERING 19 - 5 DIAGNOSIS AND TESTING (Continued) SHAKE SHUDDER VIBRATION CONDITION POSSIBLE CAUSES CORRECTION VIBRATION OF THE STEERING 1. Air in the fluid of the power 1. Steering shudder can be expected WHEEL AND/OR DASH DURING steering system. in new vehicles and vehicles with DRY PARK OR LOW SPEED recent steering system repairs.
  • Page 595 19 - 6 STEERING DIAGNOSIS AND TESTING (Continued) POOR RETURN TO CENTER CONDITION POSSIBLE CAUSES CORRECTION STEERING WHEEL DOES NOT 1. Tires not 1. Inflate tires to specified pressure. WANT TO RETURN TO CENTER inflated to specified pressure. POSITION. 2. Improper front wheel alignment. 2.
  • Page 596 STEERING 19 - 7 DIAGNOSIS AND TESTING (Continued) LOOSE STEERING CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE STEERING WHEEL 1. Air in the fluid of the power 1. Fill power steering fluid reservoir KICKBACK OR TO MUCH steering system. to the specified level. Perform STEERING WHEEL FREE PLAY.
  • Page 597 19 - 8 STEERING DIAGNOSIS AND TESTING (Continued) VEHICLE LEADS TO THE SIDE CONDITION POSSIBLE CAUSES CORRECTION STEERING WHEEL DOES NOT 1. Radial tire lead. 1.Rotate tires as recommended in WANT RETURN TO CENTER the Tire And Wheel Group of this POSITION.
  • Page 598 STEERING 19 - 9 DIAGNOSIS AND TESTING (Continued) POWER STEERING FLUID LEAK CONDITION POSSIBLE CAUSES CORRECTION LOW FLUID LEVEL WITH: NO 1. Overfilled power steering pump 1. Adjust the power steering fluid fill VISIBLE SIGNS OF A LEAK ON fluid reservoir. to the correct level.
  • Page 599 POWER POWER STEERING PUMP SHAFT STEERING HOUSING PUMP POWER STEERING PUMP FLUID SUP- POWER STEERING PUMP DISCHARGE PLY FITTING FITTING 19 - 10 STEERING POWER STEERING PUMP INDEX page page DESCRIPTION AND OPERATION POWER STEERING FLUID RESERVOIR ..22 POWER STEERING PUMP .
  • Page 600 PRESSURE HOSE STEERINGPUMP STEERING GEAR POWER POWER SPECIAL TOOL 6815 ADAPTER POWER TINGS FIT- SPECIAL ING PUMP STEER- TOOL 6815 STEERING 19 - 11 DESCRIPTION AND OPERATION (Continued) Rectangular pumping vanes in the shaft driven rotor, move power steering fluid from the intake to the cam ring pressure cavities of the power steering pump.
  • Page 601 19 - 12 STEERING DIAGNOSIS AND TESTING (Continued) should be in the range of 345-552 kPa (50-80 psi). POWER STEERING PUMP INITIAL OPERATION The flow meter should read between 1.3 and 1.4 CAUTION: The fluid level should be checked with engine off to prevent injury from moving compo- CAUTION: The following test procedure involves...
  • Page 602 POWER DISCHARGE POWER STEER- POWER STEER- STEERING CONTROL FITTING BRACKET ING PUMP PUMP FLOW PUMP LOCATING PIN POWER STEERING PRES- POWER STEERING SURE HOSE BANJO BOLT PUMP POWER STEERING FLUID SUPPLY HOSE BOLT POWER STEERING PUMP RADIATOR HOSE POWER STEERING PUMP SUCTION PORT FITTING STEERING 19 - 13...
  • Page 603 VEHICLE WIRING HAR- VEHICLE ING HARNESS NESS CONNECTOR FRONT SUSPENSION WIR- CROSSMEMBER STEERING GEAR POWER FLUID PRESSURE STEERING SWITCH POWER STEERING PRES- SURE HOSE POWER STEERING RETURN HOSE ROUTING BRACKET BOLT 19 - 14 STEERING REMOVAL AND INSTALLATION (Continued) REMOVE CAUTION: Do not use automatic transmission fluid in power steering system.
  • Page 604 POWER POWER FLUID GENERATOR STEERING STEERING PRESSURE STEERING GEAR SHIELD HOSE RESERVOIR FLUID ROUTING CLIP POWER PRESSURE SWITCH POWER BOLT RETURN HOSE STEERING POWER STEERING HOSE CLAMP POWER STEERING PRES- STEERING RETURN HOSE SURE HOSE FLUID TUBE CLIP POWER STEERING FLUID ALTERNATOR POWER STEER- POWER STEER-...
  • Page 605 POWER STEERING PRESSURE O-RING BANJO FITTING BOLT HOSE BANJO FITTING BANJO BOLT O-RING POWER STEERING PRESSURE HOSE BANJO FITTING 19 - 16 STEERING REMOVAL AND INSTALLATION (Continued) (11) Install the power steering pressure and return hose routing clip on hoses (Fig. 8). Install bolt attach- ing routing clip to front suspension crossmember.
  • Page 606 FRONT POWER STEERING RETURN GENERATOR CROSSMEMBER HOSE CLAMP GENERATOR SHIELD SUSPENSION POWER STEERING PRES- HOSE SURE HOSE ROUTING CLIP POWER POWER STEERING PRES- POWER STEERING RETURN STEERING STEEL TUBE SURE HOSE GEAR HOSE POWER POWER STEERING FLUID RETURN GENERATOR STEERING SHIELD RESERVOIR FLUID...
  • Page 607 POWER STEERING FLUID RETURN POWER STEERING SUPPLY HOSE FLUID HOSE POWER STEERING FLUID SUPPLY HOSE CLAMP POWER STEERING PUMP HOSE POWER STEERING FLUID RESERVOIR 19 - 18 STEERING REMOVAL AND INSTALLATION (Continued) installed on return hose past upset bead on (Fig.
  • Page 608 POWER POWER STEER- POWER STEER- BRACKET STEERING ING PUMP PUMP SUPPLY HOSE FLUID LOCATING PIN POWER STEERING PRES- HOSE CLAMP POWER SURE HOSE STEERING BANJO BOLT PUMP STEERING 19 - 19 REMOVAL AND INSTALLATION (Continued) (2) Install power steering fluid supply hose on power steering fluid reservoir fitting.
  • Page 609 POWER STEER- FRONT MOTOR MOUNT ING PUMP INTAKE MANIFOLD LOWER RADIATOR HOSE MOUNTING BOLTS BOLT CONDITIONING PRESSOR COOLANT TUBE COM- CAST BRACKET POWER STEERING PUMP POWER FRONT MOUNTING BRACKET STEERING ENGINE MOUNT POWER STEERING PUMP AIR CONDITIONING HOSE PUMP BOLT FRONT POWER STEERING PUMP MOUNTING BRACKET 19 - 20...
  • Page 610 POWER POWER PUMP BRACKET STEERING STEERING DRIVE BELT PUMP BREAKER BAR POWER STEERING PRESSURE O-RING SQUARE OPENING ADJUST POWER STEERING PUMP HOSE BANJO FITTING BANJO FITTING BOLT BANJO BOLT O-RING POWER STEERING PRESSURE HOSE BANJO FITTING STEERING 19 - 21 REMOVAL AND INSTALLATION (Continued) drive belt tension.
  • Page 611 OVERFLOW POWER STEERING RETURN THERMOSTAT HOUSING COOLANT RECOVERY SYS- HOSE CLAMP HOSE FROM HOSE TEM TANK POWER POWER STEERING PRES- STEERING STEEL TUBE SURE HOSE GEAR MOUNTING NUT AND STUD POWER STEERING FLUID RETURN COWL PANEL HOSE MOUNTING POWER FLUID RESERVOIR POWER STEERING FLUID SUPPLY SCREW STEERING...
  • Page 612 POWER CYLINDER HEAD CYLINDER HEAD POWER STEERING STEERING POWER STEERING FLUID RESER- RESERVOIR RESERVOIR POWER STEERING FLUID RESER- FLUID VOIR MOUNTING NUTS FLUID VOIR MOUNTING BOLTS RETURN HOSE RETURN HOSE SUPPLY HOSE SUPPLY HOSE STEERING 19 - 23 REMOVAL AND INSTALLATION (Continued) (4) Install the coolant overflow hose from the cool- ant recovery system (CRS) tank (Fig.
  • Page 613 POWER POWER STEERING POWER STEER- PUMP BRACKET PUMP ING PUMP STEERING POWER MOUNTING BRACKET STEERING PUMP POWER STEERING PUMP PULLEY SPECIAL SPECIAL TOOL C-4333 OR POWER ING PUMP PUL- C-4063 TOOL WRENCH STEER- WRENCH C-4068 POWER STEERING SHAFT PUMP HUB OF POWER STEERING PUMP PUL- LEY MUST BE FLUSH WITH PUMP SHAFT AS SHOWN TO CORRECTLY POWER...
  • Page 614 POWER STEERING POWER PUMP MOUNTING BRACKET STEERING MOUNTING POWER PUMP BOLTS MOUNTING BRACKET STEERING PUMP POWER STEERING PUMP PULLEY SPECIAL TOOL C-4333 OR POWER STEER- ING PUMP C-4068 POWER POWER STEER- PUMP BRACKET POWER ING PUMP STEERING STEERING SHAFT PUMP HUB OF POWER STEERING PUMP PUL- LEY MUST BE FLUSH WITH PUMP SHAFT AS SHOWN TO CORRECTLY...
  • Page 615 19 - 26 STEERING SPECIFICATIONS (Continued) POWER STEERING PUMP FASTENER TORQUE SPECIAL TOOLS SPECIFICATIONS POWER STEERING PUMP DESCRIPTION TORQUE Power Steering Hose: Tube Nuts Pressure And Return ......31 N·m (275 in.
  • Page 616 POWER FRONT POWER POWER LOWER CONTROL ARM TO FLUID RESERVOIR POWER STEERING STEERING STEERING PRESSURE HOSE CROSSMEMBER RETURN HOSE TIE ROD END SUSPENSION INNER TIE RODSTEERING GEAR BOOT STEERING JAM NUT HOSES FLUID FLUID PUMP FLUID STEERING GEAR ING BRACKET MOUNT- POWER STEERING GEAR STEERING...
  • Page 617 SPECIAL TOOL 6815 ADAPTER TINGS FIT- PRESSURE HOSE STEERINGPUMP STEERING GEAR POWER POWER POWER SPECIAL ING PUMP STEER- TOOL 6815 19 - 28 STEERING DESCRIPTION AND OPERATION (Continued) NOTE: The power steering gear (Fig. 1) should NOT be serviced or adjusted. If a malfunction or oil leak occurs with the steering gear, the complete steering gear needs to be replaced.
  • Page 618 PINCH BOLT BRAKE PEDAL RETAINING PIN LOWER STEERING STEERING COLUMN COUPLER PINCH BOLT NUT SHAFT COUPLER STEERING COUPLER COLUMN SAFETY CHAIN STEERING BOBBLE DAMP- KNUCKLE ENER FRONT STEERING KNUCKLE TRANSAXLE CROSSMEMBER SUSPENSION BRAKING DISC STUD TIE ROD END STUD SPECIAL TOOL MB-990635 BRAKING DISC...
  • Page 619 POWER FLUID STEERING PRESSURE STEERING GEAR HOSE POWER PRESSURE SWITCH STEERING POWER STEERING RETURN HOSE FLUID 19 - 30 STEERING VEHICLE WIRING HAR- VEHICLE ING HARNESS NESS CONNECTOR FRONT SUSPENSION WIR- CROSSMEMBER STEERING GEAR POWER FLUID PRESSURE STEERING SWITCH REMOVAL AND INSTALLATION (Continued) (7) If equipped, remove vehicle wiring harness con- nector from the power steering fluid pressure switch (Fig.
  • Page 620 SCRIBBED LINE FOR LOCATION OF FRONT SUSPENSION CROSSMEMBER LOWER CON- STEERING FRONT LOWER TROL ARM GEAR S WAY BAR CONTROL CROSSMEMBER SUSPENSION BUSHING MOUNTING BOLT TRANSMISSION JACK FRONT SUSPENSION CROSSMEMBER STEERING 19 - 31 REMOVAL AND INSTALLATION (Continued) SWAY BAR STEERING STEERING GEAR GEAR...
  • Page 621 19 - 32 STEERING TORQUE W RENCH 11/32 S OCKET CROWFOOT LOWER STEERING K NUCKLE CONTROL REMOVAL AND INSTALLATION (Continued) FRONT SUSPEN- SION MEMBER POSITIONING MARK CROSS- FRONT LOWER CROSSMEMBER SUSPENSION CONTROL LOWER CONTROL ARM/ CROSSMEMBER MOUNTING BOLT INSTALL assembly (Fig. 10). Torque power steering fluid pres- (1) Install steering gear assembly on front suspen- sure and return lines to steering gear tube nuts (Fig.
  • Page 622 INNER TIE ROD SERRA- OUTER TIE ROD JAM NUT TION INNER TIE ROD STEERING KNUCKLE OUTER TIE ROD END STEERING 19 - 33 INNER TIE ROD SERRA- OUTER TIE ROD JAM NUT TION INNER TIE ROD STEERING KNUCKLE OUTER TIE ROD END BRAKING DISC TIE ROD END STUD STEERING...
  • Page 623 SAFETY CHAIN SPECIAL TOOL CROWFOOT MB-990635 STUD 11/32 S OCKET STEERING KNUCKLE TORQUE BRAKING DISC WRENCH LOWER STEERING K NUCKLE CONTROL 19 - 34 STEERING DISASSEMBLY AND ASSEMBLY (Continued) SPECIFICATIONS STEERING GEAR FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE FRONT SUSPENSION CROSSMEMBER: To Body Mounting Bolts .
  • Page 624 STEERING 19 - 35 STEERING COLUMN INDEX page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION STEERING COLUMN ASSEMBLY ... 35 STEERING COLUMN SERVICE PROCEDURE STEERING GEAR TO STEERING COLUMN WARNINGS ......38 COUPLING .
  • Page 625 19 - 36 STEERING DESCRIPTION AND OPERATION (Continued)
  • Page 626 Chrysler vehicles. This coupling functions by STEERING COUPLING INSPECTION bending at the bellows section (Fig. 2) of the coupling...
  • Page 627 CONVOLUTED SECTION OF STEERING COLUMN COU- COUPLING PLING SEALING COLLAR 19 - 38 STEERING DIAGNOSIS AND TESTING (Continued) (4) Inspect steering column coupling in the follow- WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, ing areas for signs of damage: COMPLEX ELECTRO-MECHANICAL UNIT.
  • Page 628 SPEED FUSE HEAD STEERING COLUMN ATTACHING SCREW MOUNTING SCREWS STEERING WHEEL SWITCH ACCESS LAMP PANEL COVER ATTACHING SWITCHES CONTROL AIRBAG SCREW STEERING COLUMN COVER HEAD SWITCH LAMP ATTACHING ATTACHING SCREWS LINER SCREWS STEERING STEERING COLUMN COLUMN STEERING 19 - 39 REMOVAL AND INSTALLATION (Continued) STEERING WHEEL AIRBAG...
  • Page 629 19 - 40 STEERING SPEED CONTROL SWITCH AIRBAG MODULE ELECTRI- SPEED CONTROL SWITCH ELECTRICAL CONNECTOR ELECTRICAL CONNECTOR CONNECTOR STEERING WHEEL AIRBAG MODULE CLOCK SPRING FROM REMOVAL AND INSTALLATION (Continued) (7) Remove air bag module from center of steering wheel. Then disconnect the clock spring electrical HORN SWITCH STEERING WHEEL...
  • Page 630 STEERING 19 - 41 REMOVAL AND INSTALLATION (Continued) INSTRUMENT PANEL VEHICLE ING HARNESS WIR- MULTI-FUNCTION TURN SWITCH SWITCH SIGNAL STEERING COLUMN WIRING HARNESS JACKET ROUTING CLIP STEERING COLUMN LOWER STEERING COL- UMN SHROUD FASTEN- TILT LOWER STEERING COL- LEVER UMN SHROUD UPPER STEERING COLUMN MOUNTING STEERING...
  • Page 631 VEHICLE HARNESS WIRING IGNITION SWITCH CLOCK SPRING TILT LEVER 19 - 42 STEERING REMOVAL AND INSTALLATION (Continued) (22) Remove the vehicle wiring harness connec- (7) Be sure both breakaway capsules are still fully tors from the ignition switch and clock spring (Fig. seated in the slots of the upper steering column 19).
  • Page 632 CLOCK SPRING WIR- ING LEADS STEERING WHEEL STEERING 19 - 43 REMOVAL AND INSTALLATION (Continued) (13) Feed clock spring wiring leads through hole in inder in the run position so retaining tab can be steering wheel (Fig. 20). Position steering wheel on depressed and the pushing key cylinder into lock hos- shaft of steering column assembly, making sure to fit ing until retaining tab locks into key lock cylinder.
  • Page 634 STEERING 19 - 1 STEERING CONTENTS page page POWER STEERING PUMP ....1 STEERING GEAR ..... . . 12 STEERING COLUMN .
  • Page 635 19 - 2 STEERING REMOVAL AND INSTALLATION (Continued) The pressure switch (Fig. 2) is mounted directly to CAUTION: Do not use automatic transmission fluid the power steering gear on vehicle’s requiring its usage. in power steering system. Only use Mopar , Power Steering Fluid, or equivalent.
  • Page 636 STEERING 19 - 3 REMOVAL AND INSTALLATION (Continued) (3) Remove power steering pressure hose from routing clip on generator shield (Fig. 4). Fig. 6 Pressure Hose Attachment To Power Steering Pump INSTALL Fig. 4 Power Steering Pressure Hose Routing (1) Install power steering pressure hose in vehicle (4) Lower vehicle.
  • Page 637 19 - 4 STEERING REMOVAL AND INSTALLATION (Continued) (4) Install a new O-ring (Fig. 8) on power steering (15) Securely tighten bolt attaching power steering pressure hose banjo fitting bolt. pressure hose bracket to generator shield. (16) Start the engine and let run for a few seconds. Then turn the engine off.
  • Page 638 STEERING 19 - 5 REMOVAL AND INSTALLATION (Continued) Fig. 9 Power Steering Return Hose At Steering Gear Fig. 11 Power Steering Return Hose At Reservoir (2) Install power steering return hose on power steering fluid reservoir fitting. Install hose clamp on power steering return hose at power steering fluid reservoir (Fig.
  • Page 639 19 - 6 STEERING REMOVAL AND INSTALLATION (Continued) POWER STEERING FLUID SUPPLY HOSE RESERVOIR TO POWER STEERING PUMP WARNING: POWER STEERING OIL, ENGINE PARTS EXHAUST SYSTEM EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DIS- CONNECTED HOSES.
  • Page 640 STEERING 19 - 7 REMOVAL AND INSTALLATION (Continued) CAUTION: Care must be used when installing (4) Remove hose clamp, attaching power steering power steering fluid supply hose on power steering fluid return hose to steel tube at power steering gear (Fig.
  • Page 641 19 - 8 STEERING REMOVAL AND INSTALLATION (Continued) (9) Remove clamp attaching the power steering fluid supply hose to the suction fitting on the power steering pump (Fig. 17). Remove the power steering fluid supply hose from the power steering pump fit- ting.
  • Page 642 STEERING 19 - 9 REMOVAL AND INSTALLATION (Continued) (4) Install drive belt on power steering pump pul- ley. (5) Install a 1/2 in. breaker bar in the square hole in the front power steering pump mounting bracket (Fig. 21). Then rotate pump in to obtain the correct drive belt tension.
  • Page 643 19 - 10 STEERING REMOVAL AND INSTALLATION (Continued) (21) Lower the vehicle. Start engine again and of power steering fluid reservoir, nipples can be turn the steering wheel slowly from lock to lock. broken off the reservoir. (22) Stop the engine. Check the fluid level and (7) Remove the power steering fluid, return and refill as required.
  • Page 644 STEERING 19 - 11 REMOVAL AND INSTALLATION (Continued) (10) Lower the vehicle and turn the steering wheel slowly from lock to lock. (11) Stop the engine. Check the fluid level and refill as required. (12) If the fluid is extremely foamy, allow the vehi- cle to stand a few minutes and repeat the above pro- cedure.
  • Page 645 19 - 12 STEERING STEERING GEAR INDEX page page DESCRIPTION AND OPERATION SPECIFICATIONS POWER STEERING GEAR ....12 STEERING GEAR FASTENER TORQUE REMOVAL AND INSTALLATION SPECIFICATIONS .
  • Page 646 STEERING 19 - 13 DESCRIPTION AND OPERATION (Continued) turn, builds up hydraulic pressure and assists in the (4) Remove engine/transaxle bobble dampener, on turning effort. vehicles so equipped, from front suspension cross- The drive tangs on the pinion of the power steering member (Fig.
  • Page 647 19 - 14 STEERING REMOVAL AND INSTALLATION (Continued) (6) Remove both tie rod end studs from the steer- knuckles, using Remover, Special Tool MB-990635 (Fig. 5). Fig. 7 Power Steering Fluid Pressure And Return Hoses front suspension alignment settings to the required Fig.
  • Page 648 STEERING 19 - 15 REMOVAL AND INSTALLATION (Continued) Fig. 10 Crossmember Lowered For Removal Of Fig. 8 Marking Front Suspension Crossmember Steering Gear Location Fig. 11 Steering Gear Mounting Bolts Fig. 9 Front Suspension Crossmember Mounting Bolts the 4 steering gear mounting bolts to 68 N·m (50 ft. lbs.).
  • Page 649 19 - 16 STEERING REMOVAL AND INSTALLATION (Continued) (3) Using a soft face hammer, tap front suspension crossmember into position, until it is aligned with the 2 previously scribbed positioning marks on body of vehicle (Fig. 12). When front suspension cross- member is correctly positioned, torque the 2 rear crossmember/lower control arm mounting bolts to 163 N·m (120 ft.
  • Page 650 STEERING 19 - 17 REMOVAL AND INSTALLATION (Continued) (18) Tighten tie rod jam nut (Fig. 14) to 61 N·m SPECIAL TOOLS (45 ft. lbs.) torque. POWER STEERING GEAR Remover Tie Rod End MB–990635 Fig. 14 Outer Tie Rod End Jam Nut (19) Adjust steering gear to tie rod boots at tie rods to remove any twisting that may have occured during Toe adjustment.
  • Page 651 19 - 18 STEERING STEERING COLUMN INDEX page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION STEERING COLUMN ....18 STEERING COLUMN ASSEMBLY ... 20 STEERING GEAR TO STEERING COLUMN STEERING COLUMN SERVICE PROCEDURE COUPLING .
  • Page 652 STEERING 19 - 19 (2) Loosen the coupling pinch bolt retaining nut and remove pinch bolt (Fig. 3) from steering coupler. (Pinch bolt nut is caged to coupler and is not removable.) Then separate the steering column upper coupling from the lower coupling. Fig.
  • Page 653 19 - 20 STEERING DIAGNOSIS AND TESTING (Continued) • Uneven spacing between the corrugations on WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, the coupling. COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE • Dings or dents in the corrugations of the cou- ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL pling or anywhere else on the coupling wall.
  • Page 654 STEERING 19 - 21 REMOVAL AND INSTALLATION (Continued) Fig. 6 Fuse Access Panel Fig. 9 Steering Wheel Covers CABLE AND ISOLATE. ALLOW SYSTEM CAPACI- TOR TO DISCHARGE FOR TWO MINUTES, BEFORE BEGINIG AIR BAG REMOVAL. (7) Remove the 2 fasteners, 1 on each side of steer- ing wheel, attaching air bag module to steering wheel (Fig.
  • Page 655 19 - 22 STEERING REMOVAL AND INSTALLATION (Continued) (8) Remove airbag module from center of steering wheel. (9) Disconnect the clock spring electrical lead from the back of the airbag module (Fig. 11). Fig. 13 Steering Wheel Attaching Nut Fig. 11 Airbag Module Electrical Connector (10) Disconnect the clockspring electrical lead from the wire to the airbag module horn switch (Fig.
  • Page 656 STEERING 19 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 17 Steering Column Coupling Fig. 15 Key Lock Cylinder Access Hole In Steering Column Shrouds Fig. 18 Steering Column Lower Attaching Bolt Fig. 16 Upper And Lower Steering Column Shrouds (17) Loosen the steering column upper coupling pinch bolt retaining nut and remove pinch bolt (Fig.
  • Page 657 19 - 24 STEERING REMOVAL AND INSTALLATION (Continued) (21) Remove routing clip (Fig. 20) holding wiring (Fig. 20) holding wiring harness to jacket of steering harness to steering column jacket. Then remove wir- column. ing harness connectors from the multi- function (4) Install the studs in steering column support switch and the windshield wiper switch (Fig.
  • Page 658 STEERING 19 - 25 REMOVAL AND INSTALLATION (Continued) • From the end of travel, rotate the rotor 2 full vehicle that has had the air bag module turns and an additional half turn in the counter- removed, the following procedure should be clockwise direction.
  • Page 660 WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page 8W-01 GENERAL INFORMATION ..8W-01-1 8W-48 REAR WINDOW DEFOGGER ..8W-48-1 8W-02 COMPONENT INDEX ... 8W-02-1 8W-50 FRONT LIGHTING .
  • Page 662 8W - 01 GENERAL INFORMATION 8W - 01 - 1 8W-01 GENERAL INFORMATION INDEX page page DESCRIPTION AND OPERATION INTERMITTENT AND POOR CONNECTIONS . . . 6 CIRCUIT IDENTIFICATION ....3 TROUBLESHOOTING TESTS .
  • Page 663 8W - 01 - 2 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) NOTES, CAUTIONS, and WARNINGS WARNING: ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTH- Throughout this group additional important infor- ING. mation is presented in three ways; Notes, Cautions, and Warnings.
  • Page 664 8W - 01 GENERAL INFORMATION 8W - 01 - 3 DESCRIPTION AND OPERATION (Continued) CIRCUIT IDENTIFICATION All circuits in the diagrams use an alpha/numeric code to identify the wire and its function (Fig. 3). To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart.
  • Page 665 8W - 01 - 4 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Fig. 5 Symbol Identification...
  • Page 666 8W - 01 GENERAL INFORMATION 8W - 01 - 5 DESCRIPTION AND OPERATION (Continued) ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When han- dling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inad- vertent discharge into the component.
  • Page 667 8W - 01 - 6 8W - 01 GENERAL INFORMATION DIAGNOSIS AND TESTING (Continued) • Voltmeter - Used to check for voltage on a cir- • Wire insulation that has rubbed through causing cuit. Always connect the black lead to a known good a short to ground •...
  • Page 668 8W - 01 GENERAL INFORMATION 8W - 01 - 7 DIAGNOSIS AND TESTING (Continued) (3) Connect the other lead to the other end of the (4) The voltmeter will show the difference in volt- circuit being tested. Low or no resistance means good age between the two points.
  • Page 669 8W - 01 - 8 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (2) Remove 1 inch of insulation from each end of ment this indicates a problem in the charging/start- the wire. ing system that needs to be corrected. (3) Place a piece of heat shrink tubing over one Replacement of the fusible link is the same as side of the wire.
  • Page 670 8W - 01 GENERAL INFORMATION 8W - 01 - 9 SERVICE PROCEDURES (Continued) CONNECTOR REPLACEMENT (1) Disconnect battery. (2) Disconnect the connector that is to be repaired from its mating half/component (3) Remove connector locking wedge, required (Fig. 16) Fig. 17 Terminal Removal Fig.
  • Page 671 8W - 01 - 10 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (8) Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. (9) Spread the strands of the wire apart on each part of the exposed wires.
  • Page 672 8W - 01 GENERAL INFORMATION 8W - 01 - 11 SERVICE PROCEDURES (Continued) DIODE REPLACEMENT (1) Disconnect 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.
  • Page 674 8W - 02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 675 8W - 02 - 2 8W - 02 COMPONENT INDEX SPECIAL TOOLS (Continued) Component Page Component Page Instrument Cluster ....8W-40 Radio .
  • Page 676 8W - 02 COMPONENT INDEX 8W - 02 - 3 8W-02 COMPONENT INDEX GENERAL INFORMATION INTRODUCTION This section provides an alphabetical listing of all the components covered in group 8W. For information on system operation, refer to the appropriate section of the wiring diagrams.
  • Page 678 8W - 10 - 2 8W - 10 POWER DISTRIBUTION 8W-10 POWER DISTRIBUTION INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 679 8W - 10 - 2 8W-10 POWER DISTRIBUTION PL-RHD TOP OF POWER DISTRIBUTION CENTER FUSE 8 AUTO FUEL SHUT HORN PUMP USED DOWN RELAY RELAY RELAY FUSE 5 FUSE 3 CMPRSR STRTR CLUTCH USED USED FUSE 2 MOTOR RELAY RELAY FUSE PDC FUSE APPLICATION CHART FUSE NO.
  • Page 680 PL-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 3 BOTTOM OF POWER DISTRIBUTION CENTER CIRCUIT FUNCTION A2 12PK/BK FUSED B+ A3 12RD/WT FUSED B+ A16 14GY FUSED B+ A4 14BK/RD FUSED B+ A20 12RD/DG FUSED B+ M1 18PK FUSED B+ M1 18PK FUSED B+ A17 18RD/BK...
  • Page 681 8W - 10 - 4 8W-10 POWER DISTRIBUTION PL-RHD A0 8RD BATTERY (8W-20-2) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE (8W-10-5) (8W-10-6) (8W-10-7) (8W-10-7) PK/BK RD/WT BK/RD IGNITION S213 SOLID REAR SWITCH STATE WINDOW DEFOGGER RELAY SWITCH FUSE FUSE FUSE FUSE FUSE (8W-10-7)
  • Page 682 PL-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 5 BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-4) ENGINE STARTER MOTOR RELAY (8W-21-2) INSTRUMENT CLUSTER BRAKE (8W-40-5) PK/BK WARNING LAMP C160 C102 C102 GY/BK ENGINE S208 STARTER (8W-70-3) PK/BK MOTOR (8W-21-2) GY/BK IGNITION...
  • Page 683 8W - 10 - 6 8W-10 POWER DISTRIBUTION PL-RHD BATT A2 BATT A0 (8W-10-5) (8W-10-4) IGNITION POWER SWITCH DISTRIBUTION 1 START CENTER 2 RUN (8W-10-4) FUSE 0 OFF 3 ACC (8W-10-5) BK/OR RD/WT C102 RD/WT S217 S213 RD/WT RD/WT BK/OR HEADLAMP SWITCH (8W-50-2)
  • Page 684 PL-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 7 BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-4) BK/RD RD/DG SOLID STATE C102 RELAY (8W-42-5) BK/RD RADIATOR REAR WINDOW RELAY MOTOR DEFOGGER (8W-42-5) SWITCH (8W-35-3) (8W-48-2) PLR01006 978W-1...
  • Page 685 8W - 10 - 8 8W-10 POWER DISTRIBUTION PL-RHD BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER (8W-10-4) FUSE M1 20 PK C103 C105 M1 22 PK UNDERHOOD TRUNK DOME LAMP LAMP LAMP (8W-44-3) (8W-44-2) (8W-44-2) S203 C225 GLOVE RADIO INSTRUMENT (8W-47-2) CLUSTER LAMP (8W-40-3)
  • Page 686 PL-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 9 BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER (8W-10-4) FUSE FUSE FUSE FUSE HORN RELAY (8W-41-2) RD/BK BK/WT DG/RD DG/RD PK/DB S131 C103 COMPRESSOR CLUTCH DG/RD RELAY (IN PDC) (8W-42-2) HORN NO. 1 (8W-41-2) DB/BK BK/WT...
  • Page 687 8W - 10 - 10 8W-10 POWER DISTRIBUTION PL-RHD BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE (8W-10-4) FUEL AUTOMATIC SHUT PUMP RELAY DOWN (8W-30-10) RELAY (8W-30-2) A141 A142 DG/WT DG/OR RD/WT C105 C161 S105 A141 DG/WT RD/WT RD/WT A142 FUEL POWERTRAIN DATA DG/OR...
  • Page 688 PL-RHD 8W-10 POWER DISTRIBUTION 8W - 10 - 11 BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER (8W-10-4) FUSE WT/OR WT/OR C103 WT/OR LAMP RELAY (IN PDC) REAR (8W-50-6) LAMP SWITCH (8W-51-6) LB/WT S115 LB/WT LB/WT LEFT RIGHT LAMP LAMP (8W-50-6) (8W-50-6) PLR01010 978W-1...
  • Page 689 8W - 10 - 12 8W-10 POWER DISTRIBUTION PL-RHD BATT A1 (8W-10-5) IGNITION SWITCH 1 START 2 RUN 0 OFF 3 ACC (8W-10-5) YL/BK C241 BK/WT YL/BK C241 YL/BK C101 FUSE BLOCK (8W-11-2) CLUTCH PEDAL FUSE FUSE FUSE POSITION SWITCH (8W-11-9) (8W-11-9) (8W-11-10)
  • Page 690 8W - 10 POWER DISTRIBUTION 8W - 10 - 13 8W-10 POWER DISTRIBUTION DESCRIPTION AND OPERATION This section covers the power distribution center and all circuits involved with it. For additional infor- mation on system operation, refer to the appropriate wiring diagrams.
  • Page 692 8W - 11 - 2 8W - 11 FUSE/FUSE BLOCK 8W-11 FUSE/FUSE BLOCK INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 693 8W - 11 - 2 8W-11 FUSE BLOCK PL-RHD TOP OF FUSE BLOCK F13 18DB CIGAR LIGHTER RELAY COMBINATION RELAY F38 18RD L55 20BK/YL F38 16RD F38 18RD L32 20PK Z2 20BK/LG L44 20VT/RD L43 20VT (39) (38) (37) (40) L43 20VT L55 20BK/YL FUSE...
  • Page 694 PL-RHD 8W-11 FUSE BLOCK 8W - 11 - 3 FUSES FUSE NO. AMPS FEED CIRCUIT FUSED CIRCUIT A3 12RD/WT F38 16RD A3 12RD/WT F33 20PK/RD A3 12RD/WT F35 16RD/YL A22 12BK/OR F20 20WT A22 12BK/OR L5 20BK A22 12BK/OR C1 14DG A22 12BK/OR F20 20WT E1 20TN...
  • Page 695 8W - 11 - 4 8W-11 FUSE BLOCK PL-RHD BATT A3 (8W-10-6) FUSE BLOCK (8W-11-2) FUSE FUSE PK/RD HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD (8W-50-2) CIGAR LIGHTER RELAY (IN FB) (8W-41-3) BK/YL BK/YL RADIO FUSE (8W-47-2) BLOCK FUSE (8W-11-2) (8W-11-11) C230...
  • Page 696 PL-RHD 8W-11 FUSE BLOCK 8W - 11 - 5 FROM C230 (8W-11-4) BK/YL C105 BK/YL S113 BK/YL BK/YL LEFT RIGHT PARK/ PARK/ TURN TURN SIGNAL SIGNAL LAMP LAMP (8W-52-3) (8W-52-3) PLR01104 978W-1...
  • Page 697 8W - 11 - 6 8W-11 FUSE BLOCK PL-RHD BATT A3 (8W-10-6) FUSE BLOCK (8W-11-2) FUSE FUSE RD/YL S214 RD/YL RD/YL RD/YL C231 C205 RD/YL RD/YL LEFT RIGHT DOOR CONNECTION DOOR LOCK LOCK SWITCH SWITCH (8W-61-2) (8W-61-2) 978W-1 PLR01105...
  • Page 698 PL-RHD 8W-11 FUSE BLOCK 8W - 11 - 7 BATT A2 (8W-10-5) IGNITION SWITCH 1 START 2 RUN 0 OFF 3 ACC (8W-10-5) BK/OR S217 BK/OR BK/OR FUSE BLOCK (8W-11-2) FUSE FUSE FUSE FUSE CIRCUIT BREAKER PLR01106 978W-1...
  • Page 699 8W - 11 - 8 8W-11 FUSE BLOCK PL-RHD RUN A22 (8W-10-6) FUSE BLOCK (8W-11-2) FUSE FUSE FUSE FUSE C206 TN/LG AIRBAG TURN CONTROL SIGNAL/ HEATER MODULE HAZARD BLOWER (8W-43-2) SWITCH MOTOR (8W-52-2) (8W-42-3) S211 C103 C206 REAR BACK-UP PARK/ WINDOW LAMP NEUTRAL...
  • Page 700 PL-RHD 8W-11 FUSE BLOCK 8W - 11 - 9 ST-RUN A21 (8W-10-12) FUSE BLOCK (8W-11-2) FUSE FUSE DB/WT DG/WT C101 AIRBAG CONTROL MODULE (8W-43-2) DG/WT S109 DG/WT DG/WT DG/WT DG/WT DG/WT DG/WT DG/WT C160 TORQUE RELAY CONVERTER COMPRESSOR CLUTCH CLUTCH (8W-35-2) SOLENOID RELAY...
  • Page 701 8W - 11 - 10 8W-11 FUSE BLOCK PL-RHD RUN A22 ST-RUN A21 (8W-10-6) (8W-10-12) FUSE BLOCK (8W-11-2) CIRCUIT FUSE BREAKER (FB) DB/WT DB/WT C205 C231 CONNECTION LEFT POWER WINDOW SWITCH (8W-60-2) S138 POWER MIRROR MASTER CIRCUIT INSTRUMENT FUSE BREAKER POWER CLUSTER HOLDER...
  • Page 702 PL-RHD 8W-11 FUSE BLOCK 8W - 11 - 11 BATT F33 (8W-11-4) HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD (8W-50-2) FUSE BLOCK FUSE (8W-11-2) S210 RADIO INSTRUMENT REAR RECEIVER (8W-47-2) CLUSTER WINDOW LAMP (8W-40-2) DEFOGGER (8W-44-4) SWITCH (8W-48-2) HEADLAMP PRNDL LEVELING HEATER...
  • Page 703 8W - 11 - 12 8W-11 FUSE BLOCK PL-RHD BATT A1 (8W-10-5) IGNITION SWITCH 1 START 2 RUN 0 OFF 3 ACC (8W-10-5) BK/WT FUSE BLOCK (8W-11-2) FUSE FUSE FUSE YL/RD RD/WT RADIO (8W-47-2) C225 S206 YL/RD CIGAR WIPER WIPE/ INTERMITTENT LIGHTER MOTOR...
  • Page 704 PL-RHD 8W-11 FUSE BLOCK 8W - 11 - 13 BATT A3 (8W-10-6) HEADLAMP SWITCH CIRCUIT 0 OFF BREAKER 1 PARK 2 ON (8W-50-2) S221 REAR HEADLAMP DIMMER AND LAMP OPTICAL SWITCH HORN (8W-51-6) SWITCH 1 OPTICAL 2 LOW 3 HIGH (8W-50-2) VT/WT FUSE...
  • Page 705 8W - 11 - 14 8W - 11 FUSE/FUSE BLOCK 8W-11 FUSE/FUSE BLOCK DESCRIPTION AND OPERATION This section covers the fuse block and all circuits involved with it. For additional information on sys- tem operation, please refer to the appropriate section of the wiring diagrams.
  • Page 706 8W - 15 - 2 8W - 15 GROUND DISTRIBUTION 8W-15 GROUND DISTRIBUTION INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 707 8W - 15 - 2 8W-15 GROUND DISTRIBUTION PL-RHD RADIATOR HORN ENGINE DOWNSTREAM NO. 2 STARTER HEATED MOTOR (8W-41-2) MOTOR OXYGEN (8W-42-5) RELAY SENSOR (M/T) (8W-30-3) (8W-21-2) SOLID UPSTREAM STATE HEATED OXYGEN RELAY SENSOR (8W-42-5) (8W-30-3) S111 S119 BRAKE LEFT LEFT WARNING HEADLAMP...
  • Page 708 PL-RHD 8W-15 GROUND DISTRIBUTION 8W - 15 - 3 POWERTRAIN CONTROL MODULE (8W-30-2) POWER DATA STEERING LINK PRESSURE CONNECTOR (8W-30-4) SWITCH BK/TN (8W-30-4) CONTROLLER ANTI-LOCK BRAKE (8W-35-4) BK/TN BK/TN C160 STOP LAMP SWITCH (8W-30-12) BK/TN BK/TN BK/TN BK/OR BK/TN S104 BK/WT BK/TN G102...
  • Page 709 8W - 15 - 4 8W-15 GROUND DISTRIBUTION PL-RHD RIGHT RIGHT LEFT RIGHT PARK/ HEADLAMP TURN (8W-50-3) LAMP LAMP SIGNAL (8W-50-6) (8W-50-6) LAMP (8W-52-3) HORN RIGHT RIGHT NO. 1 HEADLAMP REPEATER (8W-41-2) LEVELING LAMP MOTOR (8W-50-3) (8W-52-3) (8W-50-4) S117 COMPRESSOR COMPRESSOR CLUTCH CLUTCH...
  • Page 710 PL-RHD 8W-15 GROUND DISTRIBUTION 8W - 15 - 5 INTERMITTENT COMBINATION REAR WIPE/ FLASHER WINDOW WASH (8W-52-2) DEFOGGER SWITCH SWITCH CONNECTION (8W-53-3) (8W-48-2) BK/LG BK/LG BK/LG BK/LG S205 RADIO (8W-47-2) BK/LG G201 BATTERY AIRBAG POWERTRAIN (8W-20-2) CONTROL CONTROL MODULE MODULE (8W-43-2) (8W-30-2) BK/PK...
  • Page 711 8W - 15 - 6 8W-15 GROUND DISTRIBUTION PL-RHD MASTER POWER POWER RIGHT POWER MIRROR FOLDING DOOR WINDOW SWITCH MIRROR LOCK SWITCH (8W-62-2) RELAY SWITCH (8W-60-2) (8W-62-4) (8W-61-2) BK/VT BK/VT BK/VT BK/VT BK/VT S310 SUNROOF POWER VENT SUNROOF HEATER SWITCH MOTOR CONTROL (8W-64-2)
  • Page 712 PL-RHD 8W-15 GROUND DISTRIBUTION 8W - 15 - 7 MAP/ PRNDL READING RECEIVER LAMP LAMPS LAMP (8W-44-4) (8W-44-4) (8W-44-4) REAR FRONT BK/OR BK/OR LAMP LAMP SWITCH SWITCH (8W-51-6) (8W-50-6) Z3 22BK/OR C225 C203 GLOVE INSTRUMENT CLUSTER LAMP (8W-40-6) SWITCH (8W-44-4) BK/OR BK/OR BK/OR...
  • Page 713 8W - 15 - 8 8W-15 GROUND DISTRIBUTION PL-RHD LEFT LEFT LEFT LEFT REAR TAIL/ TURN BACK-UP STOP SIGNAL LAMP LAMP LAMP LAMP (8W-51-3) (8W-51-7) (8W-51-5) (8W-52-4) S315 LEFT RIGHT LICENSE LICENSE LAMP LAMP (8W-51-5) (8W-51-5) CONNECTION C340 S308 G302 978W-1 PLR01507...
  • Page 714 PL-RHD 8W-15 GROUND DISTRIBUTION 8W - 15 - 9 FUEL PUMP MODULE (8W-30-10) G303 RIGHT RIGHT REAR REAR BACK-UP WINDOW LAMP DEFOGGER LAMP (8W-51-3) (8W-48-2) (8W-51-7) RIGHT RIGHT TURN TAIL/ SIGNAL STOP LAMP LAMP (8W-52-4) (8W-51-5) S307 C341 G301 PLR01508 978W-1...
  • Page 715 8W - 15 - 10 8W - 15 GROUND DISTRIBUTION 8W-15 GROUND DISTRIBUTION GENERAL INFORMATION the wiring diagrams. For an illustration of the phys- ical location of each ground, refer to group 8W-90. This section identifies the grounds, splices that connect to those grounds, and the components that connect those grounds.
  • Page 716 8W - 20 - 2 8W - 20 CHARGING SYSTEM 8W-20 CHARGING SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 717 8W - 20 CHARGING SYSTEM 8W - 20 - 3 GENERAL INFORMATION (Continued) 8W - 20 - 2 8W-20 CHARGING SYSTEM PL-RHD A0 8RD POWER BATTERY DISTRIBUTION CENTER FUSE (8W-10-4) (8W-10-10) AUTOMATIC SHUT DOWN RELAY (8W-30-2) A142 G104 G105 DG/OR (8W-15-5) (8W-15-5) C161...
  • Page 718 8W - 20 CHARGING SYSTEM 8W - 20 - 3 8W-20 CHARGING SYSTEM DESCRIPTION AND OPERATION CHARGING SYSTEM The charging system is an integral part of the bat- tery and starter systems. Since all of these systems work together, any diagnosis and testing should be done in conjunction.
  • Page 720 8W - 21 - 2 8W - 21 STARTING SYSTEM 8W-21 STARTING SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 721 8W - 21 STARTING SYSTEM 8W - 21 - 3 DESCRIPTION AND OPERATION (Continued) 8W - 21 - 2 8W-21 STARTING SYSTEM PL-RHD BATT A1 (8W-10-5) IGNITION POWER SWITCH DISTRIBUTION 1 START CENTER 2 RUN (8W-10-4) 0 OFF FUSE 3 ACC (8W-10-5) (8W-10-5) YL/BK...
  • Page 722 8W - 21 STARTING SYSTEM 8W - 21 - 3 8W-21 STARTING SYSTEM DESCRIPTION AND OPERATION Circuit A0 (battery positive cable) supplies battery voltage to the motor of the engine starter when the STARTING SYSTEM- MANUAL TRANSMISSION solenoid energizes. The Power Distribution Center (PDC) supplies bat- HELPFUL INFORMATION tery voltage to the engine starter motor solenoid •...
  • Page 724 8W - 30 - 2 8W - 30 FUEL/IGNITION SYSTEMS 8W-30 FUEL/IGNITION SYSTEMS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 725 8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM PL-RHD BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE (8W-10-4) (8W-10-10) AUTOMATIC SHUT DOWN RELAY A142 RD/WT DG/OR C161 S105 A142 DG/OR RD/WT S122 DATA (8W-10-10) A142 LINK CONNECTOR RD/WT DB/YL DG/OR (8W-30-4) POWERTRAIN FUSED CONTROL...
  • Page 726 PL-RHD 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3 BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE (8W-10-4) (8W-10-10) AUTOMATIC POWERTRAIN SHUT CONTROL UPSTREAM DOWNSTREAM DOWN MODULE HEATED HEATED RELAY OXYGEN OXYGEN (8W-30-2) SENSOR SENSOR RELAY SIGNAL SIGNAL OUTPUT A142 K141 DG/OR A142 C161...
  • Page 727 8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM PL-RHD BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE (8W-10-4) (8W-10-10) RD/WT S105 (8W-10-10) RD/WT DATA LINK CONNECTOR VT/BR WT/BK BK/TN BK/TN TWISTED S104 S102 PAIR (8W-15-3) C101 BK/TN BK/TN G102 (8W-15-3) VT/BR WT/BK AIRBAG POWER...
  • Page 728 PL-RHD 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5 S121 A142 A142 A142 A142 A142 DG/OR DG/OR DG/OR DG/OR DG/OR S122 (8W-10-10) FUEL INJECTOR NO. 4 A142 DG/OR FUEL INJECTOR NO. 3 S134 FUEL INJECTOR A142 A142 NO. 2 DG/OR DG/OR FUEL INJECTOR...
  • Page 729 8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM PL-RHD THROTTLE POSITION SENSOR VT/WT BK/LB S120 S124 (8W-70-2) BK/LB BK/LB BK/LB VT/WT VT/WT OR/DB IAT/ KNOCK SENSOR GROUND SUPPLY SENSOR SENSOR C161 SENSOR SENSOR SIGNAL SIGNAL 2.0L 2.0L DOHC SOHC BK/LB BK/LG DB/LG C161...
  • Page 730 PL-RHD 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7 CRANKSHAFT CRANKSHAFT POSITION POSITION SENSOR SENSOR SENSOR SIGNAL SUPPLY GROUND GY/BK BK/LB INSTRUMENT S123 CLUSTER (8W-30-13) (8W-40-6) CAMSHAFT POSITION SUPPLY VT/YL SENSOR CAMSHAFT S118 POSITION (8W-70-2) C103 SENSOR SENSOR GROUND SIGNAL VT/YL BK/LB BK/LB...
  • Page 731 8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM PL-RHD IDLE IDLE IDLE IDLE IDLE CONTROL CONTROL CONTROL CONTROL CONTROL MOTOR MOTOR MOTOR MOTOR MOTOR NO. 4 NO. 2 NO. 3 NO. 1 VEHICLE VEHICLE SPEED SPEED SENSOR SENSOR SENSOR GROUND SUPPLY SIGNAL YL/BK...
  • Page 732 PL-RHD 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9 ST-RUN A21 (8W-10-12) FUSE BLOCK (8W-11-2) FUSE (8W-11-9) DG/WT C101 DG/WT S109 (8W-11-9) DG/WT DG/WT DG/WT DG/WT DUTY TORQUE VAPOR C160 CYCLE CONVERTER CANISTER EVAP/ CLUTCH LEAK PURGE SOLENOID DETECTOR SOLENOID (A/T) DB/WT S126...
  • Page 733 8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM PL-RHD ST-RUN A21 (8W-10-12) INSTRUMENT POWERTRAIN FUEL CLUSTER CONTROL FUSE LEVEL (8W-40-6) MODULE BLOCK FUEL SENSOR (8W-11-2) GAUGE SIGNAL FUSE (8W-11-9) DG/WT S109 C160 (8W-11-9) DG/WT C101 DG/WT BATT A0 (8W-10-4) POWER C105 DISTRIBUTION CENTER...
  • Page 734 PL-RHD 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11 INSTRUMENT CLUSTER (8W-40-3) (8W-40-5) (8W-40-6) HIGH PRESSURE SWITCH (8W-42-5) TN/BK GY/LB BK/PK SOLID STATE RELAY C103 (8W-42-5) COMPRESSOR CLUTCH RELAY K173 (IN PDC) (8W-42-2) TN/BK GY/LB BK/PK BR/OR GENERATOR (8W-20-2) C160 K173 BK/PK BR/OR...
  • Page 735 8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM PL-RHD RUN A22 BATT A0 (8W-10-4) (8W-10-4) FUSE POWER POWERTRAIN BLOCK DISTRIBUTION CONTROL STOP (8W-11-2) CENTER LAMP MODULE FUSE FUSE (8W-10-4) SWITCH SENSE (8W-11-8) (8W-10-9) S211 (8W-11-8) WT/PK PK/DB C103 STOP LAMP SWITCH CONNECTION PARK/...
  • Page 736 PL-RHD 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13 IMMOBILIZER ENGINE SENSOR K241 GY/BK K240 S129 K241 GY/BK IMMOBILIZER SENSOR BK/LB C161 S110 (8W-30-3) S123 BK/LB CAMSHAFT VEHICLE CRANKSHAFT POWERTRAIN SENSOR POSITION SPEED POSITION CONTROL SUPPLY GROUND SENSOR SENSOR SENSOR MODULE (8W-30-7) (8W-30-8)
  • Page 737 8W - 30 - 14 8W - 30 FUEL/IGNITION SYSTEMS 8W-30 FUEL/IGNITION SYSTEMS INDEX page page DESCRIPTION AND OPERATION IGNITION SWITCH ..... . 14 AUTOMATIC SHUT DOWN RELAY .
  • Page 738 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 15 DESCRIPTION AND OPERATION (Continued) HELPFUL INFORMATION HELPFUL INFORMATION • Refer to group 14 Fuel System, for additional Circuit Z12 which supplies ground for the PCM high current drivers, has the same termination point information.
  • Page 739 8W - 30 - 16 8W - 30 FUEL/IGNITION SYSTEMS DESCRIPTION AND OPERATION (Continued) • Crankshaft position sensor HELPFUL INFORMATION • Camshaft position sensor Circuit K7 splices to supply 8 volts to the camshaft • Battery temperature sensor position sensor and vehicle speed sensor. •...
  • Page 740 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 17 DESCRIPTION AND OPERATION (Continued) a change in current draw. The K2 circuit connects to Pressure (MAP) sensor. Circuit K6 connects to cavity cavity 26 of the PCM connector. 61 of the PCM connector. The PCM provides ground for the engine coolant Circuit K1 delivers the MAP signal to the PCM.
  • Page 741 8W - 30 - 18 8W - 30 FUEL/IGNITION SYSTEMS DESCRIPTION AND OPERATION (Continued) • Circuit K11 is the ground circuit for Injector #1. The PCM provides ground for the knock sensor sig- nal (circuit K42) through circuit K4. Circuit K4 con- Circuit K11 connects to cavity 13 of the PCM.
  • Page 742 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 19 DESCRIPTION AND OPERATION (Continued) • Circuit K59 connects to cavity 58 of the PCM A21. Circuit A1 connects to battery voltage and is connector. protected by a 30 amp fuse in the PDC. •...
  • Page 744 8W - 35 - 2 8W - 35 ANTI-LOCK BRAKES 8W-35 ANTI-LOCK BRAKES INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 745 8W - 35 - 2 8W-35 ANTI-LOCK BRAKES PL-RHD ST-RUN A21 (8W-10-12) FUSE BLOCK (8W-11-2) FUSE (8W-11-9) DG/WT C101 INSTRUMENT CLUSTER (8W-40-5) WARNING LAMP S109 (8W-11-9) LG/OR DG/WT DG/WT C103 LG/BR RELAY PUMP SYSTEM MOTOR RELAY RELAY LG/BR RD/LB BR/BK S108 (8W-15-2) G101...
  • Page 746 PL-RHD 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3 BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER DATA FUSE (8W-10-4) LINK CONNECTOR (8W-10-7) (8W-30-4) RD/DG S210 (8W-11-11) RELAY PUMP MOTOR PUMP MOTOR DRIVER PUMP MOTOR RELAY B116 B120 BR/WT S103 S108 B120 (8W-15-2) BR/WT CONTROLLER...
  • Page 747 8W - 35 - 4 8W-35 ANTI-LOCK BRAKES PL-RHD BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE (8W-10-4) (8W-10-9) PK/DB STOP LAMP SWITCH (8W-30-12) WT/TN S101 (8W-30-12) WT/TN CONTROLLER STOP ANTI-LOCK LAMP LEFT LEFT RIGHT RIGHT SWITCH BRAKE FRONT REAR FRONT REAR OUTPUT DECAY...
  • Page 748 PL-RHD 8W-35 ANTI-LOCK BRAKES 8W - 35 - 5 LEFT RIGHT FRONT FRONT WHEEL WHEEL SPEED SPEED SENSOR SENSOR RD/DB WT/DB LEFT RIGHT TWISTED TWISTED REAR REAR PAIR PAIR WHEEL WHEEL SPEED SPEED SENSOR SENSOR LG/DB WT/BK DG/WT C108 C108 TWISTED TWISTED PAIR...
  • Page 749 8W - 35 - 6 8W - 35 ANTI-LOCK BRAKES 8W-35 ANTI-LOCK BRAKES INDEX page page DESCRIPTION AND OPERATION BRAKE SWITCH INPUT ....7 ABS PUMP MOTOR RELAY .
  • Page 750 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 7 DESCRIPTION AND OPERATION (Continued) WHEEL SPEED SENSORS There are four wheel speed sensors, one at each wheel. The sensors use a tone wheel to determine wheel speed. Input to the Controller Anti Lock Brake (CAB) is done on the following circuits.
  • Page 752 8W - 40 - 2 8W - 40 INSTRUMENT CLUSTER 8W-40 INSTRUMENT CLUSTER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 753 8W - 40 - 2 8W-40 INSTRUMENT CLUSTER PL-RHD BATT F33 (8W-11-4) HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD (8W-50-2) HEADLAMP DIMMER OPTICAL FUSE HORN BLOCK SWITCH (8W-11-2) FUSE (8W-50-2) (8W-11-1) RD/OR S209 (8W-50-3) S210 (8W-11-11) RD/OR INSTRUMENT CLUSTER HIGH CLUSTER BEAM...
  • Page 754 PL-RHD 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3 BATT A0 VEHICLE (8W-10-4) VEHICLE SPEED POWER SPEED SENSOR DISTRIBUTION SENSOR (8W-30-8) SIGNAL CENTER FUSE (8W-10-4) POWERTRAIN VEHICLE CONTROL (8W-10-8) SPEED MODULE TACHOMETER SENSOR WT/OR (8W-30-8) SIGNAL SIGNAL (8W-30-11) C160 C103 GY/LB WT/OR WT/OR...
  • Page 755 8W - 40 - 4 8W-40 INSTRUMENT CLUSTER PL-RHD TURN SIGNAL/ HAZARD SWITCH (8W-52-3) S212 S207 C101 C103 S112 S116 LEFT RIGHT REPEATER REPEATER LAMP LAMP (8W-52-3) (8W-52-3) RIGHT LEFT PARK/ PARK/ TURN TURN SIGNAL SIGNAL LAMP LAMP INSTRUMENT (8W-52-3) (8W-52-3) CLUSTER LEFT...
  • Page 756 PL-RHD 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5 INSTRUMENT CLUSTER SEAT BRAKE ANTI-LOCK CHARGE AIRBAG BELT INDICATOR WARNING WARNING WARNING WARNING LAMP LAMP LAMP LAMP LAMP GY/BK LG/OR TN/BK BK/TN LG/RD S208 CONNECTION (8W-70-3) GY/BK GY/BK AIRBAG AIRBAG CONTROL WARNING LAMP MODULE...
  • Page 757 8W - 40 - 6 8W-40 INSTRUMENT CLUSTER PL-RHD POWERTRAIN ST-RUN A21 (8W-10-12) CONTROL FUSE FUEL MODULE BLOCK LEVEL (8W-30-10) (8W-11-2) SENSOR FUSE SIGNAL (8W-11-10) C160 ENGINE COOLANT TEMPERATURE C105 SENSOR SENSOR SIGNAL DB/WT DB/WT (8W-30-7) VT/YL CONNECTION C230 C160 VT/YL FUEL FUEL...
  • Page 758 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 7 8W-40 INSTRUMENT CLUSTER INDEX page page DESCRIPTION AND OPERATION KEY-IN CHIME ......8 AIRBAG WARNING LAMP .
  • Page 759 8W - 40 - 8 8W - 40 INSTRUMENT CLUSTER DESCRIPTION AND OPERATION (Continued) ODOMETER door OPEN. If the key is in the ignition and the driv- ers door is OPEN, a ground path is completed from The speedometer and odometer receive their infor- the G26 circuit at the cluster, through the CLOSED mation on the G7 circuit from the Vehicle Speed Sen- key-in switch, to the G16 circuit and terminating at...
  • Page 760 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 9 DESCRIPTION AND OPERATION (Continued) There are two switches used in this system and they are wired in parallel form. A parking brake switch located on the parking brake mechanism will illuminate the lamp if the normally OPEN switch is CLOSED.
  • Page 762 8W - 41 - 2 8W - 41 HORNS/CIGAR LIGHTER 8W-41 HORNS/CIGAR LIGHTER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 763 8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET PL-RHD BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE (8W-10-4) (8W-10-9) HORN RELAY BK/RD DG/RD DG/RD S131 C101 DG/RD HORN HORN NO. 1 NO. 2 BK/RD CLOCKSPRING S111 LEFT RIGHT (8W-15-2) HORN HORN SWITCH SWITCH...
  • Page 764 PL-RHD 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3 RUN A22 BATT A0 (8W-10-6) (8W-10-4) FUSE POWER BLOCK DISTRIBUTION (8W-11-2) CENTER FUSE FUSE (8W-10-4) (8W-11-12) (8W-10-6) RD/WT C102 S206 RD/WT (8W-11-12) S213 (8W-10-6) RD/WT FUSE BLOCK (8W-11-2) CIGAR FUSE LIGHTER RELAY (8W-11-4)
  • Page 765 8W - 41 - 4 8W - 41 HORNS/CIGAR LIGHTER 8W-41 HORNS/CIGAR LIGHTER • Press the horn switch and listen for the horn DESCRIPTION AND OPERATION relay to click. A clicking relay indicates voltage is HORNS present up to the switch. •...
  • Page 766 8W - 42 - 2 8W - 42 AIR CONDITIONING-HEATER 8W-42 AIR CONDITIONING-HEATER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 767 8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER PL-RHD ST-RUN A21 (8W-10-12) FUSE BLOCK (8W-11-2) FUSE (8W-11-9) DG/WT C101 DG/WT S109 (8W-11-9) DG/WT BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE (8W-10-4) (8W-10-9) COMPRESSOR CLUTCH RELAY C3 18DB/BK DB/OR DIODE COMPRESSOR CLUTCH 20BK POWERTRAIN...
  • Page 768 PL-RHD 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3 RUN A22 BATT F33 (8W-10-6) (8W-11-4) FUSE HEADLAMP BLOCK SWITCH (8W-11-2) 0 OFF FUSE 1 PARK 2 HEAD (8W-50-2) (8W-11-8) CYCLING MODE SWITCH SWITCH C206 (8W-42-4) OUTPUT FUSE BLOCK FUSE (8W-11-2) DB/YL HEATER (8W-11-11)
  • Page 769 8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER PL-RHD RUN A22 (8W-10-6) FUSE BLOCK (8W-11-2) FUSE (8W-11-8) S211 (8W-11-8) C206 FUSED CYCLING IGN. (RUN) SWITCH CYCLING MODE SWITCH SWITCH OUTPUT OUTPUT DB/OR DB/YL C206 DB/OR C206 C101 DB/YL DB/OR HEATER CONTROL PRESSURE SWITCH...
  • Page 770 PL-RHD 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5 BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE (8W-10-4) CYCLING CYCLING SWITCH SWITCH (8W-10-7) (8W-42-4) OUTPUT DB/OR C206 SOLID STATE DB/OR RELAY C101 DB/OR K173 PRESSURE RADIATOR SWITCH MOTOR C160 DB/WT K173 HIGH PRESSURE S111...
  • Page 771 8W - 42 - 6 8W - 42 AIR CONDITIONING-HEATER 8W-42 AIR CONDITIONING-HEATER INDEX page page DESCRIPTION AND OPERATION BLOWER MOTOR OPERATION ... . . 6 A/C OPERATION ......6 HELPFUL INFORMATION .
  • Page 772 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 7 DESCRIPTION AND OPERATION (Continued) except, the C5 circuit is used for the M1 speed and circuit C6 is used for M2 speed operation. Blower motor HIGH speed operation is accom- plished on the C7 circuit which supplies battery volt- age directly to the blower motor.
  • Page 774 8W - 43 - 2 8W - 43 AIRBAG SYSTEM 8W-43 AIRBAG SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 775 8W - 43 - 2 8W-43 AIRBAG SYSTEM PL-RHD ST-RUN A21 RUN A22 (8W-10-12) (8W-10-6) FUSE BLOCK (8W-11-2) FUSE FUSE DATA (8W-11-9) (8W-11-8) LINK CONNECTOR (8W-30-4) TWISTED PAIR VT/BR WT/BK C101 DB/WT TN/GN TWISTED PAIR VT/BR WT/BK AIRBAG FUSED FUSED CONTROL IGN.
  • Page 776 PL-RHD 8W-43 AIRBAG SYSTEM 8W - 43 - 3 LEFT RIGHT INSTRUMENT AIRBAG LEFT LEFT FRONT FRONT AIRBAG AIRBAG CLUSTER RIGHT RIGHT RIGHT RIGHT WARNING IMPACT IMPACT (8W-40-5) IMPACT IMPACT IMPACT IMPACT LAMP SENSOR SENSOR (8W-40-5) SENSOR SENSOR SENSOR SENSOR DB/LB BR/LB C101...
  • Page 777 8W - 43 - 4 8W-43 AIRBAG SYSTEM PL-RHD PASSENGER DRIVER PASSENGER PASSENGER SIDE SIDE PASSENGER PASSENGER DRIVER DRIVER AIRBAG AIRBAG AIRBAG AIRBAG AIRBAG AIRBAG AIRBAG AIRBAG PRESSURE PRESSURE SQUIB SQUIB SQUIB SQUIB SWITCH SWITCH GROUND SENSE LINE 1 LINE 2 LINE 1 LINE 2 TWISTED...
  • Page 778 8W - 43 AIRBAG SYSTEM 8W - 43 - 5 8W-43 AIRBAG SYSTEM DESCRIPTION AND OPERATION PASSENGERS SIDE AIRBAG Two circuits, R42 and R44, connect the ACM to the AIRBAG CONTROL MODULE (ACM) passengers side airbag module squib (igniter). Circuit R42 from cavity 1 of the ACM 4-way connector con- Two different circuits supply battery voltage from nects to the squib.
  • Page 780 8W - 44 - 2 8W - 44 INTERIOR LIGHTING 8W-44 INTERIOR LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 781 8W - 44 - 2 8W-44 INTERIOR LIGHTING PL-RHD BATT A0 (8W-10-4) MAP/ POWER READING DISTRIBUTION LAMPS CENTER (8W-44-4) FUSE (8W-10-4) (8W-10-8) C225 C103 S220 C105 S203 (8W-10-8) CONNECTION GLOVE TRUNK LAMP LAMP SWITCH HEADLAMP C230 (8W-44-4) SWITCH (8W-50-2) GY/BK C309 DOME LAMP...
  • Page 782 PL-RHD 8W-44 INTERIOR LIGHTING 8W - 44 - 3 BATT A0 (8W-10-4) POWER DISTRIBUTION CENTER FUSE (8W-10-4) (8W-10-8) C103 S203 (8W-10-8) UNDERHOOD LAMP MERCURY SWITCH C225 S309 (8W-10-8) LEFT RIGHT VISOR/ VISOR/ VANITY VANITY LAMPS LAMPS PLR04402 978W-1...
  • Page 783 8W - 44 - 4 8W-44 INTERIOR LIGHTING PL-RHD BATT A0 BATT A3 (8W-10-4) (8W-10-6) POWER FUSE DISTRIBUTION BLOCK CENTER (8W-11-2) FUSE FUSE FUSE (8W-10-4) (8W-10-8) (8W-11-4) (8W-11-11) PK/RD HEADLAMP SWITCH 0 OFF CONNECTION 1 PARK C103 2 HEAD (8W-50-2) S220 (8W-44-2) S203...
  • Page 784 8W - 44 INTERIOR LIGHTING 8W - 44 - 5 8W-44 INTERIOR LIGHTING INDEX page page DESCRIPTION AND OPERATION MAP/READING LAMPS ....6 ASH RECEIVER LAMP .
  • Page 785 8W - 44 - 6 8W - 44 INTERIOR LIGHTING DESCRIPTION AND OPERATION (Continued) The second ground path is through the headlamp ASH RECEIVER LAMP switch. Circuit M23 is spliced in with the time out The ash receiver lamp receives power on the E2 relay.
  • Page 786 8W - 47 - 2 8W - 47 AUDIO SYSTEMS 8W-47 AUDIO SYSTEMS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 787 8W - 47 - 2 8W-47 AUDIO SYSTEM PL-RHD (8W-10-12) RUN ACC A31 BATT A3 (8W-10-6) FUSE BLOCK (8W-11-2) FUSE FUSE (8W-11-12) (8W-11-4) PK/RD BATT A0 (8W-10-4) POWER HEADLAMP DISTRIBUTION SWITCH CENTER 0 OFF FUSE (8W-10-4) 1 PARK 2 HEAD (8W-10-8) (8W-50-2) RD/WT...
  • Page 788 PL-RHD 8W-47 AUDIO SYSTEM 8W - 47 - 3 LEFT RIGHT INSTRUMENT INSTRUMENT PANEL PANEL SPEAKER SPEAKER (PREMIUM) (PREMIUM) BR/RD DB/RD LEFT RIGHT FRONT FRONT DOOR DOOR SPEAKER SPEAKER BR/RD DB/RD C231 C205 BR/RD DB/RD RADIO LEFT LEFT RIGHT RIGHT FRONT FRONT FRONT...
  • Page 789 8W - 47 - 4 8W-47 AUDIO SYSTEM PL-RHD LEFT RIGHT REAR REAR SPEAKER SPEAKER ANTENNA BR/YL BR/LB DB/WT DB/OR C230 C230 BR/YL BR/LB DB/WT DB/OR RADIO ANTENNA LEFT LEFT RIGHT RIGHT INPUT REAR REAR REAR REAR G201 (8W-15-5) 978W-1 PLR04703...
  • Page 790 8W - 47 AUDIO SYSTEMS 8W - 47 - 5 8W-47 AUDIO SYSTEMS INDEX page page DESCRIPTION AND OPERATION RADIO MEMORY ......5 HELPFUL INFORMATION .
  • Page 792 8W - 48 - 2 8W - 48 REAR WINDOW DEFOGGER 8W-48 REAR WINDOW DEFOGGER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 793 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 3 DESCRIPTION AND OPERATION (Continued) 8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER PL-RHD BATT A0 (8W-10-4) BATT F33 (8W-11-4) POWER HEADLAMP DISTRIBUTION SWITCH CENTER 0 OFF FUSE (8W-10-4) 1 PARK 2 HEAD (8W-10-7)
  • Page 794 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 3 8W-48 REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER The Rear Window Defogger system is powered by a 40 amp fuse located in the Power Distribution Center (PDC) on circuit A4. This circuit is HOT at all times. The system is also powered by a 10 amp fuse located in cavity 8 of the fuse block, this fuse is HOT in the RUN position only.
  • Page 796 8W - 50 - 2 8W - 50 FRONT LIGHTING 8W-50 FRONT LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 797 8W - 50 - 2 8W-50 FRONT LIGHTING PL-RHD BATT A3 BATT A0 (8W-10-6) (8W-10-4) FUSE POWER BLOCK DISTRIBUTION (8W-11-2) CENTER FUSE FUSE (8W-10-4) (8W-11-4) (8W-10-6) RD/WT C102 PK/RD RD/WT S213 (8W-10-6) RD/WT HEADLAMP CIRCUIT SWITCH BREAKER 1 HEAD 2 PARK 0 OFF LG/WT S221...
  • Page 798 PL-RHD 8W-50 FRONT LIGHTING 8W - 50 - 3 HEADLAMP DIMMER HIGH BEAM BEAM OPTICAL FEED FEED HORN SWITCH (8W-50-2) VT/WT RD/OR FUSE S209 BLOCK (8W-11-2) FUSE FUSE RD/OR RD/OR (8W-11-12) (8W-11-12) C101 INSTRUMENT CLUSTER (8W-40-2) RD/OR (8W-40-4) L43 20VT C103 S114 VT/RD...
  • Page 799 8W - 50 - 4 8W-50 FRONT LIGHTING PL-RHD BATT F33 (8W-11-4) HEADLAMP SWITCH 1 OFF 2 PARK 3 HEAD (8W-50-2) HEADLAMP FUSE DIMMER BLOCK BEAM (8W-11-2) OPTICAL FUSE FEED HORN SWITCH (8W-11-11) (8W-50-2) VT/WT S210 FUSE (8W-11-11) BLOCK (8W-11-2) FUSE HEADLAMP (8W-11-12)
  • Page 800 PL-RHD 8W-50 FRONT LIGHTING 8W - 50 - 5 BATT A3 (8W-10-6) FUSE BLOCK (8W-11-2) FUSE (8W-11-4) PK/RD HEADLAMP SWITCH 1 HEAD 2 PARK 3 OFF (8W-50-2) L7 20BK/YL RADIO (8W-47-2) BK/YL L7 20BK/YL C230 L7 20BK/YL FRONT C105 LAMP BK/YL SWITCH (8W-50-6)
  • Page 801 8W - 50 - 6 8W-50 FRONT LIGHTING PL-RHD BATT A0 BATT F33 (8W-10-4) (8W-11-4) POWER HEADLAMP DISTRIBUTION SWITCH CENTER 1 OFF FUSE (8W-10-4) 2 PARK 3 HEAD (8W-50-2) (8W-10-11) L7 20BK/YL L7 20BK/YL C230 WT/OR FRONT C103 LAMP WT/OR SWITCH WT/OR REAR...
  • Page 802 8W - 50 FRONT LIGHTING 8W - 50 - 7 8W-50 FRONT LIGHTING INDEX page page GENERAL INFORMATION HEADLAMP LEVELING MOTORS ... . 8 INTRODUCTION ......7 HEADLAMPS .
  • Page 803 8W - 50 - 8 8W - 50 FRONT LIGHTING DESCRIPTION AND OPERATION (Continued) Circuit L2 connects to the multi- function switch and circuit L43 is protected by a 10 amp fuse located in feeds the L4 circuit (for low beam operation). The L4 the fuse block and is the feed for the left LOW beam circuit connects to a bus bar in the fuse block.
  • Page 804 8W - 51 - 2 8W - 51 REAR LIGHTING 8W-51 REAR LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 805 8W - 51 - 2 8W-51 REAR LIGHTING PL-RHD RUN A22 (8W-10-6) FUSE BLOCK (8W-11-2) FUSE (8W-11-8) S211 (8W-11-8) C103 PARK/ BACK-UP NEUTRAL LAMP POSITION SWITCH SWITCH VT/BK VT/BK BR/YL S106 (8W-21-2) BR/YL C105 POWERTRAIN PARK/ CONTROL NEUTRAL POSITION VT/BK MODULE SWITCH (8W-30-12)
  • Page 806 PL-RHD 8W-51 REAR LIGHTING 8W - 51 - 3 FROM C105 (8W-51-2) VT/BK S301 VT/BK C340 VT/BK VT/BK C341 LEFT BACK-UP LAMP VT/BK S315 RIGHT (8W-15-8) BACK-UP LAMP C340 S307 (8W-15-9) S308 C341 (8W-15-8) G302 G301 (8W-15-8) (8W-15-9) PLR05102 978W-1...
  • Page 807 8W - 51 - 4 8W-51 REAR LIGHTING PL-RHD BATT A0 BATT A3 (8W-10-4) (8W-10-6) POWER FUSE DISTRIBUTION BLOCK CENTER (8W-11-2) FUSE FUSE (8W-10-4) (8W-10-9) (8W-11-4) PK/DB PK/RD STOP LAMP SWITCH HEADLAMP (8W-30-12) SWITCH 1 OFF 2 PARK 3 HEAD (8W-50-2) WT/TN S101...
  • Page 808 PL-RHD 8W-51 REAR LIGHTING 8W - 51 - 5 FROM C230 (8W-51-4) BK/YL S306 FROM C205 (8W-51-4) BK/YL BK/YL WT/TN LEFT RIGHT S316 LICENSE LICENSE LAMP LAMP BK/YL WT/TN WT/TN WT/TN BK/YL C341 C340 CONNECTION BK/YL WT/TN WT/TN BK/YL RIGHT LEFT TAIL/ TAIL/...
  • Page 809 8W - 51 - 6 8W-51 REAR LIGHTING PL-RHD BATT A0 (8W-10-4) POWER FRONT DISTRIBUTION CENTER LAMP FUSE (8W-10-4) SWITCH (8W-50-6) (8W-10-11) L35 20 BR/RD C101 WT/OR WT/OR BR/RD BR/RD C103 LAMP RELAY (IN PDC) WT/OR LB/WT S115 LEFT HEADLAMP (8W-50-3) LB/WT LB/WT...
  • Page 810 PL-RHD 8W-51 REAR LIGHTING 8W - 51 - 7 REAR LAMP SWITCH (8W-51-6) BR/WT C230 BR/WT S317 BR/WT BR/WT C340 C341 BR/WT BR/WT LEFT RIGHT REAR REAR LAMP LAMP S315 (8W-15-8) S307 (8W-15-9) C340 C341 S308 (8W-15-8) G302 G301 (8W-15-8) (8W-15-9) PLR05106 978W-1...
  • Page 811 8W - 51 - 8 8W-51 REAR LIGHTING PL-RHD BATT A0 BATT A3 (8W-10-4) (8W-10-6) POWER FUSE BLOCK DISTRIBUTION CENTER (8W-11-2) FUSE FUSE (8W-10-4) (8W-10-6) (8W-11-4) RD/WT PK/RD C102 HEADLAMP SWITCH (8W-50-2) RD/WT S213 (8W-10-6) RD/WT FUSE HEADLAMP BLOCK FUSE SWITCH (8W-11-2) (8W-50-2)
  • Page 812 8W - 51 REAR LIGHTING 8W - 51 - 9 8W-51 REAR LIGHTING INDEX page page DESCRIPTION AND OPERATION STOP LAMPS ......10 BACK-UP LAMPS .
  • Page 813 8W - 51 - 10 8W - 51 REAR LIGHTING DESCRIPTION AND OPERATION (Continued) STOP LAMPS to circuit A22. Circuit A22 feeds a bus bar in the fuse block. A 40 amp fuse in the PDC protects the A2 and Circuit F32 in the Power Distribution Center A22 circuits.
  • Page 814 8W - 52 - 2 8W - 52 TURN SIGNALS 8W-52 TURN SIGNALS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 815 8W - 52 - 2 8W-52 TURN SIGNALS PL-RHD BATT A0 RUN A22 (8W-10-4) (8W-10-6) POWER FUSE DISTRIBUTION BLOCK CENTER (8W-11-2) FUSE (8W-10-4) FUSE (8W-10-9) (8W-11-8) BK/WT C103 BK/WT TURN SIGNAL/ HAZARD SWITCH 1 LEFT 2 RIGHT BK/YL COMBINATION INPUT OUTPUT FLASHER (IN FB)
  • Page 816 PL-RHD 8W-52 TURN SIGNALS 8W - 52 - 3 TURN SIGNAL/ HAZARD SWITCH 1 LEFT 2 RIGHT S212 S207 (8W-40-4) (8W-50-3) C101 C103 S112 S116 LEFT LEFT RIGHT RIGHT REPEATER PARK/ PARK/ REPEATER LAMP TURN TURN LAMP SIGNAL SIGNAL LAMP LAMP BK/YL BK/YL...
  • Page 817 8W - 52 - 4 8W-52 TURN SIGNALS PL-RHD TURN SIGNAL/ HAZARD SWITCH 1 LEFT 2 RIGHT DG/RD BR/RD C230 C230 DG/RD BR/RD C340 C341 DG/RD BR/RD LEFT RIGHT TURN TURN SIGNAL SIGNAL LAMP LAMP S315 S307 (8W-15-8) (8W-15-9) C340 C341 S308 (8W-15-8)
  • Page 818 8W - 52 TURN SIGNALS 8W - 52 - 5 8W-52 TURN SIGNALS INDEX page page DESCRIPTION AND OPERATION TURN SIGNALS ......5 HAZARD FLASHERS .
  • Page 819 8W - 52 - 6 8W - 52 TURN SIGNALS DESCRIPTION AND OPERATION (Continued) • For the right front turn signal/hazard flasher Circuit L60 supplies voltage to the right front turn signal/hazard lamp. The L60 circuit splices to the lamp the Z1 circuit grounding point is in the right instrument cluster to power the right indicator lamp.
  • Page 820 8W - 53 - 2 8W - 53 WIPERS 8W-53 WIPERS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 821 8W - 53 - 2 8W-53 WIPERS PL-RHD STANDARD RUN-ACC A31 (8W-10-12) FUSE BLOCK (8W-11-2) FUSE (8W-11-12) S206 (8W-11-12) WIPE/ WASH SWITCH 0 OFF 1 LOW 2 HIGH 3 WASH DG/YL RD/YL BR/WT C101 WIPER WINDSHIELD MOTOR WASHER 1 UP PUMP 2 LOW MOTOR...
  • Page 822 PL-RHD 8W-53 WIPERS 8W - 53 - 3 INTERMITTENT RUN-ACC A31 (8W-10-12) FUSE BLOCK (8W-11-2) FUSE (8W-11-12) S206 (8W-11-12) INTERMITTENT WIPE/ WASH I/WIPE LOGIC AND SWITCH RELAY CONTROL 0 OFF 1 DELAY 2 LOW 3 HIGH 4 MIN 5 MAX 6 WASH C101 BK/LG...
  • Page 823 8W - 53 - 4 8W - 53 WIPERS 8W-53 WIPERS INDEX page page DESCRIPTION AND OPERATION WIPERS—INTERMITTENT ....4 HELPFUL INFORMATION ....4 As the windshield wiper motor turns, the park DESCRIPTION AND OPERATION switch internal to the motor moves from its grounded...
  • Page 824 8W - 60 - 2 8W - 60 POWER WINDOWS 8W-60 POWER WINDOWS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 825 8W - 60 POWER WINDOWS 8W - 60 - 3 DESCRIPTION AND OPERATION (Continued) 8W - 60 - 2 8W-60 POWER WINDOWS PL-RHD RUN A22 (8W-10-6) FUSE BLOCK CIRCUIT (8W-11-2) BREAKER (8W-11-10) C205 S138 (8W-11-10) MASTER POWER WINDOW SWITCH 1 DOWN 2 UP BR/WT VT/WT...
  • Page 826 8W - 60 POWER WINDOWS 8W - 60 - 3 8W-60 POWER WINDOWS INDEX page page DESCRIPTION AND OPERATION POWER WINDOWS ..... . 3 HELPFUL INFORMATION .
  • Page 828 8W - 61 - 2 8W - 61 POWER DOOR LOCKS 8W-61 POWER DOOR LOCKS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 829 8W - 61 - 2 8W-61 POWER DOOR LOCKS PL-RHD BATT A3 (8W-10-6) FUSE BLOCK (8W-11-2) FUSE (8W-11-6) RD/YL S214 (8W-11-6) RD/YL C231 RD/YL RD/YL LEFT DOOR LOCK SWITCH 1 UNLOCK 2 LOCK C205 PK/BK OR/BK RD/YL C231 C231 (8W-61-3) (8W-61-3) RIGHT DOOR...
  • Page 830 PL-RHD 8W-61 POWER DOOR LOCKS 8W - 61 - 3 RIGHT LEFT FRONT FRONT DOOR DOOR LOCK LOCK MOTOR MOTOR FROM FROM LEFT LEFT DOOR DOOR OR/BK PK/BK LOCK OR/BK PK/BK LOCK SWITCH SWITCH (8W-61-2) (8W-61-2) C323 C315 OR/BK PK/BK OR/BK OR/BK PK/BK...
  • Page 831 8W - 61 - 4 8W-61 POWER DOOR LOCKS PL-RHD LEFT DOOR LOCK SWITCH 1 UNLOCK 2 LOCK PK/VT OR/VT C231 C231 PK/VT OR/VT C241 C241 PK/VT OR/VT C241 C241 PK/VT OR/VT C205 C205 PK/VT OR/VT RIGHT DOOR LOCK SWITCH 1 UNLOCK 2 LOCK BK/VT...
  • Page 832 8W - 61 POWER DOOR LOCKS 8W - 61 - 5 8W-61 POWER DOOR LOCKS INDEX page page DESCRIPTION AND OPERATION POWER DOOR LOCKS ....5 HELPFUL INFORMATION .
  • Page 834 8W - 62 - 2 8W - 62 POWER MIRRORS 8W-62 POWER MIRRORS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 835 8W - 62 - 2 8W-62 POWER MIRRORS PL-RHD RUN F21 (8W-11-10) POWER MIRROR FUSE CIRCUIT BREAKER HOLDER (8W-62-4) F121 TN/BK POWER MIRROR SWITCH 1 EXTEND 2 RETRACT 3 LEFT 4 RIGHT 5 UP 6 DOWN BK/VT DB/WT YL/BK WT/YL WT/BK P110 C205...
  • Page 836 PL-RHD 8W-62 POWER MIRRORS 8W - 62 - 3 POWER FOLDING MIRROR RELAY (8W-62-4) LG/BK C205 LG/BK LG/BK C231 LG/BK LEFT RIGHT POWER POWER MIRROR MIRROR 1 DOWN 1 DOWN 2 UP 2 UP 3 RIGHT 3 RIGHT 4 LEFT 4 LEFT 5 EXTEND 5 EXTEND...
  • Page 837 8W - 62 - 4 8W-62 POWER MIRRORS PL-RHD RUN F21 (8W-11-10) LEFT RIGHT POWER POWER POWER MIRROR CIRCUIT FUSE MIRROR MIRROR BREAKER HOLDER (8W-62-3) (8W-62-3) LG/BK LG/BK C231 F121 F121 LG/BK TN/BK TN/BK C205 POWER MIRROR SWITCH (8W-62-2) P110 LG/BK POWER FOLDING...
  • Page 838 8W - 62 POWER MIRRORS 8W - 62 - 5 8W-62 POWER MIRRORS INDEX page page DESCRIPTION AND OPERATION POWER FOLDING MIRRORS ....5 HELPFUL INFORMATION ....5 POWER MIRRORS .
  • Page 840 8W - 64 - 2 8W - 64 POWER SUNROOF 8W-64 POWER SUNROOF INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 841 8W - 64 POWER SUNROOF 8W - 64 - 3 DESCRIPTION AND OPERATION (Continued) 8W - 64 - 2 8W-64 POWER SUNROOF PL-RHD RUN-ACC A31 (8W-10-12) FUSE BLOCK (8W-11-2) FUSE (8W-11-12) YL/RD C225 YL/RD S313 YL/RD YL/RD SUNROOF SUNROOF SLIDE VENT SWITCH SWITCH...
  • Page 842 8W - 64 POWER SUNROOF 8W - 64 - 3 8W-64 POWER SUNROOF DESCRIPTION AND OPERATION POWER SUNROOF Power for the tilt and slide switches is supplied on circuit F10. This circuit is HOT in the ACCESSORY and RUN position only, and protected by a 20 amp fuse located in the fuse block, cavity 14.
  • Page 844 8W - 70 - 2 8W - 70 SPLICE INFORMATION 8W-70 SPLICE INFORMATION INDEX page SCHEMATICS AND DIAGRAMS ............1 Component Page Component...
  • Page 845 8W - 70 - 2 8W-70 SPLICE INFORMATION PL-RHD DOWNSTREAM UPSTREAM VEHICLE CRANKSHAFT HEATED HEATED SPEED POSITION OXYGEN OXYGEN SENSOR SENSOR SENSOR SENSOR (8W-30-8) (8W-30-7) (8W-30-3) (8W-30-3) BK/LB BK/LB BK/LB BK/LB S118 BK/LB S120 BK/LB BK/LB BK/LB BK/LB C161 CAMSHAFT KNOCK THROTTLE POSITION...
  • Page 846 PL-RHD 8W-70 SPLICE INFORMATION 8W - 70 - 3 PARK INSTRUMENT BRAKE IGNITION BRAKE CLUSTER WARNING SWITCH SWITCH (8W-40-5) LAMP (8W-10-5) (8W-40-5) SWITCH (8W-40-5) GY/BK GY/BK GY/BK GY/BK C103 GY/BK S208 PLR07002 978W-1...
  • Page 848 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS 8W-80 CONNECTOR PIN-OUTS INDEX page SCHEMATICS AND DIAGRAMS ............1 Component Page Component...
  • Page 849 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3 DESCRIPTION AND OPERATION (Continued) Component Page Component Page Left Power Mirror ....8W-80-23 Park/Neutral Position Switch (ATX) .
  • Page 850 8W - 80 - 4 8W - 80 CONNECTOR PIN-OUTS DESCRIPTION AND OPERATION (Continued) Component Page Component Page Right Instrument Panel Speaker Sunroof Slide Switch ....8W-80-34 (Premium) .
  • Page 851 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS PL-RHD BLACK CIRCUIT FUNCTION C3 18DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 20BK GROUND A/C COMPRESSOR CLUTCH BLACK CIRCUIT FUNCTION C21 22DB/OR A/C CYCLING SWITCH OUTPUT F20 22WT FUSED IGNITION SWITCH OUTPUT (RUN) C2 22DB/YL MODE SWITCH OUTPUT A/C CYCLING...
  • Page 852 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 BLACK CIRCUIT FUNCTION C22 20DB/WT LOW PRESSURE SWITCH OUTPUT C21 20DB/OR A/C CYCLING SWITCH OUTPUT A/C LOW PRESSURE SWITCH BLACK CIRCUIT FUNCTION B142 20BR/YL LEFT FRONT DUMP SOLENOID CONTROL B143 20DG/YL RIGHT FRONT DUMP SOLENOID CONTROL B146 20BR/LB LEFT REAR DUMP SOLENOID CONTROL...
  • Page 853 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS PL-RHD BLACK CIRCUIT FUNCTION E2 22OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL Z3 20BK/OR GROUND RECEIVER LAMP GRAY CIRCUIT FUNCTION L1 20VT/BK REVERSE LAMP SENSE F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) BACK-UP LAMP SWITCH (MTX) BLACK...
  • Page 854 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 CIRCUIT CIRCUIT A41 14YL A41 14YL/BK C21 22DB/OR C21 20DB/OR L61 22LG L61 22LG BROWN BROWN V10 18BR V10 18BR X3 20BK/RD X3 18BK/RD F12 20DG/WT F12 20DG/WT R46 18BR/LB R46 18BR/LB R48 18TN R48 18TN L35 20BR/RD...
  • Page 855 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS PL-RHD CIRCUIT CIRCUIT BLACK L1 20VT/BK L1 18VT/BK BLACK L50 22WT/TN L50 20WT/TN L50 20WT/TN M1 20PK M1 22PK – – L7 20BK/YL C105 C105 L7 20BK/YL A141 16DG/WT A141 18DG/WT G4 20DB G4 20DB –...
  • Page 856 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 GRAY GRAY CIRCUIT CIRCUIT E2 22OR E2 22OR Z3 20BK/OR Z3 20BK/OR C203 C203 CIRCUIT CIRCUIT F35 18RD/YL F35 16RD/YL F35 18RD/YL P36 16PK/VT P36 18PK/VT P35 16OR/VT P35 18OR/VT Z8 14BK/VT Z8 14BK/VT P33 16OR/BK P33 18OR/BK...
  • Page 857 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS PL-RHD CIRCUIT CIRCUIT – – L7 20BK/YL L7 20BK/YL L7 20BK/YL L7 20BK/YL L62 20BR/RD L62 18BR/RD L63 20DG/RD L63 18DG/RD X51 22BR/YL X51 22BR/YL G4 18DB GRAY GRAY G4 20DB G4 20DB X52 22DB/WT X52 22DB/WT L38 18BR/WT...
  • Page 858 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 GRAY GRAY CIRCUIT CIRCUIT P33 16OR/BK P33 18OR/BK P34 16PK/BK P34 18PK/BK C301 C301 GRAY GRAY CIRCUIT CIRCUIT P33 16OR/BK P33 18OR/BK P34 16PK/BK P34 18PK/BK C303 C303 BLACK BLACK CIRCUIT CIRCUIT L50 20WT/TN –...
  • Page 859 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS PL-RHD BLACK BLACK CIRCUIT CIRCUIT P34 18PK/BK P34 18PK/BK P33 18OR/BK P33 18OR/BK C325 C325 CIRCUIT CIRCUIT BLACK L1 18VT/BK BLACK L1 18VT/BK L7 18BK/YL L7 18BK/YL Z1 18BK Z1 18BK L38 18BR/WT L38 18BR/WT L50 18WT/TN L5018WT/TN...
  • Page 860 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 CIRCUIT FUNCTION B1 20YL/DB RIGHT REAR WHEEL SPEED SENSOR (–) B2 20YL RIGHT REAR WHEEL SPEED SENSOR (+) B3 20LG/DB LEFT REAR WHEEL SPEED SENSOR (–) B4 20LG LEFT REAR WHEEL SPEED SENSOR (+) Z12 18BK/OR GROUND B6 20WT/DB...
  • Page 861 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS PL-RHD (CONTINUED) CIRCUIT FUNCTION D21 20PK SCI TRANSMIT – – – – – – – – – – B57 20BR/BK ABS SYSTEM RELAY CONTROL – – – – F12 20DG/WT ABS MODULE FEED BLACK CIRCUIT FUNCTION...
  • Page 862 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 BLACK CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUTDOWN RELAY OUTPUT Z1 18BK GROUND K4 20BK/LB SENSOR GROUND DOWNSTREAM HEATED K141 20TN/WT DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL OXYGEN SENSOR YELLOW CIRCUIT FUNCTION R45 18DG/LB DRIVER AIRBAG SQUIB LINE 2 R43 18BK/LB DRIVER AIRBAG SQUIB LINE 1...
  • Page 863 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS PL-RHD GREEN CIRCUIT FUNCTION G6 18GY OIL PRESSURE SWITCH SENSOR – – ENGINE OIL PRESSURE SWITCH CIRCUIT FUNCTION BLACK L7 20BK/YL HEADLAMP SWITCH FEED TO FRONT FOG LAMP SWITCH L35 20BR/RD FRONT FOG LAMP SWITCH TO RELAY L35 20BR/RD FRONT FOG LAMP SWITCH TO REAR FOG LAMP SWITCH 1 2 3...
  • Page 864 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 LT GRAY CIRCUIT FUNCTION Z1 18BK GROUND Z2 18BK GROUND G4 18DB FUEL LEVEL SENSOR SIGNAL A141 18DG/WT FUEL PUMP RELAY OUTPUT FUEL PUMP MODULE BLACK CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUTDOWN RELAY OUTPUT K20 18DG GENERATOR FIELD DRIVER GENERATOR...
  • Page 865 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS PL-RHD BLACK CIRCUIT FUNCTION X2 18DG/RD HORN RELAY OUTPUT Z1 20BK GROUND HORN NO. 1 BLACK CIRCUIT FUNCTION X2 18DG/RD HORN RELAY OUTPUT Z1 20BK GROUND HORN NO.2 BLACK CIRCUIT FUNCTION K4 18BK/LB SENSOR GROUND K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL...
  • Page 866 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 BLACK CIRCUIT FUNCTION Z1 22BK GROUND G9 22GY/BK RED BRAKE WARNING LAMP DRIVER A2 12PK/BK FUSED B(+) A22 12BK/OR IGNITION SWITCH OUTPUT (RUN) – – IGNITION SWITCH – – A1 14RD FUSED (B+) A31 14BK/WT IGNITION SWITCH OUTPUT (ACC/RUN)
  • Page 867 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS PL-RHD GRAY CIRCUIT FUNCTION Z2 22BK/LG GROUND V5 18DG/YL WIPER RELAY COMMON V10 18BR WINDSHIELD WASHER RELAY OUTPUT V3 18BR/WT WIPER SWITCH LOW SPEED OUTPUT INTERMITTENT F13 18DB FUSED IGNITION SWITCH OUTPUT (RUN/ACC) WIPE/WASH SWITCH V4 18RD/YL...
  • Page 868 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 WHITE CIRCUIT FUNCTION Z8 18BK/VT GROUND P36 18PK/VT DOOR UNLOCK SWITCH OUTPUT F35 18RD/YL FUSED B(+) P35 18OR/VT LEFT DOOR LOCK SWITCH OUTPUT P36 18PK/VT LEFT DOOR UNLOCK SWITCH OUTPUT LEFT DOOR LOCK SWITCH BLACK CIRCUIT...
  • Page 869 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS PL-RHD BLACK CIRCUIT FUNCTION B8 20RD/DB LEFT FRONT WHEEL SPEED SENSOR (+) B9 20RD LEFT FRONT WHEEL SPEED SENSOR (-) LEFT FRONT WHEEL SPEED SENSOR BLACK CIRCUIT FUNCTION L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT L43 18VT FUSED LEFT LOW BEAM OUTPUT Z1 18BK...
  • Page 870 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 GRAY CIRCUIT FUNCTION P90 18LG/BK LEFT/RIGHT POWER MIRROR VERTICAL SUPPLY – – P93 18YL/BK LEFT POWER MIRROR (VERTICAL) P95 18DB/WT LEFT POWER MIRROR (HORIZONTAL) P99 18GY LEFT POWER MIRROR SUPPLY LEFT POWER MIRROR P91 18WT/BK LEFT/RIGHT POWER MIRROR HORIZONTAL SUPPLY...
  • Page 871 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS PL-RHD NATURAL CIRCUIT FUNCTION L61 18LG LEFT TURN SIGNAL Z1 18BK GROUND LEFT REPEATER LAMP BLACK CIRCUIT FUNCTION L50 18WT/TN TAIL/STOP L7 18BK/YL TAIL/STOP Z1 18BK GROUND LEFT TAIL/STOP LAMP GRAY CIRCUIT FUNCTION L63 18DG/RD LEFT TURN SIGNAL LAMP FEED...
  • Page 872 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 BLACK CIRCUIT FUNCTION L1 20VT/BK REVERSE LAMP SENSE T41 20BR/YL PARK/NEUTRAL POSITION SWITCH SENSE F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN/START) PARK/NEUTRAL POSITION SWITCH (ATX) YELLOW CIRCUIT FUNCTION R51 18VT/YL PASSENGER AIRBAG PRESSURE SWITCH GROUND R50 18BR/YL PASSENGER AIRBAG PRESSURE SWITCH SENSE R44 18DG/YL...
  • Page 873 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS PL-RHD WHITE CIRCUIT FUNCTION P99 18GY LEFT/RIGHT POWER FOLDING MIRROR (B+) EXT (B-) RET – – POWER MIRROR SWITCH-C2 BLACK CIRCUIT FUNCTION K10 20WT POWER STEERING PRESSURE SWITCH SENSE Z12 22BK/TN GROUND POWER STEERING PRESSURE SWITCH CIRCUIT...
  • Page 874 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 (CONTINUED) CIRCUIT FUNCTION K6 20VT/WT 5 VOLT SUPPLY K29 20WT/PK STOP LAMP SWITCH SENSE – – C28 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL D21 20PK SCI TRANSMIT G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL K52 20PK/BK...
  • Page 875 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS PL-RHD (CONTINUED) CIRCUIT FUNCTION – – K2 20TN/DB ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL – – – – – – K41 20BK/DG UPSTREAM HEATED OXYGEN SENSOR SIGNAL –...
  • Page 876 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 CIRCUIT FUNCTION – – GRAY X55 22BR/RD LEFT FRONT SPEAKER (–) X56 22DB/RD RIGHT FRONT SPEAKER (–) L7 20BK/YL PARK LAMP SWITCH OUTPUT E2 22OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL RADIO - C2 X12 20RD/WT FUSED IGNITION SWITCH OUTPUT (ACC/RUN)
  • Page 877 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS PL-RHD WHITE CIRCUIT FUNCTION P35 18OR/VT RIGHT DOOR LOCK SWITCH OUTPUT Z8 18BK/VT GROUND F35 18RD/YL FUSED B(+) Z8 18BK/VT GROUND P36 18PK/VT DOOR UNLOCK SWITCH OUTPUT RIGHT DOOR LOCK SWITCH BLACK CIRCUIT FUNCTION Q21 14VT...
  • Page 878 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 BLACK CIRCUIT FUNCTION B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR (+) B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (–) RIGHT FRONT WHEEL SPEED SENSOR BLACK CIRCUIT FUNCTION L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT L44 18VT/BK FUSED RIGHT LOW BEAM OUTPUT Z1 18BK...
  • Page 879 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS PL-RHD GRAY CIRCUIT FUNCTION P90 18LG/BK LEFT/RIGHT POWER MIRROR VERTICAL SUPPLY – P92 18YL LEFT POWER MIRROR (VERTICAL) P94 18WT/YL LEFT POWER MIRROR (HORIZONTAL) P99 18GY – RIGHT P91 18WT/BK LEFT/RIGHT POWER MIRROR HORIZONTAL SUPPLY POWER MIRROR BLACK CIRCUIT...
  • Page 880 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 NATURAL CIRCUIT FUNCTION L60 18TN RIGHT TURN SIGNAL Z1 18BK GROUND RIGHT REPEATER LAMP BLACK CIRCUIT FUNCTION L50 18WT/TN TAIL/STOP L7 18BK/YL TAIL/STOP Z1 18BK GROUND RIGHT TAIL/STOP LAMP GRAY CIRCUIT FUNCTION L63 18DG/RD RIGHT TURN SIGNAL LAMP FEED...
  • Page 881 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS PL-RHD WHITE CIRCUIT FUNCTION Q42 18LB POWER SUNROOF CLOSE Q46 18OR POWER SUNROOF VENT OPEN/CLOSE LIMIT F10 18YL/RD FUSED IGNITION SWITCH OUTPUT (RUN/ACC) Q45 18PK/BK POWER SUNROOF VENT CLOSE Q41 18WT POWER SUNROOF OPEN SUNROOF SLIDE SWITCH WHITE...
  • Page 882 PL-RHD 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 BLACK CIRCUIT FUNCTION L60 22TN RIGHT TURN SIGNAL – – L62 20BR/RD RIGHT REAR STOP/TURN SIGNAL LAMP OUTPUT L32 20PK COMBINATION FLASHER OUTPUT L5 20BK FUSED IGNITION SWITCH OUTPUT (RUN) L9 22BK/WT FUSED B(+) –...
  • Page 883 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS PL-RHD BLACK CIRCUIT FUNCTION V10 18BR WASHER PUMP CONTROL SWITCH OUTPUT Z1 18BK GROUND WINDSHIELD WASHER PUMP MOTOR BLACK CIRCUIT FUNCTION V4 18RD/YL WIPER SWITCH HIGH SPEED OUTPUT V3 18BR/WT WIPER SWITCH LOW SPEED OUTPUT V5 18DG/YL WIPER RELAY COMMON F13 18DB...
  • Page 884 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION number identification. Refer to the index for the proper figure number. INTRODUCTION CONNECTOR/GROUND LOCATIONS This section provides illustrations identifying the For items not shown in this section a N/S is placed general location of components, grounds, and connec- in the Fig.
  • Page 885 8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Engine Oil Pressure Rear of Engine Left Airbag Impact Left Side of Switch Sensor Radiator Closure Panel EGR Transducer Left Rear of...
  • Page 886 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Power Folding Near Power Right License Lamp At Lamp Mirror Relay Mirror Right Park/Turn At Lamp Power Mirror Fuse Near Power Signal Lamp...
  • Page 887 8W - 90 - 4 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 1 Airbag Impact Sensors Fig. 2 Brake Support Bracket Connections...
  • Page 888 8W - 90 - 4 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 889 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5 DESCRIPTION AND OPERATION (Continued)
  • Page 890 8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 891 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7 DESCRIPTION AND OPERATION (Continued)
  • Page 892 8W - 90 - 8 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 893 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 9 DESCRIPTION AND OPERATION (Continued)
  • Page 894 8W - 90 - 10 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 895 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11 DESCRIPTION AND OPERATION (Continued) Fig. 11 Console Connections Fig. 12 Door Connections (Front)
  • Page 896 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11 DESCRIPTION AND OPERATION (Continued) Fig. 9 Visor/Vanity Connections Fig. 10 Steering Column Connections...
  • Page 897 8W - 90 - 12 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 898 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 13 DESCRIPTION AND OPERATION (Continued) Fig. 15 Door Connections (Rear) Fig. 16 Body Connections (Left Side)
  • Page 899 8W - 90 - 14 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 900 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15 DESCRIPTION AND OPERATION (Continued) Fig. 19 Fuel Tank Connections Fig. 20 Rear Lighting Connections...
  • Page 901 8W - 90 - 14 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 902 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15 DESCRIPTION AND OPERATION (Continued)
  • Page 903 8W - 90 - 16 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 17 Trunk Connections Fig. 18 Decklid/Rear Bumper Connections...
  • Page 904 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 17 DESCRIPTION AND OPERATION (Continued)
  • Page 906 8W - 95 SPLICE LOCATIONS 8W - 95 - 1 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS DESCRIPTION AND OPERATION The following index covers all splices shown in the INTRODUCTION wiring diagrams. If a splice is not shown in this sec- This section provides illustrations identifying the tion, a N/S will be in the Fig.
  • Page 907 8W - 95 - 2 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 908 8W - 95 SPLICE LOCATIONS 8W - 95 - 3 DESCRIPTION AND OPERATION (Continued)
  • Page 909 8W - 95 - 4 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 910 8W - 95 SPLICE LOCATIONS 8W - 95 - 5 DESCRIPTION AND OPERATION (Continued)
  • Page 911 8W - 95 - 6 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 912 8W - 95 SPLICE LOCATIONS 8W - 95 - 7 DESCRIPTION AND OPERATION (Continued)
  • Page 913 8W - 95 - 8 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 914 8W - 95 SPLICE LOCATIONS 8W - 95 - 9 DESCRIPTION AND OPERATION (Continued) Fig. 8 Door Splices...
  • Page 916 WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page 8W-01 GENERAL INFORMATION ..8W-01-1 8W-48 REAR WINDOW DEFOGGER ..8W-48-1 8W-02 COMPONENT INDEX ... 8W-02-1 8W-50 FRONT LIGHTING .
  • Page 918 8W - 01 GENERAL INFORMATION 8W - 01 - 1 8W-01 GENERAL INFORMATION INDEX page page DESCRIPTION AND OPERATION INTERMITTENT AND POOR CONNECTIONS . . . 6 CIRCUIT IDENTIFICATION ....3 TROUBLESHOOTING TESTS .
  • Page 919 8W - 01 - 2 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) NOTES, CAUTIONS, and WARNINGS WARNING: ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTH- Throughout this group additional important infor- ING. mation is presented in three ways; Notes, Cautions, and Warnings.
  • Page 920 8W - 01 GENERAL INFORMATION 8W - 01 - 3 DESCRIPTION AND OPERATION (Continued) CIRCUIT IDENTIFICATION All circuits in the diagrams use an alpha/numeric code to identify the wire and its function (Fig. 3). To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart.
  • Page 921 8W - 01 - 4 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Fig. 5 Symbol Identification...
  • Page 922 8W - 01 GENERAL INFORMATION 8W - 01 - 5 DESCRIPTION AND OPERATION (Continued) ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When han- dling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inad- vertent discharge into the component.
  • Page 923 8W - 01 - 6 8W - 01 GENERAL INFORMATION DIAGNOSIS AND TESTING (Continued) • Voltmeter - Used to check for voltage on a cir- • Wire insulation that has rubbed through causing cuit. Always connect the black lead to a known good a short to ground •...
  • Page 924 8W - 01 GENERAL INFORMATION 8W - 01 - 7 DIAGNOSIS AND TESTING (Continued) (3) Connect the other lead to the other end of the (4) The voltmeter will show the difference in volt- circuit being tested. Low or no resistance means good age between the two points.
  • Page 925 8W - 01 - 8 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (2) Remove 1 inch of insulation from each end of ment this indicates a problem in the charging/start- the wire. ing system that needs to be corrected. (3) Place a piece of heat shrink tubing over one Replacement of the fusible link is the same as side of the wire.
  • Page 926 8W - 01 GENERAL INFORMATION 8W - 01 - 9 SERVICE PROCEDURES (Continued) CONNECTOR REPLACEMENT (1) Disconnect battery. (2) Disconnect the connector that is to be repaired from its mating half/component (3) Remove connector locking wedge, required (Fig. 16) Fig. 17 Terminal Removal Fig.
  • Page 927 8W - 01 - 10 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (8) Place a piece of heat shrink tubing over one side of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area. (9) Spread the strands of the wire apart on each part of the exposed wires.
  • Page 928 8W - 01 GENERAL INFORMATION 8W - 01 - 11 SERVICE PROCEDURES (Continued) DIODE REPLACEMENT SPECIAL TOOLS (1) Disconnect the battery. WIRING/TERMINAL (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.
  • Page 930 8W - 02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX INDEX page SCHEMATICS AND DIAGRAMS ............1 GENERAL INFORMATION .
  • Page 931 8W - 02 - 2 8W - 02 COMPONENT INDEX Component Page Component Page Intermittent Wipe/Wash Switch ... 8W-53 Repeater Lamps ....8W-50, 52 Key-In Switch .
  • Page 932 8W - 02 COMPONENT INDEX 8W - 02 - 3 8W-02 COMPONENT INDEX GENERAL INFORMATION INTRODUCTION This section provides an alphabetical listing of all the components covered in group 8W. For information on system operation, refer to the appropriate section of the wiring diagrams.
  • Page 934 8W - 10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 946 8W - 10 POWER DISTRIBUTION 8W - 10 - 13 8W-10 POWER DISTRIBUTION DESCRIPTION AND OPERATION This section covers the power distribution center and all circuits involved with it. For additional infor- mation on system operation, refer to the appropriate wiring diagrams.
  • Page 948 8W - 11 FUSE/FUSE BLOCK 8W - 11 - 1 8W-11 FUSE/FUSE BLOCK INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 962 8W - 11 FUSE/FUSE BLOCK 8W - 11 - 15 8W-11 FUSE/FUSE BLOCK DESCRIPTION AND OPERATION This section covers the fuse block and all circuits involved with it. For additional information on sys- tem operation, please refer to the appropriate section of the wiring diagrams.
  • Page 964 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION INDEX page SCHEMATICS AND DIAGRAMS ............1 GENERAL INFORMATION .
  • Page 973 8W - 15 - 10 8W - 15 GROUND DISTRIBUTION 8W-15 GROUND DISTRIBUTION GENERAL INFORMATION This section identifies the grounds, splices that connect to those grounds, and the components that connect those grounds. For additional information on system operation, refer to the appropriate section of the wiring diagrams.
  • Page 974 8W - 20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 976 8W - 20 CHARGING SYSTEM 8W - 20 - 3 8W-20 CHARGING SYSTEM DESCRIPTION AND OPERATION When there is current present in the field, and the rotor is turning, the stator in the generator produces CHARGING SYSTEM a B+ voltage that is supplied to the battery through the A11 and A0 circuits.
  • Page 978 8W - 21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 980 8W - 21 STARTING SYSTEM 8W - 21 - 3 8W-21 STARTING SYSTEM STARTING SYSTEM (AUTOMATIC TRANSMISSION) DESCRIPTION AND OPERATION The Power Distribution Center (PDC) supplies bat- STARTING SYSTEM- MANUAL TRANSMISSION tery voltage to the engine starter motor solenoid The Power Distribution Center (PDC) supplies bat- through circuit T40 when the coil side of the engine tery voltage to the engine starter motor solenoid starter motor relay energizes.
  • Page 982 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEMS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 995 8W - 30 - 14 8W - 30 FUEL/IGNITION SYSTEMS 8W-30 FUEL/IGNITION SYSTEMS INDEX page page DESCRIPTION AND OPERATION IGNITION SWITCH ..... . 14 AUTOMATIC SHUT DOWN RELAY .
  • Page 996 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 15 DESCRIPTION AND OPERATION (Continued) HELPFUL INFORMATION HELPFUL INFORMATION • Refer to group 14 Fuel System, for additional Circuit Z12 which supplies ground for the PCM high current drivers, has the same termination point information.
  • Page 997 8W - 30 - 16 8W - 30 FUEL/IGNITION SYSTEMS DESCRIPTION AND OPERATION (Continued) • Crankshaft position sensor Circuit K4 connects to cavity 43 of the PCM connec- • Camshaft position sensor tor. • Battery temperature sensor • Throttle position sensor HELPFUL INFORMATION •...
  • Page 998 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 17 DESCRIPTION AND OPERATION (Continued) is a variable resistor. As coolant temperature MANIFOLD ABSOLUTE PRESSURE SENSOR changes, the resistance in the sensor changes causing From the Powertrain Control Module (PCM), cir- a change in current draw.
  • Page 999 8W - 30 - 18 8W - 30 FUEL/IGNITION SYSTEMS DESCRIPTION AND OPERATION (Continued) KNOCK SENSOR the ASD relay on circuit K51. Circuit K51 connects to cavity 67 of the PCM connector. The knock sensor provides an input to the Power- Circuit A142 supplies voltage for the fuel injectors.
  • Page 1000 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 19 DESCRIPTION AND OPERATION (Continued) • Circuit K39 connects to cavity 57 of the PCM In the START or RUN position, the ignition switch connector. connects circuit A1 from the fuse block and circuit •...
  • Page 1001 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 19 DESCRIPTION AND OPERATION (Continued) EGR TRANSDUCER (EET) SOLENOID This circuit connects to cavity 23 of the PCM connec- tor. Circuit F12 supplies battery voltage to the EET The G4 circuit is also used for the fuel gauge solenoid.
  • Page 1003 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1 8W-35 ANTI-LOCK BRAKES INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1008 8W - 35 - 6 8W - 35 ANTI-LOCK BRAKES 8W-35 ANTI-LOCK BRAKES INDEX page page DESCRIPTION AND OPERATION BRAKE SWITCH INPUT ....7 ABS PUMP MOTOR RELAY .
  • Page 1009 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 7 DESCRIPTION AND OPERATION (Continued) WHEEL SPEED SENSORS DATA LINK CONNECTOR There are four wheel speed sensors, one at each Circuit D21 is used for diagnostics of a fault with wheel. The sensors use a tone wheel to determine the ABS system.
  • Page 1011 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1017 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 7 8W-40 INSTRUMENT CLUSTER INDEX page page DESCRIPTION AND OPERATION INSTRUMENT CLUSTER ....7 AIRBAG WARNING LAMP .
  • Page 1018 8W - 40 - 8 8W - 40 INSTRUMENT CLUSTER DESCRIPTION AND OPERATION (Continued) FUEL GAUGE level sending unit (circuit G4) it illuminates the lamp. The fuel level gauge is connected to the fuel pump module on the G4 circuit. The fuel pump module con- HEADLAMP ON CHIME tains the fuel pump and a variable resistor for the The headlamp ON chime is used to indicate to the...
  • Page 1019 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 9 DESCRIPTION AND OPERATION (Continued) RIGHT AND LEFT TURN SIGNAL INDICATORS brake system pressure is below a predetermined level the switch CLOSES and completes a path to ground These lamps are used to indicate to the operator from the G9 circuit at the cluster, through the which turn signal is ON.
  • Page 1021 8W - 41 HORNS/CIGAR LIGHTER 8W - 41 - 1 8W-41 HORNS/CIGAR LIGHTER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1024 8W - 41 - 4 8W - 41 HORNS/CIGAR LIGHTER 8W-41 HORNS/CIGAR LIGHTER DESCRIPTION AND OPERATION HELPFUL INFORMATION • Check the 15 amp fuse in the PDC. • Press the horn switch and listen for the horn HORNS relay to click. A clicking relay indicates voltage is The horn system is powered by a 15 amp fuse present up to the switch.
  • Page 1025 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1030 8W - 42 - 6 8W - 42 AIR CONDITIONING-HEATER 8W-42 AIR CONDITIONING-HEATER INDEX page page DESCRIPTION AND OPERATION BLOWER MOTOR OPERATION ... . . 6 A/C OPERATION ......6 HELPFUL INFORMATION .
  • Page 1031 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 7 DESCRIPTION AND OPERATION (Continued) • Check the 10 amp fuse located in the PDC for except, the C5 circuit is used for the M1 speed and circuit C6 is used for M2 speed operation. the A/C compressor clutch relay.
  • Page 1033 8W - 43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1037 8W - 43 AIRBAG SYSTEM 8W - 43 - 5 8W-43 AIRBAG SYSTEM AIRBAG SQUIB (AIRBAG IGNITER) DESCRIPTION AND OPERATION AIRBAG CONTROL MODULE (ACM) DRIVERS SIDE AIRBAG Two circuits, R43 and R45, connect the ACM to the Two different circuits supply battery voltage from drivers side airbag module squib (igniter) after pass- the fuse block to the Airbag Control Module (ACM), ing through the clock spring connector.
  • Page 1039 8W - 44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1043 8W - 44 INTERIOR LIGHTING 8W - 44 - 5 8W-44 INTERIOR LIGHTING INDEX page page DESCRIPTION AND OPERATION MAP/READING LAMPS ....6 ASH RECEIVER LAMP .
  • Page 1044 8W - 44 - 6 8W - 44 INTERIOR LIGHTING DESCRIPTION AND OPERATION (Continued) The second ground path is through the headlamp ASH RECEIVER LAMP switch. Circuit M23 is spliced in with the time out The ash receiver lamp receives power on the E2 relay.
  • Page 1045 8W - 47 AUDIO SYSTEMS 8W - 47 - 1 8W-47 AUDIO SYSTEMS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1049 8W - 47 AUDIO SYSTEMS 8W - 47 - 5 8W-47 AUDIO SYSTEMS INDEX page page DESCRIPTION AND OPERATION RADIO MEMORY ......5 HELPFUL INFORMATION .
  • Page 1051 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1053 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 3 8W-48 REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION instrument panel right center support. The grid uses the grounding point at the rear body in the right REAR WINDOW DEFOGGER wheel house. When the system is in operation, a L.E.D.
  • Page 1055 8W - 50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1061 8W - 50 FRONT LIGHTING 8W - 50 - 7 8W-50 FRONT LIGHTING INDEX page page GENERAL INFORMATION HEADLAMP LEVELING MOTORS ... . 8 INTRODUCTION ......7 HEADLAMPS .
  • Page 1062 8W - 50 - 8 8W - 50 FRONT LIGHTING DESCRIPTION AND OPERATION (Continued) Circuit L2 connects to the multi- function switch and circuit L43 is protected by a 10 amp fuse located in feeds the L4 circuit (for low beam operation). The L4 the fuse block and is the feed for the left LOW beam circuit connects to a bus bar in the fuse block.
  • Page 1063 8W - 51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1071 8W - 51 REAR LIGHTING 8W - 51 - 9 8W-51 REAR LIGHTING INDEX page page DESCRIPTION AND OPERATION STOP LAMPS ......10 BACK-UP LAMPS .
  • Page 1072 8W - 51 - 10 8W - 51 REAR LIGHTING DESCRIPTION AND OPERATION (Continued) STOP LAMPS BACK-UP LAMPS Circuit F32 in the Power Distribution Center In the RUN position, the ignition switch connects (PDC) feeds the stop lamps. Circuit F32 connects to circuit A2 from the Power Distribution Center (PDC) the stop lamp switch.
  • Page 1073 8W - 52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1077 8W - 52 TURN SIGNALS 8W - 52 - 5 8W-52 TURN SIGNALS INDEX page page DESCRIPTION AND OPERATION TURN SIGNALS ......5 HAZARD FLASHERS .
  • Page 1078 8W - 52 - 6 8W - 52 TURN SIGNALS DESCRIPTION AND OPERATION (Continued) Circuit L60 supplies voltage to the right front turn HELPFUL INFORMATION • For the left front turn signal/hazard flasher signal/hazard lamp. The L60 circuit splices to the instrument cluster to power the right indicator lamp.
  • Page 1079 8W - 53 WIPERS 8W - 53 - 1 8W-53 WIPERS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1082 8W - 53 - 4 8W - 53 WIPERS 8W-53 WIPERS INDEX page page DESCRIPTION AND OPERATION WIPERS—INTERMITTENT ....4 HELPFUL INFORMATION ....4 As the windshield wiper motor turns, the park DESCRIPTION AND OPERATION switch internal to the motor moves from its grounded...
  • Page 1083 8W - 60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1085 8W - 60 POWER WINDOWS 8W - 60 - 3 8W-60 POWER WINDOWS INDEX page page DESCRIPTION AND OPERATION POWER WINDOWS ..... . 3 HELPFUL INFORMATION .
  • Page 1087 8W - 61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1091 8W - 61 POWER DOOR LOCKS 8W - 61 - 5 8W-61 POWER DOOR LOCKS INDEX page page DESCRIPTION AND OPERATION ENTRY ....... 5 HELPFUL INFORMATION .
  • Page 1092 8W - 61 - 6 8W - 61 POWER DOOR LOCKS DESCRIPTION AND OPERATION (Continued) LEFT DOOR UNLOCK (USING RKE Ground for the motors is supplied on circuit P34 TRANSMITTER) through a bus bar in the right switch to circuit P36. When the operator selects left front UNLOCK the The P36 circuit connects from the switch to the RKE module energizes the left front unlock realy...
  • Page 1093 8W - 62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1095 8W - 62 POWER MIRRORS 8W - 62 - 3 8W-62 POWER MIRRORS INDEX page page DESCRIPTION AND OPERATION POWER MIRRORS ..... . . 3 HELPFUL INFORMATION .
  • Page 1097 8W - 64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 1099 8W - 64 POWER SUNROOF 8W - 64 - 3 8W-64 POWER SUNROOF DESCRIPTION AND OPERATION The ground is passed through the switch to circuit Z8 and finally to ground. POWER SUNROOF When the operator selects the CLOSE function, power and ground are reversed. Power for the tilt and slide switches is supplied on circuit F10.
  • Page 1101 8W - 70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION INDEX page SCHEMATICS AND DIAGRAMS ............1 Component Page Component...
  • Page 1105 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS INDEX page SCHEMATICS AND DIAGRAMS ............1 Component Page Component...
  • Page 1106 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS Component Page Component Page Intermittent Wipe/Wash Switch ..8W-80-20 Left Rear Speaker ....8W-80-24 Key-In Switch .
  • Page 1107 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Right Door Lock Switch ....8W-80-30 Right Repeater Lamp ....8W-80-33 Right Door Window Motor .
  • Page 1141 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION number identification. Refer to the index for the proper figure number. INTRODUCTION CONNECTOR/GROUND LOCATIONS This section provides illustrations identifying the For items not shown in this section a N/S is placed general location of components, grounds, and connec- in the Fig.
  • Page 1142 8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Duty Cycle RT Strut Tower Headlamp Rear of Switch Evap/Purge Dimmer/Optical Solenoid Horn Switch Engine Coolant LT Side of Headlamp Switch Bottom of...
  • Page 1143 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Left Rear Shelf At Speaker Right Door Power At Switch Speaker Window Switch Left Rear Wheel LT Rear Frame Right Door Window At Motor...
  • Page 1144 8W - 90 - 4 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 1 Airbag Impact Sensors Fig. 2 Brake Support Bracket Connections...
  • Page 1145 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Vapor Canister RT Front Fender Wiper/Washer Rear of Switch Leak Detector Switch Vehicle Speed Side of Battery WIndshield Washer Bottom of Control Servo...
  • Page 1146 8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 1147 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7 DESCRIPTION AND OPERATION (Continued)
  • Page 1148 8W - 90 - 8 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 1149 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 9 DESCRIPTION AND OPERATION (Continued)
  • Page 1150 8W - 90 - 10 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 1151 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11 DESCRIPTION AND OPERATION (Continued)
  • Page 1152 8W - 90 - 12 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 10 Cowl Panel Connections Fig. 11 Visor/Vanity Connections...
  • Page 1153 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 13 DESCRIPTION AND OPERATION (Continued) Fig. 12 Steering Column Connections Fig. 13 Console Connections...
  • Page 1154 8W - 90 - 14 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 1155 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15 DESCRIPTION AND OPERATION (Continued)
  • Page 1156 8W - 90 - 16 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 1157 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 17 DESCRIPTION AND OPERATION (Continued)
  • Page 1158 8W - 90 - 18 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 1159 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 19 DESCRIPTION AND OPERATION (Continued) Fig. 18 Door Connections (Front) Fig. 19 Door Connections (Rear)
  • Page 1160 8W - 90 - 20 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 20 Body Connections (Left Rear) Fig. 21 Trunk Connections...
  • Page 1161 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 21 DESCRIPTION AND OPERATION (Continued) Fig. 22 Decklid/Rear Bumper Connections Fig. 23 Fuel Tank Connections...
  • Page 1162 8W - 90 - 22 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 24 Rear Lighting Connections...
  • Page 1163 8W - 95 SPLICE LOCATIONS 8W - 95 - 1 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS DESCRIPTION AND OPERATION The following index covers all splices shown in the INTRODUCTION wiring diagrams. If a splice is not shown in this sec- This section provides illustrations identifying the tion, a N/S will be in the Fig.
  • Page 1164 8W - 95 - 2 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 1165 8W - 95 SPLICE LOCATIONS 8W - 95 - 3 DESCRIPTION AND OPERATION (Continued)
  • Page 1166 8W - 95 - 4 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 1167 8W - 95 SPLICE LOCATIONS 8W - 95 - 5 DESCRIPTION AND OPERATION (Continued)
  • Page 1168 8W - 95 - 6 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 1169 8W - 95 SPLICE LOCATIONS 8W - 95 - 7 DESCRIPTION AND OPERATION (Continued)
  • Page 1170 8W - 95 - 8 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 1171 8W - 95 SPLICE LOCATIONS 8W - 95 - 9 DESCRIPTION AND OPERATION (Continued)
  • Page 1172 ENGINE 9 - 1 ENGINE CONTENTS page page 2.0L DOHC ENGINE ..... 52 ENGINE DIAGNOSIS ..... . 7 2.0L SOHC ENGINE .
  • Page 1173 CYLINDER CUP PLUG BLOCK DRIFT SECOND REMOVE PLUG FIRST STRIKE HERE WITH HAMMER WITH PLIERS 9 - 2 ENGINE GENERAL INFORMATION (Continued) assure gasket rails are flat. Flatten rails with a ham- mer on a heavy steel plate if required. Gasket sur- faces must be free of oil and dirt.
  • Page 1174 CROSS-HATCH PATTERN ENGINE 9 - 3 GENERAL INFORMATION (Continued) Insert compression gage adaptor into the #1 tory surface. Inspect cylinder walls after each 20 spark plug hole in cylinder head. Crank engine until strokes, using a light honing oil. Do not use engine maximum pressure is reached on gage.
  • Page 1175 PLASTIGAGE 9 - 4 ENGINE GENERAL INFORMATION (Continued) Fig. 4 Clearance Measurement Fig. 3 Plastigage Placed in Lower Shell ALTERNATIVE METHOD NOTE: The total clearance of the main bearings The weight of the crankshaft can be supported by a can only be determined by removing the weight of jack under the counterweight adjacent to the bearing the crankshaft.
  • Page 1176 ENGINE LEVEL STICK DIP- ENGINE 9 - 5 GENERAL INFORMATION (Continued) the oil hole (Fig. 3). In addition, suspect areas can be (5) Identify the fluid in the cylinder(s) (i.e., cool- checked by placing plastigage in the suspect area. ant, fuel, oil or other). (4) Assemble the rod cap with Plastigage in place.
  • Page 1177 ANTICIPATED TURE RANGE NEXT OIL CHANGE TEMPERA- BEFORE 9 - 6 ENGINE GENERAL INFORMATION (Continued) ENGINE OIL SPECIFICATION CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase lubricant. Engine failure can result. API SERVICE GRADE CERTIFIED Use an engine oil that is API Service Grade Certi- fied or an oil that conforms to the API Service Grade SH or SH/CD.
  • Page 1178 ENGINE 9 - 7 ENGINE DIAGNOSIS INDEX page page DIAGNOSIS AND TESTING GENERAL INFORMATION ....7 CYLINDER COMBUSTION PRESSURE INSPECTION (ENGINE OIL LEAKS IN LEAKAGE TEST .
  • Page 1179 9 - 8 ENGINE DIAGNOSIS AND TESTING (Continued) cause of low compression unless some malfunc- Perform the test procedures on each cylinder tion is present. according to the tester manufacturer’s instructions. (11) Clean or replace spark plugs as necessary While testing, listen for pressurized air escaping and adjust gap as specified in Group 8, Electrical.
  • Page 1180 ENGINE 9 - 9 DIAGNOSIS AND TESTING (Continued) (3) Using a black light, inspect the entire engine If the leakage occurs at the crankshaft rear oil seal for fluorescent dye, particularly at the suspected area area: of oil leak. If the oil leak is found and identified, (1) Disconnect the battery.
  • Page 1181 9 - 10 ENGINE DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT 1. Weak battery. 1. Test battery specific gravity. Charge or START replace as necessary. 2. Corroded or loose battery connections. 2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals.
  • Page 1182 ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in crankcase. 1. Check for correct oil level (refer to Group 0, Lubrication and Maintenance). 2. Thin or diluted oil. 2.
  • Page 1183 ENGINE IDENTIFI- CATION LOCATION 9 - 12 2.0L SOHC ENGINE 2.0L SOHC ENGINE INDEX page page DESCRIPTION AND OPERATION OIL PUMP ......37 ENGINE COMPONENTS .
  • Page 1184 OIL FILTER ADAPTER OIL PICK-UP TUBE OIL PAN GASKET OIL PUMP BODY DRAIN PLUG OIL PAN O-RING O-RING O-RING NIPPLE FILTER 2.0L SOHC ENGINE 9 - 13 DESCRIPTION AND OPERATION (Continued) Engine Lubrication Components ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION Refer to Group 0, Lubrication and Maintenance for recommended oil to be used in various engine appli- cation.
  • Page 1185 9 - 14 2.0L SOHC ENGINE DESCRIPTION AND OPERATION (Continued) route oil from main bearing journals to connecting directly to the cylinder head. It incorporates powder rod journals. metal valve guides and seats. The hollow rocker arm shafts supplies oil to the hydraulic lash adjusters, CAMSHAFT/HYDRAULIC LASH ADJUSTERS camshaft and valve mechanisms.
  • Page 1186 Refer to Cylinder Bore and Piston Specifications Table. Fig. 4 Piston Measurements Chrysler engines use pistons designed specifically for each engine model. Clearance and sizing locations vary with respect to engine model. NOTE: Pistons and cylinder bores should be mea- sured at normal room temperature, 21°C (70°F).
  • Page 1187 FEELER GAUGE FEELER GAUGE 9 - 16 2.0L SOHC ENGINE SERVICE PROCEDURES (Continued) CAUTION: Do not rotate crankshaft or the Plasti- gage may be smeared. Fig. 8 Checking Connecting Rod Bearing Clearance Fig. 5 Piston Ring Gap NOTE: The rod bearing bolts should not be reused. (2) Before installing the NEW bolts the threads should be oiled with clean engine oil.
  • Page 1188 2.0L SOHC ENGINE 9 - 17 SERVICE PROCEDURES (Continued) CONNECTING ROD BEARING OIL CLEARANCE New Part: 0.026 to 0.059 mm (0.001 to 0.0023 in.) Wear Limit: 0.075 mm (0.003 in.) CONNECTING ROD SIDE CLEARANCE New Part: 0.13 to 0.38 mm (0.005 to 0.015 in.) Wear Limit: 0.40 mm...

This manual is also suitable for:

Neon

Table of Contents