Dodge dakota 2002 Service Manual

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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

Component and System Index

Service Manual Comment Forms

(Rear of Manual)

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Summary of Contents for Dodge dakota 2002

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 FASTENER IDENTIFICATION DESCRIPTION ......1 DESCRIPTION .
Page 3: Vehicle Safety Certification Label
Country of Origin 1 = Manufactured By DaimlerChrysler Corporation 3 = Manufactured By DaimlerChrysler De Mexico Make D = Dodge Vehicle Type 2 = Incomplete with Side Airbag 3 = Truck with Side Airbag 6 = Incomplete Less Side Airbag...
Page 4: Vehicle Emission Control Information (Veci)
Z = 5.9L 8 cyl. SMPI Gasoline Light Duty Check Digit 0 through 9 or X Model Year 3 = 2003 Plant Location S = Dodge City G = Saltillo J = St. Louis (North) 12 thru 17 Vehicle Build Sequence VEHICLE EMISSION CONTROL...
Page 5: Description
INTRODUCTION BODY CODE PLATE DESCRIPTION The Body Code Plate (Fig. 5) is located on the right front hydroform fender rail just behind the headlight assembly (Fig. 4). There are seven lines of informa- tion on the body code plate. Lines 5, 6, and 7 are not used to define service information.
Page 6 INTRODUCTION BODY CODE PLATE (Continued) DIGIT 19 BODY CODE PLATE—LINE 2 Price Class • L = Low DIGIT 1 Open Space • H = Highline DIGITS 2 AND 3 Species Code. (Used for Manufacturing) DIGITS 20 AND 21 DIGIT 4 Body Type •...
Page 7: International Vehicle Control
INTRODUCTION INTERNATIONAL VEHICLE FASTENER IDENTIFICATION CONTROL & DISPLAY DESCRIPTION SYMBOLS The SAE bolt strength grades range from grade 2 to grade 8. The higher the grade number, the greater DESCRIPTION - INTERNATIONAL SYMBOLS the bolt strength. Identification is determined by the The graphic symbols illustrated in the following line marks on the top of each bolt head.
Page 8 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 6 FASTENER IDENTIFICATION...
Page 9 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 7 FASTENER STRENGTH...
Page 10: Fastener Usage
INTRODUCTION FASTENER USAGE THREADED HOLE REPAIR DESCRIPTION - FASTENER USAGE DESCRIPTION - THREADED HOLE REPAIR Most stripped threaded holes can be repaired using WARNING: USE OF AN INCORRECT FASTENER a Helicoil . Follow the vehicle or Helicoil recommen- MAY RESULT IN COMPONENT DAMAGE OR PER- dations for application and repair procedures.
Page 11 INTRODUCTION METRIC SYSTEM (Continued) Fig. 8 METRIC CONVERSION CHART...
Page 12: Torque References Description
INTRODUCTION tions Chart for torque references not listed in the TORQUE REFERENCES individual torque charts (Fig. 9). DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- Fig. 9 TORQUE SPECIFICATIONS...
Page 14 They can be unstable under certain conditions and hazardous or explosive when mixed with diesel fuel. Use good quality diesel fuel from a reputable sup- plier in your Dodge truck. For most year-round ser- vice, number diesel fuel...
Page 15: Fluid Types
0 - 2 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) Diesel fuel is seldom completely free of water. To prevent fuel system trouble, including fuel line freez- ing in winter, drain the accumulated water from the fuel/water separator using the fuel/water separator drain provided.
Page 16: Description - Power Steering Fluid
LUBRICATION & MAINTENANCE 0 - 3 FLUID TYPES (Continued) ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block.
Page 17: Genii
0 - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) must always be a minimum of 44 percent, year- DESCRIPTION - AXLE round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protec- NOTE: DaimlerChrysler recommends using Mopar tion against freezing is provided with a 68 percent lubricants or lubricants of equal quality.
Page 18: Operation - Automatic Transmission Fluid
LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) FLUID ADDITIVES 2DESCRIPTION SPECIFICATION DaimlerChrysler strongly recommends against the COOLING SYSTEM addition of any fluids to the transmission, other than 3.7L 15.4 L (16.2 qts.)** those automatic transmission fluids listed above. 4.7L 15.4 L (16.2 qts.)** Exceptions to this policy are the use of special dyes...
Page 19: Maintenance Schedules Description
0 - 6 LUBRICATION & MAINTENANCE Once a Month MAINTENANCE SCHEDULES • Check tire pressure and look for unusual wear or damage. DESCRIPTION • Inspect the battery and clean and tighten the Maintenance Schedule Information not included in terminals as required. this section, is located in the appropriate Owner’s •...
Page 20 LUBRICATION & MAINTENANCE 0 - 7 MAINTENANCE SCHEDULES (Continued) Miles 3,000 6,000 9,000 12,000 15,000 (Kilometers) (5 000) (10 000) (14 000) (19 000) (24 000) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Change rear axle fluid.
Page 21 0 - 8 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 48,000 51,000 54,000 57,000 60,000 (Kilometers) (77 000) (82 000) (86 000) (91 000) (96 000) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Drain and refill transfer case fluid.
Page 22 LUBRICATION & MAINTENANCE 0 - 9 MAINTENANCE SCHEDULES (Continued) Miles 78,000 81,000 84,000 87,000 90,000 (Kilometers) (125 000) (130 000) (134 000) (139 000) (144 000) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) models only. Change rear axle fluid.
Page 23 0 - 10 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 105,000 108,000 111,000 114,000 117,000 120,000 (Kilometers) (168 000) (173 000) (178 000) (182 000) (187 000) (192 000) Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) models only.
Page 24 LUBRICATION & MAINTENANCE 0 - 11 MAINTENANCE SCHEDULES (Continued) Schedule “A” Miles 6,000 12,000 18,000 24,000 30,000 (Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000) [Months] [12] [18] [24] [30] Change engine oil and engine oil filter. Check transfer case fluid level.
Page 25 0 - 12 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 72,000 78,000 84,000 90,000 96,000 100,000 (Kilometers) (115 000) (125 000) (134 000) (144 000) (154 000) (160 000) [Months] [72] [78] [84] [90] [96] Change engine oil and engine oil filter. Lubricate outer tie rod ends 2500/3500 (4X4) models only.
Page 26: Jump Starting
LUBRICATION & MAINTENANCE 0 - 13 CAUTION: If the cause of starting problem on dis- JUMP STARTING abled vehicle is severe, damage to booster vehicle charging system can result. STANDARD PROCEDURE - JUMP STARTING (2) When using another vehicle as a booster WARNING: REVIEW ALL SAFETY PRECAUTIONS source, park the booster vehicle within cable reach.
Page 27: Hoisting
0 - 14 LUBRICATION & MAINTENANCE • A drive shaft. HOISTING • The engine or transmission oil pan. • The fuel tank. STANDARD PROCEDURE - HOISTING • A front suspension arm. Refer to the Owner’s Manual for emergency vehicle lifting procedures. NOTE: Use the correct frame rail lifting locations only (Fig.
Page 28: Towing
LUBRICATION & MAINTENANCE 0 - 15 HOISTING (Continued) Fig. 7 FRONT LIFT PAD LOCATION 1 - BODY MOUNT BRACKET 2 - FRONT LIFT PAD 3 - TRANSMISSION CROSSMEMBER BRACKET 4 - FRAME RAIL Fig. 9 Tow Vehicles With Approved Equipment 1 - SLING TYPE 2 - WHEEL LIFT 3 - FLAT BED...
Page 29 0 - 16 LUBRICATION & MAINTENANCE TOWING (Continued) A towed vehicle should be raised until lifted wheels FOUR-WHEEL-DRIVE VEHICLE TOWING are a minimum 100 mm (4 in) from the ground. Be Chrysler Corporation recommends that a vehicle be sure there is adequate ground clearance at the oppo- transported on a flat-bed device.
Page 30 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page WHEEL ALIGNMENT ..... . 1 FRONT - LINK/COIL ..... . 28 FRONT - INDEPENDENT FRONT SUSPENSION .
Page 31: Wheel Alignment
2 - 2 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) OPERATION sive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust • CASTER is the forward or rearward tilt of the angle (Fig. 1) steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster.
Page 32: Standard Procedure
WHEEL ALIGNMENT 2 - 3 WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Replace steering gear. EFFORT 2. Column coupler binding. 2. Replace coupler. 3. Tire pressure. 3. Adjust tire pressure. 4. Alignment. 4.
Page 33: Standard Procedure - Camber And Caster Adjustment
2 - 4 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) To adjust the vehicle height turn the torsion bar adjustment bolt CLOCKWISE to raise the vehicle and COUNTER CLOCKWISE to lower the vehicle. CAUTION: ALWAYS raise the vehicle to the correct suspension height, NEVER lower the vehicle to obtain the correct suspension height.
Page 34: Standard Procedure - Alignment Link/Coil Suspension
WHEEL ALIGNMENT 2 - 5 WHEEL ALIGNMENT (Continued) angle while adjusting caster, move one pivot bolt of the upper control arm in or out. Then move the other pivot bolt of the upper control arm in the opposite direction. Install special tool 8876 between the top of the upper control arm bracket and the upper control arm (on 1500 series 4X2 &...
Page 35 2 - 6 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) (1) Start the engine and turn wheels both ways DESCRIP- SPECIFICATION before straightening the wheels. Center and Secure TION the steering wheel and turn off engine. MAX RT/LT — .40° .50° 0.06° (2) Loosen the adjustment sleeve clamp bolts.
Page 36 WHEEL ALIGNMENT 2 - 7 WHEEL ALIGNMENT (Continued) SPECIAL TOOLS WHEEL ALIGNMENT 8876 - CAMBER/CASTER ADJUSTMENT TOOL...
Page 37 2 - 8 FRONT - INDEPENDENT FRONT SUSPENSION FRONT - INDEPENDENT FRONT SUSPENSION TABLE OF CONTENTS page page FRONT - INDEPENDENT FRONT SUSPENSION LOWER CONTROL ARM DESCRIPTION REMOVAL DESCRIPTION ......9 REMOVAL - 4X4 (LD) .
Page 38: Front - Independent Front Suspension Description Description
FRONT - INDEPENDENT FRONT SUSPENSION 2 - 9 FRONT - INDEPENDENT FRONT SUSPENSION DESCRIPTION DESCRIPTION The front suspension is designed to allow each wheel to adapt to different road surfaces indepen- dently. The wheels are mounted to hub/bearings units bolted to the steering knuckle. The double-row hub bearings are sealed and lubricated for life.
Page 39: Specifications Torque Chart
2 - 10 FRONT - INDEPENDENT FRONT SUSPENSION FRONT - INDEPENDENT FRONT SUSPENSION (Continued) SPECIFICATIONS TORQUE CHART TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Shock Absorber — Upper Nut Shock Absorber — Lower Bolt Shock Absorber — Upper Nut Shock Absorber —...
Page 40: Special Tools Front Suspension
FRONT - INDEPENDENT FRONT SUSPENSION 2 - 11 FRONT - INDEPENDENT FRONT SUSPENSION (Continued) SPECIAL TOOLS FRONT SUSPENSION TORSION BAR BUSHING REMOVAL/INSTALL - 8835 PULLER - 8677 RECEIVER/ DRIVER BALLJOINT - 8698 4WD BUSHING REMOVAL/INSTALL KIT - 8682 BALL JOINT PRESS - C-4212F TORSION BAR LOADER/UNLOADER - 8686 2WD - LOWER CONTROL ARM BUSHING REMOVAL/INSTALL - 8836...
Page 41: Bushings Removal
2 - 12 FRONT - INDEPENDENT FRONT SUSPENSION BUSHINGS REMOVAL REMOVAL - LOWER CONTROL ARM BUSHINGS - 4WD (LD) (1) Remove the lower control arm (Refer to 2 - SUSPENSION/FRONT/LOWER CONTROL ARM - REMOVAL). (2) Secure the control arm in a vise. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool.
Page 42: Installation
FRONT - INDEPENDENT FRONT SUSPENSION 2 - 13 BUSHINGS (Continued) Fig. 5 TORSION BAR CROSS MEMBER BUSHING - Fig. 7 SMALL LOWER CONTROL ARM BUSHING - REMOVAL REMOVAL 1 - 8838 1 - 8839 (THREADED ROD) 2 - 8835-1 2 - 8836-6 (DRIVER) 3 - 8835-4 3 - 8836-3 (SPACER) 4 - 8835-3...
Page 43: Installation - Torsion Bar Cross Member Bushing
2 - 14 FRONT - INDEPENDENT FRONT SUSPENSION BUSHINGS (Continued) FRAME MOUNTED BUSHING NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation pro- cess.
Page 44: Hub / Bearing Removal Removal - 4X4
FRONT - INDEPENDENT FRONT SUSPENSION 2 - 15 BUSHINGS (Continued) SMALL BUSHING (1) Install the small bushings into the lower con- trol arm using tools 8836-7 (driver), 8836-2 (receiver), 8836–3 (spacer) and the bearing with the threaded rod (8839) (Fig. 13). Fig.
Page 45: Removal - 4X2
2 - 16 FRONT - INDEPENDENT FRONT SUSPENSION HUB / BEARING (Continued) NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. (6) Remove the tie rod end nut and separate the tie rod from the knuckle using special tool 8677.
Page 46: Installation - 4X2
FRONT - INDEPENDENT FRONT SUSPENSION 2 - 17 HUB / BEARING (Continued) (4) Install the ABS wheel speed sensor if equipped (5) Remove the tie rod end nut. Separate the tie (Refer BRAKES/ELECTRICAL/FRONT rod from the knuckle with Remover 8677. WHEEL SPEED SENSOR - INSTALLATION).
Page 47: Installation
2 - 18 FRONT - INDEPENDENT FRONT SUSPENSION KNUCKLE (Continued) (8) Remove the hub/bearing from the steering (8) Install the ABS wheel speed sensor if equipped knuckle (Refer to 2 - SUSPENSION/FRONT/HUB / (Refer to 5 - BRAKES/ELECTRICAL/FRONT WHEEL BEARING - REMOVAL). SPEED SENSOR - INSTALLATION) and brake shield, rotor and caliper (Refer to 5 - BRAKES/HYDRAULIC/ INSTALLATION...
Page 48: Installation
FRONT - INDEPENDENT FRONT SUSPENSION 2 - 19 LOWER BALL JOINT (Continued) (1) Install the ball joint into the control arm and press in using special tools C-4212–F (press), 8698-1 (driver) and 8698-3 (receiver) (Fig. 22). Fig. 20 LOWER BALL JOINT SEPARATION 1 - STEERING KNUCKLE 2 - SPECIAL TOOL 8677 Fig.
Page 49: Lower Control Arm
2 - 20 FRONT - INDEPENDENT FRONT SUSPENSION in the frame. The bell-shaped adapter goes against LOWER CONTROL ARM the lower suspension arm. Install the nut on top of the tool at the shock hole. REMOVAL (6) Tighten the spring compressor nut against bell- shaped adapter finger tight then loosen 1/2 turn.
Page 50: Installation
FRONT - INDEPENDENT FRONT SUSPENSION 2 - 21 LOWER CONTROL ARM (Continued) (7) Position the lower ball joint into the steering INSTALLATION knuckle. (8) Install the retaining nut on the lower ball joint INSTALLATION - 4X4 (LD) and tighten to 52 N·m (38 ft. lbs.)(on 1500 series only (1) Position the lower control arm at the frame rail an additional 90°...
Page 51: Installation
2 - 22 FRONT - INDEPENDENT FRONT SUSPENSION SPRING (Continued) Fig. 25 SPRING COMPRESSOR TOOL Fig. 26 COIL SPRING 1 - SPECIAL TOOL DD-1278 1 - COIL SPRING 2 - BELL-SHAPED ADAPTER 2 - STEERING KNUCKLE 3 - OUTER TIE ROD END NOTE: Do not allow the upper control arm and 4 - LOWER CONTROL ARM 5 - SHOCK...
Page 52: Shock
FRONT - INDEPENDENT FRONT SUSPENSION 2 - 23 SHOCK DIAGNOSIS AND TESTING - SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts.
Page 53: Stabilizer Bar Description
2 - 24 FRONT - INDEPENDENT FRONT SUSPENSION (2) Position the stabilizer bar on the frame cross- STABILIZER BAR member brackets and install the bracket and bolts finger-tight (Fig. 29). DESCRIPTION The bar extends across the front underside of the NOTE: Check the alignment of the bar to ensure chassis and connects to the frame crossmember.
Page 54: Installation Installation - 4X4
FRONT - INDEPENDENT FRONT SUSPENSION 2 - 25 STABILIZER LINK (Continued) (5) Increase the tension on the anchor arm tool INSTALLATION until the load is removed from the adjustment bolt and the adjuster nut (Fig. 30). INSTALLATION - 4X4 (6) Turn the adjustment bolt counterclockwise to (1) Install the stabilizer link to the vehicle.
Page 55: Upper Ball Joint Diagnosis And Testing - Upper Ball Joint
2 - 26 FRONT - INDEPENDENT FRONT SUSPENSION TORSION BAR (Continued) INSTALLATION (3) Mount a dial indicator solidly to the frame and then zero the dial indicator. (4) Position dial indicator plunger on the topside of CAUTION: The left and right side torsion bars are the upper ball joint (Fig.
Page 56: Upper Control Arm Removal
FRONT - INDEPENDENT FRONT SUSPENSION 2 - 27 (5) Remove the control arm pivot bolts and remove UPPER CONTROL ARM control arm (Fig. 34). REMOVAL (1) Raise and support vehicle. (2) Remove wheel and tire assembly. (3) Remove the nut from upper ball joint. (4) Separate upper ball joint from the steering knuckle with Remover 8677 (Fig.
Page 57 2 - 28 FRONT - LINK/COIL FRONT - LINK/COIL TABLE OF CONTENTS page page FRONT - LINK/COIL REMOVAL - RIGHT ....34 SPECIFICATIONS INSTALLATION TORQUE CHART .
Page 58: Special Tools
FRONT - LINK/COIL 2 - 29 FRONT - LINK/COIL (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Stabilizer Link — Stabilizer Bar Nut Hub/Bearing — Bolts Axle Nut 179 Beginning Torque, Then 132 Beginning Torque, Then — Rotate 5 to 10 Times With a Rotate 5 to 10 Times With a Final Torque of 356 Final Torque of 263...
Page 59: Hub / Bearing Removal
2 - 30 FRONT - LINK/COIL (7) Back off the hub/bearing mounting bolts 1/4 HUB / BEARING inch each (Fig. 3). Then tap the bolts with a hammer to loosen the hub/bearing from the steering knuckle. REMOVAL (8) Remove the hub/bearing mounting bolts and (1) Raise and support the vehicle.
Page 60: Installation
FRONT - LINK/COIL 2 - 31 HUB / BEARING (Continued) Fig. 5 ROTOR AND HUB/BEARING 1 - HUB BEARING 2 - ROTOR Fig. 7 Rotor, Hub/Bearing And Stud 1 - HUB BEARING 2 - ROTOR 3 - STUD NOTE: If the vehicle is equipped with a wheel speed sensor the brake shield must be positioned on the hub bearing (Fig.
Page 61: Lower Ball Joint Removal
2 - 32 FRONT - LINK/COIL HUB / BEARING (Continued) (9) Install the remaining bolts. Tighten the hub/ bearing bolts to 202 N·m (149 ft. lbs. (10) Install the washer and axle nut and tighten a beginning torque of 179 N·m (132 ft. lbs.). (11) Rotate the axle 5 to 10 times to seat the hub bearing.
Page 62: Installation
FRONT - LINK/COIL 2 - 33 LOWER BALL JOINT (Continued) UPPER BALL JOINT REMOVAL (1) Position special tool 6761 (RECEIVER) and 8445–3 (DRIVER) with C-4212–F as shown to remove upper ball stud (Fig. 14). Fig. 12 LOWER BALL JOINT REMOVAL 1 - SPECIAL TOOL C4212-F 2 - SPECIAL TOOL 8975-2 3 - KNUCKLE...
Page 63: Installation
2 - 34 FRONT - LINK/COIL KNUCKLE REMOVAL (1) Remove the hub bearing (Refer to 2 - SUSPEN- SION/FRONT/HUB / BEARING - REMOVAL). (2) Remove tie-rod or drag link end from the steer- ing knuckle arm. (3) Remove the ABS sensor wire and bracket from knuckle.
Page 64: Lower Suspension Arm Removal
FRONT - LINK/COIL 2 - 35 LOWER SUSPENSION ARM SHOCK REMOVAL DIAGNOSIS AND TESTING - SHOCK (1) Raise and support the vehicle. A knocking or rattling noise from a shock absorber (2) Paint or scribe alignment marks on the cam may be caused by movement between mounting adjusters and suspension arm for installation refer- bushings and metal brackets or attaching compo-...
Page 65: Spring Removal
2 - 36 FRONT - LINK/COIL SHOCK (Continued) SPRING REMOVAL (1) Raise and support the vehicle. Position a hydraulic jack under the axle to support it. (2) Paint or scribe alignment marks on lower sus- pension arm cam adjusters and axle bracket for installation reference.
Page 66: Stabilizer Bar Removal
FRONT - LINK/COIL 2 - 37 INSTALLATION STABILIZER BAR (1) Position the stabilizer bar on the frame rail REMOVAL and install the clamps and bolts. Ensure the bar is centered with equal spacing on both sides. (1) Raise and support the vehicle. (2) Tighten the clamp bolts to 61 N·m (45 ft.
Page 67 2 - 38 REAR REAR TABLE OF CONTENTS page page REAR INSTALLATION ......40 DESCRIPTION ......38 SHOCK DIAGNOSIS AND TESTING - SPRING AND REMOVAL .
Page 68: Rear Description
REAR 2 - 39 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 69: Jounce Bumper Removal
2 - 40 REAR JOUNCE BUMPER REMOVAL (1) Remove the two bolts securing the jounce bumper to the bracket (Fig. 1). (2) Remove the jounce bumper. Fig. 2 AUXILIARY SPRING BUMPER (3500) 1 - NUTS 2 - AUXILIARY SPRING BUMPERS SHOCK REMOVAL Fig.
Page 70: Spring Description
REAR 2 - 41 INSTALLATION SPRING (1) Position spring on axle shaft tube so spring DESCRIPTION center bolt is inserted into the locating hole in the axle tube. The rear suspension system uses a multi-leaf (2) Align the front of the spring with the bolt hole in springs and a solid drive axle.
Page 71: Installation
2 - 42 REAR SPRING TIP INSERTS (Continued) (5) Use the pry bar to spread apart the leaf (Fig. NOTE: THE SPRING TIP LINER IS PROPERLY 6). The clearance between the leaves should be INSTALLED WHEN THE RETAINING PIN IS POINT- enough to remove the old liner (if necessary) and ING TOWARD THE PAVEMENT AND THE WEAR PAD install the replacement liner.
Page 72 REAR 2 - 43 SPRING TIP INSERTS (Continued) (6) Using large adjustable pliers, close the spring clinch clip until the isolator contacts the leaf spring (Fig. 10). CAUTION: DO NOT USE A HAMMER TO CLOSE THE SPRING CLINCH CLIP. DAMAGE TO THE ISOLATOR MAY RESULT.
Page 74 DIFFERENTIAL & DRIVELINE 3 - 1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page page PROPELLER SHAFT ..... . 1 REAR AXLE - 9 1/4 .
Page 75: Propeller Shaft
3 - 2 PROPELLER SHAFT PROPELLER SHAFT (Continued) DRIVELINE VIBRATION Drive Condition Possible Cause Correction Propeller Shaft Noise 1) Undercoating or other foreign 1) Clean exterior of shaft and wash material on shaft. with solvent. 2) Loose U-joint clamp screws. 2) Install new clamps and screws and tighten to proper torque.
Page 76 PROPELLER SHAFT 3 - 3 PROPELLER SHAFT (Continued) (15) If the vibration remains unacceptable, apply the same steps to the front end of the propeller shaft. (16) Install the wheel and tires. Lower the vehicle. PROPELLER SHAFT RUNOUT (1) Remove dirt, rust, paint and undercoating from the propeller shaft surface where the dial indicator will contact the shaft.
Page 77 3 - 4 PROPELLER SHAFT PROPELLER SHAFT (Continued) (3) Rotate the shaft until transmission/transfer case output yoke bearing is facing downward. NOTE: Always make measurements from front to rear and from the same side of the vehicle. (4) Place Inclinometer 7663 on yoke bearing (A) parallel to the shaft (Fig.
Page 78 PROPELLER SHAFT 3 - 5 PROPELLER SHAFT (Continued) Fig. 7 UNIVERSAL JOINT ANGLE EXAMPLE 1 - 4.9° Angle (C) 4 - 3.0° Angle (A) 2 - 3.2° Angle (B) 5 - Output Yoke 3 - Input Yoke TWO-PIECE PROPELLER SHAFT The procedure to measure the propeller shaft angles involved with a two-piece (Fig.
Page 79: Propeller Shaft
3 - 6 PROPELLER SHAFT PROPELLER SHAFT (Continued) SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Center Bearing Bolts Front Pinion Flange Bolts Rear Pinion Flange Bolts SPECIAL TOOLS FRONT PROPELLER SHAFT REMOVAL (1) Position transmission and transfer case into neutral.
Page 80: Installation
PROPELLER SHAFT 3 - 7 FRONT PROPELLER SHAFT (Continued) Fig. 10 DUST BOOT Fig. 11 COMPANION FLANGE 1 - C/V JOINT 1 - PROPELLER SHAFT 2 - TRANSFER CASE 2 - COMPANION FLANGE 3 - BOOT CLAMP 3 - REFERENCE MARK 4 - PROPELLER SHAFT 4 - SHAFT FLANGE YOKE INSTALLATION...
Page 81: Propeller Shaft
3 - 8 PROPELLER SHAFT REAR PROPELLER SHAFT (Continued) INSTALLATION (1) Slide the slip yoke onto the transmission/trans- fer case output shaft. (2) Align and install center bearing on crossmem- ber, if necessary and tighten nutts to 54 N·m (40 ft. lbs.).
Page 82: Single Cardan Universal Joints Disassembly
PROPELLER SHAFT 3 - 9 SINGLE CARDAN UNIVERSAL JOINTS DISASSEMBLY NOTE: The following procedure is described for a propeller shaft equipped with only a cardan joint in the tube yoke. If the propeller shaft is equipped with a companion yoke, simply repeat the following steps to remove the cardan joint from the compan- ion yoke after removing the cardan joint from the tube yoke.
Page 83 3 - 10 PROPELLER SHAFT SINGLE CARDAN UNIVERSAL JOINTS (Continued) (3) Place a bearing cap over the trunnion and align the cap with the yoke bore (Fig. 19). Keep the needle bearings upright in the bearing assembly. A needle bearing lying at the bottom of the cap will prevent proper assembly.
Page 84: Diagnosis And Testing
HALF SHAFT 3 - 11 HALF SHAFT TABLE OF CONTENTS page page HALF SHAFT CV JOINT-OUTER CAUTION ......11 REMOVAL .
Page 85: Installation
3 - 12 HALF SHAFT HALF SHAFT (Continued) (9) Disengage inner C/V joint from the axle shaft (2) Apply a light coating of grease to the front axle snap-ring by apply pressure with two pry bars shaft output splines. between the C/V housing and axle housing. (3) Install half shaft into the knuckle (Fig.
Page 86: Cv Joint-Outer Removal
HALF SHAFT 3 - 13 CV JOINT-OUTER REMOVAL (1) Clamp shaft in a vise (with soft jaws) and sup- port C/V joint. (2) Remove clamps with a cut-off wheel or grinder (Fig. 4). CAUTION: Do not damage C/V housing or half shaft.
Page 87 3 - 14 HALF SHAFT CV JOINT-OUTER (Continued) Fig. 9 INNER RACE/HUB Fig. 7 BEARING 1 - HOUSING 2 - INNER RACE/HUB 3 - BEARING CAGE 4 - BALL Fig. 10 INNER RACE/HUB 1 - INNER RACE/HUB 2 - BEARING CAGE Fig.
Page 88 HALF SHAFT 3 - 15 CV JOINT-OUTER (Continued) Fig. 12 BEARING CAGE AND HOUSING Fig. 14 OUTER C/V JOINT 1 - OUTER RACE 1 - SNAP RING 2 - BEARING CAGE WINDOW 2 - SHAFT TAPER 3 - CV JOINT HOUSING 3 - SNAP RING GROVE 4 - BEARING HUB NOTE: Verify boot is not twisted and remove any...
Page 89: Cv Joint-Inner Removal
3 - 16 HALF SHAFT CV JOINT-INNER REMOVAL (1) Clamp shaft in a vise (with soft jaws) and sup- port C/V joint. (2) Remove clamps with a cut-off wheel or grinder (Fig. 16). CAUTION: Do not damage C/V housing or half shaft with cut-off wheel or grinder.
Page 90 HALF SHAFT 3 - 17 CV JOINT-INNER (Continued) Fig. 21 INNER C/V BOOT Fig. 20 HOUSING BUSHING 1 - CLAMP 1 - BUSHING 2 - BOOT 2 - HOUSING 3 - CLAMP 4 - SHAFT 5 - HOUSING (8) Position the boot on the joint and shaft in it’s original position (Fig.
Page 91 3 - 18 FRONT AXLE - C205F FRONT AXLE - C205F TABLE OF CONTENTS page page FRONT AXLE - C205F INSTALLATION ......34 DESCRIPTION .
Page 92: Front Axle - C205F Description
FRONT AXLE - C205F 3 - 19 FRONT AXLE - C205F (Continued) tial bearing noise is also constant and varies only Check for loose or damaged front end components with vehicle speed. or engine/transmission mounts. These components Axle shaft bearings produce noise and vibration can contribute to what appears to be a rear end when worn or damaged.
Page 93 3 - 20 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) Condition Possible Causes Correction Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting tube mis-alignment. 2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight on vehicle.
Page 94: Removal
FRONT AXLE - C205F 3 - 21 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 95 3 - 22 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) Fig. 1 SUSPENSION CROSSMEMBER 1 - PINION FLANGE 2 - AXLE TUBE MOUNTING BRACKET 3 - CROSSMEMBER BOLTS Fig. 3 AXLE TUBE MOUNT 1 - MOUNTING BOLTS 2 - BOLTS Fig.
Page 96 FRONT AXLE - C205F 3 - 23 FRONT AXLE - C205F (Continued) Fig. 6 ADJUSTMENT SHIM 1 - PINION GEAR DEPTH SHIM 2 - DIFFERENTIAL BEARING PRELOAD SHIM 3 - RING GEAR 4 - DIFFERENTIAL BEARING PRELOAD SHIM 5 - COLLAPSIBLE SPACER Depth Variance charts.
Page 97 3 - 24 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion cups and pin- ion bearings installed in housing. Take measure- ments with a Pinion Gauge Set, Pinion Block 8177, Arbor Discs 8541 and Dial Indicator C-3339 (Fig.
Page 98 FRONT AXLE - C205F 3 - 25 FRONT AXLE - C205F (Continued) Fig. 11 ADJUSTMENT SHIM Fig. 10 PINION GEAR DEPTH MEASUREMENT 1 - PINION GEAR DEPTH SHIM 1 - ARBOR 2 - DIFFERENTIAL BEARING PRELOAD SHIM 2 - SCOOTER BLOCK 3 - RING GEAR 3 - DIAL INDICATOR 4 - DIFFERENTIAL BEARING PRELOAD SHIM...
Page 99 3 - 26 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) (6) Install the marked bearing caps in their correct positions. Install and snug the bolts. (7) Using a dead-blow hammer to seat the differ- ential dummy bearings to each side of the differential housing (Fig.
Page 100 FRONT AXLE - C205F 3 - 27 FRONT AXLE - C205F (Continued) (20) Zero dial indicator face to pointer. (21) Push and hold differential case to ring gear side of the housing. (22) Record dial indicator reading. (23) Subtract 0.05 mm (0.002 in.) from the dial indicator reading to compensate for backlash between ring and pinion gears.
Page 101 3 - 28 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) • Gear contact pattern correct (Fig. 20). Backlash (34) Zero dial indicator face to pointer. (35) Push and hold ring gear downward while not and pinion depth is correct. allowing the pinion gear to rotate.
Page 102: Specifications
FRONT AXLE - C205F 3 - 29 FRONT AXLE - C205F (Continued) • Ring gear too far away from pinion gear (Fig. • Pinion gear set too low (Fig. 25). Increase pinion 23). Decrease backlash, by moving the ring closer to gear height, by increasing the pinion depth shim the pinion gear.
Page 103: Special Tools
3 - 30 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Mounting Nuts Differential Fill Hole Plug Differential Cover Bolts Bearing Cap Bolts Ring Gear Bolts Pinion Nut 271-475 200-350 SPECIAL TOOLS PULLER C-452 PULLER C-293-PA HOLDER 6719A...
Page 104 FRONT AXLE - C205F 3 - 31 FRONT AXLE - C205F (Continued) REMOVER 8401 INSTALLER 8693 REMOVER 8831 INSTALLER 8692 INSTALLER 8695 INSTALLER 6448 REMOVER C-4660-A INSTALLER 8694 CUP 8150...
Page 105 3 - 32 FRONT AXLE - C205F FRONT AXLE - C205F (Continued) DIAL INDICATOR C-3339 INSTALLER 5063 DUMMY SHIM 8107 PINION BLOCK 8177 DUMMY BEARING 8398 PINION DEPTH SET 6775 INSTALLER C-3718 SPREADER W-129-B PILOTS C-3288-B ADAPTER PLATES 8142A...
Page 106: Axle Shafts
FRONT AXLE - C205F 3 - 33 INSTALLATION AXLE SHAFTS (1) Clean axle shaft bore clean. REMOVAL (2) Install a new axle shaft seal with Installer 8694 and Handle C-4171. (1) Remove half shaft from vehicle. (3) Lubricate seal lip with gear lubricant. (2) Remove skid plate, if equipped.
Page 107: Installation
3 - 34 FRONT AXLE - C205F AXLE BEARINGS (Continued) (6) Install axle shaft O-ring. (7) Check the differential fluid level and add fluid if necessary. (8) Install skid plate, if necessary. (9) Install half shaft. PINION SEAL REMOVAL (1) Remove skid plate, if equipped. (2) Remove both half shafts.
Page 108 FRONT AXLE - C205F 3 - 35 PINION SEAL (Continued) Fig. 34 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER (4) Position holder against the companion flange and install four bolts and washers into the threaded holes. Tighten the bolt and washer so that the holder is held to the flange.
Page 109 3 - 36 FRONT AXLE - C205F PINION SEAL (Continued) CAUTION: Never loosen pinion nut to decrease pin- DIFFERENTIAL ion bearing rotating torque and never exceed spec- ified preload torque. If preload torque or rotating DESCRIPTION torque is exceeded a new collapsible spacer must The differential case is a one-piece design.
Page 110 FRONT AXLE - C205F 3 - 37 DIFFERENTIAL (Continued) (6) Install a Pilot Stud L-4438 at the left side of the differential housing. Attach Dial Indicator C-3339 to pilot stud. Load the indicator plunger against the opposite side of the housing and zero the indicator. (7) Spread the housing to remove the differential case from the housing (Fig.
Page 111 3 - 38 FRONT AXLE - C205F DIFFERENTIAL (Continued) ASSEMBLY (1) Install differential side gears and thrust wash- ers. (2) Install pinion mate gears and thrust washers. (3) Install pinion gear mate shaft. (4) Align the hole in the pinion gear mate shaft with the hole in the differential case.
Page 112 FRONT AXLE - C205F 3 - 39 DIFFERENTIAL (Continued) (3) Spread housing and measure the distance with the dial indicator. CAUTION: Never spread over 0.50 mm (0.020 in). If the housing is over-spread, it could be distorted or damaged. (4) Remove dial indicator. (5) Install differential case in the housing.
Page 113 3 - 40 FRONT AXLE - C205F PINION GEAR/RING GEAR REMOVAL NOTE: The ring gear and pinion are serviced in a matched set. Never replace one without replacing the other. (1) Remove differential from housing. (2) Place differential case in a vise with soft jaw (Fig.
Page 114 FRONT AXLE - C205F 3 - 41 PINION GEAR/RING GEAR (Continued) Fig. 49 FRONT PINION BEARING CUP Fig. 51 COLLAPSIBLE SPACER 1 - HOUSING 1 - COLLAPSIBLE SPACER 2 - REMOVER 2 - REAR PINION BEARING 3 - HANDLE 3 - PINION DEPTH SHIM Fig.
Page 115 3 - 42 FRONT AXLE - C205F PINION GEAR/RING GEAR (Continued) INSTALLATION (3) Install front pinion bearing cup with Installer 8693 and Handle C-4171 (Fig. 54) and verify cup is seated. NOTE: The ring gear and pinion are serviced in a matched set.
Page 116 FRONT AXLE - C205F 3 - 43 PINION GEAR/RING GEAR (Continued) (7) Place pinion depth shim (Fig. 56) on the pinion (9) Install new collapsible spacer onto the pinion shaft. shaft (Fig. 58). Fig. 56 PINION DEPTH SHIM Fig. 58 COLLAPSIBLE SPACER 1 - PINION DEPTH SHIM 1 - COLLAPSIBLE SPACER 2 - PINION GEAR...
Page 117 3 - 44 FRONT AXLE - C205F PINION GEAR/RING GEAR (Continued) (17) Install new ring gear bolts and alternately tighten to 108 N·m (80 ft. lbs.) (Fig. 61). CAUTION: Never reuse the ring gear bolts. The bolts can fracture causing extensive damage. Fig.
Page 118 FRONT AXLE - 9 1/4 AA 3 - 45 FRONT AXLE - 9 1/4 AA TABLE OF CONTENTS page page FRONT AXLE - 9 1/4 AA PINION SEAL DESCRIPTION ......45 REMOVAL .
Page 119 3 - 46 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) • Loose/broken springs. heard during a coast, the front pinion bearing is the • Damaged axle shaft bearing(s). source. • Loose pinion gear nut. Worn or damaged differential bearings usually pro- •...
Page 120 FRONT AXLE - 9 1/4 AA 3 - 47 FRONT AXLE - 9 1/4 AA (Continued) Condition Possible Causes Correction Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting tube mis-alignment. 2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight on vehicle.
Page 121 3 - 48 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) Condition Possible Causes Correction Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible damage. 2. Erratic clutch operation. 2.
Page 122 FRONT AXLE - 9 1/4 AA 3 - 49 FRONT AXLE - 9 1/4 AA (Continued) (6) Position upper and lower suspension arms in the axle brackets. Install bolts, nuts and align the suspension alignment cams to the reference marks. Do not tighten at this time.
Page 123 3 - 50 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) NOTE: Arbor should rotate freely in the arbor disc. Fig. 4 PINION DEPTH MEASUREMENT 1. DIAL INDICATOR Fig. 3 GAUGE TOOLS IN HOUSING 2. ARBOR 1.
Page 124 FRONT AXLE - 9 1/4 AA 3 - 51 FRONT AXLE - 9 1/4 AA (Continued) (6) Install ring gear side adjuster lock and bolt. Do GEAR TOOTH CONTACT PATTERN not tighten adjuster lock bolt at this time. Gear tooth contact pattern is used to verify the cor- (7) Tighten pinion gear...
Page 125 3 - 52 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) • Ring gear too close to pinion gear (Fig. 9). Increase backlash, by moving the ring away from the pinion gear using the adjusters. Fig.
Page 126 FRONT AXLE - 9 1/4 AA 3 - 53 FRONT AXLE - 9 1/4 AA (Continued) SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.73, 4.10 Ring Gear Diameter 235 mm (9.25 in.) Ring Gear Backlash 0.13-0.18 mm (0.005-0.007 in.) Pinion Bearing Preload - New Bearing 1.7-2.8 N·m (15-25 in.
Page 127 3 - 54 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) PINION DEPTH SET 6730 SEAL INSTALLER 8882 INSTALLER D-146 ARBOR DISCS 8289 SPLITTER 1130 PINION BLOCK 8878 BRIDGE 938 BEARING INSTALLER 8881...
Page 128 FRONT AXLE - 9 1/4 AA 3 - 55 FRONT AXLE - 9 1/4 AA (Continued) PINION INSTALLER 8982 SEAL INSTALLER 8885 REMOVER/EXTRACTOR 6310 CUP INSTALLER 8886 RECEIVER 8498 PINION DRIVER 8976 PULLER C-293-PA PLUG 8888...
Page 129 3 - 56 FRONT AXLE - 9 1/4 AA FRONT AXLE - 9 1/4 AA (Continued) AXLE SHAFTS REMOVAL (1) Remove wheel and tire assembly. (2) Remove brake caliper, rotor and ABS wheel speed sensor if equipped. (3) Remove axle shaft cotter pin, hub nut and washer (Fig.
Page 130 FRONT AXLE - 9 1/4 AA 3 - 57 AXLE SHAFTS (Continued) Fig. 15 HUB BEARING BOLTS Fig. 17 AXLE SHAFT OUTER U-JOINT 1 - STUB SHAFT 1 - SHAFT YOKE 2 - BEARING BOLTS 2 - BEARING CAP 3 - AXLE SHAFT 3 - SNAP RINGS 4 - BEARING CAP 5 - SPINDLE YOKE...
Page 131 3 - 58 FRONT AXLE - 9 1/4 AA AXLE SHAFTS (Continued) ASSEMBLY (7) Rotate axle several 5 to 10 times to seat the wheel bearing. (1) Pack the bearing caps 1/3 full of wheel bearing (8) Tighten axle nut to final torque of 356 N·m lubricant.
Page 132 FRONT AXLE - 9 1/4 AA 3 - 59 AXLE SHAFT SEALS (Continued) Fig. 21 AXLE SHAFT SEAL Fig. 23 SEAL EXTRACTOR 1 - ADJUSTER THREADS 1 - EXTRACTOR ROD 2 - SEAL 2 - EXTRACTOR NUT Fig. 22 SEAL RECEIVER Fig.
Page 133: Pinion Seal Removal
3 - 60 FRONT AXLE - 9 1/4 AA (7) Remove pinion flange with Pinion Flange PINION SEAL Puller 8992 (Fig. 27). REMOVAL (1) Mark the propeller shaft and pinion flange for installation reference. (2) Remove propeller shaft. (3) Remove hub bearings and axle shafts. (4) Rotate pinion gear three or four times.
Page 134 FRONT AXLE - 9 1/4 AA 3 - 61 PINION SEAL (Continued) ments, until pinion rotating torque is 0.40-0.57 N·m pinion gears is not divided equally. The pinion gears (3-5 in. lbs.) greater than recorded measurement. now rotate around the pinion mate shaft in opposite (8) Rotate pinion several times then verify pinion directions.
Page 135 3 - 62 FRONT AXLE - 9 1/4 AA DIFFERENTIAL (Continued) (4) Mark bearing caps left and right for installa- (3) Rotate differential pinion gears to differential tion reference. window and remove pinion gears and thrust washers (5) Remove bearing cap bolts and remove bearing (Fig.
Page 136 FRONT AXLE - 9 1/4 AA 3 - 63 DIFFERENTIAL (Continued) ASSEMBLY (4) Align hole in the pinion gears with hole in the differential case. NOTE: If the same gears and thrust washers are (5) Install pinion shaft. being used, install them into their orignial locations. (6) Install new pinion shaft lock bolt and tighten to 52 N·m (38 ft.
Page 137 3 - 64 FRONT AXLE - 9 1/4 AA DIFFERENTIAL (Continued) (7) Back off the ring gear side adjuster 4 holes, to (17) Measure ring gear backlash and check gear obtain initial ring gear backlash. tooth contact pattern. Refer to Adjustments for pro- (8) Install ring gear side adjuster lock and bolt.
Page 138 FRONT AXLE - 9 1/4 AA 3 - 65 DIFFERENTIAL CASE BEARINGS (Continued) INSTALLATION (1) Set differential case on Plug 8888. (2) Install differenial case bearings with Installer 8881 and Handle C-4171 (Fig. 41). Fig. 42 RING GEAR 1 - DIFFERENTIAL CASE 2 - RING GEAR 3 - HAMMER Fig.
Page 139 3 - 66 FRONT AXLE - 9 1/4 AA PINION GEAR/RING GEAR (Continued) Fig. 44 PINION FLANGE PULLER 1 - PINION FLANGE 2 - PULLER Fig. 46 REAR PINION BEARING 1 - PULLER 2 - VISE 3 - PINION SHAFT 4 - ADAPTER BLOCKS INSTALLATION (1) Install front pinion bearing cup (Fig.
Page 140 FRONT AXLE - 9 1/4 AA 3 - 67 PINION GEAR/RING GEAR (Continued) (2) Install rear pinion bearing cup (Fig. 48) with (4) Install rear pinion bearing (Fig. 50) with Installer 8886 and Handle C-4171, if bearing is Installer C-3095-A and a press. replaced.
Page 141 3 - 68 FRONT AXLE - 9 1/4 AA PINION GEAR/RING GEAR (Continued) • New Pinion Bearings: 1.7-2.8 N·m (15-25 in. (7) Install pinion into the housing and place front pinion bearing onto the pinion shaft. Draw the pinion lbs.) •...
Page 142 REAR AXLE - 9 1/4 3 - 69 REAR AXLE - 9 1/4 TABLE OF CONTENTS page page REAR AXLE - 9 1/4 INSTALLATION ......85 DESCRIPTION .
Page 143 3 - 70 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) Fig. 1 9 1/4 AXLE...
Page 144 REAR AXLE - 9 1/4 3 - 71 REAR AXLE - 9 1/4 (Continued) 1 - HUB 29 - PLUG 2 - AXLE SHAFT 30 - COVER BOLT 3 - VENT FITTING 31 - WASHER 4 - DIFFERENTIAL HOUSING 32 - CLIP 5 - CUP 33 - SIDE GEAR 6 - FRONT PINION BEARING CONE...
Page 145 3 - 72 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Replace bearing. Axle Shaft Noise 1.
Page 146 REAR AXLE - 9 1/4 3 - 73 REAR AXLE - 9 1/4 (Continued) Condition Possible Causes Correction Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level. 2. Worn axle shaft seals. 2. Replace seals. 3.
Page 147 3 - 74 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) REMOVAL (1) Raise and support the vehicle. (2) Position a lifting device under the axle. (3) Secure axle to device. (4) Remove wheels and tires assemblies. (5) Remove RWAL sensor from the differential housing.
Page 148 REAR AXLE - 9 1/4 3 - 75 REAR AXLE - 9 1/4 (Continued) sent thousands of an inch deviation from the stan- is positive, subtract that value from the thickness of dard. If the number is negative, add that value to the the depth shim.
Page 149 3 - 76 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) Fig. 7 PINION GEAR DEPTH MEASUREMENT Fig. 5 PINION HEIGHT BLOCK 1 - ARBOR 1 - PINION BLOCK 2 - SCOOTER BLOCK 2 - PINION HEIGHT BLOCK 3 - DIAL INDICATOR •...
Page 150 REAR AXLE - 9 1/4 3 - 77 REAR AXLE - 9 1/4 (Continued) (3) Rotate the ring gear to the position of the least GEAR CONTACT PATTERN backlash. Mark the gear so that all future backlash Gear tooth contact pattern is used to verify the cor- measurements will be taken with the same gear rect running position of the ring and pinion gears.
Page 151 3 - 78 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (Continued) • Ring gear too close to pinion gear (Fig. 11). Increase backlash, by moving the ring away from the pinion gear using the adjusters. Fig. 13 INCORRECT BACKLASH 1 - DRIVE SIDE TOE 2 - COAST SIDE TOE Fig.
Page 152 REAR AXLE - 9 1/4 3 - 79 REAR AXLE - 9 1/4 (Continued) Fig. 17 SIDE GEAR CALCULATIONS In some cases, the end of the axle shaft will move and contact the mate shaft when the feeler gauge is inserted.
Page 153 3 - 80 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (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 Pinion Mate Shaft Lock Screw Axle U-Bolt Nuts...
Page 154 REAR AXLE - 9 1/4 3 - 81 REAR AXLE - 9 1/4 (Continued) HOLDER 6719 ADAPTERS C-293-37 PULLER C-452 PLUG SP-3289 INSTALLER C-3718 ADAPTERS C-293-47 WRENCH C-4164 INSTALLER C-4340 PULLER C-293-PA FIXTURE 8138...
Page 155 3 - 82 REAR AXLE - 9 1/4 REAR AXLE - 9 1/4 (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 C-3095-A PINION GAUGE SET 6775...
Page 156 REAR AXLE - 9 1/4 3 - 83 AXLE SHAFTS REMOVAL (1) Place transmission in neutral. (2) Raise and support the vehicle. (3) Remove wheel and tire assembly. (4) Remove brake caliper, adapter and rotor (Fig. 18). Fig. 20 AXLE SHAFT C-LOCK 1 - C-LOCK 2 - AXLE SHAFT 3 - SIDE GEAR...
Page 157 3 - 84 REAR AXLE - 9 1/4 AXLE SHAFTS (Continued) (4) Insert pinion shaft into differential case and (4) Install differential cover and fill with gear through thrust washers and differential pinions. lubricant to the bottom of the fill plug hole. (5) Align hole in shaft with hole in the differential case and install lock screw with Loctite on the...
Page 158 REAR AXLE - 9 1/4 3 - 85 AXLE BEARINGS (Continued) (3) Coat the lip of the new axle seal with axle (8) Remove pinion seal with pry tool or slide-ham- lubricant and install with Installer C-4076-B and mer mounted screw. Handle C-4735-1.
Page 159: Differential Description
3 - 86 REAR AXLE - 9 1/4 PINION SEAL (Continued) (10) If rotating torque is low, use Holder 6719 to hold the companion flange and tighten pinion nut in 6.8 N·m (5 ft. lbs.) increments until proper rotating torque is achieved. NOTE: The bearing rotating torque should be con- stant during a complete revolution of the pinion.
Page 160 REAR AXLE - 9 1/4 3 - 87 DIFFERENTIAL (Continued) Fig. 28 DIFFERENTIAL-STRAIGHT AHEAD DRIVING Fig. 30 REFERENCE MARKS 1 - IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE SPEED 1 - REFERENCE MARKS 2 - PINION GEAR 2 - REFERENCE MARK 3 - SIDE GEAR 3 - BEARING CAPS...
Page 161: Disassembly
3 - 88 REAR AXLE - 9 1/4 DIFFERENTIAL (Continued) DISASSEMBLY ASSEMBLY (1) Remove pinion shaft lock screw (Fig. 32). (1) Install differential side gears and thrust wash- ers. (2) Install differential pinion and thrust washers. (3) Install the pinion shaft. (4) Align the hole in the pinion shaft with the hole in the differential case and install the pinion shaft lock screw.
Page 162 REAR AXLE - 9 1/4 3 - 89 DIFFERENTIAL (Continued) erated by the side gears as torque is applied through the ring gear (Fig. 36). Fig. 35 COVER SEALANT 1 - SEALANT 2 - DIFFERENTIAL COVER CAUTION: If cover is not installed within 3 to 5 min- utes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised.
Page 163 3 - 90 REAR AXLE - 9 1/4 DIFFERENTIAL-TRAC-LOK (Continued) (friction modifier) should be added after repair ser- vice or during a lubricant change. After changing the lubricant, drive the vehicle and make 10 to 12 slow, figure-eight turns. This maneu- ver will pump lubricant through the clutches.
Page 164 REAR AXLE - 9 1/4 3 - 91 DIFFERENTIAL-TRAC-LOK (Continued) (7) Position a small screw driver in slot of (9) With a feeler gauge remove thrust washers Threaded Adapter Disc C-6960-1 (Fig. 40) to prevent from behind the pinion gears (Fig. 42). adapter from turning.
Page 165 3 - 92 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. 44). Fig. 45 CLUTCH DISC PACK 1 - CLUTCH PACK 2 - RETAINER 3 - SIDE GEAR...
Page 166 REAR AXLE - 9 1/4 3 - 93 DIFFERENTIAL-TRAC-LOK (Continued) (6) Install lubricated Step Plate C-6960-3 in lower (14) Remove forcing screw, step plate and threaded side gear. adapter. (7) Install upper side gear and clutch disc pack (15) Install pinion gear mate shaft and align holes (Fig.
Page 167 3 - 94 REAR AXLE - 9 1/4 DIFFERENTIAL CASE BEARINGS (Continued) INSTALLATION (1) Install differential side bearings with Installer C-4213 and Handle C-4171 (Fig. 49). Fig. 50 RING GEAR 1 - CASE 2 - RING GEAR 3 - RAWHIDE HAMMER (8) Install bolts into two of the threaded holes in the companion flange 180°...
Page 168 REAR AXLE - 9 1/4 3 - 95 PINION GEAR/RING GEAR/TONE RING (Continued) (16) Remove rear pinion bearing cup from housing (Fig. 54) with Remover C-4307 and Handle C-4171. Fig. 52 PINION GEAR 1 - RAWHIDE HAMMER Fig. 54 REAR PINION BEARING CUP 1 - DRIVER (13) Remove pinion seal with a pry tool or slide- 2 - HANDLE...
Page 169 3 - 96 REAR AXLE - 9 1/4 PINION GEAR/RING GEAR/TONE RING (Continued) (18) Remove rear pinion bearing (Fig. 56) from the INSTALLATION pinion shaft with Puller C-293-PA and Adapters C-293-37. NOTE: The ring gear and pinion are serviced in a matched set.
Page 170 REAR AXLE - 9 1/4 3 - 97 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 59 FRONT PINION BEARING CUP 1 - INSTALLER 2 - HANDLE Fig. 61 PINION DEPTH SHIM 1 - PINION DEPTH SHIM 2 - PINION GEAR Fig. 60 PINION SEAL INSTALLER 1 - HANDLE 2 - INSTALLER 3 - HOUSING...
Page 171 3 - 98 REAR AXLE - 9 1/4 PINION GEAR/RING GEAR/TONE RING (Continued) (8) Install a new collapsible spacer on the pinion shaft (Fig. 63). Fig. 64 PINION NUT 1 - DIFFERENTIAL HOUSING 2 - HOLDER Fig. 63 COLLAPSIBLE SPACER 3 - TORQUE WRENCH 1 - COLLAPSIBLE SPACER (16) Check pinion rotating torque with an inch...
Page 172 REAR AXLE - 9 1/4 3 - 99 PINION GEAR/RING GEAR/TONE RING (Continued) (17) Position exciter ring on differential case. With a brass drift, slowly and evenly tap the exciter ring into position. (18) Position ring gear on the differential case and start two ring gear bolts.
Page 173 3 - 100 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA TABLE OF CONTENTS page page REAR AXLE - 10 1/2 AA OPERATION ......114 DESCRIPTION .
Page 174 REAR AXLE - 10 1/2 AA 3 - 101 REAR AXLE - 10 1/2 AA (Continued) • Worn or out-of-balance wheels. BEARING NOISE • Loose wheel lug nuts. The axle shaft, differential and pinion bearings can • Worn U-joint(s). all produce noise when worn or damaged. Bearing •...
Page 175 3 - 102 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) Condition Possible Causes Correction Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting tube mis-alignment. 2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight on vehicle.
Page 176 REAR AXLE - 10 1/2 AA 3 - 103 REAR AXLE - 10 1/2 AA (Continued) Condition Possible Causes Correction Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible damage. 2. Erratic clutch operation. 2.
Page 177 3 - 104 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) (10) Fill differential to specifications. ing torque should be 1.7-2.26 N·m (15-20 in. lbs.) (11) Remove lifting device from axle and lower the (Fig. 1). vehicle.
Page 178 REAR AXLE - 10 1/2 AA 3 - 105 REAR AXLE - 10 1/2 AA (Continued) (8) Slowly slide the scooter block across the pinion height block over to the arbor (Fig. 4). Move the scooter block till dial indicator crests the arbor, then record the highest reading.
Page 179 3 - 106 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) • Gear contact pattern correct (Fig. 8). Backlash (12) Tighten bearing cap bolts to 115 N·m (85 ft. lbs.). and pinion depth is correct. (13) Tighten adjuster lock bolts to 33 N·m (24 ft.
Page 180 REAR AXLE - 10 1/2 AA 3 - 107 REAR AXLE - 10 1/2 AA (Continued) • Ring gear too far away from pinion gear (Fig. • Pinion gear is set too low (Fig. 13). Increase the 11). Decrease the backlash, by moving the ring closer pinion gear height, by increasing the pinion depth to the pinion gear using the adjusters.
Page 181 3 - 108 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.73, 4.10 Ring Gear Diameter 266 mm (10.5 in.) Ring Gear Backlash 0.13-0.18 mm (0.005-0.007 in.) Pinion Bearing Preload - New Bearings 1.69-2.82 N·m (15-25 in.
Page 182 REAR AXLE - 10 1/2 AA 3 - 109 REAR AXLE - 10 1/2 AA (Continued) PULLER C-293-PA BRIDGE 938 ADAPTERS 8879 PINION DEPTH GAUGE 6730 ADJUSTER WRENCH 8883 GAUGE BLOCK 8899 BEARING INSTALLER 8956 ARBOR DISCS 6732...
Page 183 3 - 110 REAR AXLE - 10 1/2 AA REAR AXLE - 10 1/2 AA (Continued) FLANGE PULLER 8992 PINION INSTALLER 8981 FLANGE WRENCH 8979 CUP INSTALLER 8959 PINION DRIVER 8977 CUP INSTALLER 8960 PLUG 8888 CUP INSTALLER 8961...
Page 184 REAR AXLE - 10 1/2 AA 3 - 111 REAR AXLE - 10 1/2 AA (Continued) SEAL INSTALLER 8896 SOCKET 8954 AXLE SHAFTS REMOVAL (1) Remove axle shaft flange bolts (Fig. 15). SEAL INSTALLER 8963 Fig. 15 AXLE FLANGE BOLTS 1 - AXLE FLANGE 2 - FLANGE BOLT (2) Slide axle shaft out of the axle tube.
Page 185 3 - 112 REAR AXLE - 10 1/2 AA (4) Remove hub bearing nut with Socket 8954. AXLE BEARINGS (5) Remove hub and bearings from the axle. (6) Pry out hub bearing seal from the back of the REMOVAL hub. (1) Remove axle shaft flange bolts and remove axle shaft.
Page 186 REAR AXLE - 10 1/2 AA 3 - 113 AXLE BEARINGS (Continued) Fig. 19 HUB NUT SOCKET Fig. 21 FLANGE WRENCH 1 - SOCKET 1 - PINION FLANGE 2 - TORQUE WRENCH 2 - FLANGE WRENCH PINION SEAL (6) Remove pinion flange with Pinion Flange Puller 8992 (Fig.
Page 187 3 - 114 REAR AXLE - 10 1/2 AA PINION SEAL (Continued) DIFFERENTIAL DESCRIPTION The differential case is a one-piece design. The dif- ferential pinion shaft is retained with a snap ring. Differential bearing preload and ring gear backlash is adjusted by the use of adjusters. The adjuster are between the differential bearings and the differential housing.
Page 188 REAR AXLE - 10 1/2 AA 3 - 115 DIFFERENTIAL (Continued) (7) Loosen differential bearing adjusters (Fig. 28) with Spanner Wrench 8883. Fig. 26 DIFFERENTIAL-ON TURNS 1 - PINION GEARS ROTATE ON PINION SHAFT REMOVAL (1) Remove lubricant fill hole plug from the differ- ential housing cover.
Page 189 3 - 116 REAR AXLE - 10 1/2 AA DIFFERENTIAL (Continued) (2) Rotate one pinion gear with thrust washer (Fig. 30) to the differential window and remove the gear. Fig. 32 SIDE GEARS 1 - SIDE GEAR 2 - SIDE GEAR 3 - PINION GEARS ASSEMBLY Fig.
Page 190 REAR AXLE - 10 1/2 AA 3 - 117 DIFFERENTIAL (Continued) INSTALLATION (1) Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. CAUTION: Do not use water, steam, kerosene or gasoline for cleaning. (2) Lubricate differential case bearing. (3) Install differential case with bearings cups into the housing.
Page 191 3 - 118 REAR AXLE - 10 1/2 AA DIFFERENTIAL (Continued) (8) Install ring gear side adjuster lock and bolt. Do DIFFERENTIAL TRAC-RITE not tighten adjuster lock bolt at this time. (9) Tighten pinion gear side adjuster firmly DESCRIPTION against the differential case bearing cup. The Trac-Rite™...
Page 192 REAR AXLE - 10 1/2 AA 3 - 119 DIFFERENTIAL TRAC-RITE (Continued) NOTE: Mark all component locations. (6) Remove six pinion gears (Fig. 41). Fig. 39 SIDE GEAR AND THRUST WASHER Fig. 41 PINION GEARS 1 - SIDE GEAR 1 - PINION GEARS 2 - THRUST WASHER 2 - SIDE GEAR (5) Remove three pinion brake shoes (Fig.
Page 193 3 - 120 REAR AXLE - 10 1/2 AA DIFFERENTIAL TRAC-RITE (Continued) Fig. 42 PINION GEAR AND BRAKE SHOE 1 - BRAKE SHOES 2 - PINION GEAR 3 - PINION SHAFT Fig. 44 PINION/SIDE GEAR BORE 1 - PINION BORES 2 - SIDE GEAR BORE Fig.
Page 194 REAR AXLE - 10 1/2 AA 3 - 121 DIFFERENTIAL TRAC-RITE (Continued) (6) Install other set of pinion gears into the brake shoes in the case. (7) Install other set of brake shoes onto the pinion gears shafts (Fig. 46). Fig.
Page 195 3 - 122 REAR AXLE - 10 1/2 AA (7) Drive ring gear from differential case with a PINION GEAR/RING GEAR/ soft hammer (Fig. 50). TONE RING REMOVAL NOTE: The ring and pinion gears are service in a matched set. Never replace the ring gear/pinion gear without replacing the other matching gear.
Page 196 REAR AXLE - 10 1/2 AA 3 - 123 PINION GEAR/RING GEAR/TONE RING (Continued) Fig. 52 PINION FLANGE PULLER 1 - PINION FLANGE 2 - PULLER NOTE: Thread the driver on the pinion shaft till it bottoms out. Fig. 54 REAR PINION BEARING 1 - PULLER 2 - VISE 3 - PINION SHAFT...
Page 197 3 - 124 REAR AXLE - 10 1/2 AA PINION GEAR/RING GEAR/TONE RING (Continued) (2) Install new rear pinion bearing cup (Fig. 56) (4) Install rear pinion bearing (Fig. 58) with with Installer 8959 and Handle C-4171. Installer MD-998805 and a press. Fig.
Page 198 REAR AXLE - 10 1/2 AA 3 - 125 PINION GEAR/RING GEAR/TONE RING (Continued) (7) Install pinion into the housing and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer 8981 (Fig. 60).
Page 199 3 - 126 REAR AXLE - 10 1/2 AA PINION GEAR/RING GEAR/TONE RING (Continued) (18) Torque ring gear bolts to 237 N·m (175 ft. lbs.). (19) If exciter ring was removed, position differen- tial assembly on differential Plug 8888 (Fig. 64) and place exciter ring on the differential case.
Page 200 REAR AXLE - 11 1/2 AA 3 - 127 REAR AXLE - 11 1/2 AA TABLE OF CONTENTS page page REAR AXLE - 11 1/2 AA OPERATION ......141 DESCRIPTION .
Page 201 3 - 128 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) • Worn or out-of-balance wheels. BEARING NOISE • Loose wheel lug nuts. The axle shaft, differential and pinion bearings can • Worn U-joint(s). all produce noise when worn or damaged. Bearing •...
Page 202 REAR AXLE - 11 1/2 AA 3 - 129 REAR AXLE - 11 1/2 AA (Continued) Condition Possible Causes Correction Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting tube mis-alignment. 2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight on vehicle.
Page 203 3 - 130 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) Condition Possible Causes Correction Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and bearings for possible damage. 2. Erratic clutch operation. 2.
Page 204 REAR AXLE - 11 1/2 AA 3 - 131 REAR AXLE - 11 1/2 AA (Continued) (10) Remove lifting device from axle and lower the vehicle. ADJUSTMENTS Ring and pinion gears are supplied as matched sets only. Compensation for pinion depth variance is achieved with a select shim.
Page 205 3 - 132 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) (8) Slowly slide the scooter block across the pinion height block over to the arbor (Fig. 4). Move the scooter block till dial indicator crests the arbor, then record the highest reading.
Page 206 REAR AXLE - 11 1/2 AA 3 - 133 REAR AXLE - 11 1/2 AA (Continued) • Gear contact pattern correct (Fig. 8). Backlash (12) Tighten bearing cap bolts to 115 N·m (85 ft. lbs.). and pinion depth is correct. (13) Tighten adjuster lock bolts to 33 N·m (24 ft.
Page 207 3 - 134 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) • Ring gear too far away from pinion gear (Fig. • Pinion gear is set too low (Fig. 13). Increase pin- 11). Decrease backlash, by moving the ring closer to ion gear height, by increasing the pinion depth shim the pinion gear using the adjusters.
Page 208 REAR AXLE - 11 1/2 AA 3 - 135 REAR AXLE - 11 1/2 AA (Continued) SPECIFICATIONS AXLE SPECIFICATIONS DESCRIPTION SPECIFICATION Axle Ratio 3.73, 4.10 Ring Gear Diameter 292 mm (11.5 in.) Ring Gear Backlash 0.13-0.18 mm (0.005-0.007 in.) Pinion Bearing Preload - New Bearings 1.69-2.82 N·m (15-25 in.
Page 209 3 - 136 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) ADJUSTER WRENCH 8883 PINION DRIVER 8977 PINION BLOCK 8897 PINION INSTALLER 8981 FLANGE PULLER 8992 SOCKET 8954 BEARING INSTALLER 8965 FLANGE WRENCH 8979...
Page 210 REAR AXLE - 11 1/2 AA 3 - 137 REAR AXLE - 11 1/2 AA (Continued) BEARING INSTALLER D-389 CUP INSTALLER 8968 CUP INSTALLER 8153 SEAL INSTALLER 8896 CUP INSTALLER 8960 SEAL INSTALLER 8963 CUP INSTALLER 8961...
Page 211 3 - 138 REAR AXLE - 11 1/2 AA REAR AXLE - 11 1/2 AA (Continued) AXLE SHAFTS REMOVAL (1) Remove axle shaft flange bolts (Fig. 15). PLUG 8964 Fig. 15 AXLE FLANGE BOLTS 1 - AXLE FLANGE 2 - FLANGE BOLT SPLITTER 1130 (2) Slide axle shaft out of the axle tube.
Page 212 REAR AXLE - 11 1/2 AA 3 - 139 AXLE BEARINGS (Continued) Fig. 18 INNER PART OF SEAL 1 - PRY BAR 2 - AXLE TUBE 3 - REMAINING SEAL Fig. 16 RETAINER RING 1 - RETAINER RING INSTALLATION 2 - LOCKING KEY (1) Install outer hub bearing cup with Installer 3 - BEARING NUT 8961 and Handle C-4171.
Page 213 3 - 140 REAR AXLE - 11 1/2 AA AXLE BEARINGS (Continued) (7) Back off nut about 30° and align next hub nut key slot with axle tube key slot and install locking key. NOTE: play should 0.025-0.25 (0.01-0.001 in.) (8) Install retainer ring with ring end in the key slot.
Page 214 REAR AXLE - 11 1/2 AA 3 - 141 PINION SEAL (Continued) OPERATION During straight-ahead driving, the differential pin- ion gears do not rotate on the pinion mate shaft. This occurs because input torque applied to the gears is divided and distributed equally between the two side gears.
Page 215 3 - 142 REAR AXLE - 11 1/2 AA DIFFERENTIAL (Continued) REMOVAL (1) Remove fill hole plug from the differential housing cover. (2) Remove differential housing cover and drain the lubricant. (3) Remove axle shafts. (4) Remove adjuster lock bolts and adjuster locks (Fig.
Page 216 REAR AXLE - 11 1/2 AA 3 - 143 DIFFERENTIAL (Continued) Fig. 32 SIDE GEARS Fig. 30 FIRST PINION GEAR 1 - SIDE GEAR 1 - DIFFERENTIAL WINDOW 2 - SIDE GEAR 2 - PINION GEAR 3 - PINION GEARS 3 - THRUST WASHER ASSEMBLY (4) Rotate the other pinion gear with thrust...
Page 217 3 - 144 REAR AXLE - 11 1/2 AA DIFFERENTIAL (Continued) (3) Install first pinion gear into the differential INSTALLATION window and side gears. Rotate the pinion gear to the (1) Clean the housing cavity with a flushing oil, back of the case (Fig. 34). light engine oil or lint free cloth.
Page 218 REAR AXLE - 11 1/2 AA 3 - 145 DIFFERENTIAL (Continued) (8) Install ring gear side adjuster lock and bolt. Do DIFFERENTIAL TRAC-RITE not tighten adjuster lock bolt at this time. (9) Tighten pinion gear side adjuster firmly DESCRIPTION against the differential case bearing cup. The Trac-Rite™...
Page 219 3 - 146 REAR AXLE - 11 1/2 AA DIFFERENTIAL TRAC-RITE (Continued) NOTE: Mark all component locations. Fig. 41 PINION GEARS 1 - PINION GEARS Fig. 39 SIDE GEAR AND THRUST WASHER 2 - SIDE GEAR 1 - SIDE GEAR 2 - THRUST WASHER (7) Remove remaining side gear thrust washer and spacer.
Page 220 REAR AXLE - 11 1/2 AA 3 - 147 DIFFERENTIAL TRAC-RITE (Continued) Fig. 42 PINION GEAR AND BRAKE SHOE 1 - BRAKE SHOES 2 - PINION GEAR 3 - PINION SHAFT Fig. 44 PINION/SIDE GEAR BORE 1 - PINION BORES 2 - SIDE GEAR BORE (3) Install side gear thrust washer, side gear and spacer (Fig.
Page 221: Differential Case Bearings Removal
3 - 148 REAR AXLE - 11 1/2 AA DIFFERENTIAL TRAC-RITE (Continued) (4) Install one set of pinion gears into the bores next to the brake shoes, with the pinion shaft facing (5) Install other side gear and thrust washer. (6) Install other set of pinion gears into the brake shoes in the case.
Page 222 REAR AXLE - 11 1/2 AA 3 - 149 (6) Remove bolts holding ring gear to differential PINION GEAR/RING GEAR/ case. TONE RING (7) Drive ring gear from differential case with a soft hammer (Fig. 50). REMOVAL NOTE: The ring and pinion gears are service in a matched set.
Page 223 3 - 150 REAR AXLE - 11 1/2 AA PINION GEAR/RING GEAR/TONE RING (Continued) (9) Remove pinion flange from pinion with Pinion (14) Remove rear pinion bearing with Bearing Flange Puller 8992 (Fig. 52). Splitter 1130 and a press (Fig. 54). Fig.
Page 224 REAR AXLE - 11 1/2 AA 3 - 151 PINION GEAR/RING GEAR/TONE RING (Continued) (2) Install new rear pinion bearing cup (Fig. 56) (4) Install rear pinion bearing (Fig. 58) with with Installer 8968 and Handle C-4171. Installer D-389 and a press. Fig.
Page 225 3 - 152 REAR AXLE - 11 1/2 AA PINION GEAR/RING GEAR/TONE RING (Continued) (7) Install pinion into the housing and place front pinion bearing onto the pinion shaft. Draw the pinion shaft into the front bearing with Installer 8981 (Fig. 60).
Page 226 REAR AXLE - 11 1/2 AA 3 - 153 PINION GEAR/RING GEAR/TONE RING (Continued) (19) If exciter ring was removed, position differen- tial assembly on differential Plug 8965 (Fig. 64) and place exciter ring on the differential case. Fig. 65 EXCITER RING INSTALLATION 1 - EXCITER RING 2 - PUNSH 3 - RING GEAR...
Page 228 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS .
Page 229: Brakes - Base
5 - 2 BRAKES - BASE DIAGNOSIS AND TESTING - MASTER SUPPORT PLATE CYLINDER/POWER BOOSTER ... 20 REMOVAL ......29 STANDARD PROCEDURE - MASTER INSTALLATION .
Page 230 BRAKES - BASE 5 - 3 BRAKES - BASE (Continued) and cups will also have to be replaced after flush- HARD PEDAL OR HIGH PEDAL EFFORT ing. Use clean brake fluid to flush the system. A hard pedal or high pedal effort may be due to (4) Check parking brake operation.
Page 231 5 - 4 BRAKES - BASE BRAKES - BASE (Continued) and resulting fade can also be caused by riding the become covered with grease and grit during repair. brake pedal, making repeated high deceleration stops Contaminated lining should be replaced to avoid fur- in a short time span, or constant braking on steep ther brake problems.
Page 232: Standard Procedure
BRAKES - BASE 5 - 5 BRAKES - BASE (Continued) tank manufacturers pressure recommendations. Gen- STANDARD PROCEDURE erally, a tank pressure of 15-20 psi is sufficient for bleeding. STANDARD PROCEDURE - MANUAL BLEEDING Fill the bleeder tank with recommended fluid and Use Mopar brake fluid, or an equivalent quality purge air from the tank lines before bleeding.
Page 233: Adjustable Pedal Switch Removal
5 - 6 BRAKES - BASE BRAKES - BASE (Continued) CAP, MASTER CYLINDER PRESSURE BLEED 6921 Fig. 2 LOWER DRIVERS SIDE BEZEL GAUGE, BRAKE SAFE-SET C-3919 1 - SCREWS (2) 2 - ADJUSTABLE PEDAL SWITCH 3 - PEDAL SWITCH ELECTRICAL CONNECTOR 4 - BEZEL ADJUSTABLE PEDAL SWITCH (2) Reconnect the electrical connector to the...
Page 234: Standard Procedure
BRAKES - BASE 5 - 7 HYDRAULIC/MECHANICAL (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Support Plate — Mounting Bolts/Nuts Brake Line Fittings Master Cylinder Brake Line Fittings Junction Block Caliper Brake Line Banjo Bolt Brake Hose — Front Bolts To Frame Brake Hose Front Fitting Brake Hose...
Page 235: Removal - Rear Brake Hose
5 - 8 BRAKES - BASE BRAKE LINES (Continued) Fig. 3 Inverted Flare Tools Fig. 4 ISO Flaring tube can be used for emergency repair when factory 1 - ADAPTER replacement parts are not readily available. 2 - LUBRICATE HERE To make a ISO flare use an ISO flaring tool kit.
Page 236: Removal - Front Hose
BRAKES - BASE 5 - 9 BRAKE LINES (Continued) Fig. 6 REAR HOSE Fig. 8 BRAKE HOSE MOUNTED PASSENGER SIDE 1 - BRAKE HOSE 1 - MOUNTING BOLT 2 - VENT HOSE 2 - BRAKE HOSE 3 - BRAKE LINES 3 - BANJO BOLT 4 - WHEEL SPEED SENSOR WIRE (5) Remove the banjo bolt at the caliper (Fig.
Page 237: Brake Pads/Shoes
5 - 10 BRAKES - BASE BRAKE LINES (Continued) (3) Install the brake hose banjo bolt at the caliper (Fig. 8). (4) Reinstall the wheel speed sensor wire to the brake hose (Fig. 8). (5) Remove the support and lower the vehicle. Fig.
Page 238: Disc Brake Calipers
BRAKES - BASE 5 - 11 BRAKE PADS/SHOES (Continued) Fig. 14 Top Anti-Rattle Spring 1 - CALIPER ADAPTER 2 - ANTI-RATTLE SPRING Fig. 12 Inboard Brake Shoe 1 - INBOARD SHOE 2 - CALIPER ADAPTER Fig. 15 Bottom Anti-Rattle Spring 1 - ANTI-RATTLE SPRING 2 - CALIPER ADAPTER (8) Install caliper, (Refer to 5 - BRAKES/HY-...
Page 239: Operation
5 - 12 BRAKES - BASE DISC BRAKE CALIPERS (Continued) OPERATION between the rotor and lining and in wiping the rotor surface clear each revolution. When the brakes are applied fluid pressure is The caliper piston seal controls the amount of pis- exerted against the caliper piston.
Page 240: Disassembly
BRAKES - BASE 5 - 13 DISC BRAKE CALIPERS (Continued) Fig. 18 DISC BRAKE CALIPER - REAR Fig. 20 8 LUG ROTOR & CALIPER ASSEMBLY 1 - CALIPER ADAPTER 1 - ROTOR 2 - CALIPER ADAPTER MOUNTING BOLTS 2 - CALIPER ADAPTER 3 - CALIPER SLIDE BOLTS 3 - ANTI-RATTLE CLIPS 4 - BRAKE HOSE...
Page 241: Inspection
5 - 14 BRAKES - BASE DISC BRAKE CALIPERS (Continued) Fig. 23 Piston Dust Boot Removal Fig. 22 Protect Caliper Piston 1 - CALIPER 1 - CALIPER 2 - DUST BOOT 2 - PADDED BLOCK OF WOOD 3 - C-CLAMP CAUTION: Do not blow the piston out of the bore with sustained air pressure.
Page 242: Assembly
BRAKES - BASE 5 - 15 DISC BRAKE CALIPERS (Continued) Fig. 25 Bushings And Boot Seals Fig. 27 Piston Seal 1 - CALIPER 1 - CALIPER 2 - BUSHING 2 - PISTON BORE 3 - BOOT SEAL 3 - PISTON SEAL (4) Stretch boot rearward to straighten boot folds, then move boot forward until folds snap into place.
Page 243: Installation - Rear
5 - 16 BRAKES - BASE DISC BRAKE CALIPERS (Continued) INSTALLATION - FRONT NOTE: Install a new copper washers on the banjo bolt when installing (1) Install the disc brake caliper (Fig. 19) or (Fig. 20). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt.
Page 244: Installation - Rear
BRAKES - BASE 5 - 17 DISC BRAKE CALIPER ADAPTER (Continued) (2) Install the anti-rattle clips (Fig. 30). (3) Install the inboard and outboard pads (Fig. 30). (4) Install the caliper mounting bolts. (5) Install the tire and wheel assembly INSTALLATION - FRONT (1) Install the caliper adapter to the steering knuckle (Fig.
Page 245: Diagnosis And Testing - Brake Fluid Contamination
5 - 18 BRAKES - BASE DISC BRAKE CALIPER ADAPTER MOUNT (Continued) STANDARD PROCEDURE - BRAKE FLUID LEVEL Always clean the master cylinder reservoir and caps before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (Fig.
Page 246: Fluid Reservoir Removal
BRAKES - BASE 5 - 19 (6) Fill and bleed base brake system,(Refer to 5 - FLUID RESERVOIR BRAKES - STANDARD PROCEDURE). REMOVAL (1) Install the prop rod on the brake pedal to keep BRAKE JUNCTION BLOCK pressure on the brake system. (2) Remove the reservoir cap and siphon fluid into REMOVAL a drain container (Fig.
Page 247: Operation
5 - 20 BRAKES - BASE MASTER CYLINDER (Continued) cuit separation in the event of a front or rear brake (2) Start and run engine at curb idle speed for one malfunction. The reservoir compartments will retain minute. enough fluid to operate the functioning hydraulic cir- (3) Observe the vacuum supply.
Page 248: Removal - All Except Hydroboost
BRAKES - BASE 5 - 21 MASTER CYLINDER (Continued) NOTE: Using care remove the master cylinder directly forward in order not to dislodge the output rod from its seat inside the booster. Fig. 37 Vacuum Check Valve And Seal 1 - BOOSTER CHECK VALVE 2 - APPLY TEST VACUUM HERE 3 - VALVE SEAL (1) Mount master cylinder in vise.
Page 249: Installation - Hydroboost
5 - 22 BRAKES - BASE MASTER CYLINDER (Continued) NOTE: Using care remove the master cylinder (4) Reconnect the elctrical connector for the low directly forward in order not to dislodge the output fluid level switch. (5) Fill and bleed the base brake system. (Refer to rod from its seat inside the booster.
Page 250: Removal
BRAKES - BASE 5 - 23 PEDAL (Continued) Fig. 42 BRAKE PEDAL Fig. 43 PEDAL/CABLE 1 - CLIP 1 - CABLE 2 - BUSHINGS 2 - BRAKE PEDAL ASSEMBLY 3 - PIVOT SHAFT PIN 4 - PEDAL ASSEMBLY ADJUSTABLE PEDAL SHOWN NON ADJUSTABLE PEDAL IS SIMILIAR 5 - PAD REMOVAL...
Page 251: Adjustable Pedal Motor
5 - 24 BRAKES - BASE PEDAL (Continued) (10) Install the steering column opening cover (Refer to 23 - BODY/INSTRUMENT PANEL/STEER- ING COLUMN OPENING COVER - INSTALLA- TION). (11) Reconnect the negative battery cable. ADJUSTABLE PEDAL MOTOR DESCRIPTION The Adjustable Pedals System (APS) is designed to enable the fore and aft repositioning of the brake and accelerator pedals.
Page 252: Power Brake Booster Description
BRAKES - BASE 5 - 25 ADJUSTABLE PEDAL MOTOR (Continued) (2) Install the one mounting bolt for the adjustable pedal motor (Fig. 46). (3) Clip the cable fasteners to the support. (4) Reconnect the electrical connector. (5) Reconnect the adjustable pedal cables to the brake and accelerator pedals.
Page 253 5 - 26 BRAKES - BASE HYDRO-BOOST BRAKE BOOSTER (Continued) • INPUT ROD SEAL: Fluid leakage from rear HISSING end of the booster. A hissing noise may be noticed when above normal • PISTON SEAL: Fluid leakage from vent at brake pedal pressure is applied, 40 lbs.
Page 254: Standard Procedure - Bleeding
BRAKES - BASE 5 - 27 HYDRO-BOOST BRAKE BOOSTER (Continued) CONDITION POSSIBLE CAUSES CORRECTION Brakes Self Apply 1. Dump valve faulty. 1. Replace booster. 2. Contamination in hydraulic 2. Flush hydraulic system and replace system. booster. 3. Restriction in booster return hose. 3.
Page 255: Removal - Rear
5 - 28 BRAKES - BASE HYDRO-BOOST BRAKE BOOSTER (Continued) (7) Install the hydraulic booster pressure lines to the bracket and booster. (8) Tighten the pressure lines to 41 N·m (30 ft. lbs.). NOTE: Inspect o-rings on the pressure line fittings to insure they are in good condition before installa- tion.
Page 256: Installation - Front
BRAKES - BASE 5 - 29 ROTORS (Continued) INSTALLATION - FRONT (1) On models with all-wheel antilock system (ABS), check condition of tone wheel on hub/bearing. If teeth on wheel are damaged, hub/bearing assembly will have to be replaced (tone wheel is not serviced separately).
Page 257: Parking Brake Description
5 - 30 BRAKES - BASE SUPPORT PLATE (Continued) PARKING BRAKE DESCRIPTION The parking brakes are operated by a system of cables and levers attached to a primary and second- ary shoe positioned within the drum section of the rotor. The drum-in-hat design utilizes an independent set of shoes to park the vehicle (Fig.
Page 258: Removal - Front Parking Brake
BRAKES - BASE 5 - 31 CABLES REMOVAL REMOVAL - FRONT PARKING BRAKE CABLE (1) Raise and support vehicle. (2) Lockout the parking brake cable (Fig. 58). (3) Loosen adjusting nut to create slack in front cable. (4) Remove the front cable from the cable connec- tor.
Page 259: Removal - Left Rear Cable
5 - 32 BRAKES - BASE CABLES (Continued) (6) Remove the cable from the frame bracket. (7) Remove the cable from the axle bracket. (8) Remove the cable bracket from the shock bracket. (9) Remove the brake cable from the brake lever. (Fig.
Page 260: Installation - Left Rear Cable
BRAKES - BASE 5 - 33 CABLES (Continued) (6) Install the right cable to the front cable. (7) Adjust the brake cable at the equalizer and using the adjuster nut. Fig. 63 LOCK OUT PARKING CABLE 1 - LOCKING PLIERS 2 - PARKING BRAKE CABLE Fig.
Page 261: Installation
5 - 34 BRAKES - BASE SHOES (Continued) Fig. 65 AXLE SHAFT 1 - AXLE SHAFT 2 - SUPPORT PLATE 3 - CALIPER 4 - PARK BRAKE SHOE ASSEMBLY replaced and the drum checked for runout or taper Fig. 66 PARK BRAKE SHOES (Fig.
Page 262 BRAKES - BASE 5 - 35 SHOES (Continued) NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. (5) Using Brake Shoe Gauge, Special Tool C-3919, or equivalent, accurately measure the inside diam- eter of the park brake drum portion of the rotor (Fig.
Page 263: Adjustment - With Adjusting Tool
5 - 36 BRAKES - BASE SHOES (Continued) NOTE: On a new vehicle or after parking brake lin- (9) Repeat adjustment at opposite wheel. Be sure ing replacement, it is recommended that the park- adjustment is equal at both wheels. (10) Install support plate access hole plugs.
Page 264: Cable Tensioner
BRAKES - BASE 5 - 37 PEDAL (Continued) (5) Tighten the front cable grommet to the floor- (6) Check the rear brake shoe adjustment with pan and the cable retainer, roll the carpet back. standard brake gauge (Refer to 5 - BRAKES/PARK- (6) Connect the wires to the brake lamp switch.
Page 265: Release Handle Removal
5 - 38 BRAKES - BASE RELEASE HANDLE REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Reach under the driver side outboard end of the instrument panel to access and unsnap the plas- tic retainer clip that secures the park brake release linkage rod to the park brake mechanism on the left cowl side inner panel.
Page 266 BRAKES - ABS 5 - 39 BRAKES - ABS TABLE OF CONTENTS page page BRAKES - ABS HYDRAULIC/MECHANICAL DESCRIPTION ......39 DESCRIPTION - ELECTRONIC VARIABLE OPERATION .
Page 267: Description
5 - 40 BRAKES - ABS BRAKES - ABS (Continued) The purpose of the antilock system is to prevent the calipers. Then the Dump valve dumps off pres- wheel lockup. Preventing lockup helps maintain vehi- sure until the wheel unlocks. This will continue until cle braking action and steering control.
Page 268: Front Wheel Speed Sensor
BRAKES - ABS 5 - 41 BRAKES - ABS (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. RWAL Valve — Brake Line Fittings Rear Wheel Speed Sensor — Mounting Bolt FRONT WHEEL SPEED SENSOR DESCRIPTION The ABS brake system uses 3 wheel speed sensors. A sensor is mounted to each front hub/bearings.
Page 269: Installation
5 - 42 BRAKES - ABS FRONT WHEEL SPEED SENSOR (Continued) REAR WHEEL SPEED SENSOR DIAGNOSIS AND TESTING - REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first. This includes brake noise, lack of power assist, parking brake, or vehicle vibration during normal braking.
Page 270: Installation
BRAKES - ABS 5 - 43 REAR WHEEL SPEED SENSOR (Continued) INSTALLATION from the master cylinder is shut off. In order to decrease the rear brake pressure, the outlet valve for (1) Connect the harness to the sensor. Be sure the rear brake circuit is pulsed.
Page 271: Removal
5 - 44 BRAKES - ABS HCU (HYDRAULIC CONTROL UNIT) (Continued) then opens the outlet valve, which also opens the INSTALLATION return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent NOTE: If the CAB is being replaced with a new CAB wheel lock.
Page 272: Removal
BRAKES - ABS 5 - 45 RWAL VALVE (Continued) brake pressure in proportion to the front brake pres- sure. If impending rear wheel lock-up is sensed, the CAB signals the RWAL valve to modulate hydraulic brake pressure to the rear wheels to prevent lock-up. NORMAL BRAKING Since the RWAL valve also performs the EVBP or proportioning function, vehicle deceleration under normal braking may be sufficient...
Page 274 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH FLYWHEEL DESCRIPTION ......1 DIAGNOSIS AND TESTING .
Page 275 6 - 2 CLUTCH CLUTCH (Continued) (EPA), FOR THE HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS. DIAGNOSIS AND TESTING A road test and component inspection is recom- mended to determine a clutch problem. During a road test, drive the vehicle at normal speeds. Shift the transmission through all gear ranges and observe clutch action.
Page 276 CLUTCH 6 - 3 CLUTCH (Continued) • foreign material on crankshaft flange CLUTCH COVER AND DISC RUNOUT Flywheel machining is not recommended. The fly- Check the clutch disc before installation. Axial wheel clutch surface is machined to a unique contour (face) runout of a new disc should not exceed 0.50 and machining will negate this feature.
Page 277 6 - 4 CLUTCH CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Flywheel below minimum thickness 1. Improper flywheel machining. 1. Replace flywheel. specification. Flywheel has excessive taper or excessive material removal. Clutch disc, cover and/or diaphragm 1. Rough handling. Impact bent 1.
Page 278 CLUTCH 6 - 5 CLUTCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION Clutch will not disengage properly. 1. Low hydraulic linkage fluid level. 1. Add hydraulic linkage fluid. 2. Clutch cover loose. 2. Follow proper bolt tightening procedure. 3. Clutch disc bent or distorted. 3.
Page 279: Description
6 - 6 CLUTCH CLUTCH (Continued) SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Slave Cylinder Nuts Clutch Master Cylinder Nuts Pressure Plate Bolts - V6 & V8 Pressure Plate Bolts - V10 22.5 Pressure Plate Bolts - 22.5 Diesel Release Bearing Pivot Flywheel Bolts...
Page 280 CLUTCH 6 - 7 CLUTCH DISC (Continued) (10) Apply light coat of Mopar high temperature bearing grease to splines of transmission input shaft and to release bearing slide surface of the transmis- sion front bearing retainer (Fig. 6). CAUTION: Do not over lubricate shaft splines. This can result in grease contamination of the disc.
Page 281: Clutch Housing
6 - 8 CLUTCH CLUTCH DISC (Continued) (3) Replace one of the flywheel bolts with an appropriate size threaded rod that is 10 in. (25.4 cm) long (Fig. 8). The rod will be used to mount the dial indicator. Fig. 7 FORK, BEARING AND SPRING CLIPS Fig.
Page 282 CLUTCH 6 - 9 CLUTCH HOUSING (Continued) driver. Then install the housing and mount the dial indicator and check bore runout again. Rotate the dowels until the TIR is less than 0.010 inch. Clutch Housing Face Runout (1) Position dial indicator towards the housing face (Fig.
Page 283: Removal
6 - 10 CLUTCH CLUTCH HOUSING (Continued) NOTE: Maximum acceptable face runout is 0.010 inch. To correct this example (Fig. 13) the shims needed between the clutch housing and transmission are: • 0.009 in. at the 0.000 corner • 0.012 in. at the –0.003 corner •...
Page 284: Clutch Release Bearing
CLUTCH 6 - 11 CLUTCH HOUSING (Continued) (6) Install the clutch housing dust shield to the clutch housing. (7) Install transmission and transfer case, if equipped. CLUTCH RELEASE BEARING REMOVAL (1) Remove transmission and transfer case, if equipped. (2) Remove spring clip. (3) Disconnect release bearing from release fork and remove bearing (Fig.
Page 285: Removal
6 - 12 CLUTCH FLYWHEEL (Continued) bolts when remounting a flywheel and secure the WARNING: WEAR PROTECTIVE GOGGLES OR bolts with Mopar Lock And Seal or equivalent. SAFETY GLASSES AND HEAT RESISTENT GLOVES Tighten flywheel bolts to specified torque only. Over- WHEN HANDLING A HEATED RING GEAR.
Page 286: Linkage Removal
CLUTCH 6 - 13 PILOT BEARING (Continued) Fig. 20 SLAVE CYLINDER 1 - MOUNTING NUTS 2 - SLAVE CYLINDER Fig. 19 PILOT BEARING 1 - PILOT BEARING 2 - ALIGNMENT TOOL 3 - LETTER SIDE MUST FACE TRANSMISSION (3) Install clutch disc, pressure plate and trans- mission.
Page 287: Clutch Pedal Position Switch
6 - 14 CLUTCH LINKAGE (Continued) (6) Install plastic clip securing hydraulic line to OPERATION the dash panel into the lower dash panel flange. The clutch pedal position switch is used to prevent (7) Install plastic clip securing hydraulic line to starter motor engagement unless the clutch pedal is the dash panel onto the upper dash panel stud.
Page 288 COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING STANDARD PROCEDURE - COOLING DESCRIPTION SYSTEM CLEANING/REVERSE FLUSHING . . 17 DESCRIPTION - COOLING SYSTEM FLOW STANDARD PROCEDURE—DRAINING 3.7L/4.7L ENGINE ..... . 1 COOLING SYSTEM 3.7L/4.7L/5.7L ENGINE .
Page 289: Description-Cooling System Flow - 5.9L Diesel
7 - 2 COOLING COOLING (Continued) Fig. 1 Engine Cooling System Flow - 3.7L/4.7L 1 - LH CYL. HEAD 6 - LH BANK CYL. BLOCK 2 - BLEED 7 - COOLANT TEMP. SENSOR 3 - THERMOSTAT LOCATION 8 - FROM HEATER CORE 4 - RH CYL.
Page 290: Description - Hose Clamps
COOLING 7 - 3 COOLING (Continued) Fig. 2 ENGINE COOLING SYSTEM FLOW - 5.9L 1 - HEATER 3 - CROSSFLOW RADIATOR 2 - BYPASS* 4 - THERMOSTAT LOCATION DESCRIPTION - HOSE CLAMPS OPERATION The cooling system utilizes spring type hose OPERATION—COOLING SYSTEM clamps.
Page 291 7 - 4 COOLING COOLING (Continued) Fig. 3 Cooling System Circulation—Diesel Engine...
Page 292: Operation-Hose Clamps
COOLING 7 - 5 COOLING (Continued) • If an open or shorted condition has developed in the electronically controlled viscous fan clutch circuit, a Diagnostic Trouble Code (DTC) can be set. • If fan speed is not detected a DTC will be set. •...
Page 293 7 - 6 COOLING COOLING (Continued) Drops Quickly: Indicates that serious leakage is occurring. Examine the system for external leakage. If leaks are not visible, inspect for internal leakage. Large radiator leak holes should be repaired by a reputable radiator repair shop. INTERNAL LEAKAGE INSPECTION Remove the engine oil pan drain plug and drain a small amount of engine oil.
Page 294: Diagnosis And Testing - Cooling System Diesel Engine
COOLING 7 - 7 COOLING (Continued) WARNING: DO NOT REMOVE CYLINDER BLOCK CAUTION: Avoid overheating. Do not operate DRAIN PLUGS OR LOOSEN RADIATOR DRAIN- engine for an excessive period of time. Open drain- COCK WITH SYSTEM HOT AND UNDER PRESSURE. cock immediately after test to eliminate boil over.
Page 295 7 - 8 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 1. Vehicle overloaded, high ambient 1. Temporary condition, repair not HIGH. COOLANT MAY OR MAY (outside) temperatures with A/C required. Notify customer of vehicle NOT BE LEAKING FROM turned on, stop and go driving or operation instructions located in SYSTEMNOTE:...
Page 296 COOLING 7 - 9 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READING 1. Heavy duty cooling system, 1. None. System operating normally. INCONSISTENT (ERRATIC, extreme cold ambient (outside) CYCLES OR FLUCTUATES)NOTE: temperature or heater blower motor Information on dash cluster is in high position.
Page 297: Diagnosis And Testing - Preliminary Checks
7 - 10 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR CONDITIONER 1. Radiator and/or A/C condenser 1. Remove obstruction and/or clean. PERFORMANCE (COOLING air flow obstructed. SYSTEM SUSPECTED) 2. Electronically controlled viscous 2. Check fan drive. (Refer to 7 - fan drive not working.
Page 298 COOLING 7 - 11 COOLING (Continued) COOLING SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE 1. Has a Diagnostic Trouble 1. (Refer to 25 - EMISSIONS CONTROL - READS LOW Code (DTC) been set indicating DESCRIPTION) for On-Board Diagnostics a stuck open thermostat? and DTC information.
Page 299 7 - 12 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE 1. Trailer is being towed, a steep 1. This may be a temporary condition and READS HIGH OR THE hill is being climbed, vehicle is repair is not necessary. Turn off the air COOLANT WARNING LAMP operated in slow moving traffic, conditioning and attempt to drive the...
Page 300 COOLING 7 - 13 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 10. Radiator or A/C condenser 10. Remove insects and debris. (Refer to fins are dirty or clogged. 7 - COOLING - STANDARD PROCEDURE). 11. Radiator core is corroded or 11. Have radiator re-cored or replaced. plugged.
Page 301 7 - 14 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Temperature gauge reading is 1. During cold weather 1. A normal condition. No correction inconsistent (flucttuates, cycles operation, with the heater blower necessary. or is erratic) in the high position, the gauge reading may drop slightly.
Page 302 COOLING 7 - 15 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION DETONATION OR PRE- 1. Engine overheating. 1. Check reason for overheating and IGNITION (NOT CAUSED BY repair as necessary. IGNITION SYSTEM). GAUGE 2. Freeze point of coolant not 2. Check coolant concentration. (Refer to MAY OR MAY NOT BE correct.
Page 303 7 - 16 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE HEATER 1. Has a Diagnostic trouble 1. (Refer to 25 - EMISSIONS CONTROL - PERFORMANCE. Code (DTC) been set? DESCRIPTION) for correct procedures THERMOSTAT FAILED IN and replace thermostat if necessary OPEN POSITION 2.
Page 304: Standard Procedure - Cooling System Cleaning/Reverse Flushing
COOLING 7 - 17 COOLING (Continued) using air pressure in the opposite direction of normal STANDARD PROCEDURE coolant flow. It is usually only necessary with very dirty systems with evidence of partial plugging. STANDARD PROCEDURE - COOLANT LEVEL CHECK REVERSE FLUSHING RADIATOR Disconnect the radiator hoses from the radiator NOTE: Do not remove radiator cap for routine cool- inlet and outlet.
Page 305: Standard Procedure-Draining Cooling System 3.7L/4.7L/5.7L Engine
7 - 18 COOLING COOLING (Continued) CAUTION: Follow manufacturers instructions when (1) Install the cylinder block drain plugs (if using these products. removed). Coat the threads with Mopar Thread Sealant with Teflon. (2) Close the radiator draincock. STANDARD PROCEDURE—DRAINING COOLING CAUTION: Failure to purge air from the cooling sys- SYSTEM 3.7L/4.7L/5.7L ENGINE tem can result in an overheating condition and...
Page 306: Standard Procedure-Draining Cooling System 5.9L Diesel Engine
COOLING 7 - 19 COOLING (Continued) STANDARD PROCEDURE—REFILLING COOLING SYSTEM 5.9L DIESEL ENGINE Clean cooling system prior to refilling (Refer to 7 - COOLING - STANDARD PROCEDURE). (1) Close radiator drain plug. CAUTION: Due to the use of the one-way check valve, the engine must not be operating when refill- ing the cooling system.
Page 307: Torque
7 - 20 COOLING COOLING (Continued) WARNING: DO NOT REMOVE OR LOOSEN THE SPECIFICATIONS - RADIATOR CAP WITH THE COOLING SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM SPECIFICATIONS THE COOLANT OR HIGH PRESSURE STEAM CAN OCCUR. DESCRIPTION SPECIFICATION For 3.7L / 4.7L/5.9L engines, remove the radiator 3.7/4.7L Engine 15.4L (16.2 qts.)- to the cap from the coolant degas bottle to add coolant.
Page 308 COOLING 7 - 21 COOLING (Continued) Cooling System Pressure Tester - 7700A Adapter Pins 8346...
Page 309 7 - 22 ACCESSORY DRIVE ACCESSORY DRIVE TABLE OF CONTENTS page page BELT TENSIONERS - 3.7L / 4.7L DRIVE BELTS - 3.7L / 4.7L DESCRIPTION ......22 DIAGNOSIS AND TESTING - ACCESSORY OPERATION .
Page 310: Engine
ACCESSORY DRIVE 7 - 23 BELT TENSIONERS - 3.7L / 4.7L (Continued) NOTE: A used belt should be replaced if tensioner BELT TENSIONERS - 5.9L indexing arrow has moved to the minimum tension indicator. Tensioner travel stops at this point. DESCRIPTION Correct drive belt tension is required to ensure (1) Remove accessory drive belt (Refer to 7 -...
Page 311 7 - 24 ACCESSORY DRIVE BELT TENSIONERS - 5.9L (Continued) BELT TENSIONERS - 5.9L DIESEL DESCRIPTION Drive belts on all engines are equipped with a spring loaded automatic belt tensioner (Fig. 5). This tensioner maintains constant belt tension at all times and requires no maintenance or adjustment.
Page 312 ACCESSORY DRIVE 7 - 25 BELT TENSIONERS - 5.9L DIESEL (Continued) REMOVAL DRIVE BELTS - 3.7L / 4.7L WARNING: BECAUSE OF HIGH SPRING PRES- DIAGNOSIS AND TESTING - ACCESSORY SURE, DO NOT ATTEMPT TO DISASSEMBLE AUTO- DRIVE BELT MATIC TENSIONER. UNIT IS SERVICED AS AN ASSEMBLY.
Page 313 7 - 26 ACCESSORY DRIVE DRIVE BELTS - 3.7L / 4.7L (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 314 ACCESSORY DRIVE 7 - 27 DRIVE BELTS - 3.7L / 4.7L (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.
Page 315 7 - 28 ACCESSORY DRIVE DRIVE BELTS - 3.7L / 4.7L (Continued) DRIVE BELTS - 5.9L 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.
Page 316 ACCESSORY DRIVE 7 - 29 DRIVE BELTS - 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 317 7 - 30 ACCESSORY DRIVE DRIVE BELTS - 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 318 ACCESSORY DRIVE 7 - 31 DRIVE BELTS - 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. 12) (Fig. 13) for correct engine belt routing.
Page 319 7 - 32 ACCESSORY DRIVE DRIVE BELTS - 5.9L DIESEL (Continued) Refer to ACCESSORY DRIVE BELT DIAGNOSIS NOISE DIAGNOSIS CHART for further belt 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 320 ACCESSORY DRIVE 7 - 33 DRIVE BELTS - 5.9L DIESEL (Continued) CONDITION POSSIBLE CAUSES CORRECTION LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt groove 2. Pulley groove tip has worn away 2. Replace belt rubber to tensile member GROOVE JUMPING 1.
Page 321 7 - 34 ACCESSORY DRIVE DRIVE BELTS - 5.9L DIESEL (Continued) NOTE: The engine speed sensor face is very close overheat due to water pump rotating in wrong to the accessory drive belt. Inspect engine speed direction. Refer to (Fig. 15) for correct engine belt sensor and wire harness for damage when acces- routing.
Page 322 ENGINE 7 - 35 ENGINE TABLE OF CONTENTS page page COOLANT OPERATION ......51 DESCRIPTION DIAGNOSIS AND TESTING—THERMOSTAT .
Page 323 7 - 36 ENGINE WATER PUMP - 5.9L OPERATION ......67 DESCRIPTION ......62 DIAGNOSIS AND TESTING—WATER PUMP .
Page 324: Description - Hoat Coolant
ENGINE 7 - 37 COOLANT (Continued) components. Also, once ethylene-glycol and propy- coolants other than specified (non-HOAT or other lene-glycol based coolants are mixed in the vehicle, HOAT), may result in engine damage that may not conventional methods of determining freeze point will be covered under the new vehicle warranty, and not be accurate.
Page 325: Operation
7 - 38 ENGINE COOLANT (Continued) CAUTION: Do not use coolant additives that are a convenient and safe method for checking coolant claimed to improve engine cooling. level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap.
Page 326: Removal
ENGINE 7 - 39 COOLANT DEGAS CONTAINER-3.7L/4.7L (Continued) INSTALLATION (1) Align the mounting pins into the slots on the fan shroud and push the container into the fan shroud. (2) Secure the coolant container to the fan shroud with bolts. Tighten to 8.5 N-m (75 in. lbs). NOTE: Ensure the locking feature on the mounting pins has engaged.
Page 327: Cleaning
7 - 40 ENGINE RADIATOR FAN (Continued) CAUTION: Some engines equipped with serpentine drive belts have reverse rotating fans and viscous fan drives. They are marked with the word REVERSE to designate their usage. Installation of the wrong fan or viscous fan drive can result in engine overheating.
Page 328: Radiator Fan - 5.9L Diesel Removal
ENGINE 7 - 41 RADIATOR FAN - 5.9L DIESEL REMOVAL CAUTION: If the electronically controlled viscous fan drive is replaced because of mechanical dam- age, the cooling fan blades should also be inspected. Inspect for fatigue cracks, or loose rivets that could have resulted from excessive vibration.
Page 329: Engine Block Heater
7 - 42 ENGINE RADIATOR FAN - 5.9L DIESEL (Continued) (5) Install the lower fan shroud into position and verify the locking tabs have seated. (6) Connect the battery negative cables. NOTE: Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 rpm and hold for approximately two minutes.
Page 330: Removal
ENGINE 7 - 43 ENGINE BLOCK HEATER (Continued) REMOVAL ENGINE BLOCK HEATER - 5.9L (1) Disconnect the battery negative cable. DIESEL (2) Drain the coolant (Refer to 7 - COOLING - STANDARD PROCEDURE). DESCRIPTION (3) Remove the power cord from the heater by unplugging (Fig.
Page 331: Installation
7 - 44 ENGINE ENGINE BLOCK HEATER - 5.9L DIESEL (Continued) (4) Using a suitable size socket, loosen and remove When the engine is cold, the PCM will operate in the block heater element (Fig. 10). Open Loop cycle. It will demand slightly richer air- fuel mixtures and higher idle speeds.
Page 332 ENGINE 7 - 45 ENGINE COOLANT TEMPERATURE SENSOR (Continued) compressor (Fig. 13). It is installed into a water jacket at the front of the cylinder block (Fig. 14). WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOV- ING THE COOLANT TEMPERATURE SENSOR.
Page 333 7 - 46 ENGINE ENGINE COOLANT TEMPERATURE SENSOR (Continued) 5.9L V-8 Gas WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOV- COOLANT TEMPERATURE SENSOR. REFER TO GROUP 7, COOLING. (1) Partially drain the cooling system. Refer to 7, COOLING.
Page 334: Installation
ENGINE 7 - 47 ENGINE COOLANT TEMPERATURE SENSOR (Continued) (5) Replace any lost engine coolant. Refer to 7, COOLING. 5.9L Diesel (1) Apply thread sealant to sensor threads. (2) Install sensor to engine. (3) Tighten sensor to 18 N·m (13 ft. lbs.) torque. (4) Connect electrical connector to sensor.
Page 335: Operation
7 - 48 ENGINE ENGINE COOLANT THERMOSTAT- 5.7L/5.9L (Continued) REMOVAL WARNING: DO NOT LOOSEN THE RADIATOR DRAINCOCK WITH THE COOLING SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM THE COOLANT CAN OCCUR. Do not waste reusable coolant. If the solution is clean, drain the coolant into a clean container for reuse.
Page 336: Installation
ENGINE 7 - 49 ENGINE COOLANT THERMOSTAT- 5.7L/5.9L (Continued) Fig. 21 SPRING CLAMP SIZE LOCATION 1 - SPRING CLAMP SIZE LOCATION Fig. 20 Automatic Belt Tensioner – 5.9L Engines 1 - IDLER PULLEY 2 - TENSIONER 3 - FAN BLADE WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES.
Page 337: Engine Coolant Thermostat - 3.7L/4.7L Description
7 - 50 ENGINE ENGINE COOLANT THERMOSTAT- 5.7L/5.9L (Continued) Fig. 24 Belt Routing – 5.9L Engines Fig. 23 Thermostat Position—5.9L Engines 1 - IDLER PULLEY (6) Install the radiator upper hose to the thermo- 2 - GENERATOR PULLEY 3 - A/C COMPRESSOR PULLEY stat housing.
Page 338: Operation
ENGINE 7 - 51 ENGINE COOLANT THERMOSTAT - 3.7L/4.7L (Continued) emissions and crankcase condensation. This conden- the Diagnosis section of this group for other probable sation can result in sludge formation. causes. The DTC can also be accessed through the DRBIII scan tool.
Page 339: Engine Coolant Thermostat - 5.9L
7 - 52 ENGINE ENGINE COOLANT THERMOSTAT - 3.7L/4.7L (Continued) Fig. 26 Thermostat and Thermostat Housing 3.7L/4.7L 1 - THERMOSTAT HOUSING 3 - THERMOSTAT AND GASKET 2 - THERMOSTAT LOCATION 4 - TIMING CHAIN COVER ENGINE COOLANT THERMOSTAT - 5.9L DIESEL DESCRIPTION CAUTION: Do not operate an engine without a ther- mostat, except for servicing or testing.
Page 340: Removal
ENGINE 7 - 53 ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued) This system capacity will not effect warm up or the valve is still moving when the water temperature cold weather operating characteristics if the thermo- reaches 97°C (207°F), it is opening too late. Replace stat is operating properly.
Page 341: Fan Drive Viscous Clutch
7 - 54 ENGINE ENGINE COOLANT THERMOSTAT - 5.9L DIESEL (Continued) Fig. 29 Viscous Fan 1 - WATER PUMP BYPASS HOSE 2 - FAN BLADE ASSEMBLY 3 - VISCOUS FAN DRIVE 4 - WATER PUMP AND PULLEY Once the engine has cooled, the radiator discharge Fig.
Page 342: Fan Drive Viscous Clutch - 5.9L Diesel
ENGINE 7 - 55 FAN DRIVE VISCOUS CLUTCH (Continued) • 3.7L Manual/4.7L Automatic/5.9L — 85° to 91° C occur when ambient (outside air temperature) is very high. (185° to 195° F) • Engine loads and temperatures are high such as •...
Page 343: Diagnosis And Testing - Electronicly Contolled Viscous Fan Drive
7 - 56 ENGINE FAN DRIVE VISCOUS CLUTCH - 5.9L DIESEL (Continued) ELECTRONICALLY CONTROLLED VISCOUS DRIVE If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when spun by hand), replace the fan drive. This spin test must be performed when the engine is cool.
Page 344: Diagnosis And Testing-Radiator Coolant Flow
ENGINE 7 - 57 RADIATOR (Continued) WARNING: DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM THE COOL- ANT CAN OCCUR. (2) Drain the cooling system (Refer to 7 - COOL- ING - STANDARD PROCEDURE).
Page 345: Cleaning
7 - 58 ENGINE RADIATOR (Continued) NOTE: The radiator is equipped with one alignment dowel on the bottom of the outlet tank and one retaining bracket on the front side of the inlet tank. Both features have rubber insulators attached to them that must be present.
Page 346: Radiator - 5.9L Diesel
ENGINE 7 - 59 RADIATOR (Continued) (12) Install coolant reserve/overflow container or DIAGNOSIS AND TESTING—RADIATOR degas container to fan shroud and tighten the bolts COOLANT FLOW to 8.5 N·m (75 in. lbs.). Use the following procedure to determine if coolant (13) Connect upper radiator hose and install is flowing through the cooling system.
Page 347: Cleaning
7 - 60 ENGINE RADIATOR - 5.9L DIESEL (Continued) (6) Remove the power steering cooler mounting INSPECTION bolts and position the power steering cooler out of Inspect the radiator side tanks for cracks, broken the way. or missing fittings also inspect the joint where the (7) Disconnect the transmission cooler lines at the tanks seam up to the radiator core for signs of leak- transmission.
Page 348: Operation
ENGINE 7 - 61 RADIATOR PRESSURE CAP (Continued) loaded pressure relief valve. This valve opens when DIAGNOSIS AND TESTING system pressure reaches the release range of 97-to- 124 kPa (14-to-18 psi). DIAGNOSIS AND TESTING—RADIATOR A rubber gasket seals the radiator filler neck. This CAP-TO-FILLER NECK SEAL is done to maintain vacuum during coolant cool-down The pressure cap upper gasket (seal) pressure...
Page 349: Water Pump - 5.9L
7 - 62 ENGINE RADIATOR PRESSURE CAP (Continued) Fig. 39 Radiator Pressure Cap 1 - STAINLESS-STEEL SWIVEL TOP 2 - RUBBER SEALS 3 - VENT VALVE 4 - RADIATOR TANK 5 - FILLER NECK 6 - OVERFLOW NIPPLE 7 - MAIN SPRING 8 - GASKET RETAINER Fig.
Page 350 ENGINE 7 - 63 WATER PUMP - 5.9L (Continued) Fig. 40 Water Pump Location — Typical 1 - WATER PUMP BYPASS HOSE 2 - FAN BLADE ASSEMBLY 3 - VISCOUS FAN DRIVE 4 - WATER PUMP AND PULLEY REMOVAL Fig. 41 Belt Tensioner 5.9L V-8 Engine The water pump on all models can be removed without discharging the air conditioning system (if 1 - IDLER PULLEY...
Page 351: Installation
7 - 64 ENGINE WATER PUMP - 5.9L (Continued) (6) Install the coolant return tube and its mount- ing bolt to the engine (Fig. 42). Be sure the slot in the tube bracket is bottomed to mounting bolt. This will properly position return tube. (7) Connect the radiator lower hose to the water pump.
Page 352: Operation-Water Pump Bypass
ENGINE 7 - 65 WATER PUMP - 3.7L/4.7L (Continued) Fig. 44 Water Pump and Timing Chain Cover 1 - INTEGRAL WATER PUMP PULLEY 2 - TIMING CHAIN COVER 3 - THERMOSTAT HOUSING 4 - HEATER HOSE FITTINGS 5 - WATER PUMP radiator core, cooling system hoses and heater core, Fig.
Page 353: Cleaning
7 - 66 ENGINE WATER PUMP - 3.7L/4.7L (Continued) (9) Remove the water pump and gasket. Discard gasket. CLEANING Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. INSPECTION Inspect the water pump assembly for cracks in the housing, water leaks from shaft seal, worn bearing or impeller rubbing either the pump body or timing chain case/cover.
Page 354: Water Pump - 5.9L Diesel
ENGINE 7 - 67 WATER PUMP - 3.7L/4.7L (Continued) CAUTION: When installing the serpentine accessory antifreeze in the coolant mixture. Additional lubrica- drive belt, the belt must be routed correctly. If not, tion is not necessary. the engine may overheat due to the water pump OPERATION rotating in the wrong direction.
Page 355: Inspection
7 - 68 ENGINE WATER PUMP - 5.9L DIESEL (Continued) INSPECTION generator or A/C compressor from their mounting bracket is not necessary. Also, discharging the A/C Visually inspect the water pump and replace if it system is not necessary. Do not remove any refriger- has any of the following conditions: ant lines from A/C compressor.
Page 356: Removal - Water Pump Bypass Hose Without Air Conditioning
ENGINE 7 - 69 WATER PUMP INLET TUBE - 5.9L (Continued) (12) Remove the remaining bracket-to-engine bolts (Fig. 55). Fig. 53 Idler Pulley - 5.9L V-8 Gas Engine (10) Remove the heater hose coolant return tube mounting bolt (Fig. 54) (Fig. 55) and remove the tube Fig.
Page 357: Installation - Water Pump Bypass
7 - 70 ENGINE WATER PUMP INLET TUBE - 5.9L (Continued) Fig. 56 Water Pump Bypass Hose - Typical Fig. 57 Tensioner Mounting 1 - WATER PUMP BYPASS HOSE 1 - DOWEL PIN HOLE 2 - FAN BLADE ASSEMBLY 2 - TENSIONER MOUNTING BRACKET 3 - VISCOUS FAN DRIVE 4 - WATER PUMP AND PULLEY CAUTION: When installing the serpentine accessory...
Page 358 ENGINE 7 - 71 WATER PUMP - 5.7L (Continued) (6) Disconnect washer bottle wiring and hose. INSTALLATION (7) Remove fan shroud assembly. (1) Install water pump mounting bolts. (8) Remove A/C compressor and genterator brace. Tighten moubting bolts to 24 N·m (18 ft. lbs.). (9) Remove idler pulleys.
Page 359 7 - 72 TRANSMISSION TRANSMISSION TABLE OF CONTENTS page page TRANS COOLER TRANS COOLER - 5.9L DIESEL DESCRIPTION DESCRIPTION ......73 DESCRIPTION .
Page 360: Trans Cooler
TRANSMISSION 7 - 73 TRANS COOLER (Continued) Fig. 3 Transmission Oil Cooler Thermostat Removal/Installation 1 - THERMOSTAT HOUSING 2 - SPRING 3 - END PLUG 4 - SNAP RING 5 - THERMOSTAT Fig. 2 Cooling Module - 3.7L/4.7L/5.7L (3) Install the transmission oil cooler (Refer to 7 - COOLING/TRANSMISSION/TRANS COOLER 1 - TRANS OIL COOLER...
Page 361: Operation
7 - 74 TRANSMISSION TRANS COOLER - 5.9L DIESEL (Continued) ers are supplied as standard equipment on diesel engine powered models when equipped with an auto- matic transmission. The main water-to-oil transmission oil cooler is mounted to a bracket on the intake side of the engine (Fig.
Page 362: Installation-Air To Oil Cooler
TRANSMISSION 7 - 75 TRANS COOLER - 5.9L DIESEL (Continued) Fig. 6 Auxiliary Transmission Oil Cooler—Diesel Fig. 7 Transmission Water-To- Oil Cooler—Diesel Engine 1 - TRANSMISSION WATER-TO-OIL COOLER 1 - MOUNTING BOLTS (6) Check the fluid level in the automatic trans- 2 - RADIATOR 3 - QUICK-CONNECT FITTINGS mission (Refer to 21 - TRANSMISSION/TRANS-...
Page 364 AUDIO 8A - 1 AUDIO TABLE OF CONTENTS page page AUDIO OPERATION ......7 DESCRIPTION .
Page 365 8A - 2 AUDIO AUDIO (Continued) Instrument Cluster allows it to process those inputs harness routing and retention, connector pin-out and send the proper messages to the radio receiver information and location views for the various wire over the Programmable Communication Interface harness connectors, splices and grounds.
Page 366: Operation
AUDIO 8A - 3 AUDIO (Continued) CONDITION POSSIBLE CAUSES CORRECTION CLOCK WILL NOT KEEP 1. Fuse faulty. 1. Check Ignition-Off Draw (IOD) fuse in the SET TIME Integrated Power Module (IPM). Replace fuse, if required. 2. Radio connector faulty. 2. Check for loose or corroded radio connector. Repair, if required.
Page 367: Installation
8A - 4 AUDIO AMPLIFIER (Continued) (3) Remove instrument panel center bezel (Refer to right cowl side panel into the interior of the vehicle. 23 - BODY/INSTRUMENT PANEL/INSTRUMENT Inside the vehicle, the primary coaxial cable is con- PANEL CENTER BEZEL - REMOVAL). nected to a secondary instrument panel antenna (4) Remove instrument panel lower right center coaxial cable with an in-line connector that is located...
Page 368 AUDIO 8A - 5 ANTENNA BODY & CABLE (Continued) NOTE: This model has a two-piece antenna coaxial (1) Disconnect the instrument panel antenna cable cable. Tests 2 and 4 must be conducted in two coaxial connector from the back of the radio. (2) Touch one ohmmeter test lead to the tip of the steps to isolate an antenna cable problem.
Page 369: Removal
8A - 6 AUDIO ANTENNA BODY & CABLE (Continued) antenna body to fender mating surfaces and tighten (6) Install the antenna cap nut. Tighten to 7 N·m the antenna cap nut to specifications. (65 in. lbs.). (4) Check the resistance again with an ohmmeter. (7) Install the antenna mast.
Page 370: Installation
AUDIO 8A - 7 INSTRUMENT PANEL ANTENNA CABLE (Continued) (PCI) data bus network. All factory-installed receiv- ers are stereo Electronically Tuned Radios (ETR) and include an electronic digital clock function. These radio receivers can only be serviced by an authorized radio repair station. See the latest War- ranty Policies and Procedures manual for a current listing of authorized radio repair stations.
Page 371: Installation
8A - 8 AUDIO RADIO (Continued) Factory-installed radio noise suppression is accom- plished primarily through circuitry or devices that are integral to the factory-installed radios, audio power amplifiers and other on-board electrical com- ponents such as generators, wiper motors, blower motors, and fuel pumps that have been found to be potential sources of RFI or EMI.
Page 372: Removal
AUDIO 8A - 9 RADIO NOISE SUPPRESSION GROUND STRAP (Continued) REMOVAL BED TO CAB (1) Disconnect and isolate the battery negative cable. (2) Remove the attaching bolts and strap (Fig. 8). Fig. 10 GROUND STRAP TO HEAT SHIELD 1 - STUD 2 - GROUND STRAP 3 - NUT ENGINE TO HEAT SHIELD - 4.7L AND 5.7L ENGINE...
Page 373: Installation
8A - 10 AUDIO RADIO NOISE SUPPRESSION GROUND STRAP (Continued) Fig. 12 ENGINE GROUND STRAP - 5.9L (8.0L Fig. 13 Remote Radio Switch Operational View SIMILAR) 1 - PRESET SEEK 2 - SEEK UP 1 - GROUND STRAP 3 - VOLUME UP 2 - MOUNTING BOLTS 4 - MODE 5 - VOLUME DOWN...
Page 374: Diagnosis And Testing - Remote Switches
AUDIO 8A - 11 REMOTE SWITCHES (Continued) DIAGNOSIS AND TESTING - REMOTE (2) Use an ohmmeter to check the switch resis- tances as shown in the Remote Radio Switch Test SWITCHES chart. If the remote radio switch resistances check Any diagnosis of the Audio system should OK, go to Step 3.
Page 375: Removal
8A - 12 AUDIO REMOTE SWITCHES (Continued) REMOVAL AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, WARNING: DISABLE AIRBAG SYSTEM THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- BEFORE ATTEMPTING ANY STEERING WHEEL, TEM CAPACITOR TO DISCHARGE BEFORE PER- STEERING COLUMN, SEAT BELT TENSIONER, SIDE FORMING FURTHER DIAGNOSIS OR SERVICE.
Page 376: Diagnosis And Testing - Speaker
AUDIO 8A - 13 SPEAKER (Continued) appropriate wiring information. The wiring informa- cable. If vehicle is not equipped with a amplifier, tion includes wiring diagrams, proper wire and con- remove the radio receiver. If vehicle is equipped with nector repair procedures, details of wire harness an amplifier.
Page 377 8A - 14 AUDIO SPEAKER (Continued) INSTRUMENT PANEL CENTER SPEAKER REAR CAB SIDE SPEAKER (1) Disconnect and isolate the battery negative (1) Disconnect and isolate the battery negative cable. cable. (2) Remove instrument panel top cover (Refer to (2) Remove B-pillar lower trim (Refer to 23 - 23 - BODY/INSTRUMENT PANEL/INSTRUMENT BODY/INTERIOR/B-PILLAR LOWER...
Page 378: Installation
AUDIO 8A - 15 SPEAKER (Continued) INSTALLATION (2) Install instrument panel top cover (Refer to 23 BODY/INSTRUMENT PANEL/INSTRUMENT PANEL TOP COVER - INSTALLATION). FRONT DOOR SPEAKER (3) Connect battery negative cable. (1) Connect electrical harness connector install speaker. REAR CAB SIDE SPEAKER (2) Install front door trim panel (Refer to 23 - (1) Connect electrical...
Page 380 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME/BUZZER DIAGNOSIS AND TESTING - CHIME DESCRIPTION ......1 CONDITIONS .
Page 381 8B - 2 CHIME/BUZZER CHIME/BUZZER (Continued) LOW WASH INDICATOR The air bag module transmits a J1850 message requesting the instrument cluster to perform a bulb The Front Control Module (FCM) monitors the check each time the ignition is turned to the on posi- washer reservoir.
Page 382 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page COMMUNICATION DESCRIPTION - MODES OF OPERATION ..8 DESCRIPTION ......1 DESCRIPTION - 5 VOLT SUPPLIES .
Page 383 8E - 2 ELECTRONIC CONTROL MODULES COMMUNICATION (Continued) Many of the electronic control modules in a vehicle A standard node terminates the bus through an 11 require information from the same sensing device. In KW resistor and a 330 pF capacitor. the past, if information from one sensing device was The modules bias the bus when transmitting a required by several controllers, a wire from each con-...
Page 384: Description
ELECTRONIC CONTROL MODULES 8E - 3 COMMUNICATION (Continued) • Cyclic Redundancy Check (CRC) Byte - This OPERATION byte is used to detect errors during a message trans- The CAB voltage source is through the ignition mission. switch in the RUN position. The CAB contains a self •...
Page 385: Engine Control Module
8E - 4 ELECTRONIC CONTROL MODULES NOTE: ECM Inputs: ENGINE CONTROL MODULE • Accelerator Pedal Position Sensor (APPS) Volts DESCRIPTION - ECM • APPS1 Signal — For off engine APPS The Engine Control Module (ECM) is bolted to the • APPS2 Signal — For off engine APPS left side of the engine below the intake manifold (Fig.
Page 386: Installation
ELECTRONIC CONTROL MODULES 8E - 5 ENGINE CONTROL MODULE (Continued) To avoid possible voltage spike damage to either (6) Turn key to ON position. Without starting the Engine Control Module ECM, ignition key must engine, slowly press throttle pedal to floor and be off, and negative battery cables must be discon- then slowly release.
Page 387: Diagnosis And Testing - Front Control Module
8E - 6 ELECTRONIC CONTROL MODULES FRONT CONTROL MODULE (Continued) DIAGNOSIS AND TESTING - FRONT CONTROL HEATED SEAT MODULE MODULE DESCRIPTION The front control module is a printed circuit board based module with a on-board micro-processor. The front control module interfaces with other electronic modules in the vehicle via the Programmable Com- munications Interface (PCI) data bus (J1850).
Page 388: Diagnosis And Testing - Heated Seat Module
ELECTRONIC CONTROL MODULES 8E - 7 HEATED SEAT MODULE (Continued) ments and sensors, and controls the ground for the (2) Check the heated seat sensor (Refer to 8 - heated seat switch indicator lamps. ELECTRICAL/HEATED SEATS/HEATED SEAT When a heated seat switch (Driver or Passenger) is SENSOR - DIAGNOSIS AND TESTING).
Page 389: Powertrain Control Module
8E - 8 ELECTRONIC CONTROL MODULES During Closed Loop modes, the PCM will monitor POWERTRAIN CONTROL the oxygen (O2S) sensors input. This input indicates MODULE to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel.
Page 390 ELECTRONIC CONTROL MODULES 8E - 9 POWERTRAIN CONTROL MODULE (Continued) • Battery voltage IDLE MODE • Engine coolant temperature sensor When the engine is at operating temperature, this • Crankshaft position sensor is a Closed Loop mode. At idle speed, the PCM •...
Page 391: Description - 5 Volt Supplies
8E - 10 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) • Throttle position sensor (TPS) the injector pulse width by turning the ground circuit • Camshaft position sensor signal to each individual injector on and off. • The PCM monitors the O2S sensor input and During wide open throttle conditions, the following adjusts air-fuel ratio.
Page 392: Operation - Pcm
ELECTRONIC CONTROL MODULES 8E - 11 POWERTRAIN CONTROL MODULE (Continued) • Intake manifold air temperature sensor OPERATION • Knock sensors (2 on 3.7L engine) • Leak detection pump (switch) sense (if equipped) OPERATION - PCM • Manifold absolute pressure (MAP) sensor The PCM operates the fuel system.
Page 393: Operation - Ignition Circuit Sense
8E - 12 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) • supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5–volt supply: • supplies the required 5 volt power source to the oil pressure sensor. • supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped).
Page 394: Sentry Key Immobilizer Module
ELECTRONIC CONTROL MODULES 8E - 13 POWERTRAIN CONTROL MODULE (Continued) (2) Tighten bolts. Refer to torque specifications. The SKIM and the PCM both use software that (3) Check pin connectors in the PCM and the three includes a rolling code algorithm strategy, which 32–way connectors (four...
Page 395: Standard Procedure - Pcm/Skim Programming
8E - 14 ELECTRONIC CONTROL MODULES SENTRY KEY IMMOBILIZER MODULE (Continued) STANDARD PROCEDURE - PCM/SKIM NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured PROGRAMMING access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN NOTE: There are two procedures for transfering the position for one hour then enter the correct PIN.
Page 396: Removal
ELECTRONIC CONTROL MODULES 8E - 15 SENTRY KEY IMMOBILIZER MODULE (Continued) NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM, it (the key) cannot be transferred to another vehicle. (5) If ignition key programming is unsuccessful, the DRBIII scan tool will display one of the follow- ing messages:...
Page 397 8E - 16 ELECTRONIC CONTROL MODULES TRANSFER CASE CONTROL MODULE (Continued) module must receive one ignition message that denotes that the ignition is in the RUN position. • Sleep Mode will be entered, from the Reduced Power Mode, when no PCI traffic has been sensed for 20 ±1 seconds.
Page 398 ELECTRONIC CONTROL MODULES 8E - 17 TRANSFER CASE CONTROL MODULE (Continued) • The recessed Neutral Selection switch has been • Extinguish the source gear’s LED while flashing depressed continuously for 4.0 seconds ±100 msec desired transfer case position’s LED. • Engage the shift motor for a maximum of 1 sec- while all shift conditions have been continuously met.
Page 399 8E - 18 ELECTRONIC CONTROL MODULES TRANSFER CASE CONTROL MODULE (Continued) ments for shifting are not met, illuminate the 4H 2WD/AWD position, the shift is considered complete LED and flash the destination LED as an indication and the 2WD/AWD LED is illuminated. to the driver that all of the driver controllable shift NOTE: If after the 5th blocked shift and reversal conditions are not being met).
Page 400: Transmission Control Module
ELECTRONIC CONTROL MODULES 8E - 19 TRANSFER CASE CONTROL MODULE (Continued) SHIFT ATTEMPT LIMIT To protect the transfer case system, the TCCM will impose a limit on the number of shifts that can occur over a calibrated time period. The system will monitor the number of ’D’...
Page 401 8E - 20 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) NOTE: If the TCM has been replaced, the “Quick Learn Procedure” must be performed. (Refer to 8 - ELECTRI- CAL/ELECTRONIC CONTROL MODULES/TRANSMIS- SION CONTROL MODULE - STANDARD PROCEDURE) BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power.
Page 402: Standard Procedure
ELECTRONIC CONTROL MODULES 8E - 21 TRANSMISSION CONTROL MODULE (Continued) Schedule Condition Expected Operation Extreme Cold Oil temperature below -16° F -Park, Reverse, Neutral and 1st and 3rd gear only in D position, 2nd gear only in Manual 2 or L -No EMCC Super Cold Oil temperature between -12°...
Page 403 8E - 22 ELECTRONIC CONTROL MODULES TRANSMISSION CONTROL MODULE (Continued) LEARN A SMOOTH 1ST NEUTRAL TO DRIVE SHIFT itor Norm N-D UD CVI volume until the value stabi- lizes. The value will change during the N-D shift. Perform this procedure only if the complaint is for This is normal since the UD value is different for the a delayed or harsh shift the first time the transmis- N-D shift then the normal value shown which is used...
Page 404 ELECTRONIC CONTROL MODULES 8E - 23 TRANSMISSION CONTROL MODULE (Continued) (2) Repeat Step 1 until the UD volume becomes LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT somewhat stable and the shift becomes smooth. NOTE: The transmission oil temperature must be LEARN A SMOOTH 1-2 UPSHIFT AND 3-2 above 110°F (43°C).
Page 406 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 407: Battery System
8F - 2 BATTERY SYSTEM BATTERY SYSTEM (Continued) For battery system maintenance schedules and the battery, starting, and charging systems be thor- jump starting procedures, see the owner’s manual in oughly tested and inspected any time a battery needs the vehicle glove box. Optionally, refer to the Lubri- to be charged or replaced.
Page 408 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test ATTEMPTING TO START procedures.
Page 409: System
8F - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the CHARGE CANNOT BE incorrect size or rating for proper specifications.
Page 410 BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) ponents. In addition to the maintenance schedules found in this service manual and the owner’s man- ual, it is recommended that these procedures be per- formed any time the battery or related components must be removed for vehicle service.
Page 411 8F - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) INSPECTION found on the original equipment battery label. Be certain that a replacement battery has the correct The following information details the recommended Group Size number, as well as CCA, and RC or AH inspection procedures for the battery and related ratings that equal or exceed the original equipment components.
Page 412: Special Tools
BATTERY SYSTEM 8F - 7 BATTERY SYSTEM (Continued) A large capacity, low-maintenance storage battery SPECIAL TOOLS (Fig. 4) is standard factory-installed equipment on this model. Models equipped with a diesel engine BATTERY SYSTEM SPECIAL TOOLS must utilize two 12-volt batteries connected in paral- lel.
Page 413: Standard Procedure
8F - 8 BATTERY SYSTEM BATTERY (Continued) MICRO 420 BATTERY TESTER absolutely necessary due to time restraints. A battery is fully-charged when: The Micro 420 automotive battery tester is • All of the battery cells are gassing freely during designed to help the dealership technician diagnose battery charging.
Page 414 BATTERY SYSTEM 8F - 9 BATTERY (Continued) the manufacturer of the battery charger for details turer of the battery charger for details on how to on how to bypass the polarity-sensing circuitry. bypass the polarity-sensing circuitry. After the battery has been charged to 12.4 volts or (3) Battery chargers vary in the amount of voltage greater, perform a load test to determine the battery and current they provide.
Page 415: Standard Procedure - Built-In Indicator Test
8F - 10 BATTERY SYSTEM BATTERY (Continued) battery condition that each color indicates BATTERY CHARGING TIME TABLE described in the following list: Charging • Green - Indicates 75% to 100% battery state-of- 5 Amps 20 Amps Amperage Amps charge. The battery is adequately charged for further Open Circuit Hours Charging @ 21°...
Page 416: Standard Procedure - Ignition-Off Draw Test
BATTERY SYSTEM 8F - 11 BATTERY (Continued) Turn on the headlamps for fifteen seconds, then STANDARD PROCEDURE - IGNITION-OFF allow up to five minutes for the battery voltage to DRAW TEST stabilize. The term Ignition-Off Draw (IOD) identifies a nor- (2) Disconnect and isolate both battery cables, neg- mal condition where power is being drained from the ative cable first.
Page 417: Battery System
8F - 12 BATTERY SYSTEM BATTERY (Continued) ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TABLE Time Out? IOD After Time Module (If Yes, Interval And Wake-Up Input) ElectroMechanical Instrument Cluster 0.44 milliampere (EMIC) Combination Flasher 0.08 milliampere (2) Determine that the underhood lamp is operat- CAUTION: Do not open any doors, or turn on any ing properly, then disconnect the lamp wire harness electrical accessories with the lowest milliampere...
Page 418: Removal
BATTERY SYSTEM 8F - 13 BATTERY (Continued) WARNING: ALWAYS WEAR APPROPRIATE EYE BATTERY TEST RESULTS PROTECTION AND USE EXTREME CAUTION WHEN GOOD BATTERY Return to service WORKING WITH BATTERIES. GOOD - RECHARGE Fully charge battery and return to service BATTERY TESTING CHARGE &...
Page 419: Installation
8F - 14 BATTERY SYSTEM BATTERY (Continued) (7) Remove the battery from the battery tray. REMOVAL (1) Loosen and remove the battery hold down INSTALLATION retaining bolt. (1) Clean and inspect the battery. (2) Remove the battery hold down bracket from (2) Position the battery onto the battery tray.
Page 420: Diagnosis And Testing - Battery Cables
BATTERY SYSTEM 8F - 15 BATTERY CABLES (Continued) • The battery is fully-charged and tested (Refer to also provide a return path for electrical current gen- erated by the charging system for restoring the volt- 8 - ELECTRICAL/BATTERY SYSTEM/BATTERY - age potential of the battery.
Page 421: Removal
8F - 16 BATTERY SYSTEM BATTERY CABLES (Continued) between the battery positive cable terminal clamp and the battery positive terminal post. NOTE: If the vehicle is equipped with two 12v bat- teries, step #2 must be performed twice, once for each battery.
Page 422: Installation
BATTERY SYSTEM 8F - 17 BATTERY CABLES (Continued) INSTALLATION OPERATION (1) Position the battery cable in the engine com- The battery tray and the battery hold down hard- partment. ware combine to secure and stabilize the battery in (2) One at a time, install the battery cable retain- the engine compartment, which prevents battery ing pushpins, fasteners and routing clips until the movement during even the most extreme vehicle...
Page 423: Installation
8F - 18 BATTERY SYSTEM BATTERY TRAY (Continued) (6) Mark the location of the cruise servo (if equipped) and remove the retaining screws. Position the servo out of the way. (7) Remove the battery temperature sensor from the battery tray (Refer to 8 - ELECTRICAL/CHARG- ING/BATTERY TEMPERATURE SENSOR...
Page 424 CHARGING 8F - 19 CHARGING TABLE OF CONTENTS page page CHARGING OPERATION ......21 DESCRIPTION .
Page 425: Description
8F - 20 CHARGING CHARGING (Continued) • a faulty or improperly adjusted switch that (2) Inspect condition of battery cable terminals, allows a lamp to stay on. Refer to Ignition-Off Draw battery posts, connections at engine block, starter Test in 8, Battery for more information. solenoid and relay.
Page 426: Battery Temperature Sensor
CHARGING 8F - 21 CHARGING (Continued) DESCRIPTION N·m Ft. Lbs. In. Lbs. Generator Lower Pivot Bolt / Nut - 5.9L Gas Engine Generator Vertical Mounting Bolt - 3.7L / 4.7L Engines Generator (long) Horizontal Mounting Bolt - 3.7L / 4.7L Engines Generator (short) Horizontal Mounting Bolt - 3.7L / 4.7L Engines Generator B+ Output Cable...
Page 427: Generator Description
8F - 22 CHARGING (7) Remove 2 front horizontal generator mounting GENERATOR bolts (Fig. 3). (8) Remove generator from vehicle. DESCRIPTION The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly.
Page 428 CHARGING 8F - 23 GENERATOR (Continued) 5.7L 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 429 8F - 24 CHARGING GENERATOR (Continued) (4) Remove B+ terminal mounting nut at rear of generator (Fig. 8). Disconnect terminal from genera- tor. (5) Disconnect field wire connector at rear of gen- erator (Fig. 8) by pushing on connector tab. (6) Remove 1 upper generator mounting bolt (Fig.
Page 430: Installation
CHARGING 8F - 25 GENERATOR (Continued) INSTALLATION 3.7L / 4.7L (1) Position generator to engine and install 2 hor- izontal bolts and 1 vertical bolt. (2) Tighten all 3 bolts. Refer to Torque Specifica- tions. (3) Snap field wire connector into rear of genera- tor.
Page 431 8F - 26 CHARGING GENERATOR (Continued) (7) Install negative battery cable to battery. CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The 5.9L Diesel water pump may be rotating in the wrong direction (1) Position generator to upper and lower mount- if the belt is installed incorrectly, causing the ing brackets and install upper bolt and lower bolt / engine to overheat.
Page 432: Voltage Regulator Description
CHARGING 8F - 27 EVR circuitry monitors system line voltage (B+) and VOLTAGE REGULATOR battery temperature (refer to Battery Temperature Sensor for more information). It then determines a DESCRIPTION target charging voltage. If sensed battery voltage is The Electronic Voltage Regulator (EVR) is not a 0.5 volts or lower than the target voltage, the PCM separate component.
Page 433 8F - 28 STARTING STARTING TABLE OF CONTENTS page page STARTING REMOVAL ......34 DESCRIPTION .
Page 434: Diagnosis And Testing - Starting
STARTING 8F - 29 STARTING (Continued) open switch prevents the starter relay from being starter pinion gear to spin faster than the pinion energized and the starter motor from operating shaft. When the ignition switch is released to the On unless the automatic transmission gear selector is in position, the starter relay coil is de-energized.
Page 435 8F - 30 STARTING STARTING (Continued) Starting System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION STARTER ENGAGES, 1. Starter ring gear faulty. 1. Refer to Starter Motor Removal and Installation. SPINS OUT BEFORE Remove starter motor to inspect starter ring gear. ENGINE STARTS. Replace starter ring gear if required.
Page 436 STARTING 8F - 31 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 437 8F - 32 STARTING STARTING (Continued) Fig. 4 TEST BATTERY POSITIVE CABLE Fig. 2 TEST BATTERY NEGATIVE CONNECTION RESISTANCE - TYPICAL RESISTANCE - TYPICAL 1 - BATTERY 1 - VOLTMETER 2 - VOLTMETER 2 - BATTERY 3 - STARTER MOTOR tery cable attachment on engine block.
Page 438: Specifications
STARTING 8F - 33 STARTING (Continued) If reading is above 0.2 volt, clean and tighten battery cables at both batteries. Repeat test. If reading is still above 0.2 volt, replace faulty positive battery cable. If resistance tests detect no feed circuit problems, refer to Starter Motor in the Diagnosis and Testing.
Page 439: Specifications - Torque - Starting System
8F - 34 STARTING STARTING (Continued) SPECIFICATIONS - TORQUE - STARTING SYSTEM DESCRIPTION N·m Ft. Lbs. In. Lbs. Battery Cable Eyelet Nut at Solenoid (large nut - gas engines) Battery Cable Eyelet Nut at Solenoid (large nut - diesel engine) Starter Solenoid Nut (small nut - diesel engine) Starter Mounting Bolts - Gas...
Page 440 STARTING 8F - 35 STARTER MOTOR (Continued) Fig. 8 CONTINUITY BETWEEN SOLENOID TERMINAL AND CASE - TYPICAL 1 - SOLENOID TERMINAL 2 - OHMMETER 3 - SOLENOID (4) Remove 1 bolt and 1 nut if equipped with a manual transmission (Fig. 9). Fig.
Page 441 8F - 36 STARTING STARTER MOTOR (Continued) Fig. 11 STARTER R/I - 5.7L Fig. 12 STARTER R/I - 5.9L DIESEL 1 - STARTER MOTOR 1 - MOUNTING BOLTS (3) 2 - MOUNTING BOLTS 2 - STARTER MOTOR 3 - SPACER (CERTAIN TRANSMISSIONS) (4) Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing.
Page 442: Installation
STARTING 8F - 37 STARTER MOTOR (Continued) housing. Always support starter motor during this (5) Install and tighten both bolts (auto. trans.), or process, do not let starter motor hang from wire har- 1 nut and 1 bolt (man. trans.). Refer to Torque Spec- ness.
Page 443: Starter Motor Relay Description
8F - 38 STARTING STARTER MOTOR RELAY DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine com- partment.
Page 444: Removal
STARTING 8F - 39 STARTER MOTOR RELAY (Continued) (5) The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gear- shift selector lever is in Park or Neutral positions.
Page 446 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED MIRRORS ......1 HEATED SEAT SYSTEM .
Page 447 8G - 2 HEATED MIRRORS HEATED MIRRORS (Continued) heated mirror switch is depressed and released a sec- The operation of the heated mirror system can be ond time during the same ignition cycle, the elec- confirmed in one of the following manners: tronic control logic...
Page 448 HEATED SEAT SYSTEM 8G - 3 HEATED SEAT SYSTEM TABLE OF CONTENTS page page HEATED SEAT SYSTEM OPERATION ......7 DESCRIPTION .
Page 449: Heated Seat System
8G - 4 HEATED SEAT SYSTEM HEATED SEAT SYSTEM (Continued) The heated seat module monitors inputs from the heated seat sensors and the heated seat switches. In response to these inputs the heated seat module uses its internal programming to control 12v to the heated seat elements in both front seats and to control the heated seat LED indicator lamps located in both of the heated seat switches.
Page 450: Heated Seat Element
HEATED SEAT SYSTEM 8G - 5 HEATED SEAT SYSTEM (Continued) Diagnostic logic is built into the heated seat mod- Heated Seat Switch in this section for heated seat ule to help the person trying to locate the problem by switch diagnosis and testing procedures. •...
Page 451: Operation
8G - 6 HEATED SEAT SYSTEM HEATED SEAT ELEMENT (Continued) the element grids to the heated seat module through NOTE: When checking heated seat elements for the seat wire harness. continuity, be certain to move the heating element One temperature sensor is used for each front seat, being checked.
Page 452: Heated Seat Sensor
HEATED SEAT SYSTEM 8G - 7 HEATED SEAT ELEMENT (Continued) the temperature of the seat, and regulates the cur- rent flow to the seat heating elements accordingly. DIAGNOSIS AND TESTING - HEATED SEAT SENSOR NOTE: Any resistance values (OHMS ) given in the following text are supplied using the automatic range generated by a FLUKE automotive meter.
Page 453: Operation
8G - 8 HEATED SEAT SYSTEM HEATED SEAT SWITCH (Continued) diagnostic feedback for the heated seat system. Each wired resistance signal to the heated seat module. switch also has an incandescent bulb, which provides This signal tells the module to energize the heated dimmer controlled back lighting of the switch when seat element of the selected seat and maintain the the headlamps or park lamps are on.
Page 454: Removal
HEATED SEAT SYSTEM 8G - 9 HEATED SEAT SWITCH (Continued) inoperative heated seat switch indicator lamps and (6) Replace the inoperative heated seat switch the heated seat elements do not heat, proceed. If the with a known good unit and test the operation of the problem being diagnosed involves inoperative heated switch indicator lamps.
Page 456 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM REMOVAL ......2 DESCRIPTION .
Page 457: Horn Switch
8H - 2 HORN HORN (Continued) WARNING: DISABLE AIRBAG SYSTEM HORN SWITCH BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE DESCRIPTION AIRBAG, OR INSTRUMENT PANEL COMPONENT The horn switch is molded into the driver airbag. DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- The horn switch can not be serviced separately.
Page 458 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL INSTALLATION ......18 DESCRIPTION .
Page 459: Ignition Control
8I - 2 IGNITION CONTROL IGNITION CONTROL (Continued) The Auto Shutdown (ASD) relay provides battery and 5/8. These numbers can also be found on the top voltage to each ignition coil. of the intake manifold to the right of the throttle The ignition system consists of: body (Fig.
Page 460: Description
IGNITION CONTROL 8I - 3 IGNITION CONTROL (Continued) • Also to be considered part of the ignition system Knock sensors are not used with the 8.0L engine. are certain inputs from the Crankshaft Position, Cam- The ignition system consists of: •...
Page 461 8I - 4 IGNITION CONTROL IGNITION CONTROL (Continued) ENGINE FIRING ORDER - 3.7L V-6 1 - 6 - 5 - 4 - 3 - 2 ENGINE FIRING ORDER – 4.7L V-8 Fig. 2 FIRING ORDER / CABLE ROUTING - 5.7L V-8 ENGINE 1 - TOP OF INTAKE MANIFOLD 2 - CYLINDER FIRING ORDER (IGNITION COIL NUMBER)
Page 462: Spark Plug Cable Order - 8.0L V-10 Engine
IGNITION CONTROL 8I - 5 IGNITION CONTROL (Continued) SPARK PLUG CABLE ORDER – 8.0L V-10 ENGINE SPARK PLUG CABLE ORDER – 8.0L V-10 ENGINE SPARK PLUG CABLE RESISTANCE MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12,000 Ohms Per Foot SPARK PLUGS ENGINE...
Page 463: Ignition Coil Resistance - 3.7L
8I - 6 IGNITION CONTROL IGNITION CONTROL (Continued) IGNITION COIL RESISTANCE - 3.7L V-6 IGNITION COIL RESISTANCE - 5.7L V-8 SECONDARY PRIMARY RESISTANCE @ 21-27°C (70-80°F) PRIMARY RESISTANCE RESISTANCE 21-27°C 0.558 - 0.682 Ohms 21-27°C (70-80°F) (70-80°F) (Plus or Minus 10% @ 70-80° F) 0.6 - 0.9 Ohms 6,000 - 9,000 Ohms IGNITION COIL RESISTANCE - 4.7L V-8...
Page 464: Diagnosis And Testing - Asd And Fuel Pump Relays
IGNITION CONTROL 8I - 7 AUTOMATIC SHUT DOWN RELAY (Continued) • Terminal number 86 supplies voltage to the coil DIAGNOSIS AND TESTING - ASD AND FUEL side of the relay. PUMP RELAYS • When the PCM de-energizes the ASD and fuel The following description of operation and pump relays, terminal number 87A connects to termi- tests apply only to the Automatic Shutdown...
Page 465: Installation
8I - 8 IGNITION CONTROL AUTOMATIC SHUT DOWN RELAY (Continued) (3) Check condition of relay terminals and PDC 5.7L V-8 connector terminals for damage or corrosion. Repair The Camshaft Position Sensor (CMP) on the 5.7L if necessary before installing relay. V-8 engine is located below the generator on the tim- (4) Check for pin height (pin height should be the ing chain / case cover on the right/front side of...
Page 466 IGNITION CONTROL 8I - 9 CAMSHAFT POSITION SENSOR (Continued) Fig. 6 CMP OPERATION- 3.7L V-6 1 - NOTCHES 2 - RIGHT CYLINDER HEAD 3 - CMP Fig. 7 CMP AND TONEWHEEL OPERATION - 4.7L 4 - TONEWHEEL (TARGET WHEEL) 3 notches, 2 notches 1 notch, 3 notches and 1 notch. 1 - NOTCHES 2 - RIGHT CYLINDER HEAD The signal from the CMP sensor is used in conjunc-...
Page 467 8I - 10 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) 5.9L V-8 Gas change of the magnetic field causes the signal voltage to switch low to 0 volts. The CMP sensor on the 5.9L V-8 engine contains a The CMP (Fig. 10) provides a signal to the Engine hall effect device called a sync signal generator to Control Module (ECM) at all times when the engine generate a fuel sync signal.
Page 468: Removal
IGNITION CONTROL 8I - 11 CAMSHAFT POSITION SENSOR (Continued) When the cam gear is rotating, the sensor will detect the machined low area. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts).
Page 469 8I - 12 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) 5.7L V-8 The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located on right side of timing chain cover below generator (Fig. 14). (1) Disconnect electrical connector at CMP sensor. (2) Remove sensor mounting bolt (Fig.
Page 470 IGNITION CONTROL 8I - 13 CAMSHAFT POSITION SENSOR (Continued) (4) Disconnect camshaft position sensor wiring the engine has been operated, part of this rib may be harness from main engine wiring harness. sheared (ground) off. Depending on parts tolerances, (5) Remove distributor rotor from distributor shaft. some of the rib material may still be observed after (6) Lift camshaft position sensor assembly from removal.
Page 471: Installation
8I - 14 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) (4) Install mounting bolt and tighten. Refer to Torque Specifications. (5) Connect electrical connector to sensor. 5.7L V-8 The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is bolted to the right / front side of the timing chain cover (Fig.
Page 472 IGNITION CONTROL 8I - 15 CAMSHAFT POSITION SENSOR (Continued) 8.0L V–10 If Replacing Old Sensor With Original The camshaft position sensor is located on the tim- ing chain case/cover on the left-front side of the engine (Fig. 18). When installing a used camshaft position sensor, the sensor depth must be adjusted to prevent contact with the camshaft gear (sprocket).
Page 473: Description
8I - 16 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) When the engine is started, the rib material will be sheared off the face of sensor. This will automatically set sensor air gap. DISTRIBUTOR DESCRIPTION All 5.9L V-8 engines are equipped with a camshaft driven mechanical distributor (Fig.
Page 474: Removal
IGNITION CONTROL 8I - 17 DISTRIBUTOR (Continued) REMOVAL CAUTION: Base ignition timing is not adjustable on any engine. Distributors do not have built in centrif- ugal or vacuum assisted advance. Base ignition timing and timing advance are controlled by the Powertrain Control Module (PCM).
Page 475: Installation
8I - 18 IGNITION CONTROL DISTRIBUTOR (Continued) INSTALLATION (5) If a plus (+) or a minus (-) is displayed next to degree number, and/or the degree displayed is not If engine has been cranked while distributor is zero, loosen but do not remove distributor holddown removed, establish the relationship between distribu- clamp bolt.
Page 476: Distributor Rotor
IGNITION CONTROL 8I - 19 DISTRIBUTOR CAP (Continued) IGNITION COIL DESCRIPTION 3.7L V-6 The 3.7L V-6 engine uses 6 dedicated, and individ- ually fired coil for each spark plug (Fig. 30). Each coil is mounted directly into the cylinder head and onto the top of each spark plug (Fig.
Page 477: Operation
8I - 20 IGNITION CONTROL IGNITION COIL (Continued) 4.7L V-8 The 4.7L V–8 engine uses 8 dedicated, and individ- ually fired coil (Fig. 30) for each spark plug. Each coil is mounted directly to the top of each spark plug (Fig.
Page 478 IGNITION CONTROL 8I - 21 IGNITION COIL (Continued) Fig. 36 IGNITION COIL LOCATION – 5.9L HDC V-8 1 - COIL MOUNTING BOLTS 2 - IGNITION COIL 3 - COIL ELEC. CONNECTOR 4 - SECONDARY CABLE Fig. 34 IGNITION COIL R/I — 5.7L V-8 1 - SLIDE LOCK (SLIDE OUTWARD TO UNLOCK) 2 - SPARK PLUG CABLE (TO OPPOSITE CYLINDER BANK SPARK PLUG)
Page 479 8I - 22 IGNITION CONTROL IGNITION COIL (Continued) 4.7L V-8 adjust the ignition timing advance. This is done to meet changing engine operating conditions. Battery voltage is supplied to the 8 individual igni- The PCM adjusts ignition timing based on inputs it tion coils from the ASD relay.
Page 480: Removal
IGNITION CONTROL 8I - 23 IGNITION COIL (Continued) The PCM adjusts ignition timing based on inputs it (2) Disconnect electrical connector (Fig. 32) from receives from: coil by pushing downward on release lock on top of • The engine coolant temperature sensor connector and pull connector from coil.
Page 481: Installation
8I - 24 IGNITION CONTROL IGNITION COIL (Continued) WARNING: 5.9L V-8 LDC-GAS ENGINES: DO NOT 4.7L V-8 REMOVE THE COIL MOUNTING BRACKET-TO-CYL- (1) Using compressed air, blow out any dirt or con- INDER HEAD MOUNTING BOLTS. COIL taminants from around top of spark plug. MOUNTING BRACKET IS UNDER ACCESSORY (2) Check condition of coil o-ring and replace as DRIVE BELT TENSION.
Page 482: Knock Sensor
IGNITION CONTROL 8I - 25 IGNITION COIL (Continued) (6) If necessary, install throttle body air tube or box. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock.
Page 483: Installation
8I - 26 IGNITION CONTROL KNOCK SENSOR (Continued) (4) Remove sensors from engine. 5.7L V8 Two sensors are used. Each sensor is bolted into the outside of cylinder block below the exhaust man- ifold (Fig. 41). (1) Raise vehicle. (2) Disconnect knock sensor electrical connector. (3) Remove sensor mounting bolt (Fig.
Page 484: Spark Plug
IGNITION CONTROL 8I - 27 KNOCK SENSOR (Continued) NOTE: Over or under tightening the sensor mount- DIAGNOSIS AND TESTING - SPARK PLUG ing bolts will affect knock sensor performance, pos- CONDITIONS sibly causing improper spark control. Always use To prevent possible pre-ignition and/or mechanical the specified torque when installing the knock sen- engine damage, the correct type/heat range/number sors.
Page 485 8I - 28 IGNITION CONTROL SPARK PLUG (Continued) Fig. 42 NORMAL OPERATION AND COLD (CARBON) FOULING 1 - NORMAL 2 - DRY BLACK DEPOSITS 3 - COLD (CARBON) FOULING COLD FOULING/CARBON FOULING Fig. 43 OIL OR ASH ENCRUSTED Cold fouling is sometimes referred to as carbon electrode gap bridging can be cleaned using standard fouling.
Page 486 IGNITION CONTROL 8I - 29 SPARK PLUG (Continued) mal in condition and can be cleaned using standard Determine if ignition timing is over advanced or if procedures. other operating conditions are causing engine over- heating. (The heat range rating refers to the operat- ing temperature of a particular type spark plug.
Page 487: Removal
8I - 30 IGNITION CONTROL SPARK PLUG (Continued) REMOVAL Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots. 3.7L V-6 (1) Remove necessary air filter tubing at throttle Each individual spark plug is located under each body.
Page 488: Cleaning And Adjustment
IGNITION CONTROL 8I - 31 SPARK PLUG (Continued) Fig. 50 CABLE REMOVAL - 5.9L / 8.0L 1 - SPARK PLUG CABLE AND BOOT 2 - SPARK PLUG BOOT PULLER 3 - TWIST AND PULL 4 - SPARK PLUG 8.0L V-10 Fig.
Page 489 8I - 32 IGNITION CONTROL SPARK PLUG (Continued) 4.7L V-8 5.9L V-8 Special care should be taken when installing spark CAUTION: The 4.7L V–8 engine is equipped with plugs into the cylinder head spark plug wells. Be copper core ground electrode spark plugs. They sure the plugs do not drop into the plug wells as elec- must be replaced with the same type/number spark trodes can be damaged.
Page 490: Ignition Coil Capacitor Description
IGNITION CONTROL 8I - 33 IGNITION COIL CAPACITOR SPARK PLUG CABLE DESCRIPTION DESCRIPTION One coil capacitor is used. It is located in the right- Spark plug cables are sometimes referred to as sec- rear section of the engine compartment. ondary ignition wires, or secondary ignition cables. Plug cables are used only on the 5.7L V-8, 5.9L V-8 OPERATION and 8.0L V-10 engines.
Page 491: Removal
8I - 34 IGNITION CONTROL SPARK PLUG CABLE (Continued) Use an ohmmeter to test for open circuits, exces- sive resistance or loose terminals. If equipped, remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug.
Page 492: Installation
IGNITION CONTROL 8I - 35 SPARK PLUG CABLE (Continued) MUST be placed in cable tray (routing loom) into their original position. The cable retention clips (Fig. 55) must also be securly locked. Before installing spark plug cables to either the spark plugs or coils, apply dielectric grease to inside of boots.
Page 494 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER LAMP OUT INDICATOR DESCRIPTION ......2 DESCRIPTION .
Page 495: Instrument Cluster
8J - 2 INSTRUMENT CLUSTER WASHER FLUID INDICATOR WATER-IN-FUEL INDICATOR DESCRIPTION ......42 DESCRIPTION ......43 OPERATION .
Page 496 INSTRUMENT CLUSTER 8J - 3 INSTRUMENT CLUSTER (Continued) molded plastic cluster housing serves as the carrier (Refer to 8 - ELECTRICAL/CHIME/BUZZER - for the cluster circuit board and circuitry, the cluster DESCRIPTION). • Brake Lamp Control - The EMIC provides connector receptacles, the RKE interface connector, the gauges, a Light Emitting Diode (LED) for each electronic brake lamp request messages to the Front...
Page 497 8J - 4 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) cluster illumination lamps and provide electronic (PWM) output that synchronizes the dimming level headlamp low beam and park lamp request messages of all panel lamps dimmer controlled lamps with that to the Front Control Module (FCM) located on the of the cluster illumination lamps.
Page 498 INSTRUMENT CLUSTER 8J - 5 INSTRUMENT CLUSTER (Continued) • Gear Selector Indicator (with Automatic the vehicle speed remains greater than about twenty- four kilometers-per-hour (fifteen miles-per-hour). Transmission only) • Vacuum Fluorescent Display Synchroniza- • High Beam Indicator • Lamp Out Indicator tion - The EMIC transmits electronic panel lamp •...
Page 499: Operation
8J - 6 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) Fig. 3 Gauges & Indicators - Gasoline Engine 1 - MALFUNCTION INDICATOR LAMP 13 - ELECTRONIC THROTTLE CONTROL (ETC) INDICATOR 2 - VOLTAGE GAUGE 14 - ENGINE TEMPERATURE GAUGE 3 - LEFT TURN INDICATOR 15 - SECURITY INDICATOR 4 - TACHOMETER 16 - GEAR SELECTOR INDICATOR DISPLAY (INCLUDES...
Page 500 INSTRUMENT CLUSTER 8J - 7 INSTRUMENT CLUSTER (Continued) Fig. 4 Gauges & Indicators - Diesel Engine 1 - MALFUNCTION INDICATOR LAMP 14 - ENGINE TEMPERATURE GAUGE 2 - VOLTAGE GAUGE 15 - SECURITY INDICATOR 3 - LEFT TURN INDICATOR 16 - GEAR SELECTOR INDICATOR DISPLAY (INCLUDES CRUISE &...
Page 501 8J - 8 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) dles at several predetermined calibration points The illumination intensity of the VFD units is con- across the gauge faces, and illuminating all segments trolled by the EMIC circuitry based upon an input of the odometer/trip odometer and gear selector indi- from the headlamp switch and a dimming level input cator...
Page 502 INSTRUMENT CLUSTER 8J - 9 INSTRUMENT CLUSTER (Continued) ajar indicator, high beam indicator, and turn signal the operation for each indicator may be found else- indicators operate based upon hard wired inputs to where in this service information. the EMIC. The brake indicator is controlled by PCI CLUSTER ILLUMINATION data bus messages from the Controller Antilock The EMIC has several illumination lamps that are...
Page 503: Diagnosis And Testing - Instrument Cluster
8J - 10 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) • Driver Door Lock Switch MUX - with • Radio Illumination Driver • Right Door Lock Driver - with Power Locks Power Locks • Fused B(+) - Ignition-Off Draw • Right Door Unlock Driver - with Power •...
Page 504 INSTRUMENT CLUSTER 8J - 11 INSTRUMENT CLUSTER (Continued) CAUTION: Instrument clusters used in this model PRELIMINARY DIAGNOSIS automatically configure themselves for compatibil- WARNING: ON VEHICLES EQUIPPED WITH AIR- ity with the features and optional equipment in the BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT vehicle in which they are initially installed.
Page 505 8J - 12 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) ACTUATOR TEST to diagnose these components. Refer to the appropri- ate diagnostic information. WARNING: ON VEHICLES EQUIPPED WITH AIR- (1) Begin the test with the ignition switch in the BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT Off position.
Page 506 INSTRUMENT CLUSTER 8J - 13 INSTRUMENT CLUSTER (Continued) INSTRUMENT CLUSTER FAILURE MESSAGE Fault Code Description Correction Wait to start indicator circuit shorted. Refer to the appropriate diagnostic information. Wait to start indicator circuit open. Refer to the appropriate diagnostic information. BTSI output circuit shorted or open.
Page 507: Removal
8J - 14 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) INSTRUMENT CLUSTER FAILURE MESSAGE Fault Code Description Correction FCM messages not received. Refer to the appropriate diagnostic information. ACM messages not received. Refer to the appropriate diagnostic information. SKIM messages not received. Refer to the appropriate diagnostic information.
Page 508: Assembly
INSTRUMENT CLUSTER 8J - 15 INSTRUMENT CLUSTER (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- (4) Pull the bulb and bulb holder unit straight BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT back to remove it from the bulb mounting hole in the cluster electronic circuit board. SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, CLUSTER LENS, HOOD, AND MASK...
Page 509: Installation
8J - 16 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- CLUSTER LENS, HOOD, AND MASK BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT (1) Position the cluster lens, hood, and mask unit SYSTEM BEFORE ATTEMPTING ANY STEERING over the face of the instrument cluster (Fig. 7). Be WHEEL, STEERING COLUMN, DRIVER AIRBAG, certain that the odometer/trip odometer switch but- PASSENGER AIRBAG, SEAT BELT TENSIONER,...
Page 510: Abs Indicator
INSTRUMENT CLUSTER 8J - 17 INSTRUMENT CLUSTER (Continued) NOTE: Certain indicators in this instrument cluster over the Programmable Communications Interface are automatically configured. This feature allows (PCI) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instru- those indicators to be activated or deactivated for compatibility with certain optional equipment.
Page 511: Airbag Indicator Description
8J - 18 INSTRUMENT CLUSTER ABS INDICATOR (Continued) ter that control the ABS indicator, a DRBIII scan remains illuminated for about twelve seconds or until tool is required. Refer to the appropriate diagnostic the cluster receives a lamp-off message from the information.
Page 512: Operation
INSTRUMENT CLUSTER 8J - 19 BRAKE/PARK BRAKE INDICATOR (Continued) • Actuator Test - Each time the instrument clus- the translucent outer layer of the overlay when the indicator is illuminated from behind by the LED, ter is put through the actuator test, the brake indi- which is soldered onto the instrument cluster elec- cator will be turned on, then off again during the tronic circuit board.
Page 513: Cargo Lamp Indicator
8J - 20 INSTRUMENT CLUSTER BRAKE/PARK BRAKE INDICATOR (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- brake switch sense circuit between the park brake BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT switch and the instrument cluster as required. SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, CARGO LAMP INDICATOR PASSENGER AIRBAG, SEAT BELT TENSIONER,...
Page 514: Check Gauges Indicator
INSTRUMENT CLUSTER 8J - 21 CARGO LAMP INDICATOR (Continued) input from the headlamp switch, or until the ignition ate attention. This indicator is controlled by a tran- switch is turned to the Off position, whichever occurs sistor on the instrument cluster circuit board based first.
Page 515: Cruise Indicator
8J - 22 INSTRUMENT CLUSTER CHECK GAUGES INDICATOR (Continued) 12.0 volts (but less than 16.0 volts), or until the igni- cluster electronic circuit board. The cruise indicator tion switch is turned to the Off position, whichever is serviced as a unit with the VFD in the instrument occurs first.
Page 516: Door Ajar Indicator Description
INSTRUMENT CLUSTER 8J - 23 portion of the test to confirm the functionality of the DOOR AJAR INDICATOR LED and the cluster control circuitry. The instrument cluster continually monitors the DESCRIPTION door ajar switches to determine the status of the A door ajar indicator is standard equipment on all doors.
Page 517: Etc Indicator Description
8J - 24 INSTRUMENT CLUSTER ENGINE TEMPERATURE GAUGE (Continued) the cluster from the Powertrain Control Module cycled off and then on again by the appropriate (PCM) on vehicles equipped with a gasoline engine, engine temperature messages from the PCM or ECM. •...
Page 518: Operation
INSTRUMENT CLUSTER 8J - 25 ETC INDICATOR (Continued) layer of the overlay causes the icon to appear in red The PCM continually monitors the ETC system cir- through the translucent outer layer of the overlay cuits and sensors to decide whether the system is in when the indicator is illuminated from behind by the good operating condition.
Page 519: Operation
8J - 26 INSTRUMENT CLUSTER FUEL GAUGE (Continued) OPERATION is illuminated immediately. This message would indi- cate that the fuel tank sender input to the PCM or The fuel gauge gives an indication to the vehicle ECM is a short circuit. operator of the level of fuel in the fuel tank.
Page 520: Operation
INSTRUMENT CLUSTER 8J - 27 GEAR SELECTOR INDICATOR (Continued) The gear selector indicator displays the following switch is turned to the Off position, whichever occurs characters from left to right: “P,” “R,” “N,” “D,” “2,” first. • Resolved Circuit - If the transmission range and “1.”...
Page 521: Operation
8J - 28 INSTRUMENT CLUSTER HIGH BEAM INDICATOR (Continued) instrument cluster overlay. The dark outer layer of data bus and turns the high beam indicator on or off the overlay prevents the indicator from being clearly accordingly. For further diagnosis of the high beam visible when the it is not illuminated.
Page 522: Low Fuel Indicator
INSTRUMENT CLUSTER 8J - 29 LAMP OUT INDICATOR (Continued) lamp, brake lamp (excluding Center High sages received by the cluster from the Powertrain Mounted Stop Lamp [CHMSL]) circuit has been Control Module (PCM) on vehicles equipped with a detected, the lamp out indicator is illuminated. The gasoline engine, or from the Engine Control Module indicator remains illuminated until the cluster (ECM) on vehicles equipped with a diesel engine over...
Page 523: Malfunction Indicator Lamp (Mil)
8J - 30 INSTRUMENT CLUSTER LOW FUEL INDICATOR (Continued) • Actuator Test - Each time the cluster is put the cluster from the PCM or ECM over the Program- through the actuator test, the low fuel indicator will mable Communications Interface (PCI) data bus. The be turned on, then off again during the bulb check MIL Light Emitting Diode (LED) is completely con- portion of the test to confirm the functionality of the...
Page 524: Odometer Description
INSTRUMENT CLUSTER 8J - 31 MALFUNCTION INDICATOR LAMP (MIL) (Continued) sions systems may require service. For proper diag- Engine hours are displayed in the format, “hr9999”. nosis of the fuel and emissions systems, the PCM, The cluster will accumulate values up to 9,999 hours the ECM, the PCI data bus, or the electronic mes- before the display rolls over to zero.
Page 525: Oil Pressure Gauge
8J - 32 INSTRUMENT CLUSTER ODOMETER (Continued) must be displaying the odometer information when pressure gauge consists of a movable gauge needle or the trip odometer reset switch button is pressed in pointer controlled by the instrument cluster circuitry order to toggle to the engine hours display. The and a fixed 90 degree scale on the cluster overlay engine hours will remain displayed for about thirty that reads left-to-right from “L”...
Page 526: Overdrive Off Indicator
INSTRUMENT CLUSTER 8J - 33 OIL PRESSURE GAUGE (Continued) ECM indicating the engine oil pressure is below The overdrive off indicator consists of the words “O/D about 41 kPa (6 psi), the gauge needle is moved to OFF”, which appear in the lower portion of the odom- the graduation at the far left end of the gauge scale, eter/trip odometer indicator Vacuum Fluorescent Dis- the check gauges indicator is illuminated, and a sin-...
Page 527: Seatbelt Indicator
8J - 34 INSTRUMENT CLUSTER OVERDRIVE OFF INDICATOR (Continued) instrument cluster. For further diagnosis of the over- tor will be illuminated as a seatbelt reminder for drive off indicator or the instrument cluster circuitry about six seconds, or until the ignition switch is that controls the indicator, (Refer to 8 - ELECTRI- turned to the Off position, whichever occurs first.
Page 528: Operation
INSTRUMENT CLUSTER 8J - 35 SECURITY INDICATOR (Continued) nated. A red Light Emitting Diode (LED) behind the can be flashed on and off, or illuminated solid, as dic- cutout in the opaque layer of the overlay causes the tated by the SKIM message. The indicator remains indicator to appear in red through the translucent illuminated solid or continues to flash until the clus- outer layer of the overlay when it is illuminated from...
Page 529: Operation
8J - 36 INSTRUMENT CLUSTER SERVICE 4WD INDICATOR (Continued) Vacuum Fluorescent Display (VFD) unit. The VFD is The TCCM continually monitors the electronic soldered onto the cluster electronic circuit board and transfer case switch and circuits to determine the is visible through a window with a smoked clear lens condition of the system.
Page 530: Description
INSTRUMENT CLUSTER 8J - 37 SPEEDOMETER (Continued) air core magnetic unit that receives battery current from “0” to “7” for gasoline engines. On vehicles with on the instrument cluster electronic circuit board a diesel engine, the scale reads from “0” to “5”. The through the fused ignition switch output (run-start) text “RPM X 1000”...
Page 531: Trans Temp Indicator
8J - 38 INSTRUMENT CLUSTER TACHOMETER (Continued) onds, the gauge needle will return to the left end of failure. This indicator is controlled by a transistor on the gauge scale. the instrument cluster circuit board based upon clus- • Actuator Test - Each time the cluster is put ter programming and electronic messages received by through the actuator test, the tachometer needle will the cluster from the Powertrain Control Module...
Page 532: Turn Signal Indicator
INSTRUMENT CLUSTER 8J - 39 TRANS TEMP INDICATOR (Continued) • Turn Signal-On Input - Each time the cluster data bus, or the electronic message inputs to the instrument cluster that control the transmission detects a turn signal-on input from the turn signal over-temperature indicator, a DRBIII scan tool is switch circuitry of the multi-function switch on the...
Page 533: Upshift Indicator Description
8J - 40 INSTRUMENT CLUSTER TURN SIGNAL INDICATOR (Continued) sages to the Front Control Module (FCM) over the any position except On or Start. The indicator only Programmable Communications Interface (PCI) data illuminates when it is switched to ground by the bus and flashes the turn signal indicators on and off instrument cluster circuitry.
Page 534: Operation
INSTRUMENT CLUSTER 8J - 41 VOLTAGE GAUGE (Continued) reads from “8” to “18” volts. An International Control tem voltage is greater than about 9.5 volts (but less and Display Symbol icon for “Battery Charging Con- than about 15.5 volts), or until the ignition switch is dition”...
Page 535: Wait-To-Start Indicator Description
8J - 42 INSTRUMENT CLUSTER • Actuator Test - Each time the cluster is put WAIT-TO-START INDICATOR through the actuator test, the wait-to-start indicator will be turned on, then off again during the bulb DESCRIPTION check portion of the test to confirm the functionality A wait-to-start indicator is only found in the of the LED and the cluster control circuitry.
Page 536 INSTRUMENT CLUSTER 8J - 43 WASHER FLUID INDICATOR (Continued) tery current input on the fused ignition switch out- WATER-IN-FUEL INDICATOR put (run-start) circuit. Therefore, the indicator will always be off when the ignition switch is in any posi- DESCRIPTION tion except On or Start. The indicator only illumi- A water-in-fuel indicator is only found in the nates when it is switched to ground by the instrument clusters for vehicles equipped with an...
Page 537 8J - 44 INSTRUMENT CLUSTER WATER-IN-FUEL INDICATOR (Continued) • Bulb Test - Each time the ignition switch is The ECM continually monitors the water-in-fuel turned to the On position the water-in-fuel indicator sensor to determine whether there is excessive water is illuminated for about two seconds as a bulb test.
Page 538 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....24 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page...
Page 539 8L - 2 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH TAIL LAMP DESCRIPTION - TURN SIGNAL SYSTEM ..17 REMOVAL ......21 OPERATION - TURN SIGNAL SYSTEM .
Page 540: Lamps/Lighting - Exterior
LAMPS/LIGHTING - EXTERIOR 8L - 3 LAMPS/LIGHTING - EXTERIOR (Continued) within 45 seconds. The system will not activate if DIAGNOSIS AND TESTING - LAMPS/LIGHTING more than 45 seconds elapse between ignition switch - EXTERIOR OFF and headlamp switch OFF. The FCM will allow the headlamps to remain ON for 60 seconds (config- WARNING: EYE PROTECTION SHOULD BE USED urable) before they automatically turn off (If the key...
Page 541 8L - 4 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) HEADLAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM 1. Loose or corroded battery 1. Clean and secure battery cable clamps and WITH ENGINE IDLING cables. posts. OR IGNITION TURNED 2.
Page 542: Lamps/Lighting - Exterior
LAMPS/LIGHTING - EXTERIOR 8L - 5 LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS DO NOT 1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to ILLUMINATE Electrical, Wiring Information. 2. No ground at headlamps. 2. Repair circuit ground, refer to Electrical, Wiring Information.
Page 543 8L - 6 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system. Refer to WITH ENGINE Electrical, Charging. RUNNING ABOVE IDLE 2. Poor lighting circuit ground. 2.
Page 544: Description
LAMPS/LIGHTING - EXTERIOR 8L - 7 LAMPS/LIGHTING - EXTERIOR (Continued) SPECIAL TOOLS - HEADLAMP ALIGNMENT STANDARD PROCEDURE SAFETY PRECAUTIONS WARNING: EYE PROTECTION SHOULD BE USED WHEN SERVICING GLASS COMPONENTS. PER- SONAL INJURY CAN RESULT. CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced Headlamp Aiming Kit C-4466–A bulb life will result.Do not use bulbs with higher...
Page 545: Description
8L - 8 LAMPS/LIGHTING - EXTERIOR BACKUP LAMP SWITCH (Continued) BRAKE LAMP REMOVAL (1) Disconnect and isolate the negative battery cable. (2) Remove the tail lamp unit (Refer to 8 - ELEC- TRICAL/LAMPS/LIGHTING EXTERIOR/TAIL LAMP UNIT - REMOVAL). (3) Remove the bulb back plate from the tail lamp unit.
Page 546: Diagnosis And Testing - Brake Lamp Switch
LAMPS/LIGHTING - EXTERIOR 8L - 9 BRAKE LAMP SWITCH (Continued) Vehicles equipped with the speed control option use a dual function brake lamp switch. The PCM moni- tors the state of the dual function brake lamp switch. The brake switch is equipped with three sets of contacts, one normally open and the other two nor- mally closed (brakes disengaged).
Page 547: Installation
8L - 10 LAMPS/LIGHTING - EXTERIOR BRAKE LAMP SWITCH (Continued) INSTALLATION (1) Press and hold the brake pedal down. (2) Align the tab on the new switch with the notch in the switch bracket. Insert the switch in the bracket and turn it clockwise about 30° to lock it in place.
Page 548: Fog Lamp Removal
LAMPS/LIGHTING - EXTERIOR 8L - 11 CAB CLEARANCE LAMP (Continued) Fig. 6 Fog Lamp Fig. 5 CLEARANCE LAMP 1 - SCREW 1 - NUT 2 - FOG LAMP UNIT 2 - CAB ROOF 3 - CONNECTOR 3 - BULB SOCKET 4 - CLEARANCE LAMP 5 - SCREW FOG LAMP RELAY...
Page 549: Operation
8L - 12 LAMPS/LIGHTING - EXTERIOR FOG LAMP RELAY (Continued) (ISO) micro relay (Fig. 7). Relays conforming to the The front fog lamp relay can be diagnosed using ISO specifications have common physical dimensions, conventional diagnostic tools and methods. current capacities, terminal patterns, and terminal DIAGNOSIS AND TESTING - FRONT FOG LAMP functions.
Page 550: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 13 FOG LAMP RELAY (Continued) (3) Resistance between terminals 85 and 86 (elec- (1) Position the front fog lamp relay to the proper tromagnet) should be 75 ± 8 ohms. If OK, go to Step receptacle in the Power Distribution Center (PDC).
Page 551: Headlamp Switch Description
8L - 14 LAMPS/LIGHTING - EXTERIOR (4) Remove the screws that secure the headlamp HEADLAMP SWITCH switch to the instrument panel bezel (Fig. 9). DESCRIPTION The multiplexed headlamp switch is located on the instrument panel. The headlamp switch controls the parking lamps, fog lamps and the headlamps.
Page 552: Headlamp Unit Removal
LAMPS/LIGHTING - EXTERIOR 8L - 15 HEADLAMP SWITCH (Continued) (4) Install the cluster bezel onto the instrument ADJUSTMENTS panel (Fig. 9). Headlamps can be aligned using the screen method (5) Connect the battery negative cable. provided in this section. Alignment Tool C-4466-A or equivalent can also be used.
Page 553: License Plate Lamp Removal
8L - 16 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) Fig. 11 Headlamp Alignment Screen—Typical 1 - CENTER OF VEHICLE 3 - 7.62 METERS (25 FT.) 2 - CENTER OF HEADLAMP 4 - FRONT OF HEADLAMP INSTALLATION LICENSE PLATE LAMP (1) Position license plate lamp on the bumper. REMOVAL (2) Install the clip.
Page 554: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 17 MARKER LAMP UNIT (Continued) Fig. 12 License Plate Lamp Panel Fig. 14 Tailgate Marker Lamp Housing 1 - REAR BUMPER 1 - Nut 2 - WIRING CONNECTOR 2 - Tailgate 3 - CLIP 3 - Bulb Harness 4 - LICENSE PLATE LAMP UNIT 4 - Screw 5 - Lens...
Page 555: Operation - Turn Signal System
8L - 18 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) lobe, pushing on the cancel actuator, returns the DIAGNOSIS AND TESTING - MULTI-FUNCTION switch to the OFF position. SWITCH To test the turn signal, headlamp beam select and OPERATION - TURN SIGNAL SYSTEM optical horn portion of the multi-function switch: The Instrument Cluster monitors the multiplexed (1) Remove the multi-function switch, refer to...
Page 556: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 19 MULTI-FUNCTION SWITCH (Continued) Fig. 16 ISO Micro Relay 30 - COMMON FEED 85 - COIL GROUND 86 - COIL BATTERY 87 - NORMALLY OPEN 87A - NORMALLY CLOSED relay is a conventional International Standards Fig.
Page 557: Diagnosis And Testing - Park Lamp Relay
8L - 20 LAMPS/LIGHTING - EXTERIOR PARK LAMP RELAY (Continued) the park lamp relay output circuit and provides ground to the park lamps when the relay is de-ener- gized, and battery current to the park lamps when- ever the relay is energized. •...
Page 558: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 21 PARK LAMP RELAY (Continued) INSTALLATION WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 559: Trailer Tow Wiring
8L - 22 LAMPS/LIGHTING - EXTERIOR TAIL LAMP UNIT (Continued) 20). This harness includes an adapter harness that adapts the 7-pin trailer tow connector to a standard, light-duty, 4-pin trailer tow connector. Refer to the appropriate wiring information. TURN LAMP REMOVAL (1) Disconnect and isolate the negative battery cable.
Page 560: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 23 UNDERHOOD LAMP UNIT (Continued) Fig. 23 Underhood Lamp Fig. 21 Underhood Lamp Lens 1 - UNDER HOOD LAMP 2 - HOOD 1 - LAMP 3 - CONNECTOR 2 - LAMP LENS INSTALLATION (1) Install bulb. (2) Install lamp lens.
Page 561 8L - 24 LAMPS/LIGHTING - INTERIOR LAMPS/LIGHTING - INTERIOR TABLE OF CONTENTS page page DOME LAMP GLOVE BOX LAMP/SWITCH DESCRIPTION ......24 REMOVAL .
Page 562: Dome Lamp
LAMPS/LIGHTING - INTERIOR 8L - 25 DOME LAMP (Continued) (3) Reach through the glove box opening and behind the glove box lamp and switch mounting bracket to access the instrument panel wire harness connector on the glove box lamp and switch (Fig. 3). Fig.
Page 563: Description
8L - 26 LAMPS/LIGHTING - INTERIOR GLOVE BOX LAMP/SWITCH (Continued) (4) Push the glove box lamp and switch unit into REMOVAL the hole in the mounting bracket on the instrument (1) Disconnect and isolate the battery negative panel glove box opening upper reinforcement. cable.
Page 564 MESSAGE SYSTEMS 8M - 1 MESSAGE SYSTEMS TABLE OF CONTENTS page page OVERHEAD CONSOLE OPERATION ......8 DESCRIPTION .
Page 565: Operation
8M - 2 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) ent temperature sensor, refer to Ambient Tempera- ture Sensor later in this section. Following are general descriptions of the major components used in the overhead console. Refer to Wiring Diagrams for complete circuit schematics. OPERATION Refer to the vehicle Owner’s Manual for specific operation of each overhead console and its systems.
Page 566: Standard Procedure
MESSAGE SYSTEMS 8M - 3 OVERHEAD CONSOLE (Continued) (1) With the ignition switch in the Off position, STANDARD PROCEDURE - MODULE LENS simultaneously depress and hold the STEP and REPLACEMENT RESET buttons. (1) Remove the overhead console (Refer to 8 - (2) Turn the ignition switch to the On position.
Page 567: Standard Procedure - Compass Demagnetizing
8M - 4 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) The electronic compass unit features a self-cali- overhead console. Equivalent units must be rated as brating design, which simplifies the calibration pro- continuous duty for 110/115 volts and 60 Hz. They cedure. This feature automatically updates the must also have a field strength of over 350 gauss at 7 compass calibration while the vehicle is being driven.
Page 568: Overhead Console Removal
MESSAGE SYSTEMS 8M - 5 OVERHEAD CONSOLE (Continued) (4) Release the RESET push button. “VAR =XX ” will remain in the display. “XX” equals the current variance zone setting. (5) Depress and release the STEP push button to step through the zone numbers, until the zone num- ber for your geographic location appears in the dis- play.
Page 569: Special Tools
8M - 6 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) Fig. 4 Variance Settings SPECIAL TOOLS OVERHEAD CONSOLE DEGAUSSING TOOL #6029 COMPASS/MINI-TRIP COMPUTER DESCRIPTION The Compass Mini-Trip Computer (CMTC) is a module located in the overhead console. The CMTC is equipped with a mini-trip feature. The CMTC con- sists of a electronic control module with a vacuum fluorescent display (VFD) and function switches.
Page 570: Operation
MESSAGE SYSTEMS 8M - 7 COMPASS/MINI-TRIP COMPUTER (Continued) OPERATION The Compass Mini-Trip Computer module in the overhead console has buttons used to select various functions. The CMTC selector buttons will not oper- ate until the ignition is in the RUN position. When the ignition switch is first turned to the RUN position the CMTC display;...
Page 571: Operation
8M - 8 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER (Continued) Refer to ELECTRONIC VEHICLE INFORMA- function that is to be reset currently displayed, TION CENTER PROGRAMMING in the Standard momentarily depressing and releasing the Reset Procedures section of this group for more information push button once will perform a local reset, and only on the customer programmable feature options.
Page 572 MESSAGE SYSTEMS 8M - 9 ELECTRONIC VEHICLE INFO CENTER (Continued) (2) Momentarily depress and release the Menu door is opened, if the vehicle is stopped and the push button to step through the programmable fea- transmission gear selector is in Park or Neutral. The tures list.
Page 573: Removal
8M - 10 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER (Continued) memory setting 1 and the second transmitter trained (4) Install the overhead console on the headlin- will be associated with memory setting 2. Additional er(Refer to 8 - ELECTRICAL/OVERHEAD CON- transmitters will not be associated with a memory SOLE - INSTALLATION).
Page 574: Diagnosis And Testing
MESSAGE SYSTEMS 8M - 11 AMBIENT TEMP SENSOR (Continued) then sends the proper ambient temperature mes- (4) Remove the jumper wire from the ambient tem- sages to the EVIC, CMTC over the PCI J1850 data perature sensor wire harness connector. Check for bus.
Page 575: Operation
8M - 12 MESSAGE SYSTEMS UNIVERSAL TRANSMITTER (Continued) tion. The universal transmitter is capable of operat- (2) Hold the RF detector within one inch of the ing systems using either rolling code or non-rolling TRAINED universal transmitter and press any of the code technology.
Page 576: Removal
MESSAGE SYSTEMS 8M - 13 UNIVERSAL TRANSMITTER (Continued) versal transmitter and push the buttons on both REMOVAL transmitters. (1) For universal transmitter removal and installa- (4) Release both buttons. Your universal transmit- tion procedure, (Refer to 8 - ELECTRICAL/OVER- ter is now “trained”. To train the other buttons, HEAD CONSOLE/COMPASS/MINI-TRIP repeat Step 3 and Step 4.
Page 578 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER SEATS .
Page 579: Power Locks
8N - 2 POWER LOCKS POWER LOCKS (Continued) less Entry (RKE) system radio frequency transmit- button is depressed, and disarm the VTSS when the ters, if equipped. Unlock button is depressed. Certain functions and features of the power lock The RKE system includes two transmitters when system rely upon resources shared with other elec- the vehicle is shipped from the factory, but the sys- tronic modules in the vehicle over the Programmable...
Page 580 POWER LOCKS 8N - 3 POWER LOCKS (Continued) drivers and provides a voltage level to the door lock lamps, and turns ON the interior lamps. The panic motor for a specified time. All passenger doors can be alarm will remain on for three minutes, or until the locked or unlocked using a mechanical button PANIC button is actuated again or the vehicle speed mounted on the door trim panel.
Page 581: Power Lock Switch
8N - 4 POWER LOCKS POWER LOCKS (Continued) NOSIS AND TESTING) or (Refer to 8 - ELECTRI- CAL/POWER LOCKS/REMOTE KEYLESS ENTRY MODULE - DIAGNOSIS AND TESTING). • If the power lock system functions with the RKE transmitter, but not with one or both power lock switches, proceed to diagnosis of the door lock switches.
Page 582: Door Lock Motor Description
POWER LOCKS 8N - 5 • Power Window Lockout Switch - A two-way, DOOR LOCK MOTOR latching, push-button switch in the DDM allows the vehicle operator to lock out the power window DESCRIPTION switches on each passenger door so that the passen- The lock mechanisms are actuated by a reversible ger door power windows may be operated only from electric motor mounted within each door.
Page 583: Diagnosis And Testing - Driver Door Module
8N - 6 POWER LOCKS DRIVER DOOR MODULE (Continued) the Integrated Power Module (IPM) on a fused igni- DIAGNOSIS AND TESTING - DRIVER DOOR tion switch output (run-acc) circuit so that the power MODULE windows will operate whenever the ignition switch is The Light-Emitting Diode (LED) illumination in the On or Accessory positions.
Page 584 POWER LOCKS 8N - 7 DRIVER DOOR MODULE (Continued) DRIVER DOOR MODULE SWITCH TESTS LEFT FRONT DOWN PINS 9 & 12 RIGHT FRONT UP PINS 3 & 9 RIGHT FRONT DOWN PINS 6 & 9 LEFT REAR UP PINS 4 & 9 LEFT REAR DOWN PINS 9 &...
Page 585: Diagnosis And Testing - Remote Keyless Entry Module
8N - 8 POWER LOCKS REMOTE KEYLESS ENTRY MODULE (Continued) the horn to sound for about three minutes, or until a second panic message is sent to the instrument clus- ter. A vehicle speed of about 25.7 kilometers-per-hour (15 miles-per-hour) will also cancel the panic event. Refer to the owner’s manual for more information on the features, use and operation of the RKE sys- tem.
Page 586: Standard Procedure
POWER LOCKS 8N - 9 REMOTE KEYLESS ENTRY TRANSMITTER (Continued) (7) Test the horn chirp feature by pressing the STANDARD PROCEDURE LOCK button. If a chime is not heard, program mode was can- STANDARD PROCEDURE - RKE TRANSMITTER celed before the feature could be disabled. If neces- BATTERIES sary, repeat the procedure.
Page 587: Standard Procedure - Rke Transmitter Programing
8N - 10 POWER LOCKS REMOTE KEYLESS ENTRY TRANSMITTER (Continued) STANDARD PROCEDURE - RKE TRANSMITTER (4) Press release both LOCK UNLOCK buttons simultaneously on a fob to be pro- PROGRAMING grammed. A single chime will be heard, this indicates New Remote Keyless Entry (RKE) transmitters can the fob has been recognized.
Page 588 POWER MIRRORS 8N - 11 POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS REMOVAL ......13 DESCRIPTION .
Page 589 8N - 12 POWER MIRRORS POWER MIRRORS (Continued) POWER MIRROR MOTOR TEST AUTOMATIC DAY / NIGHT If the power mirror switch is receiving proper cur- MIRROR rent and ground and mirrors do not operate, proceed with power mirror motor test. Refer to the appropri- DESCRIPTION ate wiring information.
Page 590 POWER MIRRORS 8N - 13 AUTOMATIC DAY / NIGHT MIRROR (Continued) (3) Turn the ignition switch to the Off position. automatic day/night mirror wire harness connector. Disconnect and isolate the battery negative cable. Connect the battery negative cable. Turn the ignition Unplug the wire harness connector from the auto- switch to the On position.
Page 591 8N - 14 POWER SEATS POWER SEATS TABLE OF CONTENTS page page POWER SEATS REMOVAL ......17 DESCRIPTION .
Page 592: Description
POWER SEATS 8N - 15 moved in the opposite direction, the battery feed and DRIVER SEAT SWITCH ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to DESCRIPTION run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit.
Page 593: Passenger Seat Switch Description
8N - 16 POWER SEATS DRIVER SEAT SWITCH (Continued) INSTALLATION DRIVER POWER SEAT SWITCH TEST TABLE (1) Position the power seat switch on the seat DRIVER SWITCH CONTINUITY BETWEEN cushion side shield and install the screws that secure POSITION the power seat switch to seat cushion side shield. HORIZONTAL A-L, B-K (2) Connect the electrical connector.
Page 594: Operation
POWER SEATS 8N - 17 PASSENGER SEAT SWITCH (Continued) The individual switches in the power seat switch assembly cannot be repaired. If one switch is dam- aged or faulty, the entire power seat switch assembly must be replaced. OPERATION When a power switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor.
Page 595: Installation
8N - 18 POWER SEATS PASSENGER SEAT SWITCH (Continued) Fig. 6 Power Seat Switch Remove/Install 1 - SEAT SIDE SHIELD 2 - POWER SEAT SWITCH 3 - SCREWS (4) Remove the screws that secure the power seat switch (Fig. 6). Fig.
Page 596: Removal
POWER SEATS 8N - 19 POWER SEAT TRACK (Continued) the power seat track fails to operate in more than LUMBAR CONTROL SWITCH one direction, proceed as follows: (1) Check the power seat fuse in the power distri- DESCRIPTION bution center. If OK, go to Step 2. If not OK, replace The power lumbar seat option includes an electri- the faulty fuse.
Page 597: Operation
8N - 20 POWER SEATS LUMBAR MOTOR (Continued) to a molded plastic back panel and to the seat back one direction, Test the appropriate power seat switch frame. as described in this group. If the power lumbar The power lumbar adjuster cannot be repaired, and adjuster fails to operate in either direction, perform is serviced only as a unit with the seat back frame.
Page 598 POWER WINDOWS 8N - 21 POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS WINDOW SWITCH DESCRIPTION ......21 DIAGNOSIS AND TESTING - WINDOW OPERATION .
Page 599 8N - 22 POWER WINDOWS POWER WINDOWS (Continued) (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - (1) Check the fuse in the Integrated Power Module REMOVAL). (IPM) and the circuit breaker located near the park (2) Disconnect power window motor wire connector brake pedal.
Page 600 POWER WINDOWS 8N - 23 WINDOW SWITCH (Continued) REMOVAL INSTALLATION FRONT PASSENGER FRONT PASSENGER (1) Disconnect and isolate the battery negative (1) Insert switch to trim panel bezel. cable. (2) Install door trim panel (Refer to 23 - BODY/ (2) Remove the door trim panel (Refer to 23 - DOOR - FRONT/TRIM PANEL - INSTALLATION).
Page 602 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS INSTALLATION ......27 DESCRIPTION ......2 FRONT OUTBOARD SEAT BELT &...
Page 603 8O - 2 RESTRAINTS DIAGNOSIS AND TESTING - SEAT BELT SIDE IMPACT AIRBAG CONTROL MODULE TENSION REDUCER ....49 DESCRIPTION ......53 SEAT BELT TURNING LOOP ADJUSTER OPERATION .
Page 604 RESTRAINTS 8O - 3 RESTRAINTS (Continued) Fig. 1 Supplemental Restraint System 1 - AIRBAG CONTROL MODULE 5 - SIDE CURTAIN AIRBAG 2 - PASSENGER AIRBAG 6 - SIDE IMPACT AIRBAG CONTROL MODULE 3 - PASSENGER AIRBAG ON/OFF SWITCH (STD CAB ONLY) 7 - SEAT BELT TENSIONER 4 - DRIVER AIRBAG ment cluster for about six seconds as a bulb test each...
Page 605: Operation
8O - 4 RESTRAINTS RESTRAINTS (Continued) the Programmable Communications Interface (PCI) data bus network. This method of communication is used by the ACM for control of the airbag indicator on all models equipped with dual front airbags. (Refer to 8 - ELECTRICAL/ELECTRONIC CON- TROL MODULES/COMMUNICATION - DESCRIP- TION).
Page 606: Warnings - Restraint System
RESTRAINTS 8O - 5 RESTRAINTS (Continued) Impact Airbag Control Modules (SIACM). An airbag When the ACM monitors a problem in any of the indicator in the ElectroMechanical Instrument Clus- dual front airbag system circuits or components, ter (EMIC) illuminates for about six seconds as a including the seat belt tensioners, it stores a fault bulb test each time the ignition switch is turned to code or Diagnostic Trouble Code (DTC) in its memory...
Page 607: Diagnosis And Testing - Supplemental Restraint System
8O - 6 RESTRAINTS RESTRAINTS (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- THE CORRECT FASTENERS PROVIDED IN THE BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SERVICE PACKAGE SPECIFIED SYSTEM BEFORE ATTEMPTING ANY STEERING DAIMLERCHRYSLER MOPAR PARTS CATALOG. WHEEL, STEERING COLUMN, DRIVER AIRBAG, WARNING: WHEN A STEERING COLUMN HAS AN PASSENGER AIRBAG, SEAT BELT TENSIONER, AIRBAG UNIT ATTACHED, NEVER PLACE THE COL-...
Page 608: Standard Procedure - Service After Asupplemental Restraint Deployment
RESTRAINTS 8O - 7 RESTRAINTS (Continued) ment in the event of an accidental deployment. When age. Because the ACM and SIACM each contain handling a non-deployed seat belt tensioner, take impact sensors that are used by the supplemental proper care to keep fingers out from under the restraint system to monitor or confirm the direction retractor cover and away from the seat belt webbing and severity of a vehicle impact, improper orientation...
Page 609: Standard Procedure - Verification Test
8O - 8 RESTRAINTS RESTRAINTS (Continued) way inside, so that you avoid kneeling or sitting on a PERFORMING FURTHER DIAGNOSIS OR SERVICE. non-cleaned area. THIS IS THE ONLY SURE WAY TO DISABLE THE (2) Be certain to vacuum the heater and air condi- SUPPLEMENTAL RESTRAINT SYSTEM.
Page 610: Acm Cover
RESTRAINTS 8O - 9 RESTRAINTS (Continued) If the stored DTC information is successfully erased, go to Step 9. (9) Turn the ignition switch to the Off position for about fifteen seconds, and then back to the On posi- tion. Observe the airbag indicator in the instrument cluster.
Page 611: Airbag Control Module Description
8O - 10 RESTRAINTS are only serviced as a unit with the ACM. The ACM AIRBAG CONTROL MODULE cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. DESCRIPTION OPERATION The microprocessor in the Airbag Control Module (ACM) contains the front supplemental restraint sys- tem logic circuits and controls all of the front supple- mental restraint system components.
Page 612: Removal
RESTRAINTS 8O - 11 AIRBAG CONTROL MODULE (Continued) On models equipped with optional side curtain air- The hard wired inputs and outputs for the ACM bags, the ACM communicates with both the left and may be diagnosed and tested using conventional right Side Impact Airbag Control Modules (SIACM) diagnostic tools and procedures.
Page 613: Installation
8O - 12 RESTRAINTS AIRBAG CONTROL MODULE (Continued) (Refer ELECTRICAL/RESTRAINTS/ACM (7) Still working from the left side of the floor COVER - REMOVAL). panel transmission tunnel, lift the ACM upward far (4) Reach through the rearward facing opening enough to disengage the locating pins on the bottom below the instrument panel center stack support of the ACM mounting flanges from the locating holes bracket on the top of the floor panel transmission...
Page 614: Automatic Locking Retractor
RESTRAINTS 8O - 13 AIRBAG CONTROL MODULE (Continued) the locating pins on the bottom of the ACM mounting AUTOMATIC LOCKING flanges into the locating holes in the bracket. RETRACTOR (3) Still working from the left side of the floor panel transmission tunnel, install and tighten the DESCRIPTION two screws that secure the left ACM mounting flanges to the bracket that is welded onto the floor...
Page 615: Operation
8O - 14 RESTRAINTS AUTOMATIC LOCKING RETRACTOR (Continued) OPERATION The retractor is returned to standard emergency locking mode by unbuckling the combination lap and The automatic locking mode of the retractor is shoulder belt buckle and allowing the belt webbing to engaged and the retractor is switched from operating be almost fully retracted onto the retractor spool.
Page 616 RESTRAINTS 8O - 15 CHILD RESTRAINT ANCHOR (Continued) Fig. 11 Child Restraint Anchor Location - Quad Cab 1 - LOWER ANCHOR (PROVIDED FOR REAR OUTBOARD 2 - TETHER ANCHOR (PROVIDED FOR REAR CENTER AND SEATING POSITIONS ONLY) OUTBOARD SEATING POSITIONS) This model is equipped with a Lower Anchors and Tether for CHildren, or LATCH child restraint anchorage system (Fig.
Page 617: Operation
8O - 16 RESTRAINTS CHILD RESTRAINT ANCHOR (Continued) Fig. 15 Child Restraint Lower Anchor - Quad Cab Fig. 13 Child Tether Strap - Quad Cab Rear Seat 1 - TETHER STRAP (3) 1 - REAR SEAT BACK 2 - CAB BACK PANEL 2 - LOWER ANCHOR (2 PER OUTBOARD REAR SEATING 3 - SCREW (3) POSITION)
Page 618: Installation
RESTRAINTS 8O - 17 CHILD RESTRAINT ANCHOR (Continued) WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT CUT,...
Page 619: Clockspring Description
8O - 18 RESTRAINTS CLOCKSPRING DESCRIPTION Fig. 18 Turn Signal Cancel Cam 1 - LOCKING PIN 2 - CLOCKSPRING CASE 3 - CANCEL CAM 4 - LOWER CONNECTOR RECEPTACLE (2) Fig. 17 Clockspring 1 - PIGTAIL WIRE Service replacement clocksprings are shipped pre- 2 - LOCATING TAB centered and with a molded plastic locking pin that 3 - LOCKING PIN...
Page 620: Standard Procedure - Clockspring Centering
RESTRAINTS 8O - 19 CLOCKSPRING (Continued) ber boot is installed over the engagement dowel to tion relative to the other steering components. The eliminate contact noise between the dowel and the clockspring must then be re-centered following com- steering wheel. The two lobes on the turn signal can- pletion of such service or the clockspring tape may be cel cam on the lower surface of the clockspring rotor damaged.
Page 621: Removal
8O - 20 RESTRAINTS CLOCKSPRING (Continued) NOTE: Before starting this procedure, be certain to CAUTION: Be certain that the screws that secure turn the steering wheel until the front wheels are in the steering wheel puller to the steering wheel are the straight-ahead position.
Page 622: Installation
RESTRAINTS 8O - 21 CLOCKSPRING (Continued) THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. NOTE: Before starting this procedure, be certain that the front wheels are still in the straight-ahead position.
Page 623: Driver Airbag
The airbag used in this model is a Next Genera- four-spoke steering wheel. All models have a Dodge tion-type that complies with revised federal airbag Ram logo embossed in the center of the trim cover.
Page 624: Operation
RESTRAINTS 8O - 23 DRIVER AIRBAG (Continued) inflator connects the inflator initiator to the vehicle deployed, review the recommended procedures for electrical system through a yellow-jacketed, two-wire service after a supplemental restraint deployment pigtail harness of the clockspring. before removing the airbag from the vehicle. (Refer to The driver airbag cannot be repaired, and must be 8 - ELECTRICAL/RESTRAINTS - STANDARD PRO- replaced if deployed or in any way damaged.
Page 625: Installation
8O - 24 RESTRAINTS DRIVER AIRBAG (Continued) CEDURE - SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT). WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 626: Front Center Seat Belt & Retractor
RESTRAINTS 8O - 25 DRIVER AIRBAG (Continued) steering wheel hub area are not pinched between the the front center seat belt lower anchor latch plate driver airbag and the steering wheel armature. from the unique black, keyed lower anchor buckle. (5) Install and tighten the two screws that secure Use an ignition key or a small screwdriver to depress the driver airbag to the steering wheel armature.
Page 627: Installation
8O - 26 RESTRAINTS FRONT CENTER SEAT BELT & RETRACTOR (Continued) DAMAGED. NEVER ATTEMPT TO REPAIR A SEAT BELT CHILD RESTRAINT COMPONENT. ALWAYS REPLACE DAMAGED OR FAULTY SEAT BELT AND CHILD RESTRAINT COMPONENTS WITH THE CORRECT, NEW AND UNUSED REPLACEMENT PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
Page 628: Installation
RESTRAINTS 8O - 27 FRONT CENTER SEAT BELT (Continued) WARNING: DURING AND FOLLOWING ANY SEAT lower anchor, or unique black, keyed front center BELT OR CHILD RESTRAINT ANCHOR SERVICE, seat belt lower anchor buckle to the center seat sup- port bracket. CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER (3) From the front of the front seat, reach between...
Page 629: Front Outboard Seat Belt
8O - 28 RESTRAINTS FRONT CENTER SEAT BELT (Continued) buckle between the center seat cushion and the adja- RESTRAINTS). If the seat belt tensioner has been cent right or left front outboard seat cushion. deployed, review the recommended procedures for (2) From the front of the front seat, reach between service after a supplemental restraint deployment the center seat cushion and the adjacent right or left...
Page 630: Removal - Quad Cab
RESTRAINTS 8O - 29 FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued) (3) Remove the screw that secures the lower seat (9) Remove the screw that secures the seat belt belt anchor to the lower inner B-pillar (Fig. 27). web guide to the inner B-pillar near the belt line. (10) Remove the seat belt web guide from the inner B-pillar.
Page 631 8O - 30 RESTRAINTS FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 632: Installation - Standard Cab
RESTRAINTS 8O - 31 FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued) (11) Disengage the seat belt tensioner pigtail wire SYSTEM BEFORE ATTEMPTING ANY STEERING retainer from the hole in the inner B-pillar sheet WHEEL, STEERING COLUMN, DRIVER AIRBAG, metal. PASSENGER AIRBAG, SEAT BELT TENSIONER, (12) Disconnect the yellow seat belt tensioner pig- SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL tail wire connector from the body wire harness take...
Page 633: Installation - Quad Cab
8O - 32 RESTRAINTS FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued) seat belt tension reducer connector receptacle near the recommended procedures for handling non-de- the bottom of the retractor. ployed supplemental restraints. (Refer to 8 - ELEC- (7) Position the seat belt web guide to its mount- TRICAL/RESTRAINTS - STANDARD PROCEDURE ing location on the inner B-pillar near the belt line.
Page 634: Front Outboard Seat Belt Buckle Removal
RESTRAINTS 8O - 33 FRONT OUTBOARD SEAT BELT & RETRACTOR (Continued) (2) Engage the hooks on the upper retractor belt buckle on the driver’s side front seat for all mod- bracket into the slots in the lower inner B-pillar els also includes a seat belt switch. (Refer to 8 - above the retractor mounting hole.
Page 635: Installation
8O - 34 RESTRAINTS FRONT OUTBOARD SEAT BELT BUCKLE (Continued) PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. (1) From the front of the front seat, reach between the center seat cushion and the adjacent right or left front outboard seat cushion to position the front out- board seat belt buckle to the seat (Fig.
Page 636: Operation
RESTRAINTS 8O - 35 PASSENGER AIRBAG (Continued) seven integral snap features to the instrument panel those used in some prior models. The passenger air- base trim, while two screws secure the integral bag unit consists of a stamped and welded metal inboard mounting flange to the base trim, and four housing, the airbag cushion, the airbag inflator, and screws secure the lower mounting flange to the upper...
Page 637 8O - 36 RESTRAINTS PASSENGER AIRBAG (Continued) before removing the airbag from the vehicle. (Refer to (4) Remove the six screws that secure the inboard 8 - ELECTRICAL/RESTRAINTS - STANDARD PRO- and lower flanges of the passenger airbag door to the CEDURE - SERVICE AFTER A SUPPLEMENTAL instrument panel.
Page 638: Installation
RESTRAINTS 8O - 37 PASSENGER AIRBAG (Continued) take out and connector for the airbag inflator located OBSERVE THIS WARNING COULD RESULT IN on the inboard side of the housing. OCCUPANT INJURIES UPON AIRBAG DEPLOY- (9) Disconnect the instrument panel wire harness MENT.
Page 639: Passenger Airbag On/Off Switch
8O - 38 RESTRAINTS connects the switch to the vehicle electrical system PASSENGER AIRBAG ON/OFF through a dedicated take out and connector of the SWITCH instrument panel wire harness. The molded plastic harness connector insulator is keyed and latched to DESCRIPTION ensure proper and secure switch electrical connec- tions.
Page 640: Removal
RESTRAINTS 8O - 39 PASSENGER AIRBAG ON/OFF SWITCH (Continued) on/off switch or Off indicator circuits, and will illumi- nate the airbag indicator in the instrument cluster if a fault is detected. For proper diagnosis of the pas- senger airbag on/off switch or the ACM, a DRBIII scan tool is required.
Page 641: Installation
8O - 40 RESTRAINTS REAR CENTER SEAT BELT & RETRACTOR (Continued) REAR SEAT BELT BUCKLE - REMOVAL - CEN- TER ANCHOR & RIGHT OUTBOARD). WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE.
Page 642: Rear Outboard Seat Belt & Retractor
RESTRAINTS 8O - 41 REAR CENTER SEAT BELT & RETRACTOR (Continued) (1) Position the rear center seat belt and retractor unit onto the center anchor/right outboard occupant buckle and mounting bracket unit on the rear floor panel near the base of the cab back panel (Fig. 38). (2) Install and tighten the screw that secures the rear center seat belt retractor bracket to the center anchor/right outboard occupant buckle and mounting...
Page 643: Installation
8O - 42 RESTRAINTS REAR OUTBOARD SEAT BELT & RETRACTOR (Continued) WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT CUT,...
Page 644: Rear Seat Belt Buckle
RESTRAINTS 8O - 43 REAR OUTBOARD SEAT BELT & RETRACTOR (Continued) WARNING: DURING AND FOLLOWING ANY SEAT (12) Reinstall the rear seat into the vehicle. (Refer BELT OR CHILD RESTRAINT ANCHOR SERVICE, to 23 - BODY/SEATS/SEAT - REAR - INSTALLA- TION).
Page 645 8O - 44 RESTRAINTS REAR SEAT BELT BUCKLE (Continued) PARTS LISTED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG. (1) Reach between the rear seat cushion and the rear seat back to access and unbuckle the rear center seat belt lower anchor latch plate from the unique black, keyed lower anchor buckle.
Page 646: Installation - Center Anchor & Right Outboard
RESTRAINTS 8O - 45 REAR SEAT BELT BUCKLE (Continued) STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT CUT, FRAYED, TORN. STRAIGHTEN BELT THAT TWISTED. TIGHTEN ANY LOOSE FASTENERS. REPLACE ANY BELT THAT HAS A DAMAGED OR INOPERATIVE BUCKLE OR RETRACTOR.
Page 647: Seat Belt Switch
8O - 46 RESTRAINTS REAR SEAT BELT BUCKLE (Continued) WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT CUT,...
Page 648: Diagnosis And Testing - Seat Belt Switch
RESTRAINTS 8O - 47 SEAT BELT SWITCH (Continued) DIAGNOSIS AND TESTING - SEAT BELT OK, test and replace the faulty instrument cluster as required. (Refer to 8 - ELECTRICAL/INSTRUMENT SWITCH CLUSTER - DIAGNOSIS AND TESTING). If not OK, Refer to the appropriate wiring information. The repair the open seat belt switch sense circuit between wiring information includes wiring diagrams, proper the seat belt switch and the instrument cluster as...
Page 649: Operation
8O - 48 RESTRAINTS SEAT BELT TENSIONER (Continued) The seat belt tensioner cannot be repaired and, if illuminate the airbag indicator in the ElectroMe- faulty or damaged, the entire outboard front seat belt chanical Instrument Cluster (EMIC) and store a and retractor unit must be replaced.
Page 650: Operation
RESTRAINTS 8O - 49 SEAT BELT TENSION REDUCER (Continued) outboard seat belt and retractor unit must be SYSTEM BEFORE ATTEMPTING ANY STEERING replaced. (Refer to 8 - ELECTRICAL/RESTRAINTS/ WHEEL, STEERING COLUMN, DRIVER AIRBAG, FRONT OUTBOARD SEAT BELT & RETRACTOR - PASSENGER AIRBAG, SEAT BELT TENSIONER, REMOVAL).
Page 651 8O - 50 RESTRAINTS SEAT BELT TURNING LOOP ADJUSTER REMOVAL WARNING: DURING AND FOLLOWING ANY SEAT BELT OR CHILD RESTRAINT ANCHOR SERVICE, CAREFULLY INSPECT ALL SEAT BELTS, BUCKLES, MOUNTING HARDWARE, RETRACTORS, TETHER STRAPS, AND ANCHORS FOR PROPER INSTALLA- TION, OPERATION, OR DAMAGE. REPLACE ANY BELT THAT CUT,...
Page 652 RESTRAINTS 8O - 51 SEAT BELT TURNING LOOP ADJUSTER (Continued) (6) Position the seat belt turning loop onto the height adjuster on the upper inner B-pillar. (7) Install and tighten the screw that secures the seat belt turning loop to the height adjuster. Tighten the screw to 40 N·m (29 ft.
Page 653 8O - 52 RESTRAINTS SIDE CURTAIN AIRBAG (Continued) and inert gas canister are sealed and connected to a WARNING: USE EXTREME CARE TO PREVENT ANY tubular manifold so that all of the released gas is FOREIGN MATERIAL FROM ENTERING THE SIDE directed into the folded curtain airbag cushion, caus- CURTAIN AIRBAG, OR BECOMING ENTRAPPED ing the cushion to inflate.
Page 654 RESTRAINTS 8O - 53 SIDE CURTAIN AIRBAG (Continued) (8) Remove the side curtain airbag from the vehi- plastic side curtain airbag channel with their holes cle as a unit. in the roof side rail and push them straight into the roof rail until they are fully seated (Fig.
Page 655 8O - 54 RESTRAINTS SIDE IMPACT AIRBAG CONTROL MODULE (Continued) (SIACM) and its mounting bracket are secured with and stored Diagnostic Trouble Code (DTC) and sends four screws to the inside of each B-pillar behind electronic messages to the ACM over the PCI data (standard cab) or above (quad cab) the front outboard bus.
Page 656 RESTRAINTS 8O - 55 SIDE IMPACT AIRBAG CONTROL MODULE (Continued) REMOVAL REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, SEAT BELT TENSIONER, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 657 8O - 56 RESTRAINTS SIDE IMPACT AIRBAG CONTROL MODULE (Continued) WARNING: THE SIDE IMPACT AIRBAG CONTROL (5) Reach through the retractor mounting hole in MODULE CONTAINS THE IMPACT SENSOR, WHICH the inner B-pillar to access the SIACM and lift it upward far enough to disengage the hook on the ENABLES THE SYSTEM TO DEPLOY THE SIDE CURTAIN AIRBAGS.
Page 658 RESTRAINTS 8O - 57 SIDE IMPACT AIRBAG CONTROL MODULE (Continued) plastic push-in fasteners that secure the SIACM to ENABLES THE SYSTEM TO DEPLOY THE SIDE the inside of the B-pillar. CURTAIN AIRBAGS. NEVER STRIKE OR DROP THE (4) Loosely install the four screws that secure the SIDE IMPACT AIRBAG CONTROL MODULE, AS IT SIACM mounting bracket to the base of the B-pillar.
Page 660 SPEED CONTROL 8P - 1 SPEED CONTROL TABLE OF CONTENTS page page SPEED CONTROL OPERATION ......7 DESCRIPTION .
Page 661: Operation
8P - 2 SPEED CONTROL SPEED CONTROL (Continued) OPERATION DIAGNOSIS AND TESTING When speed control is selected by depressing the DIAGNOSIS AND TESTING - VACUUM SUPPLY ON switch, the PCM (the ECM with a diesel engine) allows a set speed to be stored in its RAM for speed TEST control.
Page 662: Diagnosis And Testing - Road Test
SPEED CONTROL 8P - 3 SPEED CONTROL (Continued) • Loose, damaged or corroded electrical connec- 5.9L Diesel Engines With Automatic Trans. tions at the servo (if used). Corrosion should be If equipped with a diesel powered engine and an removed from electrical terminals and a light coating automatic transmission, an electric vacuum pump Mopar MultiPurpose...
Page 663 8P - 4 SPEED CONTROL CABLE (Continued) (3) Hold throttle in wide open position. While held in this position, slide throttle cable pin (Fig. 1) from throttle body bellcrank. (4) Using a pick or small screwdriver, press release tab (Fig. 2) to release plastic cable mount from bracket.
Page 664 SPEED CONTROL 8P - 5 CABLE (Continued) Fig. 5 SERVO CABLE AT THROTTLE BODY - 5.9L 1 - VEHICLE SPEED CONTROL CABLE 8.0L Gas (1) Disconnect negative battery cable at battery. (2) Using finger pressure only, remove speed con- trol cable connector at bellcrank by pushing connec- Fig.
Page 665: Installation
8P - 6 SPEED CONTROL CABLE (Continued) (4) Remove servo cable from servo. Refer to Speed (3) Install speed control cable connector onto throt- Control Servo Removal/Installation in this group. tle body bellcrank pin (push rearward to snap into location). 5.9L Diesel —...
Page 666: Operation
SPEED CONTROL 8P - 7 SERVO (Continued) The vacuum chamber contains a diaphragm with a (6) Disconnect servo cable at throttle body. Refer to cable attached to control the throttle linkage. Servo Cable Removal/Installation. (7) Remove 2 mounting nuts holding servo cable OPERATION sleeve to bracket (Fig.
Page 667: Description
8P - 8 SPEED CONTROL SERVO (Continued) OPERATION When speed control is selected by depressing the ON, OFF switch, the PCM (ECM for diesel) 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 approxi- mately 35 and 85 mph.
Page 668: Removal
SPEED CONTROL 8P - 9 SWITCH (Continued) REMOVAL Depending on engine control computer (JTEC having a 3–plug connector or 5.7L V-8 NGC hav- ing a 4–plug connector), 2 types of switches are used. Both types of switches are internally and externally different.
Page 669: Removal
8P - 10 SPEED CONTROL VACUUM RESERVOIR (Continued) (2) Start engine and observe gauge at idle. Vac- uum gauge should read at least ten inches of mer- cury. (3) If vacuum is less than ten inches of mercury, determine source of leak. Check vacuum line to engine for leaks.
Page 670 VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY STANDARD PROCEDURE DESCRIPTION CONFIGURING A NEW MODULE / SWITCH DESCRIPTION ......1 OPERATING MODES .
Page 671 8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) to ensure proper RF communication between the OPERATION SKIM and the Sentry Key transponder. For added system security, each SKIM is pro- OPERATION grammed with a unique “Secret Key” code and a When in the Customer Usage mode of operation, security code.
Page 672 VEHICLE THEFT SECURITY 8Q - 3 VEHICLE THEFT SECURITY (Continued) placed in its “Customer Learn” programming mode. STANDARD PROCEDURE See Sentry Key Immobilizer System Transponder Programming in this section for more information on CONFIGURING A NEW MODULE / SWITCH the “Customer Learn” programming mode. OPERATING MODES For diagnosis or initialization of the SKIM and the To configure a new module or to switch operating...
Page 673 8Q - 4 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) NOTE: If a PCM is replaced, the unique “Secret (7) Repeat this process for each additional Sentry Key” data must be transferred from the SKIM to the Key transponder blank to be programmed. If any of the above steps is not completed in the PCM.
Page 674 VEHICLE THEFT SECURITY 8Q - 5 VEHICLE THEFT SECURITY (Continued) • To learn additional keys, turn the ignition OFF, ON position, as a “Bulb” test. After completion of the remove the learned key, and insert the next new “Bulb” test, the SKIM sends a PCI bus messages to blank key.
Page 676 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS REMOVAL - V-10 OR DIESEL ENGINE ..16 DESCRIPTION ......1 INSTALLATION OPERATION .
Page 677: Description
8R - 2 WIPERS/WASHERS WIPERS/WASHERS (Continued) Fig. 1 Wiper & Washer System 1 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL 4 - WASHER NOZZLE (2) SWITCH (EXCEPT V-10 & DIESEL ENGINE) 5 - WIPER ARM & BLADE (2) 2 - WASHER RESERVOIR, PUMP/MOTOR, FLUID LEVEL 6 - MULTI-FUNCTION (WIPER, WASHER, &...
Page 678 WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) • Washer Pump/Motor - The electric washer tion, as well as pin-out and location views for the pump/motor unit is located in a dedicated hole on the various wire harness connectors, splices and grounds. rearward facing surface of the washer reservoir in OPERATING MODES the engine compartment.
Page 679: Operation
8R - 4 WIPERS/WASHERS WIPERS/WASHERS (Continued) • Wipe-After-Wash Mode - When the control Wiper and washer system operation are completely knob on the control stalk of the multi-function switch controlled by the instrument cluster and FCM logic is depressed to the momentary Wash position for circuits, and that logic will only allow these systems more than about one-half second with the wiper sys- to operate when the ignition switch is in the Acces-...
Page 680 WIPERS/WASHERS 8R - 5 WIPERS/WASHERS (Continued) through the normally open contacts of the energized PULSE WIPE MODE wiper on/off relay and the normally open contacts of When the control knob on the control stalk of the the energized wiper high/low relay to the high speed multi-function switch is depressed to the momentary brush of the wiper motor, causing the wipers to cycle Wash position for less than about one-half second,...
Page 681: Diagnosis And Testing - Wiper & Washer System
8R - 6 WIPERS/WASHERS WIPERS/WASHERS (Continued) If the control knob is held depressed for more than SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL about thirty seconds, the FCM will suspend washer COMPONENT DIAGNOSIS OR SERVICE. DISCON- pump/motor operation until the knob is released for NECT AND ISOLATE THE BATTERY NEGATIVE about two seconds, then cycled back to the Wash (GROUND) CABLE, THEN WAIT TWO MINUTES FOR...
Page 682: Inspection - Wiper & Washer System
WIPERS/WASHERS 8R - 7 WIPERS/WASHERS (Continued) CAUTION: Never use compressed air to flush the the wiper blade with a new unit. Do not attempt to washer system plumbing. Compressed air pres- repair a wiper blade that is damaged. sures are too great for the washer system plumbing components and will result in further system dam- age.
Page 683: Check Valve Description
8R - 8 WIPERS/WASHERS nozzle, while other contaminants could interfere with CHECK VALVE proper nozzle operation and cause improper nozzle spray patterns. In addition, the check valve prevents DESCRIPTION washer fluid from siphoning through the washer noz- zles after the washer system is turned Off. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure unseats a diaphragm...
Page 684: Installation
WIPERS/WASHERS 8R - 9 CHECK VALVE (Continued) Fig. 5 Check Valve Remove/Install 1 - WASHER NOZZLE HOSE (RIGHT) 2 - CHECK VALVE 3 - ROUTING CLIP Fig. 6 Washer Fluid Level Switch 4 - COWL PLENUM WASHER HOSE 5 - COWL PLENUM COVER/GRILLE PANEL (UNDERSIDE) 1 - MOUNTING FLANGE 6 - WASHER NOZZLE HOSE (LEFT) 2 - BARBED NIPPLE...
Page 685: Removal
8R - 10 WIPERS/WASHERS WASHER FLUID LEVEL SWITCH (Continued) The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the right (except V-10 and diesel engines) or left (V-10 and diesel engines only) head- lamp and dash wire harness.
Page 686: Installation
WIPERS/WASHERS 8R - 11 WASHER FLUID LEVEL SWITCH (Continued) (6) Remove the washer fluid level switch from the washer reservoir. (7) Remove the rubber grommet seal from the washer fluid level switch mounting hole in the washer reservoir and discard. INSTALLATION (1) Install a new rubber grommet seal into the washer fluid level switch mounting hole in the...
Page 687: Washer Nozzle Description
8R - 12 WIPERS/WASHERS REMOVAL WASHER NOZZLE (1) Remove both wiper arms from the wiper pivots. DESCRIPTION (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ WIPER ARM - REMOVAL). (2) Unlatch and open the hood. (3) Remove the cowl plenum cover/grille panel from over the cowl plenum. (Refer to 23 - BODY/EX- TERIOR/COWL GRILLE - REMOVAL).
Page 688: Washer Pump/Motor
WIPERS/WASHERS 8R - 13 WASHER NOZZLE (Continued) (4) Reinstall the washer hose for the washer noz- housing connects the unit to the washer system zle into its routing clips on the underside of the cowl through a short washer reservoir hose. plenum cover/grille panel.
Page 689: Removal
8R - 14 WIPERS/WASHERS WASHER PUMP/MOTOR (Continued) However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the Front Control Module (FCM), or the elec- tronic message inputs to or outputs from the instru- ment cluster and the FCM that control the operation of the washer pump/motor unit.
Page 690: Washer Reservoir Description
WIPERS/WASHERS 8R - 15 opening with an integral rubber gasket. The filler WASHER RESERVOIR cap is labeled with an International Control and Dis- play Symbol icon for “Windshield Washer” and the DESCRIPTION text “Washer Fluid Only” that are molded into it and highlighted in black against the yellow plastic cap for visibility.
Page 691: Removal - Except V-10 Or Diesel Engine
8R - 16 WIPERS/WASHERS WASHER RESERVOIR (Continued) (5) Disconnect the right headlamp and dash wire REMOVAL harness connector for the washer fluid level switch from the switch connector receptacle. REMOVAL - EXCEPT V-10 OR DIESEL ENGINE (6) Disconnect the right headlamp and dash wire (1) Unlatch and open the hood.
Page 692: Installation - Except V-10 Or Diesel
WIPERS/WASHERS 8R - 17 WASHER RESERVOIR (Continued) (4) Disconnect the reservoir washer hose from the (4) Reconnect the right headlamp and dash wire barbed nipple of the inline fitting at the engine com- harness connector for the washer pump/motor unit to partment washer hose in the right headlamp and the motor connector receptacle.
Page 693: Wiper Arm Description
8R - 18 WIPERS/WASHERS entire wiper arm has a satin black finish applied to WIPER ARM all of its visible surfaces. A wiper arm cannot be adjusted or repaired. If DESCRIPTION damaged or faulty, the entire wiper arm unit must be replaced.
Page 694: Installation
WIPERS/WASHERS 8R - 19 WIPER ARM (Continued) • Superstructure - The superstructure includes INSTALLATION several stamped steel bridges and links with claw The right and left wiper arms are not interchange- formations that grip the wiper blade element. Also able. The right wiper arm is slightly longer than the included in this unit is the latching, molded plastic left.
Page 695: Installation
8R - 20 WIPERS/WASHERS WIPER BLADE (Continued) WIPER HIGH/LOW RELAY DESCRIPTION Fig. 22 ISO Micro Relay 30 - COMMON FEED Fig. 21 Wiper Blade Remove/Install 85 - COIL GROUND 86 - COIL BATTERY 1 - SUPERSTRUCTURE 87 - NORMALLY OPEN 2 - WIPER ARM 87A - NORMALLY CLOSED 3 - PIVOT BLOCK...
Page 696: Diagnosis And Testing - Wiper High/Low Relay
WIPERS/WASHERS 8R - 21 WIPER HIGH/LOW RELAY (Continued) The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: •...
Page 697: Wiper Module
8R - 22 WIPERS/WASHERS WIPER HIGH/LOW RELAY (Continued) Fig. 24 Integrated Power Module Fig. 25 Wiper Module 1 - 15 - CARTRIDGE FUSE 1 - PIVOT BRACKET (2) 16 - 53 - BLADE FUSE 2 - TUBE 54 - HEATED MIRROR RELAY 3 - CLAMP 55 - WIPER ON/OFF RELAY 4 - PIVOT SHAFT (2)
Page 698: Operation
WIPERS/WASHERS 8R - 23 WIPER MODULE (Continued) • Motor - The wiper motor features an integral REMOVAL die cast bracket to which the wiper module bracket is (1) Remove both wiper arms from the wiper pivots. secured with a stamped steel clamp and two screws (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ near the top and which has two rubber insulated WIPER ARM - REMOVAL).
Page 699 8R - 24 WIPERS/WASHERS WIPER MODULE (Continued) Fig. 26 Wiper Module Remove/Install 1 - COWL PLENUM WASHER HOSE 6 - WIPER MODULE 2 - PLASTIC FASTENER (6) 7 - WIRE HARNESS CONNECTOR 3 - SCREW (2) 8 - PLENUM PANEL 4 - WIPER ARM &...
Page 700: Wiper On/Off Relay Description
WIPERS/WASHERS 8R - 25 The wiper on/off relay terminals are connected to WIPER ON/OFF RELAY the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). DESCRIPTION The inputs and outputs of the wiper on/off relay include: •...
Page 701: Diagnosis And Testing - Wiper On/Off Relay
8R - 26 WIPERS/WASHERS WIPER ON/OFF RELAY (Continued) DIAGNOSIS AND TESTING - WIPER ON/OFF RELAY The wiper on/off relay (Fig. 28) is located in the Integrated Power Module (IPM) in the engine com- partment near the battery. Refer to the appropriate wiring information.
Page 702 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 INTERIOR LIGHTING....8W-44-1 COMPONENT INDEX .
Page 704 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION STANDARD PROCEDURE - TESTING FOR A DESCRIPTION SHORT TO GROUND ....9 DESCRIPTION - HOW TO USE WIRING STANDARD PROCEDURE - TESTING FOR A DIAGRAMS .
Page 705 8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 706 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 707 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 708: Description - Circuit Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY WIRE COLOR CODE CHART This is a list of terms and definitions used in the wiring diagrams. COLOR CODE COLOR BLUE LHD ....Left Hand Drive Vehicles BLACK RHD .
Page 709 8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CIRCUIT FUNCTIONS DESCRIPTION - SECTION IDENTIFICATION AND All circuits in the diagrams use an alpha/numeric INFORMATION code to identify the wire and it’s function. To identify The wiring diagrams are grouped into individual which circuit code applies to a system, refer to the sections.
Page 710: Description - Connector, Ground And Splice Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE SPLICE INFORMATION PROCEDURE REQUIRES IT TO BE ON. CAUTION: Not all connectors are serviced.
Page 711: Standard Procedure
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance factory items added to the vehicle before doing any between two points of a circuit. Low or no resistance diagnosis.
Page 712: Standard Procedure - Testing Of Voltage Potential
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL CONTINUITY (1) Connect the ground lead of a voltmeter to a (1) Remove the fuse for the circuit being checked known good ground (Fig.
Page 713 8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A SPECIAL TOOLS SHORT TO GROUND ON FUSES POWERING WIRING/TERMINAL SEVERAL LOADS (1) Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. (2) Replace the blown fuse.
Page 714: Connector Removal
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 INSTALLATION CONNECTOR (1) Insert the removed terminal in the same cavity REMOVAL on the repair connector. (2) Repeat steps for each terminal in the connec- (1) Disconnect battery. tor, being sure that all wires are inserted into the (2) Release Connector Lock (Fig.
Page 715 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock...
Page 716 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13 CONNECTOR (Continued) Fig. 12 TERMINAL REMOVAL 1 - TYPICAL CONNECTOR 7 - MOLEX CONNECTOR 2 - PICK FROM SPECIAL TOOL KIT 6680 8 - SPECIAL TOOL 6742 3 - APEX CONNECTOR 9 - THOMAS AND BETTS CONNECTOR 4 - PICK FROM SPECIAL TOOL KIT 6680 10 - SPECIAL TOOL 6934...
Page 717: Installation
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION DIODE TERMINAL REMOVAL REMOVAL (1) Disconnect the battery. (1) Follow steps for removing terminals described (2) Locate the diode in the harness, and remove in the connector removal section. the protective covering. (2) Cut the wire 6 inches from the back of the con- (3) Remove the diode from the harness, pay atten- nector.
Page 718: Standard Procedure - Wire Splicing
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15 (5) Solder the connection together using rosin core WIRE type solder only (Fig. 16). STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER. When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
Page 720 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page 4WD Switch ......8W-30 Electronic Throttle Control Module .
Page 721 8W - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Overdrive Switch ..... . 8W-31 Speed Control Servo ....8W-33 Overhead Map/Reading Lamp .
Page 722 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-16, 43, 44 Fuse 34 .
Page 780 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-9, 11 G120 ....... 8W-15-11 A/C-Heater Control .
Page 802 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page A/C-Heater Control ....8W-18-4 Front Control Module ....8W-18-5, 6 Airbag Control Module .
Page 808 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Auxiliary Battery ....8W-20-3 G109 ......8W-20-3 Battery .
Page 812 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Auxiliary Battery ....8W-21-3 Powertrain Control Module ..8W-21-2, 4 Battery .
Page 816 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ... 8W-30-27, 36, 83 Fusible Link ......8W-30-77 A/C Pressure Transducer .
Page 908 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Automatic Day/Night Mirror ..8W-31-7, 15 Overdrive Switch ....8W-31-9, 11, 19 Brake Lamp Switch .
Page 934 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Brake Lamp Switch ....8W-33-2, 6 G104 ......8W-33-2 Center High Mounted Stop Lamp- G201 .
Page 940 8W-34 REAR WHEEL ANTILOCK BRAKES 8W - 34 - 1 8W-34 REAR WHEEL ANTILOCK BRAKES Component Page Component Page Brake Lamp Switch ....8W-34-3 Integrated Power Module .
Page 944 8W-35 ALL WHEEL ANTILOCK BRAKES 8W - 35 - 1 8W-35 ALL WHEEL ANTILOCK BRAKES Component Page Component Page Brake Lamp Switch ....8W-35-3 Powertrain Control Module .
Page 948 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Cylinder Lock Switch-Driver ... 8W-39-5 G106 ......8W-39-3 Cylinder Lock Switch-Passenger .
Page 954 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page A/C-Heater Control ....8W-40-11 Fuse 41 ......8W-40-3 Brake Transmission Shift Interlock G201 .
Page 968 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Cigar Lighter Outlet ....8W-41-3 G302 ......8W-41-4 Clockspring .
Page 972 8W-42 AIR CONDITIONING 8W - 42 - 1 8W-42 AIR CONDITIONING Component Page Component Page A/C Compressor Clutch ....8W-42-7 G107 ......8W-42-7 A/C Compressor Clutch Relay .
Page 982 8W-43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM Component Page Component Page Airbag Control Module ....8W-43-2, 3 Fuse 52 ......8W-43-2 Airbag Control Module-Left Side Impact .
Page 986 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page Center High Mounted Stop Lamp/Cargo Fuse 17 ......8W-44-2 Lamp .
Page 990 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Amplifier Audio ....8W-47-4, 5 Remote Radio Switch-Right ... . 8W-47-7 Clockspring .
Page 998 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Ambient Temperature Sensor ..8W-49-3, 4 G202 ......8W-49-2 Automatic Day/Night Mirror .
Page 1002 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Clearance Lamp No. 1 ....8W-50-6 G104 ......8W-50-3, 4, 5 Clearance Lamp No.
Page 1008 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Backup Lamp Switch ....8W-51-3, 5 G103 ......8W-51-2, 3, 5, 6 Brake Lamp Switch .
Page 1016 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Data Link Connector ....8W-52-2 Park Lamp Relay ....8W-52-3 Front Control Module .
Page 1022 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Data Link Connector ....8W-53-2 Multi-Function Switch ....8W-53-2 Front Control Module .
Page 1026 8W-54 TRAILER TOW 8W - 54 - 1 8W-54 TRAILER TOW Component Page Component Page Brake Lamp Switch ....8W-54-5 G104 ......8W-54-3, 4, 5 Electric Brake Provision .
Page 1032 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker ....8W-60-2, 4 Power Window Motor-Passenger ..8W-60-3, 5 Driver Door Module .
Page 1040 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Cylinder Lock Switch-Driver ... 8W-61-2 Door Lock Switch- Passenger ..8W-61-3, 4 Cylinder Lock Switch-Passenger .
Page 1046 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page A/C-Heater Control ....8W-62-3 Heated Mirror Relay ....8W-62-3 Driver Door Module .
Page 1050 8W-63 POWER SEATS 8W - 63 - 1 8W-63 POWER SEATS Component Page Component Page Fuse 7 ......8W-63-2 Power Seat Motor-Driver Front Vertical .
Page 1056 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S101 ....... . 8W-15-7 S182 .
Page 1068 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page 4WD Switch (Manual Transfer Case) ..8W-80-5 C117 (Diesel) ..... . 8W-80-18 A/C Compressor Clutch .
Page 1069 8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS Component Page Component Page C317 ......8W-80-40 Door Lock Motor/Ajar Switch-Left Rear (Except Base) .
Page 1070: Speaker-Center Instrument Panel
8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Glove Box Lamp And Switch ..8W-80-63 Overdrive Switch ....8W-80-78 Headlamp Switch .
Page 1071: Speaker-Right Instrument Panel
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS Component Page Component Page Speaker-Right Instrument Panel ..8W-80-97 Transmission Range Sensor (5.9L/ Diesel) ......8W-80-105 Speaker-Right Rear .
Page 1072 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 4WD SWITCH (MANUAL TRANSFER CASE) - BLACK 2 WAY CIRCUIT FUNCTION K77 18BR/WT 4WD SWITCH SENSE K4 18BK/LB SENSOR GROUND A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C3 20DB/BK A/C CLUTCH RELAY OUTPUT Z359 18BK/BR GROUND A/C PRESSURE TRANSDUCER - BLACK 4 WAY...
Page 1073 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS A/C-HEATER CONTROL C1 - BLACK 16 WAY CIRCUIT FUNCTION F15 20DB FUSED IGNITION SWITCH OUTPUT (RUN) Z120 20WT/BK GROUND C57 20DB/GY SENSOR GROUND C33 20DB/RD MODE DOOR 2 DRIVER C12 20LG/BK EVAPORATOR TEMPERATURE SENSOR SIGNAL Y165 20OR/YL PANEL LAMPS DRIVER C62 20DB/PK...
Page 1074 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 ADJUSTABLE PEDAL MOTOR - WHITE 2 WAY CIRCUIT FUNCTION Y151 18LG/BR ADJUSTABLE PEDAL MOTOR (DOWN) Y152 18LG/OR ADJUSTABLE PEDAL MOTOR (UP) ADJUSTABLE PEDAL SWITCH - BLUE 6 WAY CIRCUIT FUNCTION Y151 18LG/BR ADJUSTABLE PEDAL MOTOR (DOWN) Y153 18DB/RD ADJUSTABLE PEDAL RELAY OUTPUT...
Page 1075 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS AIRBAG CONTROL MODULE-LEFT SIDE IMPACT - YELLOW 8 WAY CIRCUIT FUNCTION F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START) Z11 18BK/WT GROUND R77 18LB/BR LEFT CURTAIN SQUIB 1 LINE 2 R75 18LB/OR LEFT CURTAIN SQUIB 1 LINE 1 Z11 18BK/WT GROUND D25 20DB/VT...
Page 1076 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 AIRBAG-PASSENGER SQUIB 1 - YELLOW 2 WAY CIRCUIT FUNCTION R42 18BK/YL PASSENGER SQUIB 1 LINE 1 R44 18DG/YL PASSENGER SQUIB 1 LINE 2 AIRBAG-RIGHT CURTAIN SQUIB - YELLOW 2 WAY CIRCUIT FUNCTION R74 18LB/YL RIGHT CURTAIN SQUIB 1LINE 1 R76 18LB/WT...
Page 1077 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS AMPLIFIER AUDIO C2 - GRAY 18 WAY CIRCUIT FUNCTION F75 18VT FUSED B(+) X91 18WT/BK LEFT REAR SPEAKER (-) X82 18LB/VT RIGHT FRONT DOOR SPEAKER (+) X87 18LG/RD LEFT FRONT DOOR SPEAKER (+) X84 18OR/BK RIGHT INSTRUMENT PANEL SPEAKER (+) X83 18YL/RD...
Page 1078 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 BATTERY TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K118 18PK/YL BATT TEMP SIGNAL K4 18BK/LB SENSOR GROUND BLEND DOOR ACTUATOR (SINGLE-ZONE) - 2 WAY CIRCUIT FUNCTION C34 20DB/WT COMMON DOOR DRIVER C62 20DB/PK BLEND DOOR DRIVER BLOWER MOTOR - 2 WAY...
Page 1079 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS BRAKE FLUID LEVEL SWITCH - BLACK 2 WAY CIRCUIT FUNCTION G9 20GY/BK BRAKE FLUID LEVEL SWITCH SENSE Z231 20BK/DG GROUND BRAKE LAMP SWITCH - BLACK 6 WAY CIRCUIT FUNCTION A108 18TN/RD FUSED B(+) L50 18WT/TN BRAKE LAMP SWITCH OUTPUT V30 20DB/RD...
Page 1080 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 C100 (DIESEL) - (ENGINE TO DASH) CIRCUIT K152 18WT B6 20WT/DB B7 20WT Z11 18BK/WT Y1 18LG K4 18BK/LB Y169 18WT/TN Y168 18WT/LB Y3 18WT L60 18LG/TN L7 18BK/YL F15 20DB Y5 18OR K154 18GY C100 (GAS) - BLACK (DASH TO ENGINE) CIRCUIT...
Page 1081 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS C106 (5.7L) - BLACK CIRCUIT K11 18WT/DB K12 18TN K13 18YL/WT K14 18LB/BR K38 18GY K58 18BR/DB K26 18VT/TN K28 18GY/LB K91 18TN/RD K92 18TN/PK K93 18TN/OR K94 18TN/LG K95 18TN/DG K96 18TN/LB K97 18BR K98 18LB C106 (5.7L) - BLACK (ENGINE TO...
Page 1082 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 C107 (5.7L) - BLACK CIRCUIT K4 18BK/LB K1 18DG/RD K21 18BK/RD K101 18WT K6 18VT/WT K888 18BR/PK A142 16DG/OR K7 18OR K2 18TN/BK K122 18DB/GY K22 18OR/DB F855 18OR/PK A142 16DG/OR C107 (5.7L) - BLACK (ENGINE TO TRANSMISSION) CIRCUIT K4 18BK/LB...
Page 1083 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C108 (DIESEL) - (ENGINE TO TRANSMISSION) CIRCUIT G7 18WT/OR C13 18DB/OR A53 14RD/BK K118 18PK/YL G8 18LB/BK D25 18VT/YL K77 18BR/WT V32 18YL/RD K152 18WT K22 18OR/DB K154 18GY C110 (DIESEL) CIRCUIT C3 18DB/BK K29 18WT/PK K4 18BK/LB...
Page 1084 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C112 (DIESEL) CIRCUIT C3 18DB/BK A93 14RD/BK Y523 18VT/WT T503 18GY/BR C112 (DIESEL) CIRCUIT C3 18DB/BK A93 14RD/BK K69 18BR/LB K68 18BR/LG C115 (DIESEL) CIRCUIT K91 14TN/RD K12 14YL/WT K91 14TN/RD K11 14WT/DB C115 (DIESEL) - (INJECTOR SIDE) CIRCUIT K91 14TN/RD...
Page 1085 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C116 (DIESEL) - (INJECTOR SIDE) CIRCUIT K92 14TN/PK K14 14RD/WT K91 14TN/RD K13 14TN C117 (DIESEL) CIRCUIT K92 14TN/PK K58 14BR/DB K92 14TN/PK K38 14GY C117 (DIESEL) - (INJECTOR SIDE) CIRCUIT K92 14TN/PK K58 14BR/DB K92 14TN/PK K38 14GY...
Page 1086 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C130 - BLACK (DASH TO ENGINE) CIRCUIT Y112 20YL/BR (ETC) Y113 20 YL/OR (ETC) Y114 20YL/VT (ETC) Y117 20YL/DB (ETC) Y145 20DB/YL (EXCEPT DIESEL) B222 20DG/WT (EXCEPT ABS) T24 20BR/YL (DIESEL/8.0L) T752 18DG/OR (EXCEPT DIESEL/EXCEPT 8.0L) D6 18PK/LB Y215 18YL/PK (5.7L) K81 20DB/DG (5.7L)
Page 1087 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C130 - BLACK (ENGINE TO DASH) CIRCUIT A41 16YL (4.7L/5.7L/3.7L A/T) A41 14YL (3.7L M/T) A93 14RD/BK (DIESEL) K108 18WT/TN (4.7L/5.7L) V35 18LG/RD (EXCEPT 5.7L) V32 18YL/RD (EXCEPT 5.7L) V32 20YL/RD (5.7L) K4 18BK/LB (DIESEL) VT/PK (DIESEL) K51 20DB/YL...
Page 1088 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C130 - BLACK (ENGINE TO DASH) CIRCUIT Y215 20YL/PK (5.7L) K81 18DB/DG (5.7L) Y115 20YL/WT (ETC) B22 20DG/YL (5.7L) G7 18WT/OR (EXCEPT 5.7L) K52 18PK/BK (EXCEPT DIESEL) K31 18BR (EXCEPT DIESEL) Y135 18LG/BK K30 18PK (A/T) K255 18WT/DG (5.7L/DIESEL) A141 18DG/WT (EXCEPT 5.7L)
Page 1089 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS C200 - GRAY (I/P TO HVAC) CIRCUIT C7 10BK/TN C34 20DB/WT C4 16TN C32 20GY/DB C6 14LB C5 16LG C1 10DG C33 20DB/RD C12 20LG/BK C57 20DB/GY C62 20DB/PK C46 20YL/LG C35 20DG/YL C200 - (HVAC TO I/P) CIRCUIT C7 10BK/TN...
Page 1090 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C201 - WHITE (HEADLINER TO I/P) CIRCUIT D25 20VT Z104 18BK/OR L50 18WT/TN Z56 18BK Y107 20VT/RD (EXCEPT BASE) M3 20PK/DB M20 20BR M11 20PK/LB L1 18VT/BK F32 18RD/YL C202 - (DASH TO FOG LAMPS) CIRCUIT L39 18LB Z144 BK/OR...
Page 1091 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS C206 (SLT+) CIRCUIT L7 18BK/YL Z253 18BK/RD C216 - BLACK (DASH TO CHASSIS) CIRCUIT B113 20RD/VT B114 20WT/VT L76 18BK/OR L24 18WT/LG L62 18BR/RD K4 18BK/LB G8 20LB/BK L7 18BK/YL C216 - (CHASSIS TO DASH) CIRCUIT B113 18RD/VT B114 18WT/VT...
Page 1092 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C217 - BLACK (DASH TO CHASSIS) CIRCUIT Y141 18DG/WT B40 14LB Y133 14RD/OR Y174 18PK/VT A64 16DG/WT L50 18WT/TN Z52 14BK L22 18LB/WT L63 18DG/RD L1 18VT/BK Y140 18 WT/PK Z13 16BK C218 - WHITE (DASH TO BODY) CIRCUIT Y148 18YL/RD...
Page 1093 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C219 - GRAY (DASH TO I/P) CIRCUIT Y113 20YL/OR (ETC) D15 18WT/DG (EXCEPT 8.0L) L50 18WT/TN A51 16RD/WT (GAS EXCEPT 8.0L) D21 20PK A108 18TN/RD A41 16YL D20 20LG A2 10PK/BK A30 10RD/WT (EXCEPT BASE) V38 20VT/OR (5.7L) V37 20RD/LG T6 20OR/WT...
Page 1094 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C219 - GRAY (DASH TO I/P) CIRCUIT Y153 18DB/RD (EXCEPT BASE) D6 18PK/LB C16 20LB/YL (EXCEPT BASE) Y193 20YL/RD (EXCEPT NGC/DIESEL) A12 18RD/TN F75 18VT (EXCEPT BASE) Y117 20YL/DB (5.7L ETC) Y124 16DG/VT (ETC) Y112 20YL/BR (ETC) F32 20RD/YL F23 18DB/YL...
Page 1095 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C219 - GRAY (I/P TO DASH) CIRCUIT Y113 20YL/OR (SLT+) D15 18WT/DG L50 18WT/TN A51 16RD/WT D21 18PK A108 18TN/RD A41 16YL D20 20LG A2 10PK/BK A30 10RD/WT V38 20VT/OR V37 20RD/WT T6 20OR/WT L7 18BK/YL Y107 20VTRD...
Page 1096 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 C219 - GRAY (I/P TO DASH) CIRCUIT F23 18DB/YL T24 20BR/YL (SLT+) Y116 20YL/GY (SLT+) Y131 14RD/WT A31 14BK/WT A38 16OR F14 18LG/YL L39 20LB K29 20WT/PK A14 20RD/WT Y115 20YL/WT (SLT+) D25 20VT/PK Y105 20BR/RD Y114 20YL/VT (SLT+)
Page 1097 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS C220 - (BODY TO I/P) CIRCUIT Y105 20BR/RD X91 18WT/BK F32 18RD/YL X87 18LG/RD G75 20TN G77 20VT/OR X85 18LG/DG G10 20LG/RD G73 20LG/OR (EXCEPT BASE) X93 18WT/RD D25 20DB/VT Z11 18 BK/WT Y157 18TN/PK (EXCEPT BASE) P97 20WT/DG (EXCEPT BASE) P55 18DB (EXCEPT BASE)
Page 1098 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 C301 - WHITE (PASSENGER DOOR TO BODY) CIRCUIT G74 20TN/RD P76 20OR/YL P72 20YL/BK X82 18LB/RD X80 18LB/BK P74 20DB Q1 14YL Z315 20BK/LG C302 - BLACK (BODY TO PASSENGER DOOR) CIRCUIT Y107 20VT/RD Y156 18TN/WT P96 20WT/LG...
Page 1099 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS C304 - WHITE (BODY TO DRIVER DOOR) CIRCUIT G75 20TN P76 20OR/YL (EXCEPT BASE) P72 20YL/BK (EXCEPT BASE) X87 18LG/RD X85 18LG/DG P74 20DB (EXCEPT BASE) F21 12TN (EXCEPT BASE) Q1 12YL (EXCEPT BASE) F32 18RD/YL (EXCEPT BASE) Z314 20BK/LG C304 - WHITE (DRIVER DOOR TO BODY)
Page 1100 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 C305 - BLACK (DRIVER DOOR TO BODY) CIRCUIT F121 18TN/BK Q16 14BR/WT Q26 14VT/WT Y157 18TN/PK P55 15DB Z239 14BK/LB Q28 14DG/WT P97 20WT/DG G73 20LG/OR Q18 14GY/BK Q27 14RD/BK Q17 14DB/WT C306 - WHITE (BODY TO LEFT REAR DOOR) CIRCUIT Z75 20BK...
Page 1101 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS C307 (TAIL LAMP JUMPER) - (CHASSIS TO TAIL LAMPS) CIRCUIT L7 18 BK/YL Z151 18 BK L22 18LB/WT L62 18BR/RD L1 18VT/BK C307 (TAIL LAMP JUMPER) - (TAIL LAMPS TO CHASSIS) CIRCUIT L7 18BK/YL Z151 18BK L22 18WT/LG...
Page 1102 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 C308 - WHITE (I/P TO BODY) CIRCUIT G74 20TN/RD G72 20DG/OR X80 18LB/BK P96 20WT/LG G76 20TN/YL Y200 18TN/VT Y156 18TN/WT Y107 20VT/RD R53 18LG/YL R55 18LG/DG X94 18TN/VT X92 18TN/BK X82 18LB/VT C309 - WHITE (I/P TO BODY) CIRCUIT P133 20TN/DG...
Page 1103 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS C310 (TAIL LAMP JUMPER) - (CHASSIS TO LEFT TAIL) CIRCUIT Y174 18PK/VT Z150 18BK L24 18WT/LG L63 18DG/RD L1 18VT/BK C310 (TAIL LAMP JUMPER) - (LEFT TAIL TO CHASSIS) CIRCUIT Y174 18PK/VT Z150 18BK L24 18WT/LG L63 18DG/RD...
Page 1104 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 C312 - WHITE (BODY TO RIGHT REAR DOOR) CIRCUIT Z74 20BK G76 20TN/YL Y200 18TN/VT Y156 18TN/WT Q1 14YL Q18 14GY/BK Q28 14 DG/WT X92 18TN/BK X94 18TN/VT C312 - WHITE (RIGHT REAR DOOR TO BODY) CIRCUIT Z74 20BK G76 20VT/OR...
Page 1105 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS C313 - (DRIVER SEAT TO JUMPER) CIRCUIT F37 12RD/LB Z238 14BK P106 12DG/WT P13 12RD/WT P107 12OR/BK Z88 14BK/LB F37 12RD/LB P11 12YL/WT P17 12RD/LB P15 12YL/LB P21 12RD/LG P19 12YL/LG C314 - DK GRAY (DRIVER SEAT TO JUMPER) CIRCUIT Y148 16BR/YL Z300 16BK/WT...
Page 1106 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 C315 - (JUMPER TO DRIVER SEAT) CIRCUIT Z121 20BK/WT P142 18TN/DB P37 12RD/LB P144 20BK/LG P86 20PK/BK Z238 14BK C316 - (JUMPER TO PASSENGER SEAT) CIRCUIT Z121 20BK/WT P142 18TN/DB F37 12RD/LB P144 20BK/LG P86 20PK/BK Z238 14BK...
Page 1107 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS C317 - (SEAT SWITCH PASSENGER SEAT) CIRCUIT Z238 18BK P105 12LG/DB F37 12RD/LB P104 12YL/LB Z238 18BK C319 - (JUMPER TO POWER POINT) CIRCUIT Y148 16BR/YL Z300 16BK/WT C319 - (POWER POINT TO JUMPER) CIRCUIT Y148 18BR/YL Z300 18BK/WT...
Page 1108 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 C322 - (BODY TO SEAT) CIRCUIT F235 18RD P137 20VT/DG P133 20TN/DG G10 20LG/RD P139 20VT/WT P138 20VT/LG Z238 14BK F37 12RD/LB P134 20TN/LG P140 20VT/BK Z237 20BK/OR Z121 20BK/LG Y148 16YL/RD C323 - (JUMPER TO PASSENGER LUMBAR) CIRCUIT Z238 18BK...
Page 1109 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS C327 - BLACK (CHASSIS TO DUAL-REAR-WHEELS) CIRCUIT Y174 20PK/VT Z57 20BK C327 - BLACK (DUAL-REAR-WHEELS TO CHASSIS) CIRCUIT Y174 18PBK/YL Z57 18BK C328 - BLACK (CHASSIS TO DUAL-REAR-WHEELS CIRCUIT L7 20BK/YL Z48 20BK C328 - BLACK (DUAL-REAR-WHEELS TO CHASSIS) CIRCUIT...
Page 1110 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 CAPACITOR - BLACK 2 WAY CIRCUIT FUNCTION A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT CENTER HIGH MOUNTED STOP LAMP/CARGO LAMP - 4 WAY CIRCUIT FUNCTION F32 18RD/YL FUSED B(+) M3 20PK/DB CARGO LAMP DRIVER Z56 18BK GROUND L50 18WT/TN...
Page 1111 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS CLEARANCE LAMP NO. 3 (HEAVY DUTY) - 2 WAY CIRCUIT FUNCTION L7 20BK/YL HEADLAMP SWITCH OUTPUT Z253 20BK/RD GROUND CLEARANCE LAMP NO. 4 (HEAVY DUTY) - 2 WAY CIRCUIT FUNCTION L7 20BK/YL HEADLAMP SWITCH OUTPUT Z253 20BK/RD GROUND...
Page 1112 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 CLOCKSPRING C3 - BLACK 4 WAY CIRCUIT FUNCTION X3 20BK/RD HORN RELAY CONTROL K4 20BK/LB SENSOR GROUND V37 20RD/LG S/C SWITCH NO.1 SIGNAL V38 20VT/OR (ELECTRONIC SPEED CONTROL RELAY CONTROL TRANSMISSION CONTROL) CLOCKSPRING C4 - 2 WAY CIRCUIT FUNCTION...
Page 1113 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS COIL ON PLUG NO. 2 (3.7L/4.7L/5.7L) - BLACK 3 WAY CIRCUIT FUNCTION K92 18TN/PK COIL ON PLUG DRIVER NO. 2 A142 16DG/OR (NGC) ASD RELAY OUTPUT A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT K92 18TN/PK (NGC) COIL CONTROL NO.
Page 1114 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 COIL ON PLUG NO. 6 (3.7L/4.7L/5.7L) - BLACK 3 WAY CIRCUIT FUNCTION K96 18TN/LB COIL ON PLUG DRIVER NO. 6 A142 16DG/OR (NGC) ASD RELAY OUTPUT A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT K96 18TN/LB (NGC) COIL CONTROL NO.
Page 1115 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS CONDENSER FAN - BLACK 2 WAY CIRCUIT FUNCTION Z212 16LG/BK GROUND C23 16DG CONDENSER FAN RELAY OUTPUT CONTROLLER ANTILOCK BRAKE C1 - BLACK 14 WAY CIRCUIT FUNCTION B113 20RD/VT REAR WHEEL SPEED SENSOR (+) B222 20DG/WT (EXCEPT 4 WHEEL VEHICLE SPEED SIGNAL NO.2 ABS)
Page 1116 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 CRANKSHAFT POSITION SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL K7 18OR (5.7L) 5 VOLT SUPPLY K24 18GY/BK (4.7L/) CKP SIGNAL K4 18BK/LB (3.7L/4.7L/5.7L) SENSOR GROUND K4 20BK/LB (5.9L) SENSOR GROUND K7 18OR (3.7L/4.7L) 5 VOLT SUPPLY...
Page 1117 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS DATA LINK CONNECTOR - ENGINE (DIESEL) - 3 WAY CIRCUIT FUNCTION D1 18VT/BR CCD BUS (+) D2 18WT/BK CCD BUS (-) Z11 14BK/WT GROUND DOME LAMP - BLACK 3 WAY CIRCUIT FUNCTION M20 20BR COURTESY LAMP DRIVER F32 18RD/YL...
Page 1118 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 DOOR AJAR SWITCH-RIGHT REAR (BASE) - BLACK 2 WAY CIRCUIT FUNCTION G76 20VT/OR RIGHT REAR DOOR AJAR SWITCH SENSE Z74 20BK GROUND DOOR LOCK MOTOR/AJAR SWITCH-DRIVER (EXCEPT BASE) - BLACK 4 WAY CIRCUIT FUNCTION G75 20TN...
Page 1119 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS DOOR LOCK MOTOR/AJAR SWITCH-RIGHT REAR (EXCEPT BASE) - BLACK 4 WAY CIRCUIT FUNCTION G76 20VT/OR RIGHT REAR DOOR AJAR SWITCH SENSE Z74 20BK GROUND Y156 18TN/OR DOOR UNLOCK DRIVER RIGHT DOORS Y200 18TN/PK DOOR LOCK DRIVER RIGHT DOORS DOOR LOCK SWITCH-PASSENGER - WHITE 6 WAY CIRCUIT...
Page 1120 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 DRIVER DOOR MODULE C1 - BLUE 12 WAY CIRCUIT FUNCTION Q28 14DG/WT RIGHT REAR WINDOW DRIVER (DOWN) Q18 14GY/BK RIGHT REAR WINDOW DRIVER (UP) Q16 14BR/WT MASTER WINDOW SWITCH RIGHT FRONT (UP) Q17 14DB/WT LEFT REAR WINDOW DRIVER (UP) Q11 14LB...
Page 1121 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS ELECTRONIC THROTTLE CONTROL MODULE (5.7L) - BLACK 6 WAY CIRCUIT FUNCTION K22 18OR/DB TP NO.1 SIGNAL K7 18OR 5 VOLT SUPPLY F888 18BR/PK ETC MOTOR(+) K122 18DB/GY TP NO.2 SIGNAL F855 18OR/PK ETC MOTOR(-) K101 18WT TP SENSOR RETURN...
Page 1122 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 ENGINE CONTROL MODULE - C1 (DIESEL) - 60 WAY CIRCUIT FUNCTION K13 16TN FUEL INJECTOR NO. 3 DRIVER K900 18DB/DG 5 VOLT SUPPLY K9 18LB 5 VOLT SUPPLY K101 18WT APPS NOT IDLE SWITCH K62 18BR/DB LETF PUMP K58 16BR/DB...
Page 1123 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS ENGINE CONTROL MODULE - C2 (DIESEL) - 50 WAY CIRCUIT FUNCTION D25 18VT/YL PCI BUS A140 16DG/WT FUSED B(+) Y135 18LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START) K68 18BR/LG INLET AIR PRESSURE SENSE V32 18YL/RD SPEED CONTROL SUPPLY K29 18WT/PK...
Page 1124 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 ENGINE OIL PRESSURE SWITCH - BLACK 2 WAY CIRCUIT FUNCTION G60 18GY/YL ENGINE OIL PRESSURE SWITCH SENSE EVAP/PURGE SOLENOID (EXCEPT NGC) - 2 WAY CIRCUIT FUNCTION K52 18PK/BK EVAPORATIVE SOLENOID CONTROL Y134 20GY/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) EVAP/PURGE SOLENOID (NGC) - BLACK 2 WAY CIRCUIT...
Page 1125 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS FENDER LAMP-FRONT LEFT - BLACK 2 WAY CIRCUIT FUNCTION Y174 18PK/VT FUSED PARK LAMP RELAY OUTPUT Z57 18BK GROUND FENDER LAMP-FRONT RIGHT - BLACK 2 WAY CIRCUIT FUNCTION Y174 18PK/VT FUSED PARK LAMP RELAY OUTPUT Z57 18BK GROUND FENDER LAMP-REAR LEFT - BLACK 2 WAY...
Page 1126 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 FOG LAMP-RIGHT - WHITE 2 WAY CIRCUIT FUNCTION Z144 18BK/OR GROUND L39 18LB FOG LAMP RELAY OUTPUT FUEL CONTROL ACTUATOR (DIESEL) - 3 WAY CIRCUIT FUNCTION K915 18VT/RD FUEL RAIL SENSOR RETURN K102 18PK/BK FUEL PUMP DRIVER K72 18DG/OR...
Page 1127 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR NO. 2 (DIESEL) - 2 WAY CIRCUIT FUNCTION K91 14TN/RD COMMON INJECTOR DRIVER K12 14YL/WT FUEL INJECTOR NO.1 CONTROL FUEL INJECTOR NO. 2 - BLACK 2 WAY CIRCUIT FUNCTION K12 18TN FUEL INJECTOR NO.
Page 1128 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 FUEL INJECTOR NO. 4 - BLACK 2 WAY CIRCUIT FUNCTION K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER K14 18LB/BR (NGC) INJECTOR CONTROL NO. 4 A142 16DG/OR (NGC) ASD RELAY OUTPUT A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO.
Page 1129 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR NO. 7 (4.7L/5.7L/5.9L/8.0L) - BLACK 2 WAY CIRCUIT FUNCTION K26 18VT/TN FUEL INJECTOR NO. 7 DRIVER K26 18VT/TN (NGC) INJECTOR CONTROL NO. 7 A142 16DG/OR (NGC) ASD RELAY OUTPUT A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO.
Page 1130 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 FUEL PUMP MODULE - LT GRAY 4 WAY CIRCUIT FUNCTION Z211 18BK GROUND K4 18BK/LB SENSOR GROUND G8 18LB/BK FUEL LEVEL SENSOR SIGNAL A64 16DG/WT FUEL PUMP RELAY OUTPUT FUEL PUMP MOTOR (DIESEL) - 2 WAY CIRCUIT FUNCTION K31 18BR...
Page 1131 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS HEADLAMP-LEFT - BLUE 3 WAY CIRCUIT FUNCTION Y171 18WT/DG LEFT LOW BEAM OUTPUT Z141 18BK/LB GROUND Y170 18WT/LG LEFT HIGH BEAM OUTPUT HEADLAMP-RIGHT - BLUE 3 WAY CIRCUIT FUNCTION Y169 18WT/TN RIGHT LOW BEAM OUTPUT Z142 18BK/LG GROUND Y168 18WT/LB...
Page 1132 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 HEATED SEAT SWITCH-PASSENGER - BLUE 6 WAY CIRCUIT FUNCTION P138 20VT/LG PASSENGER SEAT LOW HEAT LED DRIVER Y161 20OR/RD PANEL LAMPS FEED Z260 20DG/BK GROUND P131 20RD/DG HEATED SEAT SWITCH SUPPLY P140 20VT/BK PASSENGER SEAT HIGH HEAT LED DRIVER P134 20TN/LG PASSENGER SEAT HEATER MUX SWITCH...
Page 1133 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS IDLE AIR CONTROL MOTOR (NGC) - BLACK 2 WAY CIRCUIT FUNCTION K60 18YL/BK IAC RETURN K39 18GY/RD IAC MOTOR CONTROL IGNITION COIL (5.9L) - BLACK 2 WAY CIRCUIT FUNCTION A142 16DG/OR AUTO SHUT DOWN RELAY OUTPUT K19 18BK/GY IGNITION COIL NO.
Page 1134 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 IGNITION SWITCH - BLACK 14 WAY CIRCUIT FUNCTION A2 12PK/BK FUSED B(+) A51 16RD/WT FUSED B(+) A21 16DB FUSED IGNITION SWITCH OUTPUT (RUN-START) A1 16RD FUSED B(+) G26 20LB KEY-IN IGNITION SWITCH SENSE Z42 20BK/DG GROUND A22 16BK/OR...
Page 1135 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS INSTRUMENT CLUSTER C1 - GRAY 26 WAY CIRCUIT FUNCTION F35 18RD FUSED B(+) Y200 18TN/VT DOOR LOCK DRIVER RIGHT DOORS Y204 18OR/WT BTSI SOLENOID CONTROL G10 20LG/RD SEAT BELT SWITCH SENSE Y156 18TN/WT DOOR UNLOCK DRIVER RIGHT DOORS Y201 18TN/OR DOOR UNLOCK DRIVER LEFT REAR...
Page 1136 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 INSTRUMENT CLUSTER C3 - WHITE 26 WAY CIRCUIT FUNCTION M3 20 PK/DB CARGO LAMP DRIVER M20 20BR COURTESY LAMP DRIVER M11 20PK/LB COURTESY LAMP GROUND Y165 20OR/YL PANEL LAMPS DRIVER Y108 20VT/BR WIPER/TURN/BEAM SELECT SWITCH RETURN Y167 20WT/DB HEADLAMP SWITCH RETURN...
Page 1137 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS INTEGRATED POWER MODULE C1 - 26 WAY CIRCUIT FUNCTION A112 12RD/TN (DIESEL) FUSED B(+) A17 16RD/BK (EXCEPT DIESEL) FUSED B(+) Y107 20VT/RD FUSED IGNITION SWITCH OUTPUT (RUN-START) A20 20RD/DB FUSED IGNITION SWITCH OUTPUT (RUN) Y141 18DG/WT TRAILER TOW LEFT TURN RELAY OUTPUT Y140 18WT/PK...
Page 1138 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 INTEGRATED POWER MODULE C3 - GREEN 20 WAY CIRCUIT FUNCTION V10 20BR WASHER PUMP MOTOR SENSE L62 18BR/RD RIGHT REAR TURN LAMP DRIVER Z21 18BK/LG GROUND D25 20VT/PK PCI BUS Z12 18BK/TN GROUND L1 18VT/BK BACKUP LAMP FEED...
Page 1139 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS INTEGRATED POWER MODULE C5 - 26 WAY CIRCUIT FUNCTION A38 16OR FUSED IGNITION SWITCH OUTPUT (RUN) K173 18LG (GAS EXCEPT 5.9L) GROUND K173 18LG (5.9L) GROUND K173 20LG (DIESEL) GROUND L10 18BR/LG FUSED IGNITION SWITCH OUTPUT (RUN) C23 16DG CONDENSER FAN RELAY OUTPUT...
Page 1140 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 INTEGRATED POWER MODULE C7 - GRAY 26 WAY CIRCUIT FUNCTION T40 14BR STARTER MOTOR RELAY OUTPUT V3 16BR/WT WIPER RELAY LOW SPEED OUTPUT Y105 20BR/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F235 18RD FUSED B(+) Y171 18WT/DG LEFT LOW BEAM DRIVER...
Page 1141 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS KNOCK SENSOR-LEFT (5.7L) - BLACK 2 WAY CIRCUIT FUNCTION K73 18YL/BK KNOCK SENSOR NO. 1 SIGNAL Y205 18BR/WT KNOCK SIGNAL RETURN KNOCK SENSOR-RIGHT (5.7L) - BLACK 2 WAY CIRCUIT FUNCTION K74 18BR/VT KNOCK SENSOR NO.
Page 1142 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 LICENSE LAMP-RIGHT - BLACK 2 WAY CIRCUIT FUNCTION L7 18BK/YL HEADLAMP SWITCH OUTPUT Z53 18BK GROUND LIFT PUMP MOTOR (DIESEL) - 2 WAY CIRCUIT FUNCTION K62 18BK/OR LIFT PUMP FEED Z11 18BK/WT GROUND LINE PRESSURE SENSOR (3.7L/5.7L) - BLACK 4 WAY CIRCUIT...
Page 1143 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS LUMBAR MOTOR-DRIVER - DK GRAY 2 WAY CIRCUIT FUNCTION P106 12DG/WT LUMBAR MOTOR FORWARD P107 12OR/BK LUMBAR MOTOR REARWARD LUMBAR MOTOR-PASSENGER - 2 WAY CIRCUIT FUNCTION P105 12LG/DB LUMBAR MOTOR FORWARD P104 12YL/LB LUMBAR MOTOR REARWARD MANIFOLD ABSOLUTE PRESSURE SENSOR (3.7L/4.7L/5.7L) - GRAY 3 WAY CIRCUIT...
Page 1144 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 MODE DOOR ACTUATOR 1 (PANEL TO FLOOR) - 2 WAY CIRCUIT FUNCTION C34 20DB/WT COMMON DOOR DRIVER C35 20DG/YL MODE DOOR 1 DRIVER MODE DOOR ACTUATOR 2 (DEFROST TO FLOOR) - 2 WAY CIRCUIT FUNCTION C34 20DB/WT...
Page 1145 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS OUTPUT SPEED SENSOR (DIESEL) - 2 WAY CIRCUIT FUNCTION T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL T13 18DB/BK SPEED SENSOR GROUND OVERDRIVE SWITCH - WHITE 2 WAY CIRCUIT FUNCTION T6 20OR/WT OVERDRIVE OFF SWITCH SENSE Z71 20BK/TN GROUND OVERHEAD MAP/READING LAMP (EXCEPT BASE) - NATURAL 3 WAY...
Page 1146 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 OXYGEN SENSOR 1/2 DOWNSTREAM - NATURAL 4 WAY CIRCUIT FUNCTION A141 18DG/WT (EXCEPT CALIFORNIA) FUSED AUTO SHUT DOWN RELAY OUTPUT A42 18DG (CALIFORNIA) OXYGEN SENSOR RELAY OUTPUT K199 18BR/VT (NGC) O2 1/2 HEATER CONTROL Z188 18BK/LB (NGC) SENSOR GROUND Z193 18BK/WT (CALIFORNIA)
Page 1147 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS PARK/TURN SIGNAL LAMP-LEFT FRONT - BROWN 3 WAY CIRCUIT FUNCTION L61 18LG LEFT FRONT TURN LAMP DRIVER Y174 18PK/VT FUSED PARK LAMP RELAY OUTPUT Z148 18DB/BK GROUND PARK/TURN SIGNAL LAMP-RIGHT FRONT - BROWN 3 WAY CIRCUIT FUNCTION L60 18LG/TN...
Page 1148 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 POWER MIRROR-RIGHT - BLACK 8 WAY CIRCUIT FUNCTION F121 18TN/BK HEATED MIRROR RELAY OUTPUT P76 20OR/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN) P74 20DB RIGHT MIRROR LEFT DRIVER P72 20YL/BK RIGHT MIRROR UP DRIVER Z311 20BK/LB GROUND POWER OUTLET - RED 3 WAY...
Page 1149 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS POWER SEAT MOTOR-DRIVER HORIZONTAL - BLACK 2 WAY CIRCUIT FUNCTION P17 12RD/LB LEFT SEAT HORIZONTAL REARWARD P15 12YL/LB LEFT SEAT HORIZONTAL FORWARD POWER SEAT MOTOR-DRIVER REAR VERTICAL - 2 WAY CIRCUIT FUNCTION P12 12RD/WT RIGHT SEAT REAR DOWN P10 12YL/WT...
Page 1150 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 POWER STEERING PRESSURE SWITCH (3.7L/4.7L/5.7L) - BLACK 2 WAY CIRCUIT FUNCTION Z244 20BK/DG GROUND S28 18YL/BK P/S SWITCH SIGNAL POWER WINDOW MOTOR-DRIVER - BLACK 2 WAY CIRCUIT FUNCTION Q21 14WT LEFT FRONT WINDOW DRIVER (DOWN) Q11 14LB LEFT FRONT WINDOW DRIVER (UP) POWER WINDOW MOTOR-LEFT REAR - BLACK 2 WAY...
Page 1151 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS POWER WINDOW SWITCH-LEFT REAR - BLUE 6 WAY CIRCUIT FUNCTION Q13 14DB DRIVER REAR WINDOW DRIVER (UP) Q27 14RD/BK LEFT REAR WINDOW DRIVER (DOWN) Q17 14DB/WT LEFT REAR WINDOW DRIVER (UP) Q23 14RD/WT DRIVER REAR WINDOW DRIVER (DOWN) Q1 14YL POWER WINDOW SWITCH FEED...
Page 1152 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 POWERTRAIN CONTROL MODULE - C1 (DIESEL) - 32 WAY CIRCUIT FUNCTION Z82 14BK/TN GROUND Z81 14BK/TN GROUND POWERTRAIN CONTROL MODULE - C2 (DIESEL) - 32 WAY CIRCUIT FUNCTION T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL K88 18VT/WT GOVERNOR PRESSURE SOLENOID CONTROL K54 18OR/BK...
Page 1153 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE - C3 (DIESEL) - 32 WAY CIRCUIT FUNCTION V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL V32 18YL/RD SPEED CONTROL SUPPLY T16 14RD TRANSMISSION CONTROL RELAY OUTPUT T6 18OR/WT OVERDRIVE OFF SWITCH SENSE...
Page 1154 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87 POWERTRAIN CONTROL MODULE C1 (JTEC) - BLACK 32 WAY CIRCUIT FUNCTION K93 18TN/OR (3.7L) COIL DRIVER NO. 3 K18 18RD/YL (8.0L) IGNITION COIL NO.1 DRIVER Y135 18LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START) K94 18TN/LG (3.7L) COIL DRIVER NO.
Page 1155 8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C1 (NGC) - BLACK 38 WAY CIRCUIT FUNCTION K98 18LB/RD COIL CONTROL NO.8 K97 18BR COIL CONTROL NO.7 K28 18GY/LB INJECTOR CONTROL NO.8 K26 18VT/TN INJECTOR CONTROL NO.7 B222 20DG/WT (5.7L) VEHICLE SPEED SIGNAL NO.
Page 1156 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 POWERTRAIN CONTROL MODULE C2 (JTEC) - WHITE 32 WAY CIRCUIT FUNCTION T54 18VT (5.9L/8.0L) TRANSMISSION TEMPERATURE SENSOR SIGNAL K26 18VT/TN (5.9L/8.0L) FUEL INJECTOR NO. 7 DRIVER K115 18TN (8.0L) FUEL INJECTOR NO.9 DRIVER K11 18WT/DB FUEL INJECTOR NO.
Page 1157 8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C2 (NGC) - GRAY 38 WAY CIRCUIT FUNCTION K96 18TN/LB COIL CONTROL NO.6 K95 18TN/DG COIL CONTROL NO.5 K94 18TN/LG COIL CONTROL NO.4 K58 18BR/DB INJECTOR CONTROL NO.6 K38 18GY INJECTOR CONTROL NO.5 F888 18BR/PK (5.7L) ETC MOTOR (+) CONTROL...
Page 1158 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91 POWERTRAIN CONTROL MODULE C3 (JTEC) - GRAY 32 WAY CIRCUIT FUNCTION C13 18DB/OR A/C CLUTCH RELAY CONTROL K51 18DB/YL AUTO SHUT DOWN RELAY CONTROL V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL K73 18YL/BK (3.7L) KNOCK SENSOR NO.
Page 1159 8W - 80 - 92 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C3 (NGC) - WHITE 38 WAY CIRCUIT FUNCTION K51 20DB.YL ASD RELAY CONTROL V35 18LG/RD (4.7L) S/C VENT CONTROL Y145 20DB/YL CONDENSER FAN RELAY CONTROL V32 20YL/RD (4.7L) S/C POWER SUPPLY K106 18WT/DG (4.7L) NVLD SOLENOID CONTROL K199 18BR/VT...
Page 1160 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93 POWERTRAIN CONTROL MODULE C4 (NGC) - GREEN 38 WAY CIRCUIT FUNCTION T60 18BR (4.7L) OVERDRIVE SOLENOID CONTROL T159 18DG/WT (4.7L) 4C SOLENOID CONTROL Y207 18RD/WT (5.7L) TPS NO. 1 OUTPUT T140 18VT/LG (4.7L) PRESSURE CONTROL SOLENOID CONTROL Y208 18DB/YL (5.7L) APPS NO.
Page 1161 8W - 80 - 94 8W-80 CONNECTOR PIN-OUTS RADIO (BASE) - GRAY 22 WAY CIRCUIT FUNCTION M1 18PK FUSED B(+) Y105 20BR/RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Y166 20OR/DB PANEL LAMPS DRIVER X82 18LB/VT RIGHT FRONT DOOR SPEAKER (+) X80 18LB/BK RIGHT FRONT DOOR SPEAKER (-) X85 18LG/DG LEFT FRONT DOOR SPEAKER (-)
Page 1162 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 95 RECIRCULATION DOOR ACTUATOR - 2 WAY CIRCUIT FUNCTION C34 20DB/WT COMMON DOOR DRIVER C32 20GY/DB RECIRCULATION DOOR DRIVER REMOTE RADIO SWITCH-LEFT - BLACK 2 WAY CIRCUIT FUNCTION X20 22GY (EXCEPT ETC) RADIO CONTROL MUX X20 22RD/BK (ETC) RADIO CONTROL MUX Z5 22BK/LB...
Page 1163 8W - 80 - 96 8W-80 CONNECTOR PIN-OUTS SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY CIRCUIT FUNCTION D25 20VT/WT PCI BUS Y135 20LG/BK FUSED IGNITION SWITCH OUTPUT (RUN-START) Z110 20BK/GY GROUND A14 20RD/WT FUSED B(+) SPEAKER-CENTER INSTRUMENT PANEL - WHITE 2 WAY CIRCUIT FUNCTION X83 20YL/RD...
Page 1164 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 97 SPEAKER-RIGHT FRONT DOOR - WHITE 3 WAY CIRCUIT FUNCTION X80 18LB/BK RIGHT FRONT DOOR SPEAKER (-) X82 18LB/VT RIGHT FRONT DOOR SPEAKER (+) SPEAKER-RIGHT INSTRUMENT PANEL - BLACK 2 WAY CIRCUIT FUNCTION X84 18OR/BK RIGHT INSTRUMENT PANEL SPEAKER (+) X86 18OR/RD...
Page 1165 8W - 80 - 98 8W-80 CONNECTOR PIN-OUTS SPEED CONTROL SWITCH-LEFT (ETC) - WHITE 3 WAY CIRCUIT FUNCTION V38 20VT/OR S/C SWITCH NO.2 SIGNAL Y215 20BK/LB S/C SWITCH RETURN V37 20RD/LG S/C SWITCH NO.1 SIGNAL SPEED CONTROL SWITCH-LEFT (EXCEPT ETC) - GREEN 2 WAY CIRCUIT FUNCTION V37 20RD/LG...
Page 1166 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 99 SWITCH-PASSENGER AIRBAG ON-OFF - BLUE 6 WAY CIRCUIT FUNCTION R5 18VT/YL PASSENGER AIRBAG MUX SWITCH SENSE R4 18BR/YL PASSENGER AIRBAG MUX SWITCH RETURN R166 18LG/TN PASSENGER AIRBAG INDICATOR DRIVER F14 18LG/YL FUSED IGNITION SWITCH OUTPUT (RUN-START) TAIL/STOP/TURN SIGNAL LAMP-LEFT - BLACK 6 WAY CIRCUIT FUNCTION...
Page 1167 8W - 80 - 100 8W-80 CONNECTOR PIN-OUTS TENSIONER-LEFT SEAT BELT - YELLOW 2 WAY CIRCUIT FUNCTION R54 18LB/YL LEFT SEAT BELT TENSIONER LINE 2 R56 18LB/DG LEFT SEAT BELT TENSIONER LINE 1 TENSIONER-RIGHT SEAT BELT - YELLOW 2 WAY CIRCUIT FUNCTION R53 18LG/YL...
Page 1168 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 101 TRAILER TOW CONNECTOR - 4 WAY CIRCUIT FUNCTION Z52 14BK GROUND L76 18BK/OR PARK LAMP RELAY OUTPUT Y141 18YL/PK TRAILER TOW LEFT TURN RELAY OUTPUT Y140 18WT/PK TRAILER TOW RIGHT TURN RELAY OUTPUT TRAILER TOW CONNECTOR-ADD ON - 10 WAY CIRCUIT FUNCTION...
Page 1169 8W - 80 - 102 8W-80 CONNECTOR PIN-OUTS TRANSFER CASE CONTROL MODULE C2 - GRAY 16 WAY CIRCUIT FUNCTION Y114 20YL/VT MODE SENSOR B Y113 20YL/OR MODE SENSOR A T24 20BR/YL PARK/NEUTRAL POSITION SWITCH SENSE (T41) Y117 20YL/DB 5 VOLT MODE SENSOR SUPPLY Y115 20YL/WT MODE SENSOR C Y118 20YL/LB...
Page 1170 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 103 TRANSFER CASE POSITION SENSOR (4.7L/5.9L) - BLACK 2 WAY CIRCUIT FUNCTION K77 18BR/WT TRANSFER CASE POSITION SENSOR INPUT K4 18BK/LB SENSOR GROUND TRANSFER CASE SELECTOR SWITCH - 12 WAY CIRCUIT FUNCTION Y118 20YL/LB 5 VOLT SELECTOR SWITCH SUPPLY Y187 20RD 2WD/AWD INDICATOR...
Page 1171 8W - 80 - 104 8W-80 CONNECTOR PIN-OUTS TRANSMISSION CONTROL MODULE - BLACK 60 WAY CIRCUIT FUNCTION T1 18LG/BK TRS T1 SENSE T4 18PK/OR TRS T2 SENSE T3 18VT TRS T3 SENSE Y210 18YL/RD (5.7L) EATX RPM SIGNAL K24 18GY/BK (3.7L) CRANKSHAFT POSITION SENSOR SIGNAL D15 18WT/DG SCI TRANSMIT (TCM)
Page 1172 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 105 TRANSMISSION CONTROL MODULE - BLACK 60 WAY CIRCUIT FUNCTION T52 18RD/BK INPUT SPEED SENSOR SIGNAL Z113 18BK GROUND T54 18VT TRANSMISSION TEMPERATURE SENSOR SIGNAL T59 18PK UNDERDRIVE SOLENOID CONTROL A61 16DG/BK FUSED B(+) Z13 16BK/RD GROUND T159 18DG/WT...
Page 1173 8W - 80 - 106 8W-80 CONNECTOR PIN-OUTS TRANSMISSION SOLENOID/TRS ASSEMBLY (3.7L/4.7L/5.7L) - BLACK 23 WAY CIRCUIT FUNCTION L10 18BR/LG FUSED IGNITION SWITCH OUTPUT (RUN) T120 18LG LR SOLENOID CONTROL T24 18BR/YL TRS T41 SENSE T41 18BK/WT (5.7L) TRS T41 SENSE T24 20BR/YL (4.7L) TRS T41 SENSE T42 18VT/WT...
Page 1174 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 107 VEHICLE SPEED SENSOR (DIESEL) - 3 WAY CIRCUIT FUNCTION K6 18VT/WT 5 VOLT SUPPLY K167 18BR/TL ACCELERATOR PEDAL POSITION SENSOR GROUND NO. 1 G17 18WT/TN SPEEDOMETER SIGNAL VISTRONIC FAN DRIVE (DIESEL) - 6 WAY CIRCUIT FUNCTION Y1 18LG...
Page 1175 8W - 80 - 108 8W-80 CONNECTOR PIN-OUTS WHEEL SPEED SENSOR-LEFT FRONT (ABS) - BLACK 2 WAY CIRCUIT FUNCTION B8 20RD/DB LEFT FRONT WHEEL SPEED SENSOR (-) B9 20RD LEFT FRONT WHEEL SPEED SENSOR (+) WHEEL SPEED SENSOR-REAR (ABS) - 2 WAY CIRCUIT FUNCTION B114 18WT/VT...
Page 1176 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 109 WASHER FLUID LEVEL SWITCH - BLACK 2 WAY CIRCUIT FUNCTION Y137 20VT/LB SENSOR GROUND G29 20BK/TN WASHER FLUID SWITCH SENSE WASHER PUMP MOTOR-FRONT - BLACK 2 WAY CIRCUIT FUNCTION Z216 20BK/VT GROUND V10 20BR WASHER PUMP MOTOR CONTROL WATER IN FUEL SENSOR (DIESEL) - 2 WAY...
Page 1177 8W - 80 - 110 8W-80 CONNECTOR PIN-OUTS WHEEL SPEED SENSOR-REAR (ABS)- 2 WAY CIRCUIT FUNCTION B114 18WT/VT REAR WHEEL SPEED SENSOR (-) B113 18RD/VT REAR WHEEL SPEED SENSOR (+) WHEEL SPEED SENSOR-RIGHT FRONT (ABS) - GRAY 2 WAY CIRCUIT FUNCTION B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
Page 1178 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TABLE OF CONTENTS page CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTION ......1 Use the wiring diagrams in each section for connec- CONNECTOR/GROUND/SPLICE tor, ground, and splice identification.
Page 1179 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Blower Motor Behind Right Side of Instrument Panel Blower Motor Resistor Block Behind Right Side of Instrument Panel Brake Lamp Switch Top of Brake Pedal Arm 32, 37, 39 Brake Provision-Electric Rear of Engine...
Page 1180 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. C317 At Passenger Seat C319 Bottom Left of Left Door C322 DK GY Left Rear of Frame C323 Left Side of Instrument Panel C327 Right Rear Fender 48, 49 C328...
Page 1181 8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Door Ajar Switch-Driver (Base) Left Front Door Door Ajar Switch-Left Rear (Base) Left Rear Door Door Ajar Switch-Passenger (Base) Right Front Door Door Ajar Switch-Right Rear (Base) Right Rear Door Door Lock Motor/Ajar Switch-Driver Left Front Door...
Page 1182 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Headlamp-Right At Headlamp 1, 25, 29 Heated Seat Cushion - Driver Under Driver Seat Heated Seat Cushion - Passenger Under Passenger Seat Heated Seat Switch-Driver Center of Instrument Panel 35, 37, 38 Heated Seat Switch-Passenger...
Page 1183 8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Manifold Absolute Pressure Sensor Left Front of Intake Manifold (5.9L) Mode Door Actuator 1 Right Side of HVAC Mode Door Actuator 2 Right Side of HVAC Multi-Function Switch On Steering Column Natural Vacuum Leak Detection...
Page 1184 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Powertrain Control Module C2 Right Rear Engine Compartment 21, 22, 23, 24 Powertrain Control Module C3 Right Rear Engine Compartment 21, 22, 23, 24 Powertrain Control Module C4 Right Rear Engine Compartment PTO Sense...
Page 1185 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Speed Control Switch-Right (ETC) At Steering Wheel Tail/Stop/Turn Signal Lamp-Left At Lamp Tail/Stop/Turn Signal Lamp-Right At Lamp Throttle Position Sensor Throttle Body 4, 8 Trailer Tow Connector At Trailer Hitch Trailer Tow Connector-Add On...
Page 1186 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) GROUNDS GROUND LOCATION FIG. NUMBER G100 Left Front Engine G101 Left Front Engine G102 Left Front Chassis G103 Left Front Engine Compartment G104 Left Front Engine Compartment G105 Right Front Chassis G106 Left Rear Engine Compartment 26, 31...
Page 1187 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S126 Center Rear of Engine Compartment S128 Right Rear of Engine 3, 22 S129 Top Front of Transmission 3, 23 S130 Top Front of Transmission 3, 8, 9, 12, 14, 16, 17, 21, 22, 24 S131...
Page 1188 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S183 Top of Transmission S184 Top of Transmission S191 Near Integrated Power Module S197 Left Rear Engine Compartment S201 Left Side of Instrument Panel S204 Left Side of Instrument Panel S205 Left Side of Instrument Panel...
Page 1189 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S316 At Driver Seat S317 At Passenger Seat S318 At Passenger Seat S319 Left Front Door S320 Center of Body S321 Left Front Body S322 Left Front Body S323 Left Front Body...
Page 1190 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 1 RIGHT SIDE FRONT LIGHTING Fig. 2 LEFT FRONT BUMPER AND RIGHT BATTERY TRAY...
Page 1191 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1192 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1193 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1194 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1195 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1196 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1197 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1198 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1199 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1200 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1201 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 13 LEAK DETECTION PUMP (8.0L)
Page 1202 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1203 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 15 TRANSMISSION 45RFE (4X4) (5.7L)
Page 1204 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1205 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1206 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1207 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1208 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1209 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1210 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1211 8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1212 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1213 8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1214 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1215 8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1216 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1217 8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1218 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 41 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1219 8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1220 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1221 8W - 91 - 44 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1222 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 45 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1223 8W - 91 - 46 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1224 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 47 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1225 8W - 91 - 48 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1226 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 49 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1227 8W - 91 - 50 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1228 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 51 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1229 8W - 91 - 52 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1230 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 53 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1231 8W - 91 - 54 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1232 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 55 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1233 8W - 91 - 56 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1234 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 57 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 46 ROOF Fig. 47 REAR BODY...
Page 1235 8W - 91 - 58 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1236 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 59 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1237 8W - 91 - 60 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 50 LEFT REAR FENDER (RIGHT SIDE SIMILAR)
Page 1238 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 61 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1240 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION OPERATION ......6 DESCRIPTION .
Page 1241 8W - 97 - 2 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION (Continued) enough for the resistor coil to heat up. When the SPECIAL TOOLS heating element is engaged with the contact, battery current can flow through the resistor coil to ground, POWER DISTRIBUTION SYSTEMS causing the resistor coil to heat.
Page 1242: Integrated Power Module
8W-97 POWER DISTRIBUTION 8W - 97 - 3 components: the Power Distribution Center (PDC), INTEGRATED POWER MODULE the integrated power module cover, the Front Control Module (FCM) and the Integrated Power Module DESCRIPTION Assembly which includes the power distribution cen- ter, the cover and FCM.
Page 1243 8W - 97 - 4 8W-97 POWER DISTRIBUTION INTEGRATED POWER MODULE (Continued) (4) Remove the integrated power module retaining bolt and screw (Fig. 2). Fig. 4 INTEGRATED POWER MODULE ELECTRICAL CONNECTIONS 1 - RETAINING LATCH Fig. 3 REMOVING INTEGRATED POWER MODULE 2 - GRAY CONNECTOR (5) Grasp the integrated power module with two 3 - GREEN CONNECTOR...
Page 1244 8W-97 POWER DISTRIBUTION 8W - 97 - 5 FRONT CONTROL MODULE (Continued) • Power Ground • Ambient Temperature Sensing • Ignition Switch Run • Washer Fluid Level Switch • Windshield Wiper Park Switch • PCI Bus Circuit DIAGNOSIS AND TESTING - FRONT CONTROL MODULE The front control module is a printed circuit board based module with a on-board micro-processor.
Page 1245 8W - 97 - 6 8W-97 POWER DISTRIBUTION OPERATION IOD FUSE The term ignition-off draw identifies a normal con- DESCRIPTION dition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery cur- rent when the ignition switch is in the Off position.
Page 1246: Power Outlet
8W-97 POWER DISTRIBUTION 8W - 97 - 7 IOD FUSE (Continued) INSTALLATION (4) Check for battery voltage at the insulated con- tact located at the back of the power outlet recepta- (1) Turn the ignition switch to the Off position. cle.
Page 1247 8W - 97 - 8 8W-97 POWER DISTRIBUTION POWER OUTLET (Continued) Fig. 8 ISO Relay COMMON FEED COIL GROUND COIL BATTERY NORMALLY OPEN NORMALLY CLOSED Fig. 7 Cigar Lighter and Power Outlet Remove/ OPERATION Install The ISO relay consists of an electromagnetic coil, a 1 - KNOB AND ELEMENT resistor and three (two fixed and one movable) elec- 2 - RETAINING BOSSES-ENGAGE PLIERS HERE...
Page 1248 8W-97 POWER DISTRIBUTION 8W - 97 - 9 RELAY (Continued) DIAGNOSIS & TESTING - RELAY CIRCUIT TEST MICRO RELAY (1) The relay common feed terminal cavity (30) of the integrated power module is connected to battery DESCRIPTION voltage and should be hot at all times. Check for bat- tery voltage at the fused B(+) circuit cavity in the integrated power module receptacle for the relay.
Page 1249 8W - 97 - 10 8W-97 POWER DISTRIBUTION MICRO RELAY (Continued) no continuity between terminals 87 and 30. If OK, go REMOVAL to Step 3. If not OK, replace the faulty relay. (1) Disconnect and isolate the negative battery (3) Resistance between terminals 85 and 86 (elec- cable.
Page 1250 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE - 3.7L ......1 ENGINE - 5.9L .
Page 1251 9 - 2 ENGINE - 3.7L ROCKER ARM REAR MOUNT DESCRIPTION ......36 REMOVAL ......60 REMOVAL .
Page 1252 ENGINE - 3.7L 9 - 3 IDLER SHAFT INSTALLATION ......81 REMOVAL ......79 TIMING BELT/CHAIN AND SPROCKETS INSTALLATION .
Page 1253 9 - 4 ENGINE - 3.7L ENGINE - 3.7L (Continued) Additional tests and diagnostic procedures may be DIAGNOSIS AND TESTING necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. DIAGNOSIS AND TESTING - ENGINE Information concerning additional tests and diagno- DIAGNOSIS - INTRODUCTION sis is provided within the following diagnosis:...
Page 1254 ENGINE - 3.7L 9 - 5 ENGINE - 3.7L (Continued) CONDITION POSSIBLE CAUSE CORRECTION 4. Incorrect cam timing. 4. (Refer to 9 - ENGINE/VALVE TIMING - STANDARD PROCEDURE). 1. ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped spark 1. (Refer to 8 - ELECTRICAL/ plugs.
Page 1255 9 - 6 ENGINE - 3.7L ENGINE - 3.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTIONS NOISY VALVES 1. High or low oil level in 1. (Refer to LUBRICATION & crankcase. MAINTENANCE - SPECIFICATIONS) 2.
Page 1256 ENGINE - 3.7L 9 - 7 ENGINE - 3.7L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts.
Page 1257 9 - 8 ENGINE - 3.7L ENGINE - 3.7L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL PUMPING AT RINGS; SPARK 1. Worn or damaged rings. 1. Hone cylinder bores and replace PLUGS FOULING rings. 2. Carbon in oil ring slots. 2. Replace rings (Refer to 9 - ENGINE/ENGINE BLOCK/PISTON RINGS - STANDARD PROCEDURE).
Page 1258 ENGINE - 3.7L 9 - 9 ENGINE - 3.7L (Continued) CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat. THROTTLE BODY seated properly Reface or replace, as necessary. Inspect valve springs.
Page 1259 9 - 10 ENGINE - 3.7L ENGINE - 3.7L (Continued) • Solvent or a commercially available gasket of oil and coolant. Can be used on threaded and machined parts under all temperatures. This mate- remover • Plastic or wood scraper (Fig. 2) rial is used on engines with multi-layer steel (MLS) •...
Page 1260 ENGINE - 3.7L 9 - 11 ENGINE - 3.7L (Continued) (12) Disconnect heater hoses from heater core and (35) Remove the starter. remove hose assembly. (36) Remove the ground straps from the left and (13) Disconnect throttle and speed control cables. right side of the block.
Page 1261 9 - 12 ENGINE - 3.7L ENGINE - 3.7L (Continued) (17) Connect the engine to body ground straps at SPECIFICATIONS the left side of the cowl. (18) Install the intake manifold. SPECIFICATIONS – 3.7L ENGINE (19) Install the engine oil dipstick tube. (20) Install the power brake booster vacuum hose.
Page 1262 ENGINE - 3.7L 9 - 13 ENGINE - 3.7L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Second Compression 0.37 - 0.63 mm End Play 0.052 - 0.282 mm Ring (0.0021 - 0.0112 in.) (0.0146 - 0.0249 in.) End Play (MAX) 0.282 mm (0.0112 in) Oil Control (Steel Rails) 0.25 - 0.76 mm Connecting Rod...
Page 1263 9 - 14 ENGINE - 3.7L ENGINE - 3.7L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Spring Force (Valve Length (Overall) Open) Intake 113.45 - 114.21 mm Intake 984.0 - 1040.0 N @ (4.4666 - 4.4965) 28.12 mm Exhaust 114.92 - 115.68 mm 221.2 - 233.8 lbs.
Page 1264 ENGINE - 3.7L 9 - 15 ENGINE - 3.7L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION N·m Cover Out - of -Flat 0.025 mm (0.001 in.) Lbs. Lbs. (MAX) Flexplate—Bolts — Inner and Outer Rotor Engine Mount Bracket to — Thickness 12.02 mm (0.4731 in.) Block—Bolts Outer Rotor to pocket .235 mm (.0093 in.)
Page 1265 9 - 16 ENGINE - 3.7L ENGINE - 3.7L (Continued) SPECIAL TOOLS Spanner Wrench 6958 Handle C-4171 Adapter Pins 8346 Rear Crankshaft Seal Installer 8349 Front Crankshaft Seal Remover 8511 Rear Crankshaft Seal Remover 8506 Front Crankshaft Seal Installer 8348 Connecting Rod Guides 8507...
Page 1266 ENGINE - 3.7L 9 - 17 ENGINE - 3.7L (Continued) Crankshaft Damper Installer 8512 Chain Tensioner Pins 8514 Puller 1026 VALVE SPRING COMPRESSOR 8426 Crankshaft Damper Removal Insert 8513 ENGINE LIFTING FIXTURE 8427 Chain Tensioner Wedge 8379 CAMSHAFT HOLDER 8428...
Page 1267 9 - 18 ENGINE - 3.7L ENGINE - 3.7L (Continued) HOLDER SECONDARY CAMSHAFT CHAIN 8429 INSTALLER - REMOVER - COUNTER BALANCE SHAFT 8641 Valve Spring Tester C-647 Remover, Rocker Arm 8516 Dial Indicator C-3339 Idler Shaft Remover 8517 Valve Spring Compressor C-3422-B Valve Spring Compressor Adapters 8519...
Page 1268 ENGINE - 3.7L 9 - 19 ENGINE - 3.7L (Continued) Pressure Tester Kit 7700 Bore Size Indicator C-119 Bloc–Chek–Kit C-3685–A Oil Pressure Gauge C-3292 ENGINE SUPPORT FIXTURE 8534 Piston Ring Compressor C-385...
Page 1269 9 - 20 ENGINE - 3.7L AIR CLEANER ELEMENT REMOVAL Filter Element Only Housing removal is not necessary for element (fil- ter) replacement. (1) Loosen clamp (Fig. 3) and disconnect air duct at air cleaner cover. (2) Pry over 4 spring clips (Fig. 3) from housing cover (spring clips retain cover to housing).
Page 1270 ENGINE - 3.7L 9 - 21 CYLINDER HEAD - LEFT (Continued) • Excessive steam (white smoke) emitting from (6) Remove the intake manifold(Refer to 9 - exhaust ENGINE/MANIFOLDS/INTAKE MANIFOLD • Coolant foaming REMOVAL). (7) Remove the master cylinder and booster assem- CYLINDER-TO-CYLINDER LEAKAGE TEST bly(Refer to 5 - BRAKES/HYDRAULIC/MECHANI- To determine if an engine cylinder head gasket is...
Page 1271 9 - 22 ENGINE - 3.7L CYLINDER HEAD - LEFT (Continued) Fig. 6 CAMSHAFT SPROCKET V6 MARKS (#1 TDC, Exhaust stroke) 1 - LEFT CYLINDER HEAD 2 - RIGHT CYLINDER HEAD (16) Lock the secondary timing chains to the idler NOTE: Mark the secondary timing chain prior to removal to aid in installation.
Page 1272 ENGINE - 3.7L 9 - 23 CYLINDER HEAD - LEFT (Continued) (21) Remove the retaining bolt and the camshaft (1) Clean the cylinder head and cylinder block drive gear. mating surfaces (Fig. 10). CAUTION: Do not allow the engine to rotate. Severe damage to the valve train can occur.
Page 1273 9 - 24 ENGINE - 3.7L CYLINDER HEAD - LEFT (Continued) • Step 4: Tighten bolts 1–8, 90 degrees, again. (16) Install the fan blade assembly and fan shrou- Tighten bolts 9–12, 26 N·m (19 ft. lbs.) d(Refer to 7 - COOLING/ENGINE/RADIATOR FAN - INSTALLATION).
Page 1274 ENGINE - 3.7L 9 - 25 CAMSHAFT(S) (Continued) (3) Mark one link on the secondary timing chain on both sides of the V6 mark on the camshaft sprocket to aid in installation. CAUTION: Do not hold or pry on the camshaft tar- get wheel (Located on the right side camshaft sprocket) for any reason, Severe damage will occur to the target wheel resulting in a vehicle no start...
Page 1275 9 - 26 ENGINE - 3.7L CAMSHAFT(S) (Continued) (3) Install the camshaft bearing caps, hand tighten (10) Using Special Tool 6958 spanner wrench with the retaining bolts. adapter pins 8346, torque the camshaft sprocket retaining bolt to 122 N·m (90 ft. lbs.). NOTE: Caps should be installed so that the (11) Install the cylinder head cover(Refer to 9 - stamped numbers on the caps are in numerical...
Page 1276 ENGINE - 3.7L 9 - 27 CYLINDER HEAD COVER(S) (Continued) (6) Remove the cylinder head cover mounting bolts (5) Install the resonator and air inlet hose. (Fig. 16). (6) Connect negative cable to battery. (7) Remove cylinder head cover and gasket. INTAKE/EXHAUST VALVES &...
Page 1277 9 - 28 ENGINE - 3.7L INTAKE/EXHAUST VALVES & SEATS (Continued) (5) The valve seat and valve face must maintain a face angle of 44.5 – 45 degrees angle (Fig. 17). Fig. 18 Rocker Arm Removal 1 - CAMSHAFT Fig. 17 Valve Assembly Configuration 2 - SPECIAL TOOL 8516 1 - VALVE LOCKS (3–BEAD) 2 - RETAINER...
Page 1278 ENGINE - 3.7L 9 - 29 INTAKE/EXHAUST VALVES & SEATS (Continued) adjustments. Refer to Specifications Section to obtain specified height and allowable tensions. Replace any springs that do not meet specifications (Fig. 19). Fig. 19 Testing Valve Springs 1 - SPECIAL TOOL C-647 Fig.
Page 1279 9 - 30 ENGINE - 3.7L ROCKER ARM DESCRIPTION The rocker arms are steel stampings with an inte- gral roller bearing. The rocker arms incorporate a 2.8 mm (0.11 inch) oil hole in the lash adjuster socket for roller and camshaft lubrication. REMOVAL NOTE: Disconnect the battery negative cable to pre- vent accidental starter engagement.
Page 1280 ENGINE - 3.7L 9 - 31 INSTALLATION VALVE GUIDE SEALS NOTE: All six valve springs and seals are removed DESCRIPTION in the same manner; this procedure only covers The valve guide seals are made of rubber and one valve seal and valve spring. incorporate an integral steel valve spring seat.
Page 1281 9 - 32 ENGINE - 3.7L CYLINDER HEAD - RIGHT (Continued) (6) Air ingested into oil due to broken or cracked (16) Mark the secondary timing chain, one link on oil pump pick up. each side of the V6 mark on the camshaft drive gear. (7) Worn valve guides.
Page 1282 ENGINE - 3.7L 9 - 33 CYLINDER HEAD - RIGHT (Continued) (3) Position the cylinder head onto the cylinder block. Make sure the cylinder head seats fully over the locating dowels. NOTE: The four M8 cylinder head mounting bolts require sealant to be added to them before install- ing.
Page 1283 9 - 34 ENGINE - 3.7L CYLINDER HEAD - RIGHT (Continued) (7) Position the secondary chain onto the camshaft that border the nose piece journal. Engine oil enters drive gear, making sure one marked chain link is on the hollow camshafts at the third journal and lubri- either side of the V6 mark on the gear then using cates every intake lobe rocker through a drilled pas- Special Tool 8428 Camshaft Wrench, position the...
Page 1284 ENGINE - 3.7L 9 - 35 CAMSHAFT(S) (Continued) (8) Starting at the outside working inward, loosen the camshaft bearing cap retaining bolts 1/2 turn at a time. Repeat until all load is off the bearing caps. CAUTION: DO NOT STAMP OR STRIKE THE CAM- SHAFT BEARING CAPS.
Page 1285 9 - 36 ENGINE - 3.7L CYLINDER HEAD COVER(S) (Continued) (12) Remove cylinder head cover retaining bolts. (3) For rocker arm removal on cylinder #1, Rotate (13) Remove cylinder head cover. the crankshaft until cylinder #1 is at BDC combus- tion stroke.
Page 1286 ENGINE - 3.7L 9 - 37 VALVE SPRINGS (Continued) REMOVAL NOTE: The valve springs are NOT common between intake and exhaust. (1) Remove the cylinder head cover(Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD (3) Install the spring retainer, and the spring. COVER(S) - REMOVAL).
Page 1287 9 - 38 ENGINE - 3.7L ENGINE BLOCK (Continued) (2) Deglazing of the cylinder walls may be done if CLEANING the cylinder bore is straight and round. Use a cylin- Thoroughly clean the oil pan and engine block gas- der surfacing hone, Honing Tool C-3501, equipped ket surfaces.
Page 1288 ENGINE - 3.7L 9 - 39 ENGINE BLOCK (Continued) (4) Determine taper by subtracting the smaller diameter from the larger diameter. (5) Rotate measuring device 90° and repeat steps above. (6) Determine out-of-roundness by comparing the difference between each measurement. (7) If cylinder bore taper does not exceed 0.025 mm (0.001 inch) and out-of-roundness does not exceed 0.025 mm (0.001 inch), the cylinder bore can...
Page 1289 9 - 40 ENGINE - 3.7L CRANKSHAFT (Continued) Fig. 32 BEDPLATE PRY POINT LOCATION INSPECTION (2) Thoroughly clean the bedplate to cylinder block sealing surfaces and main bearing bores. Remove all oil and sealant residue. NOTE: Thoroughly inspect the connecting rod bear- (3) Inspect the bedplate main bearing bores for ing bores and main bearing bores for scoring, blue- cracks, scoring or severe blueing.
Page 1290 ENGINE - 3.7L 9 - 41 CRANKSHAFT (Continued) INSTALLATION NOTE: Make sure that the bedplate and cylinder block sealing surfaces are clean and free of oil or other contaminants. Contaminants on the sealing CAUTION: Main bearings are select fit. Refer to surfaces may cause main bearing distortion and/or Crankshaft Main Bearings in this section for proper oil leaks.
Page 1291 9 - 42 ENGINE - 3.7L CRANKSHAFT (Continued) Fig. 35 BEDPLATE TIGHTENING SEQUENCE (7) Install the bedplate retaining bolts, making (9) Install the connecting rods and measure side sure to place the stud bolts in the correct location, clearance(Refer to 9 - ENGINE/ENGINE BLOCK/ Torque the bolts in the sequence shown (Fig.
Page 1292 ENGINE - 3.7L 9 - 43 MAIN BEARING JOURNAL DIAMETER CRANKSHAFT MAIN (CRANKSHAFT REMOVED) BEARINGS Remove the crankshaft from the cylinder block(Re- fer to 9 - ENGINE/ENGINE BLOCK/CRANKSHAFT STANDARD PROCEDURE - REMOVAL). Clean the oil off the main bearing journal. Determine the maximum diameter of the journal MAIN BEARING FITTING with a micrometer.
Page 1293 9 - 44 ENGINE - 3.7L CRANKSHAFT MAIN BEARINGS (Continued) CRANKSHAFT OIL SEAL - Crankshaft JOURNAL SIZE SIZE mm (in.) FRONT MARKING REMOVAL (.0958 - .0960 (1) Disconnect negative cable from battery. in.) (2) Remove accessory drive belt (Refer to 7 - Lower Bearing Main 1 and 4 COOLING/ACCESSORY DRIVE/DRIVE BELTS - 2.441 - 2.447...
Page 1294 ENGINE - 3.7L 9 - 45 CRANKSHAFT OIL SEAL - FRONT (Continued) (11) Using Special Tool 8511, remove crankshaft front seal (Fig. 38). Fig. 39 Crankshaft Front Seal Installation 1 - TIMING CHAIN COVER 2 - SPECIAL TOOL 8348 Fig. 38 Crankshaft Front Seal Removal 3 - SPECIAL TOOL 8512 1 - SPECIAL TOOL 8511 CRANKSHAFT OIL SEAL -...
Page 1295 9 - 46 ENGINE - 3.7L CRANKSHAFT OIL SEAL - REAR (Continued) (3) Using Special Tool 8506 (Fig. 40), remove the (3) Using Special Tools 8349 Crankshaft Rear Oil crankshaft rear oil seal. Seal Installer and C-4171 Driver Handle (Fig. 42), with a hammer, tap the seal into place.
Page 1296 ENGINE - 3.7L 9 - 47 FLEX PLATE PISTON & CONNECTING ROD REMOVAL DESCRIPTION (1) Remove the transmission. CAUTION: Do not use a metal stamp to mark con- (2) Remove the bolts and flexplate. necting rods as damage may result, instead use ink INSTALLATION or a scratch awl.
Page 1297 9 - 48 ENGINE - 3.7L PISTON & CONNECTING ROD (Continued) STANDARD PROCEDURE CONNECTING ROD BEARING FITTING Inspect the connecting rod bearings for scoring. Check the bearings for normal wear patterns, scor- ing, grooving, fatigue and pitting (Fig. 45). Replace any bearing that shows abnormal wear.
Page 1298 ENGINE - 3.7L 9 - 49 PISTON & CONNECTING ROD (Continued) Fig. 49 Measuring Bearing Clearance with Plastigage 1 - PLASTIGAGE SCALE 2 - COMPRESSED PLASTIGAGE Bearing SIZE USED WITH Fig. 48 Piston and Connecting Rod -Installation - Mark Typical JOURNAL SIZE 1 - “F”...
Page 1299 9 - 50 ENGINE - 3.7L PISTON & CONNECTING ROD (Continued) Slide snug-fitting feeler gauge between the con- necting rod and crankshaft journal flange (Fig. 50). Refer to Engine Specifications for the proper clear- ance. Replace the connecting rod if the side clearance is not within specification.
Page 1300 ENGINE - 3.7L 9 - 51 PISTON & CONNECTING ROD (Continued) (3) If necessary, remove top ridge of cylinder bores GINE BLOCK/CONNECTING ROD BEARINGS - with a reliable ridge reamer before removing pistons STANDARD PROCEDURE). from cylinder block. Be sure to keep tops of pistons Check the connecting rod for signs of twist or bending.
Page 1301 9 - 52 ENGINE - 3.7L PISTON & CONNECTING ROD (Continued) • Timing chain and cover. (Refer to 9 - ENGINE/ (5) The pistons are marked on the piston pin bore surface with an raised “F” indicating installation VALVE TIMING/TIMING BELT / CHAIN COVER(S) position.
Page 1302 ENGINE - 3.7L 9 - 53 PISTON RINGS (Continued) PISTON RING SIDE CLEARANCE PISTON RING SPECIFICATION CHART NOTE: Make sure the piston ring grooves are clean Ring Position Groove Maximum and free of nicks and burrs. Clearance Clearance (5) Measure the ring side clearance as shown (Fig. Upper Ring .051-.094mm 0.11mm...
Page 1303 9 - 54 ENGINE - 3.7L PISTON RINGS (Continued) (8) Install the oil ring expander. (9) Install upper side rail (Fig. 57) by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position.
Page 1304 ENGINE - 3.7L 9 - 55 VIBRATION DAMPER (Continued) (8) Disconnect electrical connector for fan mounted threaded rod’s threads with Mopar Nickel Anti- inside radiator shroud. Seize or (Loctite No. 771). NOTE: Transmission cooler line snaps into shroud lower right hand corner. (9) Remove crankshaft damper bolt.
Page 1305 9 - 56 ENGINE - 3.7L VIBRATION DAMPER (Continued) (5) Install fan blade assembly (Refer to 7 - COOL- INSTALLATION ING/ENGINE/FAN DRIVE VISCOUS CLUTCH - INSTALLATION). CAUTION: The structural cover must be installed as (6) Install radiator upper shroud and tighten fas- described in the following steps.
Page 1306 ENGINE - 3.7L 9 - 57 (12) Raise the engine far enough to be able to FRONT MOUNT remove the left and right engine mounts. (13) Remove the (8) mount to engine attaching REMOVAL bolts (14) Remove the engine mounts. (1) Disconnect the negative cable from the battery.
Page 1307 9 - 58 ENGINE - 3.7L FRONT MOUNT (Continued) (11) Remove the (3) bolts that attach the front axle to the left engine bracket. (12) Lower the front axle. (13) Remove the (6) through bolts (14) Raise the engine far enough to be able to remove the left (Fig.
Page 1308 ENGINE - 3.7L 9 - 59 FRONT MOUNT (Continued) Fig. 69 ENGINE INSULATOR MOUNTS 4X4 1 - RH INSULATOR TO AXLE BOLT 5 - LH INSULATOR TO AXLE BOLT 2 - NUT 6 - FRONT AXLE 3 - PINION SUPPORT MOUNT 7 - NUT 4 - LH INSULATOR MOUNT 8 - RH INSULATOR MOUNT...
Page 1309 9 - 60 ENGINE - 3.7L (1) Install the two bolts that attach the transmis- REAR MOUNT sion mount to the transmission bracket. (2) Torque the bolts to 61N·m (45 ft.lbs.) torque. REMOVAL (3) Lower the transmission so the transmission (1) Raise the vehicle on a hoist.
Page 1310 ENGINE - 3.7L 9 - 61 LUBRICATION (Continued) ENGINE LUBRICATION FLOW CHART - BLOCK: TABLE 1 FROM Oil Pickup Tube Oil Pump Oil Pump Oil Filter Oil Filter Block Main Oil Gallery Block Main Oil Gallery 1. Crankshaft Main Journal 2.
Page 1311 9 - 62 ENGINE - 3.7L LUBRICATION (Continued) Fig. 71 LUBRICATION OIL FLOW 1 - OIL FLOW TO RIGHT CYLINDER HEAD 7 - OIL FLOW TO COUNTER BALANCE SHAFT 2 - CYLINDER BLOCK MAIN OIL GALLERY 8 - OIL PUMP OUTLET TO CYLINDER BLOCK 3 - LEFT CYLINDER HEAD OIL GALLERY 9 - OIL PUMP 4 - OIL FLOW TO BOTH SECONDARY TENSIONERS...
Page 1312 ENGINE - 3.7L 9 - 63 LUBRICATION (Continued) (7) Clean the oil off the suspect oil leak area using DIAGNOSIS AND TESTING a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the DIAGNOSIS AND TESTING—ENGINE OIL LEAK engine for signs of an oil leak by using a black light.
Page 1313 9 - 64 ENGINE - 3.7L LUBRICATION (Continued) DIAGNOSIS AND TESTING - CHECKING following steps should be followed to help pinpoint the source of the leak. ENGINE OIL PRESSURE If the leakage occurs at the crankshaft rear oil seal (1) Remove oil pressure sending unit (Fig. 72)and area: install gauge assembly C-3292.
Page 1314 ENGINE - 3.7L 9 - 65 clearance at fan shroud to fan and cowl to intake OIL PAN manifold. (7) Raise engine using special tool # 8534 to pro- DESCRIPTION vide clearance to remove oil pan. The engine oil pan is made of laminated steel and has a single plane sealing surface.
Page 1315 9 - 66 ENGINE - 3.7L OIL PAN (Continued) INSPECTION (1) Inspect oil drain plug and plug hole for stripped or damaged threads. Repair as necessary. (2) Inspect the oil pan mounting flange for bends or distortion. Straighten flange, if necessary. INSTALLATION (1) Clean the oil pan gasket mating surface of the bedplate and oil pan.
Page 1316 ENGINE - 3.7L 9 - 67 OIL PRESSURE SENSOR/SWITCH (Continued) REMOVAL DISASSEMBLY (1) Disconnect the negative cable from the battery. (1) Remove oil pump cover screws and lift off cover (2) Raise vehicle on hoist. plate. (3) Remove front splash shield. (2) Remove pump inner and outer rotors.
Page 1317 9 - 68 ENGINE - 3.7L OIL PUMP (Continued) NOTE: The 3.7 Oil pump is released as an assem- bly. There are no DaimlerChrysler part numbers for Sub-Assembly components. In the event the oil pump is not functioning or out of specification it must be replaced as an assembly.
Page 1318 ENGINE - 3.7L 9 - 69 OIL PUMP (Continued) Fig. 81 Measuring Clearance Between Rotors 1 - OUTER ROTOR 2 - FEELER GAUGE Fig. 83 Oil Pump And Primary Timing Chain 3 - INNER ROTOR Tensioner Tightening Sequence (2) Using a suitable oil filter wrench loosen filter. (3) Rotate the oil filter counterclockwise (Fig.
Page 1319 9 - 70 ENGINE - 3.7L OIL FILTER (Continued) NOTE: Make sure filter gasket was removed with fil- API SERVICE GRADE CERTIFIED ter. Use an engine oil that is API Service Grade Certi- fied. MOPAR provides engine oils that conform to (5) With a wiping cloth, clean the gasket sealing this service grade.
Page 1320 ENGINE - 3.7L 9 - 71 OIL (Continued) OIL LEVEL INDICATOR (DIPSTICK) ENGINE OIL CHANGE The engine oil level indicator is located at the right Change engine oil at mileage and time intervals rear of the engine on the 4.7L engines. (Fig. 88). described in Maintenance Schedules.
Page 1321 9 - 72 ENGINE - 3.7L INTAKE MANIFOLD (Continued) (8) Disconnect left and right radio suppressor straps. (9) Disconnect and remove ignition coil towers. (10) Remove top oil dipstick tube retaining bolt and ground strap. (11) Bleed fuel system. Refer to FUEL SYSTEM. (12) Remove fuel rail.
Page 1322 ENGINE - 3.7L 9 - 73 INTAKE MANIFOLD (Continued) (9) Position and install heater hoses and tubes exhaust manifold gasket is used to improve sealing onto intake manifold. to the cylinder head. The exhaust manifolds are cov- (10) Install the heater hoses to the heater core and ered by a three layer laminated heat shield for ther- engine front cover.
Page 1323 9 - 74 ENGINE - 3.7L EXHAUST MANIFOLD (Continued) Fig. 93 Exhaust Manifold Right Fig. 94 Exhaust Manifold left 1 - HEAT SHIELD 1 - HEAT SHIELD 2 - NUTS 2 - NUTS 3 - MANIFOLD FLANGE 3 - MANIFOLD FLANGE LEFT EXHAUST MANIFOLD CAUTION: Over tightening heat shield fasteners, may cause shield to distort and/or crack.
Page 1324 ENGINE - 3.7L 9 - 75 tooth idler sprocket directly from a 25 tooth crank- VALVE TIMING shaft sprocket. Primary chain motion is controlled by a pivoting leaf spring tensioner arm and a fixed DESCRIPTION guide. The arm and the guide both use nylon plastic The timing drive system has been designed to pro- wear faces for low friction and long wear.
Page 1325 9 - 76 ENGINE - 3.7L VALVE TIMING (Continued) The idler shaft is a light press-fit into the cylinder NOTE: Components referred to as left hand or right block. A large washer on the idler shaft bolt and the hand are as viewed from the drivers position inside rear flange of the idler shaft are used to control the vehicle.
Page 1326 ENGINE - 3.7L 9 - 77 VALVE TIMING (Continued) (4) If both of the camshaft drive gears are off in TIMING - SINGLE CAMSHAFT the same or opposite directions, the primary chain or both secondary chains are at fault. Refer to Timing NOTE: to adjust the timing on one camshaft, pre- Chain and Sprockets procedure in this section.
Page 1327 9 - 78 ENGINE - 3.7L VALVE TIMING (Continued) (5) Using Special Tool 8428 Camshaft Wrench, rotate the camshaft until the alignment dowel on the camshaft is aligned with the slot in the camshaft drive gear. CAUTION: Remove excess from camshaft sprocket retaining bolt before reinstalling bolt.
Page 1328 ENGINE - 3.7L 9 - 79 BALANCE SHAFT REMOVAL (1) Remove the primary and secondary timing chains. Refer to TIMING CHAIN and SPROCKET. NOTE: The balance shaft and gear are serviced as an assembly. Do not attempt to remove the gear from the balance shaft.Remove the retaining bolt from the counterbalance shaft thrust plate (Fig.
Page 1329 9 - 80 ENGINE - 3.7L IDLER SHAFT (Continued) CAUTION: Use care when removing the idler shaft, Do not strike the radiator cooling fins with the slide hammer. (4) Using Special Tool 8517 Slide Hammer, remove the idler shaft. INSTALLATION (1) Thoroughly clean the idler shaft bore.
Page 1330 ENGINE - 3.7L 9 - 81 TIMING BELT / CHAIN COVER(S) (Continued) INSTALLATION CAUTION: Do not use oil based liquids to clean tim- ing cover or block surfaces. Use only rubbing alco- hol, along with plastic or wooden scrapers. Use no wire brushes or abrasive wheels or metal scrapers, or damage to surfaces could result.
Page 1331 9 - 82 ENGINE - 3.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 107 CAMSHAFT SPROCKET V6 MARKS, (#1 TDC EXHAUST STROKE) 2 - RIGHT CYLINDER HEAD 1 - LEFT CYLINDER HEAD Fig. 109 Cylinder Head Access Plugs 1 - RIGHT CYLINDER HEAD ACCESS PLUG 2 - LEFT CYLINDER HEAD ACCESS PLUG Fig.
Page 1332 ENGINE - 3.7L 9 - 83 TIMING BELT/CHAIN AND SPROCKETS (Continued) (8) Remove the oil fill housing to gain access to the CAUTION: Do not forcefully rotate the camshafts or right side tensioner arm fastener. crankshaft independently of each other. Damaging (9) Remove crankshaft damper (Refer to 9 - intake valve to piston contact will occur.
Page 1333 9 - 84 ENGINE - 3.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) INSTALLATION (4) Install the left side chain guide. Tighten the bolts to 28 N·m (250 in. lbs.). (1) Using a vise, lightly compress the secondary (5) Install left side chain tensioner arm, and Torx chain tensioner piston until the piston step is flush bolt.
Page 1334 ENGINE - 3.7L 9 - 85 TIMING BELT/CHAIN AND SPROCKETS (Continued) (10) Install all chains, crankshaft sprocket, and (14) Verify that all plated links are aligned with idler sprocket as an assembly (Fig. 112). After guid- the marks on all sprockets and the “V6” marks on ing both secondary chains through the block and cyl- camshaft sprockets are at the 12 o’clock position.
Page 1335 9 - 86 ENGINE - 3.7L TIMING BELT/CHAIN AND SPROCKETS (Continued) Fig. 115 TIGHTENING RIGHT SIDE CAMSHAFT SPROCKET BOLT 1 - TORQUE WRENCH Fig. 116 MEASURING IDLER GEAR END PLAY 2 - SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 - LEFT CAMSHAFT SPROCKET 1 - IDLER SPROCKET ASSEMBLY 4 - RIGHT CAMSHAFT SPROCKET 2 - DIAL INDICATOR...

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