Dodge RAM 1500 1998 Owner's Manual

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Contents
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GROUP TAB LOCATOR

Introduction

Lubrication & Maintenance

Suspension

Differential & Driveline

Brakes

Clutch

Cooling

Audio/Video

Chime/Buzzer

Electronic Control Modules

Engine Systems

Heated Systems

Horn

Ignition Control

Instrument Cluster

Lamps

Message Systems

Power Systems

Restraints

Speed Control

Vehicle Theft Security

Wipers/Washers

Navigation/Telecommunication

Wiring

Engine

Exhaust System

Frame & Bumpers

Fuel System

Steering

Transmission and Transfer Case

Tires/Wheels

Body

Heating & Air Conditioning

Emissions Control

Component and System Index

Service Manual Comment Forms

(Rear of Manual)

Table of Contents

Chapters

Table of Contents

Summary of Contents for Dodge RAM 1500 1998

Page 1 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Suspension Differential & Driveline Brakes Clutch Cooling Audio/Video Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Navigation/Telecommunication Wiring Engine...
Page 2: Vehicle Emission Control Information
Country of Origin 1 = Manufactured By DaimlerChrysler Corporation 3 = Manufactured By DaimlerChrysler De Mexico Make D = Dodge Vehicle Type 2 = Incomplete with Side Airbag 3 = Truck with Side Airbag 6 = Incomplete Less Side Airbag...
Page 3 C = 5.9L 6 cyl. Turbo Diesel High Output Check Digit 0 through 9 or X Model Year 4 = 2004 Plant Location S = Dodge City G = Saltillo J = St. Louis (North) 12 thru 17 Vehicle Build Sequence • Idle speeds (if adjustable) VEHICLE EMISSION CONTROL •...
Page 4: Body Code Plate
INTRODUCTION BODY CODE PLATE DESCRIPTION The Body Code Plate (Fig. 4) is located on the right front hydroform fender rail just behind the headlight assembly (Fig. 3). There are seven lines of informa- tion on the body code plate. Lines 5, 6, and 7 are not used to define service information.
Page 5 INTRODUCTION BODY CODE PLATE (Continued) BODY CODE PLATE—LINE 3 BODY CODE PLATE—LINE 2 DIGITS 1,2, AND 3 DIGIT 1 Open Space Paint Procedure • APA = Monotone DIGITS 2 AND 3 Species Code. (Used for Manufacturing) • AP9 = Special DIGIT 4 •...
Page 6: Fastener Identification
INTRODUCTION INTERNATIONAL VEHICLE FASTENER IDENTIFICATION CONTROL & DISPLAY DESCRIPTION SYMBOLS The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater DESCRIPTION - INTERNATIONAL SYMBOLS the bolt strength. Identification is determined by the The graphic symbols illustrated in the following line marks on the top of each bolt head.
Page 7 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 5 FASTENER IDENTIFICATION...
Page 8 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 6 FASTENER STRENGTH...
Page 9: Metric System
INTRODUCTION FASTENER USAGE THREADED HOLE REPAIR DESCRIPTION - FASTENER USAGE DESCRIPTION - THREADED HOLE REPAIR Most stripped threaded holes can be repaired using WARNING: USE OF AN INCORRECT FASTENER a Helicoil . Follow the vehicle or Helicoil recommen- MAY RESULT IN COMPONENT DAMAGE OR PER- dations for application and repair procedures.
Page 10 INTRODUCTION METRIC SYSTEM (Continued) Fig. 7 METRIC CONVERSION CHART...
Page 11 INTRODUCTION tions Chart for torque references not listed in the TORQUE REFERENCES individual torque charts (Fig. 8). DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- Fig. 8 TORQUE SPECIFICATIONS...
Page 12: Vehicle Certification Label
INTRODUCTION The label is located on the driver-side door VEHICLE CERTIFICATION shut-face. LABEL DESCRIPTION A vehicle certification label (Fig. 9) is attached to every DaimlerChrysler Corporation vehicle. The label certifies that the vehicle conforms to all applicable Federal Motor Vehicle Standards. The label also lists: •...
Page 14: Lubrication & Maintenance
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR Use good quality diesel fuel from a reputable sup- SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO plier in your Dodge truck. For most year-round ser- NOT POLLUTE, DISPOSE OF USED ENGINE OIL vice, number...
Page 15 0 - 2 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) • National Lubricating Grease Institute (NLGI) API SERVICE GRADE CERTIFIED Use an engine oil that is API Certified. MOPAR provides engine oils, that meet or exceed this requirement. SAE VISCOSITY An SAE viscosity grade is used to specify the vis- cosity of engine oil.
Page 16 LUBRICATION & MAINTENANCE 0 - 3 FLUID TYPES (Continued) YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT.
Page 17 0 - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) tic and soften solder. The increased temperature can FRONT AXLE • C205F - Mopar Gear Lubricant 75W-90 result in engine detonation. In addition, 100 percent • 9 1/4 AA - Mopar ethylene-glycol freezes at -22°C (-8°F).
Page 18: Fluid Capacities
LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) FLUID ADDITIVES DESCRIPTION SPECIFICATION DaimlerChrysler strongly recommends against the COOLING SYSTEM addition of any fluids to the transmission, other than 3.7L 15.4 L (16.2 qts.)** those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes 4.7L 15.4 L (16.2 qts.)**...
Page 19: Suspension
0 - 6 LUBRICATION & MAINTENANCE FLUID CAPACITIES (Continued) Use the schedule that best describes the driving DESCRIPTION SPECIFICATION conditions. Where time and mileage are listed, follow REAR AXLE ± .03 L (1 oz) the interval that occurs first. 9 1/4 2.32 L (4.9 pts.)*** CAUTION: Failure to perform the required mainte- 10 1/2 AA...
Page 20 LUBRICATION & MAINTENANCE 0 - 7 MAINTENANCE SCHEDULES (Continued) • Trailer towing. NOTE: If ANY of these apply to the vehicle then • Snowplowing. change the engine oil every 3,000 miles (5 000 km) • Heavy Loading. or 3 months, whichever comes first and follow •...
Page 21 0 - 8 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 33,000 36,000 39,000 42,000 45,000 (Kilometers) (53 000) (58 000) (62 000) (67 000) (72 000) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Change rear axle fluid.
Page 22 LUBRICATION & MAINTENANCE 0 - 9 MAINTENANCE SCHEDULES (Continued) Miles 78,000 81,000 84,000 87,000 90,000 (Kilometers) (125 000) (130 000) (134 000) (139 000) (144 000) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Change rear axle fluid.
Page 23 0 - 10 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 105,000 108,000 111,000 114,000 117,000 120,000 (Kilometers) (168 000) (173 000) (178 000) (182 000) (187 000) (192 000) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) models only.
Page 24 LUBRICATION & MAINTENANCE 0 - 11 MAINTENANCE SCHEDULES (Continued) Miles 36,000 42,000 48,000 54,000 60,000 66,000 (Kilometers) (58 000) (67 000) (77 000) (84 000) (96 000) (106 000) [Months] [36] [42] [48] [54] [60] [66] Change engine oil and engine oil filter.
Page 25 0 - 12 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 102,000 108,000 114,000 120,000 (Kilometers) (163 000) (173 000) (182 000) (192 000) [Months] [102] [108] [114] [120] Change engine oil and engine oil filter. Drain and refill transfer case fluid (4X4). Flush and replace engine coolant, if not done at 60 mos.
Page 26 LUBRICATION & MAINTENANCE 0 - 13 MAINTENANCE SCHEDULES (Continued) Once a Month Engine Oil Change Chart Notes • Check tire pressure and look for unusual wear • Tier 1 EPA (250 hp or 305 hp) Engines Only or damage. (see engine data label for your engine type) •...
Page 27 0 - 14 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 22,500 26,250 30,000 33,750 37,500 (Kilometers) (36 000) (42 000) (48 000) (54 000) (60 000) Change engine oil and engine oil filter. X † X† X † X† X † Lubricate outer tie rod ends 2500/3500 (4X4) models only.
Page 28 LUBRICATION & MAINTENANCE 0 - 15 MAINTENANCE SCHEDULES (Continued) Miles 60,000 63,750 67,500 71,250 75,000 (Kilometers) (96 000) (102 000) (108 000) (114 000) (120 000) Change engine oil and engine oil filter. X † X† X † X† X † Lubricate outer tie rod ends 2500/3500 (4X4) models only.
Page 29 0 - 16 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 97,500 100,000 101,250 105,000 108,750 112,500 (Kilometers) (156 000) (160 000) (162 000) (168 000) (174 000) (180 000) Change engine oil and engine X † X† X † X† X †...
Page 30 LUBRICATION & MAINTENANCE 0 - 17 MAINTENANCE SCHEDULES (Continued) • Tier 1 EPA (250 hp or 305 hp) Engines Only Inspection and service should also be performed (see engine data label for your engine type) anytime a malfunction is observed or suspected. •...
Page 31 0 - 18 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 82,500 90,000 97,500 100,000 105,000 (Kilometers) (132 000) (144 000) (156 000) (160 000) (168 000) [Months] [66] [72] [78] [84] Change engine oil and engine oil filter. X† X † X†...
Page 32: Jump Starting
LUBRICATION & MAINTENANCE 0 - 19 MAINTENANCE SCHEDULES (Continued) Miles 112,500 120,000 127,500 135,000 142,500 150,000 (Kilometers) (181 000) (193 000) (205 000) (217 000) (229 000) (241 000) [Months] [90] [96] [102] [108] [114] [150] Inspect front wheel bearings. Inspect brake linings.
Page 33 0 - 20 LUBRICATION & MAINTENANCE JUMP STARTING (Continued) CAUTION: Do not crank starter motor on disabled vehicle for more than 15 seconds, starter will over- heat and could fail. (7) Allow battery in disabled vehicle to charge to at least 12.4 volts (75% charge) before attempting to start engine.
Page 34 LUBRICATION & MAINTENANCE 0 - 21 TOWING (Continued) Fig. 9 REAR LIFT PAD LOCATION 1 - FRAME RAIL 2 - REAR LIFT PAD 3 - LEAF SPRING MOUNTING BRACKET 4 - BOX MOUNTING BRACKET TOWING STANDARD PROCEDURE - TOWING A vehicle equipped with SAE approved sling-type towing equipment can be used to tow all vehicles.
Page 35 0 - 22 LUBRICATION & MAINTENANCE TOWING (Continued) A wooden crossbeam may be required for proper remove the wheels from the lifted end of the vehicle connection when using the sling-type, front-end tow- and lower the vehicle closer to the ground, to ing method.
Page 36 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page WHEEL ALIGNMENT ..... . 1 FRONT - LINK/COIL ..... . 29 FRONT - INDEPENDENT FRONT SUSPENSION .
Page 37 2 - 2 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) OPERATION sive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust • CASTER is the forward or rearward tilt of the angle (Fig. 1) steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster.
Page 38 WHEEL ALIGNMENT 2 - 3 WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Replace steering gear. EFFORT 2. Column coupler binding. 2. Replace coupler. 3. Tire pressure. 3. Adjust tire pressure. 4. Alignment. 4.
Page 39 2 - 4 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) To adjust the vehicle height turn the torsion bar adjustment bolt CLOCKWISE to raise the vehicle and COUNTER CLOCKWISE to lower the vehicle. CAUTION: ALWAYS raise the vehicle to the correct suspension height, NEVER lower the vehicle to obtain the correct suspension height.
Page 40 WHEEL ALIGNMENT 2 - 5 WHEEL ALIGNMENT (Continued) angle while adjusting caster, move one pivot bolt of the upper control arm in or out. Then move the other pivot bolt of the upper control arm in the opposite direction. Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 &...
Page 41 2 - 6 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) (1) Start the engine and turn wheels both ways DESCRIP- SPECIFICATION before straightening the wheels. Center and Secure TION the steering wheel and turn off engine. — .40° .60° 0.06° (2) Loosen the adjustment sleeve clamp bolts. RT/LT (3) Adjust the right wheel toe position with the DIF-...
Page 42 WHEEL ALIGNMENT 2 - 7 WHEEL ALIGNMENT (Continued) SPECIAL TOOLS WHEEL ALIGNMENT 8876 - CAMBER/CASTER ADJUSTMENT TOOL...
Page 43 2 - 8 FRONT - INDEPENDENT FRONT SUSPENSION FRONT - INDEPENDENT FRONT SUSPENSION TABLE OF CONTENTS page page FRONT - INDEPENDENT FRONT SUSPENSION REMOVAL - 4X2 ..... . 21 DESCRIPTION INSTALLATION DESCRIPTION...
Page 44 FRONT - INDEPENDENT FRONT SUSPENSION 2 - 9 FRONT - INDEPENDENT FRONT SUSPENSION DESCRIPTION DESCRIPTION The front suspension is designed to allow each wheel to adapt to different road surfaces indepen- dently. The wheels are mounted to hub/bearings units bolted to the steering knuckle. The double-row hub bearings are sealed and lubricated for life.
Page 45 2 - 10 FRONT - INDEPENDENT FRONT SUSPENSION FRONT - INDEPENDENT FRONT SUSPENSION (Continued) DESCRIPTION The upper control arm bolts on frame brackets. The frame brackets have slotted holes which allow the arms to be adjusted for caster and camber. The lower control arms bolt to the lower frame brackets and pivots through bushings.
Page 46 FRONT - INDEPENDENT FRONT SUSPENSION 2 - 11 FRONT - INDEPENDENT FRONT SUSPENSION (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Lower Suspension Arm — Frame Nuts Lower Suspension Arm — Frame Nuts Lower Suspension Arm — Ball Joint Nut Then an additional 90° Then an additional 90°...
Page 47 2 - 12 FRONT - INDEPENDENT FRONT SUSPENSION FRONT - INDEPENDENT FRONT SUSPENSION (Continued) SPECIAL TOOLS FRONT SUSPENSION TORSION BAR BUSHING REMOVAL/INSTALL - 8835 PULLER - 8677 RECEIVER/ DRIVER BALLJOINT - 8698 4WD BUSHING REMOVAL/INSTALL KIT - 8682 BALL JOINT PRESS - C-4212F TORSION BAR LOADER/UNLOADER - 8686 2WD - LOWER CONTROL ARM BUSHING REMOVAL/INSTALL - 8836...
Page 48 FRONT - INDEPENDENT FRONT SUSPENSION 2 - 13 BUSHINGS REMOVAL REMOVAL - LOWER CONTROL ARM BUSHINGS - 4WD (LD) (1) Remove the lower control arm (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM - REMOVAL). (2) Secure the control arm in a vise. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool.
Page 49 2 - 14 FRONT - INDEPENDENT FRONT SUSPENSION BUSHINGS (Continued) Fig. 5 TORSION BAR CROSS MEMBER BUSHING - Fig. 7 SMALL LOWER CONTROL ARM BUSHING - REMOVAL REMOVAL 1 - 8838 1 - 8839 (THREADED ROD) 2 - 8835-1 2 - 8836-6 (DRIVER) 3 - 8835-4 3 - 8836-3 (SPACER) 4 - 8835-3...
Page 50 FRONT - INDEPENDENT FRONT SUSPENSION 2 - 15 BUSHINGS (Continued) FRAME MOUNTED BUSHING NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation pro- cess.
Page 51 2 - 16 FRONT - INDEPENDENT FRONT SUSPENSION BUSHINGS (Continued) SMALL BUSHING (1) Install the small bushings into the lower con- trol arm using tools 8836-7 (driver), 8836-2 (receiver), 8836–3 (spacer) and the bearing with the threaded rod (8839) (Fig. 13). Fig.
Page 52 FRONT - INDEPENDENT FRONT SUSPENSION 2 - 17 HUB / BEARING (Continued) NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. (6) Remove the tie rod end nut and separate the tie rod from the knuckle using special tool 8677.
Page 53 2 - 18 FRONT - INDEPENDENT FRONT SUSPENSION HUB / BEARING (Continued) (4) Install the ABS wheel speed sensor if equipped (5) Remove the tie rod end nut. Separate the tie (Refer BRAKES/ELECTRICAL/FRONT rod from the knuckle with Remover 8677. WHEEL SPEED SENSOR - INSTALLATION).
Page 54 FRONT - INDEPENDENT FRONT SUSPENSION 2 - 19 KNUCKLE (Continued) (8) Remove the hub/bearing from the steering (8) Install the ABS wheel speed sensor if equipped knuckle (Refer to 2 - SUSPENSION/FRONT/HUB / (Refer BRAKES/ELECTRICAL/FRONT BEARING - REMOVAL). WHEEL SPEED SENSOR - INSTALLATION) and brake shield, rotor and caliper (Refer to 5 - BRAKES/ INSTALLATION HYDRAULIC/MECHANICAL/ROTORS - INSTALLA-...
Page 55 2 - 20 FRONT - INDEPENDENT FRONT SUSPENSION LOWER BALL JOINT (Continued) INSTALLATION NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation pro- cess.
Page 56 FRONT - INDEPENDENT FRONT SUSPENSION 2 - 21 LOWER BALL JOINT (Continued) (12) Perform a wheel alignment (Refer to 2 - SUS- (4) Remove the shock (Refer to 2 - SUSPENSION/ PENSION/WHEEL ALIGNMENT STANDARD FRONT/SHOCK - REMOVAL). PROCEDURE). (5) Install Spring Compressor DD-1278 up through the lower suspension arm, coil spring and shock hole in the frame.
Page 57 2 - 22 FRONT - INDEPENDENT FRONT SUSPENSION LOWER CONTROL ARM (Continued) (4) Install the Spring Compressor DD-1278 up through the lower suspension arm, coil spring and shock hole in the frame. (5) Tighten the tool nut to compress the coil spring.
Page 58 FRONT - INDEPENDENT FRONT SUSPENSION 2 - 23 SPRING (Continued) Fig. 25 SPRING COMPRESSOR TOOL Fig. 26 COIL SPRING 1 - SPECIAL TOOL DD-1278 1 - COIL SPRING 2 - BELL-SHAPED ADAPTER 2 - STEERING KNUCKLE 3 - OUTER TIE ROD END (7) Remove the stabilizer link (Refer to 2 - SUS- 4 - LOWER CONTROL ARM 5 - SHOCK...
Page 59 2 - 24 FRONT - INDEPENDENT FRONT SUSPENSION SHOCK DIAGNOSIS AND TESTING - SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts.
Page 60 FRONT - INDEPENDENT FRONT SUSPENSION 2 - 25 STABILIZER BAR (Continued) ends of the bar mount to the lower suspension arm. NOTE: Check the alignment of the bar to ensure All mounting points of the stabilizer bar are isolated there is no interference with the either frame rail or by bushings (Fig.
Page 61 2 - 26 FRONT - INDEPENDENT FRONT SUSPENSION STABILIZER LINK (Continued) (5) Increase the tension on the anchor arm tool INSTALLATION until the load is removed from the adjustment bolt and the adjuster nut (Fig. 30). INSTALLATION - 4X4 (6) Turn the adjustment bolt counterclockwise to (1) Install the stabilizer link to the vehicle.
Page 62 FRONT - INDEPENDENT FRONT SUSPENSION 2 - 27 TORSION BAR (Continued) INSTALLATION (3) Mount a dial indicator solidly to the frame and then zero the dial indicator. (4) Position dial indicator plunger on the topside of CAUTION: The left and right side torsion bars are the upper ball joint (Fig.
Page 63 2 - 28 FRONT - INDEPENDENT FRONT SUSPENSION (5) Remove the control arm pivot bolts and remove UPPER CONTROL ARM control arm (Fig. 34). REMOVAL (1) Raise and support vehicle. (2) Remove wheel and tire assembly. (3) Remove the nut from upper ball joint. (4) Separate upper ball joint from the steering knuckle with Remover 8677 (Fig.
Page 64 FRONT - LINK/COIL 2 - 29 FRONT - LINK/COIL TABLE OF CONTENTS page page FRONT - LINK/COIL UPPER SUSPENSION ARM SPECIFICATIONS REMOVAL TORQUE CHART ..... . 29 REMOVAL - LEFT .
Page 65 2 - 30 FRONT - LINK/COIL FRONT - LINK/COIL (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Stabilizer Bar — Frame Bolt Stabilizer Link — Lower Control Arm Nut Stabilizer Link — Axle Bracket Stabilizer Link — Stabilizer Bar Nut Hub/Bearing —...
Page 66 FRONT - LINK/COIL 2 - 31 FRONT - LINK/COIL (Continued) RECEIVER CUP - 6761 Fig. 1 Hub Extension 1 - HUB EXTENSION 2 - HUB BALLJOINT RECIEVER/INSTALLER KIT- 8975 HUB / BEARING REMOVAL Fig. 2 Hub Nut Cotter Pin (1) Raise and support the vehicle. 1 - HUB NUT (2) Remove the wheel and tire assembly.
Page 67 2 - 32 FRONT - LINK/COIL HUB / BEARING (Continued) Fig. 4 Rotor Hub/Bearing Assembly Fig. 6 Wheel Speed Sensor 1 - ROTOR AND HUB 1 - HUB BEARING 2 - UNIT BEARING ASSEMBLY 2 - WHEEL SPEED SENSOR 3 - SEAL (3) Press the wheel studs/hub extension studs (10) Press out the wheel studs/hub extension studs through the back side of the rotor and through the...
Page 68 FRONT - LINK/COIL 2 - 33 HUB / BEARING (Continued) (6) Position the hub spacer (Fig. 8) and brake shield (Fig. 9) on bolts just installed in knuckle. NOTE: If the vehicle is equipped with a wheel speed sensor the brake shield must be positioned on the hub bearing (Fig.
Page 69 2 - 34 FRONT - LINK/COIL LOWER BALL JOINT DIAGNOSIS AND TESTING - LOWER BALL JOINT To properly diagnose the lower ball joint two read- ings from the dial indicator are necessary, The two readings must be added together to find a total ball joint movement as identified in the steps below.
Page 70 FRONT - LINK/COIL 2 - 35 LOWER BALL JOINT (Continued) Fig. 14 PRYING LOCATION Fig. 16 LOWER BALL JOINT REMOVAL 1 - PRY BAR 1 - SPECIAL TOOL 2 - UPPER BALL JOINT C4212-F 3 - AXLE YOKE 2 - SPECIAL TOOL 4 - GRESE SEAL 8975-2 5 - STEERING KNUCKLE...
Page 71 2 - 36 FRONT - LINK/COIL UPPER BALL JOINT DIAGNOSIS AND TESTING - UPPER BALL JOINT To properly diagnose the upper ball joint two read- ings from the dial indicator are necessary, The two readings must be added together to find a total ball joint movement as identified in the steps below.
Page 72 FRONT - LINK/COIL 2 - 37 KNUCKLE REMOVAL (1) Remove the hub bearing (Refer to 2 - SUSPEN- SION/FRONT/HUB / BEARING - REMOVAL). (2) Remove tie-rod or drag link end from the steer- ing knuckle arm. (3) Remove the ABS sensor wire and bracket from knuckle.
Page 73 2 - 38 FRONT - LINK/COIL LOWER SUSPENSION ARM SHOCK REMOVAL DIAGNOSIS AND TESTING - SHOCK (1) Raise and support the vehicle. A knocking or rattling noise from a shock absorber (2) Paint or scribe alignment marks on the cam may be caused by movement between mounting adjusters and suspension arm for installation refer- bushings and metal brackets or attaching compo-...
Page 74 FRONT - LINK/COIL 2 - 39 SHOCK (Continued) SPRING REMOVAL (1) Raise and support the vehicle. Position a hydraulic jack under the axle to support it. (2) Paint or scribe alignment marks on lower sus- pension arm cam adjusters and axle bracket for installation reference.
Page 75 2 - 40 FRONT - LINK/COIL STABILIZER BAR (Continued) (5) Remove the links from the axle brackets with INSTALLATION Puller C-3894-A (Fig. 25). (1) Position the stabilizer bar on the frame rail (6) Remove the stabilizer bar clamps from the and install the clamps and bolts.
Page 76 REAR 2 - 41 REAR TABLE OF CONTENTS page page REAR INSTALLATION ......43 DESCRIPTION ......41 SHOCK DIAGNOSIS AND TESTING - SPRING AND REMOVAL .
Page 77 2 - 42 REAR REAR (Continued) SPRING AND SHOCK ABSORBER CONDITION POSSIBLE CAUSES CORRECTION SPRING SAGS 1. Broken leaf. 1. Replace spring. 2. Spring fatigue. 2. Replace spring. SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification. 2. Worn bushings. 2.
Page 78 REAR 2 - 43 BUSHINGS AUXILIARY SPRING BUMPERS (3500) REMOVAL (1) Remove the spring from the vehicle. REMOVAL (2) Make small relief cuts in the flared up end of (1) Remove the nut securing the auxiliary spring the bushing metal being careful not to cut the spring. bumper to the bracket (Fig.
Page 79 2 - 44 REAR SHOCK (Continued) Fig. 3 SHOCK ABSORBER 1 - NUT 2 - AXLE 3 - SHOCK ABSORBER (3) Tighten the upper and lower bolt/nuts Tighten to 135 N.m (100 ft. lbs.) Fig. 4 REAR SPRING (4) Remove the support and lower the vehicle. 1 - LEAF SPRING 2 - PLATE 3 - NUTS...
Page 80 REAR 2 - 45 SPRING TIP INSERTS (Continued) CAUTION: When working on the front leaf spring clinch clamps finish the front before starting on the rear to prevent personal injury. (4) Use an appropriate pry bar to bend open the spring clinch clip (Fig.
Page 81 2 - 46 REAR SPRING TIP INSERTS (Continued) (5) Place one spring clinch clip isolator onto the (7) Use an appropriate pry bar to bend open the outboard side of the spring clinch clip (Fig. 9) and spring clinch clip. If necessary, remove the existing one isolator on the inboard side of the spring clinch spring clinch clip isolators.
Page 82: Differential & Driveline
DIFFERENTIAL & DRIVELINE 3 - 1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page page PROPELLER SHAFT ..... . 1 REAR AXLE - 9 1/4 .
Page 83: Brakes
3 - 2 PROPELLER SHAFT PROPELLER SHAFT (Continued) DRIVELINE VIBRATION Drive Condition Possible Cause Correction Propeller Shaft Noise 1) Undercoating or other foreign 1) Clean exterior of shaft and wash material on shaft. with solvent. 2) Loose U-joint clamp screws. 2) Install new clamps and screws and tighten to proper torque.
Page 84 PROPELLER SHAFT 3 - 3 PROPELLER SHAFT (Continued) (10) Start engine and check vibration. If there is PROPELLER SHAFT RUNOUT little or no change move the clamp to the next posi- (1) Clean propeller shaft surface, where dial indi- tions. Repeat the vibration test. cator will contact the shaft.
Page 85 3 - 4 PROPELLER SHAFT PROPELLER SHAFT (Continued) This measurement will give you the transmis- (7) Rotate propeller shaft 90 degrees and place sion yoke Output Angle (A). inclinometer on companion flange yoke bearing par- allel to the shaft (Fig. 6). Center bubble in sight glass and record measurement.
Page 86 PROPELLER SHAFT 3 - 5 PROPELLER SHAFT (Continued) Fig. 7 UNIVERSAL JOINT ANGLE EXAMPLE 1 - 4.9° ANGLE (C) 4 - 3.0° ANGLE (A) 2 - 3.2° ANGLE (B) 5 - OUTPUT YOKE 3 - INPUT YOKE Fig. 8 UNIVERSAL JOINT ANGLE 1 - YOKES MUST BE IN SAME PLANE...
Page 87 3 - 6 PROPELLER SHAFT PROPELLER SHAFT (Continued) SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Center Bearing Bolts Transfer Case Flange Bolts LD - Front Pinion Flange Bolts HD - Front Pinion Flange Bolts Rear Pinion Flange Bolts Rear Pinion Yoke Bolts SPECIAL TOOLS PROPELLER SHAFT- LD...
Page 88 PROPELLER SHAFT 3 - 7 PROPELLER SHAFT- LD FRONT (Continued) (4) Remove axle/transfer case companion flange PROPELLER SHAFT - HD bolts. Remove dust boot clamp (Fig. 10) from the C/V FRONT jonit end of the shaft if equipped. REMOVAL (1) With vehicle in neutral, position vehicle on hoist.
Page 89 3 - 8 PROPELLER SHAFT REAR PROPELLER SHAFT REMOVAL (1) With vehicle in neutral, position vehicle on hoist. (2) Mark pinion flange or yoke and propeller shaft flange or yoke (Fig. 12) for installation reference. Fig. 13 CENTER BEARING 1 - CENTER BEARING 2 - DUST BOOT 3 - MOUNTING NUTS (4) Install new bolts and tighten to:...
Page 90: Center Bearing
PROPELLER SHAFT 3 - 9 REAR PROPELLER SHAFT (Continued) (3) Remove slip joint boot clamp and separate the two shafts. (4) Use hammer and punch to tap slinger away from shaft to provide room for bearing splitter. (5) Position Bearing Splitter Tool 1130 between slinger and shaft.
Page 91 3 - 10 PROPELLER SHAFT SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY DISASSEMBLY - WITH SNAP RINGS (1) Tap outside of bearing cap with a drift to loosen snap ring. Fig. 18 PRESS OUT BEARING 1 - PRESS 2 - SOCKET Fig. 17 SNAP RING 1 - SNAP RING (2) Remove snap rings (1) from both sides of yoke (Fig.
Page 92 PROPELLER SHAFT 3 - 11 SINGLE CARDAN UNIVERSAL JOINTS (Continued) DISASSEMBLY - WITH INJECTED RINGS (1) Place shaft yoke in vise. Fig. 22 PRESS REMAINING BEARING 1 - PRESS 2 - RECEIVER Fig. 20 PRESS ON YOKE (6) Press remaining U-joint bearing cap out of 1 - PRESS 2 - RECEIVER shaft yoke.
Page 93 3 - 12 PROPELLER SHAFT SINGLE CARDAN UNIVERSAL JOINTS (Continued) Fig. 24 PRESS ON FLANGE Fig. 26 REMAINING BEARING 1 - RECEIVER 1 - RECEIVER 2 - PRESS 2 - PRESS ASSEMBLY ASSEMBLY - WITH SNAP RINGS (1) Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores.
Page 94 PROPELLER SHAFT 3 - 13 SINGLE CARDAN UNIVERSAL JOINTS (Continued) (2) Position cross (1) in yoke with lube fitting ASSEMBLY - WITH INJECTED RINGS pointing up, if equipped (Fig. 27). NOTE: Replacement joint has internal snap rings. (1) Place joint in flange with one bearing cap. Fig.
Page 95 3 - 14 PROPELLER SHAFT SINGLE CARDAN UNIVERSAL JOINTS (Continued) (3) Press bearing cap until snap ring groove (1) is (5) Position press (3) with receiver (2) on remain- through the flange (2) (Fig. 30). ing bearing cap (1) and flange (Fig. 32). (6) Press bearing cap until snap ring groove is through the flange.
Page 96 PROPELLER SHAFT 3 - 15 SINGLE CARDAN UNIVERSAL JOINTS (Continued) (8) Install flange (1) with U-joint in yoke (2) (Fig. 34). Fig. 37 REMAINING BEARING 1 - BEARING 2 - PRESS Fig. 35 PRESS ON YOKE 3 - RECEIVER 1 - RECEIVER 2 - PRESS (12) Position press (2) with receiver (3) on remain- 3 - BEARING...
Page 97 3 - 16 PROPELLER SHAFT (8) Press one bearing cap from outboard side of the DOUBLE CARDAN UNIVERSAL link yoke, enough to grasp the cap with vise jaws JOINTS (Fig. 40). DISASSEMBLY (1) Remove propeller shaft. (2) Mark propeller shaft, link yoke and flange yoke for assembly reference.
Page 98 PROPELLER SHAFT 3 - 17 DOUBLE CARDAN UNIVERSAL JOINTS (Continued) (10) Flip assembly and repeat Step 6, Step 7, Step (3) Place bearing cap over the trunnion and align 8 and Step 9 to remove the opposite bearing cap. cap with the yoke bore (Fig. 44). Keep needle bear- (11) Remove cross centering kit assembly and ings upright in the bearing cap.
Page 99 3 - 18 PROPELLER SHAFT DOUBLE CARDAN UNIVERSAL JOINTS (Continued) (5) Flip propeller shaft yoke and install other bear- (7) Install centering kit assembly inside the link ing cap onto the opposite trunnion and install a snap yoke (Fig. 48). ring (Fig.
Page 100 PROPELLER SHAFT 3 - 19 DOUBLE CARDAN UNIVERSAL JOINTS (Continued) (9) Press remaining two bearing caps into place (11) Flexing the joint beyond center, the joint and install snap rings (Fig. 50). should snap over-center in both directions if correctly assembled (Fig.
Page 101 3 - 20 HALF SHAFT HALF SHAFT TABLE OF CONTENTS page page HALF SHAFT CV JOINT-OUTER CAUTION ......20 REMOVAL .
Page 102 HALF SHAFT 3 - 21 HALF SHAFT (Continued) (8) Tilt knuckle out and push half shaft out of the knuckle (Fig. 2). Fig. 3 HALF SHAFT AND HUB/BEARING 1 - HUB/BEARING MOUNTING NUTS 2 - HALF SHAFT Fig. 2 STEERING KNUCKLE 1 - STEERING KNUCKLE (4) Install half shaft on axle shaft.
Page 103 3 - 22 HALF SHAFT (5) Spread snap ring (1) and slide the joint off the CV JOINT-OUTER shaft (Fig. 5). (6) Slide boot off the shaft and discard old boot. REMOVAL (1) Clamp shaft in a vise (with soft jaws) and sup- port C/V joint.
Page 104 HALF SHAFT 3 - 23 CV JOINT-OUTER (Continued) (10) Remove ball (4) from the bearing cage (3) (Fig. INSTALLATION (11) Repeat step above until all six balls are NOTE: If C/V joint is worn, replace entire C/V joint removed from the bearing cage. and boot.
Page 105 3 - 24 HALF SHAFT CV JOINT-OUTER (Continued) NOTE: Pull on the joint to verify the span ring has engaged. Fig. 12 BEARING CAGE AND HOUSING 1 - OUTER RACE 2 - BEARING CAGE WINDOW Fig. 14 OUTER C/V JOINT 3 - CV JOINT HOUSING 1 - SNAP RING (7) Apply the grease supplied with the joint/boot to...
Page 106 HALF SHAFT 3 - 25 CV JOINT-INNER REMOVAL (1) Clamp shaft in vise (with soft jaws) and sup- port C/V joint. Fig. 18 TRIPOD SNAP RING 1 - SNAP RING 2 - TRIPOD 3 - PLIERS (6) Remove tripod and boot from the half shaft. (7) Clean and inspect C/V components for exces- Fig.
Page 107 3 - 26 HALF SHAFT CV JOINT-INNER (Continued) Fig. 21 INNER C/V BOOT Fig. 20 HOUSING BUSHING 1 - CLAMP 1 - BUSHING 2 - BOOT 2 - HOUSING 3 - CLAMP 4 - SHAFT 5 - HOUSING (8) Position the boot on the joint and shaft in it’s original position (Fig.
Page 108 FRONT AXLE - C205F 3 - 27 FRONT AXLE - C205F TABLE OF CONTENTS page page FRONT AXLE - C205F INSTALLATION ......44 DIAGNOSIS AND TESTING .
Page 109: Clutch
3 - 28 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) VIBRATION DRIVELINE SNAP Vibration at the rear of the vehicle is usually A snap or clunk noise when the vehicle is shifted caused by: into gear (or the clutch engaged) can be caused by: •...
Page 110 FRONT AXLE - C205F 3 - 29 FRONT AXLE - C205F (Continued) Condition Possible Causes Correction Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears differential bearings. and bearings for further damage. Set differential bearing pre-load properly.
Page 111 3 - 30 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) Condition Possible Causes Correction Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible damage. 2. Erratic clutch operation. 2. Replace gears and examine the remaining parts for damage.
Page 112 FRONT AXLE - C205F 3 - 31 FRONT AXLE - C205F (Continued) REMOVAL (1) With vehicle in neutral, position vehicle on hoist. (2) Remove axle half shafts. (3) Remove exhaust crossover. (4) Mark front propeller shaft and remove shaft. (5) Remove suspension crossmember mounting bolts (Fig.
Page 113 3 - 32 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) ADJUSTMENTS Ring gear and pinion are supplied as a matched sets. Identifying numbers for the ring gear and pin- ion are painted onto the pinion gear shaft and the side of the ring gear.
Page 114 FRONT AXLE - C205F 3 - 33 FRONT AXLE - C205F (Continued) PINION GEAR DEPTH VARIANCE Original Pinion New Pinion Gear Depth Variance Gear Depth Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0.001 +0.006...
Page 115 3 - 34 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) Fig. 10 PINION GEAR DEPTH MEASUREMENT 1 - ARBOR 2 - SCOOTER BLOCK 3 - DIAL INDICATOR Pinion gear depth is essential to establishing gear backlash and tooth contact patterns. After measuring Fig.
Page 116 FRONT AXLE - C205F 3 - 35 FRONT AXLE - C205F (Continued) SHIM SELECTION NOTE: It is difficult to salvage the differential side bearings during the removal procedure. Install replacement bearings if necessary. (1) Remove side bearings from differential case. (2) Install ring gear if necessary, on differential case and tighten bolts to specification.
Page 117 3 - 36 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) (9) Attach Dial Indicator C-3339 to post and posi- tion dial indicator plunger on a flat surface on a ring gear bolt head (Fig. 15). Fig. 16 ZERO DIAL INDICATOR 1 - PINION GEAR SIDE 2 - PILOT STUD 3 - DIAL INDICATOR...
Page 118 FRONT AXLE - C205F 3 - 37 FRONT AXLE - C205F (Continued) (23) Subtract 0.05 mm (0.002 in.) from the dial 0.20 mm (0.008 in.). If backlash is not within specifi- indicator reading to compensate for backlash between cations transfer the necessary amount of shim thick- ring and pinion gears.
Page 119 3 - 38 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) Fig. 20 CORRECT CONTACT PATTERN Fig. 23 INCORRECT BACKLASH • Ring gear too far away from pinion gear (Fig. 1 - DRIVE SIDE HEEL 21). Decrease backlash by moving the ring closer to 2 - COAST SIDE HEEL the pinion gear.
Page 120 FRONT AXLE - C205F 3 - 39 FRONT AXLE - C205F (Continued) • Pinion gear set too high (Fig. 26). Decrease pin- ion depth, by decreasing the pinion depth shim thick- ness. Fig. 26 HIGH PINION HEIGHT SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio...
Page 121 3 - 40 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) SPECIAL TOOLS DIAL INDICATOR C-3339 PULLER C-293-PA INSTALLER C-3716-A PLUG C-293-3 INSTALLER C-3718 ADAPTER C-293-42 ADAPTER C-293-48 HANDLE C-4171 PILOTS C-3288-B PULLER C-452...
Page 122 FRONT AXLE - C205F 3 - 41 FRONT AXLE - C205F (Continued) REMOVER C-4660-A PINION DEPTH SET 6775 SPREADER W-129-B DUMMY SHIM 8107 INSTALLER 5063 ADAPTER PLATES 8142A INSTALLER 6448 PINION BLOCK 8177 HOLDER 6719A...
Page 123 3 - 42 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) REMOVER 8240A INSTALLER 8693 DUMMY BEARING 8398 INSTALLER 8694 REMOVER 8401 INSTALLER 8695 INSTALLER 8692 REMOVER 8831...
Page 124 FRONT AXLE - C205F 3 - 43 AXLE SHAFTS REMOVAL (1) Remove half shaft from vehicle. (2) Remove skid plate, if equipped. (3) Clean axle seal area. (4) Remove snap ring from the axle shaft. (5) Remove axle with Remove 8420A Collar 8420-3 and Slide Hammer C-3752 (Fig.
Page 125 3 - 44 FRONT AXLE - C205F AXLE BEARINGS (Continued) (2) Install axle shaft bearing Remover C-4660-A (3) (3) Install a new axle shaft seal with Installer in the bearing (1) (Fig. 29). Then tighten the nut (2) 8694 and Handle C-4171. to spread the remover in the bearing.
Page 126 FRONT AXLE - C205F 3 - 45 PINION SEAL (Continued) CAUTION: Do not exceed 271 N·m (200 ft. lbs.) the minimum tightening torque when installing the companion flange at this point. Failure to heed cau- tion may result in damage. Fig.
Page 127 3 - 46 FRONT AXLE - C205F PINION SEAL (Continued) Fig. 36 PINION ROTATION TORQUE 1 - COMPANION FLANGE Fig. 37 ADAPTER PLATES AND SPREADER 2 - INCH POUND TORQUE WRENCH 1 - ADAPTER PLATE 2 - SPREADER DIFFERENTIAL REMOVAL (1) Remove differential housing cover and drain fluid.
Page 128 FRONT AXLE - C205F 3 - 47 DIFFERENTIAL (Continued) Fig. 40 PINION MATE GEAR Fig. 39 DIFFERENTIAL 1 - THRUST WASHER 1 - HOUSING 2 - SIDE GEAR 2 - DIFFERENTIAL 3 - PINION MATE GEAR 3 - BEARING CUPS (12) Remove spreader from housing.
Page 129 3 - 48 FRONT AXLE - C205F DIFFERENTIAL (Continued) INSTALLATION DIFFERENTIAL CASE BEARINGS NOTE: If replacement differential bearings or differ- ential case are replaced, Refer to adjustments for REMOVAL Differential Bearing Preload and Gear Backlash pro- (1) Remove differential from housing. cedures.
Page 130 FRONT AXLE - C205F 3 - 49 DIFFERENTIAL CASE BEARINGS (Continued) Fig. 44 RING GEAR 1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - HAMMER Fig. 43 DIFFERENTIAL CASE BEARINGS 1 - HANDLE 2 - DIFFERENTIAL 3 - BEARING 4 - INSTALLER PINION GEAR/RING GEAR REMOVAL...
Page 131 3 - 50 FRONT AXLE - C205F PINION GEAR/RING GEAR (Continued) Fig. 46 COMPANION FLANGE REMOVER 1 - COMPANION FLANGE Fig. 48 REAR PINION BEARING CUP 2 - PULLER TOOL 1 - HOUSING 2 - REMOVER 3 - HANDLE Fig. 47 FRONT PINION BEARING CUP 1 - HOUSING 2 - REMOVER Fig.
Page 132 FRONT AXLE - C205F 3 - 51 PINION GEAR/RING GEAR (Continued) Fig. 50 REAR PINION BEARING Fig. 51 REAR PINION BEARING CUP 1 - PULLER 2 - VISE 1 - HOUSING 3 - ADAPTERS 2 - INSTALLER 4 - DRIVE PINION GEAR SHAFT 3 - HANDLE INSTALLATION NOTE: The ring gear and pinion are serviced in a...
Page 133 3 - 52 FRONT AXLE - C205F PINION GEAR/RING GEAR (Continued) (7) Place pinion depth shim (Fig. 53) on the pinion (9) Install new collapsible spacer onto the pinion shaft. shaft (Fig. 55). Fig. 53 PINION DEPTH SHIM Fig. 55 COLLAPSIBLE SPACER 1 - PINION DEPTH SHIM 1 - COLLAPSIBLE SPACER 2 - PINION GEAR...
Page 134 FRONT AXLE - C205F 3 - 53 PINION GEAR/RING GEAR (Continued) (15) Invert differential case and start two ring gear bolts to provide ring gear bolt hole alignment. (16) Invert differential case in the vise. (17) Install new ring gear bolts and alternately tighten to 108 N·m (80 ft.
Page 135 3 - 54 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA TABLE OF CONTENTS page page FRONT AXLE - 9 1/4 AA PINION SEAL DIAGNOSIS AND TESTING ....54 REMOVAL .
Page 136 FRONT AXLE - 9 1/4 AA 3 - 55 FRONT AXLE - 9 1/4 AA (Continued) VIBRATION DRIVELINE SNAP Vibration at the front/rear of the vehicle is usually A snap or clunk noise when the vehicle is shifted caused by: into gear (or the clutch engaged) can be caused by: •...
Page 137 3 - 56 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) Condition Possible Causes Correction Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears differential bearings. and bearings for further damage. Set differential bearing pre-load properly.
Page 138 FRONT AXLE - 9 1/4 AA 3 - 57 FRONT AXLE - 9 1/4 AA (Continued) Condition Possible Causes Correction Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible damage. 2. Erratic clutch operation. 2.
Page 139 3 - 58 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) Fig. 4 DRAG LINK 1 - PITMAN ARM 2 - DRAGLINK 3 - PULLER C-3894-A Fig. 2 SHOCK ABSORBER 1 - SHOCK 2 - SPRING 3 - FLAG NUT 4 - SHOCK BOLT Fig.
Page 140 FRONT AXLE - 9 1/4 AA 3 - 59 FRONT AXLE - 9 1/4 AA (Continued) (7) Connect track bar to the axle bracket and install the bolt. Do not tighten at this time. (8) Install shock absorber and tighten bolts to 121 N·m (89 ft.
Page 141 3 - 60 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) DIFFERENTIAL CASE BEARING PRELOAD AND GEAR BACKLASH Backlash is adjusted by moving the adjusters in and out or both. By moving the adjusters the case/ ring gear will move closer or further away from the pinion.
Page 142 FRONT AXLE - 9 1/4 AA 3 - 61 FRONT AXLE - 9 1/4 AA (Continued) (9) Loosen pinion gear side adjuster until it is no (2) Apply gear marking compound to all of the ring longer in contact with the bearing cup, then tighten gear teeth.
Page 143 3 - 62 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) • Pinion gear set too low (Fig. 17). Increase pinion gear height, by increasing the pinion depth shim thickness. Fig. 14 INCORRECT BACKLASH 1 - DRIVE SIDE TOE 2 - COAST SIDE HEEL Fig.
Page 144 FRONT AXLE - 9 1/4 AA 3 - 63 FRONT AXLE - 9 1/4 AA (Continued) SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.73, 4.10 Ring Gear Diameter 235 mm (9.25 in.) Ring Gear Backlash 0.13-0.18 mm (0.005-0.007 in.) Pinion Bearing Preload - New Bearing 1.7-2.8 N·m (15-25 in.
Page 145 3 - 64 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) SPECIAL TOOLS PULLER C-293-PA CUP INSTALLER D-146 INSTALLER C-3095-A DIAL INDICATOR STUD L-4438 DIAL INDICATOR SET C-3339 SPLITTER 1130 HANDLE C-4171 REMOVER/EXTRACTOR 6310...
Page 146 FRONT AXLE - 9 1/4 AA 3 - 65 FRONT AXLE - 9 1/4 AA (Continued) PINION DEPTH SET 6730 ADAPTERS 8879 ARBOR DISCS 8289 BEARING INSTALLER 8881 RECEIVER 8498 SEAL INSTALLER 8882 PINION BLOCK 8878...
Page 147 3 - 66 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) ADJUSTER WRENCH 8883 PLUG 8888 SEAL INSTALLER 8885 PINION DRIVER 8976 CUP INSTALLER 8886 FLANGE WRENCH 8979...
Page 148 FRONT AXLE - 9 1/4 AA 3 - 67 FRONT AXLE - 9 1/4 AA (Continued) PINION INSTALLER 8982 Fig. 19 AXLE NUT 1 - AXLE NUT 2 - AXLE 3 - COTTER PIN (4) Remove four hub bearing bolts (Fig. 20) from the back of the steering knuckle.
Page 149 3 - 68 FRONT AXLE - 9 1/4 AA AXLE SHAFTS (Continued) (5) Remove hub bearing from the steering knuckle. (6) Remove axle shaft (Fig. 21) from steering knuckle and axle housing. Fig. 22 AXLE SHAFT OUTER U-JOINT 1 - SHAFT YOKE 2 - BEARING CAP Fig.
Page 150 FRONT AXLE - 9 1/4 AA 3 - 69 AXLE SHAFTS (Continued) ASSEMBLY AXLE SHAFT SEALS (1) Pack the bearing caps 1/3 full of wheel bearing lubricant. Apply extreme pressure (EP), lithium-base REMOVAL lubricant to aid in installation. (1) Remove hub bearings and axle shafts. (2) Position the spider in the yoke.
Page 151 3 - 70 FRONT AXLE - 9 1/4 AA AXLE SHAFT SEALS (Continued) (6) Install Extractor Rod 6310 with Extractor Foot INSTALLATION 6310-9 through the receiver and the axle seal (Fig. (1) Install axle seal on Installer Cups 8885-2 and 27).
Page 152 FRONT AXLE - 9 1/4 AA 3 - 71 PINION SEAL (Continued) Fig. 32 PINION FLANGE PULLER 1 - PINION FLANGE 2 - PULLER Fig. 30 PINION ROTATING TORQUE 1 - PINION FLANGE 2 - TORQUE WRENCH (6) Hold pinion flange with Flange Wrench 8979 (Fig.
Page 153 3 - 72 FRONT AXLE - 9 1/4 AA DIFFERENTIAL REMOVAL (1) Remove differential housing cover and drain lubricant from the housing. (2) Remove hub bearings and axle shafts. (3) Remove adjuster lock bolts and adjuster locks (Fig. 34). Fig. 35 ADJUSTERS 1 - BEARING CUP 2 - ADJUSTER 3 - BEARING CUP...
Page 154 FRONT AXLE - 9 1/4 AA 3 - 73 DIFFERENTIAL (Continued) (3) Rotate differential pinion gears to differential (1) Lubricate all differential components with axle window and remove pinion gears and thrust washers lubricant. (Fig. 37). (2) Install differential side gears and thrust wash- ers (Fig.
Page 155 3 - 74 FRONT AXLE - 9 1/4 AA DIFFERENTIAL (Continued) (4) Align hole in the pinion gears with hole in the (7) Back off the ring gear side adjuster 4 holes, to differential case. obtain initial ring gear backlash. (5) Install pinion shaft.
Page 156 FRONT AXLE - 9 1/4 AA 3 - 75 DIFFERENTIAL (Continued) (20) Fill differential with lubricant, refer to Lubri- cation & Maintenance for capacity and lubricant type. (21) Install fill plug and tighten to 32 N·m (24 ft. lbs.). DIFFERENTIAL CASE BEARINGS REMOVAL (1) Remove the differential case from the housing.
Page 157 3 - 76 FRONT AXLE - 9 1/4 AA PINION GEAR/RING GEAR (Continued) (7) Drive ring gear from differential case with a (9) Remove pinion flange from pinion with Pinion soft hammer (Fig. 45). Flange Puller 8992 (Fig. 47). Fig. 47 PINION FLANGE PULLER Fig.
Page 158 FRONT AXLE - 9 1/4 AA 3 - 77 PINION GEAR/RING GEAR (Continued) (11) Remove pinion seal with a slide hammer or INSTALLATION pry bar. (1) Install front pinion bearing cup (Fig. 50) with (12) Remove and discard front pinion bearing Installer D-146 and Handle C-4171.
Page 159 3 - 78 FRONT AXLE - 9 1/4 AA PINION GEAR/RING GEAR (Continued) (3) Install pinion depth shim (Fig. 52) on the pin- (5) Install new collapsible spacer (Fig. 54). ion gear shaft. Fig. 54 COLAPSIBLE SPACER 1 - COLAPSIBLE SPACER 2 - PINION GEAR 3 - REAR PINION BEARING Fig.
Page 160 FRONT AXLE - 9 1/4 AA 3 - 79 PINION GEAR/RING GEAR (Continued) (8) Install new pinion seal (Fig. 56) with Installer 8882 and Handle C-4171. Fig. 56 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER (9) Apply a light coat of teflon sealant to the pin- Fig.
Page 161 3 - 80 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 TABLE OF CONTENTS page page REAR AXLE - 9 1/4 INSTALLATION ......97 DIAGNOSIS AND TESTING .
Page 162 REAR AXLE - 9 1/4 3 - 81 REAR AXLE - 9 1/4 (Continued) LOW SPEED KNOCK NOTE: All driveline components should be exam- ined before starting any repair. Low speed knock is generally caused by: • Worn U-joint. • Worn side gear thrust washers. DRIVELINE SNAP •...
Page 163 3 - 82 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) Condition Possible Causes Correction Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears differential bearings. and bearings for further damage. Set differential bearing pre-load properly.
Page 164 REAR AXLE - 9 1/4 3 - 83 REAR AXLE - 9 1/4 (Continued) Condition Possible Causes Correction Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible damage. 2. Erratic clutch operation. 2. Replace gears and examine the remaining parts for damage.
Page 165 3 - 84 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) Fig. 3 PINION ID NUMBER 1 - VARIANCE NUMBER Fig. 1 SHOCK ABSORBER 2 - SEQUENCE NUMBER 1 - NUT Compensation pinion depth variance 2 - AXLE achieved with select shims.
Page 166 REAR AXLE - 9 1/4 3 - 85 REAR AXLE - 9 1/4 (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001...
Page 167 3 - 86 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) (4) Place Arbor Disc 8541 on Arbor D-115-3 in posi- tion in the housing side bearing cradles (Fig. 7). Install differential bearing caps on arbor discs and tighten cap bolts to 41 N·m (30 ft.
Page 168 REAR AXLE - 9 1/4 3 - 87 REAR AXLE - 9 1/4 (Continued) (1) Through the axle tube use Wrench C-4164 to (8) Continue increasing the torque at the right- adjust each threaded adjuster inward until the differ- side threaded adjuster until the specified backlash is ential bearing free-play is eliminated.
Page 169 3 - 88 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) • Ring gear too far away from pinion gear (Fig. 11). Decrease backlash, by moving the ring closer to the pinion gear using the adjusters. Fig. 13 INCORRECT BACKLASH 1 - DRIVE SIDE HEEL 2 - COAST SIDE HEEL Fig.
Page 170 REAR AXLE - 9 1/4 3 - 89 REAR AXLE - 9 1/4 (Continued) (3) If side gear clearances is no more than 0.005 inch. Determine if the axle shaft is contacting the pinion mate shaft. Do not remove the feeler gauges, inspect the axle shaft with the feeler gauge inserted behind the side gear.
Page 171 3 - 90 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.21, 3.55, 3.92 Differential Case Flange Runout 0.076 mm (0.003 in.) Differential Case Clearance 0.12 mm (0.005 in.) Ring Gear Diameter 235 mm (9.25 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Page 172 REAR AXLE - 9 1/4 3 - 91 REAR AXLE - 9 1/4 (Continued) INSTALLER C-3095-A HANDLE C-4171 DIAL INDICATOR SET C-3339 INSTALLER C-4198 INSTALLER C-3718 INSTALLER C-4213 INSTALLER C-4076-B REMOVER C-4307 WRENCH C-4164...
Page 173 3 - 92 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) INSTALLER D-130 INSTALLER C-4308 REMOVER 6310 INSTALLER C-4345 HOLDER 6719A TRAC-LOK TOOLS C-4487 PINION GAUGE SET 6730/6774/6775 PULLER C-452 TRAC-LOK TORQUE FIXTURE 6790 HANDLE C-4735...
Page 174 REAR AXLE - 9 1/4 3 - 93 REAR AXLE - 9 1/4 (Continued) FIXTURE 8136 Fig. 19 REAR ROTOR 1 - ROTOR 2 - CALIPER ADAPTER TRAC-LOK TOOLS 8139 3 - CALIPER (5) Remove differential housing cover and drain lubricant.
Page 175 3 - 94 REAR AXLE - 9 1/4 AXLE SHAFTS (Continued) (7) Push axle shaft inward and remove axle shaft (3) Insert C-lock in end of axle shaft then push C-lock from the axle shaft (Fig. 21). axle shaft outward to seat C-lock in side gear. (4) Insert pinion shaft into differential case and through thrust washers and differential pinions.
Page 176 REAR AXLE - 9 1/4 3 - 95 AXLE SHAFT SEALS (Continued) (3) Install the axle shaft. (3) Coat the lip of the new axle seal with axle (4) Install differential cover and fill with gear lubricant and install with Installer C-4076-B and lubricant to the bottom of the fill plug hole.
Page 177 3 - 96 REAR AXLE - 9 1/4 PINION SEAL (Continued) (8) Remove pinion seal with pry tool or slide-ham- mer mounted screw. INSTALLATION (1) Apply a light coating of gear lubricant on the lip of pinion seal. (2) Install new pinion seal with Installer C-3860-A and Handle C-4171 (Fig.
Page 178 REAR AXLE - 9 1/4 3 - 97 PINION SEAL (Continued) (10) If rotating torque is low, use Holder 6719 to CAUTION: If housing cover is not installed within 3 hold the companion flange and tighten pinion nut in to 5 minutes, the cover must be cleaned and new 6.8 N·m (5 ft.
Page 179 3 - 98 REAR AXLE - 9 1/4 DIFFERENTIAL (Continued) (9) Loosen differential bearing adjusters through (1) Rotate one pinion gear (2) with thrust washer the axle tubes with Wrench C-4164 (Fig. 31). (3) (Fig. 32) to the differential window (1) and remove gear and thrust washer.
Page 180 REAR AXLE - 9 1/4 3 - 99 DIFFERENTIAL (Continued) ASSEMBLY (3) Install first pinion gear (3) with thrust washer into differential window (1) and side gears (2). Rotate pinion gear into the case (Fig. 36). NOTE: If same gears and thrust washers are being (4) Install remaining pinion gear and thrust used, install them into their original locations.
Page 181 3 - 100 REAR AXLE - 9 1/4 DIFFERENTIAL (Continued) DIFFERENTIAL-TRAC-LOK DESCRIPTION The optional Trac-Lok differential case has a one- piece design and the similar internal components as a standard differential, plus two clutch disc pack- s.The differential pinion mate shaft is retained with a threaded pin.
Page 182 REAR AXLE - 9 1/4 3 - 101 DIFFERENTIAL-TRAC-LOK (Continued) Fig. 41 ROTATING TORQUE TEST 1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE 2 - TORQUE WRENCH DISASSEMBLY (1) Clamp Holding Fixture 8136 in vise and set differential case on fixture (Fig. 42). Fig.
Page 183 3 - 102 REAR AXLE - 9 1/4 DIFFERENTIAL-TRAC-LOK (Continued) (4) Lubricate and install disc, that is not threaded from Trac-Lok Tool Kit 8139 into the lower side gear (Fig. 43). Fig. 44 THREAD ADAPTER DISC 1 - SOCKET 2 - SLOT IN DISC 3 - SCREWDRIVER Fig.
Page 184 REAR AXLE - 9 1/4 3 - 103 DIFFERENTIAL-TRAC-LOK (Continued) (13) Remove forcing screw and discs. (14) Remove top side gear, clutch pack retainer and clutch pack (Fig. 48). NOTE: Keep plates in correct order during removal. Fig. 46 PINION GEAR THRUST WASHER 1 - THRUST WASHER 2 - FEELER GAUGE (10) Loosen forcing screw in small increments...
Page 185 3 - 104 REAR AXLE - 9 1/4 DIFFERENTIAL-TRAC-LOK (Continued) (2) Assemble clutch discs into packs and secure disc packs with retaining clips (Fig. 49). NOTE: New Plates and discs with fiber coating (no grooves or lines) must be presoaked in Friction Modifier before assembly.
Page 186 REAR AXLE - 9 1/4 3 - 105 DIFFERENTIAL-TRAC-LOK (Continued) DIFFERENTIAL CASE BEARINGS REMOVAL (1) Remove differential case from axle housing. (2) Remove differential bearings from the case with Puller/Press C-293-PA and Adapters C-293-47 and Plug C-293-3 (Fig. 52). Fig. 51 CLUTCH PACK AND UPPER SIDE GEAR 1 - SIDE GEAR AND CLUTCH PACK 2 - DIFFERENTIAL CASE 3 - LOWER DISC...
Page 187 3 - 106 REAR AXLE - 9 1/4 DIFFERENTIAL CASE BEARINGS (Continued) INSTALLATION Fig. 54 RING GEAR 1 - CASE 2 - RING GEAR 3 - RAWHIDE HAMMER (8) Install bolts into two of the threaded holes in the companion flange 180° apart. (9) Position Holder 6719 against the companion Fig.
Page 188 REAR AXLE - 9 1/4 3 - 107 PINION GEAR/RING GEAR/TONE RING (Continued) (12) Remove pinion gear from the housing (Fig. 56). (16) Remove rear pinion bearing cup from housing (Fig. 58) with Remover C-4307 and Handle C-4171. Fig. 56 PINION GEAR Fig.
Page 189 3 - 108 REAR AXLE - 9 1/4 PINION GEAR/RING GEAR/TONE RING (Continued) (18) Remove rear pinion bearing (Fig. 60) from the pinion shaft with Puller C-293-PA and Adapters C-293-37. Fig. 61 PINION DEPTH SHIM 1 - PINION DEPTH SHIM 2 - PINION GEAR Fig.
Page 190 REAR AXLE - 9 1/4 3 - 109 PINION GEAR/RING GEAR/TONE RING (Continued) (3) Install front pinion bearing cup (Fig. 63) with Installer D-129 and Handle C-4171 and verify cup is seated. Fig. 63 FRONT PINION BEARING CUP 1 - INSTALLER 2 - HANDLE Fig.
Page 191 3 - 110 REAR AXLE - 9 1/4 PINION GEAR/RING GEAR/TONE RING (Continued) (8) Install a new collapsible spacer on the pinion shaft (Fig. 67). Fig. 68 PINION NUT 1 - DIFFERENTIAL HOUSING 2 - HOLDER Fig. 67 COLLAPSIBLE SPACER 3 - TORQUE WRENCH 1 - COLLAPSIBLE SPACER (16) Check pinion rotating torque with an inch...
Page 192 REAR AXLE - 9 1/4 3 - 111 PINION GEAR/RING GEAR/TONE RING (Continued) (17) Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position. (18) Position ring gear on the differential case and start two ring gear bolts.
Page 193 3 - 112 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA TABLE OF CONTENTS page page REAR AXLE - 10 1/2 AA DISASSEMBLY ......128 DIAGNOSIS AND TESTING .
Page 194 REAR AXLE - 10 1/2 AA 3 - 113 REAR AXLE - 10 1/2 AA (Continued) VIBRATION DRIVELINE SNAP Vibration at the rear of the vehicle is usually A snap or clunk noise when the vehicle is shifted caused by: into gear (or the clutch engaged), can be caused by: •...
Page 195 3 - 114 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) Condition Possible Causes Correction Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears differential bearings. and bearings for further damage. Set differential bearing pre-load properly.
Page 196 REAR AXLE - 10 1/2 AA 3 - 115 REAR AXLE - 10 1/2 AA (Continued) Condition Possible Causes Correction Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and quantity. 2. Improper ring gear and pinion 2.
Page 197 3 - 116 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) INSTALLATION (1) Raise axle with lift and align to the leaf spring centering bolts. (2) Install axle U-bolts and tighten to 149 N·m (110 ft. lbs.). (3) Install shock absorbers to axle and tighten to specification.
Page 198 REAR AXLE - 10 1/2 AA 3 - 117 REAR AXLE - 10 1/2 AA (Continued) Fig. 5 GAUGE TOOLS IN HOUSING 1 - ARBOR DISC 2 - PINION BLOCK 3 - ARBOR 4 - PINION HEIGHT BLOCK Fig. 7 ADJUSTER LOCK BOLT 1 - DIFFERENTIAL CASE 2 - ADJUSTER LOCK 3 - ADJUSTER LOCK BOLT...
Page 199 3 - 118 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) (6) Install ring gear side adjuster lock and bolt. Do GEAR TOOTH CONTACT PATTERN not tighten adjuster lock bolt at this time. Gear tooth contact pattern is used to verify the cor- (7) Tighten pinion gear...
Page 200 REAR AXLE - 10 1/2 AA 3 - 119 REAR AXLE - 10 1/2 AA (Continued) Fig. 12 INCORRECT BACKLASH Fig. 14 INCORRECT BACKLASH 1 - DRIVE SIDE TOE 1 - DRIVE SIDE TOE 2 - COAST SIDE HEEL 2 - COAST SIDE TOE •...
Page 201 3 - 120 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.73, 4.10 Ring Gear Diameter 266 mm (10.5 in.) Ring Gear Backlash 0.13-0.18 mm (0.005-0.007 in.) Pinion Bearing Preload - New Bearings 1.69-2.82 N·m (15-25 in.
Page 202 REAR AXLE - 10 1/2 AA 3 - 121 REAR AXLE - 10 1/2 AA (Continued) DIAL INDICATOR STUD L-4438 ARBOR DISCS 6732 BEARING INSTALLER MD-998805 ADAPTERS 8879 SPLITTER 1130 ADJUSTER WRENCH 8883 PINION DEPTH GAUGE 6730...
Page 203 3 - 122 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) PLUG 8888 SOCKET 8954 SEAL INSTALLER 8896 BEARING INSTALLER 8956 GAUGE BLOCK 8899 CUP INSTALLER 8959...
Page 204 REAR AXLE - 10 1/2 AA 3 - 123 REAR AXLE - 10 1/2 AA (Continued) CUP INSTALLER 8960 SEAL INSTALLER 8963 CUP INSTALLER 8961 PINION DRIVER 8977 CUP INSTALLER 8962 FLANGE WRENCH 8979...
Page 205 3 - 124 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) AXLE SHAFTS REMOVAL (1) Remove axle shaft flange bolts (Fig. 17). PINION INSTALLER 8981 Fig. 17 AXLE FLANGE BOLTS 1 - AXLE FLANGE 2 - FLANGE BOLT (2) Slide axle shaft out of the axle tube.
Page 206 REAR AXLE - 10 1/2 AA 3 - 125 (4) Remove hub bearing nut with Socket 8954. AXLE BEARINGS (5) Remove hub and bearings from the axle. (6) Pry out hub bearing seal from the back of the REMOVAL hub. (1) Remove axle shaft flange bolts and remove axle shaft.
Page 207 3 - 126 REAR AXLE - 10 1/2 AA AXLE BEARINGS (Continued) (5) Hold pinion flange with Flange Wrench 8979 (Fig. 23) and remove pinion flange nut and washer. Fig. 21 HUB NUT SOCKET 1 - SOCKET 2 - TORQUE WRENCH Fig.
Page 208 REAR AXLE - 10 1/2 AA 3 - 127 PINION SEAL (Continued) DIFFERENTIAL REMOVAL (1) Remove lubricant fill hole plug from the differ- ential housing cover. (2) Remove differential housing cover and drain the lubricant from housing. (3) Remove axle shafts. (4) Remove adjuster lock bolts and adjuster locks (Fig.
Page 209 3 - 128 REAR AXLE - 10 1/2 AA DIFFERENTIAL (Continued) Fig. 28 BEARING ADJUSTERS Fig. 30 FRIST PINION GEAR 1 - BEARING CUP 1 - DIFFERNTIAL CASE WINDOW 2 - ADJUSTER 2 - PINION GEAR 3 - BEARING CUP 3 - THRUST WASHER 4 - ADJUSTER (3) Rotate the other pinion gear with thrust...
Page 210 REAR AXLE - 10 1/2 AA 3 - 129 DIFFERENTIAL (Continued) Fig. 32 SIDE GEARS 1 - SIDE GEAR 2 - SIDE GEAR 3 - PINION GEARS Fig. 34 PINION GEAR 1 - DIFFERENTIAL WINDOW ASSEMBLY 2 - SIDE GEARS 3 - PINION GEAR NOTE: If the same gears and thrust washers are (4) Install the other pinion gear and thrust...
Page 211 3 - 130 REAR AXLE - 10 1/2 AA DIFFERENTIAL (Continued) INSTALLATION (9) Tighten pinion gear side adjuster firmly against the differential case bearing cup. (1) Clean the housing cavity with a flushing oil, (10) Rotate the pinion several times to seat the dif- light engine oil or lint free cloth.
Page 212 REAR AXLE - 10 1/2 AA 3 - 131 (4) Remove side gear and thrust washer (Fig. 39). DIFFERENTIAL TRAC-RITE NOTE: Mark all component locations. DESCRIPTION The Trac-Rite™ differential is a helical gear differ- ential. The differential has two side gears, six pinion gears and six pinion brake shoes.
Page 213 3 - 132 REAR AXLE - 10 1/2 AA DIFFERENTIAL TRAC-RITE (Continued) (6) Remove six pinion gears (Fig. 41). Fig. 42 PINION GEAR AND BRAKE SHOE 1 - BRAKE SHOES 2 - PINION GEAR 3 - PINION SHAFT (3) Inspect side gears teeth for chips and cracks (Fig.
Page 214 REAR AXLE - 10 1/2 AA 3 - 133 DIFFERENTIAL TRAC-RITE (Continued) Fig. 44 PINION/SIDE GEAR BORE Fig. 45 SIDE GEAR AND SPACER 1 - PINION BORES 1 - SPACER 2 - SIDE GEAR BORE 2 - SIDE SPACER ASSEMBLY NOTE: Install all component in their original loca- tions.
Page 215 3 - 134 REAR AXLE - 10 1/2 AA DIFFERENTIAL CASE BEARINGS REMOVAL (1) Remove differential case from the housing. (2) Install Plug 8888 into the end of the case. (3) Remove differental case bearings with Bearing Splitter 1130 and Bridge 938 (Fig. 47). Fig.
Page 216 REAR AXLE - 10 1/2 AA 3 - 135 PINION GEAR/RING GEAR/TONE RING (Continued) (4) Place differential on Plug 8888 and drive exciter ring off the differential case with a hammer and punch (Fig. 49). NOTE: Do not remove the exciter ring if it is not being replaced.
Page 217 3 - 136 REAR AXLE - 10 1/2 AA PINION GEAR/RING GEAR/TONE RING (Continued) (9) Remove pinion flange from the pinion with Pin- (12) Remove and discard front pinion bearing. ion Flange Puller 8992 (Fig. 52). CAUTION: Do not reuse front pinion bearing/cup. (13) Remove collapsible spacer from the pinion shaft.
Page 218 REAR AXLE - 10 1/2 AA 3 - 137 PINION GEAR/RING GEAR/TONE RING (Continued) INSTALLATION (1) Install new front pinion bearing cup (Fig. 55) with Installer 8960 and Handle C-4171. Fig. 55 FRONT PINION BEARING CUP 1 - INSTALLER 2 - HANDLE Fig.
Page 219 3 - 138 REAR AXLE - 10 1/2 AA PINION GEAR/RING GEAR/TONE RING (Continued) (5) Install new collapsible spacer (Fig. 59). (8) Install new pinion seal (Fig. 61) with Installer 8896 and Handle C-4171. Fig. 61 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER (9) Apply a light coat of teflon sealant to the pin- ion flange splines.
Page 220 REAR AXLE - 10 1/2 AA 3 - 139 PINION GEAR/RING GEAR/TONE RING (Continued) (13) Rotate pinion several times to seat bearings. (14) Measure pinion rotating torque with an inch pound torque wrench (Fig. 63). Tighten pinion nut in small increments until pinion rotating torque is: •...
Page 221 3 - 140 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA TABLE OF CONTENTS page page REAR AXLE - 11 1/2 AA DISASSEMBLY ......155 DIAGNOSIS AND TESTING .
Page 222 REAR AXLE - 11 1/2 AA 3 - 141 REAR AXLE - 11 1/2 AA (Continued) VIBRATION DRIVELINE SNAP Vibration at the rear of the vehicle is usually A snap or clunk noise when the vehicle is shifted caused by: into gear (or the clutch engaged), can be caused by: •...
Page 223 3 - 142 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) Condition Possible Causes Correction Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears differential bearings. and bearings for further damage. Set differential bearing pre-load properly.
Page 224 REAR AXLE - 11 1/2 AA 3 - 143 REAR AXLE - 11 1/2 AA (Continued) Condition Possible Causes Correction Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and quantity. 2. Improper ring gear and pinion 2.
Page 225 3 - 144 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) INSTALLATION (1) Assemble Pinion Height Block 6739, Pinion Block 8897 and rear pinion bearing onto Screw 6741 (1) Raise axle with lift and align to the leaf spring (Fig.
Page 226 REAR AXLE - 11 1/2 AA 3 - 145 REAR AXLE - 11 1/2 AA (Continued) Fig. 5 GAUGE TOOLS IN HOUSING 1 - ARBOR DISC 2 - PINION BLOCK 3 - ARBOR 4 - PINION HEIGHT BLOCK Fig. 7 ADJUSTER LOCK BOLT 1 - DIFFERENTIAL CASE 2 - ADJUSTER LOCK 3 - ADJUSTER LOCK BOLT...
Page 227 3 - 146 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) (6) Install ring gear side adjuster lock and bolt. Do GEAR TOOTH CONTACT PATTERN not tighten adjuster lock bolt at this time. Gear tooth contact pattern is used to verify the cor- (7) Tighten pinion gear...
Page 228 REAR AXLE - 11 1/2 AA 3 - 147 REAR AXLE - 11 1/2 AA (Continued) Fig. 12 INCORRECT BACKLASH Fig. 14 INCORRECT BACKLASH 1 - DRIVE SIDE TOE 1 - DRIVE SIDE TOE 2 - COAST SIDE HEEL 2 - COAST SIDE TOE •...
Page 229 3 - 148 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.73, 4.10 Ring Gear Diameter 292 mm (11.5 in.) Ring Gear Backlash 0.13-0.18 mm (0.005-0.007 in.) Pinion Bearing Preload - New Bearings 1.69-2.82 N·m (15-25 in.
Page 230 REAR AXLE - 11 1/2 AA 3 - 149 REAR AXLE - 11 1/2 AA (Continued) DIAL INDICATOR STUD L-4438 ARBOR DISCS 8289 SPLITTER 1130 ADJUSTER WRENCH 8883 PINION DEPTH GAUGE 6730 SEAL INSTALLER 8896 CUP INSTALLER 8153...
Page 231 3 - 150 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) PINION BLOCK 8897 CUP INSTALLER 8961 SOCKET 8954 SEAL INSTALLER 8963 CUP INSTALLER 8960 PLUG 8964...
Page 232 REAR AXLE - 11 1/2 AA 3 - 151 REAR AXLE - 11 1/2 AA (Continued) BEARING INSTALLER 8965 FLANGE WRENCH 8979 CUP INSTALLER 8968 PINION INSTALLER 8981 PINION DRIVER 8977 FLANGE PULLER 8992...
Page 233 3 - 152 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) AXLE BEARINGS REMOVAL (1) Remove axle shaft flange bolts and remove shaft. (2) Remove retianer ring (Fig. 18) from the axle shaft tube. BRIDGE 938 AXLE SHAFTS REMOVAL (1) Remove axle shaft flange bolts (Fig.
Page 234 REAR AXLE - 11 1/2 AA 3 - 153 AXLE BEARINGS (Continued) (4) Remove hub bearing nut with Socket 8954. (5) Remove hub and bearings from the axle. (6) Pry out hub bearing seal from the back of the hub. NOTE: The inner part of the seal may stay on the axle tube (Fig.
Page 235 3 - 154 REAR AXLE - 11 1/2 AA PINION SEAL (Continued) Fig. 25 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER Fig. 23 FLANGE WRENCH (5) Hold pinion flange with Flange Wrench 8979 1 - PINION FLANGE (Fig. 26) and tighten pinion nut until pinion end play 2 - FLANGE WRENCH is taken up.
Page 236 REAR AXLE - 11 1/2 AA 3 - 155 DIFFERENTIAL REMOVAL (1) Remove fill hole plug from the differential housing cover. (2) Remove differential housing cover and drain the lubricant. (3) Remove axle shafts. (4) Remove adjuster lock bolts and adjuster locks (Fig.
Page 237 3 - 156 REAR AXLE - 11 1/2 AA DIFFERENTIAL (Continued) (3) Rotate one pinion gear with thrust washer (Fig. 30) to the differential window and remove the gear. Fig. 32 SIDE GEARS 1 - SIDE GEAR 2 - SIDE GEAR 3 - PINION GEARS Fig.
Page 238 REAR AXLE - 11 1/2 AA 3 - 157 DIFFERENTIAL (Continued) (3) Install first pinion gear into the differential window and side gears. Rotate the pinion gear to the back of the case (Fig. 34). Fig. 35 PINION SHAFT INSTALLATION 1 - SNAP RING 2 - SIDE GEAR 3 - PINION GEAR...
Page 239 3 - 158 REAR AXLE - 11 1/2 AA DIFFERENTIAL (Continued) (5) Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained. (6) Holding the differential case toward the pinion gear, turn bearing adjusters with Spanner Wrench 8883 until they make contact with the differential...
Page 240 REAR AXLE - 11 1/2 AA 3 - 159 DIFFERENTIAL TRAC-RITE (Continued) Fig. 38 LOCATION SCREWS Fig. 40 PINION BRAKE SHOES 1 - DIFFERENTIAL COVER 1 - BRAKE SHOES 2 - LOCATION SCREWS 2 - PINION GEARS Fig. 39 SIDE GEAR AND THRUST WASHER Fig.
Page 241 3 - 160 REAR AXLE - 11 1/2 AA DIFFERENTIAL TRAC-RITE (Continued) CLEANING Clean the differential case and gears with light oil or a lint free cloth. NOTE: Never use water, steam, kerosene or gaso- line for cleaning. INSPECTION NOTE: Minor corrosion, nicks or scratches can be smoothed with 400 grit emery cloth and polished out with crocus cloth.
Page 242 REAR AXLE - 11 1/2 AA 3 - 161 DIFFERENTIAL TRAC-RITE (Continued) ASSEMBLY (7) Install other set of brake shoes onto the pinion gears shafts (Fig. 46). NOTE: Install all component in their original loca- tions. (1) Lubricate all gears and differential bores with differential lubricant.
Page 243 3 - 162 REAR AXLE - 11 1/2 AA DIFFERENTIAL CASE BEARINGS (Continued) PINION GEAR/RING GEAR/ TONE RING REMOVAL NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear. (1) Mark pinion flange and propeller shaft for installation alignment.
Page 244 REAR AXLE - 11 1/2 AA 3 - 163 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 52 PINION FLANGE PULLER Fig. 50 RING GEAR 1 - PINION FLANGE 1 - DIFFERENTIAL CASE 2 - PULLER 2 - RING GEAR 3 - HAMMER Fig.
Page 245 3 - 164 REAR AXLE - 11 1/2 AA PINION GEAR/RING GEAR/TONE RING (Continued) (14) Remove rear pinion bearing with Bearing (2) Install new rear pinion bearing cup (Fig. 56) Splitter 1130 and a press (Fig. 54). with Installer 8968 and Handle C-4171. Fig.
Page 246 REAR AXLE - 11 1/2 AA 3 - 165 PINION GEAR/RING GEAR/TONE RING (Continued) (4) Install rear pinion bearing (Fig. 58) with shaft into the front bearing with Installer 8981 (Fig. Installer D-389 and a press. 60). Fig. 60 PINION GEAR INSTALLER 1 - INSTALLER 2 - DIFFERENTIAL HOUSING (8) Install new pinion seal (Fig.
Page 247 3 - 166 REAR AXLE - 11 1/2 AA PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 62 FLANGE WRENCH 1 - FLANGE WRENCH 2 - PINION FLANGE Fig. 64 EXCITER RING 1 - EXCITER RING 2 - RING GEAR 3 - DIFFERENTIAL PLUG 4 - DIFFERENTIAL CASE Drive the ring down until it is seated against the ring gear.
Page 248 REAR AXLE - 11 1/2 AA 3 - 167 PINION GEAR/RING GEAR/TONE RING (Continued) (21) Install differential in housing and verify gear (24) Install the propeller shaft with the reference backlash and gear contact pattern. marks aligned. (22) Measure final rotating torque with an inch (25) Install differential cover with gasket and pound torque wrench.
Page 250 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS .
Page 251 5 - 2 BRAKES - BASE FLUID RESERVOIR REMOVAL - REAR DUAL WHEELS ..34 REMOVAL ......23 INSTALLATION INSTALLATION .
Page 252 BRAKES - BASE 5 - 3 BRAKES - BASE (Continued) normal and should not be mistaken for contam- to inspect and replace all worn component and make ination. the proper adjustments. (a) If fluid level is abnormally low, look for evi- SPONGY PEDAL dence of leaks at calipers, wheel cylinders, brake A spongy pedal is most often caused by air in the...
Page 253 5 - 4 BRAKES - BASE BRAKES - BASE (Continued) • Drum brake shoes binding on worn/damaged BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP WATER PUDDLES support plates. • Mis-assembled components. This condition is generally caused by water soaked •...
Page 254 BRAKES - BASE 5 - 5 BRAKES - BASE (Continued) of chatter are out-of-tolerance rotors, brake lining not (4) Open up bleeder, then have a helper press securely attached to the shoes, loose wheel bearings down the brake pedal. Once the pedal is down close and contaminated brake lining.
Page 255 5 - 6 BRAKES - BASE BRAKES - BASE (Continued) HANDLE C-4171 Fig. 2 LOWER DRIVERS SIDE BEZEL 1 - SCREWS (2) 2 - ADJUSTABLE PEDAL SWITCH (if equipped) 3 - PEDAL SWITCH ELECTRICAL CONNECTOR 4 - BEZEL ADJUSTABLE PEDAL MOTOR DESCRIPTION CAP, MASTER CYLINDER PRESSURE BLEED 6921 The Adjustable Pedals System (APS) is designed to...
Page 256 BRAKES - BASE 5 - 7 ADJUSTABLE PEDAL MOTOR (Continued) • Pedal Adjustment Inhibitors: Pedal adjust- ment is inhibited when the vehicle is in reverse or when cruise control is activated. Fig. 4 ADJUSTABLE PEDAL MOTOR 1 - ADJUSTABLE PEDAL MOTOR 2 - MOUNTING BOLT Fig.
Page 257 5 - 8 BRAKES - BASE HYDRAULIC/MECHANICAL SPECIFICATIONS SPECIFICATIONS - TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Brake Booster Mounting Nuts Master Cylinder — Mounting Nuts Caliper — Mounting Pins Front Caliper — Mounting Pins Rear Caliper —...
Page 258 BRAKES - BASE 5 - 9 HYDRAULIC/MECHANICAL (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Caliper Brake Line Banjo Bolt Rear Brake Hose — Front Bolts To Frame Brake Hose Front Fitting Brake Hose Rear Fitting Parking Brake Pedal Assembly Rotor to Hub Bolt —...
Page 259: Brake Lines
5 - 10 BRAKES - BASE HYDRAULIC/MECHANICAL (Continued) BASE BRAKE DESCRIPTION SPECIFICATION SPECIFICATIONS Rear Disc Brake Caliper 1x54 mm (2.12 in) DESCRIPTION SPECIFICATION Rear Disc Brake Caliper 2x45 mm (1.77 in) Front Disc Brake Caliper Dual Piston Sliding Type Rear Disc Brake Caliper Single Piston Sliding Rear Disc Brake Caliper 2x51 mm (2.00 in)
Page 260 BRAKES - BASE 5 - 11 BRAKE LINES (Continued) (9) Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool. This will start the inverted flare. (10) Remove the plug gauge and complete the inverted flare. Fig.
Page 261 5 - 12 BRAKES - BASE BRAKE LINES (Continued) (7) Remove the mounting bolt for the brake hose REMOVAL - FRONT HOSE at the axle (Fig. 8). (1) Install a prop rod on the brake pedal to keep (8) Remove the hose. pressure on the brake system.
Page 262 BRAKES - BASE 5 - 13 BRAKE LINES (Continued) INSTALLATION - REAR TUBE / HOSE (3) Compress the caliper. (4) Remove the caliper, (Refer to 5 - BRAKES/HY- ASSEMBLY DRAULIC/MECHANICAL/DISC BRAKE CALIPERS (1) Install the hose. - REMOVAL). (2) Install the banjo bolt at the caliper (Fig. 9) and (5) Remove the caliper by tilting the top up and off tighten fitting bolt to 27 N·m (245 in.
Page 263 5 - 14 BRAKES - BASE BRAKE PADS/SHOES (Continued) NOTE: Anti-rattle springs are not interchangeable. Fig. 16 Top Anti-Rattle Spring 1 - CALIPER ADAPTER 2 - ANTI-RATTLE SPRING Fig. 14 Inboard Brake Shoe 1 - INBOARD SHOE 2 - CALIPER ADAPTER (8) Remove the outboard brake shoe from the cali- per adapter (Fig.
Page 264 BRAKES - BASE 5 - 15 BRAKE PADS/SHOES (Continued) Fig. 18 DISC BRAKE CALIPER - REAR 1 - CALIPER ADAPTER 2 - CALIPER ADAPTER MOUNTING BOLTS 3 - CALIPER SLIDE BOLTS 4 - BRAKE HOSE 5 - CABLE 6 - CALIPER 7 - ROTOR Fig.
Page 265 5 - 16 BRAKES - BASE BRAKE PADS/SHOES (Continued) (7) Tilt the top of the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the adapter. (8) Install caliper, (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).
Page 266 BRAKES - BASE 5 - 17 DISC BRAKE CALIPERS (Continued) is just enough to maintain contact between the pis- ton and inboard brake pad. Fig. 25 Lining Wear Compensation By Piston Seal 1 - PISTON 2 - CYLINDER BORE 3 - PISTON SEAL BRAKE PRESSURE OFF 4 - CALIPER HOUSING 5 - DUST BOOT 6 - PISTON SEAL BRAKE PRESSURE ON...
Page 267 5 - 18 BRAKES - BASE DISC BRAKE CALIPERS (Continued) Fig. 28 DISC BRAKE CALIPER - REAR Fig. 26 DISC BRAKE CALIPER - FRONT 1 - CALIPER ADAPTER 1 - STEERING KNUCKLE 2 - CALIPER ADAPTER MOUNTING BOLTS 2 - DISC BRAKE CALIPER 3 - CALIPER SLIDE BOLTS 3 - CALIPER MOUNTING ADAPTER 4 - BRAKE HOSE...
Page 268 BRAKES - BASE 5 - 19 DISC BRAKE CALIPERS (Continued) CAUTION: Do not scratch piston bore while remov- ing the seals. (10) Push caliper mounting bolt bushings out of the boot seals and remove the boot seals from the caliper (Fig. 33). (11) Remove caliper bleed screw.
Page 269 5 - 20 BRAKES - BASE DISC BRAKE CALIPERS (Continued) CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never inter- change phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different.
Page 270 BRAKES - BASE 5 - 21 DISC BRAKE CALIPERS (Continued) CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. (5) Remove the prop rod from the vehicle. (6) Bleed the base brake system,(Refer to 5 - BRAKES - STANDARD PROCEDURE) OR (Refer to 5 - BRAKES - STANDARD PROCEDURE).
Page 271 5 - 22 BRAKES - BASE DISC BRAKE CALIPER ADAPTER (Continued) (4) Bottom the caliper pistons into the caliper by (2) Install the anti-rattle clips (Fig. 39). prying the caliper over. (3) Install the inboard and outboard pads (Fig. 39). (5) Remove the caliper slide bolts.
Page 272: Fluid Reservoir
BRAKES - BASE 5 - 23 DISC BRAKE CALIPER ADAPTER MOUNT (Continued) (3) Install parking brake cable in the brake lever. (4) Install the park brake shoes (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - INSTALLA- TION). (Fig. 66). (5) Install axle shaft, (Refer to 3 - DIFFEREN- TIAL &...
Page 273: Master Cylinder
5 - 24 BRAKES - BASE FLUID RESERVOIR (Continued) (5) Remove the reservoir from the master cylinder by pulling upwards. (6) Remove old grommets from cylinder body (Fig. 42). Fig. 43 JUNCTION BLOCK 1 - BRAKE LINES 2 - JUNCTION BLOCK INSTALLATION Fig.
Page 274 BRAKES - BASE 5 - 25 MASTER CYLINDER (Continued) The cylinder reservoir can be replaced when neces- sary. However, the aluminum body section of the master cylinder is not a repairable component. NOTE: If diagnosis indicates that an internal mal- function has occurred, the aluminum body section must be replaced as an assembly.
Page 275 5 - 26 BRAKES - BASE MASTER CYLINDER (Continued) STANDARD PROCEDURE - MASTER CYLINDER NOTE: Gently ease the master cylinder & reservoir assembly away from the booster, During removal BLEEDING the master cylinder should be kept as perpendicular A new master cylinder should be bled before instal- to the front of the booster as possible to avoid lation on the vehicle.
Page 276 BRAKES - BASE 5 - 27 MASTER CYLINDER (Continued) Fig. 48 HYDROBOOST MASTER CYLINDER Fig. 49 OUTPUT ROD ORIENTATION 1 - HYDROBOOST UNIT 1 - MASTER CYLINDER RESERVOIR 2 - MASTER CYLINDER RESERVOIR 2 - CHECK VALVE 3 - MASTER CYLINDER 3 - VACUUM BOOST UNIT 4 - MOUNTING NUTS 4 - BOOSTER MOUNTING STUDS...
Page 277 5 - 28 BRAKES - BASE (3) Remove the brake lamp switch and discard(Re- PEDAL fer to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTE- RIOR/BRAKE LAMP SWITCH - REMOVAL). DESCRIPTION (4) On vehicles equipped with adjustable ped- als. Disconnect the adjuster cable to the pedal (Fig. NOTE: The brake pedal is serviced as a complete 51).
Page 278: Power Brake Booster
BRAKES - BASE 5 - 29 PEDAL (Continued) REMOVAL (1) Remove master cylinder. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/MASTER CYLINDER - REMOVAL). (2) Disconnect vacuum line at booster. (3) Remove clip securing booster push rod to brake pedal (Refer to 5 - BRAKES/HYDRAULIC/MECHAN- ICAL/PEDAL - REMOVAL).
Page 279 5 - 30 BRAKES - BASE should be at least two power assisted brake applica- HYDRO-BOOST BRAKE tion with the engine off. If the system does not retain BOOSTER a charge the booster must be replaced. (2) With the engine off depress the brake pedal DIAGNOSIS AND TESTING - HYDRAULIC several times to discharge the accumulator.
Page 280 BRAKES - BASE 5 - 31 HYDRO-BOOST BRAKE BOOSTER (Continued) HYDRAULIC BOOSTER DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION Slow Brake Pedal Return 1. Excessive seal friction in booster. 1. Replace booster. 2. Faulty spool valve action. 2. Replace booster. 3. Restriction in booster return hose. 3.
Page 281 5 - 32 BRAKES - BASE HYDRO-BOOST BRAKE BOOSTER (Continued) system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. (12) Bleed the hydraulic booster (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/POWER BRAKE BOOSTER - STANDARD PROCEDURE).
Page 282 BRAKES - BASE 5 - 33 ROTORS (Continued) DISC BRAKE CALIPERS - REMOVAL) and remove caliper adapter assembly (Fig. 58). NOTE: Do not allow brake hose to support caliper adapter assembly. Fig. 56 Checking Rotor Runout And Thickness Variation 1 - DIAL INDICATOR Position the micrometer approximately 25.4 mm (1 in.) from the rotor outer circumference for each mea- surement.
Page 283 5 - 34 BRAKES - BASE ROTORS (Continued) REMOVAL - REAR DUAL WHEELS (1) Raise and support the vehicle (2) Remove the tire and wheel assembly. (3) Remove the disc brake caliper, (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - REMOVAL). (4) Remove the caliper adapter bolts.
Page 284 BRAKES - BASE 5 - 35 ROTORS (Continued) (2) Install the caliper adapter (Fig. 61) (Refer to 5 BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPER ADAPTER - INSTALLATION). (3) Install the caliper adapter bolts (Fig. 61) and tighten the mounting bolts to 135 N·m (100 ft.lbs). (4) Install the disc brake caliper, (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/DISC BRAKE CALIPERS - INSTALLATION).
Page 285: Parking Brake
5 - 36 BRAKES - BASE SUPPORT PLATE (Continued) INSTALLATION (1) Install support plate on axle flange (Fig. 66). Tighten attaching bolts to 115 N·m (85 ft. lbs.). (2) Install parking brake cable in the brake lever. (3) Install the park brake shoes (Refer to 5 - BRAKES/PARKING BRAKE/SHOES - INSTALLA- TION).
Page 286 BRAKES - BASE 5 - 37 CABLES (Continued) (5) Compress cable end fitting at underbody bracket and remove the cable from the bracket. (6) Lower vehicle. (7) Push ball end of cable out of pedal clevis with small screwdriver. (8) Compress cable end fitting at the pedal bracket and remove the cable (Fig.
Page 287 5 - 38 BRAKES - BASE CABLES (Continued) INSTALLATION INSTALLATION - FRONT PARKING BRAKE CABLE (1) From inside the vehicle, insert the cable end fitting into the hole in the pedal assembly. (2) Seat the cable retainer in the pedal assembly. (3) Engage the cable ball end in clevis on the pedal assembly.
Page 288 BRAKES - BASE 5 - 39 CABLES (Continued) Fig. 74 LOCK OUT PARKING CABLE Fig. 73 PARKING BRAKE CABLE 1 - LOCKING PLIERS 1 - SUPPORT PLAT 2 - PARKING BRAKE CABLE 2 - CABLE 3 - LEVER INSTALLATION - LEFT REAR CABLE (1) Install the brake cable to the brake lever (Fig.
Page 289 5 - 40 BRAKES - BASE SHOES (Continued) Fig. 76 AXLE SHAFT 1 - AXLE SHAFT 2 - SUPPORT PLATE 3 - CALIPER 4 - PARK BRAKE SHOE ASSEMBLY Inspect the adjuster screw assembly. Replace the Fig. 77 PARK BRAKE SHOES assembly if the star wheel or threads are damaged, or the components are severely rusted or corroded 1 - SUPPORT PLATE...
Page 290 BRAKES - BASE 5 - 41 SHOES (Continued) (8) Install the tire and wheel assembly (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCE- DURE). (9) Lower the vehicle. ADJUSTMENTS ADJUSTMENT - PARKING BRAKE SHOES CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully released position.
Page 291 5 - 42 BRAKES - BASE SHOES (Continued) (12) Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum.
Page 292 BRAKES - BASE 5 - 43 PEDAL (Continued) CABLE TENSIONER ADJUSTMENTS ADJUSTMENT NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is nec- essary, perform adjustment only as described in the following procedure.
Page 293 5 - 44 BRAKES - BASE CABLE TENSIONER (Continued) Fig. 85 Adjustment Mark 1 - TENSIONER CABLE BRACKET 2 - TENSIONER 3 - CABLE CONNECTOR 4 - 6.35mm (1/4 IN.) 5 - ADJUSTER NUT Fig. 86 Park Brake Release Handle Remove/Install RELEASE HANDLE 1 - CLIP 2 - ROD...
Page 294 BRAKES - ABS 5 - 45 BRAKES - ABS TABLE OF CONTENTS page page BRAKES - ABS TONE WHEEL DESCRIPTION ......45 DIAGNOSIS AND TESTING - REAR WHEEL OPERATION .
Page 295 5 - 46 BRAKES - ABS BRAKES - ABS (Continued) Brake fluid apply pressure is modulated according STANDARD PROCEDURE - ABS BRAKE to wheel speed, degree of slip and rate of decelera- BLEEDING tion. Sensors at each front wheel convert wheel speed ABS system bleeding requires conventional bleed- into electrical signals.
Page 296 BRAKES - ABS 5 - 47 FRONT WHEEL SPEED SENSOR DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings. The third sensor is mounted on top of the rear axle dif- ferential housing.
Page 297 5 - 48 BRAKES - ABS FRONT WHEEL SPEED SENSOR (Continued) REMOVAL NOTE: The MDS or DRB III scan tool is used to diagnose the RWAL system. For test procedures (1) Remove the front rotor (Refer to 5 - BRAKES/ refer to the Chassis Diagnostic Manual.
Page 298 BRAKES - ABS 5 - 49 TONE WHEEL HCU (HYDRAULIC CONTROL UNIT) DIAGNOSIS AND TESTING - REAR WHEEL SPEED SENSOR DESCRIPTION Diagnosis of base brake conditions which are The HCU consists of a valve body, pump motor, low mechanical in nature should be performed first. This pressure accumulators, inlet valves, outlet valves and includes brake noise, lack of power assist, parking noise attenuators.
Page 299 5 - 50 BRAKES - ABS HCU (HYDRAULIC CONTROL UNIT) (Continued) PRESSURE INCREASE RWAL VALVE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pres- DESCRIPTION sure increase cycle is used to reapply thew brakes. Rear Wheel Antilock (RWAL) brake system is stan- This cycle controls re-application of fluid apply pres- dard equipment on 1500 series vehicles.
Page 300 BRAKES - ABS 5 - 51 RWAL VALVE (Continued) REMOVAL (1) Install a prop rod on the brake pedal to keep pressure on the brake system. (2) Disconnect the battery cables from the battery. (3) Remove the battery. (4) Disconnect the electrical harness connector (Fig.
Page 302 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH REMOVAL ......11 WARNING .
Page 303 6 - 2 CLUTCH CLUTCH (Continued) Engagement problems can cause slip, chatter/shud- FLYWHEEL RUNOUT der and noisy operation. The causes may be clutch Check flywheel runout whenever misalignment is disc contamination, wear, distortion or flywheel dam- suspected. Flywheel runout should not exceed 0.08 age.
Page 304 CLUTCH 6 - 3 CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch disc facing contaminated with 1. Leak at rear main engine seal or 1. Replace appropriate seal. oil, grease, or clutch fluid. transmission input shaft seal. 2. Excessive amount of grease 2.
Page 305 6 - 4 CLUTCH CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Pilot bearing seized, loose, or rollers 1. Bearing cocked during 1. Install a new bearing. are worn. installation. 2. Bearing defective. 2. Install a new bearing. 3. Bearing not lubricated. 3.
Page 306: Clutch Disc
CLUTCH 6 - 5 CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Partial engagement of clutch disc. 1. Clutch pressure plate position 1. Replace clutch disc and cover. One side of disc is worn and the incorrect. other side is glazed and lightly 2.
Page 307 6 - 6 CLUTCH CLUTCH DISC (Continued) Fig. 1 PRESSURE PLATE POSITION-TYPICAL 1 - FLYWHEEL 2 - ALIGNMENT MARKS 3 - PRESSURE PLATE Fig. 3 LUBRICATION POINTS 1 - CLUTCH HOUSING 2 - FORK PIVOT BALL 3 - RELEASE FORK 4 - RELEASE BEARING BORE 5 - LUBE POINTS CAUTION: Do not over lubricate shaft splines.
Page 308: Clutch Housing
CLUTCH 6 - 7 CLUTCH DISC (Continued) (11) Wipe pilot bearing surface clean. CLUTCH HOUSING BORE RUNOUT (12) Install release lever and bearing in clutch housing. Verify spring clips that retain fork on pivot CAUTION: On diesel engines if housing bore runout ball and release bearing on fork are installed prop- exceeds 0.015 inch, the clutch housing/transmis- erly (Fig.
Page 309 6 - 8 CLUTCH CLUTCH HOUSING (Continued) Fig. 9 ALIGNMENT DOWEL SELECTION Fig. 7 CLUTCH HOUSING BORE RUNOUT 1 - SLOT DIRECTION OF OFFSET 1 - MOUNTING STUD OR ROD 2 - DIAL INDICATOR 2 - OFFSET DOWEL 3 - INDICATOR PLUNGER 4 - CLUTCH HOUSING BORE TIR VALUE OFFSET DOWEL REQUIRED...
Page 310 CLUTCH 6 - 9 CLUTCH HOUSING (Continued) Fig. 11 MEASUREMENT POINTS AND READINGS 1 - CLUTCH HOUSING FACE CIRCLE (AT RIM OF BORE) To correct this example (Fig. 11) the shims needed Fig. 13 TRANSMISSION/CLUTCH HOUSING-NV4500 between the clutch housing and transmission are: 1 - CLUTCH HOUSING •...
Page 311 6 - 10 CLUTCH CLUTCH RELEASE BEARING (Continued) Fig. 15 CLUTCH RELEASE COMPONENTS 1 - CONED WASHER 2 - CLUTCH HOUSING 3 - RELEASE FORK 4 - RELEASE BEARING AND SLEEVE 5 - PIVOT 23 N·m (200 IN. LBS.) 6 - SPRING CLIP Fig.
Page 312: Cooling
CLUTCH 6 - 11 FLYWHEEL (Continued) Common causes of runout are: ASSEMBLY • heat warpage • improper machining NOTE: The ring gear is a shrink fit on the flywheel. • incorrect bolt tightening This means the gear must be expanded by heating •...
Page 313 6 - 12 CLUTCH PILOT BEARING (Continued) INSTALLATION (1) Clean bearing bore with solvent and wipe dry with shop towel. (2) Install new bearing with clutch alignment tool (Fig. 17). Drive bearing into place with the letter side of the bearing facing the transmission. Bearing should be flush with edge of bearing bore.
Page 314 CLUTCH 6 - 13 LINKAGE (Continued) (2) Apply a light coating of grease to the inside diameter of the master cylinder push rod eye. (3) Install clutch master cylinder on dash panel and tighten clutch master cylinder nuts to 28 N·m (21 ft.
Page 316 COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING STANDARD PROCEDURE - COOLING DESCRIPTION SYSTEM CLEANING/REVERSE FLUSHING . . 17 DESCRIPTION - COOLING SYSTEM FLOW STANDARD PROCEDURE - DRAINING 3.7L/4.7L/5.7L ENGINE ....1 COOLING SYSTEM - ALL GAS ENGINES .
Page 317 7 - 2 COOLING COOLING (Continued) Fig. 1 Engine Cooling System Flow - 3.7L/4.7L 1 - LH CYL. HEAD 6 - LH BANK CYL. BLOCK 2 - BLEED 7 - COOLANT TEMP. SENSOR 3 - THERMOSTAT LOCATION 8 - FROM HEATER CORE 4 - RH CYL.
Page 318 COOLING 7 - 3 COOLING (Continued) Fig. 2 5.7L Engine Coolant System Flow 1 - LH CYLINDER HEAD 3 - FROM RADIATOR 2 - TO RADIATOR 4 - TO RH CYLINDER HEAD DESCRIPTION - COOLING SYSTEM FLOW - DESCRIPTION - HOSE CLAMPS 5.9L DIESEL The cooling system utilizes spring type hose clamps.
Page 319 7 - 4 COOLING COOLING (Continued) Fig. 3 Cooling System Circulation - 5.9L Diesel Engine...
Page 320 COOLING 7 - 5 COOLING (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING—ON-BOARD DIAGNOSTICS (OBD) COOLING SYSTEM RELATED DIAGNOSTICS The Engine Control Module (ECM) has been pro- grammed to monitor certain cooling system compo- nents: • If the engine has remained cool for too long a period, such as with a stuck open thermostat, a Diag- nostic Trouble Code (DTC) can be set.
Page 321 7 - 6 COOLING COOLING (Continued) that does not appear with normal system test pres- sure. If it is certain that coolant is being lost and leaks cannot be detected, inspect for interior leakage or perform Internal Leakage Test. Refer to INTER- NAL LEAKAGE INSPECTION.
Page 322 COOLING 7 - 7 COOLING (Continued) exhaust pipe may indicate a faulty cylinder head gas- COOLANT THERMOSTAT - REMOVAL). Remove ket, cracked engine cylinder block or cylinder head. accessory drive belt (Refer to 7 - COOLING/ACCES- A convenient check for exhaust gas leakage into SORY DRIVE/DRIVE BELTS - REMOVAL).
Page 323 7 - 8 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 1. Vehicle overloaded, high ambient 1. Temporary condition, repair not HIGH. COOLANT MAY OR MAY (outside) temperatures with A/C required. Notify customer of vehicle NOT BE LEAKING FROM SYSTEM turned on, stop and go driving or operation instructions located in prolonged operation at idle speeds.
Page 324 COOLING 7 - 9 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READING 1. Heavy duty cooling system, 1. None. System operating normally. INCONSISTENT (ERRATIC, extreme cold ambient (outside) CYCLES OR FLUCTUATES) temperature or heater blower motor in high position. NOTE: Information on daash cluster 2.
Page 325 7 - 10 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR CONDITIONER 1. Radiator and/or A/C condenser 1. Remove obstruction and/or clean. PERFORMANCE (COOLING air flow obstructed. SYSTEM SUSPECTED) 2. Electronically controlled viscous 2. Check viscous fan drive (Refer to fan drive not working.
Page 326 COOLING 7 - 11 COOLING (Continued) COOLING SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. (Refer to 25 - EMISSIONS (DTC) been set indicating a stuck CONTROL - DESCRIPTION) for open thermostat? On-Board Diagnostics and DTC information.
Page 327 7 - 12 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Is the temperature warning 3. (Refer to 8 - ELECTRICAL/ illuminating unnecessarily? INSTRUMENT CLUSTER - SCHEMATIC - ELECTRICAL). 4. Coolant low in coolant reserve/ 4. Check for coolant leaks and overflow tank and radiator? repair as necessary.
Page 328 COOLING 7 - 13 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 11. Radiator core is corroded or 11. Have radiator re-cored or plugged. replaced. 12. Fuel or ignition system 12. Refer to 14 - Fuel System or 8 - problems. Electrical for diagnosis and testing procedures.
Page 329: Exhaust System
7 - 14 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Temperature gauge reading is 1. During cold weather operation, 1. A normal condition. No correction inconsistent (fluctuates, cycles or is with the heater blower in the high necessary. erratic) position, the gauge reading may drop slightly.
Page 330 COOLING 7 - 15 COOLING (Continued) 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. (Refer to 7 - COOLING - CAP BLOWOFF.
Page 331 7 - 16 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE HEATER 1. Has a Diagnostic trouble Code 1. (Refer to 25 - EMISSIONS PERFORMANCE. THERMOSTAT (DTC) been set? CONTROL - DESCRIPTION) for FAILED IN OPEN POSITION correct procedures and replace thermostat if necessary 2.
Page 332 COOLING 7 - 17 COOLING (Continued) CAUTION: Internal radiator pressure must not STANDARD PROCEDURE exceed 138 kPa (20 psi) as damage to radiator may result. STANDARD PROCEDURE - COOLANT LEVEL CHECK Allow the radiator to fill with water. When the radiator is filled, apply air in short blasts.
Page 333 7 - 18 COOLING COOLING (Continued) DO NOT WASTE reusable coolant. If solution is STANDARD PROCEDURE - REFILLING clean, drain coolant into a clean container for reuse. COOLING SYSTEM - ALL GAS ENGINES (1) Attach one end of a hose to the draincock. Put the other end into a clean container.
Page 334 COOLING 7 - 19 COOLING (Continued) STANDARD PROCEDURE - REFILLING AND UNDER PRESSURE. SERIOUS BURNS FROM THE COOLANT OR HIGH PRESSURE STEAM CAN COOLING SYSTEM 5.9L DIESEL ENGINE OCCUR. Clean cooling system prior to refilling (Refer to 7 - COOLING - STANDARD PROCEDURE). (1) Close radiator drain plug.
Page 335 7 - 20 COOLING COOLING (Continued) DESCRIPTION N·m Lbs. Lbs. Nuts - Transmission Oil 31.5 Cooler Tube Bolts - Coolant Bottle Tube Nuts - Transmission Oil Cooler to Transmission 3/8” Quick Connect Release Tool - 6935 5.9L/46RE 31.5 3.7L/4.7L/5.7L/45RFE Bolts - Water Pump - Diesel Bolts - Water Pump - 4.7L Block Heater - Diesel...
Page 336 ACCESSORY DRIVE 7 - 21 ACCESSORY DRIVE TABLE OF CONTENTS page page BELT TENSIONER - 3.7L / 4.7L REMOVAL ......23 DESCRIPTION .
Page 337 7 - 22 ACCESSORY DRIVE BELT TENSIONER - 3.7L / 4.7L (Continued) (1) Remove accessory drive belt (Refer to 7 - BELT TENSIONER-5.7L COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL). DESCRIPTION (2) Remove tensioner assembly from mounting Correct drive belt tension is required to ensure bracket (Fig.
Page 338 ACCESSORY DRIVE 7 - 23 BELT TENSIONER-5.7L (Continued) INSTALLATION OPERATION (1) Install tensioner on to the mounting bracket. WARNING: THE AUTOMATIC BELT TENSIONER Tighten bolt to 41 N·m (30 ft. lbs.). ASSEMBLY IS SPRING LOADED. DO NOT ATTEMPT (2) Install tensioner and bracket assembly TO DISASSEMBLE THE TENSIONER ASSEMBLY.
Page 339 7 - 24 ACCESSORY DRIVE BELT TENSIONER - 5.9L DIESEL (Continued) INSTALLATION (1) Install tensioner assembly to water inlet bracket. A dowel is located on back of tensioner. Align this dowel to hole in tensioner mounting bracket. Tighten bolt to 43 N·m (32 ft. lbs.) torque. (2) Install drive belt (Refer to 7 - COOLING/AC- CESSORY DRIVE/DRIVE BELTS - INSTALLA- TION).
Page 340 ACCESSORY DRIVE 7 - 25 DRIVE BELT - 3.7L / 4.7L (Continued) CONDITION POSSIBLE CAUSES CORRECTION BELT SLIPS 1. Belt slipping because of 1. Inspect/Replace tensioner if insufficient tension necessary 2. Belt or pulley exposed to 2. Replace belt and clean pulleys substance that has reduced friction (belt dressing, oil, ethylene glycol) 3.
Page 341 7 - 26 ACCESSORY DRIVE DRIVE BELT - 3.7L / 4.7L (Continued) CONDITION POSSIBLE CAUSES CORRECTION CORD EDGE FAILURE 1. Incorrect belt tension 1. Inspect/Replace tensioner if (Tensile member exposed at edges necessary of belt or separated from belt body) 2.
Page 342 ACCESSORY DRIVE 7 - 27 DRIVE BELT - 5.9L DIESEL DIAGNOSIS AND TESTING—ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 9), are considered normal. These are not a reason to replace the belt.
Page 343 7 - 28 ACCESSORY DRIVE DRIVE BELT - 5.9L DIESEL (Continued) CONDITION POSSIBLE CAUSES CORRECTION LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt groove 2. Pulley groove tip has worn away 2. Replace belt rubber to tensile member GROOVE JUMPING 1.
Page 344 ACCESSORY DRIVE 7 - 29 DRIVE BELT - 5.9L DIESEL (Continued) REMOVAL (2) Rotate ratchet and tensioner assembly clock- wise (as viewed from front) until tension has been relieved from belt. CAUTION: Do not attempt to check belt tension with (3) Remove belt from water pump pulley first.
Page 345 7 - 30 ENGINE ENGINE TABLE OF CONTENTS page page COOLANT INSTALLATION ......45 DESCRIPTION ENGINE COOLANT THERMOSTAT - 5.9L DESCRIPTION - ENGINE COOLANT .
Page 346 ENGINE 7 - 31 DIAGNOSIS AND TESTING - RADIATOR OPERATION ......62 CAP ....... . 58 DIAGNOSIS AND TESTING—WATER PUMP .
Page 347 7 - 32 ENGINE COOLANT (Continued) DESCRIPTION - HOAT COOLANT COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water WARNING: ANTIFREEZE IS AN ETHYLENE-GLYCOL mixture depends upon climate and vehicle operating BASE COOLANT AND IS HARMFUL IF SWAL- conditions. The coolant performance of various mix- LOWED OR INHALED.
Page 348 ENGINE 7 - 33 COOLANT (Continued) OPERATION to the radiator to cover minor leaks and evaporation or boiling losses. Coolant flows through the engine block absorbing As the engine cools, a vacuum is formed in the the heat from the engine, then flows to the radiator cooling system of both the radiator and engine.
Page 349 7 - 34 ENGINE RADIATOR FAN - GAS ENGINES (Continued) Fig. 2 Using Special Tool 6958 Spanner Wrench Fig. 3 Fan Blade/Viscous Fan Drive - Gas Engines - Typical 1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER PINS 8346 1 - WATER PUMP BYPASS HOSE 2 - FAN 2 - FAN BLADE ASSEMBLY...
Page 350 ENGINE 7 - 35 RADIATOR FAN - GAS ENGINES (Continued) (4) Install the fan blade/viscous fan drive assembly to the water pump shaft (Fig. 3). Tighten mounting nut to 50 N·m (37 ft. lbs.). Install the coolant reserve/overflow container to the fan shroud. (6) Connect the negative battery cable.
Page 351: Engine Block Heater
7 - 36 ENGINE RADIATOR FAN - 5.9L DIESEL (Continued) INSTALLATION (10) Install the coolant recovery container (Refer to COOLING/ENGINE/COOLANT RECOVERY (1) Install fan blade assembly to electrically con- CONTAINER - INSTALLATION). trolled viscous fan drive. Tighten mounting bolts to (11) Connect the battery negative cables.
Page 352 ENGINE 7 - 37 ENGINE BLOCK HEATER (Continued) Fig. 6 Engine Block Heater - 3.7L/4.7L Fig. 7 Engine Block Heater 1 - ENGINE BLOCK HEATER 1 - FREEZE PLUG HOLE 2 - BLOCK HEATER REMOVAL 3 - SCREW 4 - POWER CORD (120V AC) (1) Disconnect the battery negative cable.
Page 353: Engine Coolant Temperature Sensor
7 - 38 ENGINE ENGINE BLOCK HEATER - 5.9L DIESEL (Continued) INSTALLATION (1) Clean and inspect the threads in the cylinder block. (2) Coat heater element threads with Mopar Thread Sealer with Teflon. (3) Screw block heater into cylinder block and tighten to 55 N·m (41 ft.
Page 354 ENGINE 7 - 39 ENGINE COOLANT TEMPERATURE SENSOR (Continued) REMOVAL (1) Partially drain the cooling system. Refer to 7, COOLING. (2) Disconnect the electrical connector from the 3.7L V-6 ECT sensor. The Engine Coolant Temperature (ECT) sensor on (3) Remove the sensor from the intake manifold. the 3.7L engine is installed into a water jacket at front of intake manifold near rear of generator (Fig.
Page 355 7 - 40 ENGINE ENGINE COOLANT TEMPERATURE SENSOR (Continued) WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOV- ING THE COOLANT TEMPERATURE SENSOR. (1) Partially drain the cooling system. (2) Disconnect the electrical connector from the sensor.
Page 356 ENGINE 7 - 41 ENGINE COOLANT TEMPERATURE SENSOR (Continued) (4) Connect electrical connector to sensor. (5) Replace any lost engine coolant. (Refer to 7 - COOLING - STANDARD PROCEDURE). 5.9L Diesel (1) Install sensor to engine. (2) Tighten sensor to 18 N·m (13 ft. lbs.) torque. (3) Connect electrical connector to sensor.
Page 357 7 - 42 ENGINE ENGINE COOLANT THERMOSTAT- 5.7L (Continued) Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse. If the thermostat is being replaced, be sure that the replacement is the specified thermostat for the vehicle model and engine type.
Page 358 ENGINE 7 - 43 ENGINE COOLANT THERMOSTAT- 5.7L (Continued) (9) Remove the thermostat housing mounting bolts, thermostat housing, gasket and thermostat (Fig. 20). Discard old gasket. Fig. 18 Automatic Belt Tensioner – 5.9L Engines 1 - IDLER PULLEY 2 - TENSIONER 3 - FAN BLADE Fig.
Page 359 7 - 44 ENGINE ENGINE COOLANT THERMOSTAT- 5.7L (Continued) Fig. 22 Belt Routing – 5.9L Engines Fig. 21 Thermostat Position—5.9L Engines 1 - IDLER PULLEY (7) Air Conditioned vehicles; Install the generator. 2 - GENERATOR PULLEY 3 - A/C COMPRESSOR PULLEY Tighten the bolts to 41 N·m (30 ft.
Page 360 ENGINE 7 - 45 ENGINE COOLANT THERMOSTAT - 3.7L/4.7L (Continued) Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse. If the thermostat is being replaced, be sure that the replacement is the specified thermostat for the vehicle model and engine type.
Page 361 7 - 46 ENGINE ENGINE COOLANT THERMOSTAT - 3.7L/4.7L (Continued) Fig. 24 Thermostat and Thermostat Housing 3.7L/4.7L 1 - THERMOSTAT HOUSING 3 - THERMOSTAT AND GASKET 2 - THERMOSTAT LOCATION 4 - TIMING CHAIN COVER ENGINE COOLANT THERMOSTAT - 5.9L DIESEL DESCRIPTION CAUTION: Do not operate an engine without a ther- mostat, except for servicing or testing.
Page 362 ENGINE 7 - 47 ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued) DIAGNOSIS AND TESTING - THERMOSTAT before this temperature is reached, it is opening too early. Replace thermostat. The thermostat should be The cooling system used with the diesel engine fully open (valve will stop moving) at 97°C (207°F).
Page 363 7 - 48 ENGINE ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued) Fig. 26 Thermostat Removal/Installation 1 - THERMOSTAT HOUSING 2 - CYLINDER HEAD 3 - THERMOSTAT Fig. 27 Thermostat - 8.0L V-10 Engine (7) Start the engine and check for coolant leaks. 1 - COOLANT TEMP.
Page 364 ENGINE 7 - 49 ENGINE COOLANT THERMOSTAT - 8.0L (Continued) The DTC can also be accessed through the DRB scan tool. Refer to the appropriate Powertrain Diag- nostic Procedures information for diagnostic informa- tion and operation of the DRB scan tool. REMOVAL WARNING: DO NOT LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND PRES-...
Page 365 7 - 50 ENGINE ENGINE COOLANT THERMOSTAT - 8.0L (Continued) Fig. 31 Viscous Fan 1 - WATER PUMP BYPASS HOSE 2 - FAN BLADE ASSEMBLY 3 - VISCOUS FAN DRIVE 4 - WATER PUMP AND PULLEY Fig. 30 Thermostat - 8.0L V-10 Engine 5 - Bolts (4) 1 - COOLANT TEMP.
Page 366 ENGINE 7 - 51 FAN DRIVE VISCOUS CLUTCH-GAS ENGINES (Continued) (4) Block the air flow through the radiator. Secure a sheet of plastic in front of the radiator. Use tape at the top to secure the plastic and be sure that the air flow is blocked.
Page 367 7 - 52 ENGINE FAN DRIVE VISCOUS CLUTCH-GAS ENGINES (Continued) CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration.
Page 368 ENGINE 7 - 53 FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL (Continued) LEAKS Viscous fan drive operation is not affected by small oil stains near the drive bearing. If leakage appears excessive, replace the fan drive unit. ELECTRONICALLY CONTROLLED VISCOUS DRIVE If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when spun by hand), do not replace the fan drive.
Page 369 7 - 54 ENGINE CAUTION: A number or letter is stamped into the RADIATOR-3.7L/4.7L/5.7L tongue of constant tension clamps. If replacement is necessary, use only an original equipment clamp DESCRIPTION with a matching number or letter and the correct The radiator is a aluminum cross-flow design with width.
Page 370 ENGINE 7 - 55 RADIATOR-3.7L/4.7L/5.7L (Continued) (11) Remove the two radiator upper mounting INSPECTION bolts (Fig. 37). Inspect the radiator side tanks for cracks, and bro- ken or missing fittings. Inspect the joint where the tanks seam up to the radiator core for signs of leak- age and/or deteriorating seals.
Page 371 7 - 56 ENGINE 6094). ALWAYS WEAR SAFETY GLASSES WHEN RADIATOR - 5.9L DIESEL SERVICING CONSTANT TENSION CLAMPS. DESCRIPTION CAUTION: A number or letter is stamped into the The radiator is a aluminum cross-flow design with tongue of constant tension clamps. If replacement horizontal tubes through the radiator core and verti- is necessary, use only an original equipment clamp cal plastic side tanks (Fig.
Page 372: Radiator Pressure Cap
ENGINE 7 - 57 RADIATOR - 5.9L DIESEL (Continued) (11) Install the coolant recovery container (Refer to COOLING/ENGINE/COOLANT RECOVERY CONTAINER - INSTALLATION). (12) Position coolant recovery tank hose, washer bottle hose and the positive battery cable into the clips located on the top of the radiator. (13) Install air box and turbocharger inlet hose.
Page 373 7 - 58 ENGINE RADIATOR PRESSURE CAP (Continued) loaded pressure relief valve. This valve opens when DIAGNOSIS AND TESTING system pressure reaches the release range of 97-to- 124 kPa (14-to-18 psi). DIAGNOSIS AND TESTING - RADIATOR A rubber gasket seals the radiator filler neck. This CAP-TO-FILLER NECK SEAL is done to maintain vacuum during coolant cool-down The pressure cap upper gasket (seal) pressure...
Page 374 ENGINE 7 - 59 RADIATOR PRESSURE CAP (Continued) Fig. 42 Radiator Pressure Cap 1 - STAINLESS-STEEL SWIVEL TOP 2 - RUBBER SEALS 3 - VENT VALVE 4 - RADIATOR TANK 5 - FILLER NECK 6 - OVERFLOW NIPPLE 7 - MAIN SPRING 8 - GASKET RETAINER Fig.
Page 375 7 - 60 ENGINE WATER PUMP - 3.7L/4.7L (Continued) Fig. 43 Water Pump and Timing Chain Cover - 4.7L 1 - INTEGRAL WATER PUMP PULLEY 2 - TIMING CHAIN COVER 3 - THERMOSTAT HOUSING 4 - HEATER HOSE FITTINGS 5 - WATER PUMP engine warm-up preventing the coolant from flowing through the radiator (Fig.
Page 376 ENGINE 7 - 61 WATER PUMP - 3.7L/4.7L (Continued) Fig. 46 Automatic Belt Tensioner—4.7L Fig. 45 Viscous Fan and Fan Drive 4.7L Engine 1 - AUTOMATIC TENSIONER 1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER PINS 8346 2 - WATER PUMP PULLEY 2 - FAN (2) Using a new gasket, position water pump and (5) Remove the radiator fan (Refer to 7 - COOL-...
Page 377 7 - 62 ENGINE WATER PUMP - 3.7L/4.7L (Continued) (3) Spin the water pump to be sure that the pump WATER PUMP - 5.9L DIESEL impeller does not rub against the timing chain case/ cover. DESCRIPTION (4) Connect the radiator lower hose to the water The water pump is mounted to the front of the pump.
Page 378 ENGINE 7 - 63 WATER PUMP - 5.9L DIESEL (Continued) WATER PUMP - 5.7L REMOVAL (1) Disconnect negative battery cable. (2) Drain coolant. (3) Remove serpentine belt. (4) Remove fan clutch assembly. (5) Remove coolant fill bottle. (6) Disconnect washer bottle wiring and hose. (7) Remove fan shroud assembly.
Page 379 7 - 64 ENGINE WATER PUMP - 8.0L (Continued) REMOVAL WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL NUMBER NOTE: 6094. ALWAYS WEAR SAFETY GLASSES WHEN The water pump on all models can be removed SERVICING CONSTANT TENSION CLAMPS.
Page 380 ENGINE 7 - 65 WATER PUMP - 8.0L (Continued) fluid in the viscous drive could drain into its bearing (11) Remove heater hose at water pump fitting. assembly and contaminate the bearing lubricant. (12) Remove the seven water pump mounting bolts (Fig.
Page 381 7 - 66 ENGINE WATER PUMP - 8.0L (Continued) (15) Remove the heater hose fitting from water pump if pump replacement is necessary. Note posi- tion (direction) of fitting before removal. Fitting must be re-installed to same position. CAUTION: Do not pry the water pump at timing chain case/cover.
Page 382 TRANSMISSION 7 - 67 TRANSMISSION TABLE OF CONTENTS page page TRANS COOLER REMOVAL DESCRIPTION ......67 REMOVAL - AIR TO OIL COOLER .
Page 383 7 - 68 TRANSMISSION TRANS COOLER (Continued) REMOVAL (1) Disconnect the battery negative cable. (2) Place a drain pan under the oil cooler lines. (3) Disconnect the transmission oil cooler line quick-connect fitting at the cooler outlet using the quick connect release tool 6935. Plug the cooler lines to prevent oil leakage.
Page 384 TRANSMISSION 7 - 69 TRANS COOLER - 5.9L DIESEL (Continued) OPERATION The transmission oil is routed through the main cooler first, then the auxiliary cooler where addi- tional heat is removed from the transmission oil before returning to the transmission. The auxiliary cooler has an internal thermostat that controls fluid flow through the cooler.
Page 385 7 - 70 TRANSMISSION TRANS COOLER - 5.9L DIESEL (Continued) DISASSEMBLY - 5.9L DIESEL ONLY INSTALLATION NOTE: The transmission oil cooler uses an internal INSTALLATION - AIR TO OIL COOLER thermostat to control transmission oil flow through (1) Carefully position the oil cooler assembly to the the cooler.
Page 386 AUDIO/VIDEO 8A - 1 AUDIO/VIDEO TABLE OF CONTENTS page page AUDIO OPERATION ......8 DESCRIPTION .
Page 387 8A - 2 AUDIO/VIDEO AUDIO (Continued) The optional navigation radio system receives GPS DIAGNOSIS AND TESTING - AUDIO signals from up to eight satellites to display the posi- Any diagnosis of the Audio system should tion and direction of the vehicle. Map information is begin with the use of the DRB III diagnostic supplied through a DVD-ROM.
Page 388 AUDIO/VIDEO 8A - 3 AUDIO (Continued) CONDITION POSSIBLE CAUSES CORRECTION CLOCK WILL NOT KEEP 1. Fuse faulty. 1. Check Ignition-Off Draw (IOD) fuse in the SET TIME Integrated Power Module (IPM). Replace fuse, if required. 2. Radio connector faulty. 2. Check for loose or corroded radio connector. Repair, if required.
Page 389 8A - 4 AUDIO/VIDEO AMPLIFIER (Continued) (3) Remove instrument panel center bezel (Refer to right cowl side panel into the interior of the vehicle. 23 - BODY/INSTRUMENT PANEL/INSTRUMENT Inside the vehicle, the primary coaxial cable is con- PANEL CENTER BEZEL - REMOVAL). nected to a secondary instrument panel antenna (4) Remove instrument panel lower right center coaxial cable with an in-line connector that is located...
Page 390 AUDIO/VIDEO 8A - 5 ANTENNA BODY & CABLE (Continued) NOTE: This model has a two-piece antenna coaxial (1) Disconnect the instrument panel antenna cable cable. Tests 2 and 4 must be conducted in two coaxial connector from the back of the radio. (2) Touch one ohmmeter test lead to the tip of the steps to isolate an antenna cable problem.
Page 391 8A - 6 AUDIO/VIDEO ANTENNA BODY & CABLE (Continued) antenna body to fender mating surfaces and tighten (5) Insert the antenna body through the hole in the antenna cap nut to specifications. the fender and install adapter. (4) Check the resistance again with an ohmmeter. (6) Install the antenna cap nut.
Page 392 AUDIO/VIDEO 8A - 7 ANTENNA - NAVIGATION (Continued) Fig. 6 ANTENNA TO RADIO 1 - RADIO 2 - LOCKING ANTENNA CONNECTOR 3 - INSTRUMENT PANEL ANTENNA CABLE Fig. 5 NAVIGATION ANTENNA ROUTING 1 - NAVIGATION ANTENNA 2 - INSTRUMENT PANEL 3 - RADIO (REAR VIEW) (5) Connect battery negative cable.
Page 393 8A - 8 AUDIO/VIDEO INSTRUMENT PANEL ANTENNA CABLE (Continued) (6) Install the glove box (Refer to 23 - BODY/IN- STRUMENT PANEL/GLOVE BOX - INSTALLA- TION). (7) Connect the battery negative cable. RADIO DESCRIPTION Available radio receivers for this vehicle include: •...
Page 394 AUDIO/VIDEO 8A - 9 electromagnetic signals by the audio system compo- RADIO NOISE SUPPRESSION nents. GROUND STRAP The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. DESCRIPTION These ground straps ensure adequate ground paths, Radio noise suppression devices are factory-in- particularly for high current components such as stalled standard equipment on this vehicle.
Page 395 8A - 10 AUDIO/VIDEO RADIO NOISE SUPPRESSION GROUND STRAP (Continued) ENGINE TO HEAT SHIELD - 3.7L ENGINE (1) Disconnect and isolate the battery negative cable. (2) Remove the attaching bolts from the cylinder heads (Fig. 11). Fig. 13 ENGINE GROUND STRAP - 4.7L AND 5.7L 1 - GROUND STRAP 2 - MOUNTING BOLTS INSTALLATION...
Page 396 AUDIO/VIDEO 8A - 11 REMOTE SWITCHES (Continued) WARNING: DISABLE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE.
Page 397 8A - 12 AUDIO/VIDEO REMOTE SWITCHES (Continued) REMOTE RADIO SWITCH TEST TABLE SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL Switch Switch Position Resistance INJURY. Right 1.210 Kilohms (1) Disconnect and isolate the battery negative Volume Up (White) ±...
Page 398 AUDIO/VIDEO 8A - 13 REMOTE SWITCHES (Continued) (1) Install remote radio switch to the steering DIAGNOSIS AND TESTING - SPEAKER wheel. Any diagnosis of the Audio system should (2) Connect the wire harness to the remote radio begin with the use of the DRB III diagnostic switch.
Page 399 8A - 14 AUDIO/VIDEO SPEAKER (Continued) (6) Disconnect wire harness connector at the inop- erative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector or if equipped, the amplifier wire harness connector and the speaker wire harness connector.
Page 400 AUDIO/VIDEO 8A - 15 SPEAKER (Continued) INSTALLATION FRONT DOOR SPEAKER (1) Connect electrical harness connector install speaker. (2) Install front door trim panel (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - INSTALLA- TION). (3) Connect battery negative cable. INSTRUMENT PANEL CENTER SPEAKER (1) Connect electrical harness...
Page 402 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME WARNING SYSTEM DIAGNOSIS AND TESTING - CHIME DESCRIPTION ......1 WARNING SYSTEM .
Page 403 8B - 2 CHIME/BUZZER CHIME WARNING SYSTEM (Continued) Engine Control Module (ECM) over the PCI data bus engine is running and that the oil pressure is low to to illuminate the check gauges indicator for a coolant illuminate the check gauges indicator. The chimes temperature high condition.
Page 404 CHIME/BUZZER 8B - 3 CHIME WARNING SYSTEM (Continued) chimes at a slow rate to announce that the hard circuits for this system may be diagnosed and tested wired input for the right or left turn signal indicator using conventional diagnostic tools and procedures. as well as vehicle distance and speed message inputs However, conventional diagnostic methods may not received from the PCM over the PCI data bus indi-...
Page 405 8B - 4 CHIME/BUZZER CHIME WARNING SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO SEAT BELT WARNING 1. Seat belt switch ground 1. Check for continuity between the ground CHIME WITH SEAT BELT circuit open. circuit for the driver seat belt switch and a good UNBUCKLED, BUT OTHER ground.
Page 406 CHIME/BUZZER 8B - 5 CHIME WARNING SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION 1. Driver door ajar switch 1. Check for continuity between the driver door sense circuit open. ajar switch sense circuit connector and the instrument cluster connector. Repair the open driver door ajar switch sense circuit, if required.
Page 408 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page COMMUNICATION DESCRIPTION - MODES OF OPERATION ..7 DESCRIPTION ......1 DESCRIPTION - 5 VOLT SUPPLIES .
Page 409 8E - 2 ELECTRONIC CONTROL MODULES COMMUNICATION (Continued) data bus, more function and feature capabilities are short, it stands for a zero bit. If the width is long, it possible. stands for a one bit. Similarly, a high (active) state In addition to reducing wire harness complexity, does not necessarily mean a one bit.
Page 410: Fuel System
ELECTRONIC CONTROL MODULES 8E - 3 COMMUNICATION (Continued) The PCI data bus can be monitored using the INSTALLATION DRBIII scan tool. It is possible, however, for the bus to pass all DRBIII tests and still be faulty if the NOTE: If the CAB is being replaced with a new CAB voltage parameters are all within the specified range is must be reprogrammed with the use of a DRB III.
Page 411 8E - 4 ELECTRONIC CONTROL MODULES ENGINE CONTROL MODULE (Continued) NOTE: ECM Inputs: To avoid possible voltage spike damage to the ECM, ignition key must be off, and both negative • Accelerator Pedal Position Sensor (APPS) Volts battery cables must be disconnected before unplug- •...
Page 412 ELECTRONIC CONTROL MODULES 8E - 5 DIAGNOSIS AND TESTING - FRONT CONTROL FRONT CONTROL MODULE MODULE DESCRIPTION The front control module is a printed circuit board The Front Control Module (FCM) is a micro con- based module with a on-board micro-processor. The troller based module located in the left front corner front control module interfaces with other electronic of the engine compartment.
Page 413 8E - 6 ELECTRONIC CONTROL MODULES ments and sensors, and controls the ground for the HEATED SEAT MODULE heated seat switch indicator lamps. When a heated seat switch (Driver or Passenger) is DESCRIPTION depressed a signal is received by the heated seat module, the module energizes the proper indicator LED (Low or High) in the switch by grounding the indicator lamp circuit to indicate that the heated seat...
Page 414 ELECTRONIC CONTROL MODULES 8E - 7 HEATED SEAT MODULE (Continued) (2) Check the heated seat sensor (Refer to 8 - POWERTRAIN CONTROL ELECTRICAL/HEATED SEATS/HEATED SEAT MODULE SENSOR - DIAGNOSIS AND TESTING). (3) Check the heated seat switch (Refer to 8 - ELECTRICAL/HEATED SEATS/DRIVER HEATED DESCRIPTION SEAT SWITCH - DIAGNOSIS AND TESTING).
Page 415 8E - 8 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) • Battery voltage During Closed Loop modes, the PCM will monitor • Engine coolant temperature sensor the oxygen (O2S) sensors input. This input indicates • Crankshaft position sensor to the PCM whether or not the calculated injector •...
Page 416 ELECTRONIC CONTROL MODULES 8E - 9 POWERTRAIN CONTROL MODULE (Continued) • Oxygen (O2S) sensors IDLE MODE Based on these inputs, the following occurs: When the engine is at operating temperature, this • Voltage is applied to the fuel injectors with the is a Closed Loop mode.
Page 417: Steering
8E - 10 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) WIDE OPEN THROTTLE MODE DESCRIPTION - SENSOR RETURN This is an Open Loop mode. During wide open The Sensor Return circuits are internal to the Pow- throttle operation, the PCM receives the following ertrain Control Module (PCM).
Page 418 ELECTRONIC CONTROL MODULES 8E - 11 POWERTRAIN CONTROL MODULE (Continued) • Data link connection for DRB scan tool • Oxygen sensor heater relays • EATX module (if equipped) • Oxygen sensors (pulse width modulated) • Engine coolant temperature sensor • Radiator cooling fan relay (pulse width modu- •...
Page 419 8E - 12 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) REMOVAL USE THE DRB SCAN TOOL TO REPROGRAM THE NEW POWERTRAIN CONTROL MODULE (PCM) WITH THE VEHICLES ORIGINAL IDEN- TIFICATION NUMBER (VIN) AND THE VEHI- CLES ORIGINAL MILEAGE. IF THIS STEP IS NOT DONE, A DIAGNOSTIC TROUBLE CODE (DTC) MAY BE SET.
Page 420 ELECTRONIC CONTROL MODULES 8E - 13 POWERTRAIN CONTROL MODULE (Continued) (8) If the previous step is not performed, a Diag- The SKIM and the PCM/ECM both use software nostic Trouble Code (DTC) will be set. that includes a rolling code algorithm strategy, which (9) If necessary, use DRB III Scan Tool to erase helps to reduce the possibility of unauthorized SKIS any Diagnostic Trouble Codes (DTC’s) from PCM.
Page 421 8E - 14 ELECTRONIC CONTROL MODULES SENTRY KEY IMMOBILIZER MODULE (Continued) STANDARD PROCEDURE - PCM/SKIM (4) Enter secured access mode by entering the vehicle four-digit PIN. PROGRAMMING (5) Select ENTER to update PCM/ECM VIN. NOTE: There are two procedures for transfering the NOTE: If three attempts are made to enter secure secret key to the SKIM: access mode using an incorrect PIN, secured...
Page 422 ELECTRONIC CONTROL MODULES 8E - 15 SENTRY KEY IMMOBILIZER MODULE (Continued) (2) Use the DRBIII scan tool and select THEFT (4) Remove the screw that secures the SKIM to ALARM, SKIM then MISCELLANEOUS. the steering column (Fig. 7). (3) Select PROGRAM IGNITION KEY’S. (5) Release the SKIM antenna ring retaining clips (4) Enter secured access mode by entering the from around the ignition switch lock cylinder housing...
Page 423 8E - 16 ELECTRONIC CONTROL MODULES Several items can cause the requested shift not to TRANSFER CASE CONTROL be completed. If the TCCM has recognized a fault MODULE (DTC) of some variety, it will begin operation in one of four Functionality Levels. These levels are: DESCRIPTION •...
Page 424 ELECTRONIC CONTROL MODULES 8E - 17 TRANSFER CASE CONTROL MODULE (Continued) • Proper transmit/receive messages are occurring • Ignition key switch is in the RUN position. • Foot Brake is applied. on the PCI bus. • Ignition key switch is in the RUN position. •...
Page 425 8E - 18 ELECTRONIC CONTROL MODULES TRANSFER CASE CONTROL MODULE (Continued) SHIFT OUT OF NEUTRAL the motor back to the original position. This process will be allowed to occur 5 times. If the transfer case The following steps describe the process for a shift has reached a non-NEUTRAL ’D’...
Page 426 ELECTRONIC CONTROL MODULES 8E - 19 TRANSFER CASE CONTROL MODULE (Continued) • Whenever an invalid mode sensor code is SHIFT REVERSAL TARGETS present. If the shift timer expires (1 second per ’D’ channel) Static motor braking is achieved by applying +12V and the transfer case has not reached the desired on both shift motor wires.
Page 427: Body
8E - 20 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE DESCRIPTION The Transmission Control Module (TCM) (Fig. 9) may be sub-module within the Powertrain Control Module (PCM), Engine Control Module (ECM - Diesel only) (Fig. 10), or a standalone module, depending on the vehicle engine.
Page 428 ELECTRONIC CONTROL MODULES 8E - 21 TRANSMISSION CONTROL MODULE (Continued) • Diagnostic capabilities (with DRBIII scan tool) NOTE: If the TCM has been replaced, the “Quick Learn Procedure” must be performed. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) BATTERY FEED A fused, direct battery feed to the TCM is used for...
Page 429 8E - 22 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) • Engine load SHIFT SCHEDULES • Fluid temperature As mentioned earlier, the TCM has programming • Software level that allows it to select a variety of shift schedules. As driving conditions change, the TCM appropri- Shift schedule selection is dependent on the follow- ately adjusts the shift schedule.
Page 430 ELECTRONIC CONTROL MODULES 8E - 23 TRANSMISSION CONTROL MODULE (Continued) forming a Neutral to Drive shift. The 1st N-D UD STANDARD PROCEDURE CVI accounts for air entrapment in the UD clutch that may occur after the engine has been off for a STANDARD PROCEDURE - TCM QUICK LEARN period of time.
Page 431 8E - 24 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) NOTE: The transmission oil temperature must be (1) With a vehicle speed below 48 km/h (30 MPH) above 80°F (27°C). and the transmission in 3rd gear, perform multiple 3-2 kickdowns. (1) With the vehicle engine running, select reverse (2) Repeat Step 1 until the 3-2 kickdowns become gear for over 2 seconds.
Page 432 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 433 8F - 2 BATTERY SYSTEM BATTERY SYSTEM (Continued) For battery system maintenance schedules and the battery, starting, and charging systems be thor- jump starting procedures, see the owner’s manual in oughly tested and inspected any time a battery needs the vehicle glove box. Optionally, refer to the Lubri- to be charged or replaced.
Page 434 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test ATTEMPTING TO START procedures.
Page 435 8F - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the CHARGE CANNOT BE incorrect size or rating for proper specifications.
Page 436 BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) CLEANING The following information details the recommended cleaning procedures for the battery and related com- ponents. In addition to the maintenance schedules found in this service manual and the owner’s man- ual, it is recommended that these procedures be per- formed any time the battery or related components must be removed for vehicle service.
Page 437 8F - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) SPECIFICATIONS The battery Group Size number, the Cold Cranking Amperage (CCA) rating, and the Reserve Capacity (RC) rating or Ampere-Hours (AH) rating can be found on the original equipment battery label. Be certain that a replacement battery has the correct Group Size number, as well as CCA, and RC or AH ratings that equal or exceed the original equipment...
Page 438 BATTERY SYSTEM 8F - 7 BATTERY SYSTEM (Continued) A large capacity, low-maintenance storage battery SPECIAL TOOLS (Fig. 4) is standard factory-installed equipment on this model. Models equipped with a diesel engine BATTERY SYSTEM SPECIAL TOOLS must utilize two 12-volt batteries connected in paral- lel.
Page 439 8F - 8 BATTERY SYSTEM BATTERY (Continued) • All of the battery cells are gassing freely during MICRO 420 BATTERY TESTER battery charging. The Micro 420 automotive battery tester is • A green color is visible in the sight glass of the designed to help the dealership technician diagnose battery built-in test indicator.
Page 440 BATTERY SYSTEM 8F - 9 BATTERY (Continued) After the battery has been charged to 12.4 volts or (3) Battery chargers vary in the amount of voltage greater, perform a load test to determine the battery and current they provide. The amount of time cranking capacity.
Page 441 8F - 10 BATTERY SYSTEM BATTERY (Continued) To read the built-in indicator, look into the sight BATTERY CHARGING TIME TABLE glass and note the color of the indication (Fig. 7). The Charging battery condition that each color indicates 5 Amps 20 Amps Amperage Amps...
Page 442 BATTERY SYSTEM 8F - 11 BATTERY (Continued) (1) Before measuring the open-circuit voltage, the STANDARD PROCEDURE - IGNITION-OFF surface charge must be removed from the battery. DRAW TEST Turn on the headlamps for fifteen seconds, then The term Ignition-Off Draw (IOD) identifies a nor- allow up to five minutes for the battery voltage to mal condition where power is being drained from the stabilize.
Page 443 8F - 12 BATTERY SYSTEM BATTERY (Continued) ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE Time Out? IOD After Time Module (If Yes, Interval And Wake-Up Input) 1 to 3 Radio milliamperes Audio Power up to 1 Amplifier milliampere Powertrain Control 0.95 milliampere Module (PCM) ElectroMechanical Instrument Cluster...
Page 444 BATTERY SYSTEM 8F - 13 BATTERY (Continued) (6) While viewing the battery test result, press the CODE button and the tester will prompt you for the last 4 digits of the VIN. Use the UP/DOWN arrow buttons to scroll to the correct character; then press ENTER to select and move to the next digit.
Page 445: Battery Cables
8F - 14 BATTERY SYSTEM BATTERY (Continued) (6) Remove the battery hold down retaining bolt. OPERATION The battery holddown secures the battery in the WARNING: WEAR A SUITABLE PAIR OF RUBBER battery tray. This holddown is designed to prevent GLOVES (NOT THE HOUSEHOLD TYPE) WHEN battery movement during the most extreme vehicle REMOVING BATTERY...
Page 446 BATTERY SYSTEM 8F - 15 BATTERY CABLES (Continued) Large eyelet type terminals are crimped onto the RELAY LOCATED IN THE POWER DISTRIBUTION opposite end of the battery cable wire and then sol- CENTER (PDC). REMOVAL OF THE ASD RELAY der-dipped. The battery positive cable wires have a MAY NOT PREVENT THE DIESEL ENGINE FROM red insulating jacket to provide visual identification STARTING.
Page 447 8F - 16 BATTERY SYSTEM BATTERY CABLES (Continued) Fig. 13 Test Battery Positive Cable Resistance - Fig. 11 Test Battery Negative Connection Typical Resistance - Typical 1 - BATTERY 1 - VOLTMETER 2 - VOLTMETER 2 - BATTERY 3 - STARTER MOTOR (4) Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block (Fig.
Page 448: Battery Tray
BATTERY SYSTEM 8F - 17 BATTERY CABLES (Continued) (2) Disconnect and isolate the remote battery neg- The molded plastic tray battery tray is located in ative cable terminal. the left front corner of the engine compartment. On (3) Remove the battery from the vehicle. Refer to this model, the battery tray also provides an anchor the procedure in this group.
Page 449 8F - 18 BATTERY SYSTEM BATTERY TRAY (Continued) INSTALLATION LEFT SIDE (1) Position the battery tray assembly and install the retaining bolts. (2) Connect the left front fender ground wire. (3) Install the purge solenoid on its mounting bracket. (4) Install the battery temperature sensor in the battery tray (Refer to 8 - ELECTRICAL/CHARGING/ BATTERY TEMPERATURE SENSOR - INSTALLA- TION).
Page 450 CHARGING 8F - 19 CHARGING TABLE OF CONTENTS page page CHARGING OPERATION ......21 DESCRIPTION .
Page 451 8F - 20 CHARGING CHARGING (Continued) • a faulty or improperly adjusted switch that (2) Inspect condition of battery cable terminals, allows a lamp to stay on. Refer to Ignition-Off Draw battery posts, connections at engine block, starter Test in 8, Battery for more information. solenoid and relay.
Page 452: Battery Temperature Sensor
CHARGING 8F - 21 CHARGING (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Generator (short) Horizontal Mounting Bolt - 3.7L / 4.7L Engines Generator B+ Output Cable Terminal Nut BATTERY TEMPERATURE SENSOR DESCRIPTION The Battery Temperature Sensor (BTS) is attached to the battery tray located under the battery. OPERATION The BTS is used to determine the battery temper- ature and control battery charging rate.
Page 453 8F - 22 CHARGING GENERATOR (Continued) The stator winding connections deliver the induced alternating current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified direct current is delivered to the vehicle electrical system through the generator battery terminal. Although the generators appear the same exter- nally, different generators with different output rat- ings are used on this vehicle.
Page 454 CHARGING 8F - 23 GENERATOR (Continued) (6) Remove generator support bracket nuts and bolt (Fig. 4) and remove support bracket. (7) Remove 2 generator mounting bolts (Fig. 5). (8) Remove generator from vehicle. Fig. 5 REMOVE / INSTALL GENERATOR - 5.7L 1 - MOUNTING BOLT Fig.
Page 455 8F - 24 CHARGING GENERATOR (Continued) 5.7L (1) Position generator to engine and install 2 mounting bolts. (2) Tighten bolts. Refer to Torque Specifications. (3) Position support bracket to front of generator and install bolt and nuts. Tighten bolt / nuts. Refer to Torque Specifications.
Page 456: Voltage Regulator
CHARGING 8F - 25 GENERATOR (Continued) (6) Install both negative battery cables to both bat- Voltage is regulated by cycling the ground path to teries. control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+) and battery temperature (refer to Battery Temperature VOLTAGE REGULATOR Sensor for more information).
Page 457: Emissions Control
8F - 26 STARTING STARTING TABLE OF CONTENTS page page STARTING REMOVAL ......33 DESCRIPTION .
Page 458 STARTING 8F - 27 STARTING (Continued) If the vehicle is equipped with an automatic trans- Once the engine starts, the overrunning clutch pro- mission, battery voltage is supplied through the low- tects the starter motor from damage by allowing the amperage control circuit to the coil battery terminal starter pinion gear to spin faster than the pinion of the starter relay when the ignition switch is...
Page 459 8F - 28 STARTING STARTING (Continued) Starting System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION STARTER ENGAGES, 1. Battery discharged or 1. Refer to Battery. Charge or replace battery if required. FAILS TO TURN faulty. ENGINE. 2. Starting circuit wiring 2. Refer to 8, Wiring Diagrams. Test and repair starter faulty.
Page 460 STARTING 8F - 29 STARTING (Continued) TESTING (6) Rotate and hold ignition switch in Start posi- tion. Note cranking voltage and current (amperage) COLD CRANKING TEST draw readings shown on volt-ampere tester. (a) If voltage reads below 9.6 volts, refer to For complete starter wiring circuit diagrams, refer Starter Motor in Diagnosis and Testing.
Page 461 8F - 30 STARTING STARTING (Continued) • To prevent a gasoline engine from starting, remove Automatic ShutDown (ASD) relay. To prevent a diesel engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.
Page 462 STARTING 8F - 31 STARTING (Continued) Fig. 5 TEST GROUND CIRCUIT RESISTANCE - Fig. 6 TEST STARTER GROUND - TYPICAL TYPICAL 1 - STARTER MOTOR 1 - VOLTMETER 2 - BATTERY 3 - VOLTMETER 2 - BATTERY 3 - ENGINE GROUND CONTROL CIRCUIT TESTING (5) Connect positive lead of voltmeter to starter The starter control circuit components should be...
Page 463 8F - 32 STARTING STARTING (Continued) Starter Motor and Solenoid Voltage 12 Volts 12 Volts Number of Brushes Drive Type Gear Reduction Conventional Free Running Test Voltage 11 Volts 11 Volts Free Running Test Amperage 73 Amperes 200 Amperes Draw Free Running Test Minimum 3601 rpm 3000...
Page 464 STARTING 8F - 33 STARTER MOTOR (Continued) (6) Note reading on ammeter and compare reading REMOVAL to free running test maximum amperage draw. Refer to Specifications for starter motor free running test 3.7L / 4.7L maximum amperage draw specifications. (1) Disconnect and isolate negative battery cable. (7) If ammeter reading exceeds maximum amper- (2) Raise and support vehicle.
Page 465 8F - 34 STARTING STARTER MOTOR (Continued) Fig. 10 STARTER R/I - 3.7L/4.7L - AUTO. TRANS. 1 - EYELET TERMINAL 2 - NUT 3 - SCREW AND WASHER (2) 4 - STARTER MOTOR 5 - WIRE HARNESS CONNECTOR 5.7L Gas Fig.
Page 466: Starter Motor Relay
STARTING 8F - 35 STARTER MOTOR (Continued) 5.7L (1) Connect solenoid wire to starter motor (snaps on). (2) Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. Refer to Torque Specifications. Do not allow starter motor to hang from wire harness.
Page 467 8F - 36 STARTING STARTER MOTOR RELAY (Continued) OPERATION The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one mov- able) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure.
Page 468 STARTING 8F - 37 STARTER MOTOR RELAY (Continued) REMOVAL The starter relay is located in the Power Distribu- tion Center (PDC) (Fig. 15). Refer to label on PDC cover for relay location. (1) Disconnect and isolate negative battery cable. (2) Remove cover from Power Distribution Center (PDC) for relay identification and location.
Page 470 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS ......1 HEATED SEAT SYSTEM .
Page 471: Rear Window Defogger Relay
8G - 2 HEATED GLASS HEATED GLASS (Continued) DIAGNOSIS AND TESTING - REAR WINDOW (1) Confirm that the ignition switch is in the On position. DEFOGGER SYSTEM (2) Make sure that the rear glass heating grid feed For circuit descriptions and diagrams, refer to Rear and ground wires are connected to the glass.
Page 472 HEATED GLASS 8G - 3 REAR WINDOW DEFOGGER RELAY (Continued) • The coil ground terminal (87) receives a ground input from the A/C-heater control when the A/C- heater control electronically pulls the control circuit to ground. • The coil battery terminal (85) receives a battery current input from fuse 36 (10 amp) in the IPM through a fused B(+) circuit only when the ignition switch is in the Run position.
Page 473: Rear Window Defogger Switch
8G - 4 HEATED GLASS REAR WINDOW DEFOGGER RELAY (Continued) INSTALLATION REAR WINDOW DEFOGGER (1) Refer to the fuse and relay layout map on the GRID inner surface of the integrated power module (IPM) for rear window defogger relay identification and STANDARD PROCEDURE - GRID LINE AND location.
Page 474 HEATED GLASS 8G - 5 REAR WINDOW DEFOGGER GRID (Continued) If the rear window defogger grid terminal(s) is damaged or separated from the rear window, the repair of the grid terminals is possible using the Mopar Grid Line Repair Package or an equivalent. (1) If the grid terminal(s) is broken and a portion of the terminal is still attached to the heating grid, remove the portion of the clip remaining in the wire...
Page 475 8G - 6 HEATED MIRRORS HEATED MIRRORS TABLE OF CONTENTS page page HEATED MIRRORS OPERATION ......6 DESCRIPTION .
Page 476: Table Of Contents
HEATED SEAT SYSTEM 8G - 7 HEATED SEAT SYSTEM TABLE OF CONTENTS page page HEATED SEAT SYSTEM REMOVAL ......11 DESCRIPTION .
Page 477: Heated Seat System Description
8G - 8 HEATED SEAT SYSTEM HEATED SEAT SYSTEM (Continued) response to these inputs the heated seat module uses its internal programming to control 12v to the heated seat elements in both front seats and to control the heated seat LED indicator lamps located in both of the heated seat switches.
Page 478: Heated Seat Element Description
HEATED SEAT SYSTEM 8G - 9 HEATED SEAT SYSTEM (Continued) is suspected, locate the diagnosis and testing proce- heat, refer to Diagnosis and Testing the Heated dure for the component in question and follow the Seat Module in Electronic Control Modules for steps until the specific problem is located and heated seat module diagnosis and testing procedures.
Page 479: Operation
8G - 10 HEATED SEAT SYSTEM HEATED SEAT ELEMENT (Continued) pigtail wires are also captured between a covering mittent open in the element which would only be and the adhesive foam rubber backing. The heated evident if the element was in a certain position. seat sensors are Negative Thermal Coefficient (NTC) Failure to check the element in various positions thermistors.
Page 480: Heated Seat Sensor Description
HEATED SEAT SYSTEM 8G - 11 HEATED SEAT ELEMENT (Continued) DIAGNOSIS AND TESTING - HEATED SEAT SENSOR NOTE: Any resistance values (OHMS ) given in the following text are supplied using the automatic range generated by a FLUKE automotive meter. If another type of measuring device is used, the val- ues generated may not be the same as the results shown here, or may have to be converted to the...
Page 481: Operation
8G - 12 HEATED SEAT SYSTEM HEATED SEAT SWITCH (Continued) dimmer controlled back lighting of the switch when seat element of the selected seat and maintain the the headlamps or park lamps are on. requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new...
Page 482: Removal
HEATED SEAT SYSTEM 8G - 13 HEATED SEAT SWITCH (Continued) problem being diagnosed involves inoperative heated REMOVAL seat switch indicator lamps and the heated seat ele- (1) Disconnect and isolate the negative battery ments do heat, go to Step 6. If the problem being cable.
Page 483: Operation
8G - 14 HEATED SEAT SYSTEM HEATED SEAT MODULE (Continued) The Low heat set point is about 36° C (96.8° F), and the High heat set point is about 42° C (107.6° F). If the seat cushion surface temperature input is below the temperature set point for the selected tem- perature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within...
Page 484: Removal
HEATED SEAT SYSTEM 8G - 15 HEATED SEAT MODULE (Continued) should be present. If OK go to Step 5, if Not, Repair (3) Disconnect the seat wire harness connector the open or shorted voltage supply circuit as from the connector receptacle on the back of the required.
Page 486 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM REMOVAL ......2 DESCRIPTION .
Page 487: Horn Switch
8H - 2 HORN HORN (Continued) REMOVAL HORN SWITCH (1) Disconnect and isolate the battery negative DESCRIPTION cable. (2) Disconnect the wire harness connectors from The horn switch is molded into the driver airbag. the horns (Fig. 1). The horn switch can not be serviced separately. For service procedures, (Refer to 8 - ELECTRICAL/RE- STRAINTS/DRIVER AIRBAG - REMOVAL).
Page 488 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL IGNITION COIL DESCRIPTION ......1 DESCRIPTION .
Page 489: Ignition Control
8I - 2 IGNITION CONTROL IGNITION CONTROL (Continued) Because of coil design, spark plug cables (second- Two knock sensors (one for each cylinder bank) are ary cables) are not used. A distributor is not used used to help control spark knock. with the 4.7L engine.
Page 490: Description
IGNITION CONTROL 8I - 3 IGNITION CONTROL (Continued) SPECIFICATIONS SPECIFICATIONS - TORQUE - IGNITION DESCRIPTION N·m Ft. Lbs. In. Lbs. Camshaft Position Sensor - 3.7L V-6 Engine Camshaft Position Sensor - 4.7L V-8 Engine Camshaft Position Sensor - 5.7L V-8 Engine Crankshaft Position Sensor - 3.7L V-6 Engine Crankshaft Position...
Page 491: Engine Firing Order - 3.7L
8I - 4 IGNITION CONTROL IGNITION CONTROL (Continued) ENGINE FIRING ORDER - 3.7L V-6 match of cables, a corresponding spark plug / coil number is displayed on each plug cable: 1/6, 2/3, 4/7 1 - 6 - 5 - 4 - 3 - 2 and 5/8.
Page 492: Ignition Coil Resistance - 3.7L V-6
IGNITION CONTROL 8I - 5 IGNITION CONTROL (Continued) IGNITION COIL RESISTANCE - 3.7L V-6 OPERATION - ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to SECONDARY PRIMARY RESISTANCE connect the oxygen sensor heater element, ignition...
Page 493: Removal
8I - 6 IGNITION CONTROL AUTOMATIC SHUT DOWN RELAY (Continued) (9) Replace the relay if it did not pass the continu- ity and resistance tests. If the relay passed the tests, it operates properly. Check the remainder of the ASD and fuel pump relay circuits.
Page 494: Camshaft Position Sensor Description
IGNITION CONTROL 8I - 7 CAMSHAFT POSITION SENSOR DESCRIPTION 3.7L V-6 The Camshaft Position Sensor (CMP) on the 3.7L 6-cylinder engine is bolted to the right-front side of the right cylinder head. 4.7L V-8 The Camshaft Position Sensor (CMP) on the 4.7L V-8 engine is bolted to the right-front side of the right cylinder head.
Page 495 8I - 8 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) 5.9L Diesel The Camshaft Position Sensor (CMP) contains a hall effect device. A rotating target wheel (tonewheel) for the CMP is located on the front timing gear. This hall effect device detects notches located on the tone- wheel.
Page 496: Removal
IGNITION CONTROL 8I - 9 CAMSHAFT POSITION SENSOR (Continued) REMOVAL 3.7L V-6 The Camshaft Position Sensor (CMP) on the 3.7L V-6 engine is bolted to the front/top of the right cyl- inder head (Fig. 10). Fig. 11 CMP LOCATION - 4.7L 1 - RIGHT CYLINDER HEAD 2 - CAMSHAFT POSITION SENSOR 3 - MOUNTING BOLT...
Page 497 8I - 10 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) Fig. 14 5.9L DIESEL CMP Fig. 13 CMP REMOVAL / INSTALLATION – 5.7L V-8 1 - CMP 1 - TIMING CHAIN COVER (RIGHT/FRONT) 2 - FUEL INJECTION PUMP (BOTTOM) 2 - CMP SENSOR 3 - ELECTRONIC CONTROL MODULE (ECM) 3 - MOUNTING BOLT 4 - ECM ELEC.
Page 498: Ignition Coil
IGNITION CONTROL 8I - 11 CAMSHAFT POSITION SENSOR (Continued) (2) Apply a small amount of engine oil to sensor o-ring. (3) Install sensor into cylinder head with a slight rocking action. Do not twist sensor into position as damage to o-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing chain cover.
Page 499: Operation
8I - 12 IGNITION CONTROL IGNITION COIL (Continued) Fig. 19 IGNITION COIL R/I — 5.7L V-8 Fig. 17 IGNITION COIL LOCATION - 4.7L V-8 1 - SLIDE LOCK (SLIDE OUTWARD TO UNLOCK) 2 - SPARK PLUG CABLE (TO OPPOSITE CYLINDER BANK 1 - IGNITION COIL SPARK PLUG) 2 - COIL ELECTRICAL CONNECTOR...
Page 500: Removal
IGNITION CONTROL 8I - 13 IGNITION COIL (Continued) • The camshaft position sensor (crankshaft posi- Base ignition timing is not adjustable. By con- trolling the coil ground circuit, the PCM is able to set tion) • The manifold absolute pressure (MAP) sensor the base timing and adjust the ignition timing •...
Page 501: Installation
8I - 14 IGNITION CONTROL IGNITION COIL (Continued) (4) Remove coil mounting nut from mounting stud 4.7L V-8 (Fig. 17). (1) Using compressed air, blow out any dirt or con- (5) Carefully pull up coil from cylinder head open- taminants from around top of spark plug. ing with a slight twisting action.
Page 502: Removal
IGNITION CONTROL 8I - 15 KNOCK SENSOR (Continued) Knock sensors contain a piezoelectric material (3) Remove sensor mounting bolts (Fig. 20), or which constantly vibrates and sends an input voltage (Fig. 21). Note foam strip on bolt threads. This foam (signal) to the PCM while the engine operates.
Page 503 8I - 16 IGNITION CONTROL KNOCK SENSOR (Continued) (1) Thoroughly clean knock sensor mounting holes. (2) Install sensors into cylinder block. NOTE: Over or under tightening the sensor mount- ing bolts will affect knock sensor performance, pos- sibly causing improper spark control. Always use the specified torque when installing the knock sen- sors.
Page 504: Spark Plug Description
IGNITION CONTROL 8I - 17 SPARK PLUG DESCRIPTION Resistor type spark plugs are used on all engines. Sixteen spark plugs (2 per cylinder) are used with 5.7L V-8 engines. DIAGNOSIS AND TESTING - SPARK PLUG CONDITIONS To prevent possible pre-ignition and/or mechanical engine damage, the correct type/heat range/number spark plug must be used.
Page 505 8I - 18 IGNITION CONTROL SPARK PLUG (Continued) SCAVENGER DEPOSITS Fuel scavenger deposits may be either white or yel- low (Fig. 26). They may appear to be harmful, but this is a normal condition caused by chemical addi- tives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies.
Page 506: Removal
IGNITION CONTROL 8I - 19 SPARK PLUG (Continued) Fig. 29 SPARK PLUG OVERHEATING Fig. 27 CHIPPED ELECTRODE INSULATOR 1 - BLISTERED WHITE OR GRAY COLORED INSULATOR 1 - GROUND ELECTRODE 2 - CENTER ELECTRODE (1) Remove necessary air filter tubing at throttle 3 - CHIPPED INSULATOR body.
Page 507: Cleaning
8I - 20 IGNITION CONTROL SPARK PLUG (Continued) removed is under coil, coil must be removed to gain access to spark plug. Refer to Ignition Coil Removal/ Installation and observe all CAUTIONS and WARN- INGS. Before removing or disconnecting any spark plug cables, note their original position.
Page 508: Ignition Coil Capacitor Description
IGNITION CONTROL 8I - 21 SPARK PLUG (Continued) (4) Install ignition coil(s). Refer to Ignition Coil Removal/Installation. 5.7L V-8 (1) Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged.
Page 509: Removal
8I - 22 IGNITION CONTROL SPARK PLUG CABLE (Continued) REMOVAL INSTALLATION Install cables into the proper engine cylinder firing 5.7L V-8 order sequence. Refer to Specifications. Spark plug cables on the 5.7L engine are paired on When replacing the spark plug and coil cables, cylinders 1/6, 2/3, 4/7 and 5/8.
Page 510 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER OPERATION ......29 DESCRIPTION .
Page 511: Instrument Cluster Description
8J - 2 INSTRUMENT CLUSTER WASHER FLUID INDICATOR WATER-IN-FUEL INDICATOR DESCRIPTION ......44 DESCRIPTION ......45 OPERATION .
Page 512 INSTRUMENT CLUSTER 8J - 3 INSTRUMENT CLUSTER (Continued) Sandwiched between the rear cover and the lens, duce audible clicks that emulate the sound of a con- hood and mask unit is the cluster housing. The ventional turn signal or hazard warning flasher. molded plastic cluster housing serves as the carrier (Refer to 8 - ELECTRICAL/CHIME/BUZZER - for the cluster circuit board and circuitry, the cluster...
Page 513 8J - 4 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) • Exterior Lighting Fail-safe - In the absence of • Panel Lamps Dimming Control - The EMIC a headlamp switch input, the EMIC will turn on the provides a hard wired 12-volt Pulse-Width Modulated cluster illumination lamps and provide electronic (PWM) output that synchronizes the dimming level headlamp low beam and park lamp request messages...
Page 514 INSTRUMENT CLUSTER 8J - 5 INSTRUMENT CLUSTER (Continued) • Electronic Throttle Control (ETC) Indicator for more than about 1.6 kilometers (one mile) and the vehicle speed remains greater than about twenty- (with 5.7L Gasoline Engine only) • Gear Selector Indicator (with Automatic four kilometers-per-hour (fifteen miles-per-hour).
Page 515: Operation
8J - 6 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) Fig. 3 Gauges & Indicators - Gasoline Engine 1 - MALFUNCTION INDICATOR LAMP 13 - ELECTRONIC THROTTLE CONTROL (ETC) INDICATOR 2 - VOLTAGE GAUGE 14 - ENGINE TEMPERATURE GAUGE 3 - LEFT TURN INDICATOR 15 - SECURITY INDICATOR 4 - TACHOMETER 16 - GEAR SELECTOR INDICATOR DISPLAY (INCLUDES...
Page 516 INSTRUMENT CLUSTER 8J - 7 INSTRUMENT CLUSTER (Continued) Fig. 4 Gauges & Indicators - Diesel Engine 1 - MALFUNCTION INDICATOR LAMP 14 - ENGINE TEMPERATURE GAUGE 2 - VOLTAGE GAUGE 15 - SECURITY INDICATOR 3 - LEFT TURN INDICATOR 16 - GEAR SELECTOR INDICATOR DISPLAY (INCLUDES CRUISE &...
Page 517 8J - 8 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) sage-controlled functions of the cluster by lighting the On or Start positions, and inactive when the igni- the appropriate indicators, positioning the gauge nee- tion switch is in the Off or Accessory positions. dles at several predetermined calibration points The illumination intensity of the VFD units is con- across the gauge faces, and illuminating all segments...
Page 518 INSTRUMENT CLUSTER 8J - 9 INSTRUMENT CLUSTER (Continued) INDICATORS actuator test. (Refer to 8 - ELECTRICAL/INSTRU- MENT CLUSTER - DIAGNOSIS AND TESTING). Indicators are located in various positions within Proper testing of the PCI data bus and the electronic the EMIC and are all connected to the EMIC elec- message inputs to the EMIC that control an indicator tronic circuit board.
Page 519: Diagnosis And Testing - Instrument Cluster
8J - 10 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) • Map/Glove Box Lamp Driver INPUT AND OUTPUT CIRCUITS • Radio Illumination Driver • Right Door Lock Driver - with Power Locks HARD WIRED INPUTS • Right Door Unlock Driver - with Power The hard wired inputs to the EMIC include the fol- Locks lowing:...
Page 520 INSTRUMENT CLUSTER 8J - 11 INSTRUMENT CLUSTER (Continued) CAUTION: Instrument clusters used in this model PRELIMINARY DIAGNOSIS automatically configure themselves for compatibil- WARNING: TO AVOID PERSONAL INJURY OR ity with the features and optional equipment in the DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, vehicle in which they are initially installed.
Page 521 8J - 12 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) ACTUATOR TEST to diagnose these components. Refer to the appropri- ate diagnostic information. WARNING: TO AVOID PERSONAL INJURY OR (1) Begin the test with the ignition switch in the DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, Off position.
Page 522 INSTRUMENT CLUSTER 8J - 13 INSTRUMENT CLUSTER (Continued) INSTRUMENT CLUSTER FAILURE MESSAGE Fault Code Description Correction Wait to start indicator circuit shorted. Refer to the appropriate diagnostic information. Wait to start indicator circuit open. Refer to the appropriate diagnostic information. BTSI output circuit shorted or open.
Page 523: Removal
8J - 14 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) INSTRUMENT CLUSTER FAILURE MESSAGE Fault Code Description Correction ABS messages not received. Refer to the appropriate diagnostic information. FCM messages not received. Refer to the appropriate diagnostic information. ACM messages not received. Refer to the appropriate diagnostic information.
Page 524: Assembly
INSTRUMENT CLUSTER 8J - 15 INSTRUMENT CLUSTER (Continued) WARNING: TO AVOID PERSONAL INJURY OR (4) Pull the bulb and bulb holder unit straight DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, back to remove it from the bulb mounting hole in the cluster electronic circuit board.
Page 525: Installation
8J - 16 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) WARNING: TO AVOID PERSONAL INJURY OR mask unit to the cluster housing. Tighten the screws DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, to 1 N·m (10 in. lbs.). (3) Reinstall the instrument cluster onto the DISABLE THE SUPPLEMENTAL RESTRAINT SYS- BEFORE ATTEMPTING...
Page 526: Abs Indicator Description
INSTRUMENT CLUSTER 8J - 17 INSTRUMENT CLUSTER (Continued) NOTE: Certain indicators in this instrument cluster OPERATION are automatically configured. This feature allows The ABS indicator gives an indication to the vehi- those indicators to be activated or deactivated for cle operator when the ABS system is faulty or inop- compatibility with certain optional equipment.
Page 527: Airbag Indicator Description
8J - 18 INSTRUMENT CLUSTER ABS INDICATOR (Continued) Each time the ABS indicator fails to light due to an ignition switch is in any position except On or Start. open or short in the cluster ABS indicator circuit, the The LED only illuminates when it is provided a path cluster sends a message notifying the CAB of the to ground by the instrument cluster transistor.
Page 528: Brake/Park Brake Indicator Description
INSTRUMENT CLUSTER 8J - 19 • Bulb Test - Each time the ignition switch is BRAKE/PARK BRAKE turned to the On position the brake indicator is illu- INDICATOR minated by the instrument cluster for about two sec- onds as a bulb test. DESCRIPTION •...
Page 529: Diagnosis And Testing - Brake Indicator
8J - 20 INSTRUMENT CLUSTER BRAKE/PARK BRAKE INDICATOR (Continued) DIAGNOSIS AND TESTING - BRAKE INDICATOR brake switch sense circuit between the park brake switch and the instrument cluster as required. The diagnosis found here addresses an inoperative brake indicator condition. If there are problems with INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM several indicators in the instrument cluster, (Refer to CHECKS OK...
Page 530: Check Gauges Indicator Description
INSTRUMENT CLUSTER 8J - 21 CARGO LAMP INDICATOR (Continued) cluster programming, a hard wired multiplex input CHECK GAUGES INDICATOR received by the cluster from the headlamp panel lamps dimmer switch on the headlamp dimmer DESCRIPTION switch mux circuit, and electronic unlock request messages received from the optional Remote Keyless Entry (RKE) receiver module.
Page 531: Cruise Indicator Description
8J - 22 INSTRUMENT CLUSTER CHECK GAUGES INDICATOR (Continued) • Engine Temperature High Message - Each itors the engine temperature, oil pressure, and time the cluster receives a message from the PCM or electrical system voltage, then sends the proper mes- ECM indicating the engine coolant temperature of a sages to the instrument cluster.
Page 532: Door Ajar Indicator Description
INSTRUMENT CLUSTER 8J - 23 CRUISE INDICATOR (Continued) off when the ignition switch is in any position except ajar indicator is serviced as a unit with the instru- On or Start. The indicator only illuminates when it is ment cluster. switched to ground by the instrument cluster cir- OPERATION cuitry.
Page 533: Engine Temperature Gauge Description
8J - 24 INSTRUMENT CLUSTER ever the ignition switch is in the On or Start posi- ENGINE TEMPERATURE tions. The cluster is programmed to move the gauge GAUGE needle back to the low end of the scale after the igni- tion switch is turned to the Off position.
Page 534: Etc Indicator Description
INSTRUMENT CLUSTER 8J - 25 ENGINE TEMPERATURE GAUGE (Continued) • Actuator Test - Each time the cluster is put instrument cluster electronic circuit board. The ETC through the actuator test, the engine coolant temper- indicator is serviced as a unit with the instrument ature gauge needle will be swept to several calibra- cluster.
Page 535: Fuel Gauge Description
8J - 26 INSTRUMENT CLUSTER ETC INDICATOR (Continued) proper lamp-on or lamp-off messages to the instru- tronic circuit board. The fuel gauge is serviced as a ment cluster. If the PCM sends a lamp-on message unit with the instrument cluster. after the bulb test, it indicates that the PCM has OPERATION detected a system malfunction and/or that the ETC...
Page 536: Gear Selector Indicator Description
INSTRUMENT CLUSTER 8J - 27 FUEL GAUGE (Continued) the PCM or ECM indicating the percent tank full is this model. The gear selector indicator information is less than empty, the gauge needle is moved to the far displayed in a Vacuum-Fluorescent Display (VFD) left end of the gauge scale and the low fuel indicator unit.
Page 537: High Beam Indicator Description
8J - 28 INSTRUMENT CLUSTER GEAR SELECTOR INDICATOR (Continued) upon electronic messages received from the electronic HIGH BEAM INDICATOR Transmission Control Module (TCM) over the Pro- grammable Communications Interface (PCI) data DESCRIPTION bus. If the transmission range sensor mux circuit is open and no electronic messages are received from the TCM within two seconds, the instrument cluster circuitry will not display any gear selector position...
Page 538: Lamp Out Indicator Description
INSTRUMENT CLUSTER 8J - 29 HIGH BEAM INDICATOR (Continued) tery saver) timed interval expires, whichever occurs circuit board based upon cluster programming and first. electronic messages received by the cluster from the • Actuator Test - Each time the cluster is put Front Control Module (FCM) over the Programmable through the actuator test, the high beam indicator Communications Interface (PCI) data bus.
Page 539: Low Fuel Indicator Description
8J - 30 INSTRUMENT CLUSTER secutive seconds and the vehicle speed is greater LOW FUEL INDICATOR than zero, the fuel gauge needle is moved to the one- eighth graduation or below on the gauge scale, the DESCRIPTION low fuel indicator is illuminated and a single chime tone is sounded.
Page 540: Malfunction Indicator Lamp (Mil) Description
INSTRUMENT CLUSTER 8J - 31 • MIL Lamp-On Message - Each time the clus- MALFUNCTION INDICATOR ter receives a MIL lamp-on message from the PCM LAMP (MIL) or ECM, the indicator will be illuminated. The indi- cator can be flashed on and off, or illuminated solid, DESCRIPTION as dictated by the PCM or ECM message.
Page 541: Odometer Description
8J - 32 INSTRUMENT CLUSTER The cluster will accumulate values up to 9,999 hours ODOMETER before the display rolls over to zero. The odometer has a “Rental Car” mode, which will DESCRIPTION illuminate the odometer information in the VFD whenever the driver side front door is opened with the ignition switch in the Off or Accessory positions.
Page 542: Oil Pressure Gauge Description
INSTRUMENT CLUSTER 8J - 33 ODOMETER (Continued) the trip odometer reset switch button is pressed in in the upper right quadrant of the instrument clus- order to toggle to the engine hours display. The ter, above the coolant temperature gauge. The oil engine hours will remain displayed for about thirty pressure gauge consists of a movable gauge needle or seconds, until the engine speed message is greater...
Page 543: Seatbelt Indicator Description
8J - 34 INSTRUMENT CLUSTER OIL PRESSURE GAUGE (Continued) • Engine Oil Pressure Low Message - Each time the cluster receives a message from the PCM or ECM indicating the engine oil pressure is below about 41 kPa (6 psi), the gauge needle is moved to Fig.
Page 544: Standard Procedure - Enhanced Seatbelt Reminder Programming
INSTRUMENT CLUSTER 8J - 35 SEATBELT INDICATOR (Continued) reminder function, each time the cluster detects an STANDARD PROCEDURE - ENHANCED open circuit on the seat belt indicator driver circuit SEATBELT REMINDER PROGRAMMING (seatbelt switch open = seatbelt unbuckled) with the The seatbelt indicator also includes a programma- ignition switch in the Start or On positions, the indi- ble enhanced seatbelt reminder or “beltminder”...
Page 545: Operation
8J - 36 INSTRUMENT CLUSTER SECURITY INDICATOR (Continued) behind by the LED, which is soldered onto the until the ignition switch is turned to the Off position, instrument cluster electronic circuit board. The secu- whichever occurs first. For more information on the rity indicator is serviced as a unit with the instru- SKIS and the security indicator control parameters, ment cluster.
Page 546: Operation
INSTRUMENT CLUSTER 8J - 37 SERVICE 4WD INDICATOR (Continued) appears in the lower portion of the odometer/trip The TCCM continually monitors the electronic odometer Vacuum Fluorescent Display (VFD) unit. transfer case switch and circuits to determine the The VFD is soldered onto the cluster electronic cir- condition of the system.
Page 547: Tachometer Description
8J - 38 INSTRUMENT CLUSTER SPEEDOMETER (Continued) trolled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Programmable Communica- tions Interface (PCI) data bus. The speedometer is an Fig.
Page 548: Tow/Haul Indicator Description
INSTRUMENT CLUSTER 8J - 39 TACHOMETER (Continued) tioned at the relative engine speed position on the prevents the indicator from being clearly visible gauge scale until the engine stops running, or until when it is not illuminated. The text “TOW/HAUL” the ignition switch is turned to the Off position, appear in an amber color and at the same lighting whichever occurs first.
Page 549: Trans Temp Indicator Description
8J - 40 INSTRUMENT CLUSTER TOW/HAUL INDICATOR (Continued) • Bulb Test - Each time the ignition switch is required. Refer to the appropriate diagnostic infor- mation. turned to the On position the transmission over-tem- perature indicator is illuminated for about two sec- onds as a bulb test.
Page 550: Operation
INSTRUMENT CLUSTER 8J - 41 TURN SIGNAL INDICATOR (Continued) • Hazard Warning-On Input - Each time the the upper edge of the instrument cluster, between the speedometer and the tachometer. Each turn sig- cluster detects a hazard warning-on input from the nal indicator consists of a stencil-like cutout of the hazard warning switch circuitry of the multi-function International Control and Display Symbol icon for...
Page 551: Operation
8J - 42 INSTRUMENT CLUSTER UPSHIFT INDICATOR (Continued) cator is electronically disabled. The upshift indicator be turned on, then off again during the VFD portion consists of an upward pointed arrow icon, which of the test to confirm the functionality of the VFD appears on the right side of the electronic gear selec- and the cluster control circuitry.
Page 552: Operation
INSTRUMENT CLUSTER 8J - 43 VOLTAGE GAUGE (Continued) • System Voltage High Message - Each time OPERATION the cluster receives three consecutive messages from The voltage gauge gives an indication to the vehi- the PCM or ECM indicating the electrical system cle operator of the electrical system voltage.
Page 553: Wait-To-Start Indicator Description
8J - 44 INSTRUMENT CLUSTER nated until the cluster receives a wait-to-start lamp- WAIT-TO-START INDICATOR off message, until the ECM detects that the engine is running or until the ignition switch is turned to the DESCRIPTION Off position, whichever occurs first. •...
Page 554 INSTRUMENT CLUSTER 8J - 45 WASHER FLUID INDICATOR (Continued) reservoir is low. This indicator is controlled by the WATER-IN-FUEL INDICATOR instrument cluster circuit board based upon cluster programming and electronic messages received by DESCRIPTION the cluster from the Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus.
Page 555 8J - 46 INSTRUMENT CLUSTER WATER-IN-FUEL INDICATOR (Continued) water in the diesel fuel system, the water-in-fuel proper water-in-fuel lamp-on and lamp-off messages indicator will be illuminated. The indicator remains to the instrument cluster. For further diagnosis of illuminated until the cluster receives a water-in-fuel the water-in-fuel indicator or the instrument cluster lamp-off message, or until the ignition switch is circuitry that controls the indicator, (Refer to 8 -...
Page 556 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....26 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page...
Page 557: Lamps/Lighting - Exterior
8L - 2 LAMPS/LIGHTING - EXTERIOR MARKER LAMP UNIT REMOVAL - WITHOUT CARGO BOX ..22 REMOVAL INSTALLATION REMOVAL - FENDER MARKER LAMP ..17 INSTALLATION - WITH CARGO BOX .
Page 558: Diagnosis And Testing - Lamps/Lighting - Exterior
LAMPS/LIGHTING - EXTERIOR 8L - 3 LAMPS/LIGHTING - EXTERIOR (Continued) Instrument Cluster transmits a message via J1850 from the headlamps, the headlamps will return to informing the the FCM. The FCM will then turn off their last state prior to being shut off. the headlamps, park lamps and fog lamps.
Page 559 8L - 4 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) HEADLAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM 1. Loose or corroded battery 1. Clean and secure battery cable clamps and WITH ENGINE IDLING cables. posts. OR IGNITION TURNED 2.
Page 560 LAMPS/LIGHTING - EXTERIOR 8L - 5 LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS DO NOT 1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to ILLUMINATE Electrical, Wiring Information. 2. No ground at headlamps. 2. Repair circuit ground, refer to Electrical, Wiring Information.
Page 561 8L - 6 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system. Refer to WITH ENGINE Electrical, Charging. RUNNING ABOVE IDLE 2. Poor lighting circuit ground. 2.
Page 562: Standard Procedure Safety Precautions
LAMPS/LIGHTING - EXTERIOR 8L - 7 LAMPS/LIGHTING - EXTERIOR (Continued) STANDARD PROCEDURE LAMP BULB Tail, Brake, Turn Signal - 1157 SAFETY PRECAUTIONS w/box off Side Marker, Tail Gate, WARNING: EYE PROTECTION SHOULD BE USED Cab Clearance WHEN SERVICING GLASS COMPONENTS. PER- SONAL INJURY CAN RESULT.
Page 563: Installation - Without Cargo Box
8L - 8 LAMPS/LIGHTING - EXTERIOR BACKUP LAMP (Continued) (2) Install the lamp back plate onto the tail lamp back-up lamp switch (Fig. 2). The backup lamp unit. switch is located in a threaded hole on the side of the (3) Install the tail lamp unit (Refer to 8 - ELEC- manual transmission housing.
Page 564: Brake Lamp
LAMPS/LIGHTING - EXTERIOR 8L - 9 INSTALLATION - WITHOUT CARGO BOX BRAKE LAMP (1) Install the brake lamp bulb into the brake lamp socket by pushing inward and rotating it clock- REMOVAL wise. REMOVAL - WITH CARGO BOX NOTE: Install the tail lamp lens with the clear por- tion (back-up lens) at the top of the housing.
Page 565: Diagnosis And Testing - Brake Lamp Switch
8L - 10 LAMPS/LIGHTING - EXTERIOR BRAKE LAMP SWITCH (Continued) Vehicles equipped with the speed control option use a dual function brake lamp switch. The PCM moni- tors the state of the dual function brake lamp switch. The brake switch is equipped with three sets of contacts, one normally open and the other two nor- mally closed (brakes disengaged).
Page 566: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 11 BRAKE LAMP SWITCH (Continued) INSTALLATION (3) Separate CHMSL from roof. (4) Disengage wire connector from body wire har- (1) Press and hold the brake pedal down. ness. (2) Align the tab on the new switch with the notch (5) Separate CHMSL from vehicle.
Page 567: Cab Clearance Lamp
8L - 12 LAMPS/LIGHTING - EXTERIOR CAB CLEARANCE LAMP (Continued) Fig. 8 Fog Lamp Fig. 7 Clearance Lamp 1 - SCREW 1 - NUT 2 - FOG LAMP UNIT 2 - CAB ROOF 3 - CONNECTOR 3 - BULB SOCKET 4 - CLEARANCE LAMP (5) Check for proper operation and beam align- 5 - SCREW...
Page 568: Operation
LAMPS/LIGHTING - EXTERIOR 8L - 13 FOG LAMP RELAY (Continued) • Normally Closed Terminal - The normally ment of the vehicle. The front fog lamp relay is a conventional International Standards Organization closed terminal (87A) is not connected in this appli- (ISO) micro relay (Fig.
Page 569: Hazard Switch Description
8L - 14 LAMPS/LIGHTING - EXTERIOR FOG LAMP RELAY (Continued) (1) Position the front fog lamp relay to the proper (3) Connect the negitive battery cable. receptacle in the Power Distribution Center (PDC). (2) Align the front fog lamp relay terminals with HEADLAMP SWITCH the terminal cavities in the PDC.
Page 570: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 15 HEADLAMP SWITCH (Continued) (2) Remove the left instrument panel bezel. (Refer (2) Reconnect the instrument panel wire harness to 23 - BODY/INSTRUMENT PANEL/CLUSTER connector for the headlamp switch. BEZEL - REMOVAL). (3) Position the left instrument panel bezal on to (3) Disconnect the harness connector.
Page 571: Adjustments
8L - 16 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) (3) Install the bolts attaching headlamp unit to the alignment screen (with tape). Use this line for fender (Fig. 11). up/down adjustment reference. (4) Align the seal and install the push pins. (7) Measure distance from the centerline of the (5) Connect the battery negative cable.
Page 572: License Plate Lamp Removal
LAMPS/LIGHTING - EXTERIOR 8L - 17 HEADLAMP UNIT (Continued) centerline. The side-to-side outboard edge of high intensity pattern should be from 150 mm (6 in.) left to 150 mm (6 in.) right of headlamp centerline (Fig. 12). The preferred headlamp alignment is 1 down for the up/down adjustment and 0 for the left/right adjustment.
Page 573: Removal - Tailgate Marker Lamp
8L - 18 LAMPS/LIGHTING - EXTERIOR MARKER LAMP UNIT (Continued) REMOVAL - TAILGATE MARKER LAMP (2) Position the lens assembly to the tailgate. Install and tighten the two screws securely. (1) Remove the two screws that secure the lens assembly to the tailgate (Fig. 15). (2) Turn the bulb sockets counterclockwise a quar- MULTI-FUNCTION SWITCH ter turn and remove the bulb sockets from the lens...
Page 574: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 19 MULTI-FUNCTION SWITCH (Continued) EXTERIOR LIGHTING FUNCTIONS Optical Horn (Flash-to-Pass) On 1 - 2 1257 - 1397 3 - 2 2643 - 2937 Turn Signal Left 3 - 2 345 - 384 Turn Signal Right 3 - 2 786 - 873 FRONT WIPER FUNCTIONS...
Page 575: Park Lamp Relay Description
8L - 20 LAMPS/LIGHTING - EXTERIOR The park lamp relay terminals are connected to PARK LAMP RELAY the vehicle electrical system through a connector in the Junction Block (JB). The inputs and outputs of DESCRIPTION the headlamp low beam relay include: •...
Page 576: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 21 PARK LAMP RELAY (Continued) (2) Remove the Power Distribution Center (PDC) cover. (3) Remove the park lamp relay by grasping it firmly and pulling it straight out from the receptacle in the PDC. INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING...
Page 577: Tail Lamp Removal Removal - With Cargo Box
8L - 22 LAMPS/LIGHTING - EXTERIOR PARK/TURN SIGNAL LAMP (Continued) Fig. 19 Park Turn Signal Bulb 1 - BULB SOCKET 2 - BULB (4) Reconnect the negative battery cable. Fig. 20 Tail Lamp Lens (3) Install the tail lamp unit (Refer to 8 - ELEC- TRICAL/LAMPS/LIGHTING EXTERIOR/TAIL TAIL LAMP...
Page 578: Installation - Without Cargo Box
LAMPS/LIGHTING - EXTERIOR 8L - 23 TAIL LAMP UNIT (Continued) Fig. 22 Tail Lamp Unit - RH Side Shown, LH Side Fig. 21 Tail Lamp Unit Typical 1 - SCREW (2) 2 - WIRE HARNESS CONNECTOR 1 - TAIL LAMP UNIT 3 - TAIL LAMP UNIT 2 - MOUNTING BRACKET 3 - TRAILER HITCH BRACKET...
Page 579: Trailer Tow Wiring Description
8L - 24 LAMPS/LIGHTING - EXTERIOR (2) Remove the four screws that secure the tail TRAILER TOW WIRING lamp lens to the tail lamp housing (Fig. 24). (3) Separate the tail lamp lens from the tail lamp DESCRIPTION housing. (4) Push the turn signal bulb inward and rotate it counter-clockwise.
Page 580: Underhood Lamp Removal
LAMPS/LIGHTING - EXTERIOR 8L - 25 INSTALLATION UNDERHOOD LAMP (1) Engage the replacement bulb wire loop to the REMOVAL terminal closest to the lamp base wire connector (Fig. 26). (1) Disconnect and isolate the battery negative (2) Depress the opposite terminal inward and cable.
Page 581 8L - 26 LAMPS/LIGHTING - INTERIOR LAMPS/LIGHTING - INTERIOR TABLE OF CONTENTS page page DOME LAMP GLOVE BOX LAMP/SWITCH DESCRIPTION ......26 REMOVAL .
Page 582: Dome Lamp Description
LAMPS/LIGHTING - INTERIOR 8L - 27 DOME LAMP (Continued) GLOVE BOX LAMP/SWITCH REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the glove box from the instrument panel. (Refer to 23 - BODY/INSTRUMENT PANEL/ GLOVE BOX - REMOVAL) for the procedures. (3) Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to access the instrument panel wire harness...
Page 583: Installation
8L - 28 LAMPS/LIGHTING - INTERIOR GLOVE BOX LAMP/SWITCH (Continued) INSTALLATION The instrument cluster monitors the door ajar switches. When a door is open the instrument cluster (1) Reach through the glove box opening and grounds the low side drivers to turn on the lamps. behind the glove box lamp and switch mounting Upon closing all doors, the instrument cluster ini- bracket to feed the instrument panel wire harness...
Page 584 LAMPS/LIGHTING - INTERIOR 8L - 29 READING LAMP (Continued) INSTALLATION into the two pivot holes in the overhead console hous- ing. (1) Position the reading and courtesy lamp lens (4) Pivot the lens back up into position and press onto the overhead console housing. upward firmly until the latch tab in the center of the (2) Align the two pivot tabs on the inboard edge of outboard edge of the reading and courtesy lamp lens...
Page 586 MESSAGE SYSTEMS 8M - 1 MESSAGE SYSTEMS TABLE OF CONTENTS page page OVERHEAD CONSOLE OPERATION ......7 DESCRIPTION .
Page 587: Operation
8M - 2 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) The temperature function is supported by an ambi- ent temperature sensor. This sensor is mounted out- side the passenger compartment near the front and center of the vehicle, and is hard wired to the Front Control Module (FCM).
Page 588: Standard Procedure
MESSAGE SYSTEMS 8M - 3 OVERHEAD CONSOLE (Continued) SELF-DIAGNOSTIC TEST (5) Reverse the above procedure to install. A self-diagnostic test is built-in to the module to STANDARD PROCEDURE - MODULE LENS determine that the electronics module is operating REPLACEMENT properly, and that all the J1850 PCI data bus mes- sages are being received for proper operation.
Page 589: Standard Procedure - Compass Demagnetizing
8M - 4 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) The electronic compass unit features a self-cali- STANDARD PROCEDURE - COMPASS brating design, which simplifies the calibration pro- DEMAGNETIZING cedure. This feature automatically updates the A degaussing tool (Special Tool 6029) is used to compass calibration while the vehicle is being driven.
Page 590: Standard Procedure - Compass Variation Adjustment
MESSAGE SYSTEMS 8M - 5 OVERHEAD CONSOLE (Continued) STANDARD PROCEDURE - COMPASS VARIATION ADJUSTMENT Compass variance, also known as magnetic decli- nation, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geo- graphic north is great enough to cause the compass to give false readings.
Page 591: Removal
8M - 6 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) (6) Depress and release the RESET push button Actuating the C/T push button will cause the to enter the displayed zone number into the EVIC/ CMTC to change to Compass/Temperature display. CMTC module memory. OPERATION (7) Confirm that the correct directions are now indicated by the compass.
Page 592: Electronic Vehicle Info Center Description
MESSAGE SYSTEMS 8M - 7 COMPASS/MINI-TRIP COMPUTER (Continued) The EVIC “Menu” push button provides the vehicle operator with a user interface, which allows the selection of several optional customer programmable electronic features to suit individual preferences. Refer to ELECTRONIC VEHICLE INFORMA- TION CENTER PROGRAMMING in the Standard Procedures section of this group for more information on the customer programmable feature options.
Page 593: Diagnosis And Testing - Electronic Vehicle Information Center
8M - 8 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER (Continued) Reset push button twice within three seconds will EVIC programming mode and to view or change the perform a global reset, and all of the trip computer selected programmable features options, proceed as information that can be reset will be reset to zero.
Page 594: Removal
MESSAGE SYSTEMS 8M - 9 ELECTRONIC VEHICLE INFO CENTER (Continued) appears, AUTO UNLOCK ON EXIT? - The options transmitters, after each transmitter is trained a again include Yes and No. The default is No. When chime will sound indicating that the training was Yes is selected, following each Auto Door Lock event successful.
Page 595: Ambient Temp Sensor Description
8M - 10 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER (Continued) (2) Install the screws holding the EVIC module in senses a specific voltage on the temperature sensor the overhead console. signal circuit, which it is programmed to correspond (3) Connect the EVIC module electrical connector. to a specific temperature.
Page 596: Removal
MESSAGE SYSTEMS 8M - 11 AMBIENT TEMP SENSOR (Continued) ness connector. There should be continuity. If OK, go tems or just about any other device that can be to Step 4. If not OK, repair the open sensor return or equipped with a radio receiver in the 286 to 399 signal circuit as required.
Page 597: Standard Procedure Standard Procedure - Erasing Transmitter Codes
8M - 12 MESSAGE SYSTEMS UNIVERSAL TRANSMITTER (Continued) (1) Turn the Radio Frequency (RF) Detector ON. A STANDARD PROCEDURE “chirp” will sound and the green power LED will light. If the green LED does not light, replace the STANDARD PROCEDURE - ERASING battery.
Page 598 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER SEATS .
Page 599: Power Locks
8N - 2 POWER LOCKS POWER LOCKS (Continued) Certain functions and features of the power lock The RKE system includes two transmitters when system rely upon resources shared with other elec- the vehicle is shipped from the factory, but the system tronic modules in the vehicle over the Programmable can retain the vehicle access codes of up to a total of Communications Interface (PCI) data bus network.
Page 600: Diagnosis And Testing - Power Locks
POWER LOCKS 8N - 3 POWER LOCKS (Continued) AUTOMATIC DOOR LOCKS DIAGNOSIS AND TESTING - POWER LOCKS When the automatic door locks are ENABLED the The most reliable, efficient, and accurate door locks will lock when the vehicle is moving at means to diagnose the power lock system about 25.7 Km/h (15 mph), all doors are closed and requires the use of a DRBIII scan tool and the...
Page 601: Power Lock Switch Diagnosis And Testing - Power Lock Switch
8N - 4 POWER LOCKS POWER LOCK SWITCH TEST TABLE POWER LOCK SWITCH DIAGNOSIS AND TESTING - POWER LOCK SWITCH POSITION RESISTANCE BETWEEN PINS 1 & 5 SWITCH NEUTRAL 10 KILOHMS ±1% The Light-Emitting Diode (LED) illumination lamp of the power lock switch receives battery current LOCK 820 OHMS ±5% through a fuse in the Integrated Power Module (IPM)
Page 602: Driver Door Module Description
POWER LOCKS 8N - 5 switch position (Lock, Unlock, and Neutral) provides DRIVER DOOR MODULE a different resistance value to the instrument cluster input, which allows the instrument cluster to sense DESCRIPTION the switch position. Based upon the power lock A Driver Door Module (DDM) is used on all models switch input, the instrument cluster controls the bat- equipped with power locks, power windows, and...
Page 603: Diagnosis And Testing - Driver Door Module
8N - 6 POWER LOCKS DRIVER DOOR MODULE (Continued) tons is depressed to move the selected mirror Up, Down, Right or Left. The DDM power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors.
Page 604: Removal
POWER LOCKS 8N - 7 DRIVER DOOR MODULE (Continued) the horn to sound for about three minutes, or until a DRIVER DOOR MODULE SWITCH TESTS second panic message is sent to the instrument clus- LEFT FRONT DOWN PINS 9 & 12 ter.
Page 605: Installation
8N - 8 POWER LOCKS REMOTE KEYLESS ENTRY MODULE (Continued) INSTALLATION The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace (1) Install remote keyless entry module to instru- the RKE transmitter batteries: ment cluster. (1) Using a thin coin, gently pry at the notch in (2) Install instrument cluster (Refer to 8 - ELEC- the center seam of the RKE transmitter case halves...
Page 606: Standard Procedure - Rke Transmitter Programing
POWER LOCKS 8N - 9 REMOTE KEYLESS ENTRY TRANSMITTER (Continued) (1) Enter the vehicle and close all doors. The following procedure can be used as long as one (2) Fasten the seat belt (this will cancel the seat programmed transmitter is available: belt chime).
Page 607: Power Mirrors Description
8N - 10 POWER MIRRORS POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS REMOVAL ......12 DESCRIPTION .
Page 608: Operation
POWER MIRRORS 8N - 11 POWER MIRRORS (Continued) (2) Disconnect wire harness connector to power OPERATION mirror switch (Fig. 1). The ambient photocell sensor is located on the for- (3) Using two jumper wires: ward-facing (windshield side) of the rear view mirror •...
Page 609: Removal
8N - 12 POWER MIRRORS AUTOMATIC DAY / NIGHT MIRROR (Continued) NOTE: The ambient photocell sensor must be cov- ered completely, so that no light reaches the sen- sor. Use a finger pressed tightly against the sensor, or cover the sensor completely with electrical tape. (7) Shine a light into the rearward facing head- lamp photocell sensor.
Page 610 POWER SEATS 8N - 13 POWER SEATS TABLE OF CONTENTS page page POWER SEATS REMOVAL ......16 DESCRIPTION .
Page 611: Power Seats
8N - 14 POWER SEATS moved in the opposite direction, the battery feed and DRIVER SEAT SWITCH ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to DESCRIPTION run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit.
Page 612: Removal
POWER SEATS 8N - 15 DRIVER SEAT SWITCH (Continued) DRIVER POWER SEAT SWITCH TEST TABLE DRIVER SWITCH CONTINUITY BETWEEN POSITION HORIZONTAL A-L, B-K FORWARD HORIZONTAL A-K, B-L REARWARD FRONT TILT UP A-M, B-N FRONT TILT DOWN A-N, B-M REAR TILT UP A-E, B-J REAR TILT DOWN A-J, B-E...
Page 613: Operation
8N - 16 POWER SEATS PASSENGER SEAT SWITCH (Continued) DIAGNOSIS AND TESTING - PASSENGER SEAT REMOVAL SWITCH (1) Disconnect and isolate the battery negative cable. For circuit descriptions and diagrams, refer to Wir- (2) Remove the seat cushion side shield from the ing.
Page 614: Diagnosis And Testing - Power Seat Track
POWER SEATS 8N - 17 POWER SEAT TRACK (Continued) (3) Check for continuity between the ground cir- cuit cavity of the power seat switch wire harness con- nector good ground. There should continuity. If OK, go to Step 4. If not OK, repair the open circuit to ground as required.
Page 615: Operation
8N - 18 POWER SEATS LUMBAR CONTROL SWITCH (Continued) shield that helps to shroud it from unintentional inboard side of the seat back panel and is connected actuation when entering or leaving the vehicle. to a worm-drive gearbox. The motor and gearbox The power lumbar switches cannot be adjusted or operate the lumbar adjuster mechanism in the center repaired and, if faulty or damaged, the seat switch...
Page 616: Removal
POWER WINDOWS 8N - 19 POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS WINDOW SWITCH DESCRIPTION ......19 DIAGNOSIS AND TESTING - WINDOW OPERATION .
Page 617 8N - 20 POWER WINDOWS POWER WINDOWS (Continued) (5) Momentarily touch the Positive (+) jumper the door trim panel (passenger doors). The drivers probe to the other motor connector terminal. door switch is included with the Driver Door Module When positive probe is connected the motor should (Refer to 8 - ELECTRICAL/POWER LOCKS/DOOR rotate in one direction to either move window up or MODULE - DIAGNOSIS AND TESTING) for service...
Page 618 POWER WINDOWS 8N - 21 WINDOW SWITCH (Continued) REAR PASSENGER (2) Install door trim panel (Refer to 23 - BODY/ DOOR - FRONT/TRIM PANEL - INSTALLATION). (1) Disconnect and isolate the battery negative (3) Connect battery negative cable. cable. (2) Remove the door trim panel (Refer to 23 - REAR PASSENGER BODY/DOORS - REAR/TRIM PANEL - REMOVAL).
Page 620 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS FRONT CENTER SEAT BELT DESCRIPTION ......2 REMOVAL .
Page 621 8O - 2 RESTRAINTS SEAT BELT TENSION REDUCER REMOVAL ......57 DESCRIPTION .
Page 622 RESTRAINTS 8O - 3 RESTRAINTS (Continued) Fig. 1 Supplemental Restraint System 1 - AIRBAG CONTROL MODULE 5 - SIDE CURTAIN AIRBAG (2) 2 - PASSENGER AIRBAG 6 - SIDE IMPACT SENSOR (2 - W/SIDE CURTAIN AIRBAGS ONLY) 3 - PASSENGER AIRBAG ON/OFF SWITCH (STD CAB ONLY) 7 - SEAT BELT TENSIONER (2) 4 - DRIVER AIRBAG into the passenger airbag door on the instrument...
Page 623: Restraints Description
8O - 4 RESTRAINTS RESTRAINTS (Continued) The ACM and the EMIC each contain a central processing unit and programming that allow them to communicate with each other using the Programma- ble Communications Interface (PCI) data bus net- work. This method of communication is used by the ACM for control of the airbag indicator on all models equipped with dual front airbags.
Page 624: Warning
RESTRAINTS 8O - 5 RESTRAINTS (Continued) Airbag Control Module (ACM). An airbag indicator in testing of the supplemental restraint system compo- the ElectroMechanical Instrument Cluster (EMIC) nents, the Programmable Communications Interface illuminates for about six seconds as a bulb test each (PCI) data bus, the electronic message inputs to and time the ignition switch is turned to the On or Start outputs from the EMIC or the ACM, as well as the...
Page 625: Diagnosis And Testing - Supplemental Restraint System
8O - 6 RESTRAINTS RESTRAINTS (Continued) WARNING: TO AVOID PERSONAL INJURY OR WITH THE CORRECT FASTENERS PROVIDED IN DEATH ON VEHICLES EQUIPPED WITH AIRBAGS, THE SERVICE PACKAGE OR SPECIFIED IN THE BEFORE PERFORMING ANY WELDING OPERA- DAIMLERCHRYSLER MOPAR PARTS CATALOG. TIONS DISCONNECT AND ISOLATE THE BATTERY WARNING: TO AVOID PERSONAL INJURY OR NEGATIVE (GROUND) CABLE AND DISCONNECT...
Page 626: Standard Procedure - Service After Asupplemental Restraint Deployment
RESTRAINTS 8O - 7 RESTRAINTS (Continued) ment in the event of an accidental deployment. When lowing any vehicle impact damage. Because the ACM handling a non-deployed seat belt tensioner, take and each impact sensor are used by the supplemental proper care to keep fingers out from under the restraint system to monitor or confirm the direction retractor cover and away from the seat belt webbing and severity of a vehicle impact, improper orientation...
Page 627 8O - 8 RESTRAINTS RESTRAINTS (Continued) AIRBAG SQUIB STATUS IF the Active DTC is: Conditions Squib Status Driver or Passenger Squib 1 AND the stored DTC minutes for both Driver or Both Squib 1 and 2 were open Passenger squibs are within 15 minutes of each used.
Page 628: Standard Procedure - Verification Test
RESTRAINTS 8O - 9 RESTRAINTS (Continued) SERVICE. THIS IS THE ONLY SURE WAY TO DIS- ABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY- MENT. (1) During the following test, the battery negative cable remains disconnected and isolated, as it was during the supplemental restraint system component removal and installation procedures.
Page 629: Acm Cover Removal
8O - 10 RESTRAINTS RESTRAINTS (Continued) If the stored DTC information is successfully erased, go to Step 9. (9) Turn the ignition switch to the Off position for about fifteen seconds, and then back to the On posi- tion. Observe the airbag indicator in the instrument cluster.
Page 630: Airbag Control Module Description
RESTRAINTS 8O - 11 outs and connectors of the instrument panel wire AIRBAG CONTROL MODULE harness. The impact sensor and safing sensor internal to DESCRIPTION the ACM are calibrated for the specific vehicle, and are only serviced as a unit with the ACM. In addi- tion, there are unique versions of the ACM for light and heavy-duty models, and for vehicles with or without the optional side curtain airbags.
Page 631: Removal
8O - 12 RESTRAINTS AIRBAG CONTROL MODULE (Continued) resistance of the input from the on/off switch. The input, determines the level of front airbag deploy- ACM will also set and/or store a DTC for faults it ment force required for each front seating position. detects in the passenger airbag on/off switch circuits, When the programmed conditions are met, the ACM and will turn on the airbag indicator in the EMIC if...
Page 632: Installation
RESTRAINTS 8O - 13 AIRBAG CONTROL MODULE (Continued) (1) Disconnect and isolate the battery negative the ACM mounting flange from the locating hole in cable. Wait two minutes for the system capacitor to the mounting bracket, then slide the ACM toward discharge before further service.
Page 633: Automatic Locking Retractor Description
8O - 14 RESTRAINTS AIRBAG CONTROL MODULE (Continued) panel transmission tunnel. Tighten the screws to 12 N·m (9 ft. lbs.). (4) From the left side of the floor panel transmis- sion tunnel, reach behind the module to access and tighten the screw that secures the right side of the ACM to the bracket on the floor panel transmission tunnel.
Page 634: Child Restraint Anchor
RESTRAINTS 8O - 15 CHILD RESTRAINT ANCHOR DESCRIPTION Fig. 10 Child Restraint Anchor Location - Standard Cab 1 - LOWER ANCHOR (PROVIDED FOR OUTBOARD SEATING 2 - TETHER ANCHOR (PROVIDED FOR CENTER AND POSITION ONLY) OUTBOARD SEATING POSITIONS) Fig. 11 Child Restraint Anchor Location - Quad Cab 1 - LOWER ANCHOR (PROVIDED FOR REAR OUTBOARD 2 - TETHER ANCHOR (PROVIDED FOR REAR CENTER AND SEATING POSITIONS ONLY)
Page 635 8O - 16 RESTRAINTS CHILD RESTRAINT ANCHOR (Continued) This model is equipped with a Lower Anchors and The three upper tether anchor straps for quad cab Tether for CHildren, or LATCH child restraint models are secured to the upper cab back panel rein- anchorage system (Fig.
Page 636: Operation
RESTRAINTS 8O - 17 CHILD RESTRAINT ANCHOR (Continued) THAT HAS A BENT OR DAMAGED LATCH PLATE ANCHOR PLATE. REPLACE CHILD RESTRAINT ANCHOR OR THE UNIT TO WHICH THE ANCHOR IS INTEGRAL THAT HAS BEEN BENT OR DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT CHILD RESTRAINT...
Page 637: Installation
8O - 18 RESTRAINTS CHILD RESTRAINT ANCHOR (Continued) (3) Reinstall the rear seat into the vehicle. (Refer to 23 - BODY/SEATS/SEAT - REAR - INSTALLA- TION). CLOCKSPRING DESCRIPTION Fig. 16 Child Tether Strap - Quad Cab 1 - TETHER STRAP (3) 2 - CAB BACK PANEL 3 - SCREW (3) INSTALLATION...
Page 638: Operation
RESTRAINTS 8O - 19 CLOCKSPRING (Continued) The clockspring rotor is movable and is keyed by an engagement dowel that is molded onto the rotor hub between two fins that are cast into the lower surface of the steering wheel armature. A yellow rub- ber boot is installed over the engagement dowel to eliminate contact noise between the dowel and the steering wheel.
Page 639: Removal
8O - 20 RESTRAINTS CLOCKSPRING (Continued) from the centered position, without damaging the clockspring tape. However, if the clockspring is removed for service or if the steering column is disconnected from the steering gear, the clockspring tape can change posi- tion relative to the other steering components.
Page 640: Installation
RESTRAINTS 8O - 21 CLOCKSPRING (Continued) (1) Place the front wheels in the straight ahead position. (2) Remove the driver airbag from the steering wheel. (Refer to 8 - ELECTRICAL/RESTRAINTS/ DRIVER AIRBAG - REMOVAL). (3) Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles.
Page 641 8O - 22 RESTRAINTS CLOCKSPRING (Continued) WARNING: TO AVOID PERSONAL INJURY OR (7) Position the upper shroud onto the steering col- DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, umn. If the vehicle is equipped with an automatic transmission, be certain to engage the gearshift lever DISABLE THE SUPPLEMENTAL RESTRAINT SYS- BEFORE ATTEMPTING...
Page 642: Driver Airbag Description
4 - TRIM COVER four-spoke steering wheel. All models have a chrome 5 - HOUSING Dodge Ram emblem in the center of the trim cover. The airbag used in this model is a multistage, Next Concealed beneath the driver airbag trim cover are...
Page 643: Removal
8O - 24 RESTRAINTS DRIVER AIRBAG (Continued) by the ACM to suit the monitored impact conditions RESTRAINTS). If the driver airbag has been by providing one of three delay intervals between the deployed, review the recommended procedures for electrical signals provided to the two initiators. The service after a supplemental restraint deployment longer the delay between these signals, the less force- before removing the airbag from the vehicle.
Page 644: Disassembly
RESTRAINTS 8O - 25 DRIVER AIRBAG (Continued) (6) Remove the driver airbag from the steering wheel. (7) If the driver airbag has been deployed, the clockspring must be replaced. (Refer to 8 - ELECTRI- CAL/RESTRAINTS/CLOCKSPRING - REMOVAL). DISASSEMBLY The following procedures can be used to replace the driver airbag trim cover and horn switch unit for service.
Page 645: Assembly
8O - 26 RESTRAINTS DRIVER AIRBAG (Continued) WARNING: TO AVOID PERSONAL INJURY OR inflator stud on the back of the driver airbag hous- DEATH, THE DRIVER AIRBAG TRIM COVER MUST ing. (6) Remove the horn switch ground pigtail wire NEVER BE PAINTED. REPLACEMENT TRIM COV- ERS ARE SERVICED IN THE ORIGINAL COLORS.
Page 646 RESTRAINTS 8O - 27 DRIVER AIRBAG (Continued) WARNING: TO AVOID PERSONAL INJURY OR precautions to prevent the trim cover from receiving DEATH, USE EXTREME CARE TO PREVENT ANY cosmetic damage during the following procedures. (5) Be certain that the horn switch feed and FOREIGN MATERIAL FROM ENTERING THE DRIVER AIRBAG, OR BECOMING ENTRAPPED BETWEEN ground pigtail wires are routed through the clearance...
Page 647: Installation
8O - 28 RESTRAINTS DRIVER AIRBAG (Continued) driver airbag housing. Tighten the nut to 7 N·m (65 WARNING: TO AVOID PERSONAL INJURY OR in. lbs.). DEATH, THE DRIVER AIRBAG TRIM COVER MUST (11) Using hand pressure, push the integral NEVER BE PAINTED. REPLACEMENT AIRBAGS retainer of the horn switch feed pigtail wire connec- ARE SERVICED WITH TRIM COVERS IN THE ORIG- tor into the locator hole just above the upper right...
Page 648: Front Center Seat Belt & Retractor Removal
RESTRAINTS 8O - 29 FRONT CENTER SEAT BELT & RETRACTOR REMOVAL A front center seat belt and retractor is used only on standard cab models. Quad cab models have a lap belt in the front center seating position. (Refer to 8 - ELECTRICAL/RESTRAINTS/FRONT CENTER SEAT BELT - REMOVAL).
Page 649: Front Center Seat Belt Removal
8O - 30 RESTRAINTS FRONT CENTER SEAT BELT & RETRACTOR (Continued) (1) Position the front center seat belt and retractor unit to the floor panel at the base of the cab back panel to the right of center (Fig. 29). (2) Install and tighten the two screws that secure the front center seat belt retractor bracket to the floor panel near the base of the cab back panel.
Page 650: Installation
RESTRAINTS 8O - 31 FRONT CENTER SEAT BELT (Continued) WARNING: TO AVOID PERSONAL INJURY OR (2) From behind the front seat, remove the screw DEATH, DURING AND FOLLOWING ANY SEAT BELT that secures the front center seat belt buckle, lap belt lower anchor, or unique black, keyed front center OR CHILD RESTRAINT ANCHOR SERVICE, CARE- FULLY INSPECT ALL SEAT BELTS, BUCKLES,...
Page 651: Front Outboard Seat Belt
8O - 32 RESTRAINTS FRONT CENTER SEAT BELT (Continued) (1) From the front of the front seat, position the ployed supplemental restraints. (Refer to 8 - ELEC- front center seat belt buckle, lap belt unit, or unique TRICAL/RESTRAINTS - STANDARD PROCEDURE black, keyed front center seat belt lower anchor - HANDLING NON-DEPLOYED SUPPLEMENTAL buckle between the center seat cushion and the adja-...
Page 652: Removal - Quad Cab
RESTRAINTS 8O - 33 FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued) (2) Disconnect and isolate the battery negative (8) Remove the upper and lower trim from the cable. Wait two minutes for the system capacitor to inner B-pillar. (Refer to 23 - BODY/INTERIOR/B- discharge before further service.
Page 653 8O - 34 RESTRAINTS FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued) before removing the front outboard seat belt and retractor from the vehicle. (Refer to 8 - ELECTRI- CAL/RESTRAINTS - STANDARD PROCEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT). WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYS- BEFORE...
Page 654: Installation
RESTRAINTS 8O - 35 FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued) (9) Remove the screw that secures the seat belt SERVICE AFTER A SUPPLEMENTAL RESTRAINT web guide to the inner B-pillar near the belt line. DEPLOYMENT). (10) Remove the seat belt web guide from the WARNING: TO AVOID PERSONAL INJURY OR inner B-pillar.
Page 655: Installation - Quad Cab
8O - 36 RESTRAINTS FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued) (4) Reconnect the yellow seat belt tensioner pigtail INSTALLATION - QUAD CAB wire connector to the body wire harness take out and The following procedure is for replacement of a connector for the tensioner.
Page 656: Front Outboard Seat Belt Buckle Removal
RESTRAINTS 8O - 37 FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued) WARNING: TO AVOID PERSONAL INJURY OR loop and, using hand pressure, press firmly and DEATH, DURING AND FOLLOWING ANY SEAT BELT evenly on the top of the trim cover until it snaps into place.
Page 657: Installation
8O - 38 RESTRAINTS FRONT OUTBOARD SEAT BELT BUCKLE (Continued) (1) Move the right or left front outboard seat sec- INSTALLATION tion (40 percent) to its most rearward position and A traveling front outboard seat belt buckle is tilt the seat back forward for easiest access to the located on the inboard side of each front outboard front outboard seat belt buckle lower anchor.
Page 658: Passenger Airbag Description
RESTRAINTS 8O - 39 airbag unit is secured by four screws through four PASSENGER AIRBAG brackets (two front and two rear) that are integral to the base of the airbag housing to the instrument DESCRIPTION panel structural support. Fig. 34 Passenger Airbag Door Fig.
Page 659: Operation
8O - 40 RESTRAINTS PASSENGER AIRBAG (Continued) OPERATION WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, The multistage passenger airbag is deployed by DISABLE THE SUPPLEMENTAL RESTRAINT SYS- electrical signals generated by the Airbag Control BEFORE ATTEMPTING STEERING Module (ACM) through the passenger airbag squib 1...
Page 660: Installation
RESTRAINTS 8O - 41 PASSENGER AIRBAG (Continued) (5) Reach through and above the glove box opening (9) Disconnect the passenger airbag pigtail wire to access and remove the two screws that secure the connector from the instrument panel wire harness passenger airbag rear brackets to the upper glove connector for the airbag.
Page 661: Passenger Airbag On/Off Switch Description
8O - 42 RESTRAINTS PASSENGER AIRBAG (Continued) WARNING: TO AVOID PERSONAL INJURY OR (9) Reinstall the lower surround onto the instru- DEATH, THE PASSENGER AIRBAG DOOR MUST ment panel. (Refer to 23 - BODY/INSTRUMENT PANEL/LOWER SURROUND - INSTALLATION). NEVER BE PAINTED. REPLACEMENT PASSENGER AIRBAG UNITS ARE SERVICED WITH DOORS IN (10) Do not reconnect the battery negative cable at THE ORIGINAL COLORS.
Page 662: Operation
RESTRAINTS 8O - 43 PASSENGER AIRBAG ON/OFF SWITCH (Continued) The passenger airbag on/off switch housing is con- The passenger airbag on/off switch connects one of structed of molded plastic and has three integral two internal resistors in series between the passen- mounting tabs.
Page 663: Installation
8O - 44 RESTRAINTS PASSENGER AIRBAG ON/OFF SWITCH (Continued) nent. (Refer to 8 - ELECTRICAL/RESTRAINTS - STANDARD PROCEDURE - VERIFICATION TEST). REAR CENTER SEAT BELT & RETRACTOR REMOVAL The rear center seat belt retractor is secured with a single screw to a mounting bracket that includes the unique black, keyed center seat belt lower anchor buckle and the right outboard occupant buckle, but can be removed from the mounting bracket and is...
Page 664: Installation
RESTRAINTS 8O - 45 REAR CENTER SEAT BELT & RETRACTOR (Continued) (3) Lift upward on the forward edge of the rear board occupant buckle and mounting bracket unit on center seat belt bezel at the top of the cab back panel the rear floor panel near the cab back panel (Fig.
Page 665: Rear Outboard Seat Belt & Retractor Removal
8O - 46 RESTRAINTS REAR CENTER SEAT BELT & RETRACTOR (Continued) WARNING: TO AVOID PERSONAL INJURY OR (9) Reach between the rear seat cushion and the DEATH, DURING AND FOLLOWING ANY SEAT BELT rear seat back to buckle the rear center seat belt lower anchor latch plate to the unique black, keyed OR CHILD RESTRAINT ANCHOR SERVICE, CARE- FULLY INSPECT ALL SEAT BELTS, BUCKLES,...
Page 666: Installation
RESTRAINTS 8O - 47 REAR OUTBOARD SEAT BELT & RETRACTOR (Continued) INSTALLATION The only component of this seat belt and retractor unit that is available for individual service replace- ment is the plastic web stop button that prevents the latch plate from falling to the floor while in the stored position.
Page 667: Rear Seat Belt Buckle
8O - 48 RESTRAINTS REAR OUTBOARD SEAT BELT & RETRACTOR (Continued) (8) Install and tighten the screw that secures the (1) Lift up the rear seat cushion into its stowed seat belt turning loop to the C-pillar. Tighten the position against the rear seat back. screw to 40 N·m (29 ft.
Page 668: Removal - Center Anchor & Right Outboard
RESTRAINTS 8O - 49 REAR SEAT BELT BUCKLE (Continued) REMOVAL - CENTER ANCHOR & RIGHT (3) Remove the screw that secures the rear center seat belt retractor to the center anchor/right out- OUTBOARD board occupant buckle and mounting bracket unit on The unique black, keyed center seat belt lower the rear floor panel near the cab back panel (Fig.
Page 669: Installation Installation - Center & Left
8O - 50 RESTRAINTS REAR SEAT BELT BUCKLE (Continued) BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. (1) Position the center or the left outboard occu- pant buckle unit onto the rear floor panel or onto the rear seat mounting bracket near the base of the cab back panel (Fig.
Page 670: Seat Belt Switch Description
RESTRAINTS 8O - 51 REAR SEAT BELT BUCKLE (Continued) (1) Position the center anchor/right outboard occu- The seat belt switch is a small, normally open, sin- pant buckle and mounting bracket unit onto the rear gle pole, single throw, leaf contact, momentary floor panel near the base of the cab back panel (Fig.
Page 671: Seat Belt Tensioner Description
8O - 52 RESTRAINTS SEAT BELT SWITCH (Continued) WARNING: TO AVOID PERSONAL INJURY OR SEAT BELT TENSIONER DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYS- DESCRIPTION BEFORE ATTEMPTING STEERING WHEEL, STEERING COLUMN, AIRBAG, SEAT BELT TENSIONER, IMPACT SENSOR, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 672 RESTRAINTS 8O - 53 SEAT BELT TENSIONER (Continued) retracted or extracted is a sure indication that the SEAT BELT TENSION seat belt tensioner has been deployed and requires REDUCER replacement. (Refer ELECTRICAL/RE- STRAINTS/FRONT OUTBOARD SEAT BELT & DESCRIPTION RETRACTOR - REMOVAL). OPERATION The seat belt tensioners are deployed by a signal generated by the Airbag Control Module (ACM)
Page 673: Operation
8O - 54 RESTRAINTS SEAT BELT TENSION REDUCER (Continued) OPERATION (1) Disconnect and isolate the battery negative cable. Disconnect the body wire harness connector for The seat belt tension reducer is controlled by a the seat belt tension reducer from the tension ground signal received from the seat belt switch on reducer connector receptacle on the driver side front the seat belt switch sense circuit and a battery cur-...
Page 674 RESTRAINTS 8O - 55 SEAT BELT TURNING LOOP ADJUSTER REMOVAL WARNING: TO AVOID PERSONAL INJURY OR DEATH, DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CARE- FULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE.
Page 675 8O - 56 RESTRAINTS SEAT BELT TURNING LOOP ADJUSTER (Continued) (4) Install the upper screw that secures the seat at the front of the vehicle to just behind the B-pillar belt turning loop height adjuster to the upper B-pil- on standard cab models, and to just behind the C-pil- lar, then tighten both the upper and lower screws to lar on quad cab models.
Page 676 RESTRAINTS 8O - 57 SIDE CURTAIN AIRBAG (Continued) pressed inert gas. When the ACM sends the proper WARNING: TO AVOID PERSONAL INJURY OR electrical signal to the airbag inflator, the electrical DEATH, WHEN REMOVING A DEPLOYED AIRBAG, energy creates enough heat to ignite chemical pellets RUBBER GLOVES, EYE PROTECTION, AND A within the inflator.
Page 677 8O - 58 RESTRAINTS SIDE CURTAIN AIRBAG (Continued) (5) Disconnect the body wire harness connector for WARNING: TO AVOID PERSONAL INJURY OR the side curtain airbag from the connector receptacle DEATH, WHEN REMOVING A DEPLOYED AIRBAG, at the back of the airbag inflator. RUBBER GLOVES, EYE PROTECTION, AND A (6) Remove the four screws (standard cab) or six LONG-SLEEVED SHIRT SHOULD BE WORN.
Page 678 RESTRAINTS 8O - 59 OPERATION SIDE IMPACT SENSOR The side impact sensors are electronic accelerome- DESCRIPTION ters that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to commu- nicate the sensor status as well as sensor fault infor- mation to the microprocessor in the Airbag Control...
Page 679 8O - 60 RESTRAINTS SIDE IMPACT SENSOR (Continued) WARNING: TO AVOID PERSONAL INJURY OR (5) Reach through the retractor mounting hole in DEATH, NEVER STRIKE OR DROP THE SIDE the inner B-pillar to access the side impact sensor and disengage the locating pin and mounting stud IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION.
Page 680 RESTRAINTS 8O - 61 SIDE IMPACT SENSOR (Continued) WARNING: TO AVOID PERSONAL INJURY OR DEATH, NEVER STRIKE OR DROP THE SIDE IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. THE SIDE IMPACT SENSOR ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS.
Page 681 8O - 62 RESTRAINTS SIDE IMPACT SENSOR (Continued) WARNING: TO AVOID PERSONAL INJURY OR (3) Reach through the large hole above the retrac- DEATH, NEVER STRIKE OR DROP THE SIDE tor mounting hole in the inner B-pillar to position and engage the locating pin and the stud on the side IMPACT SENSOR, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION.
Page 682 SPEED CONTROL 8P - 1 SPEED CONTROL TABLE OF CONTENTS page page SPEED CONTROL OPERATION ......6 DESCRIPTION .
Page 683 8P - 2 SPEED CONTROL SPEED CONTROL (Continued) 5.9L Diesel With Manual Trans. Once the speed control has been disengaged, depressing the RES/ACCEL switch (when speed is The speed control system is fully electronically con- greater than 30 mph) restores the vehicle to the tar- trolled by the Engine Control Module (ECM).
Page 684: Speed Control
SPEED CONTROL 8P - 3 SPEED CONTROL (Continued) (5) Verify operation of one-way check valve and ometer operation should be smooth and without flut- check it for leaks. ter at all speeds. (a) Locate one-way check valve. The valve is Flutter in the speedometer indicates a problem located in vacuum line between vacuum reservoir which might cause surging in the speed control sys-...
Page 685: Cable Description
8P - 4 SPEED CONTROL CABLE DESCRIPTION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable is used with 3.7L/4.7L gas powered engines only. It is also used if equipped with a 5.9L diesel engine equipped with an automatic transmission.
Page 686: Installation
SPEED CONTROL 8P - 5 CABLE (Continued) Fig. 5 SERVO CABLE AT THROTTLE LEVER — 5.9L DIESEL Fig. 3 SPEED CONTROL CABLE AT BELLCRANK - 3.7L / 4.7L 1 - PINCH (2) TABS 2 - CABLE MOUNTING BRACKET 1 - THROTTLE BODY BELLCRANK 3 - PINCH TABS (2) 2 - SPEED CONTROL CABLE CONNECTOR 4 - OFF...
Page 687: Servo Description
8P - 6 SPEED CONTROL CABLE (Continued) (5) Before starting engine, operate accelerator The PCM/ECM duty cycles the vacuum and vent pedal to check for any binding. solenoids to maintain the set speed, or to accelerate (6) Install cable/lever cover. and decelerate the vehicle.
Page 688: Switch Description
SPEED CONTROL 8P - 7 SERVO (Continued) SWITCH DESCRIPTION Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM (to the ECM for diesel) for ON, OFF, RESUME, ACCEL- ERATE, SET, DECEL and CANCEL modes.
Page 689: Removal
8P - 8 SPEED CONTROL SWITCH (Continued) The previous disengagement conditions are pro- grammed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM’s RAM (ECM for diesel).
Page 690: Vacuum Reservoir Description
SPEED CONTROL 8P - 9 (b) Connect a hand-operated vacuum pump to VACUUM RESERVOIR reservoir end of check valve. Apply vacuum. Vac- uum should not bleed off. If vacuum is being lost, DESCRIPTION replace one-way check valve. The vacuum reservoir is a plastic storage tank con- (c) Connect a hand-operated vacuum pump to nected to an engine vacuum source by vacuum lines.
Page 691: Installation
8P - 10 SPEED CONTROL VACUUM RESERVOIR (Continued) INSTALLATION (1) Position reservoir onto 2 weld studs (Fig. 11). (2) Install 2 mounting nuts and tighten. Refer to torque specifications. (3) Connect vacuum line to reservoir fitting. (4) Install cowl grill. Refer to Cowl Grill Removal / Installation.
Page 692: System
VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY DIAGNOSIS AND TESTING DESCRIPTION VEHICLE THEFT SECURITY SYSTEM ..3 DESCRIPTION - VEHICLE THEFT/ STANDARD PROCEDURE SECURITY SYSTEM ....1 CONFIGURING A NEW MODULE / SWITCH DESCRIPTION - SENTRY KEY OPERATING MODES .
Page 693: Operation - Sentry Key Immobilizer
8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) After the vehicle is locked and the last door is plant to access the SKIS for initialization, or by the closed, the VTSS indicator in the instrument cluster dealer technician to access the system for service. will flash quickly for 16 seconds, indicating that the The SKIM also stores in its memory the Vehicle arming is in process.
Page 694: Diagnosis And Testing
VEHICLE THEFT SECURITY 8Q - 3 VEHICLE THEFT SECURITY (Continued) SKIM cannot be repaired and, if faulty or damaged, (3) After the DRBIII scan tool initialization, per- the unit must be replaced. form the following: (a) Select “Theft Alarm.” (b) Select “VTSS.” DIAGNOSIS AND TESTING (c) Select “Miscellaneous.”...
Page 695: Sentry Key Immobilizer System Transponder Programming
8Q - 4 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) SENTRY KEY IMMOBILIZER SYSTEM should see a blank, if it has already programmed eight valid Sentry Keys, or if the ignition switch is TRANSPONDER PROGRAMMING turned to the OFF position for more than about fifty Two programmed Sentry Key transponders are seconds.
Page 696: Sentry Key Immobilizer System Indicator Lamp Description
VEHICLE THEFT SECURITY 8Q - 5 messages to the instrument cluster to turn the LED SENTRY KEY IMMOBILIZER off based upon the results if the SKIS self - test. If SYSTEM INDICATOR LAMP the indicator illuminates and remains illuminated after the “bulb test”, it indicates that the SKIM has DESCRIPTION detected a system malfunction and/or the system has The Sentry Key Immobilizer System (SKIS) uses...
Page 698 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS REMOVAL - DIESEL ENGINE ... . 16 DESCRIPTION ......1 INSTALLATION OPERATION .
Page 699: Wipers/Washers Description
8R - 2 WIPERS/WASHERS WIPERS/WASHERS (Continued) Fig. 1 Wiper & Washer System 1 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL 3 - WIPER MODULE SWITCH (EXCEPT DIESEL ENGINE) 4 - WASHER NOZZLE (2) 2 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL 5 - WIPER ARM & BLADE (2) SWITCH (DIESEL ENGINE ONLY) 6 - MULTI-FUNCTION (WIPER, WASHER, &...
Page 700 WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) • Continuous Wipe Mode - The control knob on is secured by integral mounting tabs and a snap fea- ture to slots in the right side of the cooling module the control stalk of the multi-function switch has two shroud in the engine compartment.
Page 701: Operation
8R - 4 WIPERS/WASHERS WIPERS/WASHERS (Continued) is released before parking the wiper blades near the low side drivers to control wiper system operation by base of the windshield. If the control knob is held in energizing or de-energizing the wiper high/low and the depressed Wash position for more than about wiper on/off relays.
Page 702 WIPERS/WASHERS 8R - 5 WIPERS/WASHERS (Continued) the wiper motor was operating at high speed, the WASH MODE FCM immediately de-energizes the wiper high/low When the control knob on the control stalk of the relay causing the wiper motor to return to low speed multi-function switch is depressed to the momentary operation.
Page 703: Diagnosis And Testing - Wiper & Washer System
8R - 6 WIPERS/WASHERS WIPERS/WASHERS (Continued) interval at which to de-energize the wiper on/off CLEANING - WIPER & WASHER SYSTEM relay to complete the wipe-after-wash mode cycle. WIPER SYSTEM DIAGNOSIS AND TESTING - WIPER & The squeegees of wiper blades exposed to the ele- WASHER SYSTEM ments for a long time tend to lose their wiping effec- tiveness.
Page 704: Inspection - Wiper & Washer System
WIPERS/WASHERS 8R - 7 WIPERS/WASHERS (Continued) INSPECTION - WIPER & WASHER SYSTEM WIPER SYSTEM The wiper blades and wiper arms should be inspected periodically, not just when wiper perfor- mance problems are experienced. This inspection should include the following points: (1) Inspect the wiper arms for any indications of damage, or contamination.
Page 705: Operation
8R - 8 WIPERS/WASHERS CHECK VALVE (Continued) When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure unseats a diaphragm from over a sump well within the valve by overriding the spring pressure applied to it by a piston (Fig. 4). With the diaphragm unseated, washer fluid is allowed to flow toward the two washer nozzles.
Page 706: Washer Fluid Level Switch Description
WIPERS/WASHERS 8R - 9 CHECK VALVE (Continued) Fig. 5 Check Valve Remove/Install 1 - WASHER NOZZLE HOSE (RIGHT) 2 - CHECK VALVE 3 - ROUTING CLIP Fig. 6 Washer Fluid Level Switch 4 - COWL PLENUM WASHER HOSE 5 - COWL PLENUM COVER/GRILLE PANEL (UNDERSIDE) 1 - MOUNTING FLANGE 6 - WASHER NOZZLE HOSE (LEFT) 2 - BARBED NIPPLE...
Page 707: Removal
8R - 10 WIPERS/WASHERS WASHER FLUID LEVEL SWITCH (Continued) (FCM) on a sensor return circuit and the washer fluid switch sense input to the FCM. When the switch closes, the FCM senses the ground on the washer fluid switch sense circuit. The FCM is pro- grammed to respond to this input by sending an elec- tronic washer fluid indicator lamp-on message to the instrument cluster over the Programmable Commu-...
Page 708: Installation
WIPERS/WASHERS 8R - 11 WASHER FLUID LEVEL SWITCH (Continued) INSTALLATION tor unit on the washer reservoir through a trough molded into the back of the reservoir above the (1) Install a new rubber grommet seal into the washer pump and to the engine compartment washer washer fluid level switch mounting hole in the hose (Fig.
Page 709: Operation
8R - 12 WIPERS/WASHERS WASHER NOZZLE (Continued) (4) From the underside of the cowl plenum cover/ grille panel, disconnect the washer nozzle hose from the barbed nipple of the washer nozzle (Fig. 11). Fig. 10 Washer Nozzle 1 - HOOD 2 - LATCH (2) 3 - NIPPLE 4 - ANTI-ROTATION TAB...
Page 710: Washer Pump/Motor Description
WIPERS/WASHERS 8R - 13 WASHER NOZZLE (Continued) (7) Reinstall both wiper arms onto the wiper piv- post on the motor housing and a snap post receptacle ots. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ molded into the reservoir that allows for mounting of WIPER ARM - INSTALLATION).
Page 711: Removal
8R - 14 WIPERS/WASHERS WASHER PUMP/MOTOR (Continued) inputs and outputs related to the washer pump/mo- (7) Pull the washer pump/motor unit straight out tor unit operation requires the use of a DRBIII scan from the washer reservoir far enough to disengage tool.
Page 712: Operation
WIPERS/WASHERS 8R - 15 WASHER RESERVOIR (Continued) tom of the shroud, while the upper tab slides into an integral channel-like slot near the top of the shroud. A molded lock feature on the forward facing surface of the reservoir engages a molded depression on the rearward facing surface of the radiator shroud when the reservoir is fully seated on the shroud, locking the unit securely in place.
Page 713: Removal - Diesel Engine
8R - 16 WIPERS/WASHERS WASHER RESERVOIR (Continued) drain from the reservoir into a clean container for REMOVAL - DIESEL ENGINE reuse (Fig. 15). (1) Unlatch and open the hood. (2) Disconnect and isolate the battery negative cable. (3) Disengage the reservoir washer hose from the integral routing clips on the top of the radiator fan shroud (Fig.
Page 714: Installation
WIPERS/WASHERS 8R - 17 WASHER RESERVOIR (Continued) INSTALLATION - DIESEL ENGINE (1) Position the washer reservoir into the left side of the engine compartment (Fig. 17). (2) Install and tighten the two screws that secure the washer reservoir to the left vertical member of the radiator support.
Page 715: Operation
8R - 18 WIPERS/WASHERS WIPER ARM (Continued) plenum cover/grille panel near the base of the wind- (2) Pull the latch on the pivot end of the wiper shield and the wiper blades on the windshield glass arm outward (Fig. 19). (Fig.
Page 716: Operation
WIPERS/WASHERS 8R - 19 WIPER BLADE (Continued) superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber ele- ment is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, yet resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions.
Page 717: Installation
8R - 20 WIPERS/WASHERS WIPER BLADE (Continued) INSTALLATION male spade-type terminals that extend from the bot- tom of the relay base. The wiper high/low relay cannot be adjusted or NOTE: The notched end of the wiper element flexor repaired and, if faulty or damaged, the unit must be should always be oriented towards the end of the replaced.
Page 718: Diagnosis And Testing - Wiper High/Low Relay
WIPERS/WASHERS 8R - 21 WIPER HIGH/LOW RELAY (Continued) The wiper high/low relay can be diagnosed using (4) Connect a battery to terminals 85 and 86. conventional diagnostic tools and methods. However, There should now be continuity between terminals conventional diagnostic methods may not prove con- 30 and 87, and no continuity between terminals 87A clusive in the diagnosis of the instrument cluster, the and 30.
Page 719: Installation
8R - 22 WIPERS/WASHERS WIPER HIGH/LOW RELAY (Continued) INSTALLATION are the only visible components of the wiper module. The wiper module consists of the following major (1) Position the wiper high/low relay to the proper components: receptacle in the Integrated Power Module (IPM) •...
Page 720: Operation
WIPERS/WASHERS 8R - 23 WIPER MODULE (Continued) OPERATION (6) Remove the two screws that secure the wiper module to the top of the cowl plenum panel at the The wiper module operation is controlled by the pivot brackets. battery current inputs received by the wiper motor (7) Remove the two screws that secure the wiper through the wiper on/off and wiper high/low relays.
Page 721: Wiper On/Off Relay Description
8R - 24 WIPERS/WASHERS WIPER MODULE (Continued) Fig. 26 Wiper Module Remove/Install 1 - COWL PLENUM WASHER HOSE 6 - WIPER MODULE 2 - PLASTIC FASTENER (6) 7 - WIRE HARNESS CONNECTOR 3 - SCREW (2) 8 - PLENUM PANEL 4 - WIPER ARM &...
Page 722: Operation
WIPERS/WASHERS 8R - 25 WIPER ON/OFF RELAY (Continued) • Normally Closed Terminal - The normally The wiper on/off relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be closed terminal (87A) is connected to ground at all replaced.
Page 723: Removal
8R - 26 WIPERS/WASHERS WIPER ON/OFF RELAY (Continued) (1) Remove the wiper on/off relay from the IPM. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ WIPER ON/OFF RELAY - REMOVAL). (2) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30.
Page 724 NAVIGATION/TELECOMMUNICATION 8T - 1 NAVIGATION/TELECOMMUNICATION TABLE OF CONTENTS page page NAVIGATION/TELECOMMUNICATION HANDS FREE MODULE DESCRIPTION ......1 REMOVAL .
Page 725 8T - 2 NAVIGATION/TELECOMMUNICATION HANDS FREE MODULE REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the instrument panel right side end cap. (3) Remove the mounting fasteners (Fig. 1). (4) Disconnect the electrical harness connector and remove module. INSTALLATION (1) Connect the electrical harness connector and position module.
Page 726 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 AUDIO SYSTEM ..... 8W-47-1 COMPONENT INDEX .
Page 728 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION STANDARD PROCEDURE - TESTING FOR A DESCRIPTION SHORT TO GROUND ....9 DESCRIPTION - HOW TO USE WIRING STANDARD PROCEDURE - TESTING FOR A DIAGRAMS .
Page 729: Wiring Diagram Information
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 730 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 731 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 732: Description - Circuit Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY WIRE COLOR CODE CHART This is a list of terms and definitions used in the wiring diagrams. COLOR CODE COLOR BLUE LHD ....Left Hand Drive Vehicles BLACK RHD .
Page 733: Description - Circuit Functions
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CIRCUIT FUNCTIONS DESCRIPTION - SECTION IDENTIFICATION AND All circuits in the diagrams use an alpha/numeric INFORMATION code to identify the wire and it’s function. To identify The wiring diagrams are grouped into individual which circuit code applies to a system, refer to the sections.
Page 734: Description - Connector, Ground And Splice Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE SPLICE INFORMATION PROCEDURE REQUIRES IT TO BE ON. CAUTION: Not all connectors are serviced.
Page 735: Standard Procedure Standard Procedure - Electrostatic Discharge (Esd) Sensitive Devices
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance factory items added to the vehicle before doing any between two points of a circuit. Low or no resistance diagnosis.
Page 736: Standard Procedure - Testing Of Voltage Potential
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL CONTINUITY (1) Connect the ground lead of a voltmeter to a (1) Remove the fuse for the circuit being checked known good ground (Fig.
Page 737: Standard Procedure - Testing For Ashort To Ground On Fuses Powering Several Loads
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A SPECIAL TOOLS SHORT TO GROUND ON FUSES POWERING WIRING/TERMINAL SEVERAL LOADS (1) Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. (2) Replace the blown fuse.
Page 738: Connector Removal
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 INSTALLATION CONNECTOR (1) Insert the removed terminal in the same cavity REMOVAL on the repair connector. (2) Repeat steps for each terminal in the connec- (1) Disconnect battery. tor, being sure that all wires are inserted into the (2) Release Connector Lock (Fig.
Page 739 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock...
Page 740 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13 CONNECTOR (Continued) Fig. 12 TERMINAL REMOVAL 1 - TYPICAL CONNECTOR 7 - MOLEX CONNECTOR 2 - PICK FROM SPECIAL TOOL KIT 6680 8 - SPECIAL TOOL 6742 3 - APEX CONNECTOR 9 - THOMAS AND BETTS CONNECTOR 4 - PICK FROM SPECIAL TOOL KIT 6680 10 - SPECIAL TOOL 6934...
Page 741: Diode Removal
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION DIODE TERMINAL REMOVAL REMOVAL (1) Disconnect the battery. (1) Follow steps for removing terminals described (2) Locate the diode in the harness, and remove in the connector removal section. the protective covering. (2) Cut the wire 6 inches from the back of the con- (3) Remove the diode from the harness, pay atten- nector.
Page 742: Wire
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15 (5) Solder the connection together using rosin core WIRE type solder only (Fig. 16). STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER. When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
Page 744 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch ....8W-42 Door Module ....8W-60, 61, 62 A/C Compressor Clutch Relay .
Page 745 8W - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Manifold Absolute Pressure Sensor ..8W-30 Speed Control Servo ....8W-33 Mode Door Actuators .
Page 746 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-17, 40 Fuse 25 .
Page 798 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-5, 8 G202 ......8W-15-11, 12, 14 A/C-Heater Control .
Page 818 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page A/C-Heater Control ....8W-18-5 G120 ......8W-18-4 Airbag Control Module .
Page 824 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Auxiliary Battery ....8W-20-3 G107 ......8W-20-2 Battery .
Page 828 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Auxiliary Battery ....8W-21-3 Integrated Power Module ..8W-21-2, 3, 4 Battery .
Page 832 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ... . 8W-30-9, 58 Fuse 36 ......8W-30-54, 61 A/C Pressure Transducer .
Page 898 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Automatic Day/Night Mirror ... 8W-31-7 Line Pressure Sensor ....8W-31-6 Brake Lamp Switch .
Page 914 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Brake Lamp Switch ....8W-33-2, 4, 5 Fuse 30 ......8W-33-4 Center High Mounted Stop Lamp- G104 .
Page 922 8W-34 REAR WHEEL ANTILOCK BRAKES 8W - 34 - 1 8W-34 REAR WHEEL ANTILOCK BRAKES Component Page Component Page Brake Fluid Level Switch ....8W-34-2 Fuse 35 ......8W-34-2 Brake Lamp Switch .
Page 926 8W-35 ALL WHEEL ANTILOCK BRAKES 8W - 35 - 1 8W-35 ALL WHEEL ANTILOCK BRAKES Component Page Component Page Brake Fluid Level Switch ....8W-35-2 G104 ......8W-35-2 Brake Lamp Switch .
Page 930 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Cylinder Lock Switch-Driver ... 8W-39-5 G104 ......8W-39-3 Data Link Connector .
Page 936 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page A/C-Heater Control ....8W-40-12 Fuse 41 ......8W-40-3 Brake Transmission Shift Interlock G201 .
Page 950 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Cigar Lighter Outlet ....8W-41-3 G302 ......8W-41-4 Clockspring .
Page 954 8W-42 AIR CONDITIONING 8W - 42 - 1 8W-42 AIR CONDITIONING Component Page Component Page A/C Compressor Clutch ....8W-42-7 Fuse 36 ......8W-42-3, 4 A/C Compressor Clutch Relay .
Page 964 8W-43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ... . 8W-43-2, 3, 4 Fuse 52 ......8W-43-2 Airbag-Driver Squib 1 .
Page 968 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page Ashtray Lamp ..... . 8W-44-4 Fuse 15 .
Page 972 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Amplifier Audio ....8W-47-4, 5 Remote Radio Switch-Left ... . . 8W-47-7 Clockspring .
Page 980 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page A/C-Heater Control ....8W-48-2 Heated Mirror Relay ....8W-48-2 Electric Backlight .
Page 982 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Ambient Temperature Sensor ..8W-49-3, 4 Fuse 28 ......8W-49-2 Automatic Day/Night Mirror .
Page 986 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Clearance Lamp No. 1 ....8W-50-6 G104 ......8W-50-3, 4, 5 Clearance Lamp No.
Page 992 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Backup Lamp Switch ....8W-51-3, 5 G104 ......8W-51-2, 4, 5, 6 Brake Lamp Switch .
Page 1000 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Data Link Connector ....8W-52-2 Park Lamp Relay ....8W-52-3 Front Control Module .
Page 1006 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Data Link Connector ....8W-53-2 Multi-Function Switch ....8W-53-2 Front Control Module .
Page 1010 8W-54 TRAILER TOW 8W - 54 - 1 8W-54 TRAILER TOW Component Page Component Page Brake Lamp Switch ....8W-54-5 Fuse 47 ......8W-54-2, 3 Electric Brake Provision .
Page 1016 8W-55 NAVIGATION/TELECOMMUNICATION 8W - 55 - 1 8W-55 NAVIGATION/TELECOMMUNICATION Component Page Component Page Automatic Day/Night Mirror ... 8W-55-2 Hands Free Module ....8W-55-2 Data Link Connector .
Page 1018 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker ....8W-60-2, 4 Power Window Motor-Left Rear ..8W-60-7 Driver Door Module .
Page 1026 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Cylinder Lock Switch-Driver ... 8W-61-2 Driver Door Module ....8W-61-2 Door Lock Motor/Ajar Switch-Driver .
Page 1030 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page A/C-Heater Control ....8W-62-3 G302 ......8W-62-2, 3 Driver Door Module .
Page 1034 8W-63 POWER SEATS 8W - 63 - 1 8W-63 POWER SEATS Component Page Component Page Fuse 7 ......8W-63-2 Passenger Lumbar Switch .
Page 1042 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S101 ....... 8W-15-7 S210 .
Page 1050 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page 4WD Switch (Manual Transfer Case) ..8W-80-5 C112 (Diesel A/T) ....8W-80-19 A/C Compressor Clutch (Diesel) .
Page 1051 8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS Component Page Component Page C315 ......8W-80-39 Crankshaft Position Sensor (3.7L) .
Page 1052 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Fuel Pump Module ....8W-80-66 Oxygen Sensor 2/1 Upstream (NGC) ..8W-80-81 Fuel Pump Motor (Diesel) .
Page 1053 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS Component Page Component Page Speaker-Right Instrument Panel ..8W-80-96 Transfer Case Control Module C3 (Electric 4x4) ....8W-80-101 Speaker-Right Rear .
Page 1054 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 4WD SWITCH (MANUAL TRANSFER CASE) - 2 WAY CIRCUIT FUNCTION K77 18BR/WT TRANSFER CASE POSITION SENSOR INPUT Z901 18BK GROUND A/C COMPRESSOR CLUTCH (DIESEL) - BLACK 2 WAY CIRCUIT FUNCTION C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT Z816 18BK GROUND...
Page 1055 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS A/C HEATER CONTROL C2 - BLACK 10 WAY CIRCUIT FUNCTION C71 16DB/BR BLOWER MOTOR LOW DRIVER C73 14DB/VT BLOWER MOTOR M2 DRIVER Z134 10BK/LG GROUND C72 16DB/OR BLOWER MOTOR M1 DRIVER C70 10DB/YL BLOWER MOTOR HIGH DRIVER A/C PRESSURE TRANSDUCER (DIESEL) - BLACK 4 WAY CIRCUIT...
Page 1056 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 ACCELERATOR PEDAL POSITION SENSOR (DIESEL M/T) - 6 WAY CIRCUIT FUNCTION K29 20WT/BR APPS NO. 2 SIGNAL K854 20VT/BR APPS NO. 2 5 VOLT SUPPLY K852 20BR/LB APPS NO. 1 5 VOLT SUPPLY K400 20BR/VT APPS NO.
Page 1057 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS ADJUSTABLE PEDAL SWITCH (EXCEPT MEMORY) - BLUE 6 WAY CIRCUIT FUNCTION P206 18LG/LB ADJUSTABLE PEDALS MOTOR REVERSE A72 18RD/OR ADJUSTABLE PEDAL RELAY OUTPUT Z146 18BK GROUND F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN) P205 18LG/WT ADJUSTABLE PEDALS MOTOR FORWARD AIRBAG CONTROL MODULE C1 - 24 WAY...
Page 1058 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 AIRBAG CONTROL MODULE C2 - 32 WAY CIRCUIT FUNCTION R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1 R56 20LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 R1 18LB/WT (LIGHT DUTY)
Page 1059 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS AIRBAG-PASSENGER ON/OFF SWITCH - 6 WAY CIRCUIT FUNCTION R106 20LG/LB PASSENGER AIRBAG MUX SWITCH SENSE R104 20LB/LG PASSENGER AIRBAG MUX SWITCH RETURN G104 20VT/GY PASSENGER AIRBAG INDICATOR DRIVER F201 18PK/OR FUSED IGNITION SWITCH OUTPUT (RUN-START) AIRBAG-PASSENGER SQUIB - 4 WAY CIRCUIT FUNCTION...
Page 1060 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 AMPLIFIER AUDIO C1 (PREMIUM) - GRAY 12 WAY CIRCUIT FUNCTION X53 20DG LEFT FRONT SPEAKER (+) X55 20DG/BR LEFT FRONT SPEAKER (-) X57 20DG/OR LEFT REAR SPEAKER (-) Z513 18BK GROUND X11 20DG RADIO 12 VOLT OUTPUT X56 20GY/BR RIGHT FRONT SPEAKER (-)
Page 1061 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS AUTOMATIC DAY/NIGHT MIRROR C1 (EXCEPT BASE) - 7 WAY CIRCUIT FUNCTION F21 20PK/DG FUSED IGNITION SWITCH OUTPUT (RUN-START) Z13 20BK/WT GROUND L1 20WT/LG BACKUP LAMP FEED AUTOMATIC DAY/NIGHT MIRROR C2 (TELEMATICS) - 12 WAY CIRCUIT FUNCTION X722 20LB/DG...
Page 1062 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 BLEND DOOR ACTUATOR (SINGLE ZONE) - 2 WAY CIRCUIT FUNCTION C34 20DB/LB COMMON DOOR DRIVER C61 20DB/LG BLEND DOOR DRIVER BLOWER MOTOR - BLACK 2 WAY CIRCUIT FUNCTION C70 10DB/YL BLOWER MOTOR HIGH DRIVER C7 10DB BLOWER MOTOR FEED BLOWER MOTOR RESISTOR BLOCK - BLACK 4 WAY...
Page 1063 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - BLACK 2 WAY CIRCUIT FUNCTION K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL Z101 18BK/VT GROUND C102 (NGC) - (AMBIENT TEMPERATURE SEN- SOR SIDE) CIRCUIT G31 20VT/LG K900 20DB/DG C103 - (HEADLAMP AND DASH SIDE) CIRCUIT...
Page 1064 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 C106 (5.7L A/T) - (INTAKE AIR FUEL MODULE SIDE) CIRCUIT K11 18BR/YL K12 18BR/DB K13 18BR/LB K14 18BR/TN K38 18BR/OR K58 18BR/VT K26 18BR/YL K28 18BR/LB K19 18DB/DG K17 18DB/TN K18 18DB/OR K15 18DB/GY K16 18DB/YL K10 18DB/OR...
Page 1065 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C107 (5.7L) - BLACK (INTAKE AIR FUEL MOD- ULE SIDE) CIRCUIT K900 18DB/DG K1 18VT/BR K21 18DB/LG K922 18BR/DB F856 18YL/PK K447 18TN/YL K342 16BR/WT F855 18PK/YL K2 18VT/OR K122 18BR/DG K22 18BR/OR K448 18TN/OR K342 16BR/WT C108 (DIESEL) - BLACK (ENGINE SIDE)
Page 1066 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C109 (DIESEL) - LT GRAY (ENGINE SIDE) CIRCUIT V35 18VT/OR V32 18VT/YL T41 18YL/DB T6 18DG T118 18DG T9 18DG/TN T38 18YL/BR T75 18YL/LB T54 18DG/OR T515 18YL/DB V36 18VT/YL T14 18DG/BR T13 18DG/VT C109 (DIESEL) - LT GRAY (TRANSMISSION SIDE)
Page 1067 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C110 (DIESEL) - BLACK (TRANSMISSION SIDE) CIRCUIT C3 20DB/YL B29 20DG/WT K900 20DB/DG V37 20VT K160 18BR/OR K161 18BR/LB F856 18YL/PK D20 20WT/LG D21 20WT/BR F202 20PK/GY K29 20WT/BR (M/T) K854 20VT/BR (M/T) K400 20BR/VT (M/T) C112 (DIESEL A/T) - (ENGINE SIDE) CIRCUIT...
Page 1068 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C112 (DIESEL M/T) - (TRANSMISSION SIDE) CIRCUIT C3 18DB/YL A961 14RD K615 18BR/WT K616 18BR/YL K167 18BR/YL K23 18BR/WT K852 18BR/VT K29 18WT/BR C130 (DIESEL) - (TRANSMISSION SIDE) CIRCUIT C3 20DB/YL T41 20YL/DB (A/T) K400 20BR/VT (M/T) K900 20DB/DG K29 20WT/BR (M/T)
Page 1069 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C131 (3.7L/4.7L EXCEPT ELECTRONIC TRANS- FER CASE) - (HEADLAMP AND DASH SIDE) CIRCUIT D20 20WT/LG D21 20WT/BR C131 (3.7L/4.7L EXCEPT ELECTRONIC TRANS- FER CASE) - DK GRAY (ENGINE SIDE) CIRCUIT D20 18WT/LG D21 18WT/BR C131 (4.7L ELECTRONIC TRANSFER CASE) - (ENGINE SIDE)
Page 1070 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C131 (4.7L ELECTRONIC TRANSFER CASE) - (HEADLAMP AND DASH SIDE) CIRCUIT T316 16YL/GY D200 20WT/LG T313 20YL/LG D202 20WT/VT T885 20YL/GY D201 20WT/DG D203 20WT/BR T315 16YL/BR D20 20WT/LG (4.7L) D21 20WT/BR (4.7L) C131 (5.7L/DIESEL) - GRAY (ENGINE SIDE) CIRCUIT T316 16YL/GY (ELECTRONIC TRANS-...
Page 1071 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS C131 (5.7L/DIESEL) - GRAY (HEADLAMP AND DASH SIDE) CIRCUIT T316 16YL/GY (ELECTRONIC TRANS- FER CASE) D200 20WT/LG (ELECTRONIC TRANS- FER CASE) T313 20YL/LG (ELECTRONIC TRANS- FER CASE) D202 20WT (ELECTRONIC TRANSFER CASE) T885 20YL/GY (ELECTRONIC TRANS- FER CASE) D201 20WT/DG (ELECTRONIC TRANS-...
Page 1072 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C200 - (I/P SIDE) CIRCUIT C70 10DB/YL C34 20DB/LB C71 16DB/BR C32 20DB/TN C73 14DB/VT C72 16DB/OR C7 10DB C29 20DB C21 20DB/LG C121 20DB/DG C61 20DB/LG C33 20LB/BR (SLT) C801 20DB/OR C201 - WHITE (HEADLINER SIDE) CIRCUIT D25 20WT/VT (PREMIUM)
Page 1073 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS C202 - BLACK (FRONT FASCIA SIDE) CIRCUIT L89 18WT/YL Z926 18BK C202 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT L89 18WT/YL Z926 18BK C206 - (CLEARANCE LAMPS SIDE) CIRCUIT L70 20WT/GY Z946 20BK C206 - (I/P SIDE) CIRCUIT L70 18WT/GY...
Page 1074 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C207 - (TRANSFER CASE CONTROL MODULE SIDE) CIRCUIT A34 16RD/WT E11 20OR/DB F21 20PK/DG T315 16YL/BR D25 20VT/DB T885 20YL/GY D200 20WT/LG T316 16YL/GY D202 20WT/VT D201 20WT/DG T41 20YL/DB T313 20YL/LG D203 20WT/BR Z905 16BK C216 - (CHASSIS SIDE)
Page 1075 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C217 - BLACK (CHASSIS SIDE) CIRCUIT L673 18YL B40 14DG (TRAILER TOW) A100 14RD/VT (TRAILER TOW) L7 18WT/YL A109 14OR/RD L50 18WT/TN Z927 12BK/OR L54 18WT/LG L63 18WT/DG L1 18WT/LG L674 18LG Z928 16BK C217 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT...
Page 1076 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C218 - NATURAL (HEADLAMP AND DASH SIDE) CIRCUIT A405 18RD/DB C16 16DB/GY (EXCEPT 3.7L BASE) A930 18RD (EXCEPT 3.7L BASE) A210 12OR/RD (EXCEPT 3.7L BASE) C15 16DB/WT (EXCEPT 3.7L BASE) C219 - (HEADLAMP AND DASH SIDE) CIRCUIT C110 20DB/LB (TRAILER TOW) D15 18WT/DG (NGC)
Page 1077 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C219 - (HEADLAMP AND DASH SIDE) CIRCUIT F984 18PK/YL F951 16PK/LG T917 20YL/TN (DIESEL A/T) A951 16RD F202 20PK/GY A72 18RD/OR (TRAILER TOW) D16 18WT/OR (GAS) K77 18BR/WT (MAUAL TRANSFER CASE) T117 20DG/YL (MANUAL TRANSFER CASE EXCEPT NGC) A205 18RD/OR A116 18YL/RD...
Page 1078 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 C219 - (I/P SIDE) CIRCUIT C110 20DB/LB (EXCEPT BASE) D15 18WT/DG L50 18WT/TN F1 16PK/WT D21 18WT/BR A103 18GY/RD T751 16YL D20 20WT/LG E11 20OR/DB (EXCEPT BASE) A970 10RD A991 10RD V38 20VT/OR V37 20VT T6 20DG L70 18WT/GY...
Page 1079 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS C219 - (I/P SIDE) CIRCUIT F100 18PK/VT A981 14RD F982 14PK/YL F922 16PK/YL F201 18PK/OR L89 20WT/YL (EXCEPT BASE) B29 20DG/WT A919 20RD D25 20WT/VT F983 20PK/YL C220 - (I/P SIDE) CIRCUIT F983 20PK/YL X295 18GY/DG X153 18DG/YL...
Page 1080 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 C220 - NATURAL (BODY SIDE) CIRCUIT F983 20PK/YL X295 18GY/DG X153 18DG/YL G75 20VT G77 20VT/OR X155 18DG/LB G10 20VT/LG G163 20VT/LB (SLT) X205 18GY/LG P5 18TN/OR (SLT) F100 18PK/VT F201 18PK/OR P393 18LG (SLT) G161 20VT/DG (SLT) P1 18TN/LG (SLT)
Page 1081 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS C250 (HANDS FREE) - BLACK (HEADLINER SIDE) CIRCUIT X712 20DG/LB X735 20BR X792 20LB/DG X835 20OR/GY X730 20GY/YL X793 20DG/YL X722 20LB/DG C301 - (BODY SIDE) CIRCUIT G74 20VT/WT P195 18LG/YL (SLT) P72 18TN/GY (SLT) X154 18GY/YL X156 18GY/LB...
Page 1082 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 C301 - (PASSENGER DOOR SIDE) CIRCUIT G74 20VT/WT P195 18LG/YL (POWER WINDOWS/ LOCKS) P72 18TN/GY (POWER WINDOWS/ LOCKS) X154 18GY/YL X156 18GY/LB P74 18TN/OR (POWER WINDOWS/ LOCKS) Q15 14OR/LB (POWER WINDOWS/ LOCKS) Z74 20BK/WT (EXCEPT POWER WIN- DOWS/LOCKS) Z461 20BK/DG (POWER WINDOWS/...
Page 1083 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS C302 - BLACK (PASSENGER DOOR SIDE) CIRCUIT F21 20PK/DG G778 18VT/LB G160 20VT/LG Q16 14OR/TN Q26 14OR/GY P392 18LG/DB Z216 20BK/DB C16 18DB/GY C304 - (BODY SIDE) CIRCUIT G75 20VT P195 18LG/YL (SLT) P72 18TN/GY (SLT) X153 18DG/YL X155 18DG/LB...
Page 1084 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 C305 (SLT) - (BODY SIDE) CIRCUIT C16 18DB/GY Q16 14OR/TN Q26 14OR/GY P393 18LG P1 18TN/LG Z461 14BK/DG Q612 14OR/DB G161 20VT/DG G163 20VT/LB Q412 14OR/LB Q611 14OR/GY Q411 14OR/WT C305 (SLT) - BLACK (DRIVER DOOR SIDE) CIRCUIT C16 18DB/GY Q16 14OR/TN...
Page 1085 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS C306 - (REAR DOOR SIDE) CIRCUIT Z79 20LG/BK G77 20VT/GY P393 18LG (POWER WINDOW/LOCKS) P5 18TN/OR (POWER WINDOW/LOCKS) Q15 14OR/LB (POWER WINDOW/ LOCKS) Q411 14OR/WT (POWER WINDOW/ LOCKS) Q611 14OR/GY (POWER WINDOW/ LOCKS) X295 18GY/DG X205 18GY/LG...
Page 1086 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 C308 - (I/P SIDE) CIRCUIT G74 20VT/WT X154 18GY/YL G160 20VT/LG (SLT) G76 20VT/YL P392 18LG/DB (SLT) G778 18VT/LB (SLT) F21 20PK/DG X206 18DG/LG X296 18DG/GY X156 18GY/LB C309 - NATURAL (BODY SIDE) CIRCUIT P7 20LG/DG P81 20TN/LB...
Page 1087 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS C311 - (BODY SIDE) CIRCUIT Z918 14BK (BASE) Z939 14BK (EXCEPT BASE) A210 12OR/RD (EXCEPT BASE) G10 20VT/LG G10 20LG/RD A405 18RD/DB Z951 20BK C311 - (DRIVER SEAT SIDE) CIRCUIT Z939 14BK A210 12OR/RD G10 20VT/LG A405 12RD/DB...
Page 1088 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 C313 - (DRIVER SEAT SWITCH SIDE) CIRCUIT P105 12LG P13 12LG/OR P21 12LG/TN P15 12LG/BR P107 12LG/WT P11 12LG/YL A210 12OR/RD Z939 14BK P17 12LG/DG P19 12LG/LB C315 - (DRIVER SEAT SIDE) CIRCUIT A405 12RD/DB P54 20OR/LG (HEATED SEATS)
Page 1089 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS C316 - (PASSENGER SEAT SIDE) CIRCUIT P89 20LG/OR P54 20OR/LG A210 12OR/RD Z939 14BK P188 18LG/VT C319 - (CENTER CONSOLE SIDE) CIRCUIT Z939 18BK A405 18RD/DB C319 - (SEAT JUMPER SIDE) CIRCUIT A405 12RD/DB (EXCEPT HEATED SEAT) Z939 14BK (HEATED SEAT) Z939 14BK (EXCEPT HEATED SEAT)
Page 1090 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 C320 - NATURAL (BODY SIDE) CIRCUIT Z72 20LG/BK G76 20TN/YL P392 18LG/DB (EXCEPT BASE) G778 18VT/LB (EXCEPT BASE) Q15 14OR/LB (EXCEPT BASE) Q412 14OR/LB (EXCEPT BASE) Q612 14OR/DB (EXCEPT BASE) X296 18DG/GY X206 18DG/LG C322 (EXCEPT HEATED SEATS) - (DRIVER SEAT SIDE)
Page 1091 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS C323 (EXCEPT HEATED SEATS) - (PASSENGER SEAT SIDE) CIRCUIT P18 12LG/DG P14 12LG/OR P10 12LG/TN P12 12LG/YL P16 12LG/BR P20 12LG/LB P104 12LG P106 12LG/WT A210 12OR/RD Z939 14BK C323 (EXCEPT HEATED SEATS) - (PASSENGER SEAT SWITCH SIDE) CIRCUIT P18 12LG/DG...
Page 1092 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 C323 (HEATED SEATS) - (SEAT JUMPER SIDE) CIRCUIT P104 12LG P106 12LG/WT A210 12OR/RD Z939 14BK C327 (DUAL REAR WHEELS) - (CHASSIS SIDE) CIRCUIT L7 18WT/YL Z948 20BK C327 (DUAL REAR WHEELS) - (DRW LAMP SIDE) CIRCUIT L7 18WT/YL...
Page 1093 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS C328 (DUAL REAR WHEELS) - (DRW LAMP SIDE) CIRCUIT L70 18WT/YL Z948 18BK CAMSHAFT POSITION SENSOR (DIESEL) - 3 WAY CIRCUIT FUNCTION F855 18PK/YL 5 VOLT SUPPLY K916 18BR/OR SENSOR GROUND K44 18DB/GY CMP SIGNAL CAMSHAFT POSITION SENSOR (NGC) - GRAY 3 WAY CIRCUIT...
Page 1094 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 CENTER HIGH MOUNTED STOP LAMP/CARGO LAMP - 4 WAY CIRCUIT FUNCTION L14 20WT/TN CARGO LAMP DRIVER Z964 20BK GROUND Z350 20BK/TN GROUND L50 20WT/TN BRAKE LAMP SWITCH OUTPUT CIGAR LIGHTER OUTLET - RED 3 WAY CIRCUIT FUNCTION F984 18PK/YL...
Page 1095 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS CLEARANCE LAMP NO. 3 (HEAVY DUTY) - 2 WAY CIRCUIT FUNCTION L70 20WT/GY FUSED PARK LAMP RELAY OUTPUT Z946 20BK GROUND CLEARANCE LAMP NO. 4 (HEAVY DUTY) - 2 WAY CIRCUIT FUNCTION L70 20WT/GY FUSED PARK LAMP RELAY OUTPUT Z946 20BK...
Page 1096 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 CLOCKSPRING C2 - YELLOW 4 WAY CIRCUIT FUNCTION R61 20LG/VT DRIVER SQUIB 2 LINE 1 R63 20LG/WT DRIVER SQUIB 2 LINE 2 R43 20LG/BR DRIVER SQUIB 1 LINE 1 R45 20LG/OR DRIVER SQUIB 1 LINE 2 CLOCKSPRING C3 - BLACK 4 WAY CIRCUIT FUNCTION...
Page 1097 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS COIL ON PLUG NO. 1 (5.7L) - 2 WAY CIRCUIT FUNCTION K342 16BR/WT ASD RELAY OUTPUT K19 18DB/DG COIL CONTROL NO. 1 COIL ON PLUG NO. 2 (3.7L/4.7L) - BLACK 3 WAY CIRCUIT FUNCTION K17 18DB/TN...
Page 1098 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 COIL ON PLUG NO. 3 (5.7L) - 2 WAY CIRCUIT FUNCTION K342 16BR/WT ASD RELAY OUTPUT K18 18DB/OR COIL CONTROL NO. 3 COIL ON PLUG NO. 4 (3.7L/4.7L) - BLACK 3 WAY CIRCUIT FUNCTION K15 18DB/GY...
Page 1099 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS COIL ON PLUG NO. 5 (5.7L) - 2 WAY CIRCUIT FUNCTION K342 16BR/WT ASD RELAY OUTPUT K16 18DB/YL COIL CONTROL NO. 5 COIL ON PLUG NO. 6 (3.7L/4.7L) - BLACK 3 WAY CIRCUIT FUNCTION K10 18DB/OR...
Page 1100 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 COIL ON PLUG NO. 7 (5.7L) - 2 WAY CIRCUIT FUNCTION K342 16BR/WT ASD RELAY OUTPUT K97 18BR COIL CONTROL NO. 7 COIL ON PLUG NO. 8 (4.7L) - BLACK 3 WAY CIRCUIT FUNCTION K98 18DB/YL...
Page 1101 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS CONDENSER FAN (NGC) - BLACK 2 WAY CIRCUIT FUNCTION Z823 16BK/DG GROUND C123 16LB/WT CONDENSER FAN RELAY OUTPUT CONTROLLER ANITLOCK BRAKE C1 - BLACK 14 WAY CIRCUIT FUNCTION B4 20DG/GY REAR WHEEL SPEED SENSOR (+) B222 20DG/WT (ETC) VEHICLE SPEED SIGNAL NO.
Page 1102 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 CRANKSHAFT POSITION SENSOR (4.7L) - 3 WAY CIRCUIT FUNCTION K24 20BR/LB CKP SIGNAL K900 20DB/DG SENSOR GROUND F855 20PK/YL 5 VOLT SUPPLY CRANKSHAFT POSITION SENSOR (5.7L) - 3 WAY CIRCUIT FUNCTION F855 20PK/YL 5 VOLT SUPPLY K900 20DB/DG SENSOR GROUND...
Page 1103 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D20 20WT/LG SCI RECEIVE (PCM) D15 18WT/DG SCI TRANSMIT (TCM) A114 18GY/RD FUSED B(+) DATA LINK CONNECTOR-ENGINE (DIESEL) - 3 WAY CIRCUIT FUNCTION D72 18WT/LB CCD BUS (+) D71 18WT/DB...
Page 1104 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 DOOR AJAR SWITCH-PASSENGER - BLACK 2 WAY CIRCUIT FUNCTION G74 20VT/WT PASSENGER DOOR AJAR SWITCH SENSE Z74 20BK/WT GROUND DOOR AJAR SWITCH-RIGHT REAR - BLACK 2 WAY CIRCUIT FUNCTION G76 20VT/GY RIGHT REAR DOOR AJAR SWITCH SENSE Z72 20LG/BK GROUND DOOR LOCK MOTOR/AJAR SWITCH-DRIVER - BLACK 4 WAY...
Page 1105 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS DOOR LOCK MOTOR/AJAR SWITCH-PASSENGER - BLACK 4 WAY CIRCUIT FUNCTION G74 20VT/WT PASSENGER DOOR AJAR SWITCH SENSE Z74 20BK/WT GROUND G778 18VT/LB DOOR UNLOCK DRIVER RIGHT DOORS P392 18LG/DB DOOR LOCK DRIVER RIGHT DOORS DOOR LOCK MOTOR/AJAR SWITCH-RIGHT REAR - BLACK 4 WAY CIRCUIT FUNCTION...
Page 1106 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 DRIVER DOOR MODULE C1 - BLUE 12 WAY CIRCUIT FUNCTION Q612 14OR/DB RIGHT REAR WINDOW DRIVER (DOWN) Q412 14OR/LB RIGHT REAR WINDOW DRIVER (UP) Q16 14OR/TN MASTER WINDOW SWITCH RIGHT FRONT (UP) Q411 14OR/WT LEFT REAR WINDOW DRIVER (UP) Q11 14OR/LG...
Page 1107 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS ELECTRIC BRAKE PROVISION - 4 WAY CIRCUIT FUNCTION A400 14TN/RD FUSED B(+) B40 14DG TRAILER TOW BRAKE B(+) L50 18WT/TN BRAKE LAMP SWITCH OUTPUT Z998 18BK GROUND ELECTRIC THROTTLE CONTROL MODULE - BLACK 6 WAY CIRCUIT FUNCTION K22 18BR/OR...
Page 1108 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 ENGINE CONTROL MODULE C1 (DIESEL) - 60 WAY CIRCUIT FUNCTION C918 18BK/LB A/C PRESSURE SENSOR GROUND K853 18DB/BR 5 VOLT SUPPLY K690 18DG/YL (A/T) INLET AIR TEMPERATURE/PRESSURE RETURN K690 18BR/YL (M/T) INLET AIR TEMPERATURE/PRESSURE RETURN K11 16WT/DB (A/T) INJECTOR CONTROL NO.
Page 1109 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS ENGINE CONTROL MODULE C2 (DIESEL) - 50 WAY CIRCUIT FUNCTION K615 18VT/WT INLET AIR TEMPERATURE SENSE K615 18BR/WT (M/T) INLET AIR TEMPERATURE SENSE V35 18VT/OR (A/T) S/C VENT CONTROL K176 18BR/OR INTAKE AIR HEATER RELAY NO 2 CONTROL K174 18BR/YL INTAKE AIR HEATER RELAY NO 1 CONTROL V32 18VT/YL (A/T)
Page 1110 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) - 2 WAY CIRCUIT FUNCTION K914 18RD/WT SENSOR GROUND K914 18BR/WT SENSOR GROUND K2 18TN/BK ECT SIGNAL K2 18VT/OR ECT SIGNAL ENGINE COOLANT TEMPERATURE SENSOR (GAS) - BLACK 2 WAY CIRCUIT FUNCTION K900 18DB/DG...
Page 1111 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS EVAPORATOR TEMPERATURE SENSOR - 2 WAY CIRCUIT FUNCTION C121 20DB/DG SENSOR GROUND C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL FENDER LAMP-FRONT LEFT (DUAL REAR WHEELS) - 2 WAY CIRCUIT FUNCTION L7 18WT/YL FUSED PARK LAMP RELAY OUTPUT Z947 18BK GROUND FENDER LAMP-FRONT RIGHT (DUAL REAR WHEELS) - 2 WAY...
Page 1112 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 FOG LAMP-LEFT - GRAY 2 WAY CIRCUIT FUNCTION Z926 18BK GROUND L89 18WT/YL FOG LAMP RELAY OUTPUT FOG LAMP-RIGHT - WHITE 2 WAY CIRCUIT FUNCTION Z926 18BK GROUND L89 18WT/YL FOG LAMP RELAY OUTPUT FUEL CONTROL ACTUATOR (DIESEL) - 3 WAY CIRCUIT FUNCTION...
Page 1113 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR NO. 2 (GAS) - 2 WAY CIRCUIT FUNCTION K12 18BR/DB INJECTOR CONTROL NO. 2 K342 16BR/WT ASD RELAY OUTPUT FUEL INJECTOR NO. 3 (GAS) - 2 WAY CIRCUIT FUNCTION K13 18BR/LB INJECTOR CONTROL NO.
Page 1114 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 FUEL INJECTOR NO. 6 (GAS) - 2 WAY CIRCUIT FUNCTION K58 18BR/VT INJECTOR CONTROL NO. 6 K342 16BR/WT ASD RELAY OUTPUT FUEL INJECTOR NO. 7 (GAS) - 2 WAY CIRCUIT FUNCTION K26 18BR/YL INJECTOR CONTROL NO.
Page 1115 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR PACK NO. 2 (DIESEL) - 4 WAY CIRCUIT FUNCTION K229 14BR/LB ENG - INJECTOR HIGH SIDE DRIVER - BANK 2 K229 14TN/PK ENG - INJECTOR HIGH SIDE DRIVER - BANK 2 K14 14BR/TN INJECTOR CONTROL NO.
Page 1116 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 GENERATOR - BLACK 2 WAY CIRCUIT FUNCTION K20 18BR/GY GEN FIELD CONTROL Z816 18BK (DIESEL) GROUND Z20 18BR/BK (NGC) GROUND GLOVE BOX LAMP AND SWITCH - BLACK 2 WAY CIRCUIT FUNCTION Z328 20BK/TN GROUND M228 18YL/LB COURTESY LAMP DRIVER...
Page 1117 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS HEADLAMP SWITCH - BLACK 8 WAY CIRCUIT FUNCTION E19 20OR/BR PANEL LAMPS DIMMER SIGNAL Z407 20BK/OR GROUND L89 20WT/YL (FOG LAMPS) FOG LAMP RELAY OUTPUT E2 20OR/BR PANEL LAMPS DIMMER SIGNAL L115 20WT/YL HEADLAMP SWITCH RETURN L116 20WT/LG HEADLAMP SWITCH SIGNAL...
Page 1118 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 HEATED SEAT CUSHION-PASSENGER - BLUE 4 WAY CIRCUIT FUNCTION P188 18LG/VT PASSENGER SEAT TEMPERATURE SENSOR INPUT Z939 20BK GROUND P54 20OR/LG PASSENGER SEAT TEMPERATURE 5 VOLT SUPPLY P89 20LG/OR SEAT HEATER DRIVER HEATED SEAT SWITCH-DRIVER - 6 WAY CIRCUIT FUNCTION...
Page 1119 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS HORN-HIGH NOTE - 2 WAY CIRCUIT FUNCTION X2 18DG/OR HORN RELAY OUTPUT Z299 18BK/OR GROUND HORN-LOW NOTE - 2 WAY CIRCUIT FUNCTION X2 18DG/OR HORN RELAY OUTPUT Z298 18BK/DB GROUND IDLE AIR CONTROL MOTOR (3.7L/4.7L) - BLACK 2 WAY CIRCUIT FUNCTION K961 18BR/VT...
Page 1120 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 INLET AIR TEMPERATURE SENSOR - 4 WAY CIRCUIT FUNCTION K690 18BR/YL (A/T) INLET AIR TEMPERATURE/PRESSURE RETURN K690 18DG/YL (M/T) INLET AIR TEMPERATURE/PRESSURE RETURN K615 18VT/WT (A/T) INLET AIR TEMPERATURE SENSE K615 18BR/WT (M/T) INLET AIR TEMPERATURE SENSE K668 18BR (A/T) SUPPLY VOLTAGE...
Page 1121 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS INSTRUMENT CLUSTER C2 - GRAY 16 WAY CIRCUIT FUNCTION G194 20VT/LG WASH/BEAM SELECT SWITCH SIGNAL G160 20VT/LG (SLT) PASSENGER DOOR LOCK SWITCH MUX G161 20VT/DG (SLT) DRIVER DOOR LOCK SWITCH MUX E2 20OR/BR PANEL LAMPS DIMMER SIGNAL L116 20WT/LG HEADLAMP SWITCH SIGNAL...
Page 1122 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 INTAKE AIR TEMPERATURE SENSOR (GAS) - BLACK 2 WAY CIRCUIT FUNCTION K900 18DB/DG SENSOR GROUND K21 18DB/LG IAT SIGNAL INTAKE AIR TEMPERATURE/MANIFOLD ABSOLUTE PRESSURE SENSOR (DIESEL) - 4 WAY CIRCUIT FUNCTION K916 18BR/OR SENSOR GROUND K21 18DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL...
Page 1123 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS INTEGRATED POWER MODULE C2 - WHITE 15 WAY CIRCUIT FUNCTION A991 10RD FUSED B(+) A34 16RD/WT (ELECTRONIC TRANS- FUSED B(+) FERCASE)) A405 18RD/DB FUSED B(+) A210 12OR/RD FUSED B(+) A970 10RD FUSED B(+) A100 14RD/VT FUSED B(+) A111 14DG/RD...
Page 1124 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 INTEGRATED POWER MODULE C4 - 10 WAY CIRCUIT FUNCTION Z116 18BK/VT GROUND L54 18WT/LG RIGHT STOP LAMP FEED W1 20BR/TN WASHER FLUID SWITCH SENSE F941 20PK/LG (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START) W7 20BR/GY WIPER PARK SWITCH SENSE F202 20PK/GY...
Page 1125 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS INTEGRATED POWER MODULE C6 - BLACK 15 WAY CIRCUIT FUNCTION A400 14TN/RD FUSED B(+) K342 16BR/WT ASD RELAY OUTPUT A961 14RD (DIESEL) FUEL HEATER RELAY OUTPUT C123 16LB/WT (NGC) CONDENSER FAN RELAY OUTPUT A960 14RD (DIESEL) FUSED B(+) A16 16RD/BR (NGC)
Page 1126 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 KNOCK SENSOR (3.7L) - BLACK 4 WAY CIRCUIT FUNCTION K42 18DB/YL KNOCK SENSOR NO. 1 SIGNAL K942 18BR/LG KNOCK SENSOR NO. 1 RETURN K242 18BR/WT KNOCK SENSOR NO. 2 SIGNAL K924 18WT/BR KNOCK SENSOR NO.
Page 1127 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS LIFT PUMP MOTOR (DIESEL) - 2 WAY CIRCUIT FUNCTION N2 18DB/YL LIFT PUMP FEED Z816 18BK GROUND LINE PRESSURE SENSOR (NGC) - 4 WAY CIRCUIT FUNCTION K900 18DB/DG SENSOR GROUND F856 18YL/PK 5 VOLT SUPPLY T38 18YL/BR LINE PRESSURE SENSOR SIGNAL...
Page 1128 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 MANIFOLD ABSOLUTE PRESSURE SENSOR (NGC) - GRAY 3 WAY CIRCUIT FUNCTION K1 18VT/BR MAP SIGNAL K900 18DB/DG SENSOR GROUND K900 20DB/DG SENSOR GROUND F856 18YL/PK 5 VOLT SUPPLY MODE DOOR ACTUATOR 1 (PANEL TO FLOOR) - 2 WAY CIRCUIT FUNCTION C34 20DB/LB...
Page 1129 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS NATURAL VACUUM LEAK DETECTION ASSEMBLY (NGC) - BLACK 3 WAY CIRCUIT FUNCTION Z910 18BK GROUND K107 18VT/WT NVLD SWITCH SIGNAL K106 18VT/LB NVLD SOLENOID CONTROL OUTPUT SPEED SENSOR (45RFE) - DK BLUE 2 WAY CIRCUIT FUNCTION T14 18DG/BR...
Page 1130 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 OXYGEN SENSOR 1/1 UPSTREAM (NGC) - BLACK 4 WAY CIRCUIT FUNCTION K99 18BR/LG O2 1/1 HEATER CONTROL Z42 18BK/LG GROUND K902 18BR/DG O2 RETURN (UP) K41 18DB/LB O2 1/1 SIGNAL OXYGEN SENSOR 1/2 DOWNSTREAM (NGC) - 4 WAY CIRCUIT FUNCTION K299 18BR/WT...
Page 1131 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS PARK/TURN SIGNAL LAMP-LEFT FRONT - BROWN 3 WAY CIRCUIT FUNCTION L61 18WT/LG LEFT FRONT TURN LAMP DRIVER L7 18WT/YL FUSED PARK LAMP RELAY OUTPUT Z377 18BK/BR GROUND PARK/TURN SIGNAL LAMP-RIGHT FRONT - BROWN 3 WAY CIRCUIT FUNCTION L60 18WT/TN...
Page 1132 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 POWER MIRROR-RIGHT - BLACK 8 WAY CIRCUIT FUNCTION C16 18DB/GY HEATED MIRROR RELAY OUTPUT P195 18LG/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P74 18TN/OR RIGHT MIRROR LEFT DRIVER P72 18TN/GY RIGHT MIRROR UP DRIVER Z216 20BK/DB GROUND POWER OUTLET - RED 3 WAY...
Page 1133 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS POWER SEAT MOTOR-DRIVER HORIZONTAL - 2 WAY CIRCUIT FUNCTION P17 12LG/DG DRIVER SEAT HORIZONTAL FORWARD DRIVER P15 12LG/BR DRIVER SEAT HORIZONTAL REARWARD DRIVER POWER SEAT MOTOR-DRIVER REAR VERTICAL - 2 WAY CIRCUIT FUNCTION P13 12LG/OR DRIVER SEAT REAR DOWN...
Page 1134 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 POWER SEAT SWITCH-DRIVER - 12 WAY CIRCUIT FUNCTION A210 12OR/RD FUSED B(+) Z939 14BK GROUND P105 12LG LUMBAR MOTOR FORWARD P13 12LG/OR DRIVER SEAT REAR DOWN P107 12LG/WT LUMBAR MOTOR REARWARD Z939 14BK GROUND A210 12OR/RD FUSED B(+)
Page 1135 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS POWER WINDOW CIRCUIT BREAKER - 2 WAY CIRCUIT FUNCTION F991 10PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-START) F30 12PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) POWER WINDOW MOTOR-DRIVER - 2 WAY CIRCUIT FUNCTION Q21 14OR/WT LEFT FRONT WINDOW DRIVER (DOWN) Q11 14OR/LG LEFT FRONT WINDOW DRIVER (UP)
Page 1136 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87 POWER WINDOW MOTOR-RIGHT REAR - 2 WAY CIRCUIT FUNCTION Q212 14TN/LB PASSENGER REAR WINDOW DRIVER (DOWN) Q112 14TN/YL PASSENGER REAR WINDOW DRIVER (UP) POWER WINDOW SWITCH-LEFT REAR - BLUE 6 WAY CIRCUIT FUNCTION Q111 14TN/YL DRIVER REAR WINDOW DRIVER (UP)
Page 1137 8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C1 (NGC) - BLACK 38 WAY CIRCUIT FUNCTION K98 18DB/YL (EXCEPT 3.7L) COIL CONTROL NO. 8 K97 18BR/YL (4.7L) COIL CONTROL NO. 7 K97 18BR (5.7L) COIL CONTROL NO. 7 K28 18BR/LB (EXCEPT 3.7L) INJECTOR CONTROL NO.
Page 1138 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 POWERTRAIN CONTROL MODULE C2 (NGC) - ORANGE 38 WAY CIRCUIT FUNCTION K10 18DB/OR COIL CONTROL NO. 6 K16 18DB/YL COIL CONTROL NO. 5 K15 18DB/GY COIL CONTROL NO. 4 K58 18BR/VT INJECTOR CONTROL NO. 6 K38 18BR/OR INJECTOR CONTROL NO.
Page 1139 8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C3 (NGC) - WHITE 38 WAY CIRCUIT FUNCTION K51 20BR/WT ASD RELAY CONTROL V35 20VT/OR (4.7L) S/C VENT CONTROL K173 18BR/VT CONDENSER FAN RELAY CONTROL V32 20VT/YL (4.7L) S/C POWER SUPPLY K106 18VT/LB NVLD SOLENOID CONTROL K299 18BR/WT...
Page 1140 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91 POWERTRAIN CONTROL MODULE C4 (NGC) - GREEN 38 WAY CIRCUIT FUNCTION T60 18YL/GY OVERDRIVE SOLENOID CONTROL T259 18YL/DG 4C SOLENOID CONTROL T118 18DG MS SOLENOID CONTROL T219 18YL/LG 2C SOLENOID CONTROL T59 18YL/LB UNDERDRIVE SOLENOID CONTROL T20 18DG/WT L/R SOLENOID CONTROL...
Page 1141 8W - 80 - 92 8W-80 CONNECTOR PIN-OUTS RADIO C1 (EXCEPT INFINITY) - GRAY 22 WAY CIRCUIT FUNCTION A114 18GY/RD FUSED B(+) F983 20PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) E14 20OR/TN PANEL LAMPS DRIVER X154 18GY/YL RIGHT FRONT DOOR SPEAKER (+) X156 18GY/LB RIGHT FRONT DOOR SPEAKER (-) X155 18DG/LB...
Page 1142 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93 RADIO C2 - 10 WAY CIRCUIT FUNCTION X704 18DG/YL RIGHT AUDIO OUTPUT X795 18DG HANDS FREE AUDIO OUTPUT COMMON X703 18DG/OR LEFT AUDIO OUTPUT RECIRCULATION DOOR ACTUATOR - 2 WAY CIRCUIT FUNCTION C34 20DB/LB COMMON DOOR DRIVER C32 20DB/TN...
Page 1143 8W - 80 - 94 8W-80 CONNECTOR PIN-OUTS SEAT BELT SWITCH-DRIVER - 2 WAY CIRCUIT FUNCTION Z951 20BK GROUND G10 20VT/LG SEAT BELT SWITCH SENSE SEAT BELT TENSIONER REDUCER (STANDARD CAB) - 2 WAY CIRCUIT FUNCTION F983 20PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC) G10 20VT/LG SEAT BELT SWITCH SENSE SEAT BELT TENSIONER-DRIVER - 2 WAY...
Page 1144 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 95 SENTRY KEY IMMOBILIZER MODULE (SKIM) - BLACK 6 WAY CIRCUIT FUNCTION D25 20WT/VT PCI BUS F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) Z120 20BK/WT GROUND A919 20RD FUSED B(+) SIDE IMPACT SENSOR-LEFT - 4 WAY CIRCUIT FUNCTION R13 20LG/TN...
Page 1145 8W - 80 - 96 8W-80 CONNECTOR PIN-OUTS SPEAKER-LEFT INSTRUMENT PANEL - BLACK 2 WAY CIRCUIT FUNCTION X209 18GY/OR LEFT INSTRUMENT PANEL SPEAKER (+) X299 18GY/YL LEFT INSTRUMENT PANEL SPEAKER (-) SPEAKER-LEFT REAR - WHITE 3 WAY CIRCUIT FUNCTION X205 18GY/LG LEFT REAR SPEAKER (+) X295 18GY/DG LEFT REAR SPEAKER (-)
Page 1146 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 97 SPEED CONTROL SERVO (DIESEL A/T/NGC) - 4 WAY CIRCUIT FUNCTION V36 20VT/YL S/C VACUUM CONTROL V35 20VT/OR S/C VENT CONTROL V30 20VT/WT S/C BRAKE SWITCH OUTPUT Z913 20BK GROUND SPEED CONTROL SWITCH-LEFT (ETC) - 3 WAY CIRCUIT FUNCTION V38 20VT/OR...
Page 1147 8W - 80 - 98 8W-80 CONNECTOR PIN-OUTS TAIL/STOP/TURN SIGNAL LAMP-LEFT - 6 WAY CIRCUIT FUNCTION L7 18WT/YL FUSED PARK LAMP RELAY OUTPUT Z928 18BK GROUND L53 18DG/WT LEFT STOP LAMP FEED L63 18WT/DG LEFT REAR TURN LAMP DRIVER L1 18WT/LG BACKUP LAMP FEED TAIL/STOP/TURN SIGNAL LAMP-RIGHT - BLACK 6 WAY CIRCUIT...
Page 1148 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 99 THROTTLE POSITION SENSOR (4.7L) - 3 WAY CIRCUIT FUNCTION F855 18PK/YL 5 VOLT SUPPLY K22 18BR/OR TP NO. 1 SIGNAL K900 18DB/DG SENSOR GROUND TOW/HAUL OVERDRIVE SWITCH - WHITE 2 WAY CIRCUIT FUNCTION T6 20DG TOW/HAUL OVERDRIVE OFF SWITCH SENSE...
Page 1149 8W - 80 - 100 8W-80 CONNECTOR PIN-OUTS TRANSFER CASE CONTROL MODULE C1 (ELECTRIC 4x4) - 16 WAY CIRCUIT FUNCTION D25 20VT/DB PCI BUS G92 20VT/OR 4WD LOW INDICATOR G91 20VT/WT 4WD HIGH INDICATOR K977 20BR/WT MODE SELECT T885 20YL/GY MODE SENSOR GROUND Z905 18BK GROUND...
Page 1150 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 101 TRANSFER CASE CONTROL MODULE C3 (ELECTRIC 4x4) - 4 WAY CIRCUIT FUNCTION Z905 16BK GROUND A34 16RD/WT FUSED B(+) T315 16YL/BR SHIFT MOTOR CONTROL A T316 16YL/GY SHIFT MOTOR CONTROL B TRANSFER CASE MODE SENSOR - 6 WAY CIRCUIT FUNCTION D200 20WT/LG...
Page 1151 8W - 80 - 102 8W-80 CONNECTOR PIN-OUTS TRANSMISSION RANGE SENSOR - 6 WAY CIRCUIT FUNCTION L10 18WT/GY FUSED IGNITION SWITCH OUTPUT (RUN) T117 20DG/YL TRANS RANGE SENSOR ELECTRONIC CLUSTER 5 VOLT SUPPLY L1 18WT/LG BACKUP LAMP FEED T917 20YL/TN TRANS RANGE SENSOR ELECTRONIC CLUSTER MUX T41 20YL/DB PARK NEUTRAL POSITION SWITCH SENSE (T41)
Page 1152 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 103 VACUUM PUMP (DIESEL) - 4 WAY CIRCUIT FUNCTION F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START) Z936 18BK GROUND VISTRONIC FAN DRIVE (DIESEL) - 6 WAY CIRCUIT FUNCTION K160 18BR/OR PARK LOCKOUT SOLENOID CONTROL K900 18DB/DG SENSOR GROUND K161 18BR/LB...
Page 1153 8W - 80 - 104 8W-80 CONNECTOR PIN-OUTS WHEEL SPEED SENSOR-LEFT FRONT - 2 WAY CIRCUIT FUNCTION B8 20DG/TN LEFT FRONT WHEEL SPEED SENSOR (-) B9 20DG/LG LEFT FRONT WHEEL SPEED SENSOR (+) WHEEL SPEED SENSOR-REAR - 2 WAY CIRCUIT FUNCTION B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL...
Page 1154 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TABLE OF CONTENTS page CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTION ......1 Use the wiring diagrams in each section for connec- CONNECTOR/GROUND/SPLICE tor, ground, and splice identification.
Page 1155 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Battery Temperature Sensor Below Battery Tray 22, 25, 26, 28 Blend Door Actuator (Single Zone) Behind Right Side of Instrument Panel Blower Motor Behind Right Side of Instrument Panel Blower Motor Resistor Block Behind Right Side of Instrument...
Page 1156 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. C315 DK GY At Driver Seat C316 At Passenger Seat C317 At Passenger Seat C319 Bottom Left of Left Door C320 Right Rear Door C322 DK GY Left Rear of Frame...
Page 1157 8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Data Link Connector - Engine Near T/O for Water In Fuel Sensor (Diesel) Dome Lamp Center of Headliner Door Ajar Switch-Driver (Base) Left Front Door Door Ajar Switch-Left Rear (Base) Left Rear Door Door Ajar Switch-Right Rear (Base)
Page 1158 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Glove Box Lamp and Switch At Glove Box 35, 39 Governor Pressure Sensor Left Rear of Transmission Hands Free Module Right Instrument Panel Headlamp Switch Left Side of Instrument Panel 32, 35, 38 Headlamp-Left...
Page 1159 8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Mode Door Actuator 2 Right Side of HVAC Multi-Function Switch On Steering Column Natural Vacuum Leak Detection Rear of Transmission 18, 50 Assembly Output Speed Sensor Left Side of Transmission 11, 14, 15, 16 Overdrive Switch...
Page 1160 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. PTO Switch Near G107 Radio C1 (Base) Rear of Radio 35, 36 Radio C1 (Premium) Rear of Radio Radio C2 (Premium) Rear of Radio Radio Antenna At Antenna Base Radio Antenna Cable...
Page 1161 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Speed Control Switch-Right (ETC) At Steering Wheel Starter Solenoid Left Engine Tail/Stop/Turn Signal Lamp-Left At Lamp 50, 51 Tail/Stop/Turn Signal Lamp-Right At Lamp 50, 51 Throttle Position Sensor Throttle Body Trailer Tow Connector...
Page 1162 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) GROUNDS GROUND LOCATION FIG. NUMBER G100 Battery Ground - Left Front Engine G101 Battery Ground - Left Front Engine G102 Battery Ground - Left Front Chassis G103 Left Front Engine Compartment G104 Left Front Engine Compartment G105...
Page 1163 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S122 Left Front Fender S123 Left Front Fender 22, 23 S124 Center Rear of Engine Compartment S125 Right Rear of Engine Compartment 4, 8 S130 Top Front of Transmission 3, 9 S132...
Page 1164 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S176 Left Side Engine Near T/O for Fuel Control Actuator S187 Rear of Engine S191 Near Integrated Power Module S203 Right Side Engine Compartment S204 Left Side of Instrument Panel S205 Left Side of Instrument Panel...
Page 1165 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S312 Right Door S313 Left Front Door S314 Left Rear Frame Rail S315 Left Front Body 40, 44, 46 S316 At Driver Seat S318 At Passenger Seat S319 Left Front Door S320...
Page 1166 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 1 RIGHT SIDE FRONT LIGHTING Fig. 2 LEFT FRONT BUMPER AND RIGHT BATTERY TRAY...
Page 1167 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1168 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 4 RIGHT REAR ENGINE COMPARTMENT...
Page 1169 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1170 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1171 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1172 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 8 RIGHT REAR ENGINE COMPARTMENT (5.7L)
Page 1173 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1174 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1175 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1176 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 12 MANUAL TRANSMISSION (DIESEL) Fig. 13 FRONT MANUAL TRANSMISSION (DIESEL)
Page 1177 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1178 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1179 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 16 1LEFT TRANSMISSION 45RFE (5.7L)
Page 1180 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1181 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1182 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 19 MANUAL TRANSMISSION (5.7L/DIESEL)
Page 1183 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1184 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1185 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1186 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1187 8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1188 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1189 8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1190 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 27 27 LEFT FRONT FACIA AND BATTERY TRAY...
Page 1191 8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1192 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1193 8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 30 STEERING COLUMN...
Page 1194 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 41 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1195 8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1196 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1197 8W - 91 - 44 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1198 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 45 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1199 8W - 91 - 46 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1200 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 47 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 37 RADIO ANTENNA...
Page 1201 8W - 91 - 48 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1202 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 49 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1203 8W - 91 - 50 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1204 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 51 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1205 8W - 91 - 52 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1206 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 53 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1207 8W - 91 - 54 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1208 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 55 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 45 STANDARD CAB RIGHT SIDE BODY...
Page 1209 8W - 91 - 56 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1210 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 57 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 47 QUAD CAB RIGHT SIDE BODY Fig. 48 ROOF...
Page 1211 8W - 91 - 58 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 49 REAR BODY...
Page 1212 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 59 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1213 8W - 91 - 60 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1214 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 61 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 52 LEFT REAR FENDER (RIGHT SIDE SIMILAR)
Page 1215 8W - 91 - 62 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1216 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION OPERATION ......5 DESCRIPTION .
Page 1217 8W - 97 - 2 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION (Continued) enough for the resistor coil to heat up. When the SPECIAL TOOLS heating element is engaged with the contact, battery current can flow through the resistor coil to ground, POWER DISTRIBUTION SYSTEMS causing the resistor coil to heat.
Page 1218: Integrated Power Module
8W-97 POWER DISTRIBUTION 8W - 97 - 3 components: the Power Distribution Center (PDC), INTEGRATED POWER MODULE the integrated power module cover, the Front Control Module (FCM) and the Integrated Power Module DESCRIPTION Assembly which includes the power distribution cen- ter, the cover and FCM.
Page 1219 8W - 97 - 4 8W-97 POWER DISTRIBUTION INTEGRATED POWER MODULE (Continued) (4) Remove the integrated power module retaining LLATION bolt and screw (Fig. 2). INSTALLATION (5) Grasp the integrated power module with two hands and slide the assembly in the direction shown (1) Connect the front control module by pushing it (Fig.
Page 1220 8W-97 POWER DISTRIBUTION 8W - 97 - 5 INTEGRATED POWER MODULE (Continued) (3) Connect the electrical connectors by pushing integrated power module connects directly to the bat- straight on and rotating the connector arm inboard, tery and provides the primary means of circuit pro- until the connector is firmly locked in place on the tection power...
Page 1221 8W - 97 - 6 8W-97 POWER DISTRIBUTION FRONT CONTROL MODULE (Continued) requires the use of a DRB III scan tool and the proper Body Diagnostic Procedures manual. Before any testing of the front control module is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle.
Page 1222: Power Outlet
8W-97 POWER DISTRIBUTION 8W - 97 - 7 IOD FUSE (Continued) becomes transparent and the fuse that has been The power outlet receptacle unit and the accessory assigned the IOD designation becomes only another power outlet protective cap are available for service. Fused B(+) circuit fuse.
Page 1223 8W - 97 - 8 8W-97 POWER DISTRIBUTION POWER OUTLET (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the pro- tective cap from the power outlet receptacle base. (3) Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangu- lar retaining bosses of the mount that secures the...
Page 1224: Introduction
ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE - 3.7L ......1 ENGINE - 5.7L .
Page 1225 9 - 2 ENGINE - 3.7L REMOVAL ......38 DIAGNOSIS AND TESTING - CHECKING INSTALLATION .
Page 1226 ENGINE - 3.7L 9 - 3 block and houses the lower half of the crankshaft ENGINE - 3.7L main bearings. The cylinders are numbered from front to rear with the left bank being numbered 1,3, DESCRIPTION and 5 and the right bank being numbered 2,4, and 6. The 3.7 liter (226 CID) six-cylinder engine is an The firing order is 1–6–5–4–3–2.
Page 1227 9 - 4 ENGINE - 3.7L ENGINE - 3.7L (Continued) Additional tests and diagnostic procedures may be DIAGNOSIS AND TESTING necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. DIAGNOSIS AND TESTING - ENGINE Information concerning additional tests and diagno- DIAGNOSIS - INTRODUCTION sis is provided within the following diagnosis:...
Page 1228 ENGINE - 3.7L 9 - 5 ENGINE - 3.7L (Continued) CONDITION POSSIBLE CAUSE CORRECTION 4. Incorrect cam timing. 4. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE). 1. ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark 1. (Refer to 8 - ELECTRICAL/ plugs.
Page 1229 9 - 6 ENGINE - 3.7L ENGINE - 3.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTIONS NOISY VALVES 1. High or low oil level in 1. (Refer to LUBRICATION & crankcase. MAINTENANCE - SPECIFICATIONS) 2.
Page 1230 ENGINE - 3.7L 9 - 7 ENGINE - 3.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts.
Page 1231 9 - 8 ENGINE - 3.7L ENGINE - 3.7L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL PUMPING AT RINGS; SPARK 1. Worn or damaged rings. 1. Hone cylinder bores and replace PLUGS FOULING rings. 2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCEDURE).
Page 1232 ENGINE - 3.7L 9 - 9 ENGINE - 3.7L (Continued) CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat. THROTTLE BODY seated properly Reface or replace, as necessary. Inspect valve springs.
Page 1233 9 - 10 ENGINE - 3.7L ENGINE - 3.7L (Continued) • Solvent or a commercially available gasket of oil and coolant. Can be used on threaded and machined parts under all temperatures. This mate- remover • Plastic or wood scraper (Fig. 2) rial is used on engines with multi-layer steel (MLS) •...
Page 1234 ENGINE - 3.7L 9 - 11 ENGINE - 3.7L (Continued) (12) Disconnect heater hoses from heater core and (35) Remove the starter. remove hose assembly. (36) Remove the ground straps from the left and (13) Disconnect throttle and speed control cables. right side of the block.
Page 1235 9 - 12 ENGINE - 3.7L ENGINE - 3.7L (Continued) (17) Connect the engine to body ground straps at SPECIFICATIONS the left side of the cowl. (18) Install the intake manifold. SPECIFICATIONS - 3.7L ENGINE (19) Install the engine oil dipstick tube. GENERAL SPECIFICATIONS (20) Install the power brake booster vacuum hose.
Page 1236 ENGINE - 3.7L 9 - 13 ENGINE - 3.7L (Continued) PISTONS DESCRIPTION SPECIFICATION Metric Standard DESCRIPTION SPECIFICATION Ring Width Metric Standard 1.472 - 1.490 0.057 - 0.058 in. Diameter 92.975 mm 3.6605 in. Compression Weight 367.5 grams 12.96 oz Ring Ring Groove Second 1.472 - 1.490...
Page 1237 9 - 14 ENGINE - 3.7L ENGINE - 3.7L (Continued) VALVE TIMING CRANKSHAFT DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Metric Standard Intake Main Bearing 63.488 - 63.512 2.4996 - 2.5005 Opens (ATDC) 0.0° Journal Closes (ATDC) 236° Diameter Duration 236° Bearing 0.002 - 0.034 Clearance Exhaust Out of Round...
Page 1238 ENGINE - 3.7L 9 - 15 ENGINE - 3.7L (Continued) VALVE SPRING CYLINDER HEAD DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Metric Standard Metric Standard Gasket 0.7 mm (0.0276 in.) Free Length Thickness (Approx) (Compressed) Intake 48.92 mm 1.9260 in. Valve Seat 44.5° - 45.0° Angle Exhaust - 48.2 mm...
Page 1239 9 - 16 ENGINE - 3.7L ENGINE - 3.7L (Continued) OIL PRESSURE DESCRIPTION N·m Lbs. Lbs. SPECIFICATION SPECIFICATION Flexplate-Bolts Metric Standard Engine Mount Bracket to At Curb Idle 25 kPa 4 psi Block-Bolts Speed (MIN)* Rear Mount to Transmission- @ 3000 rpm 170 - 758 kPa 25 - 110 psi Bolts...
Page 1240 ENGINE - 3.7L 9 - 17 ENGINE - 3.7L (Continued) SPECIAL TOOLS Spanner Wrench 6958 Handle C-4171 Adapter Pins 8346 Rear Crankshaft Seal Installer 8349 Front Crankshaft Seal Remover 8511 Rear Crankshaft Seal Remover 8506 Front Crankshaft Seal Installer 8348 Connecting Rod Guides 8507...
Page 1241 9 - 18 ENGINE - 3.7L ENGINE - 3.7L (Continued) Crankshaft Damper Installer 8512 Chain Tensioner Pins 8514 Puller 1026 VALVE SPRING COMPRESSOR 8426 Crankshaft Damper Removal Insert 8513 ENGINE LIFTING FIXTURE 8427 Chain Tensioner Wedge 8379 CAMSHAFT HOLDER 8428...
Page 1242 ENGINE - 3.7L 9 - 19 ENGINE - 3.7L (Continued) HOLDER SECONDARY CAMSHAFT CHAIN 8429 INSTALLER - REMOVER - COUNTER BALANCE SHAFT 8641 Valve Spring Tester C-647 Remover, Rocker Arm 8516 Dial Indicator C-3339 Idler Shaft Remover 8517 Valve Spring Compressor C-3422-B Valve Spring Compressor Adapters 8519...
Page 1243 9 - 20 ENGINE - 3.7L ENGINE - 3.7L (Continued) Bloc–Chek–Kit C-3685–A Bore Size Indicator C-119 Oil Pressure Gauge C-3292 ENGINE SUPPORT FIXTURE 8534 Piston Ring Compressor C-385 Pressure Tester Kit 7700...
Page 1244 ENGINE - 3.7L 9 - 21 AIR CLEANER ELEMENT REMOVAL Filter Element Only Housing removal is not necessary for element (fil- ter) replacement. (1) Loosen clamp (Fig. 3) and disconnect air duct at air cleaner cover. (2) Pry over 4 spring clips (Fig. 3) from housing cover (spring clips retain cover to housing).
Page 1245 9 - 22 ENGINE - 3.7L CYLINDER HEAD - LEFT (Continued) • Excessive steam (white smoke) emitting from (6) Remove the intake manifold(Refer to 9 - exhaust ENGINE/MANIFOLDS/INTAKE MANIFOLD • Coolant foaming REMOVAL). (7) Remove the master cylinder and booster assem- CYLINDER-TO-CYLINDER LEAKAGE TEST bly(Refer to 5 - BRAKES/HYDRAULIC/MECHANI- To determine if an engine cylinder head gasket is...
Page 1246 ENGINE - 3.7L 9 - 23 CYLINDER HEAD - LEFT (Continued) Fig. 6 CAMSHAFT SPROCKET V6 MARKS (#1 TDC, Exhaust stroke) 2 - RIGHT CYLINDER HEAD 1 - LEFT CYLINDER HEAD (16) Lock the secondary timing chains to the idler NOTE: Mark the secondary timing chain prior to sprocket using Special Tool 8429 Timing Chain Hold- removal to aid in installation.
Page 1247 9 - 24 ENGINE - 3.7L CYLINDER HEAD - LEFT (Continued) (20) Remove left side secondary chain CAUTION: When cleaning cylinder head and cylin- guide(Refer to 9 - ENGINE/VALVE TIMING/TIMING der block surfaces, DO NOT use a metal scraper BELT/CHAIN AND SPROCKETS - REMOVAL). because the surfaces could be cut or ground.
Page 1248 ENGINE - 3.7L 9 - 25 CYLINDER HEAD - LEFT (Continued) • Step 1: Tighten bolts 1-8, 27 N·m (20 ft. lbs.). (14) Install the crankshaft damper(Refer to 9 - • Step 2: Verify that bolts 1-8, all reached 27 N·m ENGINE/ENGINE BLOCK/VIBRATION DAMPER - (20 ft.
Page 1249 9 - 26 ENGINE - 3.7L CAMSHAFT(S) (Continued) (2) Set engine to TDC cylinder #1, camshaft (6) Hold the camshaft with Special Tool 8428 Cam- sprocket V6 marks at the 12 o’clock position. shaft Wrench, while removing the camshaft sprocket (3) Mark one link on the secondary timing chain bolt and sprocket (Fig.
Page 1250 ENGINE - 3.7L 9 - 27 CAMSHAFT(S) (Continued) INSTALLATION dowel is aligned with the slot in the camshaft sprocket. Install the sprocket onto the camshaft. (1) Lubricate camshaft journals with clean engine oil. CAUTION: Remove excess from camshaft sprocket bolt. Failure to do so can cause bolt over- NOTE: Position the left side camshaft so that the torque resulting in bolt failure.
Page 1251 9 - 28 ENGINE - 3.7L CYLINDER HEAD COVER(S) (Continued) REMOVAL (3) Install left side breather and connect breather tube. (1) Disconnect negative cable from battery. (4) Connect injector electrical connectors and injec- (2) Remove the resonator assemble and air inlet hose. tor harness retaining clips.
Page 1252 ENGINE - 3.7L 9 - 29 INTAKE/EXHAUST VALVES & SEATS (Continued) (5) The valve seat and valve face must maintain a face angle of 44.5 - 45 ° angle (Fig. 17). Fig. 18 Rocker Arm Removal 1 - CAMSHAFT Fig. 17 Valve Assembly Configuration 2 - SPECIAL TOOL 8516 1 - VALVE LOCKS (3–BEAD) 2 - RETAINER...
Page 1253 9 - 30 ENGINE - 3.7L INTAKE/EXHAUST VALVES & SEATS (Continued) TESTING VALVE SPRINGS NOTE: Whenever the valves are removed from the cylinder head it is recommended that the valve springs be inspected and tested for reuse. Inspect the valve springs for physical signs of wear or damage.
Page 1254 ENGINE - 3.7L 9 - 31 ROCKER ARM DESCRIPTION The rocker arms are steel stampings with an inte- gral roller bearing. The rocker arms incorporate a 2.8 mm (0.11 inch) oil hole in the lash adjuster socket for roller and camshaft lubrication. REMOVAL NOTE: Disconnect the battery negative cable to pre- vent accidental starter engagement.
Page 1255 9 - 32 ENGINE - 3.7L INSTALLATION VALVE GUIDE SEALS NOTE: All six valve springs and seals are removed DESCRIPTION in the same manner; this procedure only covers The valve guide seals are made of rubber and one valve seal and valve spring. incorporate an integral steel valve spring seat.
Page 1256 ENGINE - 3.7L 9 - 33 CYLINDER HEAD - RIGHT (Continued) (6) Air ingested into oil due to broken or cracked NOTE: Mark the secondary timing chain prior to oil pump pick up. removal to aid in installation. (7) Worn valve guides. (16) Mark the secondary timing chain, one link on (8) Rocker arm ears contacting valve spring each side of the V6 mark on the camshaft drive gear.
Page 1257 9 - 34 ENGINE - 3.7L CYLINDER HEAD - RIGHT (Continued) INSTALLATION NOTE: The cylinder head bolts are tightened using a torque plus angle procedure. The bolts must be examined BEFORE reuse. If the threads are necked down the bolts should be replaced. Necking can be checked by holding a straight edge against the threads (Fig.
Page 1258 ENGINE - 3.7L 9 - 35 CYLINDER HEAD - RIGHT (Continued) CAUTION: The nut on the right side camshaft CAMSHAFT(S) sprocket should not be removed for any reason, as the sprocket and camshaft sensor target wheel is DESCRIPTION serviced as an assembly. If the nut was removed, The camshafts consist of powdered metal steel torque nut to 5 NM ( 60 in.
Page 1259 9 - 36 ENGINE - 3.7L CAMSHAFT(S) (Continued) (5) Position Special Tool 8379 timing chain wedge between the timing chain strands. Tap the tool to securely wedge the timing chain against the ten- sioner arm and guide. (6) Remove the camshaft position sensor. (7) Hold the camshaft with Special Tool 8428 Cam- shaft Wrench, while removing the camshaft sprocket bolt and sprocket.
Page 1260 ENGINE - 3.7L 9 - 37 CYLINDER HEAD COVER(S) ROCKER ARM REMOVAL DESCRIPTION (1) Disconnect battery negative cable. The rocker arms are steel stampings with an inte- (2) Remove air cleaner assembly, resonator assem- gral roller bearing. The rocker arms incorporate a 2.8 bly and air inlet hose.
Page 1261 9 - 38 ENGINE - 3.7L INSTALLATION VALVE GUIDE SEALS NOTE: All six valve springs and seals are removed DESCRIPTION in the same manner; this procedure only covers The valve guide seals are made of rubber and one valve seal and valve spring. incorporate an integral steel valve spring seat.
Page 1262 ENGINE - 3.7L 9 - 39 ENGINE BLOCK (Continued) for this job. In addition to deglazing, it will reduce (5) After honing, it is necessary that the block be taper and out-of-round, as well as removing light cleaned to remove all traces of abrasive. Use a brush scuffing, scoring and scratches.
Page 1263 9 - 40 ENGINE - 3.7L ENGINE BLOCK (Continued) (2) Measure the inside diameter of the cylinder bore at three levels below top of bore. Start perpen- dicular (across or at 90 degrees) to the axis of the crankshaft and then take two additional reading. (3) Measure the cylinder bore diameter crosswise to the cylinder block near the top of the bore.
Page 1264 ENGINE - 3.7L 9 - 41 CRANKSHAFT (Continued) NOTE: The bedplate has pry points cast into it. Use If connecting rod bearing bores show damage, the these points only. The pry points are shown below. cylinder heads must be removed to service the piston and rod assemblies.
Page 1265 9 - 42 ENGINE - 3.7L CRANKSHAFT (Continued) INSTALLATION sealant prior to installation. Failure to do so will cause severe oil leaks. CAUTION: Main bearings are select fit. Refer to NOTE: Make sure that the bedplate and cylinder block Crankshaft Main Bearings in this section for proper sealing surfaces are clean and free of oil or other con- bearing selections.
Page 1266 ENGINE - 3.7L 9 - 43 CRANKSHAFT (Continued) NOTE: Lubricate the bedplate retaining bolts with (8) Measure crankshaft end play. clean engine oil prior to installation. (9) Install the connecting rods and measure side clear- ance(Refer to 9 - ENGINE/ENGINE BLOCK/PISTON & (7) Install the bedplate retaining bolts, making CONNECTING ROD - STANDARD PROCEDURE).
Page 1267 9 - 44 ENGINE - 3.7L CRANKSHAFT MAIN BEARINGS STANDARD PROCEDURE MAIN BEARING FITTING SELECT FIT IDENTIFICATION The main bearings are “select fit” to achieve proper oil clearances. For main bearing selection, the crank- shaft position sensor target wheel has grade identifi- cation marks stamped into it (Fig.
Page 1268 ENGINE - 3.7L 9 - 45 CRANKSHAFT MAIN BEARINGS (Continued) CRANKSHAFT MAIN BEARING SELECTION Crankshaft JOURNAL SIZE (1) Service main bearings are available in four Marking SIZE mm (in.) grades. The chart below identifies the four service Lower Main Bearing 2 and 3 grades available.
Page 1269 9 - 46 ENGINE - 3.7L CRANKSHAFT OIL SEAL - FRONT REMOVAL (1) Disconnect negative cable from battery. (2) Remove accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL). (3) Remove A/C compressor mouning fasteners and set aside. (4) Drain cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
Page 1270 ENGINE - 3.7L 9 - 47 CRANKSHAFT OIL SEAL - FRONT (Continued) (3) Install radiator cooling fan and shroud (Refer COOLING/ENGINE/RADIATOR INSTALLATION). (4) Install upper radiator hose. (5) Install A/C compressor and tighten fasteners to 54 N·m (40 ft. lbs.). (6) Install accessory drive belt refer (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
Page 1271 9 - 48 ENGINE - 3.7L CRANKSHAFT OIL SEAL - REAR (Continued) (3) Using Special Tools 8349 Crankshaft Rear Oil Seal Installer and C-4171 Driver Handle (Fig. 42), with a hammer, tap the seal into place. Continue to tap on the driver handle until the seal installer seats against the cylinder block crankshaft bore.
Page 1272 ENGINE - 3.7L 9 - 49 PISTON & CONNECTING ROD (Continued) STANDARD PROCEDURE CONNECTING ROD BEARING FITTING Inspect the connecting rod bearings for scoring. Check the bearings for normal wear patterns, scor- ing, grooving, fatigue and pitting (Fig. 45). Replace any bearing that shows abnormal wear.
Page 1273 9 - 50 ENGINE - 3.7L PISTON & CONNECTING ROD (Continued) (3) Use piston ring compressor and Guide Pins tapered journal, bent connecting rod or foreign Special Tool 8507 (Fig. 48) to install the rod and pis- material trapped between the insert and cap or ton assemblies.
Page 1274 ENGINE - 3.7L 9 - 51 PISTON & CONNECTING ROD (Continued) (10) Once you have selected the proper insert, install the insert and cap. Tighten the connecting rod bolts to 27 N·m (20 ft. lbs.) plus a 90° turn. Slide snug-fitting feeler gauge between the con- necting rod and crankshaft journal flange (Fig.
Page 1275 9 - 52 ENGINE - 3.7L PISTON & CONNECTING ROD (Continued) • Timing chain cover (Refer to 9 - ENGINE/ INSPECTION VALVE TIMING/TIMING BELT / CHAIN COVER(S) Check the connecting rod journal for excessive - REMOVAL). wear, taper and scoring (Refer to 9 - ENGINE/EN- •...
Page 1276 ENGINE - 3.7L 9 - 53 PISTON & CONNECTING ROD (Continued) Fig. 54 PISTON AND CONNECTING ROD ORIENTATION 1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SLINGER SLOT NOTE: The ring gap measurement must be made Fig. 53 PISTON AND CONNECTING ROD with the ring positioned at least 12mm (0.50 inch.) INSTALLATION from bottom of cylinder bore.
Page 1277 9 - 54 ENGINE - 3.7L PISTON RINGS (Continued) PISTON RING SIDE CLEARANCE PISTON RING SPECIFICATION CHART NOTE: Make sure the piston ring grooves are clean Ring Position Groove Maximum and free of nicks and burrs. Clearance Clearance (5) Measure the ring side clearance as shown (Fig. Upper Ring .051-.094 mm 0.11 mm...
Page 1278 ENGINE - 3.7L 9 - 55 PISTON RINGS (Continued) (8) Install the oil ring expander. (9) Install upper side rail (Fig. 57) by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position.
Page 1279 9 - 56 ENGINE - 3.7L VIBRATION DAMPER (Continued) (8) Disconnect electrical connector for fan mounted threaded rod’s threads with Mopar Nickel Anti- inside radiator shroud. Seize or equivalent. NOTE: Transmission cooler line snaps into shroud lower right hand corner. (9) Remove crankshaft damper bolt.
Page 1280 ENGINE - 3.7L 9 - 57 VIBRATION DAMPER (Continued) (5) Install fan blade assembly (Refer to 7 - COOL- ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION). (6) Install radiator upper shroud and tighten fas- teners to 11 N·m (95 in. lbs.). (7) Connect electrical connector for shroud fan.
Page 1281 9 - 58 ENGINE - 3.7L (12) Raise the engine far enough to be able to FRONT MOUNT remove the left and right engine mounts. (13) Remove the (8) mount to engine attaching REMOVAL bolts (14) Remove the engine mounts. (1) Disconnect the negative cable from the battery.
Page 1282 ENGINE - 3.7L 9 - 59 FRONT MOUNT (Continued) (11) Remove the (3) bolts that attach the front axle to the left engine bracket. (12) Lower the front axle. (13) Remove the (6) through bolts (14) Raise the engine far enough to be able to remove the left (Fig.
Page 1283 9 - 60 ENGINE - 3.7L FRONT MOUNT (Continued) Fig. 69 ENGINE INSULATOR MOUNTS 4X4 1 - RH INSULATOR TO AXLE BOLT 5 - LH INSULATOR TO AXLE BOLT 2 - NUT 6 - FRONT AXLE 3 - PINION SUPPORT MOUNT 7 - NUT 4 - LH INSULATOR MOUNT 8 - RH INSULATOR MOUNT...
Page 1284 ENGINE - 3.7L 9 - 61 INSTALLATION REAR MOUNT NOTE: Threadlocking compound must be applied to REMOVAL the bolts before installation. (1) Raise the vehicle on a hoist. (2) Using a suitable jack, support transmission. (1) Install the two bolts that attach the transmis- (3) Remove the nuts from the transmission mount sion mount to the transmission bracket.
Page 1285 9 - 62 ENGINE - 3.7L LUBRICATION (Continued) ENGINE LUBRICATION FLOW CHART - BLOCK: TABLE 1 FROM Oil Pickup Tube Oil Pump Oil Pump Oil Filter Oil Filter Block Main Oil Gallery Block Main Oil Gallery 1. Crankshaft Main Journal 2.
Page 1286 ENGINE - 3.7L 9 - 63 LUBRICATION (Continued) Fig. 71 LUBRICATION OIL FLOW 1 - OIL FLOW TO RIGHT CYLINDER HEAD 7 - OIL FLOW TO COUNTER BALANCE SHAFT 2 - CYLINDER BLOCK MAIN OIL GALLERY 8 - OIL PUMP OUTLET TO CYLINDER BLOCK 3 - LEFT CYLINDER HEAD OIL GALLERY 9 - OIL PUMP 4 - OIL FLOW TO BOTH SECONDARY TENSIONERS...
Page 1287 9 - 64 ENGINE - 3.7L LUBRICATION (Continued) (7) Clean the oil off the suspect oil leak area using DIAGNOSIS AND TESTING a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the DIAGNOSIS AND TESTING - ENGINE OIL LEAK engine for signs of an oil leak by using a black light.

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Dodge RAM 1500 1998 Owner's Manual

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