Dodge Dakota Sport 2001 Service Manual

page of 2307

/ 2307
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

GROUP TAB LOCATOR

Introduction

Lubrication & Maintenance

Suspension

Differential & Driveline

Brakes

Clutch

Cooling

Audio

Chime/Buzzer

Electronic Control Modules

Engine Systems

Heated Systems

Horn

Ignition Control

Instrument Cluster

Lamps

Message Systems

Power Systems

Restraints

Speed Control

Vehicle Theft Security

Wipers/Washers

Wiring

Engine

Exhaust System

Frame & Bumpers

Fuel System

Steering

Transmission and Transfer Case

Tires/Wheels

Body

Heating & Air Conditioning

Emissions Control

New Vehicle Preparation

Component and System Index

Service Manual Comment Forms

(Rear of Manual)

Table of Contents

Chapters

Table of Contents

Summary of Contents for Dodge Dakota Sport 2001

Page 1 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Suspension Differential & Driveline Brakes Clutch Cooling Audio Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System...
Page 2: Table Of Contents
INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page VEHICLE SAFETY CERTIFICATION LABEL INTERNATIONAL SYMBOLS DESCRIPTION ......1 DESCRIPTION .
Page 3: Vehicle Identification Number
VIN DECODING INFORMATION POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 1= USA Make B = Dodge Vehicle Type 7 = Truck F = 4001-5000 lbs. Gross Vehicle Weight Rating G = 5001-6000 lbs. H = 6001-7000 lbs. G = Dakota...
Page 4: Body Code Plate
INTRODUCTION tion reads from left to right, starting with line 4 in VECI LABEL the center of the plate to line 1 at the bottom of the plate (Fig. 4). DESCRIPTION The last code imprinted on a vehicle code plate will All vehicles are equipped with a combined VECI be followed by the imprinted word END.
Page 5 INTRODUCTION BODY CODE PLATE (Continued) DIGIT 4 BODY CODE PLATE—LINE 1 Open Space DIGITS 1 THROUGH 6 Body-in-white assembly sequence. DIGITS 5 THROUGH 8 DIGITS 7 THROUGH 9 Primary Paint Refer to Group 23, Body for color codes. Open Space DIGIT 9 DIGITS 10 THROUGH 12 Cargo box code •...
Page 6: Fastener Identification
INTRODUCTION INTERNATIONAL SYMBOLS (Continued) Fig. 6 INTERNATIONAL SYMBOLS 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...
Page 7 INTRODUCTION FASTENER USAGE (Continued) Fig. 7 FASTENER IDENTIFICATION...
Page 8 INTRODUCTION FASTENER USAGE (Continued) Fig. 8 FASTENER STRENGTH...
Page 9: Metric System
INTRODUCTION Refer to the Metric Conversion Chart (Fig. 9) to METRIC SYSTEM convert torque values listed in metric Newton- meters (N·m). Also, use the chart to convert between DESCRIPTION millimeters (mm) and inches (in.) The metric system is based on quantities of one, ten, one hundred, one thousand and one million.
Page 10 INTRODUCTION METRIC SYSTEM (Continued) Fig. 9 METRIC CONVERSION CHART...
Page 11 INTRODUCTION cations Chart for torque references not listed in the TORQUE REFERENCES individual torque charts (Fig. 10). DESCRIPTION Individual Torque Charts appear at the end of many Groups. Refer to the Standard Torque Specifi- Fig. 10 TORQUE SPECIFICATIONS...
Page 12: Lubrication & Maintenance
LUBRICATION & MAINTENANCE 0 - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page LUBRICATION & MAINTENANCE HOISTING SPECIFICATIONS ......1 STANDARD PROCEDURE .
Page 13 0 - 2 LUBRICATION & MAINTENANCE API QUALITY CLASSIFICATION This symbol (Fig. 2) on the INTERNATIONAL SYMBOLS front of an oil container means that the oil has been certified by the American Petroleum Institute (API) to meet DESCRIPTION all the lubrication requirements specified by DailmlerChrysler Corporation.
Page 14 LUBRICATION & MAINTENANCE 0 - 3 PARTS & LUBRICANT (Continued) RECOMMENDATIONS CAUTION: DO NOT use gasoline containing METH- ANOL. Gasoline containing methanol may damage When service is required, DaimlerChrysler Corpo- critical fuel system components. ration recommends that only Mopar brand parts, lubricants and chemicals be used.
Page 15 0 - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) FUEL SYSTEM CAUTIONS CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze CAUTION: Follow these guidelines to maintain your protection and less corrosion protection. vehicle’s performance: The cooling system is designed around the coolant.
Page 16 LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) tion against freezing is provided with a 68 percent SAE VISCOSITY antifreeze concentration, which prevents freezing An SAE viscosity grade is used to specify the vis- down to -67.7°C (-90°F). A higher percentage will cosity of engine oil.
Page 17 0 - 6 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) NOTE: Refer to Service Procedures in this group for fluid level checking procedures. Mopar ATF +4, type 9602, Automatic Transmis- sion Fluid is the recommended fluid for Daimler- Chrysler automatic transmissions. Dexron II fluid IS NOT recommended.
Page 18: Maintenance Schedules
LUBRICATION & MAINTENANCE 0 - 7 • Check fluid levels of coolant reservoir, power FLUID FILL/CHECK steering and transmission and add as needed. LOCATIONS • Check all lights and all other electrical items for correct operation. DESCRIPTION • Inspect and clean wiper blades. Replace if The fluid check/fill points and lubrication locations required.
Page 19 0 - 8 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) • Drain and refill automatic transmission fluid • Inspect auto tension drive belt and replace if and change filter (4.7L only). required (3.9L, & 5.9L). 37,500 Miles (60 000 km) or at 30 months 82,500 Miles (132 000 km) or at 66 months •...
Page 20 LUBRICATION & MAINTENANCE 0 - 9 MAINTENANCE SCHEDULES (Continued) • Inspect PCV valve, replace as necessary. 18,000 Miles (29 000 km) • Change engine oil. (3.9L, 4.7L, and 5.9L)* • Replace spark plugs. • Replace engine oil filter. • Inspect auto tension drive belt and replace if •...
Page 21 0 - 10 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) • Change rear axle fluid. 39,000 Miles (62 000 km) • Change front axle fluid (4x4). • Change engine oil. • Inspect brake linings. • Replace engine oil filter. • Inspect auto tension drive belt and replace if 42,000 Miles (67 000 km) required (3.9L &...
Page 22 LUBRICATION & MAINTENANCE 0 - 11 MAINTENANCE SCHEDULES (Continued) • Drain and refill automatic transmission fluid. 108,000 Miles (173 000 km) • Change engine oil. Replace filter and adjust bands (3.9L & 5.9L).‡ • Drain and refill automatic transmission fluid •...
Page 23: Jump Starting
0 - 12 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) frequent transmission service indicated with a ‡ in HOIST Schedule “B”. Perform these services if the vehicle is usually operated under these conditions. WARNING: THE HOISTING AND JACK LIFTING Important: Inspection and service should also be POINTS PROVIDED ARE FOR A COMPLETE VEHI- performed any time a malfunction is observed or sus- CLE.
Page 24 LUBRICATION & MAINTENANCE 0 - 13 JUMP STARTING (Continued) (1) Raise hood on disabled vehicle and visually inspect engine compartment for: • Battery cable clamp condition, clean if necessary. • Frozen battery. • Yellow or bright color test indicator, if equipped. •...
Page 25 0 - 14 LUBRICATION & MAINTENANCE TOWING (Continued) SAFETY PRECAUTIONS STANDARD PROCEDURE—TWO WHEEL DRIVE VEHICLE TOWING NOTE: The following safety precautions must be observed when towing a vehicle. TOWING-REAR END LIFTED • Secure loose and protruding parts. CAUTION: • Always use a safety chain system that is inde- Short bed vehicles must be towed with a Wheel-lift pendent of the lifting and towing equipment.
Page 26 LUBRICATION & MAINTENANCE 0 - 15 TOWING (Continued) (2) Attach the safety chains to the disabled vehicle (2) Attach wheel lift device to rear wheels. at the frame rails. (3) Attach safety chains to frame rails. Route chains so not to interfere with tail pipe when vehicle CAUTION: Do not use steering column lock to is lifted.
Page 28: Operation
SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page WHEEL ALIGNMENT ..... . . 1 FRONT - 4WD ......15 FRONT - 2WD .
Page 29 2 - 2 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire (Fig. 2). • TOE is the difference between the leading inside edges and trailing inside edges of the front tires.
Page 30 WHEEL ALIGNMENT 2 - 3 WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES CORRECTION VEHICLE INSTABILITY 1. Loose or worn wheel bearing. 1. Replace wheel bearing. 2. Loose or worn steering or 2. Tighten or replace components as suspension components. necessary. 3. Tire pressure. 3.
Page 31 2 - 4 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) CAUTION: ALWAYS raise the vehicle to the correct STANDARD PROCEDURE - CASTER suspension height, NEVER lower the vehicle to obtain the correct suspension height. If the vehicle NOTE: 4x4 suspension height measurement must suspension height is too high, lower the vehicle be performed before alignment.
Page 32 WHEEL ALIGNMENT 2 - 5 WHEEL ALIGNMENT (Continued) (3) Adjust the wheel toe position by turning the tie (4) Tighten the tie rod jam nut to 75 N·m (55 ft. rod as necessary (Fig. 5). lbs.). (5) Verify the specifications. (6) Turn off engine.
Page 33 2 - 6 FRONT - 2WD FRONT - 2WD TABLE OF CONTENTS page page FRONT - 2WD OPERATION......11 DESCRIPTION .
Page 34 FRONT - 2WD 2 - 7 FRONT - 2WD (Continued) DESCRIPTION - SUSPENSION ARMS The upper suspension arm bolts on frame brackets through the arm pivot shaft. The frame brackets have slotted holes which allow the arms to be adjusted for caster and camber. Pivot shaft bushings are not replaceable.
Page 35 2 - 8 FRONT - 2WD SPECIAL TOOLS FRONT SUSPENSION Compressor, Coil Spring DD-1278 Fig. 2 BUSHING REMOVAL 1 - 8441-1 2 - 8441-2 3 - 8441-3 INSTALLATION Remover Ball Joint MB-991113 (1) Install the bushing in the control arm and inserted over the shaft.
Page 36: Operation
FRONT - 2WD 2 - 9 has machined mounting locations for the front brake HUB / BEARING calipers and hub bearing. REMOVAL OPERATION (1) Raise and support vehicle. The steering knuckle pivot between the upper and (2) Remove wheel and tire assembly. lower ball joint.
Page 37 2 - 10 FRONT - 2WD KNUCKLE (Continued) Fig. 5 Upper Ball Joint 1 - UPPER BALL JOINT 2 - REMOVER Fig. 6 Lower Ball Joint Boss 3 - KNUCKLE 1 - BALL JOINT BOSS 2 - STEERING KNUCKLE (7) Install the wheel and tire assembly. (Refer to 3 - DIAL INDICATOR 22 - TIRES/WHEELS/WHEELS - STANDARD PRO- CEDURE).
Page 38 FRONT - 2WD 2 - 11 LOWER CONTROL ARM (Continued) ing components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit- tent. This condition is not repairable and the shock absorber must be replaced.
Page 39 2 - 12 FRONT - 2WD SHOCK (Continued) (2) Install the lower mounting bolts and tighten to 28 N·m (21 ft. lbs.). (3) Remove support and lower the vehicle. (4) Install the upper grommet and retainer (upper retainer is stamped with a U) on the shock absorber stud.
Page 40 FRONT - 2WD 2 - 13 SPRING (Continued) (4) Install the lower ball joint into the knuckle and tighten the nut to 127 N·m (94 ft. lbs.). Install cotter pin. (5) Remove the spring compressor tool. (6) Install the stabilizer bar link to the lower sus- pension arm and tighten nut to 47 N·m (35 ft.
Page 41 2 - 14 FRONT - 2WD UPPER CONTROL ARM (Continued) (3) Remove brake hose bracket from the arm. INSTALLATION (4) Position a hydraulic jack under the arm and raise the jack to unload the rebound bumper. NOTE: Before installation, insure pivot bar adjust- (5) Remove cotter pin and nut from upper ball joint.
Page 42 FRONT - 4WD 2 - 15 FRONT - 4WD TABLE OF CONTENTS page page FRONT - 4WD LOWER BALL JOINT ....20 DESCRIPTION .
Page 43 2 - 16 FRONT - 4WD FRONT - 4WD (Continued) CAUTION: Components attached with a nut and cot- DESCRIPTION - SUSPENSION ARMS ter pin must be torqued to specification. Then if the The upper suspension arm bolts on frame brackets slot in the nut does not line up with the cotter pin through the arm pivot shaft.
Page 44 FRONT - 4WD 2 - 17 SPECIAL TOOLS FRONT SUSPENSION Puller Tie Rod C-3894-A Fig. 2 Lower Ball Joint 1 - REMOVER 2 - LOWER BALL STUD Remover MB-991113 Remover C-4150A LOWER CONTROL ARM Fig. 3 Lower Suspension Arm REMOVAL 1 - PIVOT BOLTS (1) Raise and support the vehicle.
Page 45 2 - 18 FRONT - 4WD LOWER CONTROL ARM (Continued) (4) Install shock absorber lower bolt and tighten to CAUTION: When installing Remover MB-991113 to 108 N·m (80 ft. lbs.). separate the ball joint, be careful not to damage the (5) Install the front halfshaft.
Page 46 FRONT - 4WD 2 - 19 KNUCKLE (Continued) (5) Install the tie rod end and tighten the nut to 88 N·m (65 ft. lbs.). (Refer to 19 - STEERING/LINK- AGE/TIE ROD END - INSTALLATION). (6) Install the front halfshaft, (Refer to 3 - DIF- FERENTIAL &...
Page 47 2 - 20 FRONT - 4WD STABILIZER BAR (Continued) Fig. 8 Hub/Bearing 1 - HUB BEARING Fig. 7 Stabilizer Bar 2 - STEERING KNUCKLE 1 - LOWER SUSPENSION ARM 2 - FLAG NUT INSTALLATION 3 - STABILIZER BAR (1) Install the hub/bearing into the steering 4 - RETAINER knuckle and tighten the bolts to 166 N·m (123 ft.
Page 48 FRONT - 4WD 2 - 21 LOWER BALL JOINT (Continued) (4) Position indicator plunger against the bottom surface of the steering knuckle lower ball joint boss. NOTE: The dial indicator plunger must be perpen- dicular to the machined surface of the steering knuckle lower ball joint boss (Fig.
Page 49 2 - 22 FRONT - 4WD UPPER CONTROL ARM (Continued) (7) Install the wheel and tire assembly. (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PRO- CEDURE). (8) Remove support and lower vehicle. (9) Align front suspension. (Refer to 2 - SUSPEN- SION/WHEEL ALIGNMENT - STANDARD PROCE- DURE).
Page 50 FRONT - 4WD 2 - 23 SHOCK (Continued) through an anchor adjustment bolt that increases or decreases the angle of the torsion bar. Increasing or decreasing the bar angle changes the angle of the suspension arms. REMOVAL CAUTION: The left and right side torsion bars are NOT interchangeable.
Page 51 2 - 24 FRONT - 4WD TORSION BAR (Continued) INSTALLATION BUSHINGS - CONTROL ARM CAUTION: The left and right side torsion bars are REMOVAL NOT interchangeable. The bars are identified and (1) Remove the control arm from the vehicle. stamped R or L, for right or left. The bars do not (Refer to 2 - SUSPENSION/FRONT/UPPER CON- have a front or rear end and can be installed with TROL ARM - REMOVAL),(Refer to 2 - SUSPEN-...
Page 52 REAR 2 - 25 REAR TABLE OF CONTENTS page page REAR SPRING DESCRIPTION ......25 DESCRIPTION .
Page 53 2 - 26 REAR REAR (Continued) SPRING AND SHOCK ABSORBER CONDITION POSSIBLE CAUSES CORRECTION SPRING SAGS 1. Broken leaf. 1. Replace spring. 2. Spring fatigue. 2. Replace spring. SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification. 2. Worn bushings. 2.
Page 54 REAR 2 - 27 SHOCK (Continued) REMOVAL OPERATION (1) Raise vehicle and support rear axle. The springs control ride quality and maintain vehi- (2) Remove shock absorber lower nut and bolt from cle ride height. The shackles allow the springs to the axle bracket (Fig.
Page 55 2 - 28 REAR SPRING (Continued) STABILIZER BAR DESCRIPTION The stabilizer bar (optional) extends across the underside of the vehicle and is bolted to the top of the axle. Links at the end of the bar are bolted to frame brackets. OPERATION The stabilizer bar is used to minimize vehicle body roll.
Page 56 DIFFERENTIAL & DRIVELINE 3 - 1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page page PROPELLER SHAFT ..... . . 1 REAR AXLE - 8 1/4 .
Page 57 3 - 2 PROPELLER SHAFT PROPELLER SHAFT (Continued) Fig. 2 Rear Propeller Shaft with Center Bearing 1 - REAR AXLE 3 - TRANSMISSION EXTENSION HOUSING 2 - REAR PROPELLER SHAFT 4 - CENTER BEARING Fig. 3 Rear Propeller Shaft 1 - REAR AXLE 3 - TRANSMISSION EXTENSION HOUSING 2 - REAR PROPELLER SHAFT...
Page 58 PROPELLER SHAFT 3 - 3 PROPELLER SHAFT (Continued) Also make alignment reference marks (Fig. 4)on pended by springs in a floating motion. The propeller the propeller shaft yoke and axle, or transmission, shaft must be able to change operating angles when yoke prior to servicing.
Page 59 3 - 4 PROPELLER SHAFT PROPELLER SHAFT (Continued) DRIVELINE VIBRATION Drive Condition Possible Cause Correction Propeller Shaft Noise 1) Undercoating or other foreign 1) Clean exterior of shaft and wash material on shaft. with solvent. 2) Loose U-joint clamp screws. 2) Install new clamps and screws and tighten to proper torque.
Page 60 PROPELLER SHAFT 3 - 5 PROPELLER SHAFT (Continued) (16) Install the wheel and tires. Lower the vehicle. RUNOUT (1) Remove dirt, rust, paint and undercoating from the propeller shaft surface where the dial indicator will contact the shaft. (2) The dial indicator must be installed perpendic- ular to the shaft surface.
Page 61 3 - 6 PROPELLER SHAFT PROPELLER SHAFT (Continued) (3) Place Inclinometer 7663 (J-23498A) on yoke bearing (A) parallel to the shaft (Fig. 8). Center bub- ble in sight glass and record measurement. This measurement will give you the transmis- sion or Output Yoke Angle (A). Fig.
Page 62 PROPELLER SHAFT 3 - 7 PROPELLER SHAFT (Continued) Fig. 11 Universal Joint Angle Example 1 - 4.9° Angle (C) 4 - 3.0° Angle (A) 2 - 3.2° Angle (B) 5 - Output Yoke 3 - Input Yoke Fig. 12 Universal Joint Angle Two-Piece Shaft 1 - YOKES MUST BE IN SAME PLANE...
Page 63 3 - 8 PROPELLER SHAFT SPECIFICATIONS PROPELLER SHAFT TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Center Bearing Bolts Transfer Case Flange 30.5 22.5 Bolts Companion Flange Bolts SPECIAL TOOLS (2) Mark a line across the transfer case flange and C/V for installation reference.
Page 64: Center Bearing
PROPELLER SHAFT 3 - 9 PROPELLER SHAFT - REAR CENTER BEARING REMOVAL DESCRIPTION (1) Place the transmission into the Neutral posi- The two-piece propeller shaft uses a center bearing tion. to support the shafts. The bearing is used to support (2) Raise and support vehicle on safety stands.
Page 65 3 - 10 PROPELLER SHAFT CENTER BEARING (Continued) CENTER BEARING ADJUSTMENT Drive away shudder is a vibration that occurs at first acceleration from a stop. Shudder vibration usu- ally peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft.
Page 66 PROPELLER SHAFT 3 - 11 SINGLE CARDAN UNIVERSAL JOINTS (Continued) Fig. 18 Cross In Yoke Fig. 17 Press Out Remaining Bearing 1 - CROSS 1 - CROSS 2 - YOKE 2 - BEARING CAP ASSEMBLY NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke.
Page 67 3 - 12 HALF SHAFT HALF SHAFT TABLE OF CONTENTS page page HALF SHAFT CV BOOT DESCRIPTION ......12 REMOVAL .
Page 68 HALF SHAFT 3 - 13 HALF SHAFT (Continued) Fig. 1 C/V Drive Shaft Components...
Page 69 3 - 14 HALF SHAFT HALF SHAFT (Continued) 1 - RETAINER & HOUSING ASM 11 - RACE RETAINING RING 2 - C-CLIP 12 - SEAL RETAINING CLAMP 3 - TRIPOD JOINT SPIDER 13 - DRIVE AXLE OUTBOARD SEAL 4 - SEAL RETAINING CLAMP 14 - SEAL RETAINING CLAMP 5 - INNER BOOT 15 - AXLE SHAFT...
Page 70 HALF SHAFT 3 - 15 AXLE SHAFT (Continued) (4) Remove the cotter pin, nut lock, and spring (12) Disengage the inner C/V joint from the axle washer from the stub shaft (Fig. 3). shaft (Fig. 5). Position two pry bars between the inner C/V housing and the axle housing.
Page 71 3 - 16 HALF SHAFT AXLE SHAFT (Continued) (11) Install the spring washer, nut lock and cotter Apply only the specified lubricant amount to each pin on the stub shaft (Fig. 6) . C/V joint. (1) Clean the C/V joints and shaft of all old grease and foreign matter.
Page 72 HALF SHAFT 3 - 17 CV BOOT (Continued) (8) Install the large ladder clamp on the boot and secure as done with the small ladder clamps (Fig. 8). (9) Slide the outer C/V joint boot small clamp onto shaft. (10) Slide outer C/V joint boot onto shaft and into position on shaft.
Page 73 3 - 18 HALF SHAFT CV JOINT - OUTER (Continued) (12) Move bearing cage and hub to a vertical posi- (3) Insert one of the bearing hub lands into a bear- tion. Pull cage upward and out from the housing ing cage window.
Page 74 HALF SHAFT 3 - 19 CV JOINT - OUTER (Continued) Fig. 18 Ball Fig. 16 Bearing Cage & Hub Installation 1 - CV JOINT HOUSING 1 - BALL RACE 2 - BEARING HUB 2 - BEARING CAGE WINDOW 3 - BEARING CAGE 3 - CV JOINT HOUSING 4 - BALL Fig.
Page 75 3 - 20 HALF SHAFT CV JOINT - OUTER (Continued) (10) Align the shaft splines to the outer C/V joint splines. Push the outer C/V joint until the snap ring seats in the groove (Fig. 20). Fig. 21 Snap Retaining Ring 1 - SNAP RING 2 - TRIPOD JOINT 3 - SNAP RING PLIERS...
Page 76 HALF SHAFT 3 - 21 CV JOINT - INNER (Continued) (7) Remove tripod from the shaft and replace boot, (7) Insert small lip onto locating groove in shaft. if necessary. (8) Install small boot clamp in the boot groove. (8) Remove lubricant from the interior of the hous- Verify that the boot and lip are properly positioned ing and the tripod.
Page 77 3 - 22 FRONT AXLE - C205F FRONT AXLE - C205F TABLE OF CONTENTS page page FRONT AXLE - C205F INSTALLATION......38 DESCRIPTION .
Page 78 FRONT AXLE - C205F 3 - 23 FRONT AXLE - C205F (Continued) peak-noise range. If the noise stops or changes greatly: • Check for insufficient lubricant. • Incorrect ring gear backlash. • Gear damage. Differential side gears and pinions can be checked by turning the vehicle.
Page 79 3 - 24 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) • Transmission shift operation. Check for loose or damaged front end components • Loose engine/transmission/transfer case mounts. or engine/transmission mounts. These components • Worn U-joints. can contribute to what appears to be a rear end •...
Page 80 FRONT AXLE - C205F 3 - 25 FRONT AXLE - C205F (Continued) Condition Possible Causes Correction Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears differential bearings. and bearings for further damage. Set differential bearing pre-load properly.
Page 81 3 - 26 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) Condition Possible Causes Correction Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible damage. 2. Erratic clutch operation. 2. Replace gears and examine the remaining parts for damage.
Page 82 FRONT AXLE - C205F 3 - 27 FRONT AXLE - C205F (Continued) number (01 to 99) is on each gear. This first number is the amount (in thousandths of an inch) the depth varies from the standard depth setting of a pinion marked with a (0).
Page 83 3 - 28 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) PINION GEAR DEPTH VARIANCE Original Replacement Pinion Gear Depth Variance Pinion Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003...
Page 84 FRONT AXLE - C205F 3 - 29 FRONT AXLE - C205F (Continued) Fig. 9 Pinion Gear Depth Measurement Fig. 7 Pinion Height Block 1 - ARBOR 1 - PINION BLOCK 2 - SCOOTER BLOCK 2 - PINION HEIGHT BLOCK 3 - DIAL INDICATOR DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH Differential side bearing preload and gear backlash...
Page 85 3 - 30 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) Fig. 10 Adjustment Shim 1 - PINION GEAR DEPTH SHIM 2 - DIFFERENTIAL BEARING PRELOAD SHIM 3 - RING GEAR 4 - DIFFERENTIAL BEARING PRELOAD SHIM 5 - COLLAPSIBLE SPACER Fig.
Page 86 FRONT AXLE - C205F 3 - 31 FRONT AXLE - C205F (Continued) Fig. 15 Zero Dial Indicator Fig. 13 Seat Ring Gear Side Dummy 1 - CASE TO PINION SIDE 1 - DIFFERENTIAL HOUSING 2 - PILOT STUD 2 - DEAD-BLOW HAMMER 3 - DIAL INDICATOR EXTENSION 3 - DIFFERENTIAL CASE 4 - DIAL INDICATOR...
Page 87 3 - 32 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) (26) Remove differential case, dummy bearings and dummy shim from the housing. (27) Install new side bearing cones and cups on differential case. (28) Install Spreader W-129-B and Adapter Plates 8142-A on the housing and spread open enough to receive differential case.
Page 88 FRONT AXLE - C205F 3 - 33 FRONT AXLE - C205F (Continued) Fig. 19 Gear Tooth Contact Patterns...
Page 89 3 - 34 FRONT AXLE - C205F SPECIFICATIONS FRONT AXLE - C205F AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.55, 3.92 Differential Case Flange Runout 0.076 mm (0.003 in.) Differential Side Gear Clearance 0-0.15 mm (0-0.006 in.) Ring Gear Diameter 205 mm (7.562 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.) Ring Gear Runout...
Page 90 FRONT AXLE - C205F 3 - 35 SPECIAL TOOLS (Continued) Puller C-452 Handle C-4171 Holder 6719A Installer 8236 Installer C-3972-A Installer D-145 Installer Screw 8112 Installer D-145 Cup 8109...
Page 91 3 - 36 FRONT AXLE - C205F SPECIAL TOOLS (Continued) Installer 5063 Remover 8401 Installer 8402 Remover 8401 Gauge Block 8177 Installer 6448 Pinion Depth Set Bearing Remover C-4660 Adapter Kit 6987A Cup 8150...
Page 92 FRONT AXLE - C205F 3 - 37 SPECIAL TOOLS (Continued) (3) Remove the skid plate, if equipped. (4) Clean all foreign material from axle seal area. (5) Install Puller Adapter 8420-A onto the axle shaft. (6) Install Slide Hammer C-3752 to the puller adapter.
Page 93 3 - 38 FRONT AXLE - C205F AXLE BEARINGS REMOVAL (1) Remove the axle shaft. (2) Remove the axle shaft seal and bearing from the axle tube with Bearing Removal Tool C-4660-A. (3) Inspect the axle shaft tube bore for roughness and burrs.
Page 94 FRONT AXLE - C205F 3 - 39 PINION SEAL (Continued) (7) Rotate and record the axle rotating torque at the pinion shaft using a torque wrench. The rotating torque should be equal to the reading recorded dur- ing removal plus an additional 0.56 N·m (5 in. lbs.) (Fig.
Page 95 3 - 40 FRONT AXLE - C205F DIFFERENTIAL (Continued) (4) Note differential bearing cape reference num- DISASSEMBLY bers stamped on caps and machined flat on the hous- (1) Remove ring gear. ing. If reference numbers cannot be found, make new (2) Remove roll-pin holding mate shaft in housing.
Page 96 FRONT AXLE - C205F 3 - 41 DIFFERENTIAL (Continued) (8) Tighten the bearing cap bolts to 61 N·m (45 ft. lbs.). (9) Install the axle shafts. (10) Install the differential housing cover and fill with the correct lubricant. DIFFERENTIAL CASE BEARINGS REMOVAL (1) Remove differential from axle housing.
Page 97 3 - 42 FRONT AXLE - C205F DIFFERENTIAL CASE BEARINGS (Continued) Fig. 30 Ring Gear 1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - RAWHIDE HAMMER (10) Position Holder 6719 against the companion Fig. 29 Differential Side Bearings flange and install a bolt and washer into one of the 1 - HANDLE remaining threaded holes.
Page 98 FRONT AXLE - C205F 3 - 43 PINION GEAR/RING GEAR/TONE RING (Continued) (16) Remove front pinion bearing with Remover D-103 and Handle C-4171 (Fig. 34). Fig. 32 Companion Flange Remover 1 - COMPANION FLANGE 2 - PULLER TOOL Fig. 34 Front Bearing Cup (13) Remove pinion from differential housing (Fig.
Page 99 3 - 44 FRONT AXLE - C205F PINION GEAR/RING GEAR/TONE RING (Continued) (18) Remove the collapsible preload spacer (Fig. 36). Fig. 37 Rear Pinion Bearing 1 - SPECIAL TOOL C-293–PA 2 - VISE Fig. 36 Collapsible Spacer 3 - ADAPTERS 4 - DRIVE PINION GEAR SHAFT 1 - COLLAPSIBLE SPACER 2 - SHOULDER...
Page 100 FRONT AXLE - C205F 3 - 45 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 39 Front Pinion Bearing Cup 1 - INSTALLER 2 - HANDLE (7) Install pinion seal with Installer C-3972-A and Fig. 41 Rear Pinion Bearing Handle C-4171 (Fig. 40). 1 - PRESS 2 - INSTALLER 3 - PINION GEAR...
Page 101 3 - 46 FRONT AXLE - C205F PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 44 Pinion Rotating Torque Fig. 43 Pinion Nut 1 - COMPANION FLANGE 2 - INCH POUND TORQUE WRENCH 1 - DIFFERENTIAL HOUSING 2 - COMPANION FLANGE HOLDER 3 - TORQUE WRENCH (15) Slowly tighten the nut in 6.8 N·m (5 ft.
Page 102 REAR AXLE - 8 1/4 3 - 47 REAR AXLE - 8 1/4 TABLE OF CONTENTS page page REAR AXLE - 8 1/4 PINION SEAL DESCRIPTION ......47 REMOVAL .
Page 103 3 - 48 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) now rotate around the pinion mate shaft in opposite directions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed.
Page 104 REAR AXLE - 8 1/4 3 - 49 REAR AXLE - 8 1/4 (Continued) BEARING NOISE The axle shaft, differential and pinion bearings can all produce noise when worn or damaged. Bearing noise can be either a whining, or a growling sound. Pinion bearings have a constant-pitch noise.
Page 105 3 - 50 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) • Excessive ring gear backlash. DRIVELINE SNAP • Excessive side gear to case clearance. A snap or clunk noise when the vehicle is shifted The source of a snap or a clunk noise can be deter- into gear (or the clutch engaged), can be caused by: •...
Page 106 REAR AXLE - 8 1/4 3 - 51 REAR AXLE - 8 1/4 (Continued) Condition Possible Causes Correction Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with the correct fluid type and quantity. 2. Improper grade of lubricant. 2.
Page 107 3 - 52 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) Condition Possible Causes Correction Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and quantity. 2. Improper ring gear and pinion 2. Check ring gear and pinion adjustment.
Page 108 REAR AXLE - 8 1/4 3 - 53 REAR AXLE - 8 1/4 (Continued) Fig. 5 Pinion ID Numbers Fig. 6 Adjustment Shim Locations 1 - VARIANCE NUMBER 2 - SEQUENCE NUMBER 1 - DIFFERENTIAL HOUSING 2 - COLLAPSIBLE SPACER 3 - PINION BEARING Compensation pinion...
Page 109 3 - 54 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) PINION DEPTH MEASUREMENT Measurements are taken with pinion bearing cups and pinion bearings installed in the housing. Take measurements with Pinion Gauge Set and Dial Indi- cator C-3339 (Fig.
Page 110 REAR AXLE - 8 1/4 3 - 55 REAR AXLE - 8 1/4 (Continued) (5) Assemble Dial Indicator C-3339 into Scooter DIFFERENTIAL BEARING PRELOAD AND GEAR Block D-115-2 and secure set screw. BACKLASH (6) Place Scooter Block/Dial Indicator in position The following must be considered when adjusting in axle housing so dial probe and scooter block are bearing preload and gear backlash:...
Page 111 3 - 56 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) (2) Install dial indicator and position the plunger NOTE: left-side threaded adjuster torque against the drive side of a ring gear tooth (Fig. 12). should have approximately 102 N·m (75 ft. lbs.). If Measure the backlash at 4 positions (90 degrees the torque is considerably less, the complete apart) around the ring gear.
Page 112 REAR AXLE - 8 1/4 3 - 57 REAR AXLE - 8 1/4 (Continued) Fig. 13 Gear Tooth Contact Patterns...
Page 113 3 - 58 REAR AXLE - 8 1/4 REAR AXLE - 8 1/4 (Continued) SIDE GEAR CLEARANCE the axle shaft is not contacting the pinion mate shaft, the side gear clearance is acceptable. When measuring side gear clearance, check each (4) If clearance is more than 0.005 inch (axle shaft gear independently.
Page 114 REAR AXLE - 8 1/4 3 - 59 SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Differential Cover Bolts Bearing Cap Bolts Ring Gear Bolts Pinion Nut Minimum Adjuster Lock Screw Backing Plate Bolts SPECIAL TOOLS 8 1/4 AXLE Puller 6790 Handle C-4171 Remover 6310...
Page 115 3 - 60 REAR AXLE - 8 1/4 SPECIAL TOOLS (Continued) Holder 6719 Adapters C-293-48 Puller C-452 Adapter Plug SP-3289 Installer C-3718 Adapters C-293-47 Adjustment Wrench C-4164 Installer C-4340 Puller/Press C-293–PA Fixture 8138...
Page 116 REAR AXLE - 8 1/4 3 - 61 SPECIAL TOOLS (Continued) Trac-lok Tools 8140 Installer C-4345 Trac-lok Tools 6960 Remover C-4307 Pinion Block 8540 Installer C-4308 Installer D-130 Arbor Discs 8541 Installer 6448 Pinion Gauge Set...
Page 117 3 - 62 REAR AXLE - 8 1/4 AXLE SHAFTS REMOVAL (1) Place the transmission in NEUTRAL and raise and support vehicle. (2) Remove wheel and tire assembly. (3) Remove brake drum (Refer to 5 - BRAKES/HY- DRAULIC/MECHANICAL/DRUM - REMOVAL) .. (4) Clean all foreign material from housing cover area.
Page 118 REAR AXLE - 8 1/4 3 - 63 AXLE SHAFT SEALS (Continued) (4) Remove axle shaft bearing with Bearing Removal Tool Set 6310 and Adapter Foot 6310-9 (Fig. 20). Fig. 18 Axle Seal 1 - AXLE TUBE 2 - AXLE SEAL 3 - PRY BAR AXLE BEARINGS REMOVAL...
Page 119 3 - 64 REAR AXLE - 8 1/4 INSTALLATION PINION SEAL NOTE: The outer perimeter of the seal is pre-coated REMOVAL with a special sealant. (1) Raise and support the vehicle. (2) Mark the universal joint, companion flange and (1) Apply a light coating of gear lubricant on the pinion shaft for installation reference.
Page 120 REAR AXLE - 8 1/4 3 - 65 PINION SEAL (Continued) CAUTION: Never loosen pinion nut to decrease pin- ion bearing rotating torque and never exceed spec- ified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. (10) If rotating torque is low use Holder 6719 to hold the companion flange (Fig.
Page 121 3 - 66 REAR AXLE - 8 1/4 DIFFERENTIAL (Continued) Fig. 27 Pinion Shaft Lock Screw Fig. 25 Reference Mark 1 - LOCK SCREW 1 - REFERENCE MARKS 2 - PINION SHAFT 2 - REFERENCE MARKS 3 - DIFFERENTIAL HOUSING 4 - BEARING CAP Fig.
Page 122 REAR AXLE - 8 1/4 3 - 67 DIFFERENTIAL (Continued) INSTALLATION (1) Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups, and threaded adjusters. A dab of grease can be used to keep the adjusters in position. Carefully position the assem- bled differential case in the housing.
Page 123 3 - 68 REAR AXLE - 8 1/4 DIFFERENTIAL - TRAC-LOK (Continued) (2) Remove ring gear if the ring gear is to be replaced. The Trac-lok differential can be serviced with the ring gear installed. (3) Remove the pinion gear mate shaft lock screw (Fig.
Page 124 REAR AXLE - 8 1/4 3 - 69 DIFFERENTIAL - TRAC-LOK (Continued) (8) Install Forcing Screw C-6960-4 and tighten screw to 122 N·m (90 ft. lbs.) maximum to compress Belleville springs in clutch packs (Fig. 37). Fig. 37 Compress Belleville Spring Fig.
Page 125 3 - 70 REAR AXLE - 8 1/4 DIFFERENTIAL - TRAC-LOK (Continued) (10) Insert Turning Bar C-6960-2 into the pinion mate shaft hole in the case (Fig. 39). (11) Loosen the Forcing Screw in small increments until the clutch pack tension is relieved and the dif- ferential case can be turned using Turning Bar.
Page 126 REAR AXLE - 8 1/4 3 - 71 DIFFERENTIAL - TRAC-LOK (Continued) (2) Position assembled clutch disc packs on the side gear hubs. (3) Install clutch pack and side gear in the ring gear side of the differential case (Fig. 42). Be sure clutch pack retaining clips remain in position and are seated in the case pockets.
Page 127 3 - 72 REAR AXLE - 8 1/4 DIFFERENTIAL CASE BEARINGS REMOVAL (1) Remove differential case from axle. (2) Remove differential bearings from the case with Puller/Press C-293-PA and Adapters C-293-48 and Plug SP-3289 (Fig. 44). Fig. 45 Differential Bearing Installer 1 - HANDLE 2 - DIFFERENTIAL 3 - BEARING...
Page 128 REAR AXLE - 8 1/4 3 - 73 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 46 Ring Gear 1 - CASE 2 - RING GEAR 3 - RAWHIDE HAMMER Fig. 48 Pinion Gear (9) Hold companion flange with Holder 6719 and 1 - RAWHIDE HAMMER remove companion flange nut and washer.
Page 129 3 - 74 REAR AXLE - 8 1/4 PINION GEAR/RING GEAR/TONE RING (Continued) (15) Remove the rear bearing cup from housing (Fig. 50) with Remover C-4307 and Handle C–4171. Fig. 51 Collapsible Spacer Fig. 50 Rear Pinion Bearing Cup 1 - COLLAPSIBLE SPACER 1 - REMOVER 2 - SHOULDER 2 - HANDLE...
Page 130 REAR AXLE - 8 1/4 3 - 75 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 55 Pinion Seal 1 - HANDLE 2 - DIFFERENTIAL HOUSING 3 - INSTALLER (7) Place the proper thickness depth shim on the Fig. 53 Rear Pinion Bearing Cup pinion shaft.
Page 131 3 - 76 REAR AXLE - 8 1/4 PINION GEAR/RING GEAR/TONE RING (Continued) (9) Install a new collapsible preload spacer on pin- CAUTION: Never loosen pinion nut to decrease pin- ion shaft and install the pinion into the housing (Fig. ion bearing rotating torque and never exceed spec- 57).
Page 132 REAR AXLE - 8 1/4 3 - 77 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 59 Pinion 1 - COMPANION FLANGE Fig. 60 Ring Gear Bolts 2 - TORQUE WRENCH 1 - TORQUE WRENCH 2 - RING GEAR BOLTS (17) Position exciter ring on differential case. 3 - RING GEAR (18) Using a brass drift, slowly and evenly tap the 4 - DIFFERENTIAL CASE...
Page 133 3 - 78 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 TABLE OF CONTENTS page page REAR AXLE - 9 1/4 PINION SEAL DESCRIPTION ......78 REMOVAL .
Page 134 REAR AXLE - 9 1/4 3 - 79 REAR AXLE - 9 1/4 (Continued) Fig. 1 9 1/4 Axle...
Page 135 3 - 80 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) 1 - HUB 30 - COVER BOLT 2 - AXLE SHAFT 31 - WASHER 3 - VENT FITTING 32 - CLIP 4 - DIFFERENTIAL HOUSING 33 - SIDE GEAR 5 - CUP 34 - THRUST WASHER 6 - FRONT PINION BEARING CONE...
Page 136 REAR AXLE - 9 1/4 3 - 81 REAR AXLE - 9 1/4 (Continued) • Loose wheel lug nuts. BEARING NOISE • Worn U-joint(s). The axle shaft, differential and pinion bearings can • Loose/broken springs. all produce noise when worn or damaged. Bearing •...
Page 137 3 - 82 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) Condition Possible Causes Correction Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears and differential bearings. bearings for further damage. Set differential bearing pre-load properly. 2.
Page 138 REAR AXLE - 9 1/4 3 - 83 REAR AXLE - 9 1/4 (Continued) Condition Possible Causes Correction Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and quantity. 2. Improper ring gear and pinion 2. Check ring gear and pinion contact adjustment.
Page 139 3 - 84 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) ADJUSTMENTS Ring gear and pinion are supplied as matched sets only. The identifying numbers for the ring gear and pinion are painted onto the pinion gear shaft (Fig. 3) and the side of the ring gear.
Page 140 REAR AXLE - 9 1/4 3 - 85 REAR AXLE - 9 1/4 (Continued) PINION GEAR DEPTH VARIANCE Original Replacement Pinion Gear Depth Variance Pinion Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005...
Page 141 3 - 86 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) Fig. 6 Pinion Height Block Fig. 8 Pinion Gear Depth Measurement 1 - PINION BLOCK 1 - ARBOR 2 - PINION HEIGHT BLOCK 2 - SCOOTER BLOCK 3 - DIAL INDICATOR DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH...
Page 142 REAR AXLE - 9 1/4 3 - 87 REAR AXLE - 9 1/4 (Continued) ened to 14 N·m (10 ft. lbs.). Seat the bearing cups with the procedure described above. (5) Tighten the differential bearing cap bolts 136 N·m (100 ft. lbs.). (6) Tighten the right-side threaded adjuster to 102 N·m (75 ft.
Page 143 3 - 88 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) Fig. 11 Gear Tooth Contact Patterns...
Page 144 REAR AXLE - 9 1/4 3 - 89 REAR AXLE - 9 1/4 (Continued) SIDE GEAR CLEARANCE (4) If clearance is more than 0.005 inch (axle shaft not contacting mate shaft), record the side gear clear- When measuring side gear clearance, check each ance.
Page 145 3 - 90 REAR AXLE - 9 1/4 SPECIFICATIONS REAR AXLE - 9 1/4 AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.21, 3.55, 3.92 Differential Case Flange Runout 0.076 mm (0.003 in.) Differential Case Clearance 0.12 mm (0.005 in.) Ring Gear Diameter 235 mm (9.25 in.) Ring Gear Backlash 0.12-0.20 mm (0.005-0.008 in.)
Page 146 REAR AXLE - 9 1/4 3 - 91 SPECIAL TOOLS (Continued) Installer C-3718 Handle C-4171 Adjustment Wrench C-4164 Installer C-4076-B Puller/Press C-293–PA Handle C-4735-1 Adapters C-293-48 Holder 6719 Plug SP-3289 Puller C-452...
Page 147 3 - 92 REAR AXLE - 9 1/4 SPECIAL TOOLS (Continued) Installer C-4308 Adapters C-293-47 Installer D-130 Installer C-4340 Installer 6448 Fixture 8138 Trac-lok Tools 8140 Installer C-4345 Trac-lok Tools 6960 Remover C-4307...
Page 148 REAR AXLE - 9 1/4 3 - 93 SPECIAL TOOLS (Continued) Pinion Gauge Block 8540 Fig. 14 Pinion Mate Shaft Lock Screw 1 - LOCK SCREW 2 - PINION MATE SHAFT Arbor Discs 8541 Pinion Gauge Set AXLE SHAFTS REMOVAL (1) Place transmission in neutral.
Page 149 3 - 94 REAR AXLE - 9 1/4 AXLE BEARINGS REMOVAL (1) Remove axle shaft. (2) Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 16). Fig. 17 Axle Shaft Bearing Tool Fig.
Page 150 REAR AXLE - 9 1/4 3 - 95 AXLE SHAFT SEALS REMOVAL (1) Remove axle shaft. (2) Remove axle shaft seal from the end of the axle tube with a small pry bar (Fig. 19). Fig. 20 Seal and Bearing Installer 1 - HANDLE 2 - INSTALLER 3 - AXLE TUBE...
Page 151 3 - 96 REAR AXLE - 9 1/4 PINION SEAL (Continued) Fig. 21 Companion Flange Fig. 23 Tightening Pinion Nut 1 - COMPANION FLANGE 2 - PULLER 1 - DIFFERENTIAL HOUSING 2 - COMPANION FLANGE HOLDER 3 - TORQUE WRENCH (9) Rotatepinion using an inch pound torque wrench.
Page 152 REAR AXLE - 9 1/4 3 - 97 PINION SEAL (Continued) CAUTION: Never loosen pinion nut to decrease pin- ion bearing rotating torque and never exceed spec- ified preload torque. If rotating torque is exceeded, a new collapsible spacer must be installed. (10) If rotating torque is low, use Holder 6719 to hold the companion flange (Fig.
Page 153 3 - 98 REAR AXLE - 9 1/4 DIFFERENTIAL (Continued) (5) Lubricate all differential components with hypoid gear lubricant. INSTALLATION (1) Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups, and threaded adjusters. A dab of grease can be used to keep the adjusters in position.
Page 154 REAR AXLE - 9 1/4 3 - 99 DIFFERENTIAL (Continued) Fig. 30 Cover Sealant Fig. 31 Trac-lok Test -Typical 1 - SEALANT 1 - SPECIAL TOOL WITH BOLT IN CENTER HOLE 2 - DIFFERENTIAL COVER 2 - TORQUE WRENCH (11) Trac-lok differential equipped vehicles...
Page 155 3 - 100 REAR AXLE - 9 1/4 DIFFERENTIAL - TRAC-LOK (Continued) (2) Remove ring gear if the ring gear is to be (5) Install and lubricate Step Plate C-6960-3 (Fig. replaced. The Trac-lok differential can be serviced 35). with the ring gear installed. (3) Remove the pinion gear mate shaft lock screw (Fig.
Page 156 REAR AXLE - 9 1/4 3 - 101 DIFFERENTIAL - TRAC-LOK (Continued) Fig. 36 Threaded Adapter Disc Fig. 38 Pinion Gear Thrust Washer 1 - SOCKET 2 - SLOT IN ADAPTER 1 - THRUST WASHER 3 - SCREWDRIVER 2 - FEELER GAUGE 4 - STEP PLATE 5 - THREADED ROD 6 - THREADED ADAPTER DISC...
Page 157 3 - 102 REAR AXLE - 9 1/4 DIFFERENTIAL - TRAC-LOK (Continued) (14) Remove Forcing Screw, Step Plate Threaded Adapter. (15) Remove top side gear, clutch pack retainer and clutch pack. Keep plates in correct order during removal (Fig. 40). Fig.
Page 158 REAR AXLE - 9 1/4 3 - 103 DIFFERENTIAL - TRAC-LOK (Continued) (4) Position the differential case on the Holding (16) Lubricate all differential components with Fixture 6965. hypoid gear lubricant. (5) Install lubricated Step Plate C-6960-3 in lower side gear (Fig. 43). DIFFERENTIAL CASE BEARINGS REMOVAL...
Page 159 3 - 104 REAR AXLE - 9 1/4 DIFFERENTIAL CASE BEARINGS (Continued) Fig. 46 Ring Gear 1 - CASE 2 - RING GEAR 3 - RAWHIDE HAMMER (11) Position Holder 6719 against the companion Fig. 45 Differential Bearing Installer flange and install a bolt and washer into one of the 1 - HANDLE remaining threaded holes.
Page 160 REAR AXLE - 9 1/4 3 - 105 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 48 Pinion Gear Fig. 49 Front Pinion Bearing Cup 1 - RAWHIDE HAMMER 1 - REMOVER 2 - HANDLE (15) Remove pinion seal with a pry tool or slide- hammer mounted screw.
Page 161 3 - 106 REAR AXLE - 9 1/4 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 53 Rear Pinion Bearing Cup Fig. 51 Collapsible Spacer 1 - INSTALLER 1 - COLLAPSIBLE SPACER 2 - HANDLE 2 - SHOULDER 3 - PINION GEAR 4 - DEPTH SHIM 5 - REAR BEARING Fig.
Page 162 REAR AXLE - 9 1/4 3 - 107 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 55 Pinion Seal 1 - HANDLE 2 - DIFFERENTIAL HOUSING 3 - INSTALLER Fig. 57 Collapsible Preload Spacer 1 - COLLAPSIBLE SPACER 2 - SHOULDER 3 - PINION GEAR 4 - DEPTH SHIM 5 - REAR BEARING (12) Position Holder 6719 against the companion...
Page 163 3 - 108 REAR AXLE - 9 1/4 PINION GEAR/RING GEAR/TONE RING (Continued) (19) Position ring gear on the differential case and start two ring gear bolts. This will provide case-to- ring gear bolt hole alignment. (20) Invert the differential case in the vise. (21) Install new ring gear bolts and alternately tighten to 156 N·m (115 ft.
Page 164 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS .
Page 165 5 - 2 BRAKES - BASE POWER BRAKE BOOSTER ASSEMBLY ......28 DESCRIPTION .
Page 166 BRAKES - BASE 5 - 3 BRAKES - BASE (Continued) lines, master cylinder, booster, and parking brake (4) Attempt to stop the vehicle with the parking components. brake only and note grab, drag, noise, etc. Brake diagnosis involves determining if the prob- PEDAL FALLS AWAY lem is related to a mechanical, hydraulic, or vacuum A brake pedal that falls away under steady foot...
Page 167 5 - 4 BRAKES - BASE BRAKES - BASE (Continued) Minor drag will usually cause slight surface char- unit is still functioning normally, its braking effect is ring of the lining. It can also generate hard spots in magnified. This causes pull to switch direction in rotors and drums from the overheat-cool down pro- favor of the normally functioning brake unit.
Page 168 BRAKES - BASE 5 - 5 BRAKES - BASE (Continued) BRAKE SQUEAK/SQUEAL Brake squeak or squeal may be due to linings that are wet or contaminated with brake fluid, grease, or oil. Glazed linings and rotors with hard spots can also contribute to squeak.
Page 169 5 - 6 BRAKES - BASE BRAKES - BASE (Continued) Fig. 3 Inverted Flare And ISO Flare Fig. 2 Bleed Hose Setup 1 - ISO-STYLE FLARE 1 - BLEED HOSE 2 - DOUBLE INVERTED-STYLE FLARE 2 - FLUID CONTAINER PARTIALLY FILLED WITH FLUID (6) Push tubing through flaring tool jaws until Bleed only one brake component at a time in the tube contacts recessed notch in gauge that matches...
Page 170 BRAKES - BASE 5 - 7 BRAKES - BASE (Continued) Fig. 4 Inverted Fig. 5 ISO Flaring (7) Align the adaptor and yoke screw over the tube 1 - ADAPTER (Fig. 5). 2 - LUBRICATE HERE (8) Turn the yoke screw in until the adaptor is 3 - PILOT squarely seated on the tool bar.
Page 171 5 - 8 BRAKES - BASE SPECIFICATIONS DESCRIPTION SPECIFICATION Disc Brake Rotor 22.6 mm (0.8898 in.) BASE BRAKES Min.Rotor Thickness SPECIFICATIONS Drum Brake 228.6 x 63.5 mm (9 x Size 2.50 in DESCRIPTION SPECIFICATION Drum Brake 279 x 57 mm (11 x 2.25 Disc Brake Caliper Sliding Size...
Page 172 BRAKES - BASE 5 - 9 tion switch is turn to the on position. This is a self SPECIAL TOOLS test to verify the lamp is operational. BASE BRAKES HYDRAULIC/MECHANICAL DESCRIPTION The calipers are a single piston type. The calipers are free to slide laterally, this allows continuous com- pensation for lining wear.
Page 173: Brake Lines
5 - 10 BRAKES - BASE HYDRAULIC/MECHANICAL (Continued) In summary, fluid pressure acting simultaneously OPERATION on both piston and caliper, produces a strong clamp- The hoses and lines transmit the brake fluid ing action. When sufficient force is applied, friction hydraulic pressure to the calipers and or wheel cyl- will attempt to stop the rotors from turning and inders.
Page 174 BRAKES - BASE 5 - 11 BRAKE PADS/SHOES (Continued) Fig. 8 Removing Caliper Assembly Fig. 10 Inboard Brake Shoe 1 - CALIPER AND BRAKE SHOES 1 - CALIPER PISTON 2 - RETAINER SPRING 3 - INBOARD SHOE (9) Remove outboard brake shoe (Fig. 9). Pry one end of shoe retainer spring away from caliper.
Page 175: Combination Valve
5 - 12 BRAKES - BASE BRAKE PADS/SHOES (Continued) Fig. 12 Outboard Shoe Retainer Spring 1 - SEAT RETAINER SPRING ENDS IN CALIPER 2 - OUTBOARD SHOE the spring (Fig. 13) and hold the end under the adapter. With a screw driver pry up on the spring (Fig.
Page 176 BRAKES - BASE 5 - 13 COMBINATION VALVE (Continued) A decrease or loss of fluid pressure in either (3) Tighten the brake line to 19 N·m (170 in. lbs.). hydraulic circuit will cause the switch valve to shut- (4) Connect the wire to the pressure differential tle to the low pressure side.
Page 177 5 - 14 BRAKES - BASE DISC BRAKE CALIPERS (Continued) brake shoe lining into contact with the outer surface (5) Bottom caliper pistons in bores with large of the disc brake rotor. C-clamp. Position clamp frame on rear of caliper and In summary, fluid pressure acting simultaneously clamp screw on outboard brake shoe.
Page 178 BRAKES - BASE 5 - 15 DISC BRAKE CALIPERS (Continued) Fig. 20 Caliper Piston Seal 1 - PISTON SEAL 2 - WOOD PENCIL CLEANING Fig. 18 Piston Dust Boot Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston 1 - PISTON BOOT DUST dry with lint free towels or use low pressure com- pressed air.
Page 179 5 - 16 BRAKES - BASE DISC BRAKE CALIPERS (Continued) Fig. 21 Polishing Piston Bore 1 - SPECIAL HONE 2 - CALIPER 3 - PISTON BORE (2) Install caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brake Fig.
Page 180 BRAKES - BASE 5 - 17 DIAGNOSIS AND TESTING - BRAKE DRUM DRUM The maximum allowable diameter of the drum DESCRIPTION braking surface is indicated on the drum outer edge. Generally, a drum can be machined to a maximum of Drum brakes on all models are dual shoe, internal 1.52 mm (0.060 in.) oversize.
Page 181 5 - 18 BRAKES - BASE DRUM (Continued) (5) Vacuum brake components to remove brake lin- ing dust. (6) Remove shoe return springs with brake spring plier tool (Fig. 25). Fig. 26 Shoe Retainers, Springs and Pins 1 - STRUT AND SPRING 2 - SPRING 3 - PIN Fig.
Page 182 BRAKES - BASE 5 - 19 DRUM (Continued) worn or rusted through. Also replace the plate if it is (6) Install primary shoe on support plate. Secure bent or distorted (Fig. 27). shoe with new spring retainers and pin. (7) Install spring on parking brake strut and engage strut in primary.
Page 183 5 - 20 BRAKES - BASE DRUM (Continued) Fig. 30 Adjuster Screw 1 - WASHER 2 - SOCKET 3 - STAMPED LETTER L-LEFT BRAKE R-RIGHT BRAKE Fig. 31 Adjusting Gauge On Drum 4 - SCREW THREADS 1 - BRAKE GAUGE 5 - NUT 2 - BRAKE DRUM 6 - BUTTON...
Page 184: Fluid Reservoir
BRAKES - BASE 5 - 21 DRUM (Continued) (4) Loosen parking brake cable adjustment nut FLUID until there is slack in front cable. (5) Insert adjusting tool through support plate DIAGNOSIS AND TESTING - BRAKE FLUID access hole and engage tool in teeth of adjusting CONTAMINATION screw star wheel (Fig.
Page 185 5 - 22 BRAKES - BASE FLUID RESERVOIR (Continued) Fig. 36 Reservoir Removal 1 - RESERVOIR 2 - GROMMETS Fig. 34 Reservoir Retaining Pins 1 - PIN PUNCH 2 - RESERVOIR 3 - BODY 4 - ROLL PINS Fig. 37 Grommet Removal 1 - MASTER CYLINDER BODY 2 - GROMMETS (1) Lubricate new grommets with clean brake fluid...
Page 186: Master Cylinder
BRAKES - BASE 5 - 23 FLUID RESERVOIR (Continued) (2) Start reservoir in grommets. Then rock reser- (4) Press and hold brake pedal under light foot voir back and forth while pressing downward to seat pressure. The pedal should hold firm, if the pedal it in grommets.
Page 187 5 - 24 BRAKES - BASE MASTER CYLINDER (Continued) Fig. 41 Master Cylinder Bleeding–Typical 1 - BLEEDING TUBES 2 - RESERVOIR (2) Remove mounting nuts from the master cylin- Fig. 39 Typical Booster Vacuum Test Connections der (Fig. 42). 1 - TEE FITTING (3) Remove master cylinder.
Page 188: Power Brake Booster
BRAKES - BASE 5 - 25 MASTER CYLINDER (Continued) (3) Install brake lines and tighten to 19 N·m (170 in. lbs.) (4) Fill and bleed base brake system. (Refer to 5 - BRAKES - STANDARD PROCEDURE). PEDAL DESCRIPTION A suspended-type brake pedal is used. The pedal is attached to the pedal support bracket with a pivot bolt and bushings.
Page 189 5 - 26 BRAKES - BASE POWER BRAKE BOOSTER (Continued) (6) Install master cylinder. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/MASTER CYLINDER - INSTALLATION). (7) Fill and bleed brake system. (Refer to 5 - BRAKES - STANDARD PROCEDURE). ROTORS DIAGNOSIS AND TESTING - DISC BRAKE ROTOR The rotor braking surfaces should not be refinished unless necessary.
Page 190: Wheel Cylinders
BRAKES - BASE 5 - 27 ROTORS (Continued) CAUTION: Brake rotors that do not meet minimum thickness specifications before or after machining must be replaced. REMOVAL (1) Raise and support vehicle. (2) Remove wheel and tire assembly. (3) Remove brake caliper. (Refer to 5 - BRAKES/ HYDRAULIC/MECHANICAL/DISC BRAKE CALI- PERS - REMOVAL).
Page 191 5 - 28 BRAKES - BASE WHEEL CYLINDERS (Continued) INSTALLATION (1) Apply bead of silicone sealer around cylinder mounting surface of support plate. (2) Install cylinder mounting bolts and tighten to 20 N·m (15 ft. lbs.). (3) Connect brake line to cylinder. (4) Install brake shoe return spring.
Page 192 BRAKES - BASE 5 - 29 SUPPORT PLATE (Continued) (9) Install brake drum and wheel and tire assem- bly. (Refer to 22 - TIRES/WHEELS/WHEELS - STANDARD PROCEDURE) (Refer to 22 - TIRES/ WHEELS/WHEELS - STANDARD PROCEDURE). (10) Bleed brake system. (Refer to 5 - BRAKES - STANDARD PROCEDURE).
Page 193 5 - 30 BRAKES - BASE CABLES (Continued) PARK BRAKE CABLE TENSIONER NOTE: Tensioner adjustment is only necessary when the tensioner, or a cable has been replaced or disconnected for service. When adjustment is nec- essary, perform adjustment only as described in the following procedure.
Page 194 BRAKES - BASE 5 - 31 PEDAL (Continued) Fig. 52 Adjustment Mark On Cable Tensioner Rod 1 - CABLE CONNECTOR 2 - ADJUSTER NUT Fig. 53 Parking Brake Pedal Assembly 3 - 6.35MM (1/4 IN.) 1 - PARKING BRAKE ASSEMBLY 2 - LEFT COWL PANEL 3 - FRONT CABLE OPERATION...
Page 195 5 - 32 BRAKES - BASE RELEASE (Continued) (1) Position the park brake release handle to the instrument panel. (2) Engage one of the park brake release handle hinge tabs with one of the pivot pins on the instru- ment panel. (3) Align the second park brake release handle hinge tab hinge over the second pivot pin on the instrument panel.
Page 196 BRAKES - ABS 5 - 33 BRAKES - ABS TABLE OF CONTENTS page page BRAKES - ABS INSTALLATION......39 DESCRIPTION .
Page 197 5 - 34 BRAKES - ABS BRAKES - ABS (Continued) DESCRIPTION COMPONENT LOCATION FUNCTION RWAL CONTROLLER Driver side inner fender on a Tests, monitors and controls the bracket. rear brake system. HYDRAULIC CONTROL UNIT/ Driver side inner fender on a Modulates hydraulic pressure to RWAL VALVE bracket.
Page 198 BRAKES - ABS 5 - 35 BRAKES - ABS (Continued) The antilock system prevents lockup during high pressure at the wheel cylinders. The dump (pressure slip conditions by modulating fluid apply pressure to venting) cycle is limited to very short time periods the wheel brake units.
Page 199 5 - 36 BRAKES - ABS BRAKES - ABS (Continued) using a high impedance multi-meter or the DRB cedure involves performing a base brake bleeding, tester as described in this section. Power should followed by use of the scan tool to cycle and bleed the never be removed or applied to any control module HCU pump and solenoids.
Page 200 BRAKES - ABS 5 - 37 FRONT WHEEL SPEED SENSOR DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front steering knuckles. The third sensor is mounted on top of the rear axle differential housing.
Page 201 5 - 38 BRAKES - ABS FRONT WHEEL SPEED SENSOR (Continued) REMOVAL - 4X2 (6) In engine compartment, disconnect sensor wire and remove sensor. CAUTION: Special bolts are used to attach the front sensor. The bolts have a special shoulder, thread length and surface treatment.
Page 202 BRAKES - ABS 5 - 39 FRONT WHEEL SPEED SENSOR (Continued) Fig. 7 Rear Speed Sensor Mounting Fig. 6 Front Wheel Speed Sensor - 4x2 1 - DIFFERENTIAL HOUSING 1 - WHEEL SPEED SENSOR 2 - WHEEL SPEED SENSOR 2 - KNUCKLE 3 - MOUNTING BOLT INSTALLATION (2) Position sensor on hub/bearing and install...
Page 203 5 - 40 BRAKES - ABS TONE WHEEL (Continued) Fig. 10 Tone Wheel 4x2 1 - HUB Fig. 8 Rear Wheel Speed Sensor Location 2 - TONE WHEEL 1 - DIFFERENTIAL HOUSING 3 - BEARING 2 - WHEEL SPEED SENSOR OPERATION The pump, motor, and accumulators are combined into an assembly attached to the valve body.
Page 204 BRAKES - ABS 5 - 41 HCU (HYDRAULIC CONTROL UNIT) (Continued) brake pressure and locking the brakes. The CAB then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock.
Page 205 5 - 42 BRAKES - ABS are prevented. If the fuse is open, the braking system RWAL VALVE will operate normally but without antilock control over rear brake pressure. DESCRIPTION The valve is located on the drivers side inner REMOVAL fender under the hood.
Page 206 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH OPERATION......11 DESCRIPTION .
Page 207 6 - 2 CLUTCH CLUTCH (Continued) The clutch master cylinder push rod is connected to the clutch pedal. When the clutch pedal is depressed, the slave cylinder is operated by the clutch master cylinder mounted on the dash panel. The release fork is actuated by the hydraulic slave cylinder mounted on the transmission housing.
Page 208 CLUTCH 6 - 3 CLUTCH (Continued) Fig. 3 Clutch Components And Inspection...
Page 209 6 - 4 CLUTCH CLUTCH (Continued) CLUTCH CONTAMINATION CLUTCH MISALIGNMENT Fluid contamination is a frequent cause of clutch Clutch components must be in proper alignment malfunctions. Oil, water or clutch fluid on the clutch with the crankshaft and transmission input shaft. disc and pressure plate surfaces will cause chatter, Misalignment caused by excessive runout or warpage slip and grab.
Page 210 CLUTCH 6 - 5 CLUTCH (Continued) DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION Disc facing worn out 1. Normal wear. 1. Replace cover and disc. 2. Driver frequently rides (slips) the 2. Replace cover and disc. clutch. Results in rapid overheating and wear.
Page 211 6 - 6 CLUTCH CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch disc binds on input shaft 1. Clutch disc hub splines damaged 1. Clean, smooth, and lubricate hub splines. during installation. splines if possible. Replace disc if necessary. 2. Input shaft splines rough, 2.
Page 212 CLUTCH 6 - 7 CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Release bearing is noisy. 1. Release bearing defective or 1. Replace release bearing. damaged. Contact surface of release bearing 1. Clutch cover incorrect or release 1. Replace clutch cover and release damaged.
Page 213: Clutch Disc
6 - 8 CLUTCH SPECIFICATIONS (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Flywheel Bolts-2.5L Flywheel Bolts-3.9/5.2L (3) If clutch cover is only being removed for access CLUTCH DISC to another component, mark position of cover on fly- wheel with small punch marks (Fig. 5). DESCRIPTION The clutch disc friction material is riveted to the disc hub (Fig.
Page 214: Clutch Housing
CLUTCH 6 - 9 CLUTCH DISC (Continued) (12) Install transmission and clutch housing as assembly. Refer to 21 Transmission and Transfer Case for procedures. CLUTCH HOUSING DIAGNOSIS AND TESTING - CLUTCH HOUSING Clutch housing alignment is important to proper clutch operation. The housing maintains alignment between the crankshaft and transmission input shaft.
Page 215 6 - 10 CLUTCH CLUTCH HOUSING (Continued) Fig. 8 Clutch Housing 1 - ENGINE 5 - ENGINE 2 - TRANSMISSION 6 - CLUTCH HOUSING 3 - CLUTCH HOUSING 4 - CLUTCH HOUSING BOLTS upper transmission B bolts to 75 N·m (55 ft.lbs). OPERATION Tighten all lower transmission C bolts to 50 N·m (37 The release bearing is operated by a release fork in...
Page 216 CLUTCH 6 - 11 CLUTCH RELEASE BEARING (Continued) release fork pivot surface with Mopar high temper- ature bearing grease. (4) Install release fork and bearing. Verify fork and bearing are properly secured. (5) Install transmission. Refer to 21 Transmission and Transfer Case for procedures. PRESSURE PLATE DESCRIPTION The clutch pressure plate assembly is a diaphragm...
Page 217 6 - 12 CLUTCH Flywheel machining is not recommended. The fly- FLYWHEEL wheel clutch surface is machined to a unique contour and machining will negate this feature. However, DESCRIPTION minor flywheel scoring can be cleaned up by hand The flywheel (Fig. 12) is a heavy plate bolted to the with 180 grit emery, or with surface grinding equip- rear of the crankshaft.
Page 218 CLUTCH 6 - 13 PILOT BEARING (Continued) INSTALLATION linkage is serviced as an assembly only. The individ- ual components that form the linkage assembly can- (1) Clean bearing bore with solvent and wipe dry not be overhauled or serviced separately. with shop towel.
Page 219 6 - 14 CLUTCH LINKAGE (Continued) Fig. 14 Clutch 1 - CLUTCH FLUID RESERVOIR 6 - CLUTCH PEDAL POSITION SWITCH CONNECTOR 2 - CLUTCH PEDAL 7 - CLUTCH HYDRAULIC LINE 3 - CLUTCH SAVE CYLINDER 8 - CLUTCH MASTER CYLINDER 4 - CLUTCH HYDRAULIC LINE 5 - CLUTCH PEDAL (7) Install clutch master cylinder push rod on...
Page 220: Clutch Pedal
CLUTCH 6 - 15 LINKAGE (Continued) Fig. 15 Clutch Hydraulic Linkage 1 - CLUTCH FLUID RESERVOIR 6 - CLUTCH PEDAL POSITION SWITCH CONNECTOR 2 - CLUTCH PEDAL 7 - CLUTCH HYDRAULIC LINE 3 - CLUTCH SAVE CYLINDER 8 - CLUTCH MASTER CYLINDER 4 - CLUTCH HYDRAULIC LINE 5 - CLUTCH PEDAL (13) Verify that fluid line from master cylinder to...
Page 221 6 - 16 CLUTCH CLUTCH PEDAL POSITION SWITCH (Continued) OPERATION The switch, which is in circuit with the starter solenoid, requires that the clutch pedal be fully depressed in order to start the engine. Switch cir- cuitry and operation is provided in section 8 Electrical.
Page 222 COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING DRAINING COOLING SYSTEM 4.7L ENGINE . . 15 DESCRIPTION ......1 REFILLING COOLING SYSTEM 4.7L OPERATION .
Page 223 7 - 2 COOLING COOLING (Continued) Fig. 1 Engine Cooling System Flow 1 - WATER CONTROL VALVE 6 - TO COOLANT RESERVE BOTTLE 2 - TO WATER PUMP 7 - TO WATER PUMP 3 - THERMOSTAT HOUSING 8 - TO HEATER CORE 4 - RADIATOR CAP 9 - FROM HEATER CORE 5 - RADIATOR...
Page 224 COOLING 7 - 3 COOLING (Continued) Fig. 2 Engine Cooling System Flow 1 - HEATER 3 - CROSSFLOW RADIATOR 2 - BYPASS*...
Page 225 7 - 4 COOLING COOLING (Continued) • Coolant reserve/overflow system (integral to DESCRIPTION—COOLING SYSTEM FLOW 4.7L upper fan shroud) ENGINE • Transmission oil cooler (if equipped with an The cooling system consists of (Fig. 3): automatic transmission) • Radiator • Coolant •...
Page 226 COOLING 7 - 5 COOLING (Continued) DESCRIPTION—HOSE CLAMPS hose clamp, only use constant tension clamp pliers designed to compress the hose clamp. The cooling system utilizes both worm drive and spring type hose clamps. If a spring type clamp DIAGNOSIS AND TESTING—ON-BOARD replacement is necessary, replace with the original DIAGNOSTICS (OBD) Mopar equipment spring type clamp.
Page 227 7 - 6 COOLING COOLING (Continued) Fig. 5 Leak Detection Using Black Light—Typical Fig. 6 PRESSURE TEST POINT 2.5L ENGINE 1 - TYPICAL BLACK LIGHT TOOL 1 - TYPICAL COOLING SYSTEM PRESSURE TESTER PRESSURE TESTER METHOD The engine should be at normal operating temper- ature.
Page 228 COOLING 7 - 7 COOLING (Continued) Drops Slowly: Indicates a small leak or seepage COMBUSTION LEAKAGE TEST—WITHOUT is occurring. Examine all connections for seepage or PRESSURE TESTER slight leakage with a flashlight. Inspect radiator, DO NOT WASTE reusable coolant. If solution is hoses, gasket edges and heater.
Page 229 7 - 8 COOLING COOLING (Continued) RECENT SERVICE OR ACCIDENT REPAIR: NOTE: If investigation reveals none of the previous items as a cause for an engine overheating com- Determine if any recent service has been per- plaint, refer to COOLING SYSTEM DIAGNOSIS formed on vehicle that may effect cooling system.
Page 230 COOLING 7 - 9 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 1. Trailer is being towed, a steep 1. This may be a temporary HIGH OR THE COOLANT hill is being climbed, vehicle is condition and repair is not WARNING LAMP ILLUMINATES.
Page 231 7 - 10 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 8. Incorrect coolant concentration 8. Check coolant. (Refer to LUBRICATION & MAINTENANCE/ FLUID TYPES - DESCRIPTION). 9. Coolant not flowing through 9. Check for coolant flow at radiator system filler neck with some coolant removed, engine warm and thermostat open.
Page 232 COOLING 7 - 11 COOLING (Continued) 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) position, the gauge reading may drop slightly.
Page 233 7 - 12 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as GROUND WITHOUT PRESSURE system hoses, water pump or necessary. (Refer to 7 - COOLING - CAP BLOWOFF.
Page 234 COOLING 7 - 13 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE HEATER 1. Has a Diagnostic trouble Code 1. (Refer to 25 - EMISSIONS PERFORMANCE. THERMOSTAT (DTC) been set? CONTROL - DESCRIPTION) for FAILED IN OPEN POSITION correct procedures and replace thermostat if necessary 2.
Page 235 7 - 14 COOLING COOLING (Continued) (3) Operate the engine with both the radiator cap STANDARD PROCEDURE and reserve/overflow tank cap in place. After the engine has reached the normal operating tempera- STANDARD PROCEDURE—DRAINING COOLING ture, shut the engine off and allow it to cool. SYSTEM 2.5L ENGINE (4) Add coolant to the reserve/overflow tank as necessary.
Page 236 COOLING 7 - 15 COOLING (Continued) (1) Install cylinder block drain plugs. Coat the threads with Mopar Thread Sealant with Teflon. (2) Close radiator petcock. (3) Fill cooling system with a 50/50 mixture of water and antifreeze. (4) Fill coolant reserve/overflow tank to FULL mark on indicator stick.
Page 237 7 - 16 COOLING COOLING (Continued) When engine is cooling down, coolant will be drawn into the radiator from the reserve/overflow tank. (5) Add coolant to reserve/overflow tank as neces- sary. Only add coolant to the reserve/overflow tank when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion.
Page 238 COOLING 7 - 17 COOLING (Continued) from water pump and attach a lead-away hose to DESCRIPTION N·m water pump inlet fitting. Lbs. Lbs. CAUTION: On vehicles equipped with a heater water Radiator to Support—Bolts — control valve, be sure heater control valve is closed Thermostat Housing—Bolts —...
Page 239 7 - 18 ACCESSORY DRIVE ACCESSORY DRIVE TABLE OF CONTENTS page page BELT TENSIONERS - 2.5L ACCESSORY DRIVE BELT ....21 REMOVAL ......18 REMOVAL .
Page 240 ACCESSORY DRIVE 7 - 19 BELT TENSIONERS - 3.9L/5.9L (Continued) Fig. 2 Automatic Belt Tensioner—5.2L and 5.9L Engines 1 - AUTOMATIC TENSIONER 2 - COIL AND BRACKET 3 - SCREW AND WASHER OPERATION The automatic belt tensioner maintains belt ten- sion by using internal spring pressure, a pivoting arm and pulley to press against the drive belt.
Page 241 7 - 20 ACCESSORY DRIVE BELT TENSIONERS - 4.7L (Continued) It is not necessary to adjust belt tension on the (2) Remove tensioner assembly from mounting 4.7L engine. These engines are equipped with an bracket (Fig. 5). automatic belt tensioner (Fig. 4). The tensioner main- tains correct belt tension at all times.
Page 242 ACCESSORY DRIVE 7 - 21 DRIVE BELTS - 2.5L DIAGNOSIS AND TESTING—ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 6), are considered normal. These are not a reason to replace the belt.
Page 243 7 - 22 ACCESSORY DRIVE DRIVE BELTS - 2.5L (Continued) CONDITION POSSIBLE CAUSES CORRECTION LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt groove 2. Pulley groove tip has worn away 2. Replace belt rubber to tensile member GROOVE JUMPING 1.
Page 244 ACCESSORY DRIVE 7 - 23 DRIVE BELTS - 2.5L (Continued) REMOVAL Correct drive belt tension is required to ensure optimum performance of the belt driven engine acces- sories. There are different types of adjustment gauges for checking either a serpentine or a V-type belt.
Page 245 7 - 24 ACCESSORY DRIVE DRIVE BELTS - 2.5L (Continued) INSTALLATION (1) Check condition of all pulleys. CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction.
Page 246 ACCESSORY DRIVE 7 - 25 DRIVE BELTS - 2.5L (Continued) ACCESSORY DRIVE BELT TENSION CHART DRIVE BELTS - 3.9L/5.9L DIAGNOSIS AND TESTING—ACCESSORY BELT TENSION DRIVE BELT **NEW SERPENTINE 800-900 N (180-200 lbs.) BELT VISUAL DIAGNOSIS USED SERPENTINE 623-712 N (140-160 lbs.) When diagnosing serpentine accessory drive belts, BELT small cracks that run across the ribbed surface of the...
Page 247 7 - 26 ACCESSORY DRIVE DRIVE BELTS - 3.9L/5.9L (Continued) ACCESSORY DRIVE BELT DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING (One or more ribs 1. Foreign objects imbedded in 1. Remove foreign objects from has separated from belt body) pulley grooves.
Page 248 ACCESSORY DRIVE 7 - 27 DRIVE BELTS - 3.9L/5.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION NOISE 1. Incorrect belt tension 1. Inspect/Replace tensioner if (Objectionable squeal, squeak, or necessary rumble is heard or felt while drive 2. Bearing noise 2. Locate and repair belt is in operation) 3.
Page 249 7 - 28 ACCESSORY DRIVE DRIVE BELTS - 3.9L/5.9L (Continued) INSTALLATION CAUTION: When installing the accessory drive belt, the belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to (Fig. 15) (Fig. 16) for correct engine belt routing.
Page 250 ACCESSORY DRIVE 7 - 29 DRIVE BELTS - 4.7L (Continued) NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play.
Page 251 7 - 30 ACCESSORY DRIVE DRIVE BELTS - 4.7L (Continued) CONDITION POSSIBLE CAUSES CORRECTION LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt groove 2. Pulley groove tip has worn away 2. Replace belt rubber to tensile member GROOVE JUMPING 1.
Page 252 ACCESSORY DRIVE 7 - 31 DRIVE BELTS - 4.7L (Continued) REMOVAL INSTALLATION Belt tension is not adjustable. Belt adjustment is CAUTION: DO NOT LET TENSIONER ARM SNAP maintained by an automatic ( spring load ) belt ten- BACK TO THE FREEARM POSITION, SEVER DAM- sioner.
Page 253 7 - 32 ENGINE ENGINE TABLE OF CONTENTS page page COOLANT RECOVERY CONTAINER DIAGNOSIS AND TESTING ....47 DESCRIPTION ......33 RADIATOR COOLANT FLOW CHECK.
Page 254 ENGINE 7 - 33 COOLANT RECOVERY ENGINE BLOCK HEATER - CONTAINER 3.9L/5.9L DESCRIPTION DESCRIPTION The coolant recovery containeris integral to the WARNING: DO NOT OPERATE ENGINE UNLESS upper fan shroud assembly and is made of high tem- BLOCK HEATER CORD HAS BEEN DISCONNECTED perature plastic (Fig.
Page 255 7 - 34 ENGINE ENGINE BLOCK HEATER - 3.9L/5.9L (Continued) OPERATION (4) With heater fully seated, tighten center screw to 2 N·m (17 in. lbs.). The heater warms the engine coolant providing (5) Fill cooling system with recommended coolant. easier engine starting and faster warm-up in low (Refer to 7 - COOLING - STANDARD PROCE- temperatures.
Page 256 ENGINE 7 - 35 ENGINE BLOCK HEATER - 4.7L (Continued) OPERATION Connecting the power cord to a grounded 110-120 volt AC electrical outlet with a grounded, three wire extension cord activates the heating element warm- ing the engine coolant. DIAGNOSIS AND TESTING—ENGINE BLOCK HEATER If the unit does not operate (Fig.
Page 257: Engine Coolant Temperature Sensor
7 - 36 ENGINE ENGINE BLOCK HEATER - 4.7L (Continued) (2) Insert block heater assembly with element loop MUST BE PARTIALLY DRAINED BEFORE REMOV- pointing at twelve o’clock (Fig. 7). ING THE COOLANT TEMPERATURE SENSOR. (3) With block heater fully seated, tighten center (1) Partially drain cooling system (Refer to 7 - screw to 2 N·m (17 in.
Page 258 ENGINE 7 - 37 ENGINE COOLANT TEMPERATURE SENSOR (Continued) Fig. 10 Engine Coolant Temperature Sensor—2.5L Engines Fig. 9 Engine Coolant Temperature Sensor—4.7L V–8 Engine 1 - THERMOSTAT HOUSING 2 - ENGINE COOLANT TEMPERATURE SENSOR 1 - ECT SENSOR 3 - ELECTRICAL CONNECTOR 2 - MOUNTING BOLTS (2) 3 - MAP SENSOR 4 - INTAKE MANIFOLD...
Page 259 7 - 38 ENGINE ENGINE COOLANT THERMOSTAT - 2.5L (Continued) Coolant leakage into the pellet container will cause indicated by the instrument panel gauge or by poor the thermostat to fail in the open position. Thermo- heater performance unless a DTC is present. Refer to stats very rarely stick.
Page 260 ENGINE 7 - 39 ENGINE COOLANT THERMOSTAT - 2.5L (Continued) (8) Start and warm the engine. Check for leaks. ENGINE COOLANT THERMOSTAT - 3.9L/5.9L DESCRIPTION CAUTION: Do not operate an engine without a ther- mostat, except for servicing or testing. The thermostat on the 3.9L and 5.9L gas powered engines is located beneath the thermostat housing at the front of the intake manifold (Fig.
Page 261 7 - 40 ENGINE ENGINE COOLANT THERMOSTAT - 3.9L/5.9L (Continued) OPERATION The wax pellet is located in a sealed container at the spring end of the thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force the valve to open. DIAGNOSIS AND TESTING—THERMOSTAT ON-BOARD DIAGNOSTICS All gasoline powered models are equipped with...
Page 262 ENGINE 7 - 41 ENGINE COOLANT THERMOSTAT - 3.9L/5.9L (Continued) Fig. 18 Thermostat—3.9L and 5.9L Engines Fig. 16 Automatic Belt Tensioner—3.9L and 5.9L 1 - THERMOSTAT HOUSING Engines 2 - GASKET 1 - IDLER PULLEY 3 - INTAKE MANIFOLD 2 - TENSIONER 4 - THERMOSTAT 3 - FAN BLADE 5 - MACHINED GROOVE...
Page 263 7 - 42 ENGINE ENGINE COOLANT THERMOSTAT - 3.9L/5.9L (Continued) ENGINE COOLANT THERMOSTAT - 4.7L DESCRIPTION CAUTION: Do not operate an engine without a ther- mostat, except for servicing or testing. A pellet-type thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator.
Page 264 ENGINE 7 - 43 ENGINE COOLANT THERMOSTAT - 4.7L (Continued) Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type.
Page 265 7 - 44 ENGINE ENGINE COOLANT THERMOSTAT - 4.7L (Continued) Fig. 22 Thermostat and Thermostat Housing 4.7L 1 - THERMOSTAT HOUSING 3 - THERMOSTAT AND GASKET 2 - THERMOSTAT LOCATION 4 - TIMING CHAIN COVER A thermostatic bimetallic spring coil is located on FAN DRIVE VISCOUS CLUTCH the front face of the viscous fan drive unit.
Page 266 ENGINE 7 - 45 FAN DRIVE VISCOUS CLUTCH - 3.9L/4.7L/5.9L (Continued) (1) Drill a 3.18-mm (1/8-in) diameter hole in the top center of the fan shroud. (2) Obtain a dial thermometer with an 8 inch stem (or equivalent). It should have a range of -18° to 105°C (0°...
Page 267 7 - 46 ENGINE FAN DRIVE VISCOUS CLUTCH - 3.9L/4.7L/5.9L (Continued) (3) Do not attempt to remove fan/viscous fan drive (7) After removing fan blade/viscous fan drive assembly from vehicle at this time. assembly, do not place viscous fan drive in horizon- tal position.
Page 268 ENGINE 7 - 47 FAN DRIVE VISCOUS CLUTCH - 3.9L/4.7L/5.9L (Continued) INSTALLATION (1) Install fan blade assembly to viscous fan drive. Tighten bolts (Fig. 27) to 23 N·m (17 ft. lbs.) torque. (2) Position fan blade/viscous fan drive assembly and upper shroud into vehicle. (3) Install fan shroud retaining screws (Fig.
Page 269 7 - 48 ENGINE RADIATOR (Continued) (2) Drain cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE). WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094) (Fig.
Page 270: Radiator Pressure Cap
ENGINE 7 - 49 RADIATOR (Continued) INSTALLATION The radiator has two isolator pins on bottom of both tanks. These fit into alignment holes in radiator lower support (Fig. 35). (1) Position isolator pins into alignment holes in radiator lower support. (2) Install and tighten radiator mounting bolts to 23 N·m (200 in.
Page 271 7 - 50 ENGINE RADIATOR PRESSURE CAP (Continued) (2) Refill system with new antifreeze. (3) Conducting service procedures. (4) Checking for vacuum leaks. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE.
Page 272 ENGINE 7 - 51 RADIATOR PRESSURE CAP (Continued) Operate tester pump to bring pressure to 138 kPa (20 psi) on gauge. If pressure cap fails to hold pres- sure of at least 131 kPa (19 psi) replace cap. Refer to following CAUTION.
Page 273 7 - 52 ENGINE RADIATOR FAN MOTOR (Continued) • If no problems are detected, install the DRB HEATING & AIR CONDITIONING for additional (refer to the appropriate Powertrain Diagnostic Pro- information. cedures manual for DRB scan tool operating instruc- tions) and start the engine. Clip a 12V test light to WATER PUMP - 2.5L the battery positive terminal and probe circuit C27 (relay terminal 85).
Page 274 ENGINE 7 - 53 WATER PUMP - 2.5L (Continued) OPERATION (2) Drain the cooling system (Refer to 7 - COOL- ING - STANDARD PROCEDURE). A centrifugal water pump circulates coolant (3) Loosen (but do not remove at this time) the through the water jackets, passages, intake manifold, four fan hub-to-water pump pulley mounting nuts.
Page 275 7 - 54 ENGINE WATER PUMP - 2.5L (Continued) Fig. 43 Clamp Number/Letter Location 1 - TYPICAL CONSTANT TENSION HOSE CLAMP 2 - CLAMP NUMBER/LETTER LOCATION 3 - TYPICAL HOSE (10) If pump is to be replaced, the heater hose fit- Fig.
Page 276 ENGINE 7 - 55 WATER PUMP - 3.9L/5.9L (Continued) The water pump impeller is pressed onto the rear CAUTION: A number or letter is stamped into the of a shaft that rotates in a bearing pressed into the tongue of constant tension clamps. If replacement water pump body.
Page 277 7 - 56 ENGINE WATER PUMP - 3.9L/5.9L (Continued) Fig. 47 Fan Blade and Viscous Fan Drive 1 - WATER PUMP BYPASS HOSE 2 - FAN BLADE ASSEMBLY 3 - VISCOUS FAN DRIVE 4 - WATER PUMP AND PULLEY (9) After removing fan blade/viscous fan drive Fig.
Page 278 ENGINE 7 - 57 WATER PUMP - 3.9L/5.9L (Continued) (13) Fill cooling system. (Refer to 7 - COOLING - DESCRIPTION—WATER PUMP BYPASS STANDARD PROCEDURE). The 4.7L engine uses an internal water/coolant (14) Connect battery negative cable. bypass system. The design uses galleries in the tim- (15) Start and warm the engine.
Page 279 7 - 58 ENGINE WATER PUMP - 4.7L (Continued) OPERATION—WATER PUMP BYPASS WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. When the thermostat is in the closed position the WHEN REMOVING OR INSTALLING, USE ONLY bypass gallery is not obstructed allowing 100% flow. TOOLS DESIGNED FOR SERVICING THIS TYPE OF When the thermostat is in the open position the stub CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER...
Page 280 ENGINE 7 - 59 WATER PUMP - 4.7L (Continued) (6) Remove upper fan shroud and fan blade/viscous INSPECTION fan drive assembly from vehicle. Inspect the water pump assembly for cracks in the (7) After removing fan blade/viscous fan drive housing, Water leaks from shaft seal, Loose or rough assembly, do not place thermal viscous fan drive in turning bearing or Impeller rubbing either the pump horizontal position.
Page 281 7 - 60 ENGINE WATER PUMP - 4.7L (Continued) CAUTION: When installing the serpentine accessory RADIATOR FAN - ELECTRIC drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in DESCRIPTION wrong direction. Refer to (Fig. 55) for correct belt The fan (Fig.
Page 282 ENGINE 7 - 61 RADIATOR FAN - ELECTRIC (Continued) OPERATION INSTALLATION The PCM regulates fan operation based on input (1) Install fan assembly onto the radiator. Tighten from the engine coolant temperature sensor and vehi- bolts 5 N·m (45 in. lbs.). cle speed.
Page 283 7 - 62 ENGINE WATER PUMP INLET TUBE (Continued) WARNING: CONSTANT TENSION HOSE CLAMPS (2) Loosen both bypass hose clamps (Fig. 59) and ARE USED ON MOST COOLING SYSTEM HOSES. position to center of hose. Remove hose from vehicle. WHEN REMOVING OR INSTALLING, USE ONLY WITH AIR CONDITIONING TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER...
Page 284 ENGINE 7 - 63 WATER PUMP INLET TUBE (Continued) (10) Remove heater hose clamp and heater hose (15) Loosen and position both hose clamps to cen- from heater hose coolant return tube. ter of bypass hose. Remove hose from vehicle. (11) Remove heater hose coolant return tube INSTALLATION mounting bolt (Fig.
Page 285 7 - 64 TRANSMISSION TRANSMISSION TABLE OF CONTENTS page page TRANS COOLER STANDARD PROCEDURE ....64 DESCRIPTION ......64 FLUSHING COOLERS AND TUBES .
Page 286 TRANSMISSION 7 - 65 TRANS COOLER (Continued) (1) Remove cover plate filler plug on Tool 6906-B. (5) Connect the BLUE pressure line to the OUT- Fill reservoir 1/2 to 3/4 full of fresh flushing solution. LET (From) cooler line. Flushing solvents are petroleum based solutions gen- (6) Connect the CLEAR return line to the INLET erally used to clean automatic transmission compo- (To) cooler line...
Page 288 AUDIO 8A - 1 AUDIO TABLE OF CONTENTS page page AUDIO REMOVAL ......11 DESCRIPTION .
Page 289 8A - 2 AUDIO AUDIO (Continued) nector repair procedures, details of wire harness pre-set station advance functions of the RAZ radio routing and retention, connector pin-out information receiver. The CTM monitors the status of the remote and location views for the various wire harness con- radio switches located on the steering wheel through nectors, splices and grounds.
Page 290 AUDIO 8A - 3 AUDIO (Continued) Audio System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION 3. Wiring faulty. 3. Check for battery voltage at radio connector. Repair wiring, if required. 4. Ground faulty. 4. Check for continuity between radio chassis and a known good ground.
Page 291 8A - 4 AUDIO AUDIO (Continued) For diagnosis of the power amplifier, (Refer to 8 - SPECIAL TOOLS ELECTRICAL/AUDIO/SPEAKER DIAGNOSIS AND TESTING) For complete circuit diagrams, refer AUDIO SYSTEMS to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire har- ness routing and retention, connector pin-out infor- mation and location views for the various wire...
Page 292 AUDIO 8A - 5 coaxial cable connection under the right end of the ANTENNA BODY & CABLE instrument panel near the outboard side of the glove box opening to the antenna base, and then DESCRIPTION from the coaxial cable connection to the radio chas- All models use a black painted fixed-length stain- sis connection.
Page 293 8A - 6 AUDIO ANTENNA BODY & CABLE (Continued) TEST 3 Test 3 checks the condition of the vehicle body ground connection. This test should be performed with the battery positive cable removed from the bat- tery. Disconnect both battery cables, the negative cable first.
Page 294 AUDIO 8A - 7 ANTENNA BODY & CABLE (Continued) INSTALLATION ANTENNA BODY AND CABLE (1) Position the antenna body and cable in the opening between the right cowl side outer panel and the fender through the front door opening. (2) Push the antenna coaxial cable into the passen- ger compartment through the hole in the right cowl side outer panel.
Page 295 8A - 8 AUDIO DIAGNOSIS AND TESTING - RADIO RADIO If the vehicle is equipped with the optional remote DESCRIPTION radio switches located on the steering wheel and the problem being diagnosed is related to one of the Available factory-installed radio receivers for this symptoms listed below, be certain to check the model include an AM/FM/cassette (RAS sales code), remote radio switches and circuits.
Page 296 AUDIO 8A - 9 RADIO (Continued) switch output (acc/run) circuit to the ignition switch as required. (5) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the radio receiver from the instrument panel, but do not disconnect the wire harness connec- tors.
Page 297 8A - 10 AUDIO RADIO (Continued) (1) Position the radio receiver to the instrument and retention, connector pin-out information and panel. location views for the various wire harness connec- (2) Reconnect the instrument panel wire harness tors, splices and grounds. Inspect the ground paths connectors and the antenna coaxial cable connector and connections at the following locations: •...
Page 298 AUDIO 8A - 11 RADIO NOISE SUPPRESSION GROUND STRAP (Continued) REMOVAL REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER ELECTRICAL, RESTRAINTS BAGS, REFER ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 299 8A - 12 AUDIO RADIO NOISE SUPPRESSION GROUND STRAP (Continued) (3) On 4 cylinder engines only, remove the nut and washer that secures the left engine-to-body ground strap eyelet terminal to the stud on the left rear cor- ner of the engine cylinder head (Fig. 9). Fig.
Page 300 AUDIO 8A - 13 RADIO NOISE SUPPRESSION GROUND STRAP (Continued) (7) On 4.7L engines only, remove the screw and washer that secures the right engine-to-body ground strap eyelet terminal to the transmission at the right rear corner of the engine block (Fig. 13). Fig.
Page 301 8A - 14 AUDIO RADIO NOISE SUPPRESSION GROUND STRAP (Continued) (5) Install and tighten the nut and washer that (11) On 6 and 8 cylinder engines only, position the secures the exhaust system-to-body ground strap eye- right engine-to-body ground strap eyelet over the let terminal to the exhaust pipe clamp.
Page 302 AUDIO 8A - 15 REMOTE SWITCHES (Continued) RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. (1) Remove the remote radio switch(es) (Fig. 15) from the steering wheel. Fig. 14 Remote Radio Switches 1 - PRESET SEEK 2 - SEEK UP 3 - VOLUME UP 4 - MODE 5 - VOLUME DOWN...
Page 303 8A - 16 AUDIO REMOTE SWITCHES (Continued) nuity. If OK, go to Step 4. If not OK, repair the open ground circuit to ground as required. (4) Disconnect the 18-way wire harness connector from the Central Timer Module (CTM). Check for continuity between the radio control mux circuit cav- ity of the remote radio switch wire harness connector and a good ground.
Page 304 AUDIO 8A - 17 DIAGNOSIS AND TESTING - SPEAKER SPEAKER For complete circuit diagrams, refer to the appro- DESCRIPTION priate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing STANDARD and retention, connector pin-out information and The standard equipment speaker system includes location views for the various wire harness connec-...
Page 305 8A - 18 AUDIO SPEAKER (Continued) nect and isolate the battery negative cable, remove OK, go to Step 13. If not OK, repair the shorted the test radio receiver, and go to Step 5. amplified feed (+) and/or amplified return (–) cir- (5) Disconnect the wire harness connector at the cuit(s) to the speaker as required.
Page 306 AUDIO 8A - 19 SPEAKER - FRONT DOOR SPEAKER - REAR DOOR LOWER REMOVAL (1) Disconnect and isolate the battery negative REMOVAL cable. (1) Disconnect and isolate the battery negative (2) Remove the trim panel from the rear door. cable. (Refer to 23 - BODY/DOORS - REAR/TRIM PANEL - (2) Remove the trim panel from the front door.
Page 307 8A - 20 AUDIO (3) Position the speaker into the mounting hole in SPEAKER - REAR CAB SIDE - the rear cab side inner panel. CLUB CAB (4) Install and tighten the three screws that secure the speaker to the rear cab side inner panel. Tighten REMOVAL the screws to 2 N·m (17 in.
Page 308 AUDIO 8A - 21 SPEAKER - REAR CAB SIDE - REGULAR CAB (Continued) (5) Remove the two screws that secure the speaker (3) Reconnect the body wire harness connector to to the back of the B-pillar trim. the speaker connector receptacle. (6) Remove the speaker from the back of the B-pil- (4) Install the trim panel onto the B-pillar.
Page 310 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME WARNING SYSTEM DIAGNOSIS AND TESTING ....3 DESCRIPTION ......1 CHIME WARNING SYSTEM .
Page 311 8B - 2 CHIME/BUZZER CHIME WARNING SYSTEM (Continued) a slow rate to announce that a hard wired input from chimes will continue to sound for a duration of about the seat belt switch to the Electro-Mechanical Instru- four seconds each time the indicator is illuminated or ment Cluster (EMIC) indicates that the driver side until the ignition switch is turned to the Off position, front seat belt is not fastened with the ignition...
Page 312 CHIME/BUZZER 8B - 3 CHIME WARNING SYSTEM (Continued) reminder, and the door ajar warning. The CTM relies wire and connector repair procedures, further details upon electronic message inputs received from other on wire harness routing and retention, as well as electronic modules over the PCI data bus network to pin-out and location views for the various wire har- provide chime service for all of the remaining chime...
Page 313 8B - 4 CHIME/BUZZER CHIME WARNING SYSTEM (Continued) CHIME WARNING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION NO DOOR AJAR WARNING 1. Driver or passenger door 1. Check for continuity between the ground circuit CHIME WITH A DOOR ajar switch ground circuit cavity of the door wire harness connector for the OPENED, BUT OTHER open.
Page 314 CHIME/BUZZER 8B - 5 CHIME WARNING SYSTEM (Continued) CHIME WARNING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION 2. Faulty ignition switch. 2. Check for continuity between the key-in ignition switch sense circuit terminal and the ground circuit terminal in the ignition switch connector receptacle.
Page 316 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page ELECTRONIC CONTROL MODULES OPERATION......10 STANDARD PROCEDURE .
Page 317 8E - 2 ELECTRONIC CONTROL MODULES ELECTRONIC CONTROL MODULES (Continued) (6) Press ENTER to transfer the secret key (the If ignition key programming is unsuccessful, the SKIM will send the secret key to the PCM). DRBIII will display one of the following messages: •...
Page 318 ELECTRONIC CONTROL MODULES 8E - 3 CENTRAL TIMER MODULE (Continued) of the instrument panel wire harness. The base ver- fade-to-off, interior lighting delay, courtesy illumina- sion of the CTM is used on base models of this vehi- tion defeat, and battery saver features. •...
Page 319 8E - 4 ELECTRONIC CONTROL MODULES CENTRAL TIMER MODULE (Continued) CTM are programmable using the DRBIII scan tool. can be retrieved and diagnosed using a DRBIII scan In addition, the CTM software is Flash compatible, tool. Refer to the appropriate diagnostic information. which means it can be reprogrammed using Flash HARD WIRED INPUTS reprogramming procedures.
Page 320 ELECTRONIC CONTROL MODULES 8E - 5 CENTRAL TIMER MODULE (Continued) • High beam indicator driver and accurate means to diagnose the CTM, the PCI • Horn relay control - high-line with power locks data bus network, and the electronic modules that only provide inputs to or receive outputs from the CTM •...
Page 321 8E - 6 ELECTRONIC CONTROL MODULES CENTRAL TIMER MODULE (Continued) repair the open fused B(+) circuit(s) between the RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT CTM and the PDC as required. AND POSSIBLE PERSONAL INJURY. (4) Check the fused ignition switch output (run- NOTE: Before replacing a Central Timer Module start) fuse (Fuse 11 - 10 ampere) and the fused igni- (CTM), use a DRBIII scan tool to retrieve the cur-...
Page 322 ELECTRONIC CONTROL MODULES 8E - 7 CENTRAL TIMER MODULE (Continued) INSTALLATION required by several controllers, a wire from each con- troller needed to be connected in parallel to that sen- sor. In addition, each controller utilizing analog WARNING: ON VEHICLES EQUIPPED WITH AIR- sensors required an Analog/Digital (A/D) converter in BAGS, DISABLE THE AIRBAG SYSTEM BEFORE order to...
Page 323 8E - 8 ELECTRONIC CONTROL MODULES COMMUNICATION (Continued) • In-Frame Response (IFR) byte(s) - If a els to generate signals. Low voltage is around zero volts and the high voltage is about seven and one- response is required from the target module(s), it can half volts.
Page 324 ELECTRONIC CONTROL MODULES 8E - 9 CONTROLLER ANTILOCK BRAKE (Continued) The CAB is mounted on the top of the hydraulic The CAB contains a self check program that illu- control unit (Fig. 4). The CAB operates the ABS sys- minates the ABS warning light when a system fault tem and is separate from other vehicle electrical cir- is detected.
Page 325 8E - 10 ELECTRONIC CONTROL MODULES CONTROLLER ANTILOCK BRAKE (Continued) Fig. 7 RWAL Controller Fig. 5 Harness Connector Locks 1 - CAB CONNECTOR LOCK 1 - CONNECTOR LOCK 2 - RWAL CONNECTOR 2 - CAB 3 - MOUNTING SCREWS (2) Install the mounting screws and tighten to 6 N·m (53 in.
Page 326 ELECTRONIC CONTROL MODULES 8E - 11 The fuel injection system has the following modes POWERTRAIN CONTROL of operation: MODULE • Ignition switch ON • Engine start-up (crank) DESCRIPTION • Engine warm-up • Idle The Powertrain Control Module (PCM) is located •...
Page 327 8E - 12 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) • Engine coolant temperature sensor The PCM monitors the crankshaft position sensor. • Intake manifold air temperature sensor If the PCM does not receive a crankshaft position • Manifold absolute pressure (MAP) sensor sensor signal within 3 seconds of cranking the •...
Page 328 ELECTRONIC CONTROL MODULES 8E - 13 POWERTRAIN CONTROL MODULE (Continued) been selected by the vehicle operator and requested turning the ground circuit to each individual injector by the A/C thermostat. on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of addi- ACCELERATION MODE tional fuel.
Page 329 8E - 14 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) • Throttle position sensor compressor clutch engagement and idle speed. The • Transmission governor pressure sensor PCM can adapt its programming to meet changing • Transmission temperature sensor operating conditions. •...
Page 330 ELECTRONIC CONTROL MODULES 8E - 15 POWERTRAIN CONTROL MODULE (Continued) OPERATION - IGNITION CIRCUIT SENSE To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery The ignition circuit sense input tells the PCM the cable must be disconnected before unplugging PCM ignition switch has energized the ignition circuit.
Page 331 8E - 16 ELECTRONIC CONTROL MODULES SENTRY KEY IMMOBILIZER MODULE (Continued) access to the SKIM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key tran- sponder programming procedures. The SKIM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a PCI data bus message from the PCM during SKIS initialization.
Page 332 ELECTRONIC CONTROL MODULES 8E - 17 SENTRY KEY IMMOBILIZER MODULE (Continued) ture, the SKIM will also send messages to the CTM to flash the security indicator whenever the Cus- tomer Learn programming mode is being utilized. (Refer to 8 - ELECTRICAL/VEHICLE THEFT SECU- RITY - STANDARD PROCEDURE - SENTRY KEY TRANSPONDER PROGRAMMING).
Page 333 8E - 18 ELECTRONIC CONTROL MODULES Some examples of indirect inputs to the TCM TRANSMISSION CONTROL are: MODULE • Engine/Body Identification • Manifold Pressure DESCRIPTION • Target Idle • Torque Reduction Confirmation The Transmission Control Module (TCM) is located • Engine Coolant Temperature in the engine compartment on the right (passenger) •...
Page 334 ELECTRONIC CONTROL MODULES 8E - 19 TRANSMISSION CONTROL MODULE (Continued) put Speed Sensor provides the TCM with output For example, if the input shaft is rotating at 1000 shaft speed information. rpm and the output shaft is rotating at 500 rpm, By comparing the two inputs, the TCM can deter- then the TCM can determine that the gear ratio is mine transmission gear position.
Page 335 8E - 20 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) • Engine load SHIFT SCHEDULES • Fluid temperature As mentioned earlier, the TCM has programming • Software level that allows it to select a variety of shift schedules. As driving conditions change, the TCM appropri- Shift schedule selection is dependent on the follow- ately adjusts the shift schedule.
Page 336 ELECTRONIC CONTROL MODULES 8E - 21 TRANSMISSION CONTROL MODULE (Continued) STANDARD PROCEDURE - TCM QUICK LEARN The quick learn procedure requires the use of the DRB scan tool. This program allows the electronic transmission system to recalibrate itself. This will provide the proper transmission operation.
Page 337 8E - 22 ELECTRONIC CONTROL MODULES TRANSFER CASE CONTROL MODULE (Continued) • Sleep Mode will be entered, from the Reduced • A valid mode sensor signal is being sensed by Power Mode, when no PCI traffic has been sensed for the TCCM.
Page 338 ELECTRONIC CONTROL MODULES 8E - 23 TRANSFER CASE CONTROL MODULE (Continued) condition exists), stop driving the motor and wait for trying to achieve the desired position. To re-attempt 1.5 sec ±50 msec. The shift motor is then reversed in the desired shift, the selector switch will need to be the direction back toward the source gear for up to rotated back to the original position until the switch 0.7 seconds ±100msec.
Page 339 8E - 24 ELECTRONIC CONTROL MODULES TRANSFER CASE CONTROL MODULE (Continued) • The attempt limit will not include shifts coming reading for the nearest high position. The TCCM should never go to Neutral unless the driver is com- out of Neutral, they will be allowed regardless of the manding it and all required conditions are being met counter/timer.
Page 340 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 341 8F - 2 BATTERY SYSTEM BATTERY SYSTEM (Continued) For battery system maintenance schedules and DIAGNOSIS AND TESTING - BATTERY SYSTEM jump starting procedures, see the owner’s manual in The battery, starting, and charging systems in the the vehicle glove box. Optionally, refer to Lubrication vehicle operate with one another and must be tested and Maintenance for the proper battery jump start- as a single complete system.
Page 342 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The battery has an 1. Refer to Battery Specifications for the proper WEAK OR DEAD WHEN incorrect size or rating for size and rating.
Page 343 8F - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery Specifications for the proper CHARGE CANNOT BE incorrect size or rating for specifications.
Page 344 BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) ABNORMAL BATTERY DISCHARGING Any of the following conditions can result in abnor- mal battery discharging: • Corroded or loose battery posts and terminal clamps. • A loose or worn generator drive belt. •...
Page 345 8F - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) (4) Clean the battery thermal guard with a sodium bicarbonate (baking soda) and warm water cleaning solution using a stiff bristle parts cleaning brush to remove any acid film. (5) Clean any corrosion from the battery terminal posts with a wire brush or a post and terminal cleaner, and a sodium bicarbonate (baking soda) and warm water cleaning solution (Fig.
Page 346 BATTERY SYSTEM 8F - 7 BATTERY (Continued) loss, at normal charge and discharge rates. There- fore, the battery should not require additional water in normal service. Rapid loss of electrolyte can be caused by an overcharging condition. Be certain to diagnose the charging system before returning the vehicle to service.
Page 347 8F - 8 BATTERY SYSTEM BATTERY (Continued) DIAGNOSIS AND TESTING - BATTERY mine the state-of-charge. If the battery cell caps are not removable, or a hydrometer is not available, per- The battery must be completely charged and the form the open-circuit voltage test to determine the top, posts and terminal clamps should be properly state-of-charge.
Page 348 BATTERY SYSTEM 8F - 9 BATTERY (Continued) STANDARD PROCEDURE - BATTERY CHARGING Battery charging is the means by which the bat- tery can be restored to its full voltage potential. A battery is fully-charged when: • All of the battery cells are gassing freely during battery charging.
Page 349 8F - 10 BATTERY SYSTEM BATTERY (Continued) CAUTION: Battery electrolyte will bubble inside the rent will be low. It could take some time before the battery case during normal battery charging. Elec- battery accepts a current greater than a few milliam- peres.
Page 350 BATTERY SYSTEM 8F - 11 BATTERY (Continued) • Temperature - A longer time will be needed to charge a battery at -18° C (0° F) than at 27° C (80° F). When a fast battery charger is connected to a cold battery, the current accepted by the battery will be very low at first.
Page 351 8F - 12 BATTERY SYSTEM BATTERY (Continued) • Green - Indicates 75% to 100% battery state-of- battery the electrolyte will have a temperature-cor- charge. The battery is adequately charged for further rected specific gravity of 1.260 to 1.290. However, a testing or return to service.
Page 352 BATTERY SYSTEM 8F - 13 BATTERY (Continued) Test the specific gravity of the electrolyte in each battery cell. If the specific gravity of all cells is above 1.235, but the variation between cells is more than fifty points (0.050), the battery should be replaced. If the specific gravity of one or more cells is less than 1.235, charge the battery at a rate of approximately five amperes.
Page 353 8F - 14 BATTERY SYSTEM BATTERY (Continued) Before proceeding with this test, completely charge WARNING: IF THE BATTERY SHOWS SIGNS OF the battery. Refer to Standard Procedures for the FREEZING, LEAKING OR LOOSE POSTS, DO NOT proper battery charging procedures. TEST, ASSIST-BOOST, OR CHARGE.
Page 354 BATTERY SYSTEM 8F - 15 BATTERY (Continued) Fig. 15 Load 50% CCA Rating - Note Voltage - Fig. 12 Volt-Ammeter-Load Tester - Typical Typical minutes prior to the test, the battery will be some- what warmer. See the Load Test Temperature Table for the proper loaded voltage reading.
Page 355 8F - 16 BATTERY SYSTEM BATTERY (Continued) inadequate level. When a vehicle will not be used for ing a battery. In most cases, the battery can be twenty days or more (stored), remove the IOD fuse charged and returned to service after the excessive from the Power Distribution Center (PDC).
Page 356 BATTERY SYSTEM 8F - 17 BATTERY (Continued) place process to identify and correct all sources of WARNING: WEAR A SUITABLE PAIR OF RUBBER excessive IOD. It is now safe to select the lowest mil- GLOVES (NOT THE HOUSEHOLD TYPE) WHEN liampere scale of the multi-meter to check the low- REMOVING BATTERY...
Page 357 8F - 18 BATTERY SYSTEM BATTERY (Continued) the terminal clamp pinch-bolt hex nut to 7.9 N·m (70 When installing a battery into the battery tray, be in. lbs.). certain that the hold down hardware is properly (6) Reconnect the battery negative cable terminal installed and that the fasteners are tightened to the clamp to the battery negative terminal post.
Page 358 BATTERY SYSTEM 8F - 19 BATTERY HOLDDOWN (Continued) Fig. 20 Battery Cables 1 - POWER DISTRIBUTION CENTER 2 - CLIP 3 - BATTERY 4 - TRAY 5 - NEGATIVE CABLE 6 - POSITIVE CABLE 7 - CLIP 8 - WHEELHOUSE INNER PANEL The battery cables cannot be repaired and, if dam- aged or faulty they must be replaced.
Page 359 8F - 20 BATTERY SYSTEM BATTERY CABLE (Continued) erated by the charging system for restoring the volt- USE FLAME, OR CREATE SPARKS NEAR THE age potential of the battery. The female battery BATTERY. PERSONAL INJURY AND/OR VEHICLE terminal clamps on the ends of the battery cable DAMAGE MAY RESULT.
Page 360 BATTERY SYSTEM 8F - 21 BATTERY CABLE (Continued) nection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. Fig. 21 Test Battery Negative Connection Resistance - Typical 1 - VOLTMETER Fig.
Page 361: Battery Tray
8F - 22 BATTERY SYSTEM of the tray, which support the forward end of the BATTERY TRAY Power Distribution Center (PDC). Refer to Power Distribution Center in the index of this service DESCRIPTION manual for the location of more information on the PDC mounting.
Page 362 BATTERY SYSTEM 8F - 23 BATTERY TRAY (Continued) (3) Install and tighten the two screws that secure the battery tray support to the left side of the radia- tor yoke. Tighten the screws to 11.3 N·m (100 in. lbs.). (4) Install and tighten the one screw that secures the rear of the battery tray support to the front extension of the left front wheelhouse inner panel.
Page 363 8F - 24 CHARGING CHARGING TABLE OF CONTENTS page page CHARGING INSTALLATION......26 DESCRIPTION ......0 GENERATOR OPERATION.
Page 364 CHARGING 8F - 25 CHARGING (Continued) • a faulty or improperly adjusted switch that (2) Inspect condition of battery cable terminals, allows a lamp to stay on. Refer to Ignition-Off Draw battery posts, connections at engine block, starter Test in 8, Battery for more information. solenoid and relay.
Page 365: Battery Temperature Sensor
8F - 26 CHARGING (1) Remove battery. Refer to 8, Battery for proce- BATTERY TEMPERATURE dures. SENSOR (2) Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to DESCRIPTION vehicle near its electrical connector. The Battery Temperature Sensor (BTS) is attached (3) Pry sensor straight up from battery tray to the battery tray located under the battery.
Page 366 CHARGING 8F - 27 GENERATOR (Continued) REMOVAL WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM. (1) Disconnect negative battery cable at battery. (2) Remove generator drive belt.
Page 367: Voltage Regulator
8F - 28 CHARGING GENERATOR (Continued) • Vertical mounting bolt 4.7L engine—55 N·m (40 ft. lbs.) • Long horizontal mounting bolt 4.7L engine—55 N·m (40 ft. lbs.) • Short horizontal mounting bolt 4.7L engine—74 N·m (55 ft. lbs.) CAUTION: Never force a belt over a pulley rim using a screwdriver.
Page 368 STARTING 8F - 29 STARTING TABLE OF CONTENTS page page STARTING STARTER MOTOR ..... . 35 DESCRIPTION ......29 REMOVAL .
Page 369 8F - 30 STARTING STARTING (Continued) operating unless the automatic transmission gear starter pinion gear to spin faster than the pinion selector is in the Neutral or Park positions. shaft. When the driver releases the ignition switch to When the starter relay coil is energized, the nor- the On position, the starter relay coil is de-energized.
Page 370 STARTING 8F - 31 STARTING (Continued) Starting System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION STARTER ENGAGES, 1. Starter ring gear faulty. 1. Refer to Starter Motor in Removal and Installation. SPINS OUT BEFORE Remove starter motor to inspect starter ring gear. ENGINE STARTS.
Page 371 8F - 32 STARTING STARTING (Continued) FEED CIRCUIT TEST The starter feed circuit test (voltage drop method) will determine if there is excessive resistance in high-amperage feed circuit. For complete starter wir- ing circuit diagrams, refer 8, Wiring Diagrams. When performing these tests, it is important to remember that voltage drop is giving an indication of resistance between two points at which voltmeter probes are attached.
Page 372 STARTING 8F - 33 STARTING (Continued) Fig. 4 Test Battery Positive Cable Fig. 2 Test 1 - BATTERY 1 - VOLTMETER 2 - VOLTMETER 2 - BATTERY 3 - STARTER MOTOR (4) Connect voltmeter to measure between battery negative terminal post and a good clean ground on engine block (Fig.
Page 373 8F - 34 STARTING STARTING (Continued) (5) Connect positive lead of voltmeter to starter (6) If equipped with dual battery system (diesel), housing. Connect negative lead of voltmeter to bat- connect positive lead of voltmeter to driver side bat- tery negative terminal post (Fig. 6). Rotate and hold tery positive cable clamp.
Page 374: Starter Motor
STARTING 8F - 35 SPECIFICATIONS (Continued) Starter Motor and Solenoid Free Running Test Maximum 90 Amperes 73 Amperes 73 Amperes Amperage Draw Free Running Test Minimum 2600 rpm 3601 rpm 3601 rpm Speed Solenoid Closing Maximum 7.8 Volts 7.5 Volts 7.5 Volts Voltage Required * Cranking Amperage Draw...
Page 375 8F - 36 STARTING STARTER MOTOR (Continued) (5) Adjust carbon pile load of tester to obtain free running test voltage. Refer to Starting Specifications for starter motor free running test voltage specifica- tions. (6) Note reading on ammeter and compare reading to free running test maximum amperage draw.
Page 376 STARTING 8F - 37 STARTER MOTOR (Continued) Fig. 11 Starter Motor Remove/Install - 2.5L Engine Fig. 12 Starter Motor Remove/Install - All 3.9L/5.9L, or 4.7L Engine with Man. Trans. 1 - SCREW AND WASHER 2 - EYELET TERMINAL 1 - EYELET TERMINAL 3 - NUT 2 - NUT 4 - BATTERY POSITIVE CABLE WIRE HARNESS...
Page 377: Starter Motor Relay
8F - 38 STARTING STARTER MOTOR (Continued) (4) While supporting starter motor, remove bolt (9) Connect negative battery cable. and washer (rearward facing) securing starter motor 4.7L With Automatic Trans. to the transmission housing. (1) Position starter motor to transmission housing. (5) Lower starter motor from front of transmission (2) Connect battery cable solenoid terminal wire housing far enough to access and remove nut secur-...
Page 378 STARTING 8F - 39 STARTER MOTOR RELAY (Continued) DIAGNOSIS AND TESTING - STARTER RELAY (3) The relay normally open terminal (87) is con- nected to common feed terminal (30) in the energized The starter relay (Fig. 14) is located in Power Dis- position.
Page 379 8F - 40 STARTING STARTER MOTOR RELAY (Continued) INSTALLATION (1) See fuse and relay layout label affixed to underside of PDC cover for proper starter relay loca- tion. (2) Position starter relay in proper receptacle in PDC. (3) Align starter relay terminals with terminal cavities in PDC receptacle.
Page 380 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS ......1 HEATED MIRRORS .
Page 381 8G - 2 HEATED GLASS HEATED GLASS (Continued) • Turn the ignition switch to the On position. Set When the above steps have been completed and the the defogger switch in the On position. The rear win- rear glass heating grid is still inoperative, one or dow defogger operation can be checked by feeling the more of the following is faulty: •...
Page 382 HEATED GLASS 8G - 3 REAR WINDOW DEFOGGER GRID (Continued) DIAGNOSIS AND TESTING - REAR WINDOW (1) Follow the instructions in the repair kit for preparing the damaged area. DEFOGGER GRID (2) Remove the package separator clamp and mix For circuit descriptions and diagrams, refer to Rear the two conductive epoxy components thoroughly Window Defogger in Wiring Diagrams.
Page 383: Rear Window Defogger Switch
8G - 4 HEATED GLASS REAR WINDOW DEFOGGER GRID (Continued) (10) Check the operation of the rear window defog- The momentary-type rear window defogger switch ger glass heating grid. provides a hard wired ground signal to the rear win- dow defogger logic and timer circuitry, each time it is depressed.
Page 384 HEATED MIRRORS 8G - 5 HEATED MIRRORS TABLE OF CONTENTS page page HEATED MIRRORS HEATED MIRROR GRID DESCRIPTION ......5 DESCRIPTION .
Page 386 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM OPERATION ......3 DESCRIPTION .
Page 387 8H - 2 HORN wire harness connector(s) and a good ground. There HORN should be no measurable resistance. If OK, go to Step 2. If not OK, repair the open ground circuit to ground DESCRIPTION as required. The dual electromagnetic diaphragm-type horns (2) Check for battery voltage at the horn relay out- are standard equipment on this model.
Page 388 HORN 8H - 3 HORN (Continued) INSTALLATION DIAGNOSIS AND TESTING - HORN RELAY (1) Position the horn and mounting bracket unit The horn relay (Fig. 2) is located in the Junction onto the front of the left vertical member of the radi- Block (JB) on the left end of the instrument panel in ator support.
Page 389 8H - 4 HORN HORN RELAY (Continued) IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. (1) Disconnect and isolate the battery negative cable.
Page 390: Horn Switch
HORN 8H - 5 OPERATION HORN SWITCH When the center area of the driver side airbag trim DESCRIPTION cover is depressed, the electrically conductive grids on the facing surfaces of the horn switch membranes A center-blow, normally open, resistive membrane- contact each other, closing the switch circuit.
Page 391 8H - 6 HORN HORN SWITCH (Continued) (6) Check for continuity between the horn switch (7) Depress the center of the driver side airbag feed wire and the horn switch ground wire on the module trim cover and check for continuity between driver side airbag module.
Page 392 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL DISTRIBUTOR ROTOR DESCRIPTION ......1 DIAGNOSIS AND TESTING .
Page 393 8I - 2 IGNITION CONTROL ENGINE FIRING ORDER—4.7L V-8 ENGINE SPECIFICATIONS IGNITION TIMING Ignition timing is not adjustable on any engine. ENGINE FIRING ORDER—2.5L 4-CYLINDER ENGINE ENGINE FIRING ORDER—3.9L V-6 ENGINE ENGINE FIRING ORDER—5.2L/5.9L V-8 ENGINES...
Page 394 IGNITION CONTROL 8I - 3 SPECIFICATIONS (Continued) SPECIFICATIONS - TORQUE - IGNITION DESCRIPTION N·m Ft. Lbs. In. Lbs. Camshaft Position Sensor Bolt—4.7L V-8 Engine Crankshaft Position Sensor—2.5L Engine Crankshaft Position Sensor—3.9L/5.2L/5.9L Engines Crankshaft Position Sensor Bolt—4.7L V-8 Engine Distributor Hold Down Bolt Ignition Coil Mounting (except 4.7L) (if tapped bolts are used) Ignition Coil Mounting (except 4.7L) (if nuts/bolts are used) Ignition Coil Mounting Nut—4.7L V-8 Engine...
Page 395 8I - 4 IGNITION CONTROL AUTO SHUT DOWN RELAY DESCRIPTION - PCM OUTPUT The 5–pin, 12–volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. OPERATION - ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated.
Page 396: Camshaft Position Sensor
IGNITION CONTROL 8I - 5 AUTO SHUT DOWN RELAY (Continued) (2) With the relay removed from the vehicle, use an ohmmeter to check the resistance between termi- nals 85 and 86. The resistance should be 75 ohms +/- 5 ohms. (3) Connect the ohmmeter between terminals 30 and 87A.
Page 397 8I - 6 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) Fig. 4 CMP Location—4.7L Engine Fig. 5 CMP Sensor and Tonewheel—4.7L Engine 1 - RIGHT CYLINDER HEAD 1 - NOTCHES 2 - CAMSHAFT POSITION SENSOR 2 - RIGHT CYLINDER HEAD 3 - MOUNTING BOLT 3 - CAMSHAFT POSITION SENSOR 4 - ELEC.
Page 398 IGNITION CONTROL 8I - 7 CAMSHAFT POSITION SENSOR (Continued) REMOVAL - 4.7L INSTALLATION - 4.7L The Camshaft Position Sensor (CMP) on the 4.7L The Camshaft Position Sensor (CMP) on the 4.7L V–8 engine is bolted to the front/top of the right cyl- V–8 engine is bolted to the front/top of the right cyl- inder head (Fig.
Page 399 8I - 8 IGNITION CONTROL DISTRIBUTOR (Continued) The distributor does not have built in centrifugal or vacuum assisted advance. Base ignition timing and all timing advance is controlled by the Power- train Control Module (PCM). Because ignition timing is controlled by the PCM, base ignition timing is not adjustable on any of these engines.
Page 400 IGNITION CONTROL 8I - 9 DISTRIBUTOR (Continued) (5) Disconnect distributor wiring harness from main engine harness. (6) Remove cylinder number 1 spark plug. (7) Hold a finger over open spark plug hole. Rotate engine at vibration dampener bolt until compression (pressure) is felt.
Page 401 8I - 10 IGNITION CONTROL DISTRIBUTOR (Continued) Fig. 13 Damper-To-Cover Alignment Marks—Typical Fig. 15 Distributor Holddown Clamp—3.9/5.2/5.9L Engines 1 - ALIGNMENT MARK 2 - TIMING CHAIN COVER MARKS 1 - CLAMP BOLT 3 - CRANKSHAFT VIBRATION DAMPER 2 - HOLDDOWN CLAMP 3 - DISTRIBUTOR HOUSING returned to its proper firing stroke.
Page 402 IGNITION CONTROL 8I - 11 DISTRIBUTOR (Continued) Fig. 17 Distributor Pre-position Fig. 16 Pin Alignment Holes 1 - 1 O’CLOCK POSITION 1 - DISTRIBUTOR HOUSING (TOP VIEW) 2 - BASE SLOT 2 - PULSE RING 3 - DISTRIBUTOR BASE 3 - 4.0L 6–CYLINDER ENGINE ALIGN. HOLE 4 - 2.5L 4–CYLINDER ENGINE ALIGN.
Page 403 8I - 12 IGNITION CONTROL DISTRIBUTOR (Continued) (12) Install distributor holddown clamp and bolt. (10) Refer to the following, Checking Distributor Tighten bolt to 23 N·m (17 ft. lbs.) torque. Position. (13) Remove pin punch tool from distributor. Or, if Checking Distributor Position plastic alignment pin was used, remove it straight To verify correct distributor rotational position, the...
Page 404: Ignition Coil
IGNITION CONTROL 8I - 13 DISTRIBUTOR CAP (Continued) This is normal. Do not remove the charred com- pound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions. Fig. 19 Cap Inspection—External—Typical 1 - BROKEN TOWER 2 - DISTRIBUTOR CAP 3 - CARBON PATH 4 - CRACK...
Page 405 8I - 14 IGNITION CONTROL IGNITION COIL (Continued) OPERATION - 4.7L Battery voltage is supplied to the 8 ignition coils from the ASD relay. The Powertrain Control Module (PCM) opens and closes each ignition coil ground cir- cuit at a determined time for ignition coil operation. Base ignition timing is not adjustable.
Page 406 IGNITION CONTROL 8I - 15 IGNITION COIL (Continued) REMOVAL - 3.9L/5.2L/5.9L coil and are not serviced separately. An o-ring (Fig. 26) is used to seal the coil at the opening into the cyl- The ignition coil is an epoxy filled type. If the coil inder head.
Page 407: Spark Plug
8I - 16 IGNITION CONTROL IGNITION COIL (Continued) SPARK PLUG DESCRIPTION All engines use resistor type spark plugs. 4.7L V-8 engines are equipped with “fired in suppressor seal” type spark plugs using a copper core ground elec- trode. Because of the use of an aluminum cylinder head on the 4.7L engine, spark plug torque is very critical.
Page 408 IGNITION CONTROL 8I - 17 SPARK PLUG (Continued) Fig. 28 Normal Operation and Cold (Carbon) Fouling 1 - NORMAL 2 - DRY BLACK DEPOSITS 3 - COLD (CARBON) FOULING Some fuel refiners in several areas of the United Fig. 29 Oil or Ash Encrusted States have introduced a manganese additive (MMT) ELECTRODE GAP BRIDGING for unleaded fuel.
Page 409 8I - 18 IGNITION CONTROL SPARK PLUG (Continued) SCAVENGER DEPOSITS Fuel scavenger deposits may be either white or yel- low (Fig. 31). They may appear to be harmful, but this is a normal condition caused by chemical addi- tives in certain fuels. These additives are designed to change the chemical nature of deposits and decrease spark plug misfire tendencies.
Page 410 IGNITION CONTROL 8I - 19 SPARK PLUG (Continued) (3) Remove spark plug from cylinder head using a quality socket with a rubber or foam insert. If equipped with a 4.7L V-8 engine, also check condition of coil o-ring and replace as necessary. (4) Except 4.7L: Always remove spark plug or igni- tion coil cables by grasping at the cable boot (Fig.
Page 411 8I - 20 IGNITION CONTROL TESTING SPARK PLUG CABLE When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment DESCRIPTION manufacturer. Spark plug cables are sometimes referred to as sec- If an oscilloscope is not available, spark plug cables ondary ignition wires.
Page 412 IGNITION CONTROL 8I - 21 SPARK PLUG CABLE (Continued) To test ignition coil-to-distributor cap cable, do not remove the cable from the cap. Connect ohmmeter to rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap.
Page 414 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER MALFUNCTION INDICATOR LAMP (MIL) DESCRIPTION ......2 DESCRIPTION .
Page 415: Instrument Cluster
8J - 2 INSTRUMENT CLUSTER WASHER FLUID INDICATOR WASHER FLUID INDICATOR ....36 DESCRIPTION ......35 WATER-IN-FUEL INDICATOR OPERATION.
Page 416 INSTRUMENT CLUSTER 8J - 3 INSTRUMENT CLUSTER (Continued) • Coolant Temperature Gauge Hard wired circuitry connects the EMIC to the • Fuel Gauge electrical system of the vehicle. These hard wired cir- • Oil Pressure Gauge cuits are integral to several wire harnesses, which •...
Page 417 8J - 4 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) ture, the algorithm drives the gauge pointer to an GAUGES extreme position and the microprocessor turns on a All gauges receive battery current through the “Check Gauges” indicator to provide a distinct visual EMIC circuitry when the ignition switch is in the On indication of a problem to the vehicle operator.
Page 418 INSTRUMENT CLUSTER 8J - 5 INSTRUMENT CLUSTER (Continued) tion will toggle the VFD between the odometer and gramming, PCI data bus messages from the Airbag trip odometer modes. The word “TRIP” will also Control Module (ACM), and the hard wired seat belt appear in blue-green text when the VFD trip odome- switch input to the EMIC.
Page 419 8J - 6 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) with the headlamp switch. The illumination bright- DIAGNOSIS AND TESTING - INSTRUMENT ness of these lamps is adjusted by the panel lamps CLUSTER dimmer rheostat when the headlamp switch thumb- If all of the instrument cluster gauges and/or indi- wheel is rotated (down to dim, up to brighten).
Page 420 INSTRUMENT CLUSTER 8J - 7 INSTRUMENT CLUSTER (Continued) PRELIMINARY DIAGNOSIS dimmer thumbwheel on the headlamp switch to the full bright position. The cluster illumination lamps WARNING: ON VEHICLES EQUIPPED WITH AIR- should light. If OK, go to Step 10. If not OK, repair BAGS, DISABLE THE AIRBAG SYSTEM BEFORE the open ground circuit (Z1) between the instrument ATTEMPTING ANY STEERING WHEEL, STEERING...
Page 421 8J - 8 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) ever, there may still be a problem with the PCI data (3) While still holding the odometer/trip odometer bus, the Powertrain Control Module (PCM), the switch button depressed, turn the ignition switch to Engine Control Module (ECM), the Central Timer the On position, but do not start the engine.
Page 422 INSTRUMENT CLUSTER 8J - 9 INSTRUMENT CLUSTER (Continued) (6) The instrument cluster will begin the Vacuum includes inoperative exterior lighting controlled by Fluorescent Display (VFD) walking segment test. the headlamp switch, that system needs to be This test will require the operator to visually inspect repaired first.
Page 423 8J - 10 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) (Connector C2) for the instrument cluster. Check for continuity to a good ground. There should be no con- tinuity. If OK, go to Step 4. If not OK, repair the shorted fused panel lamps dimmer switch signal cir- cuit between the instrument cluster and the JB as required.
Page 424 INSTRUMENT CLUSTER 8J - 11 INSTRUMENT CLUSTER (Continued) (2) Remove the instrument cluster from the instru- ment panel. (Refer to 8 - ELECTRICAL/INSTRU- MENT CLUSTER - REMOVAL). (3) Turn the bulb holder counterclockwise about sixty degrees on the cluster electronic circuit board (Fig.
Page 425 8J - 12 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) ASSEMBLY (3) Reinstall the instrument cluster onto the instrument panel. (Refer to 8 - ELECTRICAL/IN- STRUMENT CLUSTER - INSTALLATION). WARNING: ON VEHICLES EQUIPPED WITH AIR- (4) Reconnect the battery negative cable. BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING CLUSTER HOUSING REAR COVER COLUMN, OR INSTRUMENT PANEL COMPONENT...
Page 426: Abs Indicator
INSTRUMENT CLUSTER 8J - 13 INSTRUMENT CLUSTER (Continued) (3) Install and tighten the four screws that secure (PCI) data bus. The ABS indicator Light Emitting the instrument cluster to the instrument panel (Fig. Diode (LED) receives battery current on the instru- 2).
Page 427 8J - 14 INSTRUMENT CLUSTER the cluster receives a single lamp-off message from AIRBAG INDICATOR the ACM, whichever is longer. • Actuator Test - Each time the cluster is put DESCRIPTION through the actuator test, the airbag indicator will be An airbag indicator is standard equipment on all turned on, then off again during the bulb check por- instrument...
Page 428 INSTRUMENT CLUSTER 8J - 15 BRAKE/PARK BRAKE INDICATOR (Continued) OPERATION sense circuit whenever the pressures in the two halves of the split brake hydraulic system are The brake indicator gives an indication to the vehi- unequal. The CAB then sends the proper lamp-on or cle operator when the parking brake is applied, or lamp-off messages to the instrument cluster.
Page 429 8J - 16 INSTRUMENT CLUSTER CHECK GAUGES INDICATOR (Continued) when it is provided a path to ground by the instru- The PCM continually monitors the engine temper- ment cluster transistor. The instrument cluster will ature, oil pressure, and electrical system voltage, turn on the check gauges indicator for the following then sends the proper messages to the instrument reasons:...
Page 430 INSTRUMENT CLUSTER 8J - 17 COOLANT LOW INDICATOR (Continued) • Bulb Test - Each time the ignition switch is OPERATION turned to the On position the coolant low indicator is The cruise indicator gives an indication to the vehi- illuminated for about two seconds as a bulb test. cle operator when the speed control system is turned •...
Page 431: Door Ajar Indicator
8J - 18 INSTRUMENT CLUSTER portion of the test to confirm the functionality of the DOOR AJAR INDICATOR cluster control circuitry. The CTM continually monitors the door ajar DESCRIPTION switches to determine the status of the doors. The A door ajar indicator is standard equipment on all CTM then sends the proper door ajar lamp-on and instrument clusters.
Page 432: Fuel Gauge
INSTRUMENT CLUSTER 8J - 19 ENGINE TEMPERATURE GAUGE (Continued) • Message Failure - If the cluster fails to receive instrument cluster circuit board based upon cluster programming and electronic messages received by an engine temperature message, it will hold the the cluster from the Powertrain Control Module gauge needle at the last indication until a new mes- (PCM) over the Programmable Communications...
Page 433 8J - 20 INSTRUMENT CLUSTER FUEL GAUGE (Continued) • Less Than Empty Percent Tank Full Mes- red. The orange gauge needle is internally illumi- nated. Gauge illumination is provided by replaceable sage - Each time the cluster receives a message from incandescent bulb and bulb holder units located on the PCM indicating the percent tank full is less than the instrument cluster electronic circuit board.
Page 434: High Beam Indicator
INSTRUMENT CLUSTER 8J - 21 GEAR SELECTOR INDICATOR (Continued) minates a rectangular box around the character that has configured itself for the transmission range sen- represents the currently selected lever position. sor input and detects a short to ground in the trans- During daylight hours (exterior lamps Off) the gear mission range sensor mux input, the cluster will selector indicator VFD is illuminated at full bright-...
Page 435 8J - 22 INSTRUMENT CLUSTER HIGH BEAM INDICATOR (Continued) bulb holder unit located on the instrument cluster CAUTIONS COULD RESULT IN ACCIDENTAL AIR- electronic circuit board. The high beam indicator is BAG DEPLOYMENT AND POSSIBLE PERSONAL serviced as a unit with the instrument cluster. INJURY.
Page 436 INSTRUMENT CLUSTER 8J - 23 HIGH BEAM INDICATOR (Continued) ground. There should be no continuity. If OK, diag- vehicle speed is zero, or for 60 consecutive seconds nose the CTM and its inputs using a DRBIII scan and the vehicle speed is greater than zero, the low tool.
Page 437 8J - 24 INSTRUMENT CLUSTER MALFUNCTION INDICATOR LAMP (MIL) (Continued) • Actuator Test - Each time the cluster is put dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. through the actuator test, the indicator will be An amber lens behind the cutout in the opaque layer turned on during the bulb check portion of the test to of the overlay causes the icon to appear in amber...
Page 438: Oil Pressure Gauge
INSTRUMENT CLUSTER 8J - 25 ODOMETER (Continued) the odometer and trip odometer display is not shown in the cluster memory. If the cluster is unable to dis- in the VFD. The unit of measure for the instrument play distance information due to an error internal to cluster odometer/trip odometer is selected at the time the cluster, the VFD display will be blank.
Page 439: Overdrive Off Indicator
8J - 26 INSTRUMENT CLUSTER OIL PRESSURE GAUGE (Continued) • Engine Oil Pressure High Message - Each board based upon cluster programming and elec- tronic messages received by the cluster from the time the cluster receives a message from the PCM Powertrain Control Module (PCM) over the Program- indicating the engine oil pressure is above about 755 mable Communications Interface (PCI) data bus.
Page 440 INSTRUMENT CLUSTER 8J - 27 OVERDRIVE OFF INDICATOR (Continued) The text “O/D OFF” appears in an amber color and trol system, the PCM, the PCI data bus, or the mes- at the same lighting level as the gear selector indica- sage inputs to the instrument cluster that control the tor information when it is illuminated by the instru- overdrive off indicator, a DRBIII...
Page 441: Security Indicator
8J - 28 INSTRUMENT CLUSTER SEATBELT INDICATOR (Continued) • Driver Side Front Seatbelt Not Buckled - (CTM) on the VTSS indicator driver circuit and, if Following the seatbelt reminder function, each time the vehicle is so equipped, by a transistor on the the cluster detects an open circuit on the seat belt instrument cluster circuit board based upon elec- indicator driver circuit (seatbelt switch open - seat-...
Page 442 INSTRUMENT CLUSTER 8J - 29 SECURITY INDICATOR (Continued) The CTM provides a hard wired ground input to by a transistor on the instrument cluster circuit the instrument cluster circuitry through the VTSS board based upon cluster programming and elec- indicator driver circuit whenever the ignition switch tronic messages received by the cluster from the is in the Off position and the VTSS is arming, armed, TCCM over the Programmable Communications...
Page 443 8J - 30 INSTRUMENT CLUSTER SPEEDOMETER (Continued) tachometer, just to the right of center in the instru- swept to several calibration points on the gauge scale ment cluster. The speedometer consists of a movable in a prescribed sequence in order to confirm the func- gauge needle or pointer controlled by the instrument tionality of the gauge and the cluster control cir- cluster circuitry and a fixed 210 degree primary scale...
Page 444 INSTRUMENT CLUSTER 8J - 31 TACHOMETER (Continued) circuit whenever the ignition switch is in the On or The transmission over-temperature indicator is ser- Start positions. The cluster is programmed to move viced as a unit with the instrument cluster. the gauge needle back to the low end of the scale OPERATION after the ignition switch is turned to the Off position.
Page 445: Turn Signal Indicator
8J - 32 INSTRUMENT CLUSTER TRANSMISSION TEMP INDICATOR (Continued) transmission over-temperature indicator turn signal and hazard warning system, (Refer to 8 - instrument cluster circuitry that controls the LED, ELECTRICAL/LAMPS/LIGHTING - EXTERIOR - (Refer to 8 - ELECTRICAL/INSTRUMENT CLUS- OPERATION - TURN SIGNAL & HAZARD WARN- TER - DIAGNOSIS AND TESTING).
Page 446 INSTRUMENT CLUSTER 8J - 33 UPSHIFT INDICATOR (Continued) cator is illuminated from behind by a Light Emitting ment cluster circuitry that controls the indicator, Diode (LED) soldered onto the instrument cluster (Refer to 8 - ELECTRICAL/INSTRUMENT CLUS- electronic circuit board. The upshift indicator is ser- TER - DIAGNOSIS AND TESTING).
Page 447 8J - 34 INSTRUMENT CLUSTER VOLTAGE GAUGE (Continued) • Charge Fail Message - Each time the cluster WAIT-TO-START INDICATOR receives a message from the PCM indicating a charge fail condition (system voltage is 10.8 volts or lower), DESCRIPTION the gauge needle is moved to the “L” graduation on A wait-to-start indicator is only found in the the gauge scale and the check gauges indicator is instrument clusters of vehicles equipped with an...
Page 448 INSTRUMENT CLUSTER 8J - 35 WAIT-TO-START INDICATOR (Continued) DRBIII scan tool is required. Refer to the appropri- instrument panel. Disconnect the instrument panel ate diagnostic information. wire harness connector (Connector C1) for the ECM from the ECM connector receptacle. Check for conti- DIAGNOSIS AND TESTING - WAIT-TO-START nuity between the wait-to-start indicator driver cir- cuit cavity of the instrument panel wire harness...
Page 449 8J - 36 INSTRUMENT CLUSTER WASHER FLUID INDICATOR (Continued) • Washer Fluid Level Switch Input - Immedi- WARNING: ON VEHICLES EQUIPPED WITH AIR- ately after the bulb test, if the cluster senses ground BAGS, DISABLE THE AIRBAG SYSTEM BEFORE on the washer fluid switch sense circuit for more ATTEMPTING ANY STEERING WHEEL, STEERING than about thirty seconds, it turns on the washer COLUMN, OR INSTRUMENT PANEL COMPONENT...
Page 450 INSTRUMENT CLUSTER 8J - 37 WASHER FLUID INDICATOR (Continued) switch sense circuit between the washer fluid level tion except On or Start. The LED only illuminates switch and the instrument cluster as required. when it is provided a path to ground by the instru- ment cluster transistor.
Page 452 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....25 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page...
Page 453 8L - 2 LAMPS/LIGHTING - EXTERIOR • Hazard Warning Switch - The hazard warning LAMPS/LIGHTING - EXTERIOR switch is integral to the multi-function switch on the left side of the steering column. The hazard warning DESCRIPTION - EXTERIOR LAMPS switch button protrudes from a dedicated opening in The exterior lighting system consist of the follow- the shroud on the top of the steering column, just ing components:...
Page 454 LAMPS/LIGHTING - EXTERIOR 8L - 3 LAMPS/LIGHTING - EXTERIOR (Continued) nector repair procedures, details of wire harness the cluster electronic circuit board. If a turn signal routing and retention, connector pin-out information remains indicated for a distance of greater than and location views for the various wire harness con- about 1.6 kilometers (1 mile) and the vehicle speed nectors, splices and grounds.
Page 455 8L - 4 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) DIAGNOSIS AND TESTING - TURN SIGNAL & 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse(s). HAZARD WARNING SYSTEM (3) Check for battery voltage at the fused B(+) fuse When diagnosing the turn signal and hazard warn- (Fuse 1 - 30 ampere) in the PDC.
Page 456 LAMPS/LIGHTING - EXTERIOR 8L - 5 LAMPS/LIGHTING - EXTERIOR (Continued) circuit(s) between the combination flasher and the DIAGNOSIS AND TESTING - EXTERIOR LAMPS multi-function switch as required. A good ground is necessary for proper lighting (10) Check for continuity between the right and/or operation.
Page 457 8L - 6 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS (HIGH & 1. No voltage at either headlamp. 1. Voltage should always be present. Trace LOW) DO NOT short circuit and replace BOTH headlamp ILLUMINATE fuses.
Page 458 LAMPS/LIGHTING - EXTERIOR 8L - 7 LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS (HIGH 1. High beam circuit from bulb to 1. Ground should be present according to BEAM) ALWAYS Multifunction switch is shorted to Multifunction switch position. Check wiring ILLUMINATE AND CAN ground.
Page 459 8L - 8 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) FOG LAMPS 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 460 LAMPS/LIGHTING - EXTERIOR 8L - 9 LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION PARK LAMPS ARE 1. Park lamp feed is shorted. 1. Check wiring circuit from park lamp fuse INOPERATIVE. FOG LAMP to headlamp switch. Trace short circuit in INDICATOR IS ON WHEN wiring and repair.
Page 461 8L - 10 LAMPS/LIGHTING - EXTERIOR BRAKE LAMP SWITCH (Continued) DIAGNOSIS AND TESTING - BRAKE LAMP SWITCH The brake lamp switch can be tested with an ohm- meter. The ohmmeter is used to check continuity between the pin terminals (Fig. 1). SWITCH CIRCUIT IDENTIFICATION •...
Page 462 LAMPS/LIGHTING - EXTERIOR 8L - 11 flasher has fourteen blade-type terminals that con- CENTER HIGH MOUNTED nect it to the vehicle electrical system through four- STOP LAMP teen matching cavities in the instrument panel wire harness connector; however, only ten of the combina- REMOVAL tion flasher terminals are used in this application.
Page 463 8L - 12 LAMPS/LIGHTING - EXTERIOR COMBINATION FLASHER (Continued) REMOVAL (3) Grasp the combination flasher and connector firmly and pull them toward the dash panel to disen- gage the connector from the mounting tab on the WARNING: ON VEHICLES EQUIPPED WITH AIR- instrument panel armature.
Page 464: Fog Lamp
LAMPS/LIGHTING - EXTERIOR 8L - 13 FOG LAMP FOG LAMP UNIT REMOVAL REMOVAL (1) Disconnect and isolate the battery negative NOTE: The fog lamps are serviced from the rear- cable. ward side of the front bumper. (2) Disengage fog lamp harness connector. (3) Rotate bulb socket a 1/4 turn counterclockwise (1) Disconnect and isolate the battery negative and pull from lamp to separate (Fig.
Page 465 8L - 14 LAMPS/LIGHTING - EXTERIOR FOG LAMP UNIT (Continued) Fig. 7 Fog Lamp Alignment 1 - VEHICLE CENTERLINE 5 - 100 mm (4 in.) 2 - CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS 6 - 7.62 METERS (25 FEET) 3 - HIGH-INTENSITY AREA 7 - FRONT OF FOG LAMP 4 - FLOOR TO CENTER OF FOG LAMP LENS...
Page 466 LAMPS/LIGHTING - EXTERIOR 8L - 15 HEADLAMP SWITCH (Continued) The headlamp switch cannot be repaired and, if HEADLAMP SWITCH CONTINUITY TABLE faulty or damaged, it must be replaced. (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING EXTERIOR/ SWITCH POSITION CONTINUITY BETWEEN HEADLAMP SWITCH - REMOVAL) for the service PIN 2 AND 4, PIN 1 AND procedures.
Page 467: Headlamp Unit
8L - 16 LAMPS/LIGHTING - EXTERIOR HEADLAMP SWITCH (Continued) (2) Install and tighten the screws that secure the (5) Connect the battery negative cable. headlamp switch. Tighten the screws to 2.2 N·m (20 in. lbs.). HEADLAMP UNIT (3) Reconnect the wire harness to the headlamp switch.
Page 468 LAMPS/LIGHTING - EXTERIOR 8L - 17 HEADLAMP UNIT (Continued) ADJUSTMENTS LAMP ALIGNMENT SCREEN PREPARATION (1) Position vehicle on a level surface perpendicu- HEADLAMP ALIGNMENT lar to a flat wall 7.62 meters (25 ft) away from front of headlamp lens (Fig. 12). Headlamps can be aligned using the screen method (2) If necessary, tape a line on the floor 7.62 provided.
Page 469: License Plate Lamp
8L - 18 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) HEADLAMP ALIGNMENT LICENSE PLATE LAMP UNIT A properly aimed low beam headlamp will project a high intensity light pattern on the screen with the REMOVAL horizontal cut-off line aligned with the tape line 130 (1) Disconnect and isolate the battery negative mm.
Page 470 LAMPS/LIGHTING - EXTERIOR 8L - 19 MULTI-FUNCTION SWITCH (Continued) the steering column shrouds. The multi-function ness that is secured by a nut to a ground stud switch control stalk has both nomenclature and located on the left cowl side inner panel, near the left International Control and Display Symbol graphics instrument panel end bracket.
Page 471 8L - 20 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) (CTM). If the Delay mode is selected, the control three additional wipe cycles before the wipers return knob can then be rotated to multiple minor detent to the selected intermittent wipe interval. positions, which actuates a variable resistor within DIAGNOSIS AND TESTING - MULTI-FUNCTION the switch and provides a hard wired output to the...
Page 472 LAMPS/LIGHTING - EXTERIOR 8L - 21 MULTI-FUNCTION SWITCH (Continued) Fig. 15 Multi-Function Switch Tests TURN & HAZARD SWITCH POSITIONS CONTINUITY BETWEEN TURN SIGNAL HAZARD WARNING Left Pins 5 & 11 Right Pins 3 & 11 Neutral Pins 1 & 11 WIPER &...
Page 473 8L - 22 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) (10) Remove the two screws that secure the multi- gap hider into the openings in the right side of the function switch to the multi-function switch mount- upper and lower shrouds. ing housing (Fig.
Page 474: Tail Lamp
LAMPS/LIGHTING - EXTERIOR 8L - 23 PARK/TURN SIGNAL LAMP (Continued) INSTALLATION (3) Remove screw holding tail lamp to cargo box (Fig. 19). (1) Install park and turn signal lamp bulb in (4) Grasp lamp, firmly pull lamp rearward to dis- socket.
Page 475 8L - 24 LAMPS/LIGHTING - EXTERIOR OPERATION TURN SIGNAL CANCEL CAM The turn signal cancel cam has two lobes and is DESCRIPTION secured to the lower hub opening of the clockspring rotor. When the turn signals are activated by moving The turn signal cancel cam is concealed within the the multi-function switch control stalk to a detent steering column below the steering wheel.
Page 476 LAMPS/LIGHTING - INTERIOR 8L - 25 LAMPS/LIGHTING - INTERIOR TABLE OF CONTENTS page page LAMPS/LIGHTING - INTERIOR DIAGNOSIS AND TESTING ....27 SPECIFICATIONS ......25 DOOR AJAR SWITCH.
Page 477: Dome Lamp
8L - 26 LAMPS/LIGHTING - INTERIOR DOME LAMP REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Using a small flat blade, pry the left side (driv- er’s side) of the dome lamp lens downward from dome lamp. (3) Allow the lens to hang down (Fig. 1), this will disengage the right side of the lamp (passenger’s side) from the headliner.
Page 478 LAMPS/LIGHTING - INTERIOR 8L - 27 DOOR AJAR SWITCH (Continued) DIAGNOSIS AND TESTING - DOOR AJAR (4) Check for continuity between the driver or pas- senger door ajar switch sense circuit cavities of the SWITCH body wire harness connector (Connector C2) and the Refer to the appropriate wiring information.
Page 479: Reading Lamp
8L - 28 LAMPS/LIGHTING - INTERIOR GLOVE BOX LAMP SWITCH (Continued) (5) Pull the glove box lamp and switch out from (4) Align the glove box lamp and switch housing the mounting hole far enough to access the wire har- with the mounting hole in the instrument panel ness connector.
Page 480 MESSAGE SYSTEMS 8M - 1 MESSAGE SYSTEMS TABLE OF CONTENTS page page OVERHEAD CONSOLE INSTALLATION......8 DESCRIPTION .
Page 481 8M - 2 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) items that may be required or desired while driving. (4) Release both of the push buttons. “VAR” along The paperclip is located near the front of the over- with the current variance zone will appear in the dis- head console and is secured in the overhead console play.
Page 482 MESSAGE SYSTEMS 8M - 3 OVERHEAD CONSOLE (Continued) service replacement compass mini-trip computer (2) Connect the degaussing tool to an electrical modules must have their compass calibrated using outlet, while keeping the tool at least 61 centimeters this procedure. Do not attempt to calibrate the com- (2 feet) away from the compass unit.
Page 483 8M - 4 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) (9) Contact the roof panel with the plastic coated (4) Pull downward on the sides of the overhead tip of the degaussing tool. Be sure that the template console housing firmly and evenly to disengage the is in place to avoid scratching the roof panel.
Page 484 MESSAGE SYSTEMS 8M - 5 OVERHEAD CONSOLE (Continued) OVERHEAD CONSOLE DISASSEMBLY mount and pushing the connector firmly toward the right side of the overhead console housing. (3) Install and tighten the four screws that secure SUNGLASS STORAGE BIN the paperclip to the overhead console housing. (1) Remove the reading and courtesy lamp housing Tighten the screws to 2.2 N·m (20 in.
Page 485 8M - 6 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) • Average fuel economy (AVG ECO) - shows (6) Install the headliner onto the roof panel. Refer to Headliner in the Removal and Installation sec- the average fuel economy since the last trip computer tion of Body for the procedures.
Page 486 MESSAGE SYSTEMS 8M - 7 COMPASS/MINI-TRIP COMPUTER (Continued) should become magnetized, the demagnetizing and the On position, the trip computer information that calibration procedures found in this group may be can be reset is reset. However, the reset will only required to restore proper compass operation.
Page 487 8M - 8 MESSAGE SYSTEMS COMPASS/MINI-TRIP COMPUTER (Continued) SELF-CHECK DIAGNOSTICS NOTE: The Fuel Used J1850 message shall be ignored if the engine type is Diesel or Compressed A self-diagnostic test is used to determine that the Natural Gas. compass mini-trip computer module is operating properly electrically.
Page 488 MESSAGE SYSTEMS 8M - 9 COMPASS/MINI-TRIP COMPUTER (Continued) yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams, refer to Wiring Diagrams. The ambient temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced.
Page 489: Universal Transmitter
8M - 10 MESSAGE SYSTEMS AMBIENT TEMP SENSOR (Continued) section of this group. If not OK, replace the faulty ambient temperature sensor. SENSOR CIRCUIT TEST (1) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire har- ness connector and the HVAC control head unit con- nector.
Page 490 MESSAGE SYSTEMS 8M - 11 UNIVERSAL TRANSMITTER (Continued) OPERATION STANDARD PROCEDURE - SETTING The UGDO operates on a non-switched source of TRANSMITTER CODES battery current so the unit will remain functional, (1) Turn off the engine. regardless of the ignition switch position. For more (2) Erase the factory test codes by pressing the information on the features, programming procedures two outside buttons.
Page 492 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER SEAT SYSTEM.
Page 493 8N - 2 POWER LOCKS POWER LOCKS (Continued) electronic functions and features not available with Many of the electronic features in the vehicle con- conventional hard wired power lock systems. trolled or supported by the CTM are programmable • Driver Door Module - A power lock switch is using the DRBIII scan tool.
Page 494 POWER LOCKS 8N - 3 POWER LOCKS (Continued) • Illuminated Entry - This feature turns on the • Door Lock Inhibit - The CTM receives inputs courtesy lamps in the vehicle for a timed interval from the key-in ignition switch, the headlamp switch, (about thirty seconds) each time a valid Unlock sig- and the door ajar switches.
Page 495 8N - 4 POWER LOCKS POWER LOCKS (Continued) uses its internal electronic programming to deter- must be replaced. The hard wired inputs or outputs mine whether the received signal is valid and what of the CTM can be diagnosed using conventional function has been requested.
Page 496 POWER LOCKS 8N - 5 POWER LOCKS (Continued) ENTRY TRANSMITTER - DIAGNOSIS AND TEST- OPERATION ING). The door cylinder lock switches are actuated by the • If the entire power lock system functions with key lock cylinder when the key is inserted in the lock the RKE transmitter, and both door cylinder lock cylinder and turned to the lock or unlock positions.
Page 497 8N - 6 POWER LOCKS DOOR CYLINDER LOCK SWITCH (Continued) REMOVAL (3) Reconnect the door cylinder lock switch pigtail wire connector to the door wire harness connector. (1) Disconnect and isolate the battery negative (4) Reinstall the door cylinder lock switch onto the cable.
Page 498 POWER LOCKS 8N - 7 DRIVER DOOR MODULE (Continued) lock and power window switch paddles, and the When the two position window lockout switch in the power mirror switch directional buttons to improve DDM is depressed and latched in the lockout posi- switch visibility in dark ambient lighting conditions.
Page 499 8N - 8 POWER LOCKS DRIVER DOOR MODULE (Continued) Disconnect the door wire harness connectors for the DRIVER DOOR MODULE SWITCH TESTS DDM from the DDM connector receptacles. POWER LOCK SWITCH (2) Test the DDM switch continuity. See the Driver RESISTANCE BETWEEN Door Module Switch Tests chart to determine if the SWITCH POSITION...
Page 500 POWER LOCKS 8N - 9 DRIVER DOOR MODULE (Continued) REMOVAL each door. A single short pigtail wire with a molded plastic connector insulator connects each lock motor (1) Disconnect and isolate the battery negative to the vehicle electrical system through a take out cable.
Page 501 8N - 10 POWER LOCKS POWER LOCK MOTOR (Continued) lock motors and the CTM. If disconnecting one power OPERATION lock motor causes the other motors to become func- The two-way, momentary, power lock switch on the tional, go to Step 3 to test the disconnected motor. passenger side front door is connected in series (3) Once it has been determined which power lock between ground and the passenger door switch mux...
Page 502: Remote Keyless Entry Transmitter
POWER LOCKS 8N - 11 POWER LOCK SWITCH (Continued) (6) Using a small thin-bladed screwdriver, gently pry the snap clips at the sides of the power lock switch receptacle on the back of the power window and lock switch bezel and pull the switch out of the receptacle.
Page 503 8N - 12 POWER LOCKS REMOTE KEYLESS ENTRY TRANSMITTER (Continued) RKE transmitter cannot be repaired and, if faulty or This procedure will erase the access code of the damaged, it must be replaced. test transmitter from the RKE receiver. OPERATION STANDARD PROCEDURE - RKE TRANSMITTER See the owner’s manual in the vehicle glove box for PROGRAMMING...
Page 504 POWER MIRRORS 8N - 13 POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS REMOVAL ......15 DESCRIPTION .
Page 505 8N - 14 POWER MIRRORS POWER MIRRORS (Continued) cuit cavity in the door wire harness half of the power (2) Turn the ignition switch to the On position. mirror switch wire harness connector and a good Check for battery voltage at the fuse in the junction ground.
Page 506 POWER MIRRORS 8N - 15 AUTOMATIC DAY / NIGHT MIRROR (Continued) switch to the On position. Place the transmission gear selector lever in the Neutral position. Place the mirror switch in the On (the LED in the mirror switch is lighted) position. Cover the forward facing ambient photocell sensor to keep out any ambient light.
Page 507 8N - 16 POWER MIRRORS SIDEVIEW MIRROR DIAGNOSIS AND TESTING - SIDEVIEW MIRROR Unplug the wire harness connector at the inopera- tive power mirror (Fig. 3). Use two jumper wires, one connected to a 12 - volt battery feed, and the other connected to a good body ground.
Page 508 POWER SEAT SYSTEM 8N - 17 POWER SEAT SYSTEM TABLE OF CONTENTS page page POWER SEAT SYSTEM REMOVAL ......18 DESCRIPTION .
Page 509 8N - 18 POWER SEAT SYSTEM DRIVER SEAT SWITCH (Continued) DIAGNOSIS AND TESTING - DRIVER SEAT REMOVAL SWITCH (1) Disconnect and isolate the battery negative cable. For circuit descriptions and diagrams, refer to Wir- (2) Remove the screw that secures the recliner ing Diagrams.
Page 510 POWER SEAT SYSTEM 8N - 19 DRIVER SEAT SWITCH (Continued) (4) Install the recliner lever on the recliner mech- seat track a short distance in the opposite direction anism release shaft. and test again to be certain that the track is not at (5) Install the screw that secures the recliner lever its travel limit.
Page 511 8N - 20 POWER SEAT SYSTEM POWER SEAT TRACK (Continued) ment seat tracks to be certain the correct part is (4) Install the power seat wire harness retainers available. on the seat track assembly. (2) If the vehicle is equipped with a split bench (5) Connect the power seat wire harness connec- seat, Install the fasteners that secure the center seat tors.
Page 512 POWER WINDOWS 8N - 21 POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS POWER WINDOW SWITCH ....23 DESCRIPTION ......21 REMOVAL .
Page 513 8N - 22 POWER WINDOWS POWER WINDOWS (Continued) selects the Lock position with the power window switch unit wire harness connector. If OK, (Refer to 8 lockout switch. - ELECTRICAL/POWER WINDOWS/POWER WIN- DOW SWITCH - DIAGNOSIS AND TESTING). If not POWER WINDOW MOTOR OK, repair the circuit to the junction block as A permanent magnet reversible motor moves the...
Page 514: Power Window Switch
POWER WINDOWS 8N - 23 POWER WINDOWS (Continued) WINDOW SWITCH - DIAGNOSIS AND TESTING) . POWER WINDOW SWITCH If OK, go to Step 4. If not OK, replace the faulty power window switch unit. DIAGNOSIS AND TESTING - POWER WINDOW (4) For complete circuit diagrams, refer to the SWITCH appropriate wiring information.
Page 515 8N - 24 POWER WINDOWS POWER WINDOW SWITCH (Continued) MOTOR - DIAGNOSIS AND TESTING). If not OK, replace the faulty switch. Fig. 1 PASSENGER DOOR SWITCH QUAD CAB Fig. 2 PASSENGER DOOR SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the power window and lock switch SWITCH POSITION CONTINUITY BETWEEN and bezel unit switch paddles receive battery current...
Page 516 POWER WINDOWS 8N - 25 (3) If the motor operates in both directions, check WINDOW MOTOR the operation of the window glass and lift mechanism through its complete up and down travel. There DIAGNOSIS AND TESTING - WINDOW MOTOR should be no binding or sticking of the window glass For complete circuit diagrams, refer to the appro- or lift mechanism through the entire travel range.
Page 518 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS INSTALLATION......21 DESCRIPTION ......1 FRONT SEAT BELT BUCKLE OPERATION .
Page 519 8O - 2 RESTRAINTS RESTRAINTS (Continued) the airbag indicator on all models. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MOD- ULES/COMMUNICATION - DESCRIPTION). Hard wired circuitry connects the airbag system components to each other through the electrical sys- tem of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many differ- ent methods.
Page 520 RESTRAINTS 8O - 3 RESTRAINTS (Continued) the driver airbag inflator, which rotates with the the EMIC to turn on the airbag indicator. Proper steering wheel. The passenger airbag on/off switch testing of the airbag system components, the Pro- allows the passenger side airbag to be disabled when grammable Communication Interface (PCI) data bus, circumstances necessitate that a child, or an adult the data bus message inputs to and outputs from the...
Page 521 8O - 4 RESTRAINTS RESTRAINTS (Continued) WARNING: REPLACE AIRBAG SYSTEM COMPO- STANDARD PROCEDURE - HANDLING NENTS ONLY WITH PARTS SPECIFIED IN THE NON-DEPLOYED PASSIVE RESTRAINTS DAIMLERCHRYSLER MOPAR PARTS CATALOG. At no time should any source of electricity be per- SUBSTITUTE PARTS MAY APPEAR INTERCHANGE- mitted near the inflator on the back of a non-de- ABLE, BUT INTERNAL DIFFERENCES MAY RESULT ployed airbag or seat belt tensioner.
Page 522 RESTRAINTS 8O - 5 RESTRAINTS (Continued) CLEANUP PROCEDURE Next, use a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside Following an airbag deployment, the vehicle inte- the vehicle and work your way inside, so that you rior will contain a powdery residue.
Page 523 8O - 6 RESTRAINTS RESTRAINTS (Continued) (1) During the following test, the battery negative then go out. This indicates that the airbag system is cable remains disconnected and isolated, as it was functioning normally and that the repairs are com- during the airbag component removal and installa- plete.
Page 524 RESTRAINTS 8O - 7 AIRBAG CONTROL MODULE (Continued) a monitored system fault, it sets an active Diagnostic impact. A pre-programmed decision algorithm in the Trouble Code (DTC) and sends messages to the ACM microprocessor determines when the decelera- EMIC over the PCI data bus to turn on the airbag tion rate as signaled by the impact sensor indicates indicator.
Page 525 8O - 8 RESTRAINTS AIRBAG CONTROL MODULE (Continued) duct adapter to the bottom of the heater-air condi- (9) Remove the ACM from beneath the instrument tioner housing. panel. (3) Remove the floor duct adapter from the bottom INSTALLATION of the heater-air conditioner housing. (4) Pull the carpet on the right and left sides of WARNING: DISABLE...
Page 526 RESTRAINTS 8O - 9 AIRBAG CONTROL MODULE (Continued) (6) Restore the carpet on the right and left sides of the floor panel transmission tunnel to its proper posi- tion beneath the instrument panel. (7) From the right side of the floor panel transmis- sion tunnel, position the floor duct adapter onto the bottom of the heater-air conditioner housing.
Page 527 8O - 10 RESTRAINTS terminates at the pigtail wire and connector recepta- CLOCKSPRING cles on the hub of the clockspring rotor that face the steering wheel. DESCRIPTION Service replacement clocksprings are shipped pre- centered and with a locking pin that snaps into a receptacle on the rotor and is engaged between two tabs on the upper surface of the rotor case.
Page 528 RESTRAINTS 8O - 11 CLOCKSPRING (Continued) steering column. Centering the clockspring indexes THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY the clockspring tape to the movable steering compo- SURE WAY TO DISABLE THE AIRBAG SYSTEM. nents so that the tape can operate within its FAILURE TO TAKE THE PROPER PRECAUTIONS designed travel limits.
Page 529 8O - 12 RESTRAINTS CLOCKSPRING (Continued) REMOVAL (8) From below the steering column, remove the two outboard screws that secure the upper shroud to The clockspring cannot be repaired. It must be the lower shroud. replaced if faulty or damaged, or if the driver airbag (9) Push gently inward on both sides of the upper has been deployed.
Page 530: Driver Airbag
RESTRAINTS 8O - 13 CLOCKSPRING (Continued) on the steering column. If clockspring centering is (5) From below the steering column, install and not maintained, the clockspring must be centered tighten the one center screw that secures the lower again before it is reinstalled. (Refer to 8 - ELECTRI- shroud to the steering column lock housing.
Page 531 8O - 14 RESTRAINTS DRIVER AIRBAG (Continued) Fig. 10 Driver Airbag Fig. 11 Horn Switch 1 - HOUSING HOOKS (12) 1 - HORN SWITCH GROUND PIGTAIL WIRE 2 - HORN SWITCH GROUND PIGTAIL WIRE 2 - HORN SWITCH 3 - HORN SWITCH FEED PIGTAIL WIRE 3 - POUCH 4 - DRIVER AIRBAG (TRIM COVER REMOVED) 5 - TRAY...
Page 532 RESTRAINTS 8O - 15 DRIVER AIRBAG (Continued) the horn switch and tray unit. Following an airbag (2) From the underside of the steering wheel, deployment, the airbag cushion quickly deflates by remove the two screws that secure the driver airbag venting the nitrogen gas towards the instrument to the steering wheel armature (Fig.
Page 533 8O - 16 RESTRAINTS DRIVER AIRBAG (Continued) Fig. 12 Driver Airbag Remove/Install 1 - CLOCKSPRING DRIVER AIRBAG PIGTAIL WIRE 5 - DRIVER AIRBAG 2 - STEERING WHEEL WIRE HARNESS 6 - SCREW (2) 3 - STEERING WHEEL 7 - CLOCKSPRING 4 - CONNECTOR FOR HORN SWITCH FEED PIGTAIL WIRE WARNING: THE HORN SWITCH IS INTEGRAL TO (4) Carefully pry back the walls of the driver air-...
Page 534 RESTRAINTS 8O - 17 DRIVER AIRBAG (Continued) retainer strap to disengage one of the retaining tabs PROPER PRECAUTIONS OR TO FOLLOW THE on the tray from one of the slits located in each side PROPER PROCEDURES COULD RESULT IN ACCI- of the pouch.
Page 535 8O - 18 RESTRAINTS DRIVER AIRBAG (Continued) (2) Route the horn switch ground pigtail wire through the clearance notch between the two upper left hooks on the driver airbag housing. Install the eyelet terminal over the upper left inflator stud and engage the terminal under the anti-rotation tab directly above the stud on the back of the driver air- bag housing.
Page 536 RESTRAINTS 8O - 19 DRIVER AIRBAG (Continued) (2) When installing the driver airbag, reconnect the clockspring driver airbag pigtail wire connector to the airbag inflator connector receptacle by press- ing straight in on the connector (Fig. 12). You can be certain that the connector is fully engaged by listen- ing carefully for a distinct, audible click as the con- nector snaps into place.
Page 537 8O - 20 RESTRAINTS FRONT SEAT BELT & RETRACTOR (Continued) WARNING: DURING AND FOLLOWING ANY SEAT (5) Unsnap and remove the front shoulder belt BELT SERVICE, CAREFULLY INSPECT ALL SEAT turning loop cover to access the screw that secures the turning loop to the height adjuster. BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS PROPER...
Page 538 RESTRAINTS 8O - 21 FRONT SEAT BELT & RETRACTOR (Continued) REMOVAL - STANDARD/CLUB CAB (5) Remove the shoulder belt turning loop from the height adjuster. (6) Remove the trim from the quarter inner panel. WARNING: DURING AND FOLLOWING ANY SEAT (Refer to 23 - BODY/INTERIOR/QUARTER TRIM BELT SERVICE, CAREFULLY INSPECT ALL SEAT PANEL - REMOVAL).
Page 539 8O - 22 RESTRAINTS FRONT SEAT BELT & RETRACTOR (Continued) (3) Install and tighten the screw that secures the (2) Install and tighten the screw that secures the retractor to the B-pillar. Tighten the screw to 40 N·m retractor to the B-pillar. Tighten the screw to 40 N·m (29 ft.
Page 540: Passenger Airbag
RESTRAINTS 8O - 23 FRONT SEAT BELT BUCKLE (Continued) (4) Remove the screw that secures the front seat SOLE - INSTALLATION - CENTER SEAT/CON- belt buckle unit to the seat adjuster (Fig. 20). SOLE). (4) If the vehicle is so equipped, reinstall the bench seat into the passenger compartment.(Refer to BODY/SEATS/SEAT INSTALLATION...
Page 541 8O - 24 RESTRAINTS PASSENGER AIRBAG (Continued) deployment, the passenger airbag and airbag door COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY- unit must be replaced. The passenger airbag cannot MENT AND POSSIBLE PERSONAL INJURY. be repaired, and must be replaced if faulty or in any WARNING: WHEN REMOVING A DEPLOYED AIR- way damaged.
Page 542 RESTRAINTS 8O - 25 PASSENGER AIRBAG (Continued) OTHER INTERIOR SURFACES. IN LARGE DOSES, THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES. WARNING: USE EXTREME CARE TO PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE PAS- SENGER AIRBAG, OR BECOMING ENTRAPPED BETWEEN THE PASSENGER AIRBAG CUSHION AND THE PASSENGER AIRBAG DOOR.
Page 543 8O - 26 RESTRAINTS PASSENGER AIRBAG (Continued) (10) Do not reconnect the battery negative cable at OPERATION this time. The airbag system verification test proce- The passenger airbag on-off switch allows the cus- dure should be performed following service of any tomer to turn the passenger airbag function On or airbag system component.
Page 544 RESTRAINTS 8O - 27 PASSENGER AIRBAG ON/OFF SWITCH (Continued) REMOVAL SERVICE. DISCONNECT AND ISOLATE THE BAT- TERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPAC- WARNING: DISABLE AIRBAG SYSTEM ITOR TO DISCHARGE BEFORE PERFORMING FUR- BEFORE ATTEMPTING ANY STEERING WHEEL, THER DIAGNOSIS OR SERVICE.
Page 545 8O - 28 RESTRAINTS REAR SEAT BELT & RETRACTOR (Continued) Fig. 25 Rear Seat Belt & Retractor - Quad Cab Fig. 24 Rear Seat Belt & Retractor - Club Cab 1 - TURNING LOOP 1 - TURNING LOOP 2 - SCREW 2 - LAP BELT/BUCKLE ANCHOR 3 - COVER 3 - BUCKLE/BUCKLE ANCHOR...
Page 546 RESTRAINTS 8O - 29 REAR SEAT BELT & RETRACTOR (Continued) panel (club cab) or the C-pillar (quad cab). Tighten ION - REMOVAL) or fold up the rear seat cushion the screw to 40 N·m (29 ft. lbs.). (quad cab). (5) Reinstall the trim onto the quarter inner panel (2) Remove the screw that secures the anchor (club cab) (Refer to 23 - BODY/INTERIOR/QUAR- plate of the rear seat buckle/buckle unit (right side -...
Page 547 8O - 30 RESTRAINTS REAR SEAT LAP BELT/BUCKLE (Continued) beneath the rear seat cushion. Club cab models have left seat cushion frame. Tighten the screw to 40 N·m a combined rear seat lap belt/buckle unit on the left (29 ft. lbs.). side of the vehicle that is secured to the rear floor (3) Fold down the rear seat cushions.
Page 548: Seat Belt Tensioner
RESTRAINTS 8O - 31 SEAT BELT SWITCH (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- SEAT BELT TENSIONER BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING DESCRIPTION COLUMN, SEAT BELT TENSIONER, OR INSTRU- Seat belt tensioners supplement the airbag system MENT PANEL COMPONENT DIAGNOSIS OR SER- for all quad cab versions of this model.
Page 549 8O - 32 RESTRAINTS SEAT BELT TENSIONER (Continued) airbag deployment following a frontal impact of the (4) Remove the screw that secures the upper end vehicle, but also helps to reduce the likelihood of a of the height adjuster to the B-pillar. harmful contact with interior components.
Page 550 RESTRAINTS 8O - 33 TURNING LOOP HEIGHT ADJUSTER KNOB REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, AND RETRACTORS PROPER INSTALLATION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT IS CUT, FRAYED, OR TORN. STRAIGHTEN ANY BELT THAT IS TWISTED.
Page 552 SPEED CONTROL 8P - 1 SPEED CONTROL TABLE OF CONTENTS page page SPEED CONTROL REMOVAL ....... 5 DESCRIPTION .
Page 553 8P - 2 SPEED CONTROL SPEED CONTROL (Continued) A “tap down” feature is used to decelerate without DIAGNOSIS AND TESTING - ROAD TEST disengaging the speed control system. To decelerate Perform a vehicle road test to verify reports of from an existing recorded target speed, momentarily speed control system malfunction.
Page 554 SPEED CONTROL 8P - 3 CABLE DESCRIPTION The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. OPERATION This cable causes the throttle control linkage to open or close the throttle valve in response to move- ment of the vacuum servo diaphragm.
Page 555 8P - 4 SPEED CONTROL CABLE (Continued) (8) Remove servo cable from servo. Refer to Speed Control Servo Removal/Installation. Fig. 4 Accelerator Cable Release Tab—4.7L V-8 Engine 1 - ACCELERATOR CABLE Fig. 3 Cable Connectors at Bell Crank—4.7L V-8 2 - PLASTIC CABLE MOUNT Engine 3 - PRESS TAB FOR REMOVAL 4 - CABLE BRACKET...
Page 556 SPEED CONTROL 8P - 5 SERVO (Continued) The PCM duty cycles the vacuum and vent sole- noids to maintain the set speed, or to accelerate and decelerate the vehicle. To increase throttle opening, the PCM grounds the vacuum and vent solenoids. To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids.
Page 557 8P - 6 SPEED CONTROL SERVO (Continued) OPERATION When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 and 85 mph.
Page 558 SPEED CONTROL 8P - 7 SWITCH (Continued) Multiplexing The PCM sends out 5 volts through a fixed resistor and monitors the voltage change between the fixed resistor and the switches. If none of the switches are depressed, the PCM will measure 5 volts at the sen- sor point (open circuit).
Page 559 8P - 8 SPEED CONTROL VACUUM RESERVOIR (Continued) (3) If vacuum is less than ten inches of mercury, determine source of leak. Check vacuum line to engine for leaks. Also check actual engine intake manifold vacuum. If manifold vacuum does not meet this requirement, check for poor engine performance and repair as necessary.
Page 560 SPEED CONTROL 8P - 9 VACUUM RESERVOIR (Continued) Fig. 11 Cowl Plenum Cover/Grille Panel Remove/Install 1 - PLASTIC RIVET 4 - PLASTIC NUT 2 - IN-LINE WASHER SUPPLY HOSE CONNECTOR 5 - COWL PLENUM COVER/GRILLE PANEL 3 - STUD (4) Connect windshield washer supply hose at in- (7) Install windshield wiper arms.
Page 562 VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY SKIS INITIALIZATION ..... 6 DESCRIPTION .
Page 563 8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) DESCRIPTION - SENTRY KEY IMMOBILIZER receives inputs indicating the status of the door ajar switches, the door cylinder lock switch, and the igni- SYSTEM tion switch. The programming in the CTM allows it The Sentry Key Immobilizer System (SKIS) is to process the information from all of these inputs available as a factory-installed option on this model.
Page 564 VEHICLE THEFT SECURITY 8Q - 3 VEHICLE THEFT SECURITY (Continued) turned on with the driver side front door open. When OPERATION - SENTRY KEY IMMOBILIZER the VTSS is pre-armed, the arming sequence is SYSTEM delayed until all of the doors have been closed. The Sentry Key Immobilizer System (SKIS) is Once the VTSS begins the passive or active arming designed to provide passive protection against unau-...
Page 565 8Q - 4 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) pin-out and location views for the various wire har- MINUTES FOR THE AIRBAG SYSTEM CAPACITOR ness connectors, splices and grounds. TO DISCHARGE BEFORE PERFORMING FURTHER However, conventional diagnostic methods may not DIAGNOSIS OR SERVICE.
Page 566 VEHICLE THEFT SECURITY 8Q - 5 VEHICLE THEFT SECURITY (Continued) SENTRY KEY IMMOBILIZER SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION SECURITY INDICATOR 1. Light-Emitting Diode (LED) 1. Perform the instrument cluster actuator test. FAILS TO LIGHT DURING faulty. (Refer to 8 - ELECTRICAL/INSTRUMENT BULB TEST CLUSTER - DIAGNOSIS AND TESTING - ACTUATOR TEST)..
Page 567 8Q - 6 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) SKIM and a good ground. There should be continuity. (5) Using this active fault information, refer to the If OK, go to Step 6. If not OK, repair the open proper procedure in the appropriate diagnostic infor- ground circuit to ground (G208) as required.
Page 568 VEHICLE THEFT SECURITY 8Q - 7 VEHICLE THEFT SECURITY (Continued) the original SKIM. The PIN code must be used to allotted time, the SKIS will exit the Customer Learn enter the Secured Access Mode in the SKIM. This programming mode and the programming will be PIN number may be obtained from the vehicle owner, unsuccessful.
Page 569 8Q - 8 VEHICLE THEFT SECURITY TRANSPONDER KEY (Continued) molded within a plastic mount into the head of the troMechanical Instrument Cluster (EMIC) will also metal key. In addition to being cut to match the respond to the invalid key message on the PCI data mechanical coding of the ignition lock cylinder, each bus by flashing the security indicator on and off.
Page 570 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS INSTALLATION ......11 DESCRIPTION .
Page 571 8R - 2 WIPERS/WASHERS WIPERS/WASHERS (Continued) front of the windshield washer reservoir on the right which, if the wipers are turned Off, will operate the outboard end of the upper radiator shroud. washer pump/motor and the wipers for as long as the •...
Page 572 WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) When the ignition switch is in the Accessory or On at the moment the Off position is selected, the park positions, battery current from a fuse in the Junction switch is closed to battery current through a fused Block (JB) is provided through a fused ignition ignition switch output (run-acc) circuit.
Page 573 8R - 4 WIPERS/WASHERS WIPERS/WASHERS (Continued) diagnosis of the Central Timer Module (CTM). In problem being diagnosed involves all wiper modes, or order to obtain conclusive testing of the CTM, the only the Low and/or High speed modes, go to Step 7. Programmable Communications Interface (PCI) data (5) Turn the ignition switch to the Off position.
Page 574 WIPERS/WASHERS 8R - 5 WIPERS/WASHERS (Continued) tions indicated in the tests below, and check for bat- wiring information. The wiring information includes tery voltage at the appropriate cavity of the wiring diagrams, proper wire and connector repair headlamp and dash wire harness connector for the procedures, details of wire harness routing and wiper motor.
Page 575 8R - 6 WIPERS/WASHERS WIPERS/WASHERS (Continued) (5) Turn the ignition switch to the Off position. tem. These products can rapidly deteriorate the Disconnect and isolate the battery negative cable. rubber seals and hoses of the washer system, as Disconnect the instrument panel wire harness con- well as the rubber squeegees of the wiper blades.
Page 576 WIPERS/WASHERS 8R - 7 WIPERS/WASHERS (Continued) cleaning the wiper blade and the glass, if the wiper of deteriorated hose can be cut out and replaced by blade still fails to clear the glass without smearing, splicing in new sections of hose using in-line connec- streaking, chattering, hazing, or beading, replace the tor fittings.
Page 577 8R - 8 WIPERS/WASHERS CHECK VALVE (Continued) (2) Open the hood and pull the hood to plenum in the washer reservoir. The float contains a small seal off of the forward flanges of the cowl grille cover magnet. When the float pivots, the changing proxim- and the plenum panel.
Page 578: Washer Nozzle
WIPERS/WASHERS 8R - 9 WASHER FLUID LEVEL SWITCH (Continued) (6) Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. (7) Reconnect the battery negative cable. WASHER HOSES/TUBES DESCRIPTION The washer plumbing consists of a small diameter rubber hose that is routed from the barbed outlet nipple of the washer pump/motor on the washer res- ervoir through the engine compartment along the...
Page 579 8R - 10 WIPERS/WASHERS WASHER NOZZLE (Continued) windshield glass. The washer plumbing fittings for WASHER PUMP/MOTOR the washer nozzles are concealed beneath the cowl plenum cover/grille panel. These fluidic washer noz- DESCRIPTION zles are constructed of molded plastic. The cowl ple- The washer pump/motor unit is located on the out- num cover/grille panel must be removed from the board side of the washer reservoir, near the bottom...
Page 580: Washer Reservoir
WIPERS/WASHERS 8R - 11 WASHER PUMP/MOTOR (Continued) (4) Reconnect the washer hose to the barbed outlet nipple of the washer pump. (5) Reconnect the headlamp and dash wire harness connector for the washer pump/motor to the motor connector receptacle (Fig. 3). (6) Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure.
Page 581 8R - 12 WIPERS/WASHERS WASHER RESERVOIR (Continued) washer fluid level switch, and the filler cap are each available for service replacement. OPERATION The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the washer system. The washer reservoir filler neck provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir.
Page 582 WIPERS/WASHERS 8R - 13 WASHER RESERVOIR (Continued) INSTALLATION while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its vis- NOTE: The washer reservoir is integral to the right ible surfaces.
Page 583: Wiper Blade
8R - 14 WIPERS/WASHERS WIPER ARM (Continued) Fig. 9 Wiper Arm Installation 1 - WIPER ALIGNMENT LINES ± 15 mm (± 0.59 in.) (4) Wet the windshield glass, then operate the wip- Fig. 7 Wiper Arm Remove/Install ers. Turn the wiper switch to the Off position, then 1 - NUT CAP check for the correct wiper arm position and readjust 2 - WIPER ARM AND BLADE...
Page 584 WIPERS/WASHERS 8R - 15 WIPER BLADE (Continued) include an anti-lift feature. The wiper blades cannot be adjusted or repaired. If faulty, worn, or damaged the entire wiper blade unit must be replaced. OPERATION The wiper blade is moved back and forth across the glass by the wiper arms when the wipers are being operated.
Page 585 8R - 16 WIPERS/WASHERS WIPER MODULE (Continued) wiper module consists of the following major compo- rent, depending upon the position of the wipers on nents: the glass. This feature allows the motor to complete • Bracket - The wiper module bracket consists of its current wipe cycle after the wiper system has a long tubular steel main member that has a been turned Off, and to park the wiper blades in the...
Page 586 WIPERS/WASHERS 8R - 17 WIPER MODULE (Continued) • 85 (Coil Ground) - This terminal is connected (6) Disconnect the headlamp and dash wire har- ness connector for the wiper motor from the wiper to the ground feed side of the relay control coil. •...
Page 587 8R - 18 WIPERS/WASHERS WIPER RELAY (Continued) the multi-function switch, and inputs from the wiper motor park switch. • The coil battery terminal (86) is connected to battery current from a fuse in the Junction Block (JB) through a fused ignition switch output (run-acc) circuit whenever the ignition switch is in the On or Accessory positions.
Page 588 WIPERS/WASHERS 8R - 19 WIPER RELAY (Continued) switch output (run-acc) circuit between the PDC and the JB as required. (4) The coil battery terminal (86) is connected to a fused ignition switch output (run-acc) fuse in the JB through a fused ignition switch output (run-acc) cir- cuit.
Page 590 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 CENTRAL TIMER MODULE... . . 8W-45-1 COMPONENT INDEX ....8W-02-1 AUDIO SYSTEM .
Page 592 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION CONNECTOR - MOLEX DESCRIPTION ......1 REMOVAL .
Page 593 8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 594 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 595 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 596 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY WARNING: DO NOT ALLOW FLAME OR SPARKS NEAR BATTERY. GASES ALWAYS This is a list of terms and definitions used in the PRESENT IN AND AROUND THE BATTERY. wiring diagrams.
Page 597 8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL (1) Connect the ground lead of a voltmeter to a known good ground (Fig. 5). (2) Connect the other lead of the voltmeter to the selected test point.
Page 598 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP (1) Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 7). (2) Connect the other lead of the voltmeter to the other side of the switch or component.
Page 599 8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION SPECIAL TOOLS CONNECTOR - AUGAT SPECIAL TOOLS - WIRING/TERMINAL REMOVAL (1) Disconnect battery. (2) Disconnect the connector from its mating half/ component. (3) Push down on the yellow connector locking tab to release the terminals (Fig.
Page 600 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 CONNECTOR - AUGAT (Continued) (2) Insert the removed wire in the same cavity on the repair connector. (3) Repeat steps for each wire in the connector, being sure that all wires are inserted into the proper cavities.
Page 601 8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR - THOMAS AND BETTS (Continued) (4) Insert the probe end of special tool 6934 into the back of the connector cavity (Fig. 13). Fig. 14 SINGLE LOCK TAB 1 - SINGLE LOCK TAB Fig.
Page 602 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 TERMINAL REMOVAL (1) Disconnect battery. (2) Disconnect the connector being repaired from its mating half/component. (3) Remove connector locking wedge, required (Fig. 16). Fig. 18 TERMINAL REMOVAL USING SPECIAL TOOL 1 - FROM SPECIAL TOOL KIT 6680 2 - CONNECTOR (5) Cut the wire 6 inches from the back of the con- nector.
Page 603 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION WIRE (Continued) CAUTION: DO NOT USE ACID CORE SOLDER. Fig. 19 SPLICE CLIP Fig. 21 SOLDER (6) Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Fig.
Page 604 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch Relay ... . 8W-42 Driver Door Power Window Motor ..8W-60 A/C Compressor Clutch .
Page 605 8W - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Oxygen Sensor 1/2 Downstream ..8W-30 Recirculation Door Actuator ... . 8W-42-6 Oxygen Sensor Downstream Heater Relay .
Page 606 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ..... 8W-10-16 Fuse 7 (PDC) .
Page 646 8W-12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK Component Page Component Page A/C Compressor Clutch Relay ... 8W-12-12 Fuse T (PDC) ......8W-12-9 A/C- Heater Control .
Page 668 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-3 Left Fog Lamp ..... . 8W-15-6 A/C Low Pressure Switch .
Page 682 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page A/C- Heater Control ....8W-18-3 Instrument Cluster ....8W-18-3 Airbag Control Module .
Page 686 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Automatic Shut Down Relay ... . 8W-20-4 Generator ......8W-20-2 Battery .
Page 690 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8W-21-2 G113 .
Page 694 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8W-30-26 G113 ......8W-30-4 A/C Low Pressure Switch .
Page 726 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Clutch Interlock Switch Jumper ..8W-31-6 Joint Connector No. 2 ....8W-31-12 Controller Antilock Brake .
Page 738 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Brake Lamp Switch ....8W-33-2 Joint Connector No. 3 ....8W-33-3 Clockspring .
Page 742 8W-34 REAR WHEEL ANTILOCK BRAKES 8W - 34 - 1 8W-34 REAR WHEEL ANTILOCK BRAKES Component Page Component Page Brake Lamp Switch ....8W-34-2 G113 .
Page 746 8W-35 ALL WHEEL ANTILOCK BRAKES 8W - 35 - 1 8W-35 ALL WHEEL ANTILOCK BRAKES Component Page Component Page Brake Lamp Switch ....8W-35-2 Joint Connector No.
Page 750 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Central Timer Module ... . 8W-39-2, 3, 4, Horn Relay ......8W-39-3 5, 6, 7, 8, 9 Instrument Cluster .
Page 760 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page Airbag Control Module ....8W-40-5 Joint Connector No. 1 ....8W-40-9 Central Timer Module .
Page 770 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Center Power Outlet ....8W-41-3 G307 ......8W-41-3 Cigar Lighter .
Page 774 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ....8W-42-5 Fuse 15 (PDC) ..... . 8W-42-9 A/C Compressor Clutch Relay .
Page 784 8W-43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ... . 8W-43-2, 3, 4 Fuse 21 (JB) ......8W-43-2 Clockspring .
Page 788 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page A/C- Heater Control ....8W-44-3 Headlamp Switch ....8W-44-2, 3, 4 Automatic Day/Night Mirror .
Page 802 8W-45 CENTRAL TIMER MODULE 8W - 45 - 1 8W-45 CENTRAL TIMER MODULE Component Page Component Page Base Overhead Console ....8W-45-7 G307 ....8W-45-11, 12, 13, 14, Cargo Lamp No.
Page 822 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Amplifier ..... . . 8W-47-5, 7, 8 Left Front Door Speaker .
Page 830 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page A/C- Heater Control ....8W-48-2 Joint Connector No. 3 ....8W-48-2 Driver Power Mirror .
Page 834 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Base Overhead Console ....8W-49-2 Fuse 11 (JB) ......8W-49-3 Central Timer Module .
Page 838 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Central Timer Module ... . . 8W-50-2, 3, 4 Left Front Park/Turn Signal Lamp No. 1 . . 8W-50-3 Fog Lamp Relay .
Page 842 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Aftermarket CHMSL Connector ..8W-51-5 Joint Connector No. 1 ... . . 8W-51-2, 3, 5 Automatic Day/Night Mirror .
Page 850 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Brake Lamp Switch ....8W-52-2 Left Front Park/Turn Signal Lamp No. 1 . . 8W-52-4 Combination Flasher .
Page 854 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Central Timer Module ....8W-53-2, 3 Fuse 5 (JB) ..... . . 8W-53-2, 3 Data Link Connector .
Page 858 8W-54 TRAILER TOW 8W - 54 - 1 8W-54 TRAILER TOW Component Page Component Page Back-Up Lamp Switch ....8W-54-3 G305 ......8W-54-3 Brake Lamp Switch .
Page 862 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker No. 28 ....8W-60-2, 4 Left Rear Power Window Switch ..8W-60-4, 6 Driver Door Module .
Page 870 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Central Timer Module ..8W-61-2, 3, 4, 5, 6, 7 Junction Block ....8W-61-2, 4, 5 Driver Cylinder Lock Switch .
Page 878 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Driver Door Module ....8W-62-2 Junction Block ..... . 8W-62-2 Driver Power Mirror .
Page 880 8W-63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT Component Page Component Page Fuse 14 (PDC) ..... . 8W-63-2 Power Seat Motors .
Page 882 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ......8W-20-2 S240 .
Page 886 8W-80 CONNECTOR PINOUTS 8W - 80 - 1 8W-80 CONNECTOR PINOUTS Component Page Component Page A/C Compressor Clutch (Except 2.5L) ..8W-80-4 C360 ......8W-80-20 A/C-Heater Control C1 Or Heater C360 .
Page 887 8W - 80 - 2 8W-80 CONNECTOR PINOUTS Component Page Component Page Diagnostic Junction Port ....8W-80-34 Junction Block C4 ....8W-80-46 Dome Lamp .
Page 888 8W-80 CONNECTOR PINOUTS 8W - 80 - 3 Component Page Component Page Oxygen Sensor 2/2 Downstream Right Front Door Woofer (Midlevel/Premium) ....8W-80-66 (3.9L/5.9L) ..... . . 8W-80-57 Oxygen Sensor 2/2 Downstream (4.7L) .
Page 889 8W - 80 - 4 8W-80 CONNECTOR PINOUTS A/C COMPRESSOR CLUTCH (EXCEPT 2.5L) - BLACK 2 WAY CIRCUIT FUNCTION C3 18DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 18BK GROUND A/C-HEATER CONTROL C1 OR HEATER CONTROL C1 - BLACK 16 WAY CIRCUIT FUNCTION F24 20RD/DG...
Page 890 8W-80 CONNECTOR PINOUTS 8W - 80 - 5 A/C LOW PRESSURE SWITCH (2.5L/3.9L/5.9L) - GRAY 2 WAY CIRCUIT FUNCTION Z1 18BK (3.9L/5.9L) GROUND C20 18BR (2.5L) A/C SWITCH SENSE C20 18BR (3.9L/5.9L) A/C SWITCH SENSE Z1 18BK (2.5L) GROUND A/C LOW PRESSURE SWITCH (4.7L) - GRAY 2 WAY CIRCUIT FUNCTION Z1 18BK...
Page 891 8W - 80 - 6 8W-80 CONNECTOR PINOUTS AIRBAG CONTROL MODULE - YELLOW 23 WAY CIRCUIT FUNCTION D25 18VT/YL PCI BUS AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION G31 18VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL G32 18BK/LB SENSOR GROUND AMPLIFIER C1 - WHITE 14 WAY CIRCUIT FUNCTION...
Page 892 8W-80 CONNECTOR PINOUTS 8W - 80 - 7 AUTOMATIC DAY/NIGHT MIRROR - BLACK 7 WAY CIRCUIT FUNCTION F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) Z1 20BK GROUND L1 18VT/BK BACK-UP LAMP FEED BACK-UP LAMP SWITCH - BLACK 2 WAY CIRCUIT FUNCTION L1 18VT/BK (3.9L/5.9L) BACK-UP LAMP FEED...
Page 893 8W - 80 - 8 8W-80 CONNECTOR PINOUTS BLOWER MOTOR - BLACK 2 WAY CIRCUIT FUNCTION C1 12DG BLOWER MOTOR FEED C73 12DB/YL BLOWER MOTOR COMMON DRIVER BLOWER MOTOR RESISTOR BLOCK - BLACK 5 WAY CIRCUIT FUNCTION C7 12BK/TN HIGH SPEED BLOWER MOTOR DRIVER C73 12DB/YL COMMON DRIVER C6 14LB...
Page 894 8W-80 CONNECTOR PINOUTS 8W - 80 - 9 C105 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT K30 18PK (3.9L/5.9L) T16 16RD (EXCEPT 2.5L) Y193 20WT/LG Y128 20DG/GY K6 18VT/WT K125 18WT/DB C18 18DB A142 14DG/OR C20 18BR F84 16YL/WT (4.7L) C106 - NATURAL (ENGINE SIDE) CIRCUIT F142 18OR/DG (3.9L/5.9L)
Page 895 8W - 80 - 10 8W-80 CONNECTOR PINOUTS C106 - NATURAL (HEADLAMP AND DASH SIDE) CIRCUIT F142 16OR/DG Y112 18YL/BR Y124 16DG/VT Y125 16DG/WT Y115 18YL/WT Y117 18YL/DB Y119 18YL/TN Y114 18YL/VT L1 18VT/BK A142 14DG/OR A169 18RD/YL (4.7L) F242 16DG/OR (3.9L/5.9L) A14 16RD/WT L10 18BR/LG G7 18WT/OR...
Page 896 8W-80 CONNECTOR PINOUTS 8W - 80 - 11 C107 (4.7L) (IN PDC) - WHITE (HEADLAMP AND DASH SIDE) CIRCUIT D22 20PK/BK D21 18PK F11 18RD/WT T15 18LG F242 18DG/PK T6 18OR/WT T10 18YL/DG F242 18DG/OR C108 (2.5L) - (ENGINE SIDE) CIRCUIT F142 18OR/DG K200 18VT/OR...
Page 897 8W - 80 - 12 8W-80 CONNECTOR PINOUTS C200 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT V40 20WT/OR G32 18BK/LB G31 18VT/LG A111 10RD/LB Y124 16DG/VT F91 12GY/RD C15 10BK/WT A19 16RD/YL Y125 16DG/WT L39 12LB D21 18PK D20 18LG V23 16BR/PK D22 20PK/BK (4.7L) Y113 18YL/OR...
Page 898 8W-80 CONNECTOR PINOUTS 8W - 80 - 13 C200 - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT V45 18VT Y128 20DG/GY Y117 18YL/DB Z2 18BK/LG D25 18VT/YL Y193 20WT/LG A34 16LB/RD V48 18RD/GY L9 14BK/WT A2 12BR/WT C40 12BR/WT A1 12RD A18 12RD/BK C80 18DB/WT F18 20LG/BK...
Page 899 8W - 80 - 14 8W-80 CONNECTOR PINOUTS C200 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT Y113 18YL/OR K4 20BK/LB (EXCEPT 2.5L) V30 20DB/RD L63 16DG/RD L62 16BR/RD T6 20OR/WT (EXCEPT 2.5L) V49 18RD/BK D25 18VT/YL D25 18VT/YL Y112 18YL/BR Y119 18YL/TN T41 18BK/WT Y115 18YL/WT Y114 18YL/VT...
Page 900 8W-80 CONNECTOR PINOUTS 8W - 80 - 15 C201 (4 DOOR) - YELLOW (BODY SIDE) CIRCUIT Z2 20BK/LG G73 20LG/OR C201 (4 DOOR) - YELLOW (INSTRUMENT PANEL SIDE) CIRCUIT M1 20PK M1 20PK M3 20PK/DB M3 20PK/DB C202 - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT C35 20DG/YL C57 20DB/GY...
Page 901 8W - 80 - 16 8W-80 CONNECTOR PINOUTS C202 - NATURAL (FRONT HVAC JUMPER SIDE) CIRCUIT C4 16TN C21 20DB/OR C32 20GYDB C1 12DG C7 12BK/TN C34 20DB/WT C246 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT X87 18LG/VT X85 18LG/DG X82 18LB/VT X80 18LB/BK X93 18WT/RD X91 18WT/BK...
Page 902 8W-80 CONNECTOR PINOUTS 8W - 80 - 17 C248 - BLACK (BODY SIDE) CIRCUIT Z1 14BK F91 12GY/RD C248 - BLACK (DRIVER SEAT SIDE) CIRCUIT Z1 12BK A4 12BK/PK C301 - BLACK (BASE CONSOLE SIDE) CIRCUIT A12 16RD/TN M1 20PK Z1 16BK Y158 20YL/VT C301 - BLACK (BODY SIDE)
Page 903 8W - 80 - 18 8W-80 CONNECTOR PINOUTS C323 - BLACK (CHASSIS SIDE) CIRCUIT Z1 18BK (STEP BUMPER) Z1 20BK (SPORT BUMPER) L7 18BK/YL C325 - BLACK (TAIL LAMPS SIDE) CIRCUIT L7 20BK/YL Z1 20BK L632 16DG/RD L1 20VT/BK C325 - BLACK (CHASSIS SIDE) CIRCUIT L7 20BK/YL Z1 20BK...
Page 904 8W-80 CONNECTOR PINOUTS 8W - 80 - 19 C341 - BLACK (CHASSIS SIDE) CIRCUIT L62 16BR/RD L1 20VT/BK Y203 16RD/WT L207 18YL/BK B40 14LB Z1 14BK Z1 14BK L63 16DG/RD C341 - BLACK (TRAILER TOW) CIRCUIT L62 18BK/PK L1 20VT/BK Y203 16RD/WT L207 18BK/OR B40 14LB...
Page 905 8W - 80 - 20 8W-80 CONNECTOR PINOUTS C352 - BLACK (CHASSIS SIDE) CIRCUIT L1 20VT/BK L62 16BR/RD L62 16BR/RD L63 16DG/RD L63 16DG/RD Y203 16RD/WT L207 18YL/BK B40 14LB L50 18WT/TN L7 20BK/YL B113 20RD/VT B114 20WT/VT K4 18BK/LB K226 18DB/WT A61 16DG/BK Z1 16BK...
Page 906 8W-80 CONNECTOR PINOUTS 8W - 80 - 21 C361 (2 DOOR) - WHITE (BODY SIDE) CIRCUIT Q16 14BR/WT G73 20LG/OR P96 20WT/LG C361 (2 DOOR) - NATURAL (RIGHT FRONT DOOR SIDE) CIRCUIT Q1 14YL P34 18PK/BK P33 18OR/BK Q26 14VT/WT Q16 14BR/WT G73 20LG/OR (VTSS) P96 20WT/LG...
Page 907 8W - 80 - 22 8W-80 CONNECTOR PINOUTS C361 (4 DOOR) - NATURAL (RIGHT FRONT DOOR SIDE) CIRCUIT L10 20BR/LG P96 20WT/LG C362 (2 DOOR) - GREEN (BODY SIDE) CIRCUIT P76 22OR/YL P74 22DB P72 22YL/BK X82 18LB/VT X80 18LB/BK G74 20TN/RD Z2 20BK/LG Z1 20BK...
Page 908 8W-80 CONNECTOR PINOUTS 8W - 80 - 23 C362 (4 DOOR) - GREEN (BODY SIDE) CIRCUIT Z2 20BK/LG C362 (4 DOOR) - NATURAL (RIGHT FRONT DOOR SIDE) CIRCUIT P76 22OR/YL P74 22DB P72 22YL/BK X82 18LB/VT X80 18LB/BK G74 20TN/RD (POWER WINDOWS/ LOCKS) Q1 14YL (POWER WINDOWS/LOCKS) F121 20TN/BK (HEATED MIRRORS)
Page 909 8W - 80 - 24 8W-80 CONNECTOR PINOUTS C363 (2 DOOR) - BLACK (LEFT FRONT DOOR SIDE (PREMIUM)) CIRCUIT C363 (4 DOOR) - GREEN (BODY SIDE (PREMI- UM)) CIRCUIT P76 22OR/YL P74 22DB P72 22YL/BK X87 18LG/VT X85 18LG/DG G75 20TN Z1 12BK (POWER WINDOWS/LOCKS) F121 20TN/BK (HEATED MIRRORS) M1 20PK...
Page 910 8W-80 CONNECTOR PINOUTS 8W - 80 - 25 C364 (2 DOOR) - NATURAL (LEFT FRONT DOOR SIDE) CIRCUIT Q1 14YL P34 18PK/BK P33 16OR/BK Q26 14VT/WT Q16 14BR/WT G73 20LG/OR P97 20WT/DG C364 (4 DOOR) - BLACK (BODY SIDE) CIRCUIT P97 18WT/DG P59 18DB P33 16OR/BK...
Page 911 8W - 80 - 26 8W-80 CONNECTOR PINOUTS C365 - WHITE (BODY SIDE) CIRCUIT Z2 20BK/LG G74 20TN/RD P33 16OR/BK P34 16PK/BK Q1 14YL (POWER WINDOWS/LOCKS) Q17 14DB/WT (POWER WINDOWS/ LOCKS) Q27 14RD/BK (POWER WINDOWS/ LOCKS) X93 18WT/RD X91 18WT/BK C365 - WHITE (REAR DOOR SIDE) (LEFT) CIRCUIT Z2 20BK/LG...
Page 912 8W-80 CONNECTOR PINOUTS 8W - 80 - 27 C366 - WHITE (REAR DOOR) (RIGHT) CIRCUIT Z2 20BK/LG G74 18TN/RD P33 16OR/BK (POWER WINDOWS/ LOCKS) P34 16PK/BK (POWER WINDOWS/ LOCKS) Q1 14YL Q18 14GY/BK Q28 14DG/WT X94 18TN/VT X92 18TN/BK CAMSHAFT POSITION SENSOR - GRAY 3 WAY CIRCUIT FUNCTION K44 18TN/YL (3.9L/5.9L)
Page 913 8W - 80 - 28 8W-80 CONNECTOR PINOUTS CENTER CONSOLE LAMP - 2 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) Y158 20YL/VT INTERIOR LAMP DRIVER CENTER HIGH MOUNTED STOP LAMP - BLACK 2 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT Z1 20BK GROUND CENTER POWER OUTLET - RED 3 WAY...
Page 914 8W-80 CONNECTOR PINOUTS 8W - 80 - 29 CENTRAL TIMER MODULE C2 - GRAY 16 WAY CIRCUIT FUNCTION M2 20YL COURTESY LAMP DRIVER P96 20WT/LG PASSENGER DOOR SWITCH MUX M3 20PK/DB CARGO LAMP DRIVER P33 18OR/BK DOOR LOCK RELAY OUTPUT P34 18PK/BK DOOR UNLOCK RELAY OUTPUT P59 18DB...
Page 915 8W - 80 - 30 8W-80 CONNECTOR PINOUTS CLOCKSPRING C1 - WHITE 6 WAY CIRCUIT FUNCTION X20 20GY/WT RADIO CONTROL MUX Z2 20BK/LG GROUND X3 20BK/RD HORN RELAY CONTROL K4 20BK/LB SENSOR GROUND V37 20RD/LG SPEED CONTROL SWITCH SIGNAL CLOCKSPRING C2 - YELLOW 4 WAY CIRCUIT FUNCTION R43 18BK/LB...
Page 916 8W-80 CONNECTOR PINOUTS 8W - 80 - 31 CLUTCH INTERLOCK SWITCH JUMPER (A/T) - BLACK 2 WAY CIRCUIT FUNCTION T141 18YL PARK/NEUTRAL POSITION SWITCH SENSE (T41) T141 18YL PARK/NEUTRAL POSITION SWITCH SENSE (T41) COIL ON PLUG NO. 1 (4.7L) - BLACK 3 WAY CIRCUIT FUNCTION K19 16BK/GY...
Page 917 8W - 80 - 32 8W-80 CONNECTOR PINOUTS COIL ON PLUG NO. 5 (4.7L) - BLACK 3 WAY CIRCUIT FUNCTION K95 16TN/DG COIL DRIVER NO. 5 A142 16DG/OR AUTMATIC SHUT DOWN RELAY OUTPUT COIL ON PLUG NO. 6 (4.7L) - BLACK 3 WAY CIRCUIT FUNCTION K96 16TN/LB...
Page 918 8W-80 CONNECTOR PINOUTS 8W - 80 - 33 COMBINATION FLASHER - BLACK 14 WAY CIRCUIT FUNCTION L302 18LB/YL RIGHT TURN SWITCH SENSE CONTROLLER ANTILOCK BRAKE C1 - BLACK 14 WAY CIRCUIT FUNCTION B113 20RD/VT REAR WHEEL SPEED SENSOR (+) D25 18VT/YL PCI BUS A20 20RD/DB FUSED IGNITION SWITCH OUTPUT (RUN)
Page 919 8W - 80 - 34 8W-80 CONNECTOR PINOUTS DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D21 20PK SCI TRANSMIT D22 20PK/BK SCI RECEIVE M1 20PK FUSED B(+) DIAGNOSTIC JUNCTION PORT - BLACK 16 WAY CIRCUIT FUNCTION D25 20VT/YL PCI BUS (MIC) D25 18VT/YL PCI BUS (TCCM)
Page 920 8W-80 CONNECTOR PINOUTS 8W - 80 - 35 DRIVER CYLINDER LOCK SWITCH - BLACK 2 WAY CIRCUIT FUNCTION Z2 20BK/LG GROUND G73 20LG/OR CYLINDER LOCK SWITCH MUX DRIVER DOOR AJAR SWITCH (BASE) - BLACK 2 WAY CIRCUIT FUNCTION G75 20TN DRIVER DOOR AJAR SWITCH SENSE Z2 20BK/LG GROUND...
Page 921 8W - 80 - 36 8W-80 CONNECTOR PINOUTS DRIVER DOOR MODULE C2 - BLUE 8 WAY CIRCUIT FUNCTION P71 22YL DRIVER MIRROR UP MOVEMENT P76 22OR/YL MIRROR COMMON DRIVER M1 20PK FUSED B(+) P74 22DB RIGHT MIRROR LEFT MOVEMENT Z1 20BK GROUND P75 22DB/WT DRIVER MIRROR LEFT MOVEMENT...
Page 922 8W-80 CONNECTOR PINOUTS 8W - 80 - 37 ENGINE COOLANT TEMPERATURE SENSOR (2.5L) - BLACK 2 WAY CIRCUIT FUNCTION K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K4 18BK/LB SENSOR GROUND ENGINE COOLANT TEMPERATURE SENSOR (3.9L/5.9L) - BLACK 2 WAY CIRCUIT FUNCTION K4 18BK/LB SENSOR GROUND...
Page 923 8W - 80 - 38 8W-80 CONNECTOR PINOUTS FRONT WASHER PUMP/MOTOR - BLACK 2 WAY CIRCUIT FUNCTION V10 18BR FRONT WASHER PUMP/MOTOR CONTROL Z1 18BK GROUND FRONT WIPER MOTOR - BLACK 6 WAY CIRCUIT FUNCTION V6 18DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC) V5 18DG/YL FRONT WIPER PARK SWITCH SENSE Z1 18BK...
Page 924 8W-80 CONNECTOR PINOUTS 8W - 80 - 39 FUEL INJECTOR NO. 2 (3.9L/4.7L/5.9L) - BLACK 2 WAY CIRCUIT FUNCTION K12 18TN FUEL INJECTOR NO. 2 DRIVER A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 3 (2.5L) - BLACK 2 WAY CIRCUIT FUNCTION K13 18YL/WT...
Page 925 8W - 80 - 40 8W-80 CONNECTOR PINOUTS FUEL INJECTOR NO. 5 (3.9L/4.7L/5.9L) - BLACK 2 WAY CIRCUIT FUNCTION K38 18GY FUEL INJECTOR NO. 5 DRIVER A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 6 (3.9L/4.7L/5.9L) - BLACK 2 WAY CIRCUIT FUNCTION K38 18GY...
Page 926 8W-80 CONNECTOR PINOUTS 8W - 80 - 41 GENERATOR - BLACK 2 WAY CIRCUIT FUNCTION K125 18WT/DB GENERATOR SOURCE K20 18DG GENERATOR FIELD GLOVE BOX LAMP AND SWITCH - BLACK 2 WAY CIRCUIT FUNCTION Y158 20YL/VT GLOVE BOX DRIVER M1 20PK FUSED B(+) HEADLAMP SWITCH - BLACK 14 WAY CIRCUIT...
Page 927 8W - 80 - 42 8W-80 CONNECTOR PINOUTS IDLE AIR CONTROL MOTOR (3.9L/5.9L) - BLACK 4 WAY CIRCUIT FUNCTION K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER K39 18GY/RD IDLE AIR CONTROL NO.
Page 928 8W-80 CONNECTOR PINOUTS 8W - 80 - 43 INSTRUMENT CLUSTER C1 - BLACK 10 WAY CIRCUIT FUNCTION F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) D25 20VT/YL PCI BUS INSTRUMENT CLUSTER C2 - GRAY 10 WAY CIRCUIT FUNCTION E2 20OR PANEL LAMPS FEED G29 18BK/TN WASHER FLUID SWITCH SENSE G13 20DB/RD...
Page 929 8W - 80 - 44 8W-80 CONNECTOR PINOUTS JOINT CONNECTOR NO. 1 (IN PDC) - GRAY 28 WAY CIRCUIT FUNCTION L50 14WT/TN BRAKE LAMP SWITCH OUTPUT A14 16RD/WT FUSED B(+) A14 16RD/WT FUSED B(+) A14 16RD/WT FUSED B(+) A14 16RD/WT FUSED B(+) JOINT CONNECTOR NO.
Page 930 8W-80 CONNECTOR PINOUTS 8W - 80 - 45 JOINT CONNECTOR NO. 3 (IN PDC) - BLACK 28 WAY CIRCUIT FUNCTION L7 20BK/YL PARK LAMP RELAY OUTPUT L7 20BK/YL PARK LAMP RELAY OUTPUT F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) JOINT CONNECTOR NO.
Page 931 8W - 80 - 46 8W-80 CONNECTOR PINOUTS JUNCTION BLOCK C2 - BLUE 15 WAY CIRCUIT FUNCTION L10 18BR/LG FUSED IGNITION SWITCH OUTPUT (RUN) F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) JUNCTION BLOCK C3 - LT. GRAY 13 WAY CIRCUIT FUNCTION F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START)
Page 932 8W-80 CONNECTOR PINOUTS 8W - 80 - 47 JUNCTION BLOCK C6 - GREEN 6 WAY CIRCUIT FUNCTION A31 12BK/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC) E1 18TN PANEL LAMPS DIMMER SWITCH SIGNAL E2 20OR PANEL LAMPS FEED A81 18DG/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) JUNCTION BLOCK C7 - BLACK 8 WAY CIRCUIT FUNCTION...
Page 933 8W - 80 - 48 8W-80 CONNECTOR PINOUTS JUNCTION BLOCK C10 - LT. GRAY 12 WAY CIRCUIT FUNCTION F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START) M1 20PK FUSED B(+) M1 20PK FUSED B(+) F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) JUNCTION BLOCK C11 - WHITE 16 WAY...
Page 934 8W-80 CONNECTOR PINOUTS 8W - 80 - 49 LEFT BACK-UP LAMP - GRAY 3 WAY CIRCUIT FUNCTION Z1 20BK GROUND L1 20VT/BK BACK-UP LAMP FEED LEFT FOG LAMP - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L39 18LB FOG LAMP RELAY OUTPUT LEFT FRONT DOOR SPEAKER (BASE) - BLACK 3 WAY CIRCUIT FUNCTION...
Page 935 8W - 80 - 50 8W-80 CONNECTOR PINOUTS LEFT FRONT PARK/TURN SIGNAL LAMP NO. 1 - BLACK 3 WAY CIRCUIT FUNCTION L61 16LG LEFT TURN SIGNAL L7 20BK/YL PARK LAMP RELAY OUTPUT Z1 20BK GROUND LEFT FRONT PARK/TURN SIGNAL LAMP NO. 2 - BLACK 3 WAY CIRCUIT FUNCTION L61 16LG...
Page 936 8W-80 CONNECTOR PINOUTS 8W - 80 - 51 LEFT REAR DOOR AJAR SWITCH (BASE) - BLACK 2 WAY CIRCUIT FUNCTION G74 18TN/RD PASSENGER DOOR AJAR SWITCH SENSE Z2 20BK/LG GROUND LEFT REAR DOOR POWER LOCK MOTOR/AJAR SWITCH (PREMIUM) - BLACK 4 WAY CIRCUIT FUNCTION G74 18TN/RD...
Page 937 8W - 80 - 52 8W-80 CONNECTOR PINOUTS LEFT REMOTE RADIO SWITCH (PREMIUM) - 2 WAY CIRCUIT FUNCTION X20 22RD/BK RADIO CONTROL MUX Z2 22BK/LG GROUND LEFT SPEED CONTROL SWITCH - WHITE 2 WAY CIRCUIT FUNCTION V37 22RD/LG SPEED CONTROL SWITCH SIGNAL V37 22RD/LG SPEED CONTROL SWITCH SIGNAL K4 22BK/LB...
Page 938 8W-80 CONNECTOR PINOUTS 8W - 80 - 53 LOW NOTE HORN - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND X2 18DG/RD HORN RELAY OUTPUT MANIFOLD ABSOLUTE PRESSURE SENSOR (4.7L) - BLACK 3 WAY CIRCUIT FUNCTION K7 18OR 5V SUPPLY K4 18BK/LB SENSOR GROUND K1 18DG/RD...
Page 939 8W - 80 - 54 8W-80 CONNECTOR PINOUTS MULTI-FUNCTION SWITCH - GRAY 20 WAY CIRCUIT FUNCTION L307 18LG/OR HEADLAMP SWITCH SENSE Z1 18BK GROUND V49 18RD/BK INTERMITTENT FRONT WIPER LOW SPEED V45 18VT FRONT WIPER LOW SPEED V48 16RD/GY FRONT WIPER HIGH SPEED V45 18VT FRONT WIPER LOW SPEED V6 18DB...
Page 940 8W-80 CONNECTOR PINOUTS 8W - 80 - 55 OVERHEAD CONSOLE - 12 WAY CIRCUIT FUNCTION D25 20VT/YL PCI BUS F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) M2 20YL COURTESY LAMP DRIVER E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL Z2 20BK/LG GROUND OXYGEN SENSOR 1/1 UPSTREAM (3.9L/5.9L) - BLACK 4 WAY CIRCUIT...
Page 941 8W - 80 - 56 8W-80 CONNECTOR PINOUTS OXYGEN SENSOR 1/2 DOWNSTREAM (3.9L/5.9L) - BLACK 4 WAY CIRCUIT FUNCTION Z11 18BK/WT GROUND F242 16DG/PK OXYGEN SENSOR DOWNSTREAM HEATER RELAY OUTPUT K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL K4 18BK/LB SENSOR GROUND OXYGEN SENSOR 1/2 DOWNSTREAM (4.7L) - BLACK 4 WAY CIRCUIT FUNCTION...
Page 942 8W-80 CONNECTOR PINOUTS 8W - 80 - 57 OXYGEN SENSOR 2/2 DOWNSTREAM (3.9L/5.9L) - BLACK 4 WAY CIRCUIT FUNCTION Z11 18BK/WT GROUND F242 16DG/PK OXYGEN SENSOR DOWNSTREAM HEATER RELAY OUTPUT K341 18TN/WT OXYGEN SENSOR 2/2 SIGNAL K4 18BK/LB SENSOR GROUND OXYGEN SENSOR 2/2 DOWNSTREAM (4.7L) - BLACK 4 WAY CIRCUIT FUNCTION...
Page 943 8W - 80 - 58 8W-80 CONNECTOR PINOUTS PASSENGER DOOR AJAR SWITCH (BASE) - BLACK 2 WAY CIRCUIT FUNCTION G74 20TN/RD PASSENGER DOOR AJAR SWITCH SENSE Z2 20BK/LG GROUND PASSENGER DOOR POWER LOCK MOTOR/AJAR SWITCH (PREMIUM) - BLACK 4 WAY CIRCUIT FUNCTION G74 20TN/RD...
Page 944 8W-80 CONNECTOR PINOUTS 8W - 80 - 59 PASSENGER DOOR POWER WINDOW SWITCH (4 DOOR) - BLUE 6 WAY CIRCUIT FUNCTION Q16 14BR/WT MASTER WINDOW SWITCH RIGHT FRONT (UP) Q22 14VT PASSENGER WINDOW DRIVER (DOWN) Q1 14YL WINDOW SWITCH FEED Q12 14BR PASSENGER WINDOW DRIVER (UP) Q26 14VT/WT...
Page 945 8W - 80 - 60 8W-80 CONNECTOR PINOUTS POWER SEAT SWITCH - BLACK 14 WAY CIRCUIT FUNCTION A4 12BK/PK FUSED B(+) Z1 12BK GROUND P21 14RD/LG SEAT FRONT DOWN SWITCH SENSE P19 14YL/LG SEAT FRONT UP SWITCH SENSE P15 14YL/LB SEAT HORIZONTAL FORWARD SWITCH SENSE P17 14RD/LB SEAT HORIZONTAL REARWARD SWITCH SENSE...
Page 946 8W-80 CONNECTOR PINOUTS 8W - 80 - 61 POWERTRAIN CONTROL MODULE C1 (2.5L) - BLACK 32 WAY CIRCUIT FUNCTION A14 16RD/WT FUSED B(+) K22 18OR/DB THROTTLE POSITION SENSOR SIGNAL K41 18BK/DG OXYGEN SENSOR 1/1 SIGNAL K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL K1 18DG/RD MAP SENSOR SIGNAL Z12 14BK/TN...
Page 947 8W - 80 - 62 8W-80 CONNECTOR PINOUTS POWERTRAIN CONTROL MODULE C2 (2.5L) - WHITE 32 WAY CIRCUIT FUNCTION K11 18WT/DB FUEL INJECTOR NO .1 DRIVER K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER K20 18DG GENERATOR FIELD K12 18TN FUEL INJECTOR NO. 2 DRIVER K14 18LB/BR FUEL INJECTOR NO.
Page 948 8W-80 CONNECTOR PINOUTS 8W - 80 - 63 POWERTRAIN CONTROL MODULE C2 (3.9L/4.7L/5.9L) - WHITE 32 WAY CIRCUIT FUNCTION C18 18DB A/C PRESSURE SIGNAL T60 18BR (A/T 3.9L/5.9L) 3-4 SHIFT SOLENOID CONTROL G60 16GY/YL (3.9L/5.9L) ENGINE OIL PRESSURE SENSOR SIGNAL G60 18GY/YL (4.7L) ENGINE OIL PRESSURE SENSOR SIGNAL T13 18DB/BK (A/T 3.9L/5.9L)
Page 949 8W - 80 - 64 8W-80 CONNECTOR PINOUTS RADIATOR FAN MOTOR - BLACK 2 WAY CIRCUIT FUNCTION C25 10LG HIGH SPEED FAN RELAY OUTPUT Z1 10BK GROUND RADIO C1 - GRAY 7 WAY CIRCUIT FUNCTION X85 18LG/DG (BASE RADIO) AMPLIFIED LEFT DOOR SPEAKER (-) X55 20BR/RD (PREMIUM RADIO) LEFT FRONT SPEAKER (-) X80 18LB/BK (BASE RADIO)
Page 950 8W-80 CONNECTOR PINOUTS 8W - 80 - 65 REAR WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B114 20WT/VT REAR WHEEL SPEED SENSOR (-) B113 20RD/VT REAR WHEEL SPEED SENSOR (+) RECIRCULATION DOOR ACTUATOR - GRAY 2 WAY CIRCUIT FUNCTION C32 20GY/DB RECIRCULATION DOOR DRIVER...
Page 951 8W - 80 - 66 8W-80 CONNECTOR PINOUTS RIGHT FRONT DOOR WOOFER (MIDLEVEL/PREMIUM) - BLACK 3 WAY CIRCUIT FUNCTION X82 18LB/VT AMPLIFIED RIGHT DOOR SPEAKER (+) X80 18LB/BK AMPLIFIED RIGHT DOOR SPEAKER (-) RIGHT FRONT PARK/TURN SIGNAL LAMP NO. 1 - BLACK 3 WAY CIRCUIT FUNCTION L60 16TN...
Page 952 8W-80 CONNECTOR PINOUTS 8W - 80 - 67 RIGHT LICENSE LAMP - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL HEADLAMP SWITCH OUTPUT RIGHT REAR DOOR AJAR SWITCH (BASE) - BLACK 2 WAY CIRCUIT FUNCTION G74 18TN/RD PASSENGER DOOR AJAR SWITCH SENSE Z2 20BK/LG GROUND RIGHT REAR DOOR POWER LOCK MOTOR/AJAR SWITCH (PREMIUM) - BLACK 4 WAY...
Page 953 8W - 80 - 68 8W-80 CONNECTOR PINOUTS RIGHT REAR POWER WINDOW SWITCH - BLUE 6 WAY CIRCUIT FUNCTION Q18 14GY/BK MASTER WINDOW SWITCH RIGHT REAR (UP) Q24 14DG RIGHT REAR WINDOW DRIVER (DOWN) Q1 14YL WINDOW SWITCH FEED RIGHT REAR SPEAKER - BLACK 3 WAY CIRCUIT FUNCTION X94 18TN/VT...
Page 954 8W-80 CONNECTOR PINOUTS 8W - 80 - 69 SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY CIRCUIT FUNCTION D25 20VT/YL PCI BUS F18 20LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START) Z11 20BK/WT GROUND M1 20PK FUSED B(+) SHIFT BEZEL LAMP - BLACK 2 WAY CIRCUIT FUNCTION Z1 20BK...
Page 955 8W - 80 - 70 8W-80 CONNECTOR PINOUTS TRANSFER CASE CONTROL MODULE C1 - BLACK 16 WAY CIRCUIT FUNCTION D25 18VT/YL PCI BUS Y122 20DG/BR 4WD LOW INDICATOR Y123 20DG/OR 4WD HIGH INDICATOR Y120 20YL/DG MODE SELECT Y119 18YL/TN MODE SENSOR GROUND Z1 18BK GROUND Y121 20YL/LG...
Page 956 8W-80 CONNECTOR PINOUTS 8W - 80 - 71 TRANSFER CASE MODE SENSOR - BLACK 6 WAY CIRCUIT FUNCTION Y119 18YL/TN MODE SENSOR GROUND Y113 18YL/OR MODE SENSOR A Y115 18YL/WT MODE SENSOR C Y114 18YL/VT MODE SENSOR B Y117 18YL/DB 5 VOLT MODE SENSOR SUPPLY Y112 18YL/BR MODE SENSOR D...
Page 957 8W - 80 - 72 8W-80 CONNECTOR PINOUTS TRANSMISSION CONTROL MODULE (4.7L) - BLACK 60 WAY CIRCUIT FUNCTION T1 18LG/BK TRS T1 SENSE T4 18PK/OR TRS T2 SENSE T3 18VT TRS T3 SENSE K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL D21 18PK SCI TRANSMIT A169 18RD/YL FUSED IGNITION SWITCH OUTPUT (START)
Page 958 8W-80 CONNECTOR PINOUTS 8W - 80 - 73 TRANSMISSION CONTROL MODULE (4.7L) - BLACK 60 WAY CIRCUIT FUNCTION T59 18PK UNDERDRIVE SOLENOID CONTROL F84 16YL/WT FUSED B(+) Z13 16BK/RD GROUND T159 18DG/WT 4C SOLENOID CONTROL T60 18BR 3-4 SHIFT SOLENOID CONTROL TRANSMISSION RANGE SENSOR (3.9L/5.9L A/T) - BLACK 6 WAY CIRCUIT FUNCTION...
Page 959 8W - 80 - 74 8W-80 CONNECTOR PINOUTS TRANSMISSION SOLENOID ASSEMBLY (3.9L/5.9L) - BLACK 8 WAY CIRCUIT FUNCTION T16 16RD TRANSMISSION CONTROL RELAY OUTPUT K6 18VT/WT 5V SUPPLY K4 18BK/LB SENSOR GROUND T25 18LG/RD GOVERNOR PRESSURE SIGNAL K88 18VT/WT GOVERNOR PRESSURE SOLENOID CONTROL T60 18BR OVERDRIVE SOLENOID CONTROL K54 18OR/BK...
Page 960 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS TABLE OF CONTENTS page CONNECTOR/GROUND LOCATIONS DESCRIPTION ......1 nector index is provided.
Page 961: Central Timer Module
8W - 90 - 2 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. C246 Lower Left of Instrument Panel 31, 38 C248 Under Driver Seat C301 Between Front Seats C323 Rear of Frame C325 At Tail Lamp 41, 42 C329 Near Cargo Lamps...
Page 962: Data Link Connector
8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Coil On Plug No.8 Right Side of Engine Combination Flasher Lower Left Side of Instrument Panel 31, 32 Controller Antilock Brake-C1 At Antilock Brake Controller Controller Antilock Brake-C2 At Antilock Brake Controller Crankshaft Position Sensor...
Page 963: G205
8W - 90 - 4 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Fuel Injector No. 8 At Injector 15, 17 Fuel Pump Module LTGY At Fuel Tank G100 Right Front of Engine Compartment G102 Left Inner Fender G105 Top Rear of Valve Cover, Right Front 9, 18...
Page 964: Left Front Door Speaker
8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Junction Block-C6 At Junction Block Junction Block-C7 At Junction Block Junction Block-C8 At Junction Block Junction Block-C9 At Junction Block Junction Block-C10 LTGY At Junction Block Junction Block-C11 At Junction Block Junction Block-C12...
Page 965 8W - 90 - 6 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Output Speed Sensor Under Transmission, Left Side of 25, 26, 27, 28 Transmission Overdrive Switch At Steering Column 31, 34 Overhead Console Headliner Oxygen Sensor 1/1 At Oxygen Sensor 20, 21, 22, 23, 25, 26, 27, Upstream...
Page 966 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7 CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Radio-C3 Upper Center of Instrument Panel Radio Case Ground Upper Center of Instrument Panel Rear Wheel Speed Sensor At Rear Axle Rear Window Defogger Upper Center of Instrument Panel Switch Recirculation Door Actuator...
Page 967 8W - 90 - 8 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Connector Name/Number Color Location Fig. Throttle Position Sensor On Throttle Body (4.7L) Trailer Tow Connector Rear of Frame Transfer Case Control Right Side of Steering Column Module-C1 Transfer Case Control Right Side of Steering Column Module-C2 Transfer Case Control...
Page 968 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 9 CONNECTOR/GROUND LOCATIONS (Continued)
Page 969 8W - 90 - 10 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 970 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 3 RIGHT FENDER AREA Fig. 4 LEFT FENDER AREA...
Page 971 8W - 90 - 12 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 5 KICK PANEL AREAS Fig. 6 ENGINE COMPARTMENT TO DASH...
Page 972 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 13 CONNECTOR/GROUND LOCATIONS (Continued)
Page 973 8W - 90 - 14 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 974 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 9 ENGINE LEFT SIDE 2.5L Fig. 10 ENGINE RIGHT SIDE 2.5L...
Page 975 8W - 90 - 16 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 11 ENGINE LEFT SIDE 3.9L Fig. 12 ENGINE RIGHT SIDE 3.9L...
Page 976 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 17 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 13 ENGINE REAR 3.9L Fig. 14 ENGINE LEFT SIDE 5.9L...
Page 977 8W - 90 - 18 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 15 ENGINE RIGHT SIDE 5.9L...
Page 978 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 19 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 16 ENGINE LEFT SIDE 4.7L...
Page 979 8W - 90 - 20 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 17 ENGINE RIGHT SIDE 4.7L...
Page 980 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 21 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 18 ENGINE CONNECTORS FRONT 4.7L...
Page 981 8W - 90 - 22 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 19 RIGHT REAR ENGINE COMPARTMENT CONNECTORS...
Page 982 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 23 CONNECTOR/GROUND LOCATIONS (Continued)
Page 983 8W - 90 - 24 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 21 MANUAL TRANSMISSION CONNECTORS 3.9L...
Page 984 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 25 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 22 MANUAL TRANSMISSION 4.7L (4X2)
Page 985 8W - 90 - 26 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 986 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 27 CONNECTOR/GROUND LOCATIONS (Continued)
Page 987 8W - 90 - 28 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 988 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 29 CONNECTOR/GROUND LOCATIONS (Continued)
Page 989 8W - 90 - 30 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 27 AUTOMATIC TRANSMISSION 4.7L (4X2)
Page 990 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 31 CONNECTOR/GROUND LOCATIONS (Continued)
Page 991 8W - 90 - 32 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 992 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 33 CONNECTOR/GROUND LOCATIONS (Continued)
Page 993 8W - 90 - 34 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 994 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 35 CONNECTOR/GROUND LOCATIONS (Continued)
Page 995 8W - 90 - 36 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 33 AIRBAG CONTROL MODULE...
Page 996 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 37 CONNECTOR/GROUND LOCATIONS (Continued)
Page 997 8W - 90 - 38 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 35 JUNCTION BLOCK CONNECTORS...
Page 998 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 39 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 36 FRONT DOOR CONNECTORS...
Page 999 8W - 90 - 40 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 37 REAR DOOR CONNECTORS Fig. 38 LEFT FRONT BODY WIRING...
Page 1000 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 41 CONNECTOR/GROUND LOCATIONS (Continued) Fig. 39 CAB WIRING...
Page 1001 8W - 90 - 42 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued)
Page 1002 8W-90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 43 CONNECTOR/GROUND LOCATIONS (Continued)
Page 1003 8W - 90 - 44 8W-90 CONNECTOR/GROUND LOCATIONS CONNECTOR/GROUND LOCATIONS (Continued) Fig. 42 TAIL LAMPS...
Page 1004 8W-95 SPLICE LOCATIONS 8W - 95 - 1 8W-95 SPLICE LOCATIONS TABLE OF CONTENTS page SPLICE LOCATIONS DESCRIPTION ......1 index is provided.
Page 1005 8W - 95 - 2 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Splice No. Location Fig. S184 In Wiring Trough S187 Near Power Distribution Center S207 In Steering Wheel Jumper S208 In Steering Wheel Jumper S240 Between Instrument Cluster T/O’s S300 Near T/O for Tweeter S301 Front of Left Door...
Page 1006 8W-95 SPLICE LOCATIONS 8W - 95 - 3 SPLICE LOCATIONS (Continued) Fig. 1 LEFT SIDE ENGINE HARNESS SPLICES 2.5L Fig. 2 RIGHT SIDE ENGINE HARNESS SPLICES 2.5L...
Page 1007 8W - 95 - 4 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Fig. 3 LEFT SIDE ENGINE HARNESS SPLICES 3.9L Fig. 4 RIGHT SIDE ENGINE HARNESS SPLICES 3.9L...
Page 1008 8W-95 SPLICE LOCATIONS 8W - 95 - 5 SPLICE LOCATIONS (Continued) Fig. 5 LEFT SIDE ENGINE HARNESS SPLICES 5.9L Fig. 6 LEFT SIDE ENGINE HARNESS SPLICES 4.7L...
Page 1009 8W - 95 - 6 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Fig. 7 RIGHT SIDE ENGINE HARNESS SPLICES 4.7L...
Page 1010 8W-95 SPLICE LOCATIONS 8W - 95 - 7 SPLICE LOCATIONS (Continued)
Page 1011 8W - 95 - 8 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued) Fig. 9 A-PILLAR SPLICES Fig. 10 CAB SPLICES...
Page 1012 8W-95 SPLICE LOCATIONS 8W - 95 - 9 SPLICE LOCATIONS (Continued)
Page 1013 8W - 95 - 10 8W-95 SPLICE LOCATIONS SPLICE LOCATIONS (Continued)
Page 1014 8W-95 SPLICE LOCATIONS 8W - 95 - 11 SPLICE LOCATIONS (Continued) Fig. 13 FRONT DOOR SPLICES...
Page 1016 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION JUNCTION BLOCK DESCRIPTION ......1 DESCRIPTION .
Page 1017 8W - 97 - 2 8W-97 POWER DISTRIBUTION Two small spring-clip retainers are located on CIGAR LIGHTER OUTLET either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold DESCRIPTION the heating element against the insulated contact long enough for the resistor coil to heat up.
Page 1018 8W-97 POWER DISTRIBUTION 8W - 97 - 3 CIGAR LIGHTER OUTLET (Continued) (5) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the instrument panel lower bezel. Check for continuity between the ground circuit cavity of the cigar lighter wire harness connector and a good ground.
Page 1019: Circuit Breaker
8W - 97 - 4 8W-97 POWER DISTRIBUTION CIGAR LIGHTER OUTLET (Continued) INSTALLATION (1) Locate the correct circuit breaker in the junc- tion block. Pull out the circuit breaker slightly, but be certain that the circuit breaker terminals still con- WARNING: ON VEHICLES EQUIPPED WITH AIR- tact the terminals in the junction block cavities.
Page 1020 8W-97 POWER DISTRIBUTION 8W - 97 - 5 GENERATOR CARTRIDGE FUSE (Continued) tem output and/or excessive electrical system current levels resulting from a faulty generator or faulty charging system control circuits. If the current rating of the fuse is exceeded, the fuse conductor melts to open the generator output circuit connection to the PDC.
Page 1021 8W - 97 - 6 8W-97 POWER DISTRIBUTION IOD FUSE (Continued) depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is disconnected from JB fuse cavity 12 when the vehicle is shipped from the assembly plant.
Page 1022 8W-97 POWER DISTRIBUTION 8W - 97 - 7 JUNCTION BLOCK (Continued) REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER-...
Page 1023: Power Distribution Center
8W - 97 - 8 8W-97 POWER DISTRIBUTION JUNCTION BLOCK (Continued) to the proper cavities of the replacement JB. Refer to Junction Block in the index of this service man- ual for the location of complete circuit diagrams and cavity assignments for the JB. (1) Reach through the outboard side of the instru- ment panel steering column opening to position the JB onto the left instrument panel end bracket.
Page 1024 8W-97 POWER DISTRIBUTION 8W - 97 - 9 POWER DISTRIBUTION CENTER (Continued) REMOVAL The Power Distribution Center (PDC) is serviced as a unit with the headlamp and dash wire harness. If any internal circuit of the PDC or the PDC hous- ing is faulty or damaged, the entire PDC and head- lamp and dash wire harness unit must be replaced.
Page 1025: Power Outlet
8W - 97 - 10 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION CENTER (Continued) NOTE: If the PDC is being replaced with a new unit, POWER OUTLET be certain to transfer each of the blade-type fuses, cartridge fuses and relays from the faulty PDC to DESCRIPTION the proper cavities of the replacement PDC.
Page 1026 8W-97 POWER DISTRIBUTION 8W - 97 - 11 POWER OUTLET (Continued) cle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. (4) Check for battery voltage at the insulated con- tact located at the back of the power outlet recepta- cle.
Page 1027: Relay Center
8W - 97 - 12 8W-97 POWER DISTRIBUTION POWER OUTLET (Continued) INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 1028 8W-97 POWER DISTRIBUTION 8W - 97 - 13 RELAY CENTER (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE.
Page 1029 8W - 97 - 14 8W-97 POWER DISTRIBUTION RELAY CENTER (Continued) more information on the instrument panel wire har- lar retaining bosses of the mount that secures the ness retainer locations. receptacle base to the instrument panel lower bezel (4) Install all of the fasteners that secure each of (Fig.
Page 1030 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE 2.5L......1 ENGINE 4.7L.
Page 1031 9 - 2 ENGINE 2.5L INSTALLATION......34 OPERATION......50 CRANKSHAFT MAIN BEARINGS DIAGNOSIS AND TESTING .
Page 1032 ENGINE 2.5L 9 - 3 ENGINE 2.5L DESCRIPTION The 2.5 liter (150 CID) four-cylinder engine is an In-line, lightweight, overhead valve engine. This engine is designed for unleaded fuel. The engine cylinder head has dual quench-type combus- tion chambers that create turbulence and fast burn- ing of the air/fuel mixture.
Page 1033 9 - 4 ENGINE 2.5L ENGINE 2.5L (Continued) DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - PERFORMANCE PERFORMANCE DIAGNOSIS CHART—GASOLINE ENGINES CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT 1. Weak or dead battery 1. Charge/Replace Battery. (Refer to 8 - CRANK ELECTRICAL/BATTERY SYSTEM/ BATTERY - STANDARD PROCEDURE).
Page 1034 ENGINE 2.5L 9 - 5 ENGINE 2.5L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 10. Plugged or restricted exhaust 10. Install new parts as necessary system 11. Faulty ignition cables 11. Replace any cracked or shorted cables 12. Faulty ignition coil 12. Test and replace, as necessary (Refer to 8 - ELECTRICAL/IGNITION CONTROL/IGNITION COIL - REMOVAL).
Page 1035 9 - 6 ENGINE 2.5L ENGINE 2.5L (Continued) DIAGNOSIS AND TESTING— ENGINE DIAGNOSIS - MECHANICAL ENGINE MECHANICAL DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust oil level by draining or adding as needed 2.
Page 1036 ENGINE 2.5L 9 - 7 ENGINE 2.5L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Excessive main bearing clearance 4. Measure bearings for correct clearance. Repair as necessary 5. Excessive end play 5. Check crankshaft thrust bearing for excessive wear on flanges 6.
Page 1037 9 - 8 ENGINE 2.5L ENGINE 2.5L (Continued) DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts.
Page 1038 ENGINE 2.5L 9 - 9 ENGINE 2.5L (Continued) (Refer to 9 - ENGINE - SPECIFICATIONS) for the Remove the spark plugs. correct engine compression pressures. Remove the oil filler cap. Remove the air cleaner. DIAGNOSIS AND TESTING—CYLINDER Calibrate the tester according to the manufactur- er’s instructions.
Page 1039 9 - 10 ENGINE 2.5L ENGINE 2.5L (Continued) retains adhesion sealing properties when locating dowel is recommended during assembly to exposed to engine oil. Moisture in the air causes the prevent smearing material off the location. material to cure. This material is available in three Mopar Gasket Sealant in an aerosol can should be ounce tubes and has a shelf life of one year.
Page 1040 ENGINE 2.5L 9 - 11 ENGINE 2.5L (Continued) (10) Install new spark plugs. Tighten the spark plugs to 41 N·m (30 ft. lbs.) torque. (11) Drain engine oil. Remove and discard the oil filter. (12) Install the drain plug. Tighten the plug to 34 N·m (25 ft.
Page 1041 9 - 12 ENGINE 2.5L ENGINE 2.5L (Continued) Thoroughly clean inside of cup plug hole in cylin- der block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with Mopar Stud and Bearing Mount. Make certain the new plug is cleaned of all oil or grease.
Page 1042 ENGINE 2.5L 9 - 13 ENGINE 2.5L (Continued) (7) Remove the radiator upper hose and coolant ERY/QUICK CONNECT FITTING - STANDARD recovery hose (Fig. 7). PROCEDURE). (8) Remove the fan shroud (Fig. 7). (18) Disconnect suction/discharge hose from A/C compressor and cap off ports to prevent intrusion of foreign material or refrigerant oil loss.
Page 1043 9 - 14 ENGINE 2.5L ENGINE 2.5L (Continued) (7) Lower the engine and engine support cushions SPECIFICATIONS onto the engine compartment brackets. (8) Remove the engine lifting device. 2.5L ENGINE (9) Raise the vehicle. ENGINE DESCRIPTION (10) Install the converter-housing access cover. (11) Install the exhaust pipe support.
Page 1044 ENGINE 2.5L 9 - 15 ENGINE 2.5L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION (2.019 - 2.020 in.) Exhaust 46.5° No. 3 51.03 - 51.05 mm Valve Head Diameter (2.009 - 2.010 in.) Intake 48.387 - 48.641 mm No. 4 50.78 - 50.80 mm (1.905 - 1.915 in.) (1.999 - 2.000 in.) Exhaust...
Page 1045 9 - 16 ENGINE 2.5L ENGINE 2.5L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION (Preferred) 0.051 mm (6.123 to 6.127 in.) (0.002 in.) Piston Pin Bore Diameter 23.59 to 23.62 mm Connecting Rod Journal (0.9288 to 0.9298 in.) Diameter 53.17 to 53.23 mm Bore (Less Bearings) 56.08 to 56.09 mm (2.0934 to 2.0955 in.)
Page 1046 ENGINE 2.5L 9 - 17 ENGINE 2.5L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION ROCKER ARMS, PUSH RODS & TAPPETS PISTON RINGS Rocker Arm Ratio 1.6:1 Ring Gap Clearance Top Compression Ring 0.229 to 0.610 mm Push Rod Length (Blue) 241.300 to 241.808 mm (0.0090 to 0.0240 in.) (9.500 to 9.520 in.) 2nd Compression Ring...
Page 1047 9 - 18 ENGINE 2.5L ENGINE 2.5L (Continued) TORQUE DESCRIPTION N·m In. Lbs 2.5L ENGINE Lbs. Bolts #2-5 — DESCRIPTION N·m In. Lbs Nuts 6 and 7 — Lbs. Flywheel/Converter — A/C Compressor Bracket — Housing Bolts to Engine—Bolts Flywheel to Crankshaft —...
Page 1048 ENGINE 2.5L 9 - 19 ENGINE 2.5L (Continued) SPECIAL TOOLS 2.5L ENGINE Pressure Tester Kit 7700 Valve Spring Compressor Tool MD-998772A Bloc–Chek–Kit C-3685–A AIR CLEANER ELEMENT REMOVAL Housing removal is not necessary for element (fil- Hydraulic Valve Tappet Removal Tool C–4129–A ter) replacement.
Page 1049 9 - 20 ENGINE 2.5L AIR CLEANER ELEMENT (Continued) • Engine misfiring INSTALLATION • Poor fuel economy (1) Install element into housing. Possible indications of the cylinder head gasket (2) Position housing cover into housing locating leaking between a cylinder and an adjacent water tabs.
Page 1050 ENGINE 2.5L 9 - 21 CYLINDER HEAD (Continued) STANDARD PROCEDURE—VALVE GUIDE STANDARD PROCEDURE—VALVE GUIDE WEAR - MEASURING SERVICE Measure valve stems for wear. If wear exceeds Service valves with oversize stems are available. 0.051 mm (0.002 in.), replace the valve. Refer to REAMER SIZES CHART .
Page 1051 9 - 22 ENGINE 2.5L CYLINDER HEAD (Continued) (15) Remove the engine cylinder head bolts. (16) Remove the engine cylinder head and gasket (Fig. 13). (17) If this was the first time the bolts were removed, put a paint dab on the top of the bolt. If the bolts have a paint dab on the top of the bolt or it isn’t known if they were used before, discard the bolts.
Page 1052 ENGINE 2.5L 9 - 23 CYLINDER HEAD (Continued) INSTALLATION (3) Remove the shop towels from the cylinder bores. Coat the bores with clean engine oil. This procedure can be done with the engine in or (4) Place the engine cylinder head gasket (with the out of the vehicle.
Page 1053 9 - 24 ENGINE 2.5L CYLINDER HEAD (Continued) CYLINDER HEAD COVER(S) REMOVAL A cured gasket is part of the engine cylinder head cover. (1) Disconnect negative cable from battery. (2) Disconnect the Crankcase Ventilation (CCV) vacuum hose from engine cylinder head cover (Fig. 17).
Page 1054: Rocker Arms
ENGINE 2.5L 9 - 25 CYLINDER HEAD COVER(S) (Continued) Check the gasket for use in head cover installation. If damaged, use a new gasket. INSTALLATION A cured gasket is part of the engine cylinder head cover. (1) Inspect the engine cylinder head cover for cracks.
Page 1055 9 - 26 ENGINE 2.5L ROCKER ARMS (Continued) the pivot contacts. Install rocker arms, pivots and STANDARD PROCEDURE—REFACING VALVES bridge above each cylinder in their original position. AND SEATS (3) Loosely install the capscrews through each bridge. VALVE REFACING (4) At each bridge, tighten the capscrews alter- The intake and exhaust valves have a 43-1/4°...
Page 1056 ENGINE 2.5L 9 - 27 INTAKE/EXHAUST VALVES & SEATS (Continued) (2) Measure the concentricity of valve seat using a dial indicator. Total runout should not exceed 0.051 mm (0.002 in.) total indicator reading. (3) Inspect the valve seat with Prussian blue, to determine where the valve contacts the seat.
Page 1057 9 - 28 ENGINE 2.5L (3) Remove push rods. Retain the push rods, VALVE SPRINGS bridges, pivots and rocker arms in the same order and position as removed. STANDARD PROCEDURE—VALVE SPRING - (4) Inspect the springs and retainer for cracks and TESTING possible signs of weakening.
Page 1058 ENGINE 2.5L 9 - 29 VALVE SPRINGS (Continued) INSTALLATION—VALVE SPRINGS This procedure can be done with the engine cylin- der head installed on the block. Inspect the valve stems, especially the grooves. An Arkansas smooth stone should be used to remove nicks and high spots.
Page 1059 9 - 30 ENGINE 2.5L ENGINE BLOCK (Continued) (13) Remove the vibration damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL). (14) Remove the timing case cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL). (15) Remove the timing chain and sprockets (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/ CHAIN AND SPROCKETS - REMOVAL).
Page 1060 ENGINE 2.5L 9 - 31 CAMSHAFT & BEARINGS (IN BLOCK) (Continued) INSTALLATION—CAMSHAFT BEARINGS (1) Inspect the camshaft bearing journals for uneven wear pattern or finish. (2) Inspect the camshaft lobes and distributor gear for wear. (3) Inspect the camshaft thrust plate for wear. If the plate shows excessive wear inspect the camshaft oil pressure relief holes in the rear cam journal.
Page 1061 9 - 32 ENGINE 2.5L CAMSHAFT & BEARINGS (IN BLOCK) (Continued) (20) Install the radiator or radiator and condenser, if equipped with A/C. (21) Fill the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE). (22) Connect negative cable to battery. CONNECTING ROD BEARINGS STANDARD PROCEDURE CONNECTING ROD BEARING - FITTING...
Page 1062 ENGINE 2.5L 9 - 33 CONNECTING ROD BEARINGS (Continued) Fig. 33 Rod and Piston Assembly Installation ance across the entire width of the insert. If the clearance varies, it may be caused by either a Fig. 34 Measuring Bearing Clearance tapered journal, bent connecting rod or foreign 1 - PLASTIGAGE SCALE material trapped between the insert and cap or...
Page 1063 9 - 34 ENGINE 2.5L CONNECTING ROD BEARINGS (Continued) (11) FOR EXAMPLE: If the initial clearance was 0.0762 mm (0.003 inch), 0.025 mm (0.001 inch) undersize inserts would reduce the clearance by 0.025 mm (0.001 inch). The clearance would be 0.002 inch and within specification.
Page 1064 ENGINE 2.5L 9 - 35 CRANKSHAFT (Continued) Fig. 38 Apply Sealant to Bearing Cap to Block 1 - MOPAR GEN II SILICONE RUBBER ADHESIVE SEALANT Fig. 37 Sealant Application to Bearing Cap NOZZLE TIP 1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS 2 - SEALANT APPLIED 2 - MOPAR GASKET MAKER (OR EQUIVALENT) 3 - CYLINDER BLOCK...
Page 1065 9 - 36 ENGINE 2.5L CRANKSHAFT MAIN BEARINGS (Continued) STANDARD PROCEDURE—CRANKSHAFT MAIN (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance. BEARINGS - FITTING Once the proper clearances have been obtained, (Refer to 9 - ENGINE/ENGINE BLOCK/CRANK- CRANKSHAFT INSTALLED SHAFT MAIN BEARINGS - INSTALLATION).
Page 1066 ENGINE 2.5L 9 - 37 CRANKSHAFT MAIN BEARINGS (Continued) Crankshaft Journals #1 - #4 Crankshaft Journals #1 - #4 0.0381 0.0254 (0.0015 (0.001 in.) in.) Undersize Undersize 63.2485 - Red - Red - Green 63.4492 - Blue - Green - 63.2358 Undersize Undersize...
Page 1067 9 - 38 ENGINE 2.5L CRANKSHAFT MAIN BEARINGS (Continued) (Fig. 40). Refer to Engine Specifications for the FOR EXAMPLE: DO NOT use a standard size proper clearance. upper insert and a 0.051 mm (0.002 inch) undersize lower insert. If the clearance exceeds specification using a pair of 0.051 mm (0.002 inch) undersize bearing inserts, measure crankshaft...
Page 1068 ENGINE 2.5L 9 - 39 CRANKSHAFT MAIN BEARINGS (Continued) (6) Remove the lower insert from the bearing cap. (7) Remove the upper insert by LOOSENING (DO NOT REMOVE) all of the other bearing caps. Now insert a small cotter pin tool in the crankshaft jour- nal oil hole.
Page 1069 9 - 40 ENGINE 2.5L CRANKSHAFT MAIN BEARINGS (Continued) Fig. 45 Crankshaft End Play Measurement 1 - DIAL INDICATOR 2 - CRANKSHAFT (17) Lower the vehicle. Fig. 44 Location of Mopar Gasket Maker (18) Install the spark plugs. Tighten the plugs to 1 - MOPAR GASKET MAKER (OR EQUIVALENT) 37 N·m (27 ft.
Page 1070 ENGINE 2.5L 9 - 41 CRANKSHAFT OIL SEAL - FRONT (Continued) (3) If front seal is suspected of leaking, check front CRANKSHAFT OIL SEAL - oil seal alignment to crankshaft. The seal installa- REAR tion/alignment Tool 6635, should fit with minimum interference.
Page 1071 9 - 42 ENGINE 2.5L tappet. Inspect the rocker arm push rod sockets HYDRAULIC LIFTERS (CAM IN and push rod ends for wear. BLOCK) (3) Valve tappet noise ranges from light noise to a DIAGNOSIS AND TESTING—HYDRAULIC heavy click. A light noise is usually caused by exces- sive leak-down around the unit plunger, or by the TAPPETS plunger partially sticking in the tappet body cylinder.
Page 1072 ENGINE 2.5L 9 - 43 HYDRAULIC LIFTERS (CAM IN BLOCK) (Continued) 20-110 seconds to leak-down. Discard tappets with leak-down time interval not within this specification. Fig. 48 Leak-Down Tester Fig. 49 Hydraulic Valve Tappet Removal/Installation 1 - POINTER Tool 2 - WEIGHTED ARM 3 - RAM 1 - HYDRAULIC VALVE TAPPET REMOVAL/INSTALLATION TOOL 4 - CUP...
Page 1073 9 - 44 ENGINE 2.5L PISTON & CONNECTING ROD (Continued) STANDARD PROCEDURE—PISTON FITTING (1) To correctly select the proper size piston, a cyl- inder bore gauge, capable of reading in 0.003 mm ( .0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer.
Page 1074 ENGINE 2.5L 9 - 45 PISTON & CONNECTING ROD (Continued) (5) Position the pistons one at a time near the bot- tom of the stroke. Use a ridge reamer to remove the ridge from the top end of the cylinder walls. Use a protective cloth to collect the cuttings.
Page 1075 9 - 46 ENGINE 2.5L PISTON & CONNECTING ROD (Continued) (4) Use a piston ring compressor to install the con- CAUTION: Verify that the oil squirt holes in the rods necting rod and piston assemblies through the top of face the camshaft and that the arrows on the pis- the cylinder bores (Fig.
Page 1076 ENGINE 2.5L 9 - 47 PISTON RINGS (Continued) Fig. 57 Gap Measurement 1 - FEELER GAUGE (5) The oil control rings are symmetrical, and can be installed with either side up. It is not necessary to Fig. 56 Ring Side Clearance Measurement use a tool to install the upper and lower rails.
Page 1077 9 - 48 ENGINE 2.5L PISTON RINGS (Continued) Fig. 59 Second Compression Ring Identification 1 - SECOND COMPRESSION RING 2 - CHAMFER 3 - ONE DOT Fig. 61 Compression Ring 1 - COMPRESSION RING 2 - RING EXPANDER RECOMMENDED Fig. 60 Compression Ring Chamfer Location 1 - TOP COMPRESSION RING 2 - SECOND COMPRESSION RING 3 - PISTON...
Page 1078 ENGINE 2.5L 9 - 49 (1) Disconnect negative cable from battery. VIBRATION DAMPER (2) Raise the vehicle. (3) Support the engine. REMOVAL (4) Remove through bolt and nut. (1) Disconnect negative cable from battery. (5) Raise engine to allow clearance when removing (2) Remove the serpentine drive belt (Refer to 7 - insulator.
Page 1079 9 - 50 ENGINE 2.5L FRONT MOUNT (Continued) Fig. 66 Rear Engine Support Fig. 65 Left Front Engine Mount Assembly 1 - TRANSMISSION 1 - STUD 2 - CROSSMEMBER 2 - BOLT 3 - INSULATOR 3 - INSULATOR 4 - SUPPORT BRACKET 4 - THROUGH BOLT 5 - FRAME 6 - NUT...
Page 1080 ENGINE 2.5L 9 - 51 LUBRICATION (Continued) crankshaft is drilled internally to pass oil from the the crankshaft could have minor nicks or scratches main bearing journals (except number 4 main bear- that can be polished out with emery cloth. ing journal) to the connecting rod journals.
Page 1081 9 - 52 ENGINE 2.5L LUBRICATION (Continued) Fig. 67 Oil Lubrication System—2.5L Engine...
Page 1082 ENGINE 2.5L 9 - 53 LUBRICATION (Continued) 1 - CAM/CRANK MAIN GALLERY (5) 5 - NUMBER 1 CAMSHAFT BEARING JOURNAL 2 - TAPPET GALLERY 6 - CAMSHAFT SPROCKET 3 - TAPPET GALLERY 7 - TAPPET GALLERY 4 - CAMSHAFT BEARING (9) Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the sus- pected source.
Page 1083 9 - 54 ENGINE 2.5L OIL (Continued) (8) Lower vehicle and fill crankcase with specified type (Refer to LUBRICATION & MAINTENANCE/ FLUID TYPES - DESCRIPTION) and amount of engine oil (Refer to LUBRICATION & MAINTE- NANCE - SPECIFICATIONS). (9) Install oil fill cap. (10) Start engine and inspect for leaks.
Page 1084 ENGINE 2.5L 9 - 55 OIL PAN (Continued) INSPECTION (4) Apply Mopar Silicone Adhesive Sealant onto the cylinder block in four location as shown (Fig. 73) Inspect oil drain plug and plug hole for stripped or damaged threads. Repair as necessary. Inspect oil pan mounting flange for bends or distor- tion.
Page 1085 9 - 56 ENGINE 2.5L OIL PAN (Continued) (12) Install the flywheel and torque converter bypass through a passage in the pump body to the housing access cover. inlet side of the pump. (13) Install the engine starter motor. Oil pump removal or replacement will not affect (14) Connect the exhaust pipe to the hanger and to the distributor timing because the distributor drive the engine exhaust manifold.
Page 1086 ENGINE 2.5L 9 - 57 OIL PUMP (Continued) The pump incorporates a nonadjustable pressure relief valve to limit maximum pressure to 517 kPa (75 psi). In the relief position, the valve permits oil to bypass through a passage in the pump body to the inlet side of the pump.
Page 1087 9 - 58 ENGINE 2.5L INTAKE MANIFOLD (Continued) • The manifold air temperature sensor at the INSPECTION intake manifold. Inspect manifold to cylinder head mating surfaces • The fuel injectors. for cracks and/or pitting. Inspect manifold for warp • The oxygen sensor. or twist.
Page 1088 ENGINE 2.5L 9 - 59 INTAKE MANIFOLD (Continued) CAUTION: Ensure that the accessory drive belt is routed correctly. Failure to do so can cause the water pump to turn in the opposite direction result- ing in engine overheating. Refer to Group 7, Cool- ing System for the proper procedure.
Page 1089 9 - 60 ENGINE 2.5L (4) Remove the fan and hub assembly and remove VALVE TIMING the fan shroud. (5) Remove the A/C compressor (if equipped) (Refer STANDARD PROCEDURE - CHECKING TIMING to 24 - HEATING & AIR CONDITIONING/PLUMB- CHAIN WEAR ING/A/C COMPRESSOR - REMOVAL) and generator bracket assembly from the engine cylinder head and NOTE: Timing chain tensioner must be removed for...
Page 1090 ENGINE 2.5L 9 - 61 TIMING BELT / CHAIN COVER(S) (Continued) (3) Remove the serpentine drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL). (4) Remove the crankshaft vibration damper (Refer ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL). (5) Remove the timing case cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
Page 1091 9 - 62 ENGINE 2.5L TIMING BELT/CHAIN AND SPROCKETS (Continued) INSTALLATION sprocket timing mark as shown in (Fig. 85). Count the number of chain pins between the timing marks The chain drive system is equipped with a timing of both sprockets. There must be 20 pins. chain tensioner which reduces noise and prolongs timing chain life.
Page 1092 ENGINE 3.9L 9 - 63 ENGINE 3.9L TABLE OF CONTENTS page page ENGINE 3.9L INSPECTION ......89 DESCRIPTION .
Page 1093 9 - 64 ENGINE 3.9L PISTON RINGS DISASSEMBLY ......113 STANDARD PROCEDURE ....102 CLEANING .
Page 1094 ENGINE 3.9L 9 - 65 ENGINE 3.9L (Continued) (Refer to 9 - ENGINE - DIAGNOSIS AND TEST- ING - Preformance) or (Refer to 9 - ENGINE - DIAG- NOSIS AND TESTING - Mechanical). Refer to 14 - FUEL SYSTEM for fuel system diagnosis. Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can- not be isolated with the Service Diagnosis charts.
Page 1095 9 - 66 ENGINE 3.9L ENGINE 3.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION ENGINE CRANKS BUT WILL NOT 1. No spark 1. Check for spark. (Refer to 8 - START ELECTRICAL/IGNITION CONTROL - DESCRIPTION) 2. No fuel 2. Perform fuel pressure test, and if necessary, inspect fuel injector(s) and driver circuits.
Page 1096 ENGINE 3.9L 9 - 67 ENGINE 3.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Worn or incorrectly gapped spark 3. Replace or clean and re-gap plugs spark plugs (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ SPARK PLUG - CLEANING) 4. Worn or burned distributor rotor 4.
Page 1097 9 - 68 ENGINE 3.9L ENGINE 3.9L (Continued) DIAGNOSIS AND TESTING— ENGINE DIAGNOSIS - MECHANICAL ENGINE MECHANICAL DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust oil level by draining or adding as needed 2.
Page 1098 ENGINE 3.9L 9 - 69 ENGINE 3.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Excessive main bearing clearance 4. Measure bearings for correct clearance. Repair as necessary 5. Excessive end play 5. Check crankshaft thrust bearing for excessive wear on flanges 6.
Page 1099 9 - 70 ENGINE 3.9L ENGINE 3.9L (Continued) DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts.
Page 1100 ENGINE 3.9L 9 - 71 ENGINE 3.9L (Continued) DIAGNOSIS AND TESTING—CYLINDER Remove the spark plugs. Remove the oil filler cap. COMBUSTION PRESSURE LEAKAGE Remove the air cleaner. The combustion pressure leakage test provides an Calibrate the tester according to the manufactur- accurate means for determining engine condition.
Page 1101 9 - 72 ENGINE 3.9L ENGINE 3.9L (Continued) CAUTION: DO NOT use engine or transmission oil, CAUTION: Excessive pressure or high RPM (beyond mineral spirits, or kerosene. the recommended speed), can damage the sealing surfaces. The mild (white, 120 grit) bristle disc is (3) Honing should be done by moving the hone up recommended.
Page 1102 ENGINE 3.9L 9 - 73 ENGINE 3.9L (Continued) (10) Install new spark plugs. Tighten the spark plugs to 41 N·m (30 ft. lbs.) torque. (11) Drain engine oil. Remove and discard the oil filter. (12) Install the drain plug. Tighten the plug to 34 N·m (25 ft.
Page 1103 9 - 74 ENGINE 3.9L ENGINE 3.9L (Continued) MOPAR ATF RTV sealing surfaces. Material in an aerosol can should be Mopar ATF RTV is a specifically designed black used on engines with multi-layer steel gaskets. silicone rubber RTV that retains adhesion and seal- REMOVAL ing properties to seal components exposed to auto- matic...
Page 1104 ENGINE 3.9L 9 - 75 ENGINE 3.9L (Continued) tor bolts. Separate engine from insulator by removing (22) Install fan shroud in position. upper nut washer assembly and bolt from engine (23) Fill cooling system (Refer to 7 - COOLING - support bracket.
Page 1105 9 - 76 ENGINE 3.9L ENGINE 3.9L (Continued) DESCRIPTION N·m DESCRIPTION N·m Bolts (2wd) Transmission Support — Bracket Generator—Mounting — Bolt —Bolts (2WD) Intake Manifold—Bolts Refer to Procedure Vibration Damper—Bolt — Oil Pan—Bolts — Water Pump to Timing — Chain Oil Pan—Drain Plug —...
Page 1106 ENGINE 3.9L 9 - 77 ENGINE 3.9L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Bearing to Journal Main Journal Taper Clearance (Max) 0.0254 mm Standard 0.0254 - 0.0762 mm (0.001 in.) (0.001 - 0.003 in.) Main Journal Beraing Max Allowable 0.127 mm Clearance (0.005 in.) No.
Page 1107 9 - 78 ENGINE 3.9L ENGINE 3.9L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Valve Seat Width (Finish) Number of Coils Intake 1.016 - 1.542 mm Installed Height 41.66 mm (0.040 - 0.060 in.) (1.64 in.) Exhaust 1.524 - 2.032 mm Wire Diameter 4.50 mm (0.040 - 0.060 in.) (0.177 in.)
Page 1108 ENGINE 3.9L 9 - 79 ENGINE 3.9L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Outer Rotor Clearance Diameter 24.996 - 25.001 mm (Max) 0.3556 mm (0.9841 - 0.9843 in.) (0.014 in.) End Play None Outer Rotor Diameter Length 75.946 - 76.454 mm (Min) 62.7126 mm (2.990 - 3.010 in.)
Page 1109 9 - 80 ENGINE 3.9L ENGINE 3.9L (Continued) OVERSIZE AND UNDERSIZE ENGINE SPECIAL TOOLS COMPONENT MARKINGS CHART ENGINE—3.9L OS-US Item Identification Location of Identification Crankshaft R or M M-2-3 Milled flat on ect. .0254 (indicating No. No. eight 2 & (.001 3 main crankshaft...
Page 1110 ENGINE 3.9L 9 - 81 ENGINE 3.9L (Continued) Distributor Bushing Puller C-3052 Valve Guide Sleeve C-3973 Distributor Bushing Driver/Burnisher C-3053 Dial Indicator C-3339 Piston Ring Compressor C-385 Puller C-3688 Crankshaft Main Bearing Remover C-3059 Front Oil Seal Installer 6635 Camshaft Holder C-3509 Cylinder Bore Gauge C-119...
Page 1111 9 - 82 ENGINE 3.9L ENGINE 3.9L (Continued) INSTALLATION (1) Install element into housing. (2) Position housing cover into housing locating tabs. (3) Pry up spring clips and lock cover to housing. CYLINDER HEAD DESCRIPTION Pressure Tester Kit 7700 The cast iron cylinder heads (Fig. 7) are mounted to the cylinder block using eight bolts.
Page 1112 ENGINE 3.9L 9 - 83 CYLINDER HEAD (Continued) • Engine misfiring REMOVAL • Poor fuel economy The alloy cast iron cylinder heads (Fig. 8) are held • Possible indications of the cylinder head gasket in place by eight bolts. The spark plugs are located leaking between a cylinder and an adjacent water at the peak of the wedge between the valves.
Page 1113 9 - 84 ENGINE 3.9L CYLINDER HEAD (Continued) INSPECTION (6) Install exhaust manifolds (Refer ENGINE/MANIFOLDS/EXHAUST MANIFOLD Inspect all surfaces with a straightedge if there is INSTALLATION). any reason to suspect leakage. If out-of-flatness (7) Adjust spark plugs to specifications. Install the exceeds 0.00075mm/mm (0.0001in./in.) times the plugs and tighten to 41 N·m (30 ft.
Page 1114 ENGINE 3.9L 9 - 85 CYLINDER HEAD COVER(S) (Continued) INTAKE/EXHAUST VALVES & SEATS DESCRIPTION Both the intake and exhaust valves are made of steel. The intake valve is 48.768 mm (1.92 inches) in diameter and the exhaust valve is 41.148 mm (1.62 inches) in diameter and has a 2.032 mm (0.080 inch) wafer interia welded to the tip for durability.
Page 1115 9 - 86 ENGINE 3.9L INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 12 Measuring Valve Guide Wear 1 - VALVE 2 - SPECIAL TOOL C-3339 Fig. 13 Valve Face and Seat Angles VALVE GUIDES 1 - CONTACT POINT Service valves with oversize stems are available. A,B,C and D Refer to VALVE FACE AND VALVE SEAT ANGLE CHART Refer to REAMER SIZES CHART...
Page 1116 ENGINE 3.9L 9 - 87 INTAKE/EXHAUST VALVES & SEATS (Continued) VALVES (1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseat- Inspect the remaining margin after the valves are ing stones. A true and complete surface must be refaced (Fig.
Page 1117 9 - 88 ENGINE 3.9L INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 16 Testing Valve Spring for Compressed Fig. 18 Measuring Valve Guide Wear Length 1 - VALVE 1 - TORQUE WRENCH 2 - SPECIAL TOOL C-3339 2 - VALVE SPRING TESTER INSTALLATION INSPECTION (1) Clean...
Page 1118 ENGINE 3.9L 9 - 89 ENGINE BLOCK CLEANING Clean cylinder block thoroughly and check all core hole plugs for evidence of leakage. INSPECTION Examine block for cracks or fractures. The cylinder walls should be checked for out-of- round and taper. Refer to Honing Cylinder Bores in the Service Procedures portion of this Section.
Page 1119 9 - 90 ENGINE 3.9L CAMSHAFT & BEARINGS (IN BLOCK) (Continued) (6) Remove rocker arms (Refer to 9 - ENGINE/ correctly. Install a new core hole plug at the rear of CYLINDER HEAD/ROCKER ARM / ADJUSTER camshaft. Be sure this plug does not leak. ASSY - REMOVAL).
Page 1120 ENGINE 3.9L 9 - 91 CAMSHAFT & BEARINGS (IN BLOCK) (Continued) plug in rear of cylinder block. Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed. (4) Install timing chain tensioner. Torque bolts to 24 N·m (210 in.
Page 1121 9 - 92 ENGINE 3.9L OPERATION CONNECTING ROD BEARINGS The crankshaft transfers force generated by com- STANDARD PROCEDURE—CONNECTING ROD bustion within the cylinder bores to the flywheel or flexplate. BEARING FITTING Fit all rods on a bank until completed. DO NOT REMOVAL alternate from one bank to another, because connect- (1) Remove the oil pan (Refer to 9 - ENGINE/LU-...
Page 1122 ENGINE 3.9L 9 - 93 CRANKSHAFT (Continued) four main bearings. Number two main bearing is flanged, this flange controls crankshaft thrust. Fig. 29 Main Bearing Orientation Fig. 27 Sealant Application to Bearing Cap OPERATION 1 - MOPAR SILICONE RUBBER ADHESIVE SEALANT SLOTS The main bearings encircle the crankshaft main 2 - LOCTITE 515 (OR EQUIVALENT) bearing journals, this aligns the crankshaft to the...
Page 1123 9 - 94 ENGINE 3.9L CRANKSHAFT MAIN BEARINGS (Continued) CRANKSHAFT IDENTIFICATION LOCATION procedures are to be cleaned and oiled before instal- CHART lation. DO NOT use a new bearing half with an old bearing half. When installing a new upper bearing shell, slightly ITEM MEASUREMENT IDENTIFICATION...
Page 1124 ENGINE 3.9L 9 - 95 CRANKSHAFT OIL SEAL - FRONT (Continued) (3) Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft (Fig. 34). (4) Remove the vibration damper bolt and seal installation tool. (5) Inspect the seal flange on the vibration damper.
Page 1125 9 - 96 ENGINE 3.9L CRANKSHAFT OIL SEAL - REAR (Continued) (a) Circular spray pattern generally indicates (3) Remove the rear main bearing cap. Remove seal leakage or crankshaft damage. and discard the old lower oil seal. (b) Where leakage tends to run straight down, (4) Carefully remove and discard the old upper oil possible causes are a porous block, distributor seal, seal.
Page 1126 ENGINE 3.9L 9 - 97 CRANKSHAFT OIL SEAL - REAR (Continued) UPPER SEAL—CRANKSHAFT INSTALLED (1) Clean the cylinder block mating surfaces before oil seal installation. Check for burrs at the oil hole on the cylinder block mating surface to rear cap. (2) Lightly oil the new upper seal lips with engine oil.
Page 1127 9 - 98 ENGINE 3.9L CRANKSHAFT OIL SEAL - REAR (Continued) ble bearing cap to cylinder block immediately after INSTALLATION sealant application. (1) Slide new bushing over burnishing end of Dis- (6) To align the bearing cap, use cap slot, align- tributor Drive Shaft Bushing Driver/Burnisher Tool ment dowel, and cap bolts.
Page 1128 ENGINE 3.9L 9 - 99 NOTE: Worn valve guides or cocked springs are HYDRAULIC LIFTERS (CAM IN sometimes mistaken for noisy tappets. If such is BLOCK) the case, noise may be dampened by applying side thrust on the valve spring. If noise is not apprecia- DIAGNOSIS AND TESTING—HYDRAULIC bly reduced, it can be assumed the noise is in the TAPPETS...
Page 1129 9 - 100 ENGINE 3.9L HYDRAULIC LIFTERS (CAM IN BLOCK) (Continued) (6) Adjust the nose of the ram to align the pointer (3) Remove rocker assembly and push rods (Refer with the SET mark on the scale of the tester and to 9 - ENGINE/CYLINDER HEAD/ROCKER ARM / tighten the hex nut.
Page 1130 ENGINE 3.9L 9 - 101 PISTON MEASUREMENTS CHART PISTON & CONNECTING ROD DESCRIPTION PISTON A DIA = PISTON BORE The pistons are made of aluminum and have three SIZE DIAMETER DIAMETER ring grooves, the top two grooves are for the compres- MIN.
Page 1131 9 - 102 ENGINE 3.9L PISTON & CONNECTING ROD (Continued) the connecting rod is centered in cylinder bore and at (part of Tool C-385). Be sure position of rings BDC. Be careful not to nick crankshaft journals. does not change during this operation. (7) After removal, install bearing cap on the mat- (4) Install connecting rod bolt protectors on rod ing rod.
Page 1132 ENGINE 3.9L 9 - 103 PISTON RINGS (Continued) must be installed with the identification mark face up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter “O”, an oval depression, or the word “TOP”...
Page 1133 9 - 104 ENGINE 3.9L (3) Install the crankshaft bolt and washer. Tighten VIBRATION DAMPER the bolt to 244 N·m (180 ft. lbs.) torque. (4) Install the crankshaft pulley. Tighten the pul- REMOVAL ley bolts to 23 N·m (200 in. lbs.) torque. (1) Disconnect the negative cable from the battery.
Page 1134 ENGINE 3.9L 9 - 105 FRONT MOUNT (Continued) Fig. 49 Engine Right Front Insulator Mount—2WD Vehicles Fig. 51 Engine Mount Insulator at Frame 1 - HEAT SHIELD 1 - NUT 2 - INSULATOR 2 - INSULATOR 3 - FRAME 4 - THROUGH BOLT (5) Left mount insulator only.
Page 1135 9 - 106 ENGINE 3.9L FRONT MOUNT (Continued) Fig. 52 Right Engine Mount Insulator and Support Fig. 53 Left Engine Mount Insulator and Support Bracket—4WD Vehicles Bracket—4WD Vehicles 1 - ENGINE SUPPORT BRACKET 1 - ENGINE SUPPORT BRACKET 2 - INSULATOR 2 - INSULATOR 3 - FRONT AXLE 3 - FRONT AXLE...
Page 1136 ENGINE 3.9L 9 - 107 REAR MOUNT (Continued) • Remove stud nuts attaching insulator to cross- member (Fig. 56). Remove insulator. Fig. 55 Rear Insulator Automatic Transmission— Fig. 54 Engine Mount 1 - NUT 1 - ENGINE SUPPORT BRACKET 2 - ENGINE SUPPORT BRACKET 2 - THROUGH BOLT 3 - INSULATOR 3 - CROSSMEMBER...
Page 1137 9 - 108 ENGINE 3.9L REAR MOUNT (Continued) Fig. 56 Rear Insulator Manual Transmission—2WD 1 - TRANSMISSION EXTENSION 2 - INSULATOR 3 - CROSSMEMBER INSTALLATION Fig. 57 Rear Insulator Automatic Transmission— 1 - AUTOMATIC TRANSMISSION (1) If the engine support bracket (Automatic 2 - INSULATOR BRACKET Transmissions) was removed, position the bracket to 3 - INSULATOR...
Page 1138 ENGINE 3.9L 9 - 109 REAR MOUNT (Continued) Fig. 59 Positive Displacement Oil Pump—Typical 1 - INNER ROTOR AND SHAFT 2 - BODY 3 - DISTRIBUTOR DRIVESHAFT (REFERENCE) 4 - COTTER PIN 5 - RETAINER CAP 6 - SPRING 7 - RELIEF VALVE 8 - LARGE CHAMFERED EDGE 9 - BOLT 10 - COVER...
Page 1139 9 - 110 ENGINE 3.9L LUBRICATION (Continued) Fig. 60 Oil Lubrication System 1 - OIL DEFLECTOR TAB 14 - OIL PUMP 2 - BOLT 15 - OIL FILTER 3 - ROCKER ARM PIVOT 16 - CRANKSHAFT 4 - ROCKER ARM 17 - FROM OIL PUMP 5 - DRIP OILING FOR VALVE TIP 18 - OIL TO FILTER...
Page 1140 ENGINE 3.9L 9 - 111 LUBRICATION (Continued) DIAGNOSIS AND TESTING—ENGINE OIL (12) Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various PRESSURE speeds approximately 24 km (15 miles). Inspect the (1) Remove oil pressure sending unit. engine for signs of an oil leak by using a black light.
Page 1141 9 - 112 ENGINE 3.9L OIL (Continued) ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in the Maintenance Schedule. This infor- mation can be found in the owner’s manual. TO CHANGE ENGINE OIL Run engine until achieving normal operating tem- perature.
Page 1142 ENGINE 3.9L 9 - 113 OIL PAN (Continued) If present, trim excess sealant from inside the engine. Clean oil pan in solvent and wipe dry with a clean cloth. Clean oil screen and pipe thoroughly in clean sol- vent. Inspect condition of screen. INSPECTION Inspect oil drain plug and plug hole for stripped or damaged threads.
Page 1143 9 - 114 ENGINE 3.9L OIL PUMP (Continued) INSPECTION Mating surface of the oil pump cover should be smooth. Replace pump assembly if cover is scratched or grooved. Lay a straightedge across the pump cover surface (Fig. 68) . If a 0.038 mm (0.0015 in.) feeler gauge can be inserted between cover and straightedge, pump assembly should be replaced.
Page 1144 ENGINE 3.9L 9 - 115 OIL PUMP (Continued) If inner rotor measures 20.9 mm (0.825 in.) or less, replace inner rotor and shaft assembly (Fig. 70) . Fig. 72 Measuring Clearance Between Rotors Fig. 70 Measuring Inner Rotor Thickness 1 - OUTER ROTOR 2 - FEELER GAUGE Slide outer rotor into pump body.
Page 1145 9 - 116 ENGINE 3.9L OIL PUMP (Continued) Fig. 74 Proper Installation of Retainer Cap 1 - RETAINER CAP 2 - CHAMFER 3 - COTTER KEY (3) Install the relief valve and spring. Insert the cotter pin. Fig. 75 Intake Manifold with Tightening Sequence— (4) Tap on a new retainer cap.
Page 1146 ENGINE 3.9L 9 - 117 INTAKE MANIFOLD (Continued) ERY - STANDARD PROCEDURE). Disconnect the fuel lines (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/QUICK CONNECT FITTING - STAN- DARD PROCEDURE). (8) Disconnect the accelerator linkage (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE CONTROL CABLE - REMOVAL) and if so equipped, the speed control and transmission kickdown cables.
Page 1147 9 - 118 ENGINE 3.9L INTAKE MANIFOLD (Continued) Fig. 79 Intake Manifold Bolt Tightening Sequence (9) Connect the coil wires. (10) Connect the heat indicator sending unit wire. (11) Connect the heater hoses and bypass hose. (12) Install distributor cap and wires. (13) Hook up the return spring.
Page 1148 ENGINE 3.9L 9 - 119 INSPECTION EXHAUST MANIFOLD Inspect manifold for cracks. DESCRIPTION Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat The exhaust manifolds (Fig. 80) are constructed of within 0.2 mm per 300 mm (0.008 inch per foot). cast iron and are LOG type with balanced flow.
Page 1149 9 - 120 ENGINE 3.9L TIMING BELT / CHAIN COVER(S) REMOVAL (1) Disconnect the battery negative cable. (2) Drain cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE). (3) Remove the serpentine belt (Refer to 7 - COOL- ING/ACCESSORY DRIVE/DRIVE BELTS - REMOV- AL).
Page 1150 ENGINE 3.9L 9 - 121 TIMING BELT/CHAIN AND SPROCKETS REMOVAL (1) Disconnect battery negative cable. (2) Drain cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE). (3) Remove timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL).
Page 1151 9 - 122 ENGINE 3.9L TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 85 Measuring Timing Chain Wear and Stretch 1 - TORQUE WRENCH 2 - 3.175 MM (0.125 IN.) INSTALLATION (1) If tensioner assembly is being replaced, install tensioner and mounting bolts. Torque bolts to 24 N·m (210 in.
Page 1152 ENGINE 4.7L 9 - 123 ENGINE 4.7L TABLE OF CONTENTS page page ENGINE 4.7L VALVE SPRINGS DIAGNOSIS AND TESTING ....124 DESCRIPTION ......161 ENGINE DIAGNOSIS - INTRODUCTION .
Page 1153 9 - 124 ENGINE 4.7L VIBRATION DAMPER OIL PUMP REMOVAL ......177 REMOVAL .
Page 1154 ENGINE 4.7L 9 - 125 ENGINE 4.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary. 2. Corroded or loose battery 2. Clean and tighten battery connections.
Page 1155 9 - 126 ENGINE 4.7L ENGINE 4.7L (Continued) CONDITION POSSIBLE CAUSE CORRECTION 7. Plugged or restricted exhaust 7. Inspect and replace as system. necessary. 8. Faulty coil. 8. (Refer to 8 - ELECTRICAL/ IGNITION CONTROL/IGNITION COIL - REMOVAL). 1. ENGINE MISSES ON 1.
Page 1156 ENGINE 4.7L 9 - 127 ENGINE 4.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTIONS NOISY VALVES 1. High or low oil level in 1. (Refer to LUBRICATION & crankcase. MAINTENANCE/FLUID TYPES - SPECIFICATIONS). 2. Thin or diluted oil. 2.
Page 1157 9 - 128 ENGINE 4.7L ENGINE 4.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts.
Page 1158 ENGINE 4.7L 9 - 129 ENGINE 4.7L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL PUMPING AT RINGS; SPARK 1. Worn or damaged rings. 1. Hone cylinder bores and replace PLUGS FOULING rings. 2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCEDURE).
Page 1159 9 - 130 ENGINE 4.7L ENGINE 4.7L (Continued) CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat. THROTTLE BODY seated properly Reface or replace, as necessary. Inspect valve springs.
Page 1160 ENGINE 4.7L 9 - 131 ENGINE 4.7L (Continued) rial is used on engines with multi-layer steel (MLS) cylinder head gaskets. This material also will pre- vent corrosion. Mopar Gasket Sealant is available in a 13 oz. aerosol can or 4oz./16 oz. can w/applicator. FORM-IN-PLACE GASKET AND SEALER APPLICATION Assembling parts using a form-in-place gasket...
Page 1161 9 - 132 ENGINE 4.7L ENGINE 4.7L (Continued) (8) Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine. (9) Disconnect crankshaft position sensor. (Fig. 4) NOTE: The following step applies to 4X4 vehicles equipped with automatic transmission only.
Page 1162 ENGINE 4.7L 9 - 133 ENGINE 4.7L (Continued) (23) Remove shroud, fan assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - REMOVAL) and accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL). (24) Disconnect transmission oil cooler lines at the radiator.
Page 1163 9 - 134 ENGINE 4.7L ENGINE 4.7L (Continued) • Pull foward and upward on the lifting fixture so that the lifting stud rest in the slotted area below the large bore. • Secure the lifting fixture to the three studs using three 7/16 –...
Page 1164 ENGINE 4.7L 9 - 135 ENGINE 4.7L (Continued) INSTALLATION (18) Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - (1) Position engine in the vehicle. INSTALLATION), fan assembly and shroud (Refer to Position both the left and right side engine mount COOLING/ENGINE/FAN DRIVE VISCOUS...
Page 1165 9 - 136 ENGINE 4.7L ENGINE 4.7L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION (0.0146 - 0.0249 in.) 4.7L ENGINE Second Compression 0.37 - 0.63 mm Ring DESCRIPTION SPECIFICATION (0.0146 - 0.0249 in.) GENERAL SPECIFICATIONS Oil Control (Steel Rails) 0.25 - 0.76 mm Engine Type 90°...
Page 1166 ENGINE 4.7L 9 - 137 ENGINE 4.7L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Taper (MAX) 0.008 mm (0.0004 in.) Length (Overall) End Play 0.052 - 0.282 mm Intake 113.45 - 114.21 mm (0.0021 - 0.0112 in.) (4.4666 - 4.4965) End Play (MAX) 0.282 mm (0.0112 in) Exhaust 114.92 - 115.68 mm...
Page 1167 9 - 138 ENGINE 4.7L ENGINE 4.7L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Number of Coils OIL PRESSURE At Curb Idle Speed 25 kPa (4 psi) Intake and Exhaust 6.69 (MIN)* Wire Diameter @ 3000 rpm 170 - 758 kPa (25 - 110 Intake and Exhaust 4.2799 - 4.3561 mm psi)
Page 1168 ENGINE 4.7L 9 - 139 ENGINE 4.7L (Continued) DESCRIPTION N·m Lbs. Lbs. Oil Pan—Drain Plug — Oil Pump—Bolts — Oil Pump Cover—Bolts — Oil Pickup Tube—Bolt and — Oil Dipstick Tube to Engine Engine Lifting Studs 8400 Block—Bolt — Oil Fill Tube—Bolts —...
Page 1169 9 - 140 ENGINE 4.7L ENGINE 4.7L (Continued) Crankshaft Damper Installer 8512 Handle C-4171 Puller 1026 Rear Crankshaft Seal Installer 8349 Crankshaft Damper Removal Insert 8513 Rear Crankshaft Seal Remover 8506 Chain Tensioner Wedge 8350 Connecting Rod Guides 8507...
Page 1170 ENGINE 4.7L 9 - 141 ENGINE 4.7L (Continued) Idler Shaft Remover 8517 Chain Tensioner Pins 8514 Valve Spring Compressor Adapters 8519 Secondary Chain Holder 8515 Valve Spring Tester C-647 Remover, Rocker Arm 8516 Dial Indicator C-3339 Valve Spring Compressor 8387...
Page 1171 9 - 142 ENGINE 4.7L ENGINE 4.7L (Continued) Bloc–Chek–Kit C-3685–A AIR CLEANER ELEMENT REMOVAL Valve Spring Compressor C-3422-B Housing removal is not necessary for element (fil- ter) replacement. (1) Pry up spring clips from housing cover (spring clips retain cover to housing). (2) Release housing cover from locating tabs on housing (Fig.
Page 1172 ENGINE 4.7L 9 - 143 CYLINDER HEAD DESCRIPTION - CYLINDER HEAD The cylinder heads are made of an aluminum alloy. The cylinder head features two valves per cylinder with pressed in powdered metal valve guides. The cylinder heads also provide enclosures for the timing chain drain, necessitating unique left and right cylin- der heads.
Page 1173 9 - 144 ENGINE 4.7L CYLINDER HEAD (Continued) Fig. 14 Camshaft Sprocket V8 Marks 1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD (17) Remove the left side secondary chain ten- (20) Remove the retaining bolt and the camshaft sioner (Refer to 9 - ENGINE/VALVE TIMING/TIM- drive gear.
Page 1174 ENGINE 4.7L 9 - 145 CYLINDER HEAD (Continued) (3) Disconnect the exhaust pipe at the right side (15) Lock the secondary timing chains to the idler exhaust manifold. sprocket using Special Tool 8515 (Fig. 18). (4) Drain the engine coolant (Refer to 7 - COOL- NOTE: Mark the secondary timing chain prior to ING - STANDARD PROCEDURE).
Page 1175 9 - 146 ENGINE 4.7L CYLINDER HEAD (Continued) Fig. 17 Camshaft Sprocket V8 Marks 1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD Fig. 19 Cylinder Head Access Plugs 1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG Fig.
Page 1176 ENGINE 4.7L 9 - 147 CYLINDER HEAD (Continued) (3) Inspect the valve guides for wear, cracks or looseness. If either condition exist, replace the cylin- der head. INSTALLATION - LEFT CYLINDER HEAD NOTE: The cylinder head bolts are tightened using a torque plus angle procedure.
Page 1177 9 - 148 ENGINE 4.7L CYLINDER HEAD (Continued) either side of the V8 mark on the gear and position the gear onto the camshaft. (8) Install the camshaft drive gear retaining bolt. (9) Install the left side secondary chain guide (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS...
Page 1178 ENGINE 4.7L 9 - 149 CYLINDER HEAD (Continued) (9) Install the right side secondary chain guide (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION). (10) Install the right side cylinder head access plug (Fig. 27). Fig. 25 Proper Tool Usage for Fig.
Page 1179 9 - 150 ENGINE 4.7L CAUTION: Do not force wedge past the narrowest CAMSHAFT(S) - LEFT point between the chain strands. Damage to the tensioners may occur. DESCRIPTION The camshafts consist of powdered metal steel (5) Position Special Tool 8350 timing chain wedge lobes which are sinter-bonded to a steel tube.
Page 1180 ENGINE 4.7L 9 - 151 CAMSHAFT(S) - LEFT (Continued) Fig. 28 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 - LEFT CYLINDER HEAD 3 - SPECIAL TOOL 8350 WEDGE 2 - RIGHT CYLINDER HEAD 4 - SPECIAL TOOL 8350 WEDGE (2) Position the camshaft into the cylinder head.
Page 1181 9 - 152 ENGINE 4.7L CAMSHAFT(S) - LEFT (Continued) NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only. Do not grip the lobes or the sprocket areas. (7) Using the adjustable pliers, rotate the cam- shaft until the camshaft sprocket dowel is aligned with the slot in the camshaft sprocket.
Page 1182 ENGINE 4.7L 9 - 153 CAMSHAFT(S) - LEFT (Continued) Fig. 32 Camshaft Sprocket Installation 1 - ADJUSTABLE PLIERS 2 - CAMSHAFT DOWEL Fig. 33 SPECIAL TOOL 8350 1 - LEFT CYLINDER HEAD 3 - SPECIAL TOOL 8350 WEDGE 2 - RIGHT CYLINDER HEAD 4 - SPECIAL TOOL 8350 WEDGE...
Page 1183 9 - 154 ENGINE 4.7L CAMSHAFT(S) - LEFT (Continued) dently of each other. Severe valve and/or piston damage can occur. CAUTION: When removing the cam sprocket, timing chains or camshaft, Failure to use special tool 8350 will result in hydraulic tensioner ratchet over exten- sion, Requiring timing chain cover removal to re-set the tensioner ratchet.
Page 1184 ENGINE 4.7L 9 - 155 CAMSHAFT(S) - RIGHT (Continued) Fig. 35 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 - LEFT CYLINDER HEAD 3 - SPECIAL TOOL 8350 WEDGE 2 - RIGHT CYLINDER HEAD 4 - SPECIAL TOOL 8350 WEDGE Fig.
Page 1185 9 - 156 ENGINE 4.7L CAMSHAFT(S) - RIGHT (Continued) CAUTION: DO NOT STAMP OR STRIKE THE CAM- (5) Torque the camshaft bearing cap retaining SHAFT BEARING CAPS. SEVERE DAMAGE WILL bolts to 11 N·m (100 in. lbs.). (6) Position the camshaft drive gear into the tim- OCCUR TO THE BEARING CAPS.
Page 1186 ENGINE 4.7L 9 - 157 CAMSHAFT(S) - RIGHT (Continued) Fig. 39 Timing Chain to Sprocket Alignment 1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD Fig. 41 Tightening Right Side Cam Sprocket Retaining Bolt 1 - TORQUE WRENCH Fig. 40 Camshaft Sprocket Installation 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 - LEFT CAMSHAFT SPROCKET 1 - ADJUSTABLE PLIERS...
Page 1187 9 - 158 ENGINE 4.7L CLEANING CYLINDER HEAD COVER(S) Clean cylinder head cover gasket surface. DESCRIPTION Clean head rail, if necessary. The cylinder head covers are made of die cast mag- INSTALLATION - RIGHT SIDE nesium, and are not interchangeable from side-to- side.
Page 1188 ENGINE 4.7L 9 - 159 CYLINDER HEAD COVER(S) (Continued) (12) Install air cleaner assembly, resonator assem- INTAKE/EXHAUST VALVES & bly and air inlet hose. SEATS (13) Connect battery negative cable. DESCRIPTION INSTALLATION—LEFT SIDE The valves are made of heat resistant steel and have chrome plated stems to prevent scuffing.
Page 1189 9 - 160 ENGINE 4.7L INTAKE/EXHAUST VALVES & SEATS (Continued) (5) The oil restrictor in cylinder head gasket or the oil passage to the cylinder head is plugged with debris. (6) Air ingested into oil due to broken or cracked oil pump pick up.
Page 1190 ENGINE 4.7L 9 - 161 ROCKER ARM / ADJUSTER ASSEMBLY (Continued) REMOVAL (1) Remove the cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). (2) Using Special Tool 8516 Rocker Arm Remover, remove the rocker arms and the hydraulic lash adjusters (Fig.
Page 1191 9 - 162 ENGINE 4.7L VALVE SPRINGS (Continued) (8) Remove the valve spring compressor. (7) Install the cylinder head cover (Refer to 9 - (9) Remove the spring retainer, and the spring. ENGINE/CYLINDER HEAD/CYLINDER HEAD (10) Remove the valve stem seal. COVER(S) - INSTALLATION).
Page 1192 ENGINE 4.7L 9 - 163 ENGINE BLOCK (Continued) The hone marks should INTERSECT at 50° to 60° for proper seating of rings (Fig. 48). Fig. 48 Cylinder Bore Crosshatch Pattern 1 - CROSSHATCH PATTERN 2 - INTERSECT ANGLE Fig. 49 Bore Gauge—Typical (4) A controlled hone motor speed between 200 and 1 - FRONT 300 RPM is necessary to obtain the proper cross-...
Page 1193 9 - 164 ENGINE 4.7L CONNECTING ROD BEARINGS STANDARD PROCEDURE—CONNECTING ROD BEARING FITTING Inspect the connecting rod bearings for scoring and bent alignment tabs (Fig. 50) (Fig. 51). Check the bearings for normal wear patterns, scoring, grooving, fatigue and pitting (Fig. 52). Replace any bearing that shows abnormal wear.
Page 1194 ENGINE 4.7L 9 - 165 CONNECTING ROD BEARINGS (Continued) (8) If bearing-to-journal clearance exceeds the specification, determin which services bearing set to use the bearing sizes are as follows: Bearing SIZE USED WITH Mark JOURNAL SIZE .025 US .025 mm 50.983-50.967 mm (.001 in.) (2.0073-2.0066 in.)
Page 1195 9 - 166 ENGINE 4.7L CORE PLUGS CRANKSHAFT REMOVAL DESCRIPTION (1) Drain the cooling system (Refer to 7 - COOL- The crankshaft is constructed of nodular cast iron. ING - STANDARD PROCEDURE). The crankshaft is a crosshaped four throw design (2) Using a blunt tool such as a drift or a screw with eight counterweights for balancing purposes.
Page 1196 ENGINE 4.7L 9 - 167 CRANKSHAFT (Continued) NOTE: The bedplate has pry points cast into it. Use (2) Thoroughly clean the bedplate to cylinder block these points only. The pry points are on both the sealing surfaces and main bearing bores. Remove all oil and sealant residue.
Page 1197 9 - 168 ENGINE 4.7L CRANKSHAFT (Continued) CAUTION: The bedplate to cylinder block mateing surface must be coated with sealant prior to instal- lation. Failure to do so will cause severe oil leaks. NOTE: The installation time to install the bedplate after the sealant has been applied is critical.
Page 1198 ENGINE 4.7L 9 - 169 CRANKSHAFT (Continued) Fig. 61 Bedplate Tightening Sequence 1 - BEDPLATE 2 - CYLINDER BLOCK Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal. The maximum allowable taper is 0.008mm (0.0004 inch.) and maximum out of round is 0.005mm (0.002 inch).
Page 1199 9 - 170 ENGINE 4.7L CRANKSHAFT MAIN BEARINGS (Continued) Fig. 64 Main Bearing Wear Patterns 1 - UPPER INSERT 2 - NO WEAR IN THIS AREA 3 - LOW AREA IN BEARING LINING Fig. 63 Main Bearing Markings on Target Wheel 4 - LOWER INSERT 1 - REARMOST CRANKSHAFT COUNTER WEIGHT 2 - TARGET WHEEL...
Page 1200 ENGINE 4.7L 9 - 171 CRANKSHAFT OIL SEAL - FRONT (Continued) INSTALLATION CAUTION: To prevent severe damage to the Crank- shaft, Damper or Special Tool 8512, thoroughly clean the damper bore and the crankshaft nose before installing Damper. (1) Using Special Tool 8348 and 8512, install crankshaft front seal (Fig.
Page 1201 9 - 172 ENGINE 4.7L REMOVAL CRANKSHAFT OIL SEAL - REAR NOTE: This procedure can be preformed in vehicle. (1) If being preformed in vehicle, remove the DIAGNOSIS AND TESTING—REAR SEAL AREA transmission. LEAKS (2) Remove the flexplate (Refer to 9 - ENGINE/ ENGINE BLOCK/FLEX PLATE - REMOVAL).
Page 1202 ENGINE 4.7L 9 - 173 CRANKSHAFT OIL SEAL - REAR (Continued) INSTALLATION (1) Position the flexplate onto the crankshaft and install the bolts hand tight. (2) Tighten the flexplate retaining bolts to 60 N·m (45 ft. lbs.) in the sequence shown (Fig. 71). (3) Install the transmission.
Page 1203 9 - 174 ENGINE 4.7L PISTON & CONNECTING ROD (Continued) (2) Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore. Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B (Fig.
Page 1204 ENGINE 4.7L 9 - 175 PISTON & CONNECTING ROD (Continued) Check the piston for scoring, or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration. INSTALLATION (1) Before installing piston and connecting rod assemblies into the bore, install the piston rings. (2) Immerse the piston head and rings in clean engine oil.
Page 1205 9 - 176 ENGINE 4.7L PISTON & CONNECTING ROD (Continued) • Oil pan and gasket/windage tray. (Refer to 9 - ing rod oil slinger slot faces the front of the engine (Fig. 76). ENGINE/LUBRICATION/OIL PAN - INSTALLA- TION). (11) Fill crankcase with proper engine oil to cor- rect level.
Page 1206 ENGINE 4.7L 9 - 177 PISTON RINGS (Continued) (7) The No. 1 and No. 2 piston rings have a differ- ent cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: •...
Page 1207 9 - 178 ENGINE 4.7L VIBRATION DAMPER (Continued) Fig. 80 Upper and Intermediate Rings—Installation Fig. 82 Fan Assembly—Removal/Installation 1 - SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER PINS 8346 2 - FAN Fig. 81 Piston Ring End Gap Position 1 - SIDE RAIL UPPER 2 - NO.
Page 1208: Structural Cover
ENGINE 4.7L 9 - 179 VIBRATION DAMPER (Continued) INSTALLATION CAUTION: To prevent severe damage to the Crank- shaft, Damper or Special Tool 8512–A, thoroughly clean the damper bore and the crankshaft nose before installing Damper. (1) Align crankshaft damper slot with key in crankshaft.
Page 1209 9 - 180 ENGINE 4.7L STRUCTURAL COVER (Continued) (5) Install the exhaust pipe on left hand exhaust manifold. (6) Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20–26 N·m (15–20 ft. lbs.). FRONT MOUNT REMOVAL (1) Disconnect the negative cable from the battery. CAUTION: Remove the fan blade, fan clutch and fan shroud before raising engine.
Page 1210 ENGINE 4.7L 9 - 181 FRONT MOUNT (Continued) Fig. 89 Engine Insulator Mount 4x2 Vehicle—Right Side 1 - ENGINE INSULATOR MOUNT-RIGHT SIDE Fig. 91 Engine Insulator Mount 4x4 Vehicle—Right 2 - MOUNTING BOLT Side 1 - ENGINE INSULATOR MOUNT-RIGHT SIDE 2 - MOUNTING BOLT INSTALLATION (1) Position the insulator mount and install the...
Page 1211 9 - 182 ENGINE 4.7L REAR MOUNT (Continued) (7) Remove the two nuts retaining the isolator to the crossmember (Manual transmission and 4x2 automatic transmission only) (Fig. 92) (Fig. 93). (8) Remove the bolts (two bolts manual transmis- sion)(three bolts 4x2 automatic transmission) retain- ing the insulator bracket to the transmission.
Page 1212 ENGINE 4.7L 9 - 183 OPERATION LUBRICATION Oil from the oil pan is pumped by a gerotor type oil DESCRIPTION pump directly mounted to the crankshaft nose. Oil pressure is controlled by a relief valve mounted The lubrication system (Fig. 95) is a full flow fil- inside the oil pump housing.
Page 1213 9 - 184 ENGINE 4.7L LUBRICATION (Continued) The camshaft exhaust valve lobes and rocker arms a bore in the number 3 camshaft bearing bore, and are lubricated through a small hole in the rocker as the camshaft turns, a hole in the camshaft aligns arm;...
Page 1214 ENGINE 4.7L 9 - 185 LUBRICATION (Continued) (5) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak. (6) If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose.
Page 1215 9 - 186 ENGINE 4.7L ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON- STANDARD PROCEDURE—ENGINE OIL SERVING is located on the label of an engine oil con- SERVICE tainer. WARNING: NEW OR USED ENGINE OIL CAN BE CONTAINER IDENTIFICATION IRRITATING TO THE SKIN.
Page 1216 ENGINE 4.7L 9 - 187 OIL (Continued) CRANKCASE OIL LEVEL INSPECTION OIL FILTER CAUTION: Do not overfill crankcase with engine oil, REMOVAL pressure loss or oil foaming can result. All engines are equipped with a high quality full- flow, disposable type oil filter. DaimlerChrysler Cor- Inspect engine oil level approximately every 800 poration recommends a Mopar or equivalent oil...
Page 1217 9 - 188 ENGINE 4.7L OIL FILTER (Continued) (10) Remove both left and right side engine mount through bolts (Fig. 103). Fig. 101 Oil Filter Sealing Surface—Typical 1 - SEALING SURFACE 2 - RUBBER GASKET 3 - OIL FILTER OIL PAN REMOVAL—4X2 (1) Drain the cooling system (Refer to 7 - COOL- ING - STANDARD PROCEDURE).
Page 1218 ENGINE 4.7L 9 - 189 OIL PAN (Continued) (14) Unbolt oil pump pickup tube and remove tube INSTALLATION—4X2 and oil pan gasket from engine. (1) Clean the oil pan gasket mating surface of the bedplate and oil pan. REMOVAL—4X4 (2) Position the oil pan gasket and pickup tube with new o-ring.
Page 1219 9 - 190 ENGINE 4.7L OIL PRESSURE SENSOR/ SWITCH DESCRIPTION The 2–wire, electrical/mechanical engine oil pres- sure sensor (sending unit) is located in an engine oil pressure gallery. OPERATION The oil pressure sensor uses two circuits. They are: • A signal to the PCM relating to engine oil pres- sure •...
Page 1220 ENGINE 4.7L 9 - 191 OIL PUMP (Continued) mm (0.4727 in.) or less the oil pump assembly must be replaced. (4) Measure the diameter of the outer rotor. If the outer rotor diameter measures at 85.925 mm (3.3829 in.) or less the oil pump assembly must be replaced. (5) Measure the thickness of the inner rotor (Fig.
Page 1221 9 - 192 ENGINE 4.7L OIL PUMP (Continued) Fig. 113 Measuring Clearance Over Rotors 1 - STRAIGHT EDGE 2 - FEELER GAUGE Fig. 111 Measuring Outer Rotor Clearance in 1 - FEELER GAUGE 2 - OUTER ROTOR Fig. 114 Oil Pump and Primary Timing Chain Fig.
Page 1222 ENGINE 4.7L 9 - 193 (12) Remove fuel rail (Refer to 14 - FUEL SYS- INTAKE MANIFOLD TEM/FUEL DELIVERY/FUEL RAIL - REMOVAL). (13) Remove throttle body assembly and mounting DESCRIPTION bracket. The intake manifold is made of a composite mate- (14) Drain cooling system below coolant tempera- rial and features long runners which maximizes low ture level (Refer to 7 - COOLING - STANDARD...
Page 1223 9 - 194 ENGINE 4.7L INTAKE MANIFOLD (Continued) (5) Install throttle body assembly. (6) Install throttle cable bracket. (7) Connect throttle cable and speed control cable to throttle body. (8) Install fuel rail (Refer to 14 - FUEL SYSTEM/ FUEL DELIVERY/FUEL RAIL - INSTALLATION). (9) Install ignition coil towers (Refer to 8 - ELEC- TRICAL/IGNITION CONTROL/IGNITION COIL - INSTALLATION).
Page 1224 ENGINE 4.7L 9 - 195 EXHAUST MANIFOLD (Continued) (3) Remove accessory drive belt (Refer to 7 - (11) Raise vehicle on hoist. COOLING/ACCESSORY DRIVE/DRIVE BELTS - (12) Disconnect exhaust pipe from manifold. REMOVAL). (13) Remove fasteners attaching starter. Move (4) Remove A/C compressor (Refer to 24 - HEAT- starter aside.
Page 1225 9 - 196 ENGINE 4.7L EXHAUST MANIFOLD (Continued) (5) Remove the front two exhaust heat shield CLEANING retaining fasteners. Raise vehicle and remove the (1) Clean the exhaust manifold using a suitable fasteners at rear of heat shield. cleaning solvent, then allow to air dry. (6) Remove heat shield (Fig.
Page 1226 ENGINE 4.7L 9 - 197 EXHAUST MANIFOLD (Continued) (3) Inspect the manifold to exhaust pipe mating CAUTION: Over tightening heat shield fasteners, surface for cracks, gouges, or other damage that may cause shield to distort and/or crack. would prevent sealing. (4) Install exhaust manifold heat shield.
Page 1227 9 - 198 ENGINE 4.7L EXHAUST MANIFOLD (Continued) (12) Install battery and connect cables. CAUTION: Over tightening heat shield fasteners, (13) Fill cooling system (Refer to 7 - COOLING - may cause shield to distort and/or crack. STANDARD PROCEDURE). (4) Install exhaust manifold heat shield (Fig. 121). LEFT EXHAUST MANIFOLD Tighten fasteners to 8 N·m (72 in.
Page 1228 ENGINE 4.7L 9 - 199 The arm and the guide both use nylon plastic wear VALVE TIMING faces for low friction and long wear. The primary chain receives oil splash lubrication from the second- DESCRIPTION—TIMING DRIVE SYSTEM ary chain drive and oil pump leakage. The idler The timing drive system (Fig.
Page 1229 9 - 200 ENGINE 4.7L VALVE TIMING (Continued) There are two secondary drive chains, both are inverted tooth type, one to drive the camshaft in each SOHC cylinder head. There are no shaft speed changes in the secondary chain drive system. Each secondary chain drives a thirty tooth cam sprocket directly from the thirty tooth sprocket on the idler sprocket assembly.
Page 1230 ENGINE 4.7L 9 - 201 VALVE TIMING (Continued) (4) If both of the camshaft drive gears are off in the same or opposite directions, the primary chain or both secondary chains are at fault. Refer to Timing Chain and Sprockets procedure in this section. (5) If only one of the camshaft drive gears is off and the other is correct, the problem is confined to one secondary chain.
Page 1231 9 - 202 ENGINE 4.7L VALVE TIMING (Continued) Fig. 126 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 - LEFT CYLINDER HEAD 3 - SPECIAL TOOL 8350 WEDGE 2 - RIGHT CYLINDER HEAD 4 - SPECIAL TOOL 8350 WEDGE NOTE: When gripping the camshaft, place the pliers on the tube portion of the camshaft only.
Page 1232 ENGINE 4.7L 9 - 203 VALVE TIMING (Continued) Fig. 129 Camshaft Sprocket Installation—Right Cylinder Head 1 - TORQUE WRENCH 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 - LEFT CAMSHAFT SPROCKET 4 - RIGHT CAMSHAFT SPROCKET Fig. 128 Camshaft Sprocket Left Cylinder Head 1 - TORQUE WRENCH 2 - CAMSHAFT SPROCKET 3 - LEFT CYLINDER HEAD...
Page 1233 9 - 204 ENGINE 4.7L TIMING BELT / CHAIN COVER(S) (Continued) (6) Install accessory drive belt tensioner assembly (Refer to 7 - COOLING/ACCESSORY DRIVE/BELT TENSIONERS - INSTALLATION). (7) Install radiator lower hose. (8) Install both heater hoses. (9) Install radiator shroud and viscous fan drive assembly (Refer to 7 - COOLING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION).
Page 1234 ENGINE 4.7L 9 - 205 TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 135 Cylinder Head Access Plug Location 1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG CAUTION: Care should be taken not to damage camshaft target wheel. Do not hold target wheel Fig.
Page 1235 9 - 206 ENGINE 4.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) CAUTION: Do not forcefully rotate the camshafts or crankshaft independently of each other. Damaging intake valve to piston contact will occur. Ensure negative battery cable is disconnected to guard against accidental starter engagement. (13) Remove left and right camshaft sprocket bolts.
Page 1236 ENGINE 4.7L 9 - 207 TIMING BELT/CHAIN AND SPROCKETS (Continued) INSPECTION Inspect the following components: • Sprockets for excessive tooth wear. Some tooth markings are normal and not a cause for sprocket replacement. • Idler sprocket assembly bushing and shaft for excessive wear.
Page 1237 9 - 208 ENGINE 4.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 140 Timing Chain System 1 - RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN 7 - PRIMARY CHAIN 2 - SECONDARY TIMING CHAIN TENSIONER (LEFT AND RIGHT 8 - IDLER SPROCKET SIDE NOT COMMON) 9 - CRANKSHAFT SPROCKET 3 - SECONDARY TENSIONER ARM...
Page 1238 ENGINE 4.7L 9 - 209 TIMING BELT/CHAIN AND SPROCKETS (Continued) (9) Lubricate idler shaft and bushings with clean engine oil. (10) Install all chains, crankshaft sprocket, and idler sprocket as an assembly (Fig. 143). After guid- ing both secondary chains through the block and cyl- inder head openings, affix chains with a elastic strap or the equivalent, This will maintain tension on chains to aid in installation.
Page 1239 9 - 210 ENGINE 4.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) CAUTION: Ensure the plate between the left sec- ondary chain tensioner and block is correctly installed. (15) Install both secondary chain tensioners. Tighten bolts to 28 N·m (250 in. lbs.). NOTE: Left and right secondary chain tensioners are not common.
Page 1240 ENGINE 4.7L 9 - 211 TIMING BELT/CHAIN AND SPROCKETS (Continued) (21) After installing all chains, it is recommended (22) Install timing chain cover (Refer to 9 - that the idler gear end play be checked (Fig. 146). ENGINE/VALVE TIMING/TIMING BELT / CHAIN The end play must be within 0.10–0.25 mm (0.004–...
Page 1241 9 - 212 ENGINE 5.9L ENGINE 5.9L TABLE OF CONTENTS page page ENGINE 5.9L ENGINE BLOCK DESCRIPTION ......213 CLEANING .
Page 1242 ENGINE 5.9L 9 - 213 PISTON RINGS OIL PUMP STANDARD PROCEDURE ....250 REMOVAL ......261 PISTON RING FITTING.
Page 1243 9 - 214 ENGINE 5.9L ENGINE 5.9L (Continued) • Cylinder Combustion Pressure Leakage Test (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING) • Cylinder Head Gasket Failure Diagnosis (Refer to 9 - ENGINE/CYLINDER HEAD - DIAGNOSIS AND TESTING) • Intake Manifold Leakage Diagnosis (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD DIAGNOSIS AND TESTING)
Page 1244 ENGINE 5.9L 9 - 215 ENGINE 5.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION ENGINE CRANKS BUT WILL NOT 1. No spark 1. Check for spark. (Refer to 8 - START ELECTRICAL/IGNITION CONTROL - DESCRIPTION) 2. No fuel 2. Perform fuel pressure test, and if necessary, inspect fuel injector(s) and driver circuits.
Page 1245 9 - 216 ENGINE 5.9L ENGINE 5.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Worn or incorrectly gapped spark 3. Replace or clean and re-gap plugs spark plugs (Refer to 8 - ELECTRICAL/IGNITION CONTROL/ SPARK PLUG - CLEANING) 4. Worn or burned distributor rotor 4.
Page 1246 ENGINE 5.9L 9 - 217 ENGINE 5.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Low oil pressure 3. Check engine oil level. If ok, Perform oil pressure test. (Refer to 9 - ENGINE/LUBRICATION - DIAGNOSIS AND TESTING) for engine oil pressure test/ specifications 4.
Page 1247 9 - 218 ENGINE 5.9L ENGINE 5.9L (Continued) CONDITION POSSIBLE CAUSES CORRECTION 7. Loose flywheel or torque 7. Inspect crankshaft, flexplate/ converter flywheel and bolts for damage. Tighten to correct torque LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if necessary 2.
Page 1248 ENGINE 5.9L 9 - 219 ENGINE 5.9L (Continued) DIAGNOSIS AND TESTING—ENGINE DIAGNOSIS - LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts.
Page 1249 9 - 220 ENGINE 5.9L ENGINE 5.9L (Continued) (6) Record the compression pressure on the third Start and operate the engine until it attains nor- revolution. Continue the test for the remaining cylin- mal operating temperature, then turn OFF the ders.
Page 1250 ENGINE 5.9L 9 - 221 ENGINE 5.9L (Continued) STANDARD PROCEDURE - FORM-IN-PLACE FORM-IN-PLACE GASKET AND SEALER APPLICATION GASKETS AND SEALERS Assembling parts using a form-in-place gasket There are numerous places where form-in-place requires care but it’s easier then using precut gas- gaskets are used on the engine.
Page 1251 9 - 222 ENGINE 5.9L ENGINE 5.9L (Continued) (1) Perform the Fuel Pressure Release Procedure strokes, depending on the bore condition, will be suf- (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - ficient to provide a satisfactory surface. Using honing STANDARD PROCEDURE).
Page 1252 ENGINE 5.9L 9 - 223 ENGINE 5.9L (Continued) (6) Disconnect the vacuum lines from the intake (26) Install engine assembly on engine repair manifold. stand. (7) Remove the distributor cap and wiring. INSTALLATION (8) Disconnect the accelerator linkage (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/THROTTLE (1) Remove engine from the repair stand and posi- CONTROL CABLE - REMOVAL).
Page 1253 9 - 224 ENGINE 5.9L ENGINE 5.9L (Continued) SPECIFICATIONS DESCRIPTION SPECIFICATION 5.9L ENGINE Bearing Journal Diameter ENGINE SPECIFICATIONS No. 1 50.723 – 50.775 mm (1.997 – 1.999 in.) DESCRIPTION SPECIFICATION No. 2 50.317 – 50.368 mm (1.981 – 1.983 in.) GENERAL SPECIFICATIONS No.
Page 1254 ENGINE 5.9L 9 - 225 ENGINE 5.9L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Journal #1 0.013 – 0.038 mm Head Diameter (0.0005 – 0.0015 in.) Intake 47.752 mm (1.88 in.) Journals # 2 - 5 0.013 – 0.051 mm Exhaust 41.072 (1.617 in.) (0.0005 –...
Page 1255 9 - 226 ENGINE 5.9L ENGINE 5.9L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION HYDRAULIC TAPPETS Piston Length 81.03 mm (3.19 in.) Body Diameter 22.949 – 22.962 mm Piston Ring Groove Depth (0.9035 – 0.9040 in.) Groove #1&2 4.761 – 4.912 mm Clearance (to bore) 0.0279 –...
Page 1256 ENGINE 5.9L 9 - 227 ENGINE 5.9L (Continued) DESCRIPTION SPECIFICATION OS-US Item Identification Location of Identification VALVE TIMING of each O/S Exhaust Valve tappet bore. Closes (ATDC) 33° Valve Milled pad Opens (BBDC) 56° Stems Duration 269° .127 mm adjacent to Intake Valve (.005 in.) 3/8 tapped...
Page 1257 9 - 228 ENGINE 5.9L ENGINE 5.9L (Continued) SPECIAL TOOLS DESCRIPTION N·m Front Insulator to Block— — 5.9L ENGINE Bolts (2WD) Generator—Mounting Bolt — Intake Manifold—Bolts Refer to Procedure Oil Pan—Bolts — Oil Pan—Drain Plug — Oil Pump—Attaching Bolts — Oil Pump Cover—Bolts —...
Page 1258 ENGINE 5.9L 9 - 229 ENGINE 5.9L (Continued) Front Oil Seal Installer 6635 Valve Guide Sleeve C-3973 Cam Bearing Remover/Installer C3132–A Dial Indicator C-3339 Camshaft Holder C-3509 Puller C-3688 Distributor Bushing Puller C-3052 Puller 1026 Distributor Bushing Driver/Burnisher C-3053 Crankshaft Damper Removal Insert 8513...
Page 1259 9 - 230 ENGINE 5.9L ENGINE 5.9L (Continued) AIR CLEANER ELEMENT REMOVAL Housing removal is not necessary for element (fil- ter) replacement. (1) Pry up spring clips from housing cover (spring clips retain cover to housing). (2) Release housing cover from locating tabs on housing (Fig.
Page 1260 ENGINE 5.9L 9 - 231 CYLINDER HEAD (Continued) dures in Cylinder Compression Pressure Test in this section. An engine cylinder head gasket leaking between adjacent cylinders will result in approxi- mately a 50–70% reduction in compression pressure. CYLINDER-TO-WATER JACKET LEAKAGE TEST WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING WITH COOLANT PRES- SURE CAP REMOVED.
Page 1261 9 - 232 ENGINE 5.9L CYLINDER HEAD (Continued) (8) Disconnect accelerator linkage equipped, the speed control and transmission kick- down cables. (9) Remove distributor cap and wires. (10) Disconnect the coil wires. (11) Disconnect heat indicator sending unit wire. (12) Disconnect heater hoses and bypass hose. (13) Remove cylinder head covers and gaskets (Refer to 9 - ENGINE/CYLINDER HEAD/CYLIN- DER HEAD COVER(S) - REMOVAL).
Page 1262 ENGINE 5.9L 9 - 233 CYLINDER HEAD (Continued) (20) Connect the evaporation control system. (1) Disconnect the negative cable from the battery. (21) Install the air cleaner. (2) Disconnect the spark plug wires form the spark (22) Fill cooling system (Refer to 7 - COOLING - plugs and set aside.
Page 1263 9 - 234 ENGINE 5.9L INTAKE/EXHAUST VALVES & SEATS (Continued) sleeve places the valve at the correct height for VALVE GUIDES checking with a dial indicator. Service valves with oversize stems are available. Refer to REAMER SIZES CHART REAMER SIZES CHART REAMER O/S VALVE GUIDE SIZE 0.076 mm...

This manual is also suitable for:

Dakota 2001 Dakota 4x4 2001 Dakota slt 2001

Dodge Dakota Sport 2001 Service Manual

Introduction

8W-47 Audio System

Fluid Cooler Removal

Transmission and Transfer Case

Automatic Transmission - 42Re

Table of Contents

Quick Links

Chapters

Related Manuals for Dodge Dakota Sport 2001

Summary of Contents for Dodge Dakota Sport 2001

This manual is also suitable for:

Table of Contents