Chrysler 2000 LHS Owner's Manual

Table of Contents

Quick Links

Introduction

INa

Introduction

Lubrication And Maintenance

Suspension

Differential And Driveline

Brakes

Instrument Panel And Systems

8Ea

Instrument Panel and Systems

Audio Systems

Horn Systems

Vehicle Speed Control System

Turn Signal And Hazard Warning Systems

Wiper And Washer Systems

8Ka

Wiper and Washer Systems

Lamps

8La

Lamps

Passive Restraint Systems

8Ma

Passive Restraint Systems

Electrically Heated Systems

GROUP TAB LOCATOR

8Ra

13a

14a

23a

25a

Power Distribution Systems

Power Lock Systems

Vehicle Theft/Security Systems

Power Seat Systems

Power Window Systems

Power Mirror Systems

Chime/Buzzer Warning Systems

Overhead Console Systems

Engine

Frames and Bumpers

Steering

42LE Transaxle

Tires And Wheels

Body

Heating And Air Conditioning

Emission Control Systems

Service Manual Comment Forms

Table of Contents

Troubleshooting

Summary of Contents for Chrysler 2000 LHS

Page 1 GROUP TAB LOCATOR Introduction Power Distribution Systems Introduction Power Lock Systems Lubrication and Maintenance Vehicle Theft/Security Systems Suspension Power Seat Systems Differential and Driveline Power Seat Systems Brakes Power Window Systems Brakes Power Mirror Systems Cooling System Chime/Buzzer Warning Systems Battery Overhead Console Systems Starting Systems...
Page 2 INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION FASTENER IDENTIFICATION ....5 VEHICLE SAFETY CERTIFICATION LABEL ..1 FASTENER USAGE .
Page 3 INTRODUCTION DESCRIPTION AND OPERATION (Continued) VIN CODE BREAKDOWN POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 2 = Built in Canada by Chrysler Canada Ltd. Make B = Dodge C = Chrysler Vehicle Type 3 = Passenger Car Passenger Safety...
Page 4 1 – BODY COPY PLATE 2 – BATTERY TRAY DIGITS 18 AND 19 Vehicle Shell Line • LH BODY CODE PLATE LINE 3 DIGITS 20 DIGITS 1, 2, AND 3 Carline Paint procedure • C = Chrysler • D = Dodge...
Page 5 INTRODUCTION DESCRIPTION AND OPERATION (Continued) • Y = Chrysler IF TWO BODY CODE PLATES ARE REQUIRED The last code shown on either plate will be fol- DIGIT 21 lowed by END. When two plates are required, the Price Class last code space on the first plate will indicate (CTD) •...
Page 6 INTRODUCTION DESCRIPTION AND OPERATION (Continued) High Beam Rear Window Washer Fog Lamps Fuel Headlamp, Parking Lamps, Panel Lamps Engine Coolant Temperature Turn Warning Battery Charging Condition Hazard Warning Engine Oil Windshield Washer Seat Belt Windshield Wiper Brake Failure Windshield Wiper and Washer Parking Brake Windscreen Demisting and Defrosting Front Hood...
Page 7 INTRODUCTION DESCRIPTION AND OPERATION (Continued) FASTENER IDENTIFICATION...
Page 8 INTRODUCTION DESCRIPTION AND OPERATION (Continued) FASTENER STRENGTH...
Page 9 INTRODUCTION DESCRIPTION AND OPERATION (Continued) THREADED HOLE REPAIR The following chart will assist in converting metric units to equivalent English and SAE units, or vise versa. DESCRIPTION Most stripped threaded holes can be repaired using a Helicoil . Follow the manufacture recommendation for application and repair procedures.
Page 10 INTRODUCTION DESCRIPTION AND OPERATION (Continued) METRIC CONVERSION CHART...
Page 11 INTRODUCTION DESCRIPTION AND OPERATION (Continued) TORQUE SPECIFICATIONS...
Page 12 2000 LHS, 300M, CONCORDE AND INTREPID INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION VIN CHECK DIGIT......2 E-MARK LABEL .
Page 13 DESCRIPTION AND OPERATION (Continued) VIN DECODING INFORMATION POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 2 = Built in Canada by Chrysler Canada Ltd. Make C = Chrysler Vehicle Type 3 = Passenger Car Passenger Safety H = Restraint System - Active Driver and Passenger Air Bags...
Page 14 2000 LHS, 300M, CONCORDE AND INTREPID INTRODUCTION DESCRIPTION AND OPERATION (Continued) BODY CODE PLATE LINE 2 DIGITS 1, 2, AND 3 Paint procedure DIGIT 4 Open Space DIGITS 5 THROUGH 7 Primary paint See Group 23, Body for color codes.
Page 15 2000 LHS, 300M, CONCORDE AND INTREPID INTRODUCTION DESCRIPTION AND OPERATION (Continued) • Refer to Vehicle Identification Number (VIN) member adjacent to the Body Code Plate. The plate paragraph for proper breakdown of VIN code. contains five lines of information: 1. Vehicle Identification Number (VIN) IF TWO BODY CODE PLATES ARE REQUIRED 2.
Page 16 LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE TABLE OF CONTENTS page page LUBRICANTS ......1 JUMP STARTING, TOWING, AND HOISTING.
Page 17 0 - 2 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) lubricants usage. Such as API GL-5 and SAE 80W- LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI. All approved products have the NLGI symbol (Fig. 2) on the label. At the bottom NLGI symbol is the usage and quality identification letters.
Page 18 LUBRICATION AND MAINTENANCE 0 - 3 MAINTENANCE SCHEDULES TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SCHEDULE – A ......3 MAINTENANCE SCHEDULES .
Page 19 0 - 4 LUBRICATION AND MAINTENANCE SPECIFICATIONS (Continued) • Inspect the front and rear brake linings and • Inspect the engine air cleaner element (fil- rotors. ter) and replace if required. See note #1 at the end of this chart. •...
Page 20 LUBRICATION AND MAINTENANCE 0 - 5 SPECIFICATIONS (Continued) Note # 1 This maintenance is recommended by 3,000 Miles (5 000 km) • Change the engine oil DaimlerChrysler Corporation to the owner but is not • Replace the engine oil filter. required to maintain the emissions warranty.
Page 21 0 - 6 LUBRICATION AND MAINTENANCE SPECIFICATIONS (Continued) • Inspect the engine air cleaner element (fil- • Replace the engine air cleaner element (fil- ter) and replace if required. See note #1 at the end ter). See note #1 at the end of this chart. •...
Page 22 LUBRICATION AND MAINTENANCE 0 - 7 SPECIFICATIONS (Continued) • Inspect the engine air cleaner element (fil- 66,000 Miles (106 000 km) • Change the engine oil. ter) and replace if required. See note #1 at the end • Replace the engine oil filter. of this chart.
Page 23 0 - 8 LUBRICATION AND MAINTENANCE SPECIFICATIONS (Continued) 105,000 Miles (168 000 km) NOTE: Operating vehicle under the following condi- • Change the engine oil. tions will require the transmission service indicated • Replace the engine oil filter. with an * in schedule “B”. •...
Page 24 LUBRICATION AND MAINTENANCE 0 - 9 JUMP STARTING, TOWING, AND HOISTING TABLE OF CONTENTS page page SERVICE PROCEDURES TOWING RECOMMENDATIONS....10 JUMP STARTING PROCEDURE....9 HOISTING RECOMMENDATIONS.
Page 25 0 - 10 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) • Always observe all state and local laws pertain- ing to warning signals, night illumination, speed, etc. • Do not attempt a towing operation that could jeopardize the operator, bystanders or other motor- ists.
Page 26 LUBRICATION AND MAINTENANCE 0 - 11 SERVICE PROCEDURES (Continued) the vehicle. Install lug nuts on wheel attaching studs HOISTING RECOMMENDATIONS to retain braking discs. Refer to Owner’s Manual provided with vehicle for proper emergency jacking procedures. TIE DOWN LOCATIONS FOR FLAT BED TOWING There are two reinforced elongated holes on each WARNING: THE HOISTING AND JACK LIFTING side of the vehicle designed to serve as hold down...
Page 28 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page WHEEL ALIGNMENT ......1 REAR SUSPENSION ..... . . 44 FRONT SUSPENSION .
Page 29 2 - 2 SUSPENSION DESCRIPTION AND OPERATION (Continued) • Toe is measured in degrees or inches and is the ment. When readjusting, do not exceed the total toe difference in width between the centered leading and specification. trailing edges of the tires on the same axle (Fig. 3). Wheel alignment on this vehicle is to be checked Toe-in means that the front width is more narrow and all alignment adjustments are to be made with...
Page 30 SUSPENSION 2 - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 2. Worn or broken C/V joint 2. Replace C/V joint 3. Worn or loose tie rod 3. Tighten or replace tie rod end 4. Worn or loose ball joint 4.
Page 31 2 - 4 SUSPENSION DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 7. Excessive friction in strut upper 7. Replace strut bearing bearing Lateral Pull 1. Unequal tire pressure 1. Inflate all tires to recommended pressure 2. Radial tire lead 2.
Page 32 SUSPENSION 2 - 5 SERVICE PROCEDURES (Continued)
Page 33 2 - 6 SUSPENSION SERVICE PROCEDURES (Continued) fuel tank full of fuel, and no passenger or luggage (1) Measure from the inboard edge of the wheel compartment load. opening fender lip directly above the wheel center Vehicle height is not adjustable. If measurement is (spindle), to the floor or alignment rack surface.
Page 34 SUSPENSION 2 - 7 SERVICE PROCEDURES (Continued) FRONT CAMBER ADJUSTMENT PROCEDURE There are camber adjustment bolts and nuts avail- able to allow front suspension camber adjustment in the event the vehicle pulls even though the camber is within specifications. This procedure involves replac- ing the original strut clevis to knuckle attachment bolts with special undersized bolts.
Page 35 2 - 8 SUSPENSION SERVICE PROCEDURES (Continued) (6) If necessary, repeat steps 2 through 5 to the other side of the vehicle. (7) Lower the vehicle. (8) Jounce the front and rear of vehicle. (9) Adjust the front camber to the preferred set- ting by pushing in or pulling outward on the top of the wheel and tire as required.
Page 36 SUSPENSION 2 - 9 NOTE: All wheel alignments are to be set with the SPECIFICATIONS vehicle at curb height. Refer to CURB HEIGHT MEA- SUREMENT in SERVICE PROCEDURES. WHEEL ALIGNMENT SPECIFICATIONS NOTE: All specifications are given in degrees. FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE CAMBER...
Page 37 2 - 10 SUSPENSION FRONT SUSPENSION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION STEERING KNUCKLE ..... 18 FRONT SUSPENSION SYSTEM....10 HUB AND BEARING (FRONT) .
Page 38 SUSPENSION 2 - 11 DESCRIPTION AND OPERATION (Continued) Fig. 1 Front Suspension 1 – STRUT ASSEMBLY 4 – TENSION STRUT 2 – STEERING KNUCKLE 5 – ENGINE CRADLE CROSSMEMBER 3 – LOWER CONTROL ARM 6 – STABILIZER BAR • Upper spring isolator STEERING KNUCKLE •...
Page 39 2 - 12 SUSPENSION DESCRIPTION AND OPERATION (Continued) OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft and tire and wheel. The five wheel mounting studs mount the tire and wheel, and brake rotor to the vehicle. LOWER CONTROL ARM DESCRIPTION The lower control arm is a steel forging with 2 rub-...
Page 40 SUSPENSION 2 - 13 DESCRIPTION AND OPERATION (Continued) TENSION STRUT rod and strut shaft seal is not unusual and does not affect performance of the strut assembly. Also inspect jounce bumpers for signs of damage or deterioration. DESCRIPTION (4) Inspect the upper strut mount assembly. Make This vehicle uses a steel tension strut on each side sure the correct mount is on the correct side of the of the vehicle’s front suspension, between the lower...
Page 41 2 - 14 SUSPENSION DIAGNOSIS AND TESTING (Continued) Fig. 4 Right Front Strut Upper Mount 1 – NOTCH 2 – STEERING ARM 3 – OUTBOARD STRUT COIL SPRING SEAT 4 – RUBBER TABS The following procedure may be used for diagnosing the condition of the front hub bearing.
Page 42 SUSPENSION 2 - 15 DIAGNOSIS AND TESTING (Continued) toward the front of the vehicle when the stabilizer CAUTION: At no time when servicing a vehicle, can bar is installed (Fig. 6). a sheet metal screw, bolt or other metal fastener be installed in the shock tower to take the place of an original plastic clip.
Page 43 2 - 16 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 8 Stabilizer Bar Link At Strut Fig. 10 Speed Sensor Cable Routing Bracket 1 – OUTER TIE ROD 1 – STRUT ASSEMBLY 2 – NUT 2 – ROUTING BRACKET 3 – STABILIZER BAR ATTACHING LINK 3 –...
Page 44 SUSPENSION 2 - 17 REMOVAL AND INSTALLATION (Continued) Fig. 13 Strut Assembly To Steering Knuckle Attaching Bolts 1 – STRUT ASSEMBLY 2 – NUTS 3 – STRUT ASSEMBLY TO STEERING KNUCKLE ATTACHING BOLTS Fig. 12 Removal And Storage Of Front Caliper 4 –...
Page 45 2 - 18 SUSPENSION REMOVAL AND INSTALLATION (Continued) (3) Install the strut assembly to steering knuckle attaching bolts (Fig. 13). Install nuts on attaching bolts. Tighten the strut assembly clevis to steering knuckle attaching bolt nuts to a torque of 203 N·m (150 ft.
Page 46 SUSPENSION 2 - 19 REMOVAL AND INSTALLATION (Continued) Fig. 17 Speed Sensor Head Removal Fig. 19 Hub And Bearing Retaining Bolts 1 – SENSOR EAR 1 – STEERING KNUCKLE 2 – PUNCH 2 – HUB/BEARING ATTACHING BOLTS 3 – SPEED SENSOR HEAD 3 –...
Page 47 2 - 20 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 21 Hub And Bearing Assembly Removal And Fig. 23 Control Arm To Steering Knuckle Installation Attachment 1 – HUB/BEARING ASSEMBLY 1 – LOWER CONTROL ARM 2 – STEERING KNUCKLE 2 – BALL JOINT STUD 3 –...
Page 48 SUSPENSION 2 - 21 REMOVAL AND INSTALLATION (Continued) Fig. 26 Hub And Bearing Assembly Mounting Fig. 25 Strut To Steering Knuckle Attaching Bolts Surfaces 1 – STRUT ASSEMBLY 1 – BE SURE THESE SURFACES ARE CLEAN AND FREE OF 2 – NUTS KNICKS BEFORE INSTALLING BEARINGS 3 –...
Page 49 2 - 22 SUSPENSION REMOVAL AND INSTALLATION (Continued) tion. Then repeat the tightening sequence to the full specified torque of 129 N·m (95 ft. lbs.). (11) Lower vehicle to the ground. CAUTION: When torquing hub and bearing assem- bly to stub shaft retaining nut, do not exceed the maximum torque of 163 N·m 14 N·m (120 ft.
Page 50 SUSPENSION 2 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 32 Hub And Bearing Removal And Installation Fig. 30 Hub And Bearing Retaining Nut 1 – HUB/BEARING ASSEMBLY 1 – HUB/BEARING ASSEMBLY 2 – STEERING KNUCKLE 2 – NUT Fig. 31 Hub And Bearing Assembly Retaining Bolts Fig.
Page 51 2 - 24 SUSPENSION REMOVAL AND INSTALLATION (Continued) (1) Install hub and bearing assembly onto stub shaft and into steering knuckle until squarely seated on face of steering knuckle (2) Install the 3 hub and bearing assembly to steering knuckle attaching bolts (Fig. 31). Equally tighten all 3 mounting bolts until hub and bearing assembly is squarely seated against front of steering knuckle.
Page 52 SUSPENSION 2 - 25 REMOVAL AND INSTALLATION (Continued) CAUTION: When lower control arm is separated from steering knuckle, do not let ball joint seal hit up against steering knuckle. If ball joint seal hits steering knuckle, seal damage may occur. If ball joint seal becomes torn, replace seal before assem- bling lower control arm to knuckle.
Page 53 2 - 26 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 41 Lower Control Arm Remove/Install 1 – ISOLATOR BUSHING 2 – TENSION STRUT 3 – CRADLE 4 – PIVOT BUSHING Fig. 39 Tension Strut To Cradle Mounting 5 – LOWER CONTROL ARM BRACKET 1 –...
Page 54 SUSPENSION 2 - 27 REMOVAL AND INSTALLATION (Continued) CAUTION: When ball joint stud is installed into (4) Remove the right stabilizer bar attaching link steering knuckle, do not let ball joint seal hit up nut at the strut assembly. Remove the attaching link from the strut assembly (Fig.
Page 55 2 - 28 SUSPENSION REMOVAL AND INSTALLATION (Continued) Puller, Special Tool C-3894A (Fig. 46), then remove (8) Remove the 2 strut assembly to steering nut and tie rod from the steering arm. knuckle attaching bolts (Fig. 48). Fig. 46 Removing Outer Tie Rod From Steering Arm Fig.
Page 56 SUSPENSION 2 - 29 REMOVAL AND INSTALLATION (Continued) raise the jack until the motor mounts clear the cradle assembly. It may be necessary to raise the jack fur- ther. Fig. 50 Motor Mount To Cradle Assembly Attachment 1 – ENGINE OIL PAN 2 –...
Page 57 2 - 30 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 54 Stabilizer Bar Isolator Bushing Fig. 53 Stabilizer Bar Removal and Installation 1 – STABILIZER BAR 1 – STABILIZER BAR 2 – STABILIZER BAR ISOLATOR BUSHING 2 – HALFSHAFT 3 – CRADLE ASSEMBLY 3 –...
Page 58 SUSPENSION 2 - 31 REMOVAL AND INSTALLATION (Continued) (15) Install the right front wheel and tire assem- bushings must be positioned on the stabilizer bly. bar so the slit in the bushing is positioned (16) Tighten the wheel mounting nuts in proper toward front of vehicle (Fig.
Page 59 2 - 32 SUSPENSION REMOVAL AND INSTALLATION (Continued) (2) Install the isolator bushing retainers back onto the stabilizer bar isolator bushings. CAUTION: When stabilizer bar is installed. Position stabilizer bar, so lower part of stabilizer bar is cen- tered in the middle of the cradle assembly. Failure to do this may cause stabilizer bar to come in con- tact with other suspension components.
Page 60 SUSPENSION 2 - 33 REMOVAL AND INSTALLATION (Continued) (2) Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the bearing flange, remove lug nut and washers from wheel stud.
Page 61 2 - 34 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 63 Shaft Nut Removal/Installation 1 – SPRING COMPRESSOR 2 – SPECIAL TOOL 6864 Fig. 62 Strut Assembly In Compressor 3 – UPPER MOUNT 1 – HOOKS 2 – STRUT ASSEMBLY with the inboard side of the strut (or rear of the cle- 3 –...
Page 62 SUSPENSION 2 - 35 DISASSEMBLY AND ASSEMBLY (Continued) • Inspect the strut for any condition of shaft bind- ing over the full stroke of the shaft. • Inspect the jounce bumper for cracks and signs of deterioration. • Check the upper mount for cracks and distortion and its retaining studs for any sign of damage.
Page 63 2 - 36 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Before installing the upper mount, make sure the correct upper mount is being installed on the strut. DO NOT install a right mount on a left front strut or a left mount on a right front strut. Incorrect mount installation may cause poor vehicle ride and steering feel, and excessive front end noise.
Page 64 SUSPENSION 2 - 37 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 69 Installing Lower Control Arm Pivot Bushing Fig. 68 Lower Control Arm Pivot Bushing Removal 1 – ARBOR PRESS RAM 1 – ARBOR PRESS RAM 2 – SPECIAL TOOL 6644-1 2 – SPECIAL TOOL 6644-2 3 –...
Page 65 2 - 38 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) Fig. 72 Removing Lower Control Arm Tension Strut Fig. 71 Tension Strut Installed In Lower Control Arm Bushing 1 – BALL JOINT STUD 1 – ARBOR PRESS RAM 2 – BALL JOINT SEAL 2 –...
Page 66 SUSPENSION 2 - 39 DISASSEMBLY AND ASSEMBLY (Continued) DISASSEMBLY (1) Raise vehicle using a frame contact type hoist or supported as required using jack stands. See Hoisting in the Lubrication and Maintenance group of this service manual for the required hoisting or jacking procedure to be used for this vehicle.
Page 67 2 - 40 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) (2) Install lower control arm and tension strut as an assembly back on the vehicle. See Lower Control Arm Installation in this section of the service manual for the required installation procedure. (3) Install washer on end of tension strut (Fig.
Page 68 SUSPENSION 2 - 41 DISASSEMBLY AND ASSEMBLY (Continued) cradle, until squarely seated against cradle assembly (Fig. 79). Fig. 80 Tension Strut To Cradle Mounting 1 – CRADLE ISOLATOR BUSHING 2 – CRADLE Fig. 79 Tension Strut Bushing Installed In Cradle 3 –...
Page 69 2 - 42 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) SPECIAL TOOLS FRONT SUSPENSION Puller C-3894A Fig. 82 Lower Control Arm Pivot Bushing Bolt 1 – CRADLE ASSEMBLY 2 – PIVOT BOLT 3 – LOWER CONTROL ARM SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUES Socket/Holder Front Strut Nut 6864 DESCRIPTION TORQUE...
Page 70 SUSPENSION 2 - 43 SPECIAL TOOLS (Continued) Installer, Ball Joint MB-990800 Remover C-4150A...
Page 71 2 - 44 SUSPENSION REAR SUSPENSION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION STRUT ASSEMBLY (REAR) ....48 REAR SUSPENSION SYSTEM ....44 SPINDLE .
Page 72 SUSPENSION 2 - 45 DESCRIPTION AND OPERATION (Continued) Fig. 1 Rear Suspension 1 – STRUT ASSEMBLY 5 – HUB AND BEARING 2 – REAR SUSPENSION CROSSMEMBER 6 – STABILIZER BAR 3 – REAR SUSPENSION CROSSMEMBER BUSHING 7 – TRAILING ARM 4 –...
Page 73 2 - 46 SUSPENSION DESCRIPTION AND OPERATION (Continued) OPERATION The lateral movement of the rear spindle is con- trolled by the lateral links connecting the front and rear centerline of the spindle to the rear suspension crossmember. The threaded adjustment sleeve of the rear link allows for setting rear wheel alignment toe adjustment.
Page 74 SUSPENSION 2 - 47 DIAGNOSIS AND TESTING (Continued) (2) Inspect for torn or damaged strut assembly this group of the service manual for the required dust boots (Fig. 3). removal and replacement procedure. Then, refer to (3) Inspect for damaged upper and lower spring Strut Assembly in the Disassembly and Assembly isolators (Fig.
Page 75 2 - 48 SUSPENSION DIAGNOSIS AND TESTING (Continued) other damage to the trailing arm. If the trailing arm (1) Remove the rear seat cushion from the interior is bent or damaged the trailing arm will require of the car. Refer to Seats in the Body section of this replacement.
Page 76 SUSPENSION 2 - 49 REMOVAL AND INSTALLATION (Continued) Fig. 6 Lateral Links To Spindle Attachment 1 – SPINDLE 2 – LATERAL LINKS 3 – LATERAL LINK ATTACHING BOLT HEAD 4 – STRUT ASSEMBLY 5 – STABILIZER BAR ATTACHING LINK 6 – BRAKE CALIPER Fig.
Page 77 2 - 50 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 8 Spindle To Strut Assembly Pinch Bolt Fig. 10 Removing Spindle From Strut Assembly 1 – PINCH BOLT 1 – BRASS DRIFT PUNCH 2 – STRUT ASSEMBLY 2 – STRUT ASSEMBLY 3 –...
Page 78 SUSPENSION 2 - 51 REMOVAL AND INSTALLATION (Continued) INSTALLATION (70 ft. lbs.) using a crow foot wrench and torque wrench in place of the wrench on the attaching nut. (1) Install the nut, washers, and rubber isolators Be sure to use a wrench to hold the link stud in securing the stabilizer bar attaching link to the strut.
Page 79 2 - 52 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 15 Speed Sensor Head 1 – STABILIZER BAR LINK 2 – STABILIZER BAR 3 – LATERAL LINK 4 – BOLT 5 – WHEEL SPEED SENSOR 6 – STRUT ASSEMBLY 7 – NUT Fig.
Page 80 SUSPENSION 2 - 53 REMOVAL AND INSTALLATION (Continued) Fig. 19 Spindle Pinch Bolt Fig. 17 Trailing Arm To Bracket Bolt 1 – PINCH BOLT 1 – SPINDLE 2 – STRUT ASSEMBLY 2 – TRAILING ARM BRACKET 3 – REAR SPINDLE 3 –...
Page 81 2 - 54 SUSPENSION REMOVAL AND INSTALLATION (Continued) (11) Tighten the lateral links to spindle attaching bolt to a torque of 135 N·m (100 ft. lbs.). (12) Tighten the trailing arm to spindle bracket attaching bolt to a torque of 100 N·m (75 ft. lbs.). (13) Check and reset rear wheel TOE to specifica- tions if required.
Page 82 SUSPENSION 2 - 55 REMOVAL AND INSTALLATION (Continued) bearing retaining nut and washer from the spindle LEFT FORWARD LATERAL LINK (Fig. 23). Then remove hub and bearing assembly from spindle. REMOVE (1) Raise vehicle on jackstands or centered on a frame contact type hoist.
Page 83 2 - 56 SUSPENSION REMOVAL AND INSTALLATION (Continued) CAUTION: Tightening the lateral link attaching bolt at this point will cause the bushing to contort when the vehicle is at curb riding height, thus contribut- ing to premature failure of the lateral link bushings. (2) Raise the fuel tank up into mounting position.
Page 84 SUSPENSION 2 - 57 REMOVAL AND INSTALLATION (Continued) Fig. 27 Lateral Link Attachment To Crossmember Fig. 26 Lateral Link Attachment To Spindle 1 – CROSSMEMBER 1 – SPINDLE 2 – EXHAUST MUFFLER 2 – LATERAL LINKS 3 – ATTACHING BOLT 3 –...
Page 85 2 - 58 SUSPENSION REMOVAL AND INSTALLATION (Continued) INSTALL CAUTION: When the trailing arm is installed to its mounting bracket, it is important to set an offset angle of 5 degrees before tightening the attaching bolt. Otherwise, the bushing will be contorted when the vehicle is at normal riding height.
Page 86 SUSPENSION 2 - 59 REMOVAL AND INSTALLATION (Continued) STABILIZER BAR (REAR) REMOVAL (1) Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the Lubri- cation and Maintenance section of this manual for the required lifting procedure to be used for this vehicle.
Page 87 2 - 60 SUSPENSION REMOVAL AND INSTALLATION (Continued) (10) Remove the stabilizer bar from the vise, and bushing and retainer on the other side of the stabi- repeat the preceding 5 steps to remove the second lizer bar. bushing from the other side of the stabilizer bar. (7) Position the rear stabilizer bar in position between the frame rails.
Page 88 SUSPENSION 2 - 61 REMOVAL AND INSTALLATION (Continued) (4) Remove the hub and bearing assembly from the press. DISASSEMBLY AND ASSEMBLY STRUT ASSEMBLY (REAR) The Strut assembly must be removed from the vehicle for it to be disassembled and assembled. Refer to REMOVAL AND INSTALLATION in this section for the required procedure.
Page 89 2 - 62 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) (4) Remove the strut upper mount assembly, upper spring. Positioning the spring compressor on the spring isolator, dust shield, and jounce bumper. The sleeve could cause the sleeve to dislodge from the jounce bumper should come off with the dust shield.
Page 90 SUSPENSION 2 - 63 DISASSEMBLY AND ASSEMBLY (Continued) Tool 6864, on strut shaft nut. Use a deep well socket SPECIAL TOOLS inserted into the opening of tool 6864 to keep strut shaft from turning. Tighten the strut shaft nut to a REAR SUSPENSION torque of 75 N·m (55 ft.
Page 92 DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION OUTER C/V JOINT SEALING BOOT ..14 DRIVESHAFT ASSEMBLIES ....1 SPECIFICATIONS DIAGNOSIS AND TESTING TORQUE SPECIFICATIONS .
Page 93 3 - 2 DIFFERENTIAL AND DRIVELINE DESCRIPTION AND OPERATION (Continued) Fig. 1 Front Driveshaft Assemblies 1 – INNER BOOT 7 – INTERCONNECTING SHAFT 2 – INTERCONNECTING SHAFT 8 – OUTER C/V JOINT 3 – OUTER BOOT 9 – INNER BOOT 4 –...
Page 94 DIFFERENTIAL AND DRIVELINE 3 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 2 Driveshaft Component Identification 1 – HOUSING ASM, RETAINER & 11 – CLAMP, SEAL RETAINING 2 – RING, SPACER 12 – SHAFT, AXLE (RH SHOWN, LH SIMILAR) 3 – SPIDER, TRIPOTD JOINT 13 –...
Page 95 3 - 4 DIFFERENTIAL AND DRIVELINE DESCRIPTION AND OPERATION (Continued) OPERATION (2) Out of balance front tires or wheels. See Group 22, Wheels And Tires for the required balancing pro- Driveshaft assemblies are designed to transmit cedure. power from the transaxle to the front wheels, while (3) Improper tire and/or wheel runout.
Page 96 DIFFERENTIAL AND DRIVELINE 3 - 5 REMOVAL AND INSTALLATION (Continued) (4) Remove front braking disk (rotor) from hub, by (6) Remove the hub and bearing to stub axle pulling it straight off wheel mounting studs (Fig. 4). retaining nut (Fig. 6). Fig.
Page 97 3 - 6 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (8) Install a wheel lug nut on wheel stud to protect CAUTION: The strut assembly to steering knuckle the threads on the stud. Install a flat blade pry tool bolts are serrated where they go through strut to keep hub from turning.
Page 98 DIFFERENTIAL AND DRIVELINE 3 - 7 REMOVAL AND INSTALLATION (Continued) is removed from the stub shaft, the retaining circlip and O-ring seal MUST BE REPLACED. The retaining circlip and O-ring seal is included in all service kits requiring removal of the inboard tripod joint from the stub shaft.
Page 99 3 - 8 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (3) Install driveshaft through hole in splash shield. (5) Hold outer C/V joint assembly with one hand. Grasp inner tripod joint in one hand and intercon- Grasp steering knuckle with other hand and rotate it necting shaft in the other.
Page 100 DIFFERENTIAL AND DRIVELINE 3 - 9 REMOVAL AND INSTALLATION (Continued) (7) Install the strut assembly to steering knuckle attaching bolts. Install nuts on attaching bolts (Fig. 17). Tighten the strut assembly to steering knuckle bolt nuts to 169 N·m (125 ft. lbs.). TURN NUTS ON BOLTS.
Page 101 3 - 10 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (11) Install front brake caliper over braking disc and align with caliper mounting holes on steering knuckle (Fig. 20). Refer to Front Disc Brake Service in the Brake Section of this service manual for cali- per installation procedure.
Page 102 DIFFERENTIAL AND DRIVELINE 3 - 11 CAUTION: When removing the spider joint from the DISASSEMBLY AND ASSEMBLY tripod joint housing. Hold the rollers in place on the spider trunions to prevent the rollers and needle INNER TRIPOD JOINT SEALING BOOT bearings from falling away.
Page 103 3 - 12 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (2) Install the spider assembly onto the intercon- necting shaft. Spider assembly must be installed on interconnecting shaft far enough to fully install the retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift.
Page 104 DIFFERENTIAL AND DRIVELINE 3 - 13 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 28 Spider Assembly Installed In Housing Fig. 30 Sealing Boot Retaining Clamp Installed 1 – INTERCONNECTING SHAFT 1 – SEALING BOOT 2 – SPIDER ASSEMBLY 2 – SPECIAL TOOL C-4975 3 –...
Page 105 2000 LHS, 300M, CONCORDE AND INTREPID 3 - 14 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) OUTER C/V JOINT SEALING BOOT (3) Wipe away grease to expose outer C/V joint to interconnecting shaft retaining ring. Spread ears apart on C/V joint assembly to interconnecting shaft CAUTION: Boot sealing is vital to retain special retaining snap ring (Fig.
Page 106 DIFFERENTIAL AND DRIVELINE 3 - 15 DISASSEMBLY AND ASSEMBLY (Continued) until jaws on tool are closed completely together, face to face (Fig. 37). Fig. 34 Outer C/V Joint Installed On Interconnecting Shaft 1 – INTERCONNECTING SHAFT Fig. 36 Crimping Tool Installed On Sealing Boot 2 –...
Page 107 3 - 16 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (7) Clamp sealing boot onto outer C/V joint hous- ing using Crimper, Special Tool C-4975 and the fol- lowing procedure. Place crimping tool C- 4975 over bridge of clamp (Fig. 38). Tighten nut on crimping tool C-4975 until jaws on tool are closed completely together, face to face (Fig.
Page 108 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BASE BRAKE SYSTEM ..... . 1 ANTILOCK BRAKE SYSTEM ....55 BASE BRAKE SYSTEM TABLE OF CONTENTS page...
Page 109 5 - 2 BRAKES For more information on the operation of any indi- DESCRIPTION AND OPERATION vidual base brake component, refer to that compo- nent elsewhere in this section. BASE BRAKE SYSTEM BRAKE PEDAL DESCRIPTION The base brake system consists of the following DESCRIPTION components: A suspended type brake pedal is used on this vehi-...
Page 110 2000 LHS, 300M, CONCORDE AND INTREPID 2000 LHS, 300M, CONCORDE AND INTREPID BRAKES 5 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 2 Master Cylinder 1 – BOOSTER 2 – MASTER CYLINDER 3 – MASTER CYLINDER FLUID RESERVOIR 4 – FLUID LEVEL FULL MARK 5 –...
Page 111 5 - 4 BRAKES DESCRIPTION AND OPERATION (Continued) OPERATION The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid devel- oped by the master cylinder to the wheel brakes of the vehicle. The flex hoses are made of rubber to allow for the movement of the vehicle’s steering and suspension.
Page 112 BRAKES 5 - 5 DESCRIPTION AND OPERATION (Continued) Fig. 5 Brake Tube Nut Thread Sizes And Tube Routing 1 – HOSE END RT. FRONT 8 – PROPORTIONING VALVE 2 – MASTER CYLINDER 9 – PROPORTIONING VALVE 3 – SECONDARY PORT 10 –...
Page 113 5 - 6 BRAKES DESCRIPTION AND OPERATION (Continued) Fig. 7 Front Disc Brake Caliper Assembly 1 – CALIPER GUIDE PIN BOLT 10 – BRAKE SHOE 2 – SLEEVE 11 – RETRACTOR CLIP 3 – BUSHING 12 – BRAKE SHOE 4 – CALIPER 13 –...
Page 114 BRAKES 5 - 7 DESCRIPTION AND OPERATION (Continued) Fig. 8 Performance Front Disc Brake Caliper Assembly (BR5) 1 – CALIPER GUIDE PIN BOLT 10 – BRAKE SHOE 2 – SLEEVE 11 – BRAKE SHOE 3 – BUSHING 12 – ANTI-RATTLE CLIP 4 –...
Page 115 5 - 8 BRAKES DESCRIPTION AND OPERATION (Continued) The brake shoe lining material rides against the PARKING BRAKE brake rotors braking surface. When the brakes are applied, the shoes apply pressure against the rotor, DESCRIPTION thus slowing the vehicle. parking brake mechanism vehicles...
Page 116 BRAKES 5 - 9 DESCRIPTION AND OPERATION (Continued) Fig. 11 Rear Disc Brake Assembly 1 – CALIPER ASSEMBLY 8 – ANTI-RATTLE WASHER 2 – HUB/BEARING ASSEMBLY 9 – WASHER 3 – NUT 10 – ADAPTER 4 – NUT LOCK 11 – DISC SHIELD 5 –...
Page 117 5 - 10 BRAKES DESCRIPTION AND OPERATION (Continued) be checked and filled to the full mark with DOT 3 brake fluid. If the brake fluid level has dropped in the brake fluid reservoir, the entire brake hydraulic system should be checked for evi- dence of a leak.
Page 118 BRAKES 5 - 11 DIAGNOSIS AND TESTING BASE BRAKE SYSTEM DIAGNOSIS CHARTS NOTE: There are three diagnosis charts following that cover the RED BRAKE WARNING LAMP, BRAKE NOISE and OTHER BRAKE CONDITIONS. RED BRAKE WARNING LAMP CONDITION POSSIBLE CAUSES CORRECTION RED BRAKE WARNING 1.
Page 119 5 - 12 BRAKES DIAGNOSIS AND TESTING (Continued) OTHER BRAKE CONDITIONS CONDITION POSSIBLE CAUSES CORRECTION BRAKES CHATTER 1. Disc brake rotor has excessive 1. Isolate condition as rear or front. thickness variation. Reface or replace brake rotors as necessary. BRAKES DRAG (FRONT 1.
Page 120 BRAKES 5 - 13 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes. 2. Power brake booster runout 2. Check booster vacuum hose and (vacuum assist). engine tune for adequate vacuum supply.
Page 121 5 - 14 BRAKES DIAGNOSIS AND TESTING (Continued) inches, the hose or check to the booster has a restric- valve is connected to each rear flex hose. One propor- tion or leak. tioning valve controls the right rear brake, and the Once an adequate vacuum supply is obtained, other proportioning valve controls the left rear brake.
Page 122 BRAKES 5 - 15 DIAGNOSIS AND TESTING (Continued) CAUTION: Be sure the pressure test fittings being installed into the proportioning valve, have the cor- rect thread sizes for installation into the proportion- ing valve and installation of the chassis brake tubes.
Page 123 5 - 16 BRAKES DIAGNOSIS AND TESTING (Continued) PROPORTIONING VALVE APPLICATIONS AND PRESSURE SPECIFICATIONS Sales Inlet Outlet Brake System Type Split Point Slope Identification Code Pressure Pressure All Disc/Disc 350 psi 0.34 Bar Code Label 1000 psi 525-625 psi BRAKE ROTOR Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action.
Page 124 BRAKES 5 - 17 DIAGNOSIS AND TESTING (Continued) If runout is in excess of the specification, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken.
Page 125 5 - 18 BRAKES DIAGNOSIS AND TESTING (Continued) Fig. 23 Index Rotor And Wheel Stud 1 – CHALK MARK Fig. 22 Checking Hub Runout If runout is not within specifications, reface or replace the brake rotor. Refer to SERVICE PROCE- 1 –...
Page 126 BRAKES 5 - 19 DIAGNOSIS AND TESTING (Continued) three internal switches as shown (Fig. 24). You SERVICE PROCEDURES should achieve the results as listed in the figure. BRAKE FLUID LEVEL CHECK Check master cylinder reservoir brake fluid level a minimum of twice a year. The master cylinder brake fluid reservoir used on this vehicle includes a brake fluid level sensor.
Page 127 5 - 20 BRAKES SERVICE PROCEDURES (Continued) BASE BRAKE BLEEDING NOTE: To bleed this vehicles antilock brakes hydraulic system, see the antilock brake system service procedures in this group of the service manual. It describes in detail the required proce- dure which needs to be followed when bleeding the antilock brake system.
Page 128 BRAKES 5 - 21 SERVICE PROCEDURES (Continued) expel all the trapped air. Be sure to monitor the fluid NOTE: Make sure the open ends of the bleeding level in the pressure bleeder. It must stay at the tubes are below the surface of the brake fluid when proper level so air will not be allowed to reenter the the reservoir is filled to the proper level.
Page 129 5 - 22 BRAKES SERVICE PROCEDURES (Continued) Fig. 32 Cutting and Flaring of Brake Line Tubing 1 – SPECIAL TOOL TFM428 Fig. 31 I. S. O. Style Tubing Flare And Fitting 2 – SPECIAL TOOL C3478A Connection 1 – ISO STYLE TUBING FLARE 2 –...
Page 130 BRAKES 5 - 23 SERVICE PROCEDURES (Continued) listed below. Be sure to place the tubing nut on BRAKE ROTOR MACHINING tube before proceeding to flare the tubing. (1) Carefully prepare the end of the tubing to be BRAKE ROTOR MACHINING flared.
Page 131 5 - 24 BRAKES SERVICE PROCEDURES (Continued) Fig. 36 Front Rotor Thickness Markings Fig. 37 Rear Rotor Thickness Markings 1 – BRAKING DISC MINIMUM THICKNESS MARKING 1 – BRAKING DISC MINIMUM THICKNESS MARKING 2 – BRAKING DISC 2 – PARK BRAKE DRUM MAXIMUM DIAMETER MARKING When mounting and using the brake lathe, strict SPECIFICATIONS AND LIMITS attention to the brake lathe manufacturer’s operating...
Page 132 BRAKES 5 - 25 BRAKE PEDAL REMOVAL AND INSTALLATION SERVICE WARNINGS AND CAUTIONS REMOVAL (1) Disconnect and isolate the remote ground bat- WARNING: ALTHOUGH FACTORY INSTALLED tery cable from the ground stud on the right strut BRAKE SHOE LININGS ARE MADE FROM ASBES- tower.
Page 133 5 - 26 BRAKES REMOVAL AND INSTALLATION (Continued) brake lamp switch until it has ratcheted out to its fully extended position. (10) Install the brake lamp switch in the brake pedal bracket (Fig. 38). Install it using the following procedure. Depress the brake pedal as far down as possible.
Page 134 BRAKES 5 - 27 REMOVAL AND INSTALLATION (Continued) INSTALL CAUTION: If the master cylinder is being replaced or or has been repaired, the master cylinder must be bled before installation. See Master Cylinder Bleeding in Service Procedures within this group of this service manual.
Page 135 5 - 28 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 44 Reinforcement Attachment To Vehicle 1 – RIGHT STRUT TOWER 2 – WIPER MODULE 3 – LEFT STRUT TOWER Fig. 46 Master Cylinder Positioning 4 – ATTACHING BOLTS 5 – ATTACHING BOLT 1 –...
Page 136 BRAKES 5 - 29 REMOVAL AND INSTALLATION (Continued) (5) Carefully position master cylinder on vacuum ing valve to the flex hose. last, fasten the steel brake booster. Position wire harness routing bracket onto tubing to the rear proportioning valve. Tighten all right master cylinder mounting stud.
Page 137 5 - 30 BRAKES REMOVAL AND INSTALLATION (Continued) (8) Remove the 3 bolts attaching the junction block INSTALL to the mounting bracket. (1) Install the proportioning valve to the rear (9) Remove the junction block from the vehicle. brake flex hose. Tighten to a torque of 17 N·m (145 in.
Page 138 BRAKES 5 - 31 REMOVAL AND INSTALLATION (Continued) Fig. 52 Storing Caliper Fig. 51 Removing Caliper Assembly 1 – WIRE HANGER 1 – BRAKE SHOES 2 – FLEXIBLE BRAKE HOSE 2 – STEERING KNUCKLE 3 – BRAKING DISC 3 – BRAKING DISC 4 –...
Page 139 5 - 32 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 54 Removing Outboard Brake Shoe 1 – RETAINING CLIP 2 – CALIPER ASSEMBLY 3 – BRAKE SHOE Fig. 53 Removing Or Installing Braking Disc 1 – HUB 2 – STEERING KNUCKLE 3 –...
Page 140 BRAKES 5 - 33 REMOVAL AND INSTALLATION (Continued) (1) Completely retract caliper piston back into pis- ton bore of caliper assembly. (2) Lubricate both steering knuckle abutments with a liberal amount of Mopar Brake Grease for Caliper Slides Lubricant, or equivalent. (3) Remove the protective paper from the noise suppression gasket on both the inner and outer brake shoe assemblies (if equipped).
Page 141 5 - 34 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 58 Front Disc Brake Caliper With Retractor Clips 1 – CALIPER GUIDE PIN BOLT 10 – BRAKE SHOE 2 – SLEEVE 11 – RETRACTOR CLIP 3 – BUSHING 12 – BRAKE SHOE 4 –...
Page 142 BRAKES 5 - 35 REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: Step 1 below is only required when install- ing the disc brake caliper after new brake shoes have been installed. (1) Completely retract caliper piston back into pis- ton bore of caliper assembly. (2) Lubricate both adapter abutments with a lib- eral amount of Mopar Multipurpose Lubricant, or...
Page 143 5 - 36 BRAKES REMOVAL AND INSTALLATION (Continued) (3) Remove the 2 caliper assembly to adapter guide pin bolts (Fig. 63). Fig. 63 Caliper Guide Pin Bolts 1 – CALIPER ASSEMBLY 2 – ADAPTER 3 – CALIPER ASSEMBLY ATTACHING BOLT 4 –...
Page 144 BRAKES 5 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 68 Removing / Installing Inboard Brake Shoe 1 – RETAINING CLIP 2 – INBOARD SHOE Fig. 66 Removing / Installing Rear Rotor (2) Lubricate both adapter abutments with a lib- 1 – BRAKING DISC eral amount of Mopar Multipurpose Lubricant, or 2 –...
Page 145 5 - 38 BRAKES REMOVAL AND INSTALLATION (Continued) specification. Then repeat the tightening sequence to (5) Lower the vehicle to the ground. the full specified torque of 129 N·m (95 ft. lbs.). (6) Remove the driver’s door opening sill cover. (11) Remove jackstands or lower hoist.
Page 146 BRAKES 5 - 39 REMOVAL AND INSTALLATION (Continued) (11) Remove the wiring harness connector from the trunk release switch in the lower instrument panel cover (Fig. 72). Fig. 74 Reinforcement Panel 1 – REINFORCEMENT PANEL 2 – MOUNTING BOLTS Fig. 72 Trunk Release Wiring (15) Remove the 2 lower mounting screws securing 1 –...
Page 147 5 - 40 BRAKES REMOVAL AND INSTALLATION (Continued) (20) Remove front seat belt anchor bolt at base of left B-pillar. (21) Pull back floor carpeting on left side of pas- senger compartment to reveal front park brake cable. (22) Remove the 2 screws securing the front park brake cable retainer bracket to the rear floor pan (Fig.
Page 148 BRAKES 5 - 41 REMOVAL AND INSTALLATION (Continued) (15) Reinstall the fuse panel cover on left side of (8) Release the latch on the routing clip for the instrument panel. intermediate cable, mounted above the left rear cable (16) Reinstall driver’s side kick panel retainer clip, on rear suspension crossmember.
Page 149 5 - 42 BRAKES REMOVAL AND INSTALLATION (Continued) (9) Raise the vehicle back up. (10) Install the rear park brake cable into the rear suspension crossmember mounting hole. (11) Install a new retainer clip, on the end of the cable housing, to secure it in place. (12) Left rear cable only - Connect the left rear park brake cable to the connector on the park brake cable tensioner.
Page 150 2000 LHS, 300M, CONCORDE AND INTREPID BRAKES 5 - 43 REMOVAL AND INSTALLATION (Continued) INSTALLATION (11) Lower vehicle to the ground. (1) Mark tensioner rod 6.35 mm (1/4 in.) from edge PARKING BRAKE SHOES (WITH REAR DISC of tensioner bracket (Fig. 81).
Page 151 2000 LHS, 300M, CONCORDE AND INTREPID 5 - 44 BRAKES REMOVAL AND INSTALLATION (Continued) BRAKE LAMP SWITCH CAUTION: Do not use excessive force when pulling back on the brake pedal to adjust the brake lamp switch. If to much force is used, damage to the REMOVAL brake lamp switch or striker can result.
Page 152 2000 LHS, 300M, CONCORDE AND INTREPID BRAKES 5 - 45 DISASSEMBLY AND ASSEMBLY (Continued) DISC BRAKE CALIPER (FRONT AND REAR) CLEANING AND INSPECTION Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any rup- tures, brittleness or damage to the piston dust boot.
Page 153 5 - 46 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) Fig. 88 Folded Caliper Guide Pin Bushing 1 – CALIPER GUIDE PIN BUSHING Fig. 86 Removing Inner Sleeve From Bushing 1 – CALIPER 2 – SLEEVE 3 – BUSHING Fig. 89 Installing Caliper Guide Pin Bushing 1 –...
Page 154 BRAKES 5 - 47 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 90 Bushing Correctly Installed In Caliper Fig. 92 Correctly Installed Caliper Sleeve And 1 – BUSHING Bushing 2 – CALIPER 1 – CALIPER 3 – BE SURE BOTH BUSHING FLANGES ARE FULLY SEATED AROUND CALIPER BUSHING BORES.
Page 155 5 - 48 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) (5) To disassemble caliper, mount in a vise equipped with protective jaws. (6) Remove guide pin sleeves and guide pin bush- ings. See Removing Guide Pin Bushings in the cali- per disassembly section of this manual. (7) Remove the piston dust boot from the caliper and discard (Fig.
Page 156 BRAKES 5 - 49 DISASSEMBLY AND ASSEMBLY (Continued) (11) If the bore does not clean up within this spec- ification, a new caliper housing should be installed. Install a new piston if the old one is pitted or scored. NOTE: When using Caliper Honing Tool, Special Tool C-4095, coat the stones and bore with brake fluid.
Page 157 5 - 50 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) The steel brake tubing should be inspected period- ically for evidence of corrosion, physical damage or contact with moving or hot components of the vehi- cle. DISC BRAKES (FRONT) BRAKE SHOE (PAD) LINING WEAR If a visual inspection does not adequately deter- mine the condition of the lining, a physical check will be necessary.
Page 158 BRAKES 5 - 51 CLEANING AND INSPECTION (Continued) remove the wheel and tire assemblies, and the cali- (5) Verify park brake cables operate freely and are pers. not binding, or seized. Remove the rear disc brake shoes. Refer to Disc (6) Check park brake shoe adjustment.
Page 159 5 - 52 BRAKES ADJUSTMENTS (Continued) BRAKE LAMP SWITCH SPECIFICATIONS (1) Depress and hold the brake pedal. BRAKE FLUID (2) Remove the brake switch from it’s bracket (Fig. 100). To do so, rotate the brake lamp switch in a The brake fluid used in this vehicle must conform counterclockwise direction approximately 30 degrees to DOT 3 specifications and SAE J1703 standards.
Page 160 BRAKES 5 - 53 SPECIFICATIONS (Continued) BRAKE FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE BRAKE TUBES: Tube Nuts ....17 N·m (145 in. lbs.) BRAKE HOSE: Caliper Banjo Bolt ..48 N·m (35 ft. lbs.) Intermediate Bracket .
Page 161 5 - 54 BRAKES SPECIAL TOOLS (Continued) Installer, Dust Boot C-4689 Dial Indicator C-3339...
Page 162 BRAKES 5 - 55 ANTILOCK BRAKE SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION ANTILOCK BRAKE SYSTEM BLEEDING ..68 ANTILOCK BRAKE SYSTEM ....55 REMOVAL AND INSTALLATION ANTILOCK BRAKE SYSTEM COMPONENTS .
Page 163 5 - 56 BRAKES DESCRIPTION AND OPERATION (Continued) body due to fore and aft movement of the suspension a DRB scan tool to detect and verify premature ABS as brake pressures are modulated. cycling. At the end of an ABS stop, ABS is turned off when Check the following common causes when diagnos- the vehicle is slowed to a speed of 3–4 mph.
Page 164 BRAKES 5 - 57 DESCRIPTION AND OPERATION (Continued) CONTROLLER ANTILOCK BRAKE (CAB) DESCRIPTION The controller antilock brake (CAB) is a micropro- cessor-based device which monitors the ABS system during normal braking and controls it when the vehi- cle is in an ABS stop. The CAB is mounted to the bottom of the HCU (Fig.
Page 165 5 - 58 BRAKES DESCRIPTION AND OPERATION (Continued) memory. These DTC’s will remain in the CAB mem- ory even after the ignition has been turned off. The DTC’s can be read and cleared from the CAB mem- ory by a technician using the DRB scan tool. If not cleared with a DRB scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen...
Page 166 BRAKES 5 - 59 DESCRIPTION AND OPERATION (Continued) common electric motor (Fig. 3). This DC-type motor (approximately 4 seconds). The amber ABS warning is integral to the HCU and is controlled by the CAB. lamp will illuminate when the CAB detects a condi- The pump/motor provides the extra amount of tion that results in the shutdown of ABS function or brake fluid needed during antilock braking.
Page 167 5 - 60 BRAKES DESCRIPTION AND OPERATION (Continued) OPERATION The traction control system monitors wheel speed. During acceleration, if the CAB detects front (drive) wheel slip and the brakes are not applied, the system enters traction control mode. Traction control opera- tion proceeds in the following order: (1) Close the normally open isolator valves.
Page 168 BRAKES 5 - 61 DESCRIPTION AND OPERATION (Continued) Fig. 6 Normal Braking Hydraulic Circuit 1 – OUTLET VALVE 6 – TO RIGHT FRONT WHEEL 2 – PUMP PISTON 7 – NORMALLY OPEN VALVE (OFF) 3 – PUMP MOTOR (OFF) 8 – MASTER CYLINDER PRESSURE 4 –...
Page 169 5 - 62 BRAKES DESCRIPTION AND OPERATION (Continued) Fig. 7 ABS Without Traction Control - ABS Mode Hydraulic Circuit 1 – OUTLET VALVE 8 – NORMALLY OPEN VALVE (MODULATING) 2 – PUMP PISTON 9 – FROM MASTER CYLINDER 3 – PUMP MOTOR (ON) 10 –...
Page 170 BRAKES 5 - 63 DESCRIPTION AND OPERATION (Continued) Fig. 8 ABS With Traction Control - Normal Braking Hydraulic Circuit 1 – OUTLET VALVE 8 – NORMALLY OPEN VALVE (OFF) 2 – PUMP PISTON 9 – NORMALLY OPEN ASR VALVE (OFF) 3 –...
Page 171 5 - 64 BRAKES DIAGNOSIS AND TESTING (Continued) Fig. 9 ABS With Traction Control - ABS Mode Hydraulic Circuit 1 – OUTLET VALVE 9 – NORMALLY OPEN ASR VALVE (OFF) 2 – PUMP PISTON 10 – FROM MASTER CYLINDER 3 – PUMP MOTOR (ON) 11 –...
Page 172 BRAKES 5 - 65 DIAGNOSIS AND TESTING (Continued) Fig. 10 Traction Control Hydraulic Circuit 1 – OUTLET VALVE 10 – FROM MASTER CYLINDER 2 – PUMP PISTON 11 – HYDRAULIC SHUTTLE VALVE 3 – PUMP MOTOR (ON) 12 – CONTROLLED WHEEL PRESSURE 4 –...
Page 173 5 - 66 BRAKES DIAGNOSIS AND TESTING (Continued) to cause the ABS to cycle. Again accelerate the vehi- DRIVE-OFF CYCLE cle past 40 kph (25 mph). Refer to the diagnostic The first time the vehicle is set in motion after an manual for further testing of the antilock brake sys- ignition off/on cycle, the drive-off cycle occurs.
Page 174 BRAKES 5 - 67 DIAGNOSIS AND TESTING (Continued) nosis and testing time. Perform a visual inspection cycled and normal voltage is again detected by the for loose, disconnected, damaged, or misrouted wires CAB, normal ABS operation resumes and the lamp or connectors;...
Page 175 5 - 68 BRAKES DIAGNOSIS AND TESTING (Continued) To test for contamination, put a small amount of (1) Make sure all hydraulic fluid lines are installed drained brake fluid in clear glass jar. If fluid sepa- and properly torqued. rates into layers, there is mineral oil or other fluid (2) Connect the DRB scan tool to the diagnostics contamination of the brake fluid.
Page 176 BRAKES 5 - 69 REMOVAL AND INSTALLATION (Continued) CAUTION: Only the recommended jacking or hoist- (2) Correctly isolate remote ground cable when ser- ing positions for this vehicle are to be used when- vicing vehicle by installing the ground cable insulator on the strut tower ground stud as shown in (Fig.
Page 177 5 - 70 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 15 Brake Tube Fittings Fig. 13 Brake Pedal Holding Tool Installed 1 – CROW FOOT WRENCH 1 – CLUTCH PEDAL (IF EQUIPPED WITH MANUAL TRANSAXLE) 2 – PRIMARY AND SECONDARY BRAKE TUBES FROM MASTER 2 –...
Page 178 BRAKES 5 - 71 REMOVAL AND INSTALLATION (Continued) INSTALLATION (2) Remove the tire and wheel assembly from the vehicle. (1) Install the ICU back in the vehicle and attach (3) Remove bolt securing the speed sensor cable it to its mounting bracket. Tighten the 3 ICU mount- routing bracket (Fig.
Page 179 5 - 72 BRAKES REMOVAL AND INSTALLATION (Continued) (1) Remove the rear seat cushion, and the rear seat back, from the interior of the car. Refer to Seats in the Body section of this manual for the required procedure to be used for this vehicle. (2) Disconnect the wheel speed sensor cable from the wire harness.
Page 180 BRAKES 5 - 73 REMOVAL AND INSTALLATION (Continued) (4) Install wheel and tire assembly on vehicle. Then torque all wheel mounting stud nuts in proper sequence until all nuts are torqued to half specifica- tion. Then repeat tightening sequence to full speci- fied torque of 129 N·m (95 ft.
Page 181 5 - 74 BRAKES WHEEL SPEED SENSOR RESISTANCE SPECIFICATIONS TONE WHEEL RUNOUT FRONT AND REAR: Allowable Resistance ..900 - 1300 ohms FRONT TONE WHEEL: BRAKE FASTENER TORQUE SPECIFICATIONS Maximum Runout ..0.15 mm (0.006 in.) REAR TONE WHEEL: DESCRIPTION TORQUE...
Page 182 2000 LHS, 300M, CONCORDE AND INTREPID BRAKES 5 - 1 BRAKES BASE BRAKE SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DISC BRAKE SHOES (FRONT) ....5 BASE BRAKE SYSTEM .
Page 183 2000 LHS, 300M, CONCORDE AND INTREPID 5 - 2 BRAKES DIAGNOSIS AND TESTING (Continued) (8) Install a Pressure Gauge, Special Tool C-4007-A into each pressure test fitting (Fig. 3). Bleed any air out of the system. This includes bleeding the air from the hose between the pressure test fitting and pres- sure gauge, which is done at the pressure gauge.
Page 184 2000 LHS, 300M, CONCORDE AND INTREPID BRAKES 5 - 3 DIAGNOSIS AND TESTING (Continued) (13) Install the proportioning valve to the rear (16) On vehicles with Antilock Brakes, repeat the brake flex hose. Tighten to a torque of 17 N·m (145 above steps for the other proportioning valve.
Page 185 2000 LHS, 300M, CONCORDE AND INTREPID 5 - 4 BRAKES REMOVAL AND INSTALLATION (Continued) ers (one on each side of the flex hose fitting) that will come off at the same time. (6) If the caliper is not being completely removed...
Page 186 2000 LHS, 300M, CONCORDE AND INTREPID BRAKES 5 - 5 REMOVAL AND INSTALLATION (Continued) DISC BRAKE SHOES (FRONT) NOTE: Before proceeding with this procedure, review SERVICE WARNINGS AND CAUTIONS at the beginning of the REMOVAL AND INSTALLATION section. REMOVAL (1) Remove caliper as described in Front Disc Brake Caliper Removal and Installation, found else- where in this section of this service manual.
Page 187 2000 LHS, 300M, CONCORDE AND INTREPID 5 - 6 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 10 Front Brake Shoe Assembly Identification Fig. 9 Inboard Brake Shoe 1 – INBOARD BRAKE SHOE 1 – PISTON 2 – WEAR INDICATOR 2 – BRAKE SHOE 3 –...
Page 188 2000 LHS, 300M, CONCORDE AND INTREPID BRAKES 5 - 7 SPECIFICATIONS BRAKE FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE BRAKE TUBES: Tube Nuts ....17 N·m (145 in. lbs.) BRAKE HOSE: Caliper Banjo Bolt .
Page 189 2000 LHS, 300M, CONCORDE AND INTREPID 5 - 8 BRAKES SPECIAL TOOLS (Continued) Installer, Dust Boot C-4689 Handle, Universal C-4171 Dial Indicator C-3339...
Page 190 COOLING SYSTEM 7 - 1 COOLING SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION COOLING SYSTEM—FILLING ....19 COOLING SYSTEM ......2 REMOVAL AND INSTALLATION COOLANT .
Page 191 7 - 2 COOLING SYSTEM • When Engine is warm: Thermostat is open, cool- DESCRIPTION AND OPERATION ant flows through the radiator, heater core, coolant bottle and by-pass. COOLING SYSTEM The cooling systems primary purpose is to main- tain engine temperature in a range that will provide DESCRIPTION satisfactory engine performance and emission levels The cooling system consists of an engine cooling...
Page 192 COOLING SYSTEM 7 - 3 DESCRIPTION AND OPERATION (Continued) • Pure Water (1 btu) boils at 100°C (212°F) and COOLANT freezes at 0°C (32°F). • 100 Percent ethylene glycol (.7 btu) can cause an DESCRIPTION engine to run hot, cause detonation, and will freeze at -22°C (-8°F).
Page 193 7 - 4 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) of approximately 95°C (203°F) so they do not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above 102°C (215°F) the coolant temperature is controlled by the radiator, fan, and ambient temperature, not the thermostat.
Page 194 COOLING SYSTEM 7 - 5 DESCRIPTION AND OPERATION (Continued) COOLING SYSTEM FAN DESCRIPTION The cooling system fan module includes two elec- tric motors, a motor support, and a one piece shroud. The module is fastened to the radiator by screws with square nuts and retaining clips (Fig.
Page 195 7 - 6 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) has been stamped on each clamp (Fig. 8). Refer to Hose Clamp Usage Chart for proper size and location of hose clamps. Fig. 9 Hose Clamp Tool 1 – HOSE CLAMP TOOL 6094 2 –...
Page 196 COOLING SYSTEM 7 - 7 DESCRIPTION AND OPERATION (Continued) A spring-loaded vent valve in the center of the cap allows the system to pressurize and depressurize without creating a vacuum. If the valve is stuck open, coolant will escape to the overflow hose. There is also a gasket in the cap to seal to the top of the filler neck.
Page 197 7 - 8 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) OPERATION ENGINE OIL COOLER—2.7L The accessory drive belts provide the link between DESCRIPTION the engine crankshaft and the engine driven accesso- ries. The 2.7L engine (Sales Code EES only) uses an engine oil cooler that is mounted inside the right AUTOMATIC TRANSMISSION OIL COOLER radiator tank (Fig.
Page 198 COOLING SYSTEM 7 - 9 DESCRIPTION AND OPERATION (Continued) Fig. 15 Engine Oil Cooler—2.7L Engine (EES only) 1 – ENGINE OIL COOLER SUPPLY LINE 3 – ENGINE OIL COOLER FITTINGS 2 – RETAINER 4 – ENGINE OIL COOLER RETURN LINE Fig.
Page 199 7 - 10 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 17 Engine Oil Cooler—3.2/3.5L 1 – SUPPLY LINE TO OIL COOLER 6 – NUT 2 – FITTING 7 – RETURN LINE 3 – OIL COOLER PRESSURE CONTROL VALVE 8 – SUPPLY LINE 4 –...
Page 200 COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING COOLING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READING 1. During cold weather operation 1. A normal condition. No correction IS INCONSISTENT (FLUCTUATES, with the heater blower in the high is necessary. CYCLES OR IS ERRATIC).
Page 201 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. System overfilled. 4. Ensure cold coolant level is between MIN and MAX marks on coolant bottle. COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1.
Page 202 COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR CONDITIONER 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean PERFORMANCE (COOLING restricted, obstructed or dirty as necessary. SYSTEM SUSPECTED). (insects, leaves, etc.). 2.
Page 203 7 - 14 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Is cooling fan operating 3. Refer to Cooling System Fan in correctly? the section for diagnosis. Repair as necessary. 4. Has undercoating been applied 4. Clean undercoating as necessary. to any unnecessary component? 5.
Page 204 COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) WATER PUMP DIAGNOSIS RADIATOR FAN CONTROL A quick test to tell whether or not the pump is work- Cooling fan control can be accomplished five ways. ing is to see if the heater warms properly. A defective A pressure transducer on the air conditioning com- pump will not be able to circulate heated coolant pressor discharge line sends a signal to the Power-...
Page 205 7 - 16 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) RADIATOR FAN OPERATION—3.2/3.5L ENGINES INTAKE (CHARGE) AIR ENGINE COOLANT TEMPERATURE TEMPERATURE Engine @ Idle <2 Km/h (1 MPH) A/C Off/On Vehicle Speed High High High Speed 102°C 110°C 99°C (210°F) - 110°C (230°F) 63°C (145°F) if 67°C (153°F)
Page 206 COOLING SYSTEM 7 - 17 DIAGNOSIS AND TESTING (Continued) TESTING SYSTEM FOR LEAKS OPERATION MUST BE RELEASED TO A SAFE PRESSURE POINT. NEVER PERMIT PRESSURE TO With engine not running, wipe the coolant bottle EXCEED 138 kPa (20 psi). neck sealing seat clean. Attach a radiator pressure tester to the coolant If the needle on the dial does not fluctuate, race bottle, as shown in (Fig.
Page 207 7 - 18 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) ACCESSORY DRIVE BELT DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION INSUFFICIENT ACCESSORY 1. Belt too loose. 1. Adjust belt tension. OUTPUT DUE TO BELT SLIPPAGE 2. Belt excessively glazed or worn. 2. Replace and tighten as specified. BELT SQUEAL WHEN 1.
Page 208 COOLING SYSTEM 7 - 19 SERVICE PROCEDURES (Continued) other (green in color) coolants. If this occurs, a reduc- ANT BOTTLE CAP, OR OPEN THE RADIATOR tion in the extended service interval will result. Refer DRAINCOCK, WHEN THE SYSTEM IS HOT AND to LUBRICATION AND MAINTENANCE for service UNDER PRESSURE BECAUSE SERIOUS BURNS schedules.
Page 209 7 - 20 COOLING SYSTEM SERVICE PROCEDURES (Continued) (1) Close radiator drain. Hand tighten only. (2) Attach one end of a 6.35 mm (0.250 in.) ID clear hose that is approximately 1200 mm (48 in.) WARNING: WHEN INSTALLING DRAIN HOSE TO long, to the bleed valve in the outlet housing (Fig.
Page 210 COOLING SYSTEM 7 - 21 SERVICE PROCEDURES (Continued) (8) Close the bleed valve and continue filling sys- tem to the top of the Filling Funnel. (9) Remove clip from overflow hose (Fig. 23). (10) Allow the coolant in Filling Funnel to drain into overflow chamber of the pressure bottle.
Page 211 7 - 22 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) NOTE: It is normal for the water pump to weep a INSTALLATION small amount of coolant from the weep hole (black (1) Clean all sealing surfaces. stain at weep passage). Do not replace the water (2) Install water pump and gasket.
Page 212 COOLING SYSTEM 7 - 23 REMOVAL AND INSTALLATION (Continued) WATER OUTLET CONNECTOR—2.7L REMOVAL WARNING: DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. (1) Drain cooling system. Refer to procedure in this section.
Page 213 7 - 24 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (4) Lubricate O-ring and insert heater tube assem- bly into outlet connector. Tighten screws to 3 N·m (30 in. lbs.). (5) Install upper intake manifold. Refer ENGINE for procedure. (6) Fill cooling system. Refer to Cooling System Filling in this section.
Page 214 COOLING SYSTEM 7 - 25 REMOVAL AND INSTALLATION (Continued) (5) Remove generator attaching bolts. Set genera- tor aside for ease of access to thermostat. (6) Remove lower radiator and heater hoses from thermostat housing. (7) Remove thermostat housing bolts (Fig. 30). (8) Remove thermostat and housing.
Page 215 7 - 26 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) THERMOSTAT—3.2/3.5L (7) Refill cooling system. Refer to Cooling System Refilling in this section. REMOVAL RADIATOR WARNING: DO NOT REMOVE PRESSURE CAP REMOVAL WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN NOTE: It is not necessary to discharge air condi- OCCUR.
Page 216 COOLING SYSTEM 7 - 27 REMOVAL AND INSTALLATION (Continued) (12) Radiator can now be lifted free from engine compartment. Care should be taken not to dam- age radiator cooling fins or water tubes during removal. INSTALLATION (1) Slide radiator down into position; seat the radi- ator assembly lower rubber isolators in the mounting holes provided in lower radiator support (Fig.
Page 217 7 - 28 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install fan module. (2) Install mounting clips and fasteners. (3) Connect fan module electrical connector. (4) Install upper radiator crossmember. Refer to BODY for procedure. TRANSMISSION OIL COOLER—EXTERNAL REMOVAL (1) Remove A/C condenser.
Page 218 COOLING SYSTEM 7 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 37 Transmission Oil Cooler Lines 1 – RADIATOR 4 – TRANSMISSION OIL RETURN LINE 2 – TRANSMISSION OIL COOLER SUPPLY LINE TO IN-TANK 5 – FROM TORQUE CONVERTER TO IN-TANK OIL COOLER COOLER 6 –...
Page 219 7 - 30 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 38 Engine Oil Cooler—2.7L (EES only) 1 – ENGINE OIL COOLER SUPPLY LINE 3 – ENGINE OIL COOLER FITTINGS 2 – RETAINER 4 – ENGINE OIL COOLER RETURN LINE Fig. 39 Engine Oil Cooler Line Installation—2.7L (EES only) 1 –...
Page 220 COOLING SYSTEM 7 - 31 REMOVAL AND INSTALLATION (Continued) (2) Installation of NEW cooler lines: ENGINE OIL COOLER—3.2/3.5L ENGINE (a) Install new line fittings to engine block and oil pan (Fig. 39). Tighten fittings to 30 N·m (260 in. REMOVAL lbs.).
Page 221 7 - 32 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION INSTALLATION (1) Thoroughly clean cylinder block heater cavity. ENGINE OIL COOLER (2) Insert heater assembly into block such that (1) Install radiator assembly. Tighten lines to radi- mounting hole is located below heater terminals. ator fittings to 18 N·m (160 in.
Page 222 COOLING SYSTEM 7 - 33 REMOVAL AND INSTALLATION (Continued) (10) Tighten tensioner locking bolt and pivot bolt to 28 N·m (250 in. lbs.) (Fig. 42). (11) Install generator/power steering belt. Fig. 43 Air Conditioning Belt Tensioner Spring Position 1 – TENSIONER 2 –...
Page 223 7 - 34 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (7) Using a 1/2” drive breaker bar, apply counter- clockwise pressure until locking bolt can be installed. (8) Install the USED belt by rotating tensioner counterclockwise until belt can be installed on pul- leys.
Page 224 COOLING SYSTEM 7 - 35 REMOVAL AND INSTALLATION (Continued) specifications. Torque pulley nut to 54 N·m (40 ft. lbs.) after adjustment. BELT TENSION CHART—3.2/3.5L POLY-V BELT GAUGE Generator/Power New Belt: 836 44 N Steering Belt (190 10 lbs.) Used Belt: 534 N (120 lbs.) V-BELT GAUGE Air Conditioning Belt...
Page 225 7 - 36 COOLING SYSTEM CLEANING AND INSPECTION (Continued) Fig. 47 Water Pump Weep Passage—2.7L Engine 1 – THERMOSTAT HOUSING/COOLANT INLET 2 – WATER PUMP WEEP PASSAGE Fig. 48 Drive Belt Inspection 1 – NORMAL CRACKS BELT OK INSPECTION 2 – NOT NORMAL CRACKS REPLACE BELT Satisfactory performance of the belt driven accesso- ries depends on belt condition and proper belt ten- sion.
Page 226 COOLING SYSTEM 7 - 37 CLEANING AND INSPECTION (Continued) There is no need to remove the pressure cap at any (2) Connect a suitable cooling system flusher and time except for the following purposes: follow instructions supplied with flusher. • Checking and adjust antifreeze freeze point. •...
Page 227 7 - 38 COOLING SYSTEM SPECIFICATIONS SPECIAL TOOLS COOLING SYSTEM CAPACITY COOLING ENGINE CAPACITY 2.7/3.2/3.5L 8.9 LITERS 9.4 QTS. CAPACITY: Includes heater and coolant pressure bottle. Most service refills are about 80 percent of capacity listed. This is because not all coolant is drained from the cooling system.
Page 228 BATTERY 8A - 1 BATTERY TABLE OF CONTENTS page page DESCRIPTION AND OPERATION BATTERY OPEN CIRCUIT VOLTAGE TEST ..7 BATTERY....... . 1 SERVICE PROCEDURES BATTERY CHARGER CAPACITY .
Page 229 8A - 2 BATTERY DESCRIPTION AND OPERATION (Continued) required for low-maintenance batteries that is not oxide, and the water back into sulfuric acid. This required on maintenance-free (sealed) batteries. action restores the difference in the electron charges deposited on the plates, and the voltage potential of NOTE: Vehicles using a Maintenance-Free battery, the battery cells.
Page 230 BATTERY 8A - 3 DESCRIPTION AND OPERATION (Continued) BATTERY STATE OF CHARGE BATTERY TEMPERATURE DESCRIPTION DESCRIPTION A longer time will be needed to charge a battery at -18°C (0°F) than at 27°C (80°F). OPERATION When a fast charger is connected to a cold battery, current accepted by battery will be very low at first.
Page 231 8A - 4 BATTERY DESCRIPTION AND OPERATION (Continued) SIZE OF BATTERY DESCRIPTION A completely discharged large heavy-duty battery may require more recharging time than a completely discharged small capacity battery. OPERATION Refer to Battery Charging Timetable. DIAGNOSIS AND TESTING BATTERY BUILT-IN TEST INDICATOR TEST INDICATOR Fig.
Page 232 BATTERY 8A - 5 DIAGNOSIS AND TESTING (Continued) STEPS POSSIBLE CAUSE CORRECTION TEST INDICATOR (1) GREEN (1) BATTERY IS CHARGED. CHECK CHARGE EYE COLOR (2) BLACK PERFORM BATTERY 0PEN (3) CLEAR CIRCUIT VOLTAGE TEST (2) PERFORM BATTERY CHARGING PROCEDURE. (3) REPLACE BATTERY. BATTERY OPEN CIRCUIT (1) BATTERY IS ABOVE 12.40 (1) PERFORM THE BATTERY LOAD...
Page 233 8A - 6 BATTERY DIAGNOSIS AND TESTING (Continued) (3) Using an multi-meter, that has least a milliam- (1) Remove battery from vehicle. The battery top, pere range of 200 mA. Set meter to the highest mA cables and posts should be clean. If green dot is not range.
Page 234 BATTERY 8A - 7 DIAGNOSIS AND TESTING (Continued) Carbon pile rheostat to apply a 300 amp load. Apply this load for 15 seconds to remove the surface charge from the battery, and return the control knob to off (Fig. 7). (3) Allow the battery to stabilize for 2 minutes, and then verify the open circuit voltage (Fig.
Page 235 8A - 8 BATTERY SERVICE PROCEDURES (Continued) CAUTION: Disconnect the NEGATIVE battery cable BATTERY CHARGING RATE remote terminal first before charging battery to avoid damage to electrical systems. Do not exceed VOLTAGE HOURS 16.0 volts while charging battery. Refer to the 16.0 VOLTS OR MORE UP TO 4 HOURS instructions supplied with charging equipment...
Page 236 BATTERY 8A - 9 SERVICE PROCEDURES (Continued) Fig. 11 Cleaning Battery Fig. 12 Cleaning Battery Post 1 – BATTERY 1 – BATTERY 2 – CLEANING BRUSH 2 – TEST INDICATOR 3 – TEST INDICATOR 3 – BATTERY POST CLEANER 4 – WARM WATER AND BAKING SODA SOLUTION 4 –...
Page 237 8A - 10 BATTERY REMOVAL AND INSTALLATION SAFETY PRECAUTIONS AND WARNINGS WARNING: WEAR SAFETY GLASSES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT.
Page 238 BATTERY 8A - 11 SPECIFICATIONS (Continued) RESERVE CAPACITY RATING TORQUE The length of time a battery can deliver 25 amps and maintain a minimum terminal voltage of 10.5 DESCRIPTION TORQUE volts at 27°C (80°F). Battery Hold Down Clamp Bolt ..14 N·m (125 in.
Page 240 STARTING SYSTEMS 8B - 1 STARTING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION FEED CIRCUIT RESISTANCE TEST... . 3 STARTING SYSTEM ..... . . 1 FEED CIRCUIT TEST.
Page 241 8B - 2 STARTING SYSTEMS DESCRIPTION AND OPERATION (Continued) DIAGNOSIS AND TESTING CONTROL CIRCUIT TEST The starter control circuit has: • Starter motor with integral solenoid • Starter relay • Transmission range sensor, or Park/Neutral Position switch with automatic transmissions •...
Page 242 STARTING SYSTEMS 8B - 3 DIAGNOSIS AND TESTING (Continued) STARTER RELAY (3) The relay normally open terminal (87) is con- nected to the common feed terminal (30) in the ener- gized position. This terminal supplies battery voltage WARNING: CHECK TO ENSURE THAT THE TRANS- MISSION IS IN THE PARK/NEUTRAL POSITION to the starter solenoid field coils.
Page 243 8B - 4 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) (1) To disable the Ignition and Fuel systems, dis- connect the Automatic Shutdown Relay (ASD). The ASD relay is located in the Power Distribution Cen- ter (PDC). Refer to the PDC cover for proper relay location.
Page 244 STARTING SYSTEMS 8B - 5 DIAGNOSIS AND TESTING (Continued) • WARNING: ON VEHICLES EQUIPPED WITH AIR- Transmission Range Sensor - Visually BAGS, REFER GROUP PASSIVE inspect the transmission range sensor for indications of physical damage and loose or corroded wire har- RESTRAINT SYSTEMS BEFORE...
Page 245 8B - 6 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION STARTER 1. BATTERY 1. REFER TO GROUP 8A, BATTERY. CHARGE OR REPLACE ENGAGES, DISCHARGED OR BATTERY AS NECESSARY. FAILS TO TURN FAULTY. 2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND ENGINE.
Page 246 STARTING SYSTEMS 8B - 7 REMOVAL AND INSTALLATION (Continued) Reconnect posi-lock connector right after starter is placed into position. STARTER RELAY The relay is located in the Power Distribution Cen- ter (PDC). Refer to the PDC cover for relay location. SPECIFICATIONS STARTER MANUFACTURER NIPPONDENSO...
Page 248 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION GENERATOR—3.2/3.5L ....2 CHARGING SYSTEM OPERATION ... . 1 SPECIFICATIONS GENERATOR .
Page 249 8C - 2 CHARGING SYSTEM 2000 LH Service Manual DESCRIPTION AND OPERATION (Continued) Publication No. 81-270-0040 TSB 26-12-99 December, 1999 Noise emitting from the generator may be caused (11) Remove pivot bolt, being careful not to lose spacer. • Worn, loose or defective bearings (12) Remove generator.
Page 250 CHARGING SYSTEM 8C - 3 GENERATOR SPECIFICATIONS Type Engine Minimun Test TORQUE Amperage Denso 2.7 L 105 Amp DESCRIPTION TORQUE Battery Terminal Nut ..10 N·m (90 in. lbs.) Melco 3.2/3.5 L 110 Amp Battery Hold Down Clamp Bolt .
Page 252 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION AUTOMATIC SHUTDOWN RELAY... . . 6 IGNITION SYSTEM ......1 CAMSHAFT POSITION SENSOR—2.7L .
Page 253 8D - 2 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 1 Platinum Pads 1 – APPLY ANTI-SEIZE COMPOUND HERE ONLY 2 – PLATINUM SPARK SURFACE Fig. 3 3.2/3.5L Coil The coil’s low primary resistance (0.4 - 0.6 ohm) the coil, boot, and fasteners is known as the ignition allows the PCM to fully charge the coil for each fir- coil assembly.
Page 254 IGNITION SYSTEM 8D - 3 DESCRIPTION AND OPERATION (Continued) other inputs, to determine injector sequence and igni- tion timing. The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Two sets contain 4 slots and one set contains 5 slots, for a total of 13 slots (Fig.
Page 255 8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) pulses generated by the notches on the camshaft sprocket. Crankshaft pulses follow each group of camshaft pulses. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage spikes high (5.0 volts).
Page 256 IGNITION SYSTEM 8D - 5 DESCRIPTION AND OPERATION (Continued) KNOCK SENSOR OPERATION The ignition key rotates the cylinder to 5 different DESCRIPTION detents (Fig. 12) : • Accessory The knock sensor threads into the cylinder block. • Off (lock) The knock sensor is designed to detect engine vibra- •...
Page 257 8D - 6 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (5) Remove the spark plug using a quality socket with a rubber or foam insert. (6) Inspect the spark plug condition. INSTALLATION (1) To avoid cross threading, start the spark plug into the cylinder head by hand.
Page 258 IGNITION SYSTEM 8D - 7 REMOVAL AND INSTALLATION (Continued) (1) Install sensor in the timing belt housing and push sensor down until contact is made with the camshaft sprocket. While holding the sensor in this position, install and tighten the retaining bolt to 12 N·m (105 in.
Page 259 8D - 8 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) REMOVAL INSTALLATION (1) Remove intake manifold plenum and intake (1) Install knock sensor. Tighten bolt to 10 N·m (7 manifold. Refer to the Engine section. ft. lbs.) torque. Over or under tightening affects (2) For the 2.7 L engine remove the right cylinder knock sensor performance, possibly causing head.
Page 260 IGNITION SYSTEM 8D - 9 REMOVAL AND INSTALLATION (Continued) Fig. 23 Ignition Switch Removal/Installation 1 – STEERING COLUMN 2 – IGNITION SWITCH Fig. 21 Ignition Coil Capacitor 1 – IGNITION COIL CAPACITOR INSTALLATION (1) A tab on the ignition switch indexes to a notch in the lock cylinder housing (Fig.
Page 261 8D - 10 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 24 Ignition Switch Alignment Fig. 26 Lock Cylinder Removal 1 – IGNITION SWITCH 1 – TAB 2 – TAB 2 – KEY IN RUN POSITION 3 – NOTCH 4 – SHAFT (2) The shaft at the end of the lock cylinder aligns with the socket in the end of the housing.
Page 262 IGNITION SYSTEM 8D - 11 REMOVAL AND INSTALLATION (Continued) (7) Install tilt lever. (8) Connect negative cable to battery. SPECIFICATIONS TORQUE Description Torque 2.7L Camshaft Position Sensor Screw ..12 N·m (105 in. lbs.) 3.2/3.5L Camshaft Position Sensor Screw . . 12 N·m (105 in.
Page 264 INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CLUSTER MASK/LENS ....12 CIGAR LIGHTER/POWER OUTLET .
Page 265 8E - 2 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) • Turn signals ELECTRO–MECHANICAL INSTRUMENT • Door Ajar CLUSTER • Decklid Ajar • ABS (optional) DESCRIPTION • Traction Control Active (optional) The mechanical instrument cluster is an electro- • Traction Control Off (optional) mechanical module which receives most of its infor- •...
Page 266 INSTRUMENT PANEL SYSTEMS 8E - 3 DIAGNOSIS AND TESTING (Continued) HEADLAMP SWITCH RESISTANCE SERVICE PROCEDURES CIGAR LIGHTER/POWER OUTLET CUSTOMER POSITION TERMINALS RESISTANCE VALUES PREFERENCE This vehicle was delivered with the Cigar Lighter/ 6 & 12 3600 - 5400 Power Outlet activated only when the ignition is ON. PARK LAMP 6 &...
Page 267 8E - 4 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION ATC IN-CAR TEMPERATURE SENSOR The In-car Temperature Sensor is part of the ATC Control Head and not a separate service part. If defective, the complete ATC head must be replaced. Fig. 6 ATC In-Car Temperature Sensor Fig.
Page 268 INSTRUMENT PANEL SYSTEMS 8E - 5 REMOVAL AND INSTALLATION (Continued) Fig. 8 Instrument Panel Components – Intrepid...
Page 269 8E - 6 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) 1 – SPEAKER, INSTRUMENT PANEL CENTER 12 – SWITCH HEADLAMP 2 – INSTRUMENT PANEL ASSEMBLY 13 – LOUVER, AIR OUTLET 3 – BEZEL, INSTRUMENT PANEL END CAP 14 – COVER, INSTRUMENT PANEL CENTER SUPPORT/BIN (6 PASS.
Page 270 INSTRUMENT PANEL SYSTEMS 8E - 7 REMOVAL AND INSTALLATION (Continued) Fig. 9 Instrument Panel Components – Concorde...
Page 271 8E - 8 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) 1 – SPEAKER, INSTRUMENT PANEL CENTER 11 – SWITCH, HEADLAMP 2 – COVER, UPPER INSTRUMENT PANEL 12 – LOUVER, AIR OUTLET 3 – INSTRUMENT PANEL ASSEMBLY 13 – COVER, INSTRUMENT PANEL CENTER SUPPORT/BIN (6 PASS.
Page 272 INSTRUMENT PANEL SYSTEMS 8E - 9 REMOVAL AND INSTALLATION (Continued) Fig. 10 Instrument Panel Components – LHS/300M...
Page 273 8E - 10 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) 1 – BEZEL, INSTRUMENT PANEL END CAP 9 – BEZEL, INSTRUMENT PANEL TRIM-CENTER 2 – COVER, UPPER INSTRUMENT PANEL 10 – BEZEL, INSTRUMENT PANEL AIR DISTRIBUTION OUTLET 3 – LOUVER, AIR OUTLET 11 –...
Page 274 INSTRUMENT PANEL SYSTEMS 8E - 11 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o’clock to the key in the instrument panel.
Page 275 8E - 12 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) Cluster and Bezel Removal and Installation in this section. Refer to (Fig. 14), (Fig. 15), and (Fig. 16) for cluster lamp locations. The lamps that are replaceable are called out on the back cover of the instrument cluster.
Page 276 INSTRUMENT PANEL SYSTEMS 8E - 13 REMOVAL AND INSTALLATION (Continued) (4) Unsnap seven retaining tabs holding mask/lens (5) Remove two retaining screws to cubby bin and to cluster housing (Fig. 18). remove. INSTALLATION For installation, reverse the above procedures DECKLID RELEASE SWITCH REMOVE (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post...
Page 277 8E - 14 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Open the glove box door, and pull out the glove (3) Remove the instrument panel center trim bezel box lamp/switch assembly from upper right hand cor- and remove the two electrical connectors from the ner of opening (Fig.
Page 278 INSTRUMENT PANEL SYSTEMS 8E - 15 REMOVAL AND INSTALLATION (Continued) INSTRUMENT PANEL AND PAD ASSEMBLY (6) On six passenger vehicles, remove the lower floor bin and proceed with Step 12. (7) On five passenger vehicles, use trim stick to REMOVAL gently remove center bezel.
Page 279 8E - 16 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (24) Disconnect the left side harness connectors to NOTE: The traction control switch, HVAC control junction block and Body Control Module (BCM). head and cigar lighter/auxiliary power outlet must (25) Remove eight remaining instrument panel be transferred to new bezel if being replaced.
Page 280 INSTRUMENT PANEL SYSTEMS 8E - 17 REMOVAL AND INSTALLATION (Continued) (5) Remove cluster mask/lens from instrument (3) Remove five cluster back cover retaining cluster. Refer to Mask/Lens Removal and Installation screws and remove the cover. in this section. (4) Remove nine screws to Printed Circuit Board (6) Remove two screws to Vacuum Fluorescent and remove.
Page 282 2000 LHS, 300M, CONCORDE AND INTREPID INSTRUMENT PANEL AND SYSTEMS 8E - 1 INSTRUMENT PANEL AND SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION INSTRUMENT CLUSTER....2 HEADLAMP LEVELING SYSTEM .
Page 283 2000 LHS, 300M, CONCORDE AND INTREPID 8E - 2 INSTRUMENT PANEL AND SYSTEMS DESCRIPTION AND OPERATION (Continued) INSTRUMENT CLUSTER Fig. 3 Electro - Mechanical Instrument Cluster The instrument cluster used on LH vehicles is an electro - mechanical module which receives most of its information via the Programable Communication Interface (PCI) bus.
Page 284 2000 LHS, 300M, CONCORDE AND INTREPID INSTRUMENT PANEL AND SYSTEMS 8E - 3 REMOVAL AND INSTALLATION (Continued) (6) Open the glove box door and remove the four (10) Connect the remote negative battery cable. screws retaining the instrument panel upper right (11) Verify switch operation.
Page 285 2000 LHS, 300M, CONCORDE AND INTREPID...
Page 286 AUDIO SYSTEMS 8F - 1 AUDIO SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION FIXED MAST ANTENNA (INTREPID ONLY) ..17 AUDIO SYSTEMS ......1 4 DISC IN-DASH CD CHANGER .
Page 287 8F - 2 AUDIO SYSTEMS DESCRIPTION AND OPERATION (Continued) OPERATION OPERATION For operation of the factory installed standard and Capacitors are mounted in various locations inter- optional radios with cassette or compact disc player, nal to the generator, instrument cluster and wind- refer to the Sound Systems Operating Instructions in shield wiper motor.
Page 288 AUDIO SYSTEMS 8F - 3 DESCRIPTION AND OPERATION (Continued) REMOTE AMPLIFIER DESCRIPTION MIDLINE AND INFINITY l SYSTEM Fig. 3 Infinity ll Remote Amplifier Location Fig. 2 Midline/InfinitylRemote Amplifier Location 1 – RIGHT DECKLID SUPPORT 1 – HVAC UNIT 2 – RETAINING SCREWS 2 –...
Page 289 8F - 4 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) BASE 4 SPEAKER SYSTEM...
Page 290 AUDIO SYSTEMS 8F - 5 DIAGNOSIS AND TESTING (Continued) BASE 4 SPEAKER SYSTEM CONTINUED...
Page 291 8F - 6 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) BASE 4 SPEAKER SYSTEM CONTINUED...
Page 292 AUDIO SYSTEMS 8F - 7 DIAGNOSIS AND TESTING (Continued) BASE 4 SPEAKER SYSTEM CONTINUED...
Page 293 8F - 8 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) AMPLIFIED...
Page 294 AUDIO SYSTEMS 8F - 9 DIAGNOSIS AND TESTING (Continued) AMPLIFIED CONTINUED...
Page 295 8F - 10 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) AMPLIFIED CONTINUED...
Page 296 AUDIO SYSTEMS 8F - 11 DIAGNOSIS AND TESTING (Continued) AMPLIFIED CONTINUED...
Page 297 8F - 12 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) AMPLIFIED CONTINUED...
Page 298 AUDIO SYSTEMS 8F - 13 DIAGNOSIS AND TESTING (Continued) AMPLIFIED CONTINUED...
Page 299 8F - 14 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) With the use of the DRB III scan tool, you may read the CD changer fault codes. Refer to the CD Changer Fault Codes table. CD CHANGER FAULT CODES FAULT DESCRIPTION CD CHANGER MECHANICAL MAGAZINE LOAD/EJECT FAILURE, ELEVATOR UP/DOWN FAILURE, FAILURE...
Page 300 AUDIO SYSTEMS 8F - 15 DIAGNOSIS AND TESTING (Continued) • Remove speaker that is still connected and lis- DIAGNOSTIC CONDITIONS ten for distortion. If distortion remains, replace speaker. NOISE DISTORTION IN ALL SPEAKERS Does the distortion occur through all operations: ONE SPEAKER NON-OPERATIVE •...
Page 301 8F - 16 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) Refer to Group 8N, Electrically Heated Systems. Any (2) Check for proper radio coaxial cable connec- repairs to either the AM or FM grid should be pre- tions at the radio and rear window antenna module. formed as in Group 8N, Electrically Heated Systems, If not OK, repair as necessary.
Page 302 AUDIO SYSTEMS 8F - 17 REMOVAL AND INSTALLATION FRONT DOOR SPEAKERS CAUTION: Do not operate the radio with speaker leads detached. Damage to the output devices may result. REMOVAL - 6.5 INCH LOWER DOOR MOUNTED SPEAKERS (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post (Fig.
Page 303 8F - 18 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) 4 DISC IN-DASH CD CHANGER REAR DOOR SPEAKERS (INFINITY ll) REMOVAL REMOVAL (1) Open hood and disconnect the negative battery (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post. cable remote terminal from the remote battery post (2) Remove ash receiver (if applicable).
Page 304 AUDIO SYSTEMS 8F - 19 REMOVAL AND INSTALLATION (Continued) INSTALLATION (2) Remove right under panel silencer/duct. Refer to Group 8E, Instrument Panel and Systems for For installation, reverse the above procedures. Be Removal and Installation procedures. sure that the wire connectors are facing forward in (3) Remove two retaining nuts to remote amplifier.
Page 306 HORN SYSTEMS 8G - 1 HORN SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SYSTEM TEST ......2 HORN SYSTEM.
Page 307 8G - 2 HORN SYSTEMS DIAGNOSIS AND TESTING (Continued) Fig. 3 Horn Switch Test Locations 1 – HORN SWITCH CONNECTOR 3 – INSIDE CONNECTOR 2 – DO NOT REMOVE NUTS (6) If no ground, repair as necessary. (a) Terminal 11 and 13 test for battery voltage (7) If wires test OK and horn(s) does not sound, from fuse F30.
Page 308 HORN SYSTEMS 8G - 3 DIAGNOSIS AND TESTING (Continued) HORN SYSTEM TEST CONDITION POSSIBLE CAUSE CORRECTION HORN SOUNDS 1. FAULTY HORN RELAY. 1. REFER TO HORN RELAY TEST. CONTINUOUSLY. 2. HORN CONTROL CIRCUIT 2. CHECK HORN RELAY TERMINAL 7 IN NOTE: IMMEDIATELY TO RELAY SHORTED TO JUNCTION BLOCK FOR CONTINUITY TO...
Page 309 8G - 4 HORN SYSTEMS REMOVAL REMOVAL AND INSTALLATION The Horn Switch is an intregal part of the Driver HORN Airbag Module and if defective, the Driver Airbag Module must replaced. REMOVAL (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post (1) Open hood and disconnect the negative battery (Fig.
Page 310 VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION ROAD TEST ......4 SPEED CONTROL SYSTEM .
Page 311 8H - 2 VEHICLE SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) • Excessive engine rpm (indicates that the trans- the solenoid closes and no more vacuum is allowed to mission may be in a low gear) enter the servo. The PCM also operates the vent sole- •...
Page 312 VEHICLE SPEED CONTROL SYSTEM 8H - 3 DESCRIPTION AND OPERATION (Continued) OPERATION tive speed control is not engaged and power- train loading is not reduced, the driver may If opening the throttle alone cannot maintain the have to completely lift off of the throttle before set speed and the vehicle speed drops more than an upshift will occur.
Page 313 8H - 4 VEHICLE SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) brake lamp switch service and adjustment proce- USE THE DRB SCAN TOOL TO REPROGRAM dures. THE NEW PCM WITH THE VEHICLES ORIGI- The brake switch is equipped with three sets of NAL IDENTIFICATION NUMBER (VIN) AND contacts, one normally open and the other two nor- THE VEHICLES ORIGINAL MILEAGE.
Page 314 VEHICLE SPEED CONTROL SYSTEM 8H - 5 DESCRIPTION AND OPERATION (Continued) be corrected before proceeding. Refer to the Instru- (3) Disconnect electrical connectors and vacuum ment Panel and Gauges for speedometer diagnosis. hose. If a road test verifies a surge following a set and (4) Remove two nuts attaching speed control cable the speedometer operates properly see “Overshoot/ and mounting bracket to servo.
Page 315 8H - 6 VEHICLE SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) (5) Disconnect electrical connectors and vacuum (4) Remove the throttle cable (with retaining tab) hose. and then slide cable speed control cable out from (6) Remove two nuts attaching speed control cable bracket.
Page 316 VEHICLE SPEED CONTROL SYSTEM 8H - 7 SPECIFICATIONS TORQUE DESCRIPTION TORQUE Vacuum Resevoir Screws ..12 N·m (8.8 ft. lbs.) Servo Mounting Bracket Nuts ... 14 N·m (10.3 ft.
Page 318 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1 TURN SIGNAL AND HAZARD WARNING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION COMBINATION FLASHER ....1 COMBINATION FLASHER .
Page 319 8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) MULTI-FUNCTION SWITCH OPERATION When the driver wishes to signal his intentions to WARNING: ON VEHICLES EQUIPPED WITH AIR- change direction of travel, he moves the lever upward BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR to cause the right signals to flash and downward to AIRBAG REMOVAL PROCEDURES.
Page 320 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3 DIAGNOSIS AND TESTING (Continued) COMBINATION FLASHER DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION SYSTEM DOES NOT FLASH 1. FAULTY EXTERNAL 1. REPLACE LAMP. ON ONE SIDE, INDICATOR LAMP. 2. CHECK AND/OR REPLACE WIRING. LAMP FLASHES AT DOUBLE 2.
Page 321 8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION SYSTEM DOES NOT 1. BROKEN CANCELLING 1. REPLACE MULTI-FUNCTION SWITCH. CANCEL AFTER FINGER ON SWITCH. 2. REPLACE CLOCKSPRING. COMPLETION OF TURN 2. BROKEN OR MISSING 3.
Page 322 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5 MULTI-FUNCTION SWITCH REMOVAL AND INSTALLATION COMBINATION FLASHER REMOVAL (1) Open hood and disconnect the negative battery REMOVAL cable remote terminal from the remote battery post. (2) Remove tilt lever. (1) Open hood and disconnect the negative battery (3) Remove both upper and lower steering column cable remote terminal from the remote battery post shrouds.
Page 324 WIPER AND WASHER SYSTEMS 8K - 1 WIPER AND WASHER SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION WASHER RESERVOIR ....14 WINDSHIELD WIPER SYSTEM .
Page 325 8K - 2 WIPER AND WASHER SYSTEMS DESCRIPTION AND OPERATION (Continued) The wiper system completes the wipe cycle when Fluid is gravity fed from the reservoir to the motor. the switch is turned OFF. The blades park in the The fluid is forced by the pump through rubber hoses lowest portion of the wipe pattern.
Page 326 WIPER AND WASHER SYSTEMS 8K - 3 DIAGNOSIS AND TESTING (Continued) Fig. 5 Multi-Function/Wiper Switch Pin Call-Out WINDSHIELD WIPER/WASHER SWITCH RESISTANCE TEST SWITCH TERMINALS RESISTANCE POSITION VALUE PINS 1 T0 3 OPEN > 300 K OHMS Fig. 3 Body Control Module Location PINS 1 TO 3 9.72 K OHMS 1 –...
Page 327 8K - 4 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) WINDSHIELD WASHER TEST CONDITION POSSIBLE CAUSE CORRECTION WASHER POWER FEED 1. JUNCTION BLOCK FUSE CHECK FUSE #5. REPLACE IF NOT OK. FUSE OPEN #5 BLOWN. BLOWN FUSE WHEN 1. SHORT IN WIPER / 1.
Page 328 WIPER AND WASHER SYSTEMS 8K - 5 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION HOOD NOZZLE WILL NOT 1. FROZEN NOZZLE. DEICE NOZZLE BY ALLOWING TIME FOR FLOW 2. NOZZLE HOSE NOT UNDERHOOD ENGINE HEAT TO THAW FLOWING. NOZZLE. IF NOT OK, MOVE VEHICLE INTO 3.
Page 329 8K - 6 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION WASHER FLUID LEVEL 1. LOOSE FLUID LEVEL 1. PROPERLY SEAT CONNECTOR TO SWITCH. INDICATOR INOPERATIVE SENSOR CONNECTOR. 2. OPEN OR DEFECTIVE CIRCUIT BETWEEN 2. OPEN POWER CIRCUIT INSTRUMENT CLUSTER CONNECTOR TO SWITCH.
Page 330 WIPER AND WASHER SYSTEMS 8K - 7 DIAGNOSIS AND TESTING (Continued) relay. If OK, check for faulty relays and go to Step 8. (2) If motor will not run on low speed, connect a If not repair as necessary. jumper wire between battery positive jump start ter- (8) Disconnect the C3 bone 12-way connector from minal and Pin 2 on the wiper motor connector.
Page 331 8K - 8 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) (5) Refer to MOTOR RUNS SLOWLY AT ALL (2) Using an ohmmeter, with the wiper motor in SPEEDS. the PARK position, check for continuity between Pin 5 and Pin 4 on the wiper motor connector. If contin- MOTOR WILL KEEP RUNNING WITH SWITCH IN uous continuity, go to Step 3.
Page 332 WIPER AND WASHER SYSTEMS 8K - 9 DIAGNOSIS AND TESTING (Continued) WIPER MOTOR TEST CONDITION POSSIBLE CAUSE CORRECTION WIPER OPERATES IN LOW 1. HI / LO RELAY 1. CHECK HI / LO RELAY WITH KNOWN GOOD SPEED OR INTERMITTENT DEFECTIVE. RELAY.
Page 333 8K - 10 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION WIPER WILL NOT PARK 1. OPEN WIPER MOTOR 1. OPEN OR DEFECTIVE CIRCUIT BETWEEN PARK CIRCUIT. WIPER MOTOR CONNECTOR TERMINAL #4 2. DEFECTIVE BCM. AND BCM TERMINAL #3C. IF NOT OK, REPAIR 3.
Page 334 WIPER AND WASHER SYSTEMS 8K - 11 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION WIPER SYSTEM WILL NOT 1. PDC FUSE “M” BLOWN. 1. SHORT CIRCUIT BETWEEN PDC FUSE “M” 2. JUNCTION BLOCK FUSE AND ON / OFF RELAY CAVITY A” OR “D” OR #5 BLOWN.
Page 335 8K - 12 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION WIPER SYSTEM MAKES 1. LOOSE ARM TO BLADE 1. INSPECT CONNECTION FOR DAMAGE, REVERSAL NOISE CONNECTION. BENDING, EXCESSIVE WARE. REPLACE ARM 2. LOOSE MASTER LINK. OR BLADE IF NOT OK.
Page 336 WIPER AND WASHER SYSTEMS 8K - 13 REMOVAL AND INSTALLATION (Continued) (3) Remove front fascia as necessary (left side only and use a 2x4 to prop left edge of fascia away from body). Refer to Group 23, Body for Removal and Installation procedures.
Page 337 8K - 14 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) (6) Disconnect hose clips from hood, tower to tower (3) Remove front fascia as necessary (left side only beam, and fender beam. and use a 2x4 to prop left edge of fascia away from (7) Disconnect washer hose from top of reservoir body).
Page 338 WIPER AND WASHER SYSTEMS 8K - 15 REMOVAL AND INSTALLATION (Continued) WASHER RESERVOIR FILLER TUBE REMOVAL (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post. (2) Hoist vehicle. (3) Remove front fascia as necessary (left side only and use a 2x4 to prop left edge of fascia away from body).
Page 339 8K - 16 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Remove front fascia as necessary (left side only and use a 2x4 to prop left edge of fascia away from body). Refer to Group 23, Body for Removal and Installation procedures.
Page 340 WIPER AND WASHER SYSTEMS 8K - 17 REMOVAL AND INSTALLATION (Continued) Fig. 14 Wiper Blade and Element Fig. 16 Wiper Module Retaining Bolts 1 – CLAW 1 – RETAINING BOLTS 2 – TO GRASP AND PULL 2 – WIPER MOTOR CONNECTOR 3 –...
Page 341 8K - 18 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) CAUTION: KEEP HANDS CLEAR OF CYCLING NOTE: When assembling master link or slave link WIPER MODULE LINKAGE. to module frame, use channel locks wrapped in cloth to prevent damage to ball and socket joint. Apply light pressure to assemble socket to ball.
Page 342 WIPER AND WASHER SYSTEMS 8K - 19 into the nozzle ball and adjust the spray pattern on CLEANING AND INSPECTION the windshield as shown in (Fig. 20). The right and left nozzles are identical. WIPER BLADES Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness.
Page 344 2000 LHS, 300M, CONCORDE AND INTREPID WIPER AND WASHER SYSTEMS 8K - 1 WIPER AND WASHER SYSTEMS HEADLAMP WASHERS TABLE OF CONTENTS page page GENERAL INFORMATION WINDSHIELD/HEADLAMP WASHER INTRODUCTION ......1 RESERVOIR FILLER TUBE .
Page 345 2000 LHS, 300M, CONCORDE AND INTREPID 8K - 2 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) WINDSHIELD/HEADLAMP WASHER TEST CONDITION POSSIBLE CAUSE CORRECTION WASHER POWER FEED 1. JUNCTION BLOCK FUSE CHECK FUSE #5. REPLACE IF NOT OK. FUSE OPEN #5 BLOWN.
Page 346 2000 LHS, 300M, CONCORDE AND INTREPID WIPER AND WASHER SYSTEMS 8K - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION WASHER FLUID LEVEL 1. LOOSE FLUID LEVEL 1. PROPERLY SEAT CONNECTOR TO SWITCH. INDICATOR INOPERATIVE SENSOR CONNECTOR. 2. ASSURE SENSOR FLOAT SWITCH IS CLOSED 2.
Page 347 2000 LHS, 300M, CONCORDE AND INTREPID 8K - 4 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION WINDSHIELD/HEADLAMP WASHER RESERVOIR REMOVAL (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post. (2) Hoist vehicle. (3) Drain washer fluid into a clean container.
Page 348 2000 LHS, 300M, CONCORDE AND INTREPID WIPER AND WASHER SYSTEMS 8K - 5 REMOVAL AND INSTALLATION (Continued) (4) Partially remove the front fascia to gain access to the windshield/headlamp washer reservoir. Refer to Group 23, Body for Removal and Installation pro- cedures.
Page 349 2000 LHS, 300M, CONCORDE AND INTREPID 8K - 6 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) HEADLAMP WASHER NOZZLE Removal (1) Hoist vehicle. (2) Partially remove the front fascia to gain access to the headlamp assembly. Refer to Group 13, Body for Removal and Installation procedures.
Page 350 2000 LHS, 300M, CONCORDE AND INTREPID WIPER AND WASHER SYSTEMS 8K - 7 REMOVAL AND INSTALLATION (Continued) HEADLAMP WASHER PUMP Removal (1) Open hood and disconnect the negative battery cable remote terminal from the battery post. (2) Hoist vehicle. (3) Drain washer fluid into a clean container.
Page 351 2000 LHS, 300M, CONCORDE AND INTREPID...
Page 352 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMP DIAGNOSIS ......1 LAMP SERVICE......18 HEADLAMP ALIGNMENT .
Page 353 8L - 2 LAMPS DESCRIPTION AND OPERATION (Continued) lamps based on ambient light levels. Ambient light HEADLAMP SYSTEM levels are monitored by the BCM using the automatic temperature control system Sun load Sensor, located DESCRIPTION on the top of the instrument panel cover. Ambient The headlamp system is controlled completely by light readings are averaged to limit cycling the lamps the Body Control Module (BCM).
Page 354 LAMPS 8L - 3 DESCRIPTION AND OPERATION (Continued) ILLUMINATED ENTRY CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. Do not use bulbs with higher DESCRIPTION candle power than indicated in the Bulb Application The Illuminated Entry System is available on vehi- table at the end of this group.
Page 355 8L - 4 LAMPS DIAGNOSIS AND TESTING (Continued) HEADLAMP SWITCH HIGH-BEAM HEADLAMP SWITCH The headlamp switch is located on the upper left The high beam headlamp switch is part of the side of the instrument panel. Refer to Group 8E, multi-function switch located on the steering column.
Page 356 LAMPS 8L - 5 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS FLASH 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground RANDOMLY locations, refer to Group 8W, Wiring Diagrams. 2. High resistance in headlamp 2. Test amperage draw of headlamp circuit.
Page 357 8L - 6 LAMPS DIAGNOSIS AND TESTING (Continued) FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING OR and posts. IGNITION TURNED OFF. 2.
Page 358 LAMPS 8L - 7 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS DO NOT 1. Blown fuse for fog lamps. 1. Replace fuse, refer to Group 8W, Wiring ILLUMINATE Diagrams. 2. No Z1-ground at fog lamps. 2. Repair circuit ground, refer to Group 8W, Wiring Diagrams.
Page 359 8L - 8 LAMPS HEADLAMP ALIGNMENT TABLE OF CONTENTS page page ADJUSTMENTS HEADLAMP AND FOG LAMP ADJUSTMENT HEADLAMP ALIGNMENT PREPARATION..8 USING ALIGNMENT SCREEN ....8 ADJUSTMENTS ALIGNMENT SCREEN PREPARATION (1) Position vehicle on a level surface perpendicu-...
Page 360 LAMPS 8L - 9 ADJUSTMENTS (Continued) Fig. 1 Headlamp Alignment Screen 1 – LOW BEAM CENTER LINE TO GROUND 4 – PREFERRED CUT OFF LOCATION 2 INS. 2 – FRONT OF HEADLAMP 5 – CENTER OF VEHICLE 3 – 7.26 METERS (25ft.) 6 –...
Page 361 8L - 10 LAMPS ADJUSTMENTS (Continued) Fig. 3 Headlamp Alignment Screws – Intrepid 1 – HORIZONTAL ADJUSTER 2 – VERTICAL ADJUSTER Fig. 5 Fog lamp Adjuster Screw – Intrepid FOG LAMP ALIGNMENT 1 – FOG LAMP Prepare an alignment screen. Refer to Alignment 2 –...
Page 362 LAMPS 8L - 11 ADJUSTMENTS (Continued) Fig. 7 Fog lamp Adjuster Screw – 300M 1 – UP/DOWN ADJUSTER SCREW 2 – FOG LAMP Fig. 6 Fog lamp Adjuster Screw – LHS 1 – UP/DOWN ADJUSTER SCREW 2 – FOG LAMP...
Page 363 8L - 12 LAMPS LAMP BULB SERVICE TABLE OF CONTENTS page page REMOVAL AND INSTALLATION FRONT SIDE MARKER LAMP BULB – LHS ..15 HEADLAMP BULB(S) – CONCORDE/LHS/300M . . 12 CHMSL BULB(S) – CONCORDE/LHS ..15 HEADLAMP BULBS –...
Page 364 LAMPS 8L - 13 REMOVAL AND INSTALLATION (Continued) Fig. 2 Headlamp Bulb – Intrepid 1 – LOW BEAM Fig. 4 Fog Lamp Bulb – 300M 2 – PARKING AND TURN SIGNAL 3 – HIGH BEAM 1 – FOG LAMP 2 – REAR COVER 3 –...
Page 365 8L - 14 LAMPS REMOVAL AND INSTALLATION (Continued) Fig. 5 Fog Lamp Bulb – LHS Fig. 6 Parking, Side Marker, and Turn Signal Lamp 1 – FOG LAMP BULB/SOCKET Bulb – Concorde 2 – FOG LAMP 1 – BULB 2 – SOCKET (2) Connect wire connector to the socket.
Page 366 LAMPS 8L - 15 REMOVAL AND INSTALLATION (Continued) CHMSL BULB(S) – CONCORDE/LHS REMOVAL (1) Release decklid latch and open decklid. (2) From under rear shelf panel, disconnect the lamp socket from the CHMSL housing (Fig. 9). (3) Remove bulb from the socket. Fig.
Page 367 8L - 16 LAMPS REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install bulb(s) in socket(s). (2) Install socket(s) into housing. (3) Verify CHMSL operation. (4) Install decklid cover. TRUNK LAMP BULB REMOVAL (1) Remove lens from lamp from the rear shelf (Fig.
Page 368 LAMPS 8L - 17 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Push bulb into socket. (2) Install socket(s) in tail lamp. (3) Place tail lamp in position on rear closure panel. (4) Install nuts attaching tail lamp to rear closure panel. (5) Install trunk lining.
Page 369 8L - 18 LAMPS LAMP SERVICE TABLE OF CONTENTS page page DIAGNOSIS AND TESTING FRONT SIDE MARKER HOUSING – LHS ..21 DAYTIME RUNNING LAMP....18 FRONT PARKING, SIDE MARKER, AND TURN ILLUMINATED ENTRY .
Page 370 LAMPS 8L - 19 REMOVAL AND INSTALLATION (Continued) INSTALLATION CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. (1) Place headlamp housing into position. (2) Connect wire connector to lamp socket(s) and/or bulbs.
Page 371 8L - 20 LAMPS REMOVAL AND INSTALLATION (Continued) Fig. 5 Roll Fascia Forward Fig. 7 Headlamp Housing – Intrepid 1 – ROLL FORWARD 1 – JACKSCREW 2 – HEADLAMP HOUSING 3 – BODY WIRE CONNECTOR INSTALLATION (1) Place headlamp housing in position on vehicle. (2) Connect wire connectors to headlamp, parking, side marker, and turn signal lamps.
Page 372 LAMPS 8L - 21 REMOVAL AND INSTALLATION (Continued) Fig. 10 Fog Lamp – 300M Fig. 8 Fog Lamp – Intrepid 1 – SCREWS 1 – FOG LAMP 2 – FOG LAMP 2 – SCREW FRONT SIDE MARKER HOUSING – LHS REMOVAL (1) Loosen fascia as necessary to access lamp.
Page 373 8L - 22 LAMPS REMOVAL AND INSTALLATION (Continued) FRONT PARKING, SIDE MARKER, AND TURN SIGNAL LAMP HOUSING – CONCORDE/300M REMOVAL (1) Remove headlamp housing to access lamp housing. (2) Rotate and pull socket from lamp housing. (3) Disconnect fastener attaching lamp housing to fascia (Fig.
Page 374 LAMPS 8L - 23 REMOVAL AND INSTALLATION (Continued) TAIL, STOP, BACK UP, AND TURN SIGNAL LAMP REMOVAL (1) Release decklid latch and open decklid. (2) Remove fasteners attaching trunk lining to lower rear trunk panel. (3) Move the trunk lining to access the tail lamp fasteners.
Page 375 8L - 24 LAMPS REMOVAL AND INSTALLATION (Continued) LICENSE PLATE LAMP – REAR BUMPER FASCIA REMOVAL (1) Remove screws holding license plate lamp to fascia (Fig. 19). (2) Remove license plate lamp from vehicle. Fig. 17 Tail, Stop, Back up, and Turn Signal – Intrepid Fig.
Page 376 LAMPS 8L - 25 BULB APPLICATION TABLE OF CONTENTS page page SPECIFICATIONS INDICATOR LAMPS ..... . . 26 DIMMER CONTROLLED INTERIOR LAMPS ..25 NON DIMMER CONTROLLED INTERIOR EXTERIOR LAMP BULBS.
Page 377 8L - 26 LAMPS SPECIFICATIONS (Continued) LAMP NAME BULB NUMBER Headlamps Concorde/Intrepid/300M High beam 9005 XS Low beam 9006 XSLL High beam 9005 XSLL Low beam 9006 License Plate Side Marker (front) Tail 300M Tail Side Marker Intrepid Tail/Brake/Turn Signal 3157K INDICATOR LAMPS INDICATOR...
Page 378 2000 LHS, 300M, CONCORDE AND INTREPID LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMP SYSTEMS ......1 LAMP SERVICE.
Page 379 2000 LHS, 300M, CONCORDE AND INTREPID 8L - 2 LAMPS DIAGNOSIS AND TESTING (Continued) HEADLAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING OR and posts.
Page 380 2000 LHS, 300M, CONCORDE AND INTREPID LAMPS 8L - 3 DIAGNOSIS AND TESTING (Continued) FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING OR and posts.
Page 381 2000 LHS, 300M, CONCORDE AND INTREPID 8L - 4 LAMPS DIAGNOSIS AND TESTING (Continued) HEADLAMP LEVELING MOTOR DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION ONE MOTOR DOES NOT 1. Poor connection at motor. 1. Secure connector on motor. OPERATE 2. No voltage at motor.
Page 382 2000 LHS, 300M, CONCORDE AND INTREPID LAMPS 8L - 5 HEADLAMP ALIGNMENT TABLE OF CONTENTS page page SERVICE PROCEDURES ADJUSTMENTS HEADLAMP ALIGNMENT PREPARATION..5 HEADLAMP AND FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN ....5...
Page 383 2000 LHS, 300M, CONCORDE AND INTREPID 8L - 6 LAMPS ADJUSTMENTS (Continued) HEADLAMP ADJUSTMENT (4) Rock vehicle side-to-side three times to allow suspension to stabilize. (5) Jounce front suspension three times by pushing NOTE: HEADLAMPS MUST BE ALIGNED WITH THE downward on front bumper and releasing.
Page 384 2000 LHS, 300M, CONCORDE AND INTREPID LAMPS 8L - 7 ADJUSTMENTS (Continued) FOG LAMP ALIGNMENT The horizontal aim should be set so that the notch between the horizontal component of the cut-off and Prepare an alignment screen. Refer to Alignment the 15°...
Page 385 2000 LHS, 300M, CONCORDE AND INTREPID 8L - 8 LAMPS LAMP BULB SERVICE TABLE OF CONTENTS page page REMOVAL AND INSTALLATION SIDE REPEATER LAMP BULB ....11 HEADLAMP BULB .
Page 386 2000 LHS, 300M, CONCORDE AND INTREPID LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) (4) Pull the bulb from the socket. Installation (1) Push the bulb into the socket. (2) Install the socket into the lamp housing. (3) Install the fog lamp assembly.
Page 387 2000 LHS, 300M, CONCORDE AND INTREPID 8L - 10 LAMPS REMOVAL AND INSTALLATION (Continued) (3) Pull the city lamp bulb straight from its socket (Fig. 6). Fig. 7 Front Fog Lamp 1 – FRONT FOG LAMP ATTACHING SCREWS 2 – FRONT FOG LAMP ASSEMBLY 3 –...
Page 388 2000 LHS, 300M, CONCORDE AND INTREPID LAMPS 8L - 11 REMOVAL AND INSTALLATION (Continued) (5) Install the fog lamp assembly attaching screws. SIDE REPEATER LAMP BULB Removal (1) Insert a small flat screwdriver between the lamp and the body panel. Disengage the lamp retain- ing tabs (Fig.
Page 389 2000 LHS, 300M, CONCORDE AND INTREPID 8L - 12 LAMPS REMOVAL AND INSTALLATION (Continued) (2) Pull lamp from fender. (3) Twist the bulb socket 1/4 turn and separate the bulb socket from the lamp (Fig. 13). Fig. 13 Side Repeater Lamp Socket 1 –...
Page 390 2000 LHS, 300M, CONCORDE AND INTREPID LAMPS 8L - 13 REMOVAL AND INSTALLATION (Continued) Installation (1) Push the bulb into the socket. (2) Install the socket into the tail lamp assembly. (3) Connect the tail lamp assembly electrical con- nector.
Page 391 2000 LHS, 300M, CONCORDE AND INTREPID 8L - 14 LAMPS REMOVAL AND INSTALLATION (Continued) (4) Pull the bulb from the socket. Installation (1) Push the bulb into the socket. (2) Install the socket into the lamp. (3) Place the license plate lamp in position in the rear bumper fascia.
Page 392 2000 LHS, 300M, CONCORDE AND INTREPID LAMPS 8L - 15 LAMP SERVICE TABLE OF CONTENTS page page REMOVAL AND INSTALLATION FRONT FOG LAMP ..... . . 16 HEADLAMP SWITCH .
Page 393 2000 LHS, 300M, CONCORDE AND INTREPID 8L - 16 LAMPS REMOVAL AND INSTALLATION (Continued) HEADLAMP LEVELING MOTOR REMOVAL (1) Remove the headlamp assembly from the vehi- cle. Refer to the procedure in this group. (2) Disconnect the headlamp leveling motor wire connector.
Page 394 2000 LHS, 300M, CONCORDE AND INTREPID LAMPS 8L - 17 REMOVAL AND INSTALLATION (Continued) SIDE REPEATER LAMP Removal (1) Insert a small flat screwdriver between the lamp and the body panel. Disengage the lamp retain- ing tabs (Fig. 6) (Fig. 5).
Page 395 2000 LHS, 300M, CONCORDE AND INTREPID 8L - 18 LAMPS REMOVAL AND INSTALLATION (Continued) (3) Remove the tail lamp assembly from the vehi- cle (Fig. 9). Fig. 10 Rear License Plate Lamp 1 – REAR LICENSE PLATE LAMPS (3) Twist and remove the socket from the lamp (Fig.
Page 396 2000 LHS, 300M, CONCORDE AND INTREPID LAMPS 8L - 19 REMOVAL AND INSTALLATION (Continued) CHMSL LAMP Removal (1) Release the deck lid latch and open deck lid. (2) Remove the deck lid cover. (3) Grasp the chmsl lamp socket and rotate coun- terclockwise.
Page 397 2000 LHS, 300M, CONCORDE AND INTREPID 8L - 20 LAMPS BULB APPLICATION TABLE OF CONTENTS page page CLEANING AND INSPECTION INTERIOR LAMP BULBS ....20 HEADLAMP CLEANING .
Page 398 PASSIVE RESTRAINT SYSTEMS 8M - 1 PASSIVE RESTRAINT SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION MAINTENANCE INSPECTION ....4 OCCUPANT RESTRAINT CONTROLLER REMOVAL AND INSTALLATION (ORC).
Page 399 8M - 2 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) DESCRIPTION rithm to discriminate the severity and direction of any vehicle event. PASSENGER AIRBAG MODULE WARNING: NEVER DISASSEMBLE THE DRIVER/ PASSENGER AIRBAG MODULES, THERE ARE NO SERVICEABLE PARTS WITHIN THE MODULES. DESCRIPTION Fig.
Page 400 PASSIVE RESTRAINT SYSTEMS 8M - 3 DIAGNOSIS AND TESTING (Continued) 5). If the heater or air conditioner was in RECIRC mode at time of airbag deployment, operate blower motor on low speed and vacuum powder residue expelled from the heater and A/C outlets. Multiple vacuum cleaning may be necessary to decontaminate the interior of the vehicle.
Page 401 WARNINGS AND PRECAUTIONS ture deployment can result. If the Driver/Passenger Airbag Module is defective and not deployed, refer to Chrysler Corporation cur- WARNING: THIS SYSTEM IS A SENSITIVE, COM- rent return list for proper handling procedures. PLEX ELECTRONIC UNIT. DISCONNECT AND ISO-...
Page 402 PASSIVE RESTRAINT SYSTEMS 8M - 5 REMOVAL AND INSTALLATION (Continued) (4) Remove speed control switch mounting screws, (11) Do not connect the battery negative cable from the back of the steering wheel, and disconnect remote terminal. Refer to Airbag System Check for the wire connectors.
Page 403 8M - 6 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) OCCUPANT RESTRAINT CONTROLLER (ORC) (14) Remove the ORC from vehicle. INSTALLATION WARNING: THE OCCUPANT RESTRAINT CON- TROLLER (ORC) CONTAINS AN ACCELEROMETER WARNING: THE ORC IS A SAFETY MODULE AND WHICH ENABLES THE SYSTEM TO DEPLOY THE FAILURE TO INSTALL AND SECURE IT PROPERLY, AIRBAGS.
Page 404 PASSIVE RESTRAINT SYSTEMS 8M - 7 REMOVAL AND INSTALLATION (Continued) • Remove the right console side trim panel. on the locking latch and disconnect the ORC 23-way connector. (5) Accessing through the glove box door, remove (11) Remove the two side module mounting screws five screws to the glove box close-out assembly (20 in.
Page 405 8M - 8 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (20) Remove the three lower left instrument panel mounting bolts. (21) Remove the three upper left instrument panel mounting bolts. (22) Disconnect the instrument panel to body har- ness electrical connector. (23) Disconnect the radio antenna connector.
Page 406 PASSIVE RESTRAINT SYSTEMS 8M - 9 REMOVAL AND INSTALLATION (Continued) INSTALLATION ing the flats on hub align with the clockspring. Ensure leads do not get pinched under the steering (1) Transfer all instrument panel components wheel. which are not damaged to NEW instrument panel (3) Install retaining nut, and torque it to 61 N·m and pad assembly.
Page 408 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 1 PASSIVE RESTRAINT SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION SIDE IMPACT AIRBAG RESTRAINT SYSTEM . . . 1 WARNINGS AND PRECAUTIONS ... . 10...
Page 409 2000 LHS, 300M, CONCORDE AND INTREPID 8M - 2 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) Fig. 1 LH FRONT SEAT BACKS EQUIPPED WITH AIRBAGS...
Page 410 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 3 DESCRIPTION AND OPERATION (Continued) 1 – FRONT SEAT BACK PANEL 5 – SEAT BACK TRIM COVERS 2 – LEFT SEAT AIRBAG MODULE 6 – SEAT BACK CUSHIONS 3 – HOLE PROVIDED IN SEAT BACK FOAM FOR SEAT AIRBAG 7 –...
Page 411 2000 LHS, 300M, CONCORDE AND INTREPID 8M - 4 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) Fig. 3 Side Impact Airbag Restraint System 1 – RIGHT SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) 4 – LEFT SEAT AIRBAG MODULE 2 – VEHICLE BODY B-PILLAR 5 –...
Page 412 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 5 DESCRIPTION AND OPERATION (Continued) SEAT AIRBAG MODULES The seat/side airbags are located in the front seat backs (Fig. 5). One in each front seat. The seat air- bag inflator assembly is within the module housing DESCRIPTION (Fig.
Page 413 2000 LHS, 300M, CONCORDE AND INTREPID 8M - 6 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) Fig. 5 LH AIRBAG FRONT SEAT BACKS...
Page 414 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 7 DESCRIPTION AND OPERATION (Continued) 1 – FRONT SEAT BACK PANEL 5 – SEAT BACK TRIM COVERS 2 – LEFT SEAT AIRBAG MODULE 6 – SEAT BACK CUSHIONS 3 – HOLE PROVIDED IN SEAT BACK FOAM FOR SEAT AIRBAG 7 –...
Page 415 2000 LHS, 300M, CONCORDE AND INTREPID 8M - 8 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) DESCRIPTION Fig. 8 Driver Airbag Location 1 – DRIVER AIRBAG MODULE Fig. 9 Passenger Airbag Location 2 – PASSENGER AIRBAG MODULE 1 – DRIVER AIRBAG MODULE 3 –...
Page 416 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 9 DIAGNOSIS AND TESTING (Continued) OPERATION The Occupant Restraint Controller (ORC) uses data collected from it’s internal accelerometers to dis- criminate the direction and severity of an impact. The ORC will activate power stages internal to the...
Page 417 If the Driver/Passenger Airbag Module is defective WARNING: THIS SYSTEM IS A SENSITIVE, COM- and not deployed, refer to Chrysler Corporation cur- PLEX ELECTRONIC UNIT. DISCONNECT AND ISO- rent return list for proper handling procedures. LATE THE BATTERY NEGATIVE REMOTE CABLE BEFORE BEGINNING AIRBAG SYSTEM COMPO- NENT REMOVAL OR INSTALLATION PROCEDURES.
Page 418 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 11 REMOVAL AND INSTALLATION (Continued) INSTALLATION INSTALLATION (1) Confirm that: WARNING: THE ORC IS A SAFETY MODULE AND • The steering wheel position is a half turn (180 FAILURE TO INSTALL AND SECURE IT PROPERLY,...
Page 419 2000 LHS, 300M, CONCORDE AND INTREPID 8M - 12 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Remove two bolts retaining Driver Airbag Mod- ule. (4) Lift module and disconnect airbag and horn wire connectors. (5) Remove Driver Airbag Module from vehicle.
Page 420 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 13 REMOVAL AND INSTALLATION (Continued) (25) Remove the three upper right instrument panel mounting bolts. (26) Pull the right side of the instrument panel back and set on right (passenger side) seat to access the passenger airbag module.
Page 421 2000 LHS, 300M, CONCORDE AND INTREPID 8M - 14 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Do not connect battery negative cable remote terminal. Refer to Diagnosis and Testing for Airbag System Test procedures. LEFT SEAT AIRBAG MODULE CAUTION: DO NOT REPLACE A DEPLOYED AIR- BAG.
Page 422 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 15 REMOVAL AND INSTALLATION (Continued) Fig. 17 Installing Seat Airbag Fig. 16 Seat Airbag Position & Orientation (4) Connect the side airbag module electrical con- 1 – SEAT BACK FRAME nector.
Page 423 2000 LHS, 300M, CONCORDE AND INTREPID 8M - 16 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) WARNING: DISCONNECT AND ISOLATE THE NEG- ATIVE BATTERY CABLE REMOTE TERMINAL BEFORE BEGINNING ANY FRONT SEAT REMOVAL OR INSTALLATION PROCEDURE. THIS WILL DIS- ABLE THE AIRBAG SYSTEM. FAILURE TO DISCON-...
Page 424 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 17 REMOVAL AND INSTALLATION (Continued) Fig. 21 Installing Seat Airbag Fig. 20 Seat Airbag Module Position & Orientation of the back cover. Refer to Group 23, Body for a 1 –...
Page 425 2000 LHS, 300M, CONCORDE AND INTREPID 8M - 18 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 22 Airbag Seat Wire Harness Fig. 23 Wire Harness Position & Orientation – 1 – YELLOW CONNECTOR LOCK Passenger Seat Shown Here Driver Seat (Mirror 2 –...
Page 426 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 19 REMOVAL AND INSTALLATION (Continued) RIGHT SEAT AIRBAG WIRE HARNESS (6) Remove the front seat cushion side shield. Refer to Group 23, Body for the procedure. (7) Disengage pushpin and remove the wire har- ness (Fig.
Page 427 2000 LHS, 300M, CONCORDE AND INTREPID 8M - 20 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (5) Install the front seat cushion side shield. Refer (6) Install the airbag module and torque bolts to 7 to Group 23, Body for the procedure.
Page 428 2000 LHS, 300M, CONCORDE AND INTREPID PASSIVE RESTRAINT SYSTEMS 8M - 21 SPECIFICATIONS (Continued) DESCRIPTION TORQUE Front seat back recliner to seat back ....12 N·m (9 ft. lbs.) Front seat rear outboard seat track to floor pan bolts .
Page 429 2000 LHS, 300M, CONCORDE AND INTREPID...
Page 430 ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS TABLE OF CONTENTS page page REAR WINDOW DEFOGGER....1 HEATED SEATS ......6 REAR WINDOW DEFOGGER TABLE OF CONTENTS page...
Page 431 8N - 2 ELECTRICALLY HEATED SYSTEMS DESCRIPTION AND OPERATION (Continued) A/C-HEATER AND ATC CONTROL HEAD Refer to Group 24, Heating and Air Conditioning for instructions on how to use the DRB III scan tool or the control head self-diagnostics to test the control head.
Page 432 ELECTRICALLY HEATED SYSTEMS 8N - 3 DIAGNOSIS AND TESTING (Continued) Fig. 4 Grid Line Test 1 – VOLTAGE FEED A 2 – BUS BARS 3 – REAR WINDOW DEFOGGER 4 – MIDPOINT C 5 – GROUND B Fig. 3 System Electrical Circuit 6 –...
Page 433 8N - 4 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING (Continued) REAR WINDOW DEFOGGER RELAY TEST VOLTAGE AT REAR WINDOW SYSTEM VOLTAGE AT REAR WINDOW DEFOGGER ON OR OFF DEFOGGER RELAY POINT TO GRID TO GOOD POTENTIAL PROBLEM WITH GOOD VEHICLE GROUND VEHICLE ENGINE GROUND...
Page 434 ELECTRICALLY HEATED SYSTEMS 8N - 5 SERVICE PROCEDURES (Continued) VENTILATION. DO NOT USE NEAR FIRE OR FLAME. CONTENTS CONTAIN 3 PERCENT FLAMMABLE SOLVENTS. KEEP OUT OF REACH OF CHILDREN. REMOVAL AND INSTALLATION HEATER-A/C ATC CONTROL Refer to Group 8E, Instrument Panel and Systems for proper Removal and Installation procedures.
Page 435 8N - 6 ELECTRICALLY HEATED SYSTEMS HEATED SEATS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION MEMORY HEATED SEAT / MIRROR MODULE HEATED SEAT SYSTEM ....6 (MHSMM) .
Page 436 ELECTRICALLY HEATED SYSTEMS 8N - 7 DESCRIPTION AND OPERATION (Continued) OPERATION The module controls the seat heaters and is con- nected to the seat harness by four connectors. There is only one module per memory and heated system. The module cannot be repaired, and if faulty or dam- aged will have to be replaced.
Page 437 8N - 8 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING (Continued) HEATED SEAT SWITCH MEMORY HEATED SEAT / MIRROR MODULE For circuit description and diagrams, refer to (MHSMM) Group 8W Wiring Diagrams. Before testing the Memory Heated Seat / Mirror Inspect the Heated Seat Switches for apparent Module (MHSMM), test the heated seat switches, the damage or sticking/binding and replace as required.
Page 438 ELECTRICALLY HEATED SYSTEMS 8N - 9 DIAGNOSIS AND TESTING (Continued) (1) Unplug the 4–way heated seat cushion wire harness connector. (2) Using an ohmmeter, measure the resistance between the heated seat switch output circuit cavity and the ground circuit cavity of the seat cushion cover half of the heated seat cushion wire harness connector.
Page 440 POWER DISTRIBUTION SYSTEMS 8O - 1 POWER DISTRIBUTION SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION POWER DISTRIBUTION SYSTEM... . . 1 JUNCTION BLOCK (JB) ....3 POWER DISTRIBUTION CENTER (PDC) .
Page 441 8O - 2 POWER DISTRIBUTION SYSTEMS DESCRIPTION AND OPERATION (Continued) front side. A small molded plastic protective cover on the front right side of the engine compartment is unsnapped to access the battery/generator cable input connection studs. OPERATION All of the PDC outputs are through the integral engine compartment wire harness, which exits from the front of the PDC housing.
Page 442 POWER DISTRIBUTION SYSTEMS 8O - 3 (6) Remove Junction Block/BCM four mounting REMOVAL AND INSTALLATION screws. (7) Remove wire harness connectors from Junction JUNCTION BLOCK (JB) Block/BCM. (8) Remove Junction Block/BCM. REMOVAL (9) Disconnect BCM wire connectors and RKE antenna connector. WARNING: ON VEHICLES EQUIPPED WITH AIR- (10) Remove Junction Block/BCM from vehicle.
Page 443 8O - 4 POWER DISTRIBUTION SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION nents. Make sure to make clip attachment into the rail located behind the PDC. Refer to 8W-90 - Con- nector Locations in Group 8W - Wiring Diagrams NOTE: If the power distribution center (PDC) is being replaced with a new unit, be certain to trans- for more information on the harness routing and fer each of the fuses, fuse cartridges, fusible links...
Page 444 POWER LOCK SYSTEMS 8P - 1 POWER LOCK SYSTEMS TABLE OF CONTENTS page page POWER DOOR LOCKS ..... . 1 REMOTE KEYLESS ENTRY .
Page 445 8P - 2 POWER LOCK SYSTEMS DESCRIPTION AND OPERATION (Continued) The BCM will automatically re-lock all doors if the REMOTE KEYLESS ENTRY (RKE) SYSTEM above conditions are met and if any of the doors become ajar and then closes again. DESCRIPTION The power lock motors are also equipped with a The Remote keyless Entry (RKE) system allows...
Page 446 POWER LOCK SYSTEMS 8P - 3 DIAGNOSIS AND TESTING (Continued) VOLTAGE The following wiring test sequence determines whether or not voltage is continuous through the body harness to switch. (1) Remove left side switch from door trim panel. (2) Carefully separate multiple terminal block on wiring harness from switch body.
Page 447 8P - 4 POWER LOCK SYSTEMS REMOTE KEYLESS ENTRY TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION REMOTE KEYLESS ENTRY (RKE) SYSTEM ..4 REMOTE KEYLESS ENTRY MODULE ..6 HORN CHIRP TOGGLE .
Page 448 POWER LOCK SYSTEMS 8P - 5 DESCRIPTION AND OPERATION (Continued) OPERATION This can be done using a DRB scan tool or by the customer. The horn chirp will enter the opposite state of its current programmed state by receiving this operation code. The BCM is responsible for keep- ing track of the horn chirp status.
Page 449 8P - 6 POWER LOCK SYSTEMS SERVICE PROCEDURES (Continued) REMOVAL AND INSTALLATION REMOTE KEYLESS ENTRY MODULE The Remote Keyless Entry (RKE) Module is located between the junction block and body control module (Fig. 4). Refer to Group 8E, Instrument Panel and Systems for Junction Block/BCM Removal and Installation procedures.
Page 450 POWER LOCK SYSTEMS 8P - 7 ADJUSTMENTS (Continued) ignition or wait 32 seconds. The BCM will chime stacked on top of eachother. The batteries are avail- again. able at local retail stores. Recommended batteries are Panasonic CR 2016 or equivalent. Battery life is about two years (Fig.
Page 452 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1 VEHICLE THEFT/SECURITY SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION VEHICLE THEFT SECURITY SYSTEM VEHICLE THEFT/SECURITY SYSTEM (VTSS) . . . 1 SELF-TESTS......5 SENTRY KEY IMMOBILIZER SYSTEM (SKIS) .
Page 453 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) Fig. 2 Sentry Key Immobilizer Module more than eight electronically coded Sentry Key transponders. The SKIS programming also enables Fig. 1 Sentry Key Immobilizer Module Location the SKIM to communicate over the Programmable 1 –...
Page 454 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3 DESCRIPTION AND OPERATION (Continued) When the ignition switch is turned to the ON or OPERATION START positions, the SKIM transmits an RF signal The SKIM sends messages to the BCM to turn the to excite the Sentry Key transponder. The SKIM then LED on for about three seconds when the ignition listens for a return RF signal from the transponder switch is turned to the ON position as a bulb test.
Page 455 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) CAUTION: The VTSS indicator LED will trigger and engine will continue to run if the vehicle is equipped with SKIS and the proper key is used to start the vehicle. This condition will occur if the VTSS has been triggered.
Page 456 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5 DIAGNOSIS AND TESTING (Continued) to Step 4. If not OK, repair the open circuit to the Keys. If two valid Sentry Keys are not available, Sen- fuse in the junction block as required. try Key programming will require the use of a DRB (4) Turn the ignition switch to the ON position.
Page 457 8Q - 6 VEHICLE THEFT/SECURITY SYSTEMS REMOVAL AND INSTALLATION BODY CONTROL MODULE For service of the Body Control Module (BCM), refer to Group 8E, Instrument Panel and Systems for Removal and Installation. NOTE: If the BCM is replaced, the VTSS must be enabled in the new BCM via the DRB lll , in order to start the vehicle.
Page 458 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 7 REMOVAL AND INSTALLATION (Continued) Fig. 7 Door Key Cylinder Switch 1 – DOOR KEY CYLINDER SWITCH Fig. 8 Negative Battery Cable Remote Terminal 2 – LOCK CYLINDER 1 – RIGHT STRUT TOWER 3 – DOOR HANDLE 2 –...
Page 460 POWER SEAT SYSTEMS 8R - 1 POWER SEAT SYSTEMS TABLE OF CONTENTS page page POWER SEATS ......1 MEMORY SEATS.
Page 461 8R - 2 POWER SEAT SYSTEMS DESCRIPTION AND OPERATION (Continued) • Seat Track Rearward ACTIVATION • Seat Front Down The Power Seat Switch Diagnostic Test can only be • Seat Rear Down activated by sending the proper PCI bus command •...
Page 462 POWER SEAT SYSTEMS 8R - 3 DIAGNOSIS AND TESTING (Continued) SEAT MOTOR TEST SEAT SWITCH CONTINUITY TEST SEAT CONNECTOR SWITCH POSITION CONTINUITY BETWEEN PINS CONNECT JUMPER SEAT ACTION DRIVER PASSENGER B (+) B (-) DRIVER PASSENGER SIDE SIDE PIN 5 TO 4 PIN 5 TO 4 PIN 5 TO 3 PIN 5 TO 3...
Page 463 8R - 4 POWER SEAT SYSTEMS SEAT SWITCH REMOVAL AND INSTALLATION SEAT ASSEMBLY REMOVAL (1) Open hood, disconnect and isolate the negative Refer to Group 23–Body, Front Seat Removal and battery cable remote terminal from the remote bat- Installation. tery post (Fig. 5). SEAT ADJUSTER REMOVAL (1) Seat removed from vehicle.
Page 464 POWER SEAT SYSTEMS 8R - 5 MEMORY SEATS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SERVICE PROCEDURES MEMORY SEAT SYSTEM....5 REMOTE KEYLESS ENTRY (RKE).
Page 465 8R - 6 POWER SEAT SYSTEMS DESCRIPTION AND OPERATION (Continued) DIAGNOSIS AND TESTING GLIDE FEATURE If seat isn’t sliding forward properly: (1) First use the DRB scan tool to check whether glide feature is enabled or not. Enable glide feature if disabled, and go to Step 2.
Page 466 POWER SEAT SYSTEMS 8R - 7 (3) Disconnect four module connectors. REMOVAL AND INSTALLATION (4) Remove module from vehicle. MEMORY HEATED SEAT/MIRROR MODULE INSTALLATION (MHSMM) For installation, reverse the above procedures. REMOVAL MEMORY SELECTOR SWITCH (1) Open hood, disconnect and isolate the negative battery cable remote terminal from the remote bat- REMOVAL tery post.
Page 468 2000 LHS, 300M, CONCORDE AND INTREPID POWER SEAT SYSTEMS 8R - 1 POWER SEAT SYSTEMS TABLE OF CONTENTS page page POWER SEATS ......1 MEMORY SEATS.
Page 469 2000 LHS, 300M, CONCORDE AND INTREPID 8R - 2 POWER SEAT SYSTEMS DESCRIPTION AND OPERATION (Continued) Fig. 1 LH FRONT SEAT BACKS EQUIPPED WITH AIRBAGS...
Page 470 2000 LHS, 300M, CONCORDE AND INTREPID POWER SEAT SYSTEMS 8R - 3 DESCRIPTION AND OPERATION (Continued) 1 – FRONT SEAT BACK PANEL 5 – SEAT BACK TRIM COVERS 2 – LEFT SEAT AIRBAG MODULE 6 – SEAT BACK CUSHIONS 3 – HOLE PROVIDED IN SEAT BACK FOAM FOR SEAT AIRBAG 7 –...
Page 471 2000 LHS, 300M, CONCORDE AND INTREPID 8R - 4 POWER SEAT SYSTEMS DIAGNOSIS AND TESTING (Continued) POWER SEAT SWITCH DIAGNOSTIC TEST SEAT MOTOR TEST The Power Seat Switch Diagnostic Test can be used to test whether the switch activations are being SEAT CONNECTOR recognized by the MHSMM.
Page 472 2000 LHS, 300M, CONCORDE AND INTREPID POWER SEAT SYSTEMS 8R - 5 DIAGNOSIS AND TESTING (Continued) SEAT SWITCH CONTINUITY TEST SWITCH CONTINUITY BETWEEN PINS POSITION DRIVER PASSENGER PIN 5 TO 4 PIN 5 TO 4 PIN 5 TO 3 PIN 5 TO 3...
Page 473 2000 LHS, 300M, CONCORDE AND INTREPID 8R - 6 POWER SEAT SYSTEMS REMOVAL AND INSTALLATION (4) Remove adjuster from seat. INSTALLATION SEAT ASSEMBLY For installation, reverse the above procedure. Refer to Group 23–Body, Front Seat Removal and Installation. SEAT SWITCH...
Page 474 2000 LHS, 300M, CONCORDE AND INTREPID POWER SEAT SYSTEMS 8R - 7 MEMORY SEATS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SERVICE PROCEDURES MEMORY SEAT SYSTEM....7 REMOTE KEYLESS ENTRY (RKE).
Page 475 2000 LHS, 300M, CONCORDE AND INTREPID 8R - 8 POWER SEAT SYSTEMS DESCRIPTION AND OPERATION (Continued) MEMORY SELECTOR SWITCH OPERATION The proper procedure of setting and recalling a DESCRIPTION memory position using the memory switches is as fol- lows: (1) Adjust the seat, recliner and side view mirrors to the desired position.
Page 476 2000 LHS, 300M, CONCORDE AND INTREPID POWER SEAT SYSTEMS 8R - 9 SERVICE PROCEDURES (Continued) (5) Press and release the UNLOCK button on one of the RKE transmitters. Do NOT press any switch for 10 seconds. (6) Set radio station presets.
Page 477 2000 LHS, 300M, CONCORDE AND INTREPID...
Page 478 POWER WINDOW SYSTEMS 8S - 1 POWER WINDOW SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION WINDOW SWITCH ......2 POWER WINDOW SYSTEMS .
Page 479 8S - 2 POWER WINDOW SYSTEMS DIAGNOSIS AND TESTING (Continued) (8) To determine if the glass is free is to disconnect SWITCH POSITION CONTINUITY BETWEEN the regulator from the glass lift plate. Remove the TERMINALS two attaching screws, and slide the window up and down by hand.
Page 480 POWER WINDOW SYSTEMS 8S - 3 REMOVAL AND INSTALLATION (Continued) SWITCH CONTINUITY POSITION BETWEEN TERMINALS PIN 2 to 5 PIN 6 to 3 PIN 6 to 3 PIN 4 to 5 DOWN PIN 2 to 5 PIN 4 to 3 Fig.
Page 481 8S - 4 POWER WINDOW SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Using a trim stick (special tool #C-4755), gently (6) Remove switch from vehicle. pry up on rear edge of switch pushing forward as you INSTALLATION pry up on switch bezel. For installation, reverse the above procedures.
Page 482 POWER MIRROR SYSTEMS 8T - 1 POWER MIRROR SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION HEATED MIRROR ......2 INTRODUCTION .
Page 483 8T - 2 POWER MIRROR SYSTEMS Test table and (Fig. 2) for appropriate mirror DIAGNOSIS AND TESTING response. (4) If test results are not obtained as shown in the AUTOMATIC DAY/NIGHT INSIDE MIRROR (Fig. 2), check for open or shorted circuit, or replace Operational test: mirror assembly as necessary.
Page 484 POWER MIRROR SYSTEMS 8T - 3 DIAGNOSIS AND TESTING (Continued) (4) Using an ohmmeter, test for continuity between the terminals of the switch (Fig. 3) as shown in the Mirror Switch Test table. (5) If test results are not obtained as shown in the Mirror Switch Test table, replace the switch.
Page 486 CHIME/BUZZER WARNING SYSTEMS 8U - 1 CHIME/BUZZER WARNING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION KEY LEFT IN IGNITION..... 3 CHIME/BUZZER WARNING SYSTEM .
Page 487 8U - 2 CHIME/BUZZER WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) Fig. 1 Chime/Buzzer Warning System Schematic No fasten seat belt lamp when ignition switch is DIAGNOSIS AND TESTING turned on. CHIME CONDITIONS (1) Use DRB lll scan tool to perform PCI bus diagnostics on BCM for battery and ignition switch No tone when ignition switch is turned on and input...
Page 488 CHIME/BUZZER WARNING SYSTEMS 8U - 3 DIAGNOSIS AND TESTING (Continued) Fasten seat belt lamp or tone continue for more (3) Inspect the BCM connectors and wires for proper connection. than 10 seconds after seat belts are fastened and ignition ON. EXTERIOR LAMPS LEFT ON (1) Use DRB lll scan tool to perform PCI bus...
Page 490 OVERHEAD CONSOLE SYSTEMS 8V - 1 OVERHEAD CONSOLE SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION UNIVERSAL TRANSMITTER CHANNEL OVERHEAD CONSOLE ..... 1 STATUS .
Page 491 8V - 2 OVERHEAD CONSOLE SYSTEMS DESCRIPTION AND OPERATION (Continued) OPERATION THERE ARE 4 BUTTONS FOR OTIS OPERATIONS The buttons operate when the ignition is in the ON position. The VFD will display the last display before ignition was turned OFF. The four outer buttons operate: •...
Page 492 OVERHEAD CONSOLE SYSTEMS 8V - 3 DIAGNOSIS AND TESTING (Continued) except the compass display. If a dash (-) is displayed, COMPASS DISPLAY OTIS is not receiving a PCI bus message from the To display the vehicle direction, the OTIS processes BCM.
Page 493 8V - 4 OVERHEAD CONSOLE SYSTEMS (2) Place an 8 1/2 in. X 11 in. piece of paper SERVICE PROCEDURES lengthwise on the roof of vehicle directly above com- pass. The purpose of the paper is to protect the roof COMPASS CALIBRATION panel from scratches and define the area to be Do not attempt to calibrate the compass near large...
Page 494 OVERHEAD CONSOLE SYSTEMS 8V - 5 SERVICE PROCEDURES (Continued) Fig. 5 Negative Battery Cable Remote Terminal 1 – RIGHT STRUT TOWER 2 – AIR CLEANER INLET TUBE 3 – REMOTE TERMINAL Fig. 4 Variance Zone Map REMOVAL AND INSTALLATION AMBIENT TEMPERATURE SENSOR REMOVAL Fig.
Page 495 8V - 6 OVERHEAD CONSOLE SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Grasp the front of console and pull downward grooves of the console. Make sure the LOOP of wire to disconnect the retaining clips. that was clipped into the OTIS module housing is (3) Disconnect wire connectors and lower the con- properly clipped into the new module before the con- sole.
Page 496: Wiring Diagrams
WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page AIR CONDITIONING-HEATER ... 8W-42-1 POWER DISTRIBUTION ....8W-10-1 ANTI-LOCK BRAKES .
Page 498 Chrysler wiring diagrams to shown complete. diagnose and repair a Chrysler vehicle, it is impor- It is important to realize that no attempt is made tant to understand all of their features and charac- on the diagrams to represent components and wiring teristics.
Page 499 8W - 01 - 2 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Wiring Diagram Example No.1...
Page 500 8W - 01 GENERAL INFORMATION 8W - 01 - 3 DESCRIPTION AND OPERATION (Continued) Wiring Diagram Example No.2...
Page 501 8W - 01 - 4 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) CIRCUIT INFORMATION CIRCUIT FUNCTIONS Each wire shown in the diagrams contains a code All circuits in the diagrams use an alpha/numeric which identifies the main circuit, part of the main code to identify the wire and its function.
Page 502 8W - 01 GENERAL INFORMATION 8W - 01 - 5 DESCRIPTION AND OPERATION (Continued) SECTION IDENTIFICATION GROUP TOPIC The wiring diagrams are grouped into individual 8W-01 thru General Information and Diagram sections. If a component is most likely found in a par- 8W-09 Overview ticular group, it will be shown complete (all wires,...
Page 503 8W - 01 - 6 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Wiring Diagram Symbols...
Page 504 8W - 01 GENERAL INFORMATION 8W - 01 - 7 DESCRIPTION AND OPERATION (Continued) TERMINOLOGY are identified using the name/number on the Dia- gram pages. This a list of terms with there definitions used in the wiring diagrams. SPLICE LOCATIONS Splice Location charts in Section 8W-70 show the Built-Up-Export .
Page 505 8W - 01 - 8 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) WARNING: TO PREVENT SERIOUS BURNS, AVOID DIAGNOSIS AND TESTING CONTACT WITH HOT PARTS SUCH AS THE RADIA- TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA- TROUBLESHOOTING TOOLS LYTIC CONVERTER, AND MUFFLER. When diagnosing a problem in an electrical circuit there are several common tools necessary.
Page 506 8W - 01 GENERAL INFORMATION 8W - 01 - 9 DIAGNOSIS AND TESTING (Continued) INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem.
Page 507 8W - 01 - 10 8W - 01 GENERAL INFORMATION DIAGNOSIS AND TESTING (Continued) (4) Start connecting the items in the fuse circuit SERVICE PROCEDURES one at a time. When the fuse blows the circuit with the short to ground has been isolated. WIRING REPAIR When replacing or repairing a wire, it is important TESTING FOR A VOLTAGE DROP...
Page 508 8W - 01 GENERAL INFORMATION 8W - 01 - 11 SERVICE PROCEDURES (Continued) TERMINAL/CONNECTOR REPAIR-MOLEX CONNECTOR REPLACEMENT CONNECTORS (1) Disconnect battery. (2) Disconnect the connector that is to be repaired (1) Disconnect battery. from its mating half/component (2) Disconnect the connector from its mating half/ (3) Remove connector locking...
Page 509 8W - 01 - 12 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) Fig. 11 Terminal Removal Fig. 13 Stagger Cutting Wires 1 – CONNECTOR 2 – FROM SPECIAL TOOL KIT 6680 1 – REPAIR SIDE WIRES 2 – STAGER CUTS 3 –...
Page 510 8W - 01 GENERAL INFORMATION 8W - 01 - 13 SERVICE PROCEDURES (Continued) Fig. 14 Augat Connector Repair Fig. 16 Connector Locking Wedge Tab (Typical) 1 – LOCKING TAB 1 – CONNECTOR 2 – CONNECTOR 2 – CONNECTOR LOCKING WEDGE TAB Fig.
Page 511 8W - 01 - 14 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (4) Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. (5) Install the new diode in the harness, making sure current flow is correct.
Page 512 8W - 01 GENERAL INFORMATION 8W - 01 - 15 SPECIAL TOOLS (Continued) Terminal Removing Tool 6932 Terminal Removing Tool 6934...
Page 514 8W - 02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page 2-4 Solenoid ......8W-31 Evap/Purge Solenoid .
Page 515 8W - 02 - 2 8W - 02 COMPONENT INDEX Component Page Component Page Overhead Travel Information System ..8W-49 Side Marker Lamps ....8W-50, 51 Oxygen Sensors .
Page 516 8W - 10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-10 Fuse F (PDC) ..... . . 8W-10-7, 13 A/C Compressor Clutch Relay .
Page 544 8W - 12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK Component Page Component Page A/C Compressor Clutch Relay ....8W-12-22 Left Front Side Marker Lamp ....8W-12-10, 31 Automatic Day/Night Mirror .
Page 576 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-5 Left Side Repeater ..... 8W-15-4 Analog Clock .
Page 594 8W - 20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Automatic Shut Down Relay ... . 8W-20-2 G108 ......8W-20-2 Battery .
Page 596 8W - 21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8W-21-2 Power Distribution Center .
Page 598 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8W-30-16 Fuse T (PDC) ....8W-30-2, 10, 11, 18 A/C Pressure Transducer .
Page 618 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Automatic Day/Night Mirror ... 8W-31-5 Junction Block ....8W-31-2, 5, 8 Autostick Switch .
Page 626 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Body Control Module ....8W-33-2 G104 .
Page 630 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1 8W-35 ANTI-LOCK BRAKES Component Page Component Page Body Control Module ....8W-35-2 G103 ......8W-35-2 Brake Lamp Switch .
Page 634 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Body Control Module ..8W-39-2, 3, 4, 5, 6 Ignition Switch ..... . 8W-39-2 Driver Door Cylinder Lock Switch .
Page 640 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page ABS Warning Indicator ....8W-40-3 G303 ......8W-40-4 Analog Clock .
Page 650 8W - 41 HORN/CIGAR LIGHTER 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER Component Page Component Page Ash Receiver Lamp ....8W-41-2 Horn Relay .
Page 652 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ....8W-42-6 Fuse E (PDC) ..... . . 8W-42-7 A/C Compressor Clutch Relay .
Page 660 8W - 43 OCCUPANT RESTRAINT SYSTEM 8W - 43 - 1 8W-43 OCCUPANT RESTRAINT SYSTEM Component Page Component Page Body Control Module ....8W-43-2, 3 Left Seat Airbag ..... 8W-43-3 Clockspring No.
Page 664 8W - 44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page Analog Clock ......8W-44-6 Junction Block .
Page 670 8W - 45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE Component Page Component Page Ambient Temperature Sensor ... 8W-45-6 Left Rear Reading Lamp Switch ..8W-45-4 Automatic Temperature Control Head .
Page 686 8W - 47 AUDIO SYSTEMS 8W - 47 - 1 8W-47 AUDIO SYSTEMS Component Page Component Page Body Control Module ....8W-47-2, 4 Left Rear Shelf Speaker ... . . 8W-47-3, 5 Center Instrument Panel Speaker .
Page 694 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page Body Control Module ....8W-48-2 Radio .
Page 698 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Body Control Module ....8W-49-2 G201 ......8W-49-2 Fuse 14 (JB) .
Page 700 8W - 50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Body Control Module ..8W-50-2, 3, 4, 5, 8, 11 Left Front Park/Turn Signal Lamp . 8W-50-7, 12, 14 Daytime Running Lamp Module .
Page 716 8W - 51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Automatic Day/Night Mirror ..8W-51-4, 5 Left Tail Lamp ....8W-51-8, 9 Brake Lamp Switch .
Page 726 8W - 52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Combination Flasher ....8W-52-2 Left Rear Turn Signal Lamp ... . 8W-52-3 Fuse 9 (JB) .
Page 730 8W - 53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Body Control Module ... . 8W-53-2, 3, 4, 5 Headlamp Washer Relay ....8W-53-5 Fuse 5 (JB) .
Page 736 8W - 60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker No. 1 8W-Cb ... 8W-60-2 Left Rear Power Window Switch ..8W-60-3 Driver Power Window Motor .
Page 740 8W - 61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Body Control Module ... . 8W-61-2, 3, 4, 5 Fuse 19 (JB) ..... . 8W-61-2, 5 Circuit Breaker No.
Page 746 8W - 62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Driver Power Mirror ....8W-62-2, 4, 6 Junction Block ....8W-62-2, 3 Fuse 14 (JB) .
Page 754 8W - 63 POWER SEATS 8W - 63 - 1 8W-63 POWER SEATS Component Page Component Page Body Control Module ....8W-63-8 Driver Power Seat Switch ... . 8W-63-2, 4 Circuit Breaker No.
Page 762 8W - 64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF Component Page Component Page Fuse 14 (JB) ......8W-64-2 Sunroof Control Module .
Page 764 8W - 65 SPEED PROPORTIONAL STEERING 8W - 65 - 1 8W-65 SPEED PROPORTIONAL STEERING Component Page Component Page Body Control Module ....8W-65-2 Speed Proportional Steering Solenoid .
Page 766 8W - 70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ....... . 8W-15-4 S209 .
Page 774 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Compressor Clutch ....8W-80-4 C319 ......8W-80-20 A/C Pressure Transducer .
Page 775 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS Component Page Component Page Fuel Injector No. 5 ....8W-80-32 Memory Heated Seat/Mirror Module .
Page 776 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Right Rear Door Speaker ... . . 8W-80-65 Short Runner Valve Solenoid ..8W-80-69 Right Rear Fog Lamp .
Page 848 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS INDEX page page DESCRIPTION AND OPERATION INTRODUCTION ......1 CONNECTOR/GROUND LOCATIONS.
Page 849 8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number C110 (2.7L) Rear of Engine C314 Left Trunk Area C111 Near Left C316 Left B Pillar Headlamp C317 Right B Pillar...
Page 850 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Data Link LT Side of Driver Power At Driver Seat Connector Steering Seat Recliner Column Motor Sensor Decklid Release Left Side of I/P Driver Power...
Page 851 8W - 90 - 4 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number G105 Near Right Junction Block Left Side of I/P Horn G106 Near Right Junction Block Left Side of I/P Horn G107 Left Side of...
Page 852 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Left High Beam At Lamp Manual Center of I/P Headlamp Temperature Control Head - Left Horn Left Fender Left License At Lamp...
Page 853 8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Park Brake At Park Brake Passenger Sail Passenger Switch Lever Speaker Door Passenger Airbag Behind I/P Passenger Side Right B Pillar Near Glove...
Page 854 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Right Front At Lamp Seat Belt Switch Left B Pillar Park/Turn Signal Sentry Key Steering Lamp Immobilizer Column Right Front...
Page 855 8W - 90 - 8 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Windshield Left Fender Windshield Wiper At Wiper Motor Washer Pump Side Shield Motor Motor...
Page 856 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 9 DESCRIPTION AND OPERATION (Continued) Fig. 1 Front of Engine Fig. 2 Right Front Engine Compartment...
Page 857 8W - 90 - 10 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 3 Left Front Engine Compartment...
Page 858 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11 DESCRIPTION AND OPERATION (Continued)
Page 859 8W - 90 - 12 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 860 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 13 DESCRIPTION AND OPERATION (Continued)
Page 861 8W - 90 - 14 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 862 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15 DESCRIPTION AND OPERATION (Continued)
Page 863 8W - 90 - 16 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 864 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 17 DESCRIPTION AND OPERATION (Continued)
Page 865 8W - 90 - 18 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 866 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 19 DESCRIPTION AND OPERATION (Continued) Fig. 12 Shelf Panel...
Page 867 8W - 90 - 20 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 868 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 21 DESCRIPTION AND OPERATION (Continued) Fig. 14 Deck Lid Fig. 15 Right Front Door...
Page 870 8W - 95 SPLICE LOCATIONS 8W - 95 - 1 8W-95 SPLICE LOCATIONS INDEX page page DESCRIPTION AND OPERATION SPLICE LOCATIONS ..... . . 1 INTRODUCTION .
Page 871 8W - 95 - 2 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Splice Location Fig. Splice Location Fig. Number Number S127 Headlamp and Dash in Power S166 Headlamp and Dash Harness Distribution Center in Power Distribution Center S128 Headlamp and Dash in Power S167 Headlamp and Dash Harness...
Page 872 8W - 95 SPLICE LOCATIONS 8W - 95 - 3 DESCRIPTION AND OPERATION (Continued) Splice Location Fig. Splice Location Fig. Number Number S316 Left Front Door Harness S338 Body Harness, Right Side Body S317 Left Front Door Harness S341 Memory Seat Harness Near S318 Left Front Door Harness T/O to Seat Motors...
Page 873 8W - 95 - 4 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 1 Right Front Lamps Fig. 2 Left Front Lamps...
Page 874 8W - 95 SPLICE LOCATIONS 8W - 95 - 5 DESCRIPTION AND OPERATION (Continued)
Page 875 8W - 95 - 6 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 876 8W - 95 SPLICE LOCATIONS 8W - 95 - 7 DESCRIPTION AND OPERATION (Continued)
Page 877 8W - 95 - 8 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 878 8W - 95 SPLICE LOCATIONS 8W - 95 - 9 DESCRIPTION AND OPERATION (Continued) Fig. 7 Right front Door...
Page 879 8W - 95 - 10 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 8 Left Side Body...
Page 880 8W - 95 SPLICE LOCATIONS 8W - 95 - 11 DESCRIPTION AND OPERATION (Continued)
Page 881 8W - 95 - 12 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
Page 882 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page 2.7L ENGINE......1 3.2/3.5L ENGINE .
Page 883 9 - 2 2.7L ENGINE ENGINE CORE AND OIL PLUGS ... . . 61 OIL PUMP ......64 DISASSEMBLY AND ASSEMBLY CYLINDER BLOCK AND BORE .
Page 884 2.7L ENGINE 9 - 3 DESCRIPTION AND OPERATION (Continued) DESCRIPTION The 2.7 Liter (167 Cubic Inches) 60 degree V-6 engine is a double overhead camshaft design with hydraulic lifters and four valves per cylinder (Fig. 1). The engine does not have provisions for a free wheel- ing valve train.
Page 885 9 - 4 2.7L ENGINE DESCRIPTION AND OPERATION (Continued) Fig. 4 Cylinder Block and Crankshaft 1 – MAIN CAP BOLT—VERTICAL 5 – MAIN CAP BOLT—HORIZONTAL 2 – MAIN CAP 6 – CYLINDER BLOCK 3 – MAIN BEARING—LOWER 7 – CRANKSHAFT 4 –...
Page 886 2.7L ENGINE 9 - 5 DESCRIPTION AND OPERATION (Continued) CRANKSHAFT DESCRIPTION The crankshaft is constructed of a forged micro alloy steel. The six throw, nine counterweight crank- shaft is supported by four select fit main bearings with the number three serving as the thrust washer location (Fig.
Page 887 9 - 6 2.7L ENGINE DESCRIPTION AND OPERATION (Continued) Fig. 6 Cylinder Head, Valves, and Springs 1 – VALVE KEEPER 7 – VALVE-EXHAUST 2 – SPRING RETAINER 8 – VALVE-INTAKE 3 – VALVE KEEPER 9 – CYLINDER HEAD 4 – VALVE SPRING-EXHAUST 10 –...
Page 888 2.7L ENGINE 9 - 7 DESCRIPTION AND OPERATION (Continued) To reduce engine NVH and timing chain loads a and exhaust camshafts (Fig. 8). The tensioner incor- camshaft damper is used. This damper mounts to the porates upper and lower chain guide faces. The lower right intake camshaft sprocket.
Page 889 9 - 8 2.7L ENGINE DESCRIPTION AND OPERATION (Continued) Fig. 8 Valvetrain Components 1 – CAMSHAFT BEARING CAP-INTAKE 7 – CAMSHAFT (SECONDARY) CHAIN TENSIONER 2 – CAMSHAFT BEARING CAP-EXHAUST 8 – CYLINDER BLOCK 3 – CAMSHAFT-EXHAUST 9 – CYLINDER HEAD 4 –...
Page 890 2.7L ENGINE 9 - 9 DESCRIPTION AND OPERATION (Continued) INTAKE MANIFOLD DESCRIPTION The two piece intake manifold is made of a com- posite material. The intake manifold features a com- pact, low rumble design that maximizes engine performance while minimizing induction noise. A manifold tuning valve (MTV) is used on some models.
Page 891 9 - 10 2.7L ENGINE DESCRIPTION AND OPERATION (Continued) Fig. 11 Cylinder Block Oil Lubrication System 1 – TO RIGHT CYLINDER HEAD 5 – OIL FILTER 2 – TO LEFT CYLINDER HEAD 6 – TO CRANKSHAFT MAIN JOURNALS 3 – OIL PUMP 7 –...
Page 892 2.7L ENGINE 9 - 11 DESCRIPTION AND OPERATION (Continued) Fig. 12 Cylinder Head Oil Lubrication System—Left Side 1 – CAM JOURNALS 4 – OIL FEED FROM BLOCK 2 – OIL FEED TO CAMSHAFT (SECONDARY) CHAIN 5 – VENT HOLE TENSIONER 6 –...
Page 893 9 - 12 2.7L ENGINE DESCRIPTION AND OPERATION (Continued) Fig. 13 Cylinder Head Oil Lubrication System—Right Side 1 – OIL FEED TO CAMSHAFT (SECONDARY) CHAIN 5 – VENT HOLE TENSIONER 6 – OIL FEED FROM BLOCK 2 – OIL FEED TO TIMING CHAIN (PRIMARY) TENSIONER 7 –...
Page 894 2.7L ENGINE 9 - 13 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. ENGINE DIAGNOSIS—INTRODUCTION Information concerning additional tests and diagno- Engine diagnosis is helpful in determining the sis is provided within the following: causes of malfunctions not detected and remedied by •...
Page 895 9 - 14 2.7L ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. Refer to POWER IGNITION SYSTEM. 2. Contamination in fuel system. 2. Clean system and replace fuel filter. 3.
Page 896 2.7L ENGINE 9 - 15 DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in crankcase. 1. Check and correct engine oil level. 2. Thin or diluted oil. 2. Change oil to correct viscosity. 3.
Page 897 9 - 16 2.7L ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level. 2. Faulty oil pressure sending unit. 2. Install new sending unit. 3. Low oil pressure. 3.
Page 898 2.7L ENGINE 9 - 17 DIAGNOSIS AND TESTING (Continued) • Leaks between adjacent cylinders or into water CYLINDER COMPRESSION PRESSURE TEST jacket. The results of a cylinder compression pressure test • Any causes for combustion/compression pressure can be utilized to diagnose several engine malfunc- loss.
Page 899 9 - 18 2.7L ENGINE DIAGNOSIS AND TESTING (Continued) section. An engine cylinder head gasket leaking Install Cooling System Tester 7700 or equivalent to between adjacent cylinders will result in approxi- pressure cap neck. Start the engine and observe the mately a 50–70% reduction in compression pressure.
Page 900 2.7L ENGINE 9 - 19 DIAGNOSIS AND TESTING (Continued) POSSIBLE CAUSES CORRECTION 5. Oil passage to cylinder head(s) plugged with debris. 5. Check cylinder head oil passages and cylinder head gasket restrictor for blockage. Clean or replace as necessary. 6. Worn valve guide(s). 6.
Page 901 9 - 20 2.7L ENGINE DIAGNOSIS AND TESTING (Continued) CAUTION: Do not exceed 20.6 kPa (3 psi). ENGINE OIL SERVICE (5) If the leak is not detected, very slowly turn the WARNING: NEW OR USED ENGINE OIL CAN BE crankshaft and watch for leakage. If a leak is IRRITATING TO THE SKIN.
Page 902 2.7L ENGINE 9 - 21 SERVICE PROCEDURES (Continued) CONTAINER IDENTIFICATION USED ENGINE OIL DISPOSAL Care should be exercised when disposing used Standard engine oil identification notations have engine oil after it has been drained from a vehicle been adopted to aid in the proper selection of engine oil.
Page 903 9 - 22 2.7L ENGINE SERVICE PROCEDURES (Continued) between two metallic surfaces, and will rapidly cure NOTE: Multi-Layer Steel (MLS) head gaskets when heat is applied. require a scratch free sealing surface. MOPAR GASKET SEALANT Only use the following for cleaning gasket surfaces: Mopar Gasket Sealant is a slow drying, perma- •...
Page 904 2.7L ENGINE 9 - 23 SERVICE PROCEDURES (Continued) CYLINDER BORE—HONING brush and the parts then thoroughly dried. The bore can be considered clean when it can be wiped (1) Used carefully, the cylinder bore resizing hone, clean with a white cloth and cloth remains clean. recommended tool C-823 or equivalent, equipped Oil the bores after cleaning to prevent rusting.
Page 905 9 - 24 2.7L ENGINE SERVICE PROCEDURES (Continued) Fig. 19 Piston Measurements PISTON PINS The piston pin is full floating and is held in place by lock rings. Pistons and rods are weight matched Fig. 21 Measuring Piston Ring Side Clearance for balance.
Page 906 2.7L ENGINE 9 - 25 SERVICE PROCEDURES (Continued) Fig. 25 Piston Ring End Gap Position Fig. 23 Side Rail—Installation 1 – SIDE RAIL UPPER 1 – SIDE RAIL END 2 – NO. 1 RING GAP 3 – PISTON PIN 4 – SIDE RAIL LOWER 5 –...
Page 907 9 - 26 2.7L ENGINE SERVICE PROCEDURES (Continued) Refer to Engine Specifications. Repeat procedure for each connecting rod. Turn crankshaft for connecting rod accessibility. Fig. 28 Connecting Rod Side Clearance Measuring CRANKSHAFT MAIN BEARING—FITTING The main bearings are “select fit” to achieve proper Fig.
Page 908 2.7L ENGINE 9 - 27 SERVICE PROCEDURES (Continued) Fig. 29 Crankshaft Main Journal Grade Marking Location Fig. 31 Main Bearing Grade Marks 1 – LOWER MAIN BEARING 2 – UPPER MAIN BEARING 3 – OIL FEED HOLE AND GROOVE 4 – GRADE SELECTION INK MARKS MAIN BEARING SELECTION CHART—2.7L Main Bearing Bore Grade Mark +0.003...
Page 909 9 - 28 2.7L ENGINE SERVICE PROCEDURES (Continued) (3) Inspect the valve seat with Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure.
Page 910 2.7L ENGINE 9 - 29 SERVICE PROCEDURES (Continued) Fig. 34 Testing Valve Spring with Tool C-647 1 – SPECIAL TOOL C-647 Fig. 36 Valve Seal and Spring 1 – VALVE RETAINING LOCKS 2 – VALVE SPRING RETAINER 3 – VALVE SPRING 4 –...
Page 911 9 - 30 2.7L ENGINE SERVICE PROCEDURES (Continued) Fig. 37 Engine Timing 1 – 12 PINS 3 – 12 PINS 2 – CAMSHAFT TIMING MARKS INTAKE MANIFOLD VACUUM PORT REPAIR— (4) Apply Mopar Thread Sealant to threads of repair nipple(s). 2.7L (5) Install repair nipple(s).
Page 912 2.7L ENGINE 9 - 31 SERVICE PROCEDURES (Continued) Fig. 39 Engine Mounting—Right, Left, and Rear 1 – NUT 6 – HEAT SHIELD 2 – REAR ISOLATOR 7 – BOLT 3 – BOLT 8 – ENGINE MOUNT BRACKET 4 – NUT 9 –...
Page 913 9 - 32 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION ENGINE ASSEMBLY (1) Position isolator onto crossmember. REMOVAL (2) Install bolts attaching isolator to crossmember and tighten to 33 N·m (250 in. lbs.) (Fig. 39). (1) Release fuel pressure. Refer to FUEL SYSTEM (3) Lower transaxle onto isolator.
Page 914 2.7L ENGINE 9 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 42 Cowl Covers Fig. 44 Air Cleaner and Inlet Hose 1 – WINDSHIELD 1 – AIR CLEANER ASSEMBLY WITH AIR INLET HOSE 2 – LEFT COWL COVER 2 – THROTTLE BODY 3 –...
Page 915 9 - 34 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) (34) Mark flex plate to torque converter position. (10) Install the transaxle oil cooler lines bracket to Remove torque converter bolts. engine (35) Disconnect both transaxle cooler line brackets (11) Install structural collar to oil pan and tran- from engine.
Page 916 2.7L ENGINE 9 - 35 REMOVAL AND INSTALLATION (Continued) Fig. 45 Engine Lifting Fixture 1 – SPECIAL TOOL 8342 ENGINE LIFTING FIXTURE 3 – ATTACHING LOCATION 2 – ATTACHING LOCATION CRANKSHAFT DAMPER (3) Remove damper center bolt while holding the damper with Special Tool 8191 (Fig.
Page 917 9 - 36 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) (4) Remove damper by using Special Tools 8194 Insert and 1023 Three Jaw Puller (Fig. 47). Fig. 48 Crankshaft Damper—Installation 1 – SPECIAL TOOL 6792–1 2 – SPECIAL TOOL 8179 (2) Install damper center bolt. Tighten center bolt Fig.
Page 918 2.7L ENGINE 9 - 37 REMOVAL AND INSTALLATION (Continued) (9) Remove engine name cover from manifold by (9) Install throttle cable bracket. applying upward pressure to release retaining clip. (10) Install throttle and speed control cables to (10) Remove manifold attaching bolts. bracket and throttle arm.
Page 919 9 - 38 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) (2) Position manifold on cylinder head surfaces. INSTALLATION (1) Install exhaust manifold and gasket. Tighten NOTE: For ease of installing upper intake manifold, bolts working from center outwards to 23 N·m (200 install a bolt 2 –...
Page 920 2.7L ENGINE 9 - 39 REMOVAL AND INSTALLATION (Continued) (4) Remove left catalytic converter. Refer NOTE: Cylinder head cover attaching bolts are cap- EXHAUST SYSTEM for procedure. tured to the cover. NOTE: Do not reuse V-Band clamp. (7) Remove cylinder head covers. (5) Remove bolt attaching transmission dipstick tube and rotate housing away from engine.
Page 921 9 - 40 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) (3) Tighten cylinder head cover attaching bolts and (2) If camshaft chain tensioner is already in the double-ended studs to 12 N·m (105 in. lbs.). compressed and locked position, proceed to step (4). (4) Connect all electrical connectors and harness (3) When the camshaft chain tensioner is removed, clips.
Page 922 2.7L ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) (12) Install primary timing chain. Refer to proce- CAUTION: Always rotate engine by turning the dure in this section. crankshaft. Failure to do so will result in valve and/or piston damage. (2) Rotate engine until the cam lobe is on its base circle (heel), on the rocker arm being removed.
Page 923 9 - 42 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) (3) Remove air cleaner housing cover and inlet hose. (4) Remove upper intake manifold. Refer to proce- dure in this section. (5) Remove cylinder head cover(s). Refer to proce- dure in this section. (6) Remove crankshaft damper, timing chain cover, and timing chain.
Page 924 2.7L ENGINE 9 - 43 REMOVAL AND INSTALLATION (Continued) (8) Connect negative cable. (12) Remove V-Band clamp(s) at exhaust manifold to catalytic converter pipe. CYLINDER HEAD NOTE: Do not reuse V-Band clamp. REMOVAL (1) Perform fuel pressure release procedure before CAUTION: Ensure cylinder head bolts 11–9 (Fig.
Page 925 9 - 44 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) (5) Tighten bolts in sequence shown in (Fig. 63), (12) Install lower and upper intake manifolds. using the following steps and torque values: Refer to procedures in this section. • Step 1: Bolts 1–8 to 48 N·m (35 ft. lbs.) (13) Install accessory drive belts.
Page 926 2.7L ENGINE 9 - 45 REMOVAL AND INSTALLATION (Continued) (3) Install valve seal/spring seat assembly over (7) Remove timing chain cover attaching bolts and valve guides on all valve stems (Fig. 66). Ensure that remove cover (Fig. 67). the garter spring is intact around the top of the rub- ber seal.
Page 927 9 - 46 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) (2) If front crankshaft seal was bench installed, (10) Install fan module and accessory drive belts. place Special Tool 6780-2, Sleeve over crankshaft Refer to COOLING SYSTEM for procedure. nose to guide and protect seal lip. (11) Install upper radiator crossmember.
Page 928 2.7L ENGINE 9 - 47 REMOVAL AND INSTALLATION (Continued) (3) Align crankshaft sprocket timing mark to mark (2) If removed, install right and left side short on oil pump housing (Fig. 70). The mark on oil pump chain guides (Fig. 69). Tighten attaching bolts to 28 housing is 60°...
Page 929 9 - 48 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 71 Primary Timing Chain Marks 1 – CAMSHAFT TIMING MARKS 6 – CHAIN TENSIONER 2 – CHAIN GUIDE 7 – CAMSHAFT TIMING MARK 3 – CRANKSHAFT TIMING MARKS 8 – INTAKE CAMSHAFT SPROCKETS 4 –...
Page 930 2.7L ENGINE 9 - 49 REMOVAL AND INSTALLATION (Continued) Fig. 72 Timing Chain Tensioner—Oil Purging 1 – TENSIONER 3 – SPECIAL TOOL 8186 2 – CHECK BALL 4 – PIN NOTE: If oil was not first purged from the ten- CAUTION: Ensure the tensioner is properly reset.
Page 931 9 - 50 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 73 Timing Chain Tensioner—Resetting 1 – TENSIONER 2 – SPECIAL TOOL 8186 (15) Install the reset chain tensioner into the right (19) Rotate engine slightly clockwise to remove cylinder head (Fig. 74). timing chain slack, if necessary.
Page 932 2.7L ENGINE 9 - 51 REMOVAL AND INSTALLATION (Continued) (2) Remove crankshaft sprocket by first installing the crankshaft damper bolt. Apply grease or equiva- lent to damper bolt head and position Special Tools 5048-1, 5048-6, and 8539 on sprocket and crankshaft nose (Fig.
Page 933 9 - 52 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) against crankshaft step flange. Use care not to rotate INSTALLATION crankshaft. (1) Install new seal using Special Tools 6780-2 (2) Verify that crankshaft sprocket is installed to Sleeve, 6780-1 Installer, and 8179 Stud (Fig. 80). proper depth by measuring from sprocket outer face (2) Install crankshaft damper.
Page 934 2.7L ENGINE 9 - 53 REMOVAL AND INSTALLATION (Continued) Fig. 81 Rear Crankshaft Oil Seal Removal—Typical 1 – REAR CRANKSHAFT SEAL 2 – ENGINE BLOCK Fig. 82 Crankshaft Rear Seal—Installation 3 – ENGINE BLOCK 4 – REAR CRANKSHAFT SEAL METAL CASE 1 –...
Page 935 9 - 54 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (7) Disconnect engine oil cooler line from pan (if equipped). (1) Clean sealing surfaces and replace gasket as needed. CAUTION: Assure removal of the two bolts attach- (2) Install gasket and loose assemble seal retainer ing the timing cover to the oil pan, as damage to to block.
Page 936 2.7L ENGINE 9 - 55 REMOVAL AND INSTALLATION (Continued) CRANKSHAFT REMOVAL (1) Remove engine from vehicle. Refer to procedure in this section. (2) Mount engine on an engine stand. (3) Drain engine oil and remove oil filter. (4) Remove oil pan and oil pick-up tube. (5) Remove idler pulley bracket for accessory drive belt.
Page 937 9 - 56 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) (3) Push crankshaft forward. Lubricate and install the front thrust washer by rolling the thrust washer onto the machined shelf between the No. 3 upper main bulk head and crankshaft thrust surface (Fig. 89).
Page 938 2.7L ENGINE 9 - 57 REMOVAL AND INSTALLATION (Continued) OIL FILTER (1) Remove oil filter using suitable oil filter wrench (Fig. 92). Dispose of oil filter following envi- romental guidelines. Fig. 90 Main Bearing Cap Identification 1 – TIE BOLTS 2 –...
Page 939 9 - 58 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) with mark on oil pump (Fig. 93). This position will INSTALLATION properly locate oil pump upon installation. (4) Remove oil pump attaching bolts (Fig. 94). CAUTION: Crankshaft position must be at 60° ATDC (5) Remove oil pump.
Page 940 2.7L ENGINE 9 - 59 REMOVAL AND INSTALLATION (Continued) CAUTION: Install piston rings in the following order: (2) Oil ring expander. (3) Upper oil ring side rail. (4) Lower oil ring side rail. (5) No. 2 Intermediate piston ring. (6) No. 1 Upper piston ring. (7) Install the side rail by placing one end between the piston ring groove and the expander.
Page 941 9 - 60 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) and tighten with the special wrench. Ensure posi- tion of rings does not change during this oper- ation. Fig. 99 Upper and Intermediate Rings—Installation (10) Position piston ring end gaps as shown in (Fig.
Page 942 2.7L ENGINE 9 - 61 REMOVAL AND INSTALLATION (Continued) Fig. 102 Piston and Connecting Rod Positioning 1 – MAJOR THRUST SIDE OF PISTON 2 – OIL SQUIRT HOLE (7) Rotate crankshaft so that the connecting rod plug rotated, grasp firmly with pliers or other suit- journal is on the center of the cylinder bore.
Page 943 9 - 62 2.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 103 Core Hole Plug Removal 1 – CYLINDER BLOCK 2 – REMOVE PLUG WITH PLIERS 3 – STRIKE HERE WITH HAMMER 4 – DRIFT PUNCH 5 – CUP PLUG DISASSEMBLY AND ASSEMBLY Fig.
Page 944 2.7L ENGINE 9 - 63 CYLINDER HEAD CLEANING AND INSPECTION INTAKE MANIFOLD CLEANING (1) Use a gasket removal compound to soften the Check for: • Damage and cracks of each section. old gasket material. • Clogged water passages in end cross over and CAUTION: When cleaning the cylinder head and clogged gas passages.
Page 945 9 - 64 2.7L ENGINE CLEANING AND INSPECTION (Continued) Fig. 108 Cam Follower Assembly 1 – LASH ADJUSTER POCKET 2 – OIL SQUIRT HOLE 3 – ROLLER Fig. 110 Measuring Valve Guide Wear—Typical VALVE GUIDES NOTE: Valve stems are chrome plated and should not be polished (Fig.
Page 946 2.7L ENGINE 9 - 65 CLEANING AND INSPECTION (Continued) (3) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 9.474 mm (0.373 in.) or less (Fig. 112), or if the diameter is 89.174 mm (3.5108 inches.) or less, replace outer rotor. Fig.
Page 947 9 - 66 2.7L ENGINE CLEANING AND INSPECTION (Continued) CYLINDER BORE INSPECTION The cylinder walls should be checked for out-of- round and taper with Tool C-119 as shown in (Fig. 117). Measure the cylinder bore at three levels in direc- tions A and B (Fig.
Page 948 2.7L ENGINE 9 - 67 CLEANING AND INSPECTION (Continued) sion. If a machined groove on the plunger is visible DESCRIPTION SPECIFICATION (Fig. 118), the timing chain and/or related compo- Clearance at Size – 0.0016 to +0.0396 mm nents are worn or stretched to service limits. Location (3) Inspect all chain guides, sprockets and tension- (–...
Page 949 9 - 68 2.7L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Side Clearance (Max.) 0.4318 mm End Play 0.13 mm (0.017 in.) (0.0051–0.0110 in.) Piston Pin Bore Diameter 22.007–22.015 mm Valve Timing—Intake Valve (0.8665–0.8668 in.) Opens (ATDC) 2° Bearing Bore Out of 0.004 mm Closes (ABDC) 44°...
Page 950 2.7L ENGINE 9 - 69 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Stem-to-Guide 0.023–0.066 mm Inner & Outer Rotor 9.475–9.500 mm Clearance—Intake (New) Thickness (0.0009–0.0026 in.) (0.3731–0.3741 in.) Stem-to-Guide 0.051–0.094 mm Outer Rotor Clearance 0.39 mm Clearance—Exhaust (Max.) (0.015 in.) (0.002–0.0037 in.) (New) Outer Rotor Diameter 89.175 mm...
Page 951 9 - 70 2.7L ENGINE SPECIFICATIONS (Continued) SPECIAL TOOLS DESCRIPTION N·m Lbs. Lbs. 2.7L ENGINE Engine Mount Bracket to Block— — Bolts Engine Mount Isolator—Nuts — Intake Manifold (Upper and — Lower)—Bolts Generator Bracket—Bolts — Oil Pan —Bolts — —Nuts —...
Page 952 2.7L ENGINE 9 - 71 SPECIAL TOOLS (Continued) Crankshaft Damper Installer 6792-1 Puller 5048 Crankshaft Damper Holder 8191 Puller Adaptor 8539 Crankshaft Seal Remover 6771 Crankshaft Rear Seal Guide 6926-1 & Installer 6926-2 Crankshaft Seal & Sprocket Installer 6780-1 Crankshaft Real Seal Retainer Alignment Fixture 8225 Crankshaft Seal Protector 6780-2 Timing Chain Tensioner Resetting Gauge 8186...
Page 953 9 - 72 2.7L ENGINE SPECIAL TOOLS (Continued) Dial Indicator C-3339 Valve Spring Tester C-647 Valve Spring Compressor 8215 Valve Spring Compressor MD-998772-A Adapter 8216 Valve Spring Adapter 6527 Valve Spring Compressor C-3422-B Indicator Bore Size C-119 Valve Spring Adapter 6526 Connecting Rod Installation Guides 8189...
Page 954 2.7L ENGINE 9 - 73 SPECIAL TOOLS (Continued) Main Bearing Remover/Installer C-3059 Cooling System Tester 7700 Combustion Leak Tester C-3685-A Adaptor 8116...
Page 955 9 - 74 3.2/3.5L ENGINE 3.2/3.5L ENGINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION ENGINE ASSEMBLY..... . 103 3.2/3.5L ENGINE ......75 CRANKSHAFT DAMPER .
Page 956 3.2/3.5L ENGINE 9 - 75 DESCRIPTION AND OPERATION 3.2/3.5L ENGINE Fig. 1 3.2/3.5L Engine...
Page 957 9 - 76 3.2/3.5L ENGINE DESCRIPTION AND OPERATION (Continued) DESCRIPTION The 3.2 Liter (167 Cubic Inches) and 3.5 Liter (214 Cubic Inches) 60 degree V-6 engines are a single overhead camshaft design with hydraulic lifters and four valves per cylinder (Fig. 1). The engines do not have provisions for a free wheeling valve train.
Page 958 3.2/3.5L ENGINE 9 - 77 DESCRIPTION AND OPERATION (Continued) Fig. 4 Cylinder Block and Crankshaft 1 – MAIN CAP BOLT - VERTICAL 5 – CYLINDER BLOCK 2 – MAIN CAP 6 – MAIN CAP BOLT - HORIZONTAL 3 – MAIN BEARING - LOWER 7 –...
Page 959 9 - 78 3.2/3.5L ENGINE DESCRIPTION AND OPERATION (Continued) PISTONS AND CONNECTING RODS OPERATION The intake valve allows the air/fuel mixture to DESCRIPTION enter the combustion chamber. The exhaust valve allows the burned air/fuel mixture to exit the com- The pistons are made of a high strength aluminum bustion chamber.
Page 960 3.2/3.5L ENGINE 9 - 79 DESCRIPTION AND OPERATION (Continued) Fig. 5 Timing Drive System 1 – TIMING BELT COVER - RIGHT REAR 8 – BOLT-CRANKSHAFT DAMPER 2 – TENSIONER-TIMING BELT 9 – TIMING BELT COVER-LOWER 3 – CAMSHAFT SPROCKET 10 – TIMING BELT COVER-RIGHT 4 –...
Page 961 9 - 80 3.2/3.5L ENGINE DESCRIPTION AND OPERATION (Continued) INTAKE MANIFOLD DESCRIPTION The composite upper intake manifold is a cross- flow type with long runners to improve air charge inertia (Fig. 8). An active Short Runner Valve (SRV) opens during certain operating conditions to improve top end performance.
Page 962 3.2/3.5L ENGINE 9 - 81 DESCRIPTION AND OPERATION (Continued) Fig. 9 Lower Intake Manifold 1 – BOLT 6 – GASKET 2 – HEATER SUPPLY TUBE 7 – BOLT 3 – BOLT 8 – O-RING 4 – BOLT 9 – INTAKE MANIFOLD-LOWER 5 –...
Page 963 9 - 82 3.2/3.5L ENGINE DESCRIPTION AND OPERATION (Continued) DIAGNOSIS AND TESTING ENGINE DIAGNOSIS—INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls).
Page 964 3.2/3.5L ENGINE 9 - 83 DIAGNOSIS AND TESTING (Continued) • Lash Adjuster (Tappet) Noise Diagnosis • Engine Oil Leak Inspection ENGINE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary.
Page 965 9 - 84 3.2/3.5L ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE MISSES ON 1. Dirty or incorrectly gapped spark 1. Clean spark plugs and set gap. Refer ACCELERATION plugs. to IGNITION SYSTEM. 2. Contamination in Fuel System. 2.
Page 966 3.2/3.5L ENGINE 9 - 85 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 967 9 - 86 3.2/3.5L ENGINE DIAGNOSIS AND TESTING (Continued) CHECKING ENGINE OIL PRESSURE specified height and allowable tensions. Replace springs that do not meet specifications. Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34 kPa (5 psi) at idle or 205 to 724 kPa (30 to 105 psi.) at 3000 RPM.
Page 968 3.2/3.5L ENGINE 9 - 87 DIAGNOSIS AND TESTING (Continued) mal firing indicators fouled, hot, oily, etc. Record cyl- Remove the oil filler cap. inder number of spark plug for future reference. Remove the air cleaner. (4) Disconnect coil wire from distributor and Calibrate the tester according to the manufactur- secure to good ground to prevent a spark from start- er’s instructions.
Page 969 9 - 88 3.2/3.5L ENGINE DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM TESTER METHOD CHEMICAL TEST METHOD Combustion leaks into the cooling system can also WARNING: WITH COOLING SYSTEM TESTER IN be checked by using Bloc-Chek Kit C-3685-A or PLACE, PRESSURE WILL BUILD UP FAST. EXCES- equivalent.
Page 970 3.2/3.5L ENGINE 9 - 89 DIAGNOSIS AND TESTING (Continued) LASH ADJUSTER (TAPPET) NOISE CHART POSSIBLE CAUSES CORRECTION 1. Engine oil level—too high or too low. This may cause 1. Check and correct engine oil level. aerated oil to enter the adjusters and cause them to be spongy.
Page 971 9 - 90 3.2/3.5L ENGINE DIAGNOSIS AND TESTING (Continued) If the oil leak source is not positively (3) Remove torque converter or clutch housing identified at this time, proceed with the air leak cover and inspect rear of block for evidence of oil. detection test method as follows: Use a black light to check for the oil leak.
Page 972 3.2/3.5L ENGINE 9 - 91 SERVICE PROCEDURES (Continued) Fig. 14 Engine Oil Fill and Dipstick Locations—3.2/ Fig. 15 Temperature/Engine Oil Viscosity—3.2/3.5L 3.5L Engines 1 – ENGINE OIL FILL CONTAINER IDENTIFICATION 2 – ENGINE OIL DIPSTICK Standard engine oil identification notations have been adopted to aid in the proper selection of engine ENGINE OIL SERVICE oil.
Page 973 9 - 92 3.2/3.5L ENGINE SERVICE PROCEDURES (Continued) (9) Start engine and inspect for leaks. MOPAR GASKET MAKER (10) Stop engine and inspect oil level. Mopar Gasket Maker is an anaerobic type gasket material. The material cures in the absence of air ENGINE OIL FILTER CHANGE when squeezed between two metallic surfaces.
Page 974 3.2/3.5L ENGINE 9 - 93 SERVICE PROCEDURES (Continued) sealing surfaces. Material in an aerosol can should be REPAIR OF DAMAGED OR WORN THREADS used on engines with multi-layer steel gaskets. Damaged or worn threads (excluding spark plug and camshaft bearing cap attaching threads) can be ENGINE GASKET SURFACE PREPARATION repaired.
Page 975 9 - 94 3.2/3.5L ENGINE SERVICE PROCEDURES (Continued) LASH ADJUSTER—BLEEDING Use this procedure to manually bleed aerated oil from the lash adjuster and remove sponginess. (1) Run the engine, bringing it to operating tem- perature in order to freshly pressurize and warm the valvetrain system oil supply.
Page 976 3.2/3.5L ENGINE 9 - 95 SERVICE PROCEDURES (Continued) refills the high pressure chamber with non-aerated oil. (e) Remove probes to allow check balls to seat. (f) Recheck for sponginess. If the lash adjuster sponginess is not completely or nearly eliminated, then repeat procedure.
Page 977 9 - 96 3.2/3.5L ENGINE SERVICE PROCEDURES (Continued) PISTON RING—FITTING CAUTION: Install piston rings in the following order: (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The (2) Oil ring expander. ring gap measurement must be made with the ring (3) Upper oil ring side rail.
Page 978 3.2/3.5L ENGINE 9 - 97 SERVICE PROCEDURES (Continued) The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. Limits of taper or out-of-round on any crankshaft journals should be held to 0.015 mm (0.0006 in.).
Page 979 9 - 98 3.2/3.5L ENGINE SERVICE PROCEDURES (Continued) NOTE: Service main bearings have a number from (1 – 5) marked in ink on the bearing surface (Fig. 33). For verification, use the Main Bearing Selection Chart for number to size identification. The upper main bearing has a oil feed hole and a center groove to allow lubrication of the main journal and must be properly positioned in the block.
Page 980 3.2/3.5L ENGINE 9 - 99 SERVICE PROCEDURES (Continued) CRANKSHAFT END PLAY—CHECKING (1) Using Dial Indicator C-3339 and Mounting Post L-4438, attach to front of engine, locating probe perpendicular on nose of crankshaft (Fig. 34). (2) Move crankshaft all the way to the rear of its travel.
Page 981 9 - 100 3.2/3.5L ENGINE SERVICE PROCEDURES (Continued) VALVE SEATS (5) Check the valve spring installed height after refacing the valve and seat (Fig. 38). (1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseat- VALVE SPRING IDENTIFICATION ing stones.
Page 982 3.2/3.5L ENGINE 9 - 101 SERVICE PROCEDURES (Continued) (2) Remove the isolator attaching nuts from top of the mounting bracket (Fig. 40). (3) Support the engine with a jack and a block of wood across the full width of the oil pan. (4) Remove the lower attaching nuts from the bot- tom of the isolator to the frame (Fig.
Page 983 9 - 102 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 40 Engine Mounting—Right, Left, and Rear 1 – NUT 6 – HEAT SHIELD 2 – REAR ISOLATOR 7 – BOLT 3 – BOLT 8 – ENGINE MOUNT BRACKET 4 – NUT 9 –...
Page 984 3.2/3.5L ENGINE 9 - 103 REMOVAL AND INSTALLATION (Continued) ENGINE ASSEMBLY REMOVAL (1) Disconnect negative cable at right strut tower (Fig. 42). (2) Mark hood position at hinges and remove hood. (3) Remove both wiper arms. (4) Remove both cowl covers (Fig. 43). (5) Remove cowl support (Fig.
Page 985 9 - 104 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) (40) For starter removal, loosen the left converter exhaust pipe band clamp and exhaust pipe support bracket at transaxle. (41) Remove starter. (42) Remove left engine mount bolts. (43) Remove right engine mount bolts. (44) Remove crankshaft position sensor.
Page 986 3.2/3.5L ENGINE 9 - 105 REMOVAL AND INSTALLATION (Continued) (25) Connect throttle and speed control cables to bracket and throttle arm. (26) Connect fuel line. (27) Install new V-Band clamp at right exhaust manifold. Tighten V-Band clamp to 11 N·m (100 in. lbs.).
Page 987 9 - 106 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 49 Air Cleaner Housing and Inlet Hose 1 – AIR CLEANER ASSEMBLY WITH AIR INLET HOSE 2 – THROTTLE BODY Fig. 48 Crankshaft Damper—Installation 1 – SPECIAL TOOL 6792–1 (6) Remove right side (Fig. 50) and left side (Fig. 2 –...
Page 988 3.2/3.5L ENGINE 9 - 107 REMOVAL AND INSTALLATION (Continued) Fig. 51 Intake Manifold Support—Left Side 1 – SUPPORT BRACKET Fig. 53 Upper Intake Manifold Tightening Sequence (7) Tighten fastener attaching throttle body to sup- port bracket. (8) Connect vacuum lines to the following: •...
Page 989 9 - 108 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) REMOVAL INSTALLATION (1) Perform fuel pressure release. Refer to FUEL (1) Clean all sealing surfaces. SYSTEM for procedure. NOTE: Gaskets can be reused provided they are (2) Drain cooling system. Refer to COOLING SYS- free of tears or cuts.
Page 990 3.2/3.5L ENGINE 9 - 109 REMOVAL AND INSTALLATION (Continued) Fig. 55 Lower Intake Manifold 1 – BOLT 6 – GASKET 2 – HEATER SUPPLY TUBE 7 – BOLT 3 – BOLT 8 – O-RING 4 – BOLT 9 – INTAKE MANIFOLD-LOWER 5 –...
Page 991 9 - 110 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) (11) Remove air conditioning compressor bracket. (12) Disconnect oxygen sensor electrical connector and remove sensor. (13) Remove heat shield attaching bolts and remove heat shield (Fig. 57). (14) Remove exhaust manifold attaching bolts (Fig. 57).
Page 992 3.2/3.5L ENGINE 9 - 111 REMOVAL AND INSTALLATION (Continued) (1) Remove air cleaner assembly and upper intake manifold. Refer to Intake Manifold in this section for procedure. (2) Cover lower intake manifold with a suitable cover during service. (3) Disconnect electrical connectors and remove ignition coils (Fig.
Page 993 9 - 112 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 61 Cylinder Head Cover Gasket and Spark Plug Tube Seals 1 – CYLINDER HEAD COVER GASKET 2 – SPARK PLUG TUBE SEALS Fig. 59 Ignition Coils Fig. 62 Spark Plug Tube Seal Installation 1 –...
Page 994 3.2/3.5L ENGINE 9 - 113 REMOVAL AND INSTALLATION (Continued) NOTE: Do not reuse V-Band Clamp. (7) Remove rear timing belt cover to cylinder head fasteners (Fig. 64). Remove the rear covers. (8) The right side rear timing belt cover has O-rings to seal the water pump passages to cylinder block (Fig.
Page 995 9 - 114 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION CAUTION: When cleaning cylinder head and cylin- der block surfaces, DO NOT use a metal scraper The cylinder head bolts are tightened using a because the surfaces could be cut or ground. Use torque plus angle procedure.
Page 996 3.2/3.5L ENGINE 9 - 115 REMOVAL AND INSTALLATION (Continued) (9) Install camshaft sprockets and timing belt. Refer to procedure in this section. (10) Install front timing belt covers. Refer to pro- cedure in this section. (11) Install crankshaft damper. (12) Install upper and lower intake manifold. Refer to procedures in this section.
Page 997 9 - 116 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) No. 2 upper main bulk head and crankshaft thrust (14) Install crankshaft sprocket. Refer to Front surface (Fig. 72). Crankshaft Oil Seal Removal and Installation for (3) Move crankshaft rearward to limit of travel. procedure.
Page 998 3.2/3.5L ENGINE 9 - 117 REMOVAL AND INSTALLATION (Continued) CAMSHAFT SPROCKETS AND TIMING PROCEDURE REMOVAL CAUTION: The 3.2/3.5L engines are NOT a free- wheeling design. Therefore, care should be taken not to rotate the camshafts or crankshaft with the timing belt removed. (1) Drain cooling system.
Page 999 9 - 118 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 77 Camshaft Sprocket Timing Marks 1 – ALIGN CAMSHAFT SPROCKET TIMING MARK BETWEEN MARKS ON REAR TIMING BELT COVER 2 – CRANKSHAFT AT TDC Fig. 75 Camshaft Alignment Special Tools 6642 1 –...
Page 1000 3.2/3.5L ENGINE 9 - 119 REMOVAL AND INSTALLATION (Continued) arm shaft assembly on the LEFT side of the engine has an oil passage hole from the cylinder head to the second rocker shaft support. REMOVAL (1) Remove cylinder head covers. Refer to proce- dure in this section.
Page 1001 9 - 120 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: Rocker arm and shaft assembly can be installed either prior to or after (preferred) cylinder head installation. (1) Rotate camshafts to the position shown in (Fig. 83). With the camshafts in these positions the lobes are in a neutral position (no load to the valve).
Page 1002 3.2/3.5L ENGINE 9 - 121 REMOVAL AND INSTALLATION (Continued) (2) Disconnect negative battery cable. (3) Remove air cleaner housing and hose assembly. (4) Remove upper intake manifold. Refer to proce- dure in this section. (5) Remove cylinder head covers and spark plugs. Refer to procedures in this section.
Page 1003 9 - 122 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 87 Valve Spring Compressors 1 – ADAPTER 6537 2 – ADAPTER 6526 Fig. 89 Valve, Spring, and Valve Seal—Installation 1 – VALVE 2 – VALVE RETAINING LOCKS 3 – VALVE SPRING RETAINER 4 –...
Page 1004 3.2/3.5L ENGINE 9 - 123 REMOVAL AND INSTALLATION (Continued) Fig. 90 Crankshaft Damper—Removal 1 – SPECIAL TOOL 1023 Fig. 92 Timing Belt Covers 2 – SPECIAL TOOL C-4685–C2 1 – RIGHT SIDE COVER (STAMPED) INSERT 2 – LEFT SIDE COVER (CAST) 3 –...
Page 1005 9 - 124 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) CAUTION: The 3.2/3.5L freewheeling NOTE: When timing belt tensioner is removed from engines. Therefore, care should be taken not to engine, always store in the vertical (plunger facing rotate the camshafts or crankshaft with the timing upward) position.
Page 1006 3.2/3.5L ENGINE 9 - 125 REMOVAL AND INSTALLATION (Continued) NOTE: When timing belt tensioner is removed from engine, always store in the vertical (plunger facing upward) position. Fig. 97 Timing Belt Installation Fig. 96 Compressing Timing Belt Tensioner 1 – ALIGN CAMSHAFTS WITH TIMING MARKS 1 –...
Page 1007 9 - 126 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) (6) Disconnect transmission oil cooler line clips. (7) Remove oil pan (Fig. 99). (8) Remove oil pan gasket. (9) Clean oil pan and all gasket surfaces. INSTALLATION (1) Apply a 1/8 inch bead of Mopar Engine RTV GEN II at the parting line of the oil pump housing and the rear seal retainer (Fig.
Page 1008 3.2/3.5L ENGINE 9 - 127 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Apply light coat of engine oil to the camshaft oil seal lip. (2) Install the oil seal using Special Tool 6788 Seal Protector Sleeve (Fig. 102) and Seal Installer 6052 (Fig.
Page 1009 9 - 128 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) CRANKSHAFT OIL SEAL—FRONT (5) Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary. REMOVAL (1) Remove timing belt. Refer to procedure in this section.
Page 1010 3.2/3.5L ENGINE 9 - 129 REMOVAL AND INSTALLATION (Continued) Fig. 108 Crankshaft Sprocket—Installation 1 – INSTALL WITH SPECIAL TOOL 6641 WITH 12mm SCREW C-4685–C1 AND THRUST BEARING AND WASHER CRANKSHAFT OIL SEAL—REAR Fig. 109 Rear Crankshaft Oil Seal Removal—Typical REMOVAL 1 –...
Page 1011 9 - 130 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) (4) While applying firm pressure to the seal retainer against Special Tools 8225 (Fig. 112), tighten seal retainer screws to 12 N·m (105 in. lbs.). Fig. 110 Crankshaft Rear Seal—Installation 1 – C-4171 HANDLE 2 –...
Page 1012 3.2/3.5L ENGINE 9 - 131 REMOVAL AND INSTALLATION (Continued) edges from crankshaft oil holes and clean out all pas- REMOVAL sages. (1) Remove oil pan, pick-up tube, and windage tray. Refer to procedures in this section. Identify CAUTION: With a forged steel crankshaft it is bearing caps before removal.
Page 1013 9 - 132 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) (4) Lubricate and install lower bearing half and strap against the base lock seam. The lock seam main cap Tighten bolts finger tight. joining the can to the base is reinforced by the (5) For installing thrust washers at the No.
Page 1014 3.2/3.5L ENGINE 9 - 133 REMOVAL AND INSTALLATION (Continued) (4) Remove timing belt. Refer to procedure in this necting rods must be removed from top of cyl- section. inder block. When removing piston (5) Remove crankshaft sprocket. Refer to Crank- connecting rod assemblies from the engine, shaft Oil Seal—Front procedure in this section.
Page 1015 9 - 134 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) (1) The No. 1 and No. 2 piston rings have a differ- ent cross section. Insure that the No. 2 ring is installed with manufacturers I.D. mark (dot) facing up, towards top of the piston (Fig. 121). CAUTION: Install piston rings in the following order: (2) Oil ring expander.
Page 1016 3.2/3.5L ENGINE 9 - 135 REMOVAL AND INSTALLATION (Continued) Fig. 126 Piston—Installation (7) The arrow on top of piston must be pointing Fig. 124 Piston Ring End Gap Position toward front of engine (Fig. 127) and oil squirt hole 1 – SIDE RAIL UPPER on connecting rod faces the major thrust (right) side 2 –...
Page 1017 9 - 136 3.2/3.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 128 Connecting Rod Positioning 1 – MAJOR THRUST SIDE OF PISTON 2 – OIL SQUIRT HOLE ENGINE CORE AND OIL PLUGS INSTALLATION Thoroughly clean inside of cup plug hole in cylin- REMOVAL der block or head.
Page 1018 3.2/3.5L ENGINE 9 - 137 REMOVAL AND INSTALLATION (Continued) Fig. 130 Oil Pressure Relief Valve 1 – RELIEF VALVE Fig. 129 Core Hole Plug Removal 2 – SPRING 1 – CYLINDER BLOCK 3 – RETAINER CAP 2 – REMOVE PLUG WITH PLIERS 4 –...
Page 1019 9 - 138 3.2/3.5L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) CYLINDER HEAD CLEANING (1) Use a gasket removal compound to soften the old gasket material. CAUTION: When cleaning the cylinder head and block mating surfaces, do not use a metal scraper because the sealing surfaces could be cut or ground.
Page 1020 3.2/3.5L ENGINE 9 - 139 CLEANING AND INSPECTION (Continued) The intake and exhaust rocker arms are different. They should be identified before disassembling the assembly (Fig. 136). Check rocker arms for wear or damage (Fig. 137) : • Roller scuffing or wear •...
Page 1021 9 - 140 3.2/3.5L ENGINE CLEANING AND INSPECTION (Continued) OIL PUMP INSPECTION AND REPAIR (1) Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. Replace pump cover if scratched or grooved. (2) Lay a straightedge across the pump cover sur- face (Fig.
Page 1022 3.2/3.5L ENGINE 9 - 141 CLEANING AND INSPECTION (Continued) Fig. 142 Measuring Inner Rotor Thickness Fig. 144 Measuring Clearance Between Rotors 1 – FEELER GAUGE 2 – OUTER ROTOR 3 – INNER ROTOR Fig. 143 Measuring Outer Rotor Clearance in Housing 1 –...
Page 1023 9 - 142 3.2/3.5L ENGINE CLEANING AND INSPECTION (Continued) CYLINDER BLOCK AND BORE ENGINE HYDRO-MOUNT INSULATORS Engine hydro-mounts may show surface cracks this CLEANING AND INSPECTION will not effect performance and mount should not be (1) Clean cylinder block thoroughly and check all replaced.
Page 1024 3.2/3.5L ENGINE 9 - 143 CLEANING AND INSPECTION (Continued) DESCRIPTION SPECIFICATION Taper (Max.) 0.051 mm (0.002 in.) Pistons Type Material Aluminum (Full Floating Pins) Clearance at Size –0.007 to +0.047 mm Location (–0.0003 to +0.0018 in.) Piston Weight —A Size 409–414 grams (14.4271–14.6035 oz.) —B Size...
Page 1025 9 - 144 3.2/3.5L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Ring Width Camshaft Top Compression Ring 1.17–1.19 mm Bore Diameter 43.038–43.059 mm (0.0461–0.0469 in.) (1.6944–1.6952 in.) 2nd Compression Ring 1.47–1.49 mm Bearing Journal Diameter 42.939–42.960 mm (0.0580–0.0587 in.) (1.6905–1.6913 in.) Oil Ring (Steel Rings) 0.445–0.470 mm Diametrical Clearance...
Page 1026 3.2/3.5L ENGINE 9 - 145 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Spring Force—Intake 836–907 N @ 29.85 mm Valves (Valve Open) (188–204 lbs. @ 1.1594 Face Angle 44.5–45° in.) Head Diameter—Intake 36.37–36.63 mm Spring Force—Exhaust 579–640 N @ 31.47 mm (1.4319–1.4421 in.) (Valve Open) (130–144 lbs.
Page 1027 9 - 146 3.2/3.5L ENGINE SPECIFICATIONS (Continued) 3.5L ENGINE DESCRIPTION SPECIFICATION Diameter 23.997–24.000 mm DESCRIPTION SPECIFICATION (0.9448–0.9449 in.) Type 60° SOHC V-6 24-Valve Piston Rings Displacement 3.5 Liters Ring Gap—Top 0.20–0.36 mm (214 Cubic Inches) Compression Ring (0.008–0.014 in.) Bore and Stroke 96.0 x 81.0 mm Ring Gap—2nd 0.23–0.50 mm...
Page 1028 3.2/3.5L ENGINE 9 - 147 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION End Play 0.10–0.30 mm Valve Seat Width— 1.25–1.75 mm Exhaust (0.0492–0.0689 in.) (0.004–0.012 in.) Guide Bore Diameter 6.975–7.00 mm —(Max.) 0.43 mm (Std.) (0.2746–0.2756 in.) (0.017 in.) Valve Guide Height* 9.5–10.5 mm Connecting Rod Journals (0.3740–0.4134 in.)
Page 1029 9 - 148 3.2/3.5L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Spring Force—Intake 309–358 N @ 38.0 mm @ 3000 rpm 170–724 kPa (Valve Closed) (69.5–80.5 lbs. @ 1.4961 (25–105 psi) in.) *CAUTION: If pressure is zero at curb idle, DO NOT Spring Force—Exhaust 314–354 N @ 38.0 mm run engine at 3000 rpm.
Page 1030 3.2/3.5L ENGINE 9 - 149 SPECIFICATIONS (Continued) N·m DESCRIPTION Lbs. Lbs. Oil Pan —M6 Bolts — 105 —M8 Bolts — 250 Oil Pan Drain Plug — Oil Filter — Oil Pump to Block—Bolts — 250 Crankshaft Damper Remover Insert C-4685-C2 Oil Pump Cover—Bolts —...
Page 1031 9 - 150 3.2/3.5L ENGINE SPECIAL TOOLS (Continued) Crankshaft Seal Remover 6341A Camshaft Seal Remover C-3981B Crankshaft Seal Installer 6342 Camshaft Seal Installer 6052 Crankshaft Sprocket Installer 6641 Dial Indicator C-3339 Camshaft Alignment 6642 Valve Spring Compressor 7068 Camshaft Seal Protector 6788 Valve Spring Compressor C-3422-B...
Page 1032 3.2/3.5L ENGINE 9 - 151 SPECIAL TOOLS (Continued) Main Bearing Remover/Installer C-3059 Valve Spring Adapter 6526 Crankshaft Rear Seal Guide 6926-1 & Installer 6926-2 Valve Spring Tester C-647 Crankshaft Rear Seal Retainer Alignment Fixture 8225 Valve Spring Compressor MD-998772-A Valve Spring Adapter 6527 Release Probe 8351 Indicator Bore Size C-119...
Page 1033 9 - 152 3.2/3.5L ENGINE SPECIAL TOOLS (Continued) Cooling System Tester 7700 Adaptor 8116 Combustion Leak Tester C-3685-A...
Page 1034 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION TAILPIPE/REAR RESONATOR....6 EXHAUST SYSTEM......1 CATALYTIC CONVERTERS .
Page 1035 11 - 2 EXHAUST SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 1 Exhaust System 1 – V-BAND CLAMPS 5 – MUFFLER 2 – BAND CLAMPS 6 – BAND CLAMP 3 – FRONT RESONATOR 7 – REAR RESONATOR/PIPE ASSEMBLY 4 – EXHAUST MODULE: INTERMEDIATE PIPE 8 –...
Page 1036 EXHAUST SYSTEM 11 - 3 DESCRIPTION AND OPERATION (Continued) HEAT SHIELDS system heat shields on cars if equipped. Light over spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat DESCRIPTION shields resulting in excessive floor pan tempera- The catalytic converters have an integral heat tures and objectionable fumes.
Page 1037 11 - 4 EXHAUST SYSTEM while the isolators are being removed. Do not use REMOVAL AND INSTALLATION any tools to remove the isolators, remove by hand only. Soapy water or silicone-based spray may be EXHAUST SYSTEM used to assist removal. Do Not use a petroleum- based lubricant on the isolators.
Page 1038 EXHAUST SYSTEM 11 - 5 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install and loose assemble the front resonator to the converter pipes. (2) Place the exhaust system on two supports (one on side of muffler, one behind the resonator). Connect the system to the converter pipes.
Page 1039 11 - 6 EXHAUST SYSTEM REMOVAL AND INSTALLATION (Continued) (2) Loosen clamp and separate rear resonator/pipe from muffler and front resonator (Fig. 3). INSTALLATION (1) Install rear resonator/pipe onto new muffler/ resonator (Fig. 3), but do not tighten clamp until exhaust system is installed on vehicle.
Page 1040 EXHAUST SYSTEM 11 - 7 REMOVAL AND INSTALLATION (Continued) (8) Install downstream oxygen sensor and connect INSTALLATION electrical connector. (1) Install converter. (9) Install SRV (Single Runner Valve) vacuum res- (2) Attach a NEW V-Band clamp and tighten to 11 ervoir and control valve assembly at right rear of N·m (100 in.
Page 1041 11 - 8 EXHAUST SYSTEM SPECIFICATIONS TORQUE DESCRIPTION N·m Lbs. Lbs. Band (Torca) Clamp — Catalytic Converter Pipe to — Support Bracket—Nut V-Band Clamp—Exhaust — Manifold to Catalytic Converter Exhaust Support to Body — Bracket—Fasteners Exhaust Support Bracket to — Transmission—Fasteners...
Page 1042 FRAMES AND BUMPERS 13 - 1 FRAMES AND BUMPERS TABLE OF CONTENTS page page BUMPERS ....... . 1 FRAME .
Page 1043 13 - 2 FRAMES AND BUMPERS DESCRIPTION AND OPERATION (Continued) Fig. 1 Rear Suspension Crossmember 1 – LATERAL LINKS 3 – LATERAL LINKS 2 – REAR CROSSMEMBER ISOLATOR BUSHINGS REAR SUSPENSION CROSSMEMBER (3) Remove fasteners attaching fascia to the front fender and splash shield, using access hole in splash BUSHINGS shield (Fig.
Page 1044 FRAMES AND BUMPERS 13 - 3 REMOVAL AND INSTALLATION (Continued) (5) Align fascia to bumper reinforcement. (6) Align the two fascia studs to the fender vertical attachments, at the same time align the fascia groove on the horizontal flange with the fender fasteners. Push fascia rearward to engage the fasteners.
Page 1045 13 - 4 FRAMES AND BUMPERS REMOVAL AND INSTALLATION (Continued) (4) Remove push in fasteners attaching the fascia to upper radiator closure panel. (5) Pull the sides of the fascia outwards to disen- gage fascia from drive pins then pull fascia forward. (6) Disconnect lamp wire...
Page 1046 FRAMES AND BUMPERS 13 - 5 REMOVAL AND INSTALLATION (Continued) REAR BUMPER FASCIA – CONCORDE/LHS/ REAR BUMPER FASCIA – INTREPID 300M REMOVAL (1) Open deck lid and remove tail lamps. REMOVAL (2) Remove fasteners attaching fascia to rear quar- (1) Release deck lid latch and open deck lid. ter and splash shields.
Page 1047 13 - 6 FRAMES AND BUMPERS REMOVAL AND INSTALLATION (Continued) REAR BUMPER REINFORCEMENT REMOVAL (1) Remove rear fascia. (2) Remove attaching bolts and nuts from attach- ing bracket to rails (Fig. 11). INSTALLATION (1) Place reinforcement in position on rear of vehi- cle.
Page 1048 FRAMES AND BUMPERS 13 - 7 FRAME TABLE OF CONTENTS page page REMOVAL AND INSTALLATION SPECIFICATIONS ENGINE CRADLE CROSSMEMBER... . 7 FRAME DIMENSIONS ..... 11 REAR SUSPENSION CROSSMEMBER .
Page 1049 13 - 8 FRAMES AND BUMPERS REMOVAL AND INSTALLATION (Continued) (12) Install nuts to hold engine mounts to cradle. 2 rearward attaching bolts also attach the front cor- (13) Align front suspension if necessary. ners of the rear suspension crossmember in place). Allow the stabilizer bar to hang down.
Page 1050 FRAMES AND BUMPERS 13 - 9 REMOVAL AND INSTALLATION (Continued) (4) Reattach left forward lateral link to crossmem- ber. Install mounting bolt though the front of the crossmember mount towards the rear. Do not install and torque nut at this time. CAUTION: The bolts attaching the forward lateral links to the crossmember must be installed with the bolts pointing rearward (Fig.
Page 1051 13 - 10 FRAMES AND BUMPERS REMOVAL AND INSTALLATION (Continued) CAUTION: The bolts attaching the forward lateral links to the crossmember must be installed with the bolts pointing rearward (Fig. 2) to prevent damage to the fuel tank and or fuel tubes. The bolt attaching the left rear lateral link must be installed with the bolt pointing forward to prevent damage to the fuel filler tube.
Page 1052 FRAMES AND BUMPERS 13 - 11 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 6 Special Tools Fig. 7 Bushing Installation 1 – SPECIAL TOOL 8173–1 1 – SPECIAL TOOL C-4212F 2 – SPECIAL TOOL C-4212F 2 – SPECIAL TOOL 8173–2 3 – SPECIAL TOOL 8173–4 3 –...
Page 1053 13 - 12 FRAMES AND BUMPERS SPECIFICATIONS (Continued) Fig. 8 Engine Compartment Top View Fig. 9 Engine Compartment Side View...
Page 1054 FRAMES AND BUMPERS 13 - 13 SPECIFICATIONS (Continued)
Page 1055 13 - 14 FRAMES AND BUMPERS SPECIFICATIONS (Continued) Fig. 11 Rear Frame Section...
Page 1056 FRAMES AND BUMPERS 13 - 15 SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS DESCRIPTION TORQUE Rear Bumper Reinforcement Attaching Nut ... . 28 N·m (21 ft. lbs.) Front Suspension Crossmember Attaching Bolt Front ..109 N·m (80 ft. lbs.) Attaching Bolt Rear .
Page 1058 2000 LHS, 300M, CONCORDE AND INTREPID FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS FRAME TABLE OF CONTENTS page page REMOVAL AND INSTALLATION FRONT TOW HOOK BRACKET ....1 FRONT LICENSE PLATE BRACKET.
Page 1059 2000 LHS, 300M, CONCORDE AND INTREPID 13 - 2 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install the front tow hook bracket and fasten- ers. Torque bolts to 23 to 34 N.m. (2) Reinstall the front fascia as necessary. Refer to Group 23, Body for Removal and Installation proce- dures.
Page 1060 FUEL SYSTEM 14 - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL DELIVERY SYSTEM....1 FUEL INJECTION SYSTEM ....21 FUEL DELIVERY SYSTEM TABLE OF CONTENTS page...
Page 1061 OPERATION quality. The Chrysler fuel pump modul is an in-tank unit Chrysler Corporation strongly supports the use of with an integral fuel level sensor and pressure regu- reformulated gasoline whenever available. Although lator.
Page 1062 FUEL SYSTEM 14 - 3 DESCRIPTION AND OPERATION (Continued) a charcoal canister where they are temporarily held. When the engine is running, the vapors are drawn into the intake manifold. Certain models are also equipped with a self-diagnosing system using a Leak Detection Pump (LDP).
Page 1063 14 - 4 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) OPERATION The injector contains a pintle that closes off an ori- fice at the nozzle end. When electric current is sup- plied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice.
Page 1064 FUEL SYSTEM 14 - 5 DESCRIPTION AND OPERATION (Continued) Fig. 5 ORVR System Schematic 1 – FUEL CAP 7 – BREATHER ELEMENT 2 – RECIRCULATION TUBE 8 – W/O LDP 3 – CONTROL VALVE 9 – CANISTER 4 – FLOW MANAGEMENT VALVE 10 –...
Page 1065 14 - 6 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) to the tank until the pressure is relieved. This is due nated fuel in this system. If it is necessary to replace to the leak detection pump closing the vapor outlet these lines/tubes/hoses, only those marked EFM/EFI from the top of the tank and the one-way check valve may be used.
Page 1066 FUEL SYSTEM 14 - 7 SERVICE PROCEDURES (Continued) (1) Perform Fuel Pressure Release Procedure. Refer to the Fuel Pressure Release Procedure in this section. (2) Disconnect negative cable from battery or aux- iliary jumper terminal. (3) Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple.
Page 1067 14 - 8 FUEL SYSTEM SERVICE PROCEDURES (Continued) CAUTION: When using the ASD Fuel System Test, (3) Clean fitting of any foreign material before dis- the Auto Shutdown (ASD) Relay remains energized assembly. (4) To disconnect quick-connect fitting, squeeze for several minutes, until the test is stopped, or until the ignition switch is turned to the Off posi- plastic retainer tabs (Fig.
Page 1068 FUEL SYSTEM 14 - 9 SERVICE PROCEDURES (Continued) and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. (8) Insert quick-connect fitting into component being serviced until a click is felt. (9) Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.).
Page 1069 14 - 10 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (2) Remove Fuel Tank refer to the Fuel Tank INSTALLATION Removal/Installation in this group. (1) Wipe seal area of tank clean and place a new seal in position in the tank opening. WARNING: THE FUEL RESERVOIR OF THE FUEL (2) Position fuel pump in the tank.
Page 1070 FUEL SYSTEM 14 - 11 REMOVAL AND INSTALLATION (Continued) FUEL PRESSURE/REGULATOR (13) Connect the battery cable. (14) Fill fuel tank. Use the DRB scan tool to pres- surize the fuel system. Check for leaks. REMOVAL (1) Release fuel pressure, Refer to Fuel System FUEL PUMP INLET STRAINER Pressure Release Procedure in the Fuel Delivery sec- tion.
Page 1071 14 - 12 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (1) Depress the retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig. 15). Fig. 17 Wire Terminal Identification 1 – GRAY (LEVEL SENSOR GROUND) 2 –...
Page 1072 FUEL SYSTEM 14 - 13 REMOVAL AND INSTALLATION (Continued) Fig. 19 Fuel Level Sensor Removal Fig. 21 Level Sensor Installation 1 – LEVEL SENSOR 1 – STANDPIPE OPENING 2 – INSTALLATION CHANNEL 2 – GROOVE 3 – BACK OF LEVEL SENSOR FUEL RAIL—2.7L ENGINE WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL RAIL.
Page 1073 14 - 14 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (3) Push injectors into fuel injector rail until clips (7) Remove mounting bolts on both sides of fuel are in the correct position. rail. (4) Position fuel rail over cylinder heads, and push (8) Lift fuel rail straight up off of cylinder head.
Page 1074 FUEL SYSTEM 14 - 15 REMOVAL AND INSTALLATION (Continued) (2) Install fuel injectors. (4) Position fuel rail over cylinder head, and push (3) Install retaining clips on fuel injectors. rail into place. Tighten fuel rail mounting bolts to 11 (4) Push injectors into fuel injector rail until clips N·m (100 in.
Page 1075 14 - 16 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 26 Stabilizer Bar Fig. 24 Battery Cable 1 – FILLER TUBE 1 – BATTERY CABLE 2 – MUFFLER 2 – SERVICE VACUUM SUPPLY TEE 3 – FUEL TANK Fig. 25 Fuel Tank Drain Fig.
Page 1076 FUEL SYSTEM 14 - 17 REMOVAL AND INSTALLATION (Continued) (6) Remove filler neck. INSTALLATION (1) Install filler neck to filler hose. (2) Tighten clamps. (3) Lower vehicle. (4) Install 3 screws to filler neck and quarter panel. (5) Fill tank and check for leaks. (6) Connect negative cable from battery.
Page 1077 14 - 18 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 32 Accelerator Pedal Removal/Installation 1 – MOUNTING NUTS 2 – ACCELERATOR PEDAL Fig. 30 Accelerator Pedal and Throttle Cable Fig. 33 Carpet and Insulation Placement 1 – PEDAL BASE 2 – CARPET 3 –...
Page 1078 FUEL SYSTEM 14 - 19 REMOVAL AND INSTALLATION (Continued) INSTALLATION ing from operation with a heavy spark knock may not be covered by the new vehicle warranty. (1) From the engine compartment, push the hous- Poor quality gasoline can cause problems such as ing end fitting into the dash panel grommet.
Page 1079 Daimler- MATERIALS ADDED TO FUEL Chrysler Corporation and may not be covered under All gasoline sold in the United States and Canada the new vehicle warranty.
Page 1080 FUEL SYSTEM 14 - 21 FUEL INJECTION SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION RADIATOR FAN RELAYS—PCM OUTPUT ..35 INJECTION SYSTEM ..... . 21 TACHOMETER—PCM OUTPUT .
Page 1081 14 - 22 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Various sensors provide the inputs necessary for PCM can fine tune injector pulse width. Fine tuning the PCM to correctly operate these systems. In addi- injector pulse width allows the PCM to achieve opti- tion to the sensors, various switches also provide mum fuel economy combined with low emissions.
Page 1082 FUEL SYSTEM 14 - 23 DESCRIPTION AND OPERATION (Continued) switch energizes the starter relay. The following The PCM adjusts injector pulse width and controls actions occur when the starter motor is engaged. injector synchronization by turning the individual • If the PCM receives the camshaft position sensor ground paths to the injectors On and Off.
Page 1083 14 - 24 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) • A/C sense width to supply a predetermined amount of addi- • Battery voltage tional fuel. • Battery temperature • Engine coolant temperature IGNITION SWITCH OFF MODE • Engine run time When the operator turns the ignition switch to the •...
Page 1084 FUEL SYSTEM 14 - 25 DESCRIPTION AND OPERATION (Continued) PCM GROUND opposite preset limit or switch point. The process then repeats itself in the opposite direction. Short term fuel correction will keep increasing or OPERATION decreasing injector pulse-width based upon the Ground is provided through multiple pins of the upstream O2 Sensor input.
Page 1085 14 - 26 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) TYPICAL ADAPTIVE MEMORY FUEL CELLS Open Open Open Open Open Open Throttle Throttle Throttle Throttle Throttle Throttle Idle Decel Vacuum Above 1,984 13 Drive Below 1,984 Neutral MAP volt = Fuel Correction Diagnostics NOTE: PCM Inputs: There are two fuel correction diagnostic routines: •...
Page 1086 FUEL SYSTEM 14 - 27 DESCRIPTION AND OPERATION (Continued) • Leak Detection Pump fuel pump and the heating element in each oxygen • Low Speed Fan Relay sensor. • MTV Actuator The PCM contains a voltage converter that • Proportional Purge Solenoid changes battery voltage to a regulated 8.0 volts.
Page 1087 14 - 28 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) tests are explained in detail in the On-Board Diag- nostic Student Reference Book. BATTERY VOLTAGE—PCM INPUT DESCRIPTION The direct battery feed to the PCM is used as a reference point to sense battery voltage. OPERATION In order for the PCM to operate, it must be sup- plied with battery voltage and ground.
Page 1088 FUEL SYSTEM 14 - 29 DESCRIPTION AND OPERATION (Continued) HEATED OXYGEN SENSOR (O2 SENSOR)— PCM INPUT DESCRIPTION The upstream oxygen sensor threads into the out- let flange of the exhaust manifold (Fig. 4) or (Fig. 5). Fig. 6 Downstream Heated Oxygen Sensor 1/2 1 –...
Page 1089 14 - 30 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) In Closed Loop operation the PCM monitors the IGNITION SENSE—PCM INPUT O2S input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop OPERATION operation the PCM ignores the O2 sensor input. The The ignition sense input informs the Powertrain PCM adjusts injector pulse width based on prepro- Control Module (PCM) that the ignition switch is in...
Page 1090 FUEL SYSTEM 14 - 31 DESCRIPTION AND OPERATION (Continued) • Engine load • Manifold pressure • Injector pulse-width • Spark-advance programs • Shift-point strategies (F4AC1 transmissions only, via the CCD bus) • Idle speed • Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a dia- phragm.
Page 1091 14 - 32 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) PARK/NEUTRAL SWITCH OPERATION The automatic transaxle manual valve lever posi- tion sensor supplies the park/neutral input to the powertrain control module. The park/neutral switch input tells the PCM whether the transmission is in Park, Neutral, or a drive gear selection.
Page 1092 FUEL SYSTEM 14 - 33 DESCRIPTION AND OPERATION (Continued) OPERATION OPERATION The PCM operates the Automatic Shut Down During the cold start warm-up period and the hot (ASD) relay and fuel pump relay through one ground start time delay, the PCM does not energize the sole- path.
Page 1093 14 - 34 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 12 Manifold Tuning Valve 1 – MTV VALVE Fig. 13 Short Runner Valve (SRV) 1 – INTAKE MANIFOLD SHORT RUNNER VALVE (SRV) 2 – SRV VALVE DESCRIPTION It is a vacuum actuated actuator attached to the intake manifold (Fig.
Page 1094 FUEL SYSTEM 14 - 35 DESCRIPTION AND OPERATION (Continued) Target Idle The Check Engine lamp comes on each time the ignition key is turned ON and stays on for 3 seconds Target idle is determined by the following inputs: • Gear position as a bulb test.
Page 1095 14 - 36 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) necessary position. This signal is sent over the PCI (3) Install the throttle body support bracket to the Bus to the instrument cluster. bottom of the throttle body. Tighten the bolts to 27.1 N·m (20 ft.
Page 1096 FUEL SYSTEM 14 - 37 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) The throttle shaft end of the throttle body slides into a socket in the TPS. The socket has two tabs inside it. The throttle shaft rests against the tabs. When indexed correctly, the TPS can rotate clockwise a few degrees to line up the mounting screw holes with the screw holes in the throttle body.
Page 1097 14 - 38 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install the IAC to the throttle body. (2) Tighten mounting screws to 3 N·m (25 in. lbs.) torque. (3) Attach electrical connector to the IAC. (4) Install air plenum and tighten the clamp. (5) Connect the negative battery cable.
Page 1098 FUEL SYSTEM 14 - 39 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Remove the negative battery cable. (2) Disconnect the electrical connector from the MAP sensor. (3) Remove bolts from sensor. (4) Remove sensor. INSTALLATION (1) Bolt sensor to intake. (2) Attach electrical connector to sensor. (3) Install the negative battery cable.
Page 1099 14 - 40 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (2) Remove air inlet hose and resonator box and air cleaner top. (3) Remove the 3 fasteners from vacuum reservoir (Fig. 25). (4) Remove electrical connector. (5) Remove vacuum hoses. (6) Remove vacuum reservoir. INSTALLATION (1) Install vacuum hoses to reservoir.
Page 1100 FUEL SYSTEM 14 - 41 REMOVAL AND INSTALLATION (Continued) cable must be disconnected before unplugging the PCM connectors. Note radio programs. (1) Remove speed control servo and bracket and reposition out of the way (Fig. 26). Fig. 27 TCM Location 1 –...
Page 1101 14 - 42 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (1) Remove the negative battery cable. (2) Raise and support the vehicle. (3) Disconnect the wire connector from the O2S. CAUTION: When disconnecting the sensor electri- cal connector, do not pull directly on wire going into sensor.
Page 1102 FUEL SYSTEM 14 - 43 REMOVAL AND INSTALLATION (Continued) FILTER ELEMENT REPLACEMENT (1) Remove air cleaner lid. Lift lid off of air cleaner housing. (2) Remove filter element (Fig. 31). (3) If necessary, clean the inside of the air cleaner housing.
Page 1103 VEHICLE EMISSION CONTROL INFORMATION LABEL DESCRIPTION All models have a Vehicle Emission Control Infor- mation (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be removed without defacing information and destroying the label. The label contains the vehicle’s emission specifica- tions and vacuum hose routings.
Page 1104 FUEL SYSTEM 14 - 45 SPECIAL TOOLS FUEL Spanner Wrench 6856 Pressure Gauge Assembly C–4799–B Fuel Line Adapter 1/4 Fuel Pressure Test Adapter 6539 O2S (Oxygen Sensor) Remover/Installer—C-4907...
Page 1106 2000 LHS, 300M, CONCORDE AND INTREPID FUEL SYSTEM 14 - 1 FUEL SYSTEM FUEL SYSTEM COMPONENTS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DISASSEMBLY AND ASSEMBLY LOCKING FUEL FILLER NECK CAP... . 1 LOCKING FUEL FILLER NECK CAP.
Page 1107 2000 LHS, 300M, CONCORDE AND INTREPID 14 - 2 FUEL SYSTEM DISASSEMBLY AND ASSEMBLY (Continued) DISASSEMBLY (3) Remove lock cylinder engagement collar and tether (Fig. 4). (1) Using a flat-bladed pry tool, pry fuel cap retaining ring free from cap assembly (Fig. 2).
Page 1108 2000 LHS, 300M, CONCORDE AND INTREPID FUEL SYSTEM 14 - 3 DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (1) Install the keyed lock cylinder in cap. (2) Position lock cylinder engagement collar and tether. (3) Position threaded portion of cap. (4) Snap retaining ring in position.
Page 1109 2000 LHS, 300M, CONCORDE AND INTREPID...
Page 1110 STEERING 19 - 1 STEERING TABLE OF CONTENTS page page POWER STEERING ......1 SPEED PROPORTIONAL POWER STEERING POWER STEERING PUMP .
Page 1111 19 - 2 STEERING DESCRIPTION AND OPERATION (Continued) OPERATION POWER STEERING FLUID COOLER Turning of the steering wheel is converted into lat- DESCRIPTION eral (side-to-side) travel through the meshing of the helical pinion teeth with the rack teeth within the All models of this vehicle are equipped with a steering gear.
Page 1112 STEERING 19 - 3 DIAGNOSIS AND TESTING (Continued) POWER STEERING NOISE CONDITION POSSIBLE CAUSES CORRECTION OBJECTIONABLE HISS 1. Damaged or mispositioned 1. Reposition or replace steering OR WHISTLE* steering column shaft/coupling dash column shaft/coupling dash panel seal. panel seal. 2. Noisy valve in power steering 2.
Page 1113 19 - 4 STEERING DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Loose power steering pump drive 4. Check and adjust power steering belt. pump drive belt to specifications. Replace belt if worn or glazed. 5. Extremely cold temperatures 5.
Page 1114 STEERING 19 - 5 DIAGNOSIS AND TESTING (Continued) STEERING WHEEL FEEL CONDITION POSSIBLE CAUSES CORRECTION STEERING WHEEL/ 1. Loose steering coupling pinch 1. Replace pinch bolt and torque to COLUMN CLICKING, bolt. specifications. CLUNKING OR RATTLING. 2. Steering column bearings. 2.
Page 1115 19 - 6 STEERING DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 9. Binding lower control arm ball 9. Replace the lower control arm. joint. 10. Excessive friction in power 10. Replace power steering gear. steering gear. 11. Worn/binding seat and bearing in 11.
Page 1116 STEERING 19 - 7 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 8. Tight shaft bearing in steering 8. Replace the steering column. column. 9. Excessive friction in steering 9. Replace steering column coupling. column coupling. 10. Excessive friction in power 10.
Page 1117 19 - 8 STEERING DIAGNOSIS AND TESTING (Continued) POWER STEERING FLUID CONDITION POSSIBLE CAUSES CORRECTION LOW FLUID LEVEL WITH 1. Loose power steering hose 1. Tighten the fitting to its specified torque. VISIBLE LEAK. fittings. 2. Damaged or missing fitting seal, 2.
Page 1118 STEERING 19 - 9 DIAGNOSIS AND TESTING (Continued) (1) Assemble hoses on Power Steering Analyzer, NOTE: On vehicles with 3.2 and 3.5 liter engines, it Special Tool 6815, as shown. Install Pressure Hose, may be easier to access the power steering pump Special Tool 6905 (in 6893 kit), in the inlet fitting on pressure fitting from the bottom of the vehicle Power Steering Analyzer.
Page 1119 19 - 10 STEERING DIAGNOSIS AND TESTING (Continued) (4) 2.7L engine — Connect Adapter Fitting, Spe- (6) Connect vehicle power steering fluid pressure cial Tool 6844 (Fig. 6), attached to pressure hose from hose to Adapter Fitting, Special Tool 6826, which inlet (gauge end) of Power Steering Analyzer to the should be already installed in the outlet hose (valve pressure fitting on the power steering pump.
Page 1120 STEERING 19 - 11 SERVICE PROCEDURES POWER STEERING FLUID LEVEL CHECK WARNING: FLUID LEVEL SHOULD BE CHECKED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS. DO NOT USE AUTOMATIC TRANS- MISSION FLUID IN THE POWER STEERING SYS- TEM. DO NOT OVERFILL THE POWER STEERING SYSTEM.
Page 1121 19 - 12 STEERING REMOVAL AND INSTALLATION (Continued) Fig. 12 Wiper Module And Cowl Cover 1 – COWL COVER 2 – WIPER MODULE COVER Fig. 10 Correctly Isolated Remote Ground Cable 1 – CABLE ISOLATOR 2 – GROUND STUD 3 – GROUND CABLE (4) Remove caps from both wiper arms at the attachment to the pivots to expose the wiper arm attaching nuts.
Page 1122 STEERING 19 - 13 REMOVAL AND INSTALLATION (Continued) (9) Using a steering wheel clamp, (Fig. 15) lock the (11) Bend back the retaining tabs on the mounting steering wheel from rotating. plate for the tie rod to steering gear mounting bolts (Fig.
Page 1123 19 - 14 STEERING REMOVAL AND INSTALLATION (Continued) NOTE: The following step should be done to pre- vent excessive spilling of power steering fluid when the power steering fluid lines are removed from the steering gear. (13) Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir.
Page 1124 STEERING 19 - 15 REMOVAL AND INSTALLATION (Continued) remaining power steering fluid drain out of the return hose and the power steering fluid cooler. Fig. 24 Power Steering Return Hose At Cooler 1 – POWER STEERING FLUID COOLER 2 – POWER STEERING FLUID RETURN HOSE 3 –...
Page 1125 19 - 16 STEERING REMOVAL AND INSTALLATION (Continued) (7) Slide steering gear and intermediate shaft back CAUTION: After tie rod attaching bolts are torqued, into dash panel sealing boot. Align the steering gear bend attaching bolt retaining tabs against heads of mounting holes with its mounting holes in crossmem- attaching bolts (Fig.
Page 1126 STEERING 19 - 17 REMOVAL AND INSTALLATION (Continued) attaching nuts. Install the caps on the wiper arms covering the pivot nuts. (21) Install the battery ground cable onto the ground stud on the shock tower. CAUTION: Do not use automatic transmission fluid. Use only the proper Mopar Power Steering Fluid or equivalent when filling the power steering fluid res- ervoir.
Page 1127 19 - 18 STEERING REMOVAL AND INSTALLATION (Continued) (8) Remove the power steering fluid cooler from SPECIAL TOOLS the radiator lower crossmember. POWER STEERING INSTALLATION (1) Install the power steering fluid cooler on the radiator lower crossmember. (2) Install the 2 nuts (Fig. 31) attaching the power steering fluid cooler to the radiator lower crossmem- ber.
Page 1128 STEERING 19 - 19 POWER STEERING PUMP TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DISASSEMBLY AND ASSEMBLY POWER STEERING PUMP ....19 POWER STEERING FLUID RESERVOIR (2.7L POWER STEERING FLUID RESERVOIR .
Page 1129 19 - 20 STEERING DESCRIPTION AND OPERATION (Continued) Fig. 2 Power Steering Pump (3.2L/3.5L Engine) Fig. 3 Power Steering Fluid Reservoir (3.2L/3.5L 1 – POWER STEERING PUMP Engine) 2 – PUMP PRESSURE FITTING 1 – SPEED CONTROL SERVO 3 – FLUID SUPPLY FITTING 2 –...
Page 1130 STEERING 19 - 21 SERVICE PROCEDURES (Continued) (8) Stop the engine. Check the fluid level and refill as required. (9) If the fluid is extremely foamy, allow the vehi- cle to stand a few minutes and repeat the above pro- cedure.
Page 1131 19 - 22 STEERING REMOVAL AND INSTALLATION (Continued) (6) Remove the power steering fluid pressure hose (10) Remove the drive belt from the power steering (Fig. 6) from the pressure fitting on the power steer- pump pulley. ing pump. NOTE: Access for the power steering pump mount- ing bolts is through the holes in the face of the power steering pump pulley.
Page 1132 STEERING 19 - 23 REMOVAL AND INSTALLATION (Continued) NOTE: The long mounting bolt for the power steer- ing pump is installed in the location where the sleeve is in the tensioner bracket. (2) Loosely install the 3 bolts mounting the power steering pump to the mounting bracket.
Page 1133 19 - 24 STEERING REMOVAL AND INSTALLATION (Continued) (7) Remove the power steering fluid pressure hose NOTE: Access for the power steering pump mount- (Fig. 11) from the pressure fitting on the power steer- ing bolts is through the holes in the face of the ing pump.
Page 1134 STEERING 19 - 25 REMOVAL AND INSTALLATION (Continued) (7) Install the power steering fluid supply hose REMOVAL onto the supply fitting on power steering pump (Fig. (1) Raise vehicle on jackstands or centered on a 10). When installing the hose clamp on the frame contact type hoist.
Page 1135 19 - 26 STEERING DISASSEMBLY AND ASSEMBLY (Continued) (1) Remove the power steering pump from the INSTALL engine. Refer to the procedure in the Removal And (1) Lubricate the O-ring seal on the power steering Installation Section in this group of the service man- fluid reservoir (Fig.
Page 1136 STEERING 19 - 27 DISASSEMBLY AND ASSEMBLY (Continued) (2) Remove the power steering pump pulley from the power steering pump shaft using Puller, Special Tool C-4333 (Fig. 18). Fig. 19 Spacer Installed In Power Steering Pump Pulley 1 – SPECIAL TOOL 6936 2 –...
Page 1137 19 - 28 STEERING SPECIFICATIONS SPECIAL TOOLS POWER STEERING PUMP FLOW POWER STEERING PUMP SPECIFICATIONS Flow At 1500 RPM and Minimum Pressure ..8.0 to 9.5 Liters/Min (2.1 to 2.5 GPM) Control Valve Pressure Relief . . . 8618 to 9308 kPa (1250 to 1350 psi) POWER STEERING PUMP FASTENER TORQUE SPECIFICATIONS...
Page 1138 STEERING 19 - 29 POWER STEERING GEAR TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DISASSEMBLY AND ASSEMBLY POWER STEERING GEAR....29 POWER STEERING GEAR HOUSING DIAGNOSIS AND TESTING BUSHING .
Page 1139 19 - 30 STEERING DESCRIPTION AND OPERATION (Continued) similar to the standard gear except for the solenoid (1) Position the vehicle on a drive on hoist or an control valve extending from its housing. For infor- alignment rack so that the tires are supporting the mation and service procedures on the speed propor- total weight of the vehicle.
Page 1140 STEERING 19 - 31 (2) Position the front tires of the vehicle so that REMOVAL AND INSTALLATION they are facing straight ahead. (3) Raise the vehicle on a frame contact type hoist SERVICE WARNINGS AND CAUTIONS until the front tires of the vehicle are just off the floor.
Page 1141 19 - 32 STEERING REMOVAL AND INSTALLATION (Continued) (7) Remove the 8 bolts, attaching the reinforce- (9) Using a steering wheel holding clamp, (Fig. 8) ment (Fig. 6) to the strut towers and the 1 bolt (Fig. lock the steering wheel from rotating. 6) attaching the wiper module to the reinforcement.
Page 1142 STEERING 19 - 33 REMOVAL AND INSTALLATION (Continued) (11) Bend back the retaining tabs on the mounting (13) Using a siphon pump, remove as much power plate for the tie rod to steering gear mounting bolts steering fluid as possible from the power steering (Fig.
Page 1143 19 - 34 STEERING REMOVAL AND INSTALLATION (Continued) (16) Remove the 2 nuts (Fig. 14) mounting the (20) Remove the 2 bolts attaching the steering master cylinder to the vacuum booster. gears right side mounting bracket (Fig. 16) to the crossmember.
Page 1144 STEERING 19 - 35 REMOVAL AND INSTALLATION (Continued) (22) Using roll pin remover, Special Tool 6831A, remove roll pin from flex joint of intermediate shaft (Fig. 18). Roll pin is removed from coupler using fol- lowing procedure. Remove knurled nut from small end of removal tool.
Page 1145 19 - 36 STEERING REMOVAL AND INSTALLATION (Continued) NOTE: If the vehicle is equipped with a 2.7 liter (b) Lift the left end of the steering gear upward, engine, rotate the front of the left front tire/wheel as with the steering gear positioned as shown, between the back of the engine and the front of the far outward as possible (Fig.
Page 1146 STEERING 19 - 37 REMOVAL AND INSTALLATION (Continued) (6) Lower the vehicle until the front tires are just (11) Install the bolts mounting the right side clear of the floor. mounting bracket for the steering gear to the cross- (7) Install the intermediate steering shaft on the member (Fig.
Page 1147 19 - 38 STEERING REMOVAL AND INSTALLATION (Continued) CAUTION: After tie rod attaching bolts are torqued, attaching nuts. Install the caps on the wiper arms bend attaching bolt retaining tabs against heads of covering the pivot nuts. (25) Install the battery ground cable onto the attaching bolts (Fig.
Page 1148 STEERING 19 - 39 REMOVAL AND INSTALLATION (Continued) (5) Lower vehicle. CAUTION: When setting the front Toe on the vehi- cle, the maximum dimension of exposed threads allowed on the adjuster and outer tie rod cannot exceed the distance shown in (Fig. 30). If the maxi- mum distance is exceeded, inadequate retention of either the adjuster or the outer tie rod can result.
Page 1149 19 - 40 STEERING (2) Place the steering gear housing against the DISASSEMBLY AND ASSEMBLY Receiver in a way that the Receiver does not come in contact with the support ribs on the gear housing (Fig. POWER STEERING GEAR HOUSING BUSHING 32).
Page 1150 STEERING 19 - 41 SPECIAL TOOLS POWER STEERING GEAR Remover / Installer, Steering Shaft Roll Pin 6831A Puller C-3894-A...
Page 1151 19 - 42 STEERING SPEED PROPORTIONAL POWER STEERING GEAR TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION SPEED PROPORTIONAL POWER STEERING SPEED PROPORTIONAL POWER STEERING GEAR ....... . 42 GEAR .
Page 1152 STEERING 19 - 43 DESCRIPTION AND OPERATION (Continued) viding a more firm, responsive feel to the power DIAGNOSIS AND TESTING steering system. With the engine running and the vehicle speed SPEED PROPORTIONAL POWER STEERING between 0 kph (0 mph) and approximately 32 kph Electronic diagnosis of the variable-effort speed- (20 mph), minimum steering effort is required.
Page 1153 19 - 44 STEERING REMOVAL AND INSTALLATION (Continued) (2) Unclip the connector from the gear end cap. (3) Remove the power steering pressure hose (Fig. 3) from the power steering gear. Fig. 4 Loosening Solenoid Control Valve 1 – SOLENOID CONTROL VALVE 2 –...
Page 1154 STEERING 19 - 45 STEERING COLUMN TABLE OF CONTENTS page page DESCRIPTION AND OPERATION STEERING COLUMN ..... . 47 STEERING COLUMN ..... . 45 STEERING COLUMN GEAR SHIFT LEVER DIAGNOSIS AND TESTING ASSEMBLY .
Page 1155 19 - 46 STEERING DIAGNOSIS AND TESTING (Continued) Fig. 1 Steering Column 1 – SHIFT LEVER (COLUMN SHIFT ONLY) 4 – STEERING COLUMN MOUNTING BRACKET 2 – TILT HOUSING 5 – STEERING COLUMN COUPLER 3 – TILT LEVER 6 – STEERING COLUMN LOWER MOUNTING BRACKET •...
Page 1156 STEERING 19 - 47 REMOVAL AND INSTALLATION (Continued) WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, DEPLOYS. IF AIRBAG MODULE IS PLACED ON A COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE BENCH OR OTHER SURFACE, PLASTIC COVER ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL SHOULD BE FACE UP TO MINIMIZE MOVEMENT IN THE AIR BAG SYSTEM COMPONENTS YOU MUST CASE OF ACCIDENTAL DEPLOYMENT.
Page 1157 19 - 48 STEERING REMOVAL AND INSTALLATION (Continued) (2) Remove the fuse panel cover from the left end of the instrument panel (Fig. 3). Fig. 5 Trunk Release Wiring 1 – WIRING HARNESS CONNECTOR 2 – TRUNK RELEASE SWITCH Fig. 3 Fuse Panel Cover 3 –...
Page 1158 STEERING 19 - 49 REMOVAL AND INSTALLATION (Continued) Fig. 9 Speed Control Switches Fig. 7 Reinforcement Panel 1 – STEERING WHEEL 1 – REINFORCEMENT PANEL 2 – SPEED CONTROL SWITCHES 2 – MOUNTING BOLTS WARNING: WHEN HANDLING AN UNDEPLOYED AIRBAG MODULE DURING SERVICING OF THE STEERING COLUMN THE FOLLOWING PRECAU- TIONS SHOULD BE OBSERVED.
Page 1159 19 - 50 STEERING REMOVAL AND INSTALLATION (Continued) (11) Remove the airbag module from the steering wheel. (12) Remove the connector lock from the airbag electrical lead connector (Fig. 11). Connector lock is removed by pulling it straight out of the airbag con- nector.
Page 1160 STEERING 19 - 51 REMOVAL AND INSTALLATION (Continued) the upper shroud from the lower. Remove the upper (21) Remove the wiring harness connectors (Fig. shroud from the steering column. 16) from the clockspring. (19) Remove the tilt lever (Fig. 14) from the steer- ing column.
Page 1161 19 - 52 STEERING REMOVAL AND INSTALLATION (Continued) (23) Disconnect the wire harness connector at the SKIM module. Remove the mounting screw and unclip the module from the key cylinder halo bezel. (24) Remove the wiring harness from the routing clip on the top of the multi-function switch.
Page 1162 STEERING 19 - 53 REMOVAL AND INSTALLATION (Continued) (c) Slide the solenoid straight off the shift lever mounting stud. Fig. 23 Shift Cable Removal 1 – STEERING COLUMN Fig. 21 BTSI Solenoid 2 – SCREWDRIVER 1 – SHIFT LEVER BRACKET 3 –...
Page 1163 19 - 54 STEERING REMOVAL AND INSTALLATION (Continued) (30) Remove the 2 air ducts (Fig. 25) from under the steering column. Fig. 27 Steering Column Mounting 1 – MOUNTING NUTS 2 – STEERING COLUMN UPPER MOUNTING BRACKET Fig. 25 Air Ducts 3 –...
Page 1164 STEERING 19 - 55 REMOVAL AND INSTALLATION (Continued) lever is locked in the park position. Then, install the shift cable on the shifter mechanism (Fig. 28). The shift cable must be fully inserted onto the pin of the shifter mechanism. Fig.
Page 1165 19 - 56 STEERING REMOVAL AND INSTALLATION (Continued) • Keeping locking mechanism disengaged, rotate the clockspring rotor in the CLOCKWISE DIRECTION to the end of the travel. Do not apply excessive torque. • From the end of clockwise travel, slowly rotate the rotor in the counterclockwise direction until yel- low appears in the centering window of clockspring.
Page 1166 STEERING 19 - 57 REMOVAL AND INSTALLATION (Continued) attaching the speed control switches to the steering STEERING COLUMN GEAR SHIFT LEVER wheel to 1.5 N·m (13 in. lbs.). ASSEMBLY (27) Install the diagnostic connector on the rein- forcement (Fig. 8). NOTE: The steering column assembly does not (28) Install the reinforcement on the instrument require removal from the vehicle to allow replace-...
Page 1167 19 - 58 STEERING REMOVAL AND INSTALLATION (Continued) (3) Remove the lower instrument panel cover. The lower instrument panel cover is attached by retain- ing clips along the top and right edge. (4) Remove the tilt lever and the upper and lower steering column shrouds from steering column assembly (Fig.
Page 1168 STEERING 19 - 59 REMOVAL AND INSTALLATION (Continued) Fig. 38 Shift Lever Assembly Attachment Fig. 40 Guide And Flange Alignment 1 – SHIFTER ASSEMBLY 1 – BRACKET FLANGE 2 – CABLE 2 – GUIDE 3 – INTERLOCK CASSETTE 4 – SHIFTER ASSEMBLY ATTACHING SCREWS 5 –...
Page 1169 19 - 60 STEERING REMOVAL AND INSTALLATION (Continued) (4) Remove the coupler from the steering column shaft INSTALL (1) Start roll pin into coupler prior to installing coupler on steering column shaft. Install roll pin into coupler just far enough to square roll pin to hole in flex coupler.
Page 1170 42LE TRANSAXLE 21 - 1 42LE TRANSAXLE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION FLUID DRAIN AND REFILL-DIFFERENTIAL 42LE TRANSAXLE ......2 SUMP .
Page 1171 21 - 2 42LE TRANSAXLE BRAKE/TRANSMISSION SHIFT INTERLOCK SCHEMATICS AND DIAGRAMS (FLOOR)......142 42LE TRANSAXLE HYDRAULIC SCHEMATICS.
Page 1172 42LE TRANSAXLE 21 - 3 DESCRIPTION AND OPERATION (Continued) 1 – DIFFERENTIAL 10 – 2/4 CLUTCH 2 – TRANSFER SHAFT 11 – REVERSE CLUTCH 3 – TRANSFER GEAR 12 – OVERDRIVE CLUTCH 4 – FRONT PLANETARY CARRIER 13 – UNDERDRIVE CLUTCH 5 –...
Page 1173 21 - 4 42LE TRANSAXLE DESCRIPTION AND OPERATION (Continued) FLUID REQUIREMENT TORQUE CONVERTER NOTE: Refer to the maintenance schedules in DESCRIPTION Group 0, Lubrication and Maintenance for the rec- The torque converter is located in the bellhousing ommended maintenance (fluid/filter change) inter- area of the transaxle, between the engine and tran- vals for this transaxle.
Page 1174 42LE TRANSAXLE 21 - 5 DESCRIPTION AND OPERATION (Continued) the coupling is produced by transmission fluid, the clutch application. Partial EMCC operation is main- turbine can slip or turn slower than the impeller. tained until Full EMCC is called for an actuated. The stator contains a one-way overrunning clutch, During Partial EMCC some slip does occur.
Page 1175 21 - 6 42LE TRANSAXLE DESCRIPTION AND OPERATION (Continued) • Manual valve OPERATION • Converter clutch switch valve As the torque converter rotates, the converter hub • Converter clutch control valve rotates the inner and outer gears. As the gears •...
Page 1176 42LE TRANSAXLE 21 - 7 DESCRIPTION AND OPERATION (Continued) Fig. 6 Valve Body—Exploded 1 – VALVE BODY 6 – MANUAL VALVE 2 – T/C REGULATOR VALVE 7 – CONVERTER CLUTCH SWITCH VALVE 3 – L/R SWITCH VALVE 8 – SOLENOID SWITCH VALVE 4 –...
Page 1177 21 - 8 42LE TRANSAXLE DESCRIPTION AND OPERATION (Continued) Fig. 7 Accumulator Assembly—Typical 1 – ACCUMULATOR PISTON (UNDERDRIVE) Fig. 9 2/4 Accumulator Assembly 2 – RETURN SPRINGS 1 – VALVE BODY 3 – SEAL RING 2 – RETAINER PLATE 4 – SEAL RING 3 –...
Page 1178 42LE TRANSAXLE 21 - 9 DESCRIPTION AND OPERATION (Continued) clutches and are contained at the rear of the tran- saxle case. (Fig. 11). Fig. 10 Input Clutch Assembly 1 – INPUT SHAFT 2 – UNDERDRIVE CLUTCH 3 – OVERDRIVE CLUTCH Fig.
Page 1179 21 - 10 42LE TRANSAXLE DESCRIPTION AND OPERATION (Continued) carrier/rear annulus assembly is held or grounded to the transaxle case. PLANETARY GEARTRAIN DESCRIPTION The planetary geartrain is located between the input clutch assembly and the rear of the transaxle case. The planetary geartrain consists of two sun gears, two planetary carriers, two annulus (ring) gears, and one output shaft (Fig.
Page 1180 42LE TRANSAXLE 21 - 11 DESCRIPTION AND OPERATION (Continued) Based on the information received from these var- ious inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs.
Page 1181 21 - 12 42LE TRANSAXLE DESCRIPTION AND OPERATION (Continued) 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element.
Page 1182 42LE TRANSAXLE 21 - 13 DESCRIPTION AND OPERATION (Continued) Schedule Condition Expected Operation Extreme Cold Oil temperature at start-up below Park, Reverse, Neutral and 2nd -16° F gear only (prevents shifting which may fail a clutch with frequent shifts) Cold Oil temperature at start-up above –...
Page 1183 21 - 14 42LE TRANSAXLE DESCRIPTION AND OPERATION (Continued) Fig. 16 Transmission Control Relay Location (Typical) Fig. 17 Solenoid/Pressure Switch Assembly 1 – TRANSMISSION CONTROL RELAY 2 – PDC 1 – SOLENOID/PRESSURE SWITCH 3 – TCM 2 – TRS 3 – TRANSFER PLATE 4 –...
Page 1184 42LE TRANSAXLE 21 - 15 DESCRIPTION AND OPERATION (Continued) PRESSURE SWITCH STATES GEAR OP = OPEN CL = CLOSED The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 2nd gear).
Page 1185 21 - 16 42LE TRANSAXLE DESCRIPTION AND OPERATION (Continued) allows reasonably normal transmission operation INPUT SPEED SENSOR with a TRS failure. DESCRIPTION TRS SWITCH STATES The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs.
Page 1186 42LE TRANSAXLE 21 - 17 DESCRIPTION AND OPERATION (Continued) OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil (Fig. 22), an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm.
Page 1187 21 - 18 42LE TRANSAXLE DESCRIPTION AND OPERATION (Continued) Fig. 26 Ignition Key/Switch Positions 1 – ACC 2 – LOCK 3 – OFF 4 – ON/RUN 5 – START Fig. 25 Sensor Relation to Planet Carrier Park Pawl Lugs 1 – OUTPUT SPEED SENSOR The following chart describes the normal operation 2 –...
Page 1188 42LE TRANSAXLE 21 - 19 DESCRIPTION AND OPERATION (Continued) being moved out of PARK without a driver in place (Fig. 27). Fig. 28 Ignition Key/Switch Positions 1 – ACC 2 – LOCK 3 – OFF 4 – ON/RUN Fig. 27 BTSI Solenoid 5 –...
Page 1189 21 - 20 42LE TRANSAXLE DESCRIPTION AND OPERATION (Continued) AUTOMATIC SHIFTS WILL OCCUR UNDER THE FOLLOWING CONDITIONS APPROXIMATE SHIFT POINT TYPE OF SHIFT 2.7L / 3.2 L 3.5L 4-3 coast downshift 13 mph 13 mph 3-2 coast downshift 9 mph 9 mph 2-1 coast downshift 5 mph...
Page 1190 42LE TRANSAXLE 21 - 21 DIAGNOSIS AND TESTING (Continued) ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER INPUT CLUTCHES HOLDING CLUTCHES Shift Lever Position Underdrive Overdrive Reverse Low/Reverse P - PARK R - REVERSE N - NEUTRAL OD - OVERDRIVE First Second...
Page 1191 21 - 22 42LE TRANSAXLE DIAGNOSIS AND TESTING (Continued) TEST ONE-SELECTOR IN L (1st Gear) (6) The vehicle should be in second gear and over- drive clutch pressure should be less than 5 psi. NOTE: This test checks pump output, pressure reg- TEST FOUR-SELECTOR IN OD (Fourth Gear) ulation and condition of the low/reverse clutch hydraulic circuit and shift schedule.
Page 1192 42LE TRANSAXLE 21 - 23 DIAGNOSIS AND TESTING (Continued) TEST RESULT INDICATIONS (1) If proper line pressure is found in any one test, the pump and pressure regulator are working prop- erly. (2) Low pressure in all positions indicates a defec- tive pump, a clogged filter, or a stuck pressure regu- lator valve.
Page 1193 21 - 24 42LE TRANSAXLE DIAGNOSIS AND TESTING (Continued) NOTE: The compressed air supply must be free of 2/4 CLUTCH all dirt and moisture. Use a pressure of 30 psi. Apply air pressure to the feed hole located on the 2/4 clutch retainer.
Page 1194 42LE TRANSAXLE 21 - 25 DIAGNOSIS AND TESTING (Continued) FLUID LEAKAGE-TORQUE CONVERTER HOUSING AREA When diagnosing converter housing fluid leaks, three actions must be taken before repair: (1) Verify proper transmission fluid level. (2) Verify that the leak originates from the con- verter housing area and is transmission fluid.
Page 1195 21 - 26 42LE TRANSAXLE DIAGNOSIS AND TESTING (Continued) TORQUE CONVERTER LEAKAGE ACTION EXPECTED RESPONSE Possible sources of torque converter leakage are: 1. Turn key to the “OFF” 1. Shifter CAN be shifted • Torque converter weld leaks at the outside diam- position.
Page 1196 42LE TRANSAXLE 21 - 27 DIAGNOSIS AND TESTING (Continued) (2) Remove the instrument panel cover below the steering column, then remove the steering column shrouds to gain access to the brake transmission shift interlock (BTSI) solenoid. (3) Disconnect the wire connector from the rear of the BTSI solenoid.
Page 1197 21 - 28 42LE TRANSAXLE DIAGNOSIS AND TESTING (Continued) CIRCUIT TEST CONDITION POSSIBLE CAUSE (1) Check the system fuse in the junction block ALL PRND3L Check wiring and (An open or blown fuse would allow the shift lever to (PRND1234 if Autostick connectors be moved in and out of the PARK position without equipped) DISPLAY...
Page 1198 42LE TRANSAXLE 21 - 29 (5) Compare the fluid temperature value with the SERVICE PROCEDURES chart. (6) Adjust transmission fluid level shown on the FLUID LEVEL AND CONDITION CHECK dipstick according to the chart. (7) Check transmission for leaks. NOTE: The transmission and differential have sep- Low fluid level can cause a variety of conditions arate oil sumps.
Page 1199 21 - 30 42LE TRANSAXLE SERVICE PROCEDURES (Continued) Transmission Fluid Temperature Chart NOTE: Only fluids of the type labeled Mopar (6) Start engine and allow to idle for at least one minute. Then, with parking and service brakes ATF+4 (Automatic Transmission Fluid) Type 9602 should be used.
Page 1200 42LE TRANSAXLE 21 - 31 SERVICE PROCEDURES (Continued) ALTERNATIVE MAINTENANCE METHODS to 3mm (1/8 in.) below the “ADD” mark on the dip- stick (Fig. 38). TRANSAXLE FLUID EXCHANGER METHOD (9) Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). CAUTION: The use of any fluid exchanger that (10) To prevent dirt from entering transaxle, make introduces additives into the transaxle is not rec-...
Page 1201 21 - 32 42LE TRANSAXLE SERVICE PROCEDURES (Continued) exchange unit. This will insure that metal particles (12) Disconnect alligator clips from battery. Recon- or sludged oil are not later transferred back into the nect flusher lines to cover plate, and remove flushing reconditioned (or replaced) transaxle.
Page 1202 42LE TRANSAXLE 21 - 33 SERVICE PROCEDURES (Continued) TRANSAXLE QUICK LEARN PROCEDURE REMOVAL AND INSTALLATION The quick learn procedure requires the use of the GEARSHIFT CABLE–COLUMN SHIFT DRB scan tool. This program allows the electronic transaxle sys- REMOVAL tem to recalibrate itself. This will provide the best possible transaxle operation.
Page 1203 21 - 34 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) Fig. 42 Lower Column Cover Screw Removal/ Fig. 44 Tilt Lever Screw Removal/Installation Installation 1 – STEERING WHEEL 2 – TURN SIGNAL LEVER 1 – LOWER COLUMN COVER 3 – TILT LEVER 2 –...
Page 1204 42LE TRANSAXLE 21 - 35 REMOVAL AND INSTALLATION (Continued) Fig. 48 Cable Routing Bracket—(3.2L/3.5L Shown/ 2.7L Similar) 1 – BRACKET 2 – CABLE Fig. 46 Column Gear Shift Cable—Removal/ Installation 1 – CONDUIT BRACKET 2 – RETAINER CLIP 3 – GEARSHIFT CABLE 4 –...
Page 1205 21 - 36 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) (4) Rotate fill tube to original location. Install and tighten fill tube bracket bolt. (5) Install cable “push pin” into bracket as shown in (Fig. 48). (6) Route transaxle shift cable through hole in dash panel (Fig.
Page 1206 42LE TRANSAXLE 21 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 55 Throttle/Gearshift Cable Bracket Fig. 53 Shift Cable Adjust Lever Nut 1 – CABLE BRACKET 1 – CONSOLE 2 – GEARSHIFT CABLE 2 – ACCESS HOLE 3 – THROTTLE CABLE 3 –...
Page 1207 21 - 38 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) Fig. 57 Gearshift Cable Routing Bracket 1 – BRACKET 2 – CABLE Fig. 58 Gearshift Cable Routing 1 – LH A/C DUCT OUTLET INSTALLATION 2 – LH LOWER HEAT DUCT (1) Make sure transaxle shift lever is in “Park.” 3 –...
Page 1208 42LE TRANSAXLE 21 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 62 Shifter Assembly Removal/Installation Fig. 60 Shift Cable Removal/Installation 1 – NUT 1 – CUP 2 – SHIFTER ASSEMBLY 2 – CABLE 3 – CONDUIT BRACKET 4 – PIN INSTALLATION (1) Install shifter assembly (Fig.
Page 1209 21 - 40 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) system is only adjusted after installing a new (2) With the shifter in Park and the key removed, cassette. It can’t be adjusted more than once. If install the cable over the hook on locking arm of the the system operates incorrectly, install and shifter mechanism.
Page 1210 42LE TRANSAXLE 21 - 41 REMOVAL AND INSTALLATION (Continued) Fig. 68 Tilt Lever Fig. 66 Fuse Panel Cover 1 – TILT LEVER 1 – FUSE PANEL COVER 2 – LOWER SHROUD 2 – INSTRUMENT PANEL Fig. 69 Lower Shroud Attaching Screws Fig.
Page 1211 21 - 42 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) Fig. 72 Flat Inside BTSI Solenoid 1 – GUIDES 2 – SOLENOID 3 – FLAT Fig. 70 Solenoid Connector 1 – BTSI SOLENOID 2 – CONNECTOR Fig. 73 Guide And Flange Alignment 1 –...
Page 1212 42LE TRANSAXLE 21 - 43 REMOVAL AND INSTALLATION (Continued) only shift out of PARK with the brake pedal being depressed. (7) Install the lower shroud (Fig. 69) on the steer- ing column. Install and securely tighten the 2 screws attaching the lower shroud to the steering column. (8) Install the tilt lever (Fig.
Page 1213 21 - 44 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) Fig. 78 Upper Column Removal/Installation Fig. 80 Lower Column Cover Removal/Installation 1 – STEERING WHEEL 1 – LOWER COLUMN COVER 2 – UPPER COLUMN COVER 3 – GEAR SHIFT HANDLE Fig. 79 Tilt Lever Screw Removal/Installation 1 –...
Page 1214 42LE TRANSAXLE 21 - 45 REMOVAL AND INSTALLATION (Continued) Fig. 84 Ignition Key/Switch Positions 1 – ACC 2 – LOCK Fig. 82 Interlock Cable Locking Tab 3 – OFF 1 – TAB 4 – ON/RUN 2 – INTERLOCK CABLE 5 – START 3 –...
Page 1215 21 - 46 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) Fig. 87 Speed Sensor/Connector Location 1 – MANUAL SHIFT LEVER 2 – OUTPUT SPEED SENSOR 3 – LONG STUB SHAFT Fig. 86 Manual Shaft Retaining Screw 4 – INPUT SPEED SENSOR 1 –...
Page 1216 42LE TRANSAXLE 21 - 47 REMOVAL AND INSTALLATION (Continued) REMOVAL (3) Connect speed sensor connector (Fig. 89). (4) Connect battery negative cable. (1) Disconnect the output speed sensor connector (Fig. 89). TRANSMISSION CONTROL MODULE REMOVAL (1) Remove speed control servo (three fasteners). (2) Remove windshield washer reservoir fill tube fastener.
Page 1217 21 - 48 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) TRANSMISSION CONTROL RELAY REMOVAL (1) Open hood and locate power distribution center in the engine compartment. (2) Remove power distribution center plastic cover. (3) Pull relay out of power distribution center (Fig. 92).
Page 1218 42LE TRANSAXLE 21 - 49 REMOVAL AND INSTALLATION (Continued) Fig. 97 Transaxle Oil Filter Fig. 95 Transaxle Oil Pan Bolts 1 – TRANSAXLE FILTER 1 – EXTENSION 2 – FILTER RETAINING CLIPS 2 – TRANSAXLE OIL PAN 3 – SOCKET (5) Remove transaxle oil pan (Fig.
Page 1219 21 - 50 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) Fig. 99 Valve Body From Transaxle Fig. 101 Overdrive Accumulator and Springs 1 – VALVE BODY 1 – OVERDRIVE ACCUMULATOR PISTON 2 – RETURN SPRINGS 3 – SEAL RING 4 – SEAL RING Fig.
Page 1220 42LE TRANSAXLE 21 - 51 REMOVAL AND INSTALLATION (Continued) (13) Remove nuts retaining exhaust pipes to trans- mission mount. (14) Loosen clamp at right extension at right cata- lytic converter. Remove right extension. (15) Disconnect crankshaft position sensor connec- tor and remove sensor (Fig. 103). The sensor is located on the upper right side of the transaxle bell housing.
Page 1221 21 - 52 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) (36) Remove connector on top of transaxle for sole- noid pack. (37) The transaxle can now be lowered from the vehicle. INSTALLATION (1) When installing transaxle, reverse the above procedure. CAUTION: To prevent damage to the structural col- lar, hand tighten all fasteners.
Page 1222 42LE TRANSAXLE 21 - 53 REMOVAL AND INSTALLATION (Continued) TRANSFER SHAFT SEAL REPLACEMENT If it has been diagnosed that one or both of the transfer shaft seals are leaking, the following proce- dure can be used to replace failed seals. This proce- dure will allow the technician to replace the seals without having to set backlash and measure differen- tial bearing turning torque.
Page 1223 21 - 54 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) (9) Install transfer shaft, transfer shaft seals, oil baffle, rear cup, rear shim, rear cone and a new nut. Refer to appropriate procedures within this section for detailed removal and installation procedures if required.
Page 1224 42LE TRANSAXLE 21 - 55 REMOVAL AND INSTALLATION (Continued) Fig. 112 Remove Stub Shaft Bearing C-clip Fig. 114 Indexing Inner Adjuster 1 – BEARING SPLITTER 1 – INNER ADJUSTER 2 – STUB SHAFT BEARING 2 – ADJUSTER LOCK 3 – CROSS HAIR MARKS Fig.
Page 1225 21 - 56 42LE TRANSAXLE REMOVAL AND INSTALLATION (Continued) (1) Place vehicle in neutral and lift vehicle on (6) Use special tool 6558 to remove old seal and hoist. install new seal (Fig. 118). (2) Remove short driveshaft. (3) Index the outer adjuster (Fig. 116). Fig.
Page 1226 42LE TRANSAXLE 21 - 57 (4) Remove Solenoid/Pressure Switch Assembly DISASSEMBLY AND ASSEMBLY from valve body (Fig. 122). VALVE BODY DISASSEMBLY (1) Remove manual shaft seal. (2) Remove manual shaft screw (Fig. 120). Fig. 122 Solenoid/Pressure Switch Assembly Location 1 – SOLENOID PACK 2 –...
Page 1227 21 - 58 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 126 Separator Plate-to-Transfer Plate Screws Fig. 124 Transfer Plate-to-Valve Body Screws 1 – SEPARATOR PLATE 1 – SCREW (24) 2 – SCREW (2) 2 – TRANSFER PLATE 3 – TRANSFER PLATE Fig.
Page 1228 42LE TRANSAXLE 21 - 59 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 129 Thermal Valve Fig. 128 Oil Screen 1 – THERMAL VALVE 1 – OIL SCREEN Fig. 130 Ball Check Location 1 – (#4) BALL CHECK LOCATION 3 – (#5) BALL CHECK LOCATION 2 –...
Page 1229 21 - 60 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 131 2/4 Accumulator Assembly 1 – VALVE BODY 2 – RETAINER PLATE Fig. 133 Remove Regulator Valve Spring Retainer 3 – DETENT SPRING 4 – SPRINGS using Tool 6302 5 – SEALS 1 –...
Page 1230 42LE TRANSAXLE 21 - 61 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 135 Vent Reservoir Check Valve and Spring Fig. 136 Valve Retainer Location 1 – RETAINER 1 – RETAINER 2 – SPRING 2 – RETAINER 3 – BALL Fig. 137 Springs and Valves Location 1 –...
Page 1231 21 - 62 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY (1) Install valves and springs as shown in (Fig. 137). (2) Install regulator valve spring retainer (Fig. 138). Fig. 140 Vent Reservoir Check Valve and Spring 1 – RETAINER 2 – SPRING 3 –...
Page 1232 42LE TRANSAXLE 21 - 63 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 143 2/4 Accumulator Assembly 1 – VALVE BODY 2 – RETAINER PLATE 3 – DETENT SPRING Fig. 142 Valve Retainer Location 4 – SPRINGS 1 – RETAINER 5 – SEALS 2 –...
Page 1233 21 - 64 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (9) Install thermal valve to the transfer plate (Fig. 145). Fig. 147 Install Separator Plate to Transfer Plate 1 – SEPARATOR PLATE Fig. 145 Install Thermal Valve to Transfer Plate 2 – TRANSFER PLATE 1 –...
Page 1234 42LE TRANSAXLE 21 - 65 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 151 Install Stiffener Plate Fig. 149 Install Transfer Plate to Valve Body 1 – STIFFENER PLATE 1 – TRANSFER PLATE 2 – VALVE BODY Fig. 152 Solenoid/Pressure Switch Assembly 1 – SOLENOID PACK 2 –...
Page 1235 21 - 66 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) End play specifications are.13 to.64 mm (.005 to.025 inch). Record indicator reading for reference when reassembling the transaxle. Fig. 153 Manual Shaft/Rooster Comb and Transmission Range Sensor 1 – TRANSMISSION RANGE SENSOR 2 –...
Page 1236 42LE TRANSAXLE 21 - 67 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 157 Remove Transaxle Oil Pan Fig. 159 Remove Valve Body Bolts (17) 1 – TRANSAXLE OIL PAN 1 – EXTENSION 2 – SOCKET 3 – VALVE BODY Fig. 158 Remove Transaxle Oil Filter 1 –...
Page 1237 21 - 68 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Tag the springs for the Overdrive Accu- mulator so that they are not confused with the springs in the Low/Reverse Accumulator. Fig. 161 Remove Underdrive Accumulator and Spring 1 – ACCUMULATOR PISTON (UNDERDRIVE) 2 –...
Page 1238 42LE TRANSAXLE 21 - 69 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 167 Low/Reverse Accumulator Fig. 165 Remove Low/Reverse Accumulator Plug 1 – ACCUMULATOR PISTON (Cover) 2 – SEAL RINGS 1 – ADJUSTABLE PLIERS 3 – RETURN SPRINGS 2 – PLUG 4 – (NOTE NOTCH) NOTE: Remove driveshaft retainer clips from drive- shafts.
Page 1239 21 - 70 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 171 Oil Pump Pullers Fig. 169 Remove Long Stub Shaft From Bellhousing 1 – OIL PUMP 1 – LONG STUB SHAFT 2 – PULLERS 2 – SPECIAL TOOL 6669 3 – SLIDE HAMMER C-3752 Fig.
Page 1240 42LE TRANSAXLE 21 - 71 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 175 Measure Outer Gear to Pocket Fig. 173 Remove Oil Pump Gasket 1 – OUTER GEAR 1 – BELL HOUSING 2 – POCKET 2 – OIL PUMP GASKET (7) Align the Plastigage to a flat area on the reac- OIL PUMP INSPECTION tion shaft support housing.
Page 1241 21 - 72 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 179 Remove No. 4 Thrust Plate Fig. 177 Remove No. 1 Caged Needle Bearing 1 – OVERDRIVE SHAFT ASSEMBLY 2 – #4 THRUST PLATE (SELECT) 1 – #1 CAGED NEEDLE BEARING 3 –...
Page 1242 42LE TRANSAXLE 21 - 73 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 181 Remove Front Carrier and Rear Annulus Fig. 183 Number 7 Bearing Assembly 1 – #7 BEARING 1 – #6 NEEDLE BEARING 2 – REAR SUN GEAR 2 – FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL).
Page 1243 21 - 74 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 185 Remove 2/4 Clutch Retainer Fig. 187 Remove 2/4 Clutch Return Spring 1 – 2/4 CLUTCH RETAINER 1 – 24 CLUTCH RETURN SPRING Fig. 186 2/4 Clutch Retainer Fig. 188 Remove 2/4 Clutch Pack 1 –...
Page 1244 42LE TRANSAXLE 21 - 75 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 191 Remove Low/Reverse Reaction Plate Snap Fig. 189 Remove Tapered Snap Ring Ring 1 – LOW/REVERSE CLUTCH REACTION PLATE 1 – SCREWDRIVER 2 – LONG TAB 2 – LOW/REVERSE REACTION PLATE FLAT SNAP RING 3 –...
Page 1245 21 - 76 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 195 Remove Chain Snubber Fig. 193 Remove Chain Cover 1 – CHAIN SNUBBER 1 – TRANSAXLE CASE 2 – CHAIN COVER Fig. 196 Remove Output Shaft Sprocket Snap Ring and Wave Washer Fig.
Page 1246 42LE TRANSAXLE 21 - 77 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 197 Remove Transfer Shaft Sprocket Snap Ring Fig. 199 Remove Chains and Both Sprockets as an and Wave Washer Assembly 1 – TRANSFER SHAFT 1 – CHAINS 2 – WAVE WASHER 3 –...
Page 1247 21 - 78 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 203 Stake Grinding Pattern Fig. 201 Main Sump Vent Baffle Location 1 – TRANSFER SHAFT 1 – OUTPUT SHAFT NUT 2 – TRANSFER SHAFT NUT 2 – MAIN SUMP VENT BAFFLE 3 –...
Page 1248 42LE TRANSAXLE 21 - 79 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 205 Remove Output Shaft Nut Fig. 207 Remove Front Bearing Cup 1 – SPECIAL TOOL 6497 1 – ARBOR PRESS 2 – SPECIAL TOOL 6498 2 – SPECIAL TOOL 6596 3 –...
Page 1249 21 - 80 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 211 Compressor Tool in Use 1 – LOW/REVERSE CLUTCH RETURN SPRING 2 – SNAP RING (INSTALL AS SHOWN) 3 – TOOL 5058A-3 4 – TOOL 5059A 5 – SPECIAL TOOL 6057 Fig.
Page 1250 42LE TRANSAXLE 21 - 81 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 213 Low/Reverse Piston Return Spring Fig. 215 Anchor Shaft Removal 1 – LOW/REVERSE PISTON RETURN SPRING 1 – PIN PUNCH 2 – PISTON 2 – GUIDE BRACKET ASSEMBLY NOTE: Using a pin punch, drive out guide bracket pivot shaft.
Page 1251 21 - 82 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 219 Remove Piston Retainer Attaching Screws Fig. 217 Guide Bracket Disassembled 1 – LOW/REVERSE CLUTCH PISTON RETAINER 1 – GUIDE BRACKET 2 – SCREWDRIVER 2 – PAWL 3 – TORX-LOC SCREWS 3 –...
Page 1252 42LE TRANSAXLE 21 - 83 DISASSEMBLY AND ASSEMBLY (Continued) (3) Remove the pump gears (Fig. 223) and check for wear and damage. Fig. 221 Remove Piston Retainer Gasket 1 – GASKET HOLES MUST LINE UP 2 – LOW/REVERSE CLUTCH PISTON RETAINER GASKET At this point the Centerline of the transaxle has been removed.
Page 1253 21 - 84 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (6) Position an appropriate piece of Plastigage across both pump gears. (7) Align the Plastigage to a flat area on the reac- tion shaft support housing. (8) Install the reaction shaft to the pump housing. Tighten the bolts to 27 N·M (20 ft.
Page 1254 42LE TRANSAXLE 21 - 85 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 230 OD/Reverse Reaction Plate Snap Ring Fig. 228 Reverse Clutch Reaction Plate 1 – OD/REVERSE PRESSURE PLATE 1 – REVERSE CLUTCH REACTION PLATE (INSTALL FLAT SIDE DOWN) 2 – SCREWDRIVER 3 –...
Page 1255 21 - 86 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 234 Overdrive Clutch Pack Fig. 232 Waved Snap Ring 1 – OVERDRIVE CLUTCH PLATE 1 – OVERDRIVE SHAFT ASSEMBLY 2 – OVERDRIVE SHAFT ASSEMBLY 2 – OD/REVERSE CLUTCH WAVED SNAP RING 3 –...
Page 1256 42LE TRANSAXLE 21 - 87 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 238 OD/UD Reaction Plate Tapered Snap Ring Fig. 236 Underdrive Shaft Assembly 1 – OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE 1 – #3 THRUST WASHER (5 TABS) TAPERED SNAP RING 2 – UNDERDRIVE SHAFT ASSEMBLY 2 –...
Page 1257 21 - 88 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 240 Remove One UD Clutch Disc Fig. 242 Underdrive Clutch Pack 1 – ONE UNDERDRIVE CLUTCH DISC 1 – CLUTCH PLATE 2 – ONE UD CLUTCH DISC 3 – CLUTCH DISC Fig.
Page 1258 42LE TRANSAXLE 21 - 89 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 246 Input Hub Tapered Snap Ring Fig. 244 UD Return Spring and Retainer 1 – INPUT SHAFT 1 – UNDERDRIVE SPRING RETAINER 2 – INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN 2 –...
Page 1259 21 - 90 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 248 Input Hub Removed Fig. 250 Remove Snap Ring 1 – INPUT SHAFT AND HUB ASSEMBLY 1 – ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING) 2 –...
Page 1260 42LE TRANSAXLE 21 - 91 DISASSEMBLY AND ASSEMBLY (Continued) (25) Remove input shaft to input clutch hub snap ASSEMBLY ring (Fig. 252). Use petrolatum on all seals to ease assembly of components. (1) Using an arbor press, install input shaft to input shaft hub (Fig.
Page 1261 21 - 92 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 256 Return Spring and Snap Ring Fig. 258 Install OD/Reverse Piston 1 – OD/REVERSE PISTON 1 – PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON 2 – RETURN SPRING 2 – INPUT CLUTCHES RETAINER 3 –...
Page 1262 42LE TRANSAXLE 21 - 93 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 262 Seal Compressor Special Tool 5067 Fig. 260 Install Input Hub Tapered Snap Ring 1 – PISTON RETURN SPRING 1 – INPUT SHAFT 2 – SPECIAL TOOL 5067 2 – INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN 3 –...
Page 1263 21 - 94 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 266 UD Clutch Flat Snap Ring Fig. 264 Install UD Spring Retainer and Snap Ring 1 – UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 1 – ARBOR PRESS RAM 2 – SCREWDRIVER 2 –...
Page 1264 42LE TRANSAXLE 21 - 95 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 268 OD/UD Reaction Plate Fig. 270 Seating Tapered Snap Ring 1 – OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN) 1 – OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 – SCREWDRIVER Fig.
Page 1265 21 - 96 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (20) If necessary, select the proper reaction plate to achieve specifications: UNDERDRIVE REACTION PLATE THICKNESS 4659939AB 5.837-5.937 mm (0.230-0.234 in.) 4659940AB 6.147-6.248 mm (0.242-0.246 in.) 4659941AB 6.457-6.557 mm (0.254-0.258 in.) (21) Install the OD clutch pack (four fibers/four steels) (Fig.
Page 1266 42LE TRANSAXLE 21 - 97 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 276 OD/Reverse Reaction Plate 1 – OVERDRIVE/REVERSE PRESSURE PLATE 2 – (STEP SIDE DOWN) Fig. 278 Measure OD Clutch Pack Clearance 1 – DIAL INDICATOR 2 – OD/REVERSE REACTION PLATE If not within specifications, the clutch is not assembled properly.
Page 1267 21 - 98 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (29) Install reverse clutch reaction plate with the flat side down towards reverse clutch (Fig. 280). Fig. 282 Pry Up Reaction Plate to Seat Against Snap Ring 1 – SCREWDRIVER Fig. 280 Install Reaction Plate 2 –...
Page 1268 42LE TRANSAXLE 21 - 99 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 285 Install No. 2 Needle Bearing 1 – #2 NEEDLE BEARING (NOTE 3 SMALL TABS) 2 – TABS UP Fig. 284 Press Down on Reverse Clutch and Zero Indicator 1 – DIAL INDICATOR 2 –...
Page 1269 21 - 100 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 289 Install Overdrive Shaft Assembly Fig. 287 Install No. 3 Thrust Washer 1 – OVERDRIVE SHAFT ASSEMBLY 1 – #3 THRUST WASHER (NOTE 5 TABS) 2 – #3 THRUST PLATE 2 –...
Page 1270 42LE TRANSAXLE 21 - 101 DISASSEMBLY AND ASSEMBLY (Continued) TRANSAXLE—ASSEMBLY To install the output bearing cups, use Special Tool # 5050A. Fig. 291 Bearing Cup Installation Special Tool 5050A Fig. 294 Install Retainer Attaching Screws 1 – LOW/REVERSE CLUTCH PISTON RETAINER 2 –...
Page 1271 21 - 102 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 298 Install Guide Bracket Pivot Shaft Fig. 296 Guide Bracket Disassembled 1 – PIVOT PIN 1 – GUIDE BRACKET 2 – GUIDE BRACKET ASSEMBLY 2 – PAWL 3 – SPLIT SLEEVE 4 –...
Page 1272 42LE TRANSAXLE 21 - 103 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 300 Install Low/Reverse Piston Return Spring Fig. 302 Compressor Tool in Use 1 – LOW/REVERSE PISTON RETURN SPRING 1 – LOW/REVERSE CLUTCH RETURN SPRING 2 – PISTON 2 – SNAP RING (INSTALL AS SHOWN) 3 –...
Page 1273 21 - 104 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 305 Bearing Installation 1 – SPECIAL TOOL 6618–A 2 – REAR OUTPUT SHAFT BEARING Fig. 304 Install Rear Carrier Front Bearing Cone 1 – ARBOR PRESS 2 – SPECIAL TOOL C-4171 3 –...
Page 1274 42LE TRANSAXLE 21 - 105 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 307 Shim Installation Fig. 308 Press Shaft Into Case 1 – SHIM 1 – SPECIAL TOOL C-4171 AND C-4171–2 2 – OUTPUT SHAFT 2 – SPECIAL TOOL MD-998911 5.17 - 5.19 mm 5.62 - 5.64 mm 5.20 - 5.22 mm 5.65 - 5.67 mm...
Page 1275 21 - 106 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (8) The new nut must be staked after the correct When reinstalling main sump baffle apply Mopar turning torque is obtained (Fig. 310). Use special tool Silicone Sealant as shown in (Fig. 312). 6639 to stake output shaft nut and special tool 6589 to stake transfer shaft.
Page 1276 42LE TRANSAXLE 21 - 107 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 316 Remove Chain Spreader Fig. 314 Output Sprocket Spacer 1 – OUTPUT SPROCKET 1 – OUTPUT SPROCKET SPACER 2 – SPECIAL TOOL 6550 2 – VENT BAFFLE 3 – TRANSFER SPROCKET 3 –...
Page 1277 21 - 108 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 318 Install Output Shaft Sprocket Snap Ring Fig. 320 Install Chain Oiler and Wave Washer 1 – CHAIN SNUBBER 1 – WAVE WASHER 2 – CHAIN OILER 2 – SNAP RING Fig.
Page 1278 42LE TRANSAXLE 21 - 109 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 324 Install One Disc Fig. 322 Install Low/Reverse Clutch Pack 1 – ONE DISC FROM LOW/REVERSE CLUTCH 1 – CLUTCH PLATES (5) 2 – CLUTCH DISCS (5) Fig. 325 Install Low/Reverse Reaction Plate 1 –...
Page 1279 21 - 110 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 328 Check Low/Reverse Clutch Clearance 1 – DIAL INDICATOR 2 – DIAL INDICATOR TIP TOOL 6268 3 – HOOK TOOL LOW/REVERSE REACTION PLATE CHART PART NUMBER THICKNESS Fig. 326 Tapered Snap Ring Instructions 4799846AA 5.88 mm (.232 in.) 4799847AA...
Page 1280 42LE TRANSAXLE 21 - 111 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 330 Stagger 2/4 Clutch Plate Pads Fig. 332 Proper Orientation of 2/4 Clutch Retainer 1 – PILOT PADS and Spring 2 – LUGS 1 – NOTE POSITION 2 – RETURN SPRING 3 –...
Page 1281 21 - 112 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) The number 7 needle bearing has three antirever- sal tabs and is common with the number 5 and num- ber 2 position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig. 336).
Page 1282 42LE TRANSAXLE 21 - 113 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 340 Select Thinnest No. 4 Thrust Plate Fig. 338 Install Front Carrier and Rear Annulus 1 – OVERDRIVE SHAFT ASSEMBLY Assembly 2 – #4 THRUST PLATE (SELECT) 1 – #6 NEEDLE BEARING 3 –...
Page 1283 21 - 114 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) See chart to select the proper No. 4 thrust plate. NO. 4 THRUST PLATE CHART PART NUMBER THICKNESS 4431662 .91mm (.036 in.) 4431663 1.14mm (.045 in.) 4431664 1.37mm (.054 in.) 4431665 1.60mm (.063 in.) 3836237 1.73mm (.068 in.)
Page 1284 42LE TRANSAXLE 21 - 115 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: To align oil pump during installation, use threaded dowels or phillips screwdrivers. Fig. 345 Install Caged Needle Bearing 1 – #1 CAGED NEEDLE BEARING 2 – NOTE: TANGED SIDE OUT Fig.
Page 1285 21 - 116 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 351 Install Long Stub Shaft Snap Ring Fig. 349 Install Oil Pump Attaching Bolts 1 – SNAP RING 1 – BELLHOUSING 2 – SNAP RING PLIERS 2 – OIL PUMP 3 –...
Page 1286 42LE TRANSAXLE 21 - 117 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 355 Accumulator Locations Fig. 353 Install Low/Reverse Accumulator Plug (Cover) 1 – OVERDRIVE ACCUMULATOR LOCATION 2 – UNDERDRIVE ACCUMULATOR LOCATION 1 – ADJUSTABLE PLIERS 3 – LOW/REVERSE ACCUMULATOR 2 – PLUG Fig.
Page 1287 21 - 118 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 357 Install Overdrive Accumulator and Springs Fig. 359 Install Valve Body Bolts (17) 1 – OVERDRIVE ACCUMULATOR PISTON 1 – EXTENSION 2 – RETURN SPRINGS 2 – SOCKET 3 – SEAL RING 3 –...
Page 1288 42LE TRANSAXLE 21 - 119 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 361 Install Transaxle Oil Pan Fig. 363 Measure Input Shaft End Play 1 – TRANSAXLE OIL PAN 1 – DIAL INDICATOR Install both speed sensors from transaxle case (Fig. be removed with the valve body in place. Refer to 362).
Page 1289 21 - 120 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 365 Remove Chain Oiler Fig. 367 Remove Output Shaft Sprocket Snap Ring and Wave Washer 1 – CHAIN SNUBBER 2 – CHAIN OILER 1 – WAVE WASHER 2 – SNAP RING Fig.
Page 1290 42LE TRANSAXLE 21 - 121 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 369 Install Chain Spreader Fig. 371 Remove Long Stub Shaft Snap Ring 1 – OUTPUT SPROCKET 1 – SNAP RING 2 – SPECIAL TOOL 6550 2 – SNAP RING PLIERS 3 –...
Page 1291 21 - 122 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 373 Remove Inner Differential Adjuster Lock Fig. 375 Loosen Outer Adjuster 1 – INNER DIFFERENTIAL ADJUSTER LOCK 1 – OUTER ADJUSTER 2 – INNER DIFFERENTIAL ADJUSTER 2 – SPECIAL TOOL 6503 Fig.
Page 1292 42LE TRANSAXLE 21 - 123 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 377 Remove Inner Adjuster By Turning Fig. 379 Grinding Stakes Clockwise 1 – TRANSFER SHAFT 1 – SPECIAL TOOL 6502–B 2 – GRIND HERE 2 – INNER DIFFERENTIAL ADJUSTER 3 – GRIND HERE 4 –...
Page 1293 21 - 124 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 381 Opening Nut Stakes 1 – CHISEL 2 – NUT STAKE Fig. 383 Transfer Bearing Cup Removal 1 – SPECIAL TOOL 6577 Fig. 384 Preload Shim Removal Fig. 382 Press Transfer Shaft Downward to Remove 1 –...
Page 1294 42LE TRANSAXLE 21 - 125 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 385 Remove Transfer Shaft Assembly From Case 1 – TRANSFER SHAFT Fig. 388 Remove Front Transfer Shaft Bearing And Pinion Depth Shim 1 – ARBOR PRESS 2 – TRANSFER SHAFT 3 –...
Page 1295 21 - 126 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (3) Install new front bearing (actual bearing to be used during reassembly) onto gauge disc (special tool 6549-3) (Fig. 391). Fig. 391 Gauge Disc and Bearing 1 – FRONT TRANSFER SHAFT BEARING 2 –...
Page 1296 42LE TRANSAXLE 21 - 127 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 395 Dial indicator, Locating Block and Extension Rod 1 – EXTENSION ROD SPECIAL TOOL 2 – LOCATING BLOCK SPECIAL TOOL Fig. 393 Disc Installation 3 – DIAL INDICATOR 1 – SPECIAL TOOL 6494–2 Fig.
Page 1297 21 - 128 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) the adjustment number to the corresponding adjust- ment factor. Utilizing the pinion depth measurement obtained in Step 11, add or subtract the adjustment factor to calculate the requred shim thickness. Refer to pinion head shim chart for shim selections.
Page 1298 42LE TRANSAXLE 21 - 129 DISASSEMBLY AND ASSEMBLY (Continued) PINION HEAD SHIM CHART Fig. 401 Bearing Installation 1 – ARBOR PRESS 2 – SPECIAL TOOL 6052 3 – FRONT TRANSFER SHAFT BEARING Fig. 400 Shim Installation 1 – PINION DEPTH SHIM 2 –...
Page 1299 21 - 130 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 403 Axle Shaft Seal Installation 1 – ARBOR PRESS 2 – OUTER DIFFERENTIAL ADJUSTER 3 – O-RING 4 – SPECIAL TOOL 6558 NOTE: To remove inner and outer adjuster races, Fig.
Page 1300 42LE TRANSAXLE 21 - 131 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 407 Seal Protector Fig. 409 Special Tool 6548 1 – SEAL PROTECTOR (6591) 1 – SPECIAL TOOL 6548 2 – SIDE COVER 2 – ⁄ ” EXTENSION 3 – TORQUE WRENCH (28) Screw on outer adjuster and tighten adjuster down finger tight (Fig.
Page 1301 21 - 132 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 410 Determining Turning Torque 1 – FT. LBS. TORQUE WRENCH 3 – IN. LBS. TORQUE WRENCH 2 – SPECIAL TOOL 6548 4 – SPECIAL TOOL 6503 (33) Install transfer shaft into transaxle case (Fig. CAUTION: Bottom of support fixture must be flush 411).
Page 1302 42LE TRANSAXLE 21 - 133 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 414 Correct Seal Orientation 1 – SEAL PROTECTOR 2 – FRONT TRANSFER SHAFT SEAL 3 – SERRATED SIDE REARWARD Fig. 412 Transfer Shaft Support Fixture 1 – SUPPORT FIXTURE (6595) Fig.
Page 1303 21 - 134 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 416 Correct Seal Orientation Fig. 418 Rear Transfer Shaft Cup Installation 1 – ARBOR PRESS 1 – REAR TRANSFER SHAFT SEAL 2 – SPECIAL TOOL 6560 2 – SPRING SIDE OUTWARD Fig.
Page 1304 42LE TRANSAXLE 21 - 135 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 421 Checking Turning Torque 1 – SOCKET (6498) 2 – TRANSFER SHAFT NUT 3 – IN. LBS. TORQUE WRENCH (46) After the correct turning torque is obtained, Transfer Shaft Rear Shim Chart use special tool 6589 to stake the new transfer shaft nut (Fig.
Page 1305 21 - 136 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 423 Correctly Staked Nut Fig. 425 Differential Assembly Installation 1 – BOTTOMED IN SLOT 1 – DIFFERENTIAL ASSEMBLY 2 – CORRECTLY STAKED NUT (52) Transfer shaft to ring gear backlash should be (48) If the carrier requires reconditioning, refer to 0.006”...
Page 1306 42LE TRANSAXLE 21 - 137 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 428 Seal Protector Fig. 426 Rocking Ring Gear Back and Forth 1 – SEAL PROTECTOR 1 – DIFFERENTIAL ASSEMBLY (6591) 2 – SIDE COVER Fig. 427 Differential Cover Installation 1 – SIDE COVER Fig.
Page 1307 21 - 138 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 432 Tap Off Ring Gear Fig. 430 Dial Indicator Installation 1 – DIFFERENTIAL CARRIER 1 – DIAL INDICATOR KIT C-3339 2 – RING GEAR 2 – ACCESS HOLE 3 – PLASTIC MALLET (62) It is easier to fill the differential prior to installing the transaxle back into the vehicle.
Page 1308 42LE TRANSAXLE 21 - 139 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 434 Remove C-Clip Fig. 436 Slide Out Differential Pinion Shaft and 1 – SIDE GEAR Remove Pinion Gears and Side Gears 2 – STUB SHAFT 1 – DIFFERENTIAL CARRIER 3 – “C” CLIP 2 –...
Page 1309 21 - 140 42LE TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (2) Pry the chains down at the center of the chains. (3) Butt a scale against the snubber and mark the scale at the bottom of the chains (Fig. 440). Fig. 440 Chain Measurement 1 –...
Page 1310 42LE TRANSAXLE 21 - 141 CLEANING AND INSPECTION (Continued) ADJUSTMENT (1) Remove upper steering column shroud. (2) Rotate cable adjuster into unlock position. Use a straight blade screwdriver to unlock adjuster (Fig. 444). Fig. 442 Chains Measurement 1 – SCALE Fig.
Page 1311 21 - 142 42LE TRANSAXLE ADJUSTMENTS (Continued) (3) Make sure that the transaxle shift lever (at transaxle) is in the Park position. This is the most rearward position. Verify park sprag is fully engaged. CAUTION: Park sprag must be engaged when adjusting linkage.
Page 1312 42LE TRANSAXLE 21 - 143 ADJUSTMENTS (Continued) (6) Install the bezel on the shifter console. (7) Install shifter handle. AUTOSTICK The autostick switch is serviced as an assembly with the gearshift mechanism. The switch is not adjustable. If a problem occurs with the switch, refer to the Diagnosis and Testing section.
Page 1313 21 - 144 42LE TRANSAXLE ADJUSTMENTS (Continued) MASTER SHIM CHART...
Page 1314 42LE TRANSAXLE 21 - 145 ADJUSTMENTS (Continued) DRIVE SPROCKET HEIGHT ADJUSTMENT If the output sprocket is higher than transfer sprocket, subtract the amount measured to the shim PROCEDURE that was installed (Fig. 450). A spacer beneath the output sprocket is used to position the output sprocket in line with the transfer sprocket.
Page 1315 21 - 146 42LE TRANSAXLE SCHEMATICS AND DIAGRAMS 42LE TRANSAXLE HYDRAULIC SCHEMATICS...
Page 1316 42LE TRANSAXLE 21 - 147 SCHEMATICS AND DIAGRAMS (Continued)
Page 1317 21 - 148 42LE TRANSAXLE SCHEMATICS AND DIAGRAMS (Continued)
Page 1318 42LE TRANSAXLE 21 - 149 SCHEMATICS AND DIAGRAMS (Continued)
Page 1319 21 - 150 42LE TRANSAXLE SCHEMATICS AND DIAGRAMS (Continued)
Page 1320 42LE TRANSAXLE 21 - 151 SCHEMATICS AND DIAGRAMS (Continued)
Page 1321 21 - 152 42LE TRANSAXLE SCHEMATICS AND DIAGRAMS (Continued)
Page 1322 42LE TRANSAXLE 21 - 153 SCHEMATICS AND DIAGRAMS (Continued)

This manual is also suitable for:

300m Concorde Intrepid

Chrysler 2000 LHS Owner's Manual

Quick Links

GROUP TAB LOCATOR

Troubleshooting

Related Manuals for Chrysler 2000 LHS

Summary of Contents for Chrysler 2000 LHS

Page 496: Wiring Diagrams

This manual is also suitable for:

Table of Contents